SPE-199077-MS

Six Years Operating a Real Time Drilling Problem Detection Software in

Downloaded from http://onepetro.org/SPELACP/proceedings-pdf/19LACP/4-19LACP/D041S035R002/2358624/spe-199077-ms.pdf/1 by Seoul National University, Aa Bb on 01 December 2022

Deepwater Environments: Results and Challenges

Fabio Rodrigues G. da Silva, Marcelo de Souza Cruz, Bruno Barduchi, Ernanda Bellumat, Maycon Vieira dos
Santos, and Vinicius Barroso de Matos, Engineering Simulation and Scientific Software; Roni Abensur Gandelman
and André Leibsohn Martins, Petrobras

Copyright 2020, Society of Petroleum Engineers

This paper was prepared for presentation at the SPE Latin American and Caribbean Petroleum Engineering Conference originally scheduled to be held in Bogota,
Colombia, 17 – 19 March 2020. Due to COVID-19 the physical event was postponed until 27 – 31 July 2020 and was changed to a virtual event. The official proceedings
were published online on 20 July 2020.

This paper was selected for presentation by an SPE program committee following review of information contained in an abstract submitted by the author(s). Contents
of the paper have not been reviewed by the Society of Petroleum Engineers and are subject to correction by the author(s). The material does not necessarily reflect
any position of the Society of Petroleum Engineers, its officers, or members. Electronic reproduction, distribution, or storage of any part of this paper without the written
consent of the Society of Petroleum Engineers is prohibited. Permission to reproduce in print is restricted to an abstract of not more than 300 words; illustrations may
not be copied. The abstract must contain conspicuous acknowledgment of SPE copyright.

Abstract
Given the complexity and high costs associated to ultra deepwater drilling, any effort to avoid unforeseen
situations is beneficial. Initiatives to optimize the drilling process in real-time are extremely important. This
article details the experience of 6 year operating a real-time software with the focus of anticipating the
detection of potential drilling problems in challenging scenarios.
Based on transient numerical simulation (hydraulics, cutting transport, torque and drag, etc.), the software
automatically identifies operational problems in real-time, providing to the rig crew anticipated information,
so that, corrective and/or preventive actions can be taken. The software incorporate relevant experimental
and theoretical research developed in multiple Brazilian universities and R&D Centers. It receives surface
and downhole data in real-time, as well as, simulates comprehensive models (which considers real data, fluid
properties, well and drilling column geometry as inputs) in order to analyze the current drilling status, by
comparing real and calculated (expected) data, with quantitative criteria. Dedicated decision trees, validated
by a representative group of senior drillers, provide reliable indication for problem alerts.
The present paper aims to detail the successes and the difficulties of detecting typical drilling problems
in Campos and Santos basins (offshore Brazil). The process of algorithm development, validation and field
implementation is detailed.
In July 2014, after almost 10 years of development, the use of the application started as a service
conducted by a drilling engineering team, on a 24x7 service in Petrobras Real Time Support Center. Since
then, it monitored every Petrobras offshore well. According to estimates, the economy by using this real-
time program reached almost 150 rig days, which is equivalent to approximately US$ 130 MM. In 2016, The
iniciative was granted the Technological Innovation ANP (Brazilian National Petroleum Agency) Award as
recognition by its relevant results. This software is in a continuous development process, aiming to acquire
new analyses in order to increasingly help the Petrobras drilling operations.
The novelty is the usage of numerical simulation in order to withdraw the subjectivity of a qualitative
data analysis, avoiding the misinterpretation of a possible operational event. Present challenges include the
2 SPE-199077-MS

proposal of hybrid solutions (modeling + machine learning) to tackle the identification of complex problems
(such as false kicks, stuck pipe in salt drilling and circulation loss prediction).

Introduction
With the constant evolution of the oil and gas industry and the increasing availability of real-time operating
data, solutions to make the best use of it are always in the operator companies' focus. That was the case of

Downloaded from http://onepetro.org/SPELACP/proceedings-pdf/19LACP/4-19LACP/D041S035R002/2358624/spe-199077-ms.pdf/1 by Seoul National University, Aa Bb on 01 December 2022

the application presented on this paper. To make the best use of the various sensor data available for drilling
operations, Petrobras decided to develop an application to interpret the receiving data, and warn about
potential problems. Along the development process, the company ESSS and some Brazilian universities
also played an important role.
Since the creation of the application represented a distuptive approach, its development and deployment
consisted on a continuous learning process. On the development side, decisions like the best physical model
to be used or the best configuration for the interface, were constantly in question. On the other hand,
the deployment process brought subjects like: how should be the interaction with the operation, or who
should be responsible for the monitoring activity. The truth is that the persistence on the maturation of both
perspective was essential for the success of the idea.

