SPE 149801

Artificial Neural Network Drilling Parameter Optimization System Improves

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

Copyright 2012, Society of Petroleum Engineers

This paper was prepared for presentation at the SPE Intelligent Energy International held in Utrecht, The Netherlands, 27–29 March 2012.

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 an artificial neural network (ANN) drilling parameter optimization system was developed to provide
rig-site personnel real-time information to ensure maximum run length from all bits and downhole tools at the highest
possible ROP. Benefits of the new system include extended tool life, fewer trips and the ability to manage the bits dull
condition.

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

The overall project results were positive and proved successful in all the trails carried out after this field trial. This paper
will address the methodology of the new approach and highlight the importance of planning and implementing the drilling
parameters in realtime.

Introduction
Traditionally, using available data from existing wells to plan new wells is a standard practice, however learning efficiently
from these previous experiences and using it has been a challenge. The planned parameters are typically applied during the
bit run without taking into consideration the true downhole conditions. The data quality and completeness of the data is
always a challenge.

The new Artificial Neural Network Drilling Parameter Optimization System is 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 the anticipated formation changes. This
enables the driller to make appropriate proactive adjustments to optimize ROP and footage drilled.

The main objective is to send optimized drilling parameter recommendations, including weight on bit, RPM and mud flow
rates to the driller on the rig floor during actual drilling operation. The program ensures that the bit’s cutting structure is
preserved to ensure a full run and minimize unnecessary trips for a new bit. The real-time delivers value by predicting or
providing:
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Formation changes/characteristics
Bit wear rates
Recognition of geological anomalies for making necessary adjustments
Recommendation for the best operating parameters to cut drilling costs

It is interesting to note that the real-time artificial neural network (ANN) drilling parameter optimization system may
recommend reducing operating parameters, which can slow ROP which normally increases drilling costs, but preserving the
bit’s cutting structure can enable the operator to complete the run without tripping for a new bit thereby reducing overall
cost/ft.
The main concept is based on the optimization of depth of cut by the bit that leads to bit wear (Figure 1). The depth of cut is
typically a function of the rate of penetration and the RPM at which the bit is rotating.

Figure 1 – Depth of cut

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
size it is important to properly manage operating parameters to fully exploit the tungsten carbide inserts (TCI) so overall bit
consumption and non-productive rig time (NPT) tripping for new tools are reduced. The project was staged as follows:

Processing Offset Data

Drilling engineers utilized the service providers drilling record database (DRB) and geographical bit data filter to identify
pertinent offset wells. The provider’s DRB is a comprehensive library that contains more than three million bit runs from
virtually 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 DRB system can be viewed with
a GIS search engine and map view interface (Figure 2) that finds data from 12 different sources then plots the specific
information in the appropriate geographic context. With its straight-forward user interface, data is assimilated and made
accessible through a variety of report styles. This is the first step to identify which offset wells had been drilled using the
same bit.
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Figure 2 - GIS search engine and map view interface, 8-1/2” bit query

Bit Selection
The next step was to identify the bit details based on the quantified 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 3).

Figure 3 – Rock strength plot with lithology description and bit selection

The rock strength program starts with a thorough 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 tools use a geologic
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mapping program, well log correlation and analysis software proprietary algorithms for rock compressive strengths, bit
performance analysis and finally bit selection. The rock strength software is highly flexible and enables engineers to analyze
various levels of information and deliver a bit strategy based on input from a single offset well, a multi-well cross section, or
a full field mapping and regional trend analyses. The rock strength program identifies the bit that possesses the appropriate
combination of cutting structure durability, gauge protection and hydraulic configuration to achieve the lowest cost/ft.

Artificial Neural Network Training

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 will attempt to
reduce the error between the two outputs (Figure 4). This iteration 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

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 bottom hole assemblies (Figure 5). The
ANN then uses this “learned experience” to offer the best combination of surface parameters including flow rate, weight on
bit (WOB) and RPM to efficiently achieve the operator’s requirements (Figure 6).

Figure 5 – Calibration of ANN ROP (red) to actual ROP (blue) for specific 8-1/2” bit type (F67Y)
SPE 149801 5

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

Data Communications
The underlying data plumbing is based on the WITSML data exchange standard that is used for providing the Realtime data
needed. WITSML has been designed to handle large volumes of real-time and contextual information to improve the
efficiency and reliability of wellsite communications and operations. The standard allows various applications to access
drilling data over the life cycle of the well without being re-entered. It provides a standard API that applications can use to
get, add, update and delete data.

