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Automation of the Drilling System: What has been done, what is being done, and why it is important John D. Macpherson Society of Petroleum Engineers Distinguished Lecturer Program www. spe. org/dl 2

Presentation Outline • • Definitions and background The drivers for automation Technical and Business Challenges SPE Drilling Systems Automation TS A brief look into automation systems Conclusions Q&A 3

Drilling Systems Automation (DSA) • Involves the control of the drilling process by automatic means, ultimately reducing human intervention to a minimum. • Employs control systems and information technologies • Includes all components downhole, on surface and remote to the drilling rig that are used in real-time to drill the wellbore. 4

What is Drilling Systems Automation? The process of creating a borehole with systems and sub-systems that are computer controlled, leading to reduced human intervention Enterprise Remote Rigsite BHA 5

Levels of Computerization Ref: Endsley and Kaber, 1999, Ergonomics, Vol. 42 Levels Functions Monitor Advise 1 Manual Control H H 2 Action Support 3 Batch Processing H C H H 4 5 6 7 8 9 Shared Control H C H Decision Support H C H Blended Decisions H C H Rigid System H C C H Auto Decisions H C Supervisory Ctrl H 10 Full Automation Implement C C H C C C C H – Human H Select/Decide C - Computer 6

Control Systems on Offshore Rigs Active Heave Drawworks Hydraulic Systems Dynamic Positioning Power Management Thruster Control BOP Control Drillship: Pacific Drilling, Pacific Santa Ana 7

Drilling Systems Automation The current level of automation in Drilling Monit or L 2 • Wellsite Monitoring Systems • Remote Data Centers • Smart Alarms Advis e L 3 -L 4 • Drilling Dynamics Diagnostic Systems • Directional Drilling Advisors Surface Digital Networks Contr ol L 5 -L 7 • Auto-Driller • Stick-Slip Surface Control • MPD Control Systems 10101011100100110001 Source: Macpherson etal, 2013, SPE 166263 Auto nomo us L 8 • MWD L 10 Rotary Steerable Systems • LWD Formation Samplers MWD Network 8

Drilling Systems Automation • The drilling industry has equipment that is highly automated (level 8+) • Automation of drilling systems and processes is quite rudimentary (level 3) • Why? • What are the business drivers? 9

DSA Drivers Well Complexity Data Overload NPT Significant Well Manufacturing • Difficult profiles, bottomhole pressure margins • Mitigate risk and control costs • Real-time measurements, complex operations • Manage, interpret, act on large volumes of data • 35 to 40% of deep-water drilling costs • Minimized by responding predictably to events • Drill many similar profile wells per field • Repetitively drill to plan with minimal risk and cost 10 Source: Baker Hughes

DSA Drivers Well Don’t exceed make-up maximum weight torque of the drill Don’t exceed the • Difficult on the profiles, bit bottomhole pressure margins string maximum RPM of Complexity • Mitigate risk and control costs the bit Drill efficiently Drill faster Data Stay on target • Real-time measurements, complex Clean the hole operations Drill this section • Manage, interpret, act on large volumes of data Avoid lateral without tripping; i. e. Overload Don’t stall the top drive. NPT vibrations with one bit • 35 to 40% of deep-water drilling costs Time is money • Minimized by responding predictably to events Don’t exceed the Significant maximum RPM of Safety first the top drive Avoid stick-slip Condition back towells bottom Well vibrations • Drill many similar. Goprofile per field the hole andwith safely • Repetitively drill tofast plan minimal risk and cost Manufacturing Source: Mark Anderson, Shell Don’t buckle the pipe Don’t stall the downhole motor Connect a new 11 fast pipe joint and safely

DSA Drivers Well Complexity Data Overload NPT Significant Well Manufacturing • Difficult profiles, bottomhole pressure margins • Mitigate risk and control costs • Real-time measurements, complex operations • Manage, interpret, act on large volumes of data • 35 to 40% of deep-water drilling costs • Minimized by responding predictably to events • Drill many similar profile wells per field • Repetitively drill to plan with minimal risk and cost 12

DSA Drivers Well Complexity Data Overload NPT Significant Well Manufacturing • Difficult profiles, bottomhole pressure margins • Mitigate risk and control costs • Real-time measurements, complex operations • Manage, interpret, act on large volumes of data • 35 to 40% of deep-water drilling costs • Minimized by responding predictably to events • Drill many similar profile wells per field • Repetitively drill to plan with minimal risk and cost Source: SPE 178875, 2016, Livingston etal, Team Approach to Horizontal Drilling Optimization in the Marcellus Delivers Record Setting Performance 13

DSA Drivers Well Complexity Data Overload NPT Significant Well Manufacturing • Difficult profiles, bottomhole pressure margins • Mitigate risk and control costs • Real-time measurements, complex operations • Manage, interpret, act on large volumes of data • 35 to 40% of deep-water drilling costs • Minimized by responding predictably to events • Drill many similar profile wells per field • Repetitively drill to plan with minimal risk and cost 14

DSA Drivers Expert Resources • Operations starved for expertise • Will make available scarce expert resources Knowledge Transfer • Skilled employees exiting the industry • Transfer knowledge from skilled to new employees HS & E • Driver is to make the work environment a safer place • Reduce the number of people in “red zones. ” 15

Technology and Business • There are significant business drivers behind drilling systems automation • But to make DSA happen we have to communicate the technology to the business 16

Task uncertainty Technology: DSA is Challenging Necessity of domain expertise in technology enablers Source: UT Austin RAPID Consortium 17

Operations 1 0 Machine Control Well Construction Enterprise Execution Non-deterministic Protocol • Wellsite & Remote Operations • Monitoring, Modeling, Simulation • Process Control Systems • Onsite Interpretation & Control OPC UA Deterministic • Machine Control Systems Protocol • Instrumentation & Measurement Wellsite 4 3 2 • Well Design, Budget, Data Repository, • Data mining WITSML & analytics Remote DSA Decision Making and Control Framework • Physical Drilling Process • No Intelligent Sensing Modified from ISA 95 for the Drilling Process Source: de Wardt etal, 2015, SPE 173010 18

DSATS Rig Control System Operators, Service Companies, Drilling Contractors, Equipment Suppliers, … SPE Drilling Systems Automation Technical Section 19

DSATS Communications Guidelines • OPC UA protocol for automation communications • Interface to proprietary or other standards • Machine independent software • data-to-information • control algorithms • Standardized method for real-time drilling data • Simplified device control architecture for drilling rigs • Standardized units, security, rig-information-model Next Step: Data 20

DSA Decision Making and Control Framework 4 3 2 Operations 1 0 Machine Control Well Construction Enterprise • Well Design, Budget, Data Repository, Data Mining • Data mining & analytics Analytics Execution • Wellsite & Remote Operations • Monitoring, Modeling, Simulation Subsurface Predictions • Process Control Systems • Onsite Interpretation & Control Swab Surge ROP • Machine Control Systems • Instrumentation & Measurement • Physical Drilling Process • No Intelligent Sensing Machine Control Data flow between levels of the framework (NO SILOS) 21

Data in Systems Automation • Without data there is no automation • “First comes data” (Lord Kelvin) • Who owns the data? – Separation of Ownership and Confidentiality – Data Silos versus Open System – Embedded in the business model 22

1 Systems Architecture Machines Equipment 2 Communications 3 Human Factors 8 4 Sensors & IMS Calibration Validity Data, Derived Data, System State Completeness Logic Proximity Accuracy Conversion Criticality Availability Data Aggregator telemetry, latency data Simulation & 7 Modeling Control Systems 6 accuracy, precision Certification & 5 Standards Instrumentation and Measurement System (IMS) -centric view of drilling systems automation, showing relationship with other challenges 23

Data Flow and Value 4 3 2 1 0 Enterprise ENTERPRISE MODELING IN STREAM ANALYTICS ACTIVE ADVISORY Machine Control SENSOR DATA VISUALIZATION CONTROL Well Construction REAL-TIME PERFORMANCE Operations Execution Source: DSATS Luncheon Presentation, 2015, SPE Digital Energy Conference 24

Data Flow and Value Level 2: Execution HUMAN Level 1: Machine Control Level 0: Physical process Source: Iversen et al. , 2016 SPE-181047 -MS COMPUTER

A BRIEF LOOK INTO SYSTEMS 1. 2. 3. 4. Control Loops Concept: Drilling Control System Implementation: Real-Time Data Modeling Implementation: Wired Pipe and DSA 26

1 Control Loops: Flight Trajectory Control Pilot Attitude Needed Servo System Rudder Action Needed Rudder Action Source: SPE-173396 • Automated Slide Drilling System and Multi-Body Dynamics Aided Slide Drilling Simulation • Ningyu Wang

1 Control Loops: Well Trajectory Control Directional Driller Drilling State Needed Servo System Actuator Action Needed Actuator Action Source: SPE-173396 • Automated Slide Drilling System and Multi-Body Dynamics Aided Slide Drilling Simulation • Ningyu Wang

2 Drilling Control System Source: Dashevskiy etal, 2003, AADE-03 -NTCE-10 29

2 Drilling Control System End of training set Source: Dashevskiy etal, 2003, AADE-03 -NTCE-10 30

3 Modeling for DSA Use of mechanical, hydraulic and thermal models, in real-time, to derive “virtual sensor data” Model data and sensor data deviate indicating a problem Model more accurate over time Source: Chmela et al, 2014, SPE 168018 31

3 Modeling for DSA • Example, models predict safe “pull-window” during tripping • Set-points and operational constraints for safe, efficient operations • Staged introduction: monitoring, shadow system, then control Source: Chmela et al, 2014, SPE 168018 32

3 Modeling for DSA • Automated Tripping System Automated System Manual System CSG SHOE DEPTH BITDEPTH Pore Pressure ECD DEPTH (m) CSG SHOE DEPTH BITDEPTH Pore Pressure ECD • System automatically adjusts running speed and acceleration to avoid swab Source: Chmela, etal. 2014, SPE 168018 33

4 Wired pipe and DSA Data Rate: 57 kbps, low latency Surface Equipment Wired Tubulars Network Repeaters Interface to MWD/LWD Source: Pixton and Craig, 2014, IADC/SPE 167965 34

4 Wired pipe and DSA Wired pipe Systems • Drilling shallow gas sands, offshore • MPD with wired pipe and downhole pressure measurements MWD Drill String Telemetry Controller Measurement While Drilling Surface System Dynamic Annular Pressure Control PLC Hydraulic Model Surface Data Logger Source: Fredericks etal, 2008, IADC/SPE 112651 35

4 Wired pipe and DSA Bottom Hole and Casing Shoe Pressure (psi) Bottom Hole Pressure from MWD Connection BHP +/-45 psi Drilling BHP +/-15 psi Connections Source: Fredericks etal, 2008, IADC/SPE 112651 Casing Shoe pressure Backpressure 36

Summary • Drilling Systems Automation (DSA) – The process of creating a borehole with systems and sub-systems, – That are computer controlled, and which – Lead to reduced human intervention • Impact is across the entire organization and drilling process: Drill Bit to Enterprise 37

Conclusions While drilling equipment is highly automated, the drilling system/process is poorly automated. Drilling systems automation is technically challenging, requires a holistic approach, and is rewarding with significant business drivers: Performance, Safety and Cost 38

Further Reading • SPE 166263, “Drilling Systems Automation: Current State, Initiatives and Potential Impact”, SPE ATCE, October 2013 • SPE 173010, “Drilling Systems Automation Roadmap - The Means to Accelerate Adoption”, SPE/IADC Drilling Conference, London, March 2015 39

Drilling Systems Automation Sources of Information connect. spe. org/dsats/home/ connect. spe. org/dsaroadmap/home/ www. iadc. org/dsaroadmap www. iadc. org/advanced-rig-technologycommittee/#access 40

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