Automatic Well Refill Control and Forecasting Potential Well Control Loss Through Refill Monitoring

Abstract This paper presents an advanced automatic well refill control system designed to calculate and monitor drilling fluid volumes in real time during tripping operations. The system enhances well control by minimizing risks such as stuck pipe and loss of well control while improving operational efficiency. Utilizing state-of-the-art sensors, sophisticated algorithms, and robust redundancy features, it offers continuous monitoring and predictive capabilities that enable early detection of anomalies such as influxes and fluid losses. Field tests demonstrate compelling results, a 30% reduction in stuck pipe incidents and a 15% improvement in overall operational efficiency, which underscore the system's potential to revolutionize well control practices by shifting from reactive to proactive strategies. In doing so, this technology contributes to the evolution of drilling operations by aligning with the industry's drive toward automation and precision. The system also provides practical tools for drilling engineers to mitigate risks effectively, enhance environmental safety, and reduce non-productive time (NPT).