![Page 1: TBA 100 A Performance Study of the New Generation 100-ton ... · Generation 100-ton Advanced Technology Rig ... •Power tong – higher moments ... Ass Jar safety clamp off x x x](https://reader031.vdocuments.net/reader031/viewer/2022022512/5ae8a20c7f8b9acc269066f9/html5/thumbnails/1.jpg)
TBA 100 – A Performance Study of the New
Generation 100-ton Advanced Technology Rig
Maximilian Trombitas,
Product Manager Bauer Deep Drilling GmbH
![Page 2: TBA 100 A Performance Study of the New Generation 100-ton ... · Generation 100-ton Advanced Technology Rig ... •Power tong – higher moments ... Ass Jar safety clamp off x x x](https://reader031.vdocuments.net/reader031/viewer/2022022512/5ae8a20c7f8b9acc269066f9/html5/thumbnails/2.jpg)
2
Outline
• Field study
• Lessons learned
• Rig design changes
• Mechanization of drill floor processes
• Example: Pipe handling
• Summary
![Page 3: TBA 100 A Performance Study of the New Generation 100-ton ... · Generation 100-ton Advanced Technology Rig ... •Power tong – higher moments ... Ass Jar safety clamp off x x x](https://reader031.vdocuments.net/reader031/viewer/2022022512/5ae8a20c7f8b9acc269066f9/html5/thumbnails/3.jpg)
Buffalo 90 is a multipurpose drill rig designed in a
cooperation of Bauer and DeWet
3
![Page 4: TBA 100 A Performance Study of the New Generation 100-ton ... · Generation 100-ton Advanced Technology Rig ... •Power tong – higher moments ... Ass Jar safety clamp off x x x](https://reader031.vdocuments.net/reader031/viewer/2022022512/5ae8a20c7f8b9acc269066f9/html5/thumbnails/4.jpg)
Buffalo 90 has drilled two horizontal wells for
CBM projects for Kalahari Gas in Botswana
4
Operations started in November 2012
• First onshore horizontal wells in
southern Africa
• Rig site in Kalahari Desert, close to
Mmashoro
• Original plan was to drill 5 exploratory
wells and with different completion
strategies
Coal bed methane
• high potential expected (depending
on findings from exploration wells)
![Page 5: TBA 100 A Performance Study of the New Generation 100-ton ... · Generation 100-ton Advanced Technology Rig ... •Power tong – higher moments ... Ass Jar safety clamp off x x x](https://reader031.vdocuments.net/reader031/viewer/2022022512/5ae8a20c7f8b9acc269066f9/html5/thumbnails/5.jpg)
The geology for both wells includes coal as the
target reservoir and dolomites above and below it
Trajectory of 1st well shows a short vertical and 3 extended lateral sections:
5
270
290
310
330
350
370
390
0 200 400 600 800 1000 1200
Sidetrack 2 Trajectory Sidetrack 1
Notes: Trajectory based on Pathfinder data, geology schematic
Coal Bed (high ROP) Dolerite (hard, low ROP) • 8 ½” section was drilled with bentonite mud
• all lateral sections were drilled with fresh water
and sweeps
![Page 6: TBA 100 A Performance Study of the New Generation 100-ton ... · Generation 100-ton Advanced Technology Rig ... •Power tong – higher moments ... Ass Jar safety clamp off x x x](https://reader031.vdocuments.net/reader031/viewer/2022022512/5ae8a20c7f8b9acc269066f9/html5/thumbnails/6.jpg)
Rig set-up
6
Pipe
Rack Dog
House
Pipe
handler
Buffalo90
Rig
Shale
Shaker
Mud
pits
![Page 7: TBA 100 A Performance Study of the New Generation 100-ton ... · Generation 100-ton Advanced Technology Rig ... •Power tong – higher moments ... Ass Jar safety clamp off x x x](https://reader031.vdocuments.net/reader031/viewer/2022022512/5ae8a20c7f8b9acc269066f9/html5/thumbnails/7.jpg)
Rig performance analysis of 23 days operation
• Rig NPT less than 0.5%:
• Weight-to-Weight-connection ~2.2 min
• Fuel Consumption ~ 500 l/day
• No HSE incidents or accidents
7
Problem Hours % NPT
Pipe handler 0.8 0.14%
Rig mechanics 0.8 0.14%
Air slips 0.6 0.1%
Rotary brake 0.3 0.05%
Total 2.5 0,43%
Step 2
Step 3 Step 4
Step 1
![Page 8: TBA 100 A Performance Study of the New Generation 100-ton ... · Generation 100-ton Advanced Technology Rig ... •Power tong – higher moments ... Ass Jar safety clamp off x x x](https://reader031.vdocuments.net/reader031/viewer/2022022512/5ae8a20c7f8b9acc269066f9/html5/thumbnails/8.jpg)
The operational problems involve both
mechanical and human errors
8
Downtimes Inefficiencies
Mechan-
ical
Errors
• Waiting on spare
parts (difficult supply
situation)
• Pump capacity
• Shale shaker capacities
Human
Errors
• Waiting on fuel (non-
attention, no
procedures available)
• No work during rain
• Major failures (e.g.
