THE ROLE OF DATA IN DRILLING P3 AND WHY QUALITY IS IMPORTANT

Transcription

1 THE ROLE OF DATA IN DRILLING P3 AND WHY QUALITY IS IMPORTANT

2 PEAKE DRILLING CONTINUOUS IMPROVEMENT PLATFORM Analytics Generate Metrics Automate Design Create Program Send Tasks to Rig/OSC. Rigs/OSC and Update as Completed Get Data from Source of Record Databases Get Data from Engineer 2

3 AUTOMATION REQUIRES DATA QUALITY 3

4 DRILLING DATA PATH Real-Time Data Instrument Digital Sampling Calibrated Data Rig Calculated Channel Rig Corrected Channel Real Time Analysis Alarming RTOC Corrected Channel Post- Process Data Score Source of Record Process Analytics Facts States Activities Events Process Improvement Metrics Expectations Actions Best Practices 4

5 GOOD INFORMATION IS A CORNERSTONE 5

6 Is Our Drilling Data Good? Question 1 Is it a problem we need to address or is magnitude of error lost in the noise Question 2 If 1 is true, how significant are the errors Question 3 If 2 is high, can we even fix it? 6

7 QUESTION 1 IS ERROR > NOISE AND IS IT IMPORTANT?

8 WHY IT MATTERS ON THE RIG Variable Observed Errors in Field Derivative Variable Errors Torque >100% MSE Rig State RPM >100% MSE, Rig State HookLoad >100% WOB, MSE, Bit Depth, Rig State Commonly Found Errors in Drilling Data and Corresponding Repercussions Small Error Consequence 5%-10% Incorrect MSE leading to sub-optimal drilling. Consumption of realtime torque data by applications like Peake Drilling leading to sub-optimal analysis and planning. 2%-10% Incorrect MSE leading to sub-optimal drilling. Incorrect rotary torque--improper feedback loop to TD's that require RPM to correctly report torque (Yaskawa, Converteam, etc.) 2%-5% Incorrect MSE leading to sub-optimal drilling. Incorrect WOB leading to poor ROP or bit wear/damage. Large Error Consequence >20% This would represent ~5000 ft*lb error for most TDS-11 type drives. Bit Failure, Motor Failure, MWD Failure, Tubular Failure, Vibrational Dysfunction, Poor Drilling Performance >20% This would represent ~25-40 RPM for most TDS-11 type drives. Bit Failure, Vibrational Dysfunction, MWD Failure, Poor Drilling Performance >10% This would represent ~50,000 lb for most sensors. Worst Case Scenario Loss of Drill String Loss of Drill String Loss of Drill String 8

9 WHY IT MATTERS ON THE RIG Variable Pump Pressure Pump Rate Observed Errors in Field >100% ΔP, MSE, Rig State >100% MSE, Rig State Commonly Found Errors in Drilling Data and Corresponding Repercussions Derivative Variable Small Large Errors Error Consequence Error Consequence 2%- 5% 2%- 5% Incorrect MSE leading to suboptimal drilling. Poor managed pressure performance. Poor well control performance. Wear/damage to down-hole motors/turbines. Incorrect MSE leading to suboptimal drilling. Wear/damage to down-hole motor/turbines. Poor managed pressure performance. Poor well control performance. Poor diagnostic ability with tracers, etc. Poor hole cleaning. >10% psi error could lead to potential damage to motors/turbines/mwd. Potential for kicks/fracturing when near pore pressure/frac gradient >10% 10 strokes/min error could significantly affect well control or managed pressure scenarios. Worst Case Scenario Blowout Blowout 9

10 WHY IT MATTERS ON THE RIG Variable Block Position Observed Errors in Field >25% (cumulati ve >50%) Flow Out >100% Rig State, Kick Detection Pit Volume >5% (100% delta) Commonly Found Errors in Drilling Data and Corresponding Repercussions Derivative Variable Small Large Errors Error Consequence Error Consequence Bit Depth, ROP ΔPit Volume, Kick Size/Density 1%-2% Block Position Error is Cumulative. In order to increase depth, the block must travel at least 2x the distance the drill string travels. Incorrect MD/TVD/Survey Measurements. 5%-10% Incorrect MSE leading to sub-optimal drilling. Poor well control detection. Poor stuck pipe/pack off detection 1%-2% Poor well control detection/performance. >5% 10ft error per joint of drilled pipe. Could lead to significant survey errors and TD compromise. >20% Inability to detect kicks, pack off or other problems. >5% 5bbl error could be 100% error in well control calculations Worst Case Scenario Wellbore Intersecti on Blowout Blowout 10

