Automated iron roughneck and advanced robotics system enhance rig floor operations

Drilling operations are essential yet inherently hazardous, with rig crews facing a multitude of risks every day. From heavy equipment and moving parts to unpredictable weather and environmental conditions, the rig floor is undeniably the most dangerous location in drilling operations. According to the International Drilling Contractors Association’s (IADC) ISP Report 2023, the most lost time and recordable injuries in drilling operations occurred on the rig floor, with the floormen experiencing the largest percentage of these injuries.¹ 

The rig floor is a high-intensity work environment, where floormen must execute essential tasks in the red zone quickly and safely, such as connecting and disconnecting drill pipes, tubulars and casing. They also must assist with tripping operations and monitor and maintain robust equipment, including the iron roughneck. Conditions, however, are difficult, demanding and exhausting, but everything must be done correctly.  

Naturally, drilling operations can be safer and more efficient by reducing the human-machine interaction on the rig floor and repositioning that expertise on-site or remotely. Drilling automation is a multi-decade journey that is not only transforming the oil and gas industry in terms of operational efficiency and environmental impact but, more importantly, the safety of the rig crew. 

MECHANIZATION AND AUTOMATION 

July 2024 marked the 36th anniversary of the Piper Alpha production platform explosion in the North Sea. This tragedy, which took the lives of 167 people, prompted a global reassessment of safety protocols. As a result, government agencies and industry bodies introduced new, stricter regulations, standards and guidelines focused on safety and risk management.  

Piper Alpha also served as a catalyst, accelerating the development of mechanized drill floor equipment, including pipe-handling and racking systems. These large, heavy-duty machines have helped manipulate tubulars on offshore rigs, reducing the need for direct human interaction in the red zone. While these early mechanized systems were a step in the right direction, they were heavy-duty machines that often required significant modifications to the rig floor, making them difficult to retrofit to existing rigs. Also, the energy-intensive nature of these systems placed additional stress on the overall rig infrastructure.  

As the industry continued to evolve, NOV recognized the need to take a more proactive approach to drilling automation. In the 2010s, the company began focusing on process automation, developing drilling and pipe-handling solutions, such as the NOVOS™ platform and Multi-Machine Control. These advancements increased the consistency and predictability of drilling operations by automating repetitive activities and enabling multiple applications, allowing rig crews to focus on more critical tasks and processes, rather than being bogged down by manual, repetitive work. 

NOV’s latest advancements represent a significant step toward autonomous operations, integrating automation and robotics into the drilling process and creating a hands-free drill floor. The company’s vision is to develop a fully automated drilling system that combines equipment automation, process automation, and situational awareness, transforming current setups into rigs of the future.  

DRILL FLOOR EQUIPMENT AUTOMATION  

Pipe handling is one of the most common, time-consuming, and risk-prone activities on the drilling rig, requiring constant attention from the entire crew.  Drillers are tasked with safely and efficiently passing tubulars between various pieces of equipment with their own interlocks, tracking their location from various places on the rig, and tracking the pipe both into and out of the well.  

At the same time, they must navigate multiple screens, alerts and messages and have situational awareness of crew safety and the data coming from the wellbore. Meanwhile, the derrickmen, who manually handle pipe and heavy drill collars, are also exposed to rig location elements.  

Since “Big Foot” entered the market nearly 50 years ago, the iron roughneck has enabled rig personnel to make and break connections more easily, rapidly, safely and consistently. The introduction of this machine not only increased efficiencies and reduced injuries and near misses on the rig floor but also improved the experience and alleviated the fatigue of rig crews conducting the operation of making and breaking connections. It also served as an alternative to the conventional method of wrapping a chain around the upper tubular, engaging a flywheel mechanism to pull on that chain, thereby causing the rotation of the tubular and spinning the pin of the rotary connection into the box end.²  

The industry’s pursuit of extended-reach horizontal and ultra-deep wells has driven a shift toward larger-diameter drill pipe, such as 5½ in. and 5⅞ in. While large-diameter drill pipe has long been a staple for offshore wells, it has only been introduced onshore within the past five years. This shift has increased the demands on drilling rigs and equipment considerably. These bigger and longer wells require equipment that can handle higher torque loads  and provide better weight distribution throughout the drillstring. The premium connections with these larger tubulars demand more robust make-up and break-out torque, as well as enhanced torque transmission from the top drive to the drill bit, Fig. 1. 