squeezing casing,
drilling towards old
well bore)
• Slow, untrained and
inexperienced crew
• Miscommunication btw.
operator & contractor
• Difficult working
circumstances (no proper
camp, no food
provided,…)
• There is no way
around providing
good training to
people
• Selecting & keeping
the good ones
• Not saving money
on crucial
equipment like mud
pumps or shale
shakers
• Establishing better
supply chains for
future large scale
operations
![Page 9: TBA 100 A Performance Study of the New Generation 100-ton ... · Generation 100-ton Advanced Technology Rig ... •Power tong – higher moments ... Ass Jar safety clamp off x x x](https://reader031.vdocuments.net/reader031/viewer/2022022512/5ae8a20c7f8b9acc269066f9/html5/thumbnails/9.jpg)
Lessons learned for the whole system out of the
first operations
9
Suggestions
for Rig
Changes
Automation
Issues
Equipment
•Driller’s cabin – more space for 2 people
•Pipe handling system – remote control vs. cabin
•Driller’s cabin – meters with metric units
•Power tong – higher moments change of power tong
•Electronic data collection and display system
•Rig leveling – less transport units
•Mast – bigger drilling axis
•Mud pumps fulfilling flow rate, pressure and noise requirements
•Shakers designed for the requirements of oil & gas operations
•Levels on diesel tanks
•Proper office for contractor on site (printers, phones, etc.)
•High risk operation still manual
•Changing of mind
•More sensors required
•Software
![Page 10: TBA 100 A Performance Study of the New Generation 100-ton ... · Generation 100-ton Advanced Technology Rig ... •Power tong – higher moments ... Ass Jar safety clamp off x x x](https://reader031.vdocuments.net/reader031/viewer/2022022512/5ae8a20c7f8b9acc269066f9/html5/thumbnails/10.jpg)
Lessons learned & main changes
PR110 Version: Prototype Buffalo 90:
Major Changes to the prototype:
• Higher degree of mechanization and
automation
• Modular system
• Focus on hands-free & crane-less rig
up/down
• Transport dimensions to fulfill world wide
road regulations
• Diesel or electric driven
• Increased sensor installation
• B-tronic
• Increased hook load
• Trailer remains on ground level
• Increased drilling axis to 800 mm.
