Oilwell 2000

Rig Floor Equipment

The way it was and in many cases still is
Photo taken 1985 and is the drawworks on the Maersk Voyager working in Saudi Arabia Built in 1980 1982

Lesson One Welcome Lesson Two Rig Floor Lesson Three hoist

Welcome to the new world

This course has been developed as an aid to guide the layman and crew members into understanding the recent developments regarding the latest drilling equipment

For crew members that have rig running experience a more advanced course has been developed that will help you get the most out of the computer systems that have been developed and designed in order to make Oilwell Drilling a far safer and easier place to work.

The important point for all to remember is the part the computer now plays, and the part you play in setting it up. As with any computer, the rules are the same: Garbage Input, Garbage Output >>>>>>>>>>>>>>>>>>>> Check you input before pressing the set link

View of Rig Tongs and Floor

To understand the new generation of rigs One first need to see where we are coming from and why it is so important that the industry move forward

Myanmar in 2004.....

Russia 2006

The Basic Standard Drawworks

The drawwork is a winch and is part of the hoisting system. It can also be used to drive the rotary. The one you see here is a National Oilwell 1625 DE with an input horse power of 3000 (2238Kw) with a rated drilling depths from 16000 ft (4877m) to 25000 ft (7620m).

Rig Floor

Pipe being pulled from the well and stood back in the derrick.

This is/was very much the view the driller will have of the rig floor while running or pulling pipe from the well

Drillers control panel

Even into-days drilling world this drillers control panel is an advanced system

Behind the drawworks

752 HP DC motors have served the industry well for over 60 years

Open View of the Drawworks

Make up High Gear cathead High clutch
the same components as main drum

Sand line drum

Low Gear Brake-out Cathead

Brake Bands Brake Flange Main Drum

Brake handle Drillers controls Low clutch

Brake equalising bar adjustment bolts

Brakes
In generally the drawworks will have two braking systems;

The brake as most driller will refer to it is a manual braking system that incorporate a handle attached to a set of brake bands and have a number of brake pads attached.

When applying weight to the brake lever the bands are tightened around the brake flange attached to the drawworks main drum and the load is slowed down and will eventually stop.

As the well gets deeper so the string weight will increase. As the string weight increases the free full maximum acceleration is reached sooner allowing the block to fall at maximum speed for a longer period of time

As with a car, the faster it is move the longer it takes to bring it to a halt. If the load moving is so heavy, it will not stop.

The heat generated by the friction of the two contacting surfaces will lift the handle so high, the driller will lose control. Therefore and auxiliary braking system is installed along with a break cooling system

It can be one of two systems. Hydromantic or electromagnetic.

Cooling Fluid circulating system.

Break Cooling Systems

Stuffing Box in Stuffing Box outlet

Return line

Heat exchange

Storage tank
Pump The above system cools only the break flange by circulating cool water in the cavity of the flange, the water should be circulation all the time the rig is running

How it works
auxiliary braking system Hydromantic uses electric + water
All the driller has to do is open and close Valves

The water level in the system is adjusted and in doing so adjust the torque use as resistance

How it works
auxiliary braking system electromagnetic. uses electric + water
All the driller has to do is open and close Valves

The water level is also adjusted however the electric current supplied to the break is adjusted as needed depending on the load, power supplied is from 1v to 50v

The Way forward

New, Varco Advance Drilling System (ADS)

Crown Block Clusters

Top Drive Systems (TDS)

Side tracker

Automated Roughneck (AR4500) (AR)

Power Slips (PS)

Hydraulic Cathead (HC26-EV)

Foxhole Subassemblies

Hydraulic Power Unit (HPU)

Pumping Units

Distribution manifold

Pipe Racking System (PRS)

Finger Boards

Pipe Deck Machine (PDM)

Pipe Transfer Conveyor (PTC-MD)

The Operators chair

Emergency Shut Down Systems

Pumps

Mixing systems

Shearing and blending systems

Lesson two
The Rig Floor

Power Choke (remote)

ADS 10 hoisting systems:

The single speed gear-driven drawworks features a direct drive design ideal for offshore applications where space, weight, and heave compensation are important considerations.

