CHAPTER # 1

Rotary Drilling Rigs

DRI LLI NG ENGI NEERI NG



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
South Louisiana marshlands: inland barge

Canadian Arctic I slands: man-made ice platform

Extensive storage & Supply
Manpower: Contractor
Operator
Service Company
Consultants

Types of Wells...
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
Support
Semi/
Submersible
FLoating Mobile Conventional
Platform
Drill ship
Jackup Barge
Self -
Contained
Tendered
Jacknife
(Deeper)
Portable
Mast (Small)
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. I nland 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 rigs
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. J ack-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:-
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

- 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.
1.2 Rig Power System
Are stated in terms of:

1. Output horse power
2. Torque
3. Fuel consumption for various engine speeds
P = e T = 2tN.F.r (1.1)

Where,
P = shaft power (hp)
e = 2tN, 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 Q
i

Q
i
= Wf.H (hp) (1.2)
E
t
= P /Q
i
= Energy Output / Energy Input

(1.3)
E
t
= overall power system efficiency
Power-System Performance Characteristics ...
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, e, is given by
e=2t(1,200) = 7,539.8 rad/min.
The power output can be computed using Eq. 1.1:
P=e T
hp lbf ft
lbf ft
/ 000 , 33
min / ) 1740 ( 8 . 539 , 7

=
= 397.5 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 w
f
is
w
f
= 31.5 gal/hr (7.2 lbm/gal)
|
.
|

\
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utes
hour
min 60
1
= 3.78 lbm/min
The total heat energy consumed by the engine is given by Eq.
1.2:
Q
i
= w
f
H
hp lbf ft
Btu lbf ft lbm Btu lbm
min/ / 000 , 33
) / 779 )( / 000 , 19 min( / 78 . 3

=
= 1,695.4 hp.
Thus, the overall efficiency of the engine at 1,200 rpm given
by Eq. 1.3 is
4 . 1695
5 . 397
= =
i
t
Q
P
E
= 0.234 or 23.4% Answer
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
1.3 Hoisting System
Components of
the hoisting
system
draw works the on imposed Load
block ing by travell supported Load
=
Principal Function:

To provide a mechanical advantage which permits easier
handling of large loads.
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 F
f
= W
f
F
W
M =
M
i
= n
n W
W
=
/

Input power of block and tackle = p
i


P
i
= F
f
V
f
(1.5)
F
f
=draw works load
V
f
=velocity of fast line
P
h
=output power of the hook load

P
n
= W.V
b
(1.6)
W =travelling block load
V
b
=velocity of travelling block
n
V
V
f
b
=
h
V
V
f
b
=
friction no
V F
n V nF
P
P
E
f f
f f
i
h
1
) / ( ) (
=

= =
Power efficiency is
n F
W
E
f
=
actual system
Tension in the fast line
h
f
E
W
F =
(1.7)
Eq. 1.7 is used to select drilling line size.

F
d
= W + F
f
+ F
s
(1.8a)
F
d
=load applied to the derrick
F
s
=tension in the lead line
|
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|

\
|
+ +
= + + =
En
En E
W
n
W
En
W
W F
d
1
fast dead
(1.8b)
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.
lbf
En
W
F
f
590 , 44
) 8 ( 841 . 0
000 , 300
= = =
(ii) The maximum hook horsepower available is
P
h
= E.
I
= 0.841 (500) = 420.5 hp

(iii) The maximum hoisting speed is given by
|
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|
|
|
.
|

\
|
|
.
|

\
|
= =
lbf
hp
lbf f t
hp
W
P
v
h
b
000 , 300
min / 000 , 33
5 . 420
= 46.3 ft/min
To pull a 90-ft stand would require

min 9 . 1
min / 3 . 46
90
= =
ft
ft
t
(iv) The actual derrick load is given by Eq. 1.8b
W
En
En E
F
d
|
.
|

\
|
+ +
=
1
) 000 , 300 (
) 8 ( 841 . 0
) 8 ( 841 . 0 841 . 0 1
|
|
.
|

\
| + +
=
= 382,090 lbf
(v) The maximum equivalent load is given by Eq. 1.9
lbf W
n
n
F
de
000 , 450 ) 000 , 300 (
8
4 8 4
=
+
=
|
.
|

\
|
+
=
(vi) The derrick efficiency factor is
= =
|
|
.
|

\
|
=
000 , 450
090 , 382
de
d
d
F
F
E 0.849 or 84.9% Answer
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

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.
1.4 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 J oint: Female is called Box.
Male is called Pin.

* Upset : Thicker portion of the pipe.
* I nternal 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.
Rotary System...
) (
4
2
1
2
2
d d A
a
=
t
) (
4
2
2
1
d d A
s
=
t
2
4
d A
p
t
=
= Capacity of pipe (1.13)
= Capacity of annulus (1.14)
= Displacement (1.15)
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 I D
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

ft bbl
d
ft
in
gal
bbl
in
gal
in d A
p
/
4 . 029 , 1
12
42 . 231
.
4
2
3
2
2
|
|
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|

\
|
=
|
|
.
|

\
|
|
|
.
|

\
|
|
.
|

\
|
|
.
|

\
|
=
t
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
ft bbl 01766 . 0
4 . 029 , 1
276 . 4
2
= =
And the capacity of the drill collars is
ft bbl 00735 . 0
4 . 029 , 1
75 . 2
2
= =
The number of pump cycles required to circulate new
mud bit is given by
| |
. 719
1781 . 0
) 500 ( 00735 . 0 ) 000 , 7 ( 01776 . 0
cycles
cycle bbl
bbl
=
+
=
Rotary System...
Similarly, the annular capacity outside the drillpipe is given by
ft bbl 0704 . 0
4 . 029 , 1
5 875 . 9
2 2
=

