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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

5
 Levels of Computerization
Ref: Endsley and Kaber, 1999,
Ergonomics, Vol. 42
Functions

Levels Monitor Advise Select/Decide Implement

1 Manual Control H H H H
2 Action Support H C H H H C
3 Batch Processing H C H H C
4 Shared Control H C H C H H C
5 Decision Support H C H C H C
6 Blended Decisions H C H C H C C
7 Rigid System H C C H C
8 Auto Decisions H C H C C C
9 Supervisory Ctrl H C C C C
10 Full Automation C C C C

H Human C - Computer 6
Control Systems on Offshore Rigs
Active Heave
Drawworks

Hydraulic
Dynamic
Systems
Positioning

Power
Thruster Management
Control

BOP Control

Drillship: Pacific Drilling, Pacific Santa Ana 7

 Drilling Systems Automation
The current level of automation in Drilling
Monitor Advise Control Autonomous
L2 L3-L4 L5-L7 L8-L10
Wellsite Drilling Auto-Driller MWD
Monitoring Dynamics Stick-Slip Rotary
Systems Diagnostic Surface Steerable
Remote Systems Control Systems
Data Directional MPD LWD
Centers Drilling Control Formation
Smart Advisors Systems Samplers
Alarms
Surface
Digital 10101011100100110001
MWD
Networks Network

8
Source: Macpherson etal, 2013, SPE 166263
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
Difficult profiles, bottomhole pressure margins
Well Complexity Mitigate risk and control costs

Data Real-time measurements, complex operations

Manage, interpret, act on large volumes of data
Overload

NPT 35 to 40% of deep-water drilling costs

Minimized by responding predictably to events
Significant

Well Drill many similar profile wells per field

Manufacturing Repetitively drill to plan with minimal risk and cost
10
Source: Baker Hughes
 DSA Drivers
Dont exceed Dont exceed make-up
maximum weight torque of the drill
Dont exceed the Difficult
on theprofiles,
bit bottomhole pressure margins
string
Well Complexity Mitigate risk and control costs
maximum RPM of
the bit Drill efficiently
Drill faster
Stay on target
Data Real-time measurements,
Clean complex
the hole operations
Drill this section
Manage, interpret, act on large volumes of data
Overload Avoid lateral without tripping;
vibrations i.e. with one bit
Dont stall the top
driveNPT
35 to 40% of deep-water drilling costs Time is money
Dont exceed the Minimized by responding predictably to events
Significant
maximum RPM of
the top drive
Safety first
Avoid stick-slip Condition
Well vibrations Drill many similarGoprofile back towells
bottom
per field
the hole
Manufacturing Repetitively drill tofast andwith
plan safely
minimal risk and cost
Dont buckle the Connect a new
Dont stall the pipe joint
11 fast
Source: Mark pipe
Anderson, Shell downhole motor and safely
 DSA Drivers
Difficult profiles, bottomhole pressure margins
Well Complexity Mitigate risk and control costs

Data Real-time measurements, complex operations

Manage, interpret, act on large volumes of data
Overload

NPT 35 to 40% of deep-water drilling costs

Minimized by responding predictably to events
Significant

Well Drill many similar profile wells per field

Manufacturing Repetitively drill to plan with minimal risk and cost
12
 DSA Drivers
Difficult profiles, bottomhole pressure margins
Well Complexity Mitigate risk and control costs

Data Real-time measurements, complex operations

Manage, interpret, act on large volumes of data
Overload

NPT 35 to 40% of deep-water drilling costs

Minimized by responding predictably to events
Significant

Well Drill many similar profile wells per field

Manufacturing Repetitively drill to plan with minimal risk and cost

Source: SPE 178875, 2016, Livingston etal, Team Approach to Horizontal Drilling 13
Optimization in the Marcellus Delivers Record Setting Performance
 DSA Drivers
Difficult profiles, bottomhole pressure margins
Well Complexity Mitigate risk and control costs

Data Real-time measurements, complex operations

Manage, interpret, act on large volumes of data
Overload

NPT 35 to 40% of deep-water drilling costs

Minimized by responding predictably to events
Significant

Well Drill many similar profile wells per field

Manufacturing Repetitively drill to plan with minimal risk and cost
14
 DSA Drivers

Expert Operations starved for expertise

Resources Will make available scarce expert resources

Knowledge Skilled employees exiting the industry

Transfer Transfer knowledge from skilled to new employees

Driver is to make the work environment a safer place

HS & E 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
 Technology: DSA is Challenging
Task uncertainty

Necessity of domain expertise in technology enablers

17
Source: UT Austin RAPID Consortium
DSA Decision Making and Control
Framework

Remote
Well Design, Budget, Data Repository,
4 Enterprise Data mining WITSML
& analytics
Non-deterministic
Protocol
Wellsite & Remote Operations
3 Operations Monitoring, Modeling, Simulation

2 Execution
Process Control Systems

Wellsite
Onsite Interpretation
OPC UA & Control
Deterministic
Machine Machine Control Systems
1 Control
Protocol
Instrumentation & Measurement

Well
0 Construction
Physical Drilling Process
No Intelligent Sensing

Modified from ISA 95 for the Drilling Process

18
Source: de Wardt etal, 2015, SPE 173010
 DSATS Rig Control System

Operators,
Service
Companies,
Drilling
Contractors,
Equipment
Suppliers,

rilling ystems utomation echnical ection

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
Well Design, Budget, Data Repository,
4 Enterprise Data mining & analytics Data Mining
Analytics
Wellsite & Remote Operations
3 Operations Subsurface
Monitoring, Modeling, Simulation
Predictions
2 Execution
Process Control Systems
Onsite Interpretation & Control
Swab Surge
Machine Machine Control Systems ROP
1 Control Instrumentation & Measurement
Machine
Well
0 Construction
Physical Drilling Process
No Intelligent Sensing
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
 Systems 1
Architecture

Machines 2 3 Human 8
Communications
Equipment Factors

data telemetry, latency

Simulation & 7

Data Aggregator
4 Completeness
Logic Modeling
Calibration Data, Derived
Sensors Proximity
Data, System Accuracy
& IMS Validity State Conversion 6
Control
Criticality
Systems
Availability
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

ENTERPRISE MODELING
4 Enterprise

3 Operations IN STREAM
ANALYTICS
ACTIVE
ADVISORY
2 Execution

SENSOR VISUALIZATION
1 Machine Control DATA CONTROL

Well
0 Construction REAL-TIME PERFORMANCE

Source: DSATS Luncheon Presentation, 2015, SPE Digital Energy Conference 24

 Data Flow and Value
HUMAN COMPUTER
Level 2: Execution

Level 1: Machine
Control

Level 0:Physical
process

Source: Iversen et al., 2016 SPE-181047-MS

A BRIEF LOOK INTO SYSTEMS

1. Control Loops
2. Concept: Drilling Control System
3. Implementation: Real-Time Data Modeling
4. Implementation: Wired Pipe and DSA

26
 1 Control Loops:
Flight Trajectory Control
Pilot Pilot Servo System

Attitude Rudder Action Rudder

Needed Needed Action
Trajectory Trajectory
We Want Flight We Get
Plane Attitude Rudder
Trajectory Plane
Control Loop Control Loop
Control Loop

Plane Position and Attitude

Source: SPE-173396 Automated Slide Drilling System and Multi-Body
Dynamics Aided Slide Drilling Simulation Ningyu Wang
 1 Control Loops:
Well Trajectory Control
Directional Servo
Driller
Driller System
Drilling State Actuator Action Actuator
Needed Needed Action
Trajectory Trajectory
We Want Well Trajectory Motor and We Get
Drilling State
Actuator Drill String
Control Loop Control Loop
Control Loop

Well Bottom/Bit Position and Attitude

Source: SPE-173396 Automated Slide Drilling System and Multi-Body
Dynamics Aided Slide Drilling Simulation Ningyu Wang
2
Drilling Control System

Rd(t)
Ad(tmd- d) drilling
C(t) Drilling downhole responses
delayed equipment controls Process Rs(t)
action
surface downhole
response measurement
s
E(t) H surface
tools Rd(td)
Driller
MWD
Cdcs(tm) Rs (ts) telemetry

command Drilling decimated surface

responses
Control
Adcs(tm) System Rd(tT-T)
advice decimated and delayed
downhole responses

Source: Dashevskiy etal, 2003, AADE-03-NTCE-10 29

2
Drilling Control System
ROP (ft/hr)
240

180

120

60

time (min)

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
Manual System Automated System
CSG SHOE DEPTH CSG SHOE DEPTH

DEPTH (m)
DEPTH (m)

BITDEPTH BITDEPTH
Pore Pore
Pressure Pressure

ECD 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: 57kbps, 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
Drilling shallow gas sands, offshore
MPD with wired pipe and downhole pressure measurements

Dynamic Annular
Drill String Pressure Control
Wired pipe Systems

Telemetry
Hydraulic
Controller PLC Model

Measurement
While Drilling Surface Data Logger
Surface System

MWD Source: Fredericks etal, 2008, IADC/SPE 112651 35

 4
Wired pipe and DSA

Bottom Hole Connection

Pressure from MWD BHP +/-45psi
Bottom Hole and Casing Shoe Pressure (psi)

Drilling
BHP +/-15psi

Connections

Casing Shoe pressure

Backpressure

36
Source: Fredericks etal, 2008, IADC/SPE 112651
 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-technology-
committee/#access

40
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