The Genesis Rig was engineered knowing that rigs often operate in remote areas, far from technical experts and readily available replacement equipment. To avoid costly work stoppages, every effort was made to make the Genesis Rig highly reliable, durable, and low maintenance.
The Rig utilizes hydraulic cylinders, which have a long and proven track record. They are extremely tough, powerful, and long-lasting. They will not overheat or burn out, and operate in very cold and hot environments.
The Genesis Rig is equipped with high pressure gear pumps (412 bar) controlled by VFD modules, which are rugged, dependable, and require minimal maintenance.
Electric motors typically function at about 90% efficiency at temperatures below 40 °C (104 °F). But at higher temperatures power rapidly declines, dropping to 35% efficiency at 60 °C (140 °F). In moderate climates, temperatures of air cooled electric motors for mud pumps and the top drive often reach 65 °C or higher. At this temperature, a 500 ton top drive with a 1000 hp electrical motor delivers only 550-600 hp to a bit. A 1600 hp mud pump produces just 900-950 hp of pressure/mud delivery to the bit. The Genesis Rig is equipped with water-cooled, explosion-proof electrical motors for the top drive, mud pumps, hydraulic power generators, and VFD inverters. Chillers (in an emergency mud system water tanks) are used to cool the motors and maintain temperatures below 40 °C, ensuring they perform at optimum power.
To minimize failures and poor functionality, engineers at B Robotic W analyzed potential causes for a rig’s failure. Components for Genesis Rig were then selected based on their reliability, field performance, and market availability. The generators are equipped with a dirt and water drainage system as well as water/fuel separators to avoid potential stops due to dirty fuel.
The key components of the Genesis Rig are engineered with backup systems to minimize work stoppages due to equipment failure. The Genesis BQ 500 rig has:
The Genesis Rig is engineered for minimal maintenance. The Rig’s hydraulic cylinders and pulling cables will operate for 15,000 hours before servicing (4-5 years).6 There is a single, easy to replace filter for all the gear pumps. Since the Rig has no drawworks, there is no annual inspection of the electromagnetic brake, brake pads, drilling cable, and brake levers.
The Genesis Rig has a smaller subbase and handling area compared to conventional rigs.
The Genesis Rig requires 40% fewer standard trailers for transportation due to its design, lighter weight, and fewer components.7 The entire Genesis Rig is transportable on standard trailers (13.5 m long, 4 m high, 2.5 m wide, with a maximum weight of 25,000 kg (55,000 pounds)). No oversize vehicles or special permissions are required.8
The Genesis Rig, without a drawworks, operates quieter than a conventional rig.
6 Cables on diesel electric rigs must be replaced annually.
7 The Genesis Rigs are transportable on 65 standard trailers verse 115 trailers (includes three oversize vehicles) for a standard drilling rig.
8 The weight of the Genesis BQ 500 Rig (2000 hp) is about 94,000 kg compared to 141,000 kg for a traditional rig (2000 hp).