Rig Equipment and Inspection

Presentation 10

Howard A. Garig

DRILLING TECHNICIAN SCHOOL

ExxonMobil Development Company
Houston, Texas
2004

1
 Learning Objectives

You should be able to:

Identify different types of drilling rigs
Describe their operating environments
Identify main rig systems and equipment
Describe the functions of the systems
Understand the rig inspection process and
your role in it

2
 Information Sources

EMDC Drilling OIMS Manual

API Recommended Practices
Previous Rig Inspection Plans
World Oil Composite Catalogs
OPL Marine Drilling Units of the World
Dave Steubner- EMDC Global Rig Coordinator
World Oil Magazine - Yearly Rig Editions
IADC Drilling Manual
Vendor Material

3
 Rigs Categorized by Operating Environment

Drill ship
Semi-submersible
Jack-up
Platform
Barge
Land

4
 Land Rigs

Heli-rig on Papua New Guinea

Solid foundation needed for land rigs

Carrier-mounted/trailerized mobile rigs for fast rig move
Helicopter transportable rigs for locations without accessible road
5
Barge Rigs

Mostly for inland water or

offshore areas with calm
weather
Inland barge often towed to
location with draft < 6 feet
Submersible barge
ballasted until lower hull
rests on soft bottom
Mud barge also available

6
 Platform Rigs

Operated anywhere a platform can

set jacket, TLP, DDCV
$20k - $40k daily rental
$20M - $100M to build
Ability for supply boat off-loading
being the limiting factor for
operations in severe weather
Weight and space requirements
impact platform design and cost

Jade - Equatorial Guinea

7
 Platform Rigs

Malaysia: Seahawk at Palas A Compact/integrated design

and tender-assisted drilling
reducing weight and space
requirements

Malaysia: Tioman T-2 at Tapis E

8
 Platform Rigs - Designed by EM

Diana Hibernia - Newfoundland

Jotun B-Norway Ringhorne - Norway

9
Jack-Up Rigs

Operated up to 400 water

depth
$20k - $120k daily rental
Relatively calm weather needed
for installation, for example:
wave height < 5 feet and wind <
15 knots
Rig can move horizontally onto
the top of a platform for
cantilever operations

10
 Drill Ships

Operated up to 10000 water

depth
$100k $200k daily rental
Moored or dynamically-
positioned in place
High Speed Mobilization
Storage Capacity

Jack Ryan

11
Semisubmersible

Operated up to 10000
water depth
$60k - $230k daily rental
Most have thrusters to
assist in towing and
positioning for mooring
Moored or dynamically
positioned in place
The deck is usually higher
than drill ship

Leiv Eirikssen

12
 Rigs Categorized by Operational Capability

By height of mast single, double, triple, fourble

By derrick hookload capacity 0.5 M lbs, 1.0 M lbs, 1.3 M lbs
By rated well depth 5000, 10,000, 20,000, 35,000
By applications drilling, workover, completions
By design
3rd, 4th, 5th generation MODU
API, light weight, integrated
SCR, mechanical

13
 Moored vs Dynamically Positioned (DP)
Ships and Semis

No drive off risk for moored rigs

More fuel consumption for DP rigs, high horsepower
needed for thrusters (5000-25,000 HP)
Shorter rig up/down time for DP rigs, allowing fast
moving to avoid hazards
In general, lower water-depth limit for moored rigs

14
 Cost Savings: DP

DP Cost Savings vs. Well Days

Operations ~ 5000' WD
Maximum Savings Realized by DP:

Net Savings
DP Cost
1500
Multiple wells or batch setting over Savings

(KUSD)
1000

an area larger than a rigs mooring 500

radius Net Loss

0
25 50 75
-500

Shorter term exploration well programs -1000

-1500

-2000
Well Days-Exclude Anchor Work

15
 Cost Savings: Moored

DP Cost Savings vs. Well Days

Maximum Savings Realized by Operations ~ 5000' WD
Mooring:

Net Savings
DP Cost
1500
Savings
Template or drill center operations

(KUSD)
1000

fitting within a rigs mooring pattern 500

0
25 50 75
Longer term operations where mooring Net Loss -500

-1000
is a small percentage of total program -1500

-2000
Well Days-Exclude Anchor Work

16
 Floating Rig Considerations

Need for heave compensation

Previously done with bumper subs - now use
of passive and active heave compensators

Crown Mounted
Compensator

Block Mounted
Compensator

17
 Rig Site Zoology

Doghouse

Mousehole

18
 Rig Site Zoology

Catwalk

Possum Belly

19
 Rig Systems and Components

5 primary systems
associated with drilling rig
Power System
Hoisting System
Rotating System
Circulation System
Well Control System

Reprinted with permission from Petroleum

Extension Service, UT Austin

20
 Power System

Engines: internal combustion engines provide shaft power

Transmission:
Mechanical - engine shaft power to compound for
distribution
Electrical - engine shaft power to electrical generators &
then distributed through silicone controlled rectifier (SCR)
that converts AC electrical power to DC for variable speed
motors 21
 Hoisting System

Drawworks, crown and traveling block -- Deliver hoisting power

to the hook

Mast/derrick and substructure -- Provide a structural reaction to

the hoisting forces and setback. Setback is the amount of pipe
weight that can be vertically racked while the maximum hook
load is being carried.
22
 Hoisting System-Hydraulic

A new type of hoisting system has recently been employed on

a few new semis and drill ships. The concept is known as a
Ram Rig or Hydra Lift Rig. Both concepts use hydraulic
cylinders to move the load up and down. 23
 Hoisting System

Hook, links & elevators -- Provide a force path from the

drill stem to the rotary drill line
Rotary swivel -- Provide for the rotation of the drill stem
with respect to the hook, while providing a force path to
the hook and a fluid path to the drill stem
Maximum hook load = heaviest string of casing (typically)
24
 Rotating System

Rotary table -- Deliver rotating power to the drill stem through

the kelly & associated bushings, usually gear driven from a side
shaft.
Kelly is typically a 40 long, square or hexagonal shaped, thick
wall pipe, with a valve (kelly cock) that can be closed to prevent
backflow. 25
 Rotating System

Top drive - Hangs from the

hook. Motor provides
torque to the drill stem
through a drive shaft.

Advantages:
1) Rotate while tripping
out
2) Can add 3 joints at a
time
3) Making up or breaking
out pipe easier

Maritime Hydraulics Varco

26
Circulating System - Mud Pits

Mud pits -- Hold drilling and

completion fluids
Various pit sizes
Slug Pits - 30-100 bbls to mix
small batches of fluid- usually
directly hooked to hoppers and
mixing lines
Active pits - 100-1000 bbls holds
fluid regularly circulated through
well
Reserve pits - 100-1000 bbls
holds fluid for reserve use on
well. On land may be earth pit
Sand Trap/Treatment Pits -
usually series of 3 pits where
mud initially returns from solids
control equipment. Pump to and
return from secondary solids
control such as desanders,
desilters etc.. 27
Circulating System - Mud Pumps

Mud pumps 2-3 piston

pumps (often with centrifugal
booster pumps) to circulate
mud
Larger pump cylinder liner for
higher flow rate and smaller
liner for higher pressure
Typically need high flowrate
for surface hole and high
pressure for production hole

28
 Circulating System- Standpipe Manifold

T o C hokeM an ifo dl

T e s tH o se
12 Standpipe Manifold -
1
directs HP mud flow
MD

MD
7
from mud pumps to
4 15
10 drill string or other
16
2 13 desired path
MD

R ise r B oo s t
5 11 L ni e

8 14
3 6

S tand p pi e # 1 Je t L ni e B rune r B oom s S tand p pi e # 2

29
 Circulating System - Solids Control

Centrifuge
Shaker

Desander Deciliter

Shale shaker, desander, desilter & centrifuge -- Provides for the

removal of drilled solids from the drilling fluid upon return from
the well bore annulus
Component selection depends on mud weight, mud cost,
equipment cost, and disposal cost 30
 Circulating System - Other Mud Treatment