Fig 1. For more than 50 years, NOV has continuously advanced the iron roughneck to meet the demands and torque requirements of increasingly rigorous drilling operations.

However, this shift also has introduced new challenges for drilling contractors. The increased torque requirements can result in declining connection efficiency and the potential for non-productive time (NPT). Plus, the larger tools necessitate modifications to the rig mast and substructure while also posing potential interference issues with the drill pipe and drill collar setback area. 

Roughly five decades after introducing “Big Foot,” NOV has developed the new standard iron roughneck. The IRX-120’s modular design combines strength, precision, and flexibility for safe, consistent and efficient tubular handling for modern drilling operations. 

To accommodate for today’s land rig, this configurable tool features a minimal footprint and consists of three assemblies. The torque wrench assembly applies the necessary normal and tangential force to deliver the torque magnitude desired by the connection. It is capable of 100,000 ft-lbs. of make-up and 120,000 ft-lbs. of break-out torque, as well as providing three-point contact on tubulars and 60o of cycle rotation.  

The spin wrench assembly applies rotation to attach one end of the connection to the other. The IRX-120’s new spin wrench offers the highest torque output in the market at 5,000 ft-lbs on a 5½-in. diameter, which saves 3 to 5 seconds per connection. Finally, the track-mounted deployment assembly precisely and consistently positions the entire tool in the desired location on the rig floor.  

Moreover, the IRX-120 is automation-ready; it can be operated remotely and integrated with rig control systems, Fig. 2. This capability enables the iron roughneck to be controlled and monitored as part of an automated drilling process, removing personnel from the red zones and away from potentially hazardous areas of the drill floor.  

Fig. 2. The IRX-120 iron roughneck’s modular design and minimal footprint enable safe, consistent and efficient tubular handling for modern drilling operations. It is automation-ready, enabling it to be controlled and monitored within an automated drilling process.

Automated control not only enhances safety by reducing the risk of injury or human error but also ensures consistent, repeatable connection and disconnection performance. The iron roughneck is also designed to capture operational data that feeds into rig control systems, which can be used to optimize the connection process, track performance metrics, and eventually enable predictive maintenance. This data-driven approach further enhances efficiency and reliability while also reducing costly NPT. 

NOV is creating a hands-free drill floor by using ATOM™ RTX, a fully automated advanced robotics system that performs various tasks to improve rig performance, Fig. 3. This robotic system automates repetitive tasks, moving rig floor workers out of the red zone and away from danger, thereby enhancing the overall safety of drilling operations. 

Fig. 3. ATOM RTX, NOV’s robotic system, automates repetitive tasks, moving rig floor personnel out of the red zone and harm’s way.

The consistent and predictable performance of the system leads to considerable improvements in operational efficiency. The ATOM RTX, with its interchangeable end effectors, is designed to execute various tasks, such as doping, guiding when stabbing, tailing, stand building, and mud containment with a high degree of precision and repeatability, Fig. 4. This eliminates the variability associated with human operators, regardless of fatigue, weather or experience, thus reducing costly delays and downtime, and enabling more reliable and consistent drilling outcomes.  

Fig. 4. The ATOM RTX’s reliable and predictable performance contributes to consistent drilling outcomes.

The system’s modular and scalable nature enables drilling contractors to tailor the technology to their specific needs and existing equipment, optimizing the capabilities to address their unique challenges, whether in land or offshore applications. On its first onshore commercial deployment in Canada, the ATOM RTX performed consistent manual tasks, resulting in zero NPT and invisible lost time. 

