SPE/lADC 29388

Low Cost Slim Hole Drilling System

A.J. Beswick and D.L. Hills, Kenting DriltingServices Ltd.
SPEIIADC Membsrs

Wvbht 1S=. S~ OdtItng Conference.

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ABSTRACT The mechanised pipe handling system includes a

hydrauiic clamping device within the top drive head and
Interest in reducing the cost of exploration in frontier an elevating and extending catwalk with hydraulic power
areas and in areas of special environmental concern breaker capable of breaking 8 in drill collars. The
. - ... .. l.mndiin~_~_.W,,
e etnm , *II
. ... arrnmmodate
SW-------- --- 13-3/8 in Range 3
has given rise to a variety or mmswvesto cieveiop ‘siim 1la
hole’ drilling systems and down hole tools. The market casing. Triplex mud pumps, power pack and generators
over capacity of conventional rigs offered at unrealistic are housed in acoustic containers. The rig and
commercial rates masks the real cost of operating associated equipment is designed to oilfield standatds
heavy drilling equipment. This acts as a disincentive to and all pressure lines are rated to 5000 lb/in2. A BOP
the development of smaller innovative drilling rigs and handling system is included especially to cater for slant
associated equipment and the development of a smaller drilling and a hydraulic crane mounted at drill floor level
scale drilling system that has wide acceptance in the together with a tugger winch provides general handling
industry. Furthermore, funding for development of such facilities around the rig. All main rig units are configured
systems has been sadly lacking. to 6 m ISO container Standads for ease of shipping and
port handling including mud tanks.
In response to a contractual commitment, an
oppmtunity arose to design and construct a small, low The rig includes a comprehensive computerised rig
cost drilling system suitabie for a range of sihn ii~i~ arid :..A”
Illall
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s lfi~~l
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downsized drilling scenarios. In this particular case, the for the site and a sensitive automatic drilling facility
equipment was required to driil both vetiical and slant operating through the hydraulic drawworks winch control
boreholes with slant angles up to 45°. The drilling unit system.
and associated equipment combine a blend of oilfield
and mining ideas with the objective of demonstrating The paper describes the background philosophy, the
that a low cost unit could satisfy the requirements of the equipment and the initial opetilons since
industry for frontier drilling. commissioningthe equipment in June 1994.

The drilling unit is capabie of both conventional INTRODUCTION

destructive ciriiiing up to 17-1/2 iii diameter and
continuous coring using heavy duty systems up to
6-1/4 in hole size. The singles rig is 100 ton capacity
with a rotary capability from the top drive system of up
~5~10m~m wi?id? giVeS a Sii!T!‘Qie over=~~~iti~
References and figures ai mid of paper
Recent interest in reduced size drilling systems for oil
and gas exploration and development has given rise to
a number of initiatives to develop ‘slim hole’ systems
Of and downhole equipment. The idea of downsizing is not
new and indeed many of the wells drilied today as ‘slim
noie’ were considered common in iii~ past. Htiw~ti~i,
progress wider use of reduced hoie sizes was
i~ads

