Systems and methods for automatic drilling of wellbores

Abstract

The invention provides a system for automatic control of the drilling an oil well. The system includes an autodrilling interface enabling parameter input data to be input and enabling the display of system output data, a controller, a hydraulic control system and at least one sensor configured to the hydraulic control system. The controller receives parameter input data from the autodrilling interface and at least one sensor and provides output instructions to the hydraulic control system such that the hydraulic control system operates to control drilling based on controller instructions and sensor data.

Claims

1. An autodrilling system for a drilling rig with a hydraulic cylinder-driven hoist system having at least one hydraulic cylinder, the autodrilling system comprising: an autodrilling interface having an input system configured for input of drilling parameter settings including rate of penetration (ROP), weight on bit (WOB) and differential pressure (DP) of drilling fluid across a drill bit, and a display system enabling display of system output data during drilling; a controller operatively connected to the autodrilling interface; a hydraulic cylinder control system for raising and lowering a rotary drill string, the hydraulic cylinder control system operatively connected to the controller, the hydraulic cylinder and a mud pump; any one of or a combination of a blind end pressure sensor and a rod end pressure sensor operatively connected to the hydraulic control system for measuring the hydraulic pressure within the hydraulic cylinder; and a combination of sensors for calculation of differential mud pressure upstream and downstream of a mud motor; wherein the controller is configured to compare one or more of the drilling parameter settings with one or more of the current ROP, WOB and DP and to provide output instructions to the hydraulic cylinder control system to automatically control drilling by adjusting the function of the hydraulic cylinder and the mud pump to adjust one or more of the current ROP, WOB and DP to maintain the drilling parameter settings.

2. A system as in claim 1 wherein the autodrilling interface is a touchscreen having at least one input area enabling input data to be input and at least one display areas displaying output data.

3. A system as in claim 1 wherein the input system enables user activation of one or more drilling modes where a drilling mode includes pre-set drilling parameters.

4. A system as in claim 1 wherein the sensors include a position sensor operatively connected to the hydraulic control system for measuring the relative position of a hydraulic control cylinder of the rig drilling equipment.

5. A system as in claim 1 further comprising a manual control interface operatively connected to the controller enabling manual control of the hydraulic control system.

6. A method for the automated drilling of an oil or gas well with well drilling equipment, the well drilling equipment having a hydraulic cylinder control system for raising and lowering a rotary drill string, a drilling fluid pump for circulating drilling fluid within the well and a plurality of sensors configured to measure hydraulic cylinder pressure data and drilling fluid pressure data and transmit the pressure data to the controller for calculation of current weight rate of penetration (ROP), weight on bit (WOB) and differential pressure (DP), a controller and an autodrilling interface, wherein after manually setting at least one ROP, WOB or DP as one or more drilling parameters on the autodrilling interface and initiating drilling, the method comprises the steps of: a. monitoring and measuring current ROP, WOB and DP; b. increasing downhole hydraulic force if the WOB is below a set WOB value and decreasing downhole hydraulic force if the WOB is higher that a set WOB value; c. increasing the rate of lowering of the drillstring if the ROP is below a set ROP value and decreasing the rate of lower of the drillstring if the ROP is above a set ROP value; and/or d. increasing downhole hydraulic force if DP is lower than a set DP value and decreasing downhole hydraulic force if DP is higher than a set DP value.

7. A method as in claim 6 wherein one of WOB, ROP or DP is set as a primary drilling parameter, the method further comprising the step of dynamically adjusting the primary parameter to one of WOB, ROP or DP not set as the primary drilling parameter during drilling if the primary drilling parameter cannot be maintained during drilling, thereby automatically adjusting the control system to achieve the set ROP value, the set WOB value or the set DP value.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The invention is described with reference to the accompanying figures in which:

(2) FIGS. 1 and 1A are schematic diagrams of drilling equipment utilized in accordance with the prior art;

(3) FIG. 1B is a schematic diagram of a top drive drilling rig utilizing the automatic drilling system in accordance with the invention;

(4) FIG. 2 is a generalized schematic overview of the hydraulic control system in accordance with one embodiment of the invention;

(5) FIG. 2A is a schematic overview of the electronic control system and sensors in accordance with one embodiment of the invention;

(6) FIG. 3 is a representation of a human machine interface (HMI) in accordance with one embodiment of the invention;

(7) FIG. 4 is a representative process flow diagram in accordance with one embodiment of the invention; and,

(8) FIG. 5 is a representative flow chart detailing the logic of the primary functions of the hydraulic control system in accordance with one embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION

(9) With reference to the figures, systems and methods for automatically drilling oil wells are described. Importantly, the systems and methods described herein improve the efficiency of drilling as well as worker safety through the automation of parts of the drilling process.

