Rotary Drilling

In rotary drilling the rock is fragmented by crushing and shearing action of the bit. The bit is pressed down by compressive force and rotated. The compressive force provides crushing and rotation provides shearing action. The cuttings produced are brought to surface by the drilling fluid which is circulated in the bore hole.

Operations required for rotary drilling

Hoisting Rotation Drilling fluid circulation Feed

Hoisting operation
Hoisting operation is done for raising and lowering the drill string. The drill string is raised and lowered down for Adding dill pipes for advancing the bore. Changing the bit. Any other operation.

Hoisting operation
The hoisting operation requires the following equipment: Draw works Crown pulley bock Mast/Derrick Traveling pulley block Hook Wire rope/line

Derrick/mast
Derrick is a steel structure used for supporting the load of drill string. It also provides necessary vertical clearance for adding the pipe or making trip for changing the bit. For making trip a stand of two or three pipes is unscrewed/ screwed for reducing trip time and wear on the threads. In order to minimise and cause uniform wear, the alternate joints are screwed/unscrewed.

Height of the derrick

The height of the derrick is either 41 m or 52 m depending whether two pipe or three pipes stand is used. Parts of the derrick: Legs Brace Girt Ladder Platform Water table Crow nest

Types of the derrick

Four legged derrick: are normally used on off shore and heavy duty drills on shore Two legged derrick- A shaped known as mast used on shore

Load on derrick

Two types of loads are subjected on derricks: Wind load Load of drill string/ casings/pull during fishing. Wind load: The wind exerts horizontal force on the derrick . p = 0.04 V2 Where p- pressure in psi V- velocity of air in miles per hour The force due to wind is maximum when the pipes are withdrawn during trip and stacked vertically along the derrick and works as wall. Force ( F ) = p*A where A is the area of wall made by pipes. A = dop*n*lp dop is out side dia of drill pipe n is no of pipes stacked lp is length of stand of pipes

Load on derrick due to drill string

The load on derrick may be considered With out friction in pulleys With friction Load with out friction: W = HL ( n+2 )/n where: W = load on derrick HL = hook load n = no of lines which is twice the no of pulleys in traveling block

Load on derrick with friction

n = no. of working sheaves or no of lines strung to Traveling block Fl = fast line tension Dl = Dead line tension K = sheave and line efficiency per sheave EF = block and tackle efficiency factor p1, p2, p3, ..pn are pull in lines 1, 2, 3,n p1 = Fl* K, p2 = Fl*k2, p3 = Fl*k3, pn = Fl*kn

Hook load (W) = p1+ p2+p3+.+pn W = Fl*k+ Fl*k2+ Fl*k3+.+Fl*kn W = Fl (1- Kn ) /(1 K) Fl = W (1- K) /K (1- Kn) Since last pulley is not rotating Dl = pn Load on derrick = Fl+ W + Dl In absence of friction Fl= p1=p2= pn pav = W/N Efficiency factor EF = Pav/Fl EF = K (! Kn)/N (1 K)

Hook load comprises of loads due bit, drill collars, weight of drill pipes and weight of swivel etc Drill collars are thick wall pipes used to provide the weight on bit. They also help in reducing the vibrations of the drill string and keep the hole straight. Weight on bit depends on the diameter of the bit and type of rock being drilled. WOB = Diameter of bit in mm * wob / mm diameter of bit wob /mm depends on rock hardness as given below: very hard rock - 90 to 120 kg/ mm diameter of bit hard rock - 70 to 90 medium hard - 60 to 70 soft rock - 40 to 60 very soft rock - 20 t0 40

Hook load

Size and length of drill collars

The diameter of the drill collar should about 15mm less than the diameter of hole being drilled. Since the well is telescopic it may not be possible to select drill collar for every bit to used fo drilling a complete well. How ever drill collar may be selected based on smallest diameter of the bit to uses. The following details have to found from drill data book. Out side dia of drill collar In side dia of drill collar Weight of drill collar/meter length

Length of drill collar string (lc)= WOB/ wt of drill collar/ meter Actual length of drill collar string should be Lc = 1.3* lc By keeping the drill collar length longer than required, null point on string will be ensured on drill collars. Null point is the point on the string where the stress is zero. The string above null point will be in tension blow it will be in compression. If the drill string is raised off the ground, the string will be in tension and its weight will be indicated on the weight indicator. To apply load on bit the string is lowered and allowed to touch the ground. The load will now be transferred to the bit. Continue transfering the load till required wob is achieved .

Length of the drill string made up of pipes

The string can be made in any of the following manner: Uniform diameter Telescopic Larger dia pipes on top and smaller dia pipes for remaining length. Uniform diameter but different thickness or different grades or different class of pipes The criteria is load on pipes. The maximum load comes on top of the string.