Braking is achieved using AC motors, which are also the prime movers for the drawworks.

ADS 10 hoisting systems:

Varco has applied the same technology used to design their AC top drives and automated pipe handling system to the hoisting process.

The result is a feature-rich hoisting system that dramatically reduces time-todepth and provides drillers with enhanced hoisting control capabilities.

The ADS-10 hoisting systems offer: AC-powered motors that provide significantly more performance a drawworks that requires approximately half the space and weight with lower maintenance than traditional drawworks

Front-Entry Chair (FEC) Workstations

The front-entry chair (FEC) workstations are the user's interface to the control network and tools. Located in the drillers cabin, each of the two FEC workstations contain:

3 Amphion touchscreens
2 joysticks 2 discrete switch control panels 1 chair 2 network switches

Driller workstations
Both driller and assistant driller workstations are identical in their equipment and system management capabilities, and therefore provide full operational redundancy.

Joysticks and discrete switches responsible for operating a particular tool are located in the same relative position on each workstation.
Joysticks and associated switches for that tool are also positioned to allow operation by opposite hands. For example, the left joystick operates the automated roughneck, while discrete switch controls for the automated roughneck are located on the workstations right control panel

Touchscreen Computers
The FEC workstation contains three self-contained touchscreens (sometimes referred to as an HMI, or a human-machine interface). Touchscreens display tool control, drilling operation, alarm, and status information.

By default, they display information pertinent to the activity being performed, allowing the operator to concentrate on the job at hand without the distraction of extraneous data. All touchscreens have access to any tool controller connected to the network.

Introduction
Automated Drawworks System (ADS) is used for hoisting the traveling equipment of a drilling rig to remove and insert tubulars into the wellbore.

The ADS is a gear-driven drawworks with VFD-controlled AC motors and multi-plate friction brakes.

Optional resistive (dynamic) braking via the main motors can be applied to augment the friction brakes.

The drawworks components are mounted on a unitized skid.

The driller, at an operator control station, uses a dedicated joystick and switches to remotely operate the ADS through a Varco Integrated Control Instrument System (VICIS).

Wire Rope Drum

The wire rope drum is supported by two bearing carries mounted to a structural steel skid. The drum is fitted with Lebus grooving for customer-specified wire.

Crown saver toggle valve

A crown saver toggle valve is located above the drum.

The valve is located where it can be activated by the wire rope, just short of the point at which a crown collision would occur.

When the valve is activated it sends a signal to a crown saver pressure switch which alerts the control system to stop the drum.

Gearboxes

The 1500 HP, single-speed, double-reduction gearboxes transfer power between the AC motors and the wire rope drum.

Lubricating oil for the gears and bearings is supplied by an external electrical pump system with a frame-mounted reservoir.

AC Motors
The ADS uses 1150 HP (continuous rating), variable speed AC motors to drive the drum. The motors are coupled to the gearboxes with double spherical gear drive couplings. The wide range of motor speed allows the ADS to achieve a broad range of hoisting speeds. Using multiple motors increases hoisting capability.

Motor Blowers

The motor blowers provide open loop, forced-air cooling to the AC motors.

The ADS Braking System

The brake is a combination spring and air-operated, multi-plate disc brake. It applies braking to the drum during operations as well as parking braking.

Friction Brakes
. Two braking methods are available to the operator: dynamic breaking using the friction brakes, and regenerative braking through the AC motors. One brake is mounted at each end of the drum-shaft.

The rotating brake discs are spline coupled to the drum-shaft, and the brake housing is attached to the skid.

Each brake has three water-cooled discs for dynamic braking control and a single, air-cooled brake disc for added static parking and emergency stopping capacity.

Sensing and Feedback Devices

Sensing devices are used to monitor equipment functions.

Sensor device outputs are sent to the control system where they are processed to provide feedback for closed-loop control and to display status information to the driller. Several types of sensing devices are used.