(10) Typical drilling equipment is shown in FIGS. 1 and 1A. As shown, a typical drilling rig (FIG. 1) includes a derrick 14 for supporting the drilling equipment. The derrick is supported on a rig floor 17, 21 which also supports a stand 16 of drill pipe secured with a monkey board 15. As drilling progresses, drill pipe 16 is manoeuvred into position over the well bore and connected to the downhole drillstring 25 and thereafter rotated to effect movement of the drillbit 26 against the formation rock. During drilling, drilling fluid is pumped by mud pump 4 from mud tank 1 through suction line 3, vibrating hose 6, standpipe 8, Kelly hose 9 and gooseneck 10 to the top of the drillstring. The drilling fluid is pumped downwardly through the drillstring through drillbit 26 where it returns to surface within the annulus between the formation and drillstring. Upon returning to the surface, drilling fluid passes through a bell nipple 22 and flow line 28 where it is then passed over a shale shaker 2 that separates drilling fluid from drill cuttings.

(11) Drill pipe is manoeuvred from the pipe stand by a travelling block 11, drill line 12, crown block 13 under the operation of drawworks 7 which is also used to both lift and lower the drillstring within the well bore. Drillpipe is secured to the drawworks by swivel 18 (or top works). A kelly drive 19 provides rotary force to the drillstring above rotary table 20.

(12) In more modern systems, as shown in FIG. 1A a top drive system 30 is used to provide rotational force to the drillstring from the top of the drillstring. The top drive system is raised and lowered by a drawworks 7 on a substructure 32 through travelling block 11.

(13) In each system, motors 5 provide power to the drawworks, mud pumps and drive systems. Wells also include blowout preventors (BOP) 23, 24 above casing head 27 as known.

(14) In still other systems, drawworks lifting/lowering systems on the drilling rig are replaced with hydraulic hoist systems 40 with hydraulic cylinders 40a that control and manage lifting and lowering of the drillstring during drilling as shown in FIG. 1B. These systems generally include a mast 33, top drive 30, travelling crown 34, chain 36, and chain anchor 38 that collectively operate to enable drilling. In these systems, the mast 33 can be lighter than a conventional derrick as the mast is primarily used to guide the top drive 20. In addition, the rig is generally more compact as there is no drawworks behind the mast. Importantly, hydraulic hoist systems allow downhole pressures to be applied to the drillstring and/or the drill bit. In these systems, hoisting tonnage of the rig is transmitted through the base of the hydraulic cylinders and through the substructure 32. The ability to push downhole is particularly important in deviated or horizontal wells.

(15) In accordance with the invention, systems and methods are provided to enable automatic drilling and more specifically to systems that electronically monitor and adjust hydraulic pressures in the hoist system of FIG. 1B, to monitor drillstring position, to monitor and control drilling fluid pump pressures and to otherwise control drillstring movement. Control of the hydraulic hoist system is based on sensor readings obtained at different locations in the drilling equipment and drilling fluid/mud pressures are measured at surface on the interior and annular sides of the drillstring.

(16) In more specific embodiments, the technology provides a computer-controlled drilling system that obtains sensor input to determine operating parameters including weight on bit (WOB), rate of penetration (ROP) and/or differential mud pressure (DP), that automatically adjust hydraulic pressures in the hoist system to control drillstring movement, and drill bit rotation and adjust these parameters to optimize drilling performance. In these embodiments, the technology allows continuous monitoring and dynamic control over WOB, ROP and DP which overcomes the problem of an operator having to monitor and respond to multiple dynamic inputs from the drilling process.

