In the fast-paced world of oil and gas exploration, operational efficiency and reliability are crucial. The automation of Rig Control Systems (RCS) promises to enhance drilling performance through advanced tools like auto-drillers and torque management systems.
However, field results often fall short of expectations, due to misaligned configurations, insufficient feedback loops, and poor integration between equipment manufacturers and field operations, leading to inefficiencies and delays.
This challenge became evident during a high-profile drilling campaign in the Arabian Gulf. Despite using state-of-the-art jack-up rigs with advanced Rig Control Systems, key performance metrics, such as Rate of Penetration (ROP) and Mean Time Between Failures (MTBF), were underperformed. Failures in downhole tools and recurring drilling malfunctions further exacerbated the problem.
Dmitry Kuravskiy, a technical leader with over 15 years of experience in Extended Reach Drilling and rig control systems, spearheaded efforts to address these issues. His expertise in managing complex global projects was crucial in developing solutions to optimize Rig Control Systems performance.
Two wells drilled close to each other using identical rigs, tools, and techniques showed vastly different results. One well achieved its intermediate section efficiently, while the other struggled with low ROP and multiple failures, causing delays. Despite extensive reviews, the discrepancy remained unresolved, uncovering a gap in the existing engineering approach and highlighting the hidden potential of Rig Control Systems.
Complexity of Rig Control Systems
Unlike downhole tools, which are designed for predictable performance, Rig Control Systems operates in a more variable environment. Systems like auto-drillers and torque management rely on complex configurations often not optimized for real-world conditions.
Manufacturers provide generic settings tested in controlled environments, which fail to account for variables such as rock formations and dynamic frictional forces. Field teams, often lacking advanced training, struggle to adapt these configurations effectively.
Dmitry’s approach involved integrating surface, downhole, and Rig Control Systems data into a unified system, allowing for real-time feedback and knowledge transfer. He provided hands-on training and created detailed roadmaps to help crews dynamically adapt configurations during operations.
The solution required a systematic review of RCS configurations across multiple rigs, analyzing high-frequency drilling data to identify patterns linking dysfunctions to specific system settings. This approach focused on understanding the physics behind these patterns.
Collaboration was key to the methodology’s success. It assembled cross-disciplinary teams of engineers, data scientists, and equipment specialists to develop a structured workflow. This included diagnostics to correlate Rig Control Systems configurations with drilling performance metrics, dynamic drilling parameter roadmaps tailored to geological conditions, and real-time integration of RCS data into advanced analytics platforms for continuous monitoring and adjustment. Training was critical, equipping field teams with the knowledge to interpret trends and implement adaptive strategies, bridging the gap between theory and practice.
The optimized RCS methodology delivered transformative results. Efficiency gains were significant, as optimized configurations minimized dysfunctions, leading to smoother operations and higher ROP.
Cost savings were equally impressive, with annual savings exceeding $10 million per rig by reducing downtime and extending tool lifespans. This approach was scalable, successfully applied to 50 percent of rigs in the campaign, proving adaptable to diverse environments.
Environmental Impact: Reducing Carbon Footprint and Fuel Consumption
The environmental impact was also notable. By saving rig days, the methodology reduced CO₂ emissions by approximately 50 metric tons per rig day. With 30 rig days saved annually per rig, this results in a reduction of 1,500 metric tons of CO₂ per rig. Across the fleet of 180 rigs in the Middle East, this amounts to 270,000 metric tons of CO₂ saved each year—equivalent to planting 4.5 million trees or the carbon sequestered by a forest of 423 square miles, about three times the size of Dubai. Additionally, reduced fuel consumption minimized reliance on fossil fuels, further enhancing sustainability.
One notable success involved a challenging deep well plagued by stick-slip oscillations. Using the new methodology, the Rig Control Systems Methodology was dynamically reconfigured, and real-time data monitoring stabilized operations, allowing the section to be completed ahead of schedule. Beyond immediate gains, this approach fostered a culture of proactive problem-solving, embedding analytics and adaptability into daily operations, ensuring long-term excellence.
Revolutionizing Drilling
By addressing systemic inefficiencies, this methodology demonstrated how technology, analytics, and collaboration can revolutionize drilling operations in the Arabian Gulf. The results speak for themselves: improved efficiency, substantial cost savings, and a clear roadmap for innovation.
As the oil and gas industry navigates a future of complexity, these lessons provide valuable insights. With continued innovation, RCS systems can evolve from mere efficiency tools to catalysts for sustainable progress, ensuring every operation contributes to a legacy of excellence.
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