Drilling automation control
Technical Specifications – Automation Control System
| Parameter | Standard | Advanced | Premium |
|---|---|---|---|
| Auto driller | WOB mode | WOB + ROP mode + auto-set | + formation response learning |
| Soft torque | Available | Standard | Standard + anti-stall |
| Anti-jam (bit balling) | No | Yes | Yes + auto cycle |
| Pipe handling integration | Elevator/slips only | + iron roughneck | + racking system |
| Remote operation | View only | Supervisory (adjust setpoints) | Full remote (driller override) |
| Data logging rate | 1 Hz | 5 Hz | 10 Hz + event trigger |
| WITSML export | Manual | Automatic | Real-time streaming |
| Predictive maintenance | Simple trend | Bearing + vibration | + pump + engine + transmission |
| MPD integration | No | Optional | Yes (with choke control) |
| Number of rigs monitored | 1 | Up to 5 | Up to 20 |
| HMI language | English | English + optional | English + Russian/Arabic/Chinese |
Hardware options:
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Control console – Single 24″ touchscreen (standard), dual 24″ (advanced), triple 24″ with physical joysticks (premium)
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PLC platform – Siemens S7-1500, Rockwell CompactLogix, or Mitsubishi (customer choice)
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Sensors – Load cells, pressure transducers, encoders, accelerometers, strain gauges
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Remote connectivity – Cellular 4G, satellite (BGAN), or fiber
Product Types – Drilling Automation Control Packages
| Package | Best For | Key Components |
|---|---|---|
| Auto Driller Basic | Small rigs, mechanical rigs retrofits | WOB control, brake interface, 1 Hz logging |
| Soft Torque Plus | Rigs with stick-slip issues (hard rock) | Soft torque + auto driller + vibration monitoring |
| Tripping Optimizer | High-activity pad rigs (shale) | Pipe handling integration + auto make/break |
| Remote Drilling Suite | Multi-rig operator with central office | Full remote control + fleet view + playback |
| Intelligent Rig (full) | Newbuild automated rigs | All modules + MPD + predictive maintenance + AI drilling optimization |
| Retrofit Kit | Existing rigs (any brand) | Sensors + PLC + HMI – minimal field modification |
Applications – Where Automation Delivers the Biggest Gains
| Operation | Without Automation | With Automation | Typical Gain |
|---|---|---|---|
| Conventional vertical drilling | WOB fluctuates ±3,000 lbs | ±500 lbs | 15% faster ROP |
| Motor drilling (horizontal) | Frequent stalls, low sliding ROP | Auto-anti-stall, optimized slide | 25-40% faster slide |
| Hard rock (granite, chert) | High stick-slip, bit destroyed every 40m | Soft torque, smooth rotation | Bit life doubled, ROP +20% |
| Clay / gumbo formations | Bit balling stops ROP, frequent wiper trips | Auto anti-jam, no wiper trips | 30% less non-productive time |
| Pad drilling (20+ wells) | Manual tripping, variable performance | Automated pipe handling | 25% faster trip times, consistent |
| Offshore platform (night crew) | Fatigue-related errors | Remote supervision, auto functions | Safety incidents reduced 60% |
| Multi-rig fleet | Each rig independent, no bench-marking | Central monitoring, performance KPIs | Best practices transferred across rigs |
Why Choose SJ Petro for Drilling Automation Control?
1. Built by Drillers – Not Just Coders
Our control system was designed by former rig personnel who know the difference between "theoretical optimum” and "what works in real mud, real vibration, and real 4 AM shifts.” The algorithms are tuned to field data from hundreds of wells in Sinopec’s own operations.
2. Open Architecture – No Vendor Lock-In
We use standard industrial PLCs (Siemens, Rockwell) and open protocols (Modbus, OPC UA, WITSML). You are not trapped with proprietary hardware. You can add third-party sensors, connect to your own analytics, or switch service providers later.
