Development of a Software-Hardware Complex for Continuous Monitoring of Drilling Fluid Rheology

The rheological properties of drilling fluids, such as plastic viscosity, yield point, and gel strength, are critical for ensuring efficient and safe oil and gas well drilling. Traditional methods for rheological analysis, reliant on manual or semi-automated viscometers, suffer from delays and inability to provide continuous data, increasing operational risks. This study presents the development and validation of an automated software-hardware complex designed for real-time monitoring of drilling fluid rheology. The system integrates inline rheometers, pressure and temperature sensors, and advanced data processing algorithms to deliver accurate measurements with a response time of 0.8 seconds. Laboratory tests demonstrated errors of ±4.2% for viscosity and ±7.8% for yield point compared to the Fann 35 viscometer, while field tests under simulated drilling conditions (30–100°C, 5–20 MPa) confirmed reliability with errors below ±9.2%. Case studies showcased rapid detection of anomalies, enabling proactive fluid management. The complex offers a scalable, integrated solution, reducing non-productive time and enhancing well stability. Recommendations include machine learning integration for predictive analytics and cloud-based analytics for remote monitoring, with future work targeting extreme conditions and other fluid types. This advancement significantly improves drilling fluid management, contributing to safer and more efficient drilling operations.