02 The Basic Rig Systems

Quartz School forBasic
2. The Well Site Supervisors in IPM

Rig Systems
Module – 1
Drilling & Work Over Rigs
Section 1.
The Basic Rig Systems
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IPM Quartz School – Module 1: Drilling & Work Over Rigs / Section 2: The Basic Rig Systems
2. The Basic Rig Systems
Contents
1. Power System
2. Hoisting System
3. Rotating System
4. Circulating System
5. Well Control System
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Five basic systems of a Drilling Unit:
2.1. Power System

2.2. Hoisting System
2.3. Rotating System
2.4. Circulating System
2.5. Well Control Prevention System
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2.1. Power System
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2.1. The Power System
• Components:
2.1.1 Power Generation
2.1.2 Power Transmission
• Mechanic Transmission
• Electric Transmission
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According to the mode of power generation and transmission, drilling rigs are classified as:
1. “Mechanic Rigs”:
Mechanical power is generated by prime movers (diesel engines) which is

transmitted by mechanical devices (drive shafts, pinions, sprockets, chains, belts,
etc.) to drive the different rig systems.
There are still some Mechanical Drilling Units in operation. Nevertheless, they
have been almost all replaced by more efficient electric or hydraulic units
2. “Electric Rigs”:
“DC – DC” Rig:
Direct Current (DC) is generated and transmitted with electric cables to

drive rig engines powered by direct current, DC.
This was the first generation of electric rigs developed during the 60’s and
still there are some drilling units in operation.
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“AC – DC” Rig also known as “SCR” Rig:
Alternate Current (AC) is generated and then converted in Direct

Current (DC) by means of one “Siliceous Controlled Rectifier” (SCR) so
that it can be used to drive the Direct Current (DC) engines that operate
the different rig systems.
AC – DC rigs were developed on the 60’s after the “diodes” and “triodes”
technology become popular.
3. “Diesel – Electronic” Rigs, also known as “Electronic” Rig:
“AC – AC” Rig:

Alternate Current (AC) is generated and used unchanged to drive the AC
electric motors for operation of all basic and auxiliary rig systems. The
“SCR” is not required.
Electronic Rigs are the last generation of Power System. They use
processors and electronic circuit boards.
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Diesel – AC/DC Rig or “SCR” Rig
Rectifying SCR
DC Output
AC Input
Filtering
Levleling
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Diesel – AC / AC Rig or “Electronic” Rig
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• Power Generation:
Mechanical Power for both mechanic and electric rigs is generated by the
“Prime Movers”, commonly known as “Internal Combustion Engines” or
“Diesel Engines”
• Mechanical Power from the Prime Movers can be used:
1. To drive systems and equipment in Mechanical Rigs,
2. To operate Electric Current Generators in Electric Rigs, as follows:
a. Direct Current Generator, DC
b. Alternate Current Generator, AC
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• Power Generation
The Prime Movers (Diesel Engines) - Operation:
• Internal Combustion Engine is fed by a compressed air and diesel oil

mixture which is injected into the combustion chambers to generate
primary mechanical power
• Diesel engines can operate individually or coupled in parallel or

“compound” as per power requirements to operate the drilling unit
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The Prime Mover (Diesel Engine) :
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The Prime Mover (Diesel Engine) - Operation:
• When the compressed mixture of air and diesel oil is ignited inside the
combustion chamber, the explosion pushes the pistons heads down to move the
crankshaft and start the cycle in each chamber.
• Pistons drive the connecting rods and rotate the crankshaft. The flywheel
assembled to the end of the crankshaft allows the connection of pinion gears and
shafts to move rig system equipment or electric generators.
• The combustion cycle may has 2 or 4 positions to configure 2 or 4 stroke engine,

respectively.
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The Prime Mover (Diesel Engine) - Operation:
• Some diesel engines use air directly taken from the atmosphere, others use
pre-heated air circulated around the exhaust tubes and diverted toward the
combustion chamber with turbochargers.
• The natural or preheated air is compressed into the chambers until getting
around 1,000 °F to initiate the ignition of the explosive mixture of air with
the diesel oil injected as spray jet by fuel injectors into the combustion
chamber.
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• Direct Current Generator:
• Takes the mechanical power from the prime mover by the driveshaft connected
to the flywheel. The design of its internal coil and electromagnetic field allows
the generation of Direct Current (continuous electric waves)
• The first generation of electric rigs was DC/DC type, as follows:
• The Direct Current (DC) generated is transmitted by electric cables to feed

DC electric motors to move main systems in the drilling unit: drawworks,
mud pumps, rotary table / top drive, etc.
• AC electric motors used to operate auxiliary systems are fed by
independent AC generators driven by dedicated diesel engines.
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1. “DC/DC” Rig - “DC” Generator
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1. “DC/DC” Rig - “DC” Generator
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2. Alternate Current Generator (Alternator):
• Takes the mechanical power from the prime mover by the driveshaft
connected to the flywheel. The design of its internal coil and electromagnetic
field allows the generation of Alternate Current (oscillating electric waves)
• Most of Diesel-Electric rigs are of the type AC/DC or “SCR” Rigs:
• Main components of AC/DC – SCR system:
• Prime Movers – Internal combustion engines

