Herrenknecht Vertical. The driving force in deep drilling.

Next Generation of Rig Automation.

David Schwarzwälder, Sales Director, Herrenknecht Vertical GmbH.

IADC World Drilling Rome, 18.06.2015

Herrenknecht Vertical. The driving force in deep drilling.

AGENDA.

Why automation?

Different kind of automation processes on a drilling rig

Which degree of automation?

Challenges

Standardisation

Potential solution

Herrenknecht Vertical. The driving force in deep drilling.

Automation – Key statement.

“We’re shifting the simple, repetitive tasks of the human driller in a 12-hour shift to automated machines by allowing the computer to perform these functions so the driller can monitor the operation and do higher-level activities such as preventive maintenance, crew competency, safety or planning.”

Drilling Superintendent SHELL

Herrenknecht Vertical. The driving force in deep drilling.

Why Automation? – Safety. Other 13.71% Forklift / Cherry picker /

Crane 0.96%

Fuel / Water storage tanks 0.24%

Pontoon 0.48%

Mud pump room 2.76%

Machinery spaces 1.32%

Vehicle 1.44%

Cellar / Substructure / Moonpool 4.68%

Crew / Work boats 0.24% Camp / Accomodation

1.44% Work, change, storage,

room/house 1.08% Rig pads / Rig decks

7.20%

Stairs/Ladders 2.88% SCR/Electrical Room

0.24% Engine/Generator room

1.32% Mud pits/tanks 3.96%

Shale shaker 1.20% Mud mixing tank/area

2.16% BOP stack, Well

head/tree area 2.16%

Derrick / Mast 5.76%

Catwalk / V-door 4.44%

Pipe rack / Pipe deck 5.88%

Rig floor 34.45%

Rig related risk reduction potential > 50%

Herrenknecht Vertical. The driving force in deep drilling.

Why Automation? – Human Factor.

Folkard 1996

Hänecke et al 1998

Akerstedt 1995

Nachreiner (Deadly 15h)

Risk [z-value] 4

3

2

1

0

-2

-1

Shift duration [h] 4 3 2 1 5 6 7 8 9 10 11 12 13 14 15 16

Accident hazard as a function of shift duration

source:

Herrenknecht Vertical. The driving force in deep drilling.

Why automation? – Performance.

source: GeoData log

Connection times on a mechanized drilling rig

Slowest

Fastest

Potential savings per connection up to 40%

Herrenknecht Vertical. The driving force in deep drilling.

Different degree of automation – Automation pyramid.

ERP

MES

SCADA HMI

PLC | PC | PID

Sensors | Actuators | Hardware

ERP - Enterprise Resource Planning MES - Manufacturing Execution System SCADA - Supervisory Control & Data Acquisition

Herrenknecht Vertical. The driving force in deep drilling.

Which degree of automation?

Combined potential savings of connection time and reduced LTIs

Herrenknecht Vertical. The driving force in deep drilling.

Which degree of automation?

Assumptions:

Average depth: 2500m

Roundtrips/well: 20

Saving / connection: 5s

Herrenknecht Vertical. The driving force in deep drilling.

Which degree of automation?

Manual Generation I Generation II Full Degree of automation <50% 75% 90% 98%

Potential savings

Recommended field Exploration Pad drilling Cluster drilling Well manufacturing

ROI Pad drilling - 6 7 8

ROI Cluster drilling - 5 5 7

ROI Well manufacturing - 4 4 5

ROI Jack-Up - 2 2 2

ROI Semi-Sub - 1 1 2

ROI Drill ship - 1 1 1

Herrenknecht Vertical. The driving force in deep drilling.

Challenges.

Machinery

Stabbing

Robot

Pipe storage

Rig floor access

Pipe handling equipment

Sensors

Fail safe / Feedback signal

Redundancy

Availability (HP Coriolis)

EX & Offshore

Tool joint indicator

Herrenknecht Vertical. The driving force in deep drilling.

Challenges.

Software

Step-In / Out procedures

Fall back options

Teach-In / Database

HMI

PLC

Fail safe

Safety PLC

Highly available

Hot-Standby

3rd Parties

Herrenknecht Vertical. The driving force in deep drilling.

Challenges.

Controls

Role model

Ergonomy

Vision

Communication

Network architecture

Bus system (Choice/Design)

Bandwith

Training

Simulator

Herrenknecht Vertical. The driving force in deep drilling.

Standardisation.

„Reduction of the complexity of the different types of drill string components or at least of the interfaces would tremendously boost the automation process.“

Automation Consultant

Well engineering has a big impact to how efficient the drilling automation process will be at the end.

Herrenknecht Vertical. The driving force in deep drilling.

Potential solution – Cantilever layout.

Top drive

Rig floor

Pipe storage

Mast

Skid system

Cantilever

Herrenknecht Vertical. The driving force in deep drilling.

Potential solution – Mast & Rig floor layout.

Top drive

Rotary table

Auxiliary crane

Cylinder hoist

Robot

Cherry picker

Unitong

Herrenknecht Vertical. The driving force in deep drilling.

Potential solution – Pipe storage layout (w/o safety fence).

Pipe Boxes (2 pc.)

Pipe feeder

Catwalk

Bucking unit

Pipe handler

Herrenknecht Vertical. The driving force in deep drilling.

Together we are building our future.