1000 HP SCR DRILLING RIG

  1. ADVANTAGES OF THE SPLIT LEVEL (SL) TYPE DESIGN


  2. SPLIT LEVEL VS. OTHER DESIGNS
    1. SL vs. IRI 1000 and Flex Rig Designs
    2. SL vs. Box-on-Box Rig Designs
    3. SL vs. Trailerized Rig Designs

  3. SPECIFICATIONS
    1. General
    2. Mast
    3. Substructure
    4. Crown
    5. Traveling Block
    6. Swivel
    7. Rotary Table
    8. Drawworks
    9. Power System
    10. Mud Sytem
    11. Rig Pumps
    12. Stand Pipe
    13. Instrumentation
    14. Drill Pipe
    15. Rig Floor Equipment
    16. Well Head Control Equipment
    17. Rig Accessories
    18. Rig Buildings

  4. COMMENTARY

I.  ADVANTAGES OF THE SPLIT LEVEL (SL) TYPE DESIGN



A key feature of the Split Level Design is that the drawworks is down below, near ground level, vs. the on-floor drawworks self-elevating and box-on-box designs. Some relevant information and favorable comparisons to other designs are as follows:

  1. The best and most popular designs today are split level types. The last 100 or so rigs Helmerich and Payne built during the last 5 years are split level designs. Not self-elevating, not box-on-box. Another leading drilling contractor, Rowan Drilling, has been using split level rigs for 30 years and the new ones they are building are also split levels. All the leading manufacturers starting with National Oilwell Varco are building more split level types than other kinds. Very simply, the split level design is better than box-on-box or self-elevating types.


  2. The split level design has been in use for over 40 years. All drilling contractors of this time period used this design: Parker Drilling, Penrod, Loffland Brothers (now Nabors), Helmerich and Payne, Rowan Drilling, etc. These contractors continue to use and favor this design.


  3. During the last 10 years, the use of disc brakes have accelerated. This has had the effect of making split levels more popular. With disc brakes, the drawworks can be controlled from anywhre on the drill floor or doghouse by simple air or hydraulic control hoses. The driller can be sitting down on the doghouse and control the drawworks from any convenient place on the drill floor. In fact, all new offshore rigs - jack-ups, semis, drill ships have this type of set-up. The need to have the driller standing by the drawworks is no longer necessary.


  4. Because of the reason stated in item C, the split level design is now the most popular and command higher day rates


  5. Compare the Split Level Design to the Self-Elevating Drawworks Design:


    1. A drawworks elevating system with a platform, parallelogram legs and raising sheaves have to be fabricated. These will have to be assembled at the drill site, the drawworks installed at near ground level, and raised using raising lines, hydraulic winches, or cylinders. All these cost money and need to be maintained and/or replaced in later years. A "grasshopper" (articulating truss or cable tray) is needed to convey electric cables and power to the drawworks on the drill floor. These designs may also require that the driller ride the drawworks elevator from the ground to floor level, a practice that safety regulators in the United States will no longer tolerate. All these are unnecessary with the split level design.


    2. The split level design with easy to control disc brake feature is very popular in the United States today. Leading contractors have started to move these types of rigs to the Middle East and some to South America, resulting in higher day rates. it is only a matter of time before these designs become popular in other parts of the world.


    3. The safety issues, cost and required rig-up time mentioned makees the split level design superior to the on-floor self-elevating drawworks design.


    4. Also, please note that without the drawworks on the floor, the rig crew has a clear open space to work on. There is no big equipment to stay away from, go around, or go to the back or other side and obstruct the view. These are very good reasons as to why the drawworks ought to stay near ground level.


  6. There is nothing wrong with self-elevating or box-on-box designs. We appreciate that some operators prefer these types of rigs. All we want to do is present relevant split level style information, and provide the reasons why we believe, along with the leading drilling contractors and operators in the United States, that the split level design is superior.


    7.

II.  SL VS. OTHER RIG DESIGNS



  1. SL VS IRI 1000 AND FLEX RIG DESIGNS


    2. The Helmerich & Payne Proprietary "Flex Rig", IRI 1000-1500, and National (NOV) Designs are the most popular designes in existence today. The SL Design compares favorable with all three (3).

