New Data-Driven Fully Automated Algorithm for the Real-Time Detection of Reamer Status Change Using Downhole Turbine RPM

In the oil and gas industry, hole-enlargement-while-drilling (HEWD) tools, commonly known as underreamers, are extensively utilized to optimize wellbore diameter and enhance drilling efficiency, particularly in challenging formations such as hard carbonates with high unconfined compressive strength. The underreamer is equipped with retractable cutting arms or blades that can expand outward to enlarge the borehole and use hydraulic or mechanical activation mechanisms to extend cutting arms that ream the hole as drilling progresses. The operational status of these reamers is critical to ensure that the wellbore is enlarged to the desired specifications, thereby facilitating smoother casing runs and improving overall well integrity. Real-time monitoring of reamer activation status is paramount, as it allows for immediate detection and correction of any issues that may arise during drilling operations. This proactive approach not only minimizes non-productive time but also mitigates risks associated with incomplete hole enlargement, such as stuck pipe incidents and compromised wellbore stability. To our knowledge, there exists no reliable method to detect the reamer status change. Downhole measurement for reamer status change detection Reamers opening or closing has a significant effect on the downhole mud circulation. If the bottom hole assembly (BHA) includes a measurement tool that has a turbine component, its turbine rotations per minute (TRPM) are directly influenced by the reamer status. If the flowrate is kept constant at the surface, but there is a drop or increase in TRPM detected downhole, it might be a valuable indicator for the reamer status change. If the reamer was opened, then the coefficient would drop, if the reamer was closed: the coefficient would increase. Figure 1 illustrates how the relationship TRPM-Flowrate changes depending on the reamer status. TRPM could be used as a valuable indicator of a reamer status.