âDrilling Modelling and Simulationâ Keynote
Special Session: Drilling Modelling and Simulation
“Drilling Modelling and Simulation” Keynote Prof. Dr. G. P. Ostermeyer, Dir. Inst. of Dynamics and Vibration, Braunschweig Technical University
Slide 2
Content
Introduction Systems and Simulations Simulators What is a Simulator? Structure of Simulators Human Machine Interfaces HIL/SIL Simulator in Celle Challenges of Drilling Modelling and Simulation Outlook
Special Session • Drilling Modelling and Simulation • Ostermeyer/Oppelt
Slide 3
Content
Introduction Systems and Simulations Simulators What is a Simulator? Structure of Simulators Human Machine Interfaces HIL/SIL Simulator in Celle Challenges of Drilling Modelling and Simulation Outlook
Special Session • Drilling Modelling and Simulation • Ostermeyer/Oppelt
Slide 4
Introduction We have a problem problem
world
Special Session • Drilling Modelling and Simulation • Ostermeyer/Oppelt
Slide 5
Introduction We have a problem problem
world
Start point: questions to the world
aim:
(understandable) answers of the world
Special Session • Drilling Modelling and Simulation • Ostermeyer/Oppelt
Slide 6
Introduction World too big for human brains:
We have a problem
We are always acting in a small Clipping region of the world
problem
world Clipping region
Start point: questions to the world
aim:
answers of the world
Special Session • Drilling Modelling and Simulation • Ostermeyer/Oppelt
Slide 7
Introduction World too big for human brains:
We have a problem
We are allways acting in a small Clipping region of the world
problem
world Clipping region
Start point: questions to the world
aim:
answers of the world
Special Session • Drilling Modelling and Simulation • Ostermeyer/Oppelt
Slide 8
Introduction World too big for human brains:
We have a problem
We are allways acting in a small Clipping region of the world
problem
world Clipping region
Start point: questions to the world
aim:
Tests for answers are still: too expensive too dangerous too confusing too big and fast too unobservable too complex …
answers of the world
Special Session • Drilling Modelling and Simulation • Ostermeyer/Oppelt
Slide 9
Introduction Building a system – subtitude of the world section of world
Selected Input data
system
world Copy of clipping region (model)
Clipping region
Selected output data
Start point: questions to the world
questions to the substitute quality of copy ?
aim:
answers of the world
answers of the substitute
Special Session • Drilling Modelling and Simulation • Ostermeyer/Oppelt
Slide 10
Introduction
section of world
Selected Input data
system
world Clipping region
Copy of clipping region (model) Selected output data
Realization of the substitute
Output data
Driller
physical model
virtual model
Output data
Output data
Output data
software
HIL / SIL
hardware
Input data
Special Session • Drilling Modelling and Simulation • Ostermeyer/Oppelt
virtual model
Input data
actuators sensors
Input dada
physical model
Human brain
Input data
Slide 11
Introduction Realization of the substitute
Output data
Driller
Input data
physical model
virtual model
Output data
Output data
Output data
hardware
software
HIL / SIL
Downscaled hardware rig “OSTRATOR” at IDS
Motorcycle
virtual model
Input data
actuators sensors
Input dada
physical model
Human brain
Input data
Traffic interaction
Special Session • Drilling Modelling and Simulation • Ostermeyer/Oppelt
Slide 12
Content
Introduction Systems and Simulations Simulators What is a Simulator? Structure of Simulators Human Machine Interfaces HIL/SIL Simulator in Celle Challenges of Drilling Modelling and Simulation Outlook
Special Session • Drilling Modelling and Simulation • Ostermeyer/Oppelt
Slide 13
Simulators What is a simulator? system shell capsuling the system Data input manipulation
Input data system manipulation
model system Output data
analysis of output
Special Session • Drilling Modelling and Simulation • Ostermeyer/Oppelt
Slide 14
Simulators What is a simulator? system shell capsuling the system Data input manipulation
Input data system manipulation
model system
Hook Load, RPM
Output data
analysis of output
Example OSTRATOR, IDS (hardware system)
Whirl
Special Session • Drilling Modelling and Simulation • Ostermeyer/Oppelt
Slide 15
Simulators 50m-BHA is drilling a given wellbore trajectory
Example OSPLAC, IDS (software simulator) Drilling process (hook load, rpm) Geology / Formation Wellbore Geometry ….
