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Analysis of vibration data of drill-strings, modelling of drill-string dynamics and model calibration. View project
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Abstract
This paper presents active vibration control to reduce the stick-slip oscillations in drill-strings. A simplified two degrees-
of-freedom drill-string torsional model is considered. The nonlinear interaction between the rock and the bit is included
in the model, where its parameters are fitted with field data from a 5 km drill-string system. Different proportional-
derivative (PD)-control strategies are employed and compared, including the one that takes into account the weight-on-
bit (axial force) and the bit speed. Optimization problems are proposed to obtain the values of the gain coefficients, and a
torsional stability map is constructed for different weight-on-bit values and top-drive speeds. It is noted that the infor-
mation of the dynamics at the bottom increases the performance of the PD-controller significantly in terms of the
torsional vibration suppression, for the system analyzed.
Keywords
Drill-string torsional dynamics, nonlinear dynamics, stability map, active control, stick-slip oscillations
considered. In Besselink et al. (2016), a feedback con- strategies to investigate the stability map of the non-
trol strategy to mitigate torsional stick-slip oscillations linear dynamics of a drill-string. To achieve this goal,
using a coupled axial–torsional model for the drill- optimization problems are set, and then solved with an
string is proposed. appropriate algorithm. Different objective functions are
Herein, we consider a torsional dynamical model, used in order to obtain the most appropriate function
which is coupled with the axial force, known as for the control of stick-slip phenomenon. In addition,
weight-on-bit. For some given conditions, a pure tor- different number of states are considered for control
sional model is enough to represent the drill-string and the performance of the controllers are compared.
dynamics, as shown in Ritto et al. (2017). A simple However, comparison among optimization algorithms,
two degrees-of-freedom (2-DOF) system is chosen to although interesting is out of the scope of this paper.
focus the attention on the control strategies, as done An efficient algorithm for optimization of nonlinear
by Jansen and van den Steen (1995), Leine et al. (2002), systems, which is based on model predictive control
Christoforou and Yigit (2003), and Richard et al. (MPC), can be found in Diehl (2001) and Sajjadi
(2007). A more complete model with coupled axial–lat- et al. (2014). MPC is a real time optimization scheme
eral–torsional vibrations can be found in Ritto et al. and is mainly used for reference tracking problems, in
(2009b) and Tucker and Wang (1999). which the response follows a given reference (Diehl,
To assure that the applied torsional model analyzed 2001). A system model is used to predict and optimize
in the present paper is representative, the field data from the future behavior of the system at every instant of
a 5 km drill-string system presented in Ritto et al. (2017) time and a real time controller is developed.
are used to calibrate the nonlinear bit–rock interaction In this paper, an inverse problem of designing con-
model and the response of the torsional model is com- stant feedback gains is considered to control the stick-
pared with the field data bit speed. Measurement while slip vibration. The optimization using an interior point
drilling tools provide real-time and recorded data, and it algorithm is chosen to find the optimum gains.
helps understanding some downhole dynamics (Shi Obviously, other iterative algorithms can also be used
et al., 2016). to solve the problem.
A proportional-derivative (PD)-control strategy, The second section of this paper depicts the 2-DOF
which includes a control law for the weight-on-bit, was system considered in the analyses, as well as the control
proposed in Monteiro and Trindade (2017). If we act on strategies employed. The third section presents the
the axial force, the bit–rock interaction curve shifts, and numerical results and, finally, the concluding remarks
stick-slip oscillations might be suppressed. One conse- are made in the last section.
