Rig Equipment and Inspection Presentation 10

Howard A. Garig

DRILLING TECHNICIAN SCHOOL
ExxonMobil Development Company Houston, Texas 2004
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Learning Objectives

You should be able to: • Identify different types of drilling rigs • Describe their operating environments • Identify main rig systems and equipment

• Describe the functions of the systems
• Understand the rig inspection process and your role in it

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Information Sources • EMDC Drilling OIMS Manual

• API Recommended Practices
• Previous Rig Inspection Plans • World Oil Composite Catalogs

• OPL Marine Drilling Units of the World
• Dave Steubner- EMDC Global Rig Coordinator • World Oil Magazine - Yearly Rig Editions

• IADC Drilling Manual
• Vendor Material
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Rigs Categorized by Operating Environment • Drill ship • Semi-submersible • Jack-up • Platform • Barge • Land 4 .

Land Rigs Heli-rig on Papua New Guinea • Solid foundation needed for land rigs • Carrier-mounted/trailerized mobile rigs for fast rig move • Helicopter transportable rigs for locations without accessible road 5 .

Barge Rigs • Mostly for inland water or offshore areas with calm weather • Inland barge often towed to location with draft < 6 feet • Submersible barge ballasted until lower hull rests on soft bottom • Mud barge also available 6 .

TLP. DDCV • $20k .Platform Rigs • Operated anywhere a platform can set – jacket.$100M to build • Ability for supply boat off-loading being the limiting factor for operations in severe weather • Weight and space requirements impact platform design and cost Jade .$40k daily rental • $20M .Equatorial Guinea 7 .

Platform Rigs Malaysia: Seahawk at Palas A • Compact/integrated design and tender-assisted drilling reducing weight and space requirements Malaysia: Tioman T-2 at Tapis E 8 .

Designed by EM Diana Hibernia .Newfoundland Jotun B-Norway Ringhorne .Platform Rigs .Norway 9 .

$120k daily rental • Relatively calm weather needed for installation. for example: wave height < 5 feet and wind < 15 knots • Rig can move horizontally onto the top of a platform for cantilever operations 10 .Jack-Up Rigs • Operated up to 400’ water depth • $20k .

Drill Ships • Operated up to 10000’ water depth • $100k – $200k daily rental • Moored or dynamicallypositioned in place • High Speed Mobilization • Storage Capacity Jack Ryan 11 .

$230k daily rental • Most have thrusters to assist in towing and positioning for mooring • Moored or dynamically positioned in place • The deck is usually higher than drill ship Leiv Eirikssen 12 .Semisubmersible • Operated up to 10000’ water depth • $60k .

1.Rigs Categorized by Operational Capability • • • • • By height of mast – single.000’. completions By design – 3rd. light weight. 5th generation MODU – API. 35. mechanical 13 . 20.3 M lbs By rated well depth – 5000’. 4th. triple. workover.5 M lbs.0 M lbs.000’. double.000’ By applications – drilling. 1. integrated – SCR. fourble By derrick hookload capacity – 0. 10.

allowing fast moving to avoid hazards • In general.000 HP) • Shorter rig up/down time for DP rigs.Moored vs Dynamically Positioned (DP) Ships and Semis • No “drive off” risk for moored rigs • More fuel consumption for DP rigs. lower water-depth limit for moored rigs 14 . high horsepower needed for thrusters (5000-25.

Cost Savings: DP Net Savings Maximum Savings Realized by DP: • Multiple wells or batch setting over DP Cost Savings vs. Well Days Operations ~ 5000' WD 1500 (KUSD) DP Cost Savings 1000 500 0 Net Loss an area larger than a rig’s mooring radius • Shorter term exploration well programs -500 -1000 -1500 -2000 25 50 75 Well Days-Exclude Anchor Work 15 .

Cost Savings: Moored Net Savings Maximum Savings Realized by Mooring: • Template or drill center operations fitting within a rig’s mooring pattern • Longer term operations where mooring is a small percentage of total program DP Cost Savings vs. Well Days Operations ~ 5000' WD 1500 (KUSD) DP Cost Savings 1000 500 0 Net Loss -500 25 50 75 -1000 -1500 -2000 Well Days-Exclude Anchor Work 16 .

now use of passive and active heave compensators Crown Mounted Compensator Block Mounted Compensator 17 .Floating Rig Considerations • Need for heave compensation • Previously done with bumper subs .

Rig Site Zoology Doghouse Mousehole 18 .

Rig Site Zoology Catwalk Possum Belly 19 .

UT Austin 20 .Rig Systems and Components 5 primary systems associated with drilling rig • Power System • Hoisting System • Rotating System • Circulation System • Well Control System Reprinted with permission from Petroleum Extension Service.

engine shaft power to electrical generators & then distributed through silicone controlled rectifier (SCR) that converts AC electrical power to DC for variable speed motors 21 .Power System • Engines: internal combustion engines provide shaft power • Transmission: – Mechanical .engine shaft power to compound for distribution – Electrical .

