Automation in Drilling: Future Evolution and Lessons from Aviation

Abstract

Automation of the drilling process has been gathering pace over the last 10 years, with progress being made on many fronts, from choke control in managed pressure drilling (MPD) operations, through a new generation of auto drillers to intelligent systems that prevent the driller from exceeding parameters that might cause downhole problems. Observing the current state of automation in drilling, it is clear that in the case of MPD, automation has resulted in closer and more stable control of a process that can be achieved by a manual system. Auto-drillers combined with downhole rotary steerable systems have resulted in improved progress rates compared to manual systems. By contrast, modern rigs with highly mechanised pipe handling systems are still controlled manually with a crewing arrangement that has changed little while the technology has evolved dramatically. These developments pose a number of questions, for example: In what direction is automation likely to evolve in the future, and why? Can the drilling community avoid the mistakes of other industries and how might this be prevented? The paper reviews developments of automation in aviation and describes some of the problems that have arisen. It then outlines the analogous efforts in drilling and identifies lessons that could be learned. The paper presents a rationale on which further automation initiatives might be based and some of the related changes that might be necessary as a result.

Drilling Automation: Potential for Human Error

“…One may speculate that the cause of these errors is the problem of understanding the state of the system at all times. This may be directly related to Billing's axioms for automation in aviation (Billings 1996) and discussed in relationship to drilling automation in Thorogood (2012).…”

“…In-depth understanding of the design and operation of automated drilling-machinery control systems Knowledge of the operating principles underlying advanced systems for controlling downhole operations Familiarization with and interpretation of increasingly sophisticated display systems and diagnosis of potential downhole problems Protection against the consequences of human error through training and demonstrated competency in the nontechnical skills associated with Crew Resource Management In the future, Thorogood (2012) predicts that drillers and their supervisors will become subject to training, competency assessment, and certification of qualifications in a way that is analogous to the training structure in commercial aviation, especially in relation to theoretical knowledge, simulator time, and then a focus on the job "type-rating" training. Although a generic qualification may be issued at the conclusion of training, this will have to be followed with rig-type and area-specific training, testing, and qualification with periodic skills tests and requalification.…”

Automated Slide Drilling System and Multi-Body Dynamics Aided Slide Drilling Simulation

“…Different approaches have been proposed which were inspired from other engineering areas (Thorogood et al 2010), especially the aviation industry (Thorogood 2013). The drilling process is very similar to the plane flying process.…”

Industry Analogies for Successful Implementation of Drilling-Systems Automation and Real-Time Operating Centers

“…Cockpit layouts and displays are designed for easy operation by the pilots; warning systems include verbal recordings of extreme conditions. An analysis of aviation relative to drilling automation has been extensively developed in a previous SPE paper (Thorogood 2012).…”