Level sensors for fluid systems

Abstract

A fluid system includes a fluid container, a level sensor configured to generate a level signal indicative of a fluid level in the fluid container, and a controller configured to set a signal threshold for the level signal based on one or more parameters of a fluid provided to the fluid container.

Description

LEVEL SENSORS FOR FLUID SYSTEMSCROSS REFERENCE PARAGRAPH

[0001] This application claims the benefit of U.S. Provisional Application No. 63 / 665,941 , entitled "LEVEL SENSORS FOR FLUID SYSTEMS," filed June 28, 2024, the disclosure of which is hereby incorporated herein by reference.BACKGROUND

[0002] This section is intended to introduce the reader to various aspects of art that may be related to various aspects of the present disclosure, which are described and / or claimed below. This discussion is believed to be helpful in providing the reader with background information to facilitate a better understanding of the various aspects of the present disclosure. Accordingly, it should be understood that these statements are to be read in this light, and not as admissions of prior art.

[0003] Natural resources, such as oil and gas, are used as fuel to power vehicles, heat homes, and generate electricity, in addition to various other uses. Once a desired resource is discovered below a surface of the earth, drilling systems are often employed to carry out drilling operations to access the desired resource. During the drilling operations, drilling fluid is pumped through a drill string into a wellbore to facilitate drilling a well. The drilling fluid then flows through an annular space defined between the drill string and the wellbore to return to surface equipment. Various types of sensors may be utilized within the drilling systems.SUMMARY

[0004] A summary of certain embodiments disclosed herein is set forth below. It should be understood that these aspects are presented merely to provide the reader with a brief summary of these certain embodiments and that these aspects are not intended to limit the scope of this disclosure. Indeed, this disclosure may encompass a variety of aspects that may not be set forth below.

[0005] In certain embodiments, a fluid system includes a fluid container, a level sensor configured to generate a level signal indicative of a fluid level in the fluid container, and a controller configured to set a signal threshold for the level signal based on one or more parameters of a fluid provided to the fluid container.

[0006] In certain embodiments, a method of operating a fluid system includes receiving, at a controller and from one or more parameter sensors, one or more parameters of a fluid. The method also includes adjusting, using the controller and based on the one or more parameters of the fluid, a signal threshold for a level sensor associated with a fluid container to generate a fluid-specific signal threshold for the fluid. The method also includes receiving, at the controller and from the level sensor, a level signal indicative of a fluid level of the fluid in the fluid container as the fluid flows into the fluid container. The method also includes comparing, using the controller, the level signal to the fluid-specific signal threshold for the fluid as the fluid flows into the fluid container. The method also includes controlling, using the controller, a pump to stop flow of the fluid into the fluid container in response to the level signal meeting or exceeding the fluid-specific signal threshold for the fluid.

[0007] In certain embodiments, a fluid system includes a fluid container with an opening that provides an automatic level for a fluid in the fluid container. The fluid system also includes a level sensor configured to generate a level signal indicative of a fluid level of the fluid in the fluid container. The fluid system also includes a controller configured to set a fluid-specific signal threshold for the level signal based on one or more parameters of the fluid and control a pump to stop flow of the fluid to the fluid container in response to the level signal exceeding the fluidspecific signal threshold.BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Various features, aspects, and advantages of the present disclosure will become better understood when the following detailed description is read with reference to the accompanying figures in which like characters represent like parts throughout the figures, wherein:

[0009] FIG. 1 is a schematic diagram of a fluid system, in accordance with an embodiment of the present disclosure;

[0010] FIG. 2 is a side view of a fluid chamber and sensors that may be utilized in the fluid system of FIG. 1 , as well as an example of a first graph with a first signal threshold, in accordance with an embodiment of the present disclosure;

[0011] FIG. 3 is a side view of the fluid chamber and the sensors that may be utilized in the fluid system of FIG. 1 , as well as an example of a second graph with a second signal threshold, in accordance with an embodiment of the present disclosure;

[0012] FIG. 4 is an example of a graph with multiple signal thresholds, in accordance with an embodiment of the present disclosure;

[0013] FIG. 5 is a schematic diagram of a cleaning process that may be implemented for the fluid system of FIG. 1 , in accordance with an embodiment of the present disclosure;

[0014] FIGS. 6 is example graphs that illustrate the cleaning process that may be implemented for the fluid system of FIG.1 , in accordance with an embodiment of the present disclosure;

[0015] FIG. 7 is a front view of a fluid testing system, which may include features of the fluid system of FIG. 1 , in accordance with an embodiment of the present disclosure; and

[0016] FIG. 8 is a perspective rear view and a corresponding schematic diagram of passageways formed in a fluid container of the fluid testing system of FIG. 7, in accordance with an embodiment of the present disclosure.DETAILED DESCRIPTION OF SPECIFIC EMBODIMENTS

[0017] One or more specific embodiments of the present disclosure will be described below. These described embodiments are only exemplary of the present disclosure. Additionally, in an effort to provide a concise description of these exemplary embodiments, all features of an actual implementation may not bedescribed in the specification. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developers’ specific goals, such as compliance with system -related and business-related constraints, which may vary from one implementation to another. Moreover, it should be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure.

[0018] When introducing elements of various embodiments of the present disclosure, the articles “a,” “an,” “the,” and “said” are intended to mean that there are one or more of the elements. The terms “comprising,” “including,” “having,” and “based on” are intended to be inclusive and mean that there may be additional elements other than the listed elements.

