drilling mud pump components free sample

The 2,200-hp mud pump for offshore applications is a single-acting reciprocating triplex mud pump designed for high fluid flow rates, even at low operating speeds, and with a long stroke design. These features reduce the number of load reversals in critical components and increase the life of fluid end parts.

The pump’s critical components are strategically placed to make maintenance and inspection far easier and safer. The two-piece, quick-release piston rod lets you remove the piston without disturbing the liner, minimizing downtime when you’re replacing fluid parts.

A wide variety of oil drilling mud pump parts options are available to you, such as 1 year, not available and 2 years.You can also choose from new, oil drilling mud pump parts,as well as from energy & mining, construction works , and machinery repair shops oil drilling mud pump parts, and whether oil drilling mud pump parts is 1.5 years, 6 months, or unavailable.

This invention relates to the circulation of fluid between the surface of a subterranean well and the bore hole and more specifically relates to the simultaneous control of drilling fluid circulation or mud pumps and a choke communicating with the pump.

Conventional apparatus used in rotary drilling operations includes a drilling fluid circulation pump or mud pump used to circulate drilling fluids from the surface through the well bore. These fluids are used to remove cuttings made by a rotary drill. In normal drilling fluid or mud circulation, the drilling fluid is pumped down through the drill pipe, discharged through the bit and returns to the surface in the annular space outside the drill pipe and inside the drill hole and casing placed in the well. The rate of drilling fluid circulation is determined by the necessary upward flow velocity required for removing cavings and drill cuttings from the hole and by the jetting requirements of the bit. The inherent advantage of the rotary system of drilling is that a fluid is circulated for the purpose of removing drill cuttings and maintaining a hole in such condition that the drill string can be withdrawn readily and returned to the bottom whenever necessary.

During conventional drilling it is not uncommon to encounter a sudden pressure increase or kick caused by the release of downhole liquids or gases under pressure which can affect drilling fluid circulation. When a kick is encountered, it can be necessary to vary the rate at which drilling fluid is injected into the well or to change the weight of the drilling fluid. A choke, in communication with the pump, is used to prevent significant pressure changes in conjunction with a change in the speed of operation of the mud pumps. For example, a significant increase in downhole pressure occurring as a result of an increase in the drilling fluid circulation can conceivably fracture the producing formation causing serious damage.

In normal drilling operations, the mud pumps are controlled by the driller, using a driller"s console located at the driller"s station on a rig to monitor relevant drilling parameters, including the speed of the mud pumps. Furthermore, conventional well control circulation operations also require manipulation of the choke to regulate or control the fluid pressure, especially during changes in the speed of the mud pump. On a conventional drilling rig, the choke is normally controlled from a choke console, which can be positioned on the drilling floor, at a position remote from the normal location of a driller"s console on a surface rig. Simultaneous control of both the mud pumps and the choke requires communication between the driller and one manning the choke console. Such communication is difficult, especially on engine driven drilling rigs. The noise and the use of different types of gauges on a rig cause confusion and makes such communication difficult, especially on engine driven drilling rigs. Furthermore, a more accurate gauge for pump strokes rate is conventionally located at the choke console, but conventional apparatus provide no means for using this more accurate gauge at the choke console to control the pumps. In a crisis situation, where the drilling crew is attempting to control the well, increased emphasis is placed on efficient communication and operation, which is difficult using prior art devices.

Apparatus for controlling the circulation of well control or kill fluid in a subterranean well includes a pump and a choke communicating with the pump to deliver drilling fluids from the surface of the well into the bore hole and return to the fluid handling equipment. Apparatus for monitoring the condition of the pump is normally employed at the driller"s console on the drilling rig and such pump monitoring apparatus includes a conventional pump control for regulating the speed and operation of the drilling fluid pumps. These pump controls can consist of pneumatic control valves or rheostats.

While control of the pump can be effected from the driller"s console, control of the choke can be simultaneously effected using a choke control apparatus located at a choke console, normally located on the drilling floor at a location remote from the driller"s console. A second pump control apparatus, again consisting of a conventional device, such as a pneumatic control valve or a rheostat, is located at the choke monitoring console and can be used to regulate pump speed and operation in the same manner as the first pump control apparatus located at the driller"s console. Apparatus is provided for overriding the first pump control upon transmission of a signal from the second pump control. Such apparatus can comprise a pneumatic valve unit or an electrical relay consisting of normally closed and normally open switches which change state upon actuation of the second pump control apparatus. In the preferred embodiment of this invention, the overriding signal is the same as the pump control signal. When this pump control signal is transmitted, a valve or relay functions to override the first pump control apparatus. Signals transmitted from the second pump control located at the choke console can then be transmitted to the pumps.

In the preferred embodiment of this invention, the overriding apparatus comprises a portion of an interface network located in the driller"s console, and the second pump control signal is transmitted from the choke console through the driller"s console and subsequently to the drilling fluid or mud pumps. In this manner, control of both the pump and the choke can be transferred to the same location on the drilling rig to provide for better control over both the rate of circulation of the drilling fluids and over the pressure maintained in the bore hole. Such centralized control is quite useful in certain situations, such as when a kick is encountered.

The preferred embodiments of the invention depicted herein are intended for use with conventional driller"s consoles and choke consoles employed on diesel or electrically powered rigs commonly used for drilling subterranean wells. The interface network and remote pump control apparatus employed in the choke console are consistent with conventional commercially available components of driller"s consoles and choke console.

FIG. 1 shows the conventional location of the driller"s console 2 and choke console 4 between which signals are transmitted to regulate or control both mud pumps 6 and the choke 8. The choke console 4 located proximate to the choke 8 separately controls the operation of the choke. The driller"s console 2 includes means for separately controlling the mud pumps 6 and signals may be transmitted from the choke console to the driller"s console for regulating the operation and speed of the mud pump. It can be seen from FIG. 2 that in the preferred embodiment of this invention the choke console controls the pumps by signals transmitted through the driller"s console 2. The transmission of signals between the various components shown in FIG. 2 can be by any of a number of conventional means, such as by electrical signals, by pneumatic or hydraulic signals, by fiber optic signals, by power line modulation, or in any other conventional form suitable for use on a drilling rig. A pneumatic control network for use with a diesel powered rig and an electrical interface network for use within an electrically powered drilling rig will be described herein.