Drill String Model
Load Spectra Energy measures ROP ….
Special Session • Drilling Modelling and Simulation • Ostermeyer/Oppelt
Slide 16
Simulators What is a simulator? system shell capsuling the system Data input manipulation
Input data system manipulation
model system Output data
Interface between Human Being and Machine Necessary!
analysis of output
Special Session • Drilling Modelling and Simulation • Ostermeyer/Oppelt
Slide 17
Simulators Human Machine Interface Input data manipulation
Type I Avatar technique
system manipulation
HMI
Human
Input data model output data
analysis of output
HMI: human as part of the model (e.g. computer games: “second life”…)
Special Session • Drilling Modelling and Simulation • Ostermeyer/Oppelt
Slide 18
Simulators Human Machine Interface
Type II
Input data man.
Emulation of real world
model
human
HMI
Input data
output data
Analysis of output data
HMI: human with “synthetic Environment” (classical simulators….)
Special Session • Drilling Modelling and Simulation • Ostermeyer/Oppelt
Slide 19
Simulators Human Machine Interface
Type II
usual form of simulators Emulation of real world
Flight simulator Krementschuck, Ukraine, American Fight helicopter
DrillSIM- 600 with CyberChair, DrillingSystems
HMI: human with “synthetic environment” (emulators of real systems….)
Special Session • Drilling Modelling and Simulation • Ostermeyer/Oppelt
Slide 20
Simulators Human Machine Interface
Type III
Input data man.
Augmented Reality (AR)
human
output data
world
computer
model
HMI
Input data
Analysis of output data
Model/simulator based additional information for the human in the real world ( e.g. “Google Glass”, …) human integrated automation Special Session • Drilling Modelling and Simulation • Ostermeyer/Oppelt
Slide 21
Simulators Model realisations in simulators Data input manipulation
Look at the world Input data model
system manipulation
Output data
Output data
Hardware
virtual
model
Output data
Software
virtual model
physical model
Input data actuators sensors
analysis of output
Input data physical model
Input dada
Output data
HIL (SIL)
Special Session • Drilling Modelling and Simulation • Ostermeyer/Oppelt
Slide 22 Name
Application
Implementation
Partial Models
Sources
Simulators
Legend: ■
yes, but not central □ no ? no information
Pipe Handling
Formation / Reservoir Model
Well Bore Completion
Bit Model
BHA-Model
Drill String Dynamics
Wellbore Stability
Mud Flow
Cost Effectiveness Model
o
Real Time
Realistic Operation Environment
Software Simulator
Hardware Simulator
Application Tool in the Field
Research and Development
Eductaion and Recruiting
yes
■/□ Application dependent
[Bjo09] , [eDr10], [eDr10], [Nyb08], [Rom06],
EDRILLING, Stavanger
IRIS Virtual Rig DART, KCADEUTAG Payzone, Univ. of Berkeley IDRILL of Smith Company Products of Drilling Systems Optimizer of Pason/ DROPS
[Rom08a], [Rom08b], [Rom08c], [Rom08d], o
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[Hod06], [Deu10]
[Pay10], [Kel09], [Abo01], [Abo03], [Coo95]
[Smi10], [JPT06] [Dri10]
[Har00a], [Har00b], [Har07], [Har08], [Pas10], [Saf04]
Company
Special Session • Drilling Modelling and Simulation • Ostermeyer/Oppelt
Slide 23 Application
Name
Implementation
Partial Models
Sources
Simulators
Legend: ■ yes
Research and Development
Application Tool in the Field
Hardware Simulator
Software Simulator
Realistic Operation Environment
Real Time
Cost Effectiveness Model
Mud Flow
Wellbore Stability
Drill String Dynamics
BHA-Model
Bit Model
Well Bore Completion
Formation / Reservoir Model
Ein Simulator der Fa.
Eductaion and Recruiting OASIS der Fa. Baker Hughes
o
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yes, but not central □ no ?