463
2 LOW COST SLIM HOLE DRILLING SYSTEM
limited by operational problems such as poor bit and
drill pipe performance, high ECD’S and inappropriate
mud systems together with a lack of understanding of
the drilling process 1.
Technological developments have overcome the
traditional barriers to slim hole. The physics of well
control in narrow annuli is now understood and early
kick detection systems using accurate electromagnetic
flowmeter have been developed. Full suites of slim
hole wireline logging and testing tools now exist.
Improvements in bit and drilling fluid technology, and
-----
particularly ine advent of RX bit% nuw eiiables
complete well sections to be drilled without tripping and
at penetration rates comparable to and often better than
conventional large sizes. Finally, developments in
completion technology permit economic development
from smaller TD diameters in certain cases.
Much attention and investment have been focused on
the in-hole developments while the evolution of an
appropriate drilling rig and associated equipment has
lagged behind. Much of the experimentation and
development of slim hole systems in recent years has
been ~rned out using modified mining or oilfield drilling
rigs ‘ and few purpose built units have been
constructed. This is partly because the specification for
such equipment has not yet evolved to a position where
there are enough common concepts developed by the
various promoters of a slim hole approach. It is also due
to the market overcapacity of conventional rigs offered
at unrealistic commercial rates based on capital values
that masks the real cost of operating heavy drilling
equipment. The trend has been to retrofit specialist
equipment on to these low technology units. In the early
experimental stages of developing the slim hole drilling
process and testing downhole tools and mud systems,
this has been of value. However, the availability of
cheap conventional rigs acts as a disincentive to the
fuflher development of smaller and innovative drilling
rigs and the associated equipment. Except in isolated
cases, the lack of funding for the development of such
equipment has been sadly lacking and somewhat
surprising, given that the potential for cost savings is so
significant.
In response to a contractual requirement, an oppotiunity
arose to design and construct a small low cost drilling
system suitable for a range of slim hole scenarios. The
project was carried out within a fixed limited budget and
time schedule. The drilling requirements in this case
.----- .. -A_ J_- J :--,..~-~ A-sL __-..__a:___l ..-4 A:-
were vanea arm mrauueu rJULrI GUIIVGIIWIKIII aim WIIII
hole sizes with both destrutilve drilling and continuous
coring in vetiical and slant boreholes up to 45°”
Previous work on this project using heavy mining and
modified oilfield equipment had already demonstrated
the value of integrating oilfield, mining and geotechnical
exploration technologies for deep exploration to
2000 m 4. The drilling unit described in this paper
combines this experience with the objecWe of
demonstrating that a low cost unit could satisfy the
464
29388
requirements of the indust~ for frontier drilling and
other specific applications.
This equipment is seen as part of the development
engineering process which is necessary to evolve a new
class of small rig for exploration purposes in the desire
to reduce drilling costs in the future. It complements
other experiences elsewhere 5’6.
The paper describes the background philosophy, the
equipment and initial operations since commissioning in
June 1994.
BACKGROUND PHILOSOPHY
Slim hole or reduced diameter drilling integrated with
control systems, geoscientific data acquisition and
drilling information systems offers significant cost
savings for frontier drilling in remote areas and for
certain other special circumstances. In some special
cases, the method is also appropriate to development
drilling.
The rejuvenation of interest in slim hole applications is
cost driven, but significant changes in approach, surface
and downhole equipment and systems are necessa~ to
realise the full potential. Cost reductions of 30°A to 50°A
have been claimed compared with conventional
exploration. There is potential for even greater savings
in certain cases.
The term ‘slim hole’ is widely used to mean a range of
smaller diameter drilling and casing sizes compared to
those considered conventional in the oil and gas
indust~. The range covers destructive (open hole)
drilling, motor drilling and continuous high speed coring.
Interest in reduced scale operations has also been
stimulated in cetiain areas by environmental
considerationswhere minimum site areas are desirable.
In some cases, low visual impact, minimal disturbance
during access to the site and environmental protection
are key issues. Minimisation of waste disposal volumes
can significantly reduce overall costs in some countries.
In frontier areas, access road construction can
overwhelm the drilling costs making heli-transport viable