Provide a structural reaction to the hoisting forces and setback. Setback is the amount of pipe weight that can be vertically racked while the maximum hook load is being carried.Deliver hoisting power to the hook • Mast/derrick and substructure -.Hoisting System • Drawworks. crown and traveling block -. 22 .

Hoisting System-Hydraulic

• A new type of hoisting system has recently been employed on a few new semis and drill ships. The concept is known as a Ram Rig or Hydra Lift Rig. Both concepts use hydraulic cylinders to move the load up and down. 23

Hoisting System

• Hook, links & elevators -- Provide a force path from the drill stem to the rotary drill line • Rotary swivel -- Provide for the rotation of the drill stem with respect to the hook, while providing a force path to the hook and a fluid path to the drill stem • Maximum hook load = heaviest string of casing (typically)
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Rotating System

• Rotary table -- Deliver rotating power to the drill stem through the kelly & associated bushings, usually gear driven from a side shaft. • Kelly is typically a 40’ long, square or hexagonal shaped, thick wall pipe, with a valve (kelly cock) that can be closed to prevent 25 backflow.

Motor provides torque to the drill stem through a drive shaft. Advantages: 1) Rotate while tripping out 2) Can add 3 joints at a time 3) Making up or breaking out pipe easier • Maritime Hydraulics Varco 26 .Rotating System • Top drive .Hangs from the hook.

Hold drilling and completion fluids Various pit sizes – Slug Pits .30-100 bbls to mix small batches of fluid.. On land may be earth pit – Sand Trap/Treatment Pits usually series of 3 pits where mud initially returns from solids control equipment.100-1000 bbls holds fluid regularly circulated through well – Reserve pits .Circulating System .100-1000 bbls holds fluid for reserve use on well. Pump to and return from secondary solids control such as desanders.Mud Pits • • Mud pits -. desilters etc.usually directly hooked to hoppers and mixing lines – Active pits . 27 .

Mud Pumps • • Mud pumps – 2-3 piston pumps (often with centrifugal booster pumps) to circulate mud Larger pump cylinder liner for higher flow rate and smaller liner for higher pressure Typically need high flowrate for surface hole and high pressure for production hole • 28 .Circulating System .

Standpipe Manifold T o C h o ke M a n if od l 12 1 MD MD T e s tH o se 7 4 2 MD 10 16 13 15 Standpipe Manifold directs HP mud flow from mud pumps to drill string or other desired path 5 8 3 6 9 11 14 R ise rB o o s t Ln ie S t andp p ie#1 Je t L n ie Br u n e rB o o ms S t andp p ie#2 29 .Circulating System.

and disposal cost 30 . mud cost.Provides for the removal of drilled solids from the drilling fluid upon return from the well bore annulus • Component selection depends on mud weight.Circulating System . desilter & centrifuge -. desander. equipment cost.Solids Control Centrifuge Shaker Desander Deciliter • Shale shaker.

mostly used in GOM top hole sections • Degassers .Circulating System .Other Mud Treatment Gumbo Chains Degassers • Gumbo Chain .for handling high volumes of soft-gumbo shales.for removal of gas from mud stream post solids control 31 .

riser joints and LMRP (lower marine riser package) for floaters • Casing often used as riser for platform drilling • Riser weight supported by buoyancy can and tensioner • Low pressure riser for floating drilling and high pressure riser for platform drilling.Drilling Riser • As a return mud flow path from well at sea floor • Typically consisting of slip joint. dual risers for extreme conditions • Kill/choke lines attached to riser and booster line used to assist cuttings transport 32 .Circulating System .

BOPs DRILL STRING FLOAT VALVE BOP Control System 33 .Well Control System FILL LINE FLOW LINE BELL NIPPLE ANNULAR BOP BOP STACK Trip Tank MUD STANDPIPE CENTRIFUGAL PUMPS Poor Boy Degasser UPPER KELLY SAFETY VALVE TO M TA UD NK FLOW RATE RECORDER PUMP-TYPE TRIP TANK LAYOUT PVT BOP REMOTE RECORDER CLOSING UNIT HYDRAULIC CHOKE CONSOLE LOWER KELLY FILL LINE SAFETY VALVE DRILL PIPE SAFETY VALVE PIT VOLUME TOTALIZER (PVT) RESERVE PIT DEGASSER SHALE SHAKER FLARE STACK INSIDE BOP FLOW RATE DETECTOR LINE FLOW RELIEF VALVE PUMP ISOLATION VALVE MUD GAS SEPERATOR BYPA SS GRAVITY TRIP TANK UD TO O M PIPE T D KIL L L STAN INE CHECK VALVE BOP STACK HYDRAULIC HYDRAULIC CHOKE CHOKE CONTROLED MANIFOLD VALVE Choke Manifold BOP ACCULULATOR UNIT MAIN CLOSING UNIT TO REMOTE CLOSING UNIT ON RIG FLOOR KILL LINE FROM MUD PUMP OR HIGH PRESSURE PUMP WELLHEAD Example Schematic Layout of Well Control Equipment Kick Detection Equip. Kick Circulating Equip. Kick Containment Equip.