Hook load
Hook load can now be calculated as given below HL = (wp1*lp1+wp2*lp2 +wc*LC )(1-m/ s) +weight of bit and swivel etc wp1= weight/m of pipe 1 in meter lp1 = length drill pipe 1 wp2= weight/m of pipe 2 lp2 = length drill pipe 2 in meter m = specific gravity of mud s = specific gravity of steel weight of bit and swivel etc may added lump sum

The forces to which drill pipes are subjected to are: Tension: due to self weight of pipes and is maximum at top. Collapse this is due the pressure exerted by mud column out side the pipe. This maximum at the bottom of the pipe. Normally this pr is zero because of equal height of mud in side out side of the pipe. In some cases, as in drill stem testing, the drill pipe is run partially full, to reduce hydrostatic pr exerted against the formation. This is done to permit the formation fluid to flow in the well bore Torsion: This is due to the twisting action of rotating drill pipes caused by resistance offered by rock to bit. This can be calculated by torsion theory. Complex stresses will develop due to tension and torsion combined.

Drill string design

Drill string design

Pa=Pt*0.9 - MOP Pt is drill pipe yield strength to be taken from drill data book as per API MOP is margin of pull normally range from 25000-50000 Kg and is provided to take care for extra pull during fishing etc Now length of smaller dia pipe is calculated Pa =( wp1*lp1 +wc*Lc) BF Length of upper pipe lp2=Well depth-(Lc+lp1) Pa for upper pipe= Pt*0.9- MOP .

Pt is for upper pipe and to be taken from drill data book Pa =( wp1*lp1+wp2*lc2 +wc*Lc) BF Pa calculated should be smaller than the permissible load on drill pipe

Power for hoisting

Hoisting power=( HL in Kg*Vel of hoisting in m/min)/4500*

Multiple pulley system

Advantages: Tension in wire line is reduced Load on derrick is reduced Velocity of hoisting is reduced We can drill deeper for a given power by reducing vel. wn = HL /n Where wn = tension in wire line n = no of lines

Power of winding
Hp of winding = wn*vel of winding/4500* vel of winding = n* vel of hoisting

Draw works
Draw works is central unit and is important to the extent that rig is known by the name of draw works, even though the other units may be of different makes. The main function of the draw work is to perform hoisting operation. It consists of the following sub units. Hoisting drum brake clutch control panel cooling system for braking drum. cat head The power for rotary table is also taken from draw works.

Design of drum
T= wn*R Hp = 2 NT/4500* The diameter and length of the drum should be designed in manner that the length of the wire rope for hoisting should be accommodated in two layers only. The drum is grooved for wrapping the wire rope. The length of the drum should be such that it should be transportable in commercial vehicles.

Control panel
All the controls and gauges of the rig are provided on the panel so that operator may control all the functions fron one location. Controls include speed of hoisting, wob, stroke per minute, pump pr, mud details etc.

Tackle block
Tackle block consist of crown pulley block traveling pulley, hook and wire line. Crown pulley block: Crown pulley block consisting a set of pulleys is mounted on top of derrick. Pulleys are mounted on the shaft with double ball bearing in steel frame which is filled with lubricant partially. It has one number of pulley higher than no. of pulleys in traveling block.

Traveling pulley block: Traveling pulley block consisting a set of pulleys is suspended with the wire rope. The hook is attached to the frame of TB.

Wire rope: A wire rope is reeved over the pulleys of CB & TB. One end of wire rope is attached to hoist drum and is called fast line. The other end is connected to dead end is called dead line. The pulley on CB connected to dead line remains stationary and does not rotate. A wire rope is made of strands and strand is made of wires. Wire rope is specified by X*Y where X is no. of strands in wire rope and Y is no. of wires in strand. Nominal diameter: The diameter is measured over top of wires and not on top of strands. Lay of wire rope: Lay of wire rope is the direction of laying wires in strand and strands in wires in strands. There are two types of lay: Lang lay and regular lay. Lang lay: in lang lay wires in strands and strands in wire rope are twisted in same direction. This can be right lay or left lay Regular lay: The wires in strands and the strands in wire rope are twisted in opposite directions. Core The central part of rope is called core which may be made of fiber or steel.

swivel
Swivel is installed above kelly, and its main function is to prevent the rotary motion of the kelly being transferred to the traveling block. Swivel is suspended to hook with link. Goose neck is connected to spindle though neck bush. The other end of the goose neck is connected to flexible hose pipe through which the mud from the pump enters the swivel and drill string which flows down to bit. The neck bush does not rotate while spindle rotates. The packing between bush and spindle prevents the leakage of mud. The spindle is supported on heavy duty roller bearings to take the load of drill string.