even for conventional rigs. Significant cost savings can
accrue by reducing the loads of rig items and materials
for these cases.
There is a sharp contrast between the traditional culture
. ..L— —..--, -.. — ,------- -: -:--
01 me pewoleum mauswy iiiitt tir~i Of the IIIIIIIIW
industry. The broad objectives are the essentially the
same, yet the approach is completely different. Both
seek to investigate the geology and economic potential
in an area, although the geological setting is generally
not the same. One of the key differences between the
two exploration scenarios is that in oil and gas drilling,
well control and the related safety implications are a
major concern. This contrasts with the relatively unusual
requirement for well control in mining applications. This
 29388 BESWICK A J AND HILLS D L
significant requirement explains many of the different
procedures and emphasis in the two applications.
These very different industrial approaches to a similar
requirement offer the oppotiunity of a rational,
integrated approach to oil and gas exploration providing
the drilling systems are developed to suit. This may
need some re-thinking by exploration teams relating to
the real goals of the exploration and the means of
achieving the objectNes. Some modification of
traditional practice or in house convention may be
necessa~ if the benefits are to be fully realised.
There have been many attempts to develop a small
diameter, less costly exploration approach for oil and
gas exploration. There have been successes and
failures. Success requires careful planning, engineering
and applying the appropriate technology and methods to
the particular case. At the present time, several
initiatives are being pursued with some significant
investment. However, no obvious standards or preferred
procedures or methods have yet evolved. The range of
options is still wide from small scale destructive drilling
methods, using the latest down hole drilling technology,
to an emulation of the mining approach using
continuous coring in traditional mining hole sizes. There
are also hybrid scenarios using both approaches.
—.-. . :mbul~ulallul1.
RIG CONCEPT AND DESIGN
The main elements of a slim hole package are
perceived as:
A Main drilling unit and associated
equipment
Support equipment (casing tools,
cementing equipment, basic logging)
Drilling instrumentation and
information system
Mud system
Multi-skilled crew
B Drill strings
c Specialist downhole tools
D Geoscientific data acquisition
E Communications system (especially for remote
locations)
F Camp facility (remote location)
G Supporting Safety, Environmental and Quality
SjjSLems
465
3
This initiative concentrated on the hardware in Group A
for the main drilling unit includingthe capability to install
casing and included a driller driven information system.
Cementing equipment was not included at this stage as
this was readily available as a standatd service. The
essential features of the equipment are the flexibility to
cater for all in hole drilling system scenarios and the
ability to add additional capability for limited extra cost.
Drill string was also not considered as there is a range
of drill strings available including both standati API
strings to more exotic dual purpose drilling and coring
----- .-
strings. The latter are as yet Iargeiy Urlpluven iri
extended use. In this case standanl API strings for
drilling in 12-1/4 in to 6-1/4 in, heavy duty wireline
coring systems with hole diameters of 159 mm (6-1/4 in)
and 123 mm (4.8 in) and 2-7/8 in tubing for testing
were used together with a range of downhole drilling
and testing tools.
The vision for the rig was developed around frontier and
special drilling projects where reduced mobilisation, site
preparation and material costs oflen outweigh the
overall drilling time costs. Modem mining rigs have
been considered for such projects, but closer
examination revealed fundamental flaws in their basic
design, safety limits and architecture when oilfield
criteria were applied. However, certain important proven
concepts from mining rigs have been identified for
----. ”,;-”
Earty generations of rigs for both oilfield and mining
were mechanical. While the oilfield has tended to move
to electric rigs, the transition in the mining industry has
been towards hydraulics for power and control.
Foiiowing an eariier success ‘vdtii a it)W cod hyckadk
top drive unit retro-fitted to a standard oilfield
mechanical rig and because many of the mechanised
anciila~ functions on ine rig couid be more easiiy
controlled by hydraulics, a full hydraulic power system
was selected in this instance. Also hydraulic systems
can be maintained by a competent rig mechanic,
whereas high voltage electrical systems with
sophisticated electronic PLC control systems invariably
require a full time electrical technician.
The main safety areas identified as requiring particular
attention were tubular and BOP handling. While
important in vedical drilling applications, these activities
