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Abstract
Stuck pipe is one of the most serious drilling problems, estimated to cost the petroleum
industry hundreds of millions of dollars annually. One way to avoid stuck pipe risks is
to predict the stuck pipe with the available drilling parameters which can be employed
to modify drilling variables. In this work, Artificial Neural Network (ANN) was used for
stuck pipe prediction according to the fact that this method is applicable when
relationships of parameters are too complicated. Based on the drilling fluid condition
from one of the Iranian oil fields, stuck pipe instances were divided into static and
dynamic types. The results of this study show more than 90% accuracy for stuck pipe
prediction in the investigated oilfield. The methodology presented in this paper enables
the Iranian drilling industry to estimate the risk of stuck pipe occurrenc during the well
planning procedure.
Keywords: Artificial Neural Network, Stuck pipe, Iranian Oil field, Differential
Sticking, Risk of Sticking, Static and Dynamic
29
Shadizadeh, Karimi, Zoveidavianpoor
risk of getting stuck can be minimized by subgroups: a) Hole pack-off and bridges;
modifying drilling variables for the condition stuck pipes which are related to wellbore
of high risk of sticking. In this work ANN instability or settled cuttings are in this
was utilized for stuck pipe prediction either category and b) Wellbore geometry
mechanically or differentially. The first use interferences; this refers to stuck pipes which
of this method for prediction of differential are related to the condition of wellbore
stuck pipe was developed by Siruvuri, et al. geometry such as key seats or an under-gage
in the Gulf of Mexico [3]. hole.
In this paper, after some introductory Major causes of mechanical stuck pipe are
material regarding the mechanisms of stuck wellbore instability and improper hole
pipe, ANN, along with the training of this cleaning. Most wellbore instability problems
network will be presented. Data acquisition, are related to shale layers due to swelling and
selection of the parameter, data pre- hole enlargements resulting from
processing, and the allocated network compressive failure owing to excessively low
architecture design will be described in the wellbore pressure [5]. Adequate hole
material and methods section. The result of cleaning, on the other hand, is an essential
this work presents the outcome analysis of part of the drilling operation. If the cuttings
drilling stuck pipe by ANN, which is are not removed from the well properly, they
summarized by dynamic and static analysis. settle around the drill string causing the drill
After a detailed discussion about the results collars to become stuck. This problem is
of this work, the successful remarks will be encountered often in over gauge sections
shown in the conclusions section. The where annular velocities are low. Also, risk
methodology presented in this paper enables of hole cleaning increases in directional
the Iranian drilling industry to estimate the wells. The directional well having an
risk of stuck pipe occurrence during the well inclination angle between 30-60o is the worst
planning procedure. condition for hole cleaning [2].
As the next category of stuck pipe,
1.1- Stuck pipe description differential sticking is due to differential
Often during drilling operations the drill pressure forces from an overbalanced mud
string becomes stuck. Sticking can occur column acting on the drill string against a
while drilling, making a connection, logging, filter cake deposited on a permeable
testing, or during any kind of operation formation. The area of the pipe that is
which may involves leaving the equipment in embedded into the mud-cake has a pressure
the hole [1]. Generally, stuck pipe problems equal to the formation pressure acting on it,
are divided into two categories: mechanical while the pressure which acts on the other
sticking and differential sticking. Mechanical section of pipe is hydrostatic pressure in the
sticking usually occurs when the drill string drilling mud. When the hydrostatic pressure
is moving and is caused by a physical (Ph) in the well bore is higher than the
obstruction or restriction [4]. Mechanical formation pressure (Pf), there will be a net
sticking can be classified into two major force pushing the collar towards the borehole
wall. The resultant force of the overbalance weighting factor and then summed with the
acting on an area of drill string is the force product of each of the other input nodes and
that sticks the string. This type of sticking their respective weighting factors. An
does not occur in shales and other very low activation threshold is then added to this sum
permeability formations where mud filter and the result is processed by a transform
cakes normally do not form. Commonly, function within the neuron. The most
differential sticking occurs when the drill common transform function, and the one
string or tool is stationary (or sometimes used in this study, is s-shaped sigmoid
when it is moving very slowly) [5]. If the function. The logistic function provides non-
pipe becomes stuck, every effort should be linearity to the model and constrains the
made to free it quickly. The probability of neuron’s output signal to fall within a fixed
freeing stuck pipe successfully diminishes range (0, 1 or -1, 1). It is also smooth and has
rapidly with time. Early identification of the easily differentiable characteristics that
most likely cause of a sticking problem is facilitate network training algorithms [9]. A
crucial, since each cause must be remedied multilayer network usually consists of an
with different measures. An improper input layer, one or more hidden layers, and
reaction to a sticking problem could easily an output layer. The layer of input neurons
make it worse. An evaluation of the events receives the data from the input files. The
leading up to the stuck pipe occurrence number of neurons in the input layer
frequently indicates the most probable cause corresponds to the number of parameters that
and can lead to the proper corrective are being presented to the network as input.
