超乎想象的未来钻井技术(英)

1、drilling advancesfuture drilling technology: closer than you thinksafer, more automated drilling and with greater capabilities for managing difficult pressure environments than the best we have today-in other words, a reach into the future-is making good progress. even remotely operated drilling is

2、possible.steinar strom, mohsen karimi balov, halvor kjorholt, rune gaas0, statoilhydro; erlend h. vefring , iris; rolv rommetveit, sintef petroleum researchstatoilhydro believes that a new, fully automated drilling system (ads), while a major technological effort, is achievable in the relatively nea

3、r future the company is pursuing various sub-systems for in corporati on into an all-i nclusive in teg rated system. two different solutions are the drilltronics (iris/nov) and the econtrol/edrilling (sintef /hpd/aker solutions) conceptsthe drilltronics system is based on mathematical computer model

4、s for dynamic real-time analysis of drilling processes; critical limits for operational parameters, such as drilling fluid pump rate, trip velocity and optimal process parameters are calculated. the result is used to control drilling equipment in real time. the new system has been field tested on th

5、e statfjord c platform combining the new system with wired pipe, decision support programs and continuous measurements of drilling fluid parameters give synergy effects that, in the future, may allow remotely operated drilling systems.edrilling is an innovative system for real-time drilling simulati

6、on, 3d visualization and control from a remote drilli ng expert center and is the tech no logy basis for econtrol, which is a rig supervisi on, optimizatio n and control system that will in teg rate 3d visualizati on of the wellbore with advaneed drilling process modelsthis article gives an overview

7、 of field-tested, pilot-tested equipment and the synergy effect when combing different technical solutions in future drilling scenariosbackgroundthe tech no logy, as such, is to a large exte nt at hand. it is a matter of applyi ng the tech no logy in an in teg rated manner. our experie nee is that m

8、any drilling problems are related to human error, or rather, slow response with respect to corrective actions. the ads has the capability, if designed correctly, to eliminate this type of misbehavior. it is mandatory to design the ads such that the general progress in operation is not slowed.the ess

9、ential part in the future drilling concept is use of high-speed telemetry through drill pipe. the technology is regarded as an emerging commercial product that is now being applied the ads should have the function of optimizing operations; these are: speeding up drilling/tripping operations when con

10、ditions permit slowing down drilling/tripping operations when required early kick detection, improved well control automated pump startup/stop automated mud checks effective use of telemetric drill pipe; i.e., real-time downhole data from the well automation of the drilling process-a great opportuni

11、ty to minimize operationaldown time by han dling borehole problems correctly an d con sistently, thus sign ifica ntly reducing human errors establish drilling programs in a semi automatic manner.automated drilling processthere are several tech no logies in volved in an ads. these in elude: automated

12、 pipe handling automated drilli ng operati on s, i ncludi ng drilli ng on bottom, reami ng and trippi ngwe regard these as compleme nting technologies that all have the potential to con tribute toward an automated drilling process. the general idea of how the future will look is shown in fig. 1. it

13、is of great importance that the interfaces between the various technologies are han died in a con siste nt manner by the operator. we, as an operator, n eed to define these in terfaces to allow for future improveme nts and in particular allow for new inno vati ons to be impleme nted. hen ce, it is i

14、mportant to have ope n mplug-n-playm type in terfaces based on ethernet technology.modulcs/models optirnizatian date quality module realtime models: dowrthote pressure and flow tbcquft/drag drilling vibrations rop wellbore stabuyprocess and operation modiie (analyze) forward kxmunrsimutiit>on5 di

15、agnosisifeer mterfocc(?0ami 3d)vtsualeation via standard pcwitsmle2ewnsmiopccompony debasecompany well.3ni part applicationbfig. 1 . flowchart of the fully automated drilling process.drilling control system automationstatoilhydro is pursuing two different solutions: the drilltronics (iris/nov) and t

16、he econtrol/edrilling (sintef) concepts.drilltronics. this system applies dynamic process models for well flow and drillstring mechanics, using advaneed dynamic rheological modeling with gelling, thermo-physical modeling, solids transport and equation-of-state modeling. the applied torque and drag m

17、odeling is based on a “soft string” model. pre-processing of measured mechanical data through filteri ng and derivation of required model in put is performed by a previously developed system for improvement of drilling data. the applied flow-model solver is a semi-implicit matrix solver, explicit wi

18、th regards to mass transport, that enables solving complex flow situations in real-time. model calibration is performed through application of kalman filtering techniques, where a proportional flow-friction factor is applied for pressure calibration.limitations for tripping/reaming dynamics and pump

19、 dynamics are calculated through forward modeling based on the pressure limitations of the well and mechanical limits of the drill pipe through automatic enforcement of these dynamic limits, depletion and pipe sticking issues will be dealt with.diag no sties of wellbore stability and cutti ngs tran