Pipe Handling
no information ■/□ Application dependent
[Bak10] [Hal03] [Hal03]
Halliburton Ein Simulator nach Dubinsky
[Dub98]
der Fa. Baker Hughes Simulator der University of
[Ahm10]
Oklahoma Simulator aus Veröffentlichung
[Boo01]
von J. Booth Simulator der Louisiana State
[Ahm10]
University [Lyo08][Net10]
Extreme Drilling Laboratory (XDL) at NETL (National
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Energy Technology Lab)
Special Session • Drilling Modelling and Simulation • Ostermeyer/Oppelt
Slide 24 Application
Name
Implementation
Partial Models
Sources
Simulators
Legend: ■ yes
Research and Development
Application Tool in the Field
Hardware Simulator
Software Simulator
Realistic Operation Environment
Real Time
Cost Effectiveness Model
Mud Flow
Wellbore Stability
Drill String Dynamics
BHA-Model
Bit Model
Well Bore Completion
Formation / Reservoir Model
Ein Simulator der Fa.
Eductaion and Recruiting OASIS der Fa. Baker Hughes
o
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yes, but not central □ no ?
Pipe Handling
no information ■/□ Application dependent
[Bak10] [Hal03] [Hal03]
Halliburton Ein Simulator nach Dubinsky
[Dub98]
der Fa. Baker Hughes Simulator der University of
[Ahm10]
Oklahoma Simulator aus Veröffentlichung
[Boo01]
von J. Booth Simulator der Louisiana State
[Ahm10]
University [Lyo08][Net10]
Extreme Drilling Laboratory (XDL) at NETL (National
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Energy Technology Lab)
Special Session • Drilling Modelling and Simulation • Ostermeyer/Oppelt
Slide 25 Application
Name
Implementation
Partial Models
Sources
Simulators
Legend: ■ yes o
Eductaion and Recruiting
Research and Development
Application Tool in the Field
Hardware Simulator
Software Simulator
Realistic Operation Environment
Real Time
Cost Effectiveness Model
Mud Flow
Wellbore Stability
Drill String Dynamics
BHA-Model
Bit Model
Well Bore Completion
Formation / Reservoir Model
Drilling Laboratory der Ecole
yes, but not central
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□ no ? no information
Pipe Handling
■/□ Application dependent
[Eco10]
des mines de Paris Full Scale Test Rig der
[Tul10]
University of Tulsa Full Scale Test Rig der Fa.
[Lun09]
Terratec Full Scale Test Rig der Baker
[Lun09]
Hughes Full Scale Test Rig der Fa.
[Lun09]
Schlumberger Full Scale Test Rig der Fa.
[Lun09]
Amoco Full Scale Test Rig der Fa.
[Lun09]
Reed Hycalog
And many others ……, but: Special Session • Drilling Modelling and Simulation • Ostermeyer/Oppelt
Slide 26
Simulators Model realisations in simulators Data input manipulation
look at the world Input data model
system manipulation
Output data
Output data
Hardware realisations: many
virtual
model
Output data
Software few
virtual model
physical model
Input data actuators sensors
analysis of output
Input data physical model
Input dada
Output data
HIL (SIL) very few
Special Session • Drilling Modelling and Simulation • Ostermeyer/Oppelt
Slide 27
Simulators Model realisations in simulators Data input manipulation
HIL – Drilling Simulator Input data model
system manipulation
Ostermeyer, TU Braunschweig Denkena, Uni Hannover ……
Output data
virtual model
physical model
analysis of output
actuators sensors
Input data
Output data
HIL (SIL)
Special Session • Drilling Modelling and Simulation • Ostermeyer/Oppelt
Slide 28
The HIL – Drilling Simulator Real world
Loop
time t Complex geometry by forces in interface
t := t + Dt
Computer
Cut
Realize geometry in interface of test rig
Interface M
Test rig
Measure forces in interface of test rig
Special Session • Drilling Modelling and Simulation • Ostermeyer/Oppelt
Slide 29
The HIL – Drilling Simulator Real world Full virtual model with realistic bit and BHA- Info without model simplifications real time appl.
Computer
Cut
Interface M
(HIL – Simulation)
Small Hardware model moves like a part of the total model (SIL – Simulation)
Test rig Special Session • Drilling Modelling and Simulation • Ostermeyer/Oppelt
Slide 30
The HIL – Drilling Simulator - Realization Stone chamber Length: 1000mm
Drillstring chamber short/long
Hexapod 5D 20mm/ 20 Hz
HIL/SIL simulation motion controller
motor WOB: 40t
Short chamber: Bit Rig (RPM, WOB, controlled bouncing, controlled whirl motion,….) Long chamber: Tool – and BHA – Tester (in add.: vibrations, reliability, lifetime, M-Motor, ….