The Application
The analysis of PWD data together with other operating parameters (such as flow rate, rate of penetration
(ROP), standpipe pressure, torque, drag, etc.) is important in order to identify and anticipate several
operational problems (ARAGÃO et al., 2005). Correct interpretation of this real-time data set provide the
possibily to reduce downtime, risks and operating costs. Downhole pressure analysis and control is intended
to keep this parameter within the operating window (whose lower limit is pore pressure or lower collapse
pressure and the upper limit is fracture pressure or upper collapse pressure).
According to Teixeira et al. (2005), most events and operational problems influence downhole pressure as
well as standpipe pressure. Other problems directly impact on torque and drag measured at both the surface
and the bottom hole. Problems such as poor hole cleaning, annular obstructions, pack offs, kicks, washouts,
and circulation losses will directly affect the amount of solids and/or load loss in the annular space and,
therefore, will have a direct impact on downhole and standpipe pressures. Thus, analysis of pressure data is
extremely important for identifying operational problems. However, the addition of other parameters (flow
rate, torque and drag, drill string rotation, ROP) on the analysis contributes to build a better view of the
current well condition and greatly enriches the analysis performed.
Generally, real-time analysis of drilling operating parameters is performed by a specialist who interprets
curve trends and tries to identify possible operational problems. However, it is a subjective analysis as
it depends on the criteria and experience of the specialist. It is usual to observe two or more different
interpretations for a same situation. In order to reduce the subjectivity of interpretation a computational
tool for automated analysis of operating parameters based on quantitative criteria was developed. The
software is based on a series of simulators (solids transport, thermohydraulics, torque & drag, pressure
transmissibility, etc.) which, based on real-time surface and downhole parameters, creates a digital twin of
the well, representing its current condition.
At each timestep, the variables calculated by the models are compared with the measured variables. For
example, the current measured ECD is compared over time with the calculated ECD. If the measured and
calculated variables show the same trend over time, this is a sign that the operation is behaving as expected.
However, if these trends start to become different, it will be an indication that something not expected by
modeling is occurring.
The steps for identifying an operational problem are:
SPE-199077-MS 3

1. Using parameters from rig sensors (such as ROP, flow rate, drill string rotation, hole depth, bit
depth, etc.), the application calculates the solids concentration profile over the depth and over time,
considering all the well history.
2. In parallel, considering the solids concentration profile, the application calculates the pressure profile
along the wellbore for each timestep (both inside the drill string and in annular space).
3. In addition to the pressure profile, the application also calculates the drill string stresses (axial and

Downloaded from http://onepetro.org/SPELACP/proceedings-pdf/19LACP/4-19LACP/D041S035R002/2358624/spe-199077-ms.pdf/1 by Seoul National University, Aa Bb on 01 December 2022

lateral load), as well as pressure transmissibility due to surge & swab effects and pump flow variations
(NEGRÃO et al., 2015).
Once the program identifies divergent trends between calculated and measured curves, a diagnostic
module is triggered. Such module consists of a series of rules and flowcharts based on quantitative criteria
aimed at determining a possible cause for the identified abnormal behavior. If a problem is identified, the
application alerts the user of the identified risk situation and suggests corrective and/or preventive actions.
The software had its development started in 2005. Since the first deployment in 2012, it has already been
used to monitor more than 300 wells. All of these drilling operational data were used to refine the diagnostics
logic. Table 1 shows a list of the main features and real-time diagnostics developed for the application.

Table 1—Aplication's features and real-time diagnostics.

