2003

1

Rig Repair

• Unscheduled Rig Repair

2003

2

Rig Repair

• An interruption in planned operations caused by a breakdown of the drilling rig equipment.

• Running the rig equipment to failure is not cost effective for the Drilling Contractor, Operator or Wellbore.

2003

3

Rig Repair

THE IMPACT OF UNSCHEDULED RIG REPAIR

The Drilling Contractor

• Financial penalties

• Cost of emergency repairs

• Possible personnel injury

• Extensive equipment damage

• Loss of future contracts

2003

4

Rig Repair

THE IMPACT OF UNSCHEDULED RIG REPAIR

The Wellbore

• A high risk of more unscheduled events

• Extended exposure time

• Loss of a hole section

• Loss of the well

2003

5

Rig Repair

THE IMPACT OF UNSCHEDULED RIG REPAIR

The Operator

• Increased well cost

• Delayed production

• Loss of production

2003

6

Rig Repair

PRIMARY DRILLING CONTRACTOR

AND

OPERATOR

OBJECTIVES

2003

7

Rig Repair

Drilling Contractor

• No personnel injury• No well control incident• Optimise equipment life• Minimise rig repair• Control equipment cost• Long term drilling

contract

Operator

• No personnel injury• No well control incident• Optimise drilling

operation• Minimise unscheduled

events• Control final well cost• Cost effective

performance

2003

8

Rig Repair

2003

9

Rig Repair

Preventive Maintenance Program (PMP)

• A program designed to schedule regular inspection, maintenance and/or repair of drilling equipment prior to failure.

• The historical life expectancy of rig equipment is based on the frequency of maintenance.

2003

10

Rig Repair

THE FOUR COMPONANTS OF A PREVENTIVE MAINTENANCE PROGRAMME

CLOSED LOOP

CREW FEEDBACK

RECORD KEEPING

AUDITING

Management to rig

Refining and tailoring of the

system

Equipment history

Through inspection

Rig to management

Equipment trends

Well designed checklists

Roles defined Equipment maintenance

Follow-up plans and reports

Clear guidelines

2003

11

Rig Repair

COMPREHENSIVE PMP EQUIPMENT LIST• MAIN ENGINES• GENERATORS/SCR SYSTEM• BOP & ACCUMULATOR CONTROL SYSTEM• HOIST EQUIPMENT• TOP DRIVE SYSTEM• ROTARY SYSTEM• HP MANIFOLD/VALVES/HOSES• HYDRAULIC OPERATING SYSTEM• RIG MOVE EQUIPMENT

2003

12

Rig Repair

TOP DRIVE

SYSTEM

2003

13

Rig Repair

COMPREHENSIVE PMP EQUIPMENT LIST• COMPRESSED AIR SYSTEM• CRANES• PIPE HANDLING SYSTEM• CIRCULATION SYSTEM• MUD PUMPS• BULK SYSTEM• MIXING SYSTEM• SOLIDS CONTROL SYSTEM• RIG COMPUTER SYSTEM

2003

14

Rig Repair

PMP FREQUENCY SCHEDULEHOURLY BI-MONTHLY EVERY TWO

YEARS

DAILY QUARTERLY EVERY THREE YEARS

WEEKLY EVERY FOUR MONTHS

EVERY FOUR YEARS

BI-WEEKLY SEMI-ANNUALLY

EVERY FIVE YEARS

MONTHLY ANNUALLY EVERY EIGHT YEARS

2003

15

Rig Repair

BENEFITS OF A SUCCESSFUL PMP PROGRAM• ENSURE EQUIPMENT LIFE EXPECTANCY• REDUCE DOWNTIME FOR UNSCHEDULED RIG

REPAIR• LOWER WELL COST• REDUCE SEVERITY OF DAMAGE TO EQUIPMENT• MAINTENANCE COST LESS THAN EMERGENCY

REPAIR• LESS CHANCE OF PERSONNEL INJURY• INCREASE IN DRILLING CONTRACTOR PROFITS

2003

16

Rig Repair

BENEFITS OF A SUCCESSFUL PMP PROGRAM

• REDUCED RISK OF STUCK-PIPE, WELL CONTROL OR OTHER UNSCHEDULED EVENTS

• COMPONENT FAILURE FREQUENCY RECORDS DEFINES RIG AND OFFICE SPARE PARTS INVENTORY

• INCREASE OPERATOR AWARENESS OF DRILLING CONTRACTOR NEEDS

• AN OPPURTUNITY FOR THE DRILLING CONTRACTOR TO INPUT AND HAVE INVOLVEMENT IN THE WELL PLANNING PROCESS

2003

17

Rig Repair

EVALUATE RIG REPAIR FAILURE SEVERITY

• WHO SHOULD BE NOTIFIED?

