Drilling Automation: The Step Forward for Improving Safety, Consistency, and Performance in Onshore Gas Drilling

Abstract

In the current oil and gas drilling industry, the modernization of rig fleets has been shifting toward high mobility, artificial intelligence, and computerized systems. Part of this shift includes a move toward automation. This paper summarizes the successful application of a fully automated workflow to drill a stand, from slips out to slips back in, in a complex drilling environment in onshore gas. Repeatable processes with adherence to plans and operating practices are a key requirement in the implementation of drilling procedures and vital for optimizing operations in a systematic way. A drilling automation solution has been deployed in two rigs enabling the automation of both pre-connection and post-connection activities as well as rotary drilling of an interval equivalent to a typical drillpipe stand (approximately 90 ft) while optimizing the rate of penetration (ROP) and managing drilling dysfunctionalities, such as stick-slip and drillstring vibrations in a consistent manner. So far, a total of nine wells have been drilled using this solution. The automation system is configured with the outputs of the drilling program, including the drilling parameters roadmap, bottomhole assembly tools, and subsurface constraints. Before drilling every stand, the driller is presented with the planned configuration and can adjust settings whenever necessary. Once a goal is specified, the system directs the rig control system to command the surface equipment (draw works, auto-driller, top drive, and pumps). Everything is undertaken in the context of a workflow that reflects standard operating procedures. This solution runs with minimal intervention from the driller and each workflow contextual information is continuously displayed to the driller thereby giving him the best capacity to monitor and supervise the operational sequence. If drilling conditions change, the system will respond by automatically changing the sequence of activities to execute mitigation procedures and achieve the desired goal. At all times, the driller has the option to override the automation system and assume control by a simple touch on the rig controls. Prior to deployment, key performance indicators (KPI), including automated rig state-based measures, were selected. These KPIs are then monitored while drilling each well with the automation system to compare performance with a pre-deployment baseline. The solution was used to drill almost 60,000 ft of hole section with the system in control, and the results showed a 20% improvement in ROP with increased adherence to pre-connection and post-connection operations. Additionally, many lessons were learned from the use and observation of the automation workflow that was used to drive continuous improvement in efficiency and performance over the course of the project. This deployment was the first in the region and the system is part of a comprehensive digital well construction solution that is continuously enriched with new capabilities. This adaptive automated drilling solution delivered a step change in performance, safety, and consistency in the drilling operations.