    1. The SL does not have very large hydraulic cylinders required to raise the mast. The mast is installed at near ground level and raised using conventional sling (raising) lines. There have been several hydraulic failures with the use of large cylinders, resulting in a dropping of the mast. The SL does not have that inherent risk.


    2. The IRI 1000, Flex Rig, and NOV ideal rig masts install on the drill floor. The mast has to climb to the drill floor using two (2) ramps on the driller's and off-driller's sides. Failures have been experienced on these ramps before. The SL does not have this inherent risk.


    3. The IRI 1000 and Flex Rigs assemble and telescope the mast near ground level on the drawworks side. The drawworks and the equipment behind the drawworks (pumps, tanks, etc.) cannot be rigged-up until the mast is installed on the drill floor.


    4. The SL does not have and does not need hydraulic cylinders to telescope the substructure to operating position.


    5. The SL is the most stable rig under erection and operating loads. The safety factors against overturning are higher than any of the other rig designs mentioned.




  2. SL VS BOX-ON-BOX RIG DESIGNS


    1. Box-on-Box type rigs are the longest to assemble at the drill site. These rigs require 20 truck loads to transport and about 250 pins and bolts to put together the many pieces. These 20 loads are as follows:


      2. MAST SUBSTRUCTURE
      1. Top Section with Crown
      2. Upper Mid Section
      3. Mid Section
      4. Lower Mid Section
      5. Bottom Section
      6. Mast A-Frame
      7. Racking Board
      8. Brace/Girts/Boom Kits
      9. Block-Hook, Equalizer, Mast Raising
        Lines, Misc.
      1. Lower Box, Driller's Side
      2. Lower Box, Off-Driller's Side
      3. Top Box, Driller's Side
      4. Top Box, Off-Driller's Side
      5. Setback
      6. Rotary Spreaders/Drawworks Spreaders/ Substructure Braces at Ground Level (note that each one has to be assembled piece by piece)
      7. Flooring Panels
      8. Drawworks
      9. Engine 1
      10. Engine 2
      11. Compound

      The hundreds of bolts and pins to install are usually all mixed together in a barrel that needs to be sorted on-site. Pins and bolts are lost and need to be replaced.

    2. The Box-on-Box rig requires a large crane with a long boom to assemble on site. The on-floor mast has to either climb a ramp or be lifted to the floor. The on-floor drawworks also requires a crane to install. The two (2) engines and compound also require a large crane to be put together.


    3. The SL design requires a significantly lesser number of loads.


    4. The SL drawworks is installed at near ground level and does not have to be lifted to the drill floor with big cranes and long booms.


    5. The SL takes less time to rig-up and rig-down.




  3. SL VS TRAILERIZED RIG DESIGNS


    4. Trailerized Rigs available in the 750 HP - 1500 HP market include IDECO-H44, IDECO 1000, Wilson 75, Cabot 900, Skytop TR 800, and several others.

    1. Trailerized Rigs have less allowable hook loads:


      1. IDECO H-1000: 358,000 lbs.
      2. Wilson 75: 368,000 lbs.
      3. Skytop TR 800: 410,000 lbs.

        The SL 1000 HP has a 500,000 lbs. Hook Load.


    2. Trailerized Rigs have doubles mast whereas the SL has trebles mast. There are 1/3 less connections to make.


    3. Trailer Rig Substructures are 15-16 ft. high whereas the SL substructure is 18 ft. high. Options for taller substructures are also available.


    4. Trailer Rigs use hydraulic cylinders to raise and extend/telescope the mast (sometimes wireline scoping is used using a hydraulic winch). The SL does not use hydraulic cylinders or hydraulic winches

III.  SPECIFICATIONS



  1. GENERAL


    1. Rig Power: 1250 HP GE-752 (or equal)


    2. Drilling Depth: 10,000 ft (3000 M) using 4-1/2" dia. drill pipe


    3. Drill Line: 1-1/8" dia., 6 x 19 1 WRC IPS


    4. Hook Load: 500,000 lbs.



  2. MAST


    1. One (1) New Mast, 131 ft. high with an API static hook load of 500,000 lbs. with ten (10) lines to the traveling block. Setback capacity is 250,000 lbs. Maximum wind velocity is 100 mph without setback and 84 mph with full setback.