Real-Time Diagnostics Features

Kick (with and without circulation) MPD parameters optimization

Fluid losses MPD control strategy analysis

Operating window limits Identification of equipment in front of BOP rams

Washouts Washout position calculation

Poor hole cleaning Kick circulation module

High vibration level Caliper inference module

Drill bit jet loss/obstruction Fracture type identification (natural or induced)

Kick (with and without circulation) Equipment failure probabilistic analysis based on lateral vibration

Fluid losses Casing wear calculation

Figure 1 shows the software screen during a real-time well monitoring. Part of the received data in real-
time is shown in tracks over time (right plot). These same tracks show the variables predicted by the models,
so that the user can easily view their expected and real trends. Concomitantly, on that same time profile
tracks, the program presents the automatically performed diagnostics. On the left plot, the application allows
the user to see a depth profile, showing a well scheme and all calculated parameters along measured depth
(pressures, stresses, solid concentration, casing wear, etc.)
4 SPE-199077-MS

Downloaded from http://onepetro.org/SPELACP/proceedings-pdf/19LACP/4-19LACP/D041S035R002/2358624/spe-199077-ms.pdf/1 by Seoul National University, Aa Bb on 01 December 2022

Figure 1—Software interface while monitoring a well in real-time.

The tool works throughout all the drilling time, assisting in the decision making process.

Deployment
A big part of the work spent along the process was dedicated on understanding how the software would
fit into the daily operation. For that, a couple of attempts were evaluated. In 2008, it started to be used for
real-time drilling monitoring. Between 2008 and 2011, the application was continuously calibrated, so that
simulators, models and diagnostic flowcharts were tuned. In September 2011, the validation phase within
Petrobras Real Time Support Center during business hours started. Initially, an engineer was assigned to
operate the application in the Petrobras exploratory wells monitoring center. In December 2012, a new
engineer was designated to use the software during drillings on the Santos Basin wells. The next year, 2013,
a third operator started to monitor the Campos Basin wells.
In these three years, although the software runs 24 hours a day, there was an available operator just during
business hours in order to read the automatic diagnostics about operational problems. However, statistically,
less than 1/3 of the detected problems happened during business hours and were reported in time for the
responsible for the operation.
Therefore, in July 2014, Petrobras decided to establish 24x7 real-time drilling monitoring service team
that would uninterruptedly monitor all the Petrobras drilling operations from a centralized Real Time
Support Center. Since then, this service team is responsible for setting up the application with all the
input data (well geometry, drill string geometry, current drilling fluid properties, operating window limits,
lithology information, etc.) required for the running the digital twin. Once the software automatically warns
the operator about any operational problem (kick, circulation loss, washout, bit jet obstruction, bit jet loss,
stuck pipe, etc.), the team should make contact with those responsible for that specific ongoing drilling,
alerting them about this not predicted situation. This way, mitigating and/or preventive actions can be
performed on time.
The software architecture provides the possibility that not only the operators visualize their responses
and tracks, but also any of the direct responsibles for the ongoing drilling operations. All the simulated
SPE-199077-MS 5

and real data are stored on a central database. Remotely, any user can view real-time data from their own
workstation, further facilitating the program responses access.

Relevant Results Obtained

Hydraulic simulator have been widely validated in hundreds of wells monitored by the software. Predicted
ECD, ESD, and pumping pressure data are compared with measured data for the verification of the digital

Downloaded from http://onepetro.org/SPELACP/proceedings-pdf/19LACP/4-19LACP/D041S035R002/2358624/spe-199077-ms.pdf/1 by Seoul National University, Aa Bb on 01 December 2022

twin. Moreover, the developed models are capable of running at a very low computational cost and are
suitable for real-time applications. Finally, several tests have been performed to validate the diagnostics
module with good results.
In the six years of operation, the application had the opportunity to deal with many different drilling
situations, observing distinct project types and drilling operational problems. This was important for the
maturation of the application. In the following section, specific results from 5 wells, called wells A, B, C,
D and E are presented.

