Custom Nabors rig built for coiled-tubing MPD enables North Slope redevelopment project | Drilling Contractor

drillingcontractor.org /custom-nabors-rig-built-f or-coiled-tubing-mpd-enables-north-sloperedevelopment-project-4663 By Clyde Treybig, Drew Byers and Bob Mize, Nabors Alaska; Lamar Gantt; ConocoPhillips In 2003, ConocoPhillips Alaska initiated the Kuparuk Redevelopment Study on the North Slope to optimize patterns in the Kuparuk water f lood. More than 130 potential development opportunities f or coiled-tubing drilling (CT D) were identif ied in the f ield as a result of the study. One key element of the redevelopment plan was to use CT D technology to deliver lower-cost and higher-value development operations. CT D sidetracking operations involve the use of a continuous string of tubing that is spooled of f a reel into an existing wellbore to convey drilling tools and drill bits to the reservoir. One advantage is that drilling operations can be conducted through the existing well completion. T hese operations have been perf ormed on Kuparuk since 1998. However, they were only marginally successf ul until 2004, when technology that included a new generation of downhole directional-drilling tools was developed to enable CT D to deliver more economic sidetracks. T he program delivered promising results f rom 2004 to 2006, yet the redevelopment ef f ort was hampered by limited coiled-tubing rig availability. T he number of opportunities f or CT D drilling justif ied a dedicated CT D rig custom-built f or the Kuparuk f ield.

The c us to m-b uilt Nab o rs CDR2-AC rig c an d rill b o th c o nve ntio nally and with c o ile d tub ing . Ho we ve r, it was d e s ig ne d s p e c ific ally to o p timiz e c o ile d -tub ing d rilling MPD o p e ratio ns o n the No rth Slo p e s Kup aruk Fie ld .

In early 2007, ConocoPhillips collaborated with Nabors Alaska Drilling to design and construct a CT D rig that could address the requirements of the proposed Kuparuk program and accommodate the challenges of the Arctic environment. T he result of this collaboration was Nabors rig CDR2-AC, an Arctic coiled-tubing drilling rig capable of drilling either conventionally or with coiled tubing, and with a top-drive and mast conf iguration. T he rig was designed and built specif ically to optimize CT D managed pressure drilling (MPD) operations in the Kuparuk Field. MPD provides more precise control of wellbore pressure and theref ore improved saf ety, decreased costs and increased wellbore lengths. T he rig design was developed by Nabors Canada as an Arctic package that could better serve drilling

conditions on the North Slope. T he Arctic design allows all equipment, including the entire coiledtubing string, to maintain proper warmth and eliminate f reeze-up, and of course, protect all personnel f rom the harsh environment. T his is the f irst time in Alaska that a rig has been designed and built f rom the ground up, specif ically f or CT D operations. T he design enhancements that have been included are targeted to provide a saf er, more ef f icient drilling machine and will enable CT D to deliver lower-cost, higher-value results. T HE T ECHNOLOGY Rig CDR2-AC of f ers a twist on conventional CT D in the way the rig is powered. Nabors discontinued the use of hydraulic power in f avor of a proprietary AC electric drive system with a complete AC power distribution and control system. It has a variable f requency drive unit that provides continuous, variable AC power to the drilling and support machinery. T he system is powered by three motor/generator sets, as well as a utility package that allows the rig to operate on 13.8kV electrical power when available. T he rig is also equipped with an injector that has 100,000 lbs of pull capacity or 35,000 lbs of snubbing capacity. T he injector travels on the main structural rails of the rig f loor using an independent handling system f or the deployment of drilling tools and f or of f line maintenance and coil-cutting operations. T he injector-handling system of f ers 10 f t of vertical lif t f or mounting to the lubricator while maintaining the necessary coiled-tubing tension back to the reel. T he rig contains a coiled-tubing reel drive system f or a reel of 180 in. outside diameter and 96 in. overall width. It uses the Foremost plug-and-play design, allowing the shipping reel to be the working reel. T he rig substructure complex contains two complete pressure deployment lubricators capable of inserting 66 f t of BHA components. Other equipment include a Pacif ic Rim Commander 350, 400-hp, 150-ton drawworks and a 150-ton Foremost Model F-150T AC top drive that utilizes a f ixed torque guide in the mast. T he pipe shed includes an 8,000-lb capacity pipe-handler system that can handle tubulars with a 20-in. maximum diameter and 45-f t maximum length. T he pipe shed also contains a work space f or the maintenance and storage of the bottomhole assembly. Special tooling and work benches allow f or improved handling and maintenance of BHA tools, with reduced exposure to injury f or rig crews. T he mud complex contains approximately 600 bbl of active mud capacity and 900 bbl of storage mud capacity. Fluid pumping is handled Tho ug h ro ad s are fro z e n fo r mo s t o f the ye ar o n the No rth Slo p e s Kup aruk Fie ld , Nab o rs CDR2-AC rig was by two triplex mud pumps, along with a BOP test d e s ig ne d to minimiz e imp ac t o n the lo c al ro ad s ys te m, pump that can divert 10,000 psi service us ing ad vanc e d d e s ig n and lig hte r mate rials to ke e p o ve rall we ig ht d o wn. downhole if needed. A mud pallet lif t system accommodates outdoor placement of the mud pallet while providing lif ting capabilities inside the mud pit area to saf ely and ef f iciently transf er mud sacks to the hopper. Housed within the rig on top of the mud pit complex and adjacent to the rig f loor is the training/conf erence room, which provides a convenient location f or saf ety meetings, breaks and

