Closed-Loop Digital Workflow to Drive Drilling Performance

Abstract

Abstract Drilling performance is becoming the top differentiator in the market, especially in highly competitive US land basins. This drives operators to input more energy into the system with higher rev/min, flow, and weight on bit (WOB). In many cases this energy is transformed into drilling dysfunction (shock and vibration [S&V]) instead of higher rate of penetration (ROP). To minimize drilling dysfunction and maximize energy efficiency, a fully digital and closed-loop workflow was developed. The workflow begins with use of a proprietary at-bit sensor, which captures high-resolution at-bit measurements of three-axis acceleration, torsional vibration, and rev/min. The tool is placed inside any existing bit and does not require an additional sub, thus not introducing extra connections, bottomhole assembly (BHA) integrity risk, and/or length. The high-resolution data is automatically processed and analyzed to reveal critical drilling dynamics, which are replicated in a digital model. This creates a highly accurate virtual environment in which to evaluate bit design, eliminating the cost and risk of real-world trial and error, enabling efficient, fit-for-purpose introduction of new technologies. The new digital workflow was first used in a challenging, interbedded application in East Texas. High frequency at-bit measurements were used to develop a new bit and data-driven operating parameter roadmaps. These yielded improved drilling performance, with 69% higher ROP, better dull conditions, and 67% lower vibrations locally, when compared to the direct operator offsets. The workflow was then used in a curve/lateral application in the Permian Basin, known for challenging S&V conditions. Key performance targets were single-run to total depth (TD), high dogleg severity (DLS) output in the curve, and record ROP in the lateral. A new bit was designed, and recommended drilling parameters were defined within the data-driven virtual environment. Field testing confirmed the model’s predictions, with a 10% average increase in ROP. High-resolution at-bit downhole measurements coupled with digital simulation capabilities have led to development of a new workflow driving the evolution of drill bit design. Instead of the traditional trial and error approach that costs resources, time, and performance, the new workflow with data-enhanced digital modelling and virtual drilling environment enables increased confidence, optimized solutions, and decreased cycle time.