THE ROLE OF DATA IN DRILLING P3 AND WHY QUALITY IS IMPORTANT PEAKE - PowerPoint PPT Presentation

THE ROLE OF DATA IN DRILLING P3 AND WHY QUALITY IS IMPORTANT

PEAKE DRILLING CONTINUOUS IMPROVEMENT PLATFORM Analytics Generate Metrics Automate Design Create Program Send Tasks to Rig/OSC. Rigs/OSC and Update as Completed Get Data from Source Get Data from Engineer of Record Databases 2

AUTOMATION REQUIRES DATA QUALITY 3

DRILLING DATA PATH Real-Time Rig Rig Digital Calibrated Instrument Calculated Corrected Data Sampling Data Channel Channel Real Time RTOC Post- Source of Alarming Corrected Process Analysis Record Channel Data Score Process Facts States Activities Events Analytics Process Best Metrics Expectations Actions Improvement Practices 4

GOOD INFORMATION IS A CORNERSTONE 5

Is Our Drilling Data Good? • Quest stio ion n 1 — Is it a problem we need to address or is magnitude of error lost in the noise • Quest stio ion n 2 — If 1 is true, how significant are the errors • Quest stio ion n 3 — If 2 is high, can we even fix it? 6

QUESTION 1 IS ERROR > NOISE AND IS IT IMPORTANT?

WHY IT MATTERS ON THE RIG Commonly only Found nd Errors in Drilling illing Data a and Corres esponding onding Repercus ussions ions Observed Derivative Worst Errors in Variable Small Large Case Variable iable Field Errors Error Consequence Error Consequence Scenario Torque ue >100% MSE 5%-10% Incorrect MSE leading >20% This would represent ~5000 Loss of Rig State to sub-optimal drilling. ft*lb error for most TDS-11 Drill Consumption of real- type drives. Bit Failure, String time torque data by Motor Failure, MWD Failure, applications like Tubular Failure, Vibrational Peake Drilling leading Dysfunction, Poor Drilling to sub-optimal Performance analysis and planning. RPM >100% MSE, Rig 2%-10% Incorrect MSE leading >20% This would represent ~25-40 Loss of State to sub-optimal drilling. RPM for most TDS-11 type Drill Incorrect rotary drives. Bit Failure, String torque--improper feed- Vibrational Dysfunction, back loop to TD's that MWD Failure, Poor Drilling require RPM to Performance correctly report torque (Yaskawa, Converteam, etc.) HookLoad Load >100% WOB, 2%-5% Incorrect MSE leading >10% This would represent Loss of MSE, Bit to sub-optimal drilling. ~50,000 lb for most sensors. Drill Depth, Incorrect WOB leading String Rig State to poor ROP or bit wear/damage. 8

WHY IT MATTERS ON THE RIG Commonly only Found nd Errors in Drilling illing Data a and Corres esponding onding Repercus ussions ions Observed Derivative Worst Errors in Variable Small Large Case Variab iable le Field Errors Error Consequence Error Consequence Scenario Pump >100% ΔP, MSE, 2%- Incorrect MSE leading to sub- >10% 500-750 psi error could lead Blowout Pressure re Rig State 5% optimal drilling. Poor to potential damage to managed pressure motors/turbines/MWD. performance. Poor well control Potential for kicks/fracturing performance. Wear/damage when near pore pressure/frac to down-hole motors/turbines. gradient Pump >100% MSE, Rig 2%- Incorrect MSE leading to sub- >10% 10 strokes/min error could Blowout Rate State 5% optimal drilling. significantly affect well control Wear/damage to down-hole or managed pressure motor/turbines. Poor scenarios. managed pressure performance. Poor well control performance. Poor diagnostic ability with tracers, etc. Poor hole cleaning. 9

WHY IT MATTERS ON THE RIG Commonly only Found nd Errors in Drilling illing Data a and Corres esponding onding Repercus ussions ions Observed Derivative Worst Errors in Variable Small Large Case Variab iable le Field Errors Error Consequence Error Consequence Scenario Block k >25% Bit Depth, 1%-2% Block Position Error is >5% 10ft error per joint of drilled Wellbore Positi Po tion on (cumulati ROP Cumulative. In order to pipe. Could lead to significant Intersecti ve >50%) increase depth, the survey errors and TD on block must travel at compromise. least 2x the distance the drill string travels. Incorrect MD/TVD/Survey Measurements. Flow ow Out >100% Rig State, 5%-10% Incorrect MSE leading to >20% Inability to detect kicks, pack Blowout Kick sub-optimal drilling. off or other problems. Detection Poor well control detection. Poor stuck pipe/pack off detection Pit >5% ΔPit Volume, 1%-2% Poor well control >5% 5bbl error could be 100% Blowout Volume (100% Kick detection/performance. error in well control delta) Size/Density calculations 10 10

QUESTION 2 WHAT ARE THE REAL-WORLD ERRORS

ERRORS FOUND THROUGH CALIBRATION • Every rig has had devices significantly out of calibration Rig A Rig B Rig C Rig D Rig E Rig F Rotary Torque 17% 17% 22% 24% 21% 18% • Most rigs have rig-ups or Makeup Torque 23% 11% 12% 17% 60% 13% practices that will lead to device error or drift. Rotary RPM 1% 1% 1% 1% 2% 1% Pump Rate 1% 32% 1% 1% 40% 1% • Errors are common to all rigs and contractors Block Position 6" <0.5” <0.5” 6ft <0.5” <0.5” Hookload 11% 18% 12% Pit Volumes 15% 12% 18% 16% 15% 22% Pump Pressure 5% 4% 4% 4% 3% 5% 12 12