are particularly hazardous in slant drilling operations for
which the rig was to be first used. Mechanisation has
been used to replace these heavy, repetitive and often
dangerous operations that are performed manually on
conventional rigs. The degree of mechanisation remains
simple and does not extend to automation as this is
inevitably complex and maintenance intensive.
Another important decision in the earty phase involved
transport and rig-up logistics. While a heli-transportable
configuration would be ideal, this would have been
expensive and added substantially to the complexity
and time required to design and build the rig.
4 LOW COST SLIM HOLE DRILLING SYSTEM
Discussionswith major Operators established that most
frontier sites can be economically accessed provided
the individual equipment loads are sized for locally
available 10 ton trucks. The same criteria is also true for
many environmentally sensitive urban sites. Thus the
decision was made for the entire unit, including the
mast, to be modular and capable of being spilt into
loads that fti standad ISO 6 m shipping containers. The
camept was carried through by basing all peripheral
items such as the rig control cabin, mud tanks, mud
pumps, generator unit and accommodation modules on
standard ISO 6 m containers. These are economic,
secure to ship and easy to handle. They also lend
themselves to modification for effective noise
attenuation.
Key features of the rig are presented in Appendix A and
a general view of the equipment is shown in Figure 1.
The rig design centres around a lattice open box type
singles mast of 100 ton hookload capacity, reducing to
70 ton at 45° slant angle. The rig includes a custom built
hydraulic top drive capable of rotary speeds up to
400 rpm through a wide torque range as shown in
Figure 2. This basic specification permits vertical slim
hole drilling to depths up to 3500 m depending on drill
pipe selection, hole size and overpull reserve.
The top drive incorporates a proven hydraulic power
clamp or chuck which, combined with power slips and
an elevating, extending and tilting V-se&Ion catwalk,
makes all tubular handling operations virtually hands-
free. This simple yet elegant system shown on Figure 3
allows tubulars to be transferred to and from either pipe
rack and allows for a wide range of drill pipe and drill
collar diameters to be handled. It also permits casing
installation and make-up to precise toques using the
top drive. A standard 27-1/2 in dummy rotary table is
set into the drill floor under the power slip device to
enable conventional inserts and slips to be used.
A floating spindle in the top drive ensures that the
threads of delicate slim hole tubulars are not damaged
during stabbing, make-up and breakout operations. The
top drive rotation can be remotely locked and oriented
for directional drilling operations. The controls for the
elevating catwalk at the driller’s console are duplicated
by a set at ground level next to the pipe racks. This
all--- *he
L1lG#lr9m8-hatl
allww~ ,,””, ,,-,, d % be !OX!!r!~ er?ct !x?!oadir?gP!pe
while the driller concentrates on the pipe joint in the
mast. While designed to handle up to 6 in drill collars,
the system has been used for 8 in collars. This required
the power breaker, which is integral with the mast foot,
to be uprated. A back-up pipe handling system
comprising an 8 ton metre deck mounted ‘cherry picker’
hydraulic crane and power tong is available. The crane
has proved invaluable for handling equipment up to and
around the drill floor especially as the elevating catwalk
negates the need for a conventional V-door.
in contracts to typical mining and truck or trailer
mounted oilfield rigs, the rig design has all heavy
466
29388
components such as drawworks, ancillary winches and
main power unit situated at ground level while the drill
floor and control cabin are raised to a height of 4 m on a
self-elevating substructure. A novel hydraulic BOP
handling device within the substructure allows an
annular diverter or full BOP stack to be picked up and
positioned precisely on the wellhead. The operator
controls are well away from any potential danger area.
The drill floor structure comprises interconnecthg
channels that act as a gutter system to collect spillage
and redirect it to the mud tanks thereby keeping the
BOP, substructureand cellar clean.
The ‘drawworks’ is a proprietary approved hydraulic
marine winch unit with internal hydraulic gearing. This
unit combines fast tripping speeds with extremely fine
feed control for drilling. Tripping is always carried out
under hydraulic power. This helps control trip speeds to
minimise swab and surge problems in the wellbore.
Drilling is controlled by precise balancing of the
drawworks winch hydraulics. Hence, there is no brake
noise and the small band brake is purely for parking and
emergency purposes.
The drawworks winch hydraulic control interfaces with a
kinetic energy monitoring system to provide normal
override crownsaver and floorsaver protet%on.This also
