Term 252

CLAYDYN: Closed-Loop Drilling Mud Property Control and Mixing System

Project Type: Self-Initiated

Project Description

CLAYDYN is a low-cost, lab-safe drilling-fluid control skid that stabilizes key mud properties—density (ρ), plastic viscosity (PV), and yield point (YP)— using real-time sensing and automated additive dosing. The system targets ρ = 1.20 ± 0.01 g/mL, PV = 20 ± 2 cP, and YP = 20 ± 2 lb/100 ft2, and is designed to recover to these bands within ≤ 5 minutes (with ≥ 60 s stability hold) after realistic disturbances including 10% water dilution, 3 wt% NaCl contamination, and 2 wt% drill cuttings. A 6-L baffled acrylic mixing tank, driven by a variable-speed geared motor, provides controlled agitation while peristaltic pumps (20–60 mL/min, ±10% dosing accuracy) inject polymer solution and CaCO3 slurry as control actions along with impeller speed. Rheology is estimated without a full rheometer by correlating motor torque/current at 600/300 rpm to a Fann equivalent PV/YP, while density is measured via either hydrostatic pressure sensing or a tank load-cell option; all signals and dosing volumes are logged at ≥ 1 Hz. The project integrates chemical formulation (safe, water-based additives with SDS compliance), mechanical design and fabrication, embedded control and optimization, and petroleum-engineering validation against drilling-fluid practice. The expected outcome is a repeatable teaching and research platform that demonstrates closed-loop control, disturbance rejection, and data-driven recipe development within a defined budget and semester schedule.