Rig Repair
Rig Repair
Rig Repair
2003
Rig Repair
Rig Repair
Rig Repair
THE IMPACT OF UNSCHEDULED RIG
REPAIR
The Wellbore
A high risk of more unscheduled events
Extended exposure time
Loss of a hole section
Loss of the well
2003
Rig Repair
THE IMPACT OF UNSCHEDULED RIG
REPAIR
The Operator
Increased well cost
Delayed production
Loss of production
2003
Rig Repair
PRIMARY DRILLING
CONTRACTOR
AND
OPERATOR
OBJECTIVES
2003
Rig Repair
Drilling Contractor
No personnel injury
No well control incident
Optimise equipment life
Minimise rig repair
Control equipment cost
Long term drilling
contract
2003
Operator
No personnel injury
No well control incident
Optimise drilling
operation
Minimise unscheduled
events
Control final well cost
Cost effective
performance
7
Rig Repair
2003
Rig Repair
Preventive Maintenance Program (PMP)
A program designed to schedule regular
inspection, maintenance and/or repair of
drilling equipment prior to failure.
The historical life expectancy of rig equipment
is based on the frequency of maintenance.
2003
Rig Repair
THE FOUR COMPONANTS OF A PREVENTIVE
MAINTENANCE PROGRAMME
CLOSED
LOOP
CREW
FEEDBACK
RECORD
KEEPING
AUDITING
Management to
rig
Refining and
tailoring of the
system
Equipment
history
Through
inspection
Rig to
management
Equipment
trends
Well designed
checklists
Roles defined
Equipment
maintenance
Follow-up plans
and reports
Clear guidelines
2003
10
Rig Repair
COMPREHENSIVE PMP EQUIPMENT LIST
MAIN ENGINES
GENERATORS/SCR SYSTEM
BOP & ACCUMULATOR CONTROL SYSTEM
HOIST EQUIPMENT
TOP DRIVE SYSTEM
ROTARY SYSTEM
HP MANIFOLD/VALVES/HOSES
HYDRAULIC OPERATING SYSTEM
RIG MOVE
EQUIPMENT
2003
11
Rig Repair
TOP DRIVE
SYSTEM
2003
12
Rig Repair
COMPREHENSIVE PMP EQUIPMENT LIST
13
Rig Repair
PMP FREQUENCY SCHEDULE
HOURLY
BI-MONTHLY
EVERY TWO
YEARS
DAILY
QUARTERLY
EVERY THREE
YEARS
WEEKLY
EVERY FOUR
MONTHS
EVERY FOUR
YEARS
BI-WEEKLY
SEMIANNUALLY
EVERY FIVE
YEARS
MONTHLY
2003
ANNUALLY
EVERY EIGHT14
Rig Repair
BENEFITS OF A SUCCESSFUL PMP PROGRAM
ENSURE EQUIPMENT LIFE EXPECTANCY
REDUCE DOWNTIME FOR UNSCHEDULED RIG
REPAIR
LOWER WELL COST
REDUCE SEVERITY OF DAMAGE TO EQUIPMENT
MAINTENANCE COST LESS THAN EMERGENCY
REPAIR
LESS CHANCE OF PERSONNEL INJURY
INCREASE IN DRILLING CONTRACTOR PROFITS
2003
15
Rig Repair
BENEFITS OF A SUCCESSFUL PMP PROGRAM
REDUCED RISK OF STUCK-PIPE, WELL CONTROL
OR OTHER UNSCHEDULED EVENTS
COMPONENT FAILURE FREQUENCY RECORDS
DEFINES RIG AND OFFICE SPARE PARTS
INVENTORY
INCREASE OPERATOR AWARENESS OF DRILLING
CONTRACTOR NEEDS
AN OPPURTUNITY FOR THE DRILLING
CONTRACTOR TO INPUT AND HAVE INVOLVEMENT
IN THE WELL
16
2003 PLANNING PROCESS
Rig Repair
EVALUATE RIG REPAIR FAILURE
SEVERITY
17
Rig Repair
EVALUATE RIG REPAIR FAILURE
SEVERITY
ARE PERSONNEL OR THE RIG IN DANGER?
