Scale-Up Journey on Advanced Rig Mechanized Automation (RMA) for Autonomous Drilling Operation in Offshore Peninsula Malaysia

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Abstract In 2022, a groundbreaking initiative marked the world's first integration of three automation systems on an International Jack Up rig provider, kickstarting a 10-well campaign. Based on the result from the 10 wells campaign, it has been viewed as extremely successful which led the way for upscaling subsequently in 2023 on a locally owned Jack Up rig in Malaysia. The key objectives encompass replicating the high performance attained with international jack up rigs onto local rigs. This expansion aims to elevate the utilization of automation platforms, ensure operational consistency, bolster efficiency, shorten delivery times, mitigate well risks, and ultimately lead to both cost, schedule & carbon emission reduction to the lowest possible. The rig automation strategy brought together three systems: the Intelligent Rig Control System, an on-bottom drilling system and a protection system. The Intelligent Rig Control System enables off-bottom automation workflows and integration of additional systems. The on-bottom drilling system focuses on Rate of Penetration (ROP) optimization using advanced Artificial Intelligence (AI) models, shock and vibration mitigation and closed loop control of directional drilling with automated flow and RPM downlinking, while another third-party solution ensures dynamic safety limits through real-time data analysis of the drill-a-stand workflow. This implementation brought together three systems in Field B, Offshore West Malaysia, on the First Malaysian's Local Jack-Up rig. The main challenge replicating Rig Mechanized Automation (RMA) on the different types of rig control system lies in ensuring stable integration of automated systems, addressed through System Integration Test (SIT) and System Acceptance Test (SAT). Facilitating crew adjustment required the sequential deployment of these systems in different hole sections. Comprehensive training and support on-site by Third Party Rig Performance Consultant (RPC) and Field Deployment Engineer (FDE) during the Hypercare program, were crucial for user proficiency. The successful ground deployment commenced with drilling the 12-1/4" section in Well #1, followed by the 8-1/2" section where there was controlled on-bottom drilling with the computing automatic protection. Full automation was employed for the remaining three wells, including a trial to automate the 13-3/8" directional Casing While Drilling (CWD). This was successfully achieved in the 3rd and 4th wells, marking the world's first 13-3/8" directional CWD automated drilling." Driller acceptance, measured by more than 80% utilization throughout the campaign, was positive due to feedback on eliminating rapid human responses during challenging scenarios. Autonomous Directional Drilling (ADD) delivered 98.5% closed loop control in the 12-1/4" section and 97% in the 8-1/2" section accounting for 6338ft of footage drilled. The team focused on critical tasks with autonomous drilling operations like monitoring hole cleaning and stuck pipe trends. The deployment of autonomous drilling operations has been seamless, challenging, and rewarding, unlocking new success stories like World First Autonomous Directional Drilling and Directional Casing While Drilling on a local rig, signaling a significant shift toward global automation and digitization in drilling operations.

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