RIGS OF THE FUTURE 

NOV’s proactive approach to drilling automation enables the company to develop integrated technologies and products that meet today’s and tomorrow’s requirements. As the industry continues to face challenges, such as cost pressures, skills shortages, and the need for more sustainable practices, the increasing adoption of automation and robotics will be crucial in driving innovation and maintaining competitiveness. 

The integration of automation and robotics into the drilling process is not just a matter of improving operational efficiency; it is a critical step in safeguarding the well-being of rig crews and minimizing the industry’s environmental impact. As the industry continues to push the boundaries of well construction, the need for more advanced and reliable drilling technologies will only become more pressing. 

By leveraging industrial robotics and advanced control systems, the company has developed solutions like the IRX-120 iron roughneck, which can be more easily retrofitted to existing rigs without the need for major modifications. This approach allows drilling contractors to capitalize on their current assets and transform them into the rigs of the future, enhancing safety, consistency, efficiency, and productivity.  

CHALLENGES 

While the potential benefits of drilling automation are clear, the adoption and implementation of these technologies are not without their challenges. Drilling contractors and operators must navigate a range of technical, operational and organizational hurdles to integrate automation and robotics into their operations successfully. 

One of the primary challenges is achieving seamless integration with existing rig infrastructure and control systems. Drilling rigs, being complex and highly customized, require thoughtful retrofitting when introducing new automation technologies. Although this process can be intricate and time-consuming, NOV’s approach is to use technologies that are adaptable to the current skill set of today’s drillers and rig hands. Drilling contractors need to carefully assess how these solutions fit with their current equipment and workflows, ensuring a smooth transition that minimizes operational disruptions. 

Another key challenge is the need for comprehensive training and upskilling of rig crews. Automation and robotics technologies require skills and knowledge different from traditional methods. Rig crews must be trained to effectively operate, monitor and maintain these advanced systems, ensuring they can fully leverage the capabilities of these technologies.  

To overcome these challenges and fully realize the benefits of drilling automation, a collaborative approach between operators, drilling contractors, suppliers, and original equipment manufacturers will be essential. 

Drilling contractors must work closely with technology providers like NOV to ensure the development of solutions that seamlessly integrate with their existing equipment and workflows. This collaboration will enable the creation of customized, fit-for-purpose automation and robotics technologies that address the unique needs and challenges of each drilling operation.  

Operators, on the other hand, must be willing to invest in and adopt these technologies, recognizing their long-term value in improving safety, efficiency, consistency and sustainability. By embracing drilling automation, operators can gain a competitive edge, enhance their operational performance, and contribute to the industry’s overall transformation.   

CONCLUSION 

The journey toward fully automated drilling operations has been a multi-decade endeavor and will continue in this constantly changing industry. Still, the industry has already made significant strides in enhancing safety and efficiency through the integration of automation and robotics into the drilling process. 

As the industry faces mounting challenges, the adoption of these cutting-edge technologies will be essential in driving innovation, maintaining competitiveness, and ensuring long-term viability. NOV’s focus on developing automation and robotics solutions that can be easily integrated into existing rigs and modernizing workflows is a testament to the company’s commitment to supporting drilling contractors in their transition toward the rigs of the future. 

The benefits of drilling automation extend beyond just safety and efficiency. By removing personnel out of the red zone and harm’s way, repositioning expertise, and minimizing the risk of human error, these technologies also can contribute to more consistent and predictable drilling outcomes. This, in turn, can lead to improved decision-making, better resource allocation, and enhanced overall performance. 

REFERENCES 

1. IADC ISP Program 2023 – Issued March 30, 2024. 
2. Plessis, G., D. Morgan, D. Meinders, et al., “Drill string failures: Inevitable or Not?”, Presented at the IADC/SPE International Drilling Conference and Exhibition, Galveston, Texas, USA, March 5–7, 2024. https://doi.org/10.2118/217953-MS.