SPE 143838

Mechatronics Technology in Drilling Operations Used to Enhance Safety

Ardia Karnugroho, Steve Nas, Julmar Shaun S. Toralde / Weatherford, Tutuko Prajogo Ph. D. / Swiss German
University

Copyright 2011, Society of Petroleum Engineers

This paper was prepared for presentation at the SPE Digital Energy Conference and Exhibition held in The Woodlands, Texas, USA, 19–21 April 2011.

This paper was selected for presentation by an SPE program committee following review of information contained in an abstract submitted by the author(s). Contents of the paper have not been
reviewed by the Society of Petroleum Engineers and are subject to correction by the author(s). The material does not necessarily reflect any position of the Society of Petroleum Engineers, its
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Abstract

According to Wikipedia, “mechatronics” is the synergistic combination of mechanical engineering, electronic engineering,
computer engineering, control engineering, and systems design engineering in order to design, and manufacture useful
products. The combination of these technologies is now actively being used to enhance the safety of drilling operations.

This paper presents an overview of how mechatronics is now used in the oil & gas industry to significantly enhance the
safety of drilling operations. In the drilling industry this technology is known as managed pressure drilling.

Automating the control of bottom hole pressures whilst drilling the well significantly enhances the safety of the drilling
operation. Using control technology combined with accurate sensors and additional equipment when drilling provides an
unprecedented level of detection and control of the well whilst it is being drilled. This in turn enhances the efficiency and
safety of the drilling operations.

This technology has been used on a number of high pressure high temperature wells and it is now being used on deepwater
wells to provide early kick detection as well as riser gas handling.

This paper demonstrates the use of mechatronics in the drilling process and the applications of managed pressure drilling in
deepwater and high pressure wells.

Introduction

Mechatronics is an engineering term that originated in Japan back in the 1970’s. The term was created due to predicaments
that were encountered when designing products that combined mechanical, electrical, and control systems engineering. Even
though the term was born more than 40 years ago, very few people are as yet familiar with this engineering term.
Mechatronics technology which also involves a lot of automation techniques has been used widely around the world to
improve engineering designs and to increase the safety, efficiency, and profitability of engineered systems.

The Technical Committee of Mechatronics of the International Federation for the Theory of Machines and Mechanism,
define mechatronics as: "The synergistic combination of mechanical precision engineering, electronic control and systems,
thinking in the design of products and manufacturing processes".

Currently mechatronics is being applied in different equipment and drilling techniques in oil and gas industry. The use of
mechatronics technology in the extraction of oil and gas helps both Operators and Service Providers increase the level of
safety of their operations as well as improve their efficiency and profitability.

Mechatronics

Mechatronics consists of three different key elements, specifically mechanical engineering, electrical engineering, and
control system engineering. Please see Figure 1 for a visual representation of the definition of mechatronics. When a system
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has these three different key elements, the system can be called a mechatronic system. The objectives of mechatronics is to
enhance the strength of an engineered system and to design-out any weaknesses that could be resulting from a combination of
different engineering disciplines.

When designing a system with several different designers with different backgrounds, disagreements, compromises and
possibly mistakes will occur not only during the design process but also in the final product. For example, a mechanical
engineer might design a system to the best of his or her ability to satisfy mechanical engineering requirements. However, if
the requirements for electrical engineering get overlooked, the electrical engineer might have problems when designing the
electrical requirements for the system. An engineer with a mechatronics background should have the capability to design a
system that satisfies both the electrical and mechanical standpoints. With this, the final product will hopefully be better than
if the system was designed by different engineers with different backgrounds.

Figure 1. Mechatronics

Mechatronics in the Oil and Gas Industry

Mechatronics has been around in the oil and gas industry for a while now. Top drive systems contain the basic elements of
mechatronics. It contains a Programmable Logic Controller (PLC) as the main control system, a driller’s panel as an input for
the system, and a hydraulic motor and gearbox that provide the output.

Another example would be a remotely controlled hydraulic valve complete with sensors, control panel, and control system. In
daily operations, opening a valve with high pressures could be considered high risk and safety critical. If a sensor is placed in
the flowline behind the valve that is connected to a control system, we can eliminate some of the risks. The control panel and
the valve will also be connected to the same control system. When an operator opens the valve, and he makes the mistake of
not paying attention to the pressure reading, the valve will not open due to the safety systems set in the PLC. The valve will
not open as the pressure sensor will inform the PLC not to open the valve with high pressure. Once the pressure has been
reduced and a safe pressure reading has been provided by the sensor, the PLC will allow the valve to open. Please see Figure
2 for a simple illustration of the example cited above and Figure 3 for the flow chart process.

Figure 2. Example of a Mechatronics Application in the Oil and Gas Industry.

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Figure 3. Flow Chart for the Example Shown in Figure 2.

