Research Papers: Petroleum Engineering

Adaptive and Real-Time Optimal Control of Stick–Slip and Bit Wear in Autonomous Rotary Steerable Drilling

[+] Author and Article Information
Mahmoud A. Kamel

Systems and Control Engineering,
King Fahd University of Petroleum & Minerals,
Dhahran 31261, Kingdom of Saudi Arabia
e-mail: g201405840@kfupm.edu.sa

Salaheldin Elkatatny

Petroleum Department,
King Fahd University of Petroleum & Minerals,
Dhahran 31261, Kingdom of Saudi Arabia;
Cairo University,
Cairo 5049, Egypt
e-mail: elkatatny@kfupm.edu.sa

Muhammad Faizan Mysorewala

Systems and Control Engineering,
King Fahd University of Petroleum & Minerals,
Dhahran 31261, Kingdom of Saudi Arabia
e-mail: mysorewala@kfupm.edu.sa

Abdulaziz Al-Majed

Petroleum Department,
King Fahd University of Petroleum & Minerals,
Dhahran 31261, Kingdom of Saudi Arabia
e-mail: aamajed@kfupm.edu.sa

Moustafa Elshafei

Systems and Control Engineering,
King Fahd University of Petroleum & Minerals,
Dhahran 31261, Kingdom of Saudi Arabia
e-mail: elshafei@kfupm.edu.sa

1Corresponding author.

Contributed by the Petroleum Division of ASME for publication in the JOURNAL OF ENERGY RESOURCES TECHNOLOGY. Manuscript received December 10, 2016; final manuscript received September 27, 2017; published online October 24, 2017. Assoc. Editor: Arash Dahi Taleghani.

J. Energy Resour. Technol 140(3), 032908 (Oct 24, 2017) (12 pages) Paper No: JERT-16-1497; doi: 10.1115/1.4038131 History: Received December 10, 2016; Revised September 27, 2017

Deviated, horizontal, and multilateral wells are drilled to increase the contact area between the well path and the reservoir and as a result, the well productivity will be increased. Directional steering systems (DSS) are used to control the direction in nonvertical wells. Rotary steerable system (RSS) is the current state of the art of DSS. In this research, the problem of real-time control of autonomous RSS with unknown formation rock strength was presented. The aim of this study is to develop a real-time control scheme for real-time optimization of drilling parameters to (1) maximize the rate of penetration (ROP), (2) minimize the deviation from the planned well bore trajectory, (3) reduce the stick–slip oscillations, and (4) assess the degree of bit wear. Nonlinear model for the drilling operation was developed using energy balance equation, where rock specific energy (RSE) is used to calculate the minimum power required for a given ROP. A proposed mass spring system was used to represent the phenomena of stick–slip oscillation. The model parameters have been adaptively estimated at each control iteration to tackle any disturbances or variations in the formation properties. The bit wear is mathematically represented using Bourgoyne model. Detailed mathematical formulation and computer simulation were used for evaluation of the performance of the proposed technique based on real well field data. The obtained results showed excellent ability to accommodate the changes in the formation properties. In addition, the rates of bit wear and stick–slip oscillations have been optimized.

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Fig. 2

Stick–slip oscillation mechanism

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Fig. 3

Stick–slip model

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Fig. 4

Overall control strategy of the RSS

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Fig. 5

Projection of the BHA on the trajectory

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Fig. 10

Input RPM—without optimizing the rate of change of RPM

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Fig. 11

Input RPM—with optimizing the rate of change of RPM

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Fig. 12

Bit roll angular velocity—with optimizing the rate of change of RPM

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Fig. 9

Bit roll angular velocity—without optimizing the rate of change of RPM

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Fig. 7

Three-dimensional view of the trajectory tracking

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Fig. 6

Particle swarm optimization (PSO) flowchart

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Fig. 13

Mean square error between actual and model bit roll angle

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Fig. 14

Fitness values for the different six cases

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Fig. 16

Earth and body frames



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