SPE-152231-PP

BHA Selection and Parameter Definition Using Vibration Prediction Software

Leads to Significant Drilling Performance Improvements
Dalmo Amorim, Chris Hanley, National Oilwell Varco, SPE; Daltro J. Leite, Petrobrs, SPE
Copyright 2012, Society of Petroleum Engineers

This paper was prepared for presentation at the SPE Latin American and Caribbean Petroleum Engineering Conference held in Mexico City, Mexico, 1618 April 2012.

This paper was selected for presentation by an SPE program committee following review of information contained in an abstract submitted by the author(s). Contents of the paper have not been reviewed
by the Society of Petroleum Engineers and are subject to correction by the author(s). The material does not necessarily reflect any position of the Society of Petroleum Engineers, its officers, or
members. Electronic reproduction, distribution, or storage of any part of this paper without the written consent of the Society of Petroleum Engineers is prohibited. Permission to reproduce in print is
restricted to an abstract of not more than 300 words; illustrations may not be copied. The abstract must contain conspicuous acknowledgment of SPE copyright.


Abstract

The understanding and mitigation of downhole vibration has been the subject of intense scientific research in the drilling industry
in recent years, as inefficient drilling results in slower and more expensive operations. In order to drill ahead, a sufficient amount
of energy must be supplied by the rig to overcome the rock strength, the reactive torque of the drilling system, drag forces, fluid
pressure losses, as well as the energy lost by way of downhole vibrations.

It has been well documented that downhole vibrations are a significant drain on the amount of effective drilling energy available to
the bit. When the drill string enters resonant modes of vibration, not only does the drilling efficiency decrease, but the likelihood of
catastrophic drill string component failures increase. The amount of destructive energy expended in these resonant modes of
vibration, when left unchecked, may overcome the material limits of components in the drill string. In this sense, the mitigation of
downhole vibrations will result in faster, smoother, and cheaper drilling operations.

Software using Finite Element Analysis (FEA) has been developed to understand these vibration phenomena and to predict which
combinations of drilling parameters should result in more efficient drilling. The software graphically presents the results, depicting
undesired levels of resonant vibration produced with specific drilling parameter combinations, based on the BHA geometry and
wellbore design. Predictions made by this software have produced notable results, including a world record for Rate of Penetration
(ROP) in the Gulf of Mexico.

This paper also examines different Bottom Hole Assembly (BHA) designs and the resonant vibration modes that may be initiated
while drilling, using the proprietary software package. The combination of proper BHA design and the correct selection of
parameters results an overall improvement to drilling efficiency. A variety of case studies from Latin America, incorporating the
results of the vibration analysis, will demonstrate solid improvements to drilling operations in terms of time and cost savings,
increased penetration rates, and improved dull conditions. The use of field validated software for vibration prediction and
mitigation has a potential role in the drilling industry as important as the introduction of PDC bits in the 1980s.

Fundamentals

The natural frequency of a dynamic system is defined as the frequency at which the system will oscillate in free vibration with no
input motion driving the system. If a single degree-of-freedom mass, spring, damper system is examined, the undamped natural
frequency can be calculated for translational motion using the following equation
1
:

M
k
n =

2 SPE SPE-152231-PP
where:

n
(rad/s) is the Undamped Natural Frequency
k (N/m or lbf/ft) is the System Stiffness or Spring Rate
M (kg or lbm) is the System Mass
As there is damping present in the analysis practical mechanical systems, this quantity is largely a theoretical value describing the
free vibration frequency of the system with no damping. Though, the damped natural frequency can also be calculated for the same
single degree-of-freedom mass, spring and damper system for translational motion using the following equation
1
:

2
1 * = n d

where:

d
(rad/s) is the Damped Natural Frequency

n
(rad/s) is the Undamped Natural Frequency
( ) is the Damping Ratio (as defined below)

c c
c
=

where:
( ) is the Damping Ratio
c (N*s/m or lbf*s/ft) is the System Damping
c
c
(N*s/m or lbf*s/ft) is the Critical Damping for the System (as defined below)

k M cc * 2 =

where:
c
c
(N*s/m or lbf*s/ft) is the Critical Damping for the System
M (kg or lbm) is the System Mass
k (N/m or lbf/ft) is the System Stiffness or Spring Rate

Driving the system into forced vibration at an input frequency close to a natural frequency of the system can result in large
amplitude output motion called resonance. The input frequency that results in this large amplitude output motion in forced
vibration is the resonant frequency for the system
1
. It has been previously demonstrated with measured downhole dynamics data
that resonance does in fact exist in drilling systems, manifested as axial, lateral, torsional or combinations of vibration modes in
the drill string, that can escalate to severe magnitudes if left unchecked
2
.

