References Incroduction and Objectives Resumé Topic 1 Rotary equipment 1 Rotary table 2 Master bushing 3. Kelly bushing and kelly 3.1. Kelly bushing 3.2 Kelly 4 Kelly accessories 41 Kelly cocks 4.2 Saver sub Swivel Slips Rotary tong 8 — Power congs sas Topic 2. Hoisting equipment 1 General 2 Draw-works 3 Drum 4 Brakes Al Main 4.2 Auxiliary 4.3 Comparison of the different cypes 4.4 Battery back-ups 5 Blocks 6 Hook 7 Blevators 8 "Top drive" drilling system 9 Automacic pipe handling Topic 3. Wire ropes 1 Construction Cores Types of lay Pre-forming Serand design and construction Physical properties ‘Terminations Fleet angle BY AUVaUN WDIP - Rotary & hoisting equipment i 12 12 12 1B B 15 16 3/2117 7 18 1 20 20 22 24 25 2 26 28 32 34 3/2136 36 36 37 38 38 40 42 44 bi Page 3/2/1 v2.009 10 u Topic Nou RUN Capacity of drums & reels Inspection and records Slings 4 The block line Dimensions: Reel co drum transfer Reeving, Guidance equipment Crown block provection Dead line anchor Service life 7.1 General 7.2 Evaluation of block line work 7.3. Equations for work done 7.4 Slip and cut programme 7.5 Maximum block line service Appendix 1: Block line calculations Appendix 2 : Derivation of equations for block line work ‘Appendix 3 : Types of damage to wire ropes Questions Page 3/2/2 45 45 47 3/2/48 48, 49 50 51 52 33 54 34 94 35 35 36 3/2/59 3/2065 3/2168 3/2/71 ‘WDLP- Rotory & hoisting equipment v2.00References ‘Well Engineer's Notebook, Sections A, B, C & D IFP Drilling Dara Handbook, Section F Production Handbook, Volume 2 API Spee 7 API RP 7G API Spec 7K API Spec 8A API RP 8B API Spec 8C API Spec 9A API RP 9B API Bull DLO Specification for Rotary Drill Scem Elements, Recommended Practi for Drill Stem Design and Operating Limies Specification for Drilling Equipment Specification for Drilling and Production Hoisting Equipment Recommended Practice for Procedures for Inspection, Maintenance, Repair, and Remanufaccure of Hoisting Equipment Specification for Drilling and Production Hoisting Equipment (PSL 1 and PSL 2) Specification for Wire Rope Recommended Practice on Application, Care, and Use of Wire Rope for Oil Field Service Procedure for Selecting Rotary Drilling Equipmen A Primer of Oil Well Drilling by Ron Baker, Petroleum Extension Service, University of Texas WDIP - Rotary & hoising equipment Page 3/2/3 v2.00Introduction and Objectives ‘This Part will explain the use of rotary and hoisting equipment including wire ropes and, in particular, the block line. ‘The hoisting system of rigs is fairly standard and comprises: + the drawworks + auxiliary brake + the crown block + travelling block. + hook. * links and elevators. * wire rope (block line). © deadline anchor ‘The rotary system basically consists of the rotary table, the kelly and the swivel, with torque being cransmicced co che bit via the drill pipe. Every drilling rig will be fitted with these items, but this simple set-up is not always used. One common alternative is to use a down- hole motor (either a turbine or a Moineaau motor) co drive the bit by converting drilling fluid pressure into torque - such a motor can be used by any rig. ‘These are described in Section 6 Pare 1 - The Drillstring and Section 7 Part 3 - Directional Drilling The other alternative is to use a "Top Drive System" (TDS) in which che torque is provided by a motor (cither hydraulic or eleccric) built into a very much more sophisticated version of the swivel. In this case the disadvantage of the increased complication of the rotary equipment is more chan offser by hav- ing corque available over a +30 m incerval rather than +10 m. It is @ relatively expensive ‘option as it can only be used in combination with a strengthened detrick; however it needs to be understood that with the complexity of today's wells the overall cost/m (costift.) ‘cases lower than previously, Ic is also possible to use a downhole motor wich a TDS, in most ‘When diesel mechanical drive is used both che drawworks and che basic rotary are driven by he same engines via a transmission. On diesel-electric driven rigs, the rotary and drawworks have their own independent morors. After scudying this Part, consulting other relevant documents and, if necessaty, discussions with your mentor, you will be able to: + describe the composition and use of a rotary table, © describe the function, constcuction and structure of master bushing, kelly bushing, kelly and swivel. + ist