Drilling Simulator in Celle. Simulate, but what?

Transcription

1 Drilling Simulator in Celle Simulate, but what? PD Dr. Dr-Ing. habil C. Teodoriu Clausthal University Institute of Petroleum Engineering Hannover, Celle, Oct. Oct. 16, 16,

2 Shell RTOC history! 2001 Shell and Halliburton launched a pilot program using real-data from rigs in the Gulf of Mexico. Target: optimize the drilling process by identifying the variations between PLANNED parameters and REALITY. RTOC Real Time Operation Center Institute of Petroleum Engineering TU Clausthal 2

3 Shell RTOC New Orleans Institute of Petroleum Engineering TU Clausthal Source: Greg Guidry, GOM Outlook, energy summit

4 Drilling Simulator in Celle - Overview! Drilling Simulator Unit (DSU)! Flow Loop Unit (FLU)! Drilling Autoclave Systems (DAS) Institute of Petroleum Engineering TU Clausthal 4

5 Drilling Simulator DrillSim Unit (DSU) Server Ethernet ethercad Drilling Autoclave M Flow loop Institute of Petroleum Engineering TU Clausthal 5

6 Drilling HIL Simulator from NOV Institute of Petroleum Engineering TU Clausthal 6

7 Drilling Simulators between Software and Hardware Institute of Petroleum Engineering TU Clausthal 7

8 Drilling Simulator in Celle 1! Based on DrillSIM- 600 with CyberChair! Combined with extensive and state of the art hardware integration:! Flow Loop! Drilling Autoclave Institute of Petroleum Engineering TU Clausthal 8

9 Drilling Simulator in Celle - 2! Research level implementation has been negotiated. ROP DS-Database! Option to communicate with real hardware through I/O module of DS Input Parameter DS Model ITE Model Output Parameter Software switch Institute of Petroleum Engineering TU Clausthal 9

10 Dateneingabe Auswertungstechnik Modul 1 Sitzkiste Modul 2 Modul 3 HMI Mensch Modul 4 Modul n Offener CAN - Bus Institute of Petroleum Engineering TU Clausthal 10

11 Dateneingabe Auswertungstechnik Research Option: Sensor Signatur Sensor Signatur Modul 1 Modul 2 Sitzkiste Hardware - Realisierung von Modul 3 Sensor Signatur Sensor Signatur Modul 3 HMI Mensch Sensor Signatur Modul 4 Sensor Signatur Modul n Offener CAN - Bus Institute of Petroleum Engineering TU Clausthal 11

12 Hands On Simulators CT Institute of Petroleum Engineering TU Clausthal 12

13 Hands On Simulators CT Institute of Petroleum Engineering TU Clausthal 13

14 The Drilling DrillSim Autoclave Systems (DAS) Server Ethernet ethercad Drilling Autoclave Systems M Flow Loop Unit Institute of Petroleum Engineering TU Clausthal 14

15 DAS worldwide concepts Chain Hydraulic cylinder Wash pipe Top Drive Dead Weight Frame Displacement transducers Drilling hammer Sample rock or Steel block Water reservoir Terratek Drilling Autoclave Institute of Petroleum Engineering TU Clausthal 15

16 DAS - Research Focus! Development of an intelligent bit concept to test various sensors and other bit features.! Understanding of bit rock interaction and standardization of testing setups.! Testing of various bit types! Testing of various hydraulic concepts for bits! Mathematical description of bit-rock interaction. Institute of Petroleum Engineering TU Clausthal 16

17 Overview of existing Rock-Bit interaction testing stands 1. Simulation 2.Single Cutter test 3.Small scale laboratory test 4.Full scale laboratory test 5.Field test Institute of Petroleum Engineering TU Clausthal 17

18 Modeling and Simulation Theoretical analysis of PDC bit rock interaction Proposed generelized equations for TOB and WOB Wear mechanism due to PDC bit rock interaction Das Bild kann nicht angezeigt werden. Dieser Computer verfügt möglicherweise über zu wenig Arbeitsspeicher, um das Bild zu öffnen, oder das Bild ist beschädigt. Starten Sie den Computer neu, und öffnen Sie dann erneut die Datei. Wenn weiterhin das rote x angezeigt wird, müssen Sie das Bild möglicherweise löschen und dann erneut einfügen. Where, T c, T f, T v torque/t b conponents W c, W f, - weight components m number of blades, n number of cutters on a blade Patil and Teodoriu, 2013, Oil Gas European Magzine, Vol.3. Patil and Teodoriu, 2013, DGMK/ÖGEW-Frühjahrstagung, Celle Institute of Petroleum Engineering TU Clausthal 18

