Tripping Optimization via Multi-Thread Rig State Control
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Solution Overview
Problem
Current drilling operations face inefficiencies in tripping operations due to the lack of optimized control over the top drive, iron roughneck, and pipe handler equipment, leading to increased time and complexity in connecting and disconnecting pipe segments during drilling and tripping processes.
Innovation Solution
Implementing a system that utilizes sensor data to identify and manage multi-thread rig states, allowing for overlapping operations between the top drive, iron roughneck, and pipe handler, thereby optimizing the timing and efficiency of tripping in and tripping out processes by calculating optimal rig state characteristics and adjusting equipment actions accordingly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional sequential control methods are used for tripping operations, then operational simplicity is maintained, but total tripping time increases due to inability to overlap equipment actions
Solution Approach 1:
The control system pre-plans and pre-coordinates the sequence of operations for multiple pieces of equipment before tripping operations begin. By analyzing the required workflow and establishing optimal timing schedules in advance, the system enables equipment to be ready and positioned for overlapping operations without requiring complex real-time coordination during execution.
Solution Approach 2:
The system maintains continuous productive action by overlapping the operation cycles of the top drive, iron roughneck, and pipe handler. Instead of waiting for one piece of equipment to complete its cycle before starting the next, the control system coordinates them to operate in parallel where possible, ensuring that no equipment remains idle and the tripping process flows continuously without interruptions.
2Loss of time
If multiple pieces of equipment operate simultaneously during tripping, then total operation time decreases, but coordination complexity and risk of interference increases
Solution Approach 1:
The control system continuously monitors the status and position of all tripping equipment through sensors and feedback signals. By tracking the actual state of the top drive, iron roughneck, and pipe handler in real-time, the system can detect deviations from the planned sequence and make automatic adjustments to prevent conflicts, ensuring reliable coordination even during simultaneous operations.
Solution Approach 2:
The tripping operation is divided into discrete sequential phases or states, with each phase having clearly defined start and end conditions. The control system manages transitions between these segmented phases, ensuring that overlapping equipment actions occur only when safety conditions are met and that each equipment completes its current phase before entering the next, preventing interference while maintaining parallel operation benefits.
3Productivity
If optimized rig state characteristics are implemented, then tripping efficiency improves, but data processing and calculation requirements increase
Solution Approach 1:
The system optimizes tripping operations by dynamically adjusting key parameters such as equipment speed, positioning coordinates, and timing intervals based on real-time sensor data and pre-calculated optimal rig state characteristics. By modifying these parameters within defined ranges and constraints, the system achieves improved efficiency without requiring complete redesign of the control architecture or excessive computational resources.
Data Source
AI summary
Methods and systems for optimizing timing for drilling and tripping operation. An example method may include receiving a plurality of sensor data characterizing rig equipment and tripping status. The method may include identifying a plurality of multi-thread rig states based on the plurality of sensor data. The method calculates a plurality of optimal rig state characteristics (RSCs), wherein the plurality of optimal RSCs are calculated based on the plurality of sensor data as it relates to the plurality of multi-thread rig states. The method also performs a tripping operation with the rig equipment after applying the plurality of optimal RSCs. The method may also gather a plurality of updated sensor data from the rig equipment during the tripping operation for a recalculation of the plurality of optimal RSCs.