SPE 81093

Advacned Drillstring Dynamics System Intergrates Real-Time Modeling and Measurements

SPE 81093
Advanced Drillstring Dynamics System Integrates Real-Time Modeling and
Measurements
David C-K Chen, Mark Smith, and Scott LaPierre, Halliburton Sperry-Sun
Copyright 2003, Society of Petroleum Engineers Inc.
This paper was prepared for presentation at the SPE Latin American and Caribbean Petroleum
Engineering Conference held in Port-of-Spain, Trinidad, West Indies, 2730 April 2003.
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Abstract
This paper presents a newly developed drillstring dynamics
system designed to avoid resonance and to reduce vibrations.
The system integrates real-time dynamics modeling with realtime downhole vibration data to provide accurate modeling
results and data analyses. Unlike conventional BHA dynamics
software that is run for well planning or post-run analysis, this
system uses real-time data (e.g., WOB, inclination, DLS) to
produce real-time updates of critical rotary speeds. The
updates are then displayed along with the rotary speed to show
if the rotary speed is too close to one of the predicted critical
rotary speeds. In addition, the modeling results can be
compared with actual real-time downhole vibration data to
corroborate the actual downhole condition. This paper will
show why real-time modeling is more accurate than the
conventional stand-alone modeling. Field runs of the new
system in the GOM have demonstrated the accuracy of
modeling is critical in avoiding harmful vibrations.
Introduction
Severe vibrations have been shown to be harmful to downhole
equipment. Among them, lateral vibrations (particularly
backward whirl) are commonly associated with drillstring
fatigue failure (wash-outs, twist-offs), excessive bit wear, and
MWD tool failure1-5. Lateral vibrations are caused by one
common reason - mass imbalance through a variety of
sources: bit/formation interaction, mud motor, and drillstring
mass imbalance.
A rotating body is unbalanced when its center of gravity
does not coincide with the axis of rotation. Due to the
crookedness or mass imbalance, centrifugal forces are
generated while rotating the unbalanced drillstring. The
magnitude of the centrifugal force depends on its mass, the
eccentricity and the rotary speed. In general, the higher the

rotary speed, the larger the centrifugal force. Thus, the

common practice is to lower the rotary speed when severe
lateral vibration occurs. However, vibration will not be
reduced if the lower rotary speed results in a resonant
condition in the assembly. A resonant condition occurs when
the frequency of any one of the excitation mechanisms
matches the natural frequencies of the BHA (often called the
critical rotary speeds). Under a resonant condition, the BHA
has a tendency to vibrate laterally with continuously
increasing amplitudes, resulting in severe vibration and
causing drillstring and MWD failures.
Thus, it is important to identify and avoid critical rotary
speeds during drilling operation. A number of finite element
based computer programs have been developed to predict
critical rotary speeds. However, the accuracy of their
predictions is often limited due to the uncertainties in the input
data and boundary conditions. Conventional BHA dynamics
software is usually run during well planning or, sometimes, at
the rig when the BHA is made up. And a set of predicted
critical speeds (CRPM) to be avoided is provided to the driller.
Common operational difficulties with this approach are: (i)
complex BHA modeling and results; (ii) inaccurate results due
to incorrect input data; (iii) modeling results not being used in
conjunction with the real-time vibration data to optimize the
drilling process.
To provide accurate modeling results on a timely basis
that are easy to understand, an integrated drilling dynamics
system has been developed. The system combines real-time
modeling with downhole MWD vibration data. While running
the real-time mode, real-time data (e.g., WOB, inclination,
DLS, etc.) are used to produce real-time updates of critical
rotary speeds. The updates are then displayed along with the
rotary speed to show if the rotary speed is too close to one of
the predicted critical rotary speeds. The modeling results are
confirmed by actual real-time downhole vibration data for
accurate vibration diagnosis. To integrate the real-time
modeling and measurements, an integrated dynamics system
has been developed for data acquisition, display, diagnosis,
and optimization.
Real-Time BHA Modeling
In mid 1990s Sperry-Sun developed a BHA dynamics
program WHIRL for predicting the critical rotary speeds.
The program consists of three parts: (i) a BHA static analysis
using a semi-analytical method to predict the upper boundary

