During my first month as a young drilling engineer, I was sent for a hitch on a drilling rig at offshore Terengganu. My head was giddy with the vision of the awe I would receive upon stepping on to the semi, and impress people with my genius. After all, I had in my backpack my university TI82 graphing calculator, a thick company issued laptop, Excel pre-installed and I had made a point to read at least 1/3 of the Drilling for Dummies book during the weekend before. I entered the chopper cabin with hopes and dreams, and was sure that this was the start of an illustrious career.
Unfortunately, my earlier personal euphoria was gutted swiftly when I exited the chopper in a dazed stupor, trying to get my bearings on which was port and starboard, and wondering why nobody can just say left or right. Pointed to the briefing room direction by the HLO, I still managed to successfully go down the wrong set of stairs, while struggling to keep upright on non existent sea legs fighting against the rig sway. After finally being pushed impatiently by a fellow traveler to the right doorway, I sat gratefully in the front row through the safety induction, looking for the nearest waste paper basket in case my digested lunch decides to come up the wrong way. After the last presentation slide, I shook hands with the rig OIM and jolly old rotund medic, who then proceeded excitedly to show me locations of the galley, lifeboats and room. The images of the food being prepared in the galley, and the sight of tightly made top bunk in the four person occupied room, filled my mind with hopes for dinner and a deep slumber. Unfortunately those images were replaced with dread, when I was informed that actually my work shift had started. And like everyone else, especially as a newcomer, I would start my shift with the honour of meeting the drilling supervisor, aka the king of the rig, aka the company man.
Gingerly swaying in my shiny boots, I walked through the corridors and found the company man's office, eerily situated at the dimly lit end with the door half open. I knocked, and only silence greeted me. I knocked again, and a sudden bravado overcame my senses and I stepped in, because it occurred to me that technically, I was a company man too. Shifting to the middle of the room, my presence continued to go unnoticed by the man in charge. He was just sitting there on a rickety chair, gazing out to the rig floor through the smudged safety glasses and half opaque window. He looked very uncomfortable, hunched in filthy coveralls withered by what I assume to be continuous rig laundry and exposure to mud and sun, but he maintain his slouched posture in deep thought. I tried to calm my nerves and grunted a half swallowed "Hello, I'm Adrin, boss", and waited for him to respond. For another full 5 mins he continued his silent meditation, his deadlocked eyes just continued to stare into space. Then, his cracked lips moved ever so slightly, lisping the words no driller ever wants to hear, "We just stuck pipe". Unfortunately for me, I didn't know how dire a situation that actually was, and with the cheeriest voice I could muster, I said, "Oh good, then I can learn about what stuck pipe is!". He looked up and peered at me through his safety glasses, and gave me the most disgusted grunt. "You are here to learn, right? Then by all means, learn. Get your PPE, I'll show you what a stuck pipe is. I want you to figure out how to get free, and until you let me know how you are able to do that, or we free the pipe, you will spend your shifts on the rig floor. You will only come down for meals and safety meetings. Is that clear, whoever you say you are?".
Side note: Just for the benefit of non-drillers, during drilling operations, a pipe often with expensive bottom hole assembly (tools, or referred to as BHA) is considered stuck if it cannot be freed from the hole without damaging the pipe, and without exceeding the drilling rig’s maximum allowed hook load.
So there I was, first week offshore, already incurring the wrath of the company man, and already bought a front row seat on a stuck pipe event. The experience itself, is as interesting as the namesake, a pipe stuck, stationery and unmoving. Most days were spent with me spewing obvious solutions like "pull harder...let's try twisting it...let's pull now because maybe whatever has the pipe in its jaws has tired of holding on to it.." As time passed to days, and into the second week, I saw the mighty top drive pull and jar up and down on the pipe in futility, and over time people started to talk to it, hug it, curse at it, but most of the time stare at it. Somebody actually suggested that we slaughter a black chicken and drip the chicken's blood on to the stick up, but when I took the idea seriously and suggested it to town, I could still recall the cruel laughter on the other line and comments about how the contracting to buy the animal alone would take too long. What i learned though was, once a pipe is stuck, it generally stays stuck. The only recovery was to continue to work on the pipe until we received approval to cut the pipe as deep as we can, and pump cement across the tools downhole and leave it buried. As we had nuclear sources in the tools, it was only until the government gave the approval on the 10th day, could the attempts to free the pipe cease, and I saw wireline tools run to cut the pipe, and the recalcitrant pipe finally was freed without the tools downhole, and cement plugs pumped above the abandoned BHA, tools worth millions of dollars left for the next generation to unearth.