[0019] Fluid systems are employed in various contexts and environments. For example, fluid systems are employed in various industrial environments, manufacturing environments, laboratory environments, research environments, and so forth. As one specific example, fluid systems are employed during drilling and / or production operations. Indeed, in drilling operations, drilling fluid is pumped through a drill string into a wellbore to facilitate drilling a well. The drilling fluid then flows through an annular space defined between the drill string and the wellbore to return to surface equipment located at a surface. Further, during the drilling operations, a fluid testing system may monitor certain properties of the drilling fluid. For example, during the drilling operations, the fluid testing system may be operated to periodically monitor rheological properties of the drilling fluid.

[0020] It is presently recognized that it is desirable to utilize various types of sensors in fluid systems, such as to detect fluid parameters, test fluid properties, monitor fluid levels, and so forth. It is also presently recognized that it may be desirable to utilize non-contact sensors to monitor fluid levels (e.g., for accurate measurements, block residue buildup on the sensors, additional placement or location options). However, it is also presently recognized that the non-contactsensors, such as capacitance sensors, may benefit from use with an adjustable signal threshold. Accordingly, the present disclosure relates generally to fluid systems, such as fluid testing systems, that utilize non-contact sensors to monitor fluid levels in a fluid container, and further that implement an adjustable signal threshold (e.g., multiple signal thresholds; multiple fluid-specific thresholds; different from one another) based on one or more fluid parameters (e.g., water content, electrical conductivity, time to fill a volume between two level sensors). For example, the fluid system may detect the one or more fluid parameters and then automatically and dynamically adjust the adjustable signal threshold based on the one or more fluid parameters. The present disclosure also relates generally to techniques that facilitate cleaning the fluid system.

[0021] FIG. 1 is a schematic diagram of a fluid system 10, in accordance with an embodiment of the present disclosure. As shown, the fluid system 10 includes a container assembly 12 (e.g., testing assembly) that includes a fluid container 14, a level sensor(s) 16, and a fluid parameter sensor(s) 18. The fluid system 10 also includes or is coupled to multiple fluid sources, such as a first fluid source 20, a second fluid source 22, a first cleaning fluid source 24, a second cleaning fluid source 26. The fluid system 10 also include or is coupled to at least one outlet 28 (e.g., drain). Each of the multiple fluid sources 20, 22, 24, 26, and the at least one outlet 28 may be coupled to the container assembly 12 via a respective valve and one or more pumps, as shown.

[0022] While the fluid parameter sensor(s) 18 are shown as being part of container assembly 12, it should be appreciated that the fluid parameter sensor(s) 18 may be at any suitable location upstream of the fluid container 14 (e.g., any suitable location along a pathway 32 that extends between the fluid container 14 and one or more of the multiple fluid sources 20, 22, 24, 26; along an inlet to the fluid container 14 inside of a housing of the container assembly 12; along a conduit outside of the housing of the container assembly 12, and between the fluid container 14 and the multiple fluid sources 20, 22, 24, 26; in the multiple fluid sources 20, 22, 24, 26). As described herein, the fluid system 10 may be a fluid testing system. In such cases, the fluid system 10 may include a fluid testingsensor(s) 30, such as a rheology testing sensor(s) to test rheological properties of the fluid within the fluid container 14. Accordingly, the fluid parameter sensor(s) 18 herein generally relate to sensor(s) that detect one or more fluid parameters (e.g., water content, electrical conductivity, time difference between two signal levels) upstream of the fluid container 14, such as for purposes of automatically and dynamically adjusting an adjustable signal threshold (e.g., multiple signals thresholds). For example, based on the one or more fluid parameters, the fluid system 10 may adjust the adjustable signal threshold to facilitate proper fluid levels within the fluid container 14. The fluid parameter sensor(s) 18 may include an oil / water ratio meter (e.g., to detect water content) and / or an electrical stability meter (e.g., to detect electrical conductivity), for example. Additionally or alternatively, the fluid parameter sensor(s) 18 may include or be implemented as the level sensor(s) 16, as described herein. However, the fluid testing sensor(s) 30 herein generally relate to sensor(s) that test fluid properties of the fluid within the fluid container 14 (e.g., the fluid at a desired level within the fluid container 14).

[0023] FIG. 2 is a side view of an embodiment of the fluid container 14, as well as one level sensor 16 and the fluid parameter sensor(s) 18 that may be utilized in the fluid system 10 of FIG. 1. FIG. 2 also includes an example of a first graph 40 with a first signal threshold 42, in accordance with an embodiment of the present disclosure. The first graph 40 includes a signal level 44 along a y-axis, and a proximity 46 along an x-axis. As shown in the first graph 40, the signal level 44 of a first signal 48 generated by the level sensor 16 increases as the proximity 46 between the level sensor 16 and a first fluid 50 in the fluid container 14 decreases (e.g., the first fluid 50 fills the fluid container 14). The first signal threshold 42 may correspond to a defined level 52 (e.g., desired level; high-high level) of the first fluid 50 in the fluid container 14. In operation, when the signal level 44 of the first signal 48 reaches the first signal threshold 42, this indicates that the first fluid 50 is at a target proximity 54 (e.g., distance) from the level sensor 16, which in turn indicates that the first fluid 50 is at the defined level 52. The defined level 52 may provide a “high-high” alarm signal, block overflow of the fluid container 14, facilitateaccurate testing via the fluid testing sensor(s) 30 of FIG. 1 , and / or other advantages.

