A Case Study for the Development and Use of a Well Control Simulator as a Digital Twin of a Real Scenario

Simulators in the petroleum industry have been used mainly for training purposes even though they present different applications like digital twins. In this regard, a simulator must approximate the well environment to reflect operative actions and reactions. This paper describes a case study where a well control simulator has been developed to be used as a digital twin where operators may try different scenarios in a safe environment before applying them to the physical well. To cover all aspects of the operation, the simulator should simulate surface equipment as well as a downhole environment. Numerical modeling techniques and hydraulic simulators are used to design the well response to operations. Different scenarios were established to cover most of the possible downhole problems and equipment malfunctions including electrical and hydraulic failures. The study compares a pre-determined set of KPIs common to three different types of simulation: well control, procedural and an integration of both. The target of the study is to collect the data resulting from the use of the simulator while it replicates a real-life situation. This virtual model of the rig and the well can be used to calibrate the main drilling parameters like SPM, RPM and WOB. The digital twin is also used to optimize operational procedures and improve performance and efficiency of rig crews as well as reduce their response time to possible problems. The results show an increase in performance when the knowledge of the rig is combined with the downhole feedback experience. This proves that training of the crew by reproducing their own equipment allows for a major jump in readiness and faster response with minimal mistakes. In addition, conducting the operation virtually allows the crew to uncover any possible issues before tackling the physical well. This in turn helps to reduce errors and safeguard both well and equipment integrity. This paper discusses the integration of the use of downhole environment behavior into a complete digital twin which will play an important role for providing a source of data for regular case studies concerning well control, Maintenance, Scheduling and other critical decisions. This new method candidates itself as a major contender for the future of simulation in the drilling business and shows the importance of that for reducing risks and errors.