Technology Roundtable: Top Drives

1. Through 2018 we have seen an ever increasing demand for Top Drives throughout the Russian Federation. What do you feel are the key factors which have driven top drive adoption in the region over the last few years?

National Oilwell Varco: Increase of directional drilling, increase of safety requirements during oil and gas well construction, drilling time reduction requirements

NorDrill: We believe there are several key factors involved in the increasing demand for Top Drives in the region. Among the most important are the renewal and upgrade of the drilling fleet, increased complexity of the wells tbeing drilled, especially with regards to directional and horizontal wells and a demand for higher drilling efficiency. The safety and HSEQ focus are also an important factor, as a Top Drive allows the drilling contractors to remove personnel from potential danger on the drill floor. In addition, we believe the domestic companies producing Top Drives, showcasing the need for it, setting a trend, and providing competition to the foreign players, forcing all producers to lower margins and price their equipment’s more reasonably, plays a major role in the increasing demand.

Drillmec: In Russia, Kazakhstan and other CIS countries, the value of operation with top drives is increasing every year. Realizing that, the operators are including the requirement to drill with top drives in an increasing amount of drilling projects.

There are many reasons and advantages in using a Top Drive. First of all, a top drive can drill, without interruption, a section 60 to 90 foot long (18–27 m) whereas a rotary table can drill 30-foot (9.1 m) sections of drill pipe.

Top Drives also present an increase of equipment life time, due to the better working conditions (compared to a Rotary Table) especially regarding cooling and lubrication of moving parts. This also means a reduction in operating costs.

Finally, Top Drives guarantee more safety because when drilling using rotary table, drilling crew have to operate elevators manually during drilling operations, which normally increases chances of accidents in the rig floor.

However, when drilling using Top Drive, the automatic driller operated pipe elevators eliminate accidents caused by drilling crews. Top Drives also increase safety of the rig equipment by reducing BOP wear and allowing the BOP/rotating head to pack off against round tubular.

Global Drilling Support: The increased demand for top drive systems in the Russian Federation is due to the increasing requirements for drilling programs and the increasing complexity of well profiles, HSE requirements at the drill site, and the desire to reduce the time and cost of well construction.

2. Russia’s rig fleet is comparatively old considering Russia’s leading position as one of the world’s leading hydrocarbon suppliers. What challenges does this older fleet present when upgrading to top drive systems and what solutions do you have to combat these challenges?

National Oilwell Varco: Necessity of outdated drilling controls upgrade, transition to VFD drives. NOV is ready to offer package solutions for transition to top drive systems, including complete drilling rig equipment controls upgrade.

NorDrill: The main challenges posed by the comparatively old rig fleet, with regards to retrofitting or upgrading to Top Drives are interface issues are structural uncertainties and missing or outdated drawings and models of the derrick structure. These challenges can pose great difficulties when considering upgrading or retrofitting a Top Drive to an existing rig, especially if the remoteness of the rig suggest that accurate surveys might be unobtainable.

NorDrill offers several solutions on how to integrate a new Top Drive into an existing rig. First and foremost, NorDrill provides Top Drive Systems that are comparatively compact, and physically small in size, which is an advantage when retrofitting to older structures. In addition, we offer our Torque Arrest System, to be integrated into an existing rig. This relocates the interface point between NorDrill and the customer to a strictly mechanical, non-moving interface, as NorDrill integrates the Torque Arrest System into the client’s derrick structure.

Drillmec: There are many challenges in renewing old rigs and updating them with Top Drives, but these challenges are necessary to be technologically up to date and allows Russian oil companies to compete worldwide.

There will be the necessity to invest, to have a new approach and organization to the oil & gas. In fact, now it is important also to consider the operating costs and not only the purchase price. Doing so, during the life time of the rig there will be more return on your investment.

In order to overcome these difficulties, many ancillary actions can be taken but the most important is to train employees. In fact, well trained workers will be able to take full advantage of the new technologies, and that will allow the company to increase productivity and earnings.

Global Drilling Support: GDS has been specializing in working with top drives for over 10 years. The team of technical specialists is highly qualified and experienced in adapting top drive systems to different types of drilling rigs, not only in Russia, but throughout the world. Thus, we see no problem, if a customer wishes to upgrade a drilling rig to use a top drive system.  You should not also forget about the need to upgrade the a TDS itself, for example, our company offers an upgrade of the Varco TDS 11 system (torque increase from 50 kNm to 73 kNm and other modern technical solutions).

However, it is worth noting that, if a drilling rig needs to be upgraded, the GDS innovation portfolio does not stop at the offer of a top drive system installation. We also carry out modernization of drilling rigs by installing Z-Torque systems-preventing tool stick-slip downhole and Friction Reduction tool orientation systems allowing  the tool rotation to be continued while sliding, thereby increasing the speed of penetration.