che main parts of the hoisting equipment. + describe the composition of a draw-works. * explain why draw-works have grooved drums. + describe the composition and operation of the various types of brakes used in draw-works. + draw a diagram of, and explain che speed/torque characteriscies of draw-works brakes. * describe why sheaves with large diameters are used with blocks and how blocks are inspected Ce v2.00+ describe che composition of che hook and explain the function of the spring between the shank and the housing ‘+ name the various types of elevators and their application in oil-well drilling. + describe the Top Drive system. ‘+ lise che situations in which the use of a top drive system is advantageous. + describe che composition and use of slip-type elevator/spiders. + describe the automatic pipe handling system + lise che checks to be carried out to ensure the proper use of elevators, + describe the construction and physical properties of wire rope + describe the correct use of wire rope grips (clamps). + name the several kinds of wire rope cerminacions and give their strength in relation co che breaking strength of the wire rope. + explain the advantage of ordering a longer block line. + calculate the capacity of a drum or reel + explain what is meant by the fleet angle and why this angle is limited. + explain: ~ the use of wireline guides. ~ the function and use of the Crown O’Matic. = the use of the dead line anchor. ‘+ describe the reeving of a new block line. + name the points of critical wear: * calculate the work done during round crip, drilling, coring and casing jobs. + explain che aim of a slip and cue programme and how che cut-off length can be decer- mined. + give cen factors to ensure maximum block line service. + name the principal causes of wireline problems, + describe why and how visual inspections are carried out. * make complete block line calculations. WOIP - Rotary & hoist "Page 3/2/5, v200 equipmerResume “This Part deals with the various parts of the rotary and handling equipmene and their acces- sories Ic provides general information about wire ropes, and goes into more derail about the block line and its use. Page 3/2/6 WDIP - Rotary & hoisting equipment v2.00INTRODUCTION & LEARNING OBJECTIVES, ‘This Topic deals with che basic equipment on and around the rig floor that is involved in applying corque to the drill pipe. Such torque is required in order to: ‘+ Turn the drill pipe to drive the bit + Counteract the reactive torque produced by a down-hole motor that is driving the bit + Make/break screwed connections in che drill pipe/drill collars + Manipulate down-hole tools © Assist in freeing drill pipe or other equipment chat has become stuck in the hole Note however that although the Well Engineer must know what the basic Rotary Table System is, and how it works, this basic system has been superseded in most Shell operations by the more sophisticated Top Drive System that is described in the following Topic, in Sub- Topic 8. While studying chis Topic, you should focus on the following learning objectives: * To be able to describe the principal parts of a rotary cable * To be able to describe the construction and use of the two bushings that are used in combination with the rotary table + To be able to explain why kelly cocks are used + To be able to describe the principal parts of a swivel + To be able co give examples of the correct and incorrect use of slips + To be able to name and describe the principals of the tools used to screw additional sections of drill pipe or casing into the pipe that is hanging in the well. 1 THE ROTARY TABLE 1.1 FUNCTION ‘The rotary has a double function: + To rotate clockwise or anti-clockwise, and o apply torque to the drill string and any¢hi attached to it. + When the pipe is being pulled from or run into the wellbore, the rotary supports the string on slips during those intervals in which che pipe is noc suspended from the hook. ‘Ac such moments it carries the weight of the entire string. 