Gumbo Chains Degassers

Gumbo Chain - for handling high volumes of soft-gumbo

shales- mostly used in GOM top hole sections
Degassers - for removal of gas from mud stream post solids
control
31
Circulating System - Drilling Riser

As a return mud flow path from

well at sea floor
Typically consisting of slip joint,
riser joints and LMRP (lower
marine riser package) for floaters
Casing often used as riser for
platform drilling
Riser weight supported by
buoyancy can and tensioner
Low pressure riser for floating
drilling and high pressure riser
for platform drilling, dual risers
for extreme conditions
Kill/choke lines attached to riser
and booster line used to assist
cuttings transport
32
 Well Control System

FLOW
LINE BELL
FILL
LINE NIPPLE
Trip Tank
CENTRIFUGAL
ANNULAR
Poor Boy Degasser
BOP MUD
PUMPS STANDPIPE
BOP
STACK FLOW RATE PIT VOLUME TOTALIZER
RECORDER (PVT)
PUMP-TYPE TRIP TANK LAYOUT UPPER KELLY
PVT SAFETY VALVE RESERVE PIT
BOP REMOTE RECORDER
CLOSING UNIT DEGASSER SHALE SHAKER
INSIDE FLARE STACK
TO HYDRAULIC BOP
M CHOKE CONSOLE
TA UD LOWER KELLY FLOW RATE
NK SAFETY VALVE LINE
DETECTOR
FILL
LINE FLOW
DRILL PIPE MUD GAS
SAFETY VALVE SEPERATOR
RELIEF
VALVE BYPA
SS
GRAVITY
PUMP CHECK
TRIP TANK HYDRAULIC
ISOLATION
VALVE
VALVE
BOP
HYDRAULIC CHOKE
CHOKE
Choke Manifold
CONTROLED
UD STACK
TO TO M PIPE VALVE MANIFOLD
KIL D
L L STAN
INE

KILL LINE WELLHEAD Example Schematic Layout of

FROM MUD PUMP Well Control Equipment
OR
BOP ACCULULATOR UNIT HIGH PRESSURE Kick Detection Equip.
MAIN CLOSING UNIT
TO REMOTE
CLOSING UNIT
PUMP
BOPs Kick Containment Equip.
Kick Circulating Equip.
ON RIG FLOOR
DRILL STRING
FLOAT VALVE
BOP Control System

33
Well Control System

Blowout preventer
(BOP) stack -- Provides
pressure isolation and
control during kicks

Pressure rating is based

on maximum anticipated
surface pressure during
a well control event

BOP stack arrangement

important. Annular,
Ram, pipe shear rams
BOP

34
 Well Control System

Annular Rotating Head

WH Connectors
Rams

35
Well Control System

Land
BOP
Stack

Subsea
BOP
Stack

36
 Well Control System

Accumulators store fluid

under high pressure for
control devices

37
 Well Control System

Activated by remote control

unit on rig floor. Can open
or close BOP quickly.
Choke also remotely
controlled

38
 Well Control System

G a s L in e
T o M u d G a s S e p a ra to r

Choke Manifold provides

34
T e s tP o r t
H 33 32 H

positive pressure and flow

31 30 29 28 rate control of the well
during a kick or live drilling
operation
20 22
19
24 26

27
Equipped with both manual
16 15 14 13
and remote chokes
F ro n tV iew

Allows flow to be directed to

9 12 18
poor boy de-gasser, flare
8
line, other routes
H 11 17

C HO K E L N
I E
B ack S d
ie T e s tP o r t
4 H
T e s tP o r t

1 2 5 7 10 K IL L L N
I E

35 H
3
DM

T o S ta n d P ip e M a n i fo ld

39
Well Control System

Manual Choke

Remote Choke

40
 Well Control System

Poor Boy Degasser

Vessel Size
Internal Baffles
Gas Outlet
Target Plate
U- tube liquid seal

41
 Rig Floor Layout

New Offshore Platform

Typical STX Land Rig

42
Drilling Equipment Controls

43
 Rig Floor Equipment

Iron Roughneck
Make-up and Breakout of
tubulars
Replaced Manual Tongs
Increased Safety
Integral Spinner
Still use manual tongs for
large DCs or BHA components