• Alternators or AC Generators
• “SCR” to convert the AC generated into DC
• Electric Transmission (isolated electric cables) to conduct DC to main
and secondary electric motors operating different rig functions
• Auxiliary AC Motors using the electric power directly from alternator.
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• AC Generator (Alternator)
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• Electric Motors (Secondary Motors)
Two types of electric motors are currently used in Electric Rigs to operate basic
systems of the drilling unit:
1. DC Electric Motors (Mono phase electric current motors)
a. Are the most commonly used in “Electric Rigs”

b. Require the use of one “SCR” unit if the current generated is “AC”.
2. AC Electric Motors (Three phase electric current motors)
a. Those of lower power used for operation of the auxiliary systems in the
drilling unit (centrifugal charger pumps, air compressors, hydraulic pumps,
shale shakers, solids control equipment feeder pumps, etc.)
b. High power AC motors for operation of main rig systems (drawworks, mud
pumps, top drive, hydraulic systems, etc.)
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• Electric Motor (Secondary Motor)
1. DC Electric Motor, (mono phase electric current)
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2. AC Electric Motor, (Three phase electric current)
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2. AC Electric Motor, (Three phase electric current)
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• Electric Motors and Diesel Engines comparison:
1. “DC” Motors Vs. Diesel Engines:
a. “DC” motors develop more torque at low speeds than diesel engines of
same power.
b. Extensively used in “DC/DC” and “AC/DC” drilling rigs
2. “AC” Vs. “DC”:
a. “AC” motors are smaller and light than “DC” motor of same power
b. With “AC” motors both torque and power output are easily controlled
at all velocities
c. “AC” motors develop more torque and speed than “DC” power
equivalent
d. “AC” motors can perform more work with less energy saving fuel and
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• Electric Motors and Diesel Engines Comparison:
2. “AC” Vs. “DC” (continued):
e. “AC” motors do not use carbon brush and have less components
which means less maintenance.
In summary, “AC” motors perform better than power equivalent “DC” motors;
are more versatile, easier to operate and need less maintenance.
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Electric Transmission for ”DC/DC“ Rigs:
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Mechanic Transmission:
• Set of shafts, pinions, sprockets, chains, belts, gears compounding one or several
prime movers (diesel engines) to transmit the mechanical power toward the main
systems of the drilling unit (drawworks, rotary table / top drive, mud pumps, etc.)
• This type of transmission is the so called “Compound Set”
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Power Transmission Summary:

Mechanic Rig Electric Rig
Power House / SCR
Drawworks
Rotary Table
Mud Pumps
Engine / Generator Set
Driller’s Console
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• Power Requirements
Total power requirements is the sum of all individual requirements for

each rig system:
a. Drawworks
b. Rotary Table or Top Drive System
c. Mud Pumps
d. Centrifugal pumps for mud handling
e. Auxiliary equipment: compressors, light plants, camp,
etc.
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• Power Requirements
1. The real power needed at a given time is a function of the

operation performed
2. Maximum power is required when several functions are

carried out at same time: circulating, rotating, and raising the
drill string
3. Minimum power is used when running logs or while

conducting BOP tests or DST
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2.2. The Hoisting System
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Components:
• Supporting equipment
•Derrick or Mast
•Sub Structure
• Lifting equipment
•Crown Block
•Traveling Block
•Hook
•Drilling Line
•Drawworks
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•Design Considerations:
1. Total drilling depth

2. Maximum hook load anticipated while drilling or running
casing strings
3. Load capacity of mast and other components of the
hoisting system in the drilling unit
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• Supporting Equipment
• Derrick or Mast
•Allows vertical movement of tubular loads
suspended by drilling line, sheaves and
drawworks.
•Gives the required room for standing and

setting back drill string in doubles or triples.
•Sub – Structure
•Support the derrick and the set back or
hanging string besides the drill string set on
rotary slips
•Gives room underneath the Rotary Table’s
supporting beams for installation of BOP stack
and well control accessories rigged up on the
well head
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• Lifting Equipment
• Crown Block – Components:
1. Fast line sheave (of higher speed)
2. Main shaft retainer
3. Main (central) shaft
4. Sand line sheave (optional)
5. Set of parallel sheaves on the crown block
6. Dead line sheave (stationary)
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• Traveling Block – Components:
1. Housing
2. Set of parallel sheaves
3. Shaft for sheaves mounting
4. Shock absorber
5. Swivel hook
6. “Eyes” for links / bails

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• Shave efficiency factor:
For sheaves on crown block & traveling block with roller bearings:
N°of Lines Efficiency Factor
6 0.870
8 0.842
10 0.810
12 0.782
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• The drilling line or “wire rope”

rope”
Set of wires stranded around a central core to form a “rope” of wire
with high strength and flexibility. It is built in a variety of designs
depending of the number of strands, wires per strand, type of laid of
wires and strands, diameter, wire material. It is built in lengths of
thousands of feet.
Components
“Wire Rope” = Drilling line
“Wire” = individual steel filament in a strand
“Core” = central wire of fiber to rolling strands
“Strand” = set of a given number of wires
“Center” = central wire in each strand
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• The Drilling Line Specs:
• Number of Strands
• Number of wires per strand
• Type of core: Independent wire strand or fiber core
• Type of laid of wires and strands
Wire Rope Classification and Specs

Type of Core Type of Laid
IADC N° of Strands N° of wires per
(Material)
Specification Strand
6x7 6 7 Steel wire Regular Lay
6 x 19 6 16 – 27 Natural Fiber Left Lay
6 x 37 6 27 – 49 Synthetic Fiber “Lang”
8 x 19 8 16 - 26
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• The Drilling Line – design and construction
Strand Design:
• “Pre-Formed Strands”, “PRF”
For drilling lines one of the following patterns for PRF are used :
1. Simple layer
2. “Filler wire”
3. “Seale”
4. Warrington
5. “Combined”
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Strand Design options:
a. Simple layer
(a) (b) (c)
b. Filler wire
c. Sealed
d. Warrington
e. Combined Pattern
(e) (d)
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Types of strand:
Depending on the orientation of the wires forming the strands and of strands
around the core, the stranded can be:
• Right Regular Lay – RRL:
Strands turning to the right, wires in strands turning to the left
• Left Regular Lay – LRL:
Strands turning to the left, wires in strands turning to the right
Right Regular Lay Left Regular Lay

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Wire Rope Core:

Gives support to the strands braided around it with helical path
Two common types of wire rope core are:
1. Fiber Core - FC – made from synthetic fibers like propylene or from
natural fiber like “jute” (manila rope material)
2. Independent Wire Rope Core – IWRC – internal strand of
braided wires
The drilling line regularly has IWRC type core.
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• The Drilling Line – Materials
Grade of Steel used for wires in stranded lines:

1. “IPS” – Improved Plow Steel
2. “EIPS” – Extra Improved Plow Steel
One stranded line with 6 strands and 19 wires per strand made of EIPS steel,
has a nominal breaking strength which is 15% higher than that of another
made of IPS steel, having the same lay and design.
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• The Drilling Line – Size
The drilling size is referred to the outer diameter of the strand measured
between two opposite lobes of the stranded:
Drilling line sizes range from ½” to 2 ½” depending on the power and rig
capacity for handling loads with the hoisting system and line arrangement
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• The Drilling Line – Specification & Description. Example:
Drilling line Spec: 1”– 5000’ – 6 x 19 – S – PRF – RRL – IPS – IWRC
Descripción:
1” = Size, drilling line OD.

5000’ = Length of wire rope in the reel
6 = Number of strands
19 = Number of wires per strand
S = “Seale Pattern” – wires’ array in the strand
PRF = “Preformed Strands” – strand design
RRL = “Right Regular Lay” – type of lay
IPS = “Improved Plow Steel” – Type of steel alloy
IWRC = “Independent Wire Rope Core” – type of core
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• The Drilling Line – Nominal Breaking Strength. Example:
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• The Drilling Line – Design Factor:
Knowing the “breaking strength” of a given drilling line, its Design

Factor can be calculated as follows:
DF = Nominal Breaking Strength (lb) / Load on the Drilling Line , Tdl, in (lb)
Where,
Tdl = Load Tension in Drilling Line (fast line)
Wds = Weight of Drill String (including TBA)
n = Number of lines
Minimum Design Factor for Drilling Lines :

For Drilling or Tripping: 3
For Casing Running: 2
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• The Drilling Line – Cable Work Calculations:

Work = (Force or Load) x distance
An amount of Work is done by the drilling line when the hoisting system lifts
loads of tubular strings run into or out of hole.
The work done is calculated by multiplying the hook load (in tons) times the
distance between the upper and lower position of the traveling block every time
it goes up or down to drill, trip the drill string or run casing.
The work is expressed in Ton x Mile or in Ton x Kilometer, depending on the
unit system used.
Conversion Factors applied:
1 “Ton x Mile” = 10,560,000 lb x ft
1 “Ton x Km” = 1,000,000 kg x meter
When a given amount of Ton x Miles or Ton x Km is accumulated, the drilling line
must be cut and / or slipped through out the reeving, in order to avoid permanent
damages or early failures of it.
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Ton x Mile accumulated by making a round trip with the string in the hole (TRT):
C
) D (M +
D * ( L s + D )W e
TRT = + 2
10 ,560 , 000 2 , 640 , 000
Where,
D = Measured Depth of well bore (ft),
Ls = Average length of one DP stand (ft),
We = Effective weight of DP in the mud, (lb/ft)
M = Weight of Traveling Block Assembly (lb),
C = Excess of weight of DC above the DP: C = Ldc x (Wdc - Wdp) x BF, (lb).
Ldc = Length of DCs and BHA, (ft)
Wdc = Weight of DC in the air, (lb/ft)
Wdp = Weight of DP in the air, (lb/ft)
BF = Buoyancy factor of mud, (fraction)
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Ton x Km accumulated by making a round trip with the string in the hole (TRT):
D (Ls + D) We + 2D ( 2M + C)
TRT =
1,000,000
Where,
D = Measured Depth of well bore, (m),
Ls = Average length of a DP stand, (m)
We = Effective weight of DP in the mud, (Kg/m)
M = Weight of Traveling Block Assembly, (Kg)
C = Excess of weight of DC over DP: C = Ldc (Wdc - Wdp) x BF, (Kg)
Ldc = Length of DC and BHA, (m)
Wdc = Weight of DC in the air, (Kg/m)
Wdp = Weight of DP in the air, (Kg/m)
BF = Buoyancy factor of mud, (fraction)
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Work done for drilling (Tdrilling), coring (T

(Tcoring) and running casing (T
(Tcasing)
1. Work done to drill from depth D1 to depth :

Tdrilling = 3 (T2 - T1)
2. Work done to take a core from D1 to D2 :
Tcoring = 2 (T2 - T1)

3. Work done to run casing to a given depth, D
Tcasing = ½ TRT (using C = 0 because the lack of DC)

Where,
T2 = Work done for a round trip to the final depth D2 in drilling or coring before
pulling the string out of hole.
T1 = Work done for a round trip to the initial depth D1 for drilling or coring
TRT = Work done for a round trip with the drill string to the casing depth setting, D
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Exercise – Calculate the work done by the drilling line in ton x miles and
ton x km when a round trip is made at 15,000 ft with the following drilling
string:
Drill Collars: 21 x 30 ft, 6 ¾”OD x 2 ¾”ID, (101 lb/ft),

Drill pipe: 5”OD, (19.5 lb/ft),
Average of DP stands: 90 ft
Weight of Traveling Block Assembly: 12,000 lbs.
Mud weight: 12 ppg
Buoyancy Factor = (65.44 – MW in ppg)/65.44
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• The Drawworks National Oil Well. Electric Drawworks, Model UDBE
Types:
• Mechanical
• Electric
• Hydraulic
National Oil Well. Mechanical Drawworks, Model 1625M