[0024] However, it is presently recognized that the fluid system 10 may utilize different fluids with different properties, and further that the different fluids with the different properties may affect signals generated by the level sensor 16 (e.g., at the defined level 52, the different fluids result in different signal levels 44). Accordingly, the first signal threshold 42 of FIG. 2 may be determined for the first fluid 50 based on the one or more fluid parameters (e.g., water content, electrical conductivity) detected by the fluid parameter sensor(s) 18.

[0025] FIG. 3 is a side view of an embodiment of the fluid container 14, as well as the level sensor 16 and the fluid parameter sensor(s) 18 that may be utilized in the fluid system 10 of FIG. 1. FIG. 3 also includes an example of a second graph 60 with a second signal threshold 62, in accordance with an embodiment of the present disclosure. The second graph 60 includes the signal level 44 along the y- axis, and the proximity 46 along the x-axis. As shown in the second graph 60 the signal level 44 of a second signal 58 generated by the level sensor 16 increases as the proximity 46 between the level sensor 16 and a second fluid 70 in the fluid container 14 decreases (e.g., the second fluid 70 fills the fluid container 14). The second signal threshold 62 may correspond to the defined level 52 of the second fluid 70 in the fluid container 14. In operation, when the signal level 44 of the second signal 68 reaches the second signal threshold 62, this indicates that the second fluid 70 is at the target proximity 54 (e.g., distance) from the level sensor 16, which in turn indicates that the second fluid 70 is at the defined level 52. The defined level 52 may provide a “high-high” alarm signal, block overflow of the fluid container 14, facilitate accurate testing via the fluid testing sensor(s) 30 of FIG. 1 , and / or other advantages.

[0026] As described herein, the second signal threshold 62 of FIG. 3 may be determined for the second fluid 70 based on the one or more fluid parameters (e.g. , water content, electrical conductivity) detected by the fluid parameter sensor(s) 18. In this way, the fluid system 10 may implement the adjustable signal threshold (e.g.,the first signal threshold 42, the second signal threshold 62; multiple signal thresholds; multiple trigger thresholds) to detect when a fluid (e.g., the first fluid 50, the second fluid 70) reaches the defined level 52 in the fluid container 14. In this way, the fluid system 10 may carry out one or more actions (e.g., be triggered to carry out the one or more actions), such as stop flow of the fluid into the fluid container 14 (e.g., stop the pump of FIG. 1 ), in response to the signal (e.g., the first signal 48, the second signal 58) generated by the level sensor 16 reaching its respective (e.g., fluid-specific; adjusted) signal threshold (e.g., the first signal threshold 42, the second signal threshold 62).

[0027] While two fluids (e.g., the first fluid 50, the second fluid 70) and corresponding signal thresholds (e.g., the first signal threshold 42, the second signal threshold 62) are shown and described to facilitate discussion, it should be appreciated that the fluid system 10 may be configured to determine and utilize any number of signal thresholds for any number of fluids (e.g., 1 , 2, 3, 4, 5 or more). Further, to facilitate comparison of the first signal 48 and the first signal threshold 42 of FIG. 2 with the second signal 58 and the second signal threshold of FIG. 3, the first signal 48 and the first signal threshold 42 of FIG. 2 are overlaid onto the second graph 60. It should be appreciated that the fluid system 10 may determine or categorize a type of fluid flowing toward and / or filling the fluid container 14 (e.g., by comparing the one or more parameters to a lookup table that associates one or more respective known parameters with available fluid types; corresponds to or is similar to a Type 1 profile, Type 2 profile, Type 3 profile, and so forth), and then the fluid system 10 may select or determine a corresponding signal threshold for the type of fluid (e.g., using the lookup table that associates respective known signal thresholds with the available fluid types; use the corresponding signal threshold for Type 1 , Type 2, Type 3, and so forth). It should be appreciated that known parameters and / or known signal thresholds may be determined in any suitable manner, such as based on empirical data, modeled data, published data, and / or inputs by an operator. Alternatively, the fluid system 10 may input the one or more parameters into one or more algorithms to adjust or determine a corresponding signal threshold based on the one or more parameters (e.g., theone or more algorithms receive the one or more parameters as one or more inputs and provide the corresponding threshold as an output). It should be appreciated that the one or more algorithms may be generated in any suitable manner, such as based on empirical data, modeled data, published data, and / or inputs by an operator. Further, the one or more algorithms may include one or more machine learning algorithms trained on training data that includes empirical data, modeled data, published data, and / or inputs by an operator.

[0028] FIG. 4 is an example of a graph 80 with multiple threshold, such as a first signal threshold 82, a second signal threshold 84, and a guard level threshold 86 based on signals from the level sensor 16 (e.g., FIGS. 1 -3), in accordance with an embodiment of the present disclosure. The graph 80 includes a signal level 94 along a y-axis, and a proximity 96 along an x-axis. As shown in the graph 80 the signal level 94 of a first signal 100 generated by the level sensor 16 increases as the proximity 46 between the level sensor 16 and a first fluid (e.g., the first fluid 50 of FIG. 2) in the fluid container 14 (FIGS. 1 -3) decreases (e.g., the first fluid fills the fluid container 14). Similarly, the signal level 94 of a second signal 102 generated by the level sensor 16 increases as the proximity 46 between the level sensor 16 and a second fluid (e.g., the second fluid 70 of FIG. 2) in the fluid container 14 decreases (e.g., the first fluid fills the fluid container 14).