(17) Autodrilling System

(18) The autodrilling system generally consists of five subsystems as shown in FIG. 2 including a human-machine interface (HMI) or autodrilling interface 50, manual control interface 51, a controller 52 (such as a programmable logic controller (PLC), single board computer (SBC) or the like), hydraulic control system 54 and hydraulic hoist system 56. The manual control interface 51 enables basic manual control of the drilling system. The autodrilling interface 50 enables operator input to the system and displays system output information to the operator to enable autodrilling to be set up and to be controlled. The controller 52 receives and interprets operator input from either the autodrilling interface 50 or manual control interface 51 and provides output to the hydraulic control system 54 that in turn controls the operation of the hydraulic hoist system 56. Various sensors including a blind end pressure sensor 56a, rod end pressure sensor 56b, position encoder 56c and mud pressure sensors 56d are configured to the system to provide feedback to the controller and autodrilling interface for the control of the system hydraulics and for display and input to/by an operator.

(19) FIG. 2A shows a more detailed layout of the system components in accordance with one embodiment. As shown, the autodrilling interface 50 is connected to the controller 52 which in turn is connected to a manual control interface 51 (or rig control panel) that would normally be present within a driller's control cabin 53. The controller is connected to a servo valve system 55 that controls the flow of hydraulic fluid within the hydraulics system and receives input from the various sensors for display on the autodrilling interface and/or display on the rig control panel. The servo valve system 55 is connected to the hydraulic hoisting system 56, a mast sheave system 59 and a mud pump system 61.

(20) Typical sensors within the hydraulic hoisting system 56, mast sheave system 59 and mud pump system 61 include oil supply pressure 56f, cylinder blind end pressure 56a, cylinder rod pressure 56b, Pilot Operated check 56g, and cylinder hydraulic proportional control 56e sensors. The mud pump system 61 will typically include at least one mud pump pressure 56d sensor within the drillstring and the mast sheave will typically include a cylinder position 56c sensor. Collectively, the sensors provide feedback to the controller 52 for interpretation and to allow the controller to control system hydraulics to enable automatic drilling control. In addition, the controller will interpret the values obtained from each sensor and produce an alarm signal to the autodrilling interface and rig control panel in the event of a threshold event. For example, the oil pressure sensor 56f monitors the oil pressure in the hydraulic oil system. In the event that the PLC detects an oil pressure drop below a threshold value, the controller will produce an alarm signal to the autodrilling interface and rig control panel to signal the need for operator input. Preferably, the alarm signal is both a visual signal, such as a pop-up window on the autodrilling interface, and an audible signal.

(21) Autodrilling Interface/HMI

(22) In one embodiment, the autodrilling interface/HMI 50 is a touchscreen as shown in FIG. 3. The HMI generally allows the operator to set operational parameters to enable operation of the system as well as providing visual output to the operator regarding the operation and performance of the system. As shown, the autodrilling interface enables the operator to set parameters including weight on bit (WOB) 50a, rate of penetration (ROP) 50b and differential pressure (DP) 50c. For each parameter, a manually input set point can be entered with a further display of the actual or current measured value during autodrilling. In addition, the autodrilling interface may also provide visual output as to whether or not a particular parameter is enabled or not.

(23) In operation, and as explained in greater detail below, for the primary function of enabling automatic drilling, the operator may enter a set point for one or more of the parameters and thereafter enable drilling. Thereafter, as automatic drilling is commenced, the controller will monitor feedback from the sensors and make adjustments to the hydraulic control systems to maintain drilling at the set points.

(24) In addition, within the system, there are preferably multiple modes of operation. In each mode, values (or ranges) for the one or more of the parameters can be set and the system will seek to control drilling such that drilling progresses within the set ranges. Each parameter can be set as a primary parameter, with the remaining parameters not set or set as secondary or tertiary parameters. Thus, with the three parameters, 13 modes of operation are possible based on the various possible combinations of the parameters wherein one of the parameters is always a primary parameter and the secondary and tertiary parameters are optional.

