2019-06-12 Team UiS Drillbotics 2019 Finals

Team UiS Drillbotics 2019

12.06.2019

(Team Lead)

Agenda:

• 12:40– PresentationOutline:

1. Introduction of TeamUiS&UiSDrillboticsOrganization2. Design&Engineering3. Control System&HardwareArchitecture4. Plug&Play Concept&Implementation5. DirectionalDrilling (DDOP) Program6. Graphical UserInterface(s)7. Autonomous Drilling Algorithms &Machine Learning8. BudgetConsiderations &TeamWorkflow9. RigPerformance, Lessons Learned&FutureVision

• 13:15– Q&A(feelfreetoaskquestionsatanytime!)Rig ready on site in Celle, Germany

12.06.2019

Team:• Five(5)graduatingstudents

(+three(3)1st yearMasterstudents)

• 3xPetroleumEngineering: (1 BSc,2MSc)

• 2xComputerScience: (2BSc)

• Supervisors:

• ProfessorDanSui,Associate Professor TomaszWiktorski

• 3rd yearparticipatinginDrillboticsTM competition

1.IntroductionofTeamUiS&UiSDrillboticsOrganization

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Organization&KPIs:• Organizeseminar&companyvisits(AkerBP,Canrig,

Promet,Norce,NOV,SmithBits,Sekal,etc.)

(seminarcostsapprox.45000NOK=5211USD)

• Thesisfacilitation(acrossdifferentUiSDept.)

• Publishpapersannually(Celle, IFAC,OMAEetc.)

• OrganizationKPIs:1. Acceleratestudentsunderstandingofindustrialautomationefforts

2. AnnuallyparticipateinDrillboticsTMcompetition

3. Generateresearch/attenddrilling&automationconferences

4. Facilitateforhands-on,multidisciplinaryproject-experience

5. Energyconsumption&cost

6. Industrialcollaboration

1.IntroductionofTeamUiS&UiSDrillboticsOrganization

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Laboratory-ScaleDrilling Rig:

2.Design&Engineering

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KeySystems:

a) ControlSystem(PythonandgRPC)

b) Hoisting(drawworks)

c) Pneumaticsystem(downholemotor)

d) WPUsystem(whipstockinsertion/riser)

e) Powersystem(bothsingle-phase+3-phase)

f) Rotational(conventionaltopdrive)

g) Circulation(conventionalmudpumps+pit)


a) b) c)

d) f)

g)

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SystemCapabilities:a) ControlSystem(Python):90Hz;multithreading-based (gRPC

APIformodules);OPC-UA compatiblePlug&Play

b) Hoisting(drawworks): Force≈500N(compr.&tension);

Speed ≈30mm/s(ifrequired)– 3actuators

c) Pneumaticsystem (downholemotor):2.1/4.9Nm;1500/660

RPM;6baroperatingpressure;Q≈320LPM

d) WPUsystem(whipstock insertion/riser):2-axis(4actuators);

Speed ≈30mm/s;riserID≈32mm,whipstockangle≈7deg

e) Powersystem(both single-phase +3-phase):230VAC50Hz

singlephase; 230VAC/400VAC3phase

f) Rotational(conventionaltopdrive):2.87Nmrated.;8.59Nm

instantanious;0- 3500RPM;brushless&hollow-shafted

g) Circulation(conventionalmudpumps +pit):3.1bar/19LPM


Rigsensors:

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AluminumDrill-pipe:


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DirectionalDrilling Enablers:

• Downholemotor(pneumaticallyoperated)

• BendableBHA

• Downholesensors&positiontracking

• Whipstock&WPU(insertionsystemtoshift

betweenriser&whipstock)

• Whipstock,knucklejointandsensorsub

haveallbeenprintedin316Lstainlesssteel

throughadditivemanufacturing


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AdditiveManufacturing ResultsLastYear:(proofofconceptusingsuchtechnology)


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HIDDEN SLIDE DURING PRESENTATION

HIDDEN SLIDE DURING PRESENTATION

BHAComponents:


Downholemotor: Knuckle-joint: Sensor-sub:

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DownholeSensorSub:

• Microcontrollerintegratedin

sensorhouse

• 9DOF:acc.(3x),magn.(3x),gyro(3x)+T

• 60Hzwiredpipetransmissiontosurface

(USBprotocol).I2Cprotocolfromsensor

à downholemicrocontroller

• Controlsystemsendsa“push”

notificationtomicrocontrollerto

synchronizeincomingdownholedata

withsurfacesensors/systems


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KnuckleJoint:

• 316Lstainlesssteel,4components

• 10degbendatmaximumflex

• Spring-activatedflex:

bendoccursat12kg(118N)WOB

• OD:28mm(1.1”)


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PneumaticDownholeMotor:

• 2.9Nmtorqueoutput(high-speed)

• 1500RPMidle/750RPM@maxtorque

• Maximumaxialforce:380N(onshaft)

• Maximumradialforce:50N(onshaft)

• Qmax =320LPM

• Pmax =6barg


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Pneumaticsetup:


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Whipstock&Insertion:


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Challenges:• Communication

• Incompatibility

• Changing demands

• Sensor dataacquisition

• Parallelization

• Stand thetestoftime..

