FlexFusion® Technology Package

Q: What is FlexFusion® technology and how does it differ from standard drilling automation?

FlexFusion® is H&P’s most advanced drilling automation solution. A fully integrated technology package that combines cutting-edge rig controls with H&P’s FlexRig® fleet to automate the entire process of drilling a stand. Unlike point solutions that address a single challenge (such as stick-slip mitigation alone), FlexFusion orchestrates multiple technologies simultaneously, including Autodriller Pro, FlexB2D® 2.0, FlexTorque®, StallAssist®, and the Automation Sequencer to manage the complete drilling cycle from bit engagement to end-of-stand. The result is consistent, optimized well delivery at scale, not just automation of individual tasks.

Q: What does it mean to “drill a full stand without intervention”?

A stand is the section of drillpipe — typically 90 feet — drilled between connections. FlexFusion automates all the critical processes within that stand: applying weight on bit (WOB), managing bit engagement to prevent vibration, detecting and recovering from motor stalls, mitigating stick-slip, and cleanly disengaging the bit at the end. All of this happens without the driller needing to manually intervene at each step, reducing variability and cognitive load on the crew while improving consistency and performance.

Q: How does FlexFusion integrate different technologies to automate the drilling process?

FlexFusion acts as an orchestration layer that ties together H&P’s suite of rig controls technologies. Its Automation Sequencer coordinates the timing and sequencing of mud pumps, the top drive, and the drawworks to smoothly execute processes such as pre-slide setup, WOB application and removal, stall recovery, and end-of-stand procedures. Each sub-technology, Autodriller Pro for axial vibration control, FlexTorque® for torsional vibration, FlexB2D® for lateral vibration at bit engagement, operates within this framework, so that they work in concert rather than independently.

Q: What is the Automation Sequencer and why is it central to FlexFusion?

The Automation Sequencer is the core logic engine within FlexFusion. It manages the automated processes of applying and removing weight on bit while integrating all other active technologies to drill a stand. Its primary focus is minimizing bit whirl by ensuring consistent, controlled bit engagement and disengagement. Without the Sequencer, the individual technologies would function in isolation. With it, they execute in a coordinated, repeatable sequence — eliminating the variability that comes from manual driller decision-making during each stand.

Q: What are bit whirl, stick-slip, and bit bounce — and how does FlexFusion address each?

These are three distinct forms of downhole vibration that damage bits and BHAs, reduce ROP, and drive up costs. Bit whirl is a lateral vibration where the bit rotates off-center, causing chaotic contact with the formation. It’s managed by FlexB2D® technology and the Automation Sequencer through controlled, rapid bit engagement. Stick-slip is a torsional oscillation where the bit momentarily sticks and then suddenly releases, sending shockwaves up the drillstring. FlexTorque® technology actively modulates top drive RPM to counteract this. Bit bounce is an axial vibration where the bit lifts off and slams back into the formation — Autodriller Pro addresses this by stabilizing block velocity to maintain consistent WOB.

Q: How does FlexB2D® 2.0 technology minimize lateral vibrations during bit engagement?

FlexB2D® (Bit-to-Depth) technology manages the process of engaging the bit with sufficient depth of cut quickly, whether rotating or sliding. By rapidly reaching the target depth of cut at the start of WOB application, it limits the window during which the bit is most vulnerable to whirl. The 2.0 version includes a fully customizable WOB application sequence and enables analysis of results for ongoing setpoint optimization, allowing operators to refine their engagement parameters well-by-well based on actual data.

Q: How does FlexTorque® technology help manage torsional vibrations and trapped torque?

FlexTorque® actively monitors surface torque fluctuations and interprets them as indicators of stick-slip downhole. It then modulates top drive RPM to dampen the torsional oscillations before they reflect back down the drillstring and amplify at the bit. An important additional function is managing trapped torque, the stored torsional energy in the drillstring that must be safely released when hoisting off bottom. FlexFusion coordinates this release automatically, preventing overactivity in stick-slip controls and ensuring a safe, controlled end-of-stand process.

Q: What is Autodriller Pro and how does it improve rate of penetration (ROP)?

Autodriller Pro is an advanced control system that regulates weight on bit by prioritizing stable block velocity rather than simply targeting a static WOB value. This approach is more effective at reducing bit bounce because it responds dynamically to changing formation conditions. The result is more consistent bit engagement, which leads to higher rotating-on-bottom ROP and improved bit life. Autodriller Pro can regulate WOB, differential pressure, and torque across a wide range of drilling applications, making it a versatile baseline from which to optimize drilling parameters.

Q: What causes a PDM stall and how does StallAssist® technology detect and recover from one?

A positive displacement motor (PDM) stalls when the torque required to drill exceeds the motor’s capacity, a common occurrence on directional wells where the motor is working hard against the formation. StallAssist® technology continuously monitors drilling parameters to detect the onset of a stall and responds automatically: it safely disengages the bit from bottom and returns control to the driller to initiate recovery. By catching stalls early and managing recovery consistently, StallAssist® extends motor life and reduces the frequency of unplanned trips caused by motor damage.

Q: How does FlexFusion protect the bit and BHA to extend their lifespan?

