SPE 142880

Real-Time Drilling Parameter Optimization System Increases ROP by

Predicting/Managing Bit Wear
Yashodhan Gidh, Hani Ibrahim, Arifin Purwanto, Smith Bits, A Schlumberger Company

Copyright 2011, Society of Petroleum Engineers

This paper was prepared for presentation at the SPE Digital Energy Conference and Exhibition held in The Woodlands, Texas, USA, 19–21 April 2011.

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 necessar ily 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 prohi bited. 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
Tool manufacturers have made significant progress improving downhole drilling technologies, but little effort has focused on
optimizing the drilling process. The set-it-and-forget-it approach and inherent inefficiencies of the automatic driller are
inadequate for keeping bit parameters matched to lithology and wellbore conditions. The industry requires a new
methodology to help rig-site personnel make informed drilling parameter decisions based on real-time offset data analysis
that increases operating efficiency to reduce drilling costs.

To solve the problem, the service provider launched an artificial neural network (ANN) drilling parameter optimization
system (DBOS OnTime) which provides rig-site personnel real-time information to ensure maximum run length from all bits
and downhole tools at the highest possible penetration rates (ROP). Benefits of the new system include extended tool life,
fewer trips and the ability to manage the bit’s dull condition.

The objective is to replace the human factor of applying operating parameters such as weight on bit (WOB) and RPM with
the intelligent ANN “learned experience.” By using the ANN based software system, operating parameters can be selected
based on the documented physical rock characteristics (offset log data) of the formations being penetrated and then fine tuned
for the bit’s specific cutting structure and wear rate. By following the real-time ANN recommendations, changes can be
implemented to increase overall penetration rates (ROP) while maximizing bit life by managing the dull condition.

Introduction
Historically, once a bit was on-bottom and drilling ahead, the manufacturer had little influence on a driller’s decision to
increase bit performance or to survive adversity. To help solve this issue, a new real-time drilling parameter system was
designed to optimize applied drilling parameters on a foot-by-foot basis, ahead of the bit’s current position. Through
continuous correlation, recommended drilling parameter changes are determined and communicated to the driller, ahead of
anticipated formation changes. This enables the driller to make appropriate proactive adjustments to optimize ROP and
footage drilled.

The main objective is to send the driller optimized parameter recommendations that include weight on bit, RPM and mud
flow rates during actual borehole construction. The program helps preserve the bit’s cutting structure to ensure a full run and
minimize unnecessary trips for a new bit. The real-time system delivers value by predicting or providing the following:

 Formation changes/characteristics
 Bit wear rates
 Recognition of geologic anomalies for necessary adjustments
 Recommendation of the best operating parameters to reduce drilling costs

It is interesting to note, that the real-time optimization system may recommend reducing operating parameters which might
slow ROP which can increase drilling costs. But the reduction in parameters can preserve the bit’s cutting structure enabling
the operator to complete the run without tripping for a new bit.
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The new system is currently being field tested in areas with ample offset data and modern logging information, but a diligent
search is underway to identify other regions and applicable lithologies suited for additional studies. To further expand the
RTOS application envelope, the industry is working on upgrading the operating environment and data transmission
requirements to support the new technology. When programmers are able to bridge the gap between OPC Standard and
WITSML data exchange languages total automation should be possible.

Case Study (East Texas)

The Travis Peak formation in East Texas is a well known for its extremely hard and abrasive rock layers. In the 8-1/2” hole
section, proper management of operating parameters is important to fully exploit the rollercone’s tungsten carbide cutting
structure (TCI) so overall bit consumption and non-productive rig time (NPT) spent tripping for new tools are reduced. The
project was staged as follows:

Set Up and Data Selection

Application engineers utilized the service providers drilling record system (DRS) and geographical bit data filter to identify
pertinent offset wells. The provider’s DRS is a comprehensive bit run library that contains more than three million records
from practically every oil and gas field in the world. The database was initiated in May 1985 and has been continuously
updated with oil, gas and geothermal well data in addition to specific drive system information. The DRS database contains a
wealth of information that enables design engineers to evaluate individual bit runs anywhere in the world. Armed with this
detailed data set and the accurate FEA-based dynamic modeling system, engineers can simulate bit performance and make
design changes to optimize performance in a specific application before the bit leaves the factory.