Initiators: Ostermeyer, TU Braunschweig Denkena, Uni Hannover
Special Session • Drilling Modelling and Simulation • Ostermeyer/Oppelt
Slide 31
The HIL – Drilling Simulator - Realization Stone chamber Length: 1000mm
Anulus space: up to 100 bar
Hexapod 5D 20mm/ 20 Hz
Pressure differential up to 400 bar
HIL/SIL simulation motion controller
motor WOB: 40t
pump Short chamber: Bit Rig (RPM, WOB, controlled bouncing, controlled whirl motion,….) Long chamber: Tool – and BHA – Tester (vibrations, reliability, lifetime, M-Motor, ….
Short flow loop Initiators: Ostermeyer, TU Braunschweig Denkena, Uni Hannover Teodoriu TU Clausthal
Special Session • Drilling Modelling and Simulation • Ostermeyer/Oppelt
Slide 32
The HIL – Drilling Simulator Stone chamber Length: 1000mm
Anulus space: 100 bar
Hexapod 5D 20mm/ 20 Hz
Difference pressure up to 400 bar
HIL/SIL simulation motion controller
motor WOB: 40t
pump Short chamber: Bit Rig (RPM, WOB, controlled bouncing, controlled whirl motion,….) Long chamber: Tool – and BHA – Tester (vibrations, reliability, lifetime, M-Motor, ….
Short flow loop Initiators: Ostermeyer, TU Braunschweig Denkena, Uni Hannover Teodoriu TU Clausthal
Special Session • Drilling Modelling and Simulation • Ostermeyer/Oppelt
Slide 33
Content
Introduction Systems and Simulations Simulators What is a Simulator? Structure of Simulators Human Machine Interfaces HIL/SIL Simulator in Celle Challenges of Drilling Modelling and Simulation Outlook
Special Session • Drilling Modelling and Simulation • Ostermeyer/Oppelt
Slide 34
Challenges of Drilling Modelling and Simulation Classical applications of Modelling and Simulation
Object: length/width: user: quantities: environment: observability: Production aims:
Applications:
Automotive Industry
Drilling Industry
~ 1:10 laymen ~ 100,000,000 good rather good
~ 1: 1000 only specialists ~ 10,000 very bad very bad
comfort
Research Field
robustness
Research Field
Special Session • Drilling Modelling and Simulation • Ostermeyer/Oppelt
Slide 35
Challenges of Drilling Modelling and Simulation Classical applications of Modelling and Simulation
Analyses/Tests • • • • • •
Failure analysis Durabitily analysis Cost analysis Time analysis Product analysis Product competitiveness analysis
Development • • • •
Workbench development Product development Process development Market development
Education Advertising optimization • Market strategy optimization • Product optimization • Process optimization
observer and realtime-controller • Field data completion/ finalization • Identification of non-measurable data • Control and automation…..
automation • …..
Special Session • Drilling Modelling and Simulation • Ostermeyer/Oppelt
Slide 36
Challenges of Drilling Modelling and Simulation Problems in modeling
scaling:
stationary ok, general processes no!
stability:
often depends on scale!
confidence:
validation of system (= copy of clipping region) depends on questions
suggestion:
nice pictures suggest reality,
pictures are stronger then physics (Jurassic park, …)
idealization:
main problems!!!!!
Special Session • Drilling Modelling and Simulation • Ostermeyer/Oppelt
Slide 37
Challenges of Drilling Modelling and Simulation Example: Small Perturbations can change the dynamics of a drill string drastically
[Halliburton]
Example: Flow and particle transport in idealized flow loops
Special Session • Drilling Modelling and Simulation • Ostermeyer/Oppelt
Slide 38
Content
Introduction Systems and Simulations Simulators What is a Simulator? Structure of Simulators Human Machine Interfaces HIL/SIL Simulator in Celle Challenges of Drilling Modelling and Simulation Outlook
Special Session • Drilling Modelling and Simulation • Ostermeyer/Oppelt
Slide 39
Outlook
Guideline for realistic Drilling Modelling and Simulation: Break Symmetries! Disturb Boundary Conditions! Use Dirty Experiments!