FIGS. 3-5 depict the operation of a pneumatic interface network for a diesel powered rig. Only those portions of the pump control and the interface network relevant to the control of drilling fluid, circulating or mud pumps are depicted. Numerous other components are employed in a driller"s console or in a choke console. Such components are, however, conventional and the components shown in FIG. 3 are compatible with other conventional components controlling the operation of a drilling rig. The pneumatic interface network for the diesel powered rig shown in FIG. 3 is intended for use in controlling two mud pumps. On conventional drilling rigs, two or more mud pumps are employed, although it is common practice to use only a single mud pump at a time, retaining the other mud pumps for redundancy and/or for emergency situations. The two pneumatic control valves 12 and 26 contained within the driller"s console comprise conventional valves commonly employed in driller"s console. Valves manufactured by American Standard having a pressure range of 0 to 100 psi for clutch and throttle signals represent one conventional valve for controlling the mud pump. A plurality of shuttle valves 18, 20, 32 and 34, each comprising a dual input-single output valve, are employed on opposite sides of each of the first or main pneumatic control valves 12 and 26 for controlling the operation of the mud pumps. Shuttle valves 18, 20, 32 and 34 may comprise conventional valves, such as the P-54350-2 shuttle valve manufactured by Wabco, an American Standard Company. Of course other similar valves could be used to form the isolation function of these shuttle valves. Valve 70, also located at the driller"s console, comprises a four element stack valve unit consisting of valve elements 70a, 70b, 70c and 70d. Pneumatic valves 70 each comprise spring loaded, dual input, single output valves forming a valve stack 70. Individual valves are of conventional construction and comprise valves such as the A222PS valves manufactured by ARO Inc. which can be secured together by using an MKN stacking kit and an isolator plate manufactured by ARO Inc.

The pneumatic control valve 46 employed in the choke console comprises, in the preferred embodiment of this invention, an HD-2-FX pneumatic control valve having a pressure range from 0 to 100 psi, manufactured by American Standard. Pneumatic control valve 46 has a single input and three separate outputs. Valve 46 is located in the choke console and communicates with a conduit 40 providing air under pressure for use in actuating the various components depicted herein. A toggle switch 42 and an indicator light 44 are located on the choke console to insure that control is not transferred between the choke console and the driller"s console at a time when the differences in the throttle settings between the choke console and the driller"s console will create a serious pressure increase below the well, thus damaging the formation.

The rig air input from conduit 64 into stack valve units 70a and 70b passes through lines 66 and 68 respectively to the pump control valves 12 and 26 when stack valves 70a and 70b are in the open position. Essentially, the stack valve units 70a and 70b are connected in parallel to the rig air source 64. The output conduits 61 and 62 leading from the stack valve units 70c and 70d are respectively connected to shuttle valves 18 and 34. Communication is normally established between throttle line 48 and valves 18 and 34 through the stack valve units 70c and 70d when the spring loaded valves are in their normally open position.

FIG. 3 depicts a condition in which the mud pumps 6 and 6" can be controlled by using the first or primary mud pump controllers 12 and 26. It should be understood that in an actual practice, only one pump is normally used. Solid lines have been used to indicate that pneumatic signals communicate through the line, while dashed lines indicate that the line has been disabled and no signal is transmitted. As shown by the solid lines in FIG. 3, pressure in line 64, which is obtained from a source of rig air, communicates through the normally open stack valves 70a and 70b to lines 66 and 68 respectively. Rig air is then applied to pneumatic control valves 12 and 26. Referring to control valve 12, the presence of rig air at the input of this first control valve permits clutch and throttle signals to be generated in lines 14 and 16 respectively. Since the choke console pneumatic control valve is in the off position, as shown in FIG. 3, and there is no pressure in lines 48, 50 and 52, a pneumatic signal is applied in only one of the dual input ports of shuttle valves 18 and 20. A pneumatic clutch signal in line 14 can be transmitted through shuttle valve 20 and clutch line 22 directly to the drilling fluid or mud pump. Similarly, a throttle signal in line 16 would be transmitted through shuttle valve 18 and line 24 to the pump. Thus the pneumatic throttle and clutch signals to pump 6 are employed to control the operating speed of an internal combustion engine, for example, driving pump 6 and an operating clutch to engage or disengage the pump as desired or required.

FIG. 4 shows the condition in which the choke console pneumatic control valve 46 is actuated to apply a pneumatic signal in clutch line 52 and in throttle line 48. Pneumatic control valve 46 is of the type that actuation of a control lever in one direction will induce a clutch signal during initial movement and thereafter will produce a throttle signal. The pneumatic signal in clutch line 52 acts through lines 54 and 56 on the actuator ports of stack valve units 70a and 70d. Pressure applied at the actuator ports plugs the input lines to stack valve units 70a and 70d. Thus the rig air from line 64 is plugged by stack valve unit 70a thus disabling the first mud pump control valve 12 which comprises the primary means of regulating the mud pump 6 from the driller"s console. The pneumatic signal in line 52 is, however, transmitted to the second input port of shuttle valve 20. Since there is no pressure in line 14, any clutch signal in line 52 at shuttle valve 20 will be transmitted through line 22. The pneumatic signal in line 52 communicating with line 56 also disables the throttle input to stack valve unit 70d isolating shuttle valve 34 from the throttle line 48. Stack valve unit 70c, however, remains open and the pneumatic signal in throttle line 48 will be transmitted through line 61 to shuttle valve 18. This pneumatic signal in line 61 is in turn transmitted through throttle line 24 to the first mud pump. Similarly, the stack valve unit 70b remains open and rig air from conduit 64 flows through line 68 to the secondary driller mud pump control valve 26.

