Energies: An Outlook of Drilling Technologies and Innovations: Present Status and Future Trends
Energies: An Outlook of Drilling Technologies and Innovations: Present Status and Future Trends
Review
An Outlook of Drilling Technologies and Innovations: Present
Status and Future Trends
Catalin Teodoriu * and Opeyemi Bello
Abstract: The present article analyzes the technological advancement and innovations related to
drilling operations. It covers the review of currently proven and emerging technologies that could
mitigate the drilling operational deficiencies and instabilities that could hinder operational per-
formance activities and the economic part of drilling development with great effort to minimize
their environmental footprint. Drilling system design and operations are among the major aspects
and cost-effective endeavors of the oil and gas industries, which are therefore technology depen-
dent. They are also considered to be among the most expensive operations in the world, as they
require huge expenses daily. Drilling success, depending on prevalent conditions, is a function of
several general factors. These include the selection of the best technologies and tools, procedural
optimization, concrete problem-solving, accurate prediction, and rapid decision-making. Conse-
quently, any sorts of tools or advanced technologies that can improve the time-efficient operational
and economic performance of drilling activities are essential and demanded. The paper provides
a review of available technologies and developmental innovations based on both company-based
and academic research-enabled drilling solutions over the past 5 years in the field of drilling systems
and technological design. The paper further highlighted potential technologies that could be tapped
in from other industries and could possibly be adopted by pushing the conventional boundaries of
Citation: Teodoriu, C.; Bello, O. An drilling operations.
Outlook of Drilling Technologies and
Innovations: Present Status and Keywords: drilling; advanced technologies; emerging technologies; operational and economic
Future Trends. Energies 2021, 14, 4499. performance; environmental footprint
https://doi.org/10.3390/en14154499
1. Introduction
Received: 19 May 2021
Accepted: 21 July 2021
The world’s need for energy demand and transformation towards harvesting hydro-
Published: 26 July 2021
carbons is accelerating. This is attributable to a combination of technological progress,
development priorities, and environmental concerns. The drilling operation is one of
Publisher’s Note: MDPI stays neutral
the most sensitive divisions in the oil and gas industry. With geothermal energy as a
with regard to jurisdictional claims in
stable energy resource, deep drilling at attractive costs is pushed every day to the lim-
published maps and institutional affil- its. Advancements in the processes, techniques, technologies, and innovations associated
iations. with well drilling activities all have significant impacts on drilling operational efficiency,
safety, and economy, which must be maintained within acceptable levels in unlocking
hydrocarbon resources.
Subsurface resource development is subject to drilling wells in safe and cost-efficient
Copyright: © 2021 by the authors.
manners. Since the discovery of the first oil well in Titusville by Edwin Drake and the
Licensee MDPI, Basel, Switzerland.
progression of the petroleum business over the years, the cable tool and rotary drilling
This article is an open access article
were the first techniques applied in the drilling phase. In recent years, drilling activities
distributed under the terms and for searching hydrocarbons have shown considerable technological advances in order to
conditions of the Creative Commons obtain safe, environmentally friendly, and cost-effective well construction with increased
Attribution (CC BY) license (https:// performance. Some of the early advancements in drilling technology seeking innovative
creativecommons.org/licenses/by/ approaches towards better drilling efficiency were based on three basic factors: safety, mini-
4.0/). mum, and usable hole. These technologies include horizontal drilling, multilateral drilling,
extended reach drilling (ERD), complex path drilling, casing drilling technology, positive
displacement motor technology, and laser technology—which is a newer technology [1–4].
Today’s challenge in the field of drilling is to reach deeper targets as fast as possible,
minimizing the cost with the continuous improvement of operational efficiency without
overlooking health, safety, and environmental guidelines. These factors have rendered
drilling activities open to robust techniques and state-of-the-art technologies for an accu-
rate understanding of potential hydrocarbons to be drilled. Improvements in techniques,
materials, equipment’s, autonomous processes, and advanced technologies have played
a role in advancing economically recoverable subsurface resources and reducing the en-
vironmental impact at the surface and in the underground. Modern drilling technology
is categorized as an advanced suite of both surface tools and downhole tools with the
capability of drilling entire well sections in one run with far less impact on the surface and
subsurface environments.