Well Control System • Blowout preventer (BOP) stack -.Provides pressure isolation and control during kicks • Pressure rating is based on maximum anticipated surface pressure during a well control event • BOP stack arrangement important. Annular. Ram. pipe shear rams BOP 34 .

Well Control System Annular Rotating Head WH Connectors Rams 35 .

Well Control System Land BOP Stack Subsea BOP Stack 36 .

Well Control System • Accumulators store fluid under high pressure for control devices 37 .

• Choke also remotely controlled 38 .Well Control System • Activated by remote control unit on rig floor. Can open or close BOP quickly.

Well Control System G as L n ie 34 T e s tP o rt T o M u d G a s S e p a ra to r 33 H 32 H 31 30 29 28 • Choke Manifold provides positive pressure and flow rate control of the well during a kick or live drilling operation 27 20 22 19 24 26 16 15 14 13 F ro n t V e iw • Equipped with both manual and remote chokes • Allows flow to be directed to poor boy de-gasser. flare line. other routes T e s tP o rt 9 12 18 8 C HO KE L N I E H 11 17 B a ck S d ie 4 T e s tP o rt H 5 7 35 10 H 1 2 3 K IL L L N I E DM 6 T o S ta n d P p i e M a n ifo d l 39 .

Well Control System Manual Choke Remote Choke 40 .

tube liquid seal 41 .Well Control System • Poor Boy Degasser • Vessel Size • • • • Internal Baffles Gas Outlet Target Plate U.

Rig Floor Layout New Offshore Platform Typical STX Land Rig 42 .

Drilling Equipment Controls 43 .

Rig Floor Equipment Iron Roughneck • Make-up and Breakout of tubulars • Replaced Manual Tongs • Increased Safety • Integral Spinner • Still use manual tongs for large DCs or BHA components 44 .

Rig Floor Equipment Manual Tongs • Make-up and Breakout of tubulars • Safety focus on proper use and tong BU lines • Pipe spinner in place of chain for safety • Still use manual tongs for large DCs or BHA components Pipe Spinner Tongs 45 .

MU/BO line – Traditional method still widely in use • Hydraulic Cathead – Found on newer rigs or installed on older ones – Safer. dedicated unit 46 .Rig Floor Equipment Torque-up Devices • Draw works .

Rig Floor Equipment Flush Mounted Slips DP Elevators BX Adjustable Elevators Slips 47 .

Pipe Handling Equipment 48 .

Large OD Handling Equipment • Casing • Riser 49 .

Rig Inspections 50 .

Rig Inspections • Purpose of Rig Inspections • Inspection Requirements • 3rd Party Inspections • QA/QC of Inspections • Inspection Planning and Follow-up 51 .

Purpose of Rig Inspections • Safety • Regulatory Requirements • OIMS Requirements • Assure rig meets contract requirements • Equipment verification • Familiarity with rig capabilities 52 .

OIMS Requirements • Sections 3.6 and 8 of the OIMS Manual “Procedures shall be in place for initial inspection and acceptance of critical drilling equipment” • In Reference to: – Safety – Regulatory Requirements – Drilling Design Standards – Drill Team Specific Acceptance Criteria 53 .

where practical” • Guidelines: – Safety – Regulatory Requirements – Well Type.. 54 . customized for the specific rig. Duration of Program. area and/or operation. Equipment acceptance criteria shall be incorporated into the checklist. Drilling Design Standards – Inspection Team Make-up: EM personnel specialists.Inspection Requirements “A checklist shall be developed. 3rd party Inspectors etc.

Hill or other • Tubulars. some ModuSpec • Marine Safety .ModuSpec • NDT testing personnel .URC aid on critical subjects.Inspection Team • BOP and Well Control Equipment .T.Mud Company selected as contractor 55 . Hill • Hygiene . handling Equipment .EM Health Inspection Team • Solids Control .H.West Inc. ModuSpec • Rig Equipment Acceptance .H.T.

testing verification 56 .QA/QC of Inspections • Document Verification • Daily Interaction-discussion of inspection progress • Witnessing of tests • Critical equipment .

Inspection Planning and Follow-Up • Coordinate with Superintendent on inspection schedules • Develop Checklist to track progress • Develop Follow Up list to track outstanding items • Track Progress on Follow-up items until completed 57 .