IS THE WELLBORE IN DANGER?
WHAT SAFETY PRECAUTIONS ARE
REQUIRED?
CAN THE FAILURE BE REPAIRED AT THE RIG
SITE?
WHAT IS THE PREVENTIVE ACTION PLAN?18
2003
Rig Repair
DRILLING SYSTEM EMERGENCY
BREAKDOWN PROCEDURES
IF RIG EUIPMENT FAILURE SHUTS-DOWN A
MAJOR DRILLING SYSTEM, IMMEDIATE
ACTION MUST BE TAKEN TO PROTECT THE
PERSONNEL, RIG, AND THE WELLBORE
FROM ASSOCIATED EVENTS
2003
19
Rig Repair
DRILLING SYSTEM EMERGENCY BREAKDOWN PROCEDURES
DRILLING
SYSTEM
BREAKDOW
N
INITIAL RESULT
POSITIONING
1.
2.
RIG MOVES
OFF LOCATION
DRILLSTRING
SHEARED-OFF
SECONDARY
RESULT
1.
2.
3.
4.
STUCK-PIPE
BOP DAMAGE
DRILLSTRING
DAMAGE
SURFACE
EQUIPMENT
DAMAGE
ACTION PLAN
1.
2.
3.
4.
2003
STOP ROTARY
&
CIRCULATION
POSTION T.J.
ABOVE HANGOFF RAMS
CLOSE RAMS &
HANG-OFF
INITIATE
EMERGENCY
PROCEDURES
20
Rig Repair
DRILLING SYSTEM EMERGENCY BREAKDOWN
PROCEDURES
DRILLING
SYSTEM
BREAKDOWN
TOTAL LOSS OF
POWER
INITIAL
RESULT
1.
2.
3.
2003
SECONDARY
RESULT
LOSS OF
1.
HOISTING
2.
LOSS OF
CIRCULATION 3.
LOSS OF
ROTATION
STUCK-PIPE
WELL
CONTROL
SURFACE
EQUIPMENT
DAMAGE
AND/OR
FAILURE
ACTION
PLAN
1.
2.
3.
START
EMERGENCY
GENERATOR
CIRCULATE
WITH THE
CEMENT UNIT
MONITOR THE
WELL FOR
FLOW
21
Rig Repair
DRILLING SYSTEM EMERGENCY BREAKDOWN
PROCEDURES
DRILLING
SYSTEM
BREAKDOWN
INITIAL
RESULT
TOTAL DRILLING 1.
POWER
2.
3.
LOSS OF
1.
HOISTING
LOSS OF
2.
CIRCULATION
LOSS OF
ROTARY
SECONDARY
RESULT
ACTION PLAN
STUCK-PIPE
1.
WELL
CONTROL
2.
3.
2003
START
EMERGENCY
GENERATOR
CIRCULATE
WITH THE
CEMENT UNIT
MONITOR THE
WELL FOR
FLOW
22
Rig Repair
DRILLING SYSTEM EMERGENCY BREAKDOWN
PROCEDURES
DRILLING
SYSTEM
BREAKDOWN
TOP DRIVE
SYSTEM
(TDS)
INITIAL
RESULT
1.
2.
3.
LOSS OF
HOISTING
LOSS OF
CIRCULATION
LOSS OF
ROTARY
SECONDARY
RESULT
ACTION PLAN
1.
STUCK-PIPE
1.
2.
WELL
CONTROL
2.
3.
4.
2003
TRIP TO THE
SHOE FOR REPAIR
ROTATE THE PIPE
IN THE SLIPS
RIG-UP TO
CIRCULATE
MONITOR THE
WELL FOR FLOW
23
Rig Repair
DRILLING SYSTEM EMERGENCY BREAKDOWN
PROCEDURES
DRILLING
SYSTEM
BREAKDOWN
HOISTING
SYSTEM
INITIAL
RESULT
1.
