John Hedengren
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Primary funding for the Society of Petroleum Engineers Distinguished Lecturer Program is provided through member donations to the SPE Foundation and a contribution from Offshore Europe. Additional support comes from AIME. The program offers lectures from industry professionals on various topics, and is grateful to companies that allow their employees to participate as lecturers.
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John Hedengren
- 1. Primary funding is provided by The SPE Foundation through member donations and a contribution from Offshore Europe The Society is grateful to those companies that allow their professionals to serve as lecturers Additional support provided by AIME Society of Petroleum Engineers Distinguished Lecturer Program www.spe.org/dl
- 2. Society of Petroleum Engineers Distinguished Lecturer Program www.spe.org/dl John D. Hedengren, Ph.D. Brigham Young University Drilling Automation and Downhole Monitoring with Physics-based Models
- 3. Outline • Why and how to automate drilling? • 3 elements of automation • Automation case study • Closed loop downhole automation • Challenges and opportunities: Physics-based or machine learned models • Create fit-for-purpose digital twins for automation • Unlock a new way of thinking • Predictive versus reactive automation • Combine pressure and rate control • Conclusions http://graphics8.nytimes.com 3
- 4. Why Automate Drilling? •Benefits of Automated Drilling • HSE– faster response to problems • Economic– operate closer to constraints, shorter drilling time, especially with challenging market conditions • Average of 4 uncontrolled well situations in the Gulf of Mexico each year (SPE 170756 & Morris, 2014) http://graphics8.nytimes.com 4 •Recent Success in Automation (SPE 184694, 139848, 150973, 73159) • Greater accuracy and consistency • Faster drilling with fewer interruptions • More accurate directional drilling
- 5. Automation OpportunitiesAutomation Across Industries 5 Sensors, Actuators, and Algorithms
- 6. Automation Opportunities Source:PetroWiki Levels of Automation 6 Level 1 Level 2 Level 3
- 7. Automation Opportunities Source:PetroWiki Levels of Automation 7 Level 5 Level 8 Level 10
- 8. Automation Opportunities Source: Tesla What Level of Automation? 7
- 9. How to Automate Drilling? •Three elements for automation • Sensor (measurement) • Actuator (valve, motor, pump) • Controller (computer) •Considerations • Open or proprietary • Centralized or distributed • Simple or complex 9 Sensor Actuator Controller Reservoir Weight on Bit Rotation Speed Drill String Annulus Back Pressure Pump Main Mud Pump Choke Valve
- 10. Transmit Downhole Sensor Data 10 Sensor 25 GB/hour 150,000 points/sec 51,200 GB/hr Source: Simafore, Fortune, RTInsights, Cisco Hedengren, J. D., Eaton, A. N., Overview of Estimation Methods for Industrial Dynamic Systems, Springer, 2017, DOI: 10.1007/s11081-015-9295-9.
- 11. Monitor Bottom Hole Pressure 11 Sensor Depth Pressure Connections BHP Drilling Window Adjust Choke Valve
- 12. Need Managed Pressure Drilling 12 Sensor Depth Pressure and Mud Density Mud Density Depth Pressure and Mud Density Mud Density Wide Pressure Margins Narrow Pressure Margin
- 13. Managed Pressure Drilling Overview Actuated Sensor Estimated Mud Pump Flow Rate Bottom Hole Pressure Annulus Drill Fluid Density Choke Valve Opening Annular Pressures Annulus Friction Factor Back Pressure Pump Flow Choke Valve Pressure Reservoir Pore Pressure Actuators for MPD and ROP SPE-173045 13 Choke Valve Opening Mud Pump Flow Rate Pressure Controller Pressure Weight on Bit (WOB) Rev per Minute (RPM) ROP Controller Rate of Penetration (ROP) Managed Pressure Drilling (MPD) Rate of Penetration (ROP) Cuttings LoadingFluid Influx
- 14. Pressure Control Through Automation • Normal drilling operations and a pipe connection procedure, offshore SE Asia with WDP • Choke pressure adjusted to control bit pressure • Bit pressure •±1 bar (±15 psi) during normal drilling •±3 bar (±45 psi) during a pipe connection 14IADC/SPE 112651