[0029] As noted herein, it is presently recognized that the fluid system 10 may utilize different fluids with different properties, and further that the different fluids with the different properties may affect signals generated by the level sensor(s) 16 (e.g., non-contact, capacitance level sensors). Accordingly, the first signal threshold 82 and the second signal threshold 84 of FIG. 4 may be determined for the first fluid and the second fluid, respectively, based on one or more fluid parameters (e.g., time difference between two signal levels).

[0030] With reference to FIG. 4, the fluid is pumped at a constant rate into the fluid container 14 (FIG. 1 ) monitored by the level sensor 16 (FIG. 1 ). The fluid level is directly proportional an amount of fluid pumped in, and pumping the fluid in at a constant rate results in the fluid level rising a constant rate. As the fluid, either thefirst fluid or the second fluid is pumped into the fluid container 14, the guard level threshold 86 is monitored. The guard level threshold 86 represents a lower fluid level (points C or E) as opposed to the defined level 52. Once the fluid reaches the guard level threshold 86 (the first fluid at point E, or the second fluid at point C), a timer is started, and the second signal threshold 84 is now monitored. As the fluid rises (either the first fluid or the second fluid), the second signal threshold 84 will be reached eventually, (the first fluid at point D, or the second fluid at point B).

[0031] By using a measured time difference between the guard level threshold 86 and the second signal threshold 84 (e.g., points E to D for the first fluid, points C to B for the second fluid), it can be determined if the first fluid (e.g., having a shorter time difference) or the second fluid (e.g., having a longer time difference) is being pumped into the fluid container 14. For example, the fluid system 10 (FIG. 1 ) may determine or categorize a type of fluid flowing toward and / or filling the fluid container 14 (FIG. 1 ) (e.g., by comparing the measured time difference to a lookup table that associates respective known time differences with available fluid types), and then may select or determine a corresponding signal threshold for the type of fluid (e.g., using the lookup table that associates respective known signal thresholds with the available fluid types). It should be appreciated that known time differences and / or known signal thresholds may be determined in any suitable manner, such as based on empirical data, modeled data, published data, and / or inputs by an operator. Alternatively, the fluid system 10 (FIG. 1 ) may input the measured time difference into one or more algorithms to adjust or determine a corresponding signal threshold based on the measured time difference (e.g., the one or more algorithms receive the measured time difference as an input and provide the corresponding threshold as an output). It should be appreciated that the one or more algorithms may be generated in any suitable manner, such as based on empirical data, modeled data, published data, and / or inputs by an operator. Further, the one or more algorithms may include one or more machine learning algorithms trained on training data that includes empirical data, modeled data, published data, and / or inputs by an operator.

[0032] If it is determined that the second fluid is being pumped into the fluid container 14, the pump stops in this case (e.g., at the second signal threshold 84). If it is determined that the first fluid is being pumped into the fluid container 14, the pump continues to pump the first fluid into the fluid container 14 until reaching the first signal threshold 82. It should be appreciated that, the “guard level” could also be triggered by other types of measurements. Examples could be the change of temperature at a process sensor, torque on a rheometer when the fluid is introduced into the fluid container 14 and reaches the “guard” level, and so forth. The defined level 52 may provide a “high-high” alarm signal, block overflow of the fluid container 14, facilitate accurate testing via the fluid testing sensor(s) 30 of FIG. 1 , and / or other advantages.

[0033] In this way, the fluid parameter sensor(s) 18 (FIG. 1 ) may include or be implemented as the level sensor(s) 16 (FIG. 1 ), and the one or more fluid parameters may include the time difference. It should be appreciated that the fluid system 10 (FIG. 1 ) may use or consider the time difference in combination with one or more other fluid parameters (e.g., water content, electrical conductivity) to determine the type of fluid flowing toward and / or filling the fluid container 14 (FIG. 1 ). For example, the fluid system 10 (FIG. 1 ) may input the measured time difference and the one or more other measured fluid parameters into one or more algorithms to adjust or determine a corresponding signal threshold based on the measured time difference and the one or more other measured fluid parameters (e.g., the one or more algorithms receive the measured time difference and the one or more other measured fluid parameters as multiple inputs and provide the corresponding threshold as an output).

[0034] FIG. 5 is a schematic diagram of a cleaning process 110 that may be implemented for the fluid system 10 of FIG. 1 , in accordance with an embodiment of the present disclosure. As shown in FIG. 5, the fluid container 14 could be outfitted with two level sensors, a first level sensor 16A and a second level sensor 16B. The first level sensor 16A may be a non-contact, capacitance sensor that remains above the fluid in the fluid container 14 (e.g., above the desired level). The second level sensor 16B may be any suitable type of sensor that is intended to bewetted by the fluid. The first and second level sensors 16A, 16B can be the same type of sensors, or different types of sensors. After the fluid is drained from the fluid container 14, the second level sensor 16B can be used to determine a relative likelihood of fluids or residue being left in the fluid container 14. If the fluid container 14 drains and the second level sensor 16B goes back to a baseline or a lower level (e.g., signal level; output; below a cleaning signal threshold), the fluid system 10 will assume the fluid container 14 is clean, and it is ready for another test.