Kelly
Kelly is upper most pipe of drill string. It is either square or hexagonal shape. Its main function is to transmit rotary motion of rotary table to bit through drill string. Kelly also serves as medium for flow of mud to drill pipes and bit. During tipping the kelly with swivel is put in side hole called rat hole. Kelly is made of high grade chrome molybdenum Steel heat treated, quenched and tempered over the length, normalised and tempered. Hardness is Bhn = 281 to 341, length is 12.2m and 16.5m Diameter is 2.5 inch to 6 inch. Kelly bushing and master bushing are provided in rotary table for transfer of motion from rotary table to kelly. Kelly savers and kelly cocks are provided at both ends of kelly to save wear on spindle of swivel and wear on threads of kelly itself due to screwing and unscrewing of pipes for adding pipe or during tripping. Kelly cocks are used for closing the passage through kelly in case of kick of over pressure

Drill Stem
The drill stem consists of drill pipes, drill collars, accessories and bit. Drill Pipe: The main function of drill pipe is to transmit rotary motion and mud under high pressure to drill bit. Classification of drill pipes: Nominal diameter range 63.3mm to 168.3 mm Length 18-22 ft, 27-30 ft, 38-45 ft Grade of materials E75, X95, G105, S135 End condition Internal upset, External upset and internal external upset. Class of pipe New pipe, premium wall thickness 80%, class two wall thick ness 65%, class three wall thickness 55%.

Drill bits
Drrii bits

Coring bits

Noncoring bits

T C Bits

Diamond bits

Drag bit Rock Roller bit Diamond bit

Drag bits
Drag Bits: Drag bits cuts due to shearing and crushing action of blades on the formation. They are two types: Two blade type and three blade type. The flushing holes are so placed that the mud strikes at 2/3 radius of bit for keeping blades clean. The front side of the blades are made wear resistant by welding TC tips. These are used for drilling in soft and sticky formations.

Rock roller cone bits

Tri cone rock roller bit: These bits employs roller cones which rotates about their axis. The bit has three main parts Legs, cone and bearings Legs are made of forged steel by forging separately. Each cone is mounted on bearings which run on a pin that forms an integral part of the bit leg. Three legs are welded together and form the cylindrical section, Which is threaded to make a pin at top to make connection with drill string. Each leg is provided with a hole in which a nozzle is fitted to provide a constriction in order to obtain a high jetting velocity of mud for effective cleaning of bore well.

Design features of roller bit

Design features of roller bit depends on type and hardness of formation and size of hole to be drilled. Design features include (a) journal angle (b) Amount of offset (c) teeth (d) bearings and (e) interrelationship between (c) & (d) Journal angle: angle between a line perpendicular to axis of journal and axis of bit. The smaller the journal angle the greater the gouging and scraping action by three cones. The optimum journal angles for soft and hard rock roller bits are 330 & 360, respectively.

Offset
Offset angle: The offset is defined as the horizontal distance between the axis of the bit and vertical plane passing through the axis of journal. It is the angle between the journal axis and geometrical axis of the cones if they are placed at 1200. For hard rocks the offset angle is zero and cones have pure rolling action. For soft rock rocks cones should have offset angle. With offset cones have rolling and sliding action. To dislodge the chip cut by bit sliding action is required. For rocks of medium hardness the skew angle can be upto 20.

Teeth
Teeth: The are two types- Integral, milled or cut teeth and other are inserted teeth Milled teeth are normally for comparatively for softer rock and inserted teeth are for harder rocks. Spacing and interfitting of teeth large spacing is used for softer formation and permits meshing of teeth for cleaning. Shape and length of teeth: Long, slender and widely spaced teeth are used for drilling soft formation rocks. The included angle for soft bit tooth ranges from 390 to 420. For hard formations the teeth are manufactured shorter, heavier and more closely spaced, to with stand the high compressive loads required to break the rock. For medium hard formation would have moderate no of teeth.

Bearings
Bearings are used for supporting radial loads, thrust and secure the cones on the legs. Radial forces are born by roller bearings and thrust is taken by ball bearing. Ball bearing also works as retainer for the cone.

Forces on drill pipes and properties

The drill pipes are subjected to following forces: Tensile force: Due to self weight, maximum at top Collapse Pressure: Due to mud pressure maximum at bottom Shear force: due to twist of drill pipe cyclic stresses due to bending

PROPERTIES
The drill pipes should be seamless, straight, should have uniform thickness. Screws at ends should not be damaged and Pipes should be strong to bear all types of forces. There are two tool joints, box and pin joints which are threaded and welded at both ends of each pipe. The joint of two pipes is made between box end of one pipe and pin end of other pipe. The threads on tool joints are tapered to save the time of screwing and unscrewing. These joints are replaceable on wear of screws. Thus life of pipes is increased.

TOOL JOINTS

Drill Collars as discussed before. Other components of drill string are Reamers Stabilizers Tool joints

Bit selection
Bit selection depends on the following Cost per meter C = B + ( T + t ) R/L B = bit cost T = trip time T = rotating time R = Rig cost per hour L = Length drilled by bit Specific energy Bit dullness Offset well bit records