Abstract
Industry has been actively integrating advanced solutions to enhance drilling efficiency and reduce Non-Productive Time (NPT), which are critical to any drilling project. As a result, use of downhole drilling sensors has become increasingly common, from vertical to complex well profiles. These sensors enable real-time monitoring of downhole drilling dynamics, allowing for parameter adjustments that extend bit life, reduce Bottomhole Assembly (BHA) wear, and improve overall operational performance.
This approach aimed to minimize drill string dysfunctions caused by interactions between drill string components and formation layers of varying compressive strengths, which can lead to dynamic vibrations. To determine ideal placement of real-time downhole sensors in the drill string, Finite Element Analysis (FEA) was employed for simulations and modeling, incorporating field operational criteria to evaluate BHA configurations. The simulations produced high-frequency measurements, which were validated using offset data from actual field runs, confirming the accuracy of the results.
The results highlighted that real-time sensor placement near cutting elements in the BHA, particularly above the BHA steering drive and close to the drill bit, could significantly improve drilling performance. This optimized configuration, enriched by real-time downhole data, enhanced the drilling process without compromising the steering efficiency required to meet trajectory goals as demonstrated in the presented case study for the reliability and consistency of this engineering analysis, by early detection of drill string dysfunctions, including shock and vibration, led to higher mitigation capabilities, resolving string hanging issues in rotary mode and improving overall control and effectiveness.
Field results showed a remarkable 50% increase in the rate of penetration (ROP) and a reduction in total bit runs, resulting in enhanced operational productivity and saving over $2 million in overall drilling costs. This study, leveraging case data from the North Sea, United Kingdom, provides valuable insights into optimizing downhole sensor placement in the BHA. By enabling early detection of drilling dynamics and minimizing downhole vibrations, this approach significantly reduces NPT and hidden costs in drilling projects.
