Drill with Confidence: Real-Time Automated Drilling Fluid Testing and Dynamic Hydraulic Modeling for Drilling Optimization

Abstract

Abstract Manual drilling fluid measurements typically conducted 2–4 times per day, lack the resolution required for precise hydraulic calculations and management in high-performance wells. This paper details the implementation of a closed-loop workflow involving an inline automated fluid testing device and real-time hydraulics simulation and monitoring across two wells in the field. The primary objective was to replace intermittent manual sampling with high-frequency data integrated into a live hydraulic and hole-cleaning simulator to monitor and optimize drilling performance parameters such as Rate of Penetration (ROP), tripping speeds, and circulation times. The technology utilized an inline dual-sampling drilling fluid characterization device to continuously analyze mud properties in the circulating system. The automated system achieved a significant increase in data density, providing 46 rheology tests and 1,920 density readings per day, a massive improvement over the conventional 2–4 rheology tests and 48 density readings. These real-time parameters (Density, PV, YP, and 6-speed readings) and drilling parameters were streamed to a Real-Time Center where a hydraulics modelling software was used for real-time monitoring and optimization. This allowed for the continuous monitoring of the Hole-Cleaning Index (HCI), Cuttings Bed Height (CBH), and Equivalent Circulating Density (ECD) against planned pressure and fracture gradients and identify opportunities for drilling parameter optimization. The integration of real-time data into predictive simulations yielded substantial operational efficiencies as follows: Drilling Performance: The system enabled a maximum ROP of 400 ft/hr while maintaining good hole cleaning. A field-best 24-hour footage of 3,945.68 feet was achieved in the 6-inch section at this time.Circulation Optimization: While the original plan was six bottom-up cycles, predictive simulations suggested optimizing this sequence to just two (a potential saving in circulation time of 67% whilst ensuring a clean wellbore)Tripping Efficiency: Real-time surge/swab monitoring enabled potential tripping speed increases of nearly 100% over previous rig KPIs, offering 15–25% time savings compared to the best-performing rigs in the region.Data Accuracy: Comparative analysis showed a high correlation between simulated ECD and actual annular pressure while drilling (APWD) data, confirming the reliability of automated fluid inputs for pressure management. This work demonstrates that automating the fluid-data-to-simulation loop moves the industry from reactive monitoring to proactive drilling management. It quantifies the specific "time-savings" value of high-frequency rheology data, proving that automated testing is a critical precursor to fully autonomous drilling systems.