Rotary Encoders

Rotary encoders provide speed and block position information.

Encoders are direct coupled to each motor and are coupled to the intermediate shaft by a drive belt.

Operating the drawworks is a simple matter of holding the joystick back to pick up or forward to lower ,

note the finger holding the dead-man switch in while in operation

Should you ever need to lower the block if the computer fails there is an emergency manual leaver that can be used after the rig air is bleed off the system

However I will not go into detail on how to use this emergency system and will only be taught on a need to know base

ADS Control System

The ADS control system is provided by a multi-tool controller that processes all data from the operator controls to the drawworks, all feedback from the drawworks, and all data to the operator. The processed data is used to control all drawworks functions and inform the operator of drawworks operations and status. The control system also provides these safety features: Drill line protection

Collision protection
Equipment protection

System Features:

It has a touch screen user-friendly, Electronic Driller interface V-ICIS Advanced drill floor control system with integrated functionality major installations. Incorporates all the functionality of V-ICIS eD plus additional features to fully integrate the ADS into the center of rig floor operations.

The V-ICIS eD Provides a comprehensive control and instrumentation system and incorporates the Electronic Driller and includes a custom drillers display screen; hook load weight indicator; control with interfaces to other equipment such as SCR, Iron Roughneck, Top Drive, and an optional Rig-Sense display screen. Continue

T D S
S y s t e m

Main Components
Integrated Swivel Bail Counterbalance Cylinder

Integrated Swivel Gooseneck Wash-pipe Assembly

Brake

AC Drilling Motor
Motor Support Bonnet Swivel Bearing Bull Gear Rotating Link Adapter Main Shaft/Drive Stem Motor Pinion Gear Upper Gear case Compound Gear Lower Gear case

GE GEB-20 A2 AC 1150 HP drilling motor

Fluid Path

Drilling motor brakes

During the course of the next few slides it is hope that drillers using the top drive will get to understand why it is so important that they have an understanding of the way the top drive works and how they play a very important part

The first top drive to be installed was in 1982 and gained quite a reputation to out drilling the kelly, but its major selling point back then was the inside BOP could be installed fast,

More recently the reputation has been on its ability to drill horizontal well due to the fact that only one connection is needed for 90 + feet. The new generation of jackups and semis will improve on the 90+ and drill 120 ft with the one connection

Although the top drive has many advantages It has one major disadvantage, that being cost, unlike the kelly that cost very little to run and maintain the top drive needs regular inspections

It is not the drillers job to repair tools, we have mechanics and electricians to do this. But it is the drillers responsibility to look after the tools they uses, and a drillers that understands the tools workings is an asset to any rig

TDS-8SA

Side view

Retract Guide Dolly Motor Frame

Bail Assembly

Hydraulic manifold for retracting arms

Greases points

Counterbalance Lug For adjusting counterbalance

top guide rollers

Accumulator & manifold Main electrical panel

Retract/Extend arm

Moisture separator

Blower Duct to AC Drilling Motor with Rearward Facing Air Intake

Transmission Cooler with Axial Fan

Explosion Proof AC Blower Motor

S-Pipe (Typical)

Air Brake J Box

Lower roller
Gearbox Fill Plug

Gearbox Oil Level Indicator Suction Hose

Gearbox Drain

Oil pump Dip stick

Gearbox
Powered Rotating Link Adapter
Shot Pin Assembly Hydraulic Drive Motor

Link Tilt

Wash Pipe Packing Box Assembly is behind the protecting guard Lower Gear-case

Retract Guide Dolly

Side view
Upper Retract arm

Accumulator & manifold

Upper Retract cylinder

J Box Lower guide rollers

Hydraulic manifold

Side view

Lower retracting arm

Gearbox
Gearbox Drain Shot Pin Assembly Hydraulic Drive Motor

Powered Rotating Link Adapter

Counterbalance system
The counterbalance system prevents damage to tool joint threads while making or breaking connections with the TDS. It provides cushioned stroke similar to that provided by the hook.