3. How does the top drive improve drilling efficiency for Russia’s drillers within horizontal and deviated wells?

National Oilwell Varco: Main TDS benefits are:

1. Reduced stuck tool possibility;

2. Back reaming while tripping in and out of hole;

3. More accurate directional drilling;

4. Increased drilling crew operation safety;

5. Additional built-in IBOP for additional safety;

6. More efficient casing running operation due to rotation and circulation;

7. Reduced connection time.

NorDrill: The Top Drive allows the rig to drill deeper, and with more precision. With a Top Drive, it is easier to precisely steer the drill string, when using directional tools to drill horizontal wells, because of the ability to rotate the drill string incrementally and measurably, allowing the driller better control of the directional tool face.

Drillmec: Top drives are also preferable for challenging extended-reach and directional wells. If wellbore stability allows, connections can be made in the background during directional drilling, eliminating the need to re-orient the directional tool face after each new connection.

Global Drilling Support: The top drive system allows you to carry out the process of drilling oil and gas wells with more precise control of torque and speed of rotation of the drilling tool, as well as reducing the time during making a connection and RIH/POOH.

4. What challenges does the regions extreme weather conditions pose for a top drive and how are these resolved?

National Oilwell Varco: In regions with extremely low temperatures, there could be difficulties with the initial start-up of the drive (after installation, technological stops). This problem is solved by using air heaters, as well as lubricants for extremely low temperatures.

NorDrill: The temperatures and extreme weather conditions pose certain challenges indeed. Hydraulic oil viscosity, wear and tear on components, difficulty doing maintenance and changing parts, ice build-up and wind are some of the many challenges faced by drilling companies working in this region.

As for NorDrill’s Top Drive System, it was developed by engineers and drillers used to working offshore on the Norwegian Continental Shelf (NCS), meaning a lot of the choices made with regards to design, like durable components, redundancy, remote monitoring, onboard HPU, heating measures and so on, is based on enduring the conditions faced offshore on the Norwegian Continental Shelf. Many of the same challenges met on the Norwegian Continental Shelf, are likely to be met working in, for example, Eastern Siberia, with regards to weather conditions and temperature. We therefore believe that our design philosophy and familiarity with extreme conditions, allows our Top Drives to be well equipped to face such conditions, offshore as well as onshore.

Drillmec: Extreme arctic climates are certainly very challenging not only for the workforce but also for machinery. In order to avoid any kind of problems, Top Drives for arctic climate use a suitable steel that maintain its strength and mechanical properties even at very low temperatures (up to -45°). In addition, electric cables are thermally insulated to prevent any malfunction and all the lubricant needed are suitable for low temperature so that they will anyhow guarantee the correct viscosity to flow around mechanical parts.

Global Drilling Support: The main problem that arises during the TDA operation in areas with low temperature conditions is non-specialized hydraulic fluids used in the hydraulic system of top drive assemblies. The solution to this problem is strict compliance with the recommendations of the equipment manufacturer, as well as the timely preparation of measures for the operation of equipment in the winter period.

5. Do you have a Top Drive you could call a regional ‘Best Seller’? If so, why is this particular model a popular choice for your regional clients? What are the key design features and advantages of this system?

National Oilwell Varco: Yes, this is the TDS-11SA system. This model has established itself as an effective, reliable and durable mechanism. The recent upgrade to TDS-11HD model with increased torque allows to satisfy the needs of a wider range of Customers.

The main advantage of the TDS-11SA / HD systems is the design that has been proven over the years of operation, simplicity and ease of maintenance, reliable elements: electric motors, gearbox, electrical and hydraulic systems components, metal structures.

NorDrill: NorDrill deliver Top Drives in the range between 160 short tons and 650 short tons rated hook load (both electrical and hydraulic driven), meaning we can serve the majority of the existing rigs in the region. So far, our most popular model has been the ND500AC machine. At 500 short tons capacity and electrically driven, we believe this will continue to be the “best seller” in this region, based on the technical specifications, durability in rough conditions and the demand for increasingly higher rig capacity. The small size and light weight of the ND500AC, compared to its high torque/rpm output means it will be suitable for the full range of heavy-duty drilling rigs currently operating in this region.

Drillmec: HTD250 CR is the most preferred Top Drive in Russia, due to its reliability and the adaptability to most kind of mobile rig actually on the market.

It features a Compact Power Swivel, driven by one top-head hollow shaft dual hydraulic motor, suitable to perform up to 36.000 Nm top drive torque and a maximum shaft speed of 180 RPM.

Top Drive’s guide beam sections will be pinned together and fixed on the upper section with guy-lines and the bottom section will be pinned with reaction beam.

