NO20191412A1

NO20191412A1 - Drilling systems and methods

Info

Publication number: NO20191412A1
Application number: NO20191412A
Authority: NO
Inventors: Søren Øydna; Kim André Evensen
Original assignee: Mhwirth As
Priority date: 2018-11-29
Filing date: 2019-11-28
Publication date: 2020-06-01
Also published as: GB2579366B8; GB201819435D0; GB2579366A8; GB2579366A; GB2579366B

Description

DRILLING SYSTEMS AND METHODS

The present invention relates to drilling systems and methods, including but not limited to systems and methods for operating offshore drilling rigs and associated equipment.

BACKGROUND

In drilling operations, such as offshore petroleum exploration, various operations are usually carried out by highly specialized vessels or rigs. The operation of such vessels or rigs can be very costly and make up a substantial part of the cost of a well. Due to the high cost, operational efficiency and reliability during these processes is of great importance.

Moreover, as regulatory requirements become ever-more stringent, while for example petroleum exploration takes place in more challenging areas (such as deepwater fields or arctic areas), safety is also a key issue among most stakeholders in the relevant industries. For example, controlling the relevant process variables within certain margins is crucial in petroleum drilling operations in order to maintain the stability of the formation, avoid loss of drilling fluid (commonly known as mud), and avoiding uncontrolled influx of reservoir fluids into the wellbore.

Documents which may be useful for understanding the background include US 8,397,837; WO 2010/101473; WO 2018/203753, and WO 2013/082498.

There is consequently a continuous need for improved systems and techniques for operating drilling plants efficiently, while maintaining a high level of safety. The present invention has the objective to provide drilling systems and methods which can realise advantages over known solutions and techniques in the abovementioned or other areas.

SUMMARY

According to a first aspect of the invention we provide a drilling system comprising a drilling parameter sensor, a drilling automation module which receives data from the drilling parameter sensor and uses this to generate an operating command, an equipment controller which is operable, on receipt of an operating command, to control the operation of an item of drilling equipment, a process controller which is in communication with the drilling parameter sensor, the drilling automation module and the equipment controller, wherein the process controller comprises a verification application which is operable to verify the integrity of an instruction signal received from the drilling automation module, and to allow the instruction signal to be transmitted to the equipment controller if it determines that the integrity of the instruction signal meets a required standard.

The verification application may carry out one or more of the following checks:

a) that the operating command is in the correct format,

b) where it includes a value, that the operating command includes a value in a pre-determined range,

c) that the operating command does not include conflicting or mutually opposed instructions,

d) that the operating command consists of a valid sequence of signals, e) that the operating command was transmitted via a communication link of adequate quality,

f) that the operating command contains instructions to an equipment controller to which the process controller has access,

g) is issued by a drilling automation module which is approved to issue instructions to the equipment controller(s).

If the verification application determines that the drilling automation module, or the communication link by which the drilling automation module is connected to the process controller, is faulty, the process controller may block communication between the drilling automation module and the equipment controller.

If the verification application determines that the drilling automation module, or the communication link by which the drilling automation module is connected to the process controller, is faulty, the process controller may issue a warning signal to an operator.

The drilling system may also include a user interface which includes a display apparatus and an input apparatus, and is in bidirectional communication with the process controller, so that the process controller may send information to the user interface for display, and also receive commands, or data from the user interface.

The user interface may be operable by a user to create and send to the process controller, a user generated operating command, the process controller being programmed to relay the user generated operating command to the equipment controller, the user generated operating command overriding an operating command relayed from the drilling automation module.

The drilling system may comprise a plurality of equipment controllers each of which is in communication with the process controller, and programmed, on receipt of an operating command, to control the operation of an item of drilling equipment.

The drilling system includes an anti-collision processor which is in communication with the process controller, and uses information received from the process controller to generate operating commands for the equipment controller or equipment controllers, said operating commands being created in order to prevent collision between drilling equipment, people, pipes and stationary objects on the drilling rig.

The drilling system may comprise a plurality of drilling automation modules.

The process controller is programmed to control the access of the drilling automation modules to the equipment controller or equipment controllers so that before an operating command generated by one of the drilling automation modules is relayed to an equipment controller, the process controller must grant the drilling automation module access to the relevant equipment controller.

The process controller may be programmed to grant a second drilling automation module to access an equipment controller only if access to that equipment controller has not already been granted to a first automation module, or if access to that equipment controller has already been granted to a first automation module, but the second drilling automation module issues a high priority request for access to the equipment controller.

The process controller may comprise a functions application, in which is stored a plurality of pre-set functions, which may be accessed by the or a drilling automation modules, and forwarded to the relevant equipment controller or controllers.

The functions application may be programmed to translate an operating command from a drilling automation module into a series of the pre-set functions, or to insert additional information from the operating command into one of the pre-set functions, before forwarding the operating command to the required equipment controller in the form of one or more of these pre-set functions.

The process controller may also be configured to use the functions application to forward a user generated operating command to the or an equipment controller in the same way.

The verification application may communicate with the functions application to notify the functions application if it has determined that there is a problem with an operating command from the or any of the drilling automation module(s), the functions application being programmed to not forward operating commands from the drilling automation module concerned to the equipment controller or any of the equipment controllers.

The process controller may further include a limitations application which forwards limitations from the drilling automation modules to the or any relevant equipment controller, the limitations setting a window in which an item of drilling equipment connected to the equipment controller should operate.

The limitations application may be programmed such that if multiple limitations have been set for the same item of drilling equipment by different drilling automation modules, the strictest limitations will be applied.

The verification application may communicate with the limitations application to notify the limitations application if it has determined that there is a problem with an operating command from the drilling automation module or any of the drilling automation modules, the limitations application being programmed not to forward limitations from the drilling automation module concerned to the equipment controller or any of the equipment controllers.

The limitations application may also be programmed send an instruction to an equipment controller to remove any limitations set by an automation module found by the verification application to be faulty.

The process controller may also include an information application which stores information it receives from the drilling parameter sensor, the or each equipment controller, and the or each drilling automation module, and, where necessary, forward this information to the or one or more of the equipment controller(s) and / or drilling automation module(s).

