Fully Automated Land Rig Pipe Handling: Learnings from the First Year in Operation

Abstract

Abstract Objectives/Scope A look at learnings from the first year of operations on a fully automated rig floor package retrofitted to a 2000hp Permian Basin rig. Technical issues and optimization efforts will be reviewed as the factors driving next-generation pipe handling system that improves safety while meeting well delivery metrics. Methods, Procedures, Process The retrofittable automation system controls several tools and technologies automating pipe handling for drilling, tripping, casing running, offline stand building and routine BHA handling. Keeping the focus on this area provides a drilling environment where risk due to man / machine interactions are substantially reduced or eliminated. During this proof period, improvements have continued in casing handling and running that are being optimized based on the learnings from the current pipe handling system. These improvements are being flowed through engineering and will support the next generation automated rig floor improvements. Results, Observations, Conclusions While the industry continues to focus on improvements in crew safety and consistency, applications of automated drilling systems often cannot justify the expense of a next generation drilling rig. Automation systems specifically designed to be retrofitted to existing rig designs provide these capabilities for a fraction of the cost of a new rig. This means the next evolution in safety can be affordable and installed on current drilling rigs with only short windows of down time. Existing technologies like robotics, modern control systems, closed-loop feedback, and zone management for both machines and crew all combined to focus on getting the job done safely are no longer exercises in what could be, rather what is available. Within the contractor fleet several rigs of the same design are working in the same field drilling the same wells which allows for direct comparison of key performance indicators for the automation system. Learnings from the first year will be reviewed and discussed. Novel/Additive Information Versions of pipe handling have been with the industry since the advent of harsh environment floaters. Today's automated functionality brings a new level of crew-less operations. Keeping crew separated from hazards is the next step in rig floor operations. This improved level of safety can now be achieved through more economical, retrofittable upgrades while maintaining similar rig performance metrics.