measures [2]. The same is true for the output layer. The
neurons in the hidden layer or layers are
responsible primarily for feature extraction.
1.2- ANN description They provide increased dimensionality and
ANNs are information processing systems accommodate such tasks as classification and
that are a rough approximation and pattern recognition [7].
simplified simulation of a biological learning There are several types of ANNs; the most
process and have performance characteristics common types are the feed-forward and
similar to those of biological neural networks back-propagation architectures which are
[6,7]. These are adaptive, parallel used in this study. A feed-forward network
information processing systems, which are has a layered structure and feed-forward
able to develop associations, transformations topology. Each layer consists of units which
or mappings between objects or data and receive their input from units of a layer
have proven to have potential in solving directly below and send their output to units
problems that require pattern recognition [8]. in a layer directly above the unit. There are
The basic elements of an ANN are the no connections within a layer. The term back
neurons (the processing elements) and their propagation refers to the mechanism of
connection strengths (weights). The input to adjusting network weights and biases for
each neuron is multiplied by its associated reduction of error, which is propagated back
through the system causing changes to the possible error. This problem is called the
weights and biases of the network [6, 9]. local minima problem [6, 11]. In order to
overcome this problem, some practical
1.3- ANN training recommendations are suggested such as
In a typical neural data processing procedure, randomizing the initial weights with small
the database is divided into three separate numbers in an interval [- 1/n, 1/n], where n is
portions: training, validation, and testing. the number of the neuronal inputs or using
The training set is used to calibrate the another formula for calculating the output
model. The validation set is used to ensure error. Probabilistic methods can help to avoid
the generalization of the developed network this problem, but they tend to be slow [12,
during the training phase. The testing set is 13]. During the training process, the question
used to examine the final performance of the of when to stop the training arises. How
network. In the training process, the desired many times should the network go through
output in the training set is used to help the the data in the training set to learn the system
network adjust the weights between its behavior? When should the training stop?
neurons or processing elements [7-10]. These are legitimate questions because a
Given a topology of the network structure network can be over trained. In the neural-
expressing how the neurons are connected, a network-related literature, overtraining is
learning algorithm takes an initial model with also referred to as memorization. Once the
some prior connection weights (usually network memorizes a data set, it is incapable
random numbers) and produces a final model of generalization, even if it fits the training
by numerical iterations. Hence learning data set very accurately [7, 14].
implies the derivation of the posterior
connection weights when a performance 2- Material and methods
criterion is established. Learning can be It is clear that the performance of ANNs
performed by supervised or unsupervised hinges heavily on the data. If one does not
algorithm. The former requires a set of have data that cover a significant portion of
known input-output data patterns (or training the operating conditions or if they are noisy,
patterns), while the latter requires only the then ANN technology is probably not the
input patterns [8]. right solution. On the other hand, if there is
Through the course of training, the network plenty of data and the problem is poorly
is continuously trying to correct itself and understood to derive an approximate model,
achieve the lowest possible error (global such as drilling stuck problems, then ANN
minimum). Usually, there are locations on technology is a good choice. At present,
the error surface that will cause temporary ANNs are emerging as the technology of
convergence, even before sufficient learning choice for many applications, such as pattern
has taken place by the network. This occurs recognition, prediction, system identification,
when the network system finds an error that and control.
is lower than the surrounding possibilities According to the fact that this method is
but does not ultimately reach the smallest applicable when relationships of parameters
are too complicated, ANN technology was were collected as the input data are as
applied for drilling stuck pipe prediction in follows: mud properties, depths, hole
this work. The sigmoid function which is the geometry information, hydraulics, bottom
most common transform function, was used hole assembly size, inclination angle, drill
in this study. Based on a typical neural data pipe size, Weight on Bit (WOB), formation
processing procedure, a partitioning ratio of pressure, and mud loss volume at formation.