D. C-K CHEN, M. SMITH, AND S. LAPIERRE

condition, (ii) a finite element based program to calculate the

natural frequencies6, and (iii) proprietary methods to calculate
the critical rotary speeds.
The WHIRL software has been upgraded to run in realtime mode by using the data supplied from mud logging and
MWD data. Conventional mud logging data used in the model
are BHA configuration, WOB, RPM, and mud weight. These
can be obtained from an integrated surface system, or via
WITS transfer from third party mud logging or other digital
rig monitoring systems commonly employed by drilling
contractors. MWD data used for the modeling are inclination,
DLS and hole size if the AcoustiCaliper is run. Fig. 1 shows
the flow chart of the WHIRL program and Fig. 2 shows the
display of the real-time WHIRL using the MWD and surface
drilling data.
Why Real-Time Modeling?
Conventional dynamics software is usually run during well
planning or sometimes at the rig when the BHA is made up.
As drilling progresses, the input parameters (i.e. inclination,
DLS, WOB, etc.) may change intentionally or unintentionally.
As a result, the conventional stand-alone computer software
requires manually constant updating the BHA dynamics model
which is proven to be impractical. On the contrary, a real-time
BHA modeling is automatically updated using the correct
input data. The results are no doubt more accurate than the
stand-alone modeling. In addition, real-time modeling is
always on allowing the analyses being monitored all the
time to prevent drilling accidents.
To investigate how much error could occur from using
incorrect input data, a sensitivity study has been conducted for
different WOB, inclination and hole size. The BHA used for
the study is a steerable assembly with a near-bit stabilizer.
Fig. 3 shows the analysis results for 1-3 degrees inclination, 810 klbs WOB and 6 1/8-in.- 6 3/8-in. hole size. The results
indicate that critical rotary speeds are particularly sensitive to
WOB and inclination where small variations could result in
sizeable errors. For example, changing the inclination from 1
to 3 degrees in the modeling would produce an 18% error in
critical RPM. Changing the WOB from 8 to 10 klbs would
cause a 16% error in the critical RPM.
Real-Time Downhole Vibration Sensor
Real-time downhole vibration data are supplied by SperrySuns DDS (Drillstring Dynamics Sensor) developed in
early 90s7. The DDS is located in the existing MWD tool
such as the Gamma Ray sub (see Fig. 4). Three mutually
orthogonal accelerometers are used to measure three axes of
accelerations: X, Y, and Z. The X-axis is used to measure both
lateral and radial accelerations. The Y-axis is used to measure
both lateral and tangential accelerations, and the Z-axis is used
to measure axial accelerations.
The signal from each axis is conditioned using three
different methods: average, peak and instantaneous (burst).
The average measurement range of 0 to 45 gs represents the
average acceleration over the sampled period. The peak
measurement range of 0 to 200 gs represents the highest
acceleration that has occurred over the sampled period. The
instantaneous (burst) measurement records high frequency

SPE 81093

data for frequency analysis. Details of the DDS design can be

found in the SPE paper #26341.
Using three different accelerations and measurements,
various modes of downhole dynamics (e.g., bit and BHA
whirl, bit bounce and stick-slip, etc.) can be detected using
proprietary methods. Indications of destructive vibration
mode(s) are then transmitted to the surface. A traffic light
display is used to indicate the vibration severity (low, medium,
high, and very high). Recommendations are made to correct
various modes of downhole vibration that can be identified by
the tool. (Note: a next generation of DDS is currently being
developed which will enhance the capability and also simplify
the diagnosis process.)
Integrated Real-Time Modeling with Measurements
The integration of the real-time modeling results with the
downhole vibration data is built on Sperry-Suns Windows NT
based INSITE software (Integrated System for Information
Technology and Engineering). This integrated rigsite
information system is used to acquire the mud logging and
downhole data, run the engineering software, and process and
display the data in real-time8. The integrated information is
derived by intelligent combination of the various data into
useable information and is displayed in an informative manner
such as shown in Fig. 5. This information may be viewed by
any workstation on the network, which may include locations
such as the drilling office, rig floor, geologists and company
mans workstations. Real-time satellite or network links can
make the displays available in the operators shore based
office as well. Fig. 6 shows an INSITE network that allows
the rig information be shared in any place in the world.
Field Testing
Three case studies presented in this paper involve the use of
bi-centered drilling assemblies in the Gulf of Mexico. Due to
their inherently high imbalance force, bi-centered assemblies
are prone to vibrations resulting in many MWD and BHA
failures. The first run shows a case without the integrated
dynamics system resulting in a parted motor. It illustrates that
vibration data alone may not be adequate to comprehend the
onset of bit whirl. The second and third examples show how
the integrated dynamics system can help to optimize the
drilling operation.
Case #1. A straight mud motor assembly with a 14.5-in. x
17.5-in. bi-centered bit was used to drill a vertical section in
the Gulf of Mexico. This section was drilled without the
integrated dynamics system. The run ultimately ended early as
a result of a parted mud motor.
The DDS vibration data collected did not show high
magnitude of vibrations. The average lateral accelerations (X
and Y) were about 2 to 3 gs indicating a low to medium
severity. The axial accelerations (Z) were also very low. See
Fig. 7 for the DDS log with Gamma Ray and ROP data. The
majority of the vibrations from this run occurred while drilling
in sand as shown by the Gamma Ray data. While the
magnitudes of the lateral vibrations appear benign, frequency
analyses of the high frequency DDS burst data (recorded)
reveals sustained vibrations at a frequency about 8.3 Hz (see
Fig. 8). The vibration frequency matched to the motor rotor