3.ControlSystem&HardwareArchitecture

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Microservice:• Independent application

• API

• Share databy communicating

• Network protocols

• gRPC


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Module:• Microserviceapplication

• Clientsandservers

• Datastreams

• Processeddata

• Subscription

• Parameters

• Singleresponsibility


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Controlsystemarchitecture:

• Modules

• Layers

• Similaroperations

• Subscriptions

• Subsequentmodules

• Unidirectional dataflow


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Overview:

• HBM,downholesensor

• 60Hz

• Arduino

• Virtualsystem state

• Recentdata

• Independentmodels

• Prioritization

• Database


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Advantages:

• Flexible

• Synchronizedsensordata

• Programminglanguageindependent:

• Python,C++,Go,Node.js,PHP,Java, Ruby,

Android,Dart, C#,Objective-CandWeb

• Platformindependency

• EasytointegratePLCs/microcontrollers/etc.

• Parallelcomputing

• Redundancy


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Possibilities:• Cloudcomputing

• Workloaddistribution

• Remoteoperation

• Templates

• Industrytest

• Start-upcompany?


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Implementation:• Collaboration

• OPC-UA

• Hierarchical structure

• Importedinformationmodel

• Nodes

• Requests

• Events

• Rig data

4.Plug&PlayConcept&Implementation

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Requests:• Representsaprocedure

• Callablemethod

• Inputparameters+uniqueID

• Nooutput arguments

• Different types:1. General

2. Rig

3. Parallel

4. Casing

5. SuperCommand


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RigData:• Customnode

• On-demand

• Callablemethods

• Includes:1. Systemlimits

2. Realtimedata


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Events:• Subscriptionbased

• Triggeredbyserver

• Informclients

• Callbacksystem

• Uniform

• Arguments:1. Progress

2. Status

3. RequestID


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AutonomousDrilling Concept:

7.AutonomousDrillingAlgorithms&MachineLearning

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DirectionalDrilling Phases:

• 8phases:

1. Systeminitiation

2. Systemcalibration

3. Tagbottom,defineTD&HL

4. Drillpilothole

5. POOH,insertwhipstock

6. Expandpilothole

7. DrilloutpastKOP

8. POOH(onprompt)

5.DirectionalDrilling(DDOP) Program

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DownholePositionTracking- ProofofConcept:• Downholesensormeasurementsand

virtualrigenvironmentarebothinputs

• Updatesevery5seconds

• Calculatesactualtrajectory,

ellipsisofuncertaintyandchecksbuild/depth

toprovidesteeringrecommendation

• 3plots:sideview,bird´seyeview&rearview

5.DirectionalDrilling(DDOP) Program

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ControlWindow,VirtualRig&PerformanceVisualizationGUIs:

6.GraphicalUser Interface(s)

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DownholeTrajectoryTrackingGUI:

6.GraphicalUser Interface(s)

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HillClimbAlgorithm(testedlastyear):• Univariate(one-variable)search-algorithm

• Initialconditionsheavilydetermine

efficiency

• Evaluateseffectofchangeof

eitherRPMorWOBsetpoint

• Evaluatesdrillingefficiencythrough

calculatingmechanical specificenergy

(MSE)


ROP=!"#%"&' ()*(')#"'%

+*,-%"&'()*(')#"'%

&.

&#= 𝑓(𝑊𝑂𝐵, 𝑇𝑂𝐵/𝜔,Q/P, A,….)

Cost function &Heuristic function State-space (RPM,WOB, T,Q)

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GradientDescentMethod(implemented in2019):

Step1.DetermineROPgradient:

Step2.Determinelearningrate(stepsize):

Step3.Updategradientdescentalgorithm:

Step4.Definetheterminationcriterion:


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Machine LearningRockFormationClassification:


PredictionsFeatureimportanceanalysisFiltereddata

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Machine Learning IncidentDetection– PressureExample:


Filtereddata Unsupervised learningtoevaluate&organizefeatures

Supervisedlearningtopredictleak,overpressureandnormalpressure

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Directional Steering:Inclination:

• Evaluateshorizontalbuild/TVD(orMD)every1mm

• IfH/TVDactual <=H/TVDplanned-trajectory :

• Activatebuild-inclinationmode:(WOBrange12-18kg)

• IfH/TVDactual >=H/TVDplanned-trajectory :

• Activatedrop-inclinationmode:(WOBrange12-18kg)