• No cabin at the pipe handler
![Page 11: TBA 100 A Performance Study of the New Generation 100-ton ... · Generation 100-ton Advanced Technology Rig ... •Power tong – higher moments ... Ass Jar safety clamp off x x x](https://reader031.vdocuments.net/reader031/viewer/2022022512/5ae8a20c7f8b9acc269066f9/html5/thumbnails/11.jpg)
Evaluation and benchmarking of every single process
on the drill floor
Basics:
• List all tools that you want to handle (representative tools)
• Analyze the work flow of handling those tools (for example: flow charts)
• List all work steps and rank them
11
Break-down & Visualization
Definition & Categorization
Evaluation & Ranking
![Page 12: TBA 100 A Performance Study of the New Generation 100-ton ... · Generation 100-ton Advanced Technology Rig ... •Power tong – higher moments ... Ass Jar safety clamp off x x x](https://reader031.vdocuments.net/reader031/viewer/2022022512/5ae8a20c7f8b9acc269066f9/html5/thumbnails/12.jpg)
Drilling tools: BHA
Standardization for the assembling of a BHA is difficult, the different tools
vary immense in many aspects
• Different types of tools
• Different design of tools
• Different dimensions of tools
• Different manufacturers of tools
• Different handling requirements of tools
• Different layout of the drill string (setup, diameter…)
12
![Page 13: TBA 100 A Performance Study of the New Generation 100-ton ... · Generation 100-ton Advanced Technology Rig ... •Power tong – higher moments ... Ass Jar safety clamp off x x x](https://reader031.vdocuments.net/reader031/viewer/2022022512/5ae8a20c7f8b9acc269066f9/html5/thumbnails/13.jpg)
BHA tools
Can we define a list of BHA tools that represent all/most of the tools that are
available on the market? (If I can handle those tools, I can probably handle
all the other tools!)
• Which tools
• Specifications of those tools
• Handling of those tools
• Logistic of those tools
13
![Page 14: TBA 100 A Performance Study of the New Generation 100-ton ... · Generation 100-ton Advanced Technology Rig ... •Power tong – higher moments ... Ass Jar safety clamp off x x x](https://reader031.vdocuments.net/reader031/viewer/2022022512/5ae8a20c7f8b9acc269066f9/html5/thumbnails/14.jpg)
Example: Drilling Bit
Roller-cone bits
Drag bits
Specifications: 3 ½” PDC 22” PDC 28” PDC
Length 400 mm 700 mm 750 mm
Weight 5 kg 750kg 900kg
ID - - -
OD 75 mm 240 mm 260 mm
Max. OD 90 mm 558 mm 710 mm
Thread 2 3/8” Reg. Pin 7 5/8” Reg. Pin 8 5/8” Reg. Pin
Make-up Torque 2,5 kNm 85 kNm 160 kNm
14
![Page 15: TBA 100 A Performance Study of the New Generation 100-ton ... · Generation 100-ton Advanced Technology Rig ... •Power tong – higher moments ... Ass Jar safety clamp off x x x](https://reader031.vdocuments.net/reader031/viewer/2022022512/5ae8a20c7f8b9acc269066f9/html5/thumbnails/15.jpg)
Example: Jar Disassembling Work Steps
15
![Page 16: TBA 100 A Performance Study of the New Generation 100-ton ... · Generation 100-ton Advanced Technology Rig ... •Power tong – higher moments ... Ass Jar safety clamp off x x x](https://reader031.vdocuments.net/reader031/viewer/2022022512/5ae8a20c7f8b9acc269066f9/html5/thumbnails/16.jpg)
Work Steps
16
![Page 17: TBA 100 A Performance Study of the New Generation 100-ton ... · Generation 100-ton Advanced Technology Rig ... •Power tong – higher moments ... Ass Jar safety clamp off x x x](https://reader031.vdocuments.net/reader031/viewer/2022022512/5ae8a20c7f8b9acc269066f9/html5/thumbnails/17.jpg)
Work Steps
17
![Page 18: TBA 100 A Performance Study of the New Generation 100-ton ... · Generation 100-ton Advanced Technology Rig ... •Power tong – higher moments ... Ass Jar safety clamp off x x x](https://reader031.vdocuments.net/reader031/viewer/2022022512/5ae8a20c7f8b9acc269066f9/html5/thumbnails/18.jpg)
Work Steps – Manual and On Rig Floor
18
Autom. Manual On Rig Fl. Hazard. Time Frequent Realizable Knowl.