Counterbalance systems vary widely in configuration. The principles are the same regardless of which counterbalance configuration your rig uses.

The counterbalance system prevents damage to the threads of the saver sub and drill pipe by offsetting the weight of the top drive while stabbing into a connection.

When properly adjusted, the counterbalance system supports all but about 800 lb of the weight of the top drive over a full 8" to 10" of travel.

25,000 lb (11339 kg) Nitrogen Charged Accumulators (2)

25,000 lb (11339 kg) Counterbalance Cylinders (2)

Counterbalance Manifold From Hydraulic Power Supply

800 lb (363 kg) Weight on Threads

50,000 lb (22,680 kg) Typical System Weight with Retract Dolly

Counterbalance system
The system also incorporates a complete backup. The two accumulators, constantly maintained at system pressure, are always able to provide pressure to the counterbalance cylinders if the HPU is off or non-operational for any reason. For normal operation, however, the HPU is on when using the torque wrench for breaking out the top drive at the floor and is left on while making up the next stand.

When adding a stand to the string during drilling operations, the driller takes a stand into the elevators and stabs it into the box in the rotary.

The system consists primarily of two hydraulic cylinders, a counterbalance manifold, and two hydraulic accumulators.

The hydraulic cylinder assemblies connect the integrated swivel bail and the block, adapter bracket, spreader beam or hook, as appropriate.

The two hydraulic cylinders are connected to two hydro-pneumatic accumulators located in the motor frame.

A manual valve can extend the cylinders to assist during rig-up. The accumulators are charged with nitrogen and maintained at a predetermined pressure setting.

The derrick graphic displays the current block height, and contains markers for both high and low block travel limits. Proximity indicators display green as the block travels past the switches. Red proximity switch displays indicate a switch fault.

The guide dolly

The motor frame/guide dolly attaches to the motor housing assembly.

The entire assembly moves vertically on two rails installed in the derrick. The vertical rails react the motor torque during drilling operations.

The vertical rails (Guide Track) start at the water table and are connecter to the main structure of the derrick at set points all the way down to within 10 feet of the rig floor

Care and maintenance of guide track

Guide Track

Inspect the track annually for wear on roller surfaces.

If wear is substantial (1/8" reduction I thickness), the track should be replaced. . ,

Inspect bolt connections at supports and splices. Tighten as necessary to ensure proper alignment.

This excellent and very descriptive photo was taken the day we installed the lower section of the derrick.

The guide dolly (the main traveling frame) runs on eight sets of rollers, four at the front and four at the back.

You can clearly see the grease point, these need greasing on a daily base

The Top Drive Guide Dolly is attached to The guide dolly by four arms with pins at both end allowing them to privet (retract or extend). Thus holding the drill sting over the well center when in the drilling mode (extended) and retracted (the top drive is of center) for such operation as pulling and running the drill string. Of course the retracting can only be done when the string weight is off the block

Side View

Back guide rollers

Top Retract/Extend arm

Top drive and associated tools protective frame

Retract/Extend Hydraulic Cylinder Back guide rollers

Lower Retract/Extend arm

Modification

Modification

When parking the TDS to the side the main track is slid towards the drillers cabin Before sliding the vertical rails to the side, disengage pin D, remove pin A and connect point C to point B using an air tugger and the pin from B to secure the track so as it will not hit the drillers cabin B

Pin A

Note: There is a securing lock for when the TDS is retracted for such occasions as towing or when swinging the TDS out of the way. There is one on all the arms so if you have to move the TDS be sure to check they are in the correct position

Inside BOP
Kelly valves, Inside Blowout Preventors (IBOP) Drop-in valve and Float Valves are designed to close in the drillstring in the event of the well flowing.

All valves that are installed in the drill string to control back flow are regarded as part of the secondary well control equipment (BOPE) and should be test at the same rate as the Blowout Preventors ( BOP) with the exception of the Near Bit float valve.

Some of the valve are installed in the drillstring at all times, other are stabbed in at surface while other are dropped and pumped into place.

