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Eight Years Experience with a Drilling Optimization Simulator in the North Sea
R. Nygaard and G. Hareland, Drops Technology, Y. Budiningsih, Conoco Indonesia, H.E. Terjesen, Statoil ASA and F.
Stene, Norsk Hydro ASA
Copyright 2002, IADC/SPE Asia Pacific Drilling Technology
This paper was prepared for presentation at the IADC/SPE Asia Pacific Drilling Technology
held in Jakarta, Indonesia, 911 September 2002.
This paper was selected for presentation by an IADC/SPE Program Committee following
review of information contained in an abstract submitted by the author(s). Contents of the
paper, as presented, have not been reviewed by the International Association of Drilling
Contractors or the Society of Petroleum Engineers and are subject to correction by the
author(s). The material, as presented, does not necessarily reflect any position of the IADC or
SPE, their officers, or members. Papers presented at the IADC/SPE meetings are subject to
publication review by Editorial Committees of the IADC and SPE. Electronic reproduction,
distribution, or storage of any part of this paper for commercial purposes without the written
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presented. Write Librarian, SPE, P.O. Box 833836, Richardson, TX 75083-3836, U.S.A., fax
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Abstract
During the past eight years a drilling optimization simulator
has been applied to different fields in the North Sea with good
results. The simulator is based on penetration rate models and
uses offset drilling data through inverted drilling models to
obtain an apparent rock strength log (ARSL), which describes
the drillability in a field or area. The ARSL from an offset
well in the field or from nearby wells is correlated to the
survey of the upcoming well or wells that will penetrate the
same formations. The ARSL is then used as the driver in the
simulator and different combinations in terms bit designs,
operating parameters, mud weight programs and hydraulics
are simulated to obtain the lowest drilling cost. Experience
from different operators and different fields have shown that
the drilling simulator concept works with good accuracy and
that the simulator in advance can predict the penetration rates
on upcoming wells. The simulator is today used as a preplanning, day to day and post analysis tool. The concept of
the simulator is to obtain the lowest time based drilling cost
and to increase the experience transfer from one well to the
next and therefore increase the learning process. Using the
simulator while drilling is a powerful tool to troubleshoot
during the drilling process and examples have indicated that
changes in pore pressure from estimate, faults and formation
tops can be predicted continuously while updating the ARSL
and correlating it to the predetermined ARSL The simulator
also predicts the bit wear in the hole while drilling and clearly
identifies the slow drilling zones so that bits are not pulled
prematurely due to low penetration rates.
The main conclusions are that the simulator is a powerful tool
in real drilling operations and that the experience transfer from
well to well is increased. Cost savings using the simulator
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EIGHT YEARS EXPERIENCE WITH A DRILLING OPTIMIZATION SIMULATOR IN THE NORTH SEA
and increasing WOB through the upper section would save the
bit gage cutters for the harder, limestone-sections in the
Shetland Group formation. This is where most of the savings
in drilling costs could be achieved, since ROP is relatively low
in this section. Generally, the simulations indicate that
increasing WOB instead of RPM is preferable to maintain a
high ROP, since the increase in weight tends to shift some of
the wear from the gage cutters towards the center of the bit.
The DROPS simulations indicate that following these general
guidelines results in a higher average ROP for the entire
section.
Based on our analysis, it was recommended to use a low
speed high torque motor so that the RPM be kept as low as
possible and use higher WOB than previously for bit A bit to
get the best performance. The highest increase in ROP, and
subsequent decrease in drilling cost can be gained in the
vertical subsection of the well, where the Shetland Group
formations are entered. Herein the simulations indicated that
increasing the WOB while being conservative with the RPM
yields the best overall results, and decreases the risk of
premature gage wear.
Initial Analysis of Different Bit Design Performance
Evaluating 6 different bits designs and optimizing their
performance gave the results in Figure 3. These different PDC
bit design had variations in number of PDC cutters, size of
PDC cutters, variations in PDC layer thickness, cutter back
and siderake and junk slot area. Combined with the best bit
design features for the this section and the optimum operating
parameters used for the selected bit, a recommendation on
how to best drill the well#1 was made. It is evident that the
$/m analysis is close for the different the bit design with bit A
having the lowest overall drilling cost.