Well A – Pipe washouts

The present example was the first identified after officializing the 24/7 team service. It happened during a
challenging hole section (18 1/8" bit × 22" reamer) drilling operation. There were two washout occurrences
in two different runs, with just five days of difference between the events. In both situations, the software
quickly identified the problems, which provided the opportunity to stop the operation in time, so that,
investigation processes could be iniciated. Then, with the pumps still off, the drill string was tripped out of
hole in order to search for the washout location. Once found, the damaged pipe was changed and the drilling
resumed. The early washout identification contributed by avoiding drill string rupture, which would cause
several days of fishing and, thus, a huge non-productive time (NPT).
In Figure 2, it can be seen that, at approximately 1 pm on July 30th, a gradual pressure drop began and
continued until 3 pm (3700 − 3570 psi / 4177 − 4181 m MD). The application diagnosed the problem
as soon as there was a trend change between the real and calculated standpipe pressure curves. Initially,
the monitoring team contacted the drilling responsibles on the Real Time Support Center and on rig site.
However, people onboard justified the pressure drop by the occurrence of a drilling fluid treatment in the
system. About 20 minutes after the first contact, the support team contacted once again the rig crew insisting
that the gradual pressure drop was a strong evidence of a washout as the observed pressure drop was larger
than the one expected by the fluid treatment (amount of organic phase added). After the second warning,
rig crew accepted to stop drilling in order to assess a possible washout.
6 SPE-199077-MS

Downloaded from http://onepetro.org/SPELACP/proceedings-pdf/19LACP/4-19LACP/D041S035R002/2358624/spe-199077-ms.pdf/1 by Seoul National University, Aa Bb on 01 December 2022

Figure 2—Washout identification performed by the software.

After drill string removal, rig crew found a fissure on a drill collar, as shown in Figure 3.

Figure 3—10 centimeters fissure on a drill collar.

SPE-199077-MS 7

After identifying the first washout, drilling could proceed. Just one day after the drilling restarted, a
new gradual pressure drop was diagnosed around 6 am, which continued until 7 am (4760 − 4610 psi /
4320 − 4323 m MD), as can be seen in Figure 4. Again, the support team immediately alerted the drilling
responsibles, on Real Time Support Center and onboard.

Downloaded from http://onepetro.org/SPELACP/proceedings-pdf/19LACP/4-19LACP/D041S035R002/2358624/spe-199077-ms.pdf/1 by Seoul National University, Aa Bb on 01 December 2022

Figure 4—Second washout identification performed by the software.

The onboard mud engineer informed that the standpipe pressure drop could be generated by the decrease
in the ROP (hole cleaning). However, the software takes into account the effect of solids concentrarion in
its models and it was clear that the observed pressure drop could not be explained by the reduction of solids
concentration in the annular space.
Thus, it was decided to trip the drill string out of hole for investigations. The second washout was found
on the 22" reamer, as can be seen in Figure 5.
8 SPE-199077-MS

Downloaded from http://onepetro.org/SPELACP/proceedings-pdf/19LACP/4-19LACP/D041S035R002/2358624/spe-199077-ms.pdf/1 by Seoul National University, Aa Bb on 01 December 2022

Figure 5—Found washout on the 22" drilling reamer.

Well B – Tool miscalibration

This situation occurred during a 17 ½" hole section drilling. It was noted that the current ECD (transmitted
by PWD sensor) did not correspond to the measured annular pressure. The difference between the data
transmitted to the application and the calculated ECD helped to identify the potential failure.
In order to confirm the service company miscalculation, transmitted data was collected (Annular Pressure
and ECD) at surveys depths, according to Table 2.

Table 2—Annular Pressure and ECD data for each directional record.

MD [m] TVD [m] TVD w/ offset (8.18 m) ECD [ppg] Anular Pressure [psi]

4233 4228 4219.82 11.83 8440

4307 4301 4292.82 11.83 8592

4456 4449 4440.82 11.81 8874

4568 4559 4550.82 11.88 9152

4642 4632 4623.82 11.85 9278

4829 4817 4808.82 11.93 9721

Table 3 compares the transmitted ECD with the one calculated, highlighting the difference between
them. After discussing with the directional company operators, based on the application-calculated data,
the downhole tool miscalibration was confirmed.

Table 3—Comparison between transmitted ECD and calculated ECD.

Application
TVD [m] TVD ARC [m] Transmitted ECD [ppg]
Calculated ECD [ppg]

4228 4219.82 11.83 11.74

4301 4292.82 11.83 11.75

4449 4440.82 11.81 11.73

4559 4550.82 11.88 11.80

4632 4623.82 11.85 11.78

4817 4808.82 11.93 11.86

SPE-199077-MS 9

In operations with narrow operating window, this calibration failure can induce ECD reduction actions
even when not required. For the drilling of this hole section, as the recorded ECD of 11.93 ppg was close
to the FIT of 12 ppg (performed on the 20" casing shoe at 3372 m), the drilling was interrupted for 1 hour
to pump a viscous pill. Considering the above analysis, there was no real need for pill pumping.