The drilling system may also include a simulation application which is programmed to simulate the drilling system one or more of the items of drilling equipment so that the effect on the drilling system of an equipment controller acting on particular operating command can be tested virtually before said operating command is released to the equipment controller.

According to a second aspect of the invention we provide a drilling system comprising a drilling parameter sensor, a drilling automation module which receives data from the drilling parameter sensor and uses this to generate an operating command, an equipment controller which is operable, on receipt of an operating command, to control the operation of an item of drilling equipment, a process controller which is in communication with the drilling parameter sensor, the drilling automation module and the equipment controller, wherein the process controller comprises a functions application, in which is stored a plurality of pre-set functions, which may be accessed by the drilling automation modules and used to create an operating command for the process controller to relay to the equipment controller.

The functions application may be programmed to translate an operating command from a drilling automation module into a series of the pre-set functions, or to insert additional information from the operating command into one of the pre-set functions, before forwarding the operating command to the equipment controller in the form of one or more of these pre-set functions.

The process controller may also be configured to use the functions application to forward a user generated operating command to the equipment controller.

The functions application may be programmed to translate a user generated operating command into a series of the pre-set functions, or to insert additional information from the user generated operating command into one of the pre-set functions, before forwarding the user generated operating command to the equipment controller in the form of one or more of these pre-set functions.

The process controller may comprise a verification application which is operable to verify the integrity of an instruction signal received from the drilling automation module, and to allow the instruction signal to be transmitted to the equipment controller if it determines that the integrity of the instruction signal meets a required standard.

The verification application may communicate with the functions application to notify the functions application if it has determined that there is a problem with an operating command from the drilling automation modules, the functions application being programmed to not forward operating commands from the drilling automation module to the equipment controllers.

At least one drilling automation module may be operatively connected to an external system, whereby the drilling automation module is operable to set the limitations sent to the limitations application based at least partly on limitations provided by the external system.

The external system may be in bi-directional communication with the drilling system and operable to receive data from at least one of the drilling parameter sensor, the drilling automation module, the process controller or the equipment controller, and the limitations provided by the external system can be a function of data received by the external system from the drilling system.

The external system may be a first external system arranged on a drilling vessel on which the drilling system is arranged, and the drilling system may comprise a second external system in bi-directional communication with the drilling system and operable to receive data from at least one of the drilling parameter sensor, the drilling automation module, the process controller or the equipment controller, wherein each of the first and second external systems is operable to set limitations for the limitations application.

The second external system may comprise a well plan and the limitations set by the second external system may be a function of the well plan and data received from at least one of the drilling parameter sensor, the drilling automation module, the process controller or the equipment controller.

The second external system may be configured to repeatedly update the well plan in response to operational data received from at least one of the drilling parameter sensor, the drilling automation module, the process controller or the equipment controller.

The second external system may be arranged at an onshore location.

In one embodiment, there is provided a method of operating a drilling system, the method comprising: providing a drilling system; operating the process controller to execute an automated sequence of activities whereby a drilling automation module provides at least one instruction signal to the process controller; operating the verification application to verify the integrity of the at least one instruction signal; and operating the process controller to transmit the at least one instruction signal to the equipment controller.

In one embodiment, there is provided a method of operating a drilling system, the method comprising: providing a drilling system; operating the process controller to execute an automated sequence of activities whereby a drilling automation module provides at least one instruction signal to the process controller; operating the limitations application to apply a limit to the instruction signal prior to the process controller transmitting the at least one instruction signal to the equipment controller.

Further embodiments are described below and in the appended claims.

Embodiments of the invention will now be described with reference to the accompanying drawings of which:

FIGURE 1 is a schematic illustration of a first embodiment of drilling system according to the invention,

FIGURE 2 is a schematic illustration of a second embodiment of drilling system according to the invention.

Referring now to Figure 1, there is shown a drilling system comprising a drilling parameter sensor 10, an equipment controller 20 which is operable, on receipt of an operating command, to control the operation of an item of drilling equipment, a drilling automation module 30 which receives data from the drilling parameter sensor and uses this to generate an operating command for the equipment controller 20, a process controller 40 which is in communication with the drilling parameter sensor 10, the equipment controller 20 and the drilling automation module 30. The communication between the process controller 40, drilling parameter sensor 10, and the equipment controller 20 may use any common PLC communication method, or more advanced, certified communication methods such as OPC, UA etc.

The drilling parameter sensor 10 can be any sensor operable to sense at least one drilling parameter,i.e. a physical feature of an aspect of the drilling operation, and to provide raw data regarding the drilling parameter to the process controller 40. There may be bidirectional communication with the process controller 40, so that it can receive operating commands from the process controller 40. It could be connected to the process controller 40 by a wired or wireless communication link. Moreover, although it is for clarity illustrated as one item, the drilling parameter sensor 10 may in all embodiments described herein comprise a plurality of separate sensors – either to provide redundancy, or to measure a plurality of drilling parameters.

The or each drilling parameter sensor 10 can be placed in any location necessary to sense the drilling parameter being monitored. It could be mounted on a drilling rig, or downhole.

Examples of drilling parameter sensors 10 which could be mounted on the drilling rig include sensors for monitoring the operation of the top drive, the draw works, mud pumps, pressure control equipment such as chokes or valves or blowout preventers, pipe handing equipment, iron roughnecks, separating equipment such as shakers or centrifuges, heave compensators and dynamic positioning systems. Examples of the parameters which could be measured using such sensors include the temperature of the equipment or of the fluid flowing through the equipment, the pressure of fluid flowing through equipment or conduits such as the drilling string or mud return line, the rate of flow of fluid through the equipment, the speed of rotation (RPM) – for example of the pumps, the drill string or cable storage drum, the speed of translational movement or acceleration – for example of the drill string or components in the draw works or heave compensation system, or the weight on bit (WOB).