11 QUESTION 2 WHAT ARE THE REAL-WORLD ERRORS

12 ERRORS FOUND THROUGH CALIBRATION Every rig has had devices significantly out of calibration Most rigs have rig-ups or practices that will lead to device error or drift. Errors are common to all rigs and contractors Rig A Rig B Rig C Rig D Rig E Rig F Rotary Torque 17% 17% 22% 24% 21% 18% Makeup Torque 23% 11% 12% 17% 60% 13% Rotary RPM 1% 1% 1% 1% 2% 1% Pump Rate 1% 32% 1% 1% 40% 1% Block Position 6" <0.5 <0.5 6ft <0.5 <0.5 Hookload 11% 18% 12% Pit Volumes 15% 12% 18% 16% 15% 22% Pump Pressure 5% 4% 4% 4% 3% 5% 12

13 TORQUE, HOOKLOAD, MSE AVERAGE >15% OVERESTIMAT ION OF APPLIED MSE 13

14 SHARED FIELD OBSERVATIONS FROM ~10 DIFFERENT RIGS Hookload is generally over-reported by hydromechanical gauges. This means we get less WOB than we think Torque is generally over over-reported by flux output of VFD This means we get less torque than we think 14

15 Number Number TORQUE HISTOGRAMS: IR VS IR TESTER n = 298 tests 70 Torque Difference +/- 2,000 lbs % Difference Torque Difference (ft-lbs) +/- 10% >80% of observations are out of DS1 recommended tolerance % -45% -40% -35% -30% -25% -20% -15% -10% -5% 0% 5% 10% 15% 20% 25% 30% Torque Difference (%) 15

16 Iron Roughneck (ft-lbs) TORQUE SCATTERPLOT: IR VS IR TESTER 25,000 IR overstating torque (Under make-up) 22,500 20,000 17,500 IR understating torque (over make-up) 15,000 15,000 17,500 20,000 22,500 25,000 Iron Roughnecck Tester (ft-lbs) 16

17 Error in Volume Calculation [bbl/in] MEASURED ERROR IN PIT VOLUMES PIT VOLUME CHANGES ARE GENERALLY UNDER -REPORTED 60% Sand Trap 40% Settling 1 Settling 2 Settling 3 20% Settling 4 Suction Slugging 0% Active Error -20% -40% -60% Fluid Level [in] 17

18 Active System Volume [bbls] ACTIVE SYSTEM VOLUME UNDERESTIMAT ION HAS MANY CONSEQUENCES Calculated Measured Fluid Level [in] 18

19 Volumetric Efficienty (%) PUMP RATE ERROR Volumetric Efficiency is not constant Effected by Pressure Fluid Swab 100% 90% 80% 70% 60% 50% Temperature Difficult to measure at operating conditions 40% 30% 20% 10% 0% --swab 1 --swab 2 --swab Pressure (psi) 19

20 CAN WE RELY ON TODAY S TOOLS? Are they accurate? Are they reliable? Are they repeatable? Do they vary from well-to-well and day-to-day Can we measure every value of interest? Makeup torque? Actual pump rate? 20

21 Percentage Error RIG A ERROR TREND 30% 25% Makeup Torque PumpRate 20% BlockPosition Surface RPM Surface Torque 15% 10% 5% 0% 24-Jul 9-Sep 21-Sep Calibration Date Nomac 27 21

22 Percentage Error RIG B ERROR TREND 18% 16% 14% 12% 10% Makeup Torque PumpRate BlockPosition Surface RPM Surface Torque 8% 6% 4% 2% 0% 1-Aug 27-Aug 10-Sep 25-Sep Calibration Date 22

23 Percentage Error RIG C ERROR TREND 40% 35% 30% 25% Makeup Torque PumpRate BlockPosition Surface RPM Surface Torque 20% 15% 10% 5% 0% 6-Aug 26-Aug 14-Sep Calibration Date 23