Downloaded from http://onepetro.org/SPELACP/proceedings-pdf/19LACP/4-19LACP/D041S035R002/2358624/spe-199077-ms.pdf/1 by Seoul National University, Aa Bb on 01 December 2022

Well C – Porr Hole Cleaning
The third well exposed in this paper reports the diagnosis of poor hole cleaning performed. Such alert had
a direct impact on the operation, leading to changes on the operational sequence.
When the directional record pointed 33° of inclination during drilling, the operation proceeded with an
average ROP of 30 m/h, as can be seen on Figure 6. During this period, the software recorded a high solids
concentration while in slant with mobile cuttings bed formation due to poor hole cleaning conditions, as
illustrated on Figure 7.

Figure 6—Application screenshot showing a moment of a high ROP.

10 SPE-199077-MS

Downloaded from http://onepetro.org/SPELACP/proceedings-pdf/19LACP/4-19LACP/D041S035R002/2358624/spe-199077-ms.pdf/1 by Seoul National University, Aa Bb on 01 December 2022

Figure 7—Depth profile showing simulated high solids concentration with solids bed formation.

A discrepancy between trends of measured and calculated torques was also observed. The diagnosis was
passed on, by the engineer in charge of the application, to the Real Time Support Center's mud engineer.
Then, drilling was interrupted to pump a viscous pill for hole cleaning.
Later, the application logics released a new warning of poor hole cleaning conditions. The onboard
personnel confirmed that the solids simulation was correct after pumping another viscous pill. A relevant
amount of rock cuttings returning to surface was observed. Following this new warning, chemists also
decided to increase fluid rheology and pump viscous pills every three hours.
It is noteworthy that the problem had not been detected until the diagnostic made by the application.
Finally, it is possible to conclude that the software identification might have prevented serious
complications, such as stuck pipe, for example, avoiding non-productive time (NPT) generation.

Well D – Rock Fluid Interaction

Throughout the day, the application support team reported to the Real Time Support Center's engineer, the
anomalies observed in the Active Tank Volume and ECD data. It was known that this hole section could
SPE-199077-MS 11

present slightly higher ECD levels due to a test with a new type of water based fluid. Figure 8 shows the
parameter ECD variation of almost 1 ppg of amplitude for a few hours, and the tank volume presenting the
same behavior (relevant variation).

Downloaded from http://onepetro.org/SPELACP/proceedings-pdf/19LACP/4-19LACP/D041S035R002/2358624/spe-199077-ms.pdf/1 by Seoul National University, Aa Bb on 01 December 2022

Figure 8—Abnormal behavior of ECD and active tank volume.

The first action taken by the engineers in charge (to remedy the situation triggered by the diagnosis
provided) was the pumping of a viscous pill to observe the ECD response. This action did not produce the
desired effect. Afterwards, some huge rock cuttings started to come up on surface (as can be observed on
Figure 9), which proved that the application's alert about hole cleaning was correct. Fluid rock interaction
seems to have caused the problems.
12 SPE-199077-MS

Downloaded from http://onepetro.org/SPELACP/proceedings-pdf/19LACP/4-19LACP/D041S035R002/2358624/spe-199077-ms.pdf/1 by Seoul National University, Aa Bb on 01 December 2022

Figure 9—Rock cuttings that came up on surface.

Well E – Caliper Estimation

At the end of the drilling of the second hole section of Petrobras ultradeepwater wells, in which seawater is
used as drilling fluid and it still returns to the seabed, it is common to verify significant hole enlargement.
If the open hole caliper is not known, it is not possible to accurate calculate the required cement volume
which would ensure a minimum cement height in the annular space, while cementing the surface casing
(an important safety barrier).
Given that the costs associated with the caliper downhole tool are quite high, the software provides a
caliper calculation based on a methodology that consists of inferring the open hole caliper through the
differential pressure measured by PWD (Figure 11) while pumping a conditioning heavier fluid (Figure 10),
which is positioned in the annular space.

Figure 10—Conditioning fluid (heavier) pumping illustration.

SPE-199077-MS 13

Downloaded from http://onepetro.org/SPELACP/proceedings-pdf/19LACP/4-19LACP/D041S035R002/2358624/spe-199077-ms.pdf/1 by Seoul National University, Aa Bb on 01 December 2022

Figure 11—Surface and downhole pressures after conditioning fluid (heavier) pumping.