Managed Pressure Drilling

Managed pressure drilling is an unconventional drilling technique that has been used to drill difficult wells around the world.
The International Association of Drilling Contractors (IADC) defines Managed Pressure Drilling (MPD) as “an adaptive
drilling process used to precisely control the annular pressure profile throughout the wellbore. The objectives are to ascertain
the downhole pressure environment limits and to manage the annular hydraulic pressure profile accordingly. MPD is
intended to avoid continuous influx of formation fluids to the surface”. In other words, with MPD, downhole pressure can be
maintained (managed) at a certain desired value. Others call MPD as “walk-the-line” drilling, because the pressure
maintained is very close to pore and fracture pressures.

In conventional drilling, bottom hole pressure (BHP) is equal to mud weight (MW) plus equivalent circulating density
(ECD); BHP = MW + ECD.

When drilling stops, the ECD drops to zero because ECD only exists when the pumps are on and circulation occurs. In
managed pressure drilling, we can add another variable to the equation - backpressure.

In MPD operations, the bottom hole pressure (BHP) is equal to mud weight (MW) plus equivalent circulating density (ECD)
plus surface back pressure (SBP); BHP = MW + ECD + SBP.

To change the bottom hole pressure in MPD, the surface backpressure value is adjusted. This can be done quickly and thus
allows full control of the bottom hole pressure both in static and dynamic conditions. Managed Pressure Drilling equipment
can now be used to apply mechatronics technology to enhance the safety, reliability, and efficiency of the entire drilling
system.
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Mechatronics in Drilling Operations

Using surface back pressure in a closed well bore to control the well and detect kicks can now be done in either manual or
fully automatic mode during the drilling process.

In conventional drilling operations, the BOP would have to be closed to apply more back pressure to the well. In managed
pressure drilling operations, the well bore is already capped or closed using a Rotating Control Device (RCD). The closed
well bore system can be supplemented by a choke manifold and an accurate flow meter that allows automatic monitoring of
the drilling process and the required bottom hole pressures.

By doing this automatically, there would be no need for an operator to control the backpressure. This does not mean that we
are relying one hundred percent on a machine. A competent person who understands the drilling and well control process
(like the driller) can still be monitoring the system. By relying on a well designed MPD system, a driller could concentrate on
the drilling process whilst the fully automated MPD system provides well control and supplies the driller with the appropriate
warnings.

With the well closed in, the flow into the well can be monitored using the mud pumps.
Pressures such as injection pressure and surface back pressure, as well as flow out and fluid
densities can be measured automatically. The system can monitor the barrel in, barrel out
principles as well as mud weight and pressures. The computer system can calculate the
bottom hole pressure in real time both in circulating mode as well as in static mode. Using a
PWD sensor can provide the required feed back to ensure that the computer model is
calibrated.

Any deviation from the steady flow in and out of the well can be detected and adjustments
can be made as required. The system is only looking at the well and can ignore any fluid
transfers and mixing requirements that are required in the mud pits.

The system can be designed to measure and collect the following data:
• Injection pressure;
• Surface back pressure;
• Mud weight out;
• Flow rate into the well;
• Flow rate out of the well;
• Temperature in;
• Temperature out;
• Gas concentration in return flow;
• Cuttings concentration in return flow;
• Bit depth;
• Bit speed and direction.

Figure 4. Closed Loop Drilling.

Combining all of the above listed parameters and feeding the collected data into a computer system that runs a highly
accurate flow model would allow the drilling process to proceed whilst monitoring and calculating pressures in the well bore.
If a kick is detected the system can automatically increase the surface back pressure to contain the well. The system could be
smart enough to detect an increasing level of gas in the fluid and then apply more back pressure to ensure that the pressure
remains controlled. If losses are detected the system will provide warnings and can be adjusted to reduce back pressure and
thus reduce the loss rate. The system can monitor the well during connections and look at potential ballooning issues as well
as monitoring well fill during tripping operations.

To be able to apply managed pressure drilling some additional equipment is needed, the main components being a rotating
control device (RCD) and a choke manifold.

There are currently many different models of rotating control devices and not all of them can be operated remotely. Some
RCDs can be remotely controlled and already have pressure measurements included in their control systems in order to avoid
release of the seal assembly under pressure. Choke manifold that are automatically controlled are also available and with the
autochoke systems, the control of back pressure can easily be controlled from the rig floor.
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Currently most of the equipment is designed to work separately and each piece of equipment has its own control system.
When considering the introduction of a mechatronics system for managed pressure drilling, a fully automated and integrated,
system could be designed and manufactured.

The rotating control device, choke manifold, remote controlled valves, and mud pumps can all be driven and controlled by
the same system. During drilling operations, the driller can set the required bottom hole pressure parameters and drilling
parameter and the mechatronics system could drill the hole section in fully automated mode.

Ideally, the system can then be expanded to work closely with the currently remote-controlled rig floor equipment and
tripping and connections could also be made hands off. Discussions of rig floor automation is covered in numerous papers,
but adding wellbore monitoring to this process, which is now possible, opens the doors to increased automation and
optimization of the drilling process.