TORQUE, HOOKLOAD, MSE AVERAGE >15% OVERESTIMATION OF APPLIED MSE 13 13

SHARED FIELD OBSERVATIONS FROM ~10 DIFFERENT RIGS • Hookload is generally over-reported by hydro- mechanical gauges. ˃ This means we get less WOB than we think • Torque is generally over over-reported by flux output of VFD ˃ This means we get less torque than we think 14 14

TORQUE HISTOGRAMS: IR VS IR TESTER n = = 298 tests Torque ue Differen erence +/- 2,000 lbs +/ 70 70 60 60 50 50 Number 40 40 30 30 20 20 10 10 >80% of 0 observations are out Torque Differ erence ence (ft-lb lbs) of DS1 recommended % Differen erence tolerance +/ +/- 10% 10% 100 80 60 Number er 40 20 0 -50% -45% -40% -35% -30% -25% -20% -15% -10% -5% 0% 5% 10% 15% 20% 25% 30% Torque Differ erence ence (%) 15 15

TORQUE SCATTERPLOT: IR VS IR TESTER 25,000 IR ove verstatin stating torque que (Under der make-up) 22,500 s) ck (ft-lbs) hneck Iron Roughne 20,000 IR understating erstating torq rque e (over ver make-up) 17,500 15,000 15,000 17,500 20,000 22,500 25,000 Iron Roughne hnecck cck Tester er (ft-lbs) s) 16 16

MEASURED ERROR IN PIT VOLUMES PIT VOLUME CHANGES ARE GENERALLY UNDER-REPORTED 60% Sand Trap Settling 1 40% Settling 2 Settling 3 l/in] ulation [bbl/in] Settling 4 20% Suction ume Calculation Slugging Active Error 0% Error in Volume -20% -40% -60% 10 20 30 40 50 60 70 Fluid Level l [in] 17 17

ACTIVE SYSTEM VOLUME UNDERESTIMATION HAS MANY CONSEQUENCES 700 600 ls] ume [bbls 500 em Volum 400 e System ive 300 Activ 200 Calculated 100 Measured 0 0 10 20 30 40 50 60 70 Fluid Level l [in] 18 18

PUMP RATE ERROR • Volumetric Efficiency is not constant 100% 90% • Effected by 80% ˃ Pressure 70% nty (%) ˃ Fluid 60% ient ic Efficie 50% ˃ Swab etric umetr 40% Volum ˃ Temperature 30% • Difficult to --swab 1 20% --swab 2 measure at 10% --swab 3 operating 0% conditions 0 2000 4000 6000 8000 10000 Pressur ure e (psi) 19 19

CAN WE RELY ON TODAY’S TOOLS? • Are they accurate? • Are they reliable? • Are they repeatable? ˃ Do they vary from well-to-well and day-to-day • Can we measure every value of interest? ˃ Makeup torque? ˃ Actual pump rate? 20 20

RIG A ERROR TREND 30% Makeup Torque 25% PumpRate BlockPosition 20% Surface RPM Percentage Error Surface Torque 15% 10% 5% 0% 24-Jul 9-Sep 21-Sep Calibration Date Nomac 27 21 21

RIG B ERROR TREND 18% 16% Makeup Torque 14% PumpRate BlockPosition 12% Surface RPM Percentage Error Surface Torque 10% 8% 6% 4% 2% 0% 1-Aug 27-Aug 10-Sep 25-Sep Calibration Date 22 22

RIG C ERROR TREND 40% 35% Makeup Torque PumpRate 30% BlockPosition Surface RPM 25% Percentage Error Surface Torque 20% 15% 10% 5% 0% 6-Aug 26-Aug 14-Sep Calibration Date 23 23

RIG D ERROR TREND 35% 30% Makeup Torque PumpRate 25% BlockPosition Surface RPM Percentage Error 20% Surface Torque 15% 10% 5% 0% 1-Sep 19-Sep Calibration Date Nomac35 24 24

RIG E ERROR TREND 20% 18% Makeup Torque 16% PumpRate BlockPosition 14% Surface RPM Percentage Error 12% Surface Torque 10% 8% 6% 4% 2% 0% 27-Jul 19-Sep Calibration Date 25 25

RIG F ERROR TREND 7% 6% Makeup Torque PumpRate 5% BlockPosition Surface RPM Percentage Error 4% Surface Torque 3% 2% 1% 0% 18-Aug 2-Sep 13-Sep Calibration Date 26 26

QUESTION 3 CAN WE FIX IT? YES WE CAN!

NEW TOOLS ARE NEEDED • Had to use new tools when old ones did not satisfy requirements ˃ TTS to Measure Torque and Hookload • Had to invent new tools when none existed ˃ Iron Roughneck Calibration Tool • Recommended new types of tools when calibration is not practical with current tools ˃ Radar Pit Level Sensors ˃ Coriolis meters 28 28

CAN WE CALIBRATE EXISTING TOOLS? Rig F TOP-DRIVE WAS CALIBRATED TO MATCH TTS SUB 29 29