In general, the fluids industry has not kept up with the rest of the upstream industry when it comes to automation, digitization, optimization, and prediction. Most fluid property tests (density, rheology, emulsion stability, retort, etc.) still are run manually. Not only do fluids data often suffer from inconsistent quality and insufficient quantity, but the data normally are not integrated with analytical and decision-making tools, work flows, or data from other elements of the drilling operation. As a result, the stakeholders neither fully understand the dynamics of their drilling and completions fluids nor have the ability to make the best decisions possible before and during drilling operations.

Over the last two years, Halliburton met with numerous operators to discuss their needs and challenges related to fluids automation and optimization. The emerging message had several common elements across both regions and operators:
• Automation of tests will drive better understanding and management of fluid properties;
• Improved data resolution will enable better models and management of drilling activity;
• Data and equipment are not enough; automation must enable better decisions to be made sooner;
• Automation and real-time optimization will enable reductions in personnel at the rig site, non-productive time (NPT), drilling risk, drilling time, and time to production – ultimately reducing cost and accelerating cash flow for operators;
• Operators want systems that are vendor-neutral. In other words, they want the ability to integrate selective elements from a variety of vendors at optimal times;
• While complying with or mirroring API standards for manual testing is preferred, it is not always possible when automating the test. Further, the consistent ability to capture, trend, and understand data in meaningful ways often is more important (especially new types of data from new tests); and
• Easy-to-interpret data visualization is important, but rarely is delivered by current technology.

Based on industry feedback and identifiable challenges, it is safe to say that the emerging market will fundamentally change the fluids industry. Using this information will help companies develop a vision of where the trend is taking the industry. It can be thought of as a digital ecosystem. Portions of the vision include:
• Critical elements of an efficient, effective system include improved planning capabilities, automated testing equipment, real-time monitoring and intervention, predictive models, collaboration, and post-well analysis;
• Technology alone is not sufficient; to gain maximum benefit, it has to be combined with expert knowledge and appropriate process;
• A portfolio of plug-and-play elements is preferable to a proprietary A-Z system that manages the entire fluids life cycle. This approach allows clients to choose the specific elements and vendors they want. Also, it helps open the fluids data silo, permitting multiple stakeholders to optimize the overall drilling operation;
• Access to a large quantity of high-quality data will help the industry better understand relationships between activities and outcomes. The ability to correlate changing sensor readings with changes in the external environment is a relationship that makes sense in hindsight, but it was not previously identified simply because the data was not available. Other trends are appearing in newly investigated datasets that are not yet understandable. This sort of outcome will likely drive the development of new fluids-related solutions in coming years; and
• New digital solutions developments may not flourish in a narrow silo. Being open to pushing or sharing data solutions with other product lines within the company helps to realize the full potential or partner with clients, suppliers, third parties, and competitors to develop and deploy emerging solutions.

Halliburton, Baroid, Automated Mud Monitoring Equipment, South Texas

Halliburton global technical advisor with the Automated Mud Monitoring Equipment during a field trial in South Texas. (Image courtesy of Halliburton Baroid)

Having a vision is a nice start, but what has been accomplished to date? Earlier this year, Halliburton commercialized two applied fluids optimization (AFO) engineering services. The first works collaboratively with the rest of the client’s well-planning team to design future wells. The second monitors real-time current and predicted hydraulics to improve drilling efficiency (NPT avoidance and rate of penetration optimization). The services are not dependent on providing fluids at the rig site. In a recent pilot of the AFO monitoring service, engineers made 10 interventions. One intervention prevented a pack off, saving the client time and money.

Halliburton conducted months of yard tests and several field trials of the first two pieces of automated mud measuring equipment: a density /viscosity sensor and an emulsion stability sensor. A long-term commercial pilot of second-generation units is scheduled to start later this year. Prototypes of other pieces of automated equipment have been built with evaluation starting in 2011. The equipment pushes real-time data so it can be recorded, pulled into modeling applications, and securely monitored by multiple stakeholders. Compared to standard manual tests, trials to date show improved test data quality with more frequent test data points. The data enabled fluid and solids control engineers to be more efficient and effective in managing their fluids and waste streams.

Several operators are pushing to bring fluids management into the “digital oilfield.” Most others see the potential the emerging ecosystem has to impact their operations. All have been interested in one or more technologies, particularly the automated testing equipment.

Halliburton is not alone in developing and testing new solutions. There has been work done over the last few years as several players, from major service companies to start-up firms, have taken various approaches to develop fluids automation and real-time monitoring technologies. As a result, the upstream industry can expect increasing levels of activity and marketing over the coming years.