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TBA 100 – A Performance Study of the New
Generation 100-ton Advanced Technology Rig
Maximilian Trombitas,
Product Manager Bauer Deep Drilling GmbH
2
Outline
• Field study
• Lessons learned
• Rig design changes
• Mechanization of drill floor processes
• Example: Pipe handling
• Summary
Buffalo 90 is a multipurpose drill rig designed in a
cooperation of Bauer and DeWet
3
Buffalo 90 has drilled two horizontal wells for
CBM projects for Kalahari Gas in Botswana
4
Operations started in November 2012
• First onshore horizontal wells in
southern Africa
• Rig site in Kalahari Desert, close to
Mmashoro
• Original plan was to drill 5 exploratory
wells and with different completion
strategies
Coal bed methane
• high potential expected (depending
on findings from exploration wells)
The geology for both wells includes coal as the
target reservoir and dolomites above and below it
Trajectory of 1st well shows a short vertical and 3 extended lateral sections:
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270
290
310
330
350
370
390
0 200 400 600 800 1000 1200
Sidetrack 2 Trajectory Sidetrack 1
Notes: Trajectory based on Pathfinder data, geology schematic
Coal Bed (high ROP) Dolerite (hard, low ROP) • 8 ½” section was drilled with bentonite mud
• all lateral sections were drilled with fresh water
and sweeps
Rig set-up
6
Pipe
Rack Dog
House
Pipe
handler
Buffalo90
Rig
Shale
Shaker
Mud
pits
Rig performance analysis of 23 days operation
• Rig NPT less than 0.5%:
• Weight-to-Weight-connection ~2.2 min
• Fuel Consumption ~ 500 l/day
• No HSE incidents or accidents
7
Problem Hours % NPT
Pipe handler 0.8 0.14%
Rig mechanics 0.8 0.14%
Air slips 0.6 0.1%
Rotary brake 0.3 0.05%
Total 2.5 0,43%
Step 2
Step 3 Step 4
Step 1
The operational problems involve both
mechanical and human errors
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Downtimes Inefficiencies
Mechan-
ical
Errors
• Waiting on spare
parts (difficult supply
situation)
• Pump capacity
• Shale shaker capacities
Human
Errors
• Waiting on fuel (non-
attention, no
procedures available)
• No work during rain
• Major failures (e.g.
squeezing casing,
drilling towards old
well bore)
• Slow, untrained and
inexperienced crew
• Miscommunication btw.
operator & contractor
• Difficult working
circumstances (no proper
camp, no food
provided,…)
• There is no way
around providing
good training to
people
• Selecting & keeping
the good ones
• Not saving money
on crucial
equipment like mud
pumps or shale
shakers
• Establishing better
supply chains for
future large scale
operations
Lessons learned for the whole system out of the
first operations
9
Suggestions
for Rig
Changes
Automation
Issues
Equipment
•Driller’s cabin – more space for 2 people
•Pipe handling system – remote control vs. cabin
•Driller’s cabin – meters with metric units
•Power tong – higher moments change of power tong
•Electronic data collection and display system
•Rig leveling – less transport units
•Mast – bigger drilling axis
•Mud pumps fulfilling flow rate, pressure and noise requirements
•Shakers designed for the requirements of oil & gas operations
•Levels on diesel tanks
•Proper office for contractor on site (printers, phones, etc.)
•High risk operation still manual
•Changing of mind
•More sensors required
•Software
Lessons learned & main changes
PR110 Version: Prototype Buffalo 90:
Major Changes to the prototype:
• Higher degree of mechanization and
automation
• Modular system
• Focus on hands-free & crane-less rig
up/down
• Transport dimensions to fulfill world wide
road regulations
• Diesel or electric driven
• Increased sensor installation
• B-tronic
• Increased hook load
• Trailer remains on ground level
• Increased drilling axis to 800 mm.