Drilling parameter sensors 10 can be located downhole on a bottom hole assembly (BHA) or at any location on the portion of drill string which is within the well bore being drilling. Examples of such sensors include sensors for monitoring the temperature, pressure or other characteristics of fluid in the well bore, the WOB, RPM, translational velocity and/or acceleration, and/or vibration of the drilling string, or characteristics of the formation into which the well bore is being drilled.

The equipment controller 20 may be configured to control the operation of drilling equipment such as a top drive, a hydraulic roughneck, draw works, vertical pipe handling equipment, mud pumps, pressure control equipment such as valves, chokes or blowout preventers, mud cleaning equipment such as centrifuges or shakers, heave compensation systems or dynamic positioning systems (hereinafter referred to as machines). The equipment controller 20 may be connected to more than one machine.

The drilling parameter sensor 10 may be incorporated in a machine, or order to measure an aspect of the performance of the machine.

The equipment controller 20 may be in bidirectional communication with the process controller 40 by means of a wired, or wireless communication link, so that the equipment controller 20 may send information to the process controller 40. For example, the equipment controller 20 may report one of the following statuses to the process controller 40:

i) ready to run

ii) currently running

iii) finished running

iv) state (position, grip open or closed, etc)

v) aborted.

The drilling automation module 30 is a module which is used to enhance the control of a drilling operation, for example by automating repetitive tasks such as tripping in a stand, running by reciprocation or carrying out a friction test. It takes data from one or more drilling sensors 10, maybe also information from the process controller 40, and determines what action, if any, needs to be taken in order to fulfil its particular function, and releases an operating command for one or more equipment controllers, in order to operate the drilling equipment to bring about the desired change in the drilling process. It may also send information to the process controller 40 for use by other drilling automation modules, or applications in the process controller 40.

The process controller 40 may be provided with a single processor, or may be distributed over various computing elements. It comprises a verification application 41 which is operable to verify the of an instruction signal received from the drilling automation module 30, and to allow the instruction signal to be transmitted to the equipment controller 20 if it determines that the integrity of the instruction signal meets a required standard.

The verification application 41 may carry out one or more of the following checks, namely that the operating command:

a) is in the correct format,

b) where it includes a value, includes a value in a pre-determined range, c) does not include conflicting or mutually opposed instructions,

d) consists of a valid sequence of signals,

e) was transmitted via a communication link of adequate quality,

f) contains instructions to an equipment controller to which the process controller has access,

The verification application 41 may, for example, have built-in algorithms to establish that the signal is in the correct format or includes values within the pre-determined range (cases a and b), or, for example, carry out a check that the drilling automation module has a digital identifier which is one of a set of pre-approved identifiers. The latter may, for example, be relevant in the case of replaceable drilling automation modules, such as if a drilling system is provided with the capability to allow third party suppliers add drilling automation modules.

If the verification application 41 determines that the integrity of the operating command is not sound, for example because the drilling automation module 30, or the communication link by which the drilling automation module 30 is connected to the process controller 40, is faulty, the process controller 40 blocks communication between the drilling automation module 30 and the equipment controller 20. In this example, the process controller 40 also issues a warning signal to an operator to notify an operator that there is a problem with the drilling automation module 30 and that communication between the drilling automation module 30 and the equipment controller has been blocked.

In this example, the drilling system also includes a user interface 50 which includes a display apparatus and an input apparatus, and is in bidirectional communication with the process controller 40, so that the process controller 40 may send information to the user interface 50 for display, and also receive commands, or data from the user interface 50. The communication link between the process controller 40 and the user interface 50 may be wired or wireless.

The user interface may comprise a visual display apparatus such as screen with a connected input apparatus such as a keyboard, keypad or joystick, and/or a touch screen. The user interface 50 is, in use, typically located at the driller’s chair. The warning signal may therefore comprises a visual or audible warning, or both, issued by the user interface 50.

If a user of the drilling system wishes to run an automated drilling sequence, the user uses the input apparatus to select the appropriate function, and the user interface sends an appropriate command to the process controller 40, which forwards the command, along with any relevant data from the drilling parameter sensor 10, to the drilling automation module 30. The drilling automation module 30, if necessary using data received from the drilling parameter sensor 10, generates an appropriate operating command and transmits this to the process controller 40. The operating command is checked by the verification application 41, and if no problem is detected, the process controller 40 forwards the operating command to the equipment controller 20, which, in turn, controls the machines to which it is connected to carry out the desired functions. Such an automated sequence may, for example, be a number of sequential steps in a trip-in or trip-out procedure, where the drilling automation module 30 controls various functions of different machines such as pipe handling machines and a hoisting system.

Advantageously, the drilling system comprises a plurality of equipment controllers 20a, 20b, 20c, 20d, 20e, as illustrated in Figure 2. These may comprise any number and combination of the equipment controllers described above. Each equipment controller 20a, 20b, 20c, 20d, 20e may be connected to a single machine, but it is possible for one machine to be connected to more than one equipment controller 20a, 20b, 20c, 20d, 20e or an equipment controller 20a, 20b, 20c, 20d, 20e to be connected to more than one machine, or to control more than one function on one machine.

In one embodiment, the drilling system includes equipment controllers for a top drive 20a, a hydraulic roughneck 20b, draw works 20c, a vertical pipe handler 20d and mud pumps 20e.

By virtue of connecting all the equipment controllers 20a, 20b, 20c, 20d, 20e to a process controller 40, if data transfer from one equipment controller 20a, 20b, 20c, 20d, 20e to another of the equipment controllers 20a, 20b, 20c, 20d, 20e is required, this can be carried out via the process controller 40. This simplifies the implementation of the drilling system, as additional communication links between equipment controllers 20a, 20b, 20c, 20d, 20e are not required, and may also reduce the total computational load on the equipment controllers 20a, 20b, 20c, 20d, 20e.

