PEH:Drilling-Data Acquisition

Publication Information

Vol2DECover.png
Petroleum Engineering Handbook

Larry W. Lake, Editor-in-Chief

Volume II - Drilling Engineering

Robert F. Mitchell, Editor

Copyright 2006, Society of Petroleum Engineers

Chapter 15 - Drilling-Data Acquisition

By Iain Dowell, Halliburton Energy Services, Andrew Mills, Esso Australia Ltd.; Marcus
Ridgway and Matt Lora, Landmark Graphics Corp.

Pgs. 647-685

ISBN 978-1-55563-114-7
Get permission for reuse

The prototype data-collection system for drilling wells previously consisted of paper reports from
data collected and recorded by hand, culminating in the daily "morning report" of well progress.
Because of the progress in computer hardware and software over the past 20 years, spurred by the
increased use of measurement-while-drilling (MWD) and logging-while-drilling (LWD) tools,
wellsite data collection, storage, and use have increased many times above the meager data
available only a few years ago.
Contents [hide]
1 Surface-Data Sensors
1.1 Depth-Tracking Sensors
1.2 Flow-In Tracking Sensors
1.3 Pressure-Tracking Sensors
1.4 Flow-Out Tracking Sensor
1.5 Drill-Monitor Sensors
1.6 Pit-Monitor Sensor
1.7 Gas-Detection Sensors
1.8 Additional Sensors
2 MWD and LWD Applications
2.1 Introduction
2.2 Measurement While Drilling (MWD)
2.3 Logging While Drilling (LWD)
2.4 Formation Testing While Drilling
3 Drilling-Data Management and Reporting
3.1 Overview
3.2 Rigsite Software Systems
3.3 Enter It Once! The Value of Integration
3.4 Value from Data
3.5 Data-Management Systems
3.6 Key Features and Functions of Project Data-Management Systems
4 Nomenclature
5 References
6 General References
7 SI Metric Conversion Factors
[Collapse]
Surface-Data Sensors

By analyzing cuttings, drilling mud, and drilling parameters for hydrocarbon-associated

phenomena, we can develop a great deal of information and understanding concerning the
physical properties of a well from the surface to final depth. A critical function in data analysis is
familiarity with the different sensors used for gathering surface data. These sensors can be
grouped as follows:
Depth Tracking.
Flow-In Tracking.
Pressure Tracking.
Flow-Out Tracking.
Drill Monitoring.
Pit Monitoring.
Gas Detection.
Depth-Tracking Sensors
Current depth-tracking sensors digitally count the amount of rotational movement as the draw-
works drum turns when the drilling line moves up or down. Each count represents a fixed amount
of distance traveled, which can be related directly to depth movement (increasing or decreasing
depth). Moreover, the amount of movement also can be tied into a time-based counter, which will
give either an instantaneous or an average rate of penetration (ROP).

Alternatively, some companies still use a pressurized depth-tracking/ROP sensor. The pressurized
ROP system works on the principle of the change in hydrostatic pressure in a column of water as
the height of that column is varied. This change can then be indirectly related to a depth
measurement. Again, a time-based counter is used to calculate an instantaneous or average ROP.

Additionally, accurate depth measurement on offshore rigs such as semisubmersibles,

submersibles, and drill ships is affected by both lateral (tidal movement) and axial (the up-and-
down motion of the rig, also called "rig heave") effects. To properly compensate for this, most of
these rigs have a rig-compensator system installed on their traveling block. As the rig moves up,
the compensator opens, thereby allowing the bit to stay on bottom. Similarly, as the rig moves
down, the compensator must shut to keep the same relative bit position and weight on the bit.

The same digital sensors are attached to the compensators so that any change in movement can be
taken into account, allowing accurate depth measurement (Fig. 15.1).

Fig. 15.1—Example of a typical depth-tracking system.

Flow-In Tracking Sensors

Flow-tracking sensors are used to monitor fluid-flow rate being applied downhole as well as the
pump strokes required to achieve this flow rate. Data gathered from these sensors are essential
inputs to calculating drilling-fluid hydraulics, well control, and cuttings lag. Monitoring changes
in trends may also indicate potential downhole problems such as kicks or loss of circulation.

Two commonly used types are proximity and/or whisker switches. A proximity switch, activated
either by an electromagnet (coil) or a permanent magnet, acts as a digital relay switch when it
incorporates electrical continuity. A whisker switch, on the other hand, is a microswitch that is
activated only when an external rod (called a whisker) forces a piston to raise a ball bearing to
initiate contact against it (Fig. 15.2). Both types are digital counters; an increase in counts will
correspond to a specific increase in both flow rate and pump rate.

Fig. 15.2—Example of proximity and whisker switch.

Pressure-Tracking Sensors
Pressure-tracking sensors are used mainly to monitor surface pressure being applied downhole.
Data gathered from these sensors are used either to validate calculated values or to confirm
potential downhole problems such as washouts, kicks, or loss of circulation.