• WHAT IMMEDIATE ACTION IS REQUIRED?

• CAN NORMAL OPERATIONS CONTINUE?

• CAN PARTIAL OPERATIONS CONTINUE?

• IS OPERATIONAL SHUT-DOWN REQUIRED?

2003

18

Rig Repair

EVALUATE RIG REPAIR FAILURE SEVERITY

• ARE PERSONNEL OR THE RIG IN DANGER?• IS THE WELLBORE IN DANGER?• WHAT SAFETY PRECAUTIONS ARE

REQUIRED?• CAN THE FAILURE BE REPAIRED AT THE

RIG SITE?• WHAT IS THE PREVENTIVE ACTION PLAN?

2003

19

Rig Repair

DRILLING SYSTEM EMERGENCY BREAKDOWN PROCEDURES

IF RIG EUIPMENT FAILURE SHUTS-DOWN A MAJOR DRILLING SYSTEM, IMMEDIATE

ACTION MUST BE TAKEN TO PROTECT THE PERSONNEL, RIG, AND THE WELLBORE

FROM ASSOCIATED EVENTS

2003

20

Rig RepairDRILLING SYSTEM EMERGENCY BREAKDOWN PROCEDURES

DRILLING SYSTEM

BREAKDOWN

INITIAL RESULT SECONDARY RESULT

ACTION PLAN

POSITIONING 1. RIG MOVES OFF LOCATION

2. DRILLSTRING SHEARED-OFF

1. STUCK-PIPE

2. BOP DAMAGE

3. DRILLSTRING DAMAGE

4. SURFACE EQUIPMENT DAMAGE

1. STOP ROTARY & CIRCULATION

2. POSTION T.J. ABOVE HANG-OFF RAMS

3. CLOSE RAMS & HANG-OFF

4. INITIATE EMERGENCY PROCEDURES

2003

21

Rig Repair

DRILLING SYSTEM EMERGENCY BREAKDOWN PROCEDURES

DRILLING SYSTEM

BREAKDOWN

INITIAL RESULT

SECONDARY RESULT

ACTION PLAN

TOTAL LOSS OF POWER

1. LOSS OF HOISTING

2. LOSS OF CIRCULATION

3. LOSS OF ROTATION

1. STUCK-PIPE

2. WELL CONTROL

3. SURFACE EQUIPMENT DAMAGE AND/OR FAILURE

1. START EMERGENCY GENERATOR

2. CIRCULATE WITH THE CEMENT UNIT

3. MONITOR THE WELL FOR FLOW

2003

22

Rig Repair

DRILLING SYSTEM EMERGENCY BREAKDOWN PROCEDURES

DRILLING SYSTEM

BREAKDOWN

INITIAL RESULT

SECONDARY RESULT

ACTION PLAN

TOTAL DRILLING POWER

1. LOSS OF HOISTING

2. LOSS OF CIRCULATION

3. LOSS OF ROTARY

1. STUCK-PIPE

2. WELL CONTROL

1. START EMERGENCY GENERATOR

2. CIRCULATE WITH THE CEMENT UNIT

3. MONITOR THE WELL FOR FLOW

2003

23

Rig RepairDRILLING SYSTEM EMERGENCY BREAKDOWN

PROCEDURES

DRILLING SYSTEM

BREAKDOWN

INITIAL RESULT

SECONDARY RESULT

ACTION PLAN

TOP DRIVE SYSTEM

(TDS)