For simple systems, such as a single degree-of-freedom mass, spring, damper system in translational motion, the natural
frequencies can be calculated quite simply as described above using classical analytical method assuming the mass, stiffness, and
damping can all be quantified. As the systems we want to analyze grow more complex, so to do the methods required to accurately
characterize the natural and resonant frequencies of the systems. Drilling assemblies are typically composed of various tools and
components with numerous geometric changes and as a result these systems can be difficult to characterize and analyze using the
classical analytical methods described above.

Finite Element Analysis (FEA) is a method that can be applied for solving complex systems where the finding the solution using
classical analytical methods is too complicated or inefficient. The fundamental use of finite element analysis is to provide a
method to model a system in such a manner that a numerical solution can be found for a specific problem. This type of numerical
solution lends itself to computer processing as hundreds or thousands of simultaneous equations may be required to arrive at the
final solution
3
. A proprietary software system employing FEA to solve for the dynamics of a drill string system has been
developed to help avoid encountering resonant modes of vibration while drilling.

In order to predict and avoid resonance frequencies for the drilling assembly, a finite element model of the entire drill string is
created using the proprietary software system based on the geometry and material of the component in the BHA and drill string.
The software also builds a model of the borehole that the drilling assembly will be operating within for the analysis based on the
three-dimensional well path and borehole sizes and also incorporates mud properties and expected surface and downhole drilling
SPE SPE-152231-PP 3
parameter ranges. Then a series of calculations are run in the FEA engine to predict the drill string dynamic behavior as the drilling
assembly drills through a set sequence in the well.

The software provides the end user with input frequencies throughout the drilling interval in question that should excite the system
into resonance. The primary frequencies induced into the system are generated by the rotation of the drill string and, that being the
case, the input frequencies that would excite the system into resonance can be resolved into combinations of surface and downhole
drilling parameters.

The intention of the simulation is to find which excitation frequencies in terms of input drilling parameters will lead to string
resonance and give the end user of the system methods to avoid these input frequencies when possible. This optimization
methodology is much more effective than the current bit selection based on the offset wells
4
, ROP and IADC Bit Wear, as bit
selection would be the refinement and not the source of the optimization.

BHA Design

Various techniques exist in predicting the behavior of drilling assemblies when rotated at different speeds through different
trajectories. Under the operational point of view, if the correct measures are achieved the bit will ideally rotate concentrically, with
little or no variations in the angular speed, torque, or weight applied. Under this ideal situation the Mechanical Specific Energy
(MSE) would meet the compressive strength of the rock and efficiency of the operation would be 100%
5
.

Even though these methods help to reduce the chances of encountering damaging vibration events and improve overall
performance, they do little to damp out vibrations when they are encountered. Without these techniques, though, the resources
available at the rig site would be traditional drill-off test and tentative parameter adjustments, searching for increments in the rate
of penetration as drilling advances.

When hard formations are being drilled, the coefficients of restitution of the formations raise the importance of giving focus to the
drilling dynamics, which should even precede bit selection in importance. Severe or catastrophic damage is commonly
encountered in these situations due to shocks to the bit and in BHA components, associated with erratic and/or poor performance.
High drilling costs are experienced and the learning curve
4
can effectively be endless. The most common practice in these
situations is to replace the existing bits for impregnated diamond bits or higher IADC roller cone bits, leading to longer bit runs but
very likely with even lower penetration rates and less catastrophic damages. Then, these results are usually taken as the
benchmarks of an area with the assumption that a new optimum point has been reached.

One of the objectives of the techniques described in this paper is to introduce rational changes to the BHA that would generate the
least number of modes of inefficiency. This would permit the operator to build a BHA with a wider range of safe parameters.
Another objective would be to anticipate the combinations of parameters where vibrations levels and performances would be
optimal if BHA design changes are limited for the operation. BHA modeling might include analysis of standard rotary assemblies,
downhole motor assemblies, and rotary steerable assemblies and these analyses can cover all the types of drilling applications and
trajectories that may be applied in the field under investigation.

