Drilltronics: An Integrated System for Real-Time Optimization of the Drilling Process

Abstract

Drilltronics is the project name of a new and innovative system for drilling automation and simulation. The concept uses all available drilling data (surface and downhole) in real time to optimize the drilling process. If a sensor is failing (PWD for example) then advanced models mirroring the drilling process will calculate the parameter missing (pressure at the PWD sensor position). The system is composed of the following elements:Software modelling with algorithms that reflect the wellbore behaviour and its interaction with the drilling equipment. Currently under development are transient flow and heat transfer models, a drillstring torque and drag model, weight on bit optimization, and stick/slip analysis.The models are driven in real time by drilling data that are logged at high acquisition rate. The system is continuously calibrated through analysing the data with advanced filtering techniques.Real-time diagnosis of the drilling process is obtained from comparing measured data with model predictions. This makes up a basis for continuous adjustments to the drilling strategy.An integrated drilling simulator is developed by linking the modules together, and combining it with an ROP model. This can be used for pre-planning, sensitivity analysis during drilling, post-well analysis, and training objectives.Selected, critical sub-operations will be automated for fast and reliable reaction, e.g. automatic control of the drawwork based on dynamic surge and swab calculations, and automatic detection and first action after easily recognised symptoms on hole problems like pack off or stuck pipe. In order to realize the full potential of Drilltronics, surface and downhole drilling data must be available in real time. The drilling equipment will need to be computer controlled with an interface that supports automatic responses to the model's analysis. Introduction Other systems The oil industry has made significant progress in developing new facilities to improve the drilling operation and its technology. Examples are real-time formation evaluation, directional control while drilling, improved bottom hole assembly components, and improved drilling fluids. In the last few years, the request for real-time applications to improve performance and, at the same time, maintain safety for personnel and environments has increased related research activities. A historical view of the driller's role from the early start of the oil industry at the beginning of the twentieth century until today is given in [1]. The driller's role will need to evolve from one of basic drilling mechanics into that of real time drilling supervisor. This was emphasized when Havrevold and Hytten presented their Analysis-While-Drilling (AWD) in 1991 [2], one of the first real-time applications for drilling operations. At this time the increasing amount of available data from Measurement-While-Drilling tools (MWD) not only gave valuable information on many drilling conditions, but also enforced the need for a more efficient data handling. Based on relatively simple prediction models, the AWD concept included a real-time application with modules handling crucial parts of drilling operations such as standpipe pressure analysis and tripping optimization.

Drilling-Systems Automation: Current State, Initiatives, and Potential Impact

“…Even though surface instrumentation has lagged in development, automationquality sensors are available (Florence and Iversen 2010;Ronaes et al 2012). Software models are being developed and tested that provide monitoring and prediction capability in real time as the well is drilled (Dashevskiy et al 2003;Rommetveit et al 2004;Iversen et al 2006;Cayeux and Daireaux 2009;Cayeux et al 2011;Wong et al 2013;among others). Software models address the entire automation spectrum.…”

“…The workflows will convert remote operations into an active solution embedded into the drilling operation. Examples of this workflow are described by Rommetveit et al (2004).…”

Real-Time Minimization of Mechanical Specific Energy with Multivariable Extremum Seeking

“…As the downhole conditions change, the repeated tests can identify how the WOB and RPM should be adjusted to drill more efficiently, given the new circumstances. Rommetveit et al [18] describe an approach of making changes in the WOB and RPM to gather information on how the ROP reacts to these changes. The gathered information can then be used to generate recommendations for the driller or for closed loop control by an optimization algorithm [18].…”

“…Rommetveit et al [18] describe an approach of making changes in the WOB and RPM to gather information on how the ROP reacts to these changes. The gathered information can then be used to generate recommendations for the driller or for closed loop control by an optimization algorithm [18]. An automated golden search algorithm that varies the WOB to identify drilling with minimal MSE has been tested on a lab-scale drilling rig [19].…”