spe 199601 large-scale deployment of a closed …spe 199601 large-scale deployment of a closed-loop...
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13–5 March 2020Galveston Island Convention Center, Galveston, Texas
IADC/SPE International Drilling Conference and Exhibition
SPE 199601
Large-Scale Deployment of a Closed-Loop Drilling Optimization System:
Implementation and Field Results
Stephen Lai, James Ng, Aaron Eddy, Sergey Khromov,
Dan Paslawski, Ryan van Beurden, Lars Olesen, Pason Systems
Gregory Payette, Benjamin Spivey, ExxonMobil Upstream Research Company
SPE 199601 Large-Scale Deployment of a Closed-Loop Drilling Optimization System Stephen Lai
23–5 March 2020Galveston Island Convention Center, Galveston, Texas
IADC/SPE International Drilling Conference and Exhibition
Introduction
• Reduce well cost:
• Minimize spud-to-TD time.
• Maximize ROP / minimize flat-time.
• Rotary drilling optimized by continuous adjustment of
process parameters (WOB, RPM).
• Challenge: Formations can change rapidly.
• Automation solution:
• Closed-loop system based on proven advisory application.
• Field results from 270 rigs and 1700 wells.
Rock
Strength
Rock
Composition
35
0 fe
et
Sandstone Shale
0 25ksi
Coal
SPE 199601 Large-Scale Deployment of a Closed-Loop Drilling Optimization System Stephen Lai
33–5 March 2020Galveston Island Convention Center, Galveston, Texas
IADC/SPE International Drilling Conference and Exhibition
Optimization Application
Control
Measurements
1 Hz data rate
Outer Loop
Control
Control Scheme
Driller supervises process and manages parameter limits.
Driller
On/Off
Optimization Limits
Autodriller Limits
Autodriller
Control
Measurements Rig
Drilling
Inner Loops
Top Drive PLC
Control
Measurements
>20 Hz data rate
The Plant
SPE 199601 Large-Scale Deployment of a Closed-Loop Drilling Optimization System Stephen Lai
43–5 March 2020Galveston Island Convention Center, Galveston, Texas
IADC/SPE International Drilling Conference and Exhibition
Main Optimization Loop
Main loop runs once per second: Start
Read inputs
Calculate internal signals
In drilling dysfunction?
N
Y
ROP/MSE optimization:
• calculate new WOB
• calculate new RPM
Update ADR and top drive setpoints
Execute ADRmanagement protocol
Execute dysfunction mitigation protocol
Need ADR management?
Y
N
• If drilling dysfunction is detected,
- mitigation protocol is executed.
• If autodriller (ADR) is not in good state,
- ADR management protocol is executed.
• Otherwise,
- perform ROP/MSE optimization.
SPE 199601 Large-Scale Deployment of a Closed-Loop Drilling Optimization System Stephen Lai
53–5 March 2020Galveston Island Convention Center, Galveston, Texas
IADC/SPE International Drilling Conference and Exhibition
ROP/MSE Optimization
Challenges:
• Extremum Seeking Control (input signal dithering):
• Simple – minimal tuning parameters.
• Adaptable – continuously seeks the peak.
• Robust – no model-based assumptions.
Solution:
Drill-off testing
ESC algorithm
start
• Formation variation is random and non-stationary.
• Drilling process is difficult to model accurately.
• Scalability – must work at all rigs/formations/basins.
RPM WOB
f (R
OP,
MSE
)
SPE 199601 Large-Scale Deployment of a Closed-Loop Drilling Optimization System Stephen Lai
63–5 March 2020Galveston Island Convention Center, Galveston, Texas
IADC/SPE International Drilling Conference and Exhibition
ROP/MSE Optimization
ROP
increase
WOB
increase
RPM
increase
constant
MSE
SPE 199601 Large-Scale Deployment of a Closed-Loop Drilling Optimization System Stephen Lai
73–5 March 2020Galveston Island Convention Center, Galveston, Texas
IADC/SPE International Drilling Conference and Exhibition
Dysfunction Mitigation
When drilling dysfunction is detected, an automated protocol is used to remove the condition.
• Stick-slip protocol
• Stringer protocol
• RCD protocol
• Motor stall protocol
• Etc.
Stick-slip exceeds threshold.
1
Optimization stops to focus on stick-slip. WOB decreased. Stick-slip
reduced below threshold.
3
RPM increased. WOB is returned to original value.
Optimization resumes.
