World First Closed Loop Downhole Automation Combined with Process Automation System Provides Integrated Drilling Automation in the Permian Basin.

Abstract

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.

Autonomous Decision-Making While Drilling

“…The application of standardized procedures under the protection of SOE and FDM functions have shown that automated drilling operations were both possible [5] and increased the efficiency [6]. Attempts have been made to integrate downhole measurements from high-speed telemetry in a closed loop control architecture [7,8]. Also, the control of drilling parameters has been automated using closed loop control [9,10].…”