[0035] If the fluid system 10 determines that the second level sensor 16B now has a higher level (e.g., signal level; output; at or above the cleaning signal threshold), which suggests or indicates that a residue has coated the second level sensor 16B, the fluid system 10 will also assume or determine that a similar residue exists within the fluid container 14 and trigger a cleaning cycle (e.g., circulation of a first cleaning fluid from the first cleaning fluid source 24 of FIG. 1 and / or a second cleaning fluid from the second cleaning fluid source 26 of FIG. 1 ). After the cleaning cycle is complete, the fluid system 10 may return to a testing cycle (e.g., filling the fluid container 14 with the first fluid or the second fluid, and carrying out fluids tests on the first fluid or the second fluid that is within the fluid container 14). In certain embodiments, it may be possible that even after a cleaning cycle, the second level sensor 16B could remain covered or coated by the residue and thus output the higher level. This could either send the fluid system 10 into one or more additional cleaning cycles, or it could simply move onto the testing cycle. The fluid system 10 may send a notification (e.g., visual notification via a display and / or audible notification via a speaker) to an operator to indicate to the operator that the fluid container 14 should be inspected (e.g., complete preventative maintenance; change the cleaning fluid, and so forth).

[0036] FIGS. 6 provides example graphs (e.g., a first cleaning pattern graph 120 and a second cleaning pattern graph 130) that illustrate the cleaning process that may be implemented for the fluid system 10 of FIG.1 , in accordance with an embodiment of the present disclosure. The first cleaning pattern graph 120 indicates a potential pattern of a sensor reading of the second level sensor 16B (FIG. 5) over time (e.g., to trigger the cleaning cycle after a third test cycle; due tothe signal level being below a cleaning signal threshold 132, such as after draining and emptying the fluid container 14 of FIG. 1 ), and the second cleaning pattern graph 130 indicates another potential pattern of the sensor reading of the second level sensor 16B over time (e.g., to trigger the cleaning cycle after a first test cycle; due to the signal level being at or above the cleaning signal threshold 132 after the first test cycle, such as after draining and emptying the fluid container 14 of FIG. 1 ).

[0037] It should be appreciated that the cleaning signal threshold 132 may be adjustable (e.g., across different fluid testing systems and / or for the fluid system 10 of FIG. 1 over time). For example, the cleaning signal threshold 132 may be established for the fluid system 10 at manufacturing and / or installation based on features of the fluid system 10 of FIG. 1 (e.g., sensor sensitivities; testing tolerances; fluid properties to be tested; fluid types to be tested; operator preferences for a site). Additionally or alternatively, the cleaning signal threshold 132 may be adjustable for the fluid system 10 of FIG. 1 over time, such as based on one or more inputs provided by an operator, current testing schedules and / or protocols, current fluid properties being measured, fluid types being tested, and / or any combination thereof. For example, the cleaning signal threshold 132 may be adjusted to a higher level if current fluid properties being measured are less affected by residue in the fluid container 14 of FIG. 1 , while the cleaning signal threshold 132 may be adjusted to a lower level if current fluid properties being measured are more affected by residue in the fluid container 14 of FIG. 1 . In certain embodiments, the fluid system 10 may be configured to automatically and dynamically adjust the cleaning signal threshold 132, such as based on or in response to receipt of the one or more inputs described herein.

[0038] In certain embodiments, the fluid system 10 may determine and select a type of cleaning fluid (e.g., the first cleaning fluid from the first cleaning fluid source 24 of FIG. 1 or the second cleaning fluid from the second cleaning fluid source 26 of FIG. 1 ) based on characteristics (e.g., properties, parameters, as measured by one or more sensors including any sensors described herein, as received via input by an operator) of the first fluid and / or the second fluid, as wellas the order in which the fluid tests are carried out. In particular, the fluid system 10 may receive and analyze the characteristics to determine a type of cleaning fluid as appropriate based on the characteristics, and then the fluid system 10 may select and route the type of cleaning fluid through the fluid system 10 to carry out the cleaning cycle. For example, if the first fluid is a non-aqueous fluid and the second fluid is a water-based fluid, to clean between a first fluid test on the first fluid and a second fluid test on the second fluid, the fluid system 10 may first flush with a base oil, then a mutual solvent, and then water or the second fluid. However, to clean between a second fluid test on the second fluid and a first fluid test on the first fluid, the fluid system 10 may first flush with water, then with a base oil, and then the non-aqueous fluid.

[0039] FIG. 7 is a front view of a fluid testing system 150, which may include structural and / or operational features of the fluid system 10 of FIG. 1 , in accordance with an embodiment of the present disclosure. As shown, the fluid testing system 150 includes an enclosure 152 (e.g., which may correspond to and / or house components of the container assembly 12 of FIG. 1 ). For example, the enclosure 152 may house the fluid container 14 within the enclosure 152. In certain embodiments, the enclosure 152 forms a fully enclosed and sealed interior cavity 154 that houses the fluid container 14 and related fluid testing equipment. In an inset provided in FIG. 7, one wall of the enclosure 152 is removed to show placement of the fluid container 14 and the related fluid testing equipment within the enclosure 152. In operation, the enclosure 152 may be purged and pressurized via a flow of compressed air into the enclosure 152 to block ingress of other gases into the enclosure 152, which may enable introduction of sample fluid (e.g., drilling fluid) and / or other fluid (e.g., cleaning fluid) that may be flammable (e.g., capable of releasing flammable gases) into the fluid container 14 within the enclosure 152. For example, the sample fluid and / or the other fluid within the fluid container 14 may release gases into a space within the fluid container 14 (e.g., the space above the sample fluid and / or the other fluid). The pressure within the enclosure 152 may block ingress of the gases into the enclosure 152, and instead may force the gases to pass through a reference port 156 (e.g., atmospheric reference port) to anoutside of the enclosure 152. Accordingly, the pressure within the enclosure 152 may block ingress of the gases into the enclosure 152, which may block (e.g., prevent) arcing, sparking, and fire conditions within the enclosure 152 and enable use of various types of equipment within the enclosure 152 (e.g., fluid testing equipment, electrically powered equipment).

