Pashchenko O.A., Khomenko V.L., Kamyshatskyi О.F., Yavorska V., Zybalov D.S. In-situ monitoring of drilling mud viscosity using advanced sensor technologies

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Parent Category: Geo-Technical Mechanics, 2025

Category: Geo-Technical Mechanics, 2025, Issue 173

Geotech. meh. 2025, 173, 123-132

 

IN-SITU MONITORING OF DRILLING MUD VISCOSITY USING ADVANCED SENSOR TECHNOLOGIES

¹Pashchenko O.A.

¹Khomenko V.L.

²Kamyshatskyi О.F.

¹Yavorska V.

¹Zybalov D.S.

¹Dnipro University of Technology

²Mining Equipment Plant Tehpostavka LLC

UDC 622.243:543.4:681.5:53:620.1

Language: English

Abstract.Real-time monitoring of drilling mud viscosity is essential for optimizing drilling operations, enhancing efficiency, and ensuring safety in the oil and gas industry. This study investigates the application of advanced sensor technologies – ultrasonic, optical, and microfluidic – for real-time viscosity measurement of drilling mud, a critical parameter in optimizing drilling operations within the oil and gas industry. Study addresses the limitations of traditional viscosity measurement methods, such as rotational viscometers and Marsh funnel tests, which rely on offline sampling and introduce significant delays (2–4 hours) and errors (up to 15%) due to sample handling and dynamic downhole conditions. These delays hinder timely adjustments to mud properties, increasing risks like stuck pipes, poor hole cleaning, or well instability, which can raise operational costs by 15–25%.

The research evaluates the performance of three sensor types under laboratory and field conditions, including high-pressure, high-temperature environments (up to 150°C and 100 MPa). Ultrasonic sensors measure viscosity via sound wave attenuation, optical sensors use light scattering, and microfluidic sensors analyze flow resistance in microchannels, with governing equations provided for each (e.g., Hagen-Poiseuille for microfluidic). Laboratory tests used a flow loop simulating downhole conditions, while field tests at 3,000 m depth involved water-, oil-, and synthetic-based muds. Optical sensors demonstrated superior performance, achieving a 2% error margin and a 0.3-second response time, compared to 4% and 0.5 seconds for ultrasonic and 3% and 0.8 seconds for microfluidic sensors. Field results showed real-time monitoring reduced non-productive time by 15%, yielding daily cost savings of ~$5,000 in offshore operations by enabling proactive mud adjustments, preventing complications like wellbore instability.

The study highlights the transformative potential of in-situ viscosity monitoring, improving efficiency, safety, and sustainability by minimizing mud waste and operational risks. Future research should focus on enhancing sensor durability, developing multi-sensor systems, and standardizing calibration for diverse mud types. The optical sensor’s performance positions it as a key technology for advancing drilling practices, with broader implications for high-pressure, high-temperature and unconventional reservoir operations.

Keywords: drilling mud, viscosity, in-situ monitoring, advanced sensors, drilling efficiency, real-time measurement, sensor technologies, operational optimization.

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Pashchenko Oleksandr, Candidate of Technical Sciences (Ph. D.), Director of the Interbranch Institute of Continuing Education (MIBO), Associate Professor at the Department of Oil and Gas Engineering and Drilling, Dnipro University of Technology, Dnipro, Ukraine, This email address is being protected from spambots. You need JavaScript enabled to view it. (Corresponding author)

Khomenko Volodymyr, Candidate of Technical Sciences (Ph. D.), Associate Professor at the Department of Oil and Gas Engineering and Drilling, Dnipro University of Technology, Dnipro, Ukraine, This email address is being protected from spambots. You need JavaScript enabled to view it.

Kamyshatskyi Oleksandr, Candidate of Technical Sciences (Ph. D.), Mining Equipment Plant Tehpostavka LLC, Dnipro, Ukraine, This email address is being protected from spambots. You need JavaScript enabled to view it.

Yavorska Viktoriia, Assistant of the Department of Oil and Gas Engineering and Drilling, Dnipro University of Technology, Dnipro, Ukraine, This email address is being protected from spambots. You need JavaScript enabled to view it.

Zybalov Dmitro, Assistant of the Department of Cyber-Physical and Information-Measuring Systems (CPIMS), Dnipro University of Technology, Dnipro, Ukraine, This email address is being protected from spambots. You need JavaScript enabled to view it.

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