1.2 COMPOSITION The rotary table rests on reinforced beams in the rig floor so that the high drilling loads are cransferred ro the sub-structure see Figure 3.2.1 fine seaiemede eeceTreeereece tat Page 37277‘The rocary has a cast or reinforced steel base which acts as a foundation to provide the strength and stability required for such a massive machine. Oil reservoirs for oil-bath lubrication are an integral part of the base. ing goss spt mater bushing suetbla nin shal in beng QO Oo inion locking paw whoo sprocket Figure 3.2.1 : Rotary lable with split mostr bushing ‘The turntable can rorate in the base using a heavy ball bearing and a ring gear shrunk over the carntable. ‘The ring gear is driven by a pinion and a pinion shaft with roller bearings and seals. A detachable sprocket is connected to the pinion shaft (for diesel mechanical drive) ot, when an electric motor is used, a coupling is mounted on this shaft. Special seals are fitted to prevent he oil from leaking or being contaminated by mud. ‘The ting gear and pinion have spiral ceething which allows the table to work as smoothly as possible. The great advantage of this type of construction is chac che cable does not jetk and is less noisy. Every rotary table is equipped with a locking device allowing the driller co lock it while mak- ing up and breaking out che bit or hold the table when drilling with a mud motor. This lock should noc be used to replace the back-up tong when making up or breaking out connections ‘on a round crip as the combination of a torque and a bending moment could result in the pipe scrength being exceeded. IF the string has insufficient weight the pipe could also turn in the slips. ‘The turntable has an opening in the centre, cylindrical at the botcom and square at the cop. ‘The master bushing is fitted into this specially shaped recess. 2 THE MASTER BUSHING 2.1 FUNCTION The master bushing firs into the curntable and makes it possible to * drive the kelly bushing (sce opposite and Figure 3.2.4), which in curn dives the kelly + accommodate the slips when the pipe is suspended in the slips. Master bushings are used in rotary tables: * co match the inside diameter of the rotary to the pipe passing through ic. As the bushing is a loose and replaceable insert it automatically acts as a wear sleeve 2.2. CONSTRUCTION Master bushings can be constructed in two ways: # Split: Made in ewo halves with a taper for che slips machined into chem (Figure 3.2.1). Page 3/2/8 WDIP - Rotary & hoisting equipment v200+ Solid: Made as a single piece with the taper for the slips. Loose inserts or bowls are used to reduce the inside diameter of the master bushing to accommodate a range of pipe and slip sizes (Figure 3.2.2). The inserts themselves can be split, solid or hinged sod masta ushing zboni =| t si2bow ~ square hole \ tapering _W4 aaisthio i Figure 3.2.2 : Solid master bushing with bow! 3 > THE KELLY BUSHING AND KELLY 3.1. KELLY BUSHING The kelly bushing can be engaged with the master bushing by a square drive or 4-pin drive (Figures 3.2.3 & 3.2.4). Ir is equipped with rollers that permit che kelly co move freely upwards or downwards when the rotary is turning or when it is stationary, Kellies can be square or hexagonal. When the kelly is square the kelly bushing is fitted with four plane rollers. When a hexagonal kelly is used the kelly bushing contains two plane rollers and wo 120° V-rollers (Figure 3.2.5) —— kelly bushing —_____[ square drive =e pin drive taper 4°+ 0.0187 9°27'45" + 2°90%side square drive pin drive © © Figure 3.2.3 : Square drive and pin drive for master bushing and kelly bushing WOIP Rotary & Boiting equipment age 3/219 v200To pass the kelly bushing over one of the upsets of the kelly, the rollers must first be FITR removed and are then a I replaced, ‘The rollers rotate and are adjustable to Rape keep the play 4 o between kelly and - rollers t0 a mini- mum, preventing, ‘Square drive Pin drive vibration on the i Figure 3.2.4 + Kelly bushings rotary and drill sering and reducing wear on che kelly. ‘There is also a two-roller rao" vrote type kelly bushing (Figure bg \ CN Ht. 3.2.6). This. has two secs of Li Case m= soles, one above the oher, Gi Dh wes ATA imal nae eee a 7 T square bly block. The flac roller y { { assembly type is for square DY J kellies and the tapered roller assembly type is for Figure 3.2.5 Oneroller kelly bushingfor hexagonal kelly hexagonal keltes ‘The kelly bushing is closed off ac the top by a cover. This cover and the roller blocks have co be removed before the kelly bushing can be installed — |e fea non-roraing around che kelly. The kelly bushing rollers can be adjusted for kelly and |uard over ehe kelly roller wear by removing or adding shims below the tapered roller assembly |drive bushing 0) blocks. prevene incidenes Te is recommenced Flat