SPE 81093

Advacned Drillstring Dynamics System Intergrates Real-Time Modeling and Measurements

speed suggesting that motor vibration was responsible for the

parting of the mud motor. However, the majority of vibration
energy was absorbed by the motor itself, thus was not detected
by the vibration sensor located at the MWD tool.
Case #2. A rotary assembly with a 14 x 17.5-in. bi-centered
bit with two 14 -in. stabilizers was used to drill a vertical
section in the GOM. Rotary speed was operated close to and
away from critical RPMs (CRPMs) to assess validity of the
model using DDS information. Good correlation between
CRPM and the increased lateral vibrations were seen as shown
in Fig. 9. This time-based plot shows drilling parameters,
including rotary speed in the 4th column along with calculated
CRPMs #3 to #5. In the 5th column, accelerations (in gs)
show the peak measurements of each of the three
accelerometers of the DDS tool. These curves are shaded
according to the severity of vibration present: green for low,
yellow for medium, and red for high severity. Recommended
practice is to never operate a drilling assembly under high
severity vibration, since such operation commonly results in
component failure. During the period between 01:00 and
01:10, the rotary RPM had been reduced until at around
105 RPM it was close to the 4th CRPM, which triggered
high severity vibrations as indicated by the DDS.
At 01:10 the rotary speed was increased to 130, placing it
between the 4th and 5th CRPMs, (a safe zone), and the
downhole vibration reduced immediately. Note that the
normal recommendation in the event of high severity vibration
is to stop drilling and shut down the rotary to allow string
oscillations to dissipate, then to resume drilling with a lower
rotary speed. In this case, according to the WHIRL prediction,
the RPM was increased to remove the resonant excitation and
the vibration stopped.
In order to further verify the predictions of the Whirl
model, the rotary speed was increased at 01:17 to around 155
RPM, close to the 5th CRPM. As before, there was an
increase in vibration severity as a result of resonance in the
BHA, which continued until the RPM was reduced at 01:32.
This time the reduction in RPM did not completely cure the
vibration, only reduce its severity. The downhole shocks only
reduced to a benign level after the RPM was further reduced at
01:48 when the string was picked up to back-ream prior to
making a connection. This observation proves that it is
sometimes necessary to stop drilling to fully eliminate
resonant vibration.
Frequency analysis of some of the high frequency sampled
burst files taken around the first of these periods shows bit
whirl at a frequency around 4.9 Hz (or 294 RPM). See Fig. 10
for the frequency plots of the two lateral (X and Y)
accelerations. The vibration frequency of 249 RPM was very
close to twice the rotary RPM suggesting a correlation to the
bi-centered bit.
Case #3. A straight mud motor assembly with a 14-in. PDC
bit combined with a bi-centered reamer tool that opened the
hole to 17-in..
This BHA incorporated three 14.5-in.
stabilizers and utilized real-time vibration sensor to monitor
vibration because of difficulties on previous bit runs.