Azimuth(disabledduringcompetitionduetoEMIandinstalledbrake):

• PulsesTopDrive(-10Vto10V)tosteerleft(negativevoltage)andright(positivevoltage)

• Suggestedsetpointtosteertowards:3degreerotationtowardstarget


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Drilling IncidentDetection:

• Six(6)drillingincidentsgetdetected:

• StuckPipe:(nextpage)

• Downholevibrations:eitherSVMorKNNsupervisedmachinelearningmodels

(3vibrationlevels:low,moderate,high)

• Leak:P<3barfor3consecutivemeasurements innon-NPT phases

• Overpressure:P>6.5barfor3consecutivemeasurements innon-NPT phases

• Twistoff:non-NPTphase on-going,leaktriggered,WOB(near zero)and<<WOBsetpoint

• Axialvibrations:WOB>= 1.5*WOBsetpoint

• Remedialactions: shutdownsystem(leak, overpressure, twistoff), lowerWOB(axialvibrations),POOH1mm

before commencedrilling(stuckpipe),lowerRPM(downholevibrations=high,continuously)


12.06.2019

StuckPipeDetection:Ifusingdownholemotor:sequentialalgorithm: Ifusingconventionaltopdrive:machinelearning

• PID-controllerpermissibleovershootrange: -1to0.5kg

• ActivatedinDDOP-phases: 4,6,7,8

• Activationcriterion:ROP <=0.2mm/15s

• Remedialaction:- 5kgWOB(pull)activateduntil1mmabovestuckpoint

• Continuouslyoperatingandifdetected:• overridesROPsearch/DDOPstrategy/steeringalgorithm


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TeamWorkflow (ProjectManagement):

• WeeklyTeamSprint

• Trello(Organize&trackprogress);updatedeveryday

• Budgets/ordersapprovedinweeklymeetings

• Monthlymeetingswithindustry

• Monthlycompanyvisits

• Aheadofseminar,weeklyplanmeetingswithpartnerNPF

8.BudgetConsiderations&TeamWorkflow

SnapshotofTrelloworkflowduringsemester

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Budget2018-2019:ComponentCosts:• Components purchased in 2018: 50% off

• Shipping and VATexcluded

• Labor cost excluded

8.BudgetConsiderations&TeamWorkflow

Construction hours:• Assuming 5xstudents working full time (6hours/day, 6days/week, 6months)

• 4860 hours invested since December

• Assuming hourly wageof ≈300 NOK• 1458000 NOK(145 800EUR)

• Inaddition, several hours gointo meetings with manufacturers, research, on-topicthesis work and soon...

• Conclusion: component costs aremarginal compared tototal project costs

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RigPerformance:

9.RigPerformance,Lessons Learned&FutureVision

MedianandKalmanfiltersgetusedtosmoothenplotsforWOB,inclinationandazimuth

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RigPerformance:


First directional well drilled in homogeneous cement in 2019 atUiS achieving approx. 55 mmbuildPlanned trajectory ahead of project commencement(determining whipstock´sinclination and knuckle joint bend)

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LessonsIdentified:

• gRPC andmultithreadingdrasticallyimprovesystem´srobustness;bigcontrolsystempotential

• VibrationsandBHA-wellborefrictionsignificantlyreducedwithdownholemotor

• High-torquedownholemotortolerateshighervibrationlevels,yetmoresusceptibletostuckpipeiflowRPM

• Slip-ringhighlysusceptibletonoise(EMI)from3-phasetopdrive

• Downholesensor-packageshouldbeplacednearbitinfuture

• Whipstocksof7and10degbuildatKOPbothproviderequiredbuildtoachieve65mmhorizontalbuild;

(yet10degreewhipstockismorelikelytocausestuckbitatKOP)

• PIDcontrolandstuck-pipedetectionisdifficultwithbendableBHA


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FutureVisions&PotentialProjectResearch:


• ROPoptimizationanddrillingratedeterminationApplication:AssistDriller/DDduringoperation

• FormationclassificationApplication:Establishreal-timesituationalawarenessandgenerateTripRiskLog

• IncidentDetection&PredictionAlgorithmsApplication:WellIntegritychallengesandpredictionofpotentialhazards/incidentsatanearlystage

• RobustcontrolsystemarchitectureenablingremoteconnectivityApplication:facilitateforeventhandlingandmodel´sintegration

• Driller/machineinteractionthroughe.g.voicetechnologyApplication:Facilitateforearlywarning/situationalawareness/highlightingdecisionpoints

à Importanceofhighdataqualitytoensureaccuracyandreliabilityinalgorithms

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Doyouhaveanyquestions?

Thankyouforyourattention!

12.06.2019

2019-06-12 Team UiS Drillbotics 2019 Finals

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Transcript of 2019-06-12 Team UiS Drillbotics 2019 Finals