A Control panel is included, which is suitable to manage all the parameters for Top Drive operations (Torque control, speed control, engine management, hydraulic circuits and so on), and is complete with hoses and connection for installation.

With all these characteristics, combined with the necessary (but not difficult to implement) modification to resist arctic temperatures, Drillmec hydraulic Top Drive HTD250 is by far the most requested in the Russian market.

The market is currently moving towards Electrical Top drives and Drillmec has already delivered several to the  FSU, with the most common requested models being 250 to 350 ton, but we also delivered 500 and 750 ton. Advantages mentioned above for Hydraulics model are the same for the electrical ones.

Global Drilling Support: Today, in the Russian Federation, our company is concentrating on the supply of spare parts and overhauls of TDAs made by third parties.  However, it is worth noting that the line of our GDM top drive systems with carrying capacities ranging from 275 tons to 850 tons successfully work in the CIS countries and many other countries of the world (including on drilling platforms in the regions of Africa, South and North America).

The advantages of our TDSs are an increased torque (for example: compact models with a carrying capacity of 375 tons have a torque of 56.9 kNm, and larger models with a carrying capacity of 500 tons have a torque of up to 103 kNm), an HMI, which allows to display the control modes, TDS condition diagnosis, accident recording, and troubleshooting.  The GDS-manufactured TDS is also equipped with a default black box, an anti-collision control system, and a pipe handler position memory system, which facilitates the work of personnel during RIH/POOH.

6. When purchasing a Top Drive the customer has to consider not only the purchase cost but also maintenance and servicing costs. How does your system reduce the total cost of ownership for the customer?

National Oilwell Varco: Due to its reliability and simplicity in work, as well as extended service intervals.

NorDrill: As a consequence of our design philosophy stemming from offshore drilling on the Norwegian Continental Shelf, as referred to earlier, maintenance and serviceability has been an integral part of our Top Drives. Maintenance and service done in remote and hard to reach areas in this region, bears many resemblances to the challenges of maintaining and servicing equipment offshore. We’ve therefore opted to be relentless when it comes to the quality response time and safety factors of critical parts, incorporated a modular design aimed at easing access to replaceable parts and ensuring efficient repairs and have sensors continuously monitoring operation to log trends and anticipate errors. In addition, we offer our Remote Access System, which allows NorDrill’s service personnel, or the client’s own personnel, to access the machine from the office anywhere in the world, through internet access, enabling problems and errors to be fixed without having to spend huge amounts of time and money sending service personnel to hard to reach locations.

Drillmec: Top Drives allow to reduce costs in many ways.

The first one is time efficiency: in fact, when the bit progresses under a kelly drive, there is no need for the swivel because the top drive performs all the necessary actions unlike Rotary Tables. Also, the possibility to move the drill string 90 foot instead of 30 foot will make operations much faster.

Top drives are able to rotate the pipe while tripping pipe into/out of the hole, which helps reduce problems associated with stuck pipe, which is one of the most significant causes of loss of rig time.

Furthermore, Top drives typically decrease the frequency of stuck pipe, which contributes to cost savings because of energy saving.

Finally, the increased safety means economic gain: in fact, beyond the crew safety, every accident means stopping all the operation with a resulting big loss in profits.

Global Drilling Support: The development and design of GDM top-drive systems was based on the need to produce strong and durable equipment with a large safety margin. In the practice of manufacturing and supplying GDM brand TDss, there are examples of equipment operations for more than 7 years in the extreme operating conditions on drilling platforms without a non-productive time. Also on GDM top drives there is a number of consumables similar to the ones used on other top drives brands, which allows the operating organization to service the TDS fleet without the need to create a separate spare parts warehouse for our brand of equipment.

7. What level of after sales support do you offer to your customers?

National Oilwell Varco: NOV customer service is available 24/7. Our service engineers are ready to provide both consulting assistance and perform the necessary repairs and maintenance upon the first request of the Customer.

NorDrill: NorDrill’s service department is available 24/7, worldwide. However, when discussing drilling operations in remote areas, it is very important to make thorough preparations and keep more spare parts on hand. NorDrill offers different levels of spare parts packages, all dependent on the customers needs and intended drilling location. We are also open to tailor-made spare parts solutions, for example having a spare parts storage in the closest relevant town or city.

Our strategic philosophy is to always have a local partner company, which can be called out on short notice for service, and that also carries a supply of the most relevant spare parts, in an effort to eliminate rig down time. We’re currently in conversations with potential partner companies in the region.

Drillmec: After sales is very important, in fact a complete 24 hours service is guaranteed. It is based on various level, depending on the seriousness of the problem.

It can vary from telephonic/informatics remote assistance, to on-rig-assistance operated by well qualified staff that will find and solve problems as fast as possible.