FIG. 5 shows the same pneumatic control circuit in which the choke console pump control valve 46 has been actuated to generate a pneumatic clutch C2 signal in line 50. This pneumatic signal in line 50 communicates through lines 58 and 60 to the actuating ports of stack valve units 70b and 70c to close the input ports from the rig air conduit 64 and from the throttle line 48 respectively. Valve units 70a and 70d, however, remain open. Rig air can thus be applied to pump control valve 12 and the pneumatic signal in throttle line 48 can be transmitted through stack valve unit 70d to one input port of shuttle valve 34. Similarly, the pneumatic signal in clutch C2 line 50 is transmitted to an input port of shuttle valve 32. A clutch signal derived from the pneumatic control valve 46 can thus be applied through line 36 to the second mud pump. Similarly, a throttle signal 38 determined by the position of pneumatic control valve 46 can be applied through shuttle valve 34 and line 38 to the second mud pump. Choke console pneumatic control valve 46 is of the type that actuation of an input lever in a first direction will apply a signal in clutch C1 line 52 and in throttle line 48, while actuation of the control valve unit in the opposite direction will result in the presence of a pneumatic signal in clutch C2 line 50 and in the throttle line 48. It will be understood that separate choke control elements are contained within the choke console for positioning the choke in the proper position. When the apparatus is in the configurations of FIGS. 4 and 5, the choke control valve 46 can also be used to control either mud pump 6 or mud pump 6".

FIG. 6 shows an electrical interface network for use with an electrically powered rig. Again, separate drillers and choke consoles can be used in the same manner as shown in FIG. 2. In this electrically powered network, rheostat 72 provides a control signal through path 88 and normally closed relay 84a and line 86 to an SCR housing for controlling the operation and speed of a single mud pump. A second rheostat 90 located on the choke console is normally isolated from SCR housing line 86 by a normally open relay 84b. The configuration of FIG. 6 shows the conventional operation of the mud pump 6 by means of the pump controlling rheostat 72 located in the driller"s console. When it is desired to control the mud pump by use of the choke mud pump control rheostat 90, switches 76 and 77 are closed. When switch 76 is closed, the relay 84 changes state and the normally open relay 84b is closed permitting regulation of the mud pump by the choke console mud pump rheostat 90. Closure of switch 76 results in the application of a voltage to the relay 84 thus changing the state of relays 84a and 84b to override the signal from the driller"s console mud pump rheostat 72 when it is desired to control the mud pump from the remote position of the choke console. Note that the common +V line 80 and ground line 82 lead between the driller"s console and the choke console. If for any reason these lines are severed, control of the mud pump automatically reverts to the driller"s console rheostat 72. Thus, the mud pump 6 or mud pump 6" can be controlled from the driller"s console or through the remote position of the choke console depending upon closure of electrical switch 76.

If you run a mud rig, you have probably figured out that the mud pump is the heart of the rig. Without it, drilling stops. Keeping your pump in good shape is key to productivity. There are some tricks I have learned over the years to keeping a pump running well.

First, you need a baseline to know how well your pump is doing. When it’s freshly rebuilt, it will be at the top efficiency. An easy way to establish this efficiency is to pump through an orifice at a known rate with a known fluid. When I rig up, I hook my water truck to my pump and pump through my mixing hopper at idle. My hopper has a ½-inch nozzle in it, so at idle I see about 80 psi on the pump when it’s fresh. Since I’m pumping clear water at a known rate, I do this on every job.

As time goes on and I drill more hole, and the pump wears, I start seeing a decrease in my initial pressure — 75, then 70, then 65, etc. This tells me I better order parts. Funny thing is, I don’t usually notice it when drilling. After all, I am running it a lot faster, and it’s hard to tell the difference in a few gallons a minute until it really goes south. This method has saved me quite a bit on parts over the years. When the swabs wear they start to leak. This bypass pushes mud around the swab, against the liners, greatly accelerating wear. By changing the swab at the first sign of bypass, I am able to get at least three sets of swabs before I have to change liners. This saves money.

Before I figured this out, I would sometimes have to run swabs to complete failure. (I was just a hand then, so it wasn’t my rig.) When I tore the pump down to put in swabs, lo-and-behold, the liners were cut so badly that they had to be changed too. That is false economy. Clean mud helps too. A desander will pay for itself in pump parts quicker than you think, and make a better hole to boot. Pump rods and packing last longer if they are washed and lubricated. In the oilfield, we use a petroleum-based lube, but that it not a good idea in the water well business. I generally use water and dish soap. Sometimes it tends to foam too much, so I add a few tablets of an over the counter, anti-gas product, like Di-Gel or Gas-Ex, to cut the foaming.

Maintenance on the gear end of your pump is important, too. Maintenance is WAY cheaper than repair. The first, and most important, thing is clean oil. On a duplex pump, there is a packing gland called an oil-stop on the gear end of the rod. This is often overlooked because the pump pumps just as well with a bad oil-stop. But as soon as the fluid end packing starts leaking, it pumps mud and abrasive sand into the gear end. This is a recipe for disaster. Eventually, all gear ends start knocking. The driller should notice this, and start planning. A lot of times, a driller will change the oil and go to a higher viscosity oil, thinking this will help cushion the knock. Wrong. Most smaller duplex pumps are splash lubricated. Thicker oil does not splash as well, and actually starves the bearings of lubrication and accelerates wear. I use 85W90 in my pumps. A thicker 90W140 weight wears them out a lot quicker. You can improve the “climbing” ability of the oil with an additive, like Lucas, if you want. That seems to help.

Outside the pump, but still an important part of the system, is the pop-off, or pressure relief valve. When you plug the bit, or your brother-in-law closes the discharge valve on a running pump, something has to give. Without a good, tested pop-off, the part that fails will be hard to fix, expensive and probably hurt somebody. Pop-off valve are easily overlooked. If you pump cement through your rig pump, it should be a standard part of the cleanup procedure. Remove the shear pin and wash through the valve. In the old days, these valves were made to use a common nail as the shear pin, but now nails come in so many grades that they are no longer a reliable tool. Rated shear pins are available for this. In no case should you ever run an Allen wrench! They are hardened steel and will hurt somebody or destroy your pump.

One last thing that helps pump maintenance is a good pulsation dampener. It should be close to the pump discharge, properly sized and drained after every job. Bet you never thought of that one. If your pump discharge goes straight to the standpipe, when you finish the job your standpipe is still full of fluid. Eventually the pulsation dampener will water-log and become useless. This is hard on the gear end of the pump. Open a valve that drains it at the end of every job. It’ll make your pump run smoother and longer.

