Inside - Schramm Inc.

quarterly news
V2 • Issue 3 • WINTER 2013
Schramm Quality Now API-Q1,
ISO-9001: 2008 Certified
Inside
THIS ISSUE
Schramm Quality Now API-Q1,
ISO-9001: 2008 Certified......................1
Schramm Invests Millions on
New T500XD Testing ............................2
Schramm GeoCase Demonstrates
Innovative Technology.........................3
Service Tips From
The Schramm-Man................................4
Q
uality means different things
to different people. In the
energy sector, the American
Petroleum Institute (API) provides
the most rigorous of quality
standards for firms like Schramm
that manufacture equipment used
in oil & gas drilling, where safety
is paramount in field conditions
that present unique challenges to
operators and crews.
Over the past 112 years, quality has
always been a given at Schramm,
but as we expand into new energy
markets around the world with
Extend Drill Rig Life Cycle
with System Upgrades.........................5
Upcoming Events...................................6
INDepth Editor
Cheryl Zultewicz
Corporate Vision:
We will continue our tradition as a privately
owned company focused on providing
superior drill rigs and services, personalized
to meet customer requirements.
Schramm, Inc. is a company dedicated to
meeting the needs of the drilling contractor.
Driven by contractor requirements, Schramm
personnel design and manufacture products
around the traditions of superior quality,
innovation and flexibility. Utilizing the
capabilities of computer aided design
workstations and a fully integrated
manufacturing process capability;
contractor ideas are transformed into
drilling solutions to meet the ever
increasing demands of the industry.
Q1-1568
“
Over the past two years,
Schramm has fully
engaged with API to
document our quality
system across all aspects
that impact our design
engineering, manufacturing and order fulfillment
processes.”
Telemast drill rigs in the 500,000 lb.
hook load class, our new customers
need the ultimate in quality assurance,
independently verified and recognized
by the ultimate global authority, API.
To fulfill this critical expectation, over
the past two years, Schramm has
fully engaged with API to document
our quality system across all aspects
that impact our design engineering,
manufacturing and order fulfillment
processes. An in depth API audit took
place at our West Chester, Pennsylvania
facilities at the end of 2012 with very
favorable results.
As 2013 begins, we are now authorized
by API to announce that Schramm is
certified API-Q1, ISO-9001:2008, ISO/TS
29001, API-4F, API-8C and API-7K for the
design and manufacture of drilling and
Continued on page 6
INDepth
Dynamic Test Pad
A
t Schramm we realize the importance of
verifying that the products
we send out meet all the
functional, performance,
design and implementation requirements identified. In preparation for final
assembly and testing of the
new T500XD, Schramm has
invested over $2.5 million
dollars on a multi-use test
pad.
This test pad provides a
unique combination of a
cased hole at 12 ½ inch
diameter and 1,250 deep,
along with the capability of
handling a pullback of over
500,000 pounds.
The cased hole allows the
driller the ability to hang
drill collars and provides a
“weight on bit” simulation
to thoroughly test the control system of the rig. The
pullback feature permits the
testing of each T500XD at
full load.
The concrete base of the
pad varies in thickness
from 18 inches to 8 feet
thick and contains over
300,000 pounds of rebar,
depending upon required
characteristics of the
various sections of the
pad. In addition, the pad is
equipped with an environmentally friendly, selfcontained drainage system
connected to a 10,000
gallon oil/water separator
to capture any liquids during the assembly or testing
process.
M
Test pad and crane fully assembled and ready to begin testing
Schramm acquired a 104 ton crane located on the pad for use
during the final assembly process of the mast to the mast trailer.
This new crane will allow Schramm to move components of the
drill rig, sub-structure and pipe handler with ease.
The entire test pad project took approximately 9 months to construct and was completed on time, enabling the maiden T500XD
to be assembled and tested on site. g
Top Head Dyno Test Fixture
accelerated lifecycle test designed to reflect real world drilling conditions by utilizing a 1,200 HP hydraulic power unit
capable of developing 4,500 psi and 350 gpm attached to a
fixture that replicates the T500XD mast mounting assembly.
This system can develop 35,000 ft-lbs of torque with a rotational speed of 140 RPM. Hydraulic cylinders within the test
fixture are capable of a static pull load of 500,000 lbs, a push
of 80,000 lbs and a radial load of 10,000 lbs to simulate real
world horizontal drilling.
