Physics-Guided Data Augmentation Combined with Unsupervised Learning Improves Stability and Accuracy of Bit Wear Deep Learning Model

Abstract

Data is one of the most important limiting factors of deep machine learning (ML) model in drilling applications. Though a big size of historical data can be available, high-quality cleaned and labeled data is usually limited. In this case study, we show that with limited labeled data, physics-based data augmentation combined with unsupervised learning significantly improves both stability and accuracy in bit wear ML model. It provides a pathway to overcome labeled data shortage and field data quality limitations. Labeled bit wear data is usually limited because only the final bit dull state can be labeled using dull photos for the entire drilling distance. To overcome this difficulty, an encoder-decoder unsupervised ML framework based on Bi-directional LSTM architecture is first applied to the data of entire drilling distance to extract and maximize data learnings. Then, a physics-based wear estimator is implemented in the learned latent space to augment labeled wear dataset, guided by true wear labels and offset-well data. Weighting factor in loss function is applied to optimize augmented and true datasets in final supervised learning step. The proposed real-time bit wear model is built on a combination of physics-based data augmentation and unsupervised data learning method. The model is applied on multiple field bit runs. Results show that by implementing the unsupervised data learnings only, the prediction accuracy is improved by 30% compared to the baseline ML model. By combining physics-based augmentation, the accuracy is further improved by 10%. More importantly, adding physics-based data augmentation significantly reduces prediction variance and unphysical wear outputs, therefore improving prediction stability by more than 30%. It should be noted that the prediction stability of AI/ML model is crucial in real-time application and decision making. The results show physics-based data augmentation not only increases the size of label dataset and prevents model overfitting, but also applies physics-based guidance to the ML model effectively. It is learned weighting factor plays a crucial role in balancing loss contributions from true wear labels and physics-based labels. While low weighting factor of physics-based labels diminishes the augmented data, high weighting factor disrespects the true wear labels leading to a high prediction bias. Overall, the bit wear model study shows physic-based data augmentation combined with unsupervised data learning can effectively improve model accuracy, stability, and overcome labeled data shortage difficulty. The proposed paper shows a case study for the bit wear ML model using a combination of physics-based data augmentation and unsupervised data learning. While labeled data is one of the major challenges of ML models in many drilling applications, this study provides a pathway to improve both accuracy and stability of deep ML models with limited labeled data.