fehlervermeidung & effizienzsteigerung …...tubular-running operations are essential to...

70. BHT - FREIBERGER UNIVERSITÄTSFORUM 2019

Kolloquium 3 -„Kollege Roboter (?) – Digitalisierung in der Bohrtechnik“ am 6. und 7. Juni 2019

Helms, Martin; Berger, Mario (Weatherford Oil Tool GmbH)

FEHLERVERMEIDUNG & EFFIZIENZSTEIGERUNG

Bist du sicher? – Konzepte zur Fehlerbeschreibung in der Industrie 4.0"

Objectives/Scope Tubular-running operations are essential to life-of-well integrity. Simple, operator-influenced makeup errors—from applying incorrect torque, to misreading a connection graph or miskeying an entry—can wreak havoc on connection quality, operational efficiency, and long-term well integrity. Especially in premium-connection casing or completion installations, operators must ensure that each connection is properly torqued, evaluated, and documented. A new, automated tubular-makeup and evaluation system meets those needs while enhancing efficiency and safety.

Methods, Procedures, Process The Weatherford Vero® system delivers verifiable connection integrity by automating final connection makeup and evaluation. As a fully integrated tubular-running technology, this system combines a hydraulic tong with an onboard computer and connection-makeup evaluation software. Using high-resolution data to autonomously appraise connections in real time, the tong-mounted computer manages each connection with smooth, computer-controlled precision. By reducing nearly any chance for negative human influence, the system removes connection-makeup errors, lowers safety risks, eliminates flat time, and decreases tubular-running costs by 20 percent.

Results, Observations, Conclusions Compared to traditional equipment, this automated tubular-makeup and evaluation system delivers connection integrity with fewer personnel and in less time. It requires just a single user for both the tong and torque-turns monitoring system, which eliminates the need for dedicated personnel to approve graphs. On an average offshore tubular-running operation, the AutoTong system reduces the number of personnel in the red zone from three to two. This built-in efficiency improves operational costs and enhances safety.

This system minimizes manual—and potentially erroneous—input that can lead to catastrophic con-nection failures. With a single click, the operator initiates the final makeup process. The system takes control of the procedure to make up pipe with continuous torque monitoring and speed-controlled precision.

Rather than relying on an operator’s visual check of the makeup graph against known profiles, system software automates the connection-evaluation process. Using proprietary algorithms and real-time makeup data, the software automatically evaluates the makeup graph to ensure conformance with OEM criteria.



Novel/Additive Information The system software accurately interprets 10 times more data points than the human eye can distin-guish.

The Vero system has been successfully used on +40 completion-running jobs since its field launch. Major operators in different regions of the globe have taken part in these trials, and the system has completed more than 10,000 connection makeups to exceed previous operational KPIs.



Tubular Management Systems (TMS)

The oil and gas sector has redefined the way it conducts business in one of the most transformative periods in its history. Since 2014, the industry has adjusted to low oil prices by reducing expenditures and cutting drilling costs. A focus on completing wells with the utmost efficiency and avoiding expensive rig day rates has helped to manage during these hard times. Addressing nonproductive time (NPT) and invisible lost time (ILT) creates opportunities to reduce the time to complete the well. Although this strategy offers time savings, the results vary across all operations. In another strategy, operators target flat time to improve overall efficiency. Eliminating non-essential operations directly impacts the flat time; however, operators have not made significant efforts to reduce flat time during essential operations. Running tubulars contributes to a large portion of the total flat time, and technology can optimize operations to reduce this time. The ability to make up connections offline and reduce the amount of connections on the rig floor positively contributes to completing wells in a shorter timeframe. Operators have implemented the practice of offline stand building in global offshore operations, which has decreased drill floor activity and the associated risks. In typical onshore operations, each tubular is delivered from the horizontal position to a vertical running position, made up to the string, and run in the hole. Because each tubular is handled one at a time, the time to run all of them adds up to significant flat time. Adopting offline stand building technology definitely increases efficiency and enhances safety in onshore operations. This paper presents the details of a tubular management system (TMS) deployed in the UAE. The stand-alone, fully mechanized, hands-free pipe system made up drillpipe, casing, tubular stands and assemblies. Analyzing the process and results both before and after installation of the TMS reinforces the improved efficiencies by building stands offline at the onshore rig site. The results display improved efficiencies of the total well time by more than 10%, therefore highlighting the reduced time on the well path, removing operations and manual handling from the drill floor along with the potential for injury and associated NPT. An essential part of the TMS, the coupling application machine (CAM) delivers rotational makeup and breakout of tubular joints. A torque process control system analyzes and evaluates the data from the connections. An individual technician drives the entire offline stand-building process from a control cabin. The technician uses a mechanized pipe lift to lift single tubulars from pre-loaded preparation racks and to position them onto pipe conveyors. These conveyors then feed the individual tubulars directly through the CAM unit to prepare the joint for connection. The same process mechanically positions an additional tubular to complete the preparation for the connection. The CAM unit then completes the connection by making it up to the desired preset torque. The technician either repeats the process for triples, or the stand is fed directly out onto the pipe conveyor on the opposite side of the preparation racks. The technician uses a mechanized pipes lift to lift the completed stand from the pipe conveyor and position it onto the adjustable discharge racks until ready for the hydraulic catwalk. Source: SPE-188331-MS