20、sportatio n is performed through trend analysis of the friction between wellbore and drillstring using a torque-anebdrag model. the trend of the calculated friction will indicate the state of the hole with regard to cuttings and borehole condition. through application of an automated pick-up and sla

21、ck-off tests, the diagnostics may be improved, as the test will be identical each time it is run. repeated testing combined with analysis of results will indicate whether the wellbore condition is deteriorating.testing in active mode. statoilhydro performed a full scale offshore pilot test in januar

22、y 2008 of a new control system enhancement for optimization of drilling control. the test was at the statfjord c platform on the norwegian con tine ntal shelf. the drilltronics system was run in passive (advisory) mode in a previous test autumn 2007 and was run in active mode in the time frame from

23、january 21 to january 29, 2008.feedback from the operations group indicated that the system worked satisfactory and as inten ded. no hse in cidents were encoun tered duri ng the fun ction test while in active control mode some modificati on of the system is required to optimize the man-machine in te

24、rface in addition, we learned that the sensors on the relatively old rig were not ideally located and, to a large extent, too inaccurate to serve as input to an ads. other active control modules were tested as followsthe friction test module. this module consists of programmable automated tests of f

25、riction in the well in relation to pick-up and slack-off with and without rotation. the module may also be used to program an automatic reaming function. automatic analysis of measured dynamics gives an in dication of frictio n in the well. trend an alysis of the fricti on will give an in dicati on

26、on cuttings accumulation, well stability and quality. this module was used on every connection while drilling.tripping/reaming control. this module limits speed and acceleration of the string to avoid excessive surge and swab pressures, i.e., outside the pore/fracturing pressure window. the trippi n

27、g control assists in avoidi ng in flux, fracturi ng and mud loss to the formatio n. reaming control limits the speed of the string to avoid pack-off/stuck pipe. in case of “full throttle” on the joystick, this module limits the tripping/reaming speed to an acceptable value. this module was used when

28、 trippi ng into and out of ope nhole and in combi nation with the automatic friction test.pump startup. this module limits the circulation step-up of the pump rate to an acceptable level to avoid a well pressure that exceeds the fracturing pressure (weak zone), resulting in loss of drilling mud. the

29、 module in eludes both semi-automatic and manual modes the semi-automatic function comprises a small number of in steps to reach the predetermi ned flowrate, where pump-rate buildup phases are optimized and automatic. the manual function limits incremental circulati on in crease rate within a predef

30、i ned win dow, where the driller must ack no wledge in cremental in crease in pump rate the semi-automatic optimized functi on was used on pipe connections in the pilot test.narrow pressure windows. to handle drilling through large pressure variations between individual layers or between the overbur

31、den and the reservoir, future drilling practice will continue to improve. rotary steerable liner drilling systems will be available near the end of this year. statoilhydro and one of statoilhydro's suppliers are developing a 95/8-in. and a 7-in. rotary, steerable liner drilling system. a full dr

32、illi ngtool package can be in eluded in the system. by combining steerable liner drilling with the expandable pipe technology and managed pressure drilling methods, many of today's drilling challenges can be solved.econtrol/edrilling. edrilling is an innovative system for real time drilling simu

33、lation, 3d visualization and control from a remote drilling expert center and is the technology basis for econtrol. econtrol is a rig supervision, optimization and control system that integrates 3d visualization of the wellbore with the most advaneed drilling process models. the concept uses all ava

34、ilable real time drilli ng data (surface and dow nhole) in combi nation with real time modeling to monitor, optimize and control the drilling process. the system comprises the following elements, some of which are unique and ground-breaking: automated pipe handling an advaneed and fast integrated dr

35、illing simulator, which has the capacity to model different drilling sub-processes dynamically, and also the interaction between these sub-processes in real time, used for automatic forward-looking during drilling, and can be used for uwhat-if evaluations as well automated drilling based on advaneed

36、 simulator models and 3d visualization automatic quality check and correct!ons of drilling data, making them suitable for processing by computer models real time supervision methodology for the drilling process using time-based drilling data, as well as drilling models/the integrated drilling simula

37、tor methodology for diagnosis of the drilling state and conditions, which is obtained from comparing model predictions with measured data advisory tech no logy for more optimal drilli ng data flow and computer infrastructure.the combi nation of the various elements will make edrilling very attractiv

38、e to new people comi ng into the in dustry; the so-called "game boy gen eratiorv virtual wellbore will be a key element in the system, with advaneed visualization of the downhole process, i.e., a new, open 3d visualization motor that can visualize all drilling and well related operations involv

39、ed. the next-generation visualization system is designed to collaborate with all participants involved, en abli ng enhan ced in teg rati on of all drilli ng and well activities in a global environ merit. the open system architecture allows equipme nt suppliers, service compa nies, con tractors and o