FlexFusion attacks the root causes of premature bit and BHA wear from multiple angles. By minimizing bit whirl through controlled engagement (FlexB2D®), it prevents the chaotic lateral forces that chip cutting structures. By mitigating stick-slip (FlexTorque®), it protects MWD/LWD tools and motor connections from torsional shock. By detecting stalls early (StallAssist®), it avoids the thermal and mechanical damage caused by a stalled motor. And by managing the Bit Off Bottom (BOB) process during WOB removal, it ensures consistent, safe disengagement at the end of every stand.

Q: What is the Bit Off Bottom (BOB) process and why does it matter?

The Bit Off Bottom process refers to the controlled sequence of disengaging the bit from the formation, a step that is just as important as engagement for managing bit whirl. When WOB is removed improperly, the bit can momentarily enter a low depth-of-cut regime that promotes whirl before fully lifting off. FlexFusion includes automated BOB sequences in all processes that involve removing WOB, and each of these sequences also incorporates steps to release trapped torque safely– preventing sudden torsional energy releases that could damage the BHA.

Q: How does FlexFusion maintain consistent performance across different crews and experience levels?

One of FlexFusion’s most significant operational benefits is its ability to standardize drilling execution regardless of who is operating the rig. By automating the sequencing of stand-level processes, FlexFusion removes the variability that naturally occurs between drillers of different experience levels, shift changes, or fatigue states. The system executes the same preplanned sequence every stand, every shift, every well. Meaning that performance is tied to the quality of the programmed roadmap rather than individual driller judgment in the moment.

Q: How does Automated Parameter Execution reduce human variability?

Automated Parameter Execution allows FlexApp parameters, the specific procedural steps for bit engagement, slide setup, and stall recovery, to be pre-loaded into the system before drilling begins. Rather than relying on drillers to interpret a paper roadmap and manually execute each step, the system executes those steps automatically and precisely. This eliminates misread or misapplied roadmaps, reduces the risk of parameter errors during shift handover, and ensures that operator-specified best practices are applied with consistency across every stand.

Q: Can drilling roadmaps be pre-loaded, and how does that reduce risk?

Yes. A key feature of FlexFusion is the ability to pre-configure and load drilling roadmaps into FlexApp before spudding a well. This means the engineering team can define optimal parameters for each section of the well in advance, and the rig will execute to those specifications automatically. The primary risk reduction comes from eliminating misapplied parameters: studies have shown that roadmap execution errors are a meaningful source of performance variability, and pre-loading removes that human touchpoint entirely from the critical path.

Q: What types of rigs is FlexFusion compatible with?

FlexFusion® is currently compatible with H&P’s FlexRig® fleet. This is because the technology package is deeply integrated with the rig’s control systems — the top drive, drawworks, and mud pumps must all communicate seamlessly with the Automation Sequencer for the orchestrated stand-level automation to work. H&P’s FlexRig fleet was purpose-built with these integrations in mind, making it the ideal platform for FlexFusion deployment.

Q: What rig specifications are required to run FlexFusion?

FlexFusion requires a super-spec AC drive rig with integrated rig controls capable of communicating with the FlexApp system. H&P’s FlexRig® fleet meets these requirements. If you are evaluating FlexFusion for your drilling program, H&P’s drilling consultants can confirm specific rig availability and configuration. Contact the H&P sales team to discuss the technical requirements for your specific application.

Q: How widely is FlexFusion deployed today?

FlexFusion has seen rapid adoption across H&P’s operations. In 2024 alone, FlexFusion technology automated more than 1.5 million processes across nearly 4,000 wells. This scale of deployment provides H&P with an unmatched dataset for continuous improvement and setpoint optimization, and gives operators confidence that the system has been tested and validated across a wide range of formations, well designs, and operating conditions.

Q: What cost savings can operators expect when using FlexFusion?

Cost savings from FlexFusion come from several interconnected improvements. Extended bit and BHA life reduces the frequency of unplanned trips, which are among the most expensive events in drilling operations. Higher and more consistent ROP reduces drilling cycle time. Reduced downhole vibrations lower the risk of tool failures which drive non-productive time (NPT). Previous results have shown, H&P customers drilling 10 or more wells saved an average of 24 days and over $1.5 million compared to competitors. This was driven by fewer trips, less NPT, and faster cycle times.

Q: How does FlexFusion help operators standardize best practices across a multi-well program?

FlexFusion gives operators a different mechanism to codify and enforxe their best practices at the rig level. By pre-loading proven drilling parameters and execution sequences in, operators can ensure that every rig in a program drills to the same specification, regardless of which crew is on shift, or what personnel are involved. This is powerful for large pad drilling programs where consistency across wells directly impacts well economics and resevoir development outcomes.

Q: How does FlexFusion reduce unplanned trips?

Unplanned trips can be primarily driven by bit or BHA damage, motor stalls, and tool failures. All of which FlexFusion directly targets. By reducing the severity and frequency of bit whirl, stick-slip, and bit bounce, FlexFusion extends the service life of bits and BHA components. StallAssist® catches motor stalls before they cause damage that would require a trip. The combined effect is a valuable reduction in the number of trips per well, which is one of the highest impact levers for reducing drilling costs.