44
 Rig Floor Equipment

Manual Tongs
Make-up and Breakout of Pipe Spinner
tubulars
Safety focus on proper use
and tong BU lines
Pipe spinner in place of chain
for safety
Still use manual tongs for
large DCs or BHA components

Tongs

45
 Rig Floor Equipment

Torque-up Devices
Draw works - MU/BO line
Traditional method still
widely in use
Hydraulic Cathead
Found on newer rigs or
installed on older ones
Safer, dedicated unit

46
 Rig Floor Equipment

Flush Mounted
Slips

DP
Elevators

BX
Adjustable
Elevators

Slips

47
Pipe Handling Equipment

48
Large OD Handling Equipment

Casing
Riser

49
Rig Inspections

50
 Rig Inspections

Purpose of Rig Inspections

Inspection Requirements
3rd Party Inspections
QA/QC of Inspections
Inspection Planning and Follow-up

51
 Purpose of Rig Inspections

Safety
Regulatory Requirements
OIMS Requirements
Assure rig meets contract requirements
Equipment verification
Familiarity with rig capabilities

52
 OIMS Requirements

Sections 3,6 and 8 of the OIMS Manual

Procedures shall be in place for initial inspection
and acceptance of critical drilling equipment
In Reference to:
Safety
Regulatory Requirements
Drilling Design Standards
Drill Team Specific Acceptance Criteria

53
 Inspection Requirements

A checklist shall be developed, customized for the

specific rig, area and/or operation. Equipment
acceptance criteria shall be incorporated into the
checklist, where practical
Guidelines:
Safety
Regulatory Requirements
Well Type, Duration of Program, Drilling Design
Standards
Inspection Team Make-up: EM personnel
specialists, 3rd party Inspectors etc..

54
 Inspection Team

BOP and Well Control Equipment - West Inc, some

ModuSpec
Marine Safety - URC aid on critical subjects, ModuSpec
Rig Equipment Acceptance - ModuSpec
NDT testing personnel - T.H. Hill or other
Tubulars, handling Equipment - T.H. Hill
Hygiene - EM Health Inspection Team
Solids Control - Mud Company selected as contractor

55
 QA/QC of Inspections

Document Verification
Daily Interaction-discussion of inspection progress
Witnessing of tests
Critical equipment - testing verification

56
 Inspection Planning and Follow-Up

Coordinate with Superintendent on inspection

schedules
Develop Checklist to track progress
Develop Follow Up list to track outstanding items
Track Progress on Follow-up items until
completed

57
 MODU Rig Inspections

Up to date Manufacturer- equipment Recalls

Structural Inspection

Marine Safety Audit and Stability Review and EER Analysis Rig Acceptance Checklists- Witness of operation

Derrick Inspection/Risk Assessment Environmental Aspects: Closed drain systemetc...

Riser/Slip Joint/Flex joint Inspection Medical & Hygiene Facilities and Personnel

BOP and Diverter Equipment High pressure piping survey and repairs

Risk Assessment Issues Identified

3rd Party Drill Tools
Handling Tools
Solids Control Equipment
Water tight doors

BOP Control System Helicopter Facilities

Burner booms
C&K Manifold and Lines

Poor Boy Degasser Supply Vessels

Personnel Qualifications
All tubulars DS-1 cat.4

Mooring Equipment Lifting Equipment

Production Test Lines

Fluid systems operability
Classification survey of hull, structure and well controll equipment