One or more valves installed at the wellhead to prevent the escape of pressure either in the annular space between the casing and the drill pipe or in open hole (for example, hole with no drill pipe) during drilling or completion operations. See annular blowout preventer and ram blowout preventer.†

The arrangement of piping and special valves, called chokes, through which drilling mud is circulated when the blowout preventers are closed to control the pressures encountered during a kick.†

A centrifugal device for removing sand from drilling fluid to prevent abrasion of the pumps. It may be operated mechanically or by a fast-moving stream of fluid inside a special cone-shaped vessel, in which case it is sometimes called a hydrocyclone.†

A centrifugal device, similar to a desander, used to remove very fine particles, or silt, from drilling fluid. This keeps the amount of solids in the fluid to the lowest possible level.†

The hoisting mechanism on a drilling rig. It is essentially a large winch that spools off or takes in the drilling line and thus raises or lowers the drill stem and bit.†

The cutting or boring element used in drilling oil and gas wells. Most bits used in rotary drilling are roller-cone bits. The bit consists of the cutting elements and the circulating element. The circulating element permits the passage of drilling fluid and uses the hydraulic force of the fluid stream to improve drilling rates.†

The heavy seamless tubing used to rotate the bit and circulate the drilling fluid. Joints of pipe 30 feet long are coupled together with tool joints.†

A wire rope hoisting line, reeved on sheaves of the crown block and traveling block (in effect a block and tackle). Its primary purpose is to hoist or lower drill pipe or casing from or into a well. Also, a wire rope used to support the drilling tools.†

A series of open tanks, usually made of steel plates, through which the drilling mud is cycled to allow sand and sediments to settle out. Additives are mixed with the mud in the pit, and the fluid is temporarily stored there before being pumped back into the well. Mud pit compartments are also called shaker pits, settling pits, and suction pits, depending on their main purpose.†

A trough or pipe, placed between the surface connections at the well bore and the shale shaker. Drilling mud flows through it upon its return to the surface from the hole.†

A diesel, Liquefied Petroleum Gas (LPG), natural gas, or gasoline engine, along with a mechanical transmission and generator for producing power for the drilling rig. Newer rigs use electric generators to power electric motors on the other parts of the rig.†

A mud pit in which a supply of drilling fluid has been stored. Also, a waste pit, usually an excavated, earthen-walled pit. It may be lined with plastic to prevent soil contamination.†

The hose on a rotary drilling rig that conducts the drilling fluid from the mud pump and standpipe to the swivel and kelly; also called the mud hose or the kelly hose.†

The principal component of a rotary, or rotary machine, used to turn the drill stem and support the drilling assembly. It has a beveled gear arrangement to create the rotational motion and an opening into which bushings are fitted to drive and support the drilling assembly.

A series of trays with sieves or screens that vibrate to remove cuttings from circulating fluid in rotary drilling operations. The size of the openings in the sieve is selected to match the size of the solids in the drilling fluid and the anticipated size of cuttings. Also called a shaker.†

A vertical pipe rising along the side of the derrick or mast. It joins the discharge line leading from the mud pump to the rotary hose and through which mud is pumped going into the hole.†

A rotary tool that is hung from the rotary hook and traveling block to suspend and permit free rotation of the drill stem. It also provides a connection for the rotary hose and a passageway for the flow of drilling fluid into the drill stem.†

Cavitation is an undesirable condition that reduces pump efficiency and leads to excessive wear and damage to pump components. Factors that can contribute to cavitation, such as fluid velocity and pressure, can sometimes be attributed to an inadequate mud system design and/or the diminishing performance of the mud pump’s feed system.

When a mud pump has entered full cavitation, rig crews and field service technicians will see the equipment shaking and hear the pump “knocking,” which typically sounds like marbles and stones being thrown around inside the equipment. However, the process of cavitation starts long before audible signs reveal themselves – hence the name “the silent killer.”

Mild cavitation begins to occur when the mud pump is starved for fluid. While the pump itself may not be making noise, damage is still being done to the internal components of the fluid end. In the early stages, cavitation can damage a pump’s module, piston and valve assembly.

The imperceptible but intense shock waves generated by cavitation travel directly from the fluid end to the pump’s power end, causing premature vibrational damage to the crosshead slides. The vibrations are then passed onto the shaft, bull gear and into the main bearings.

If not corrected, the vibrations caused by cavitation will work their way directly to critical power end components, which will result in the premature failure of the mud pump. A busted mud pump means expensive downtime and repair costs.

To stop cavitation before it starts, install and tune high-speed pressure sensors on the mud suction line set to sound an alarm if the pressure falls below 30 psi.

Although the pump may not be knocking loudly when cavitation first presents, regular inspections by a properly trained field technician may be able to detect moderate vibrations and slight knocking sounds.

Gardner Denver offers Pump University, a mobile classroom that travels to facilities and/or drilling rigs and trains rig crews on best practices for pumping equipment maintenance.

Severe cavitation will drastically decrease module life and will eventually lead to catastrophic pump failure. Along with downtime and repair costs, the failure of the drilling pump can also cause damage to the suction and discharge piping.

When a mud pump has entered full cavitation, rig crews and field service technicians will see the equipment shaking and hear the pump ‘knocking’… However, the process of cavitation starts long before audible signs reveal themselves – hence the name ‘the silent killer.’In 2017, a leading North American drilling contractor was encountering chronic mud system issues on multiple rigs. The contractor engaged in more than 25 premature module washes in one year and suffered a major power-end failure.

Gardner Denver’s engineering team spent time on the contractor’s rigs, observing the pumps during operation and surveying the mud system’s design and configuration.

The engineering team discovered that the suction systems were undersized, feed lines were too small and there was no dampening on the suction side of the pump.

Following the implementation of these recommendations, the contractor saw significant performance improvements from the drilling pumps. Consumables life was extended significantly, and module washes were reduced by nearly 85%.

Although pump age does not affect its susceptibility to cavitation, the age of the rig can. An older rig’s mud systems may not be equipped for the way pumps are run today – at maximum horsepower.

It may be impractical to flush system piping during drilling operations. However, strainer screens should be checked daily to remove any debris or other flow restrictions.

The present disclosure relates to a drilling mud management system and method. The system and method have application in the field of ground drilling where drilling mud is used or required for various purposes including not limited to downhole pressure control, hole stabilisation, lubrication, flushing of drill cuttings and downhole temperature control.