The drilling system may also comprise a plurality of drilling automation modules 30a, 30b, 30c and 30d as illustrated also in Figure 2. The first drilling automation module 30a may be a Configurable Automated Drilling System (CADS) which provides for the automation of tripping sequences such as moving a vertical pipe handler to the finger board to collect a pipe, moving a pipe to well centre for installing in the drill string, or moving the drilling string during an automatic tripping operation, and which sends operating commands and limitations to equipment controllers relating to the draw works,20c, top drive 20a, hydraulic roughneck 20b and vertical pipe handler 20d. The second drilling automation module 30b may be a Driller’s Assist module – tools which aids the driller in constructing a well bore by executing functions using and send operational limitations to the equipment controllers for the draw works 20c, top drive 20a and mud pumps 20e.

The drilling system may also include one or more drilling automation module 30c, 30d which does not issue any operating commands for any of the machines. These could include early kick detection (EKD) software which analyses drilling sensor inputs to determine if a kick (i.e. uncontrolled flow of formation fluid into the well bore) is likely to occur or has occurred in the well bore, Performance Analyser which carries out analyses of the efficiency or other parameters of the drilling process (see e.g. the previously referenced WO 2018/203753) or inventory software which monitors the usage of components, such as pipes on the pip deck or finger board, in order to keep track of the remaining number of components.

One or more of the drilling automation modules 30a, 30b, 30c, 30d may be in communication, bidirectional or one-way, with one or more of the other drilling automation modules 30a, 30b, 30c, 30d, thus allowing information to be exchanged between connected drilling automation modules 30a, 30b, 30c, 30d, as required.

The drilling automation modules 30a, 30b, 30c, 30d can be made by third parties, i.e. a different entity to the provider of the other drilling automation modules 30a, 30b, 30c, 30d and/or the process controller 40, and/or the equipment controllers 20a, 20b, 20c, 20d, 20e.

Although not essential, this embodiment of the invention includes first and second user interfaces 50, 51,which may comprise a visual display apparatus such as screen with connected input apparatus such as a keyboard, keypad or joystick, and/or a touch screen.

Both user interfaces are in bidirectional communication with the process controller 40 as described above, but, at least one may be also be in direct communication with at least one of the equipment controllers 20a, 20b, 20c, 20d, 20e.

As with the embodiment illustrated in Figure 1, if a user of the drilling system wishes to run an automated drilling sequence, the user uses an input apparatus associated with one of the first or second user interfaces 50, 51 to select the appropriate function, and the user interface 50, 51 sends an appropriate command to the process controller 40, which forwards the command, along with any relevant data from the drilling parameter sensor 10, to the relevant drilling automation module 30a, 30b, 30c, 30d. The drilling automation module 30a, 30b, 30c, 30d, if necessary using data received from the drilling parameter sensor 10, generates an appropriate operating command and transmits this to the process controller 40. The operating command is checked by the verification application 41, and if no problem is detected, the process controller 40 forwards the operating command (or sequence of operating commands) to the relevant equipment controller(s) 20a, 20b, 20c, 20d, 20e.

Operating commands can also originate with a user of the drilling system (user generated commands), and be conveyed to the process controller 40 via the input apparatus associated with one of the user interfaces 50, 51. It should be appreciated that the process controller 40 is advantageously configured such that automatic functions, i.e operating commands generated by the drilling automation modules 30a, 30b, 30c, 30d, can be aborted by a user, or over-ridden by user generated commands. However, which input apparatus can be used to generate such user generated commands may depend on which of the drilling automation module 30a, 30b, 30c, 30d is active at the time. For example, if the CADS module 30a is active, the automatic functions can be overridden by the operation of joysticks or buttons at the operator’s chair. Manual control of the drilling equipment will then resume, the user generated commands being relayed to the equipment controllers 20a, 20b, 20c, 20d, 20e via the process controller 40.

In contrast, when the Driller’s Assist module 30b is active, these input devices are used as part of the normal drilling operation, and the process controller 40 may be configured not to override or abort automatic operating commands generated by the Driller’s Assist module 30a as a result of user generated commands originating from these. Instead, an easily accessible stop button or switch is provided to allow an operator quickly to abort any activity generated by the Driller’s Assist module 30b.

The process controller 40 may be configured such that if the stop button or switch is activated for more than a pre-determined length of time, such as 1 minute, it will completely abort the drilling automation module control. Otherwise, when the stop button / switch is released, the process controller 40 will resume the relaying the operating commands generated by the drilling automation module 30a, 30b, 30c, 30d, as it was before the stop button / switch was activated. This allows an automatic operating sequence to be paused, but also prevents unexpected movement arising from the resumption of an automatic operating commands when the drilling system is restarted a long time after stopping the activity.

The drilling system is designed to be modular such that the operator may choose which drilling automation modules 30 are connected to the process controller 40, and may add or remove drilling automation modules 30 as needs change. By virtue of connecting the or each drilling automation module 30 to the equipment controller 20 or equipment controllers 20a, 20b, 20c, 20d, 20e via the process controller 40, adding or replacing modules can be achieved without the need to make new connections or any physical or software changes to the equipment controller(s) 20, 20a, 20b, 20c, 20d, 20e (a process which on a drilling rig in operation is costly and carries a significant risk). Moreover, a fault in one of the drilling automation modules 30a, 30b, 30c, 30d does not affect the operation of any of the equipment controllers 20a, 20b, 20c, 20d, 20e. Each equipment controller 20a, 20b, 20c, 20d, 20e can continue to operate normally when instructed by one of the non-faulty drilling automation modules 30a, 30b, 30c, 30d.

When a new drilling automation module is added, or a faulty drilling automation module is replaced, it is merely necessary to make the process controller 40 aware that a new module has been added, so that it knows which signals from the drilling sensors 10 to send to the new module.

The fact that the drilling parameter sensors 10 are connected to the process controller 40 means that the equipment controllers 20a, 20b, 20c, 20d, 20e can share data from and access to the drilling parameter sensors 10. As such, where more than one equipment controller 20a, 20b, 20c, 20d, 20e requires data from the same drilling sensor, it is not necessary to provide one such drilling sensor for each equipment controller 20a, 20b, 20c, 20d, 20e.

The verification application 41 ensures that the operating commands sent to the equipment controllers 20a, 20b, 20c, 20d, 20e are valid, something which is particularly important when the drilling system uses third party drilling automation modules 30a, 30b, 30c, 30d, or where new modules are added.

