TBA 100 A Performance Study of the New Generation 100-ton Advanced Technology Rig. Maximilian Trombitas, Product Manager Bauer Deep Drilling GmbH

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1 TBA 100 A Performance Study of the New Generation 100-ton Advanced Technology Rig Maximilian Trombitas, Product Manager Bauer Deep Drilling GmbH

2 Outline Field study Lessons learned Rig design changes Mechanization of drill floor processes Example: Pipe handling Summary 2

3 Buffalo 90 is a multipurpose drill rig designed in a cooperation of Bauer and DeWet 3

4 Buffalo 90 has drilled two horizontal wells for CBM projects for Kalahari Gas in Botswana 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) 4

5 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: Sidetrack 2 Trajectory Sidetrack ½ section was drilled with bentonite mud all lateral sections were drilled with fresh water and sweeps Coal Bed (high ROP) Dolerite (hard, low ROP) Notes: Trajectory based on Pathfinder data, geology schematic 5

6 Rig set-up Buffalo90 Rig Shale Shaker Mud pits Pipe handler Dog House Pipe Rack 6

7 Rig performance analysis of 23 days operation Rig NPT less than 0.5%: Problem Hours % NPT Step 1 Step 2 Pipe handler % Rig mechanics % Air slips % Rotary brake % Total 2.5 0,43% Step 3 Step 4 Weight-to-Weight-connection ~2.2 min Fuel Consumption ~ 500 l/day No HSE incidents or accidents 7

8 The operational problems involve both mechanical and human errors Mechanical Errors Downtimes Waiting on spare parts (difficult supply situation) Inefficiencies Pump capacity Shale shaker capacities There is no way around providing good training to people Selecting & keeping the good ones Human Errors Waiting on fuel (nonattention, 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, ) Not saving money on crucial equipment like mud pumps or shale shakers Establishing better supply chains for future large scale operations 8

9 Lessons learned for the whole system out of the first operations Suggestions for Rig Changes 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 Equipment 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.) Automation Issues High risk operation still manual Changing of mind More sensors required Software 9

10 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

11 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 Break-down & Visualization Definition & Categorization Evaluation & Ranking 11

12 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

13 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

14 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

15 Example: Jar Disassembling Work Steps 15

16 Work Steps 16

17 Work Steps 17

18 Work Steps Manual and On Rig Floor 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 18

19 Evaluation and benchmarking of every single process on the drill floor Break-down & Visualization Definition & Categorization Evaluation & Ranking 19

20 Example for a project to mechanize a process on a drilling rig Manual Semi-remote controlled Remote controlled Fully mechanized 100% Hands free 20

21 Example for a project to mechanize a process on a drilling rig Length measurement sledge Cylinder length measurement inclination Cylinder measurement V-door Cylinder length measurement clamp Cylinder length measurement trip-in/trip-out inclination Pipe isolating proximity switch 21

22 Examples of the selection of sensors for a fully automated drilling rig. 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 22

23 Summary 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 26

24 Thank you for your attention!!! Maximilian Trombitas, Product Manager - Bauer Deep Drilling GmbH 27

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