Two types of sensors are available, and both monitor pressure from a high-pressure diaphragm
unit (knock-on head) located on either the standpipe or the pump manifold. The first sensor type
derives its physical input from mud pressure expanding a rubber (or viton when high temperature
is involved) diaphragm within the knock-on head. This expansion proportionally increases the
pressure in the hydraulic-oil-filled system and, in doing so, relays the mud pressure to the
appropriate transducer. The second sensor type makes a direct connection with the standpipe
manifold itself (i.e., the transducer face is in contact with the mud; see Fig. 15.3).

Fig. 15.3—Example of pressure transducers.

Flow-Out Tracking Sensor

Commonly called a "flow paddle," this sensor measures flow rate coming out of the annulus using
a strain-gauge analog transducer (Fig. 15.4). Changes in resistance values are directly related to
either an increase or a decrease in mud-flow rate. This sensor provides an early warning of either a
kick condition (sudden increase in flow rate) or a loss of circulation (sudden decrease in flow
rate).

Fig. 15.4—Schematic of a flow-paddle sensor.

Drill-Monitor Sensors
Drill-monitor sensors monitor surface revolutions-per-minute (RPM) values, rotary torque, and
hook load. The torque sensor is a clamp (Fig. 15.5) that sits around the main power cable to the
top-drive system (TDS). It works on the principle of the deformation of Hall-effect chips by the
magnetic field produced around the cable owing to the current being drawn through it (i.e., the
greater the torque being produced as the pipe rotates, the greater the current drawn by the TDS and
therefore the greater the Hall effect). (Note: the Hall effect is a transverse voltage caused by
electric current flow in a magnetic field.) Torque changes can then be related to either formation
lithology or downhole drilling problems such as pipe stick/slip or motor stalling.

Fig. 15.5—Example of a torque (left) and an RPM sensor (right).

A digital rotary sensor is similar to a proximity sensor used in a pump. It is shaped differently but
acts on the same principle. RPM changes are used to drill the well efficiently and minimize
downhole vibration effects.

The combined weight of the bit, bottomhole assembly (BHA), drillpipe, etc., is called the string
weight (SW). The block weight (BW) is the weight of the lines and blocks (including top drive or
kelly). When the bit is on bottom (i.e., drilling), the hook load is seen to reduce. The amount of
weight suspended by the bottom of the hole is the amount of weight on bit (WOB), as shown
below:

RTENOTITLE

This hook-load sensor uses the same transducer type as in a pressure-tracking sensor. As the
deadline experiences strain, the reservoir has load applied across it, which pressures the hydraulic
fluid. This pressure increase is translated to a measurement value (Fig. 15.6). These measurement
values are then correlated to potential downhole problems such as kicks or stuck pipe.

Fig. 15.6—Example of a hook-load sensor.

Pit-Monitor Sensor
Most pit-monitor sensors use ultrasonic transit time to measure mud level. The sensor is mounted
over the pit above the maximum mud level and continuously sends a sonic wave that is reflected
back to the receiver (Fig. 15.7). The transit-time measurement is then directly transformed to a
volume measurement. This critical measurement is actively used to monitor potential kicks (rapid
increase in pit volume) or loss of circulation (rapid decrease in pit volume).

Fig. 15.7—Example of a sonic pit-volume sensor.

Gas-Detection Sensors
The gas-detection sensors consist mainly of a gas trap, a pneumatic line linking the gas trap to the
gas-detection equipment (which is found inside a mud-logging unit), and the gas-detection
instruments (chromatograph and total-gas detectors).

The gas trap is basically a floating chamber with a rotating "agitator" inside. It works on the
principle that mud flowing through the gas trap is agitated, thereby releasing the vast majority of
any gases contained within the mud. This gas is then extracted from the trap through the unit
sample line to be analyzed in the unit (Fig. 15.8).

Fig. 15.8—Example of a gas trap.

The principle behind gas chromatography is simple. The gas from an oil well consists of several
hydrocarbon components, ranging from light gases (methane) to oil. A gas chromatograph then
takes a sample of gas and separates out some of these components for individual analysis.
Typically, methane (C1) through pentane (C5) are the gases of interest. These can be plotted
individually, or they may be used in gas-ratio analysis for reservoir characterization.

Most logging companies currently use a flame ionization detector (FID) gas chromatograph and
total-gas detector (Fig. 15.9). The FID responds primarily to hydrocarbons and has the widest
linear range of any detector in common use. The output signal is linear for a given component
when concentrations vary from less than one part per million (ppm) to percent levels, and with
care, resolution can be obtained in the low part-per-billion (ppb) range. The total-gas detector
samples gas in a manner similar to that of a chromatograph, the only difference being that there is
no column in the detector and, hence, no separation of components (i.e., it burns the "total"
hydrocarbon gas sample as one). This also means that there is no injection time and, therefore, the
gas is being sampled continuously (Fig. 15.8).

Fig. 15.9—Example of an FID chromatograph and a total-gas detector.

Additional Sensors
In addition, exploration and production companies may require specialized services such as
formation-pressure monitoring and drilling optimization. To effectively support these services,
additional sensors may be required such as fluid temperature, density, and conductivity. In areas of
high H2S or CO2 gas, corresponding sensors that exclusively monitor these gases may be required
as well.