      Racking capacity is 10,000 ft. with 4-1/2" drill pipe. Mast is designed for treble joint stands (93').

      Mast is complete with racking board, two (2) tong counter weight bucktes, two (2) catlines sheave units, and two (2) leveling jacks with hand pumps (including hoses and connections).



  3. SUBSTRUCTURE


    1. One (1) New Substructure, with 18 ft. floor height, 500,000 lbs. rotary (casing) load capacity simultaneous with a setback load of 250,000 lbs. (750,000 lbs. total combined load).

      The Substructure includes A-Frame Structures, Setback, Rotary Table Beams, Flooring, and Handrails.



  4. CROWN


    1. One (1) New Crown Block, with five (5) sheaves and one (1) fast line sheave. All sheaves furnished with two-row tapered roller bearings and grooved for 1-1/8" dia. wireline and mounted on crown frame.



  5. TRAVELING BLOCK


    1. One (1) Refurbished Traveling Block and Hook, with 265 short tons capacity on ten (10) lines. Traveling block has five (5) sheaves.



  6. SWIVEL


    1. One (1) Refurbished Swivel, with 300 short ton capacity.



  7. ROTARY TABLE


    1. One (1) Refurbished Rotary Table, 17-1/2"



  8. DRAWWORKS


    1. One (1) Refurbished Drawworks, rated at 1000 HP, with one (1) refurbished GE752 electric motor. Drawworks is grooved for 1-1/8" dia. wireline. Control console is located at driller's position including air controls, transmission shifting lever and brake levers. Electric control panel mounts at driller's location.


    2. One (1) New Disc Brakes, Witchita Model 7-337-310-115


    3. One (1) Brake Cooling System



  9. POWER SYSTEM


    1. One SCR/MCC System, complete with:


      • 4-Bay SCR DC Drive System.


      • Control Section for three (3) generator sets.


      • MCC and distribution panels, including sychronizing, logic and control, remote start/stop stations for auxiliary motors.


      • 600 V-480V dry Type Transformer.


      • 600 V-120/208V dry Type Transformer.


      • Plug board with plugs and receptacles.


      • Two (2) Air Conditioning Units.


      • Electrical system including all wiring connectors, lights, trays, J-boxes.


      • Rig floor located at Driller's console to accommodate all switches, gauges, and made of stainless steel suitable for Class 1, Div. 1 Area classification.


      • Foot Throttle


      • Enclosed Steel Building with stainless steel door on typical oilfield skid base.



    2. Three (3) Diesel Engine Generator Sets, Detroit Diesel 12V4000 1200 RPM, 60 hz.


    3. One (1) lot Electrical Distribution System, including all cables and suitcases to distribute power to equipment for the rig.



  10. MUD SYSTEM


    1. One (1) Mud System, 900 BBLS required.


    2. One (1) Shaker Tank, 400 BBLS capacity including sandtrap and a 10 ft. porch for two (2) 6 x 8 centrifugal pumps to power degasser, desander, and desilter.


    3. One (1) Suction Tank, 500 BBLS capacity.


    4. One (1) Water Tank, 400 BBLS capacity with two (2) 3 x 2 water transfer pumps.


    5. Mixing Unit

      1. Two (2) Mixing Hoppers, with table, venturi and jet nozzle.

        Mixing Hoppers are mounted above Mixing Tank


      2. Two (2) Centrifugal Pumps, 6 x 8 with 50 HP electric motors.

        Centrifugal Pumps are mounted below Mixing Hoppers at Mixing Tank.

    6. Mud System Accessories

      1. Two (2) Linear Motion Shale Shakers.


      2. One (1) Desander, with 3 cones x 12" dia.


      3. One (1) Desilter, with 12 cones x 4" dia.


      4. One (1) Mud Cleaner, with 8 cones x 4" dia.


      5. Eight (8) Agitators, with 15 HP explosion-proof motors, 50 hz, with one (1) for shaker tank and two (2) for each of the other tanks.


