Drilling Systems Automation Decision Making and Control Framework

The paper “Drilling Systems Automation Roadmap - The Means to Accelerate Adoption” SPE 173010, presented in London March 2015, introduced the DSA Decision Making and Control Framework derived from ISA-95. In the Sensors to Solutions SPE workshop September 2015, I described the development of this framework from the original Purdue Model, through ISA – 95 and the Manufacturing Execution System. Subsequently, I led the team that developed a poster describing this development which was displayed at the SPE DSATS Symposium March 2016 and at the IADC World Drilling Conference Portugal June 2016.

The DSA Decision Making and Control Framework is a very powerful model that relates the physical processes of well construction up through machine control to enterprise planning. The foundation derivation is from the Purdue Model created in 1989 for a Computer Integrated Manufacturing Model. It was created to improve the probability that a truly integrated information system could be rapidly achieved through all levels of a manufacturing organization. The model provides a construct of the relationship connecting enterprise decision making to shop floor activities and vice versa.

                The International Society of Automation (ISA) developed the details within the hierarchical Purdue Model to improve guidance on application. ISA particularly added interface standards. Applications experts continued the evolution by overlaying the Manufacturing Execution Systems (MES) connecting the higher levels to lower levels through manufacturing flow in design, planning and execution.   The mapping of these design, planning and execution work flows through the levels within the ISA-95 hierarchy provided the basis for development of similar workflows for drilling planning and operations.

                 The DSA Decision and Control Making Framework is the most current mapping of the ISA-95 five levels for well construction as listed below:

• Level 4 - Enterprise management. Managing business-related activities of the drilling operation (business planning and logistics).
• Level 3 - Operations management. Managing workflows to drill, protect the hole, and complete the well.
• Level 2 - Execution management. Supervising, monitoring, and controlling the physical processes with real-time controls and software.
• Level 1 - Machine control. Sensing and manipulating the physical processes.
• Level 0 - Physical processes. Defining actual physical processes of the drilling and completion operation (Well construction).

The version included above highlights the work flows in the Well Construction Execution System and Data Acquisition. It also locates the onsite and remote centers relative to the hierarchy. The distinction between control / operations and interpretation / excellence centers is that the former performs in the supervisory control loop and the latter analyzes data to feed new parameters to the former.

                The levels in the hierarchy operate at different frequencies with the highest in the control mode at level 2 through to the lowest at the information mode at level 4. This DSA framework provides the hierarchy from the proprietary modes of machine control through the control interface transitioning from OPC-UA at the control level to WITSML at the information enterprise level. The OPC-UA / WITSML interface as well as the OPC-UA / DDS interface are currently being mapped by industry teams to enable complete interoperability.

The DSA Decision and Control Framework model provides the foundation for the development of controls hierarchy in the application of automation as well as defining the most appropriate decision loops in manual drilling. Mapping the data acquisition process, analysis, decision making, action implementation through display loops in this hierarchy will add value to all drilling operations – manual, partial automation, supervisory control of autonomous systems.

Further guidance on the application of the DSA Decision making and Control Framework is being developed as part the DSA Roadmap initiative which is currently developing the Phase II Stage I report under an industry JIP sponsored by Shell, ExxonMobil Upstream Research, Total, Occidental, Saudi Aramco, NOV, Huisman Equipment, proNova TDE, Houston Mechatronics,