rolior assembly ‘Tapered roller assembly Figure 3.2.6 : Tworoller kelly bushings Page 3/2/10 WOIP - Rotary & hoisting equipment v200‘One advantage of two-roller kelly bushing is an improved kelly guide and therefore reduced vibration and wear. This applies only when the kelly has not been bent by careless use or transport 3.2. KELLY The kelly, which is square or hexagonal, transmits or absorbs torque co or from the drilling scring while carrying all the censile load. Ic also directs drilling fluid into the string under high pressure. Ir is therefore the most heavily loaded component of the drill string, Note however that che kelly is rapidly being, phased out in favour of a TDS, because of the ever increasing complexity of our wells. 3.2.1 Standard sizes See Figure 3.2.7 Length overall (L) * 12.19 m (40 ft) for 9.14 m (30 fi) length singles. © 16.46 m (54 fe) for 9.14 m (30 ft) singles in offshore use (due to ship's heave). © 16.46 m (54 fe) for 12.19 m (40 fe) length singles. Dimensions across the flats (nominal size: Dru): 63.5 mm (24) square only. 76.2 mm (3") square or hexagonal 88.9 mm (3%") square or hexagonal 108.0 mm (44°) square or hexagonal. 133.4 mm (54) square or hexagonal. 152.4 mm (6°) hexagonal only. length overall drive Section 1-Dp 4 aa iA cori 7 eel ial etn dct Figure 3.2.7 : Square and hexogonel kelies 3.2.2 Loading and strength considerations Square kellies are normally forged (pressed or rolled in shape when the metal is ted hor) over the drive section, whereas hexagonal kellies are machined (excess macerial removed) from round bar stock, WDLP - Rotary & hoisting equipment Page 3/2/11 v2.00The upsets are kept relatively long so chat che kelly can be re-threaded if top or bottom threads are damaged. If kellies with che same outside diameter (max. diameter) are compared, it will be apparenc that the hexagonal kelly with a simi lar bore has a substantially stronger drive sec- tion (See Figure 3.2.8). Under similar loading conditions the hexago- nal design is subject to lower stress levels and therefore has a longer service life, In addition, the machined flats have a greater resistance to wear than the forged surfaces. ‘This is why the hexagonal kelly is generally prefered; but the life of the drive section of either type is greatly influenced by the fit of the drive bushing. It is therefore extremely important that fre- ‘quent adjustments of the rollers should be made to remove slack ‘This is the driller’s responsibilicy. 3.2.3 Connections: @) kelly stop cock swivel * Top: LH thread (box. * Bottom: RH thread (pin). 3.2.4 Material: upset kelly Fully heat-treated chrome molybdenum steel, 4145 hardness range, Brinel 285-341 or Rockwell C 30-50. Refer to API RP7G for kelly strength specifications. 4 KELLY ACCESSORIES See Figure 3.2.9. 4.1 KELLY COCKS lefthand thread i 1 | right-hand thread ‘These provide protection against flow from the drill pipe and iso- late the swivel washpipe packing and rotary hose from high pres- sure: + Above Kelly: Flapper type, bulbous (Omsco, TIW,, Shaffer) ‘Manually operated. /| kelly stop cock * Below kelly: Flush joine. Manually operated ball valve (Hydril). Used to shuc off drill pipe pressure so that kelly can be disconnected. 4.2 KELLY SAVER SUB saver sub protector ‘This is made up to the kelly bottom connection and provided with a rubber protector. ‘The sub is replaced when the downward facing pin of the saver ___inallpint sub becomes worn after making repeated connections, preserving rill pipe the actual kelly connections and keeping che pin which mates with the drill pipe in good condition, The thread must be inspected fre Figure 3.2.9 = Kelly ond connections Page 3/2/12 a ‘WoL? - ont Vv 200quently by the driller because replacing the sub coo lace could result in excessive damage to pipe connections or even parting of the string and therefore also in high costs Note Special scabbards are used when moving the kelly from one location to another co prevent che kelly being bent during transpore. ‘The scabbard also serves as a kelly hole on the rig floor and is usually called che rat hole. Ifa bent kelly is used, this could result in: * severe vibrations. © rubbing and extra wear on the drill pipe tool joints and inside of the wellhead/BOP stack. + excra alternative bending stresses in the upper part of the string. + excra wear of kelly and master bushing. 