Automation consists of the use of control systems to control processes, reducing the need for human intervention. There has been considerable progress made in automating key tasks on the drill floor (i.e. mechanization), and in providing control of the weight on bit and bit rotation, etc. (e.g. Dupriest, 2005) to optimize the rate of penetration. In this paper we look at a stepwise implementation of adaptive drilling automation that responds to changing conditions in the wellbore. Within well construction, one specific process that may be well suited to this adaptive automation is the tripping of drillpipe or casing into or out of the well. Tripping operations today are guided by pre-drill analysis to determine safe tripping speeds and require the driller to react to changing downhole conditions to avoid problems such as swab, surge, or hole collapse. In this paper we describe a stepwise approach to partial adaptive automation of the tripping operation. The stepwise approach consists of continuously performing engineering-while drilling calculations to determine the dynamic hydraulic pressure profile variations within the wellbore at all depths for any driller-induced string motions or pump rates. Next we use these calculations to determine safe operational envelopes for the drilling machinery (accelerations, decelerations, rates and velocities), helping the driller to trip pipe in or out of the well while ensuring that the full wellbore hydraulic pressure profile always stays within the prescribed safe geopressure window based on current conditions. Finally, we reach the automation step where the operational envelopes guide the automated control of the drilling equipment.
This paper addresses important and largely overlooked challenges that exist when making up premium casing connections with a top drive and it describes how these issues can be controlled. To investigate them, tests were performed both in the Test Lab and in the field to examine the accuracy of torque measuring equipment normally associated with top drive casing make up tools (TDCM) when considering the following situations:Dynamic Torque - since the TDCM and the top drive are mechanically connected to the top of the casing or tubing joint during make up, their combined rotating mass represents kinetic energy. This in turn adds dynamic torque to the connection being made up when rotation comes to a sudden stop - i.e. when the connection reaches a shoulder contact."Backswing" - When the applied top drive make up torque is released abruptly, torsion generated static energy stored in the joint accelerates the above mentioned masses in the breakout direction. This translates to kinetic energy which applies breakout torque or "backswing" to the connection which can be significant depending on how rapidly the top drive make up torque is released. The test results identified these forces conclusively and also lead to the conclusion that standard top drive torque measurement systems are not capable of measuring either of them. In this paper the author will discuss these torque situations and present the results of the tests performed. He will conclude that both of these torque anomalies do in fact exist and that, though the response time of standard top drive torque measuring systems is sufficient for general drilling operations, it will in many cases be too slow for shouldered connections. He will also conclude that without alternative torque measuring systems the final make up speed of the top drive for premium connections must be drastically reduced to avoid the possibility of damage. Introduction The basic functions of a Top Drive mounted Casing Makeup Tool (TDCM) are as follows:To transfer torque from the top drive to the casing joint during makeup, thereby replacing the function of the power tong.To transfer the string load to the top drive while hoisting and lowering the casing string into the well, in essence replacing the casing elevator.To enable circulation of drilling fluids through the casing.To enable rotation of the entire casing string inside the well bore to mitigate well problems and for reaming and drilling with casing purposes.