Transp Pick up sensible string x x
Transp Lay down sensible string x x
Transp Lay down item x x x x
Transp Pick up item x x x x
Ass Safety clamp on x x x x
Ass Safety clamp off x x x x
Ass Jar safety clamp on x x x
Ass Jar safety clamp off x x x
Handl Slips in x x
Handl Slips out x x
Handl Bushing in x x x
Handl Bushing out x x x
Handl Bit breaker plate frame on x x x
Handl Bit breaker plate frame off x x x
Ass Bit breaker plate on bit x x
Ass Bit breaker plate off bit x x
Handl Bit breaker plate in frame x x
Handl Bit breaker plate off frame x x
Ass Bit + bit breaker plate in frame x x
Ass Bit in bit breaker plate x x
Ass String revolution indicator x x x
Ass Breake connection man. x x x x x
Ass Make-up connection man. x x x x x
Ass Screw connection man. x x
Ass Unscrew connection man. x x x
Handl Change elevator x x x x
Handl Guide pipe up x x x x
Handl Guide pipe down x x x x
Handl Cover borehole x x
Handl Push string x x x
Transp Winch on x x
Transp Winch off x x
Serv Add ball/chip to well x x
![Page 19: TBA 100 A Performance Study of the New Generation 100-ton ... · Generation 100-ton Advanced Technology Rig ... •Power tong – higher moments ... Ass Jar safety clamp off x x x](https://reader031.vdocuments.net/reader031/viewer/2022022512/5ae8a20c7f8b9acc269066f9/html5/thumbnails/19.jpg)
19
Evaluation and benchmarking of every
single process on the drill floor
Break-down & Visualization
Definition & Categorization
Evaluation & Ranking
![Page 20: TBA 100 A Performance Study of the New Generation 100-ton ... · Generation 100-ton Advanced Technology Rig ... •Power tong – higher moments ... Ass Jar safety clamp off x x x](https://reader031.vdocuments.net/reader031/viewer/2022022512/5ae8a20c7f8b9acc269066f9/html5/thumbnails/20.jpg)
Example for a project to mechanize a process on a
drilling rig
20
Manual Semi-remote
controlled Remote controlled
Fully mechanized 100% Hands free
![Page 21: TBA 100 A Performance Study of the New Generation 100-ton ... · Generation 100-ton Advanced Technology Rig ... •Power tong – higher moments ... Ass Jar safety clamp off x x x](https://reader031.vdocuments.net/reader031/viewer/2022022512/5ae8a20c7f8b9acc269066f9/html5/thumbnails/21.jpg)
21
Cylinder length measurement
trip-in/trip-out inclination
Length measurement
sledge Cylinder length measurement
inclination
Cylinder length
measurement
clamp
Pipe isolating
proximity switch
Cylinder measurement
V-door
Example for a project to mechanize a process on a
drilling rig
![Page 22: TBA 100 A Performance Study of the New Generation 100-ton ... · Generation 100-ton Advanced Technology Rig ... •Power tong – higher moments ... Ass Jar safety clamp off x x x](https://reader031.vdocuments.net/reader031/viewer/2022022512/5ae8a20c7f8b9acc269066f9/html5/thumbnails/22.jpg)
Examples of the selection of sensors for a
fully automated drilling rig.
22 22
Information of sensors are required to
achieve a fully automated drilling
process
• Drilling torque, vibration & tension
sensor
• Sensors on top drive
• OPC-interface for „Plug and Play“
• B-Tronic
![Page 23: TBA 100 A Performance Study of the New Generation 100-ton ... · Generation 100-ton Advanced Technology Rig ... •Power tong – higher moments ... Ass Jar safety clamp off x x x](https://reader031.vdocuments.net/reader031/viewer/2022022512/5ae8a20c7f8b9acc269066f9/html5/thumbnails/23.jpg)
Summary
26
• The performance of the protoytyp rig was excellent with:
• NPT less 0,5%
• No LTI
• Training, crucial equipment and supply chain shouldn’t be the bottleneck
• Benchmark and evaluate all processes on the rig to understand the way to
get a fully automated solution
• Push automation & mechanisation to the limit by increasing the efficiency
• Modular systems to offer a range of different applications to customer
![Page 24: TBA 100 A Performance Study of the New Generation 100-ton ... · Generation 100-ton Advanced Technology Rig ... •Power tong – higher moments ... Ass Jar safety clamp off x x x](https://reader031.vdocuments.net/reader031/viewer/2022022512/5ae8a20c7f8b9acc269066f9/html5/thumbnails/24.jpg)
27
Thank you for
your attention!!!
Maximilian Trombitas,
Product Manager -
Bauer Deep Drilling GmbH