A very detailed list of spare parts will help the staff to bring all the items needed to operate the repair.

Thanks to more than a decade partnership with Russian partner “Piper Services”, Drillmec can offer a complete and reliable aftersales support which include 24/7 assistance, more than 20 field engineers based in Russia, No language barrier, all of them trained in Italy and can perform commissioning, rig up, test, assistance while drilling and maintenance. Several warehouses are present in West Siberia and Astrakhan region where Drillmec Top Drives are working in order to deliver spare parts in shortest time possible.

In west Siberia we also have a facility for capital repair, overhaul and test of Top Drives and other drilling equipment.

Global Drilling Support: GDS Service Company, LLC, being a GDS International representative office in the Eastern Hemisphere, has been operating in the Russian Federation, namely in the city of Tyumen, since 2013. In addition to the production of GDM brand TDSs, our company also specializes in overhauls, service maintenance and supply of spare parts for top drive systems produced by third parties.  We are importing all the supplied spare parts, tools and accessories from North America. In most cases, to respond faster to service needs of the customer the supply of spare parts carried out by air. Today, the business footprint of our unit covers projects in the Russian Federation, Georgia, Uzbekistan, Kazakhstan, and Ukraine.

8. What training do you offer either in top drive maintenance or operational use?

National Oilwell Varco: The company has training courses for all of the top drive systems, manufactured by NOV. The Customer can independently choose the course of interest on the site and book it at a convenient time.

NorDrill: As a standard, NorDrill offers personnel to assist with commissioning, training and startup of the machine, included in our quotes. This stay can be extended, based on the customers needs and level of experience. NorDrill also offers training courses online, at our location, or on site. The training course topic is dependent on the customer but is usually directly related to operation and maintenance of the Top Drive and Power Pack. Topics like Safety, Rig up/Rig down, E&I and Hydraulics can be added to the standard training courses, if needed.

Drillmec: The training is vital for safe operations and getting maximum value from our TD performance. In drillmec portfolio we have either classroom training or field training. Classroom training includes all the topics related with the top drive, maintenance and operation. Thanks to drillmec simulator our trainee can learn how to operate top drives and complete drilling rigs. Our main training center is situate in Piacenza, but we also have a Training center in Aksai close to the border with Russia which could be more convenient for our Russian clients. Usually the trainings are performed during Top Drive production so that trainee while having classroom training can also assist to Top drive production and test. Regarding field training, our technicians perform the first rig up in the field and client can assist, our technical staff are skilled also to instruct our clients while carring out such operations. Additionally we are available to provide field engineers to assist while drilling the first well. Through our partner we also offer  client maintenance or assistance contracts which guarantee the constant support of dedicated technicians.

Global Drilling Support: GDS offers various training programs for the maintenance and operation of TDSs.  When it comes to training programs for any models of TDSs, our training programs are divided into both theoretical and practical modules, during which the technical staff of the customer has the opportunity to improve their skills on the job.  In the case of purchase of GDM brand TDSs, the owner of equipment also gets the opportunity to train staff using a pre-installed program in one of the sections of the interface supplied with the TDS.

9. What is your outlook for the Top Drive market in Russia and the CIS over the coming years?

National Oilwell Varco: Top drive market will remain stable. Transition to top drive systems is inevitable and all new drilling rigs will be equipped with such systems.

NorDrill: Russia and the CIS will continue to be a main focus area for NorDrill over the next couple of years. As said, we’re looking into partnering with local service companies, and we attended the KDR Well Engineering Forum in Astana in September 2018, and will attend the RDCR 2019 in April. We expect to see a significant growth in existing drilling rigs replacing older equipment and installing Top Drive Systems the next couple of years, and combined with recent numbers citing 70% of new built rigs coming equipped with Top Drives, we believe Russia and the CIS is the place to be for NorDrill, and our portfolio of Top Drive Systems.

Drillmec: We expect that requests for Top Drives from Russia will increase in the next years, both from the necessity to update already existing rigs and the purchase of new ones. This is a technology that will became essential in the oil & gas industry due to its characteristic of money-saving, more efficient and safe working conditions. This cannot be a change to be made in months or few years, but it will definitely be the future of drilling rigs, allowing them to operate more than ever to satisfy the increasing demand of low-priced energy.

Our TDS fleet now amounts to more than 400 units (about one-third of the drilling rig fleet). In 2017, the top drive market volume was 75 units– 70% of new drilling rigs are purchased complete with a TDS. Improved top drive pricing coupled with their technological advantages we expect will drive a steady growth in the TDS market volume.

Global Drilling Support: In connection with the constantly growing needs in hydrocarbon extraction, the demand in the TDS market will remain constantly stable.  However, it is worth noting that the TDS fleet already in operation today in Russia will constantly need regular repairs and overhauls.