The evolution in drilling technologies developed over the last five to ten years for
both onshore and offshore development has been focused on several distinct areas of
drilling operations, including the monitoring and optimization of surface equipment,
drilling methodologies, and downhole tools. Proven technologies seek to reduce both well
construction and operational costs while also providing maximum operational efficiency
and environmental safety. Some examples of advancements and proven innovation in
drilling technology acting as enablers in the discovery of new sources of oil–natural gas
and geothermal energy are presented in this article. These existing technologies include
horizontal drilling, underbalanced drilling, multilateral drilling, extended reach drilling
(ERD), automated drilling, and data analysis. As the topic of onshore and offshore novel
developments is extremely broad, this paper sought to provide a synopsis of the Special
Issue of MDPI Energies, collecting relevant developments that are related to the MDPI-
published papers within the last 5 years.
applicable both offshore and onshore. A typical example is the launching of the first fully
autonomous offshore platform capable of performing drilling operations with little or no
operational staff by a European oil and gas company [8,9]. Another example is that of
integrated drilling systems, such as Amphion and Cyber base, which increase drilling
control over the rig equipment, enhance safety and efficiency, and reduce redundancy
on rigs by providing control systems that automate drill floor processes and equipment
interaction for both offshore and onshore activities [10]. IoT in offshore operations seems
to have become an important “added value” concept for most operators [11]. Moreover,
as of 2021, automation has been mostly transferred from offshore to onshore activities,
particularly those activities with intensive and repetitive activities, such as those involved
in shale and coal bed methane drilling. Figure 1 shows that a full automation level is
defined as the level at which the computer solely takes care of the whole activity, namely
monitoring and data analysis, generating the decisions, selecting the best option, and
implementing the selected decision. Although Endsley et al. [12] published this concept
about levels of automation two decades ago, Macpherson et al. [13] have adapted Endsley
concept for drilling activities, proposing the same 10 levels of automation, whereas the
autonomous level involves self-decisional systems such as rotary steerable systems. As
of 2021, the new direction is trending towards autonomous drilling rigs that can perform
drilling without direct human intervention. The levels of automation shown in Figure 1 are
ranked from 1 to 10, where L10 will represent the autonomous drilling system. According
to Macpherson et al. [13], the rotary steerable systems are ranked L8–L10, meaning that
the need for human intervention is minimal, and only during monitoring/generating
of the process. To date, a fully autonomous system, as per the definition provided by
Endsley et al. [12], has not yet been realized, however, a few attempts have been already
published [14]. Although not comparable, it is worth mentioning that the mining industry
has reported fully autonomous blast hole drilling systems since 2018.
In the article by Creegan and Jeffrey [15], an intelligent drilling optimization applica-
tion performs as an adaptive autodriller. This novel technology uses artificial intelligence
(AI) algorithms to enhance on-bottom drilling performance. The system features continu-
ous learning capabilities, enabling it to provide proactive drilling dysfunction mitigation
Energies 2021, 14, 4499 4 of 12
while maximizing the rate of penetration (ROP) and optimizing mechanical specific energy.
The system’s advantage is that it entails less dependence on human beings in the drilling
process, lowering the risk of slow or incorrect responses in drilling dysfunction. During
the field application, ROP was improved by 61% and drilling performance—measured as
hours on the bottom—was improved by 25%.
Invented over 100 years ago, directional drilling or horizontal directional drilling
(HDD) is a trenchless and valuable technology used in oil fields to increase oil production.
The rate of technological innovation has never decreased to date, especially not for offshore
projects where continuous accumulated experience has served to reduce the total drilling
time and the cost of drilling, thus enhancing the profitability of these companies. The
trend of automation, propelled by the utilization of 3D visualization tools, has expanded
the capabilities of downhole tool technologies, improving the drill bit’s performance, and
reducing drilling vibrations. One of the new evolutionary alternatives to the traditional
rotary steerable system (RSS) is the Steer-At-Bit Enteq Rotary Tool (SABER) tool that uses
internally directed pressure differentials to steer away from the drill bit face, delivering
true “at-bit” geosteering [16,17]. Based on the successful initial testing, the tool does offer a
robust, reliable, simple, and cost-effective directional drilling alternative to current RSS op-
tions, minimizing downtime whilst maximizing reliability and drilling speeds. For accurate
well placement, Haliburton introduced their product called iCruise, an intelligent push-
the-bit RSS, which allows for improved steerability and drilling performance. This tool is
automation-enabled for precise steering and accurate well placement, helping operators
reduce well time through faster drilling, reliable performance, and predictable results [18].