19 Testing and Comparing Drill Bits a Challange? Testing vs. Comparing Chowdhury, BHI, IDEC 2011 Slb, Drill. Dyn. Sensors and Optimization, 2010 Institute of Petroleum Engineering TU Clausthal 19

20 Selected Testing facilities specifications A B C D E G H WOB*(k*lbs) Rotary*Speed*(RPM) Circulation*rate*(GPM) ROP*(ft/hr) TOB*(ftElb) ,000 5, ,250 10,000 Rotary*power*(HP) ConGining*pressure*(psi) , N/A +N/A N/A+ 15,000 Overburden*pressure*(psi) , N/A ,000 Borehole*pressure N/A+ 10, N/A N/A+ 10,000 Max.*Bit*Size*(in.) 7+7/ /8+ 4+½+ 4+¾+ 7+7/8 12+1/4 Institute of Petroleum Engineering TU Clausthal 20

21 Main Parameters of a Multipurpose Testing Rig WOB vibrations TOB RPM MSE directional Flow Rate Institute of Petroleum Engineering TU Clausthal 21

22 MSE values for a PDC Bit after SPE MSE = psi TOB (ft-lb) MSE (psi) TOB (ft-lb) MSE (psi) A B C D E F G ITE 0 Institute of Petroleum Engineering TU Clausthal 22

23 The New Testing Facilities Specifications ITE*Experimental*Drilling*Facility WOB*(k*lbs) 120 Rotary*Speed*(RPM) Max+120 Circulation*rate*(GPM) ~+800 ROP*(ft/hr) 500* TOB*(ftElb) Max Rotary*power*(HP) ~+500 ConGining*pressure*(psi) 7500+(upgradable) Overburden*pressure*(psi) 7500+(upgradable) Borehole*pressure*(psi) 7500+(upgradable) Max.*Bit*Size*(in.) 26 MSE*(psi) *estimated+values Institute of Petroleum Engineering TU Clausthal 23

24 Schematic View of DAS Rota5ng)head Main) hydraulic) cylinders Rota5ng)head Drilling) assembly Drill) bit Pressurized) rock) container Til5ng) hydraulic) cylinders Institute of Petroleum Engineering TU Clausthal 24

25 DrillSim Flow-loop Unit (FLU) Server Ethernet ethercad Bohrversuchsstand M Flowloop Institute of Petroleum Engineering TU Clausthal 25

26 FLU Worldwide Concepts Max)Pres) 50)MPa Full)range)of)Drilling)Simulator)Zentrum)in)Celle Institute of Petroleum Engineering TU Clausthal 26

27 The Flow Loop Institute of Petroleum Engineering TU Clausthal 27

28 The Flow Loop Institute of Petroleum Engineering TU Clausthal 28

29 The FLU Schematic Institute of Petroleum Engineering TU Clausthal 29

30 Flow Loop Description! Unique full size pumping system! Pressure rating up to 500 bar! Flow rate up to 3000 l/min! Horizontal test section length ~70 m! Total length upgradable to 300 m

31 Research Focus! Perform fundamental research on hydraulic modeling for drilling fluids, especially under the consideration of downhole tools effect.! Implement the pump as Hardware in the Loop into the DrillSim System, in order to simulate Transient Modes for the hydraulic system! Testing of downhole tools under wellbore pressure conditions! Testing of mud pumps and electric drivers under field loading conditions! Testing of power control units (high power electronics)

32 Other Research Interests! High power electric systems (up to 1.2 MW) require attention, e.g. when continuous control is needed.! Managed pressure drilling techniques involve continuous pump control.! New electric control systems could allow the pump to perform better, while also reducing energy consumption.

33 The Flow Loop Components! Tanks and solids preparation units (shacker, hydrocyclons, etc)! Mud pump! Mud pump controlling unit! Flow loop itself! Tool assembly line! Data Acqusition Institute of Petroleum Engineering TU Clausthal 33

34 Top Drive Derrick Weight on Bit Torque on Bit Hook load Institute of Petroleum Engineering TU Clausthal 34

35 Thank you for your attention Contact: Drilling Simulator in Celle Institute of Petroleum Engineering TU Clausthal 35