facilitates feed control by a simple, but highly effective,
autodrillerthat can use weight-on-bti for rotary drilling or
a combination of weight-on-bit and standpipe pressure
to optimise penetration when motor drilling. A similar
winch is incorporated which allows a 15 ton pulldown
capability for conductor drilling or short radius m-entry
drilling.
The rig’s single hydraulic power pack consists of a
280 kW (385 hp) diesel engine driving a bank of
hydraulic pumps, all enclosed in an ISO based 6 m
container and located outside the hazard zone.
The driller’s console illustrated in Figure 4 comprises a
wraparound operating console with all controls and
gauges positioned ergonomically relative to their
impoflance and function. The console is also housed in
an ISO container sized unit modified to give maximum
visibility to the drill floor, pipe handler and up the mast
to the top drive and crown. In contrast to convention,
came
tha mnhin ic +mtml
.!.” -“. !r .“ “. ““.”” nq
“. the
.,0” —.. . ~~d~~S !h~ rn~d ?~~k~
so the driller can oversee operations in this important
area. The console incorporates the driller’s node of the
computerised instrumentation system that is described
later.
All peripheral units are based on ISO 6 m container
sized units. The twin tank, 55 m2 (320 bbl) mud system
comprises six compartments plus a separate trip tank,
all ftied with non-contacting level sensors. Buttertly
dump valves are recessed into the container structure
for ease of transport and to prevent accidental opening.
Twin 30 kW mixing pumps are plumbed to allow either
mix pump to transfer drilling fluid to and from any
 29388 BESWICK A J AND HILLS D L
compartments, while all areas subject to severe
corrosion are stainless steel, galvanised or epoxy
coated. A relatively modest solids control package
suffices for the initial programme. It comprises a single
shaker and centrifuge with a compact vacuum degasser
located adjacent to the tanks, The shaker discha~e
allows sufficient height for cutthgs to be discharged
directly into a skip.
These units can be heli-transposable if required.
Adddional pumps can be added and the drilling
instrumentation and control system can accommodate
up to four pumps without modification to suit a particular
drilling programme.
The rig includes a 100 bbl water tank and 380 I (80 gal)
accumulator unit which are each housed in 3 m
container units located directiy beneath the dtiiier’s
cabin.
A 210 kW generator with an auto cut-in 50 kW standby
unit is housed in a separate ISO unit that also
accommodates a small compressor for rig service air. A
free standing 25 m3 double skinned fuel tank unit
constructed to ISO container dimensions setves the
entire rig.
Various additional ISO 6 m container based units
complete the invento~ including toolhouse, Rig
Managets facility and crew welfare unit.
The site layout presented in Figure 5 is for a slant
drilling application and shows a rig footprint of
approximately 40 m x 20 m (800 m2). Some redutilon in
site size may be possible for vettkal wells as pump
units can be relocated directly behind the rig. However,
hazard zone constraints and tubular storage
requirements are likely to determine the ultimate
minimum site area. The layout shown is based on a
hazatd area conforming to the current 1P Code Pad 15,
1990 which is similar to codes now being adopted
throughout Europe.
A padicular feature of the rig is the extremely low noise
level that not only contributes to environmental
acceptance, but also improves working condiions and
communications around the site. Noise attenuation is
acMeved by special soundproofing of all buildings and
equipment to a level of 80 dB(A) at 1 m. A custom built
acou~lc jacket is also available for the top drive. Mud
tanks covers, originally provided to maintain mud
properties during tracer use on a special project have
also assisted in reducing overall noise levels from
shakers and associated SOikk COiltFOi eqiiipmefit.
RIG INSTRUMENTATION SYSTEM
Following the successful application of a computerised
rig instrumentation system, designed initially for
offshore platforms and successfully used on three
standard onshore oilfield rigs, a similar unmanned
487
5
instrumentation and information package was designed
into the rig. The computer based data acquisition
system is driller driven and provides access to a
comprehensive range of real time data by any number
of usem at different locations on and off the rig site. The
system has been designed to integrate all of the main
rig instrumentation fun~lons into a single system
-., . 44[0:.. 4-1” mnniinr ~;;
amwmg tiie urmtrrg GWi to fXCUf%cwlJ ,, ,Wr,,sw.
aspec& of the drilling process. As a result, the key
personnel, be they involved directty with the drilling
process or indirectly with rig or operational
management, have instant access to accurate
information. As a result, significant savings in cost can
be achieved through improved opetilonal management
and by optimizing drilling performance thereby