To automate decision-making during drilling operations, Motive Drilling Technologies
developed a premier directional drilling bit guidance system, which automates decision
making at the rig. The mentioned merits of this system include drilling time reduction
without compromising wellbore quality, which also results in higher productivity. The bit
guidance system is built using the latest downhole computer generation, with an improved
data-driven automated decision-making algorithm. There are many numbers of this intelli-
gent RSS, for example, the Baker Hughes [19] i-Trak drilling automation and others on the
market with advanced electronics for tool prognosis, diagnosis and high-speed processors
which help directional drillers make efficient drilling decisions and manage vibration in
real time.
A better understanding of downhole drilling dynamics and optimization conditions
is very vivacious in terms of drilling operations and performance. According to NOV, an
improper BHA design leads to lower drilling efficiency, which implies the need for BHA
redesign at high costs and time lost. To reach the borehole total depth (TD) with exces-
sive drag and reduced tortuosity at the end of the well, NOV developed the SelectShift
downhole adjustable motor that allows higher surface RPM, improved hole condition and
cleaning, minimizing spiraling/tortuosity and improving ROP [20]. Another innovative
BHA optimization tool is the Schlumberger [21] OptiDrill real-time drilling intelligence
tool, which is capable of collecting a wide range of surface and downhole data and using
advanced algorithms and enables event detection and customized reporting. This system
was developed to allow operators to mitigate risk, reduce premature tool failure, and
upsurge downhole drilling efficiency.
Well control is another key and crucial sub-sectional area of the drilling operation. The
blowout incident from the Macondo oil field and past blowout accidents have reflected the
need for rigorous safety measures, ensuring safe and environmentally responsible drilling
operations. Devising some well control automation systems will enable fast identification,
decision making, and reaction to well control events. Some of the latest technology aiming
to reduce well control risks led to the development of automated well control solutions
by Safe Influx. It has been successfully demonstrated that this system can provide support
to the driller, dramatically reducing our exposure to risks from human factors. The system
has the ability to detect the presence of a fluid influx condition in a wellbore, make a
decision against criteria to favor a shut-in, and then automatically initiate an initial well
Energies 2021, 14, 4499 5 of 12
control protocol that results in the well-being safely shut-in. This revolutionary technology
is capable of reducing the size of an influx compared to conventional techniques. This
implies reductions in delays, costs, and operational issues in getting back to drilling [22,23].
The combination of these technologies will provide an automated secondary well control
which will result in enhanced well control and integrity while improving the drilling
efficiency [24].
novel automatic real-time approach based on the minimization of the mechanical specific
energy (MSE). The ES algorithm collects a wide range of information to assess the current
downhole conditions. Additional parameters are generated during drilling changes in the
applied weight on bit (WOB) and the drill string rotational rate (RPM). The process is per-
formed automatically, and the process is optimized using downhole real-time information.
The proposed algorithm is said to handle various drilling constraints related to drilling
dysfunctions and hardware limitations especially when ROP and torque parameters are
limited. The methodology is yet to be field validated, but the authors are expecting an ROP
improvement of up to 20–170%.
Thakur and Samuel [29] established a novel method to predict downhole data by
employing deep learning using surface data that can improve wellbore placement and
increase drilling efficiency by improving the rate of penetration (ROP) and reducing
downtime caused by tool failure. In their approach and for initial prediction, the model
was trained on analog wells. In the absence of an analog well, surface WOB data can also
be used as estimates of downhole WOB. The next step of their method was the use of
relatively inexpensive technology to collect downhole data, on mud pumps for example,
and sync the data in time. Then, a new model is trained, or the trained model is updated
for the existing well. The model is then used to predict downhole data for the current well.
The model can be updated as more and more data become available for better prediction.
The novel study is yet to be validated on the field; however, the developed model has a
median error as low as 3% and can accurately predict downhole data in real-time with the
prediction accuracy varying from well to well and drilling depths. The model is also very
robust to the amount of noise or outliers present in the data and can predict downhole
conditions 50–60 ft. ahead with reasonable accuracy. The results demonstrate how deep
learning can be cost-effectively employed for downhole data prediction.