In this example, the drilling system also includes an anti-collision processor 61 which works to avoid collision between drilling equipment, people, pipes and stationary objects on the drilling rig. This is in bidirectional communication with the process controller 40 and so may receive information or instructions from the process controller 40, and can send instructions to relevant equipment controllers 20a, 20b, 20c, 20d, 20e via the process controller 40. It is also in bidirectional communication with relevant equipment controllers – in this example the controllers for the hydraulic roughneck 20b, the draw works 20c and vertical pipe handler 20d, and therefore can receive information or instructions directly from these equipment controllers 20b, 20c, 20d or send operating commands directly thereto.

The drilling system may further include one or more external systems which is in bidirectional communication with the process controller 40, or which does not communicate directly with the process controller 40, but which is in bi-directional communication with one or more of the drilling automation modules 30a, 30b, 30c.

30d.

The drilling system illustrated in Figure 2, includes a first external system 60 which does not communicate directly with the process controller 40, but which is in bidirectional communication with one or more of the drilling automation modules 30a, 30b, 30c, 30d, and, as such, can communicate with the process controller 40 via a drilling automation module 30a, 30b, 30c, 30d. This can be used where the external system does not communicate on a protocol that is supported by the process controller 40, as the drilling automation module 30a, 30b, 30c, 30d can act as an interface allowing for communication between the external system 60 and the process controller 40. By virtue of this arrangement, the process controller 40 can be used to provide an external system communicating on a protocol it does not use with access to the equipment controllers 20a, 20b, 20c, 20d, 20e.

In this example, the drilling system also includes a second external system 70, which is in bi-directional communication with the process controller 40.

Where more than one drilling automation module 30a, 30b, 30c, 30d is provided, the process controller 40 is configured to control the access of the drilling automation modules 30a, 30b, 30c, 30d to the equipment controllers 20a, 20b, 20c, 20d, 20e. Before a drilling automation module 30a, 30b, 30c, 30d can control equipment functions, it must request, and be granted access to the relevant equipment controller 20a, 20b, 20c, 20d, 20e by the process controller 40. If the requested machines are available for control, the process controller 40 assigns those machines to the active drilling automation module 30a, 30b, 30c, 30d. The relevant equipment controllers 20a, 20b, 20c, 20d, 20e will now be sent operating commands generated by the active drilling automation module 30a, 30b, 30c, 30d.

The system may be set up so that a machine cannot be assigned to more than one drilling automation module at any one time, and so if a drilling automation module 30a, 30b, 30c, 30d issues operating commands for a machine of which it is not in control, the process controller 40 will ignore these operating commands.

To achieve this, the process controller 40 includes a priority controller 42 which operates to prioritise the right to send operating commands and limitations to the equipment controllers 20a, 20b, 20c, 20d, 20e from the drilling automation modules 30a, 30b, 30c, 30d based on predefined prioritization rules.

For example, the prioritization rules may be that all drilling automation modules 30a, 30b, 30c, 30d have the same priority, and that access to each equipment controller 20a, 20b, 20c, 20d, 20e or each associated machine is granted on a first come, first served basis. A machine may be prevented from being controlled by another drilling automation module 30a, 30b, 30c, 30d until the active drilling automation module 30a, 30b, 30c, 30d relinquishes control.

The prioritization rules may, however, additionally state that a high priority access request can take precedence over regular operating commands. In this case, the priority controller 42 evaluates high priority operating commands from any of the drilling automation modules 30a, 30b, 30c, 30d, and can remove access to one of more of the equipment controllers 20a, 20b, 20c, 20d, 20e from the controlling drilling automation module 30a, 30b, 30c, 30d if a high priority operating command for that equipment controller 20a, 20b, 20c, 20d, 20e is received from a different drilling automation module 30a, 30b, 30c, 30d.

This may be required if an event occurs in the well which requires immediate action, and that action requires control of the drilling equipment to be given to a different drilling automation module 30a, 30b, 30c, 30d to the one currently controlling the relevant drilling equipment. In this case, the reactive drilling automation module 30a, 30b, 30c, 30d concerned sends a high priority access request to the process controller 40. The priority controller 41 assesses the request, and, in accordance with the predefined prioritization rules, gives the reactive drilling automation module 30a, 30b, 30c, 30d access to the relevant equipment controller 20a, 20b, 20c, 20d, 20e, so that the operating commands required to deal with the event can be issued to the equipment controller or controllers 20a, 20b, 20c, 20d.

The priority controller 42 may also prioritise which information received from the drilling automation modules 30a, 30b, 30c, 30d is forwarded to one or more of the equipment controllers 20a, 20b, 20c, 20d, 20e.

In this example, the process controller 40 also comprises a functions application 43, in which is stored a plurality of pre-set functions, which may be accessed by the drilling automation modules 30a, 30b, 30c, 30d, and forwarded to the relevant equipment controller or controllers 20a, 20b, 20c, 20d, 20e.

For example, for the top drive, the functions may be to extend or retract the dolly, or to rotate the top drive clockwise or counter clockwise at a particular rotational speed (RPM). For the vertical pipe handler, the functions may be to go to the finger board, to open or close grip, or to move to well centre. For the draw works, the function may be to elevate to a particular height at a particular speed. For the mud pumps, the function may be to pump at a particular rotational speed (RPM) or to stop pumping. Finally, for the hydraulic roughneck, the functions may be to move to well centre, to make up a joint to a particular torque, to spin in or out, to break out, or to move to a park position.

An operating command from a drilling automation module 30a, 30b, 30c, 30d may be translated by the functions application 43 into a series of these functions, or it may comprises additional information to include into one of these functions, such as the desired speed of rotation of the pumps, or a combination of both. The functions application 43 thus forwards an operating command received from a drilling automation module 30a, 30b, 30c, 30d to the required equipment controller 20a, 20b, 20c, 20d, 20e using these pre-set functions.