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• The Drawworks
Types:
• Mechanical
• Electric
• Hydraulic
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• The Drawworks
Types:
• Mechanical
• Electric
• Hydraulic
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• The Drawworks
Types:
• Mechanical
• Electric
• Hydraulic
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• The Drawworks
Components:
• Transmission
• Main Shaft
• Clutch System
• Drum
• Main Break System
• Auxiliary Break System
• Break Cooling System
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• The Drawworks - Components
Main Shaft
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Main Break – Friction Disc
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Main Break – Friction Band
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Friction Clutch System
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Auxiliary Break – Electro Magnetic Break
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Auxiliary Break – HydroMatic Break
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Break cooling system
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Transmission Chains – Mechanical Drawworks
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• The Drawworks - Specifications
Mechanical Drawworks – Examples:
“National Oil Well”

Horse Power (HP) 550 750 1000 1500 2000 3000
Depth Range 3 - 7 6 - 10 8 - 12 11 - 16 13 – 20 16 – 30
K. feet (K. meters) (0.9 – 2.1) (1.8 – 3.05) (2.4 – 3.65) (3.35 – 4.88) (3.96 – 6.09) (4.88 – 9.14)
Drilling Line Size 1 1/8” 1 1/8” 1 1/4” – 1 3/8” 1 1/4” – 1 3/8” 1 3/8” – 1 1/2” 1 3/8” – 1 3/4”
Drum Size 18” x 38 ¾” 20” x 46 ¾” 25” x 49” 27” x 49” 30” x 56 ¼” 36” x 62”
Break Rim Size 42” x 8" 42” x 8” 46”x 10 3/8” 50”x 10 3/8” 54”x 10 3/8” 66” x 12”
Drum Chain Size and Type 1 ½” - D 2” – D 2” - D 2” - T 2” - Q 2 ½” - T Hvy
Transmission Chain Size 1 ½” – D 1 3/4” - D 2” - D 2” - T 2” - Q 2” – Q

and Type
Lifting Speed 2 6 6 6 6 6
Rotary Speed 2 3 3 3 3 3
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Mechanical Drawworks – Load Lifting Capacity:

Drawworks Ellis Williams co. - Lewco
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Electric Drawworks – Examples:
“National Oilwell”
Horse Power (Kw) 410 559 746 1119 1492 2238 2983
Drilling Depth Range 3 - 7 6 - 10 8 - 12 11 - 16 13 – 20 16 – 30 20 – 40

K feet (K meters) (0.9 – 2.1) (1.8 – 3.05) (2.4 – 3.65) (3.35 – 4.88) (3.96 – 6.09) (4.88 – 9.14) (6.09 – 12.19)
Drilling Size 1 1/8” 1 1/8” 1/4” – 1 3/8” 1 1/4” – 1 1 3/8” – 1 1/2” 1 3/8” – 1 3/4” 1 5/8” – 2”
3/8”
Drum Size 18” x 38 20” x 46 ¾” 25” x 49” 27” x 49” 30” x 56 ¼” 36” x 62” 42” x 72”
¾”
Brake Rim Size 42” x 8" 42” x 8” 46”x 10 3/8” 50”x 10 3/8” 54”x 10 3/8” 66” x 12” Disco
Drum Chain Size & 1 ½” - D 2” – D 2” - D 2” - T 2” - Q 2 ½” - T Hvy 2 ½” – Q

Type
Transmission Chain 1 ½” – D 1 3/4” - D 1 ½” - Q 1 ½” - Q 1 ½” - S 2” – Q 1 ¾”” – S
Size & Type
Lifting Speed 2 4 2 4 4 4 4
Rotary Speed 2 2 2 2 2 2 2
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• Hoisting Equipment Calculations:
Where:
Ld = Derrick Load, lbs
n = Number of lines
W = Maximum Hook Load, lbs
Hhp = Hook Horsepower, hp
Hs = Hoisting Speed in ft/min
Dhp = Drawworks horsepower, hp
Shaft efficiency: 0.98 for mechanical & 0.65 for electrical
A rule of thumb states that the drawworks should have a power of 1hp for every 10 feet to drill
So, to drill a 20,000 ft well it should be required a rig with a horsepower of at least 2,000 hp
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2.3. The Rotary System
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2.3. The Rotating System
Components:
1. Surface Equipment for Drill String Rotation:

a. Conventional System: Rotary Table + Kelly + Swivel
b. Drill String Rotation Driven by “Top Drive System”
2. The Drilling String
3. The Drill Bit
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2.3. The Rotating System – Surface Equipment
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Rotary Table:
A turning table mounted on the rig substructure, receives power from prime mover
or electrical motor and makes the “Kelly” (hexagonal or square bar) rotate and so
the drill string connected below it. The swivel, connected above the Kelly, allows
the injection of drilling fluid, supporting of string load while rotating.
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Rotary Table - Types:
• Mechanical: driven by chains and pinions that transmit power

from prime movers in mechanical drilling rigs
• Electric: Driven by DC or AC electric motors assembled to gear

box for speed regulation
• Hydraulic: Driven by hydraulic power generated with hydraulic

pumps operated by diesel engines or electric motors
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Rotary Table – Driving Mechanism:
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Rotary Table - Components:
• Housing - steel plate

• Coupling Ring - transmits rotation to
the master bushing .
• Replaceable Box - set of gears, shaft
and hoses
• Locks – to prevent accidental rotation
• Lube Port - to grease bearings
• Rollers – Rolling balls and track made of
high strength steel heat resistant.
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2.3. The Rotating System

Master Bushing
• Transmits rotation from Rotary Table to the Kelly via Kelly adaptor
• It is regularly split in two halves for easy installation in the RT opening.
• Put together, the two halves form a conical bowl to accommodate the Rotary Slips
on which the drill string in the hole is set
• The internal design varies with the Kelly type and size as well as the adapter
bushing used
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• Conventional System: Rotary Table + Kelly + Swivel