The DRS system can be accessed with a GIS search engine that finds data from 12 different sources then plots the specific
information in the appropriate geographic context (Figure 1). The straight-forward user interface assimilates data and makes
it accessible through a variety of report styles. As it continues to mature, the search engine and display system will become a
comprehensive knowledge management tool for all geographically indexed data.

Figure 1 - GIS search engine and map view interface, 8-1/2” bit query

Bit Selection
The next step was to quantify rock strength and abrasiveness factors to define each formation’s “drillability” with regards to
the casing design and to meet operator ROP and non-productive time (NPT) avoidance goals and objectives. To determine
rock strength and abrasiveness, engineers utilized a rock strength software service to determine the correct bit for the
application (Figure 2).

The rock strength program starts with a comprehensive analysis of offset well data including well logs, formation tops, mud
logs, core analysis, rock mechanics, drilling parameters, bit records and dull bit conditions. The software tool uses a geologic
mapping program, well log correlation and analysis software algorithms to determine rock compressive strength, bit
SPE 142880 3

performance and final bit selection. The flexible software program enables engineers to analyze various levels of information
and deliver a bit strategy based on input from a single well, multiple well cross-section, or a full field mapping and regional
trend analyses. The program identifies the bit that has the appropriate combination of cutting structure durability, gauge
protection and hydraulic capabilities to achieve the lowest cost/ft.

Figure 2 – Rock strength plot with lithology description and bit selection

WITSML/Communications Links
In 2000, the drilling industry initiated new standards for drilling information transfer. These efforts ultimately resulted in the
development of Wellsite Information Transfer Standard Markup Language (WITSML) for managing the flow of information
that is generated when drilling a well (Figure 3). More specifically, the purpose of the WITSML standard can be found in its
published goal: “Deliver a seamless flow of real-time wellsite data between the operator and service providers to speed and
enhance the decision-making process.” Since this development, the service provider has committed significant resources to
develop real-time data exchange and analysis capabilities to optimize operating parameters, hydraulics, and bit selection. The
features and benefits of the WITSML datastore are:

Wellsite Service Providers

 Contributes expert knowledge in a common receptacle through WITSML interface
 Enables users to query datastore for combined information with other wellsite services
 Supports programmatic analysis, visualization, and potential corrective actions

Operating Personnel
 Compiles information from a variety of vendor sources
 Capable of monitoring current well conditions from any worldwide location
 24-hour well report capabilities, not just morning and afternoon

Service provider
 Establishes stewardship of all real-time and historical well-project data
 Collects and stores data from any/all contributing vendors
 Maintains a single, secure and managed, web-accessible environment
4 SPE 142880

Figure 3 - Typical work flow using WITSML as a transfer mechanism

Artificial Neural Network Training

Artificial neural network (ANN) training is a key enabling technology for the new real-time optimization system. The value
of applying artificial neural networks in the oil and gas industry is well established. 1-14 The artificial neural network concept
of data processing was inspired by biological neurons analogous to those found in the human brain. ANN, like humans,
learns by collecting data samples and analyzing the relationship between input and output. The system has two desired
outputs that are compared continuously. The differences are then fed back to the neuron. The neuron attempts to reduce the
error between the two outputs (Figure 4). This iterative process continues until the output and the desired output become
reasonably close. At this point a neural “understand and learn” has established the required connection between input and the
desired output.

Figure 4 – Artificial neural network “understand and learn” concept

SPE 142880 5

In the case of the new real-time drilling parameter optimization program, the sophisticated ANN system actually “learns”
how the bit drills and dulls in similar lithologies and downhole tendencies of similar bottomhole assemblies (Figure 5). The
ANN then uses this “learned experience” to efficiently achieve the operator’s requirements by offering the best combination
of surface parameters: they include flow rate, weight on bit and RPM (Figure 6).

Figure 5 – Calibration of ANN ROP (red) to actual ROP (blue) for specific 8-1/2” bit type (F67Y)

Figure 6 – 3-D surface modeling from rock strength neural net training program
6 SPE 142880

Real-time data delivery with rig floor display (Figure 7) enables access to current data and offset well records that were used
for ANN training and geologic correlation (Figure 8).

Figure 7 – Drillers page with lithology, offset correlation and parameter recommendations are displayed on the rig floor

Figure 8 – Office screen with real-time correlation to offset well; RPM, WOB and ROP values are illustrated along with
parameter recommendations ahead of the bit
SPE 142880 7

Project execution - the subject well intervals are drilled according to ANN-driven real-time parameter delivery and offset
correlation (Figure 9).

