Automated drilling system

• US 9,593,567 B2
• Filed: 11/30/2012
• Issued: 03/14/2017
• Est. Priority Date: 12/01/2011
• Status: Active Grant

• Current Assignee: National Oilwell Varco LP (NOV, Inc.)
• Original Assignee: National Oilwell Varco LP (NOV, Inc.)
• Inventors: Pink, Tony, Reid, David, Bruce, Andrew
• Primary Examiner(s): Gay, Jennifer H
• Application Number:
  US14/361,198
• Publication Number:
  US 20140353033A1
• Time in Patent Office: 1,565 Days
• 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
• CPC Class Codes: E21B 44/02 Automatic control of the tool feed E21B44/005, E21B44/10 take precedence

Abstract

A drilling system comprises a drilling parameter sensor in communication with a sensor application 22 that generates processed data from raw data that is received from the drilling parameter sensor. A process application 24 is in communication with the sensor application 22 and generates an instruction based on the processed data. A priority controller is in communication with the process application 24 and evaluates the instruction for release to an equipment controller 14 that then issues the instruction to one or more drilling components.

Claims

1. A drilling system comprising:

a plurality of drilling parameter sensors;

a plurality of sensor applications, wherein each of the plurality of sensor applications is in communication with at least one of the plurality of drilling parameter sensors and is operable to generate processed data from raw data that is received from the at least one of the plurality of drilling parameter sensors, wherein a first one of the plurality of sensor applications computes a mechanical specific energy, and wherein a second one of the plurality of sensor applications computes a dynamic movement of the drill string;

a plurality of process applications, wherein each of the plurality of process applications are in communication with at least one of the plurality of sensor applications and is operable to generate an instruction based on the processed data generated by the at least one of the plurality of sensor applications, wherein each one of the process applications generates an instruction to change surface weight on bit and an instruction to change surface torque;

a priority controller in communication with the plurality of process applications and operable to evaluate the instructions for release, wherein the priority controller assesses priority of the instructions based on a priority plan that at least includes, in this order, avoiding collapse or fracture of the well, formation target accuracy, rate of penetration, and quality of well, and wherein the priority controller determines whether the instructions can be released based on the assessed priority; and

an equipment controller in communication with the priority controller and operable to issue the instructions to one or more drilling components when the instructions are released by the priority controller.

2. The system of claim 1, further comprising a network interface operable to control data transmission between the plurality of drilling parameter sensors, the plurality of process applications, and the plurality of sensor applications.

3. The system of claim 2, further comprising data storage coupled to the network interface.

4. The system of claim 1, further comprising a simulator interface operable to receive instructions from the priority controller.

5. The system of claim 1, further comprising a control station coupled to the equipment controller and operable to display the status of one or more drilling components.

6. The system of claim 1, wherein at least one of the plurality of process applications is operable to generate an instruction based on processed data generated by more than one of the plurality of sensor applications.

7. The system of claim 1, wherein at least one of the plurality of drilling parameter sensor is a downhole sensor.

8. The system of claim 1, wherein at least one of the plurality of drilling parameter sensors is a rig-mounted sensor.

9. A method of controlling a drilling process comprising:

collecting data using a plurality of drilling parameter sensors;

transmitting the data to a control system including a plurality of sensor applications and a plurality of process applications;

processing the data using at least one of the plurality of sensor applications to provide a representation of a drilling parameter;

generating an instruction by analyzing the representation of a drilling parameter using at least one of the plurality of process applications;

evaluating the instruction with a priority controller to determine if the instruction can be released based on a priority plan that includes, in this order, avoiding collapse or fracture of the well, formation target accuracy, rate of penetration, and quality of well; and

transmitting the instruction to one or more drilling components when the instruction is released by the priority controller.

10. The method of claim 9, further comprising transmitting additional data to the control system from a network interface.

11. The method of claim 10, further comprising coupling data storage to the network interface.

12. The method of claim 9, further comprising transmitting the instruction to a simulator interface.

13. The method of claim 9, further comprising displaying a status of one or more drilling components on a control station.

14. The method of claim 9, whereby the priority controller is operable to evaluate a plurality of instructions issued by the plurality of process applications.

15. The method of claim 9, wherein at least one of the plurality of drilling parameter sensors is a downhole sensor.

16. The method of claim 9, wherein at least one of the plurality of drilling parameter sensor is a rig-mounted sensor.

17. A drilling control system comprising:

a plurality of sensor applications operable to generate processed drilling data from raw drilling data that is received from one or more sensors, wherein a first one of the plurality of sensor applications computes a mechanical specific energy, and wherein a second one of the plurality of sensor applications computes a downhole pressure;

a plurality of process applications operable to generate operating instructions based on the processed drilling data that is generated by the plurality of sensor applications, wherein a first one of the process applications generates an instruction to change a mud motor pressure, and wherein a second one of the process applications generates an instruction to change a pump pressure;

a priority controller operable to evaluate and selectively release the operating instructions, wherein the priority controller assesses a priority of the instructions based on a priority plan that at least includes, in this order, avoiding collapse or fracture of the well, formation target accuracy, rate of penetration, and quality of well, and wherein the priority controller determines whether the instructions can be released based on the assessed priority; and

a plurality of equipment controllers operable to receive operating instructions that have been released by the priority controller and issue released operating instructions to one or more drilling components.

18. The system of claim 17, further comprising a control station operable to display the status of one or more drilling components.

19. The system of claim 17, wherein the one or more sensors comprises a downhole sensor.

20. The system of claim 17, wherein the one or more sensors comprises a rig-mounted sensor.