Casing Bushing
• Adaptors directly installed in the RT opening
• A range of casing sizes can be run through
the same set of Casing Bushings
• Some models allow rotation of casing string
set in rotary slips while it is cemented
• Casing string can be centralized in the RT
opening while is hung of Traveling block or
once has been cemented
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Kelly Bushing
• Wrapped around the Kelly is inserted in the rotary table via drive pins
or square box and transmits its rotation to the Kelly
• Kelly Bushing Varco series HDP withstand high torque and protects the
Kelly from premature wear. It can handle 5 ¼” and 6” hexagonal Kelly
Type XHDP Type HDP Type HDS Type MDS
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Rotary Table - Specifications:
Description Range
Rotary Table Bore (central opening) 12” - 60 ½”
Maximum Rotary Speed 250 - 400 RPM
Maximum Torque 25,000 – 40,000 lbf-pie
Maximum Static Load 85 - 1000 Ton.
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The “Kelly”
Tubular with hexagonal, square or triangular external configuration
that connects the top of the drilling string with the “Swivel”.
Transmits rotation from the RT to the drill string via “Kelly Bushing”
installed around the Kelly and inserted in the RT opening.
Most common Kelly’s configurations:
•Square bar
•Hexagonal bar
Typical Lengths:
•40 foot (effective length: 37 ft)
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• Conventional System: Rotary Table + “Kelly” + Swivel

The “Swivel”
The “Swivel” is considered the fundamental

element of the Rotary Drilling as it performs
simultaneously the following three functions:
• Supports the weight of drill string in the

hole
• Lets the drill string rotation while hanging
from the hook or setting on the rotary slips
• Allows circulation of the drilling fluid
under pressure through the drill string
while rotating
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The “Swivel” – Components
• Bail – to hang swivel from hook in TBA
• Goose neck – to connect the rotary hose
for injection of pressured drilling fluid
• Housing – cover of internal mechanism
• Main Bearing
• Lower Bearing
• Wash Pipe and rotating seals
• Top seal & bottom seal
• Rotating Shaft
• LH Connection to make up the Kelly
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The “Swivel” – Components (Example)
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b. String Rotation driven by “Top Drive System”:
Description:
Rotation device assembled to the Traveling
Block that runs up and down along a
stationary track mounted on the rig derrick.
The “Top Drive System” has a “Swivel” that
is connected directly to the drill string and to
the rotary hose. It is driven by a power system
also mounted on the TBA and operated with
hydraulic pumps or electric DC motor. The
TDS allows drill string rotation and fluid
circulation while moving up or down for
drilling or tripping out of hole. It does not
require “Kelly” and Rotary Table assembly
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Description (continued):
Most Top Drive Systems have hydraulic & electro
hydraulic controls with operating console at the
Driller’s station.
TDS has automatic pipe handling system to easily
pick up, connect, and run the drill string: bails, pipe
elevators, pipe spinner, power tongs and torque meter
TDS speeds up the drilling and tripping operations
since it handles two or three joints stands. Less
connection time
Ideal for tripping out of hole through tight spots with
back reaming due to its capacity to trip out while
circulating and rotating string.
C. Alvarez 90/146
TDS Components:
Transmission
• Transmission and Main Shaft
• Electric Motor / Hydraulic pump
• Swivel (integral or attached)
• Pipe Handling System (includes power tong and torque Swivel
converter)
• Hydraulic system Transmission
• Links and Bails Hydraulic

Pipe Handling
• Race Track and Torque support System
Race Track
and Torque support
C. Alvarez 91/146
Top Drive Performance:

Torque applied by the Top Drive on the drill pipe is a function of the
rotating speed of the string
C. Alvarez 92/146
Top Drive and Rotary Table Horsepower calculation:
Where,
Rhp = Rotary Table or Top Drive Horsepower, hp

N = Rotary Table or Top Drive RPM
T = Maximum Torque or DP make up torque, lb x ft
e = Transmission Efficiency (0.98 for mechanical, 0.65 for electrical)
C. Alvarez 93/146
“Top Drive” Vs. “Kelly”
The TDS has several advantages over the Conventional Rotary

System as follows:
• Less risk of personal injuries having automatic pipe handling

system
• Well shut in time in the event of a to a kick is reduced
• Connection time is reduced: one connection every three joints
• Increases ROP
• Ideal for “back reaming”
• Withstand more reactive torque and helps in sliding drilling
• More efficient “UBD” and “MPD” operations
• Reduces surface mud losses by activating the retention valve
C. Alvarez 94/146
2.3. The Rotating System – Down hole Equipment
The Drill String
C. Alvarez 95/146
2.3. The Rotating System – Down hole Equipment
The Drill String
Transmits rotation from RT or TDS to the drill bit and conducts the drilling fluid
pumped in through out the circulating system to clean the bottom and drill the hole
Components: From above to bottom, the drill string is formed by:
• Drill Pipe (DP) – set of tubular joints connected together by high strength
threads that withstand torque and all type of stresses
• Heavy Weight Drill Pipe (HWDP) – thick wall tubulars with higher
stiffness than the common DP. Act as transition elements between the
heavier and more stiff “Drill Collars” and the more flexible and lighter DP
• Drill Collars (DC) – Tubulars of high weight to provide weight on bit and
the required stiffness to the drill string
• Drill Bit – Rotary element with cutting structure to drill hole through the
sub surface formations (rocks) by the combined rotation, weight, and
bottom hole cleaning of cuttings generated
• Drill string Components will be discussed in a separate Section
C. Alvarez 96/146
2.4. Fluid Circulating System
C. Alvarez 97/146
Components:
Mud Pump
a. Drilling Fluid
Mud Tanks
b. Pumping and Circulating
Equipment
c. Solids Control Equipment Casing
Drill Pipe
d. Mud Conditioner (Degassers)
Annulus Open Hole
BHA
Drill Bit
C. Alvarez 98/146
Components:
a. The Drilling Fluid
Mix of fine particles of shale dispersed into a continuous liquid phase (water or oil base) to
form a fluid with special rheological properties (viscosity, gel strength and tixothropy)
which is circulated down hole through out the drill string and up the annulus transporting
the cuttings of formation drilled by the bit, cooling the drill string and performing several
other critical functions in drilling the well.
Functions :
1. Supply hydraulic power to the bit to clean the bottom of the hole and construct well
bore
2. Transport drill cuttings and cavings from bottom to surface
3. Keep stable walls of the drilled hole
4. Maintain the Primary Well Control at all times
5. Cool and lubricate the bit and the drill string
Conventional Drilling Fluids:
1. Water Based Mud, WBM
2. Oil Based Mud, OBM
3. Pneumatic Drilling Fluids (Air, Gas, Foams, Nitrogen, mix of Mud and Nitrogen, etc.)
C. Alvarez 99/146
Components:
a. The Drilling Fluid - Building and Maintenance
Four (4) routine operations performed to the drilling fluid are:
1. Initial Preparation
2. Weighing up (MW increasing)
3. Dilution (MW cut back)
4. Treating and Conditioning (contaminations)
Mixing dry additives in the mud system:
Mud hopper is used to feed dry powder material into a