Special Session • Drilling Modelling and Simulation • Ostermeyer/Oppelt
Slide 40
Acknowledgements / Thank You / Questions
“Drilling Modelling and Simulation” Keynote Prof. Dr. G. P. Ostermeyer, Dir. Inst. of Dynamics and Vibration, Braunschweig Technical University
Slide 2
Content
Introduction Systems and Simulations Simulators What is a Simulator? Structure of Simulators Human Machine Interfaces HIL/SIL Simulator in Celle Challenges of Drilling Modelling and Simulation Outlook
Special Session • Drilling Modelling and Simulation • Ostermeyer/Oppelt
Slide 3
Content
Introduction Systems and Simulations Simulators What is a Simulator? Structure of Simulators Human Machine Interfaces HIL/SIL Simulator in Celle Challenges of Drilling Modelling and Simulation Outlook
Special Session • Drilling Modelling and Simulation • Ostermeyer/Oppelt
Slide 4
Introduction We have a problem problem
world
Special Session • Drilling Modelling and Simulation • Ostermeyer/Oppelt
Slide 5
Introduction We have a problem problem
world
Start point: questions to the world
aim:
(understandable) answers of the world
Special Session • Drilling Modelling and Simulation • Ostermeyer/Oppelt
Slide 6
Introduction World too big for human brains:
We have a problem
We are always acting in a small Clipping region of the world
problem
world Clipping region
Start point: questions to the world
aim:
answers of the world
Special Session • Drilling Modelling and Simulation • Ostermeyer/Oppelt
Slide 7
Introduction World too big for human brains:
We have a problem
We are allways acting in a small Clipping region of the world
problem
world Clipping region
Start point: questions to the world
aim:
answers of the world
Special Session • Drilling Modelling and Simulation • Ostermeyer/Oppelt
Slide 8
Introduction World too big for human brains:
We have a problem
We are allways acting in a small Clipping region of the world
problem
world Clipping region
Start point: questions to the world
aim:
Tests for answers are still: too expensive too dangerous too confusing too big and fast too unobservable too complex …
answers of the world
Special Session • Drilling Modelling and Simulation • Ostermeyer/Oppelt
Slide 9
Introduction Building a system – subtitude of the world section of world
Selected Input data
system
world Copy of clipping region (model)
Clipping region
Selected output data
Start point: questions to the world
questions to the substitute quality of copy ?
aim:
answers of the world
answers of the substitute
Special Session • Drilling Modelling and Simulation • Ostermeyer/Oppelt
Slide 10
Introduction
section of world
Selected Input data
system
world Clipping region
Copy of clipping region (model) Selected output data
Realization of the substitute
Output data
Driller
physical model
virtual model
Output data
Output data
Output data
software
HIL / SIL
hardware
Input data
Special Session • Drilling Modelling and Simulation • Ostermeyer/Oppelt
virtual model
Input data
actuators sensors
Input dada
physical model
Human brain
Input data
Slide 11
Introduction Realization of the substitute
Output data
Driller
Input data
physical model
virtual model
Output data
Output data
Output data
hardware
software
HIL / SIL
Downscaled hardware rig “OSTRATOR” at IDS
Motorcycle
virtual model
Input data
actuators sensors
Input dada
physical model
Human brain
Input data
Traffic interaction
Special Session • Drilling Modelling and Simulation • Ostermeyer/Oppelt
Slide 12
Content
Introduction Systems and Simulations Simulators What is a Simulator? Structure of Simulators Human Machine Interfaces HIL/SIL Simulator in Celle Challenges of Drilling Modelling and Simulation Outlook
Special Session • Drilling Modelling and Simulation • Ostermeyer/Oppelt
Slide 13
Simulators What is a simulator? system shell capsuling the system Data input manipulation
Input data system manipulation
model system Output data
analysis of output
Special Session • Drilling Modelling and Simulation • Ostermeyer/Oppelt
Slide 14
Simulators What is a simulator? system shell capsuling the system Data input manipulation
Input data system manipulation
model system
Hook Load, RPM
Output data
analysis of output
Example OSTRATOR, IDS (hardware system)
Whirl
Special Session • Drilling Modelling and Simulation • Ostermeyer/Oppelt
Slide 15
Simulators 50m-BHA is drilling a given wellbore trajectory
Example OSPLAC, IDS (software simulator) Drilling process (hook load, rpm) Geology / Formation Wellbore Geometry ….
