Rig Repair

Unscheduled Rig Repair

2003

Rig Repair

An interruption in planned operations

caused by a breakdown of the drilling
rig equipment.
Running the rig equipment to failure
is not cost effective for the Drilling
Contractor, Operator or Wellbore.
2003

Rig Repair

THE IMPACT OF UNSCHEDULED RIG

REPAIR
The Drilling Contractor
Financial penalties
Cost of emergency repairs
Possible personnel injury
Extensive equipment damage
Loss of future contracts
2003

Rig Repair
THE IMPACT OF UNSCHEDULED RIG
REPAIR

The Wellbore
A high risk of more unscheduled events
Extended exposure time
Loss of a hole section
Loss of the well
2003

Rig Repair
THE IMPACT OF UNSCHEDULED RIG
REPAIR
The Operator
Increased well cost
Delayed production
Loss of production

2003

Rig Repair

PRIMARY DRILLING
CONTRACTOR
AND
OPERATOR
OBJECTIVES
2003

Rig Repair
Drilling Contractor

No personnel injury
No well control incident
Optimise equipment life
Minimise rig repair
Control equipment cost
Long term drilling
contract
2003

Operator
No personnel injury
No well control incident
Optimise drilling
operation
Minimise unscheduled
events
Control final well cost
Cost effective
performance
7

Rig Repair

2003

Rig Repair
Preventive Maintenance Program (PMP)
A program designed to schedule regular
inspection, maintenance and/or repair of
drilling equipment prior to failure.
The historical life expectancy of rig equipment
is based on the frequency of maintenance.
2003

Rig Repair
THE FOUR COMPONANTS OF A PREVENTIVE
MAINTENANCE PROGRAMME
CLOSED
LOOP

CREW
FEEDBACK

RECORD
KEEPING

AUDITING

Management to
rig

Refining and
tailoring of the
system

Equipment
history

Through
inspection

Rig to
management

Equipment
trends

Well designed
checklists

Roles defined

Equipment
maintenance

Follow-up plans
and reports

Clear guidelines
2003

10

Rig Repair
COMPREHENSIVE PMP EQUIPMENT LIST

MAIN ENGINES
GENERATORS/SCR SYSTEM
BOP & ACCUMULATOR CONTROL SYSTEM
HOIST EQUIPMENT
TOP DRIVE SYSTEM
ROTARY SYSTEM
HP MANIFOLD/VALVES/HOSES
HYDRAULIC OPERATING SYSTEM
RIG MOVE
EQUIPMENT
2003

11

Rig Repair

TOP DRIVE
SYSTEM

2003

12

Rig Repair
COMPREHENSIVE PMP EQUIPMENT LIST

COMPRESSED AIR SYSTEM

CRANES
PIPE HANDLING SYSTEM
CIRCULATION SYSTEM
MUD PUMPS
BULK SYSTEM
MIXING SYSTEM
SOLIDS CONTROL SYSTEM
RIG COMPUTER SYSTEM
2003

13

Rig Repair
PMP FREQUENCY SCHEDULE
HOURLY

BI-MONTHLY

EVERY TWO
YEARS

DAILY

QUARTERLY

EVERY THREE
YEARS

WEEKLY

EVERY FOUR
MONTHS

EVERY FOUR
YEARS

BI-WEEKLY

SEMIANNUALLY

EVERY FIVE
YEARS

MONTHLY
2003

ANNUALLY

EVERY EIGHT14

Rig Repair
BENEFITS OF A SUCCESSFUL PMP PROGRAM
ENSURE EQUIPMENT LIFE EXPECTANCY
REDUCE DOWNTIME FOR UNSCHEDULED RIG
REPAIR
LOWER WELL COST
REDUCE SEVERITY OF DAMAGE TO EQUIPMENT
MAINTENANCE COST LESS THAN EMERGENCY
REPAIR
LESS CHANCE OF PERSONNEL INJURY
INCREASE IN DRILLING CONTRACTOR PROFITS
2003

15

Rig Repair
BENEFITS OF A SUCCESSFUL PMP PROGRAM
REDUCED RISK OF STUCK-PIPE, WELL CONTROL
OR OTHER UNSCHEDULED EVENTS
COMPONENT FAILURE FREQUENCY RECORDS
DEFINES RIG AND OFFICE SPARE PARTS
INVENTORY
INCREASE OPERATOR AWARENESS OF DRILLING
CONTRACTOR NEEDS
AN OPPURTUNITY FOR THE DRILLING
CONTRACTOR TO INPUT AND HAVE INVOLVEMENT
IN THE WELL
16
2003 PLANNING PROCESS

Rig Repair
EVALUATE RIG REPAIR FAILURE
SEVERITY

WHO SHOULD BE NOTIFIED?