The functions application 43 may also be used to forward operating commands issued manually by a user and sent to the process controller 40 via one of the user interfaces 50, 51 (operator issued commands). The use of the same functions for operating commands generated by a user, and those generated by a drilling automation module 30a, 30b, 30c, 30d may simplify implementation in the equipment controllers 20a, 20b, 20c, 20d, 20e as it limits the form and number of types of instructions they can receive, and may also simplify testing of the system, as there is no need to test the same functions both for operator issued commands and automatic commands.

The verification application 41 may communicate with the functions application 43 to notify the functions application 43 if it has determined that there is a problem with an operating command from any of the drilling automation modules 30a, 30b, 30c, 30d. From then on, the functions application 43 will not forward operating commands from the drilling automation module 41 concerned to any of the equipment controllers 20a, 20b, 20c, 20d, 20e. Similarly, the priority controller 42 may communicate with the functions application 43, and instruct the functions application 43 which operating command it is to forward to an equipment controller 20a, 20b, 20c, 20d, 20e in the event that two or more drilling automation modules 30a, 30b, 30c, 30d have issued conflicting operating commands for the same equipment controller 20a, 20b, 20c, 20d, 20e.

The functions application 43 may also send an operating command to an equipment controller 20a, 20b, 20c, 20d, 20e to put the connected equipment in a safe state, if the equipment controller 20a, 20b, 20c, 20d, 20e has acted on an operating command issued by an automation module 30a, 30b, 30c, 30e now found by the verification application 41 to be faulty.

The process controller 40 may further include a limitations application 44 which forwards limitations from the drilling automation modules 30a, 30b, 30c, 30d to the relevant equipment controller 20a, 20b, 20c, 20d, 20e. The limitations set the window in which the item of drilling equipment connected to the equipment controller 20a, 20b, 20c, 20d, 20e should operate, i.e. the upper and lower limits for a drilling parameter associated with the drilling equipment. For example, the desired upper and lower limits for the rotational speed (RPM) of the top drive or torque might be sent to the equipment controller 20a associated with the top drive, the maximum pumping rate or maximum pump acceleration might be sent to the equipment controller 20e associated with the mud pumps, and the maximum / minimum position, maximum / minimum position and maximum acceleration / deceleration may be sent to the equipment controller 20c associated with the draw works.

A drilling automation module 30a, 30b, 30c, 30d does not need to request access to a machine in order to set limits to that machine. As such, by providing the process controller 40 as an interface between the drilling automation modules 30a, 30b, 30c, 30d and the equipment controllers 20a ,20b, 20c, 20d, 20e limitations set by one drilling automation module 30a, 30b, 30c, 30d may be applied to an equipment controller 20a, 20b, 20c, 20d, 20e, even if that drilling automation module 30a, 30b, 30c, 30d is not active control of, i.e. actively issuing operating commands to, that equipment controller 20a, 20b, 20c, 20d, 20e. If multiple limitations have been set for the same machine by different drilling automation modules 30a, 30b, 30c, 30d, the strictest limitations will be applied. As such, a first drilling automation module 30a, 30b, 30c, 30d may be issuing operating commands to the equipment controller 20a, 20b, 20c, 20d, 20e, but the stricter limitations set by a second drilling automation module 30a, 30b, 30c, 30d will be applied, and respected by the equipment controller 20a, 20b, 20c, 20d, 20e when following operating commands from the first drilling automation module 30a, 30b, 30c, 30d, in order to ensure safe and efficient operation of the drilling system.

Limitations set by the anti-collision processor 61 can also be applied by the limitations application 44, in the same way as limitations from the drilling automation modules 30a, 30b, 30c, 30d are set. This may assist in simplifying the testing of the drilling system, as there is no need to test the anti-collision limits and the drilling automation module set limits separately.

The limitations application 44 ensures that the limitations are applied when the equipment controllers 20a, 20b, 20c, 20d, 20e, 20e are acting on user generated operating commands. However, advantageously, an operator is provided with means to override these limitations from the driller’s chair, but if a limitation is overridden by the operator whilst a sequence originating from a drilling automation module 30a, 30b, 30c, 30d is being executed, the sequence will be aborted by the drilling automation module concerned.

The verification application 41 may communicate with the limitations application 44 to notify the limitations application 44 if it has determined that there is a problem with an operating command from any of the drilling automation modules 30a, 30b, 30c, 30d. From then on, the limitations application 44 will not forward limitations from the drilling automation module 41 concerned to any of the equipment controllers 20a, 20b, 20c, 20d, 20e. Similarly, the priority controller 42 may communicate with the functions application 43 and instruct the limitations application 44 which limitation it is to forward to an equipment controller 20a, 20b, 20c, 20d, 20e in the event that two or more drilling automation modules 30a, 30b, 30c, 30d have issued conflicting limitations for the same equipment controller 20a, 20b, 20c, 20d, 20e.

The functions application 43 may also send an instruction to an equipment controller 20a, 20b, 20c, 20d, 20e to remove any limitations set by an automation module 30a, 30b, 30c, 30e now found by the verification application 41 to be faulty.

In this embodiment, the process controller 40 also includes an information application 45 which stores information it receives from the drilling parameter sensors 10, the equipment controllers 20a, 20b, 20c, 20d, 20e, and the drilling automation modules 30a, 30b, 30c, 30d, and, where necessary, forwards this information to the equipment controllers 20a, 20b, 20c, 20d, 20e and / or drilling automation modules 30a, 30b, 30c, 30d. The information application 45 is configured to forward information to a drilling automation module 30a, 30b, 30c, 30d about a particular machine irrespective of whether that drilling automation module 30a 30b, 30c, 30d has access to that particular machine.

Examples of such information are the measured position and speed of the draw works, the direction of rotation, measured speed and measured torque of the top drive, and for the mud pumps, the current flow and assigned pumps.

In this embodiment, the drilling system also includes a simulation application 46 which is programmed to simulate the drilling system one or more of the items of drilling equipment so that the effect on the drilling system of an equipment controller 20a, 20b, 20c, 20d, 20e acting on particular operating command can be tested virtually before said operating command is released to the equipment controller 20a, 20b, 20c, 20d, 20e.

