Well Rig Supervisory Control for Automated Equipment Coordination
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Solution Overview
Problem
Existing well construction systems rely heavily on human intervention for coordination and control of subsystems, limiting efficiency, speed, and safety.
Innovation Solution
Implementing a supervisory control system with a central controller that integrates local controllers for well construction equipment, enabling real-time communication and coordinated operation of subsystems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If human operators manually control and monitor well construction equipment, then operational flexibility and decision-making capability are maintained, but operational speed, efficiency, and safety are limited
Solution Approach 1:
The system enables self-service automation where the control system automatically monitors sensor data, detects well construction events, and executes operational sequences without continuous human intervention. The supervisory controller autonomously coordinates between the rig control system and well construction equipment, allowing the system to manage itself while maintaining safety and efficiency.
Solution Approach 2:
The patent replaces manual mechanical control operations with an automated electronic control system. The supervisory controller uses sensor data processing and automated decision-making algorithms to substitute human operators' manual control actions, thereby increasing operational speed and efficiency while reducing human intervention requirements.
2Reliability
If a centralized control system integrates all subsystems for coordinated operation, then operational coordination and safety are improved, but system complexity increases
Solution Approach 1:
The control system is segmented into distinct functional layers: the rig control system handles immediate equipment control, while the supervisory controller manages high-level coordination and event detection. This segmentation allows complex control functions to be distributed across manageable modules, improving reliability through specialized functions while keeping individual components relatively simple.
Solution Approach 2:
The supervisory controller acts as an intermediary layer between the rig control system and the well construction equipment. It receives sensor data from the rig control system, processes it to detect well construction events, and generates operational sequences that are sent back to the rig control system for execution. This intermediary structure improves coordination and safety while managing system complexity through clear interface definitions.
3Productivity
If automated event detection and operational sequencing are implemented, then operational efficiency and consistency are enhanced, but system complexity and initial setup requirements increase
Solution Approach 1:
The system employs preliminary action by pre-programming operational sequences that define the correct order of operations for well construction events. When a well construction event is detected through sensor data analysis, the supervisory controller automatically retrieves and executes the corresponding pre-defined operational sequence, ensuring consistent and efficient operations without requiring complex real-time decision-making logic.
Data Source
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AI summary
A supervisory control system for a well construction rig operable to perform well construction operations to construct a planned well at a wellsite. The supervisory control system may be installable in association with the well construction rig. The supervisory control system may comprise a supervisory controller communicatively connectable with a central controller of a rig control system of the well construction rig. The rig control system may be communicatively connected with and operable to control well construction equipment of the well construction rig. The supervisory controller may be operable to control the well construction equipment via the rig control system to cause the well construction equipment to perform the well construction operations. The central controller may be operable as an I/O interface for matching inputs and outputs of the supervisory controller with corresponding inputs and outputs of at least one piece of the well construction equipment.