Research Studies

The first lesson learned in the computational BHA analysis using FEA is that the combination of well design, BHA design, and
input drilling parameters that lead to a safe condition in a given borehole size is not valid for other borehole sizes. A generic
packed BHA was modeled in the software for a vertical section to drill from 0 to 1000 m, as per the description below:

Bit, Bit Sub, Stabilizer, 9 Drill Collar, Stabilizer, 9 Drill Collar, Stabilizer, 9 Drill Collar, Crossover, 6 x 8 Drill
Collars, Crossover, 6 Drill Collar, Crossover, 12 x 5 Heavy Weight Drill Pipe, and 5 19.5 lb. Drill Pipe to surface.

Three different borehole sizes were then used in the analysis for the same BHA design: 26, 17 and 12. In the graphs below
(Figure 1) on the left are the results of the analysis for the BHA in a 26 hole section and on the right are the results of the analysis
for the BHA in a 17 hole section.

4 SPE SPE-152231-PP
0
200
400
600
800
1000
1200
0 25 50 75 100 125 150 175 200
M
D
[
m
e
t
e
r
s
]
String RPM
Stabilized BHA - High WOB
Critical Speed Analysis - 26 vertical section
20,000 lb
24/ 30,000 lb
30,000 lb
30,000 lb
Vertical
30,000 lb

0
200
400
600
800
1000
1200
0 25 50 75 100 125 150 175 200
M
D
[
m
e
t
e
r
s
]
String RPM
Stabilized BHA - High WOB
Critical Speed Analysis - 17.5 vertical section
Vertical
20,000 lb
24/ 30,000 lb
30,000 lb
30,000 lb
30,000 lb

Figure 1. Comparisons of the BHA analysis in the 26 hole section to the BHA analysis in the 17 hole section.

The 26 hole section analysis from the model shows high risks of lateral vibration events at the range of 45 to 75 RPM (depicted as
yellow triangles in the chart). For the same BHA in a 17 hole section, the zone where the same high risk of lateral vibration is
identified by the model is displaced to a notably higher RPM. The same phenomenon occurs in the second mode of lateral
vibration identified by the model. This zone is originally found in the range of 135 to 175 RPM for the BHA in a 26 hole section,
however, the second lateral vibration zone almost disappears from the chart for the BHA in a 17 hole section as the resonance
would occur at input frequencies higher than 200 RPM.

Resonance in a larger diameter borehole leads to relatively flexible drill string components chaotically accelerating and
decelerating laterally for considerably large distances, with the potential for very high magnitude impacts with the hole wall. These
forces and impacts can lead material fatigue and wall collapse. An increased risk of getting stuck or drilling equipment failure can
exist in these conditions. And, being that the borehole is further enlarged by these circumstances, the actual resonance of the
system may occur at rotary speeds more reduced than what was initially identified by the scientific model.

The torsional modes of vibration present an identical migration of frequencies to higher RPMs as the borehole diameter is
decreased. The axial vibrations, however, do not show changes as the borehole diameter is decreased in the vertical section.

In the graphs below (Figure 2) on the left are the results of the analysis for the BHA in a 17 hole section and on the right are the
results of the analysis for the BHA in a 12 hole section. When looking now at the BHA modeled in a 12 hole section and
comparing the results to the previous analyses, the same phenomenon is repeated: lateral vibrations and harmonics migrate to
higher frequencies, the torsional harmonics undergo a small increase in frequency while axial harmonics remain unchanged for the
BHA.

0
200
400
600
800
1000
1200
0 25 50 75 100 125 150 175 200
M
D
[
m
e
t
e
r
s
]
String RPM
Stabilized BHA - High WOB
Critical Speed Analysis - 17.5 vertical section
Vertical
20,000 lb
24/ 30,000 lb
30,000 lb
30,000 lb
30,000 lb

0
200
400
600
800
1000
1200
0 25 50 75 100 125 150 175 200
M
D

[
m
e
t
e
r
s
]
String RPM
Stabilized BHA - High WOB
Critical Speed Analysis - 12.25 vertical section
Vertical
20,000 lb
24/ 30,000 lb
30,000 lb
30,000 lb
30,000 lb

Figure 2. Comparisons of the BHA analysis in the 17 hole section to the BHA analysis in the 12 hole section.

SPE SPE-152231-PP 5
As so, a conservative parameter recommendation to use 85 RPM for the BHA in the 26 and 12 hole sections would be
acceptable to minimize the potential for lateral resonance, but this 85 RPM parameter recommendation could be catastrophic for
the same BHA when drilling in the 17 hole section.