Drilling muds are used extensively in ground drilling particularly for oil and gas exploration. The composition of the drilling mud is critical to particularly, though only, controlling the pressure conditions of the hole. For example, the composition of the drilling mud can be varied to provide an under pressure or overpressure condition as required in the hole; as well as to kill a well.

In order to ensure the correct drilling mud composition it is common for a specialist mud engineer to be on-site 24 hours a day to monitor downhole conditions and ensure the drilling mud composition is as required to achieve a desired effect. Due to the margins involved in oil and gas industry the cost of the specialist mud engineers can be readily absorbed and amortised. However, this is not the case for mineral exploration which may be typically conducted using a land-based mobile drill rig operating in regional/outback areas with two operators. While drilling mud is still critical for efficient mineral exploration drilling the risk of catastrophic events due to lack of control of downhole pressure conditions is substantially lower than for oil and gas exploration. For this and other reasons the cost of having a specialist mud engineer on-site 24 hours a day cannot usually be not justified for mineral

To address the lack of on-site drilling mud expertise it is a regular practice in the mineral exploration industry to provide the ingredients for the drilling mud and mixing instructions to the drill rig operators. There is an expectation that the drill rig operators will follow the instructions to provide a supply of drilling mud to meet predicted ground conditions. However, there is no substantive quality control and no ability to modify the drilling mud composition in the event that downhole conditions are not in line with predictions.

a portable mud measurement system having: one or more measurement devices arranged to measure at least one property and/or characteristic of drilling mud; and a pumping system arranged to pump a batch sample of drilling mud from a supply of drilling mud to the one or more measurement devices and subsequently flush the batch sample of drilling mud from the one or more measurement devices; and a communications system enabling bidirectional communications between the mud management system and a remote location to enable transfer of data therebetween and the exertion of control from the remote location to the mud management system.

In one embodiment the automated drilling mud management comprises a dosing system arranged upon instruction from: the mud measurement system; or the communications system; to automatically dose the drilling mud supply with one or more drilling mud ingredients on a basis of minimising differences between the measured at least one property or characteristic of the mud and a desired

In one embodiment the automated drilling mud management comprises an interface to enable a local operator to enter data relating to a manual additional of one or more ingredients to the drilling mud supply and wherein the communications system is arranged to communicate the entered data to the remote location.

In one embodiment the mud measurement system is arranged to automatically issue a notification at least one property or characteristic of the mud falls outside the desired specification.

In one embodiment the mud management system is arranged to provide feedback control in association with the dosing system and the mud measurement system to perform a test cycle on the mud after operation of the dosing system and cause subsequent operations of the dosing system and the mud management system

In one embodiment the automated drilling mud management comprises a supply of one or more components or ingredients for making drilling mud operatively associated with the dosing system.

In one embodiment the dosing system includes an inventory control system arranged to receive data relating to the supply of the one or more components or ingredients to facilitate ordering of additional components or ingredients.

In one embodiment the automated drilling mud management comprises a supply of a flushing fluid for delivery by the pumping system to the one or more measurement devices.

In one embodiment the pumping system is arranged to circulate mud from an external mud supply through a hose and back to the mud supply through a return pipe prior to delivering a batch sample of mud to the one or more measurement devices.

In one embodiment the pumping system is arranged to maintain a volume of the flushing fluid in contact with the one or more measurement devices after a

In one embodiment the pumping comprises a mud pump and a separate flushing fluid pump; wherein the pumping system is arranged to: run the flushing fluid pump to introduce a flushing fluid into the one or more measurement devices; and subsequently operate the mud pump to empty the flushing fluid from the one or more measurement devices.

In one embodiment the mud pump is reversible to enable the mud pump to pump the mud sample or the flushing fluid from the one or more measurement devices to the mud supply.

In one embodiment the pumping system comprises valve connected between the mud pump, the return pipe and the one or more measurement devices, the valve having: a recycling state where the valve directs mud from the pump to flow only to the return pipe; and a flow-through state where the valve allows mud to flow from the pump to the at least one more measurement devices and blocks flow of mud to the return pipe.

In one embodiment the automated drilling mud management comprises a single reversible pump having first and second ports and a first three-way valve connected

between the first port, the supply of drilling mud and the one or more measurement devices; and a second three-way valve connected between the second port of the pump, the supply of drilling mud and the supply of flushing fluid. In one embodiment the automated drilling mud management comprises a filtrate measurement system arranged to measure fluid loss of the drilling mud;

In one embodiment the mobile unit further carries one or more of: the dosing system; the supply of one or more components or ingredients for making drilling mud; the supply of flushing fluid; and the filtrate system. In a second aspect there is disclosed a drilling mud management system comprising: a portable housing;

one or more measurement devices are arranged to measure at least one property or characteristic of drilling mud, the one or more measurement devices being located within the housing;

a pumping system located within the housing and arranged to pump a sample of mud to the one or more measurement devices and subsequent pump the sample from the housing.

one or more measurement devices that are arranged to measure at least one property or characteristic of drilling mud, the one or more measurement devices being located within the housing; and

a pumping system located within the housing and arranged to pump a sample of mud to the one or more measurement devices and subsequent pump the sample from the housing the pumping system having a mud pump and a separate flushing fluid pump;

wherein the pumping system is arranged to: run the flushing fluid pump to introduce a flushing fluid into the housing and the one or more measurement devices; and subsequently operate the mud pump to empty the flushing fluid from the one or more measurement devices.

one or more measurement devices arranged to measure at least one property and/or characteristic of drilling mud wherein one of the properties measured is viscosity; and

a pumping system located within the housing and arranged to pump a sample of mud to the one or more measurement devices and subsequent pump the sample from the housing, the pumping system arranged to pump a sample volume of drilling mud no more than 1 L to the one or more measurement devices.

a pumping system located within the housing, the pumping system arranged to pump a sample of drilling mud to the one or more measurement devices and subsequently flush the sample of drilling mud from the housing. In some embodiments of some the above aspects the pumping system is arranged to maintain a volume of the flushing fluid in contact with the one or more

In some embodiments of some the above aspects the mud pump is arranged to pump the sample of mud from an external mud supply through a hose to enable all of the properties and/or characteristics to be measured. In embodiments of the above aspects the mud pump is reversible to enable the mud pump to pump the mud sample from the housing to the mud supply.

