DRILLING ENGINEERING

CHAPTER # 1
Rotary Drilling Rigs
Objective
To familiarize the student with
(1) the basic rotary drilling equipment and operational
procedures.
(2) introduce the student to drilling cost evaluation.

Drilling Team
 Large companies vs. small
 Specialized skills
 Service companies
Types of Wells
(1) Wildcat Well: to discover new petroleum reservoir.
(2) Development Well: exploit a known reservoir.
 Geological Group: recommends wildcat location.
 Reservoir Engg. Group: recommends development
 Drilling Group: designs and cost estimate.
 Tool pusher
 Driller
 Ass. Driller
 Derrickman (monkey board)
 2-3 rotary helpers (floormen – or – rough necks)
 Motor man
 Rig mechanics
 Types of Wells...
 Rig electrician
 Company man
 Roust abouts
 Head roust about is the crane operator
 Mud engineer
 Casing crew
 Cementing service
 Legal Group: secures drilling rights
 Surveyors: establish and stake well location
 Drilling Contractor (Bid basis)
 Cost per Foot – drilling in area is routine.
 Cost per Day – unknown area
 Location Preparation
 Water Wells
 Types of Wells...

• South Louisiana marshlands: inland barge

• Canadian Arctic Islands: man-made ice platform

• Extensive storage & Supply

• Manpower: Contractor
Operator
Service Company
Consultants
1.1 Types of Drilling Rigs
Drilling and workover rigs come in a variety of shapes and sizes with
each having its own characteristics suited for a particular job. Although
there are many factors to be considered in selecting the best rig for the
job, a few are especially critical. They are:
 Surface location (land, inland water, offshore)
 Estimated maximum hole depth
 Horsepower requirements
 Cost
 Availability
 As can be imagined, the selecting of drilling and workover rigs is best
accomplished by use of good, sound judgement and engineering
experience.
 Rigs

Marine Land

Bottom FLoating Conventional Mobile

Support

Semi/ Drill ship Jacknife Portable

Submersible Mast (Small)
(Small
(Deeper)

Platform Barge Jackup

Self Tendered
-Contained
Common Types of Drilling Rigs
1. Land Rigs
As the name implies, these rigs are primarily used on
land; however, some have been transported offshore for
structure rig assignments. Most land rigs have to be
transported to location in sections, but some are self-
contained, permanently mounted on trucks. On location
they are usually set up on a board mat with a substructure
of 8 to 40 feet high, and a few are capable of drilling
holes to 30,000+ feet.
2. Inland Barges
Inland Barges are composed of two types:

a. Barge mounted rigs

This type rig is capable of drilling in water depths from 0 to
12 feet. After being towed on location, the rig’s hull is
filled with water until it rests on bottom.

b. Posted barge mounted rigs

These type rigs have an upper deck supported by posts from
the lower hull. The deck contains all drilling equipment and
accommodations. Posted barges are capable of drilling in
water depths from 0 to 20 feet. The rig is towed on location
and the lower hull filled with water to secure it on bottom.
3. Submersible Rigs
These rigs are towed on location and are capable of working in
water depths from 18 to 70 feet. They are composed of an upper
deck and lower hull connected by beams. On some types a large
bottle, or something similar, is located on each corner of the rig for
stability. These bottles, as well as the lower hull itself, are filled
with water to set the rig on bottom and stabilize against movement.

4. Jack-up Rigs
These rigs are normally towed on location, but a few are self-
propelled. They are composed of an upper deck supported by
either three or more legs attached to mats or spud cans and are
capable of working in water depths from 30 to 350 feet. These
mats or cans rest on the ocean floor with the deck jacked up into
drilling position. There are two common types of jack-up rigs;
Bethlehem and Letourneau. The former uses stabilized column
legs attached to mats while the latter uses three, truss-type legs
mounted on spudcans.
5. Semi-Submersible
These rigs can be towed on location, or some types are self-
propelled. They are capable of drilling in water depths of 20
to 2,000+ feet. The rig itself remains stationary in the
drilling position by a series of anchors (usually two
connected at each corner of the rig) positioned on the ocean
floor at a distance away from the rig. It should also be noted
that some Semis can be used as a submersible rig.

