CONSTRUCTION OF AN AUTONOMOUS LABORATORY SCALE-DRILLING RIG FOR TESTING AND CONTROL OF DRILLING SYSTEMS

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1 CONSTRUCTION OF AN AUTONOMOUS LABORATORY SCALE-DRILLING RIG FOR TESTING AND CONTROL OF DRILLING SYSTEMS Authors: Erik Andreas Løken (UiS) & Suranga C.H. Geekiyanage (UiS) Co-Authors: Dan Sui (UiS) & Robert Ewald (IRIS)

2 OUTLINE 1. Introduction Rig structure (system design, components, sensors) Data acquisition & data quality improvement Control system design (WOB regulation, fault detection) Rig performance optimization Conclusion Future work

3 INTRODUCTION Team Drillbotics 2017 competition Fully autonomous laboratory-scale rig 2.

4 RIG STRUCTURE SYSTEM DESIGN 3.

5 RIG STRUCTURE SYSTEM DESIGN Power transmission Swivel Top Drive Hoisting Circulation Actuator hoisting system Drill pipe Pressure valve Drill string, BHA & bit BHA Return line Leak valve PDC bit Multifiltration system Rock 4. Dual-Pump setup

RIG STRUCTURE POWER TRANSMISSION Hollow-shaft brushless top drive (0 3500 RPM) 2.86 Nm rated torque (8.

6 RIG STRUCTURE POWER TRANSMISSION Hollow-shaft brushless top drive ( RPM) 2.86 Nm rated torque (8.59 Nm instantaneous torque) Direct torque transfer to drill string assembly Low vibration-signature 5. Programmable auto-braking

7 RIG STRUCTURE HOISTING SYSTEM Three actuators w/ stepper motors and brakes 500 N WOB capacity (hook load = 168 N) F z F x F y Z-axis Top Drive Actuator #1 Variable speed adjustment for different drilling stages X-axis Actuator #2 Actuator #3 6.

RIG STRUCTURE CIRCULATION SYSTEM P max = 4.1 bara Q = 11.5 l/min (min. velocity range of 0.5 0.

8 RIG STRUCTURE CIRCULATION SYSTEM P max = 4.1 bara Q = 11.5 l/min (min. velocity range of m/s for cuttings transportation) Attached w/ swivel (1000 RPM capacity) Filtration deposit system 7.

9 RIG STRUCTURE DRILL STRING, BHA & BIT Interchangable string (DP), BHA & bit Aluminum pipe (WT = 0.889mm) Stainless steel BHA w/ three stabilizers 8. PDC bit with raked cutters

10 DATA ACQUISITION SENSOR INTEGRATION Three triaxial load cells (LC), 0-100N range (Fx, Fy, Fz) RPM &T TD LC RPM and torque (T TD ) in top drive sensors LC H T LC Ferromagnetic torque sensor (T) h Pressure transmitter (P) Rock P 9. Reference height sensor (H)

11 DATA ACQUISITION DATA LOGGING & SAMPLING Torque Sensor sample rate << 17 ms at 1000 RPM Arduino DUE loop-time for other sensors Data logging: uploaded every 100ms 10.

12 DATA QUALITY IMPROVEMENT FILTERING OF DATA T, RPM, P, Fx/Fy, h low-pass (LP) filtered Fz (WOB) median, moving avg. & LP filters Frequency-analysis for cut-off frequency 11.

CONTROL SYSTEM HIERARCHICAL TWO-LAYER STRUCTURE STRATEGIC DECISION CONTROLLER + VISUALIZATION Normal Drilling Fault Detection Main computer Nondeterministic control loop Arduino DUE (3x) HOISTING

13 CONTROL SYSTEM HIERARCHICAL TWO-LAYER STRUCTURE STRATEGIC DECISION CONTROLLER + VISUALIZATION Normal Drilling Fault Detection Main computer Nondeterministic control loop Arduino DUE (3x) HOISTING SYSTEM CONTROLLER ROTATIONAL SYSTEM CONTROLLER CIRCULATION SYSTEM CONTROLLER Arduino DUE programmed as finitestate machines (FSMs) Sensor distribution TRIAXIAL LOAD CELLS & HEIGHT SENSOR 2 TORQUE SENSORS + RPM FEEDBACK PRESSURE SENSOR

14 CONTROL SYSTEM NORMAL DRILLING STATE Complete closed-loop PIDcontroller for WOB Input Phases (1. calibration, 2. pilot hole drilling, 3. normal drilling, 4. optimization, 5. completion) RPM max 13. Incremental increase of RPM and WOB setpoint (sweep algorithm) max WOB

15 CONTROL SYSTEM FAULT DETECITON & INCIDENT MANAGEMENT Coordinator implemented Stick slip detected (T increase, RPM decrease) Detects axial vibrations, stick slip, lateral vibrations, pack-off (OP), leak, keyseating & overpull Pick-up off-bottom (10mm) Increase RPM by 10%, reduce WOB 10-15%. Retag bottom Problems simulated in laboratory Yes Stick slip? No Drilling commences 14. Example: stick-slip management If still stick slip at RPM/WOB-thresholds, pick-up offbottom. Set very low WOB & very high RPM. Continue slow drilling before sweep can commence

16 CONTROL SYSTEM FAULT DETECTION & INCIDENT MANAGEMENT Stick slip & lateral vibrations get detected System attempts to correct the faults and reduce vibrations 15.

17 CONTROL SYSTEM HUMAN MACHINE INTERFACE 16.

18 RIG PERFORMANCE ROP CALCULATION 17. ROP calculated ( h t ) Instantaneous- and average-rop calculated using arrays of 15 s & 180 s Effect of DP deflection will be implemented (depth-based measurement) Replace oldest value with newest every second 1 st second < > 2 nd second < > 3 rd second < > Etc. sum height array # of datapoint array 60 = ROP [ mm min ]

19 WOB(kg) WOB(kg) Torque of bit(nm) Torque of bit(nm) ROP(mm/min) ROP(mm/min) RPM RPM RIG PERFORMANCE RESULTS, NORMAL DRILLING Weak formation (cement) Hard-drilling formation (floor tiles) time(min) time(min) time(min) time(min) Time(min) Time(min) Time(min) Time(min) 18.

20 UCS(MPa) UCS(MPa) MSE(MPa) MSE(MPa) RIG PERFORMANCE NEW FORMATION DETECTION MSE = 4 τ bit RPM π d 2 bit ROP + 4 WOB 2 π d bit Weak formation (cement) Hard-drilling formation (floor tiles) Time(min) Time(min) Time(min) Time(min) 19. UCS = 0.35 MSE

21 CONCLUSION ADVANTAGES Understanding, evaluating and investigating current solutions available Experiments for developing models, control system algorithms etc. Prototyping of BHA / sensors / components / bits CHALLENGES Not necessarily scalable to industry Some components (i.e. actuators for hoisting) only work well on lab-rig Limited sensors & processing power 20.

22 FUTURE WORK Drill string dynamics model development Machine-learning fault detection Kalman filtering for WOB and ROP estimation Gauss-Seidel Constraint Control for ROP-optimization New BHA design w/ real-time downhole measurements 21. Mud design & cuttings transportation

23 QUESTIONS? 22.

Using Drilling Dynamics To Reduce Drilling costs

1 Welcome Using Drilling Dynamics To Reduce Drilling costs 2 Using Drilling Dynamics The cost of the drill bit, mud motor, and other BHA components depends the downhole conditions in which they operate.