Today, during the development of unconventionals, the lack of knowledge of the downhole dynamics environment creates a culture of conservatism where excessive safety margins need to be applied to prevent damage to the rig equipment, drill bits, drill string and sensitive drilling tools. By using downhole data in real time, this risk can be reduced and drilling performance can be significantly improved. This paper discusses the results of the latest field test program of an automated drilling system where direct closed loop control of machines performs drilling optimization tasks using high speed downhole data. The downhole data is measured by a downhole drilling dynamics sub and is then transmitted to the surface via wired drill pipe. The downhole data is visualized and analyzed by a surface application. The surface application then sends set points through a control interface to the rig's pre-existing control system. The paper focuses on two main areas. The first is the rate of penetration improvements that occurred, while rotating, sliding, and sliding using an automated rocking application (Maidla and Haci 2004) and secondly, the positive behavioral change that occurs when the downhole environment is fully understood. These technologies bring significant benefit to our industry especially in the development of unconventional assets where sliding becomes slow and more challenging the longer the horizontal. The results demonstrated that these technologies significantly improve sliding performance up to 100%, especially when combined with a surface top drive rocking technology. The high speed downhole drilling dynamics data allowed the driller and the customer representatives to maximize the performance of the rig without compromising safety or the reliability of the equipment.
TX 75083-3836 U.S.A., fax 1.972.952.9435. AbstractThe
Objectives/Scope Today, during the development of unconventionals and particularly in the challenging rock of the Permian Basin, a lack of knowledge about the downhole environment creates a culture of conservatism where excessive safety margins need to be applied to prevent damage to the rig equipment, drill bits, and sensitive drilling tools. Due to varying crew capabilities, inconsistent performance is the norm and lessons learned are poorly implemented on each rig and across the fleet. This paper discusses the implementation and the performance impact of drilling with a fully integrated automation system. That system combines high-speed surface and downhole data, a process controller, and a modern 1500-HP AC land rig. This is the first time in the world that this combination has been utilized in drilling. Methods, Procedures, Process This paper discusses the equipment involved in a fully integrated drilling automation system. It will discuss the various impacts on performance of components of the system and the additional benefits of a fully integrated system. The process controller can derive its setpoints from surface data, high-speed downhole data, and a comprehensive model, using accurate information that reflects the true downhole environment and allows the system to be run without conservative safety margins. Throughout the drilling process, the drilling applications and software interface with the control system, providing real-time downhole dynamics data such as weight on bit (WOB), toolface control, wellbore stability, cuttings monitoring, and performance steering. When the well was completed, the lessons learned were automatically captured and the new optimized well program was uploaded to the system for the next well in the sequence, where it repeated the improved process. Through integrated automation, the rig drilled close to its technical limit, applying proven drilling processes for consistent, repeatable performance. Results, Observations, Conclusions These technologies bring significant benefits to our industry, especially in the development of unconventional assets where it is becoming increasingly difficult to deliver step changes in performance with current crews and technology. The fully integrated automation system allowed the driller and the customer representatives to maximize the performance of the rig without compromising safety or the reliability of the equipment. The integrated system significantly reduced the spread of spud-to-total-depth (TD) times and learnings were efficiently and consistently implemented, delivering continuous improvement. Novel/Additive Information In the challenging economic environment that our industry currently faces the implementation of game-changing technology as described above has a huge potential impact on reducing the lifting costs of oil in unconventional plays worldwide. Integrated automation provides a huge upgrade in performance for the current fleet of high-end AC rigs. Success of this project was also achieved by having a business model where customer, contractor, and equipment provider were all aligned and shared in the performance gains.
Objectives/Scope: Today, during the development of unconventionals, lack of knowledge about the downhole dynamics environment creates a culture of conservatism where excessive safety margins need to be applied to prevent damage to the rig equipment, drill bits, drill string and sensitive drilling tools. By using a combination of high-speed downhole data, surface applications, and an automated control system, this risk can be reduced, drilling performance improved and non-productive time reduced. Unconventional wells are typically drilled with several different types of drive systems, so on this project the impact of the automated drilling system was methodically tested in combination with the following BHA drive types:1. Conventional motors 2. Rotary steerable tools 3. Downhole motorized rotary steerable tools. Methods, Procedures, Process:This paper discusses the test program implemented across a 6-well project drilling in the Eagle Ford unconventional shale formation in South Texas. It was essential at the pre-planning phase that key performance indicators were identified and a solid test plan was designed. A road map was put in place to fully analyze the performance benefits where the automated drilling applications were tested against drive system, formation type and wellbore geometry. The primary objectives were to identify which applications combined with which drive system delivered the largest, consistent performance gains and the greatest cost savings. The paper includes a detailed description of the various automated applications tested: 1. A surface-located, active stick-slip mitigation device 2. A closed-loop high-speed downhole weight on bit controller 3. An automated closed-loop, high-speed downhole data driven autodriller, aimed at maximizing rate of penetration whist minimizing all modes of vibration. Results, Observations, Conclusions:These technologies bring significant benefits to our industry, especially in the development of unconventional assets where it is becoming increasingly difficult to deliver step changes in performance with current crews and technology. The high-speed downhole-driven control of the rig equipment allowed the driller and the customer representatives to maximize the performance of the rig without compromising safety or the reliability of the equipment. Drilling with automated motor BHAs and automated non-motorized rotary steerable BHAs allowed for repeated improvements in drilling performance of 37%, well on well. The fact that this performance increase is repeatable offers significant bottom line value for operators, by allowing reliable well delivery, forecasting and overall reduced well cost.Novel/Additive Information: Downhole-automated drilling control described within this case study is a powerful tool to be used by existing drillers and directional drillers. The drilling crew must use the automated control system in partnership with specialized automated drilling applications to realize higher performance, without sacrificing safety margins or tool life. Even wit...
TX 75083-3836 U.S.A., fax 1.972.952.9435. AbstractThe
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