In one embodiment of the above aspects the pumping system comprises a return pipe capable of receiving mud from the mud pump pumped in a forward direction to enable a recirculating flow of mud from the supply through the hose and mud pump and back to the supply. In this embodiment the pumping system comprises valve connected between the mud pump, the return pipe and the one or more

measurement devices, the valve having: a recycling state where the valve directs mud from the pump to flow only to the return pipe; and a flow-through state where the valve allows mud to flow from the pump to the at least one more measurement devices and blocks flow of mud to the return pipe. Also, in this embodiment the flush fluid pump may be arranged to introduce flushing fluid into the housing at a location downstream of where the return pipe receives mud from the mud pump operated in the forward direction, and upstream of the one or more measurement devices.

In one embodiment of the above aspects the pumping system may be arranged to operate in a flushing cycle in which the flushing fluid pump pumps flushing fluid into the housing and the drilling mud pump is operated in a reverse direction wherein the

In some embodiments the drilling mud measurement system comprises a mud density measurement system having at least two fluid pressure transducers the pressure transducers arranged to be suspended at a known vertical separation from each other in a volume of the drilling mud.

In one embodiment the drilling mud measurement system comprises a float arranged to suspend the at least two fluid pressure transducers above a bottom of a container or other receptacle or reservoir holding the volume of drilling mud.

In one embodiment the drilling mud measurement system is arranged to provide real time or near real-time information from the one or more measurement devices to an in-situ user of the drilling mud management system.

In one embodiment the drilling mud measurement system comprises an electronic data collection system arranged to automatically collect measurement data from the one or more measurement devices.

In one embodiment the drilling mud measurement system is arranged to make an in situ comparison between the measurement data and reference data relating to properties and/or characteristics of the drilling mud and provide, to a user of the drilling mud measurement system, information indicative of (a) the properties and/or characteristics of the drilling mud; and/or (b) one or more differences between the measurement data and reference data.

In one embodiment the drilling mud measurement system comprises one or both of (a) an internal memory device capable of storing the reference data; and (b) a provision for receiving the reference data from an external source.

In one embodiment the drilling mud measurement system comprises a data communication system arranged to electronically transmit the measurement data to a remote location.

In one embodiment the drilling mud measurement system is arranged for operable association with a dosing system wherein the dosing system is arranged upon instruction from the drilling measurement system to dose the drilling mud supply with one or more drilling mud ingredients on a basis of minimising differences between the measurement data and the reference data.

In one embodiment the drilling mud measurement system comprises an audit system arranged to automatically issue a notification when a quantity of a drilling mud ingredient in a supply of one or more drilling mud ingredients falls below a threshold level.

In one embodiment the drilling mud measurement system comprises a filtrate measurement system arranged to measure loss of a fluid component of the drilling mud.

In one embodiment the drilling mud measurement system comprises a dosing system arranged upon instruction from the drilling measurement system to dose a drilling mud supply with one or more drilling mud ingredients on a basis of minimising

In one embodiment the drilling mud measurement system comprises an electronic controller enabled to automatically control the one or more measurement devices and the pumping system.

In one embodiment the drilling mud measurement system comprises one or both of a local user interface and remote user interface for inputting instructions for execution by the controller to automatically control the one or more measurement devices and the pumping system

In one embodiment the drilling mud measurement system comprises a power module arranged to connect with and provide power to one or more of the: one or more measurement devices; the pumping system; the filtrate measurement system; and the dosing system.

Figure 1 is a schematic representation of an embodiment of the disclosed drilling mud management system and which may be used to perform the disclosed method;

Figure 2A is a schematic representation of a drill mud measurement system which may constitute or form part of a first embodiment of the drilling mud management system shown in Figure 1 ;

Figure 2B is a schematic representation of a drill mud measurement system which may constitute or form part of a second embodiment of the drilling mud management system shown in Figure 1 ;

Figure 2C is a schematic representation of a drill mud measurement system which may constitute or form part of a third embodiment of the disclosed drilling mud management system shown in Figure 1 ;

Figure 4 schematic representation of a filtrate management system which may be incorporated in either the drilling mud management system shown in Figure 1 or the drill mud measurement system shown in either Figure 2A or Figure 2B.

Figure 1 is a schematic layout of an embodiment of the disclosed drilling mud management system 1 (hereinafter referred to as the "system 1 "). The system 1 includes at least a mud measurement system 10 which is arranged to measure at least one property and/or characteristic of the drilling mud (also known as "drilling fluid"). Additional subsystems or modules of the system 1 include: a filtrate measurement system 70; a mud dosing and mixing system 1 10; a communications module 120; a power module 130; and a portable "smart" device 140. Each of the modules and subsystems 10, 70, 1 10, 120, 130 and 140 is a stand-alone item with plug and play connectivity to provide corresponding functionality to the system 1 . The hub 150 shown in Figure 1 is not a part of the system 1 , but rather is a remote data collection and storage facility with which the system, 1 is able to

As explained in the following description the system 1 provides a portable and in substance complete and automated mud management system for drilling without the need for an on-site mud engineer. The management provided by the system 1 includes measurement and diagnostics of the mud, the ability to automatically vary the mud composition, conduct audits of mud characteristics compared with ratios of components used in mixing the mud, and just-in-time ordering and delivery of mud components to site. The mud management system 1 is automated to the extent that once it has been set up it is able to function automatically to perform a measurement of the characteristics of the mud, the filtrate, and operator otherwise control the mud dosing and mixing system 1 10. The system can be activated to perform its automates functions either locally by for example a drill operator, or remotely using the communications system.

Figure 2A shows a schematic representation of mud measurement system 10 (hereinafter referred to in general as "system 10") which includes a housing 12 (illustrated in Figure 3) that houses measurement devices 14a-14f (hereinafter referred to in general as "measurement devices 14") and a pumping system 16. The measurement devices 14 are arranged to measure at least one property or characteristic of drilling mud. The pumping system 16 is arranged to pump a batch

sample of mud to one or more of the measurement devices 14 and to subsequently pump the mud sample from the one or more of the measurement devices 14 and housing 12. By conducting batch sampling, a static sample of mud is presented to the measurement devices 14. The system 10 is a low-pressure system, with the only pressure applied to the sample when being delivered to the measuring devices being the that provided by the pumping system which utilities one or more low pressure positive displacement pumps.