• No cabin at the pipe handler
Evaluation and benchmarking of every single process
on the drill floor
Basics:
• List all tools that you want to handle (representative tools)
• Analyze the work flow of handling those tools (for example: flow charts)
• List all work steps and rank them
11
Break-down & Visualization
Definition & Categorization
Evaluation & Ranking
Drilling tools: BHA
Standardization for the assembling of a BHA is difficult, the different tools
vary immense in many aspects
• Different types of tools
• Different design of tools
• Different dimensions of tools
• Different manufacturers of tools
• Different handling requirements of tools
• Different layout of the drill string (setup, diameter…)
12
BHA tools
Can we define a list of BHA tools that represent all/most of the tools that are
available on the market? (If I can handle those tools, I can probably handle
all the other tools!)
• Which tools
• Specifications of those tools
• Handling of those tools
• Logistic of those tools
13
Example: Drilling Bit
Roller-cone bits
Drag bits
Specifications: 3 ½” PDC 22” PDC 28” PDC
Length 400 mm 700 mm 750 mm
Weight 5 kg 750kg 900kg
ID - - -
OD 75 mm 240 mm 260 mm
Max. OD 90 mm 558 mm 710 mm
Thread 2 3/8” Reg. Pin 7 5/8” Reg. Pin 8 5/8” Reg. Pin
Make-up Torque 2,5 kNm 85 kNm 160 kNm
14
Example: Jar Disassembling Work Steps
15
Work Steps
16
Work Steps
17
Work Steps – Manual and On Rig Floor
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Autom. Manual On Rig Fl. Hazard. Time Frequent Realizable Knowl.
Transp Pick up sensible string x x
Transp Lay down sensible string x x
Transp Lay down item x x x x
Transp Pick up item x x x x
Ass Safety clamp on x x x x
Ass Safety clamp off x x x x
Ass Jar safety clamp on x x x
Ass Jar safety clamp off x x x
Handl Slips in x x
Handl Slips out x x
Handl Bushing in x x x
Handl Bushing out x x x
Handl Bit breaker plate frame on x x x
Handl Bit breaker plate frame off x x x
Ass Bit breaker plate on bit x x
Ass Bit breaker plate off bit x x
Handl Bit breaker plate in frame x x
Handl Bit breaker plate off frame x x
Ass Bit + bit breaker plate in frame x x
Ass Bit in bit breaker plate x x
Ass String revolution indicator x x x
Ass Breake connection man. x x x x x
Ass Make-up connection man. x x x x x
Ass Screw connection man. x x
Ass Unscrew connection man. x x x
Handl Change elevator x x x x
Handl Guide pipe up x x x x
Handl Guide pipe down x x x x
Handl Cover borehole x x
Handl Push string x x x
Transp Winch on x x
Transp Winch off x x
Serv Add ball/chip to well x x
19
Evaluation and benchmarking of every
single process on the drill floor
Break-down & Visualization
Definition & Categorization
Evaluation & Ranking
Example for a project to mechanize a process on a
drilling rig
20
Manual Semi-remote
controlled Remote controlled
Fully mechanized 100% Hands free
21
Cylinder length measurement
trip-in/trip-out inclination
Length measurement
sledge Cylinder length measurement
inclination
Cylinder length
measurement
clamp
Pipe isolating
proximity switch
Cylinder measurement
V-door
Example for a project to mechanize a process on a
drilling rig
Examples of the selection of sensors for a
fully automated drilling rig.
22 22
Information of sensors are required to
achieve a fully automated drilling
process
• Drilling torque, vibration & tension
sensor
• Sensors on top drive
• OPC-interface for „Plug and Play“
• B-Tronic
Summary
26
• The performance of the protoytyp rig was excellent with:
• NPT less 0,5%
• No LTI
• Training, crucial equipment and supply chain shouldn’t be the bottleneck
• Benchmark and evaluate all processes on the rig to understand the way to
get a fully automated solution
• Push automation & mechanisation to the limit by increasing the efficiency
• Modular systems to offer a range of different applications to customer
27
Thank you for
your attention!!!
Maximilian Trombitas,
Product Manager -
Bauer Deep Drilling GmbH