Optimizing Drilling Mud Shearing

Abstract

Viscosity and other properties are determined at desired temperatures in drilling mud and other fluids by using a versatile cavitation device which, operating in the cavitation mode, mixes and heats the fluid to a specified temperature, and, operating in the shear mode, acts as a spindle for application of Couette principles to determine viscosity as a function of shear stress and shear rate. The invention obviates the practice of adjusting rheology of a drilling fluid by passing it through the drill bit. Drilling fluid may be managed by a “straight-through” method to the well, or by placing the cavitation device in a loop which isolates an aliquot of known volume and circulating the fluid through the loop including the cavitation device. A controller may be programmed to manage the viscosity and other properties at various temperatures by controlling the power input and angular rotation of the “spindle” (which has cavities on its cylindrical surface), and feeding viscosity-adjusting agents and other additives to the fluid. Data may be collected from the loop and used in the “straight-through” mode until it is determined that conditions require a new set of data, or the loop may be used continuously. The system may be used with a supplemental viscometer, density meter, and other instruments.

1 - 8 . (canceled) 
     
     
         9 . A cavitation mixer comprising (a) a cylindrical rotor having a plurality of cavities on its cylindrical surface (b) a housing for said cylindrical rotor, said housing having a fluid inlet and a fluid outlet and defining an interior space including a cylindrical interior surface substantially concentric to said rotor's cylindrical surface, (c) a shaft for rotating said rotor, and (d) at least one of (i) a transducer for generating a signal representing torque on said shaft, and (ii) a transducer for generating a signal representing angular velocity of said shaft. 
     
     
         10 . The cavitation mixer of  claim 9  including a processor for generating a signal as a function of at least one of said torque and said angular velocity. 
     
     
         11 . The cavitation mixer of  claim 10  including a remote receiver for receiving said at least one signal generated by said processor and for regulating rotation of said rotor. 
     
     
         12 . The cavitation mixer of  claim 9  including a flow director on said rotor. 
     
     
         13 . Apparatus for controlling the preparation of drilling fluid for drilling a well comprising a drilling fluid flow loop including a cavitation mixer, said cavitation mixer having transducers for generating signals representing torque and angular velocity in said cavitation mixer. 
     
     
         14 . Apparatus of  claim 13  wherein said cavitation mixer is a flow-directed cavitation mixer. 
     
     
         15 . Apparatus of  claim 13  including a process controller for receiving said signals representing torque and angular velocity, computing viscosity of said fluid as a function of said signals, and controlling the adjustment of viscosity in said fluid in response to said computed viscosity. 
     
     
         16 . Apparatus of  claim 13  wherein said loop includes a density meter. 
     
     
         17 . Apparatus of  claim 13  wherein said loop includes an in-line viscometer. 
     
     
         18 . Apparatus of  claim 13  wherein said loop includes one or more sensors for at least one of flow, pH, percent solids, water cut or oil/water ratio, electrical stability, particle size, and temperature of said fluid in said loop. 
     
     
         19 . Apparatus for shearing and adjusting properties of drilling mud comprising (a) a drilling mud flow loop including valves capable of isolating an aliquot of said mud in said flow loop, (b) a cavitation mixer in said loop, and (c) a process controller for controlling angular velocity and power input to said cavitation mixer in response to intermittent or continuous viscosity measurements of said mud. 
     
     
         20 . Apparatus of  claim 19  including a meter in said flow loop for measuring density of said mud in said loop and reporting it to said process controller. 
     
     
         21 . Apparatus of  claim 19  wherein said process controller is programmed to receive readings of conditions in a well and adjust properties of said mud in said loop as programmed. 
     
     
         22 . Apparatus of  claim 19  wherein said flow loop is located on a conduit leading from sources of one or more drilling mud ingredients to a well. 
     
     
         23 . Apparatus of  claim 19  wherein said process controller is programmed to control said cavitation mixer to (a) heat, by cavitation, said drilling mud in said loop to a first predetermined temperature, (b) shear said drilling mud at said first predetermined temperature, without cavitation, (c) further heat, by cavitation, said drilling mud in said loop to a second predetermined temperature, and (d) shear said drilling mud at said second predetermined temperature. 
     
     
         24 . Apparatus of  claim 23  wherein said process controller is programmed to heat, by cavitation, said drilling mud to at least one additional predetermined temperature and to shear, without cavitation, said drilling mud at said at least one additional predetermined temperature. 
     
     
         25 - 44 . (canceled) 
     
     
         45 . Apparatus of  claim 19  wherein said loop includes at least one meter for viscosity, flow, pH, percent solids, water cut or oil/water ratio, electrical stability, particle size, or temperature of said fluid in said loop. 
     
     
         46 . Apparatus of  claim 19  wherein said process controller is programmed to receive readings of conditions in a well and adjust properties of said mud in said loop as programmed. 
     
     
         47 - 55 . (canceled)