Taking advantage that all needed information (drill string and well geometry, conditioning fluid density,
etc.) is already inputed on the software, it gives an average result for the open hole diameter.
It is noteworthy that the process of pumping a conditioning fluid occurs after pumping a bottoms' up to
guarantee the hole cleaning, by the end of the hole section drilling.
For this specific well, the caliper inference module calculated the average diameter of 39" for the open
hole that was drilled by a 26" bit. After cementing the surface casing and tripping in hole a new bit for
drilling the next hole section, the top of cement depth was reached. According to the volume of cement that
was pumped in the previous cementation stage and on the encountered cement height, it was found that the
average (effective) open hole diameter was 38". A result that proved be very close to the one obtained by
the software inference.

Lessons Learned
Along the six years operating the software, many challenges were faced. On the development side, the need
to validate models and to keep adding value to the application were always a constant concern. On the
deployment side, the unceasing commitment to be part of the solution on the daily operation, combined with
the users' initial disbelief, were some of the main challenges. Thus, for the project continuity and health,
some important lessons needed to be learned and applied. The list below shows the relevant lessons learned,
which were essential for the achievement of the software and service as it is today.
1. 24/7 staff: Since the first monitored well it was observed that the service needed to be continuous.
Statistically, less than 1/3 of the detected problems happened during business hours.
2. Staff dedicated to the application: Along the years, it was observed that the service (build
well configuration, feed the application with updated information, understand operation, filter false
14 SPE-199077-MS

diagnostics, contact operation, etc.) demanded at least one operator full time dedicated to handle the
application.
3. Knowledge of data reception logics: 24h monitoring showed us that the communication with the
data sources is not always constant and suffers of diverse quality problems. Missing data periods
can greatly impair the well monitoring (diagnostics of punctual events, diagnostics of cumulative
events, accounting for cuttings concentration on annular, accounting for casing wear, etc.). Thus, the

Downloaded from http://onepetro.org/SPELACP/proceedings-pdf/19LACP/4-19LACP/D041S035R002/2358624/spe-199077-ms.pdf/1 by Seoul National University, Aa Bb on 01 December 2022

knowledge of data reception logics was crucial for the staff, so that, communication issues can be
quickly treated and solved. Based on this acquired knowledge, on the third year of service, the team
became also responsible for managing the Petrobras data quality service.
4. Data Quality: Since the application is fed with real-time sensor data, any mistake with the input
data, will directly affect the simulation and, consequently, the final interpretation. In order to avoid
this, every received parameter has a specific corresponding filter. These filters can handle spurious
data or manage their frequency. Only the experience on monitoring drilling operations brought this
knowledge to the staff.
5. Interaction between development and deployment teams: Since the first years of operation a huge
necessity on having a good interaction between the development and deployment team was evident.
Both teams have important issues to contribute with each other. For example, the knowledge of how
the input data should be treated and how the results should be presented are obtained only by the
operational front. On the other hand, the knowledge of how the models and simulators work are
mastered by the development team, and must be widespread, for the proper use of the application. For
this purpose, regular trainings are performed and documentation is made, always keeping the front
team updated.
6. Unified information between the staff: The operation of a real-time drilling software is a continuous
service, and so, it is extremely important for all members to be aware of the past events when shifts
turn. Ideally, the lessons learned by one member should spread to all the others. For that, mechanisms
to centralize the information and optimize the shift change were created.
7. Well-defined diagnostics report logics: In order to react properly to a diagnosed drilling problem,
ensuring that the solution affects the operation on time, the diagnostic report logics should be well
defined and in agreement with the operation personell.
8. Alert logics recalibration: At every new drilling problem occurred, decision-making flowcharts are
reviewed and recalibrated. This increases the assertiveness of future events. Along the six years of
operation, there was a record of more than 120 drilling problem diagnosed by the software.
9. Customization to meet end customer needs: Initially, the software was designed to monitor and
interpret real-time drilling data. Diagnostics were mainly based on the current or past drilling situation.
However, in order to better meet the operation needs, real-time redesign analyzes were incorporated.
Thus, predictions of future situations can be performed. Some examples of it were publicated by Grein
et al. (2017) and Vanni et al. (2019)

