How REALologyDR Helped Reduce NPT Through Early Anomaly Detection in Southwest China

Background and Challenge

In drilling operations, adding gel additives is a routine method for adjusting drilling fluid properties. However, many traditional operations still rely on scheduled manual sampling and experience-based judgment. This approach is labor-intensive and time-consuming, unable to detect dosage deviations in real time, leaving drilling fluid properties vulnerable to sudden instability.

Figure 1. Traditional manual drilling fluid sampling conducted during drilling operations.

During the drilling operation of a well in Southwest China (Sichuan-Chongqing region, Changxing Formation, at a depth interval of 4856 m), Vertechs REALology Intelligent Drilling Fluids Monitoring System (REALologyDR) detected a sudden anomaly and immediately triggered an alarm, showing a sharp decline in key parameters. 

Figure 2. Key drilling fluid parameter variations identified by the REALology Intelligent Drilling Fluids Monitoring System.

Without continuous online monitoring, this abnormality would likely have occurred between routine manual sampling intervals, delaying corrective action and increasing the risk of well-control incidents such as kicks or lost circulation.

Technical Mechanism

On-site investigation confirmed that the anomaly was caused by an excessive injection rate of a pre-mixed drilling fluid gel solution (water + 0.5% LV-PAC + 2% SMP-2 + 2% SMC). Because the gel solution was water-based, excessive injection temporarily diluted the inlet drilling fluid before full mixing, resulting in a measurable decrease in both density and apparent viscosity. REALologyDR detected this transient abnormality in real time.

Figure 3. REALologyDR supporting real-time drilling fluid monitoring in the field.

Under conventional intermittent sampling, such an anomaly would be difficult to catch in time, significantly increasing well-control risks such as kicks and lost circulation.

On-Site Response

Acting on the early alert, field engineers immediately verified the anomaly against engineering parameters and mud logging data. The gel injection rate was promptly adjusted before drilling fluid properties deteriorated further, avoiding potential well-control risks and allowing drilling to continue safely.

Figure 4. REALologyDR issuing an anomaly warning during drilling operations.

Results and Value

This deployment highlights the value of intelligent real-time monitoring:

· Early warning and proactive control: shifts drilling fluid management from reactive correction to preventive action, enabling real-time detection and faster response to drilling fluid anomalies while helping reduce well-control risks such as kicks

· Lower NPT: in a neighboring well within the same block, a similar overflow event resulted in approximately 38 hours of NPT. In this deployment, REALologyDR enabled earlier anomaly detection and timely intervention before the condition escalated, helping avoid comparable non-productive time and associated well-control costs.

· Reduced reliance on manual sampling and testing: decreases dependence on intermittent manual sampling and experience-based judgment

· Data-driven decision-making: provides continuous automated records and trend analysis to support more reliable engineering adjustments

Proven Performance

To date, REALologyDR has been successfully deployed in more than 130 wells across a wide range of operating environments. By providing continuous, high-frequency drilling fluid monitoring and early anomaly detection, the system helps operators improve drilling safety, reduce operational risk, and support more efficient, data-driven drilling operations.