Bumper-to-bumper re-thinking creates a workover rig unlike any other.

Programmable logic control" and "workover rig" are not items often heard in the same sentence, or even in the same building, for that matter. But you had better get used to it. The traditional workover rig - essentially, a large, self-propelled power tool - has collided with the 21st century. The result? The New Technology Rig.
The most starkly visible merging of steel and silicon is the joystick - yes, joystick - control at the center of the crew chief console. Those who have served in a crew-chief capacity on a workover rig may find it hard to believe that the joystick provides video-game control refinement and touch, but it does. In fact, it takes very little time to get comfortable with the joystick operation. And the control system can do some impressive tricks, but more on that later.
First, let's take a tour.
Six years in design and construction, the New Technology Rig is a joint development effort between Nabors Well Services and the company now called National Oilwell Varco. It combines a variety of features to create a rig that is efficient, economical and durable.
Starting at the back, we see the Crew Chief Console and its joystick. There are no mechanical connections between the joystick and the rig. Everything is controlled through Programmable Logic Control (PLC) chips. These PLCs run custom software, and the PLCs and software make it possible to easily modify control characteristics. The system provides single-stick control of operations, improved rig performance and reduced operator fatigue.
Other features of the crew chief console include an easy-to-comprehend LCD screen that displays several key parameters not available for display in other well service rigs, including block speed and block height. An adjustable soft-stop crown and floor saver automatically slows and stops the block for greater safety and operational efficiency. This is an extremely useful feature that prevents collisions - and their consequences - between the block and wellhead.
Programmable controls enable "creep" control and weight-on-bit auto driller features, which allow the operator to move the blocks slowly under load. An adjustable speed control limits block speed to the chosen level when tripping in or out of the hole. "Dead-man" controls stop operations automatically when the joystick is released.
Although the digital control system is the star of the show, the rig has numerous other well thought-out features, large and small. Several changes were made to the crew chief floor to enhance safety and operational performance. The crew chief floor rises and falls with the work floor and is always the same height as the work floor, providing the operator with a better view of the work floor and greater access. Since they move simultaneously, no additional action is required to maintain the crew chief floor at the same height as the rig work floor. The crew chief floor also has less weight - the result of using composite material in place of bar grating. It also folds to protect the operator console during moves and stores easily.
The work floor is designed for safety and efficiency. It folds from vertical to horizontal and back by hydraulic cylinders. The traditional method used a wireline. This eliminates the need to climb on the work floor or the derrick to install the lifting gear. The work floor does not require support lines from the tubing board. This reduces obstructions in the work area, which contributes to a safer working environment. The rig also has air-powered flooring pinning, eliminating the need to climb on a suspended load to set pins. There is also reduced weight in the flooring that results from using lightweight composite material, an improvement over the old method that utilized corrugated metal grating.
Ladders and stairs are designed for maximum safety. Made of lightweight aluminum, they are easy to install and remove and substantially reduce the risks of slips and falls. Each has an integrated handrail as opposed to the traditional ladder. All removable stairs are adjustable to reach various heights while still maintaining the proper stair angle and tread position. Fixed steps are integrated into the carrier with a fold out bottom step to get to the first fixed step - a significant improvement over the footstools previously used.
The New Technology Rig is equipped with state-of-the-art disc brakes, which replace conventional band brakes. These brakes are air cooled, environmentally friendly and eliminate the need to store or transport cooling water to the location. The disc brakes are also designed to make inspection and change of pads quick and easy. The brakes are quieter and more reliable.
The New Technology Rig contains many other improvements:
• The engine and transmission are visible and accessible above the frame, making them easier to service. The engine and transmission are unitized for easy removal as a package.
• A central lubrication system allows grease to be applied to all major lubrication points on the rig from one easily accessible location.
• The drop cab provides better visibility for the operator when driving the carrier onto and off of well locations. It allows the driver to easily enter and exit the cab because it is closer to the ground.
• The hinged Y base allows easy access to tall pump jacks.
• When the New Technology Rig is used with a base beam, anchors are not required, eliminating all of the problems associated with their use. A smaller footprint is an additional benefit, with the New Technology Rig capable of working on a location as narrow as 40 ft (12 m). The base beam also provides a stable foundation and a hard base for rig jack screws.
• The handrails are collapsible, telescoping into the carrier frame for easy storage during transportation and eliminating hazards associated with unfolding the handrails that exist on other models. Since the handrails do not have to be removed, stored and then reinstalled on the carrier after moving, mobilization is faster and more efficient.
• The carrier walkways fold up and out of the way for storage during transport. They are also lightweight as a result of being constructed from composite material.
• The load guylines have durable crew tension adjustors that facilitate and enhance the tensioning of load lines.
• The derrick has a wide-base stance that provides better overall stability, especially when the rig is being raised or lowered before guylines have been set.
• The sandline drum is designed for quicker installation and removal since it is pinned with four pins versus multiple bolting on earlier sandline drum models.
As hinted at earlier, the New Technology Rig can do some impressive tricks. You wouldn't want to
try this one with a conventional rig, but performing it with the New Technology Rig could win you some wagers. Place a plastic cup on the work floor. Punch a few buttons on the control panel. Run the block all the way to the top. Run the block down as fast as you can, while talking to a co-worker, staring into space, or otherwise completely ignoring the process. If you pressed the right buttons, the block will stop by itself, a fraction of an inch from the top of the cup and leave it undamaged. Proceed to collect your wager and enjoy the looks of amazement on the faces of your audience.

Comments