4 Mooring Equipment Production Test Lines Environmental Aspects: Closed drain systemetc.Witness of operation Derrick Inspection/Risk Assessment Riser/Slip Joint/Flex joint Inspection BOP and Diverter Equipment Risk Assessment Issues Identified Handling Tools Water tight doors BOP Control System C&K Manifold and Lines Poor Boy Degasser All tubulars DS-1 cat. Medical & Hygiene Facilities and Personnel High pressure piping survey and repairs 3rd Party Drill Tools Solids Control Equipment Helicopter Facilities Burner booms Supply Vessels Personnel Qualifications Lifting Equipment Fluid systems operability Classification survey of hull.MODU Rig Inspections Structural Inspection Marine Safety Audit and Stability Review and EER Analysis Up to date Manufacturer. structure and well controll equipment 58 ..equipment Recalls Rig Acceptance Checklists..

West & 3 rd party NDE 0 0 0 0 0 0 0 0 0 0.Rig Inspections.Opts. Third Party Drill Tools.EMDC OS Lifting Equipment Shore-Logistics Supervisor Rig Acceptance Checklist.Inspection Plans 9-Jun-03 FOLLOW UP SHEET FOR HAKURYU V INSPECTION PLAN PRIORITY DATE complete COMMENTS % FINISH 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 20 40 60 80 100 DESCRIPTION Structural Inspection Stability Review-ModuSpec Marine Safety Audit-ModuSpec Derrick Inspection-Dreco Derrick Risk Assessment-JDC and EMDC OS EER Analysis-ModuSpec Mooring Equipment-EMDC Eng & ModuSpec Mooring Analysis-URC Riser Analysis-URC Riser Inspection-West & 3rd party NDE Riser Slip Joints-West & 3rd party NDE Riser Flex Joint and Riser Adaptor-West Riser Tensioners-West Riser Handling Tools-West & 3rd party NDE Diverter & Ball Joint-West BOP Preventers-West & 3rd party NDE BOP Annulars-West BOP Connectors-West BOP Control System-West BOP Flexible Hoses-West & 3rd party NDE Choke Manifold & Lines-West & 3rd party NDE Poor Boy Degasser-West Production Test Line-West & 3rd party NDE Drill String-EMDC OS and 3rd party NDE Lifting Equipment-Cargo.3rd party inspections Helicopter Operations Audit-MPN Aviation Helicopter Facilities Rigsite-MPN Aviation Total finish (average on all items above) Lifting Equipment-Drilling. Supt.IMOHD & AEA SMI Doctor Personnel Qualifications.00 % 59 .EMDC OS& West Medical Hygeine.

Non Destructive Testing • Magnetic Particle Inspection • Ultraviolet • Eddy Current • Ultrasonic Riser Spider 60 .Rig Inspections .

structural areas 61 .Rig Inspections .Non Destructive Testing Handling Equipment Lifting Equipment • Ideal for identification of fatigue related failures • Highly dependant on experience level of inspector • Also applied to other areas .such as crane pedestals.

Non Destructive Testing • • • • UT of HP piping is a high priority Focus on high flow areas(tees.Rig Inspections . elbows) Well control and standpipe Lines in close proximity to cement and mud pumps Freshly painted lines may have been painted to cover extensive corrosion • HP Piping 62 .

Rig Inspections .Visual Wire Rope 63 .

Being Thorough Shows normal wear and tear. BOP C&K Line Hose 64 . Passed both low and High pressure tests to company guidelines.Rig Inspections .

Being Thorough Upon visual inspection of the inside of the hose with a boroscope the inner lining was found to be damaged and the hose rejected.Rig Inspections . 65 .

get off rig!! 66 . Varies on well requirements • • • Dependent on Inspector Quality Perform as early as possible in case of high rejection rate Mark and separate failed tubulars .Tubulars Tubular inspection based on DS1 Criteria.Rig Inspections .

Rig Inspections .do we need it ? 67 .Visual: Human Factors • Does driller have a clear view ? • What type of work are we going to be doing with the rig ? • Weight Indicator working properly ? • Pressure monitoring sufficient ? • Do we have a mudloggers screen on the rig floor .

Visual: Human Factors 68 .Rig Inspections .

Visual: Human Factors 69 .Rig Inspections .

Rig Inspections .Rig Operability: Equipment • • • Does the rig have sufficient pump capacity for our planned operations ? Is the solids control equipment up to our program requirements ? How will this rig’s equipment capability limit us? 70 .

Rig Operability: Space and Layout • • Does the rig have enough room for our planned operations ? Is pit capacity sufficient ? 71 .Rig Inspections .

their functions and some broad selection criteria • Learned about tubular and other rig type handling equipment • Learned about rig acceptance inspection work 72 .Summary • Learned about different types of rigs and their operating environment • Learned about 5 main rig systems.