3. Retrofits Any Rig – Old or New
We’ve automated rigs built in 1975 with mechanical clutches and air brakes, as well as brand-new AC VFD rigs. Our retrofit package includes:
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Sensor installation (non-invasive where possible)
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PLC enclosure (environmentally protected)
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HMI console (retrofit mount or new stand)
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Interface to existing drawworks, top drive, pumps
No rig is "too old” for automation.
4. Field-Proven in Extreme Conditions
Our systems operate in:
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Sichuan shale – High humidity, vibration, dust
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Tarim deep gas – 7,000m depth, 80°C ambient at wellhead
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Jungle (Indonesia) – 99% humidity, power fluctuations
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Arctic (Kazakhstan) – -45°C with condensation-resistant electronics
We design for reliability, not just features.
5. Local Support & Remote Diagnostic Access
Our support team can dial into your PLC network (via secure VPN) to troubleshoot software issues, update parameters, or recover from configuration errors – often solving problems without a site visit. For hardware failures, we stock common modules (PLC CPUs, I/O cards, touchscreens) at regional hubs.
6. Scalable – Start Small, Add Later
You don’t have to buy the full system upfront. Start with auto driller, then add soft torque after six months, then pipe handling, then remote monitoring. Our modular software licensing allows pay-as-you-grow.
7. Backed by Sinopec’s R&D Resources
We have access to Sinopec’s drilling research center, including:
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Full-scale rig simulator for control algorithm testing
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Vibrations lab for sensor calibration
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Data science team for AI drilling optimization
When you buy our automation, you tap into a continuous stream of improvements.
FAQ – Drilling Automation Control
Q1: Can your automation system work on a mechanical rig with no VFD?
A: Yes. Our auto driller can interface with an air brake regulator (pneumatic) or hydraulic brake valve on mechanical drawworks. We add a brake actuator (proportional valve) controlled by the PLC. For top drive/rotary table without VFD, soft torque is not possible – but auto driller and data acquisition are.
Q2: How much does the system cost? (rough budget)
A: For a basic auto driller retrofit on a land rig: $30,000-$50,000 (hardware + sensors + installation). For a full automation package (auto driller + soft torque + pipe handling + remote ops): $150,000-$300,000 depending on rig size and sensors. New-build fully automated control system as part of a rig: typically 5-8% of total rig cost. We give firm quotes after site assessment.
Q3: How long does installation take? Does the rig need to be offline?
A: For retrofits: 5-10 days for sensor and hardware installation, plus 2-3 days for commissioning. We schedule during planned maintenance or rig moves whenever possible. For new builds, the system is integrated during fabrication – no extra downtime.
Q4: Will my drillers accept automation? Will they lose jobs?
A: We’ve found the opposite. Drillers embrace automation because it reduces physical fatigue and mental stress. The driller remains in control (override always available) but no longer spends 12 hours fighting stickslip or micro-adjusting WOB. Automation handles the tedious, repetitive tasks while the driller supervises and handles exceptions. No job losses – we’ve automated over 200 rigs without a single crew reduction.
Q5: What happens if the automation system fails? Can the rig still drill?
A: Yes. The system is designed with manual backup. Every automated function can be disabled, returning the rig to conventional manual control. The PLC can be bypassed, and air/hydraulic brake valves have manual overrides. Safety-critical functions are hardwired, not software-dependent.
Q6: How do you ensure the system works with my existing BOP, pumps, etc.?
A: We conduct a site survey (remote or in-person) to document existing equipment, control voltages, and communication protocols. We then design interface circuits that are electrically isolated and non-invasive. Most installations require no modifications to existing equipment – just additional sensors and a parallel control network.
Q7: Can I connect your system to my existing rig data system (e.g., my operator’s platform)?
A: Yes. We support standard data export: WITSML, CSV, or direct SQL database write. We can also integrate with third-party EDR systems by emulating their serial protocol (many cases we’ve done). Tell us your data destination; we’ll make it work.
Q8: Do you offer ongoing software updates and support?
A: Yes. Annual software maintenance contract (approx 10% of system cost) includes: 24/7 remote support, software updates (new algorithms, features), and discounted hardware replacement. No contract? We still support by the hour or per call. But we recommend the contract for active rigs.
