Operators often use real-time operation centers (RTOC) as a funnel point for data streams transmitted from multiple rigs during the well construction process. A RTOC is typically staffed by subject matter experts (SMEs), with the primary goals of interpreting real-time wellbore conditions and relaying actionable recommendations to help reduce nonproductive time (NPT) and well control incidents. Automation is a strong industry trend. Autonomous systems are being developed to flag potential NPT events before they occur; however, these systems are not yet widely used. In the absence of these systems, workflows among complementary disciplines have been developed to identify potential NPT events in large data streams transmitted to a RTOC. This paper presents example scenarios from deepwater prospects with potential actionable recommendations. Robust data streams transmitted to a RTOC can be received by the overlapping disciplines of hydraulics optimization, drilling optimization, and geomechanics. Staff from each discipline filter through the raw data to capture incoming information relevant to their respective output analysis. A key goal of each discipline is to mitigate the risk of NPT through real-time identification of warning trends observed during deepwater drilling in narrow pressure window situations. The multidisciplinary overlapping efforts produce a process that is much more effective than is possible with each discipline operating independently. Because real-time geomechanics seeks to update the bounding conditions of the downhole pressure operating windows, collaborative workflows are structured around validation and calibration of the real-time geomechanical model. Collaborative workflows are presented for specific operations during the well construction process in which NPT events are likely to occur, such as tripping out of the hole and drilling. In the examples, real-time calculated equivalent circulating density (ECD) models, hole cleaning parameters, swab pressure models, and torque/drag plots provide input to the real-time geomechanical model. Outputs of this analysis are actionable recommendations, such as an extended flow check, check trip, or mud weight increase. The workflows were developed based on lessons learned from information in a central database and the resulting best practices from multiple deepwater wells. Decision makers are provided with data-supported recommendations at crucial junctures; these recommendations typically involve costly rig time. The trade-off between increased rig time and benefits gained from the recommendation is difficult to quantify. The workflows derived from a library of NPT events address the perception of wasted rig time and provide context to real-time interpretations. Combined plots supporting the recommendation provide confidence for the driller that the increased rig time is time justified.
The challenging offshore drilling environment has increased the need for cost-effective operations to deliver accurate well placement, high borehole quality, and shoe-to-shoe drilling performance. As well construction complexity continues to develop, the need for an improved systems approach to delivering integrated performance is critical. Complex bottom hole assemblies (BHA) used in deepwater operations will include additional sensors and capabilities than in the past. These BHAs consist of multiple cutting structures (bit/reamer), gamma, resistivity, density, porosity, sonic, formation pressure testing/sampling capabilities, as well as drilling dynamics systems and onboard diagnostic sensors. Rock cutting structure design primarily relied on data capture at the surface. An instrumented sensor package within the drill bit provides dynamic measurements allowing for better understanding of BHA performance, creating a more efficient system for all drilling conditions. The addition of intelligent systems that monitor and control these complex BHAs, makes it possible to implement autonomous steering of directional drilling assemblies in the offshore environment. In the Deepwater Gulf of Mexico (GOM), this case study documents the introduction of a new automated drilling service and Intelligent Rotary Steerable System (iRSS) with an instrumented bit. Utilizing these complex BHAs, the system can provide real-time (RT) steering decisions automatically given the downhole tool configuration, planned well path, and RT sensor information received. The 6-3/4-inch nominal diameter system, coupled with the instrumented bit, successfully completed the first 5,400-foot (1,650m) section while enlarging the 8-1/2-inch (216mm) borehole to 9-7/8 inches (250mm). The system delivered a high-quality wellbore with low tortuosity and minimal vibration, while keeping to the planned well path. The system achieved all performance objectives and captured dynamic drilling responses for use in an additional applications. This fast sampling iRSS maintains continuous and faster steering control at high rates of penetration (ROP) providing accurate well path directional control. The system-matched polycrystalline diamond (PDC) bit is engineered to deliver greater side cutting efficiency with enhanced cutting structure improving the iRSS performance. Included within the bit is an instrumentation package that tracks drilling dynamics at the bit. The bit dynamics data is then used to improve bit designs and optimize drilling parameters.
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