Case Studies

Compact Downhole Drilling Dynamics Recorders (DDDRs) distributed at multiple locations in the drilling system have been used
in many global drilling application to better understand the downhole drilling dynamics associated with that drilling process and to
optimize drilling operations
6,7,8
. In the Southern Gulf of Mexico field of Cantarell DDDRs were used to measure drilling
vibrations with the intent of validate surface actions initiated to improve penetration rates and reduce shocks in the drill string. The
Cantarell field has been drilled for approximately 50 years, which presumably would leave little space for performance
improvements. Any strategy for optimization would require careful monitoring any gains in performance so the same practices
could be repeated afterwards in subsequent operations.

Identical 14 PDC bits were programmed to be run in two consecutive wells in Cantarell field. A BHA that included a rotary
steerable system with a positive drilling motor was used for both wells. The intent of the BHA design was to deliver higher total
RPM at the bit and reduce the RPM of the string. This was expected to reduce the total amount of energy available in the system
and as so reduce the potential shock levels at the BHA tools. Being so, the efficient usage of the energy input in the hole for
drilling would presumably bring benefits for the rate of penetration.

In both 14 sections the prediction of undesired level of vibrations was plotted in a depth based chart, orienting the operator to
select parameters where overall MSE would be minimized. An upper limit of 100 RPM (surface) and a lower limit of 50 RPM
(surface) were imposed for the downhole motor applied in the BHA.

The DDDRs were used to provide actual downhole measurements during both operations to help fully understand the effects of
the interactions between the drill string geometry, hole trajectory, drive type, and other downhole tools. In each BHA two DDDRs
were applied, one sensor at the bit and another sensor at the upper part of the BHA, with each DDDR tool monitoring vibration
levels, shocks, downhole RPM and temperature. Measurement of the actual downhole dynamic behavior is extremely important
due to the complex nature of the interactions between the drill string and wellbore. The use of the DDDRs also allowed for
validation of the software predictions based on actual measurements, giving confidence in the method used for vibration prediction
due to the positive correlations established.

Well 1 Performance: in the first well a 6 bladed, 16 mm cutter PDC bit was used to drill the entire section, building from 0 to
44 and completing 1822 meters in 27.45 hours. A pre-run analysis of the dynamics of the run was conducted. The results of the
pre-run analysis are shown in the left side of figure 3 including the recommended parameters, shown as green arrows. The results
of the post-run analysis are shown in the right side of figure 3, with actual parameters charted in black. The shaded areas in both
charts represent the safe parameters for the entire run.

The highest string RPMs available were selected for the run within the limits established by the motor operators, with an attempt
to produce the best performance possible.

The post-analysis demonstrate that during the run the recommended parameters were followed, nonetheless some types of
vibrations were encountered. It is not uncommon in the field that, despite recommendations given based on vibration predictions,
some recommended parameters are not used in practice either because the subject is unknown by the field operations team or there
is enough confidence in past experience to ignore the new methodology.

6 SPE SPE-152231-PP

Figure 3. Pre-run analysis with recommended RPM in green (left). Post-run analysis with actual RPM in black (right).

The cost per meter was observed while drilling to detect any decrease in drilling performance and MSE was monitored as well to
verify changes in the tendency of the cost per meter curve. Both metrics provided net positive indications during the run that good
performance overall was being achieved (the charted metrics for the run are shown below in Figure 4).


Figure 4. Cost per meter analysis showing continuous decrease. MSE analysis showing consistent slight increase.

The bit was pulled at total depth exhibiting an IADC dull grade of 1-3-CT-N-X-I-BT-TD (photos of the dull bit are shown below
in Figure 5).



Figure 5. Pictures of the steel bit after the run, showing little wear at the cutting structure.

SPE SPE-152231-PP 7
This run established a new ROP World Record of 66.3 m/hr for 14 PDC bits, validated by Harts E&P. Furthermore, another
record was set on this run for the longest interval drilled in 24 rotating hours in offshore basins in Mexico, drilling 1630 meters in
24 hours. And, lastly, the total interval drilled set an international record for the directional drilling company of the longest run
combining their rotary steerable system with a positive displacement motor. A field comparison of drilling performance in terms of
ROP and equivalent extension are shown in the charts below (Figure 6).

0.0
10.0
20.0
30.0
40.0
50.0
60.0
70.0
S
0
6
1
6
M
0
7
1
9
M
0
7
1
9
S
0
6
1
6
M
0
7
1
9
S
0
8
1
6
S
0
8
1
6
S
0
8
1
6
M
0
7
1
9
S
0
8
1
6
S
0
8
1
6
M
0
7
1
9
R
O
P

(
m
e
t
e
r
/
h
o
u
r
)
Cantarell Field
Highest ROP's in 14.