shofiening the learning cuwe for any project.
A}1:-c- -.”-- IS
; uqma~
A.-I-.,* -i ewdam tarrnipalq (nodes)
nil Illlurmulhnl “ -. “,”.y... .“. . . .. ---- ,---- -,
on colour monitors. The user accesses the information
using the cursor control keys from the system menu.
Each user may independently access a display page,
setting their alarms to suit their own needs. Information
as required can be accessed and printed at the rig site
or remotely by modem links.
The system may be configured to present information in
analogue, digital, trend and graph form with user
adjustable high and low alarm settings for all measured
and derived parameters. Trend pages allow data to be
displayed in a form that mimics that of a conventional
drilling recorder. Graphs may be produced comparing
one parameter with another over a specific time period.
Access to data using simple keyboard commands
facilitates rapid review of recent drilling trends and
events. The entire stock of infommtion held by the
system, including the alarm settings, alarm events, real
time measured parameters and derived parametem, is
compiled into an archive file. This file is retained within
the system on hard disc storage m~la and may be
downloaded then replayed at a later date to produce
pseudo real time recording of a past drilling operation.
A typical system comprises a main processing unit
assembly (MPUA) which collects sensor data from a
chain of local and remote input/output modules installed
at different locations throughout the rig. The MPUA is
f~ed with an industrial PC that comelates all incoming
information, compiles and transmits the data to other
users over a local area network (tAN) and provides
display and keyboan2facilities to the driller.
Additional sensors may be added and interfaced with
the system via modular, muitiichannel, input/output
,m~~ie$. EaG$ m...,.
tit ,Ia cornmunie~?esw-h the MPIJA
over a high speed, two wire, data highway. Analogue
and digital modules can be added at or remote to the
MPUA in safe or hazardous areas.
The standard parameter list of a typical system inctudes
hook load, rota~ RPM, rotary toque, pump pressure,
choke pressure, drill pipe make-up and break-out
 LOW COST SLIM HOLE DRILLING SYSTEM
..— .- ,A .I_.., .- ~A fit q mq-nn RPM nuqm strokes,
UJ~LIG, iTIUU IIUW h, =~,u vu , y.. S.I. -. .. .. ~-. .~ -------
block positions, bit depth and pit levels. Other
parametem and derivation software can be added to suit
specific drilling programmed such as kick detection
algorithms with appropriate warning alarms. In this case,
total gas and H2S sensors were added and flow in and
return flow during coring or slim hole operations were
measured using electromagnetic flow meters. During
large diameter open hole drilling, flow in was derived
from aggregated pump strokes having demonstrated
over previous use of electromagnetic flow meters that
the correlation with displacement data was veiy good. A
derived flow difference from these measurements was
-I- UlaplLayGu
Ulau ~;~~]~.,~ tm =ecici in mnnitnripn
.- ---,”.
the
..s . . .. . .... . . .= -
flows in the
small annulus during wireline coring and slim hole
drilling.
The system has proved very reliable and offers the
potential for futiher development as an information and
technical suppofi system and as a base for an electronic
reporting for the future. It can also be interfaced with a
standard mud logging service. It essentially provides an
information technology centre for the rig site.
A schematic showing the system layout is shown in
Figure 6. The driller station node with intrinsically safe
keyboard is shown in the driller’s cabin in Figure 4.
INITIAL FIELD OPERATIONS
The rig was commissioned in June 1994 and has drilled
two slant boreholes to modest depth of up to 1000 m
and carried out two workover operations, all to schedule
and without incident. The boreholes have been
destructively drilled in 12-1/4, 8-1/2 in and 6-1/4 in sizes
using both the top drive rotary and downhole motors.
Continuous coring has been undertaken using a heavy
duty mining wireline system in 159 mm and 123 mm
sizes. Standard API Range 3 casing has been installed
and torqued in 13-3/8 in, 9-5/8 in, 7 in and 5-1/2 in
sizes. Extensive testing has been carried out using
2-7/8 in tubing with a variety of testing assemblies for
DST’s and hydrogeologicaltesting programmed.
In the slant mode, special dollies running in the mast
rails were included in the package to handle wireline
logging tools and coiled tubing heads used for gas Iitl
programmed.
Trin . . ... . the
, sly time
with
.,, ,,” . . .. sinriles
-.. .*--- cQ!’!f@U~atiOn and Sblt W@%
are naturally slower than a vertical triples or doubles rig,
but trip speeds in the slim hole sections using wireline
coring were constrained by swab and surge pressure
concerns. Nevertheless, this is an important factor. In
this case, and in others where environmental impact is
an issue necessitating the use of limited height
equipment on environmental grounds, longer tripping
times have to be accepted. However, the number of