[0040] As shown in FIG. 7, the fluid container 14 is coupled to a rheology sensor 155 (e.g., viscometer; the fluid testing sensor(s) 30 of FIG. 1 ) and a temperature control system 158. The fluid container 14 is also supported on a frame 160 that is coupled (e.g., via one or more fasteners, such as threaded fasteners) to the enclosure 152. As described in more detail herein, an inlet line 162 may provide fluid (e.g., sample fluid, such as drilling fluid; cleaning fluid) to the fluid container 14, and an outlet line 164 may enable extraction of the fluid from the fluid container 14. To facilitate discussion, the fluid system 10 and its components (e.g., the fluid container 14) may be described with reference to a vertical axis or direction 170, a first lateral axis or direction 172, a second lateral axis or direction 174, and / or a circumferential axis or direction 176.

[0041] FIG. 8 is a perspective rear view and a corresponding schematic diagram of passageways formed in the fluid container 14 of the fluid testing system 150 of FIG. 7, in accordance with an embodiment of the present disclosure. As shown, the fluid container 14 includes a cross-drilled passageway 182 with ports 184, 186, as well as a level limit switch port 188 that supports at least one of the level sensor(s) 16. The level sensor 16 may be at any suitable orientation relative to the fluid container 14 (e.g., angled relative to the vertical axis 170 or along the vertical axis 170). An opening 190 to the cross-drilled passageway 182 defines and / or is placed at a target level 192 (e.g., appropriate for the rheology testing of the sample fluid). In operation, the sample fluid may flow through the cross-drilled passageway 182 to the outlet line 164 to provide an automatic level (e.g., positive level; the target level 192) for the sample fluid. In certain embodiments, a suction pump may apply suction at the outlet line 164 to facilitate the flow through the cross-drilled passageway 182 to the outlet line 164 to provide an automatic level for the sample fluid.

[0042] The level sensor 16 monitors fluid within the fluid container 14, as described herein. For example, the level sensor 16 may generate signals that are compared to respective signal thresholds (e.g., adjustable signal thresholds), which may be set or determined based on the one or more parameters of the fluid (e.g., water content, electrical conductivity, time difference between two signal levels). In context of the fluid testing system 150 of FIG. 7 and the fluid container 14 of FIGS. 7 and 8, the level sensor 16 (e.g., the signals generated by the level sensor 16) may operate as a high-high sensor and the defined level 52 may provide or operate as a high-high limit (e.g., trigger action, such as stop and / or reverse the pump and / or provide an alarm, if the fluid level reaches the defined level 52, which may indicate that the fluid is not properly flowing out of the crossdrilled passageway 182 or some other improper operation of the fluid testing system 150). Accordingly, together the techniques shown and described with reference to FIGS. 1-8 may enable adjustable signal thresholds (e.g., trigger thresholds), such as to indicate that the fluid has reached a defined level (e.g., high-high limit). Advantageously, the adjustable signal thresholds may reduce false alarms, reduce manual and / or operator involvement to re-run the level sensor 16 when changing the fluid, and / or provide correct alarm signals for specified and / or determined fluid types.

[0043] In certain embodiments, the fluid system may be located at a wellsite (e.g., on a skid placed at a surface above a wellbore). In certain embodiments, the fluid testing system may be subject to ATEX, UKEX, and / or lECex standards. For example, the fluid testing system may be subject to ATEX, UKEX, and / or lECex standards due to presence of flammable fluid (e.g., the fluid may be a drilling fluid or a type of flammable cleaning fluid) and / or due to being located in an area with a potential presence of explosive gases. ATEX refers to “Atmospheres Explosibles” and is a set of European Union regulations related to products used in explosive environments. UKEX refers to “The Equipment and Protective Systems Intended for Use in Potentially Explosive Atmospheres Regulations” and is a set of regulations that apply to products sold in Great Britain. lECex refers to “International Electrotechnical Commission for Explosive Atmospheres” and is aset of regulations accepted in several countries and related to products used in explosive environments. It should be appreciated that the fluid system may be subject to any of a variety of regulations set forth by one or more countries, agencies, or so forth, and features of the fluid system may enable the fluid system to satisfy or meet any of a variety of regulations set forth by one or more countries, agencies, or so forth.

[0044] Additionally, the fluid system 10 enables the fluid to be periodically introduced into the fluid container 14, characterized via analysis (e.g,, via the fluid testing sensor(s) 30) while in the fluid container 14, and then removed from the fluid container 1 . Further, the fluid system 10 enables the fluid to circulate through the fluid container 14 in a manner that provides a fresh fluid aliquot for each analysis (e.g., for each rheological characterization).