Dyno Test Fixture set up in the Schramm factory
S
chramm recently installed
a massive test fixture
specifically designed to verify
mechanical design life and
operating integrity of the
2
T500XD drill rig top head drive
and slab-back.
With our new dyno test fixture,
we have essentially created an
Schramm GeoCaseTM Demonstrates Innovative
option is a special drill table that conTechnology
tains a rotating mechanism with jaws
Written By: Todd Giddings, Ph.D., P.G.,
PGWA Education Committee Chairman
The test pad occupies
over 1 acre of real estate
and provides a complete
simulation of the drill site
set-up, including: SubStructure, Power Trailer,
Mast Unit, LoadSafe and
Control Room.
We can now rigorously test each T500XD top head drive in
the plant with full performance documentation before the rig
is assembled and placed into final test at the factory prior to
shipment to the field. This multi-stage QC process provides
documented validation to the highest standards of the oil &
gas industry, and shows the additional steps Schramm takes
to maximize rig reliability and performance.
For more information on the test pad, the dyno test fixture
and Schramm’s validation process, contact Michael Horchuck,
Manufacturing Engineering Manager at
[email protected] g
INDepth
Schramm Invests Millions on New T500XD Testing
any bedrock formations, especially
those that have weathered and
decomposed over millennia of geologic
time, today have a thick overburden
composed of sand, silt, clay, and remnant boulders of the underlying bedrock. Often this overburden is unstable,
and it caves in before the casing can be
installed in the borehole. Re-drilling the
same 10- or 20-foot caving zone again
and again does not always get the hole
to stay open, and it takes time and fuel
that reduces the net income on the
job. The case-as-you-drill method also
provides an important safety benefit,
because without any casing in the hole,
a caving zone can collapse up to the
ground surface, undermine the drill rig
support jacks, and cause the drill rig to
tip over.
A drill rig that can advance steel casing
with the airrotary drill bit can overcome
these caving overburden conditions
and safety issues. The casing keeps the
hole open, while the hammer bit breaks
up and drills through the boulders in
the caving overburden. When there
are no boulders in the overburden, the
air cleans the hole as the casing with a
special drive shoe (with carbide minibuttons) is rotated into the overburden
with no bit hammering at all. This innovative drilling and casing advancement
technology is applicable to both drilling
water-supply wells and to drilling geothermal boreholes in a loopfield.
The Pennsylvania Ground Water Association demonstrated how the case-asyou-drill innovative technology works
at their June 2012 Summer Field Conference in State College, Pennsylvania. The
drilling site was on the caving overburden developed on the Gatesburg Formation sandy dolomite bedrock, which,
because of its caving overburden, is one
The Schramm T450GT with GeoCase™ casing rotator
option drilling demonstration at the PGWA Summer
Field Conference
of the most difficult to drill bedrock formations in all of Pennsylvania. The Gatesburg
Formation sandy dolomite bedrock at this
site has several hundred feet of silty, clayey,
sand overburden that contains layers of
iron ore and remnant quartzite sandstone
zones. The commercial geothermal loopfield that was constructed at this location
had to use mud-rotary drilling to overcome
these caving overburden conditions.
Many residential water wells constructed in
the Gatesburg Formation start out with a
10-inch surface casing, and then telescope
down to an 8-inch, and then a 6-inch, and
then a 5-inch casing to get through the
caving overburden. These residential water
wells may cost more than 30 thousand
dollars when completed. This particular
demonstration site was chosen to give this
new case-as-you-drill technology a major
challenge.
that grip either a 6-inch or an 8-inch
diameter steel casing. This special drill
table has a 7-foot vertical travel within
the mast to advance (and withdraw)
the steel casing. The deck compressor
is rated at 1,050 cubic feet per minute
(cfm) of air at 350 pounds per square
inch, and we used a down-the-hole
hammer for this drilling demonstration. Because the steel casing is
advanced right behind the drill bit
and down-the-hole hammer, the air
and drill cuttings are returned to the
ground surface inside the steel casing.