      6. One (1) lot Piping Distribution System, for all tanks, mud pumps, and drillfloor including:
        • Mud Lines
        • Water Lines
        • Gun Lines
        • Equalizer Lines (top and bottom) as needed


    7. One (1) Trip Tank, 100 BBLS capacity complete with heat exchanger, two (2) 3 x 2 mud transfer centrifugal pumps all mounted on the same oilfield type skid.


    8. One (1) Rig Parts Storage, for drilling equipment


    9. Four (4) Centrifugal Pumps, 6 x 8, 50 HP, 50 hz for desander and desilter, all mounted on Shaker Tank and the other two (2) are for mixing.



  11. RIG PUMPS


    1. Two (2) Triplex Mud Pumps, 1000 HP, rated at 5000 psi. Each pump with one (1) GE 752 motor.


    2. Two (2) Supercharging Pumps, 6 x 8



  12. STAND PIPE


    1. One (1) 4" Dia. Stand Pipe, rated at 5000 psi from mud lines to Stand Pipe manifold at drill floor.


    2. One (1) Stand Pipe Manifold, with five (5) 4" dia. gate valves and two (2) 2" dia. gate valves, Demco or equal.


    3. One (1) Jetting Line


    4. One (1) Fill Line

    5. Two (2) Rotary Hoses, rated at 5000 psi test pressure.



  13. INSTRUMENTATION


    1. Driller's Console, AOI Custom, Single Bay with:
      • Model 100 Weight Indicator
      • Electric Torque Indicator
      • Rotary RPM Indicator
      • Pump Pressure Gauge
      • Tong Line Pull Indicator
      • Down Time Valve
      • Pump Stroke Counter
      • Satellite Automatic Driller


    2. Driller's Control Console (DCC)
      • One (1) 12-Position Selector Switch
      • One (1) Drilling/Tripping
      • One (1) Drawworks Speed Selection
      • One (1) SCR/MP-1/MP-2, Drawworks/Rotary, TA Control Unit
      • One (1) Hydraulic Tong Controls
      • One (1) Emergency Brake Control


    3. Drilling Recorder
        One (1) ARG Series 5-Pen Recorder to record:
      • Hook Load
      • ROP
      • Rotary Torque
      • Pump Pressure
      • Rotary RPM
      • Totco Deviation Tool, 0-8 degrees



  14. DRILL PIPE


    1. 4-1/2" Drill Pipe, 10,000 ft.



  15. RIG FLOOR EQUIPMENT


    1. Slips
      1. Two (2) each Wooley XL type A for:
        1. 8" drill collars
        2. 6-1/4" drill collars
        3. 4-1/2" drillpipe

    2. Elevators
      1. Two (2) each Wooley 350 ton for 4-1/2" drillpipe

    3. Tongs
      1. Wooley Super B for:
        1. 8" drill collars
        2. 6-1/4" drill collars
        3. 4-1/2" drill collars

    4. Spinning Tongs
      1. JT Flour International Model SSW40

    5. Hydraulic Cathead
      1. Two (2) Hydraulic Cylinders with independent controls on driller's console

    6. Dog Collars/Safety Clamps
      1. One (1) 8-1/2" DC, type C collar clamp with wrench
      2. One (1) 6-1/4" DC

    7. TW Valve
      1. One (1) 4-1/2" XH pin x 4-1/2" XH box 6-1/2" OD

    8. Hydraulic Power Unit
      1. One (1) World Wide, 30 gpm, Hartmann PVX464-CKXXX-20FL pump w/ 20 hp model XWWE20-18-256TC, electric drive

