Development of a highly automated mobile rig for the Australian CSG market

Abstract

In Q2 2020, a fully automated rig will enter the coal seam gas fields of Queensland, to work for a major operator. It is expected to be 20–30% faster than current operations. This document describes the upfront iterative design process with local potential users. Following discussions with various contractors and operators it became evident that there was a gap to bridge between operator and contractor targets and in what current operations have to offer. Both strive for the highest safety levels and operational efficiency, reducing the overall time per well, completed by minimising environmental impact. The above fits in the overall industry trend of transformation from mechanised rigs towards fully automated hands-free operated rigs. It was with these ingredients that the basis of a new iterative design process was formed, in which input from the operator field lieutenants, contractor rig crews and the supporting office was translated into a technical design. The target was set to reduce 20–30% of time per well. Key elements were the choice for road legal trailerised loads with no loose items, which resulted in rig moves of 4–6 h. Fully automated sequenced pipe tripping and casing running contributed to big improvements in efficiency and safety level (no people on the floor during standard operations). Performance can be real-time evaluated and optimised by collecting all rig and downhole data on the OPC server. The server also controls the mud system, downhole data and other important systems. This enables through-life time optimisation.