5 SWIVEL 5.1 FUNCTION The swivel is suspended from the hook and travel- ling block and forms the top of the drill stem and permits this to rotace freely. Ic also provides a con- nection for the rotary hose and a passage for the flow of drilling fluid into the drill string. In some cases a hydraulic or electric motor is buile into the swivel, which is chen known as a “top drive" (TDS). This is a very much more sophisti- cated and heavy (and therefore expensive) piece of equipment than a standard swivel and requires a specially strengthened derrick that can handle both the weight and the reaction torque. Top drives are described in Topic 3. 5.2 CONSTRUCTION Figure 3.2.10 : Typical swivel ‘The swivel (Figure 3.2.10) is made up of a stationary and « rovating part and has to support the entire string weight during drilling. The material of gooseneck and washpipe assembly needs to have high resistance to the abrasive action of the drilling fluid which passes the swiv- el at high speed. ‘The rotating part turns over the main axial bearing which is mounted in an oil-filled housing The fluid-tight connection between the stationary part of the swivel and the rotating part is called the washpipe assembly, ‘The seal unit is the most vulnerable part of the swivel Greasing the seals and checking the quantity of oil in the body daily is very importanc. If there is any leakage, the washpipe assembly has to be replaced as soon as possible by the driller. A spare washpipe assembly should always be at hand. 6 SLIPS 6.1 FUNCTION Slips are wedge-shaped segments wich special dies inserted on the inside, which support the pipe when suspended in the rotary bushings. WOU Rotary & boing eauipned Page 372/12 v2.0.0Figure 3.2.12 : Casing slips Figure 3.2.11 : Drill poe slips Drill pipe and tubing slips consist of three body segments (Figure 3.2.11). The slips for deill collacs and casing, however, are made up of a large number of segments (Figure 3.2.12) The heavy weight of long casing strings and the relatively thin pipe wall make it imporcane that the slips provide full circumferential grip for even load discribution. 6.2 DESIGN “The wedging action of che slips in the master bushing converts che downwatd force of the weight of the string into a much increased lateral or transverse force on the pipe. See Figure 3.2.13. If friction is disregarded it could be compared to a load suspended from a spreader bar hanging on two slings which have an angle with horizon equal to chat of che angle of the slips (q). The resultant compression force in the spreader bar is equal ro P/(2 tan 0). Sowatae pears seas some fnew ee texsa \Wevopbot te poe sin Figure 3.2.13 : Wedging ection The slip angle commonly used is 9°27'45". Disregarding friction, a string weight of 445 kN (100,000 tbs) would result in a compression load on the pipe in the slips of 1,334 kN (300,000 tbs), equal to 29,552 kPa (4,286 psi) collapse pressure on a 127.0 mm x 29.02 kg/m (5" x 19.5 Ib/fe) drill pipe in 35.6 cm (14") long slips having full circumferential grip over the total length. The rated collapse pressure of E pipe is 68,950 kPa (10,000 psi). There is more information on designing for slip crushing in the Well Engineer's Notebook, Section C. Slips have concave replaceable inserts called dies, clesigned for specific sizes of pipe, vo provide full circumferential gripping action. 6.3 PROPER SLIP USAGE Some important points have to be taken into account when handling slips: Page 3/2/14 WOL? - Rotary & hoisting equipment v200+ Check that the slips are the right size for the pipe, including the inserts, + Make sure that the inserts are sharp. Check that all che inserts grip the pipe. + Make sure that the outside of the slips is clean and well greased. Check chat the taper of the slips is nor damaged and matches that of the master bush- ings in che rorary table. * Make sure chat the master bushing fits without play in the rotary. * Make sure thar all slip handles are present and securely fastened Ic is extremely bad practice to: + use the slips to stop the downward movement of the drill pipe. + lee the slips ride on the pipe while pulling out of the hole, © catch the tool joine box wich che slips. Refer to the IADC Drilling Manual (Section B) for furcher information about handling slips. A spider is often used in the rotary instead of hand slips while running casing. The spider will be discussed in Topic 3. 