Computing power available is also steadily rising and with the introduction of touch screen technology, such as what we now
see applied in tablet computers, the need for multiple screens in a driller’s control cabin could also be reduced. Combining
the auto driller systems, pipe handling systems and closed wellbore MPD systems with advanced computing power makes
further enhanced rig automation possible.

Remote Monitoring

As soon as computer controlled systems are used to measure, sense and control drilling systems, the data can also be easily
transmitted to the shore base, where a team of drilling and equipment experts can monitor vital rig systems to ensure that all
of the systems are operated as required. Remote monitoring also allows drilling experts to look at the drilling and geology
process and make relevant interpretations and more informed and relevant decisions.

Mechatronics and Safety

How can mechatronics enhance safety?

1) Fewer personnel involved. On older rigs, manual tongs and hand slips are still used. At least three to four personnel
are needed on the rig floor to operate this manual equipment. Modern rigs are already using parts of mechatronics
technology, such as iron roughnecks and flush-mounted spiders and elevators. With this technology, only one person
is needed to run the whole process and the operator does not have to be on the rig floor. The systems can be operated
using remote controlled panels to operate the systems.
2) Reducing mistakes. To err is human and mistakes are being made. Allowing a computer do the work, can reduce if
not eliminate mistakes.
3) Response times. Response time can be reduced. People busy with other tasks may need to move to the correct
location to respond and make corrections to the system. A high technology system with sensors remains in place
and is able to respond to the requirements of the system extremely quickly.
4) Automation and real time technology. Using sensors, control systems, combined with the mechanical actuators, real
time detection can be achieved. This can be applied to kick detection. If a kick can be detected in volumes less than
a barrel with automated action taken, thus reducing the influx volume, the risks of blow outs and well control issues
can be significantly reduced.

Issues

Geological Uncertainties: One of the main issues that remain is uncertainties encountered in the geological strata and the
system will have to be controlled. Humans will still be required to deal with the uncertainties of the earth models. Pore
pressures and fracture pressures can vary from the plan and certain formation issues will require changes in the plan. The
systems must be flexible enough to deal with the required geological issues and variations in weather and surface issues.
Reducing the head count on rigs still drives a fundamental safety issue of lowering the exposure of people to a risky
environment.

Equipment Reliability: Adding more and more complex equipment does also require more advanced service, maintenance,
trouble shooting and spare parts. Equipment engineers must be highly trained and must be comfortable with the electrical,
hydraulic and computer technology required for mechatronics systems. Maintenance and error detection and analysis systems
must also keep pace with the advanced systems used to take the driller off the rig floor. Systems that send advanced
diagnostics to remote control rooms and warn about potential equipment failures could further enhance remote controlled
drilling operations.
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Conclusions

Mechatronics technology has been used widely in today’s modern engineering world. Airplanes fly on auto pilot and Cat III
runway systems allow fully automated landings of the biggest airplanes in thick fog. The introduction of new technologies is
now helping the oil and gas industry to increase safety and it allows the drilling of wells that were previously deemed
undrillable.

With the proper engineering techniques and technology, deepwater, extended reach wells, and high pressure high temperature
wells can now be drilled. Managed pressure drilling, which mainly utilizes concepts and systems involving mechatronics
technology, is now providing capabilities to drill wells more efficiently and wells with rotating control devices, making them
closed and pressurizable, reduce the potential for well control incidents. Extending and expanding the use of mechatronics in
managed pressure drilling, and in the drilling operation as a whole, has the potential to produce a fully automated system that
can both optimize the process and simultaneously minimize risks to personnel, thereby greatly enhancing and raising the
level of safety in well construction.

References

Bolton, W. (2003) Mechatronics Electronic Control Systems in Mechanical and Electrical Engineering Third Edition.
Harlow: Pearson Education Limited

Boyadjieff, G.I., Varco Intl. Inc, “The Application of Robotics to the Drilling Process”, SPE paper no 17232, presented at the
SPE/IADC Drilling Conference, 28 February-2 March 1988, Dallas, Texas

Castro, S. Industrial Mechatronics

http://www.monografias.com/trabajos12/monoi/monoi.shtml [accessed 02/15/2011]
Gala, Deepak M. and Julmar Shaun Toralde (2011) Managed Pressure Drilling 101: Moving Beyond “It’s Always Been
Done That Way”. The Way Ahead, Vol. 7, No. 1, pp. 12-14

Reid, David, Varco International, “The Development of Automated Drilling Rigs “, SPE paper no 39373, presented at the
IADC/SPE Drilling Conference, 3-6 March 1998, Dallas, Texas.

Nas, S. Weatherford Solutions, “Kick Detection and well control in a Closed Wellbore”, SPE paper no 143099, prepared for
presentation at the IADC/SPE Managed Pressure Drilling and Underbalanced Operations Conference and Exhibition held in
Denver, Colorado, USA, 5–6 April 2011.

Wikipedia (2011) Mechatronics

http://en.wikipedia.org/wiki/Mechatronics [accessed 02/18/2011]
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Figure 5. Mechatronics in a Closed Loop and Managed Pressure Drilling System.