Herrenknecht Vertical. The driving force in deep drilling. Next Generation of Rig Automation.

Transcription

1 Herrenknecht Vertical. The driving force in deep drilling. Next Generation of Rig Automation. David Schwarzwälder, Sales Director, Herrenknecht Vertical GmbH. IADC World Drilling Rome,

2 AGENDA. Why automation? Different kind of automation processes on a drilling rig Which degree of automation? Challenges Standardisation Potential solution

3 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

4 Why Automation? Safety. Rig floor 34.45% Other 13.71% Forklift / Cherry picker / Crane 0.96% Fuel / Water storage tanks 0.24% Pontoon 0.48% Mud pump room 2.76% Pipe rack / Pipe deck 5.88% Catwalk / V-door 4.44% Derrick / Mast 5.76% Rig related risk reduction potential > 50% BOP stack, Well head/tree area 2.16% Mud mixing tank/area 2.16% 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%

5 Why Automation? Human Factor. Accident hazard as a function of shift duration Risk [z-value] Hänecke et al 1998 Folkard 1996 Akerstedt 1995 Nachreiner (Deadly 15h) source: Shift duration [h]

6 Why automation? Performance. Connection times on a mechanized drilling rig Slowest Fastest Potential savings per connection up to 40% source: GeoData log

7 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

8 Which degree of automation? Combined potential savings of connection time and reduced LTIs

9 Which degree of automation? Assumptions: Average depth: 2500m Roundtrips/well: 20 Saving / connection: 5s

10 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 ROI Cluster drilling ROI Well manufacturing ROI Jack-Up ROI Semi-Sub ROI Drill ship

11 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

12 Challenges. Software Step-In / Out procedures Fall back options Teach-In / Database HMI PLC Fail safe Safety PLC Highly available Hot-Standby 3rd Parties

13 Challenges. Controls Role model Ergonomy Vision Communication Network architecture Bus system (Choice/Design) Bandwith Training Simulator

14 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.

15 Potential solution Cantilever layout. Mast Top drive Rig floor Pipe storage Skid system Cantilever

16 Potential solution Mast & Rig floor layout. Cylinder hoist Top drive Cherry picker Unitong Rotary table Robot Auxiliary crane

17 Potential solution Pipe storage layout (w/o safety fence). Pipe handler Bucking unit Pipe feeder Pipe Boxes (2 pc.) Catwalk

18 Together we are building our future.