trips required has been dramatically reduced in recent
years by the development of PDC bits that often allow a
468
29388
complete well interval to be drilled between casing
pointswith one bit.
The rig and associated equipment were designed to
operate with a three man crew comprising Driller,
Assktant Driller or leading hand and one floorhand. For
slant operations, one additional floorhand is used. A
support mechanic with hydraulic systems experience
works on a day shift and call out basis. The unmanned
computerised rig instrumentation system has required
minimum maintenance and once set up and
commissioned after rig moves the system has proved
been extremely mgged and reliable. However, a part
time instrumentation technician has been in attendance
at the rig site.
After minor initial teething problems, the rig settled
down quickly and has proved to be very effective and
reliable over a wide range of drilling and testing
applications
The safety features of the rig, where personnel are not
required to use manual tongs or work close to the pipe
handling system, has demonstrated the value of
removing these hazards from the process. No lost time
or minor accidents have been reported in the first six
months of operations.
FUTURE APPLICATIONS AND DEVELOPMENT
This low cost equipment, conceived and designed to
fulfil a range of drilling and rig site operations for
exploration and development programmed, has proved
very successful. The initiative steps away from
conventional oilfield or mining rig design and offers an
alternative approach for serious review by those
searching for one of the key elements of the slim hole
package. It is an attempt to promote a paradigm shift in
the architecture of rigs for this application. Integration of
services and roles together with multi-skilling is also
necessary if the full benefits of slim hole applications
are to be realised.
It is also part of a wide ranging development or re-
engineering process that is starting to gain momentum
and must continue if the industry is to be successful in
improving safety and reducing drilling costs, especially
in exploration. The basic concepts can be refined and
supplemented as ‘required to suit any specific
application. The rig unit, for example, can be configured
to be mounted on a self propelled carrier, configured for
helicopter transportation or mounted on rails for
development clusters. A doubles version is quite
feasible.
This particular unit will be used for an extended
programme of vertical and slant drilling over the next
two years that will provide significant operating
experience in this class of operation. It will provide
valuable information for operational review and critique
to help guide future slim hole rig development.
 29388 BESWICK A J AND HILLS D L
The key point is that the rig design is based on relatively
simple proven concepts from both mining and oilfield
experience and uses readily available standard
components. The overall initial cost is e#lmated to be
only about 20°A of that for an equivalent driiiing rig
designed for conventional sizes to the traditional
architecture and only about 40% to 50% of comparative
purpose built oilfield slim hole rigs. Hence, a rig of this
type becomes a relatively small cost element for a long
!e.~ programme and compares well with the cost of a
used and refurbkhed conventional standard rig.
ACKNOWLEDGEMENTS
The authors wish to thank Kenting Drilling Services
Limited and Bohrgesellschaft Rhein-Ruhr mbH for
permission to publish this paper. The authors
acknowledge the contribution of James Howden and
Company Limited and Cathead Limited to this project.
1. Worrall R N, van Luijk J M, Hough R B, Rettberg A
and Makohl F. ‘M evolutionary approach to
slimhole drilling, evaluation and completion; SPE
Paper 24965 presented at the European Petroleum
Conference, Cannes, France, Nov 1992, P47.
7
2. Walker S H and Millheim K K. ‘An innovative
approach to exploration drilling : the slim-hole high-
speed drilling systemt SPE Paper 19525 presented
at 1989 Annual SPE Technical Conference, San
A~~o~@ Texe~, Qti I $)~g,P~3.
3. Murray P. Barriers to slim hole drilling; World Oil,
March 1904 pp 58-61.
4. Beswick A J, Scarrow J A and Muller-Ruhe W. The
integration of oiifiekl, m;ning and ge~!~~hd~i
exploration technologies for a deep scientific
investigation to depths up to 2000 m: lADC/SPE
Paper 23911 presented at 1992 lADC/SPE Drilling
Conference, New Orleans, Feb 1992.
5. Dupuis D and Fanuel Ph. Well cost systems
approach : achieving well cost reduction through
slim hole drilling with a purpose built drillstring and
ngt lADC/SPE Paper 25721 presented at 1993
lADC/SPE Drilling Conference, Amsterdam, Feb
1994.
6. Sp&ker H F, Cambar E, Machado P and Mochizuki
D. The world’s first multi-year slim hole exploration
project : a successful partnership between operator
and contractor lADC/SPE Paper 29356 presented
at 1995 lADC/SPE Drilling Conference,
Amste~am, Mar 1995.
469
8 LOW COST SLIM HOLE DRILLING SYSTEM 29388