1. LOSS OF HOISTING

2. LOSS OF CIRCULATION

3. LOSS OF ROTARY

1. STUCK-PIPE

2. WELL CONTROL

1. TRIP TO THE SHOE FOR REPAIR

2. ROTATE THE PIPE IN THE SLIPS

3. RIG-UP TO CIRCULATE

4. MONITOR THE WELL FOR FLOW

2003

24

Rig Repair

DRILLING SYSTEM EMERGENCY BREAKDOWN PROCEDURES

DRILLING SYSTEM

BREAKDOWN

INITIAL RESULT

SECONDARY RESULT

ACTION PLAN

HOISTING SYSTEM

1. CANNOT RAISE DRILLSTRING

1. STUCK-PIPE 1. CONTINUE CIRCULATION AND ROTATION

2003

25

Rig Repair

DRILLING SYSTEM EMERGENCY BREAKDOWN PROCEDURES

DRILLING SYSTEM

BREAKDOWN

INITIAL RESULT

SECONDARY RESULT

ACTION PLAN

ROTARY SYSTEM

1. CANNOT ROTATE THE DRILLSTRING

1. STUCK-PIPE 1. RECIPROCATE THE DRILLSTRING

2. TRIP TO THE SHOE FOR REPAIR

3. MAINTAIN FULL CIRCULATION

2003

26

Rig RepairDRILLING SYSTEM EMERGENCY BREAKDOWN PROCEDURES

DRILLING SYSTEM

BREAKDOWN

INITIAL RESULT

SECONDARY RESULT

ACTION PLAN

CIRCULATNG SYSTEM

1. CANNOT CIRCULATE THE WELL

1. STUCK-PIPE

2. WELL CONTROL

1. TRIP TO THE SHOE FOR REPAIR

2. ROTATE AND RECIPROCATE THE DRILLSTRING IF REPAIRS ARE MADE IN OPEN HOLE

2003

27

Rig RepairDRILLING SYSTEM EMERGENCY BREAKDOWN

PROCEDURES

DRILLING SYSTEM

BREAKDOWN

INITIAL RESULT

SECONDARY RESULT

ACTION PLAN

WELL CONTROL SYSTEM

1. CANNOT SHUT-IN THE WELL ON A KICK

2. BLOWOUT

1. EQUIPMENT DAMAGE

2. PERSONNEL INJURY

3. LOSS OF THE WELL

4. ENVIRONMENTAL DAMAGE

1. NON – EMERGENCY, SECURE THE WELL TO MAKE REPAIRS

2. INITIATE EVACUALTION PROCEDURES

2003

28

TeamsDrilling Problems

2003

29

Rig Repair

INTEGRATED PREVENTIVE MAINTENANCE PROGRAMME (IPMP)

RIG EQUIPMENT MAINTENANCE LIST

1. SERVICE MAIN ENGINE 8. SERVICE CENT. PUMPS 15. SERVICE VECHILES 22.

2. SERVICE GENERATORS 9. 4,5,6 16. SERVICE CENT. PUMPS 23.

3. SERVICE AIR COMPRESSOR 10. SERVICE D/WORKS BRAKES 17. SERVICE FLOOR WINCHES 24.

4. SLIP/CUT DRILL LINE 11. SERVICE TDS 18. SERVICE WATER COOLER 25.

5. SERVICE CRANE 12. SERVICE DIVERTER 19. SERVICE PUMP MANIFOLD 26.

6. LIFTING EQUIPMENT INSPECT 13. SERVICE SOLIDS CONTROL 20. SERVICE ST/PIPE MANIFOLD 27.

7. SERVICE BOP ACCUMULATOR 14. CHANGE SWIVEL PACKING 21. TEST PUMP 28.

LEGEND

PLANNED MAINTENANCE

LOW RISK MAINTENANCE

HIGH RISK MAINTENANCE

SERVICE COMPANY MAINTENANCE LIST

CEMENT UNIT LOGGING UNIT MUD LOGGING UNIT

OTHER

1. SERVICE TRANS #1 6. SERVICE P/TANK VALVES

11. SERVICE ENGINE 16. SERVICE COMPUTER

2. SERVICE ENGINE #1 7. SERVICE PUMP #1 12. SERVICE TRANS 17. INSPECT SENSORS

3. SERVICE TRANS #2 8. 13. SERVICE OP. CHAIR 18. RESUPPLY UNIT

4. SERVICE ENGINE #2 9. 14. REPLACE WIRE REEL

19. SERVICE OP. CHAIR

5. SERVICE PUMP #1 10. 15. 20. SERVICE LIGHTING

2003

30

Rig Repair

SERVICE IPMP 4-5-6-10-12 #2 12 9-22-23 16 13

RIG IPMP 1-2-4-5-6-10-12-29 15 11

19 17-16-20 18 10

DAYS FROM SPUD 0-----5-----10-----15-----20-----25------30------35------40------45------50------55------60------65------70

WELL PLAN 26” HOLE 20” CASING

W.OC.

CASING----------DEPTH 17½” HOLE 13⅜” CASING

RUN CASING

30” 1284 FT W.O.C.

12¼” HOLE 9⅝” CASING

20” 2600 FT RUN CASING

W.O.C.

13⅜” 5080 FT 8½” HOLE 7” LINER

RUN CSG

9⅝” 12,250 FT WOC

7” 14,540 FT