Pictured: A picture I found online on how other crews help start the well process with prayers or Pooja. I hope that the flowers and belief did help this particular rig stay trouble free.
If there is anything that the oil fields ingrain into a man, it's humility. We can try to predict what will occur, be ready with an assortment of fallback plans and equipment, and try to avoid certain conditions that might lead to catastrophe. Unfortunately in drilling, we deal with the unknown. The mystery of the unknown is more prominent in exploration or appraisal drilling, but even in development mode, the formation drilled can throw us a curve ball. Every single meter drilled have different characteristics, but challenges for every single meter cannot be addressed with real time changes, at least not with the technology available now. Apart from managed pressure drilling technology, all wells are drilled with normalised planned parameters, tools, fluids and practices, and the mode is always progressing while avoiding catastrophe. But when stuck pipe occurs, while we can likely deduce that its most likely caused by a deviation, a practice that went wrong, we cannot expel the notion that there is the element of the unknown that the sentences the pipe to its final grave.
For non-drillers, I often explain a stuck pipe as an earthquake catching our tools. Indeed the simplified metaphor covers the likely causes of stuck pipe. Formation movement, debris, collapse, ruptures, key seats, pressure differentials are what the common man associates earthquakes with, albeit on a much larger scale. Unfortunately, more often than not, a stuck pipe is notched to a mistake made by the drilling crew. But drilling crews are also human. Training, drills, procedures, data analytics and supervision are all available for the driller and crew to make decisions, but just like our normalised parameters, they are often unable to predict and react easily for every single meter drilled. Thus a stuck pipe event will still remain a real catastrophic event, that until our technology catches up with real time response of equipment with real time inflow of data, we will have to put our faith on the team with the right attitude and knowledge to keep us out of trouble.
However, a stuck pipe event still remains a commercial event. While it does introduce its safety risks with possible flow inside the pipe due to trapped pressure, there are many other drilling incidents that are far worse, often involving immediate injuries, explosive events and death. While any stuck pipe event often brings me back to the memories of my youth, standing across an unmoving stub, full of despair, I would take a hundred stuck pipe events before I would go through the ordeal of having casualties under my watch. Our focus on performance and continued diligence in trouble shooting should never falter, and make we have less stuck pipes in our careers, but more importantly we all stay safe and return to our homes unhurt.
Something interesting to share?
Join NrgEdge and create your own NrgBuzz today
Pioneering technology expert tells ADIPEC Energy Dialogue up to 80 per cent of plant shutdowns could be mitigated through combination of advanced electrification, automation and digitalisation technologies
Greater use of renewables in power management processes offers oil and gas companies opportunities to create efficiencies, sustainability and affordability when modernising equipment, or planning new CAPEX projects
Abu Dhabi, UAE – XX August 2020 – Leveraging the synergies created by the convergence of electrification, automation and digitalisation, can create significant cost savings for oil and gas companies when making both operational and capital investment decisions, according to Dr Peter Terwiesch, President of Industrial Automation at ABB, a Swiss-Swedish multinational company, operating mainly in robotics, power, heavy electrical equipment, and automation technology areas.
Participating in the latest ADIPEC Energy Dialogue, Dr Terwiesch said up to 80 per cent of energy industry plant shutdowns, caused by human error, or rotating machinery or power outages, could be mitigated through a combination of electrification, automation and digitalisation.
“Savings are clearly possible not only on the operation side but also, using the same synergies between dimensions, you can bring down the cost schedule and risk of capital investment, especially in a time when making projects work economically is harder,” explained Dr Terwiesch.