All communication in the drilling system can be monitored by rolling counters. If the communication is interrupted for more than a defined time, the system can be set up to change to a safe state as described below.

In the event that an equipment controller 20a, 20b, 20c, 20d, 20e loses communication with the process controller 40, the action taken depends on which equipment the disconnected equipment controller 20a, 20b 20c, 20d, 20e controls. For the mud pumps, the equipment controller 20e can be programmed to continue pumping at the current rate. Where the equipment controller 20a controls the top drive, the equipment controller 20a can be programmed to continue rotating the top drive at the current speed. For all other machines, if they lose communication with the process controller 40, they can be configured to stop executing any operating commands generated by the drilling automation modules.

If the process controller 40 loses communication with a machine, the process controller 40 notifies the drilling automation module 30a, 30b, 30c, 30d which is currently in control of the machine, and puts the other machines involved in the sequence of functions comprising the operating command currently being executed into their safe state.

The system can be arranged so that if one of the drilling automation modules 30a, 30b, 30c, 30d, loses communication with the process controller 40, all the machines being controlled by that drilling automation module 30a, 30b, 30c, 30d can be put into a safe state, and the limitations application 44 will disregard any limitations set by that drilling automation module 30a, 30b, 30c, 30d.

In one embodiment, the external system 60,70 may be operatively connected to the drilling automation module(s) 30, and the drilling automation module(s) 30 be operable to set the limitations to the limitations application 44 based at least partly on limitations provided by the external system 60,70. The connection between the drilling automation module(s) 30 and the external system 60,70 may allow bidirectional communication, such that the external system 60,70 is operable to receive data from at least one of the drilling parameter sensor, the drilling automation module, the process controller or the equipment controller. The limitations provided by the external system 60,70 can in such a case be a function of data received by the external system from the drilling system.

This is illustrated schematically in Fig.3, in which a drilling vessel 80 operates using most or all the components described above, such as a top drive 81, a hoisting system 82 operating the top drive 81 in a rig structure 83 to suspend a drill string 84 having a drill bit 85 into a subterranean wellbore 86. Several components of the drilling system, such as drilling automation modules 30, the user interface(s) 50,51 and the process controller 40, may be arranged in a driller’s cabin 87 on the vessel 80.

In this embodiment, the external system 70 is arranged in a shore-based location, here illustrated as office 88. The external system 70 comprises a computer 89 located at the office 88. The computer 89 may be in bi-directional communication with the drilling system via a data link, in Fig.3 illustrated with the double arrows and an intermediate “cloud” storage, however the data link may be a direct link between the vessel 80 and the office 88. The computer 89 is operable to receive data from at least one of the drilling parameter sensor(s) 10, the drilling automation module(s) 30, the process controller 40 or the equipment controller(s) 20. The data link may be a substantially real-time data link, or it may be set up to provide repeated, intermittent communication of the relevant data.

The computer 89 is operable to provide limitations to the limitations application 44. The computer 89 may comprise a well plan, and the limitations set by the computer 89 can be a function of the well plan and the (real-time or historical) operational data received from at least one of the drilling parameter sensor(s) 10, the drilling automation module(s) 30, the process controller 40 or the equipment controller(s) 20. Advantageously, this may provide enhanced operational safety, in that the limitations to be calculated with better accuracy. For example, the personnel in the office 88 may include a geologist (not normally present on the vessel 80) or have access to better geological models of the formation into which the well bore 86 is being drilling which is not available to the driller. This geologist or the geological model might, for example, suggest that the drill bit 85 will shortly be entering a part of the formation which contains fluid at a higher pressure than previously. In such a case, it may be advantageous to set an automated sequence executed by the drilling system with an increased fluid pressure in the well bore 86, in order to minimize the risk of a blowout. Similarly, for example during automated tripping operations, limitations on the tripping speed in different sections of the wellbore 86 may be imposed from the office 88 in order to avoid damaging the formation.

In any of the embodiments described here, the computer 89 may be configured to repeatedly update the well plan in response to operational data received from at least one of the drilling parameter sensor(s) 10, the drilling automation module(s) 30, the process controller 40 or the equipment controller(s) 20.

Both the remote external system 70 (in this embodiment, the computer 89) and any local external system 60 on the rig may be operable to set limitations for the limitations application 44. Alternatively, or additionally, the remote external system and one or more of the drilling automation modules 30 may operate to set limitations for the limitations application 44 simultaneously. In the event that two or more limitations exist (e.g. two or more “operating envelopes” for a given machine), then ordinarily the drilling system should be so configured as to apply the narrowest operating envelope.

Some embodiments may thus allow limitations to automated sequences to be applied on the drilling process based on best possible information. For example, a combination of limitations from the computer 89, based on a continuously updated well plan, and limitations from an early kick detection (EKD) drilling automation module 30 could provide a fast response in the event of a blow-out risk, as well as an optimization of the drilling processes based on the well plan and reservoir models.

Claims

1. A drilling system comprising a drilling parameter sensor, a drilling automation module which receives data from the drilling parameter sensor and uses this to generate an operating command, an equipment controller which is operable, on receipt of an operating command, to control the operation of an item of drilling equipment, and a process controller which is in communication with the drilling parameter sensor, the drilling automation module and the equipment controller.

2. A drilling system according to claim 1, wherein the process controller comprises a verification application which is operable to verify the integrity of an instruction signal received from the drilling automation module, and to allow the instruction signal to be transmitted to the equipment controller if it determines that the integrity of the instruction signal meets a required standard.

3. A drilling system according to claim 2, wherein the verification application carries out one or more of the following checks:

a) that the operating command is in the correct format,

4. A drilling system according to claim 2 or 3 wherein the process controller is programmed such that when the verification application determines that the drilling automation module, or the communication link by which the drilling automation module is connected to the process controller, is faulty, the process controller blocks communication between the drilling automation module and the equipment controller.

5. A drilling system according any one of claims 2-4, wherein the process controller is programmed such that when the verification application determines that the drilling automation module, or the communication link by which the drilling automation module is connected to the process controller, is faulty, the process controller issues a warning signal to an operator.