Novel Development
• Operational Control of Cuttings Dryer System:
Offshore discharge of cuttings drilled with NAF requires drying, a topic of frequent NPT
generation. The cuttings dryer system efficiency varies with equipment installation layout,
lithology, and hole section diameter. If it gets overloaded, drilling must be stopped until system
operation is restored. Thus, it is important to control the cuttings generation, so that the solids
output rate, which reaches the dryer system, is compatible with its processing capacity.
SPE-199077-MS 15

In order to improve the control method, new control parameters were established, both calculated
by the software: ROP based on the last drilled meter and the solids output rate. Figure 1 illustrates
both curves during a real-time drilling monitoring.
On the operation above, it was possible to verify that both curves (ROP and solids output rate)
were increasing with time. Thus, the reference values are monitored based on quantitative criteria,
leading to a control of operating parameters at the highest levels, within the optimum dryer system

Downloaded from http://onepetro.org/SPELACP/proceedings-pdf/19LACP/4-19LACP/D041S035R002/2358624/spe-199077-ms.pdf/1 by Seoul National University, Aa Bb on 01 December 2022

capacity. It provides a significant increase in operational efficiency (increase in ROP and reduction
of NPT with dryer system repair).
Since its implementation, no problems related to cuttings dryer overloading were verified.
Besides, several reference rates of penetrationvalues have been increased.
New control methods are still being developed, such as a new instrumentation (electrical current
measurement) and a fault recording system that will allow real-time assessment of the degradation
of the dryer operating conditions.
• Kick circulation:
The main goal of this module is to serve as a visual guide during the monitoring of real-time
well control operations. Based on the well information (already available) and the kick information
(obtained right after the wellbore closure), the software is able to plot for users the expected
pressures (kill, choke and standpipe) along a well control operation as well as the pressure limit
allowed. Thus, during operation, these expected curves can be compared, side-by-side with the
real-time sensor readings for the same parameters.
In order to make this tool even more useful, automatic diagnostics flowcharts are generated.
These diagnostics, based on the comparison between measured and expected curves, intends to
warn the operation in real-time for any unexpected behavior (washout, bit jet loss or obstruction,
choke/kill valve wear, etc.).
• Casing Wear Calculation:
The purpose of this module is to provide a useful tool for monitoring the integrity of
this important well safety barrier. Taking advantage of the stiff-string torque and drag model
(MITCHEL, 2009) implemented, it was decided to apply the side force calculations to evaluate,
in real-time, the level of wear on the casings (SAMUEL ET AL., 2016). For that, it was necessary
to ensure that the results of the side force profiles were precisely representing the reality. A large
divergence in the normal force calculation would directly affect a good estimate of wear. Thus, an
extensive comparison between its results with other commercial softwares was performed.
Figure 13 shows the comparison between the results for casing wear obtained by the application,
the predicted wear calculated by a commercial software and the wear measured during the casing
logging. As observed, the application calculated wear is very close to the predicted wear, besides
presenting a behavior very similar to the measured wear.
• Drill String Element Detection Passing Through BOP Rams:
This is a feature which aims to track each drill string element that pass in front of the BOP rams.
Formerly, only the tubular elements lengths were considered to track the equipments in the well. By
taking advantage of the Torque and Drag simulator results in real-time, it became possible to take
into consideration the effect of axial elongation while tracking each equipment in any well depth.
Figure 14 illustrates the module results, with the status and their colors assigned. Since there is
a tool joint in front of the upper blind shear ram (UBSR). For this particular moment, it would not
be recommended to cut the drill string by actuating the UBSR.
• New Approach with Hybrid Solutions:
Until recently, the software was just based on phenomenological analysis, simulating drilling
operations in real-time and providing alerts to the responsible engineers. Present challenges include
the proposal of hybrid solutions (modeling + machine learning) to tackle the identification of
16 SPE-199077-MS

complex problems (such as false kicks, stuck pipe in salt drilling and loss circulation prediction).
On the example for the stuck pipe forecast module, a finite element based simulator is used to
calculate, in real-time, the closure of each salt formation already drilled. In order to enrich the
analysis and bring greater assertiveness in the prediction of salt stuck pipe events, in parallel with
the Mechanistic Analysis, a Data Analysis is also being developed. The main purpose of this
analysis is to attempt to discover patterns in historical data of stuck pipe (in salt formations) through

Downloaded from http://onepetro.org/SPELACP/proceedings-pdf/19LACP/4-19LACP/D041S035R002/2358624/spe-199077-ms.pdf/1 by Seoul National University, Aa Bb on 01 December 2022

statistical models and artificial intelligence (AI).
After building the model and training with historical events, the algorithm is able to identify
triggering evidences similar to those observed in the past cases of stuck pipe events. Algorithm
response is a probability of stuck pipe over a real-time well being monitored, as shown in Figure 15.