Figure 7 - Typical work flow using WITSML as a transfer mechanism

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Typical architecture for managing the flow of information generated when drilling a well is depicted in Figure 7. The
published goal of the WITSML standard is to “Deliver a seamless flow of real-time wellsite data between the operator and
service providers to speed and enhance the decision-making process.” Since its inception, the service provider has
committed significant resources to develop software applications and real-time data exchange and analysis capabilities to
optimize operating parameters, hydraulics and bit selection. The features and benefits of the WITSML datastore to different
people involved are:

Wellsite Service Providers

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

Domain Experts
Compile information from a variety of vendor sources
Can monitor current well conditions from any worldwide field location
Can extract well reports at anytime, not just morning and afternoon

Service provider
Establish stewardship of all real-time and historical data for a given well project
Collect and store data from any/all contributing vendors
Maintain a single, secure and managed, web-accessible environment

Real-time data delivery with rig floor display (Figure 8) enables real time access to the current well and all offset data
utilized as a basis for ANN training and geological correlation (Figure 9).

Figure 8 – Drillers page with lithology, offset correlation and parameter recommendations are displayed on the rig floor
SPE 149801 7

Figure 9 – Office screen with real-time correlation to offset well; RPM, WOB and ROP values are illustrated along with
parameter recommendations ahead of the bit

Project execution - the subject well intervals are drilled according to ANN-driven real time parameter delivery and offset
correlation (Figure 10).

Figure 10 – Correlation with geological offset confirmed with built-in algorithm supported by the operator’s geologist
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Project Summary
The results of the interval optimized drilling are analyzed and evaluated against the estimated results as well as the initial
offset data to quantify the aberration from the planned performance (Figure 11). Additional recommendations for
supplementary features may be applicable at this point, e.g. diamond enhanced gauge cutters as a result of severe wear
observed on the dull bit (Figure 12).

Calculated
OffsetActual

Figure 11 – Comparison of offset vs current well bit performance along with ANN-based estimates

Figure 12 – Study of the dull characteristics and modifications to cutting structure components leads to improvements in
drilling performance

The continuous improvement processes (Figure 13) may indicate a total revamping of the cutting structure or other
prominent components which warrants new bit design rather than minor changes to an existing design. Should the well
section be logged, either while drilling or afterwards, the logs are compared to the original offset geological data to determine
and calibrate the geological analysis, rock compressive strength and the Neural Network learning.
SPE 149801 9

Figure 13 – Continuous Improvement Processes examine current well bit performance versus ANN-based estimates

Post Run Analysis

The post run analysis report comprise of several charts displaying the variance between the suggested and actual parameters
and their effect that fashioned the bit performance (Figure 14) in what can be described as Compliance Chart.

Figure 14 - WOB vs ROP data points show good compliance (>80%) and the subsequent improvement in bit performance

Other metrics captured are the correlated formation elements of the drilled well versus the planned interval (Figure 15), the
actual bit wear in comparison to the projected (Figure 16) and the Savings (or Losses) attained during the run/section.
10 SPE 149801

Figure 15 – Post-well interval analysis illustrates correlation of offset data to the actual drilled interval(s) along with overall
parameter compliance and predicted dull (T-5) vs actual dull condition of bit

Figure 16 - Dull bit field graded 5-7-BT; ANN system calculated dull grade accurately at T-5

The monitoring system displays the actual versus calculated WOB and RPM as well as the bit dull grading. The chart
(Figure 17) reflects the highlighted variance shaded to show whether parameters were exceeded or unrealized.
SPE 149801 11

Figure 17 – Shaded area highlights the difference between actual parameters applied and calculated parameters

Project Results
The chart below (Figure 18) emphasizes the progressive improvement in one project as a result of compliance to the real-
time parameters optimization throughout a project drilling 8 ½” section with Tungsten Carbide Insert Rock bits (TCI):

 Bit Run #5 was the first run with reduced compliance; due to lack of system knowledge and a slightly higher Rock’s
UCS than used in the offset training data and the result was a 17% decrease in overall ROP.

 Bit Run #6 reflects an improvement in compliance with real-time parameters displayed at the rig floor resulting in a
9% improvement in bit performance with a higher UCS.

 Bit Run #7 shows an ROP matching the offset and the bit was run past its design limits (exceeded recommended
rotating hours and K-REVS) resulting in a lost cone in the hole, which was subsequently fished out in one trip.

 Bit Run #8 illustrates a decrease in confidence of parameters delivered to the rig floor due to cone loss and a
subsequent reduction in performance (approximately 4%) was observed.

 Bit Run #9 displayed a true reflection of the system’s capabilities whenever the full parameter compliance was
achieved. A 30% increase in overall bit performance, even though the formation is approximately 5% harder than
the offset.

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

 Bit Run #11 was the last one in this intermediate hole section. The rock strength was slightly softer (12%) and the
bit performance enhanced by approximately 46%.
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% 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
-20 -10 0 10 20 30 40 50
% Δ ROP % Δ CMPS

Figure 18 – 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
essential for the success of such a delivery system. Additionally, the trial has underscored the potential cost savings and
emphasized the importance of monitoring run parameters among other factors as a valuable tool for optimizing bit
performance.

Acknowledgments
The authors would like to thank management at Smith Bits, a Schlumberger Company for permission to publish the data and
paper respectively. Also, thanks to Craig Fleming, Smith Bits for his technical writing and editorial contributions.

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