6. Drill Ships
Drill ships are self-propelled drilling vessels capable of
drilling in water depths of 18 to 2,000+ feet. There are two
basic types of drill ships - one that positions itself with
anchors and one that uses dynamic positioning.
7. Structure Rigs
Structure rigs are mounted on a fixed platform with all
drilling equipment secured on deck. The rig itself is
capable of changing positions on the structure;
however, the structure is permanently based and
designed to last many years. Structures are capable of
being set in water depths of 10 to 850+ feet. Structure
set-ups usually follow a successful exploratory program
in order that many development wells can be drilled
from one location. These wells are almost always
directional.
Rotary Drilling Process
• Rotary table rotates the drill string
 Downward force applied to the bit
 Cuttings are lifted to the surface by circulating a fluid down the
drill string.

Main Component Parts of a Rotary Rig are:-

are
1. Power System
2. Hoisting System
3. Fluid Circulating System
4. Rotary System
5. Well Control System
6. Well Monitoring System
A Rotary Drilling Rig
1.2 Rig Power System
 Most power consumed by :
hoisting system and fluid circulation

 Not used at same time

 Total power requirements 1000 – 3000 hp

 Old days steam

 Now internal combustion diesel engines types (1) diesel-

electric type (electric motors), (2) direct-drive type (gears-
chains) depending on power method.
Power-System Performance Characteristics
Are stated in terms of:

1. Output horse power

2. Torque
3. Fuel consumption for various engine speeds

P =  T = 2N.F.r (1.1)
Where,
P = shaft power (hp)
 = 2N, Angular velocity of the shaft (engine speed), rad/min
T = output torque (lb-ft)
N = Rev./min
 Power-System Performance Characteristics …...

 Overall power efficiency determines the rate of fuel consumption

(Wf) at a given engine speed.
 Heating values (H Btu/lbm) of various fuels for internal combustion
engines are shown in Table 1.1.
Fuel Density (lbm/gal) Heating Value H(Btu/lbm)
Diesel 7.2 19,000
Gasoline 6.6 20,000
Butane 4.7 21,000
Methane -- 24,000

• Heat energy to the engine Qi

Qi = Wf.H (hp) (1.2)
Et = P /Qi = Energy Output / Energy Input (1.3)
Et = overall power system efficiency
Example 1.1: A diesel engine gives an output torque of
1,740 ft-lbf at an engine speed of 1,200 rpm. If the fuel
consumption rate was 31.5 gal/hr, what is the output
power and overall efficiency of the engine?

Solution: The annular velocity, , is given by

=2(1,200) = 7,539.8 rad/min.
The power output can be computed using Eq. 1.1:
P=  T
7,539.8(1740) ft  lbf / min
 = 397.5 hp
33,000 ft  lbf / hp
Since the fuel type is diesel, the density  is 7.2 lbm/gal
and the heating value H is 19,000 Btu/lbm (Table 1.1).
Thus, the fuel consumption rate is wf is
wf = 31.5 gal/hr (7.2 lbm/gal) 1hour 

 60 min utes 

= 3.78 lbm/min
The total heat energy consumed by the engine is given by Eq.
1.2:
Qi= wf H
3.78lbm / min(19,000Btu / lbm)( 779 ft  lbf / Btu )

33,000 ft  lbf / min/ hp

= 1,695.4 hp.
Thus, the overall efficiency of the engine at 1,200 rpm given
by Eq. 1.3 is
P 397.5
Et   = 0.234 or 23.4% Answer
Qi 1695.4
1.3 Hoisting System
Function:
Function
Used to lower or raise drill strings, casing string and other subsurface equipment
into or out of hole.
Principal Components:
1. Derrick and substructure
2. Block and tackle
3. Draw works
Functions of Derrick:
1. Provides vertical height required to raise sections of pipe.
2. Rated according to their ability to withstand compressive loads and
(wind loads)
Components of Block and Tackle:
1. Crown block
2. Travelling block
3. Drilling line
Components of
the hoisting
system
Principal Function:
To provide a mechanical advantage which permits easier
handling of large loads.
Load supported by travelling block

Load imposed on the draw works
W
M
Ff
M= Mechanical advantage
F = tension in the fast line
The ideal mechanical advantage that assumes no friction in
the block and tackle can be determined from a force analysis
of the travelling block.
n Ff= W
W
Mi = n
W /n
Input power of block and tackle = pi

Pi = Ff Vf (1.5)
Ff = draw works load
Vf = velocity of fast line
Ph = output power of the hook load

Pn = W.Vb (1.6)
W = travelling block load
Vb = velocity of travelling block
Vf
Vb 
n
Vf
Vb 
h
Ph ( nF f )  (V f / n )
E  1 no friction
Pi Ff V f
Power efficiency is
W
E actual system
Ff n

Tension in the fast line

W
Ff  (1.7)
Eh
Eq. 1.7 is used to select drilling line size.