Figure 9 – Correlation with offset data confirmed with built-in algorithm supported by the operator’s geologist

Project Summary Report

All interval performance information is reviewed and compared with offsets and calculated results (Figure 10).
Recommendations on new bit types and special features (example - diamond enhanced gauge row to minimize wear) may be
made at this time for continuous improvement. Geology and rock strengths are scrutinized to compare offset data against the
subject well so direct comparisons can be made. Changes in bit design are noted for improvements on subsequent
applications if necessary.

Est w/optimized RPM, WOB

Figure 10 – Comparison of offset vs current well bit performance along with ANN-based estimates
8 SPE 142880

Post Run Analysis

After the project, there are several metrics that can be graphically displayed to determine the degree of compliance with
parameter recommendations influenced ROP, bit wear and cost savings/performance degradation (Figures 11, 12, 13).

Figure 11 - WOB vs ROP data points show good compliance (>80%) and subsequent improvement in bit performance

Figure 12 – Post-well analysis illustrates overall parameter compliance and predicted dull (T-5) vs actual dull condition
SPE 142880 9

Figure 13 - Dull bit field graded 5-7-BT; ANN system calculated dull grade dead-on accurate at T-5

Project Results
The seven-run synopsis below details the progressive improvement in performance that resulted from increased compliance
with the real-time parameter optimization recommendations (Figure 14).

 Bit Run #5 was the first run in the ANN-optimized, 8-1/2” interval. The results showed poor compliance by the
driller due to lack of system knowledge. This occurred in spite of extensive well-site training prior to project
commencement. The rock drilled has a slightly higher UCS than that which was used for the offset training data and
the result was a 17% decrease in overall ROP.

 Bit Run #6 shows an improvement in driller compliance with real-time parameters displayed at the rig floor. Even
with the same general trend of harder formation (as compared to the offset) the optimized parameters resulted in a
9% improvement in bit performance.

 Bit Run #7 shows that even in a harder formation, the ROP matched the offset. No significant gain in bit
performance was realized with this particular TCI bit. The bit was run past its design limits (exceeded
recommended rotating hours and K-revs) and a cone was lost in the hole, which was subsequently fished out in one
trip.

 Bit Run #8 illustrates a temporary loss of confidence regarding the parameters delivered to the rig floor. The loss of
one cone on the previous run reduced compliance with WOB and RPM recommendations and a subsequent
reduction in performance (approximately 4%) was observed.

 Bit Run #9 is a true reflection of the system’s capabilities. Parameter compliance was excellent (renewed
confidence in network-derived recommendations) and the result was a 30% increase in overall bit performance, even
though the formation is approximately 5% harder than the offset.

 Bit Run #10 continues the positive trend. Parameter compliance was excellent and the improvements were even
better; ROP was increased 32%.

 Bit Run #11 was the last bit in the intermediate hole section. The rock strength was somewhat softer (12%)
although parameter compliance by the driller was 100%. Bit ROP performance improved by approximately 46%.
10 SPE 142880

% Change - Correlated Intervals

#5-F67YOD 3.3
-17.2
#6-F90YOD 9.0
12.6

#7-FHi90YOD 0.3
3.8

#8-F90YOD -3.8
4.5

29.5
#9-F90YOD 4.8

#10-F90YOD 32.3
11.1

#11-F67YOD -11.9
45.8
Figure 14 – Bit run analysis showing performance changes as functions of ROP and formation UCS
-20 -10 0 10 20 30 40 50
% Δ ROP % Δ CMPS

Figure 14 – Bit run analysis showing performance changes as functions of ROP and formation UCS

Conclusion
The overall project results were positive. The operator completed the 8-1/2” hole section almost three days ahead of plan
even with the unplanned trip to retrieve the lost cone. The reduction in drilling days saved the operator approximately
$150,000USD. The successful field trial provided valuable insight about the “human” element and the confidence factor
required from rig personnel prior to spud. As drillers become better acquainted with the system and potential cost savings,
the program will become a valuable tool for optimizing real-time bit performance.

Acknowledgments
The authors would like to thank management at Smith Bits, A Schlumberger Company for permission to publish the data and
information contained in this paper. Special thanks to Craig Fleming, Smith Bits for his technical writing and editorial
contributions.

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