US-12618318-B2 - Robotic systems and associated automated well completion operations

US12618318B2US 12618318 B2US12618318 B2US 12618318B2US-12618318-B2

Abstract

A method of using dual-use pump systems to reduce greenhouse emissions and completion costs that includes positioning a first pump system (“FPS”) and a drilling apparatus (“DA”) at a first well pad and a second pump system (“SPS”) at a second well pad. The method includes performing a drilling operation using the FPS and the DA on at the first well pad, and then moving the DA to the second well pad to couple with the SPS. A completion unit is then coupled to the FPS at the first well pad. While the DA performs a drilling operation using the SPS at the second well pad, the completion unit performs a completion operation using the FPS at the first well pad.

Inventors

Frank J. Husband
Malini MANOCHA
Colin Oliver

Assignees

NABORS DRILLING TECHNOLOGIES USA, INC.

Dates

Publication Date: 20260505
Application Date: 20240828

Claims (20)

1 . A method of performing completion operations and drilling operations on well pads, the method comprising: positioning a drilling and completion system in a first configuration on a first well pad of the well pads and a second well pad of the well pads that is different from the first well pad; wherein the drilling and completion system comprises a first pump system and a drilling apparatus located on the first well pad and a second pump system located on the second well pad; wherein, when in the first configuration, the drilling apparatus is operably coupled to the first pump system at the first well pad; performing a first drilling operation, using the first pump system and the drilling apparatus, on a first well on the first well pad; moving the drilling and completion system from the first configuration to a second configuration on the first well pad and the second well pad; wherein, when in the second configuration, the drilling apparatus is operably coupled to the second pump system at the second well pad; wherein the drilling and completion system further comprises a completion unit; wherein, when in the second configuration, the completion unit is operably coupled to the first pump system on the first well pad; performing a second drilling operation, using the second pump system and the drilling apparatus when the drilling and completion system is in the second configuration, on a second well on the second well pad that is different from the first well pad; and performing a first completion operation, using the first pump system and the completion unit when the drilling and completion system is in the second configuration, on the first well on the first well pad.
2 . The method of claim 1 , wherein performing the second drilling operation, using the second pump system and the drilling apparatus, on the second well pad and performing the first completion operation, using the first pump system and the completion unit, on the first well pad occurs simultaneously.
3 . The method of claim 1 , further comprising: saving, by the drilling and completion system, drilling data generated during the first drilling operation on the first well; and creating, by the drilling and completion system, a first well completion program using the drilling data generated during the first drilling operation; wherein performing the first completion operation, using the first pump system and the completion unit, on the first well comprises the drilling and completion system executing the first well completion program.
4 . The method of claim 3 , further comprising: creating, by the drilling and completion system, a digital twin of the first well; wherein the digital twin is a virtual representation that integrates real-time data from the first well; and using the digital twin to simulate and optimize the first well completion program prior to execution, thereby enhancing accuracy and efficiency in the completion operation.
5 . The method of claim 3 , wherein the completion unit further comprises: a sensor monitoring a completion parameter associated with the first completion operation; a completion unit controller capable of controlling the operation of the first pump system when the drilling and completion system is in the second configuration; wherein the first well completion program comprises a target parameter; and wherein the completion unit controller, when the drilling and completion system is in the second configuration and when the first pump system and the completion unit are performing the first completion operation, is capable of: receiving the completion parameters from the sensor; determining a difference between the completion parameter and the target parameters; and generating control signals, based on the difference, for the first pump system to reduce the difference such that the completion unit controller, the sensor, and the first pump system form a closed loop system when in the drilling and completion system is in the second configuration.
6 . The method of claim 5 , wherein the completion unit controller further comprises a robotic sequence controller capable of executing predefined robotic sequences for automated tasks during the first completion operation; wherein the robotic sequence controller, based on the completion parameters and the target parameters, adjusts the robotic sequences to enhance precision and efficiency of the first completion operation; and wherein the automated tasks of the robotic sequences are performed in coordination with the first pump system and the completion unit to improve performance of the first well completion program.
7 . The method of claim 5 , wherein the first completion operation comprise a wireline pump down.
8 . The method of claim 7 , wherein the completion unit comprises a wireline unit; wherein the sensor is a plurality of sensors; wherein the plurality of sensors monitor one or more of line speed of the wireline unit, depth, or line tension such that the completion parameters comprise one or more of: line speed of the wireline unit, depth, or line tension; wherein the target parameter is one of a plurality of target parameters; and wherein the plurality of target parameters comprise one or more of a target line speed of the wireline unit, a target depth, or a target line tension.