Due to the salt formation, DDS data indicate sustained

high magnitude lateral vibrations. Fig. 11 shows the time
based plot of the rotary speed (green) along with calculated
critical RPMs #2 and #3. For the first 30 minute interval the
rotary speed was close to the 3rd CRPM. After the connection
at 00:00, drilling was resumed with a rotary speed close to the
2nd CRPM. At 01:25 the speed was increased again to be right
on the 3rd CRPM. Throughout this period there was medium
to high severity vibration detected by the MWD tool, but the
vibration often interfered with MWD detection, resulting in no
real-time data. Thus, real-time vibration data should not be the
only means to detect vibrations as it could become unavailable
during high vibrations when it is most needed.
At 01:45 the rotary speed was reduced to be less than the
2nd CRPM, but as with the previous example, reduction did
not immediately eliminate the downhole dynamics. Vibration
severity remained medium severity until after 02:15, when a
slight reduction in WOB decreased the vibration to a benign
level. Note that the lower vibration coincided with an increase
in ROP suggesting that reducing vibrations not only prolong
bit and BHA life but also can improve the ROP .
Fig. 12 shows a scatter plot of DDS data versus operating
rotary speeds. The higher severity of vibrations was associated
with 43 RPM (2nd CRPM) and 60 RPM (3rd CRPM), whereas
other rotary speeds produced a distribution across the range of
severities. Post-run frequency analyses of the DDS burst data
confirmed this motion to be whirl with a frequency at about 9
Hz.
Conclusions
1. Resonance can be an important cause of BHA and bit
whirl. Good correlation between the critical rotary speed
predictions and the onset of BHA and bit whirl confirm its
importance.
2. Frequency analyses of the high frequency burst vibration
data have shown to be effective in identifying the
vibration mechanisms and supporting the accuracy of the
modeling.
3. Because the input parameters are constantly being
updated using the pertinent input data, real-time modeling
is more accurate than conventional pre-run modeling. In
addition, real-time modeling complements the lack of
real-time vibration data in the situation when MWD
dictation is poor particularly during severe vibrations.
4. BHA instability due to an enlarged hole is an important
cause of BHA and bit whirl. Wells drilled by the bicentered bits or by downhole reamers commonly used in
the Gulf of Mexico frequently produce BHA and bit
whirl. Available field data show that avoiding critical
RPMs mitigates the vibration created by BHA instability.
5. Combining the real-time modeling and real-time
downhole vibration data in an integrated system is an
effective tool in identifying the vibration mechanism and
in avoiding harmful vibrations, even for unstable BHA
such as those in the enlarged wellbore.
Acknowledgements
The authors wish to thank the management of Halliburton
Company for permission to publish this paper.

D. C-K CHEN, M. SMITH, AND S. LAPIERRE

References
1.

2.
3.
4.

5.

6.
7.

8.

Allen M.B., "BHA Lateral Vibrations: Case Studies and

Evaluation of Important Parameters, SPE/IADC paper #16110,
presented at the 1987 Drilling Conference in New Orleans,
Louisiana.
Mitchell, R.F. and Allen M.B., "Case Studies of BHA Vibration
Failure, SPE paper #16675, presented at the 1987 Annual
Technical Conference and Exhibition, Dallas, Texas.
Close, D.A., Owens, S.C., and MacPherson, J. D., Measurement
of BHA Vibration Using MWD", IADC/SPE paper #17273,
presented at the 1988 Drilling Conference, Dallas, Texas.
Vandiver, J.K., Nicholson, J.W., and Shyu, R.J., Case Studies of
the Bending Vibration and Whirling Motion of Drill Collars,
SPE/IADC paper #18652 presented at the 1989 Drilling
Conference in New Orleans, Louisiana.
Dykstra, M.W., Chen, D. C-K, Warren, T.M., and Azar, J.J.,
Drillstring Component Mass Imbalance: A Major Source of
Downhole Vibrations, SPE/IADC paper #29350 presented at the
1995 SPE/IADC Drilling Conference in Amsterdam.
Dykstra, M. W.,Nonlinear Drill String Dynamics, Ph. D.
Dissertation, The University of Tulsa, Oklahoma, 1996.
Zannoni, S.A., Cheatham, C.A., Chen, D. C-K., and Golla, C.A.,
Development and Field Testing of a New Downhole MWD
Drillstring Dynamics Sensor, SPE paper #26341 presented at the
1993 SPE Annual Technical Conference and Exhibition in
Houston.
Hudson, P., Riley, E.D., and Gidley, J.K.,A New Model for
Integrity in Management Systems, SPE paper 46694, presented at
the 1998 SPE International Conference on Health, Safety and
Environment in Oil and Gas Exploration and Production held in
Caracas, Venezuela.

