Advanced Drilling Simulation Environment for Testing New Drilling Automation Techniques

Abstract

Newly developed drilling automation systems locate a computer interface between commands issued by the driller and instructions transmitted to the drilling machinery. Such functions are capable of faster and more precise control than achieved by an unaided operator and thus can help drilling within narrow margins. To ensure that these systems work properly in all circumstances, an advanced drilling simulator has been developed to enable testing under a wide range of simulated conditions.The environment described in this paper uses hardware in the loop simulation to verify that the automation techniques being tested respond correctly in real-time. Rigorously validated physical models of the drilling process simulate the response of the well to the commands given to the drilling machines. Abnormal drilling conditions (pack-offs, kicks, etc.), and equipment or machine related problems (plugged nozzles, power shortage, etc.) are convincingly recreated.The drilling simulator models the behavior of surface equipment like the activation of gate valves to line up different pits or the flow in the mud return. It simulates changes in the drilling fluid properties when mixing additives to the mud. It is therefore possible to focus training sessions on cooperation between different groups at the wellsite. This is particularly useful when planning the introduction of drilling automation that involves new work procedures as a result of automation and adaptation of the drilling team to a new operational environment.Drilling operations are becoming more and more complex. Automation has the potential to provide large improvements in efficiency and safety, but automation technologies must be implemented correctly at the workplace. In the same way as the aviation industry has utilized simulated environments for decades, drilling simulation environments are the key to the safe and successful implementation of drilling automation and the development of crew skills to face future challenges.

Drilling Automation: Potential for Human Error

“…The tests were performed with a rig simulator and support center together in test facilities built to conduct such testing (Cayeux et al 2012a, b). The integrated automation system was configured differently for the various test cases, providing variations in both type and degree of automation.…”

“…The test environment, described by Cayeux et al (2012a), contains a virtual drilling rig (Fig. 1), with drilling control stations connected to programmable-logic controllers (PLCs) simulating drilling-machinery response.…”