[0045] The fluid system 10 described herein may be an automated system that is configured to circulate and / or test the fluid, as well as circulate the cleaning fluid, via automated processes (e.g., move between at least some steps without human intervention). Additionally, the fluid system 10 may perform other types of tests on the fluid, such as weight, density, water-oil content, emulsion electrical stability, fluid conductivity, particle size, rheology, and so forth within the fluid container 14 and / or outside of the fluid container 14.

[0046] As shown in FIG. 1 , the fluid system 10 may include an electronic controller 200 with a processor(s) 202 and a memory device(s) 204. In certain embodiments, at least some hardware components of the electronic controller 200 may be supported in an electronics housing 206 of FIG. 7, which may be supported by (e.g., fastened to) a skid 210 of FIG. 7. In certain embodiments, as shown in FIG. 7, the electronics housing 206 and the enclosure 152 are both supported by (e.g., fastened to) the skid 210. Further, in certain embodiments, as shown in FIG. 7, the electronics housing 206 may include a display 212 (e.g., display screen).

[0047] The electronic controller 200 may operate to carry out the fluid routing, fluid leveling, fluid monitoring, fluid tests, cleaning protocols, selections, determinations, baseline and / or threshold comparisons, processing, analysis,algorithm training, lookup table access, and any other techniques disclosed herein. For example, the electronic controller 200 may receive signals (e.g., data; from sensors and / or inputs), and the electronic controller 200 may also provide control signals (e.g., to pumps, valves, sensors, the display 212, and / or another display) to control operation of components (e.g., the pumps, valves, sensors, the display 212, and / or another display).

[0048] The processor(s) 202 may be processing circuitry that includes one or more processors configured to execute software, such as software for processing the signals and / or the inputs, and / or generating the control signals to control operation of the components of the fluid system 10. The memory device(s) 204 may include one or more memory devices (e.g., a volatile memory, such as random access memory [RAM], and / or a nonvolatile memory, such as read-only memory [ROM]) that may store a variety of information (e.g., sensor data; test and / or cleaning protocols; one or more thresholds; one or more lookup tables; known values, such as known parameters of various fluids, known signal thresholds that are appropriate for various fluids, and so forth; one or more algorithms) and may be used for various purposes. For example, the memory device(s) 204 may store processor-executable instructions (e.g., firmware or software) for the processor(s) 202 to execute, such as instructions for processing the signals and / or the inputs, and / or generating the control signals to control operation of the components of the fluid system 10.

[0049] The electronic controller 200 may also include other components, such as a communication device to transmit signals (e.g., data, information, control signals) via wireless and / or wired protocols. For example, the communication device may transmit signals to another display, such as another display that is remote from the skid 210 of FIG. 7, such as another display that is part of a desktop computer, a laptop computer, a tablet, and / or a mobile phone. Further, the electronic controller 200 may also be considered to include or be coupled to an output device (e.g., the display 212, another display, and / or speaker) to provide information for visualization by the operator, provide audible alarms, and so forth. The electronic controller 200 may be local (e.g., on-board) a structure of the fluidsystem 10. In certain embodiments, the electronic controller 200 may be a distributed controller with portions in various locations (e.g., local, remote, cloud).

[0050] It should be appreciated that the electronic controller 200 may be configured to instruct display of various information on the display 212 and / or another display, and that such various information may include a fluid type identified by the fluid system 10 via techniques described herein, one or more fluid parameters (e.g., water content, electrical conductivity, time difference) measured as described herein, one or more fluid properties (e.g., rheological properties) measured described herein, a current status of the fluid system 10 (e.g., indication of a current testing and / or cleaning stage), one or more thresholds, one or more lookup tables, one or more known values, such as known parameters of various fluids, known signal thresholds that are appropriate for various fluids, and so forth, any of a variety of graphs, including any graphs (or portions of any graphs) shown or described herein, or any combination thereof. Further, the electronic controller 200 may be configured to instruct display of various information in response to receipt of input from the operator (e.g., a request by the operator) and / or automatically based on current operations of the fluid system 10 (e.g., a graph with a respective signal relative to a respective signal threshold for a fluid as the fluid is added to the fluid container 14 of FIG. 1 ; a graph with a respective signal relative to the cleaning signal threshold while and / or after the fluid container 14 of FIG. 1 is emptied following a fluid test).

[0051] While the disclosure may be susceptible to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and have been described in detail herein. However, it should be understood that the disclosure is not intended to be limited to the particular forms disclosed. Rather, the disclosure is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the disclosure as defined by the following appended claims. Any features shown in FIGS. 1 -8 or described with reference to FIGS. 1-8 may be combined in any suitable manner.

[0052] The techniques presented and claimed herein are referenced and applied to material objects and concrete examples of a practical nature that demonstrably improve the present technical field and, as such, are not abstract, intangible or purely theoretical. Further, if any claims appended to the end of this specification contain one or more elements designated as “means for (perform)ing (a function)...” or “step for (perform)ing (a function)...”, it is intended that such elements are to be interpreted under 35 U.S.C. 112(f). However, for any claims containing elements designated in any other manner, it is intended that such elements are not to be interpreted under 35 U.S.C. 112(f).

Claims

CLAIMS1 . A fluid system, comprising: a fluid container; a level sensor configured to generate a level signal indicative of a fluid level in the fluid container; and a controller configured to set a signal threshold for the level signal based on one or more parameters of a fluid provided to the fluid container.