A pioneering technology leader, who works closely with utility, industry, transportation and infrastructure customers, Dr Terwiesch said despite the increasing investment by oil and gas companies in renewables and the growing use of renewables to generate electricity, both for individual and industrial uses, hydrocarbons will continue to have an important role in creating energy, in the short to medium term.
“If you look at the energy density constraints, clearly electricity is gaining share but electricity is not the source of energy; it is a conduit of energy. The energy has to come from somewhere and that can be hydrocarbons, or nuclear, or renewables.” he said.
Nevertheless, he added, the greater use of renewables to generate electricity offers oil and gas companies the option of integrating a higher share of renewables into power management processes to create efficiencies, sustainability and affordability when modernising equipment, or planning new CAPEX projects.
The ADIPEC Energy Dialogue is a series of online thought leadership events created by dmg events, organisers of the annual Abu Dhabi International Exhibition and Conference. Featuring key stakeholders and decision-makers in the oil and gas industry, the dialogues focus on how the industry is evolving and transforming in response to the rapidly changing energy market.
With this year’s in person ADIPEC exhibition and conference postponed to November 2021, the ADIPEC Energy Dialogue, along with insightful webinars, podcasts and on line panels continue to connect the oil and gas industry, with the challenges and opportunities shaping energy markets in the run up to, and following, a planned three-day live stream virtual ADIPEC conference taking place from November 9-11.
An industry first of its kind, the online conference will bring together energy leaders, ministers and global oil and gas CEOs to assess the collective measures the industry needs to put in place to fast-track recovery, post COVID-19.
To watch the full ADIPEC Energy Dialogue series go to: https://www.youtube.com/watch?v=QZzUd32n3_s&t=6s
Utility-scale battery storage systems are increasingly being installed in the United States. In 2010, the United States had seven operational battery storage systems, which accounted for 59 megawatts (MW) of power capacity (the maximum amount of power output a battery can provide in any instant) and 21 megawatthours (MWh) of energy capacity (the total amount of energy that can be stored or discharged by a battery). By the end of 2018, the United States had 125 operational battery storage systems, providing a total of 869 MW of installed power capacity and 1,236 MWh of energy capacity.
Battery storage systems store electricity produced by generators or pulled directly from the electrical grid, and they redistribute the power later as needed. These systems have a wide variety of applications, including integrating renewables into the grid, peak shaving, frequency regulation, and providing backup power.
Most utility-scale battery storage capacity is installed in regions covered by independent system operators (ISOs) or regional transmission organizations (RTOs). Historically, most battery systems are in the PJM Interconnection (PJM), which manages the power grid in 13 eastern and Midwestern states as well as the District of Columbia, and in the California Independent System Operator (CAISO). Together, PJM and CAISO accounted for 55% of the total battery storage power capacity built between 2010 and 2018. However, in 2018, more than 58% (130 MW) of new storage power capacity additions, representing 69% (337 MWh) of energy capacity additions, were installed in states outside of those areas.
In 2018, many regions outside of CAISO and PJM began adding greater amounts of battery storage capacity to their power grids, including Alaska and Hawaii, the Electric Reliability Council of Texas (ERCOT), and the Midcontinent Independent System Operator (MISO). Many of the additions were the result of procurement requirements, financial incentives, and long-term planning mechanisms that promote the use of energy storage in the respective states. Alaska and Hawaii, which have isolated power grids, are expanding battery storage capacity to increase grid reliability and reduce dependence on expensive fossil fuel imports.
Source: U.S. Energy Information Administration, Form EIA-860, Annual Electric Generator Report
Note: The cost range represents cost data elements from the 25th to 75th percentiles for each year of reported cost data.
Average costs per unit of energy capacity decreased 61% between 2015 and 2017, dropping from $2,153 per kilowatthour (kWh) to $834 per kWh. The large decrease in cost makes battery storage more economical, helping accelerate capacity growth. Affordable battery storage also plays an important role in the continued integration of storage with intermittent renewable electricity sources such as wind and solar.
Additional information on these topics is available in the U.S. Energy Information Administration’s (EIA) recently updated Battery Storage in the United States: An Update on Market Trends. This report explores trends in battery storage capacity additions and describes the current state of the market, including information on applications, cost, market and policy drivers, and future project developments.