7 ROTARY TONG 7.1 FUNCTION ‘The rotary tong is nor part of the lifting equipment. It is however an importane tool in che running in and pulling, out of most of the pipes being used in the well. Its function is to tighten che screwed connections in the drill sering and casing to the recommended torque and co break these connections when required. 2.2 COMPOSITION ‘A drawing of the cong is shown in Figure 3.2.15. It is made up of @ cong arm co which the jaws are attached with hinge pins. The whole tong assembly is suspended by wireline from a point in the derrick such that it hangs close to where it is applied to the pipe. The suspending line runs over a sheave with a counterweight attached co the other end. This allows the tong to be moved vertically to the correct height for the cool joine or collar. The tong operator swings the tong against che collar closing the jaws. When a force is applied to the free end of the arm the jaws grip the pipe with dies. Increasing the force on the arm increases the gripping action of the jaws on che pipe preventing the cong from slipping over the tool joint, Extension pieces of different Jengch can be inserted co adapt the jaws to different sizes rool joint or collar. Dies are made of hardened steel having ribs on one side. They fit into dove-tail grooves in the jaws and are held in Figure 8.2.15 : Manual tong assembly place by split pins. It is important that che ribs are kept clean allowing chem to “bite” inco che material of the joint or coll: Figure 3.2.14 : Typical monval tong A tension meter is often installed at che end of the cong arm co which the tong line is, attached. The dial of the read-out of the tension meter is normally calibrated in a torque scale. WD? - Rotary & hoisting equipment Page 3/2/15. v200Ic is cherefore important to check whether the read-out is che correct one for the length of the tong arm, 8 POWER TONGS Making up and breaking out pipe manually is a time consuming operation. To speed this up hydraulically or pneumatically driven tongs, called power tongs, have been developed. The jaws, carrying che dies, have been set in a semi-circular frame which, after the lock in the housing has been closed, is driven by a motor to rotate rr the pipe. A tension meter is normally installed on the back-up wire to enable accurate torquing up of the con- nections (the tension sensor can be seen hanging from the power cong depicted in Figure 3.2.16). Initially these tongs were only used for the running of casing, but from these tongs new machines were devel- ‘oped capable of spinning in drill pipe and making up the tool joint to the required torque afterwards. This coo! is, usually set up €0 work cogether with power slips. Both tools are operated by remote control from the deiller's Figure 3.2.16 : Hydraulic cosing tong position. ‘The spinning and torquing tool is called an “Iron Roughneck” (see Figure 3.2.17). An Iron Roughneck is made up of a pipe spinning cool, a power tong and a back-up tong. ‘The function of the last tong is to grip the bottom part of the joint and prevent ic from rotation when the power tong is applying the make-up or break-out torque. Iron roughnecks are expensive tools and could suffer break-downs as a result of incorrect of rough handling by the drill crew. They need co be posi- tioned exactly in line with che pipe co allow slips and tongs to grip the pipe and cool joint or collar first time If set-up and operated correctly they save time, but more importantly they improve the safety on the rig floor by performing the dangerous work of the cong men. The disadvanc although such incidents are rare, ifan arm or hand is caught by che rocacing machinery ie can cause a serious injury! .¢ of this heavy equipment is hac, Figure 3.2.17 + Iron roughneck Page 3/2/16 WDIP- Rotary & hoisting equipment v200INTRODUCTION & LEARNING OBJECTIVES, ‘This Topic introduces the basic equipment that is used to raise and lower the drill string, cas- ing, erc. in the well as ir is heing drilled, excluding, che wire rape which is dealt with in a fol- lowing Topic. While studying this Topic, you should focus on the following learning objectives To be able to describe the elements that form the draw-works + To be able to list the advancages and disadvantages of the different type of brake + To be able to describe the equipment in the derrick/mast. + To be able to name the different types of elevacors and list at least five of the points chat need to be checked to ensure safe