5
Stick-Slip Protocol
4
2
SPE 199601 Large-Scale Deployment of a Closed-Loop Drilling Optimization System Stephen Lai
83–5 March 2020Galveston Island Convention Center, Galveston, Texas
IADC/SPE International Drilling Conference and Exhibition
Autodriller (ADR) Management
ADR Condition System Response
Control loop oscillationsAdjust setpoints to put ADR back in WOB-control mode
Torque limiting
DIFP limiting
• Operating state of ADR is critical for closed-loop optimization.
• ADR control issues [1]:
• Poor setpoint tracking.
• Control loop oscillations.
• ADR should be in a favorable control state for optimization.
[1] Pastusek et al. “Drill Rig Control Systems: Debugging, Tuning, and Long Term Needs”. SPE-181415.
SPE 199601 Large-Scale Deployment of a Closed-Loop Drilling Optimization System Stephen Lai
93–5 March 2020Galveston Island Convention Center, Galveston, Texas
IADC/SPE International Drilling Conference and Exhibition
Deployment Challenge #1: Human Factors
• User trust is needed:
• Driller must have confidence that system operating as designed → notifications/alerts.
• Organizational buy-in is needed [2].
[2] Behounek et al. “Change Management Challenges Deploying a Rig-Based Drilling Advisory System”. SPE-194184.
SPE 199601 Large-Scale Deployment of a Closed-Loop Drilling Optimization System Stephen Lai
103–5 March 2020Galveston Island Convention Center, Galveston, Texas
IADC/SPE International Drilling Conference and Exhibition
Deployment Challenge #2: Conservative Parameter Limits
For optimal drilling, true equipment limits should be used.
Upper WOB Limit
RPM
WOB
Lower WOB Limit
Low
er
RP
M L
imit
Upp
er
RP
M L
imit
optimization space
Upper WOB Limit
RPM
WOB
Lower WOB Limit
DIFP Limit (Autodriller)
ROP Limit (Autodriller)
Low
er
RP
M L
imit
Upp
er
RP
M L
imit
reduced optimization
space
SPE 199601 Large-Scale Deployment of a Closed-Loop Drilling Optimization System Stephen Lai
113–5 March 2020Galveston Island Convention Center, Galveston, Texas
IADC/SPE International Drilling Conference and Exhibition
Depth (ft)0 2000 4000 6000 8000 10000 12000
Depth (ft)
0 2000 4000 6000 8000 10000 12000 14000 16000 18000 20000
Deployment Challenge #3: Following the Limit Roadmap
• Small optimization window
• Frequent, ad-hoc changes
Bad Practice:
• Wide limit window
• Infrequent changes
• Allow system to optimize
Good Practice:
SPE 199601 Large-Scale Deployment of a Closed-Loop Drilling Optimization System Stephen Lai
123–5 March 2020Galveston Island Convention Center, Galveston, Texas
IADC/SPE International Drilling Conference and Exhibition
Field Deployment
SPE 199601 Large-Scale Deployment of a Closed-Loop Drilling Optimization System Stephen Lai
133–5 March 2020Galveston Island Convention Center, Galveston, Texas
IADC/SPE International Drilling Conference and Exhibition
ROP Improvement
1st well
No system
2nd well
No system
3rd well
With system
Each drilling trial has 3 consecutive wells.
~90 trials ~90 trials
Top quartile ROP improvement = 18.1% and 17.4%.
SPE 199601 Large-Scale Deployment of a Closed-Loop Drilling Optimization System Stephen Lai
143–5 March 2020Galveston Island Convention Center, Galveston, Texas
IADC/SPE International Drilling Conference and Exhibition
Conclusions
• Formations change rapidly → need closed-loop optimization:
• Simple (no model) algorithm is best for scalability.
• Mitigate dysfunction with triggered protocols.
• Create a good limit roadmap and follow it.
• Large-scale deployment: 270+ rigs, 1700+ wells, 8 countries.
• Average rotary ROP improvement of 7% (top quartile = 18%)
in 90 drilling trials.
SPE 199601 Large-Scale Deployment of a Closed-Loop Drilling Optimization System Stephen Lai
153–5 March 2020Galveston Island Convention Center, Galveston, Texas
IADC/SPE International Drilling Conference and Exhibition
Acknowledgements / Thank You / Questions
The staff at ExxonMobil Upstream Research Company.
The many field and office personnel who contributed to deployment of this system.
Mark Pawson, David Holoboff, Abdulkareem Dolapo, and Usman Farooq.
Special thanks to: