Drilling control method and system

• US 9,175,557 B2
• Filed: 03/01/2010
• Issued: 11/03/2015
• Est. Priority Date: 03/02/2009
• Status: Active Grant

• Current Assignee: Sekal AS (Sumitomo Corporation)
• Original Assignee: Drilltronics Rig Systems AS (Sumitomo Corporation)
• Inventors: Cayeux, Eric, Iversen, Fionn
• Primary Examiner(s): Masinick, Michael D
• Application Number:
  US13/254,734
• Publication Number:
  US 20120059521A1
• Time in Patent Office: 2,073 Days
• Field of Search: 700/275, 166/285, 166/272.1, 166/272.6, 166/250.07
• US Class Current: 1/1
• CPC Class Codes: E21B 44/00 Automatic control systems specially adapted for drilling operations, i.e. self-operating systems which function to carry out or modify a drilling operation without intervention of a human operator, e.g. computer-controlled drilling systems; Systems specially adapted for monitoring a plurality of drilling variables or conditions

Abstract

Method and system for drilling control comprising a plurality of controllers adapted to control performance process parameters, on the basis of driller controls from a driller that provides this as instructions to said controllers, wherein the system further comprises sensors and means for obtaining process values, such as downhole pressure, temperature and torque, wherein the system is adapted to, continuously and/or repeatedly, calculate safeguard envelopes for performance process parameters on the basis of process values and drilling process models and that it is adapted to restrain said controllers from applying performance process parameters outside said safeguard envelopes as a result of driller instructions, and—a method and system for automatically triggering a remedying action in case of an evolving or existing critical situation, comprising calculation of process parameter boundaries which represent a critical condition for the well by using calibrated drilling process models, comprising (i) triggering an emergency action if a parameter exceeds said boundaries, said emergency action being intended to minimize the effect of said critical situation, (ii) then further analyzing the well in order to determine which remedying action to then be applied, the remedying action being intended to remedy the cause of said effect; (iii) if said remedying action is not capable of remedying the cause of said effect, then applying predetermined safe process parameters or shutting down.

Claims

1. A drilling control method for automatically triggering a remedying action responsive to an evolving or existing critical condition, the method comprising the steps of:

(i) calculating process parameter boundaries which represent a critical condition for a well by using calibrated drilling process models,

(ii) triggering an emergency action if a process parameter exceeds said process parameter boundaries, said emergency action being intended to minimize the effect of said critical condition,

(iii) then further analyzing the well in order to determine a remedying action to then be applied, the remedying action being intended to remedy the cause of said critical condition, the remedying action being determined dynamically as a function of the response of the well to the remedying action;

(iv) if said remedying action is not capable of remedying the cause of said critical condition, then applying predetermined safe process parameters or shutting down.

2. The drilling control method according to claim 1 where the critical condition is packoff, wherein

(a) packoff is detected based on one or more of rapid build up of pump pressure or steady increase in torque or erratic torque behavior, wherein detection is achieved by comparing predicted values, by using models, to actual behavior;

and

(b) the process parameter boundaries for triggering emergency action with respect to pump pressure and torque behavior are calculated as a function of fluid flowrate, pipe torque and rpm; and

(c) immediate emergency action comprises a predefined %-wise reduction of flowrate; and

(d) if packoff is diagnosed based on one or more of rapid build up of pump pressure or steady increase in torque or erratic torque behavior, automatic shutdown of pumps is performed.

3. The drilling control method according to claim 1 where the critical condition is bridging, wherein

(a) bridging is detected based on one or more of rapid build up of pump pressure or steady increase in torque or erratic torque behavior, wherein detection is achieved by comparing predicted values, by using models, to actual behavior;

and

(b) the process parameter boundaries for triggering emergency action with respect to pump pressure and torque behavior are calculated as a function of fluid flowrate, pipe torque and rpm; and

(c) immediate emergency action comprises a predefined %-wise reduction of flowrate; and

(d) if bridging is diagnosed based on one or more of rapid build up of pump pressure or steady increase in torque or erratic torque behavior, then flowrate is automatically increased to a maximum allowable flowrate as a function of bridge, as defined by remediating algorithms with calculated input parameters.

4. The method as claimed in claim 1, where calculating process parameter boundaries which represent a critical condition for the well uses calibrated drilling process models and current or past process values.

5. The method as claimed in claim 1, further comprising determining the emergency action using calibrated drilling process models and current or past process values.

6. The method as claimed in claim 1, where further analysing the well comprises comparing measured process values with triggering limits for the process values.

7. The method as claimed in claim 1, where determining the remedying action uses the calibrated drilling process models and current or past process values.

8. The method as claimed in claim 1, where determining the remedying action is repeatedly performed during the performance of the remedying action using at least current process values.

9. The method as claimed in claim 1, further comprising:

calculating instructions for machine controllers for controlling drilling operations using the calibrated drilling process models, the instructions for the machine controller defining a process parameter boundary and an emergency action to be taken automatically by the machine controller if a process parameter applied by an operator exceeds said process parameter boundary; and

communicating the calculated instructions to the machine controller.

10. The method as claimed in claim 1, further comprising:

calculating instructions for a machine controller controlling drilling operations using the calibrated drilling process models, the instructions for the machine controller defining a dynamic remedying action to be taken automatically by the machine controller if an emergency action is taken; and

communicating the calculated instructions to the machine controller.

11. The method as claimed in claim 9, wherein the instructions for the machine controllers comprise set points or curves or surfaces for machine controller algorithms implemented directly in the machine controllers.

12. The method as claimed in claim 10, wherein the instructions for the machine controllers comprise set points or curves or surfaces for machine controller algorithms implemented directly in the machine controllers.

13. The method as claimed in claim 1, further comprising:

predicting expected drilling process values on the basis of at least the calibrated drilling process model and past or current process values;

comparing previously predicted expected drilling process values with current process values; and

if current process values deviate outside predetermined allowed deviation values, input remedying instructions to machine controllers in order to provide remedying performance process parameter from said controllers.

14. The method as claimed in claim 13, wherein the instructions for the machine controllers comprise set points or curves or surfaces for machine controller algorithms implemented directly in machine controllers.

15. The method as claimed in claim 1, wherein values and/or parameters used to calibrate the calibrated drilling process models are provided by application of one or more of the following systems:

i) a drilling machinery data acquisition system, which is an integrated part of a machine control system and which is adapted to provide control system values;

ii) a mud logging system; and

iii) a downhole measurement data acquisition system, comprising downhole sensor tools for providing downhole measurements, such as downhole pressure, downhole temperature and survey measurements.

16. A drilling control system, for automatically triggering a remedying action responsive to an evolving or existing critical condition, the system comprising:

a process parameter calculation element operative to calculate process parameter boundaries which represent a critical condition for a well by using calibrated drilling process models,

enforcement elements operative to trigger an emergency action if a process parameter exceeds said process parameter boundaries, said emergency action being intended to minimize the effect of said critical condition,

a remedying action calculation element, operative to analyze the well further in order to determine a remedying action to then be applied, the remedying action being intended to remedy the cause of said critical condition the remedying action being determined dynamically as a function of the response of the well to the remedying action;

wherein the enforcement elements are operative to apply the remedying action and if said remedying action is not capable of remedying the cause of said critical condition, the enforcement elements are operative to apply predetermined safe process parameters or to shut down the well.

17. The drilling control system as claimed in claim 16, wherein the enforcement elements are machine controllers for controlling drilling operations, the machine controllers having machine controller algorithms directly implemented therein, where the behaviour of the machine controller algorithms is uniquely defined through machine controller instructions defining a process parameter boundary and an emergency action to be taken automatically by the machine controller if a process parameter applied by an operator exceeds said process parameter boundary.

18. The drilling control system as claimed in claim 16, wherein the enforcement elements are machine controllers for controlling drilling operations, the machine controllers having machine controller algorithms directly implemented therein, where the behaviour of the machine controller algorithms is uniquely defined through machine controller instructions defining a dynamic remedying action to be taken automatically by the machine controller if an emergency action is taken.

19. The drilling control system as claimed in claim 17, comprising a central database communicating calculated machine controller instructions defining triggering and dynamic remediating action to the machine controllers.

20. The drilling control system as claimed in claim 18, comprising a central database communicating calculated machine controller instructions defining triggering and dynamic remediating action to the machine controllers.

21. A drilling control system for automatically triggering a remedying action responsive to an evolving or existing critical condition, the drilling control system being adapted to apply calibrated drilling process models in calculating acceptable threshold conditions used to determine whether a well has entered a critical condition, wherein, in case a parameter is exceeding the continuously updated conditions for a critical situation, an automatic action is triggered to minimize the effect of the critical situation, wherein this automatic action can adapt itself as a function of the response of the well to the automatic action, and the system comprises

machine controllers adapted to automatically trigger emergency remediating action based on machine controller algorithms implemented directly in the machine controllers;

the machine controllers being arranged to apply a dynamic remediating action based on machine controller algorithms implemented directly in the machine controllers; and

a central database communicating calculated setpoints or curves or surfaces defining emergency remediating action and dynamic remediating action to the machine controllers;

wherein the machine controllers are adapted to continuously compare measured process values with the triggering limits, and wherein, if triggering limits are exceeded then emergency remediating action is automatically triggered; and

wherein after triggering, further remediating control is performed dynamically as a function of response, as defined by the setpoints or curves or surfaces defining appropriate dynamic remediating action.