58
 Rig Inspections- Inspection Plans

9-Jun-03 FOLLOW UP SHEET FOR HAKURYU V INSPECTION PLAN

PRIORITY DATE
0 20 40 60 80 100
DESCRIPTION % FINISH complete COMMENTS
Structural Inspection 0
Stability Review-ModuSpec 0
Marine Safety Audit-ModuSpec 0
Derrick Inspection-Dreco 0
Derrick Risk Assessment-JDC and EMDC OS 0
EER Analysis-ModuSpec 0
Mooring Equipment-EMDC Eng & ModuSpec 0
Mooring Analysis-URC 0
Riser Analysis-URC 0
Riser Inspection-West & 3rd party NDE 0
Riser Slip Joints-West & 3rd party NDE 0
Riser Flex Joint and Riser Adaptor-West 0
Riser Tensioners-West 0
Riser Handling Tools-West & 3rd party NDE 0
Diverter & Ball Joint-West 0
BOP Preventers-West & 3rd party NDE 0
BOP Annulars-West 0
BOP Connectors-West 0
BOP Control System-West 0
BOP Flexible Hoses-West & 3rd party NDE 0
Choke Manifold & Lines-West & 3rd party NDE 0
Poor Boy Degasser-West 0
Production Test Line-West & 3rd party NDE 0
Drill String-EMDC OS and 3rd party NDE 0
Lifting Equipment-Drilling- West & 3 rd party NDE 0
Lifting Equipment-Cargo- EMDC OS 0
Lifting Equipment Shore-Logistics Supervisor 0
Rig Acceptance Checklist- EMDC OS& West 0
Medical Hygeine- IMOHD & AEA SMI Doctor 0
Personnel Qualifications- Opts. Supt. 0
Third Party Drill Tools- 3rd party inspections 0
Helicopter Operations Audit-MPN Aviation 0
Helicopter Facilities Rigsite-MPN Aviation 0

Total finish (average on all items above) 0.00 %

59
Rig Inspections - Non Destructive Testing

Magnetic Particle
Inspection
Ultraviolet
Eddy Current
Ultrasonic

Riser Spider

60
 Rig Inspections - Non Destructive Testing

Handling Equipment Lifting Equipment

Ideal for identification of fatigue related failures

Highly dependant on experience level of inspector
Also applied to other areas - such as crane pedestals,
structural areas
61
Rig Inspections - Non Destructive Testing

UT of HP piping is a
high priority
Focus on high flow
areas(tees, elbows)
Well control and
standpipe
Lines in close
proximity to cement
and mud pumps
Freshly painted lines -
may have been painted to
cover extensive corrosion

HP Piping

62
Rig Inspections - Visual

Wire Rope
63
 Rig Inspections - Being Thorough

Shows normal
wear and tear.
Passed both low
and High
pressure
tests to company
guidelines.
BOP C&K Line Hose

64
Rig Inspections - Being Thorough

Upon visual inspection of the

inside of the hose with a
boroscope the inner lining
was found to be damaged and
the hose rejected.
65
 Rig Inspections - Tubulars

Tubular inspection based on DS-

1 Criteria.
Varies on well requirements

Dependent on Inspector
Quality
Perform as early as possible -
in case of high rejection rate
Mark and separate failed
tubulars - get off rig!!
66
 Rig Inspections - Visual: Human Factors

Does driller have a

clear view ?
What type of work are
we going to be doing
with the rig ?
Weight Indicator
working properly ?
Pressure monitoring
sufficient ?
Do we have a
mudloggers screen
on the rig floor - do
we need it ?

67
Rig Inspections - Visual: Human Factors

68
Rig Inspections - Visual: Human Factors

69
 Rig Inspections - Rig Operability: Equipment

Does the rig have sufficient pump capacity for our planned
operations ?
Is the solids control equipment up to our program
requirements ?
How will this rigs equipment capability limit us?

70
 Rig Inspections - Rig Operability: Space and Layout

Does the rig have enough room

for our planned operations ?
Is pit capacity sufficient ?

71
 Summary

Learned about different types of rigs and their

operating environment

Learned about 5 main rig systems, their

functions and some broad selection criteria

Learned about tubular and other rig type

handling equipment

Learned about rig acceptance inspection work

72