TDS-8SA Top Drive

Retract Guide Dolly

PH-100 Pipehandler

IBOP

Top Drive at a glance

TDS

IBOP

PH-100 Pipehandler

IBOP Top Drive System

The upper inside BOP (IBOP) is a hydraulically operated valve installed in the drive shaft of the top drive and is operated by the driller from the computer screen or key board

The Drill Stem Upper Safety Valves (IBOPs) are balltype valves with full internal openings to provide unrestricted flow of drilling fluids. The IBOPs are rated at 15,000 psi working pressure.

If the driller notices a kick developing, the upper IBOP can be closed remotely, and the lower IBOP can be closed manually. The lower IBOP can be broken out by the torque wrench and left in the string if required.

Pipehandler
The splined upper valves are an integral part of the Varco pipe handler of the TDS. A remotely operated actuator is attached to the upper IBOP and can be operated at any height in the derrick from the drillers console.

The upper IBOP can also be operated manually using a 7/8 in. hex wrench.

There is a port on the upper IBOP below the valve crank for a grease fitting and reducer bushing for purging any debris that may get in the wave spring area. Click on graphic for more info

Upper IBOP
main drawing

7 5/8 Reg RH ?

Upper seat

Valve assy

24 inc For part numbers an main drawing on the upper inside BOP click here

Lower seat

3.82

7 5/8 Reg RH ?

Side tracker
Port and aft of the drill floor is an area set aside for parking the top drive should there be a need.
Moving the Top drive from the well center to the parking area is accomplished with the use of a side tracker ( a section of the main guide runner that can be moved)

The lower section of the guide track is separate from the main guide track, and by the use of hydraulic pistons can be move to one side (normally in the direction of the driller cabin) to allow the side track to be place directly under the top drive.

Introduction
Once the Top drive has been lowered and secured to the side tracker it is released from the hosting assembly (un hooked).

The side tracker and the top driver are then pushed back away form the well center using the hydraulic piston to a parking area where the top drive can be worked on should there be a need

The side tracker and the guide runner are hinged together at the top and bottom and held in position by the use of hydraulic pins

Side tracker

Useful Definitions
The following are definitions of the acronyms, abbreviations, and terminology's used in this Course. Standard acronyms and abbreviations, such as AC, DC, in., ft-lb, etc., and industrystandard terminology's are not listed. ADS - Automated Drawworks System. CPU - Central Processor Unit. E-Stop - Emergency Stop. GB - Gearbox HMI - Human-Machine Interface. Nomenclature for the drillers screen. Usually a third party component Hoisting Deceleration Point - When hoisting, the hoisting deceleration point is the uppermost position at which the block begins deceleration to safely stop the blocks without passing the upper travel limit and keep tension on the drill line. J-box - Junction box.

Lower Deceleration Point - When lowering, the lower deceleration point is the lowest point at which dynamic braking can be utilized to safely stop without passing the lower travel limit.

Lower Travel Limit - The lower travel limit is the operator-defined position of lower most travel. The control system will not allow the lower travel limit position to be set below the know position on the rig floor. It is the responsibility of the operator to ensure the lower travel limit position is adequate to prevent equipment hanging below the blocks, or the top drive from hitting the floor or other equipment. PLC - Programmable Logic Controller. This function is made up of individual cards/ modules. PROFIBUS - Process Field Bus. A network that allows ADS devices to communicate over a common bus without the need for specially designed interfaces. dynamic Braking - Defined as the use of the ac motors, in generator mode, to provide braking.

RTD - Resistive Thermal Device. A device that measures temperature. Upper Travel Limit - The upper travel limit is the operator-defined position of uppermost travel. The control system will not allow the upper travel limit to be set above the known maximum height before hitting the crown block, thus preventing crown collisions. VFD - Variable Frequency Drive. Normally a customer-supplied item. The VFD works as a velocity control system. V-ICIS - Varco Integrated Control and Information System. WOB - Weight on Bit.

ZMS - Zone Management System. A system of monitoring and managing the movement of equipment within its predefined operational space to prevent interference and collisions with the rig structure and other equipment's.