VALIDATE WELL INTEGRITY WITH ABSOLUTE CERTAINTY

Martin Helms

Engineering Manager

VALIDATE WELL INTEGRITY FROM THE WELLHEAD TO TD WITH ABSOLUTE CERTAINTY

©2019 Weatherford International plc. All rights reserved.

Weatherford International

What’s The Problem?

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sealingthreading

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LEAKING CONNECTION CAUSED BY HUMAN JUDGMENT AND / OR INATTENTION

IOC #1 $300M IN COST INCLUSIVE OF LOST PRODUCTION

IOC #2 $40M SPENT TO PULL AND RECOMPLETE

IOC #3 $15M WASTED ON COSTLY INTERVENTION

IOC #4 $10M LOST IN FAILED PRESSURE TEST

REAL EXAMPLES OF CATASTROPHIC WELL INTEGRITY LOSSES


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VERO VS CONVENTIONAL TRS

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REVOLUTIONIZING CONNECTION MAKEUP

Automated Makeup – Operational Efficiency

– Automates connection makeup

– Eliminates operator influence

– Provides consistent, precise tong control

– Improves operational efficiency

Autonomous Evaluation – Cost Avoidance

– Automates connection acceptance process to OEM criteria

– Eliminates subjective graph interpretation by operator

– Reduces personnel required: Removed JAM unit/operator

– Resolves rejected connections: Joint Issue Advisor


8VALIDATE WELL INTEGRITY FROM THE WELLHEAD TO TD WITH ABSOLUTE CERTAINTY



Vero technical accuracy video



PROVEN - GLOBALLY

24+ jobs with zero laid out connections

Saved 80+ hours of rig time

Reduced 6,500+ manhours of rig floor operations exposure



INDUSTRY LEADERS IN OPEN ARCHITECTURE FOR RIG EQUIPMENT INTEGRATION

PRECISE AUOTMATED POSITIONING

INSERT VIDEO file PA41_TEST

Multi Coupler System

TUBULAR RUNNING SERVICES



• SAVE MINIMUM 1 HOUR PER

CHANGE OUT

• SAVE MINIMUM 12 HOURS PER

WELL

• IMPROVE SAFETY

• HANDS FREE OPERATION OF

EXCHANGE

TRANSITION FROM DRILL PIPE TO CASING RUNNING OPERATIONS

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THANK YOU

JAM Graph

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Anomalities found on Graphs

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Fehlervermeidung & Effizienzsteigerung

Ein- & Ausbau vorkomplementierter Gestänge-Züge am Beispiel ZADCO Islands, offshore - Abu Dhabi

2017

Mario Berger

• Die E&P Industrie passt sich in den letzten Jahren stark an, um

die Effizienz im heutigen Erdöl- und Erdgasmarkt zu steigern.