stream of liquid that suctions the material from the funnel
due to a vacuum effect created when it passes through
“venturi” tube . The liquid is circulated through the active
Embudo de Mezcla system by a centrifugal pump
C. Alvarez 100/146
Components:
a. The Drilling Fluid - Basic Properties
Mud properties continuously monitored:
Mud Weight: using a specially designed balance
Marsh Viscosity: time required for ¼ gal to flow (drop) through

the bottom opening of a special funnel
Rheological Properties : Yield Point, Plastic Viscosity, and Gel

Strength measured with a type VG – 6 rotational viscosimeter
C. Alvarez 101/146
Components:
b. Pumping and Circulating Equipment
• Mud Tanks (discharge,

treatment, suction)
• Pump suction line
• Mud Pumps
• Pump discharge line
• High pressure surface lines
• Stand pipe
• Rotary hose
• Drill String
• Drill string/hole annulus
• Flow line (discharge line)
• Settling tank
• Mud conditioning tanks &
Equipment
C. Alvarez 102/146
Components:
b. Pumping and Circulating Equipment – Mud Pumps and Tanks
C. Alvarez 103/146
Components:
b. Pumping and Circulating Equipment – Mud Pumps
• Mud pumps are the heart of the circulating system

• Drilling mud pumps are reciprocant with two or three pistons, single or double action
– Duplex, Double Action Pump – 2 pistons – 2 liners – 4 suction valves y 4 discharge
valves. Used at the beginning of oil & gas drilling, have very low efficiency, high weight and
big size. Not used anymore for well drilling
– Triplex, Single or Double Action Pump – 3 pistons – 3 liners. If Single Action, have 3
suction valves and 3 discharge valves; if Double Action, have 6 suction valves and 6
discharge valves.
• With the reciprocating action, pistons move back and forth inside the liner to suction
and pump a small fluid volume in every stroke
• “Single Action” pumps only displace (pump) volume when piston goes forward.
“Double Action” pumps displace (pump) volume in both directions
• Liner size (ID x Length) determines the pump output and its wall thickness determines
the maximum pumping pressure
C. Alvarez 104/146
Components:
b. Pumping and Circulating Equipment – “Triplex – Single Action” mud pumps
Triplex pumps driven by independent DC Electric Motors

C. Alvarez 105/146
Components:
b. Pumping and Circulating Equipment – “Triplex – Single Action” mud pumps
Note that the pumping action is performed only when the piston travels forward
When piston travels backwards, suction valves open and chamber is filled with mud
C. Alvarez 106/146
Components:
b. Pumping and Circulating Equipment – “Triplex” mud pump - Components

Pulsation
Dampener
Transmission and
Connecting Rods
Pump Steel Housing
Suction and
Discharge
Modules
Discharge Manifold
Suction Manifold
C. Alvarez 107/146
Components:
C. Alvarez 108/146
Components:
Pump Steel Body

Power Assembly
Shaft Pinion Crank Shaft

C. Alvarez 109/146
Components:
C. Alvarez 110/146
Components:
Discharge Module
Suction Module
C. Alvarez 111/146
Components:
Suction & Discharge Manifolds
C. Alvarez 112/146
Components:
Pumping (Discharge) Module
C. Alvarez 113/146
Components:
C. Alvarez 114/146
Components:
Valve Cap
Pulsation Dampener Discharge Valve Pressure Gauge
A sealed diaphragm with 750 to 1000 psi

of nitrogen pressure acts as a cushion to Cover
damper pump pulsations derived of the Diaphragm
Plate
reciprocating action of pistons.
The result is a more steady flow for the

pumped fluid which eliminates line
vibrations and pressure noise which affect
surface equipment and down hole tools
(MWD equipment)
The dampener is connected directly to the Diaphragm

Body insert
discharge module exit to “rectify” or
soften pressure pulsations
C. Alvarez 115/146
C. Alvarez 116/146
Components:
b. Pumping and Circulating Equipment – “Triplex” mud pump – Spare Parts
C. Alvarez 117/146
Components:
Dimensions to consider:
•Piston stroke length (run inside liner)