change-outs. Of f ices were built f or company representatives, toolpushers/drillers and service providers. T his arrangement enhanced communications and enabled rig personnel to f unction as a coordinated rig team. A NEW LEVEL OF CONT ROL T he rig also gives the operator the ability to monitor and manage all major equipment, including drawworks, top drive, injector, coiled-tubing reel drive, managed pressure choke, mud pumps and mud pits f or independent and activity-based operations. T he control system includes a joystick f or operating the push and pull of the injector and the hoisting and lowering of the block. Operational controls and parameters, such as hook load, block height, speed and ROP, as well as status and alarms, are accessed via touch screens connected to the drilling control network. Features that help the driller optimize ef f iciency and saf ety include coiled-tubing tension set points (minimum and maximum), coiled-tubing stress analysis, pipe lif e management, managed pressure choke control, pump control, block position limits, block speed limits, drillers set points, over pull/snubbing limits, drilling/tripping process screens and pit volume, f low and valve control. Remote cameras are strategically located to provide continuous monitoring of key areas. T he electronic drilling control algorithms help drillers signif icantly reduce costs and improve saf ety. Up to f our parameters can be monitored or maintained simultaneously: WOB, ROP, drilling torque and Delta-P (dif f erential downhole motor pressure). T hese f eatures, when coupled with MPD, provide a consistent steady state at the bit, resulting in longer bit lif e, optimum bit perf ormance and enhanced wellbore stability. Directional drilling control is also improved. LIGHT ENING UP T he operating conditions, environmental stipulations and regulations in the Arctic also played a part in the design of the CDR2-AC. To minimize pad size, drilling pads on the North Slope are designed on a well row that can only be accessed f rom one side of the well. Consequently, rigs are cantilevered. In addition, Nabors wanted to reduce impact on the North Slope road system. T hough roads stay f rozen f or much of the year even in summer months, an excessively heavy rig can break through the road surf ace. Nabors targeted a goal of a maximum 1.2 million lbs f or each of the two modules, knowing it also had to be designed to work ef f iciently. Advanced design and lighter materials helped keep the weight down. Nabors achieved its design goals, constructed and delivered CDR2-AC to the North Slope, and spudded the f irst well within 20 months of contract approval. T he rig, which began drilling in May 2009, now has operated f or one summer season without incident. AIRLINE CHECKLIST When it came time to train employees to operate the new rig, Nabors Canada employees spent three months in Alaska providing crews with hands-on training. During the construction phase, new rig operating procedures were developed because of the complexity of the operations, compared with those on a rotary drilling rig. Once in operation, the new procedures were augmented with checklists that are essentially f low charts of each operation on the rig. T he charts walk the crew through all tasks on the rig step-bystep in real time, as opposed to simply giving a list of manual-style instructions. T he method is akin

to the checklist a pilot must go through when preparing to f ly a plane. It ensures the crew is completing every task and f orces conf irmation that each step has been completed bef ore the crew moves on to the next step. T his approach has led to the ef f icient and saf e operation that is required in MPD operations. T he rig leadership, crew and Anchorage-based team members have adopted A New Era of Operational Excellence as their motto to create a saf er, cleaner and more ef f icient drilling rig and operation. T he CT D teams have been committed to this operation, resulting in a successf ul start-up.