Experimental Design, Instrumentation, and Testing of a Laboratory-Scale Test Rig for Torsional Vibrations—The Next Generation

Abstract

Drilling technology and specially drilling equipment has dramatically changed in the last 10 years through intensive and innovative technologies, both in terms of hardware and software. While engineers are focusing on safer, faster, and more reliable than ever technologies, big data and automation are currently considered the way forward to achieve these goals. Especially when automation concepts are proposed, the prior testing and qualification under a laboratory-controlled environment are mandatory. Drilling simulators have been hugely successful in training industry personnel and academic professionals. A big reason for its success lies in the seamless integration of hardware and software to include an interactive user interface. Physical experimental simulators have the advantage of exposing the user with visual and auditive aids to better understand the real process. This paper provides an insight into the construction and results obtained using a dedicated laboratory setup, which is also configured to various levels of automation. The setup is capable of safely recreating drilling vibrations that occur in wells, including stick-slip vibrations, which are detrimental in nature. With advanced sensor capabilities, the impact of proper sampling rates on the diagnosis of stick-slip vibrations has been analyzed in the paper. The results show that these vibrations are not only dependent on drilling parameters, such as rotational speed (RPM), torque, and weight on bit, but also on stick-slip parameters, such as bit sticking time period and frequency.

Experimental Comparison of PID Based RPM Control for Long Horizontal vs. Vertical Drillstring

“…The control system software is designed using National Instruments LabVIEW. A detailed description of the setup is presented in a previous work [15].…”

An Outlook of Drilling Technologies and Innovations: Present Status and Future Trends

“…Sharma et al [25] designed and developed an instrumentational laboratory-scale test rig (stick-slip simulator) to identify and predict downhole vibration events such as torsional vibrations. According to Sharma et al [25], "the setup is capable of safely recreating drilling vibrations that occur in wells, including stick-slip vibrations, which are detrimental in nature".…”

“…Sharma et al [25] designed and developed an instrumentational laboratory-scale test rig (stick-slip simulator) to identify and predict downhole vibration events such as torsional vibrations. According to Sharma et al [25], "the setup is capable of safely recreating drilling vibrations that occur in wells, including stick-slip vibrations, which are detrimental in nature". Their experimental test rig was built to analyze drill string vibrations using the so-called mechatronic concept, which is a combination of mechanical and electrical components fully controlled by complex real-time software.…”

Process Monitoring in Heavy Duty Drilling Rigs—Data Acquisition System and Cycle Identification Algorithms

“…In addition to the characterization of rock properties, process parameters can be used for the on-line diagnostics of drilling tool wear and other parts of machine equipment. By conducting laboratory tests on the wear resistance of drill bits inserts made of Cemented Tungsten Carbide [18] or their optimal selection and performance [19], it is difficult to approach the real contact conditions due to the possible dynamical effects related to elastic deformations of the drill-string and other structural elements [20]. For example, the effects of coupling modes on torsional, bending and axial vibrations can be observed in drilling units [21].…”