As the pumping system 16 is within the housing it relies on applying a suction or relative negative pressure to draw mud and other fluids into the housing 12 and the measurement devices 14. As also explained below the pumping system 16 is operable in a reverse direction to pump out or otherwise flush fluids from the housing 12.

The pumping system 16 includes a drilling mud pump 16a and a flushing fluid pump 16b. The pumps 16a and 16b are separately controlled. In this embodiment the pumpsl 6a and 16b are positive displacement pumps such as, but not limited to, peristaltic pumps. Peristaltic pumps are inherently low-pressure pumps. The pumping system 16a is connected to an external supply 18 of drilling fluid via a hose 20. The hose 20 is connected to one port 22 of the drilling mud pump 16a. A second port 24 of the drilling mud pump 16a is connected by a conduit 26a to a manifold 28. The manifold 28 is connected by a conduit 26b to a cup 30. A conduit 26c connects a port 32 of the flushing fluid pump 16b to the conduit 26a. A second port 34 of the flushing fluid pump 16b is in fluid communication via a hose 36 with a supply 38 of freshwater or other flushing fluid.

The system 10 also includes an electronic controller 40 located within the housing 12. Conveniently the controller 40 may be in the form of a programmable logic controller. A user interface (not shown) including for example a display and one or more buttons (touch screen or physical) is provided to enable a user to operate the controller 40 and thus the system 10. A local communications network represented by dashed lines 41 provides a communication and control path for the controller 40 to other components of the system 10. The local network may comprise wires, optical cables, wireless devices, or any combination thereof.

The controller 40 is connected to the measurement devices 14 via the corresponding converters 15 and the pumping system 16. Additionally, the controller 40 is

connected to fluid level system that is used to provide information relating to the level of fluid within the cup 30; and, a mud density measurement system 44.

The fluid level system in this embodiment is in the form of a flowmeter 14m which is downstream of the pumping system 16 and upstream of the cup 30 with reference to a direction of flow of mud from the supply 18 or 38 to the cup 30. In this embodiment

the flowmeter 30 is between the pumping system 16 and the manifold 28. The flowmeter 14m measures the flow of liquid into and out from the cup 30. This measurement is used by the controller 40 to determine the level of liquid in the cup 30.

The mud density measurement system 44 comprises at least two hydrostatic pressure transducers 46 and 48 (hereinafter "transducers 46 and 48"). The mud density measurement system 44 may be held within a storage compartment of the housing 12. However, when the system 10 is in use measuring characteristics or properties of the drilling fluid/mud the mud density, the measurement system 44 is removed from the housing 12 and placed into the external supply 18 of drilling fluid. The transducers 46 and 48 are held or otherwise suspended at different respective heights or depths within the external supply 18 of drilling fluid/mud. In one example the transducers 46 and 48 may be submerged in the supply 18 in the range of 200mm to 2000mm. Any vertical separation or offset between the transducers 46 and 48, which will provide a basis for calculating mud weight. Nevertheless, accuracy of the mud weight calculation may be enhanced by maximising the vertical separation. In one example this separation may be a minimum of 100mm.

Due to the difference in respective depths within the external supply 18 the transducers 46 and 48 are subjected to different fluid pressures. This difference in pressure is directly dependent upon the respective volumes of drilling fluid bearing on the transducers 46 and 48. Given that the difference in level between the sensors 46 and 48 is known or can be set by an operator, and the configuration of a container or other receptacle forming the supply 18 is known, the controller 40 can be programmed to automatically calculate the density of the drilling fluid using the differences in fluid pressure sensed by the sensors 46 and 48.

The mud density measurement system 44 can be placed at any depth or location within the external supply 18. Accordingly, embodiments of the present system 10 enable the mud density measurement system 44 to be spaced above the bottom of the external supply 18. This can be achieved for example by using a float which is attached to both of the sensors 46 and 48. By suspending the measurement system 44 above a bottom of the external supply 18 it is possible to minimise measurement

The system 10 in the housing 12 is transported to a drilling location where drilling mud is to be used. It is envisaged that the housing 12 may be of the general size and figuration of a piece of luggage suitable for carrying as checked in luggage on a commercial aircraft. To this end the housing 12 can be provided with a retractable handle and wheels (neither being shown). Alternately the mud management system 1 incorporating: the mud measurement system 10, inclusive of its housing 12; and one or more of the filtrate measurement system 70; mud dosing and mixing system 1 10; communications module 120; and power module 130; is transported to the drilling location, for example in a trailer or on a powered vehicle.

Once on-site the mud density measurement system 44 is taken out of the housing 12 and placed within the external supply 18 ensuring that the transducers 46 and 48 are free to be suspended at a known vertical/depth offset from each other. The external supply may for example be inside of a hole being drilled in the ground. A free end of the hose to 20 (i.e. the end not coupled to the port 22) is placed in the external supply 18. Likewise, a free end of the hose 36 (i.e. the end not coupled to the port 34) is placed in the freshwater supply 38. The mud management system 1 and/or the mud measurement system 10 can be activated locally by the drill rig operator and then function automatically, or remotely using the communications system 120 by a mud engineer or other officer; or a combination of both where for example a mud engineer may sent instructions for communication system 120 to the drill rig operator to perform various functions.

The controller 40 may be ideally, but not necessarily, provided with a set of reference parameters pertaining to the drilling mud. These parameters for example may be desired characteristics of the drilling mud to be used in a particular drilling

The controller 40 is switched to a measurement cycle mode. This mode executes two cycles, a fill cycle in which the cup 30 and manifold 28 are filled with drilling fluid, and a data cycle where the sensors 14a-14f are activated to provide measured data relating to the drilling fluid. In the fill cycle of this mode the controller 40 operates the drilling fluid pump 16a to draw drilling fluid into the housing 12. Thus, the port 22 acts

as an inlet port and the port 24 acts as an outlet port. The drilling mud is passed by the conduit 26a, through the flowmeter 14m to the manifold 28 and by the conduit 26b to the cup 30. This transfer of drilling fluid continues until the controller 40 using measurements from the flowmeter 14m senses that the drilling fluid within the cup 30 has reached a prescribed level. It is envisaged that the total volume of drilling fluid/mud pump into the housing 12 to facilitate measurement of the desired characteristics and properties will be in the order of between 0.3 L to 1 L. In one example of the volume required to carry out all of the tests and measurements may be in the order of 0.7 L.