SPE 81093

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Advacned Drillstring Dynamics System Intergrates Real-Time Modeling and Measurements

Drillstring Data

Mud Logging Data

(WOB, RPM Mud Wt.)
MWD Data (Inc., DLS,
hole size, etc.)

Real-Time WHIRL Module:

(1) Static BHA analysis to calculate
the upper boundary condition.
(2) Finite element based program to
calculate the natural freqs and mode
shapes
(3) Proprietary methods to calculate
the critical rotary speeds

Display input
data and the
current RPM
with the
predicted
RPMs

Fig. 1 Flow Chart of Real-Time WHIRL program

Fig. 2 The real-time WHIRL display shows the real-time input data on the right. The program is
automatically rerun every 30 seconds to 3 minutes ( selected by the user) using the updated data. The
main screen shows the critical RPM (red lines) to be avoided and the operating rotary speed (yellow
line).

D. C-K CHEN, M. SMITH, AND S. LAPIERRE

SPE 81093

Fig. 3A Sensitivity analysis on inclination for a steerable motor assembly. A change of inclination
from 1 to 3 deg will increase the critical rotary speed from 158 to 187 (18%).

Fig. 3B Sensitivity analysis on WOB for the same steerable motor assembly. A change of WOB from
8,000 lbs to 10,000 lbs will increase the critical rotary speed from 161 to 187 (16%).

Fig. 3C Sensitivity analysis on hole size for the same steerable motor assembly. A change of hole
size from 6 1/8-in. to 6 3/8-in. will decrease the critical rotary speed from 158 to 155.

SPE 81093

Advanced Drillstring Dynamics System Intergrates Real-Time Modeling and Measurments

Fig. 4 The Drillstring Dynamics Sensor (DDS) is located at the MWD tool like the Gamma Ray sub.
Three accelerometers (X, Y, Z) are used to measure lateral, axial, and torsional vibrations.

Fig. 5 The display of the integrated drillstring dynamics system. The intelligent information is derived
from raw data and is displayed in an informative manner. It includes the real-time critical RPMs vs. the
operating RPM, the downhole vibration data (severity and mechanisms) with remedy
recommendations, and time and depth based vibration log.

D. C-K CHEN, M. SMITH, AND S. LAPIERRE

SPE 81093

Fig. 6 Layout of the Integrated Rigsite Information System INSITE. INSITE can be used to link
information between rig floor and offices outside the rig using Internet, satellite or direction
connection.

Fig. 7 Depth-based vibrations from the DDS show lateral vibrations occurring while drilling sands.

SPE 81093

ADVANCED DRILLISTRING DYNAMICS SYSTEM INTERGRATES REAL-TIME MODELING AND MEASUREMENTS

Fig. 8 Frequency analyses of the DDS burst File clearly show motor vibration at a frequency of 8.3 Hz,
close to the motor rotor speed. The motor vibration resulted in a parted motor.

Fig. 9 Time-based drilling parameters and MWD vibration data compared to real-time Whirl Critical
RPM predictions (CRPM). The results show that critical rotary speeds correlated well with high
downhole vibrations.

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D. C-K CHEN, M. SMITH, AND S. LAPIERRE

SPE 81093

Fig. 10 Frequency analyses of the DDS burst File clearly show bit whirl with lateral vibrations at a
frequency of 4.88 Hz, close to twice the rotary RPM of around 150, which is close to the 5th CRPM

SPE 81093

ADVANCED DRILLISTRING DYNAMICS SYSTEM INTERGRATES REAL-TIME MODELING AND MEASUREMENTS

11

Fig. 11 Time-based drilling parameters and MWD vibration compared to real-time Whirl Critical RPM
predictions (CRPM). The results verify the modeling when drilling with mud motor coupled with a bit
and a simultaneous reaming device.

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D. C-K CHEN, M. SMITH, AND S. LAPIERRE

SPE 81093

Fig. 12 Cross-plot of MWD vibration versus rotary RPM shows higher severity vibrations occurred
when rotating at predicted critical rotary speeds of around 43, and 60 RPM