WHAT IMMEDIATE ACTION IS REQUIRED?
CAN NORMAL OPERATIONS CONTINUE?
CAN PARTIAL OPERATIONS CONTINUE?
IS OPERATIONAL SHUT-DOWN REQUIRED?
2003

17

Rig Repair
EVALUATE RIG REPAIR FAILURE
SEVERITY
ARE PERSONNEL OR THE RIG IN DANGER?
IS THE WELLBORE IN DANGER?
WHAT SAFETY PRECAUTIONS ARE
REQUIRED?
CAN THE FAILURE BE REPAIRED AT THE RIG
SITE?
WHAT IS THE PREVENTIVE ACTION PLAN?18
2003

Rig Repair
DRILLING SYSTEM EMERGENCY
BREAKDOWN PROCEDURES
IF RIG EUIPMENT FAILURE SHUTS-DOWN A
MAJOR DRILLING SYSTEM, IMMEDIATE
ACTION MUST BE TAKEN TO PROTECT THE
PERSONNEL, RIG, AND THE WELLBORE
FROM ASSOCIATED EVENTS
2003

19

Rig Repair
DRILLING SYSTEM EMERGENCY BREAKDOWN PROCEDURES
DRILLING
SYSTEM
BREAKDOW
N

INITIAL RESULT

POSITIONING

1.
2.

RIG MOVES
OFF LOCATION
DRILLSTRING
SHEARED-OFF

SECONDARY
RESULT

1.
2.
3.
4.

STUCK-PIPE
BOP DAMAGE
DRILLSTRING
DAMAGE
SURFACE
EQUIPMENT
DAMAGE

ACTION PLAN

1.
2.
3.
4.

2003

STOP ROTARY
&
CIRCULATION
POSTION T.J.
ABOVE HANGOFF RAMS
CLOSE RAMS &
HANG-OFF
INITIATE
EMERGENCY
PROCEDURES
20

Rig Repair
DRILLING SYSTEM EMERGENCY BREAKDOWN
PROCEDURES
DRILLING
SYSTEM
BREAKDOWN
TOTAL LOSS OF
POWER

INITIAL
RESULT
1.
2.
3.

2003

SECONDARY
RESULT

LOSS OF
1.
HOISTING
2.
LOSS OF
CIRCULATION 3.
LOSS OF
ROTATION

STUCK-PIPE
WELL
CONTROL
SURFACE
EQUIPMENT
DAMAGE
AND/OR
FAILURE

ACTION
PLAN
1.
2.
3.

START
EMERGENCY
GENERATOR
CIRCULATE
WITH THE
CEMENT UNIT
MONITOR THE
WELL FOR
FLOW
21

Rig Repair
DRILLING SYSTEM EMERGENCY BREAKDOWN
PROCEDURES
DRILLING
SYSTEM
BREAKDOWN

INITIAL
RESULT

TOTAL DRILLING 1.
POWER
2.
3.

LOSS OF
1.
HOISTING
LOSS OF
2.
CIRCULATION
LOSS OF
ROTARY

SECONDARY
RESULT

ACTION PLAN

STUCK-PIPE

1.

WELL
CONTROL

2.
3.

2003

START
EMERGENCY
GENERATOR
CIRCULATE
WITH THE
CEMENT UNIT
MONITOR THE
WELL FOR
FLOW
22

Rig Repair
DRILLING SYSTEM EMERGENCY BREAKDOWN
PROCEDURES
DRILLING
SYSTEM
BREAKDOWN
TOP DRIVE
SYSTEM
(TDS)

INITIAL
RESULT
1.
2.
3.

LOSS OF
HOISTING
LOSS OF
CIRCULATION
LOSS OF
ROTARY

SECONDARY
RESULT

ACTION PLAN

1.

STUCK-PIPE

1.

2.

WELL
CONTROL

2.
3.
4.

2003

TRIP TO THE
SHOE FOR REPAIR
ROTATE THE PIPE
IN THE SLIPS
RIG-UP TO
CIRCULATE
MONITOR THE
WELL FOR FLOW
23

Rig Repair
DRILLING SYSTEM EMERGENCY BREAKDOWN
PROCEDURES
DRILLING
SYSTEM
BREAKDOWN
HOISTING
SYSTEM

INITIAL
RESULT
1.

2003

CANNOT
RAISE
DRILLSTRING

SECONDARY
RESULT
1.

STUCK-PIPE

ACTION PLAN

1.