(25) TABLE-US-00001 TABLE 1 Possible Parameter Combinations Primary Secondary Tertiary WOB ROP DP WOB ROP WOB DP ROP WOB ROP DP WOB ROP DP WOB DP ROP ROP WOB DP ROP DP WOB DP ROP WOB DP WOB ROP

(26) Generally, only one parameter will control the drilling sequence at a given time. If the operator wishes the control system to ignore a parameter, then the parameter can be set as “disabled” and thereby be displayed as a disabled parameter on the main screen. In the event that the set parameter has a malfunction, such as a feedback sensor failing, then the system will stop and hold the load. The operator may then disable the parameter and allow control either manually or through other working control routines.

(27) The autodrilling interface also allows operator input to provide manual control of the system to prepare the drilling equipment for autodrilling. Such input includes the ability to raise or lower the drill string, set the pump pressure or stopping all operations. In addition, other parameters may be displayed back to the operator including for example, pump pressure, hook load and/or top drive height.

(28) Operation

(29) With reference to FIGS. 4 and 4A, the system is generally operated as follows:

(30) Initially, the operator will enable “Drill Mode” on the autodrilling interface. The operator will enter desired alarm and warning settings as well as set the drill parameters. After the desired settings and parameters have been entered, the operator will enable the autodrilling system which will then perform a sensor check to ensure the system sensors are operating properly. If the sensor check is ok, the hydraulic system will be activated for drilling. If the sensor check returns an error, an alarm signal will be presented to the operator.

(31) Once the operator has received verification that the hydraulic system has been activated, the operator will be prompted to start autodrilling.

(32) In one embodiment, the autodrilling process will start by prompting the operator to lift the drillstring off bottom. In this case, using the lift buttons on the autodrilling interface, the operator will lift the drillstring off the bottom.

(33) Alternatively, the autodrilling interface will automatically lift the drillstring off bottom after actuation of the hydraulic system. Automatic lifting may be achieved by the system measuring the current hookload, initiating lifting and monitoring the hookload and/or rate of change of hookload.

(34) In the manual case, the autodrilling interface will then prompt the operator to confirm that the drillstring is off bottom. If the drillstring is confirmed as being off bottom, the system will measure the hookload and the mud pump pressure while off bottom as baseline values. Alternatively, the autodrilling interface will give the operator the option of manually entering the hookload and/or stringweight. The system will then begin to lower the drillstring towards the bottom in a controlled manner based on the ROP settings, if activated, or at a fixed rate.

(35) As the WOB increases as a result of contacting the bottom, the system will operate to drill within the set parameters. While drilling is underway, when a parameter value is reached, that value will be capped. For example, for a given set WOB value, the system will continue to lower the drillstring such that the measured WOB will be less than the set value. If ROP is set as well, the system will be simultaneously measuring the WOB and ROP values. If the WOB maximum value is reached and the ROP value is not reached, the WOB value will be maintained but not exceeded.

(36) Similarly, in the event that the ROP value is reached, for example if drilling through a soft formation, the system will hold the ROP value but allow the WOB value to drop. If drilling conditions change, and the ROP value is not being met the WOB will increase. If the system cannot maintain these conditions during the course of the drilling sequence the system will notify the operator and new weight on bit, rate of penetration, and differential pressure settings may need to be entered. Generally, the system will operate to ensure that drilling progresses smoothly.

(37) During drilling, the system will normally be able to provide hands-off control while the system may be encountering dynamic changes in the drilling conditions such as changes in formation conditions. However, for safety reasons, the system will shut-down if as a maximum value is reached, the system cannot maintain the parameter in question below the set value.

(38) In addition, autodrilling will stop if any shutdown input is received from another source, such as an emergency shutdown input, control cabin manual input (e.g. joystick movement), a major rig shutdown event and/or a self-diagnostic alarm that may be generated from within the autodrilling system. In the event that a shutdown event does occur, the autodrilling process can be re-initiated as described above. Alternatively, the autodrilling process can be continued from where it stopped drilling without having to re-initiate the drilling process from the start.

(39) The autodrilling system also includes a floor saver system to provide appropriate feedback to the driller regarding the position of the travelling assembly. That is, as the travelling assembly reaches various levels during drilling, warnings are provided to the operator to indicate that different levels have been reached. Higher warning levels may be manually set depending on the particular dimensions of a specific rig but all will generally include a hard shut-off system at the lowest level to prevent damage to rig surface equipment. Upon completion of drilling with the current section of drill string, the operator can either use the autodrilling interface or the manual drill rig controls to lift the top drive in preparation for the next section of drillstring.