Drill String Model
Load Spectra Energy measures ROP ….
Special Session • Drilling Modelling and Simulation • Ostermeyer/Oppelt
Slide 16
Simulators What is a simulator? system shell capsuling the system Data input manipulation
Input data system manipulation
model system Output data
Interface between Human Being and Machine Necessary!
analysis of output
Special Session • Drilling Modelling and Simulation • Ostermeyer/Oppelt
Slide 17
Simulators Human Machine Interface Input data manipulation
Type I Avatar technique
system manipulation
HMI
Human
Input data model output data
analysis of output
HMI: human as part of the model (e.g. computer games: “second life”…)
Special Session • Drilling Modelling and Simulation • Ostermeyer/Oppelt
Slide 18
Simulators Human Machine Interface
Type II
Input data man.
Emulation of real world
model
human
HMI
Input data
output data
Analysis of output data
HMI: human with “synthetic Environment” (classical simulators….)
Special Session • Drilling Modelling and Simulation • Ostermeyer/Oppelt
Slide 19
Simulators Human Machine Interface
Type II
usual form of simulators Emulation of real world
Flight simulator Krementschuck, Ukraine, American Fight helicopter
DrillSIM- 600 with CyberChair, DrillingSystems
HMI: human with “synthetic environment” (emulators of real systems….)
Special Session • Drilling Modelling and Simulation • Ostermeyer/Oppelt
Slide 20
Simulators Human Machine Interface
Type III
Input data man.
Augmented Reality (AR)
human
output data
world
computer
model
HMI
Input data
Analysis of output data
Model/simulator based additional information for the human in the real world ( e.g. “Google Glass”, …) human integrated automation Special Session • Drilling Modelling and Simulation • Ostermeyer/Oppelt
Slide 21
Simulators Model realisations in simulators Data input manipulation
Look at the world Input data model
system manipulation
Output data
Output data
Hardware
virtual
model
Output data
Software
virtual model
physical model
Input data actuators sensors
analysis of output
Input data physical model
Input dada
Output data
HIL (SIL)
Special Session • Drilling Modelling and Simulation • Ostermeyer/Oppelt
Slide 22 Name
Application
Implementation
Partial Models
Sources
Simulators
Legend: ■
yes, but not central □ no ? no information
Pipe Handling
Formation / Reservoir Model
Well Bore Completion
Bit Model
BHA-Model
Drill String Dynamics
Wellbore Stability
Mud Flow
Cost Effectiveness Model
o
Real Time
Realistic Operation Environment
Software Simulator
Hardware Simulator
Application Tool in the Field
Research and Development
Eductaion and Recruiting
yes
■/□ Application dependent
[Bjo09] , [eDr10], [eDr10], [Nyb08], [Rom06],
EDRILLING, Stavanger
IRIS Virtual Rig DART, KCADEUTAG Payzone, Univ. of Berkeley IDRILL of Smith Company Products of Drilling Systems Optimizer of Pason/ DROPS
[Rom08a], [Rom08b], [Rom08c], [Rom08d], o
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[Hod06], [Deu10]
[Pay10], [Kel09], [Abo01], [Abo03], [Coo95]
[Smi10], [JPT06] [Dri10]
[Har00a], [Har00b], [Har07], [Har08], [Pas10], [Saf04]
Company
Special Session • Drilling Modelling and Simulation • Ostermeyer/Oppelt
Slide 23 Application
Name
Implementation
Partial Models
Sources
Simulators
Legend: ■ yes
Research and Development
Application Tool in the Field
Hardware Simulator
Software Simulator
Realistic Operation Environment
Real Time
Cost Effectiveness Model
Mud Flow
Wellbore Stability
Drill String Dynamics
BHA-Model
Bit Model
Well Bore Completion
Formation / Reservoir Model
Ein Simulator der Fa.
Eductaion and Recruiting OASIS der Fa. Baker Hughes
o
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yes, but not central □ no ?
