Machine Learning Assisted Framework for Advanced Subsurface Fracture Mapping and Well Interference Quantification

The oil and gas industry has historically spent significant amount of capital to acquire large volumes of analog and digital data often left unused due to lack of digital awareness. It has instead relied on individual expertise and numerical modelling for reservoir development, characterization, and simulation, which is extremely time consuming and expensive and inevitably invites significant human bias and error into the equation. One of the major questions that has significant impact in unconventional reservoir development (e.g., completion design, production, and well spacing optimization), CO2 sequestration in geological formations (e.g., well and reservoir integrity), and engineered geothermal systems (e.g., maximizing the fluid flow and capacity of the wells) is to be able to quantify and map the subsurface natural fracture systems. This needs to be done both locally, i.e., near the wellbore and generally in the scale of the wellpad, or region. In this study, the conventional near wellbore natural fracture mapping techniques is first discussed and integrated with more advanced technologies such as application of fiber optics, specifically Distributed Acoustic Sensing (DAS) and Distributed Strain Sensing (DSS), to upscale the fracture mapping in the region. Next, a physics-based automated machine learning (AutoML) workflow is developed that incorporates the advanced data acquisition system that collects high-resolution drilling acceleration data to infer the near well bore natural fracture intensities. The new AutoML workflow aims to minimize human bias and accelerate the near wellbore natural fracture mapping in real time. The new AutoML workflow shows great promise by reducing the fracture mapping time and cost by 10-fold and producing more accurate, robust, reproducible, and measurable results. Finally, to completely remove human intervention and consequently accelerate the process of fracture mapping while drilling, the application of computer vision and deep learning techniques in new workflows to automate the process of identifying natural fractures and other lithological features using borehole image logs were integrated. Different structures and workflows have been tested and two specific workflows are designed for this purpose. In the first workflow, the fracture footprints on actual acoustic image logs (i.e., full, or partial sigmoidal signatures with a range of amplitude and vertical and horizontal displacement) is detected and classified in different categories with varying success. The second workflow implements the actual amplitude values recorded by the borehole image log and the binary representation of the produced images to detect and quantify the major fractures and beddings. The first workflow is more detailed and capable of identifying different classes of fractures albeit computationally more expensive. The second workflow is faster in detecting the major fractures and beddings. In conclusion, regional subsurface natural fracture mapping technique using an integration of conventional logging, microseismic, and fiber optic data is presented. A new AutoML workflow designed and tested in a Marcellus Shale gas reservoir was used to predict near wellbore fracture intensities using high frequency drilling acceleration data. Two integrated workflows were designed and validated using 3 wells in Marcellus Shale to extract natural fractures from acoustic image logs and amplitude recordings obtained during logging while drilling. The new workflows have: i) minimized human bias in different aspects of fracture mapping from image log analysis to machine learning model selection and hyper parameter optimization; ii) generated and quantified more accurate fracture predictions using different score matrices; iii) decreased the time and cost of the fracture interpretation by tenfold, and iv) presented more robust and reproducible results

A Review of the Application of Machine Learning and Data Mining Approaches in Continuum Materials Mechanics

Machine learning tools represent key enablers for empowering material scientists and engineers to accelerate the development of novel materials, processes and techniques. One of the aims of using such approaches in the field of materials science is to achieve high-throughput identification and quantification of essential features along the process-structure-property-performance chain. In this contribution, machine learning and statistical learning approaches are reviewed in terms of their successful application to specific problems in the field of continuum materials mechanics. They are categorized with respect to their type of task designated to be either descriptive, predictive or prescriptive; thus to ultimately achieve identification, prediction or even optimization of essential characteristics. The respective choice of the most appropriate machine learning approach highly depends on the specific use-case, type of material, kind of data involved, spatial and temporal scales, formats, and desired knowledge gain as well as affordable computational costs. Different examples are reviewed involving case-by-case dependent application of different types of artificial neural networks and other data-driven approaches such as support vector machines, decision trees and random forests as well as Bayesian learning, and model order reduction procedures such as principal component analysis, among others. These techniques are applied to accelerate the identification of material parameters or salient features for materials characterization, to support rapid design and optimization of novel materials or manufacturing methods, to improve and correct complex measurement devices, or to better understand and predict fatigue behavior, among other examples. Besides experimentally obtained datasets, numerous studies draw required information from simulation-based data mining. Altogether, it is shown that experiment- and simulation-based data mining in combination with machine leaning tools provide exceptional opportunities to enable highly reliant identification of fundamental interrelations within materials for characterization and optimization in a scale-bridging manner. Potentials of further utilizing applied machine learning in materials science and empowering significant acceleration of knowledge output are pointed out

Prognostic-based Life Extension Methodology with Application to Power Generation Systems