0
200
400
600
800
1000
1200
1400
1600
1800
2000
S
0
6
1
6
M
0
7
1
9
M
0
7
1
9
S
0
6
1
6
M
0
7
1
9
S
0
8
1
6
S
0
8
1
6
S
0
8
1
6
M
0
7
1
9
S
0
8
1
6
S
0
8
1
6
M
0
7
1
9
E
x
t
e
n
s
i
o
n

(
m
e
t
e
r
s
)
Cantarell Field
Equivalent extension drilled in 14.

Figure 6. Best ROPs achieved and the longest equivalent extension drilled in Cantarell field per bit run.

Well 2 Performance: in the following well an identical 6 bladed, 16 mm cutter PDC bit was used, once more succeeding to drill
the entire section. Identical procedures were adopted on the second well regarding mitigation of vibrations by pre-run analysis of
drill string dynamics. For Well 2, an additional tool was added to the BHA. The new tool applied in the system was an
Asymmetric Vibration Damping Tool (AVDT) designed to damp drilling vibrations
9
. The addition of the AVDT to the system was
expected to change the dynamics of the upper BHA and reduce the intensity of shocks reaching the bit. It was also anticipated that
the reduction in shock magnitudes and vibration intensity would be confirmed by the two DDDRs run the drill string in similar
configuration to two DDDRs applied in Well 1.

Due to a significant increase in drilling performance, the optimized parameters were abandoned after less than 100 meters had
been drilled. The enormous amount of cuttings surpassed the cleaning capacity of the cutting removal system on the rig site. At
this time, the average ROP had surpassed 100 m/hr and a set of more point moderate drilling parameters were adopted to limit the
drilling rate.

The bit built from 0 to 25, drilling 740 meters in 14.78 hours, at an average ROP of 50.1 m/hr. A trip was made after the build
section to add a LWD tool to the BHA. During the trip, the AVDT was removed from the BHA and no signs of wear on the cutting
structure of the bit were detected. From this point, the applied drilling parameters followed the conventional recommendations for
the drilling process, and the bit drilled additional 300 meters in 21.97 hours before reaching total depth, at an average ROP of 13.7
m/h. The bit came out of the hole in excellent condition with an IADC dull grade of 0-1-WT-S-X-I-CT-TD. However, a sudden
change in the both the Cost per Meter and the MSE curves can be seen directly after the trip to change the BHA (as shown below
in Figure 7).


8 SPE SPE-152231-PP
Figure 7. Cost per Meter and MSE charts showing a change in behavior and increase in both curves after the trip.

The average MSE levels across all runs where parameter optimization was conducted are a good indication of the success of the
optimization methods adopted. In Well 1 the overall average MSE was 4.2 kpsi; in the first section of Well 2 with the AVDT and
optimized parameters the average MSE was 2.3 kpsi; in the next section of Well 2 with controlled parameters the average MSE
was 4.4 kpsi; and in the final section of Well 2 without the AVDT and with no indication of optimized parameters the average
MSE was 33.0 kpsi.

Similar tendencies are seen when comparing the measured vibration levels achieved in both wells (shown below in Figure 8). In
the charts, BB1 stands for measurements from the DDDR sensor directly above the bit and BB2 for measurements from the DDDR
sensor in the upper part of the BHA. The -VS denotes the run in first well without the AVDT in the BHA, and the +VS indicates
the first run in the second well with the AVDT in the BHA.



Figure 8. Comparison of Maximum and RMS Lateral Accelerations measured by the DDDRs in the first and second wells

The average lateral vibrations for both runs measured by the DDDR tools were under 1 g RMS, which is in the low vibration range
for the DDDR sensors. These low overall levels of measured vibrations denote the success of the optimization methodology
applied on both runs. Also, both DDDR sensor locations in the BHA show decreases in the peak values after the AVDT was added
to the BHA indicating improvements to the drilling dynamics when using the AVDT in the BHA.
SPE SPE-152231-PP 9
References

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February 2005
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Amsterdam, The Netherlands, 20-22 February 2007
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Petroleum Engineering Conference, Cartagena, Colombia, 31 May-3 June 2009
9. Forster, I., Macfarlane, A., Dinnie, R.: Asymmetric Vibration Damping Tool - Small Scale Rig Testing and Full Scale
Field Testing paper IADC/SPE 128458 presented at the 2010 IADC/SPE Drilling Conference and Exhibition, New
Orleans, Louisiana, USA, 2-4 February 2010