Pipe Handling
no information ■/□ Application dependent
[Bak10] [Hal03] [Hal03]
Halliburton Ein Simulator nach Dubinsky
[Dub98]
der Fa. Baker Hughes Simulator der University of
[Ahm10]
Oklahoma Simulator aus Veröffentlichung
[Boo01]
von J. Booth Simulator der Louisiana State
[Ahm10]
University [Lyo08][Net10]
Extreme Drilling Laboratory (XDL) at NETL (National
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Energy Technology Lab)
Special Session • Drilling Modelling and Simulation • Ostermeyer/Oppelt
Slide 24 Application
Name
Implementation
Partial Models
Sources
Simulators
Legend: ■ yes
Research and Development
Application Tool in the Field
Hardware Simulator
Software Simulator
Realistic Operation Environment
Real Time
Cost Effectiveness Model
Mud Flow
Wellbore Stability
Drill String Dynamics
BHA-Model
Bit Model
Well Bore Completion
Formation / Reservoir Model
Ein Simulator der Fa.
Eductaion and Recruiting OASIS der Fa. Baker Hughes
o
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yes, but not central □ no ?
Pipe Handling
no information ■/□ Application dependent
[Bak10] [Hal03] [Hal03]
Halliburton Ein Simulator nach Dubinsky
[Dub98]
der Fa. Baker Hughes Simulator der University of
[Ahm10]
Oklahoma Simulator aus Veröffentlichung
[Boo01]
von J. Booth Simulator der Louisiana State
[Ahm10]
University [Lyo08][Net10]
Extreme Drilling Laboratory (XDL) at NETL (National
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Energy Technology Lab)
Special Session • Drilling Modelling and Simulation • Ostermeyer/Oppelt
Slide 25 Application
Name
Implementation
Partial Models
Sources
Simulators
Legend: ■ yes o
Eductaion and Recruiting
Research and Development
Application Tool in the Field
Hardware Simulator
Software Simulator
Realistic Operation Environment
Real Time
Cost Effectiveness Model
Mud Flow
Wellbore Stability
Drill String Dynamics
BHA-Model
Bit Model
Well Bore Completion
Formation / Reservoir Model
Drilling Laboratory der Ecole
yes, but not central
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□ no ? no information
Pipe Handling
■/□ Application dependent
[Eco10]
des mines de Paris Full Scale Test Rig der
[Tul10]
University of Tulsa Full Scale Test Rig der Fa.
[Lun09]
Terratec Full Scale Test Rig der Baker
[Lun09]
Hughes Full Scale Test Rig der Fa.
[Lun09]
Schlumberger Full Scale Test Rig der Fa.
[Lun09]
Amoco Full Scale Test Rig der Fa.
[Lun09]
Reed Hycalog
And many others ……, but: Special Session • Drilling Modelling and Simulation • Ostermeyer/Oppelt
Slide 26
Simulators Model realisations in simulators Data input manipulation
look at the world Input data model
system manipulation
Output data
Output data
Hardware realisations: many
virtual
model
Output data
Software few
virtual model
physical model
Input data actuators sensors
analysis of output
Input data physical model
Input dada
Output data
HIL (SIL) very few
Special Session • Drilling Modelling and Simulation • Ostermeyer/Oppelt
Slide 27
Simulators Model realisations in simulators Data input manipulation
HIL – Drilling Simulator Input data model
system manipulation
Ostermeyer, TU Braunschweig Denkena, Uni Hannover ……
Output data
virtual model
physical model
analysis of output
actuators sensors
Input data
Output data
HIL (SIL)
Special Session • Drilling Modelling and Simulation • Ostermeyer/Oppelt
Slide 28
The HIL – Drilling Simulator Real world
Loop
time t Complex geometry by forces in interface
t := t + Dt
Computer
Cut
Realize geometry in interface of test rig
Interface M
Test rig
Measure forces in interface of test rig
Special Session • Drilling Modelling and Simulation • Ostermeyer/Oppelt
Slide 29
The HIL – Drilling Simulator Real world Full virtual model with realistic bit and BHA- Info without model simplifications real time appl.
Computer
Cut
Interface M
(HIL – Simulation)
Small Hardware model moves like a part of the total model (SIL – Simulation)
Test rig Special Session • Drilling Modelling and Simulation • Ostermeyer/Oppelt
Slide 30
The HIL – Drilling Simulator - Realization Stone chamber Length: 1000mm
Drillstring chamber short/long
Hexapod 5D 20mm/ 20 Hz
HIL/SIL simulation motion controller
motor WOB: 40t
Short chamber: Bit Rig (RPM, WOB, controlled bouncing, controlled whirl motion,….) Long chamber: Tool – and BHA – Tester (in add.: vibrations, reliability, lifetime, M-Motor, ….
