Digital Twin in a Deepwater Well: Reducing NPT with Automated Drilling Fluid Properties Measurement

Drilling deepwater wells requires efficiency and precision to reach offshore reserves. Fully automated online drilling fluid measurements, combined with Digital Twin technology, can enhance decision-making and mitigate risks. A Digital Twin—a real-time virtual replica of the wellbore integrating sensor data and hydraulic simulations—optimizes drilling performance and reduces non-productive time (NPT). This paper presents a successful case of its application in a deepwater pre-salt well, demonstrating its efficiency and reliability in reducing NPT. A fully automated unit on the rig's active pits periodically measured drilling fluid density and rheology online. These measurements fed proprietary hydraulics simulation software, creating a digital twin that provided insights into wellbore pressures, annular cuttings load distribution, and hole cleaning management. It established real-time operational limits for Equivalent Circulating Density (ECD) and Equivalent Static Density (ESD). Specialists at a Remote Operating Center (ROC) used workflow-driven processes and optimization algorithms to flag potential drilling issues and predict NPT-related events. They followed a structured communication protocol to send timely alerts. Rig personnel implemented these recommendations, successfully preventing operational issues. The digital twin system was implemented in three drilled sections of a deepwater pre-salt well: 16 in, 12.25×13.5 in, and 8.5 in. It successfully identified potential risks such as pack-off due to insufficient hole cleaning and wellbore surging during tripping operations. The system provided early detection of these hazards, allowing for proactive interventions that prevented delays and equipment damage. The comparison between simulated and measured ECD values from Pressure While Drilling (PWD) tools demonstrated high accuracy, with average differences of 0.008 ppg in the 16 in section, 0.018 ppg in the 12.25×13.5 in section, and 0.05 ppg in the 8.5 in section. Notably, when a tool failure rendered the PWD unavailable in the first 8.5 in bit run, the operator decided to rely entirely on the simulated ECD values. An additional 79 meters were drilled avoiding the NPT from an unnecessary trip to change the bottom hole assembly (BHA). This reduction in rig time proved the accuracy of the simulation generated by the proprietary software. This case study showcases how integrating real-time automated drilling fluid properties measurement with hydraulic simulations can optimize operational performance while drilling a deepwater well. This technology can be considered as a reliable assistant to evaluate real-time measurements in drilling operations, enhance decision making and reduce NPT along with the cost of rig time. The use of Digital twin marks a step forward in drilling automation and reinforces the industry's commitment to continuous improvement and innovation.