24 Percentage Error RIG D ERROR TREND 35% 30% 25% Makeup Torque PumpRate BlockPosition Surface RPM 20% Surface Torque 15% 10% 5% 0% 1-Sep Calibration Date 19-Sep Nomac35 24

25 Percentage Error RIG E ERROR TREND 20% 18% 16% 14% 12% 10% Makeup Torque PumpRate BlockPosition Surface RPM Surface Torque 8% 6% 4% 2% 0% 27-Jul Calibration Date 19-Sep 25

26 Percentage Error RIG F ERROR TREND 7% 6% Makeup Torque PumpRate 5% BlockPosition Surface RPM 4% Surface Torque 3% 2% 1% 0% 18-Aug 2-Sep 13-Sep Calibration Date 26

27 QUESTION 3 CAN WE FIX IT? YES WE CAN!

28 NEW TOOLS ARE NEEDED Had to use new tools when old ones did not satisfy requirements TTS to Measure Torque and Hookload Had to invent new tools when none existed Iron Roughneck Calibration Tool Recommended new types of tools when calibration is not practical with current tools Radar Pit Level Sensors Coriolis meters 28

29 CAN WE CALIBRATE EXISTING TOOLS? Rig F TOP-DRIVE WAS CALIBRATED TO MATCH TTS SUB 29

30 CAN WE CALIBRATE EXISTING TOOLS? Vibrations not measured by TD PLC Ammeter Connection Torque Measured by TTS Inertia of Top Drive Slows TD but not DrillString Current Tools are not sensitive enough and their source measurement(s) mask inertial, electrical and other sources of noise 30

31 WHAT PROCESS IS REQUIRED? Comprehensive Covers all aspects of quality Simple Can be performed and communicated by roughnecks Economic Can be scaled quickly with minimal expense Sustainable Can be repeated ad infinitum 31

32 P3 COMPREHENSIVE QUALITY GOALS Calibration Trust but Verify Scheduled and Event Driven calibration Collection Existence and Continuity Ensure >99.9% availability in Real-Time Constraints Equipment Limits A system cannot report values in excess of device physical limits Consistency Reality Checks Example: drilling only occurs on bottom Confidence Bayesian Statistics in Real-Time Are data relationships maintained across the network of sensors? Communication Check/Act in Real-Time Set alarms and communicate them objectively Manage escalation paths to ensure timely resolution 32

33 SIMPLE PHILOSOPHY You cannot improve what you cannot measure! ALWAYS Calibrate to Actual Units ALWAYS Recalibrate IF The instrument has no calibration records The instrument is known to be untruthful The environment in which the instrument operates changes significantly The recommended calibration interval has been exceeded ALWAYS Demand Proof of Calibration EVERY device must have a certification with a valid date ALWAYS Trace Back to NIST ALWAYS Calibrate using AT LEAST three measurements If It Doesn t Seem Right, CHECK AGAIN Follow Your Instincts 33

34 RECOMMENDED PRACTICES Developed Recommended Practices Meet Following Requirements Must be roughneck-proof Must be cost-effective and sustainable Must add <1 hour total to rigup Reviewed by: DTG Senior Engineers Drilling Contractors Equipment Vendors Company Men/Superintendents CHK Controlled Document Version Controlled Highly Structured 34

35 ORGANIZATION AND TRAINING Spent 8 months organizing and training vendors Some vendor still require a lot of improvement (BOP) Put teeth behind efforts by working with Supply Chain Certified 10 independent auditors (1/2 day class + field shadowing) Provided multiple field-level training sessions for company men and superintendents Trained OSC staff on how to manage data 35

36 MANAGEMENT OF CHANGE PROCESS Device Details What does it measure Directly/Indirectly Units of Measure Device Thresholds Calibration Details Method Frequency Reporting/Visualization Details Alarming Details 36

37 INDUSTRY STANDARDIZATION Peer participation is paramount to: Improve Recommended Practices Lower Cost Encourage Vendor Participation, Training, Staffing, etc.. Several E&P Companies already on board: Apache, BP, Chesapeake, Chevron, Exxon, Hess, OXY, Statoil Data Quality is an Industry Problem that Requires and Industry Solution 37

38 QUESTIONS? THANK YOU!