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High frequency torsional oscillation (HFTO) has gained considerable attention over the past several years due, in large part, to the continued use of motor-assisted Rotary-Steerable Systems. The consequences of such vibration events can be increased repair and maintenance costs, noisy measurements, and/or premature failures. While there are commercial tools available that can provide some relief to the symptoms of HFTO, data gathered thus far does not point to a consistent, reliable, and cost-effective solution to the problem. In light of current HFTO mitigation limitations, a new solution has been developed that shows promise in limiting the HFTO response in the BHA, if not removing it entirely. This new mitigation component is integrated directly into a Rotary-Steerable System. As a result, there are no requirements for additional tooling, connections, or special handling to mitigate these vibrations. The development of the presented method for mitigating HFTO stems from several years of gathering, and thoroughly analyzing, downhole data captured in a rotary-steerable system run below mud motors. A method for detecting HFTO in real-time is also presented, and the frequency and vibrational pattern of this dynamic phenomenon is confirmed in post-well reviews of high frequency data. Proprietary modeling is used to confirm that the measured frequencies seen downhole are associated with torsional resonant frequencies of the BHA, which is a defining characteristic of this particular vibration mode. A concept is developed for mitigating these types of downhole vibrations, based on the detailed understanding of the vibration characteristics, using a proven approach from outside the industry. Feasibility of this technology is confirmed through extensive vibration modeling. Prototype tools have been built and tested downhole in several US land basins over the past year. The positive results seen during initial field-testing has led to the new HFTO mitigation tool now being a standard technology for motor-assist RSS applications. Results have shown a consistent reduction in HFTO vibration, both in terms of amplitude and duration. Amplitude reductions between 50-100% have been observed routinely, which has led to a measureable increase in reliability and longevity of components being run below a mud motor. Based on how the mitigation tool is set up, a greater or lesser damping effect is seen in the measured HFTO response. This suggests the mitigation tool can be adjusted for targeted damping in certain scenarios, and may have a benefit in more than just rotary-steerable applications.
High frequency torsional oscillation (HFTO) has gained considerable attention over the past several years due, in large part, to the continued use of motor-assisted Rotary-Steerable Systems. The consequences of such vibration events can be increased repair and maintenance costs, noisy measurements, and/or premature failures. While there are commercial tools available that can provide some relief to the symptoms of HFTO, data gathered thus far does not point to a consistent, reliable, and cost-effective solution to the problem. In light of current HFTO mitigation limitations, a new solution has been developed that shows promise in limiting the HFTO response in the BHA, if not removing it entirely. This new mitigation component is integrated directly into a Rotary-Steerable System. As a result, there are no requirements for additional tooling, connections, or special handling to mitigate these vibrations. The development of the presented method for mitigating HFTO stems from several years of gathering, and thoroughly analyzing, downhole data captured in a rotary-steerable system run below mud motors. A method for detecting HFTO in real-time is also presented, and the frequency and vibrational pattern of this dynamic phenomenon is confirmed in post-well reviews of high frequency data. Proprietary modeling is used to confirm that the measured frequencies seen downhole are associated with torsional resonant frequencies of the BHA, which is a defining characteristic of this particular vibration mode. A concept is developed for mitigating these types of downhole vibrations, based on the detailed understanding of the vibration characteristics, using a proven approach from outside the industry. Feasibility of this technology is confirmed through extensive vibration modeling. Prototype tools have been built and tested downhole in several US land basins over the past year. The positive results seen during initial field-testing has led to the new HFTO mitigation tool now being a standard technology for motor-assist RSS applications. Results have shown a consistent reduction in HFTO vibration, both in terms of amplitude and duration. Amplitude reductions between 50-100% have been observed routinely, which has led to a measureable increase in reliability and longevity of components being run below a mud motor. Based on how the mitigation tool is set up, a greater or lesser damping effect is seen in the measured HFTO response. This suggests the mitigation tool can be adjusted for targeted damping in certain scenarios, and may have a benefit in more than just rotary-steerable applications.
A drill bit dynamics sensor system has been developed with a new approach that enables economical, widespread use of downhole data to improve bit design. The system emphasizes ease of deployment and minimal manpower requirements for data interpretation. The goal was to develop a system appropriate for deployment on a new scale to the bit industry. The system consists of a small in-bit sensor coupled with an automated software system that provides direct design guidance targeted at drill bit specialists. This paper aims to detail the design considerations used to develop this system and provide an example application of the technology from field testing.
Vibration from High Frequency Torsional Oscillation (HFTO) damages drilling tools and electronics. Destructive HFTO can occur in harsh drilling environments which reduces drilling performance and reliability and leads to non-productive time and associated costs. Because it is faster, cheaper, more precise, and more controllable compared to field testing, a laboratory test environment is optimal for developing HFTO countermeasures. However, until now, a full-scale test rig that reliably generates controllable HFTO did not exist. This paper will describe for the first time a laboratory drilling rig that generates HFTO and, therefore, can be used to develop and qualify anti-HFTO procedures and tools. To study the HFTO susceptibility of bit-rock interactions, the full-scale laboratory drilling rig consists of a mud circulation system, hoisting system, bit, and BHA coupled with high-frequency instrumentation to measure torsional vibrations on a millisecond scale. Finite element models (FEM) built to characterize the drilling simulator are used to correctly interpret the results of drilling data. An experimental modal analysis (EMA) is used to validate and refine the FEM models. Next, PDC-bits are used to drill several rocks under varying pressures, RPMs, and weights on bit (WOB). The resulting high-frequency torque and tangential acceleration data are compared to a checklist of necessary criteria to prove that self-excited HFTO occur in the lab. These measurements, when considered with their axial sensor positions, are used to reliably identify HFTO and compare bit-rock combinations by their susceptibility to HFTO. Results of the FEM-models and the EMA agree on the characteristic mode shapes and dominant frequencies which match dynamic measurements. Recorded data show that self-excited HFTO are reliably excited when the criteria for self-excitation are fulfilled. Vibration energy is concentrated in one dominant mode, the vibration amplitude is scaled by the RPM, and the frequency of torsional oscillations is independent of the rig RPM. HFTO-prone rocks are identified using segmented rock specimen tests. The excitation mechanism in the laboratory test rig corresponds to the mechanism in the field. Stability maps show that bits differ in excitability allowing a comparison based on bit features and subsequent bit improvements. Methods and tools tested in the lab environment form a framework for developing anti-HFTO field solutions and operational guidelines. The upgraded full-scale drilling rig reliably generates HFTO in a laboratory environment under realistic drilling conditions. When coupled with extended research into the combination of bit, rock and BHA variables that lead to HFTO susceptibility, this rig will enable faster and cost-efficient product and procedure development cycles for proven and validated anti-HFTO tools and field guidelines. An HFTO suppressing bit or an HFTO suppressing damping device will have a significant impact on BHA reliability, drilling performance, and reduced NPT.
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