Dumitrescu et al. [30] conducted a numerical performance analysis for the corrosion
repair of pipelines using a modern composite materials system. The authors revealed
that composite repair systems are highly effective in restoring corroded pipes when the
selected repair materials have consistent mechanical properties that are compatible with
the base steel pipe. For example, a composite material with a Young modulus equal or
similar with steel pipe seems to yield the best results. According to their finite elements
simulation results, the width of the corroded area has limited influence on the stress state
of the repaired zone. They further emphasized the following observations from the finite
element analysis of the influence of the defect orientation and fillet radius upon the stress
distribution: machining the defect area as an inclined rectangle will reduce the preparation
time without influencing pipe safety and the angle of the defect orientation will increase
the von Misses stresses by only 10%.
Sliwa et al. [31] conducted a study to improve the impact understanding of rotational
speed, drill bit diameter, and air pressure on drilling velocity for the down-the-hole (DTH)
drilling method, for a given lithology. The study approach was validated using well
information from the Lubin Basin in Poland with such an enhanced solution aiding drilling
efficiency and process for wellbore heat exchanger (BHE) installations for selected locations.
To conduct the study, nine boreholes with common geological profiles were drilled using
the rotary down-the-hole drilling with the air method. A down-the-hole hammer (DTH)
with a diameter of 4 inches was used and the horizontal distance between the boreholes
was about six meters. The following conclusions were drawn from their study: “for every
analyzed situation, the highest drilling velocity is achieved when the greatest drilling
pressure is applied.” The authors pointed out that the lowest ROP was recorded at the
lowest drilling pressure. Additionally, they noticed that the increase in air pressure in the
drill pipe causes an increase in the consumption of feed energy, resulting in high operating
costs. The test also demonstrates that the DTH ROP also depends on the rotational speed
of the drill bit. The lithology was found to have a major impact on the ROP.
The study by Fang et al. [32] addressing the narrow density window achieves effective
control of the downhole pressure in complex geological environments, leading to the de-
Energies 2021, 14, 4499 7 of 12
velopment of an MPD wellbore transient flow dynamic model using the “compressible
gas–fluid two-phase flow with the drift flux” model. The developed model was built to
accurately describe the characteristics of transient multiphase flow in the wellbore. To
verify the established model, a simple experimental device was designed to accommodate
a wellbore simulator, liquid circulation system, and an air supply unit. In their findings,
the pressure followed a trend of a gradual decline, sharply followed by a pressure fall
induced by the original fluid being dispelled with the ingress of gas before an incremental
increase again. The control of wellhead backpressure is performed using the throttle valve.
Higher wellhead backpressure means lower downhole pressure. The authors have stated
that “When the gas–liquid two-phase flow in the wellbore reaches an equilibrium state, the
downhole pressure will decrease less with the increase of drilling fluid displacement, and
the time of gas reaching the wellhead will be earlier”.
Table 1 highlights the technologies covered in this paper.
4. Conclusions
Drilling is a highly dynamic process and has multiple needs that can be addressed
through the increased adoption of automation and control due to the complexity of drilling
operations.
In this article, we expounded the necessity of leveraging emerging technologies that
will change the trajectory in the field of drilling to reduce both well construction and
operational costs, while also providing maximum operational efficiency and environmental
safety. Additionally, selected companies and academic research that have enabled drilling
performance through advancing technologies were identified.
Results have shown that utilizing this novel technology allows faster decision making,
tracking new business opportunities, reorganizing operations, and significantly reduce well
control risks and operational costs. With a strong partnership between oil–gas–geothermal
industries and academia, there are high probabilities of developing more novel and pro-
found tools and technologies to address unsolvable drilling problems, thus increasing
discoveries of oil–gas–geothermal sources in highly challenging locations.
Author Contributions: Conceptualization, C.T. and O.B.; methodology, C.T. and O.B.; validation, C.T.
and O.B.; formal analysis, C.T. and O.B.; investigation, C.T. and O.B.; data curation, O.B.; writing—
original draft preparation, C.T. and O.B.; writing—review and editing, O.B. and C.T.; supervision,
C.T.; project administration, C.T. and O.B. Both authors have read and agreed to the published version
of the manuscript.
Funding: This research received no external funding.
Institutional Review Board Statement: Not applicable.
Informed Consent Statement: Not applicable.
Conflicts of Interest: The authors declare no conflict of interest.
Nomenclature
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