    9. Air Hoists
      1. Two (2) Texas First Industrial JQHSB-50X12, for 5/8" line size

    10. Air Tuggers
      1. One (1) Ingersol Rand Model LS2-600R-PH6N 3/8" line

    11. Kelly Spinner, Air Drive, Reversible


    12. Lift Assist Assembly, including Geronimo Seat and Escape Slide


    13. Wire Line Unit
      1. One (1) Fire Star Rig & Supply, Model 097X15000 w/15,000 ft 0.092 wire


  16. WELL HEAD CONTROL EQUIPMENT


    1. Preventor

      1. One (1) Annular Type, 13-5/8", 5,000 psi, API, Shaffer


      2. One (1) Ram Type, 13-5/8" 5,000 psi, Cameron Type "U" Double


      3. One (1) Ram Type, 13-5/8" 5,000 psi, Cameron Type "U" Double


      4. One (1) ea. Ram Set: 13-3/8", 9-5/8", 7", 6-5/8"


      5. One (1) Set Blind Rams


      6. One (1) Adapter/Spacer spool, 13-5/8", 5,000 lbs.


      7. One (1) Set Risers and Bell Nipples


    2. Accumulator Unit and Control

      • One (1) Consolidated Pressure Control, 5S-2160-25 Manifold 5036, triplex pump, 220 gallon, 3,000 psi, 12-bottle, 300 gal reservoir w/ air pump and 25 HP driver.

    3. Choke Manifold
      • One (1) 5,000 psi, Cameron with SWACO Adjustable, 2-9/16" API
      • One (1) Remote Control Panel on rig floor


      • One (1) Gas Buster, OEM Poor Boy, 26"


      • One (1) ea. Float Valves: 7-5/8", 6-5/8", 4-1/2", and 3-1/2" connections


      • One (1) ea. IBOP Valve: 4-1/2" IF x 3-1/2" API



  17. RIG ACCESSORIES


    1. One (1) V-Door, with stair and set of walkways for drillfloor.


    2. Six (6) Pipe Racks

    3. Two (2) Heavy Duty Oxygen-Acetylene Units


    4. Four (4) Chain Block: 0.5 ton, 2 ton, 0.5 ton, 0.7 ton


    5. One (1) Lot 1" dia. Hose, rated at 150 psi, approximately 1000 ft (300 M) or twenty (20) hose reels with 50 ft. each for entire rig.



  18. RIG BUILDINGS


    1. One (1) Skid Mounted Rig Office, for Toolpusher or Engineer consisting of two (2) rooms with a small bath, swivel chairs, arm chairs, file cabinet, table, refrigerator, air conditioning unit, and space heater. Bedroom to be furnished with two (2) beds with blankets, air conditioning unit, space heater, table and chairs.


    2. One (1) Skid Mounted House, divided into two (2) separate rooms, each room furnished with two (2) armchairs, small cabinet, table, bed set with blanket. Air conditioning unit, space heater, and refrigerator to be provided.

IV.  COMMENTARY



  1. These rigs are SRC Electric, not mechanically powered.


  2. These are Split Level Type; The drawworks is located near ground level and does not need to be lifted to drill floor level (e.g. box-on-box type).


  3. The drawworks has both band brakes and brand new disc brakes. Disc brakes are easily controlled at floor level.


  4. The Mast has beam legs (not angle iron, which requires a lot of fan bracing resulting in inside crowding and restricted visibility and clearance for traveling block, top service loops catlines, tong lines). Beam legged masts have better resistance and are less susceptible to damage when trucking or handling during rig moves.


  5. New SCR Unit


  6. One (1) New Brake Reserve/Tank


  7. One (1) New Suction Tank


  8. One (1) New Shaker Tank


  9. Mud Processing Equipment: New Desander, New Desilter, New Agitators, and two (2) Refurbished Shale Shakers.


  10. Three (3) New Engines, 1200 RPM (Not 1800 or 2200 RPM) with new generators (completely new power package.


  11. New Air Compressors.


  12. New Dog House


  13. New Change House


  14. New Fuel Tank


  15. New Water Tank


  16. New Drill Pipe


  17. New Toolpusher's House


  18. New Crew Sleeper Unit


  19. New Drill Line


  20. New Air Powered Drill Line Spooler


  21. New Dead Line Anchor


  22. New Mast Raising (Lift) Lines


  23. New V-Door


  24. Two (2) New Catwalks


  25. Eight (8) New Piperacks


  26. Two (2) New Hoppers