Bit A was recommended with operating parameter as listed
in Table 1. These were followed closely and the resultant time
vs. depth curve for the pre-simulated and actual is plotted in
Figure 4.
Conclusion Well#1
Based on the analysis using the DROPS simulator an
optimized drilling plan was recommended and followed.
Changing from a high speed low-torque to a low speed
high-torque motor in conjunction with selecting the best bit
design and operating parameter the cost savings on this 12,25
section was over $100,000. Even if it was believed that the
12.25 section was drilled close to optimal it was room for
large savings using the DROPS.
Field Application Well#2 - 8.5 Section
The drilling optimization study was performed on an 8.5
section, which was to be drilled in an area where the geology
was described as abrasive sandstone with interbeded shale and
coal stringers. Hard and abrasive sandstone had in the area
historically favored the use of wear resistant impregnated
diamond drilling bits mounted on turbines. Even though the
ROP from these bits are generally low, they are frequently
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EIGHT YEARS EXPERIENCE WITH A DRILLING OPTIMIZATION SIMULATOR IN THE NORTH SEA
Depth (MD),
m
1482-1940
1941-2455
2456-2800
2801-3024
WOB
(tons)
8
5.5
18
18
RPM
170
120
170
180
W e ll T r a je c to r y &
A R S L fo r
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1 2 1 /4 " S e c tio n
D e v ia tio n (m )
0
2 0 0
4 0 0
6 0 0
8 0 0
1 0 0 0
1 2 0 0
A R S L
W e ll P a t h
1 4 0 0
1 6 0 0
H o r d a la n d
G p.
1 8 0 0
2 0 0 0
2 2 0 0
R o g a la n d
G p.
2 4 0 0
S h e tla n d
G p .
2 6 0 0
2 8 0 0
0
2 0
4 0
6 0
8 0
1 0 0
R o c k S tre n g th (M P a )
1.8
1.6
1.4
1.2
1
0.8
1.6-1.8
1.4-1.6
ROP/ROP*
1.2-1.4
1-1.2
0.8-1
0.6
0.6-0.8
0.4-0.6
0.4
0.2-0.4
0-0.2
0.2
180
220
251
RPM
280
320
360
3
5.5
10
11
12
EIGHT YEARS EXPERIENCE WITH A DRILLING OPTIMIZATION SIMULATOR IN THE NORTH SEA
Bit number
550
500
450
400
350
300
1 (A)
2 (A)
3 (B)
4 (C)
5 (C)
6 (C)
7 (D)
Figure 3: Well#1-Average Cost ($/m) vs. the bits evaluated. The bits were run at their optimum parameters
m / hr
0
50
100
1200
1300
1400
1500
1600
1700
1800
1900
Depth, mTVD
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2000
2100
2200
2300
2400
2500
2600
2700
2800
2900
3000
3100
3200
R O P O b ta in e d F r o m D r illin g
R O P S im u la te d u s in g D D S
Figure 4: Well#1- ROP vs. depth graph comparing simulated time to actual field time.
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3900
Coring
3950
Depth, mMD
4000
4050
4100
Bit AA 2 Turbine
4150
4200
Bit BB 1
Turbine
4250
4300
Bit AA 3
Turbine
4350
TD
4400
10
20
30
40
Tim e, hrs
Sim ulated
Field Progress
Figure 5: Well#2-Time vs. Depth graph comparing pre-simulated to actual field time
ARSL (Mpa)
0
30
60
Bit Hours
90
2700
2700
2900
2900
25
50
WOB [tonnes]
75
100
Depth (m)
Shetland
12
RPM
16
100
2700
2700
2900
2900
3100
3100
3100
3100
3300
3300
3300
3300
3500
3500
3500
3500
3700
3700
3700
3700
3900
3900
3900
3900
4100
4100
4100
4100
4300
4300
4300
4300
4500
4500
4500
4500
4700
4700
4700
4700
4900
4900
4900
4900
5100
5100
5100
5100
5300
5300
5300
5300
5500
5500
5500
5500
Crom er Knoll
Target
Simulated
Actual
Figure 6: Well#3-Time vs. Depth graph comparing simulated time to actual field time.
Pre-simulated operational parameters plotted with actual parameters.
120
140
160
180
200