Offline Tubular Management System Improves Efficiencies of Total Well Time by More Than 10%

Abstract

The oil and gas sector has redefined the way it conducts business in one of the most transformative periods in its history. Since 2014, the industry has adjusted to low oil prices by reducing expenditures and cutting drilling costs. A focus on completing wells with the utmost efficiency and avoiding expensive rig day rates has helped to manage during these hard times.

Addressing nonproductive time (NPT) and invisible lost time (ILT) creates opportunities to reduce the time to complete the well. Although this strategy offers time savings, the results vary across all operations. In another strategy, operators target flat time to improve overall efficiency. Eliminating non-essential operations directly impacts the flat time; however, operators have not made significant efforts to reduce flat time during essential operations.

Running tubulars contributes to a large portion of the total flat time, and technology can optimize operations to reduce this time. The ability to make up connections offline and reduce the amount of connections on the rig floor positively contributes to completing wells in a shorter timeframe. Operators have implemented the practice of offline stand building in global offshore operations, which has decreased drill floor activity and the associated risks.

In typical onshore operations, each tubular is delivered from the horizontal position to a vertical running position, made up to the string, and run in the hole. Because each tubular is handled one at a time, the time to run all of them adds up to significant flat time. Adopting offline stand building technology definitely increases efficiency and enhances safety in onshore operations.

This paper presents the details of a tubular management system (TMS) deployed in the UAE. The stand-alone, fully mechanized, hands-free pipe system made up drillpipe, casing, tubular stands and assemblies. Analyzing the process and results both before and after installation of the TMS reinforces the improved efficiencies by building stands offline at the onshore rig site. The results display improved efficiencies of the total well time by more than 10%, therefore highlighting the reduced time on the well path, removing operations and manual handling from the drill floor along with the potential for injury and associated NPT.

An essential part of the TMS, the coupling application machine (CAM) delivers rotational makeup and breakout of tubular joints. A torque process control system analyzes and evaluates the data from the connections. An individual technician drives the entire offline stand-building process from a control cabin. The technician uses a mechanized pipe lift to lift single tubulars from pre-loaded preparation racks and to position them onto pipe conveyors. These conveyors then feed the individual tubulars directly through the CAM unit to prepare the joint for connection. The same process mechanically positions an additional tubular to complete the preparation for the connection. The CAM unit then completes the connection by making it up to the desired preset torque. The technician either repeats the process for triples, or the stand is fed directly out onto the pipe conveyor on the opposite side of the preparation racks. The technician uses a mechanized pipes lift to lift the completed stand from the pipe conveyor and position it onto the adjustable discharge racks until ready for the hydraulic catwalk.