operation + To be able to explain the principles of top drive system, and list its advantages and disadvantages. + To be able to state the main advantage of automatic pipe handling systems 1 GENERAL ‘The entire hoisting installation is shown schemacically in Figure 3.2.18. The factors o be considered when a hoisting system is designed or chosen are: + che maximum required hoisting ‘astlne capaciy. + che maximum speed at which loads re can be pulled. ‘© che strength of che line. ipsa + che maximum speed at which an ‘empty block can be raised. ead ne All these factors are strongly related to the: © power and speed of the motor. © cransmission characteristics. © drum diameter. storage rel “These factors, cogether with the number of sum ata lines strung in the system, determine the hook load and the speed at which it can be Figure 3.2.18 : The hoisting systemof of o rig handled. WDIP - Rotary & hoisting equipment sere Page 3/2/17, v2.00{A few drilling units have recently been fiteed wich a fully hydraulic raising and lowering sys- tem instead of the conventional drum and wi tures of such a system are: © reduced weight and space requirement. + improved safety. * highly accurate stroke movement. + beeter braking capacity * aucomatic heave compensation for floating drilling we draw-works system. Some of the main fea- * elimination of the time spent on wire rope maintenance (slipping and cutting) and replacement ‘Whether hydraulic hoisting systems will eventually replace the drawworks will depend on reliability, economics and experience with che systems currently in use. 2 DRAW-WORKS Figure 3.2.19 is a picture of a draw-works with an auxiliary electro-dynamic brake. The drive can be can be either diesel mechanical or diesel electrical. The shaft diagram is shown in Figure 3.2.20 Shafts with sprockets and chains provide the internal drive transmission. A gear wheel is connected co the main drive for reversing. Shifting the sprocket co one side will engage a jaw clutch and chis makes forward movement possible. A toothed clutch on the jack shaft is used co shift into low or second gear. Drum, rotary, sand reel and cat head ate all cluech activat- ed Figure 3.2.19 : Typical draw works Figures 3.2.19 & 20 show a ewin drum eaw-works. The upper (and reat-moso) dean i to accomodate a sund-line. ‘The Laer are noc often used in Shell opess-| tions due to the high incidene rave asso- ciated wich such use. Page 3/2/18 WDIP- Rotary & hoisting equipment v2.0.03 DRUM ‘The drum is an imporcant part of a hoisting system. ‘The size depends on che height of the derrick or mast. Iks surface should be grooved so that spooling is controlled and the wire is not deformed. A wedge-shaped guide against the inside of che flange cogecher with curn- back rollers on a bracket above che drum eases the line over for its return wrap. The flanges are wide to accommo- date the mechanical brake bands Figure 3.2.21 illus- 4 sae! trates a drum with two-step grooving - see below. mete Figure 3.2.21 : Schematic of « drum In ewo-step grooving the grooves are divided into two sections where the grooves run parallel to the drum flanges and two sections where the grooves run spirally. ‘The line spooling is guided by these grooves which prevents the drum geccing out of balance and reduces line [= Figure 3.2.20 : Shoft diagram of o diawaworks ‘On mosc drums manufactured nowadays one- step (called parallel) or two-step (called counter~ balance) grooving is used as shown in Figure 3.2.22. These patterns prevent line build-up ae che cross-over points (places where one line crosses over a previous wrap). ‘Ser Ta pice long paralel Sector 2 pie t pelt Secton | 172 piich ston Section 4 whip beeween drum and crown block when spooling at high speed. _@ One-step drum WLP - Rotary & hoisting equipme v2.0.0 l b. Two-step or counter-balanced drum Figure 3.2.22 : Tho oxtonded length of « grooved drum Page 3/2/19‘One-step grooved drums are suitable for two or three layers of line only. Counter-balanced ot two-step grooved drums with only half the angle of pitch give good spooling with many more layers of lines. The spooling is faster with less line scrubbing and whip. 4 BRAKES Brakes can be divided into: + main brakes; these are the mechanical brakes on the drum flanges or a hydraulic/mechanical dise brake system. + auxiliary brakes; these can be either hydrodynamic, electrodynamic or magnetic particle brakes. 