(40) A representative flow chart of the decision making processes of the autodrilling system is shown in FIG. 5 for the different parameters if set.

(41) As shown, if ROP is set and autodrilling has commenced, the system will measure the current ROP. If the ROP is less than the set ROP, ROP may be increased by releasing hydraulic fluid from the lower chamber of the rig's hydraulic cylinders such that the WOB is increased. In the case of a horizontal or deviated well this may also require an increase in hydraulic pressure at the top of the hydraulic cylinders. The system will then re-measure the current ROP and the loop will repeat. If the ROP is not less than the set ROP and no alarm condition exists, the system will increase or hold hydraulic fluid pressure within the lower chamber of the rig's hydraulic cylinders.

(42) Similar routines are followed for set WOB and DP as shown in FIG. 5.

(43) Differential Pressure

(44) In the context of the technology, differential pressure (DP) is the measured difference in drilling mud pressure before loading and after the drill bit has contacted the formation face, and variations in the differential pressure are indicative of a change in the downhole conditions, such as a harder formation. This change is registered by sensors at surface that relay this information to the controller which then calculates the optimum rate at which to drill.

(45) Generally, if the measured DP value increases, indicating that flow of drilling fluid through the drill bit is more difficult (i.e. reduced), possibly due to a harder formation, the system may decrease or hold the WOB to allow the formation to be drilled and thereby increase drilling fluid flow rates through the bit. If the DP value decreases indicating rapid flow through the drill bit, the WOB may be increased.

(46) Other System Features

(47) Other features of the system may include the ability to work in multiple modes simultaneously. In this embodiment, the system will monitor the different drilling parameters namely two or more of WOB, DP and ROP as drilling is progressing. If one of the set points of one of the drilling parameters is reached, that one drilling parameter becomes the controlling parameter wherein the other parameters will be varied to maintain the controlling parameter at its set point. Thus, if under drilling conditions, the controlling parameter cannot be maintained, then the controlling parameter may then dynamically change.

(48) For example, WOB and ROP may be enabled. WOB is set at 10,000 daN and ROP is set at 100 meters/hour. Initially, the drill bit is working in hard material and the controlling WOB of 10,000 daN is obtained but the ROP is only 50 m/hour. Thereafter, the drill bit encounters a softer formation and with a 10,000 daN WOB, the ROP increases to 100 m/hour. In this case, the ROP will be automatically held at 100 m/hour and the WOB would be reduced or held to ensure the ROP is not exceeded.

(49) In another example, each of WOB, ROP and DP may be enabled. WOB is set at 10,000 daN, ROP is set at 100 meters/hour and DP is set at 1100 psi. In a hard formation, the WOB may be reached but, as above, the ROP is not reached and the DP is only 1050 psi. In this case, the system may then increase the WOB to increase the DP value in an attempt to increase the ROP.

(50) In a horizontal or deviated formation, WOB may not be able to be set or measured accurately and thus, the operator may choose to engage DP as the primary drilling parameter.

(51) In addition, the system may also have the ability to change values while active, set alarm condition ranges and the ability to save parameter combinations as preferred drill modes.

(52) For example, the system will allow different drilling modes to be created that may be designed or set by the operator. For example, drilling modes such as “lateral rotate”, “lateral slide”, “build rotate”, “build slide”, etc. may be created and saved by the operator. Each of these drilling modes may be created based on an operator's experience in a given type of formation.

(53) With respect to the alarm system, for each parameter, the alarm system may include/require the ability to set any one of or a combination of maximum values, an alarm value, a warning value, a set point and/or a minimum value. Such alarm conditions may be set and saved for each drill mode. The system may also include maximum or minimum parameters that cannot be overridden by the operator for safety reasons.

(54) The system may include a modem interface to enable all data from the system to be returned to a central server.

(55) As known to those skilled in the art, the system may also include the ability to set scaling parameters for different sensors to enable appropriate calibration. Similarly, the floor saver values may be set from within the autodriller system.

(56) Although the present invention has been described and illustrated with respect to preferred embodiments and preferred uses thereof, it is not to be so limited since modifications and changes can be made therein which are within the full, intended scope of the invention as understood by those skilled in the art.