CONTINUE
CIRCULATION
AND
ROTATION

24

Rig Repair
DRILLING SYSTEM EMERGENCY BREAKDOWN
PROCEDURES
DRILLING
SYSTEM
BREAKDOWN
ROTARY
SYSTEM

INITIAL
RESULT
1.

SECONDARY
RESULT

CANNOT
1.
ROTATE THE
DRILLSTRING

STUCK-PIPE

ACTION PLAN

1.
2.
3.

2003

RECIPROCATE
THE
DRILLSTRING
TRIP TO THE
SHOE FOR
REPAIR
MAINTAIN FULL
CIRCULATION
25

Rig Repair
DRILLING SYSTEM EMERGENCY BREAKDOWN PROCEDURES
DRILLING
SYSTEM
BREAKDOWN
CIRCULATNG
SYSTEM

INITIAL
RESULT
1.

2003

CANNOT
CIRCULATE
THE WELL

SECONDARY
RESULT

ACTION PLAN

1.

STUCK-PIPE

1.

2.

WELL
CONTROL

2.

TRIP TO THE
SHOE FOR
REPAIR
ROTATE AND
RECIPROCATE
THE
DRILLSTRING
IF REPAIRS ARE
MADE IN OPEN
HOLE
26

Rig Repair
DRILLING SYSTEM EMERGENCY BREAKDOWN
PROCEDURES
DRILLING
SYSTEM
BREAKDOWN
WELL CONTROL
SYSTEM

1.

2.

2003

INITIAL
RESULT

SECONDARY
RESULT

CANNOT
1.
SHUT-IN THE
WELL ON A
2.
KICK

EQUIPMENT
1.
DAMAGE
PERSONNEL
INJURY
LOSS OF THE WELL
ENVIRONMENTAL 2.
DAMAGE

BLOWOUT

3.
4.

ACTION PLAN

NON
EMERGENCY,
SECURE THE
WELL TO
MAKE REPAIRS
INITIATE
EVACUALTION
PROCEDURES
27

Teams
Drilling Problems

2003

28

Rig Repair
INTEGRATED PREVENTIVE MAINTENANCE PROGRAMME (IPMP)
RIG EQUIPMENT MAINTENANCE LIST
1. SERVICE MAIN ENGINE

8. SERVICE CENT. PUMPS

15. SERVICE VECHILES

22.

2. SERVICE GENERATORS

9. 4,5,6

16. SERVICE CENT. PUMPS

23.

3. SERVICE AIR COMPRESSOR

10. SERVICE D/WORKS BRAKES

17. SERVICE FLOOR WINCHES

24.

4. SLIP/CUT DRILL LINE

11. SERVICE TDS

18. SERVICE WATER COOLER

25.

5. SERVICE CRANE

12. SERVICE DIVERTER

19. SERVICE PUMP MANIFOLD

26.

6. LIFTING EQUIPMENT INSPECT

13. SERVICE SOLIDS CONTROL

20. SERVICE ST/PIPE MANIFOLD

27.

7. SERVICE BOP ACCUMULATOR

14. CHANGE SWIVEL PACKING

21. TEST PUMP

28.

LEGEND

SERVICE COMPANY MAINTENANCE LIST

PLANNED
MAINTENANCE
LOW RISK
MAINTENANCE
HIGH RISK
MAINTENANCE

CEMENT UNIT

LOGGING UNIT

MUD LOGGING
UNIT

1. SERVICE TRANS #1

6. SERVICE P/TANK
VALVES

11. SERVICE ENGINE

16. SERVICE
COMPUTER

2. SERVICE ENGINE #1

7. SERVICE PUMP #1

12. SERVICE TRANS

17. INSPECT SENSORS

3. SERVICE TRANS #2

8.

13. SERVICE OP. CHAIR

18. RESUPPLY UNIT

4. SERVICE ENGINE #2

9.

14. REPLACE WIRE

REEL

19. SERVICE OP.

CHAIR

5. SERVICE PUMP #1

10.

15.

20. SERVICE
LIGHTING

2003

OTHER

29

Rig Repair
SERVICE IPMP

4-5-6-10-12

#2

RIG IPMP

1-2-4-5-6-10-12-29

15

11

12

9-22-23

16

1
3

19

17-16-20

18

1
0

DAYS FROM SPUD

0-----5-----10-----15-----20-----25------30------35------40------45------50------55-----60------65------70

WELL PLAN

26 HOLE 20 CASING

W.OC.
CASING----------DEPTH

17 HOLE 13 CASING
RUN CASING

30

1284 FT

W.O.C.
12 HOLE 9 CASING

20

2600 FT

RUN CASING
W.O.C.

13

5080 FT

8 HOLE 7 LINER
RUN CSG

12,250 FT

14,540 FT

WO
C

2003

30