6. A drilling system according to any preceding claim further comprising a user interface which includes a display apparatus and an input apparatus, and is in bidirectional communication with the process controller, so that the process controller may send information to the user interface for display, and also receive commands, or data from the user interface.

7. A drilling system according to claim 6 wherein the user interface is operable by a user to create and send to the process controller, a user generated operating command, the process controller being programmed to relay the user generated operating command to the equipment controller, the user generated operating command overriding an operating command relayed from the drilling automation module.

8. A drilling system according to any preceding claim comprising a plurality of equipment controllers, each of which is in communication with the process controller, and programmed, on receipt of an operating command, to control the operation of an item of drilling equipment.

9. A drilling system according to any preceding claim, wherein the drilling system includes an anti-collision processor which is in communication with the process controller, and uses information received from the process controller to generate operating commands for the equipment controller or equipment controllers, said operating commands being created in order to prevent collision between drilling equipment, people, pipes and stationary objects on the drilling rig.

10. A drilling system according to any preceding claim comprising a plurality of drilling automation modules.

11. A drilling system according to claim 10, wherein the process controller is programmed to control the access of the drilling automation modules to the equipment controller or equipment controllers so that before an operating command generated by one of the drilling automation modules is relayed to an equipment controller, the process controller must grant that drilling automation module access to the equipment controller.

12. A drilling system according to claim 11, wherein the process controller is programmed to grant a second drilling automation module to access an equipment controller only if access to that equipment controller has not already been granted to a first automation module, or if access to that equipment controller has already been granted to a first automation module, but the second drilling automation module issues a high priority request for access to the equipment controller.

13. A drilling system according to any preceding claim, wherein the process controller further comprise a functions application, in which is stored a plurality of pre-set functions, which may be accessed by the or a drilling automation module, and forwarded to the relevant equipment controller or controllers.

14. A drilling system according to claim 13, wherein the functions application is programmed to translate an operating command from a drilling automation module into a series of the pre-set functions, or to insert additional information from the operating command into one of the pre-set functions, before forwarding the operating command to the required equipment controller in the form of one or more of the pre-set functions.

15. A drilling system according to claim 13 or 14 where dependent on claim 8 wherein the process controller is programmed to use the functions application to forward a user generated operating command to the or an equipment controller.

16. A drilling system according to any one of claims 13-15 where dependent on claim 2, 3, 4 or 5, wherein the verification application communicates with the functions application to notify the functions application if it has determined that there is a problem with an operating command from any of the drilling automation modules, the functions application being programmed to not forward operating commands from the drilling automation module concerned to the equipment controller or any of the equipment controllers.

17. A drilling system according to any preceding claim, further including a simulation application which is programmed to simulate the drilling system one or more of the items of drilling equipment so that the effect on the drilling system of an equipment controller acting on particular operating command can be tested virtually before said operating command is released to the equipment controller.

18. A drilling system according to any preceding claim, wherein the process controller further includes a limitations application operable to set limitations from the drilling automation modules to the or any relevant equipment controller, the limitations setting a window in which an item of drilling equipment connected to the equipment controller should operate.

19. A drilling system according to claim 18 where dependent on claim 10 wherein the limitations application is programmed such that where multiple limitations have been set for the same item of drilling equipment by different drilling automation modules, the strictest limitations will be applied.

20. A drilling system according to claim 18 or 19 where dependent on claim 2, 3, 4 or 5, wherein the verification application communicates with the limitations application to notify the limitations application if it has determined that there is a problem with an operating command from the drilling automation module or any of the drilling automation modules, the limitations application being programmed not to forward limitations from the drilling automation module concerned to the equipment controller or any of the equipment controllers.

21. A drilling system according to any one of claims 18 to 20 where dependent on claim 2, 3, 4 or 5, wherein the limitations application is programmed send an instruction to an equipment controller to remove any limitations set by an automation module found by the verification application to be faulty.

22. A drilling system according to claim 21, wherein the process controller also includes an information application which stores information it receives from the drilling parameter sensor, the or each equipment controller, and the or each drilling automation module, and is operable to forward this information to the or one or more of the equipment controller(s) and / or drilling automation module(s).

23. A drilling system according to any one of claims 18 to 22, wherein at least one drilling automation module is operatively connected to an external system, and whereby the drilling automation module is operable to set the limitations sent to the limitations application based at least partly on limitations provided by the external system.

24. A drilling system according to claim 23, wherein the external system is in bidirectional communication with the drilling system and operable to receive data from at least one of the drilling parameter sensor, the drilling automation module, the process controller or the equipment controller,

and wherein the limitations provided by the external system is a function of data received by the external system from the drilling system.

25. A drilling system according to claim 23 or 24, wherein the external system is a first external system arranged on a drilling vessel on which the drilling system is arranged,

and the drilling system comprises a second external system in bi-directional communication with the drilling system and operable to receive data from at least one of the drilling parameter sensor, the drilling automation module, the process controller or the equipment controller,

wherein each of the first and second external systems is operable to set limitations for the limitations application.

26. A drilling system according to claim 25, wherein the second external system comprises a well plan and the limitations set by the second external system is a function of the well plan and data received from at least one of the drilling parameter sensor, the drilling automation module, the process controller or the equipment controller.

27. A drilling system according to claim 26, wherein the second external system is configured to repeatedly update the well plan in response to operational data received from at least one of the drilling parameter sensor, the drilling automation module, the process controller or the equipment controller.

28. A drilling system according to any of claims 25-27, wherein the second external system is arranged at an onshore location.

29. A method of operating a drilling system, the method comprising:

providing a drilling system according to claim 2 or any claim appendant thereon;

operating the process controller to execute an automated sequence of activities whereby a drilling automation module provides at least one instruction signal to the process controller;

operating the verification application to verify the integrity of the at least one instruction signal;

operating the process controller to transmit the at least one instruction signal to the equipment controller.

30. A method of operating a drilling system, the method comprising:

providing a drilling system according to claim 18 or any claim appendant thereon;

operating the limitations application to apply a limit to the instruction signal prior to the process controller transmitting the at least one instruction signal to the equipment controller.