Therefore, this drill rig has a diverter
that sits on top of the steel casing and
diverts the air stream and cuttings
through a 5-inch diameter hose to a
cyclone that is mounted on the side
of the drill rig. The 1,050 cfm of air and
the drill cuttings swirl around inside
the cyclone where the centrifugal
force of the swirling and gravity cause
the drill cuttings to discharge from
the bottom of the cyclone and cause
the air to be separated and discharge
from the top of the cyclone.
For more information about the PGWA
please visit www.pgwa.org, call 814-9338714 or email toddgiddings@verizon.
net. To contact Todd Giddings or to
register for any of his Accredited Training
Programs please visit www.toddgiddings.
com.
For more information on the Schramm
T450GT GeoCase™ Casing Rotator
System please visit www.schramminc.
com/products/t450gt or email sales@
schramminc.com. g
The drill rig used in this demonstration
was a Schramm model T450GT air-rotary,
track-mounted, drill rig with the GeoCase™
casing rotator option. The casing rotator
3rd Quarter 2012 Issue of the Pennsylvania Driller Newsletter of the PGWA
For the full article and step-by-step operation visit:
www.schramminc.com/wp-content/uploads/2012/11/Case-As-You-Drill-Through-Caving-Overburden.pdf
INDepth • Quarterly Newsletter
V2 • Issue 3 • WINTER 2013
3
INDepth
Hydraulic System Maintenance
(6): Relief Valve
Limits the circuit pressure to protect all of
the components in the system
system will rise to overcome the restriction
to flow. Herein lays the logic of “controlling
a leak under pressure”.
(7): Filter
Ensures the fluid is kept contaminant free
One of the most common causes of failure
within a hydraulic system is contamination.
A filter in the return line of the system
will ensure that any contaminants that are
created or dislodged within the system
under normal operation are captured and
will prevent component failure.
(8): Drive System
Provides the power to rotate the pump
(9): Gauge
Monitors system operation
A gauge installed in the system between
the pump and the rest of the circuit will
monitor the operating conditions. This
gauge tells us how much pressure it takes
to overcome the restriction to flow. If flow
of oil to the actuator is blocked, we can use
the gauge to determine at what pressure
the relief valve opens.
Steve Hanley, The Schramm-Man
I
was once told that a hydraulic
system is “controlling a leak
under pressure”. After a little
thought, this started to make
perfect sense to me. In order
to understand this logic and
properly maintain a hydraulic
system, we need to understand
what a hydraulic system is
and what the functions of the
components involved are.
Let’s take a minute to consider
what components would make
up a simple hydraulic system.
The minimum requirements
should be:
(Numbers referenced in Fig.1)
(1): Tank
Provides a reservoir to hold the
fluid that will transmit the power
(2): Pump
Creates the flow of fluid
from the tank to the circuit
components
(3): Hose
Carries the fluid for
transmission of power
(4): Actuator
Performs work through rotary
motion or a cylinder for linear
motion, typically motor updated
(5): Directional Control Valve
Controls movement of the
actuator, either forward or
reverse
4
(Fig.1) Diagram of a simple hydraulic system
Once the drive system is activated the
pump will begin the flow of oil from the tank
through the hoses into the system. Based
on the volume of the pump at a given RPM
we can determine the speed at which the
actuators within the circuit will operate. Or as
one trainer said so well, “It takes flow to go”.
A common logic miscue is that the pump
is the cause of pressure within the circuit.
Pressure is actually the result of restriction to
flow from the pump. If we continue to pump
oil into the circuit with nowhere for the oil
to go, the pressure within the circuit will rise
until something gives. To avoid catastrophic
damage within the system we add a relief
valve to limit system pressure. The relief valve
opens at a preset pressure value to vent (leak)
the oil back to the tank.
When we shift the directional control valve,
we allow the oil from the pump to flow (leak)
into an actuator and perform work in a linear
or rotary direction. When the actuator has
a resistance to work, pressure within the
Because a hydraulic system is doing work
it is generating heat. Now consideration
has to be given to two other components
in our hydraulic system. A heat exchanger
is required to dissipate the heat generated
in the system. A thermostat is used to
maintain a desired operating temperature
by either by-passing or diverting the oil to
the heat exchanger.
Final consideration should be given to
the most important part of the hydraulic
system and that is the hydraulic diagram.
