Drilling automation and control is one industry segment that typically generates as much product innovation buzz as any other, with companies sometimes fine-tuning industry standards more effectively than starting with a blank sheet of paper.

M/D Totco’s Wildcat Automatic Drilling System (ADS) is an example of making good equipment

Figure 1. RigSense 2.2 is a robust and comprehensive wellsite information and reporting system. In addition to its e-Wildcat integration, RigSense 2.2’s enhancements include an ROP Gas Log, lag-inclusive sample reminders and an option to integrate the e-Totco electronic drift indicator. The latter provides inclination data storage capability and removes the requirement of manually completing paper reports.
better by re-design. The original Wildcat was implemented as a pneumatic control system with an interface of knobs and gauges. In contrast, the e-Wildcat, with an electric motor and electronic controls replacing the previous system’s pneumatics, has a touch-screen interface for the driller. In making the transition to e-Wildcat, the research and development team focused on improved performance and ease of use, but they also began the move from a pneumatic system that could only be controlled locally to an electronic system that permits remote control. When the system is integrated with the company’s other control systems, drilling set points can be initiated at the rig or from a remote site.

The system provides constant force and feed to generate a higher quality well bore and optimize the rate of penetration (ROP). While in auto drill mode, the system provides smooth and accurate operation and control of the brake handle using precise variable frequency drive technology and multiple drilling parameter monitoring.

Information and reporting
The new electronic platform works seamlessly with RigSense 2.2, a robust and comprehensive wellsite information and reporting system. (In addition to its e-Wildcat integration, RigSense 2.2’s enhancements include an ROP Gas Log, lag-inclusive sample reminders and an option to integrate the e-Totco electronic drift indicator. The latter provides inclination data storage capability and removes the requirement of manually completing paper reports.) This gave the system archiving and display capabilities, while the system’s control requirements doubled the RigSense system’s total computational power.

New capability
The new system provides constant force and feed to generate a higher quality well bore and optimize ROP. It also expands control parameters to include not only weight on bit (WOB) and Delta P, but also ROP and torque, each of which has its control setpoints. The system’s “Time Drill” mode lets operators drill at a specific rate, specified as easily as so many inches in so many minutes, to address specialized requirements of casing sidewall milling and sidetrack operations within multilateral, openhole well bores.

Its electronic features include reduced dependence on pneumatics; torque control loop; a drill stop point, which saves Kelly bushings; a hydraulic cut-out in the event that pump pressure is lost; and an indicator showing which loop is in control. Three of the most notable features are much-improved dynamic range, a simple interface allowing for easy control adjustments over wide ranges of formations and a fail-safe lift unit.

Expert system
The company provides an open interface to its automation and control equipment such as e-Wildcat. The protocol is shared with any oil and gas or service company, which can keep its proprietary systems to itself but can take advantage of the interface provided between their proprietary logic and drilling machines on the rig.

This leads to the next logical step of allowing remote control of the drilling process. That can be done by either a remote expert or “expert system” that evaluates all the options and decides on the optimal course. Thus, it might be “expertly” determined that it is better to drill a remaining portion of the well at a slow ROP rather than at maximum WOB or Delta P, if the expert feels it preserves the bit to the point that an additional bit trip is made unnecessary.
Unlike pneumatic autodrillers with a limited range of speeds, the new system’s fine range of the electronic control allows users to drill down to very low penetration rates without having to change any settings. The system is also able to drill tricky, or “ratty,” formations (e.g., 300 ft/hr or 91.5 m/hr, then suddenly down to only 10 ft/hr or 3 m/hr).

User-friendly
Allaying concerns that the control system’s complexity would hamstring drillers, initial field reports have rated it high in ease of use, largely because of the screen’s presentation of the information. Current users of RigSense 2.2 have familiarity because the two systems are very similar onscreen. As a result, the upgrade may seem transparent to many users, and training on e-Wildcat by an installer dispatched to the drilling site typically takes no more than a half-hour.

Drilling process information
RigSense System includes proven drilling algorithms for real-time onsite data analysis and control, state-of-the-art touch-screen displays, wireless networking and remote access, and business integration with the company’s Web site information system. The system allows the driller to configure screens to display drilling information that best suits his or her needs. The driller can view data numerically and in graphs. Alarm conditions can be set, and alarm parameters are easily modified for changing conditions and rig activity.

An electronic drilling recorder records all rig activity for up to one year. Records are searchable and can be viewed at a variety of resolutions. The system operates as a single interface, allowing rig personnel to access historical information, make notations and send messages to communicate with other displays on the rig.

A pipe tally function assists the driller by automating mundane tasks such as calculating bottomhole assembly lengths, drill pipe length, drill string length and kelly-down depth.
A pit volume totalizer function delivers vital information on mud volume and flow conditions. Rig personnel can monitor these parameters to deal with a potential kick quickly and effectively. The company man and toolpusher can instantly review the same information on their displays so that decisions on courses of action can be reached efficiently and effectively.
The same functionality available to the driller is available to the drilling engineer, rig supervisor and other key rig personnel. Workstations can be located virtually anywhere around the rig to provide the same consistent, high-quality information to the company man, tool pusher and mud engineer.

Manage reporting
A report management system streamlines rig reporting operations. Data collection for billing and payroll purposes is easily automated to provide IADC-approved format morning and payroll reports. Relevant data from the previous day is populated in the forms along with new information collected. The company can configure custom reports. Reports can be filled out in less time.

Reports can be sent directly to the home office via email or can be viewed through a Web browser anywhere — correct and on time. To provide timely information, report information can be automatically populated from the system’s databases to the company’s business integration system and directly into the operator’s business-critical applications. This enhances cost management control and reduces administrative tasks.

Remote diagnostics
Potential equipment problems on the rig can be detected by the company’s remote diagnostics system. If the instrumentation is starting to deliver a questionable reading, this system can identify the problem before the failure occurs — down to the part number level. The company can notify service technicians to attend to the situation without stopping the drilling operation.

For all of these, e-Wildcat is on the low end of the cost scale. Marketed exclusively as a rental product, the day rate is a small fraction of the drilling spread costs, and it produces immediate payback. Environmentally, the product’s use in cold weather operations such as Canada and the US Rocky Mountains has been well received because the electrical system does not freeze. Based on initial field performance, e-Wildcat has met or exceeded expectations by producing a high-quality well bore, reduced drilling curve time while reducing drilling program costs, improving service for directional drillers and extending bit life.