In response to industry requirements for a reduction in rig crew numbers and an increase in safety, significant advances have been made in the mechanization of the pipe running and handling process in the last two years. This paper will outline the advances made in the industry to bring up to date process in pipe running and handling without making them too complex. Introduction Highlighted are the new systems for adapting hydraulic roughnecks to carry casing and tubing tongs, and for this equipment to operate remotely. Initially, this development was in response to Norwegian Petroleum Directorate requirements, but is now finding wider use in many countries because of the opportunities to reduce the number of personnel on the rig floor. There have also been significant advances in the moving of pipe from the racks to the catwalk, up to the Vee Door and in presenting pipe to the pipe makeup machine for running, these developments will also be described. Surveys have shown that the handling of pipe, especially on offshore rigs, is one of the most hazardous operations for rig personnel and service crews. Handling and running of pipe has always been hard and repetitive manual work with many attendant safety hazards. This paper will show how these new systems reduce the need for direct personnel intervention and result in an improvement in safety. Attempts have been made in the past to completely automate all mechanical functions on a rig, but these have proved too costly and complex. Recently there has been a focus on the improvement of specific parts of the rig systems which have shown great economic and safety benefits, such as Top Drives, Racking Systems, pipe handling without cranes, etc. The key ingredient in many of these advances has been the use and adaptation of Programmable Logic Controllers (P.L.C.'s). These topics will also be discussed. At a time when the upgrading of many offshore rigs is in sharp focus, these developments are showing major benefits for operators and drilling contractors alike. Description and Application of Equipment In 1994 Weatherford together with Maritime Hydraulics A/S introduced the Casing Modems where casing tongs and free floating backups were mounted to a special frame attached to the hydraulic roughneck (Fig. 1). These hydraulic tongs are remotely operated by a technician standing at a safe distance away from the well center using a portable control panel incorporating a joystick for maneuvering. The tong and it's accompanying free floating hydraulic backup are suspended from a compensation device attached to the casing modem frame. The casing modem and tongs can be mounted to the hydraulic roughneck in approximately 30 minutes. In operation the hydraulic roughneck provides the motion to move the whole assembly out to the well center so that the makeup of the pipe connection can be carried out. Automatic doors close around the pipe, first on the hydraulic backup then on the tong. The jaws are then engaged and makeup commences. All forces from the tong react directly to the free floating backup. No snub lines are required and no excess force is transferred to the casing modem frame. The free floating backup is specially designed so that shearing and bending forces are not imparted to the pipe or the connection. This is a critically important feature. P. 233
Safety is continuing to evolve as a worldwide driving force in rig operations and, as a result, is a major consideration in all drilling rig operations and planning. Therefore, designing hazards out of the system is the key goal in safety engineering, one which has resulted in rig mechanisation. Rather than wholesale automation, rig mechanization involves taking existing hardware and "mechanizing" it for modularity and, preferably, remote control. Traditional automation concepts often required complete re-design of certain rig components, even derrick structures were modified to fulfill the requirements of a completely automated process. This resulted in automation concepts becoming very expensive and cost prohibitive, to the point where they were being eliminated from consideration. Rig mechanization is a much more cost-effective approach which achieves safety goals by distancing the rig personnel from the hazardous location. This paper will present the latest developments in rig mechanization and their effect on improving safety and operational performance. It will also compare the safety performance of mechanized rig operations with previous methods of conducting the same tasks. Specific items whose role in rig mechanisation will be addressed are:Soft PLC Control Systems. These systems use software, microprocessors and fiber-optics to remotely control the equipment.Power Frame™ System. This system is designed to run on rails and is modularized to handle the suspending of any Power Tong to run casing and tubing.Mechanized Casing and Tubing Tongs. These tongs come complete with Free Floating Hydraulic Backups and remote operating capabilities.Stabberless System.This system engineers much of the hazard out of the stabbing operation by removing personnel from the derrick. Finally, this paper will present and discuss the four major driving forces that are serving to promote the development of this type of equipment. They are Safety, Economics, Legislation and Industry Trends. Introduction Historically, the closer to the wellbore (center of the well) the rig crew and service company personnel were working, the higher the potential for injury. This was due to conditions such as moving parts, being caught between hazards, pinch points and objects falling to the rig floor, all being inherent at the point of operation. Figure 1 depicts a variety of rig floor operations and equipment, and specialty operating personnel, where several of these hazards are present. As a result of this type of exposure and over time, rig operations can incur personnel injuries of varying severity, even including loss of life.
TX 75083-3836, U.S.A., fax 01-972-952-9435.• Stabberless System. This system engineers much of the hazard out of the stabbing operation by removing personnel from the derrick.Finally, this paper will present and discuss the four major driving forces that are serving to promote the development of this type of equipment. They are Safety, Economics, Legislation and Industry Trends.
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