•Liner inside diameter and piston head outer diameter
Theoretical displaced (pumped) Volume:
•Assume 100% of volumetric efficiency
Actual displaced (pumped) Volume:
Actual Vol. = Theoretical Vol. x Real Vol. Efficiency
Vol. Eff. for Triplex pumps is in the range 95% - 98%
C. Alvarez 118/146
Components:
C. Alvarez 119/146
Components:
b. Pumping and Circulating Equipment – “Triplex” mud pump – Operation
General Recommendations for Mud Pump Operation:
1. All liners specified for a given mud pump have same OD and Length but
different ID (wall thickness) that define the output (volume per stroke) and
working pressure
2. Smaller ID liners are used to drill the deepest interval where pressure losses
are maximum
3. Pump pressure if a function of the flow rate (GPM), pressure losses along
the circulating system which varies with the string design, well bore
geometry, drilling fluid properties and total flow area selected for the bit.
C. Alvarez 120/146
Components:
b. Pumping and Circulating Equipment – “Triplex” mud pump – Operation
4. A detailed hydraulic program must be calculated to determine pump

pressure requirements.
5. Mud pump size is specified by the stroke length, maximum liner size (ID)
that can be installed and the mechanical horsepower required for its
operation. Example: Triplex pump, 9” x 6.5” (meaning 9” of stroke length
and maximum liner size of 6.5” ID.). It also could be named by the internal
code and classification of the manufacturer. In this case, Triplex pump,
Gardner Denver, Model PZ – 9, 1000 HP.
6. Technical information on the pump output, maximum pump speed and

operating pressures for all liner sizes is always supplied by the
manufacturer
C. Alvarez 121/146
Components:
b. Pumping and Circulating Equipment – “Duplex – Double Action” mud pump
4 Discharge Valves
2 Pistons
Pump Power End
4 Suction Valves
C. Alvarez 122/146
Components:
C. Alvarez 123/146
Components:
Spare Parts:
C. Alvarez 124/146
Components:
Volumetric Efficiency:
1. The actual mud volume displaced by the piston in the liner chamber is
always lower than the theoretical due to several conditions (slippage, gas
or air in the mud, etc.)
2. Volumetric Efficiency Ev. is the ratio between the actual and theoretical
volume displaced. For Triplex – Single Acting pumps Ev. is in the range 95%
to 98%. For Duplex – Double Acting pumps, it is around 90%.
3. Mechanical Efficiency for most pumps with mechanical transmission is

around 85%.
C. Alvarez 125/146
Components:
Hydraulic and Mechanical Horse Power Requirements:
Flow Rate (GPM) x Pump Pressure (psi)

Hydraulic Horse Power (HHP) =
1713.6
Hydraulic Horse Power (HHP)

Mechanical Horse Power (HP) =
Mechanical Efficiency
C. Alvarez 126/146
Components:
b. Pumping and Circulating Equipment – Centrifugal Pumps
Charging and Recirculation Centrifugal Pumps - Description:
Rotating impeller of curved paddles inside a circular housing with one suction inlet
in the center and one eccentric outlet on the top through which the circulating
impeller expels the suctioned fluid due to the centrifugal force.
The volute shaped housing pumps the fluid in continuous pattern (no pressure
peaks nor pulsation vibrations as with the reciprocant pumps).
Centrifugal pumps are widely Discharge

used for charging Reciprocating
(piston) pumps, to feed the Solids
Control Equipment components
and to transfer fluids in the active Suction
surface system
C. Alvarez 127/146
Components:
b. Pumping and Circulating Equipment – Centrifugal Pumps
Charging and Recirculation Centrifugal Pumps - Description:
The spiraled design paddles are right or left oriented and the impeller can rotate
clockwise or counterclockwise
The impeller is mounted on a rotating shaft which can be connected to power end
of one diesel or gas operated engine or, more common, to an electric motor. The
pumped volume is a function of the impeller size and the HP of the electric motor.
C. Alvarez 128/146
Components:
c. Solids Control Equipment – Shale Shakers
Description:
The “Shale Shaker” is the primary equipment for

mud conditioning. It retains the cuttings of higher
size when the mud returning from the well bore
flows over a vibrating screen (steel mesh). The
solids are discarded out the shaker while the
liquid mud returns to the active system in surface
tanks.
The vibrating screens are mounted on a mobile

deck supported by springs. The deck movement
is generated by rotating weights driven by
Shale Shaker (vibrating Screen) electric motors which produce different types of
shaking movement: Linear, Circular, Elliptical
Non Balanced or Elliptical Balanced Motion.
C. Alvarez 129/146
Components:
c. Solids Control Equipment – Hydro Cyclones
Description:
Separation of fine solids dispersed in the mud by centrifugal force when the mixture is
pumped tangentially on the top of a conical shaped device made of polish plastic when it is
created internal vortices or twister which sends the heavier solids particles to the cone
walls and the clean fluid is sent upwards in to the over flow exit on the top of the cone.
The solids fall by gravity and leave through the outlet in the lower part of the cone.
The pattern of flow created inside the cone is called hydro cyclone which identifies the
principle of operation of the equipment.
Larger size particles are discarded with cones of higher OD (8”, 10”, 12”). Fines and
colloidal size particles are eliminated with smaller cones (3”, 4”).
D-Sander, D -Silter and Mud Cleaner are Hydro Cyclone arrangement used for elimination
of undesired solids in the mud system. They need special design to perform their functions.
C. Alvarez 130/146
Components:
c. Solids Control Equipment – Hydro Cyclones
D-Sander
D - Silter
C. Alvarez 131/146
Components:
c. Solids Control Equipment – Examples
D-Sander (eliminates Sand