40、perators to connect via standard interfaces (i.e., witsml, etc.). the system is designed to handle the expected high data rates as a result of the use of wired pipe and similar tech no logies costly failures will be reduced and better knowledge of the process will be obtained. total visualizati on o

41、f the drilli ng process will be possible in real time. this in eludes the well path; geological horizons encountered; seismic information while drilling in real time (not complete); depth by visualizing the tally/bha; useeingn the bit or tool joint going through restricted areas like the bop or casi

42、ng shoe; and linking real time software models with real time data to analyze and optimize drilling performanee, e.g.5 visualizing well pressure profile and prediction of pressure when drilling ahead; recording and backtracking of operations in 3d.the system is also well suited for training. a typic

43、al edrilling infrastructure is shown in fig. 1 managed pressure drilling (mpd). mpd is a necessary building block for automated drilling. as we see it, mpd solutions will make a differenee in specific areas of the world, especially the gulf of mexico (gom). statoilhydro does not have any ongoing dev

44、elopment projects in gom, but has a large portfolio of prospects199020002nd and 3rd gen. rig如;18%nn.b0psurface bop21-in. lp marine riser kill and choke lineshtgh pressure riser1980 and 3rd gen. rig4 th and 5th gen. r>g18%-in. bop s器沪fig. 2 mpd solutions process.figure 2 shows the agr and ors solu

45、tions for dual-gradient mpd solutions in deep water. the agr's cmp system may be used with existing bop and drilling riser systems, while the ors's lrrs system is intended to be used with, as we see it, the future slim bop and hp riser system common for both solutions are: well control issue

46、s: mpd action:as indicated above, automated mpd solution can avoid letting the uhuman facto广 become an obstacle. we are also considering the available solutions for continuous circulation while making/breaking drill pipe connections. typical for the existing dual-gradient systems is that a relativel

47、y large amount of fluid is moved to compensate for ecd effect on conn ections. continuous circulation systems, such as circsub, nov's ccv, or others, could reduce time spent on connectionscontinuous fluid/cuttings measurement. real time monitoring and measuring of drilling fluid and drill cuttin

48、gs properties (cmfp) is necessary in a fully automated system, since it affects all of the real time drilling parameters such as rop, ecd, mpd, etc. and it improves decision making. further, it is essential for remotely operated drilling.geoservices is developing an automated system as described abo

49、ve in cooperation with statoilhydro. the intention is to take elements of the system into operation in 2008 to build confide nee in them. this particular system will measure fluid: viscosity, electric stability, loss, density, h2s, ph, particle size distribution and particle content.it will also mea

50、sure: the volume of cuttings and cavings monitoring (shape characterization), and the mineralogy of cuttings (using raman spectroscopy).drilling operations tracking system (dots). we are working with the company trac id systems as to develop a system for automatic tracking of drill pipe. initially,

51、the focus will be on tracki ng pipe in and out of the borehole. the next gen erati on of the system will in elude the history for each individual joint. the company has configured an atex-certified dots, in cludi ng a purpose-built rfid antenna system for in teg rati on in the drill floor of a conve

52、n tional offshore drilling rig and supporting pipe tally softwarethe rfid tran sponder moun ting tech nique is a prove n tech no logy (fig. 3), and is used and verified by a major drill pipe rental company. the transponders are certified according to governing atex regulations. each transponder incl

53、udes references to the atex certificate the transponders are passive and are proven to withstand temperatures and pressures present in oil and gas exploration and production wells. a separate test rig has been acquired to perform testing and verification.a software tool is also included in the dots

54、to tie all technical data, documentation, historical data, administration codes, etc. to each joint of drill pipe, as well as automatic tally-book gen erati on.liner drilling. drilling through sections with large pressure variations, or narrow pressure windows, continues to be a challenge rotary ste

55、erable liner drilling systems will be available near year-end 2008. statoilhydro and one of its suppliers are developing a 95/8-in. and a 7-in. system. a full drilling tool package can be in eluded in the system by combi ning steerable liner drilling with expa ndable pipe tech no logy and man aged p

56、ressure drilli ng methods, many of today's drilling challenges can be solved.summarystatoilhydro's intention is to tie all of the technologies briefly discussed above together into an automated drilling system flexibility is a key issue. one of the major challenges is to specify a solution t

57、hat enables future developments for new suppliers in the market, overlapping systems, and so forth. it is obvious that the system must be based on ethernet-type in terfaces to a central computer, where all the data and information are handled correctly. we are in the process of specifying such a sys

58、tem. a pilot is planned in 2009 where in teg rati on of different systems is the key issuefully automated drilling systems are now about ready to “take off.” there are several independent sub-systems being developed and others that are now commercial. the key issue for statoilhydro is to tie all these