2. The fluid system of claim 1 , wherein the controller is configured to adjust the signal threshold for the level signal based on one or more respective parameters of an additional fluid provided to the fluid container.

3. The fluid system of claim 1 , comprising one or more fluid parameter sensors configured to detect the one or more parameters of the fluid.

4. The fluid system of claim 3, wherein the one or more fluid parameter sensors are positioned along a pathway that is configured to transfer the fluid from a fluid source to the fluid container.

5. The fluid system of claim 1 , wherein the one or more parameters comprise water content, electrical conductivity, or both.

6. The fluid system of claim 1 , wherein the controller is configured to: detect presence of the fluid at a first level in the fluid container; detect presence of the fluid at a second level in the fluid container; and determine a time between the fluid reaching the first level and the second level, wherein the one or more parameters of the fluid comprise the time.

7. The fluid system of claim 1 , comprising: an additional sensor configured to contact the fluid in the fluid container and to generate a residue signal indicative of presence of residue in the fluid container; wherein the controller is configured to instruct a cleaning cycle in response to the residue signal meeting or exceeding a cleaning signal threshold after the fluid is drained from the fluid container.

8. The fluid system of claim 7, wherein the controller is configured to adjust the cleaning signal threshold based on an operator input, the one or more parameters of the fluid, one or more upcoming scheduled test protocols for the fluid, or any combination thereof.

9. The fluid system of claim 1 , wherein the fluid system comprises a fluid testing system comprising a rheology sensor configured to test rheological properties of the fluid in the fluid container.

10. The fluid system of claim 1 , wherein the level sensor comprises a noncontact capacitance sensor that is positioned relative to the fluid container to remain above the fluid level in the container.

11. The fluid system of claim 10, wherein the fluid container comprises an opening that provides an automatic level for the fluid in the fluid container, and the level sensor is configured to operate as a high-high level sensor such that the controller is configured to control a pump to stop flow of the fluid to the fluid container in response to the level signal exceeding the signal threshold.

12. The fluid system of claim 1 , wherein the controller is configured to compare the one or more parameters of the fluid to one or more known parameters in a lookup table to set the signal threshold.

13. A method of operating a fluid system, the method comprising: receiving, at a controller and from one or more parameter sensors, one or more parameters of a fluid; adjusting, using the controller and based on the one or more parameters of the fluid, a signal threshold for a level sensor associated with a fluid container to generate a fluid-specific signal threshold for the fluid; receiving, at the controller and from the level sensor, a level signal indicative of a fluid level of the fluid in the fluid container as the fluid flows into the fluid container; comparing, using the controller, the level signal to the fluid-specific signal threshold for the fluid as the fluid flows into the fluid container; and controlling, using the controller, a pump to stop flow of the fluid into the fluid container in response to the level signal meeting or exceeding the fluidspecific signal threshold for the fluid.

14. The method of claim 13, comprising: receiving, at the controller and from the one or more parameter sensors, one or more respective parameters of an additional fluid; adjusting, using the controller and based on the one or more respective parameters of the additional fluid, the signal threshold for the level sensor associated with the fluid container to generate an additional fluid-specific signal threshold for the additional fluid; receiving, at the controller and from the level sensor, an additional level signal indicative of an additional fluid level of the additional fluid in the fluid container as the additional fluid flows into the fluid container; comparing, using the controller, the additional level signal to the additional fluidspecific signal threshold for the additional fluid as the additional fluid flows into the fluid container; and controlling, using the controller, the pump or an additional pump to stop flow of the additional fluid into the fluid container in response to the additional levelsignal meeting or exceeding the additional fluid-specific signal threshold for the additional fluid.

15. The method of claim 13, comprising: receiving, at the controller and from the one or more parameter sensors, the one or more parameters of the fluid as the fluid flows along a pathway from a fluid source toward the fluid container; and adjusting, using the controller and based on the one or more parameters of the fluid, the signal threshold for the level sensor associated with the fluid container to generate the fluid-specific signal threshold for the fluid as the fluid flows along the pathway or as the fluid flows into the fluid container.

16. The method of claim 13, comprising: receiving, at the controller and from the level sensor, presence of the fluid at a first level in the fluid container; receiving, at the controller and from the level sensor, presence of the fluid at a second level in the fluid container; and determining, using the controller, a time between the fluid reaching the first level and the second level, wherein the one or more parameters of the fluid comprise the time.

17. The method of claim 13, comprising: receiving, at the controller and from a residue sensor in the fluid container, a residue signal indicative of presence of residue in the fluid container; and instructing, using the controller, a cleaning cycle in response to the residue signal meeting or exceeding a cleaning signal threshold after the fluid is drained from the fluid container.

18. The method of claim 13, comprising instructing, using the controller, a rheology sensor to test rheological properties of the fluid in the fluid container.

19. The method of claim 13, comprising: instructing, using the controller, a display to present the fluid-specific signal threshold for the fluid, the level signal, a graph of the level signal over time overlaid onto the fluid-specific signal threshold, or any combinations thereof.

20. A fluid system, comprising: a fluid container comprising an opening that provides an automatic level for a fluid in the fluid container; a level sensor configured to generate a level signal indicative of a fluid level of the fluid in the fluid container; and a controller configured to: set a fluid-specific signal threshold for the level signal based on one or more parameters of the fluid; and control a pump to stop flow of the fluid to the fluid container in response to the level signal exceeding the fluid-specific signal threshold.

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