8:1:1 was considered for splitting data into Mud properties are Mud Weight (MW),
three subsets (i.e., training subset constitutes Plastic Viscosity (PV), Yield Point (YP), 10-
80% of the total data and each of the Second Gel Strength (GL1) & 10-Minute Gel
validation and testing subsets include 10% of Strength (GL2), Marsh funnel viscosity, pH
the database). In the first part of this section, or Alkalinity of any solution (ALK) for Oil
data acquisition will be presented. Selection Base Mud (OBM), Fluid loss (conventional
of the appropriate parameters will be API or High Temperature High Pressure
explained as the main factors that had to be (HPHT) API), Chloride Content (CL),
chosen as input data for ANN. Data pre- Calcium Content (CA) or Stability of Mud
processing and network architecture design (ES) for OBM), Solid percent, and Oil/Water
will be described at the end of this section. ratio.
3- Results
3.1- Dynamic condition
Based on a partitioning ratio of 8:1:1, the
numbers of training, validation, and testing
data sets for dynamic condition were 155, 20
and 20 respectively. Initially a network with
six processing elements in its hidden layer
was selected. Then, the number of neurons
was reduced and finally a network with 3 Figure 1. Selected network for dynamic analysis.
neurons in its hidden layer was selected.
Through eliminating unnecessary parameters, Weights and biases which are related to the
the appropriate parameters were selected to final network for stuck pipe prediction are
improve network performance. For this shown in Table 5. Results of the selected
purpose different parameters were removed network for three data sets and their
individually and the network performance respective errors are shown in Table 6.
was examined. This procedure led to
Table 6. Results of selected network for three data sets and their respective error in the dynamic condition
Table 8. Results of selected network for three data sets and their respective error in static condition
cases in this set include 15 correct answers was observed that most of the stuck pipes
out of 16 cases (95.6% accuracy). Finally, in occurred in a normal condition for the
the case of stuck data, from eight cases, the available drilling parameters. The existing
network response for the testing data set data have some non-stuck objects which are
included six correct responses (75% very similar to the stuck cases, either in the
accuracy), while non-stuck data responded selected parameters for analysis or in other
without any error (100% accuracy). Overall, parameters. Considering this similarity, it can
in the static condition the training, validation, be said that causes of sticking in these cases
and testing data sets had a greater than 93% were not related to the available parameters.
accuracy. Therefore, error of prediction in these cases
As the input parameters, the network is not related to the networks performance,
topology, the performance function, and the but is related to data or these kinds of
learning rule were chosen by the network sticking are related to unpredictable sources
designer, the criteria to stop the training and cannot be predicted with any procedure.
phase will be chosen by him/her too. The
criteria of the desired outputs were 5- Conclusions
considered 70% and 50% for stuck and non- 1- Selected network can be utilized for
stuck cases respectively. In this way, for calculating the risk of stuck pipe either
stuck cases a response which is greater or mechanical or differential before any
equal to 70 percent is a correct response and drilling operations.
any percent less than 70 percent is referred to 2- Successful stuck pipe shows that there
as an incorrect answer. However, for the case are analytical or statistical differences
of non-stuck, any percent less than was 50 between days that the stuck pipe
considered as a good estimation of reality, happened and the non-stuck days which
which means such a condition has some are completely safe.
potential for stuck pipe occurrence. As a 3- High accuracy for stuck pipe prediction
matter of fact, 70% and 50% criteria were using selected parameters illustrates that
used to stop the training phase. So, in order most causes of stuck pipe are due to
to gain the lowest possible error (global inappropriate values of the selected
minimum) and on the other hand, to avoid parameters. Chosen parameters were pH,
over-fitting or memorizing during training, PV, YP, Gel, RPM, ROP, Pdiff, and GF.
the mentioned assumptions were considered 4- Use of GF and the success of this
in this work. Note that over-fitting includes a parameter in this work demonstrated that
quick decrease in error for the training set, some parameters can be replaced with a
while error of validation and testing sets new defined parameter. In this way,
increases rapidly. dimensionless parameters can be more
Referring to the networks responses, it can be beneficial.
seen that some stuck data were predicted
incorrectly. The types of stuck pipe cases
were compared with non-stuck pipe cases. It
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