Practicable life extension of engineering systems would be a remarkable application of prognostics. This research proposes a framework for prognostic-base life extension. This research investigates the use of prognostic data to mobilize the potential residual life. The obstacles in performing life extension include: lack of knowledge, lack of tools, lack of data, and lack of time. This research primarily considers using the acoustic emission (AE) technology for quick-response diagnostic. To be specific, an important feature of AE data was statistically modeled to provide quick, robust and intuitive diagnostic capability. The proposed model was successful to detect the out of control situation when the data of faulty bearing was applied. This research also highlights the importance of self-healing materials. One main component of the proposed life extension framework is the trend analysis module. This module analyzes the pattern of the time-ordered degradation measures. The trend analysis is helpful not only for early fault detection but also to track the improvement in the degradation rate. This research considered trend analysis methods for the prognostic parameters, degradation waveform and multivariate data. In this respect, graphical methods was found appropriate for trend detection of signal features. Hilbert Huang Transform was applied to analyze the trends in waveforms. For multivariate data, it was realized that PCA is able to indicate the trends in the data if accompanied by proper data processing. In addition, two algorithms are introduced to address non-monotonic trends. It seems, both algorithms have the potential to treat the non-monotonicity in degradation data. Although considerable research has been devoted to developing prognostics algorithms, rather less attention has been paid to post-prognostic issues such as maintenance decision making. A multi-objective optimization model is presented for a power generation unit. This model proves the ability of prognostic models to balance between power generation and life extension. In this research, the confronting objective functions were defined as maximizing profit and maximizing service life. The decision variables include the shaft speed and duration of maintenance actions. The results of the optimization models showed clearly that maximizing the service life requires lower shaft speed and longer maintenance time

Optimisation of welding parameters to mitigate the effect of residual stress on the fatigue life of nozzle–shell welded joints in cylindrical pressure vessels.

Doctoral Degree. University of KwaZulu-Natal, Durban.The process of welding steel structures inadvertently causes residual stress as a result of thermal cycles that the material is subjected to. These welding-induced residual stresses have been shown to be responsible for a number of catastrophic failures in critical infrastructure installations such as pressure vessels, ship’s hulls, steel roof structures, and others. The present study examines the relationship between welding input parameters and the resultant residual stress, fatigue properties, weld bead geometry and mechanical properties of welded carbon steel pressure vessels. The study focuses on circumferential nozzle-to-shell welds, which have not been studied to this extent until now. A hybrid methodology including experimentation, numerical analysis, and mathematical modelling is employed to map out the relationship between welding input parameters and the output weld characteristics in order to further optimize the input parameters to produce an optimal welded joint whose stress and fatigue characteristics enhance service life of the welded structure. The results of a series of experiments performed show that the mechanical properties such as hardness are significantly affected by the welding process parameters and thereby affect the service life of a welded pressure vessel. The weld geometry is also affected by the input parameters of the welding process such that bead width and bead depth will vary depending on the parametric combination of input variables. The fatigue properties of a welded pressure vessel structure are affected by the residual stress conditions of the structure. The fractional factorial design technique shows that the welding current (I) and voltage (V) are statistically significant controlling parameters in the welding process. The results of the neutron diffraction (ND) tests reveal that there is a high concentration of residual stresses close to the weld centre-line. These stresses subside with increasing distance from the centre-line. The resultant hoop residual stress distribution shows that the hoop stresses are highly tensile close to the weld centre-line, decrease in magnitude as the distance from the weld centre-line increases, then decrease back to zero before changing direction to compressive further away from the weld centre-line. The hoop stress distribution profile on the flange side is similar to that of the pipe side around the circumferential weld, and the residual stress peak values are equal to or higher than the yield strength of the filler material. The weld specimens failed at the weld toe where the hoop stress was generally highly tensile in most of the welded specimens. The multiobjective genetic algorithm is successfully used to produce a set of optimal solutions that are in agreement with values obtained during experiments. The 3D finite element model produced using MSC Marc software is generally comparable to physical experimentation. The results obtained in the present study are in agreement with similar studies reported in the literature

Predicting the Future

Due to the increased capabilities of microprocessors and the advent of graphics processing units (GPUs) in recent decades, the use of machine learning methodologies has become popular in many fields of science and technology. This fact, together with the availability of large amounts of information, has meant that machine learning and Big Data have an important presence in the field of Energy. This Special Issue entitled “Predicting the Future—Big Data and Machine Learning” is focused on applications of machine learning methodologies in the field of energy. Topics include but are not limited to the following: big data architectures of power supply systems, energy-saving and efficiency models, environmental effects of energy consumption, prediction of occupational health and safety outcomes in the energy industry, price forecast prediction of raw materials, and energy management of smart buildings