Without this item we cannot map out the
flow and pressure performance of the
system. For the last ten years Schramm
has created a rig specific diagram for each
rig despite the fact that many rigs are
optioned with similar equipment. You can
contact Schramm for an e-copy of your
hydraulic diagram. Make sure to provide
the serial number of your rig.
N
o one can argue that preventative
maintenance programs are good,
and generally maximize the life of
drill rigs. As rig life extends, industry
standards and customer requirements
change. When you consider available
options to upgrade your drill rig, you
need to consider up front cost offset by
reduction in future operating expense,
along with any increase in the asset
value after the upgrade is completed.
Equally important, increased safety
and compliance with evolving industry
requirements need to be factored in
before you make a decision to upgrade
or just buy new.
When does upgrading make sense?
At Schramm, we have found the
most popular areas of upgrades are:
adding automated pipe handing (both
automated pipe arms), high capacity
pipe carousels and Schramm’s LoadSafe
system; rotation gearboxes and
electronic controls (air compressor).
Upgrading pipe handling on the drill rig
can typically cost $30,000 to $300,000
depending on which option is selected.
With pipe handling as the number one
cause of drill rig related accidents, the
benefits of upgrading to a safer solution
are far reaching. Typically, safety is the
highest priority. Safer operation leads
to lower insurance costs, less downtime,
and more contracts. For water well and
For additional service questions or to
speak with a Service Technician today call
610-696-2500 or email service@schramminc.
g
Schramm pipe carousel mounted on a T450GT
INDepth • Quarterly Newsletter
geothermal drill rigs pipe carousels can
hold up to 375 feet of drill pipe. This
allows the driller to drill to maximum
depth without helper support. The
helper can focus on other activities like
supporting other rigs, which are typically
found on a large commercial geothermal
site.
While the trend is to use pipe carousels
on water well and geothermal drill
rigs, they can also be used on Reverse
Circulation (RC) mineral exploration drill
rigs. The deeper RC work usually uses
an automated pipe handling arm. The
automated arm is capable of removing
pipe from a rod box or service truck.
The operator can lift and rotate the
pipe to the tophead to make the pipe
connection. The arms are hydraulically
operated and can have either manual
hydraulic controls or radio remote. The
loading arms are size specific and have
the greatest use in mineral exploration.
Schramm’s LoadSafe Pipe Handling
System can handle all tubulars including
pipe, drill collars, stabilizers, downhole
tools, and casing up to 30 inches. In
order to retrofit, the LoadSafe requires
a tilting tophead on the rig. Tilting
tophead retrofits are available on all
Telemast rigs and can be retrofitted to
other manufacturer’s fixed mast designs.
When retrofitted to a Schramm rig or
any rig with a tilting tophead, LoadSafe
creates the safest drill site for pipe
handling.
In the next issue of the INDepth Quarterly
Newsletter we will begin to cover the
importance of each component and their
maintenance requirements.
com
“
In a competitive marketplace, the choice to retrofit
existing equipment over
new equipment is a viable
option. The key is recognizing all the possibilities, costs
and benefits available for
your rig.”
V2 • Issue 3 • WINTER 2013
Mast mounted hydraulically operated
INDepth
Extend Drill Rig Life Cycle with System Upgrades
Service Tips with The Schramm-Man
power breakouts add to the drive to a
hands-free operation environment by
eliminating any type of pipe wrench
that requires a driller or helper to
swing the wrench to the drill pipe and
hold in place for making or breaking
tool joints. Power breakouts can be
retrofitted to T450, T685 and Telemast
model drill rigs.
Rotation gearboxes are the heart of the
drill rig; therefore, reliability is critical
to drilling performance. Schramm’s
single reduction design used across
all of its drill rigs is the most reliable
gearbox available. With both boltin and trunnion mount designs, as
well as pullback ratings of 40,000 lbs
to 200,000 lbs, Schramm’s rotation
gearboxes can be retrofitted to both
Schramm and other manufacturer’s
drill rigs. The gearboxes have the
added benefit of using geroler type
hydraulic motors with one, two or
four motor options including single or
two-speed. This provides a wide range
of performance in speed and torque to
match your drilling needs.