• Die Effizienz wird dabi duch multiple Faktoren ermittelt und

gemessen. Diese sind im Wesentlichen:

- NPT (Non productive time)

- ILT (Invisible lost time)

- Flat time

• Flat time wird dabei generell mit dem Ein- und Ausbau von

Gestängen in Verbindung gebracht (running/tripping).

SPE-188331 • Offline Tubular Management System Improves

Efficiencies of Total Well Time by more than 10%

Einführung

• Implementierung von existierenden Prozessen und Technologienaus dem Offshore Markt

• Reduzierung der Anzahl von Verbindungen die am Bohrlochverschraubt werden

- Offline makeup- Einbau von Gestängezügen (doubles casing&tubing / DP triples) statt einzelnen Rohren

- Zusammenbau von BHA’s

• Erhöhte Sicherheit durch “hands free” Operationen



Flat Time Reduzierung - Strategie

• Platzbeschränkungen

• Unebener oder loser Untergrund

• Nicht-permanente Installation

• Kran-Verfügbarkeit

• Extreme Hitze und hohe Salinität

• Tubular Handling

• 90/60ft Catwalk erforderlich

• Hohe Verschraubmomente/Chromrohre



Herausforderungen

• Rig-basierte Verschraubanlage > Coupling Application Machine (ComCAM)

• Komplettes “hands free” Rohrtransportsystem zur Beschickung der ComCAM

• “Make & break” Anlage, geeignet für: tubinge, casings, completions, drill pipe, inkl. Chrome/Super Chrome Rohre (erf. Spezialmesser-Einsätze)

• Transfer von stands direkt zum und vom hydraulischen catwalk

• Be- und Entladung der ComCAM mit/von individuellen Rohren



Lösung

• ComCAM

- Modulares Design ermöglicht minimale Rüstzeit.

Rig up/rig down des TMS Systems in weniger als einer Schicht

- Spannbereich: 2 7/8” to 22” OD

- Maximalmoment (make/break): 216,931 Nm (160k ft.-lb), auch bei kleinen

Durchmessern

- Drehmomentüberwachung

- Prozessierung vor-installierter Centralizer

- 24” Durchlass

- Modulares Design



Lösung

• Tubular Management System

- Pipe Conveyor, Preparation Racks, Discharge Racks

- Nur modulare Komponenten

- Optimierte Lösungen für unterschiedliche Rig Lokationen

- Mechanisierte pipe lifts und discharge racks

- Übergabe der Rohre direkt zum catwalk



Lösung

• TMS Layout



Lösung

Direction of Rig

• Vergleich zwischen Einbau von doubles und singles: 6-5/8” Liner

- 333 joints: 8.5 joints/Stunde - 39.18 Stunden

- 333 joints: 15.32 joints/Stunde (7.66*2) - 21.74 Stunden

• Die gesammelten Daten können direkt miteinander verglichen werden, da in beide Bohrungenjeweils ein 333 joint liner eingebaut wurde



Ergebnisse

Pipe Length Joint QTY Total Hours Joints/ hour

Singles 333 39.18 8.5

Doubles 333 21.74 15.32

Savings 17.4 44% faster

• Einsparungen > “total well time” wenn ein TMS-System eingesetzt wird:

- Annähernd 32 Tage über 8 Bohrungen eingespart- 12% Reduktion in “Total Well Time”- Jährliche Projektion: 44 Tage eingespart



Ergebnisse

• Reduzierte Flat Time – Implementierung eines Tubular Management

Systems

• Gesteigerte Effizienz - Offline Stand Building

• Erhöhte Arbeitssicherheit - Reduktion von “human intervention”

• Optimierte Lösungen - Modulares TMS für harsche Anwendungen.



Zusammenfassung

Anerkennungen / Danksagung / Fragen

Wir bedanken uns ausdrücklich bei der der TU Freiberg dass wir die Gelegenheit bekommen haben, hier und heute vor diesem Auditorium unsere

Technologie vorzustellen.

Für Fragen stehen wir ihnen natürlich im Anschluss gerne zur Verfügung.

Martin Helms & Mario Berger



fehlervermeidung & effizienzsteigerung …...tubular-running operations are essential to...

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