- 15. Controllers for Automation 15 •Sequence control for batch processes •Feedback control for continuous systems •Feedforward control anticipates disturbances https://commons.wikimedia.org FUTUREPAST k Actuator P+I+D+FF P = proportional error I = integral error D = derivative error FF = feedforward
- 16. PID Temperature Control 16 Sensor T (oC) Actuator Heater Controller apmonitor.com/heat.htm
- 17. FUTUREPAST k Conventional Feedback Control Model Predictive Control Driving While Looking in Reverse (Feedback) Driving While Looking Forward (Predictive or Feedforward) 17 Improve with Predictive Automation
- 20. Challenge: Nonlinearity in Drilling Increasing mud pump flow Typical Operation Range DownholePressure(bar) Choke Valve Opening (%) 20
- 21. What are the Opportunities? •Data-based Modeling • Deep Learning / Artificial Intelligence •Physics-based Modeling • Wellbore Hydraulics • Drill String Dynamics •Optimize • Computing hardware and optimization algorithms • Optimization Benchmarks 2,500,000,000 times faster • Moore’s law (17,000x faster) and optimizer improvements (150,000x faster) in 30 years Data Optimize Models Automation 21
- 24. Advances in Physics-based Models •Complex Models • Wellbore Hydraulics • Drill String Dynamics SPE-112109 Courtesy eDrilling 24
- 25. Advances in Physics-based Models •High Fidelity Modeling • Wellbore Hydraulics • Drill String Dynamics SPE-173154 Courtesy MSC Software 25
- 27. Need Fit-for-Purpose Models Downhole pressure Mud pump pressure Choke valve pressure 27 P(bar)P(bar)P(bar) Lower order, machine learned model matches physics-based model Time (sec)
- 28. Machine Learning with Automation 28 Controller apmonitor.com/heat.htm
- 29. ConventionalControl Mud Pump Constant Improved Pressure Control ModelPredictiveControl Lower Pump Limit Maintains Cuttings Transport 29 Flow Excellent setpoint tracking Choke Pump Coordinates with Choke Small Choke Adjustments
- 30. New Way of Thinking: Multivariate Single-Input Single-Output Multi-Input Multi-Output Conventional Control Action Set Point Measurement Model Predictive Control Set point or Range Conventional Control Action Set Point Measurement Measurements Control Coordinated Action Multiple 30
- 31. Automated Kick Response Improvement with Combined Control Automation Improvement New Way of Thinking: Pressure Control and Rate Optimization Choke Valve Opening Mud Pump Flow Rate Pressure Controller Pressure Weight on Bit (WOB) Rev per Minute (RPM) ROP Controller Rate of Penetration (ROP) Rev per Minute (RPM) Weight on Bit (WOB) Choke Valve Opening Downhole Pressure Rate of Penetration Combined Controller Pump Flow Rates SPE-170275 ROP 20% higher 31
- 32. Challenges of Predictive Automation •Requires digitization as a foundation •Automation can become unreliable if the control model is not calibrated or is not sufficiently accurate •Advanced nonlinear, predictive controllers can fail to converge and result in lost or poor control •To address these challenges, reinforcement learning maintains model accuracy and controller stability without interrupting the drilling process 32
- 33. Conclusion • Automation leads to: •Greater accuracy and consistency •Faster drilling with fewer interruptions • Essential elements for automation: Sensors, Actuators, Controllers • Predictive automation and optimization needs fit-for-purpose modeling • Multivariate control coordinates among several actuators and objectives • There are many challenges and opportunities for predictive automation 33
- 34. Resources and Collaborations •Open Source Drilling Models + Cases + Data • Pastusek, P., Payette, G., Shor, R., Cayeux, E., Aarsnes, U.J., Hedengren, J.D., Menand, S., Macpherson, J., Gandikota, R., Behounek, M., Harmer, R., Detournay, E., Illerhaus, R., Liu, Y., Creating Open Source Models, Test Cases, and Data for Oilfield Drilling Challenges, SPE/IADC Drilling Conference, The Hague, Netherlands, March 2019, SPE-194082-MS. https://github.com/APMonitor/drilling •Online Course •Machine Learning and Dynamic Optimization •January-April 2019: https://apmonitor.com/do •Connect on LinkedIn: https://www.linkedin.com/in/hedengren 34
- 36. Society of Petroleum Engineers Distinguished Lecturer Program www.spe.org/dl 36 Your Feedback is Important Enter your section in the DL Evaluation Contest by completing the evaluation form for this presentation Visit SPE.org/dl #SPEDL 36