Shale Shaker (to discard Size solids from the mud)
cuttings and larger solids)
C. Alvarez 132/146
Components:
c. Solids Control Equipment – Examples
Mud Cleaner
(to eliminate fine size solids) Decanting Centrifuge (High Speed Centrifuge)
(to discard low gravity solids)
C. Alvarez 133/146
Components:
d. Mud Conditioning Equipment - Degasser
The formation gas can be dissolved (entrained) in the mud system and affect
aversively its properties, in special the density which is of the utmost importance
for keeping the primary well control.
Other mud properties and conditions may be altered with the presence of gas in
the mud system. It reduces the volumetric efficiency of mud pumps blocks the
liner’s chambers or pump valves and eventually could cause stop pumping drilling
fluid in the hole.
The dissolved gas difficult both kick detection and well control operations in Oil
Based Mud or can be very critical when migrates in Water Based Mud.
C. Alvarez 134/146
Components:
d. Mud Conditioning Equipment - Degasser
Vacuum Type Degasser
C. Alvarez 135/146
2.5. Blow Out Prevention and Well Control Equipment
C. Alvarez 136/146
Functions
1. Stop unexpected or programmed well flow and contain pressure

2. Allow circulation or injection of control fluids
3. Allow the introduction of pipe with well under pressure (stripping)
4. Recover the primary well control lost
C. Alvarez 137/146
Surface Installation – Components:
• BOP Stack
• Annular BOP
• Pipe Rams BOP
• Blind Rams BOP
• Shear Rams BOP (for Offshore operations)
•Mud Cross (Drilling Spool) With outlets for Choke & Kill Lines
• Closing Unit – Remote Control Panels
•Choke Line
•Choke Manifold
•Kill Line
• Well Control Equipment Accessories:
•Emergency Kill Line
•Kick detection devices (PVT, Flow Line Indicator, Trip Tank)
•Mud Gas Separator
•Safety Valves
•Inside BOP
C. Alvarez 138/146
Example of Surface BOP Stack:
Annular BOP
Pipe Rams
Blind / Shear Rams
Choke Line
Kill Line
Pipe Rams (Variable Bore)
Master Pipe Rams
C. Alvarez 139/146
1. BOP Stack
3. Choke Manifold
2. Choke Line 4. Kill Line

5. Closing Unit (Remote Control)
C. Alvarez 140/146
Annular BOP Ram Type BOP
Shaffer Cameron Tipo “U”
C. Alvarez 141/146
BOP Closing Unit – Remote Control

C. Alvarez 142/146
Schematic of a BOP Closing Unit – Remote Control

C. Alvarez 143/146
Console for remote choke operation

C. Alvarez 144/146
Mud Gas Separator (“Poor Boy Degasser”)
C. Alvarez 145/146
Surface Installation:
Guidelines for the Design and Selection of BOP and WC Equipment
1. Maximum anticipated surface pressure (formation or operating pressure)
2. Type of well (low or high pressure formations)
3. Type of BOP installation (Surface or Subsea)
4. Maximum size of pipe & tools to be handled
5. Specific operating conditions (fluid corrosiveness, hydrate formation
potential, etc.)
6. Free space below rotary table for surface installations
7. Environment Considerations
8. Government Regulations
9. Oil & Gas Agencies’ Regulations
10. Company / Operator Policies in Well Control
C. Alvarez 146/146

02 The Basic Rig Systems

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02 The Basic Rig Systems

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Quartz School forBasic

2. The Well Site Supervisors in IPM

5. Well Control System

Five basic systems of a Drilling Unit:

2.1. Power System

2.1. Power System

2.1.1 Power Generation

2.1.2 Power Transmission

Mechanical power is generated by prime movers (diesel engines) which is

“DC – DC” Rig:

Direct Current (DC) is generated and transmitted with electric cables to

“AC – DC” Rig also known as “SCR” Rig:

Alternate Current (AC) is generated and then converted in Direct

3. “Diesel – Electronic” Rigs, also known as “Electronic” Rig:

“AC – AC” Rig:

Diesel – AC / AC Rig or “Electronic” Rig

• Mechanical Power from the Prime Movers can be used:

1. To drive systems and equipment in Mechanical Rigs,

2. To operate Electric Current Generators in Electric Rigs, as follows:

a. Direct Current Generator, DC

b. Alternate Current Generator, AC

The Prime Movers (Diesel Engines) - Operation:

• Internal Combustion Engine is fed by a compressed air and diesel oil

• Diesel engines can operate individually or coupled in parallel or

The Prime Mover (Diesel Engine) - Operation:

• The combustion cycle may has 2 or 4 positions to configure 2 or 4 stroke engine,

The Prime Mover (Diesel Engine) - Operation:

• The first generation of electric rigs was DC/DC type, as follows:

• The Direct Current (DC) generated is transmitted by electric cables to feed

1. “DC/DC” Rig - “DC” Generator

1. “DC/DC” Rig - “DC” Generator

• Most of Diesel-Electric rigs are of the type AC/DC or “SCR” Rigs:

• Main components of AC/DC – SCR system:

• Prime Movers – Internal combustion engines

1. DC Electric Motors (Mono phase electric current motors)

a. Are the most commonly used in “Electric Rigs”

2. AC Electric Motors (Three phase electric current motors)

• Electric Motor (Secondary Motor)

1. DC Electric Motor, (mono phase electric current)

• Electric Motor (Secondary Motor)

1. DC Electric Motor, (mono phase electric current)

• Electric Motor (Secondary Motor)

1. DC Electric Motor, (mono phase electric current)

• Electric Motor (Secondary Motor)

1. DC Electric Motor, (mono phase electric current)

• Electric Motor (Secondary Motor)

2. AC Electric Motor, (Three phase electric current)

• Electric Motor (Secondary Motor)

2. AC Electric Motor, (Three phase electric current)

1. “DC” Motors Vs. Diesel Engines:

2. “AC” Vs. “DC”:

• Electric Motors and Diesel Engines Comparison:

2. “AC” Vs. “DC” (continued):

Power Transmission Summary:

Engine / Generator Set

Total power requirements is the sum of all individual requirements for

1. The real power needed at a given time is a function of the

2. Maximum power is required when several functions are

3. Minimum power is used when running logs or while

2.2. The Hoisting System

1. Total drilling depth

•Gives the required room for standing and

• Crown Block – Components: