Fast-paced pad drilling, longer laterals and the move into increasingly complex reservoirs and harsh frontiers have challenged the oil and gas industry to take rig operations to a new level and have raised the bar for safety, efficiency and well integrity. Pipehandling, arguably one of the most dangerous and labor-intensive activities on the rig, has undergone a significant shift in the past decade, with varying degrees of automation replacing manual handling to provide a safer, more streamlined process for mechanically lifting, racking and tripping drillpipe stands and collars.

The approach is designed to take workers out of harm’s way to reduce the potential for injury and lost-time incidents (LTI). A system that can perform in extremely cold, harsh environments is especially important as producers move into regions such as the Arctic, where the effects of extremely cold temperatures can inhibit productivity and lead to worker fatigue and mistakes.

In a move to boost safety and improve efficiency, two operators successfully implemented a semiautomated pipehandling system on rigs in British Columbia, Canada, where temperatures can drop as low as -30 C (-22 F).

Weatherford’s latest-generation Iron Derrickman S-3 Pipe-Handling System uses industrial robotics to move pipe from the well center to the racking board by lifting and racking triple stands of pipe, heavyweight collars and drillcollars with programmed sequential movements.

The Arctic-rated system transforms what traditionally has been a manual activity, where a crewmember on the drill floor pushes a stand of pipe to a derrick worker on the racking board for placement into the slots. This conventional approach involves the use of a platform positioned halfway up the derrick, with a monkeyboard where the derrickman works, and several steel fingers with slots in between to hold the drillpipe in place.

The semiautomated system eliminates manual handling of pipe to provide a consistent, reliable and safe operation remotely controlled from the driller’s cabin or the rig floor by a single driller. The system can be installed with minimal modifications on double and triple land rigs, defined by two or three joints per stand of pipe in the derrick.

Datalogging software
In 2014 Weatherford enhanced the semiautomated pipehandling system with datalogging software, adding the capability to remotely monitor the tool at all times, detect any deviation from proper operation, improve trip times in the event of slowdown and track sensor and valve performance.

Unlike other automated pipehandling solutions that push pipe into the slot, the Iron Derrickman system actually picks up pipe and moves it into the slot, preventing the pipe from swinging when the entire stand is lifted into the box. This eliminates the need for a derrick hand to stand on the high-risk racking board during pipe tripping and racking to manually stop the pipe from swinging or banging on the drill floor.

The compact system can be installed on most rig types, including jackups, platforms and barges, but it is especially suited to today’s land rigs, which are smaller and designed to move quickly on multiwell pads for consistent, repetitive drilling operations. Because all pipehandling is done on the racking board, the Iron Derrickman unit does not intrude on the rig floor.

Pipe can be tripped at speeds equal to the highest-performing manual operations while eliminating the risks of human factors that can compromise safety and slow the process. The system can rack up to 45 stands per hour and, when paired with an offline system, can build stands away from the critical path without interrupting drilling operations.

The system maintains consistent tripping speeds in temperatures as low as -35 C (-31 F) and as high as 50 C (122 F) and in high-wind environments, enabling pipehandling operations to continue uninterrupted.

The system enhances well integrity, extending well life by providing better control during loading, racking, moving and stabbing. This control protects the drillstring from pipe damage caused by swinging pipe, accidental pin-stump contact and misalignment, and it protects the drillpipe threads from excessive wear and tear.

The new datalogging feature of the Iron Derrickman enables continuous monitoring of input, functionality, operator error, faults and trip times. This allows performance tracking and quick diagnosing and remediating of any issues that may occur as well as signal a need for preventative maintenance. (Source: Weatherford)

Pushing for safety, efficiency
Safety was the primary motivator for two operators to install the semiautomated pipehandling system on two 3,000-hp rigs in British Columbia’s South Ft. Liard gas field in late 2014. The modern rigs operating on pads were drilling horizontal wells that in some cases extended 6,096 m (20,000 ft) and therefore require a full pipe rack.

Both operators wanted to deploy rigs with the most advanced technology and maintain strong safety records by moving the derrick hand from the racking board to a safer zone on the rig. They also wanted to mitigate the risk of HSE incidents by eliminating “hands-on pipe” during the tripping process in the harsh climate conditions and to establish consistent trip times using safe pipehandling procedures.

Since the semiautomated pipehandling system was installed on each of the two rigs and began operating in January and February 2015, they have achieved similar trip times to conventional tripping methods at consistent rates, even in periods of extremely low temperatures.

Monitoring during operations
The installations incorporate the new datalogging feature to continually monitor input, axial positions while the semiautomated pipehandling system is functioning, operator error and faults generated within the system. On one rig, the datalogs indicated the crew was tripping one stand every two to three minutes just two months after the new system was introduced. The datalogs also have been useful in diagnosing and remediating intermittent issues caused by interference on the rig. In one case it was determined that a tool issue was the result of improper sequencing of an operation.

Trip times at each stage of the trip-in/trip-out process also are being monitored. More specifically, the datalogs files can show which sections of the trip are taking longer than others. The capability to compare newer datalogs with older logs reveals if a specific valve is driving or working harder than previously, which could signal a need for preventative maintenance.

Incorporation of the automated pipehandling system on the rigs also has resulted in a calmer, safer and quieter environment on the rig floor, with less crashing and smoother transfer of pipe between the fingers and the top drive. This has resulted in a dramatic decrease in LTIs during the tripping process. Since switching to the semiautomated pipehandling process, there have been no injuries or safety incidents. Both operators have reported stronger camaraderie on the rigs because of the more technologically advanced and comfortable working environment.

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