The controller 40 now ceases the fill cycle by stopping the pump 16a and the data cycle starts where the controller 40 operates or otherwise polls the sensor 14 for data relating to specific characteristics or properties of the drilling fluid. In this particular embodiment the controller 40 will operate the viscometer 14a to conduct the measurements and tests described above, and subsequently received

From a display on the controller 40 a drill rig operator can view the characteristics or properties of the drilling fluid and compare them to the prescribed or desired characteristics. The prescribed or desired characteristics may be provided to the driller in a variety of different ways. For example, by way of a written document in a mud preparation/handling manual. Alternately these characteristics may be provided in an electronic memory of the controller 40 (e.g. pre-programmed in the controller 40); a portable memory device connectable to or otherwise able to communicate with the controller 40; or by download into an electronic memory of the controller 40 from a remote location via a remote user interface.

Irrespective of how the prescribed mud characteristics are conveyed to the operator, the operator is informed by the controller 40 of the measured mud characteristics. From here either (a) the operator can determine the differences if any between the measured and prescribed characteristics of the drilling mud, or (b) the controller 40 can determine and inform the operator of the differences if any between the measured and prescribed characteristics of the drilling mud. Once the differences are known, the operator (or, as described later, the system 1 10 if in use in the system 1 ) is able to take corrective action to vary the composition of the drilling mud to minimise or reduced to zero these differences.

Once the measurement cycle has been completed the controller 40 can be switched to a flushing cycle mode. In this mode the controller 40 controls the drilling fluid pump 16a to operate in a reverse direction so as to pump the drilling fluid out of the housing 10. Therefore, in the flushing cycle the port 24 is an inlet port and the port 22 is an outlet port. After the pump 16a has pumped out the drilling mud; or simultaneously with the pump 16a being operated to pump out the drilling mud; the controller 40 operates the flushing fluid pump 16b to pump freshwater into the

housing 12. The flushing fluid is a liquid such as but not limited to water. Specifically, the pump 16b pumps water from the external supply 38 via the hose 36 and through conduits 26c and conduit 26a filling the manifold 28 and the cup 30 until the controller 40, using measurements from the flowmeter 14m determines that cup 30 is full. The controller then stops the pump 16b and activates the viscometer 14a to spin at 600rpm for a period of time. After this time period the viscometer 14a is stopped by controller 40 and subsequently the pump 16a is run in reverse. Port 24 is now a suction port and port 22 is a delivery or discharge port. The fluid in the cup 30 and manifold 28 is emptied via conduit 20 into external supply 18. This cleaning/flushing cycle may be repeated a number of times, such as but not limited to 2-4 times. After the last of the repeated cleaning cycles the pump 16b fills manifold 28 and cup 30 and stops. This is done so that the probes 14b-14f remain in a fluid whilst not being operated. The system 10 remains in this state up until a new measurement cycle starts. A new measurement cycle is started by running pump 16a in reverse to empty cup 30 and manifold 28 into external supply 18 via conduit 20.

The purpose of the return pipe 45 and three-way valve 43 is to modify the above described filling cycle to include a priming cycle in which drilling fluid is recirculated through the hose 20, valve 43 pipe 45 act to the supply 18. This minimises the risk of the drilling fluid being diluted prior to flowing into the cup 30 and manifold 28 due to the presence of water in the hose 20 remaining from a previous cleaning/flushing cycle. The recirculation is achieved by opening ports P1 and P2; and closing P3 on the valve 43, placing the valve in a recycling state; while running the pump 16a in the forward direction.

The duration of the priming cycle is dependent on the flow rate (i.e. the viscosity) of the drilling fluid and the length of the pipe 20. After this period of time the controller 40 closes the port P2 and opens the port P3 (the port P1 remaining open) allowing the drilling fluid to now flow through the flowmeter 14m, manifold 28 and into the cup 30. Here the valve 43 is in a flow through state. The controller 40 turns off the pump

The controller 40 can now perform a measurement cycle taking readings from the viscometer 14a, and other senses 14b - 14f. If desired, a second or indeed further measurement cycles can be performed without an intervening cleaning cycle. In this way multiple samples measurements can be made and averaged to minimise distortion of readings. To take multiple sample measurements, the controller 40 can be programmed to, after each measurement cycle, reverse the direction of the pump 16a to pump fluid from the cup 30 and delivered back to the supply 18. The pump is stopped, and the above cycle is restarted with the port P2 being opened, port P3 being closed and the pump 16a operated in the forward direction to recirculate the fluid through the pipe 45 back to the supply 18 for a predetermined period of time, after which the port P2 is closed and the port P3 opened to again fill the cup 30. Now the second or any subsequent sample measurement can be taken and averaged with a measurement of the previous sample in the same sample set.

After the sample measurements(s) have been taken the controller is switched to a flushing cycle mode which operates to empty the drilling fluid from the housing and subsequently clean the cup 30 and senses 14a-14f. While this is the same function as the flushing cycle mode described in relation to the first embodiment the specific method of operation is different. The steps are as follows:

a) the pump 16a is operated in a reverse direction with the ports P1 and P3 open and port P2 closed so that fluid in the cup 30 and manifold 28 is drained back into the supply 18, and the pump 16a is stopped (this is in substance the same as in the first embodiment);

d) after that period of time the pump 16b is stopped, the ports P1 and P3 on the valve 43 are opened, the port P2 is closed, and the pump 16a is run in the reverse direction to drain the cleaning fluid from the cup 30 and manifold 28. Thus, the mud pump 16a is also flushed in this step.

The above steps a) through to d) may be repeated one or more times to enhance the degree of cleaning. Irrespective of how many times the steps a) through to d) are cycled, as a final step the port P3 can be closed and the pump 1 6b run to fill the manifold 28 and cup 30 with clean water or other flushing fluid so that the sensors 14a-14f remain wet prior to the next measurement cycle.

The substantive difference between the second embodiment shown in Figure 2B and the third embodiment shown in Figure 2C is the replacement of the flushi