AUTOMATED MIDLINE SHIFT DETECTION ON BRAIN CT IMAGES FOR COMPUTER-AIDED CLINICAL DECISION SUPPORT

Midline shift (MLS), the amount of displacement of the brain’s midline from its normal symmetric position due to illness or injury, is an important index for clinicians to assess the severity of traumatic brain injury (TBI). In this dissertation, an automated computer-aided midline shift estimation system is proposed. First, a CT slice selection algorithm (SSA) is designed to automatically select a subset of appropriate CT slices from a large number of raw images for MLS detection. Next, ideal midline detection is implemented based on skull bone anatomical features and global rotation assumptions. For the actual midline detection algorithm, a window selection algorithm (WSA) is applied first to confine the region of interest, then the variational level set method is used to segment the image and extract the ventricle contours. With a ventricle identification algorithm (VIA), the position of actual midline is detected based on the identified right and left lateral ventricle contours. Finally, the brain midline shift is calculated using the positions of detected ideal midline and actual midline. One of the important applications of midline shift in clinical medical decision making is to estimate the intracranial pressure (ICP). ICP monitoring is a standard procedure in the care of severe traumatic brain injury (TBI) patients. An automated ICP level prediction model based on machine learning method is proposed in this work. Multiple features, including midline shift, intracranial air cavities, ventricle size, texture patterns, and blood amount, are used in the ICP level prediction. Finally, the results are evaluated to assess the effectiveness of the proposed method in ICP level prediction

Friction Stir Welding Manufacturing Advancement by On-Line High Temperature Phased Array Ultrasonic Testing and Correlation of Process Parameters to Joint Quality

Welding, a manufacturing process for joining, is widely employed in aerospace, aeronautical, maritime, nuclear, and automotive industries. Optimizing these techniques are paramount to continue the development of technologically advanced structures and vehicles. In this work, the manufacturing technique of friction stir welding (FSW) with aluminum alloy (AA) 2219-T87 is investigated to improve understanding of the process and advance manufacturing efficiency. AAs are widely employed in aerospace applications due to their notable strength and ductility. The extension of good strength and ductility to cryogenic temperatures make AAs suitable for rocket oxidizer and fuel tankage. AA-2219, a descendent of the original duralumin used to make Zeppelin frames, is currently in wide use in the aerospace industry. FSW, a solid-state process, joins the surfaces of a seam by stirring the surfaces together with a pin while the metal is held in place by a shoulder. The strength and ductility of friction stir (FS) welds depends upon the weld parameters, chiefly spindle rotational speed, feedrate, and plunge force (pinch force for self-reacting welds). Between conditions that produce defects, it appears in this study as well as those studies of which we are aware that FS welds show little variation in strength; however, outside this process parameter “window” the weld strength drops markedly. Manufacturers operate within this process parameter window, and the parameter establishment phase of welding operations constitutes the establishment of this process parameter window. The work herein aims to improve the manufacturing process of FSW by creating a new process parameter window selection methodology, creation of a weld quality prediction model, developing an analytical defect suppression model, and constructing a high temperature on-line phased array ultrasonic testing system for quality inspection

Active thermography for the investigation of corrosion in steel surfaces

The present work aims at developing an experimental methodology for the analysis of corrosion phenomena of steel surfaces by means of Active Thermography (AT), in reflexion configuration (RC). The peculiarity of this AT approach consists in exciting by means of a laser source the sound surface of the specimens and acquiring the thermal signal on the same surface, instead of the corroded one: the thermal signal is then composed by the reflection of the thermal wave reflected by the corroded surface. This procedure aims at investigating internal corroded surfaces like in vessels, piping, carters etc. Thermal tests were performed in Step Heating and Lock-In conditions, by varying excitation parameters (power, time, number of pulse, ….) to improve the experimental set up. Surface thermal profiles were acquired by an IR thermocamera and means of salt spray testing; at set time intervals the specimens were investigated by means of AT. Each duration corresponded to a surface damage entity and to a variation in the thermal response. Thermal responses of corroded specimens were related to the corresponding corrosion level, referring to a reference specimen without corrosion. The entity of corrosion was also verified by a metallographic optical microscope to measure the thickness variation of the specimens

Eddy current defect response analysis using sum of Gaussian methods

This dissertation is a study of methods to automatedly detect and produce approximations of eddy current differential coil defect signatures in terms of a summed collection of Gaussian functions (SoG). Datasets consisting of varying material, defect size, inspection frequency, and coil diameter were investigated. Dimensionally reduced representations of the defect responses were obtained utilizing common existing reduction methods and novel enhancements to them utilizing SoG Representations. Efficacy of the SoG enhanced representations were studied utilizing common Machine Learning (ML) interpretable classifier designs with the SoG representations indicating significant improvement of common analysis metrics

Making Tactile Textures with Predefined Affective Properties

A process for the design and manufacture of 3D tactile textures with predefined affective properties was developed. Twenty four tactile textures were manufactured. Texture measures from the domain of machine vision were used to characterize the digital representations of the tactile textures. To obtain affective ratings, the textures were touched, unseen, by 107 participants who scored them against natural, warm, elegant, rough, simple, and like, on a semantic differential scale. The texture measures were correlated with the participants' affective ratings using a novel feature subset evaluation method and a partial least squares genetic algorithm. Six measures were identified that are significantly correlated with human responses and are unlikely to have occurred by chance. Regression equations were used to select 48 new tactile textures that had been synthesized using mixing algorithms and which were likely to score highly against the six adjectives when touched by participants. The new textures were manufactured and rated by participants. It was found that the regression equations gave excellent predictive ability. The principal contribution of the work is the demonstration of a process, using machine vision methods and rapid prototyping, which can be used to make new tactile textures with predefined affective properties