The time needed to eliminate complications and accidents accounts for 20–25% of total well construction time, according to a 2020 SPE paper (SPE 200740). The same paper notes that digital twins have proven to be a key enabler in improving sustainability during well construction, shrinking the carbon footprint by reducing overall drilling time and encouraging and bringing confidence to contactless advisory and collaboration. The paper also points out the potential application of digital twins to activities such as geothermal drilling.
Advanced data analytics and machine learning (ML) potentially can reduce engineering hours up to 70% during field development, according to Boston Consulting Group. Increased field automation, remote operations, sensor costs, digital twins, machine learning, and improved computational speed are responsible. It is no surprise, then, that digital twins are taking on a greater sense of urgency for operators, service companies, and drilling contractors working to improve asset and enterprise safety, productivity, and performance management. For 2021, digital twins appear among the oil and gas industry’s top 10 digital spending priorities.
DNV GL said in its Technology Outlook 2030 that this could be the decade when cloud computing and advanced simulation see virtual system testing, virtual/augmented reality, and machine learning progressively merge into full digital twins that combine data analytics, real-time, and near-real-time data for installations, subsurface geology, and reservoirs to bring about significant advancements in upstream asset performance, safety, and profitability. The biggest challenges to these advancements, according to the firm, will be establishing confidence in the data and computational models that a digital twin uses and user organizations’ readiness to work with and evolve alongside the digital twin. JPT looked at publications from inside and outside the upstream industry and at several recent SPE papers to get a snapshot of where the industry stands regarding uptake of digital twins in well construction and how the technology is affecting operations and outcomes.
Why Digital Twins
Gartner Information defines a digital twin as a digital representation of a real-world entity or system. “The implementation of a digital twin,” Gartner writes, “is an encapsulated software object or model that mirrors a unique physical object, process, organization, person or other abstraction.” Data from multiple digital twins can be aggregated for a composite view across several real-world entities and their related processes.
In upstream oil and gas, digital twins focus on the well—and, ultimately, the field—and its lifecycle. Unlike a digital simulation, which produces scenarios based on what could happen in the physical world but whose scenarios may not be actionable, a digital twin represents actual events from the physical world, making it possible to visualize and understand real-life scenarios to make better decisions. Digital well construction twins can pertain to single assets or processes and to the reservoir/subsurface or the surface. Ultimately, when process and asset sub-twins are connected, the result is an integrated digital twin of the entire asset or well. Massive sensor technology and the ability to store and handle huge amounts of data from the asset will enable the full digital twin to age throughout the life-cycle of the asset, along with the asset itself (Fig. 1).
Implementation of Digital Twin for Engine Block Manufacturing Processes