2003
CANNOT
RAISE
DRILLSTRING
SECONDARY
RESULT
1.
STUCK-PIPE
ACTION PLAN
1.
CONTINUE
CIRCULATION
AND
ROTATION
24
Rig Repair
DRILLING SYSTEM EMERGENCY BREAKDOWN
PROCEDURES
DRILLING
SYSTEM
BREAKDOWN
ROTARY
SYSTEM
INITIAL
RESULT
1.
SECONDARY
RESULT
CANNOT
1.
ROTATE THE
DRILLSTRING
STUCK-PIPE
ACTION PLAN
1.
2.
3.
2003
RECIPROCATE
THE
DRILLSTRING
TRIP TO THE
SHOE FOR
REPAIR
MAINTAIN FULL
CIRCULATION
25
Rig Repair
DRILLING SYSTEM EMERGENCY BREAKDOWN PROCEDURES
DRILLING
SYSTEM
BREAKDOWN
CIRCULATNG
SYSTEM
INITIAL
RESULT
1.
2003
CANNOT
CIRCULATE
THE WELL
SECONDARY
RESULT
ACTION PLAN
1.
STUCK-PIPE
1.
2.
WELL
CONTROL
2.
TRIP TO THE
SHOE FOR
REPAIR
ROTATE AND
RECIPROCATE
THE
DRILLSTRING
IF REPAIRS ARE
MADE IN OPEN
HOLE
26
Rig Repair
DRILLING SYSTEM EMERGENCY BREAKDOWN
PROCEDURES
DRILLING
SYSTEM
BREAKDOWN
WELL CONTROL
SYSTEM
1.
2.
2003
INITIAL
RESULT
SECONDARY
RESULT
CANNOT
1.
SHUT-IN THE
WELL ON A
2.
KICK
EQUIPMENT
1.
DAMAGE
PERSONNEL
INJURY
LOSS OF THE WELL
ENVIRONMENTAL 2.
DAMAGE
BLOWOUT
3.
4.
ACTION PLAN
NON
EMERGENCY,
SECURE THE
WELL TO
MAKE REPAIRS
INITIATE
EVACUALTION
PROCEDURES
27
Teams
Drilling Problems
2003
28
Rig Repair
INTEGRATED PREVENTIVE MAINTENANCE PROGRAMME (IPMP)
RIG EQUIPMENT MAINTENANCE LIST
1. SERVICE MAIN ENGINE
22.
2. SERVICE GENERATORS
9. 4,5,6
23.
24.
25.
5. SERVICE CRANE
26.
27.
28.
LEGEND
PLANNED
MAINTENANCE
LOW RISK
MAINTENANCE
HIGH RISK
MAINTENANCE
CEMENT UNIT
LOGGING UNIT
MUD LOGGING
UNIT
1. SERVICE TRANS #1
6. SERVICE P/TANK
VALVES
16. SERVICE
COMPUTER
2. SERVICE ENGINE #1
7. SERVICE PUMP #1
3. SERVICE TRANS #2
8.
4. SERVICE ENGINE #2
9.
5. SERVICE PUMP #1
10.
15.
20. SERVICE
LIGHTING
2003
OTHER
29
Rig Repair
SERVICE IPMP
4-5-6-10-12
#2
RIG IPMP
1-2-4-5-6-10-12-29
15
11
12
9-22-23
16
1
3
19
17-16-20
18
1
0
0-----5-----10-----15-----20-----25------30------35------40------45------50------55-----60------65------70
WELL PLAN
26 HOLE 20 CASING
W.OC.
CASING----------DEPTH
17 HOLE 13 CASING
RUN CASING
30
1284 FT
W.O.C.
12 HOLE 9 CASING
20
2600 FT
RUN CASING
W.O.C.
13
5080 FT
8 HOLE 7 LINER
RUN CSG
12,250 FT
14,540 FT
WO
C
2003
30