Retrofitting electronic controls
embodies the greatest technological
change in our industry today. A
complete change from electric to
hydraulic controls will most likely not
meet expectation, but we can’t rule it
out. Instead, the retrofit of electric over
hydraulic sub-systems on a drill rig is a
viable option. The most popular subsystem to retrofit has been traditional
air regulation compressor controls
with Schramm’s patented air-CONTROL
system.
In a competitive marketplace, the
choice to retrofit existing equipment
over new equipment is a viable
option. The key is recognizing all
the possibilities, costs and benefits
available for your rig. For a review of
your equipment and to discuss options
email [email protected] or to
speak with a Service Technician call
610-696-2500 g
5
INDepth
Schramm Quality (continued)
• API-8C includes hoisting sheaves,
power swivels, wire-line anchors,
pressure vessels and piping mounted
onto hoisting equipment. Schramm
is now licensed to apply the API-8C
monogram on Schramm top-heads
(power swivels) used on Schramm
rigs or retrofit to other brands.
The first three specifications (API-Q1, ISO9001:2008 and ISO/TS 29001) certify that
Schramm complies with internationally
recognized quality management system
requirements. This helps us ensure that
our design, manufacturing and order
fulfillment processes consistently satisfy
our customers across all markets served;
including energy, mineral exploration,
geothermal and water well drilling.
While the first three specifications above
relate to Schramm as an organization,
API-4F, API-8C and API-7K relate directly to
specific key equipment subsets typically
found on Schramm Telemast rigs utilized in
the oil & gas industry.
• API-4F covers derricks, masts, crown
block assemblies and substructures.
requirements within the oil & gas
industry continue to grow.
Schramm is now licensed to apply
the API-4F monogram on Schramm
Telemast rig masts and crown block
assemblies.
well-servicing structures and equipment.
More than ever, Schramm is well equipped
to honor our corporate quality traditions
as we raise the bar higher with every
opportunity.
• API-7K relates rotary bushings.
Schramm is now licensed to apply
the API-7K monogram on Schramm
bowls and slips used on Schramm
rigs or other brands.
Schramm is committed to supporting
Telemast rig owners’ documentation
requirements above and beyond
API requirements as the regulatory
Schramm Telemast rig purchasers can
now obtain at additional cost, detailed
rig manufacturing data histories for
their API monogrammed rigs. These
books include a full range of material
certifications and NDT test reporting for
load path critical items within the API
monogramed design as part of our API
quality system.
This data provides additional
assurance of Schramm commitment
to our customers across the full
life cycle of our Telemast rigs. For
additional details on Schramm’s API
Certification, contact Michael Horchuck,
Manufacturing Engineering Manager
and API Management Representative at
[email protected] or visit the
API Composite List Website:
http://compositelist.api.org/companylist.
aspx?Facility_ID=8075 g
Upcoming Events
Wisconsin Ground Water Conference
Tennessee Water Well Association Show
India Unconventional Gas Forum
Prospectors & Developers Association of Canada Show
January 17th & 18th
Kalahari Resort & Convention Center • Wisconsin Dells, WI
January 18th
Mumbai, India
Pennsylvania Ground Water Association Winter Meeting
January 24th & 25th
Holiday Inn Hershey/Harrisburg • Grantville, PA
Maryland/Delaware Water Well Show
February 7th & 8th
Martin’s West Convention Center • Baltimore, MD
Mountain States Ground Water Expo
February 7th & 8th
Aquarius Casino Resort • Laughlin, NV
Missouri Water Well Association Convention
February 18 - 20
Country Club Hotel • Lake Ozark, MO
th
th
February 28th - March 3rd
Park Vista Hotel • Gatlinburg, TN
March 3rd - 6th
Metro Toronto Convention Centre • Toronto, Canada
Schramm Spring Service Schools
March 5th - 7th (en español) & March 12th - 14th
Schramm, Inc. • West Chester, PA
Ohio Oil & Gas Association Meeting
March 6th - 8th
Hilton Columbus at Easton • Columbus, OH
New England Water Well Expo
March 15th - 16th
Marriott Courtyard • Fitchburg, MA
China International Petroleum & Petrochemical
Technology & Equipment Show
March 19th - 21st
China International Exhibition Center • Beijing, China
800 East Virginia Ave • West Chester, PA 19380 • Phone: 610-696-2500 • Fax: 610-696-6950 • www.schramminc.com
6
V2 • Issue 3 • WINTER 2013