Initiators: Ostermeyer, TU Braunschweig Denkena, Uni Hannover
Special Session • Drilling Modelling and Simulation • Ostermeyer/Oppelt
Slide 31
The HIL – Drilling Simulator - Realization Stone chamber Length: 1000mm
Anulus space: up to 100 bar
Hexapod 5D 20mm/ 20 Hz
Pressure differential up to 400 bar
HIL/SIL simulation motion controller
motor WOB: 40t
pump Short chamber: Bit Rig (RPM, WOB, controlled bouncing, controlled whirl motion,….) Long chamber: Tool – and BHA – Tester (vibrations, reliability, lifetime, M-Motor, ….
Short flow loop Initiators: Ostermeyer, TU Braunschweig Denkena, Uni Hannover Teodoriu TU Clausthal
Special Session • Drilling Modelling and Simulation • Ostermeyer/Oppelt
Slide 32
The HIL – Drilling Simulator Stone chamber Length: 1000mm
Anulus space: 100 bar
Hexapod 5D 20mm/ 20 Hz
Difference pressure up to 400 bar
HIL/SIL simulation motion controller
motor WOB: 40t
pump Short chamber: Bit Rig (RPM, WOB, controlled bouncing, controlled whirl motion,….) Long chamber: Tool – and BHA – Tester (vibrations, reliability, lifetime, M-Motor, ….
Short flow loop Initiators: Ostermeyer, TU Braunschweig Denkena, Uni Hannover Teodoriu TU Clausthal
Special Session • Drilling Modelling and Simulation • Ostermeyer/Oppelt
Slide 33
Content
Introduction Systems and Simulations Simulators What is a Simulator? Structure of Simulators Human Machine Interfaces HIL/SIL Simulator in Celle Challenges of Drilling Modelling and Simulation Outlook
Special Session • Drilling Modelling and Simulation • Ostermeyer/Oppelt
Slide 34
Challenges of Drilling Modelling and Simulation Classical applications of Modelling and Simulation
Object: length/width: user: quantities: environment: observability: Production aims:
Applications:
Automotive Industry
Drilling Industry
~ 1:10 laymen ~ 100,000,000 good rather good
~ 1: 1000 only specialists ~ 10,000 very bad very bad
comfort
Research Field
robustness
Research Field
Special Session • Drilling Modelling and Simulation • Ostermeyer/Oppelt
Slide 35
Challenges of Drilling Modelling and Simulation Classical applications of Modelling and Simulation
Analyses/Tests • • • • • •
Failure analysis Durabitily analysis Cost analysis Time analysis Product analysis Product competitiveness analysis
Development • • • •
Workbench development Product development Process development Market development
Education Advertising optimization • Market strategy optimization • Product optimization • Process optimization
observer and realtime-controller • Field data completion/ finalization • Identification of non-measurable data • Control and automation…..
automation • …..
Special Session • Drilling Modelling and Simulation • Ostermeyer/Oppelt
Slide 36
Challenges of Drilling Modelling and Simulation Problems in modeling
scaling:
stationary ok, general processes no!
stability:
often depends on scale!
confidence:
validation of system (= copy of clipping region) depends on questions
suggestion:
nice pictures suggest reality,
pictures are stronger then physics (Jurassic park, …)
idealization:
main problems!!!!!
Special Session • Drilling Modelling and Simulation • Ostermeyer/Oppelt
Slide 37
Challenges of Drilling Modelling and Simulation Example: Small Perturbations can change the dynamics of a drill string drastically
[Halliburton]
Example: Flow and particle transport in idealized flow loops
Special Session • Drilling Modelling and Simulation • Ostermeyer/Oppelt
Slide 38
Content
Introduction Systems and Simulations Simulators What is a Simulator? Structure of Simulators Human Machine Interfaces HIL/SIL Simulator in Celle Challenges of Drilling Modelling and Simulation Outlook
Special Session • Drilling Modelling and Simulation • Ostermeyer/Oppelt
Slide 39
Outlook
Guideline for realistic Drilling Modelling and Simulation: Break Symmetries! Disturb Boundary Conditions! Use Dirty Experiments!
Special Session • Drilling Modelling and Simulation • Ostermeyer/Oppelt
Slide 40
Acknowledgements / Thank You / Questions