Fd = W + Ff + Fs (1.8a)
Fd = load applied to the derrick
Fs = tension in the lead line
W W  1  E  En 
Fd  W   W  (1.8b)
En n  En 
fast dead
Example 1.2: A rig must hoist a load of 300,000 lbf. The
drawworks can provide an input power to the block and tackle
system as high as 500hp. Eight lines are strung between the
crown block and traveling block.

Calculate
(i) the static tension in the fast line when upward motion is
impending,
(ii) the maximum hook horsepower available,
(iii) the maximum hoisting speed,
(iv) the actual derrick load
(v) the maximum equivalent derrick load, and
(vi) the derrick efficiency factor.
Assume that the rig floor is arranged as shown in Fig 1.17.
Solution:
(i) the power efficiency of n=8 is given as 0.841 in Table 1.2.
The tension in the fast line is given by Eq. 1.7.
W 300,000
Ff    44,590lbf
En 0.841(8)
(ii) The maximum hook horsepower available is
Ph = E.I = 0.841 (500) = 420.5 hp

(iii) The maximum hoisting speed is given by

  33,000 ft  lbf / min  
 420.5hp  
Ph   hp 
vb   = 46.3 ft/min
W 300,000lbf 
 
 
To pull a 90-ft stand would require
90 ft
t  1.9 min
46.3 ft / min
(iv) The actual derrick load is given by Eq. 1.8b
 1  E  En 
Fd   W
 En 
 1  0.841  0.841(8) 
  (300,000) = 382,090 lbf
 0.841(8) 
(v) The maximum equivalent load is given by Eq. 1.9
n4 84
Fde   W  (300,000)  450,000lbf
 n  8
(vi) The derrick efficiency factor is
 Fd  382,090
Ed      0.849 or 84.9% Answer
 Fde  450,000
Drawworks
Provide the hoisting and braking power required to raise or
lower the heavy strings of the pipe.

Principle Parts
• The drums
• The brakes
• The transmission
• The catheads
 1.4 Rotary System
Main Parts:
1. Swivel
2. Kelly
3. Rotary Drive
4. Rotary Table
5. Drill Pipe
6. Drill Collar

1. Swivel:
Supports the weight of the drillstring and permits rotation i.e. Bail
and Gooseneck.

2. Kelly:
Square or Hexagonal to be gripped easily. Torque is transmitting
through kelly bushings. Kelly saver sub is used to prevent wear on
the kelly threads.
 Rotary System…...
3. Slips:
During making up a joint slips are used to prevent drillstring
from falling in hole.

4. Rotary Drive:
Provides the power to turn the rotary table.
* Power Sub: can be used to connect casing.
5. Drill Pipe:
Specified by (a) Outer Diameter
(b) Weight per foot
(c) Steel grade
(d) Range Length
Range Length (ft)

1 18 to 22
2 27 to 30
3 38 to 45
 Rotary System…...
* Tool Joint: Female is called Box.
Male is called Pin.
* Upset : Thicker portion of the pipe.
* Internal upset: Extra thick.
* Thread Type: Round, tungsten carbide hard facing.
6. Drill Collar:
Thick walled heavy steel pipe used to apply weight to the bit.
* Stabilizer Subs : Keep drill collars centralized.
* Capacity : Volume per unit Length.
 2
Ap  d = Capacity of pipe (1.13)
4
 2
Aa  ( d 2  d12 ) = Capacity of annulus (1.14)
4
 2 = Displacement (1.15)
As  ( d1  d 2 )
4
 Rotary System…...

Capacity and displacement nomenclature

 Rotary System…...