quence is that an extra gain coefficient must be con-
sidered in the analysis. In this paper we follow a
similar strategy to that proposed in Monteiro and 2. Formulation
Trindade (2017), but: (1) four PD-control strategies are
compared with increasing parameters and information
2.1. Dynamical model
required; (2) optimization algorithms are applied to min- The 2DOF drill-string torsional system sketched in
imize cost functions and to obtain the control gain coef- Figure 1 is considered. The degrees of freedom are 0
ficients; and (3) the stability map (top-drive speed vs. and bit, which are the rotations of the top-drive and of
weight-on-bit) is constructed for each control strategy. the bottom-hole-assembly (BHA)/bit. A control law is
Five control strategies are compared: (i) imposed applied at the top-drive and a nonlinear bit–rock inter-
top-drive speed; (ii) PD-control (two gain coefficients) action torque occurs at the bottom of the column.
considering the response at the top; (iii) PD-control It is assumed that the BHA is a rigid body, and that
(three gain coefficients) considering the response at the drill-pipe is flexible. The inertia and the natural fre-
the top and information about the weight-on-bit; (iv) quency of the system are obtained calibrating the model
PD-control (three gain coefficients) considering the with the field data found in Ritto et al. (2017). A linear
response at the top, information about the weight- model with linear viscous damping is considered for the
on-bit, and the response at the bit; and (v) PD-control column, but the bit–rock interaction is nonlinear. The
(five gain coefficients) considering the response at the equations of motion of the system are given by
top, information about the weight-on-bit, and the
:
response at the bit. The main goal of this paper is to I0 €0 þ kð0 bit Þ þ cð0 _bit Þ ¼ Ttop ,
construct the stability map for different strategies, and : ð1Þ
to analyze how the stability region changes as more I€bit þ kðbit 0 Þ þ cð_bit 0 Þ ¼ Tbit
information is included in the control strategy.
The main contribution of the present paper is the where I0 and I are the top-drive and drill-string
proposal and comparison of different PD-control moments of inertia, k is the drill-pipe stiffness, and c
Ritto and Ghandchi-Tehrani 3
I0 0 c c
M¼ , C¼ ð4Þ
0 I c c
Figure 1. Sketch of a drill-string.
k k Ttop
K¼ , TðyÞ ¼ ð5Þ
k k Tbit
15
field data Note that linear models are assumed for stiffness and
model
viscous damping; the nonlinearity comes only from the
bit–rock interaction Tbit. It should be remarked that a
Torque on the bit (kNm)
is the damping parameter. The torque at the top and When the PD-control is applied, the control gain
the torque at the bit (Khulief et al., 2007; Sampaio coefficients k is obtained by solving an optimization
et al., 2007; Ritto et al., 2017) are problem, where an objective function should be mini-
ðjÞ
mized. That is, for each pair f!ðiÞ ref , W ref g, fi ¼ 1,
Ttop ¼ Tcontrol , 2, ::, ng, fj ¼ 1, 2, ::, mg, an optimization problem is
! solved to compute the optimal gain coefficients, as
b2 _bit ð2Þ
Tbit ¼ b0 tanhðb1 _bit Þ þ shown in
1 þ b3 _bit
2
this factor is equal to zero and the system is stable. Monteiro and Trindade (2017). However, now infor-
If there is a limit cycle oscillation for the bit speed, mation from the bottom is needed to implement this
this factor is greater than zero, and the system is con- strategy. Note that _bit appears in the second equation
sidered to be unstable. below
2.2.1. Control strategy 1. The first control strategy Ttop ð0 Þ ¼ kP ð!ref t 0 Þ þ kD ð!ref _0 Þ,
adopted is the following one ð12Þ
W ¼ W ref þ kW ð_bit !ref Þ
Ttop ð0 Þ ¼ kP ð!ref t 0 Þ þ kD ð!ref _0 Þ ð8Þ
The control gain coefficients are k ¼ ðkP , kD , kW Þ.
with control gain coefficients k ¼ ðkP , kD Þ and !ref as For this strategy a multi-objective cost function is pro-
the reference speed at the top-drive. In this strategy the posed, to include the bit dynamics, _bit
cost function is defined as
JðkÞ ¼ jj!ref _0 ðkÞjj þ ð!max min
bit ðkÞ !bit ðkÞÞ ð13Þ
JðkÞ ¼ jj!ref _0 ðkÞjj ð9Þ
which means that there are two goals put together: (1)
which means that the goal is to obtain k such that the obtain k such that the top-drive speed is as close as
top-drive speed is as close as possible to the reference possible to the reference speed; and (2) the bit oscilla-
speed. Note that only information at the top is taken tions are as small as possible.
into account, that is, 0 and _0 . It should be remarked that usually, in the field, this
information is not available, but we want to investigate
2.2.2. Control strategy 2. The second control strategy how much the control strategy would improve if this
adopted is similar to the one proposed by Monteiro information was available. And, also, an observer can
and Trindade (2017), where the weight-on-bit is also be constructed to estimate _bit .
included in the control law, such that the bit–rock inter-
action curve can be changed. Note that the axial force 2.2.4. Control strategy 4. The fourth control strategy
at the top (weight-on-hook) is directly related to the which is proposed in the present paper is similar to
axial force at the bottom (weight-on-bit). the strategy 3, nevertheless it considers the bit speed
in the control law of the torque. Doing so we reinforce
Ttop ð0 Þ ¼ kP ð!ref t 0 Þ þ kD ð!ref _0 Þ, the main objective, which is to reduce the torsional
ð10Þ vibration of the system.
W ¼ W ref þ kW ð_0 !ref Þ
Ttop ð0 Þ ¼ kP1 ð!ref t 0 Þ þ kP2 ð!ref t bit Þ
The control gain coefficients are k ¼ ðkP , kD , kW Þ,
þ kD1 ð!ref _0 Þ þ kD2 ð!ref _bit Þ, ð14Þ
and kW is limited so that the actual weight-on-bit vari-
ations are smaller than 20%. As explained in Monteiro W ¼ W ref þ kW ð_bit !ref Þ
and Trindade (2017) ‘‘Therefore, if the angular velocity
is larger than the reference one, the weight-on-bit is The control gain coefficients are k ¼ ðkP1 , kP2 , kD1 ,
increased relative to the target one (which allows kD2 , kW Þ. The cost function is the same one used in the
higher rate of penetration). But, in the opposite case, previous strategy
where the angular velocity is smaller than the target
one, meaning that stick-slip is potentially occurring, JðkÞ ¼ jj!ref _0 ðkÞjj þ ð!max min
bit ðkÞ !bit ðkÞÞ ð15Þ
the weight-on-bit is reduced to alleviate the frictional
reaction torque.’’
We propose to obtain the control gain coefficients
3. Numerical results
using the same cost function of the previous strategy,
The feedback control gain coefficients are constraint to
JðkÞ ¼ jj!ref _0 ðkÞjj ð11Þ kP 2 ½0, 105 , kD 2 ½0, 103 , and kW is limited so that the
actual weight-on-bit variations are smaller than 20%.
As in the strategy 1, only information at the top is To compute the gain coefficients, optimization is car-
taken into account, that is, 0, _0 and weight-on-hook ried out using an interior-point algorithm, and the
(directly related to the weight-on-bit). system dynamics is computed with the Runge–Kutta
integration scheme. For all the simulations, it is verified
2.2.3. Control strategy 3. The third control strategy that the response of the closed loop system does not
adopted is again similar to the one proposed by grow indefinitely with time, that is, it is bounded.
Ritto and Ghandchi-Tehrani 5
60 RPM
250 field data 100 RPM
model 140 RPM
250
Bit rotational speed (RPM)
200
150
150
100
100
50
50
0
0 10 20 30 40 50 60 0
0 10 20 30 40 50 60
time (s) time (s)
Figure 3. Bit rotational speed: field data versus computational Figure 4. Bit rotational speed: field data versus computational
model response, equation (6), point (120 revolutions per minute, model response, equation (6), with constant top-drive speeds (60
245 kN). revolutions per minute (RPM), 100 RPM, and 140 RPM).
The following system were obtained, calibrated with Usually for lower weight-on-bit the system escapes
the available field data in Ritto et al. (2017): !n ¼ 0:85 from the stick-slip condition.
[rad/s] (natural frequency), ¼ 0:25 (damping ratio), In the sequence, stability maps are constructed, vary-
I ¼ 383 [kg.m2], I0 ¼ 9:58 [kg.m2], b0 ¼ 5671, b1 ¼ ing the top-drive speed !ref and the weight-on-bit W ref ,
0:4775, b2 ¼ 8:7854, b3 ¼ 4:5595. The bit–rock inter- for the five different control strategies. The five control
action parameters were obtained for W equals to strategies analyzed are the following ones: (i) imposed
245 kN. Assuming that Tbit is linear with respect to top-drive speed; (ii) control strategy 1 (PD-control); (iii)
the weight-on-bit, a coefficient is used to multiply Tbit control strategy 2 (PD-control using the weight-on-bit;
such that different values of W can be simulated. For only information at the top); (iv) control strategy 3
example, if the W is 200 kN, then Tbit must be multi- (PD-control using the weight-on-bit; with information
plied by 200=245 ¼ 0:816. from the bit); and (v) control strategy 4 (PD-control
Figure 3 shows the bit rotational speed obtained using the weight-on-bit and the bit response).
integrating equation (6) with top-drive speed 120 revo- Figure 5 shows the stability map obtained by the
lutions per minute (RPM) and W ref equals to 245 kN. model that imposes the speed at the top, equation (6).
The computational model response is compared with A 10 10 grid is considered and the contour plot rep-
the available field data (Ritto et al., 2017). The model resents the values of the stick-slip severity factor. The
is not perfect, but it performed very well to capture the dark blue region is the stable region, where there is no
stick-slip oscillations, with amplitude and frequency of torsional oscillation. The points in the regions with
oscillation in the same order of magnitude of the field other colors represent responses with torsional oscilla-
data signal. Recalling that a one-degree-of-freedom tions, SSS > 0.1 (where 0.1 is an arbitrary tolerance).
system is being used to represent a 5 km drill-string Figure 5 shows that, for high top-drive speeds and low
system. weight-on-bit there is less bit oscillation, and for low
Figure 4 shows the bit rotational speed obtained top-drive speeds and high weight-on-bit the oscillation
from integrating equation (6) for three different top- is more intense.
drive speeds: 60 RPM; 100 RPM; and 140 RPM. Figure 6 shows the particular characteristics of the
Depending on the top-drive speed the response has dif- nonlinear system under investigation. The same equa-
ferent amplitudes of torsional oscillation (and different tion is analyzed, equation (6), but while in Figure 5 the
frequency of oscillation), or it can simply not oscillate. initial speed of the simulations is _bit ðt ¼ 0Þ ¼ 0, in
The corresponding SSS values are 1.66, 1.22, and 0.02. Figure 6 the initial speed is _bit ðt ¼ 0Þ ¼ !ref . It can be
The value of SSS decreases with increasing top-drive observed that the stability region increases when the
speeds. initial condition is changed.
Usually for higher speeds the system escapes from For the next simulations only the worst-case scen-
the stick-slip condition, that is, the bit speed is equal to ario, when _bit ðt ¼ 0Þ ¼ 0, is considered.
the top-drive speed. A similar analysis can be done with Another preliminary investigation is carried out for
respect to the weight-on-bit, but in a different sense. the linearized system, around the nominal rotational
6 Journal of Vibration and Control 0(0)
1
280 3.5 280
260 3 0.8
260
240 2.5
240
WOB [kN]
WOB [kN]
0.6
2
220 220
1.5 0.4
200 200
1
180 180 0.2
0.5
160 160
0 0
50 100 150 50 100 150
top speed RPM top speed RPM
Figure 5. Stability map for imposed top-drive speed. The Figure 7. Stability map of the linearized system. Yellow region
colors represent the values of the stick-slip severity factor. represents instability (at least one eigenvalue with positive real
part), while the dark blue region represents stability (all eigen-
values with negative real part).
(a) (a)
280 3.5 280 3.5
260 3 260 3
WOB [kN]
2 2
220 220
1.5 1.5
200 200
1 1
180 180
0.5 0.5
160 160
0 0
50 100 150 50 100 150
top speed RPM top speed RPM
(b) (b)
280 3.5 280 3.5
260 3 260 3
WOB [kN]
2 2
220 220
1.5 1.5
200 200
1 1
180 180
0.5 0.5
160 160
0 0
50 100 150 50 100 150
top speed RPM top speed RPM
Figure 8. Stability map, PD-control strategy 1: (a) initial guess Figure 10. Stability map: (a) PD–control strategy 3; and (b) PD-
(kp ¼ 10000, kd ¼ 100) (b) using previous identified (kp, kd) as control strategy 4. The colors represent the values of the stick-
initial guess. slip severity factor.
Figure 9. Stability map for PD-control strategy 2. The colors kP 6:2 104
represent the values of the stick-slip severity factor. kD 900
8 Journal of Vibration and Control 0(0)
(iii) Gain coefficients for the control strategy number 2 for the gain coefficients in the optimization algorithm,
might lead to completely different stability maps.
kP 2 ½0:1 104 , 7:5 104 Four different control strategies with increasing
kD 900 information required were investigated, and the control
gain coefficients were obtained through optimization. It
kW 2 ½0:1, 950
is noted that, for the system analyzed, the information
of the dynamics at the bottom (bit speed) increases the
(iv) Gain coefficients for the control strategy number 3 performance of the PD-controller significantly in terms
of torsional vibration reduction.
kP 5:4 104 As future work, a multiple DOF system and uncer-
kD 950 tainties should be taken into account in order to con-
struct a robust control strategy. The linearized system
kW 2 ½400, 600
can also be investigated, using different control strate-
gies, for instance, pole placement in the frequency
(v) Gain coefficients for the control strategy number 4 domain (Ghandchi-Tehrani et al., 2013, 2015).
Especially, if many simulations are needed to generate
kP1 ½0:1 104 , 0:9 104 the numerical simulations, fast computations with a
kD1 950 linearized system could be of great value.
kW 2 ½400, 600
Acknowledgements
kP2 0:1 104
The second author would like to acknowledge the financial
kD2 2 ½25, 300 support of the Brazilian agencies Conselho Nacional
de Desenvolvimento Cientı́fico e Tecnológico, Coordenação
de Aperfeiçoamento de Pessoal de Nı́vel Superior, and
Fundação de Amparo à Pesquisa do Estado do Rio de Janeiro.
Let us emphasize some aspects of these results. For
control strategy 1, for all the domains analyzed, the Declaration of Conflicting Interests
identified control gain coefficients are pretty much the The author(s) declared no potential conflicts of interest with
same. For control strategy 2, another control gain kW is respect to the research, authorship, and/or publication of this
included, and the proportional gain coefficient kP might article.
vary from about 0:1 104 to about 7:5 104 N.m, and
the gain coefficient related to the weigh-on-bit varies
Funding
a lot depending on the values of the reference top-
The author(s) disclosed receipt of the following financial sup-
drive speed and reference weight-on-bit. For control
port for the research, authorship, and/or publication of this
strategy 3, the proportional gain coefficient does not
article: This research was partially funded by FAPERJ (grant
change much (in a level lower than the value presented number E-26/201.572/2014) and CNPQ (grant number
for the control strategy 1), and the gain related to the 400933/2016-0).
weigh-on-bit varies less, compared to the control strat-
egy 2. Finally, for control strategy 4, two more control
ORCID iD
gain coefficients are added. This allows the propor-
Thiago G Ritto http://orcid.org/0000-0003-0649-6919
tional gain coefficient kP1 to assume lower values.
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