Figure 12—ROP based on the last drilled meter and the solids output rate during a hole section drilling.

Figure 13—Comparison of the proposed casing wear estimation, with

measured and predicted AS BUILT wear by commercial software.
SPE-199077-MS 17

Downloaded from http://onepetro.org/SPELACP/proceedings-pdf/19LACP/4-19LACP/D041S035R002/2358624/spe-199077-ms.pdf/1 by Seoul National University, Aa Bb on 01 December 2022

Figure 14—Drill String Element Detection passing through BOP Rams results illustration.

Figure 15—Stuck Pipe Forecast Model in real-time.

Final Remarks
The paper described a real-time drilling problem diagnosis software, developed in order to optimize drilling,
reducing time, costs and operational risks. The software already has a history of use in about 300+ Petrobras
wells and the results are promising. Proper diagnostics of operational problems show that logic for detecting
these problems based on trend curves gives good results.
Comparative tests performed with other commercial softwares available on the market made clear the
superiority of the proposed application, both as regards the ease of program use, as the efficiency and
reliability of the performed diagnostics. Part of the good results achieved with the software are due to the
big availability of data, employed on the model validation. Another factor that positively influenced for the
application was the good interaction between the development and deployment teams.
In the near future, the model will govern the communication with control layers to allow drilling
automation.
18 SPE-199077-MS

References
1. Aragao, A.F.L., Teixeira, G.T., Martins, A.L., Gandelman, R.A., and Silva, R.A.: PWD analysis
in Deepwater Environments: Campos Basin Studies. Deep Offshore Technology, Vitoria, Brazil,
November 8-10, 2005.
2. Teixeira, G. T.; Aragao, A. F. L.; Martins, A. L.; Gandelman, R. A.; Leal, R. A. F.; Silva, R.

Downloaded from http://onepetro.org/SPELACP/proceedings-pdf/19LACP/4-19LACP/D041S035R002/2358624/spe-199077-ms.pdf/1 by Seoul National University, Aa Bb on 01 December 2022

A.: PWD: Data Analysis and Conceptual Project of a Computational Tool for Interpretation (in
Portuguese). Well Engineering Seminar (in Portuguese), 6. 2005, Búzios.
3. Mitchell, R. F. How Good Is The Torque/Drag Model? SPE Journal Paper SPE 105068-PA,
March. 2009.
4. Oliveira, G. M., Franco, A. T., Negrão, C. O. R., Vadinal, R. B., Lomba, B. S., Fonseca, T. U.,
& Martins, A. L. (2015, March 17). Pressure Transmission in Gelled Drilling Fluids. Society of
Petroleum Engineers. SPE/IADC International Drilling Conference. DOI:10.2118/173128-MS
5. Grein, E. A., Dannenhauer, C. E., Cruz, M. S., da Silva, F. R. G., Martins, A. L., Vanni, G. S.,
Ribeiro, V. J. S., Veja, M. P., Evolution of Control Strategies to Minimize Pressure Fluctuation
During Connections in MPD Deepwater Operations. Offshore Technology Conference. DOI:
10.4043/27990-MS, 2017
6. Vanni, G. S., Fernandes, A. A, Teixeira, G. T., Lage, A. C. V. M, Martins, A. L., Terra, F. S.,
Cruz, M. S., da Silva, F. R. G., Dannenhauer, C. E., Real Time MPD Optimization in Challenging
Scenarios. SPE/IADC International Drilling Conference. DOI: 10.2118/194097-MS, 2019
7. Samuel, R., Kumar, A., Gonzales, A., Marcou, S., & Rød, A. M. Solving the Casing Wear Puzzle
Using Stiff String Model. Society of Petroleum Engineers. 2016 doi:10.2118/178833-MS.