Automated Closed-loop Drilling with ROP Optimization Algorithm Significantly Reduces Drilling Time and Improves Downhole Tool Reliability

Abstract

Abstract The use of an ROP Optimization algorithm within an automated closed loop process has dramatically increased ROP in its first deployments in Iraq, Algeria, and Mexico. Additionally, an unexpected reduction in downhole tool failures was observed resulting in a notable decrease in non-productive time. Importantly, the closed-loop automation, where the algorithm is allowed to send commands directly to the rig control system, shows yet another step change in ROP improvement compared to the algorithm that just presents recommendations to the driller. This paper briefly describes the optimization algorithm and then focuses on the system architecture used to integrate the algorithm with the rig control system. Similar to the SPE DSA-TS Comms Team architecture, the deployed architecture enables the algorithm to receive real-time data from the rig control system and drilling acquisition system to provide a complete data set to the ROP Optimization algorithm. The algorithm constrained by a set of operational limits dynamically computes RPM and WOB commands and sends these to a SCADA system which converts the generic commands into rig specific commands for each rig type used. The driller controls the use of the system via an "Automation Console" provided by the SCADA system and located adjacent to the driller’s console. The driller is able to engage or disengage from the system. Failsafe conditions are also incorporated into the automation system. Results showing the improved ROP and downhole reliability compared to field averages across various hole sizes and trajectory profiles are given. These results consistently demonstrate the effectiveness of a closed-loop automation system to improve ROP and tool reliability.