APPENDIX A

KEY FEATURES

Depth rating 3500 m (slim hole)

Overall height 26 m

Footprint 40 m x 20 m (800 m2)

Mast Singles lattice open box

Hydraulic power system 385 hp

Hook load 100 ton (200 000 lb)

Traveling equipment 100 ton, &lines

Drawworks winch 6-speed hydraulic with 1 in (EIPS) drilling line with hydraulic braking and emewency
band brake

Pulldown winch Single speed hydraulic with 1 in (EIPS) line

Wireline winch Hydraulic variable speed for wireline coring

Substmcture 220000 lb rating, 4.0 m high (3.6 m clear) hydraulic self elevating with BOP lifting
and positioningsystem

Top drive Hydraulic 400 rpm 22500 Nm (16 500 ft lb) with hydraulic tilt and swing, floating
shaft and integral hydraulic power clamp

Standpipe pressure 5000 lb/in2

Pfirnaw rnedmised handling Hydraulic elevating and extending catwalk, top drive power clamp, power slips,
power breaker

Secondary handling system Hydraulic floor mounted crane, bushing for standanl inserts, 7-5/8 in hydraulic power
tong, tugger winch and forklifi with hydraulic pipe clamps

Maximum casing size 13-318 in Range 3

Mud pumps 165 hp triplex (two to four) with independent diesel engines

Mud system 320 bbl 7-compartment with associated solids control equipment, degasser and
pumps

Generator system 210 kW main unit with 50 kW standby unit

Instrumentation Rlg instrumentation package, computerised rig instrumentation system, kinetic

energy monitoring system with multi-functionautodriller

Noise attenuation 80 dB(A) at 1 m

Buildings Drillers station, Rig Manager, crew welfare, workshop, stores

Load packaging 6 m ISO container or equivalent including mast

470
 —
—
35 —

30 — TOP DRIVE SPEED VS. TORQUE CHARACTERISTIC

Power cuwe based on 198 kW power output
—

-k
25

20 —

15

10
*-1
N
5

Figure 2: Top drive rotaryspeed v torque

 Figure 4: Driller’s coneole

2CAE

11,11111’’l’’’’l””~ !5 28
m 5 10

wzAPnm AFEABA=OmlPm PMf’T15.199E.

@
-,

Figure5: Typical site Ieyout

473
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474