Example 1.4: A drillstring is composed of 7,000 ft of 5-in.,

19.5-lbm/ft drillpipe and 500 ft of 8-in. OD by 2.75-in ID
drill collars when drilling a 9.875-in. borehole. Assuming
that the borehole remains in gauge, compute the number
of pump cycles required to circulate mud from the
surface to the bit and from the bottom of the hole to the
surface if the pump factor is 0.178 bbl/cycle.

Solution:
For field units of feet and barrels, Eq. 1.13 becomes

  2  2  gal  bbl  12in   d 

2
Ap   d in.  
3 
    bbl / ft
4   231in.  42 gal  ft   1,029.4 
 Rotary System…...

Using Table 1.5, the inner diameter of 5-in., 19.5 lbm/ft

drillpipe is 4.276 in.; thus, the capacity of the drillpipe is
4.2762
  0.01766 bbl ft
1,029.4
And the capacity of the drill collars is
2.752
  0.00735 bbl ft
1,029.4
The number of pump cycles required to circulate new
mud bit is given by


 0.01776(7,000)  0.00735(500)bbl  719cycles.
0.1781bbl cycle
 Rotary System…...

Similarly, the annular capacity outside the drillpipe is given by

9.8752  52
  0.0704 bbl ft
1,029.4
And the annulus capacity outside the drill collars is
9.8752  82
  0.0326 bbl ft
1,029.4
The pump cycles required to circulate mud from the
bottom of the hole to the surface is given by


 0.0704(7,000)  0.0326(500)  2,858cycles
Answer
0.1781 bbl cycle
Components of the rotating system
 1.5 Circulating System
Components:
1. Mud Pumps
2. Mud Pits
3. Mud Mixing Equipment
4. Contaminants Removal Equipment
Pumps:
Reciprocating Positive Displacement Piston Pumps.
• Two-Cylinders - Duplex (Double Acting Forward-Backward)
• Three-Cylinders - Triplex (Forward only Single Acting)

Duplex Triplex
Heavy Light
Bulky More Compact
High Output PressureLower
Pulsation Without Pulsation
Require more Maint. Cheaper to Operate
Therefore majority of new pumps are Triplex .
 Circulating System…...
Advantages
(1) Ability to move high solid content fluids
(2) Ability to move large particles
(3) Ease to operation and maintenance
(4) Reliability
(5) Ability to operate over wide range of pressure s and flow rates by
changing the diameters of the pump liners and pistons.

Overall Pump Efficiency =Mechanical Efficiency x Volumetric Efficiency

Em= Mechanical Efficiency ~ 90%
Ev= Volumetric Efficiency ~ 100%

Two Circulating pumps are installed on the rig.

• Shallow portion both are used.
• Deeper portion one is used.
 Circulating System…...

Components of the circulating System.

 Circulating System…...

Circulating System
 Circulating System…...

Pump Displacement

(1) Double Acting

Figure 1.25 (a)

dr = Piston rod diameter

dL= Liner diameter
Ls= Stroke Length (Stroke = one complete pump revolution).

Forward Stroke Volume Displaced = (/4) dL2 Ls

Backward Stroke Volume Displaced = (/4) (dL2 - dr2 ) Ls (for
one Cylinder)

Total Volume =Fp= 2 Ls(/4) (2LL2 - Lr2 ) . Ev (1.10)

(for two Cylinders)
Fp= Pump factor or pump displacement cycle.
Example 1.3: Compute the pump factor in units of barrels
per stroke for a duplex pump having 6.5-in. liners, 2.54-
in. rods, 18-in. strokes and a volumetric efficiency of
90%?

Solution:
The pump factor for a duplex pump can be determined
using Eq 1.10:

Fp = 2 Ls(/4) (2LL2 - Lr2 ) . Ev

= (/2) (18) [ 2(6.5)2 - (2.5)2] . (0.9)
= 1991.2 in.3 /stroke
or = 0.2052 bbl/stroke. Answer
 (2) Triplex Acting
Figure 1.25(b)

Fp= 2 (/4) dL2 Ls. Ev (1.11)

q=flow rate = Fp . N
(Where N = no. of cycles per unit time)

Pumps are rated for

1. Hydraulic Power
2. Maximum Pressure
3. Maximum Flowrate
P  q (1.12)
PH 
1714
PH = Pump Pressure, hp
∆P = Increase in pressure, psi
q = Flow rate (gal/min)