9 . The method of claim 8 , wherein drilling data generated during the first drilling operation on the first well comprises a curve in a wellbore associated with specific wellbore depth; and wherein the first well completion program comprises target parameters based on the curve in the wellbore associated with the specific wellbore depth.
10 . The method of claim 5 , wherein the first completion operation comprise a leak off test.
11 . The method of claim 10 , wherein the sensor monitors a wellbore pressure; and wherein target parameter comprises a target test pressure.
12 . The method of claim 1 , further comprising: moving the drilling and completion system from the second configuration to a third configuration on the second well pad and a third well pad; and wherein, when in the third configuration, the drilling apparatus is operably coupled to the second pump system at the second well pad; wherein, when in the third configuration, the first pump system is located at the third well pad; performing a third drilling operation, using the second pump system and the drilling apparatus, on a third well on the second well pad; moving the drilling and completion system from the third configuration to a fourth configuration on the second well pad and the third well pad; and wherein, when in the fourth configuration, the drilling apparatus is operably coupled to the first pump system at the third well pad; wherein, when in the fourth configuration, the completion unit is operably coupled to the second pump system at the second well pad; and performing a fourth drilling operation, using the first pump system and the drilling apparatus, on a fourth well on the third well pad while simultaneously performing a second completion operation, using the second pump system and the completion unit, on the third well at the second well pad.
13 . A drilling and completion system for performing completion operations and drilling operations on well pads, wherein the drilling and completion system is capable of being positioned in a first configuration and a second configuration, wherein the system comprises: a first pump system, a second pump system, a drilling apparatus, and a completion unit; wherein, when in the first configuration, the first pump system and the drilling apparatus are located on a first well pad of the well pads and the second pump system is located on a second well pad of the well pads that is different from the first well pad; wherein, when in the first configuration, the first pump system and the drilling apparatus are capable of performing a first drilling operation on a first well on the first well pad; wherein, when in the second configuration, the drilling apparatus is operably coupled to the second pump system at the second well pad and the completion unit is operably coupled to the first pump system; wherein, when in the second configuration, the second pump system and the drilling apparatus are capable of performing a second drilling operation on a second well on the second well pad that is different from the first well pad; and wherein, when in the second configuration, the first pump system and the completion unit are capable of performing a first completion operation on the first well on the first well pad.
14 . The system of claim 13 , wherein, when in the second configuration, the second pump system and the drilling apparatus perform the second drilling operation on the second well on the second well pad and the first pump system and the completion unit perform the first completion operation on the first well on the first well pad simultaneously.
15 . The system of claim 13 , wherein the drilling apparatus comprises a drilling apparatus controller; wherein the drilling apparatus controller is configured to save drilling data generated during the first drilling operation on the first well; wherein the completion unit comprise a completion controller; and wherein the completion controller is configured to create a first well completion program using the drilling data generated during the first drilling operation on the first well; wherein the completion controller is configured to execute first well completion program.
16 . The system of claim 15 , wherein the completion unit further comprises a sensor monitoring a completion parameter associated with the first completion operation; wherein the completion controller is capable of controlling the operation of the first pump system when the drilling and completion system is in the second configuration; wherein the first well completion program comprises a target parameter; and wherein the completion unit controller, when the drilling and completion system is in the second configuration and when the first pump system and the completion unit are performing the first completion operation, is capable of: receiving the completion parameters from the sensor; determining a difference between the completion parameter and the target parameters; and generating control signals, based on the difference, for the first pump system to reduce the difference such that the completion unit controller, the sensor, and the first pump system form a closed loop system when in the drilling and completion system is in the second configuration.
17 . The system of claim 16 , wherein the first completion operation comprise a wireline pump down; wherein the completion unit comprises a wireline unit; wherein the sensor is a plurality of sensors; wherein the plurality of sensors monitor one or more of line speed of the wireline unit, depth, or line tension such that the completion parameters comprise one or more of: line speed of the wireline unit, depth, or line tension; wherein the target parameter is one of a plurality of target parameters; and wherein the plurality of target parameters comprise one or more of a target line speed of the wireline unit, a target depth, or a target line tension.
18 . The system of claim 17 , wherein drilling data generated during the first drilling operation on the first well comprises a curve in a wellbore associated with specific wellbore depth; and wherein the first well completion program comprises target parameters based on the curve in the wellbore associated with the specific wellbore depth.
19 . The system of claim 16 , wherein the first completion operation comprise a leak off test.
20 . The system of claim 19 , wherein the sensor monitors a wellbore pressure; and wherein target parameter comprises a target test pressure.

