B Robotics W
B Robotics W is the world’s leading manufacturer of automated oil and gas drilling rigs. Automated rigs have many advantages over conventional rigs. They drill faster, operate more efficiently, and are much safer.
In 2015, B Robotics W unveiled the BQ Genesis Automated Hydraulic Drilling Rig – the world’s first fully automated drilling rig. Its key innovation that makes possible hands-free drilling is the replacement of the drawworks with long-stroke hydraulic cylinders, which are very precise, more powerful, more dependable, and safer.
Safer Better Faster
The long-stroke hydraulic cylinders lift weight by pulling a piston rod, rather than pushing – the common design on small rigs. When pulling a piston rod, there’s on dead end load. A 5″ range-2, S 135 drill pipe can pull up to 950,000 lbs (430 tons). To lift this same amount of weight by pushing on the piston rod would require a 45″ rod at a minimum.
The Genesis and Stargate Rigs are equipped with high pressure gear pumps (412 bar) that are controlled by VFD modules. The pumps are highly rugged, dependable, and require minimum maintenance. They operate when oil is less than completely clean and can even function with water and additives. Because gear pumps are mass produced, they also are easily replaced in necessary.
The Genesis and Stargate Rigs are equipped with water-cooled, explosion-proof electrical motors on the top drive, hydraulic power generators, and VFD inverters to ensure efficiency and reliability.
Electric motors typically function at about 90% efficiency at temperatures below 104-113 degree F. At higher temperatures power rapidly declines, dropping to 65% efficiency
BQ Genesis 400 Automated Hydraulic Drilling Rig
The BQ Genesis Rig was engineered from the ground up to be the most productive and safest rig possible. The rig’s key components, such as gear pumps, were selected based on their high reliability, field tests, and market availability.
All critical systems all have backups to minimize work stoppages. The rig automatically starts/stops pumps, breaks and makes connections, adds tubulars, increases/ decreases the top drive rpm, weight on the bit, etc.
Automation is more precise than humans and is not susceptible to fatigue. As a result, the rig trips in and out at more than 1.5 meters/sec., compared to .5-.6 meters/sec. for a conventional rig. More advantages:
- Only three workers are required to operate the rig in a 12-hour shift.
- It automatically handles three range-3 or two range-2 drill pipes/drill collars, and has low and easy maintenance.
- 40% fewer standardized trailers are required for transportation
- Is much quieter than a conventional rig; the noise level on the working floor is only 50-55 decibels, making it ideal for drilling in populated areas.
- Consumes 20% less fuel (energy is recovered during tripping in and electric motors are water-cooled to maintain efficiency).
- It trips in and out, as well as drill to a defined depth, without the intervention of a driller or “hands-free.” This means the driller, after setting the depth to drill and starting the hands-free drilling program, does not have to manipulate any controls thereafter.
- The rig operates efficiently in harsh climates, from -50 degrees C to +65 degrees C (-58 degrees F to 149 degrees F).
BQ 400 Automated Hydraulic Drilling Rig
Startgate Automated Hydraulic Drilling Rig
The Stargate Automated Drilling Rig takes automated drilling to the next level of performance and efficiency.
The rig’s long-stroke hydraulic cylinders, which replace the drawworks, are located horizontally in a substructure below the drilling floor, rather than vertically on the mast as the Genesis Rig.
The hydraulic pumps, control systems, power unit, cooling system, and traveling and crow blocks are all positioned on the substructure. The rig’s hydraulic hoses, piping, and electrical wiring remain connected during rig drilling and transport, eliminating potential setup complications, spills, and incorrect wiring.
The only operation necessary for rig up and down is to make/break a connection to a diesel generator. The rig’s new design makes possible rig up and down in less than 24 hours.
It also greatly facilitates rig transportation, reducing the number of loads to just 26 (without camp). The Stargate’s components are all self-unloading from trailers and are assembled without a crane or gin pole. Workers are never higher than six feet off the ground during rig assembly.
- Camp is less than half the size of a conventional camp since fewer workers needed.
- Fully digital (can be accessed via internet to reprogram and troubleshoot).
- Hydraulic pinning.
- Shorter mast (hydraulic cylinders have fixed stroke; can’t hit crown block).
- Easy to operate (typically can train driller in one week).
- Pull-down ability makes possible fast penetration of permafrost and hard formations.
The Stargate Rig trips in and out, as well as drills to a defined depth, hands-free and without the intervention of a driller. This means the driller, after setting the depth to drill and starting the hands-free drilling computer program, does not have to manipulate any controls thereafter.
The rig automatically starts/stops pumps, breaks and makes connections, adds tubulars as necessary, increases/decreases the top drive rpm, weight on bit, etc.
If the rig stops for any reason, an alert sounds, at which time the drill has to intervene. Automation is more precise than humans and eliminates human fatigue problems.
And it’s faster. It trips in and out at more than 1.5 meters/sec., compared to .5-.6 meters/sec. for a conventional rig. The rig’s automation is engineered for simplicity and reliability.
Each operation of a automated system is divided into separate steps that are executed by computer-controlled hydraulics. The driller can operate the rig in two modes:
- Semi-automated mode – the driller activates a switch to complete each step forward (also used for special tasks, such as fishing for an object in the wellbore or using certain tools attached to the top drive).
- Full-automated mode – rig actions are activated sequentially by a computer program.
CCTV monitors in the driller’s cabin allow the driller to closely view each step of the rig’s operation. At any time, the driller can switch between semi-automation and full-automation. Operating the rig is easy to learn; drillers typically require only a week of training.
B Robotics W
B Robotics W designs and manufactures automated/traditional oil and gas drilling rigs (mechanical and hydraulic), as well as reconditions and services rigs worldwide.
The company, located near Piacenza, Italy, was founded in 1992 by Walter Bagassi, whose family has been involved in oil drilling for three generations. After earning a degree in aeronautical engineering, Mr. Bagassi worked as a logging engineer at Gearhart-Owen for 16 years, traveling extensively and contributing to the development of the Gearhart WMD system in 1979. Mr. Bagassi returned to Italy in 1986 to work as a rig designer and commercial director for a rig manufacturer. Six years later he founded his own company.
B Robotics W has a field-based understanding and appreciation of drilling equipment, having constructed and reconditioned complete rigs for more than two decades. Its engineers take pride in their design of equipment to ensure the highest level of safety, performance, durability, and have an appreciation of long distances that often exist between drilling fields and technical support.
B Robotics W Via Boscarella, 60 29010 Besenzone, Italy (tel) 39-0523-832185 – Italy (tel) 207-333-1557 – United States www.bwrobotics.co