4.1 MAIN BRAKES ‘The main brake of a drilling rig is the mechanical band brake or the hydraulic! mechanical disk brake system. As the name implies, the primary method of stopping the draw-works drum is by use of the main brake. Ic is therefore essential that the drillet is familiar with ies operation, adjustmene and maintenance. 4.1.1 Band brakes ‘The brake assembly consists basically of ewo flexible steel lined bands that fie around the drum flanges. Each drum band is anchored on one side while the other side is free co move ‘The brake lever is attached to the free side by means of a lever shaft. When che brake is applied, the bands clamp around the drum flanges and che drum is halted by friction. This friction generates considerable heat so most drum flanges are provided with a wacer-cooling system otal othe ‘using nots om balan yal yoo NC esi Figure 3.2.23 : Bond brakes with brake adjusiment “The brake bands are lined with brake blocks which improve the fr of the brake bands. These are made of bonded kevlar fibres interwoven with copper/brass wire and carbon fibres, and are shaped to fic the contours of the brake flanges. Brake blocks with asbestos fibre are no longer allowed for health reasons. Countersunk brass bolts are used co connect the brake blocks to che brake bands to avoid damaging the wear-resistant rims on the brake flanges. on and allow redressing “The actual braking action of the draw-works may make a considerable noise in the near vicini- ty of the drill floor with the potential ato damage hearing. Ear defenders should be worn! Ie may also cause local public disturbance on land locations. Page 3/2/20 WDLP - Rotary & hoisting equipment v200Operation When the brake is applied, che segment nearest ¢o the live end (ie. the brake handle) comes into contact with the brake flange first with a pressure dependent on the force applied to the handle. This starts co take up the load. Friction then brings the second segment into contact wich an increased tension and therefore 38a aaa ape eased pressure and frictional force. This braking action goes round the flange with ever increasing. values of tension and friction uncil ic"? reaches a maximum at the dead end. A celative- ly light pressure on the handle can thus provide 158 Ps a very high braking torque. The brakes are said ne to be self-energising when lowering the load. 117 4Fe ‘The opposite happens when the draw-works wo may starts to hoist, there may be a sudden “kick- Figure 3.2.24 : Schematic illusration of relative pressures opplied on the diferent segments of the broke flange back" of the brake lever may cause. ‘The opera- tor on the draw-works needs 0 be aware of this. In severe weather conditions with torrential rains, the actual braking operation may be affected if the brake rim becomes wet. Capacity ‘The braking capacity of band brakes depends on + che diameter of the drum flange. + che wideh of che drum flange and band. + che angle of wrap of che band around che drum flange (this should be at least 270°). Equaliser ‘Normally each brake has co cake half the load and for chis purpose che heavy adjustable hold- down bolts are connected co an equalising yoke which ensures that each brake band will bear an equal amount of tension. The hinge of this equalising yoke is bolced co che frame of the draw-works and needs to be well lubricated. If one brake band fails, che equaliser switches the {all load to the other band. Ic is importane chat both the adjustmenc and the condition of the brake bands should be checked regularly. In normal circumstances the wear of blocks and rims is checked according, to schedule during rig downtime. The API values for allowable wear on rims apply and chey can be found in API Spec. 7 section 18. 4.1.2 Disc brakes ‘The disk brake system consists of three major components: + The disks “The system uses two hard faced dises wich an internal water jacket either side of the main drum, Depending on the draw-works size the disc chickness will vary from ewo to three inches. Disc diameter is normally four to five inches larger than with brake bands. + The calliper assembly Depending on the size of the draw-works there are four or six brake calliper assemblies (cwo or three on each disc). Each assembly consists of two brake pad assemblies (one on either side of the disc) and an operating cylinder mounted in the middle on cop of the WDIP - Rotary & hoisting equipment Page 3/2/21 v2.00