Description

CROSS-REFERENCE TO RELATED APPLICATION This application claims the benefit of the filing date of, and priority to, U.S. Patent Application No. 63/579,796, filed Aug. 30, 2023, the entire disclosure of which is hereby incorporated herein by reference. TECHNICAL FIELD This disclosure relates in general to systems and related methods for well stimulation, and specifically to using an automated sequence to stimulate a reservoir using dual-use pumping system(s). BACKGROUND Modern high-volume hydraulic well stimulation is a technique used to enable the extraction of natural gas or oil from shale and other forms of “tight” rock, or impermeable rock formations that lock in oil and gas and make fossil fuel production difficult. Large quantities of water, chemicals, and sand are injected into these formations at pressures high enough to crack the rock, allowing the once-trapped gas and oil to flow to the surface. With conventional systems, hydraulic well stimulation requires an extensive amount of equipment, such as high-pressure, high-volume well stimulation pumps; blenders for well stimulation fluids; and storage tanks for water, sand, chemicals, and wastewater. This stimulation infrastructure, along with other additional equipment, conventionally arrives at drill sites via heavy trucks. With conventional systems, the stimulation infrastructure arrives on site and replaces the drilling infrastructure after the drilling infrastructure has been removed; therefore, both sets of infrastructure are not in operation on the well pad at the same time. This sequence of drilling infrastructure being removed before stimulation infrastructure is set in place is, at least in part, due to space limitations on the well pad. Conventionally, the footprint associated with conventional stimulation infrastructure is too large to share the well pad with the drilling infrastructure. Waiting to set up the stimulation infrastructure until the drilling infrastructure is removed limits the number of wells that can be completed in a time period, such as for example a year. Moreover, the use of heavy trucks and personnel associated with the delivery and set up of the conventional stimulation infrastructure can introduce greenhouse gas emissions and increase the risk of personnel injuries, etc. Therefore, what is needed is a system, method, or apparatus that addresses one or more of the foregoing issues, and/or one or more other issues. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a schematic diagram of well pads upon which a portion of a drilling and completion system is in a first configuration, wherein the system comprises a first computing device, according to one or more aspects of the present disclosure. FIG. 2 is a schematic diagram of the first computing device of FIG. 1, according to one or more aspects of the present disclosure. FIGS. 3A and 3B together illustrate a schematic diagram of the well pads of FIG. 1 upon which the drilling and completion system is in a second configuration, wherein the system comprises a second computing device, according to one or more aspects of the present disclosure. FIG. 4 is a schematic diagram of the second computing device of FIG. 3, according to one or more aspects of the present disclosure. FIG. 5 is a flow-chart diagram of a method of using the system of FIGS. 1 and 3, according to one or more aspects of the present disclosure. FIG. 6 is a diagrammatic illustration of a data flow used during the method of FIG. 5, according to one or more aspects of the present disclosure. FIG. 7 is a schematic diagram of the well pads of FIG. 3 upon which the drilling and completion system is in a third configuration, according to one or more aspects of the present disclosure. FIG. 8 is a schematic diagram illustrating the system of FIG. 1 in the first configuration, the second configuration, the third configuration, and a fourth configuration, according to one or more aspects of the present disclosure. FIG. 9 is a diagrammatic illustration of a node for implementing one or more example embodiments of the present disclosure, according to one or more aspects of the present disclosure. DETAILED DESCRIPTION The following disclosure provides many different embodiments or examples. Specific examples of components and arrangements are described below to simplify the present disclosure. These are, of course, merely examples and are not intended to be limiting. In addition, the present disclosure may repeat reference numerals and/or letters in the various examples. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various embodiments and/or configurations discussed. A drilling and completion system, an example of which is illustrated in FIG. 1, provides improvements to conventional hydraulic well stimulation apparatuses and methods. Some example improvements are associated with the use of a dual-use pump system that is configured to switch between drill