MULTIMEDIA SIMULATION, INCREASES UNDERSTANDING OF OIL FIELD TOOLS

Ken Schwendemann
Halliburton Energy Services
Carrollton, Tex.

Intelligence augmentation using multimedia techniques shows great promise in letting oil field personnel obtain a better understanding of the operation of downhole tools and surface equipment.

Whereas artificial intelligence (Al) includes knowledge-based expert systems to identify and analyze situations and recommend solutions, intelligence augmentation (IA) is a different genre. In the IA process, the designer/operator/engineer works with a fully simulated, animated, multimedia demonstration of what will occur on the proposed work. He receives no direct recommendations made by the system; however, the system may assist in identifying pitfalls or to simply provide better understanding.

The simulation includes the sound of engines, pumps, pressured air, shearing pins, rupturing diaphragms, etc. Viewing may be in an office environment or at the well site. A personal computer (PC) monitor is the only equipment needed in addition to a computer keyboard-sized processor.

IA promises to be an improvement over printed manuals, still slide shows, and models as a means of teaching and demonstrating processes. One veteran executive in oil field research saw the system at work and remarked that IA would become the "word processor for the technologist."

Hardware and startup software costs are modest enough to allow placing the units in every office and field camp of an operating or service company. The most significant expenditure is in engineering time spent developing the presentations for the company's inventory of equipment and processes. Halliburton is currently devoting the time of three veteran engineers to this work.

THE SYSTEM

IA language is integrated into the engineering work environment. Thus, one can simulate his own equipment and processes. In one case, an engineer learned the system and simulated a triplex pump for cementing and fracturing in 1 week. Simulation of all processes in a company would be somewhat similar to making every engineer on the staff available at the rig site.

The multi-processor platform is especially suited for real-time multimedia simulations. The simulation establishes frame-wise control (of animations) using equations of state for the devices, such as the status of the equipment.

The hardware, including central processing units, hard drives and floppy drives, is about the size of a standard PC keyboard. Presentations can be viewed on any PC monitor.

A drill stem test simulation includes equations of state based on pressure, loads, temperature, and other physical attributes. The "global simulator," which is a finite tool program, can assemble a number of tools together to perform a time-wise analysis based on inputs for each tool. Tool attributes are input separately using a mouse to drag each icon of the tool needed. The operator may construct a complete drill stem test string.

The ease with which the entire tool string can be assembled makes the simulator into a systems design tool. Accordingly, even experienced design engineers benefit from this IA technology.

Fig. 1 (18886 bytes) is a single tool illustration featuring downhole jars. In cases where the test string sticks, applied torque, weight, and pressure can cause the internal parts of the jars to release and deliver a shock that can free the test string.

In the simulation, gauges move to indicate force buildup inside the jars and show elapsed build-up time. The simulation responds to inputs according to specifications for the jars part number, such as the equation of state. Engineering calculations controlling the simulation use the exact structural information contained in the tool specifications.

When the simulated buildup specifications have been met, a resounding "thud" of the jars is heard and the gauges return to the zero position.

Just like the tool itself, the simulator can repeat the process an infinite number of times. Fig. 2 (44197 bytes) shows the simulation of a resettable, annular pressure-responsive circulating valve. In a well, the valve can be opened and, closed an infinite number of times, without tripping the tool string, to control well fluids during drill stem tests.

Successive increases and decreases of annular pressure cause J-slots to ratchet the tool through its various stages (15 iterations take the tool through one complete menu of its capabilities). Compressed nitrogen contained in a chamber furnishes a "spring" force to operate the tool.

The simulated response is governed by engineering calculations for the specified tool part number and the initial setup, including nitrogen charge and tool depth. These conditions define the equations of state for the tool.

A tool string and the simulated tool interaction are shown in Fig. 3. (51061 bytes) In this global simulation, each individual element is communicating with its single-tool simulation (Fig. 1) (18886 bytes) and (Fig. 2) (44197 bytes). The global simulation is then drawing upon the knowledge base embedded in the individual tools to give an accurate animated-system response.

IA USES

Every exposure of the IA system either brings a new idea for its use or solidifies its position as a practical alternative to classroom instruction and personal visits by large staffs of experts. Primary uses to date are:

Training-The simulator is probably best used to train equipment operators. IA has also been successful in the general education of planners and designers from both the operating and service companies.
Communications-Tool and systems simulations cross language barriers to help global communication when describing equipment and its function.
Job design and clarification-Often, job design is a joint effort of the personnel from the service and operating companies. A simulation of the proposed job cuts through the most complicated procedures to help eliminate misunderstanding, even with the additional handicap of language barriers.
Actual job setup-Because the global simulator is a time-based system, jobs can be optimized for cost/time-vs.-work performed and/or data gathered. This can save rig time. The screen or printout can be a "blueprint" to follow in assembling the tool string. Pre-job practice on the simulator helps to keep operators focused on specific job requirements.
Troubleshooting-A review in the simulator can often help pinpoint trouble spots. Quality control in real-time is obtained by comparing the actual to the planned job. Also, one can witness visually the effect of problems introduced into the simulator.
Explanation and understanding-After completing each job, the IA system provides a way for reviewing and evaluating the work so that future jobs can be improved.

FUTURE WORK

The software framework is capable of supporting modules as diversified as circulating valves, pumps, separators, burners, well reservoir models, tubing movement models, completions, and well control.

As new modules are added to the system, the modules become the building blocks that allow users to easily construct and simulate complex systems of tools and equipment.

These simulations, with their foundation in engineering principles, incorporate the nuances of each tool and give an overview that represents the best engineering and operational advice that can be given for that system.

Halliburton expects to have about 50 systems in use by the end of 1994.

THE AUTHOR

Ken Schwendemann is the team leader for development, training, and production of simulator technology at Halliburton's Dallas/Ft. Worth technology center in Carrollton, Tex. He has 15 years of design experience with Halliburton. Schwendermann is a 1978 graduate of the Colorado School of Mines, with a BS degree in mineral engineering. He is a registered professional engineer in Texas and has seven U.S. patents issued.