=
And the annulus capacity outside the drill collars is
ft bbl 0326 . 0
4 . 029 , 1
8 875 . 9
2 2
=

=
The pump cycles required to circulate mud from the bottom
of the hole to the surface is given by
| |
cycles
cycle bbl
858 , 2
1781 . 0
) 500 ( 0326 . 0 ) 000 , 7 ( 0704 . 0
=
+
=
Answer
Rotary System...
Components of the rotating 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 Pressure Lower
Pulsation Without Pulsation
Require more Maint. Cheaper to Operate

Therefore majority of new pumps are Triplex.

1.5 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
E
m
= Mechanical Efficiency ~ 90%
E
v
= 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
d
L
= Liner diameter
L
s
= Stroke Length (Stroke = one complete pump revolution).

Forward Stroke Volume Displaced = (t/4) d
L
2

L
s
Backward Stroke Volume Displaced = (t/4) (d
L
2
- d
r
2
) L
s

(for one Cylinder)


Total Volume =Fp= 2 L
s
(t/4) (2L
L
2
- L
r
2
) . Ev (1.10)


(for two Cylinders)

Fp= Pump factor or pump displacement cycle.
Circulating System...
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 L
s
(t/4) (2L
L
2
- L
r
2
) . Ev
= (t/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 (t/4) d
L
2
L
s
. 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


1714
q P
P
H
- A
=
P
H
=Pump Pressure, hp
P =I ncrease in pressure, psi
q =Flow rate (gal/min)
P cannot more than 3500 psi
(1.12)
Circulating System...
Flow conduits between pump and drill string include:

1. Surge chamber (Pulsation Damper)
2. 4 or 6 inch heavy-walled pipe connecting the pump to
a pump manifold located on the rig floor.
3. Standpipe and rotary hose.
4. Swivel
5. Kelly


Go over EXAMPLE 1.3.
Circulating System...
1. Shale shaker for coarse rock cuttings
2. Hydrocyclones and decanting centrifuge for fine particles.
3. Degasser

Gas as a drilling Fluid (Air, Natural gas)
1. Penetration rate is higher than water especially when
formation is strong and extremely low K.
2. Water flow is a problem.
3. Isolate by injecting
(a) Low Viscosity Plastic
(b) Silicon Tetrachloride
(c) Using Packers
4. Min. annular velocity is 3000 ft/min for injection pressure.
5. Use Foam.
Contaminant Removal
Circulating System...
Parameters displayed
1. Depth
2. Penetration rate
3. Hook Load
4. Rotary Speed
5. Rotary Torque
6. Pump Rate
7. Pump Pressure
8. Mud Density
9. Mud Temperature
10. Mud Salinity
11. Gas content of mud
12. Hazardous gas content of air
13. Pit Level
14. Mud Flow Rate.

* Centralized well monitoring system
* Mud Logger
* Subsurface well-monitoring and data telemetry systems
(mud pulser).
1.6 Well Monitoring System
Function:
Prevents the uncontrolled flow of formation fluids from the
wellbore.

Kick:
Flow of formation fluids in the presence of drilling fluid
(blowout).

Uses:
1. Detect the Kick
2. Close the well at the surface.
3. Circulate the well under pressure to remove
formation fluids and increase density.
4. Move drillstring under pressure.
5. Divert flow away from rig personnel and equipment.
1.7 Well Control System
Kick Detection During Drilling Operation
Kick Detection:
a. Pit volume indicator
b. Flow indicator
c. Hole fill up indicator (during tripping)
d. Count the pump strokes.

BOP (Blow Out Preventer)
Multiple BOPS used in series: BOP Stack

Ram Preventers Semi circular openings which
Pipe Rams match diameter of pipe

Blind Rams : Closes the hole, no pipe present.
Shear Rams: Blind rams that shear the pipe.
Working press: 2000, 5000, 10000, 15000 psig.

Annular Preventers (Bag-type): Rubber Ring

BOPE:Closed hydraulically or using screw-type locking.
Well Control System...
Accumulators
High pressure hydraulic system used to close the BOP.
* Fluid Capacity : 40, 80 120 gal.
* Max. Operating Pressure : 1500-3000 psig.
* has a small pump independent of rig power.

Strip Pipe
Lower pipe with preventer closed. Must be able to vary
closing pressure using pressure regulating system.

Drilling Spool
Placed between ram preventers
(1) provide space for stripping
(2) flowline attached to it.
Well Control System...
Kill Line
conduit used to pump into the annulus.

Choke Line Conduit used to release fluid
Diverter Line from the annulus.


Drilling Spools
Must be large enough to allow next casing to be put in
place without removing the BOP.

Casing Head (Braden Head)
Attached to BOP, welded to the first string of casing
cemented in the well.

Control Panel
To operate the BOP stack. RSRRS
Well Control System...
Rotating Head
Seals around the kelly at top of BOP stack, used for drilling with
slight surface pressure at annulus.

Kelly Cock
Close the flow inside kelly.

I nternal Blowout Preventers
Prevents flow inside drill string.

Adjustable Choke
Used during Kick circulation, controlled from a remote panel on
the rig floor.
Sufficient pressure must be held against the well by the choke so
that the bottomhole pressure in the well is maintained slightly
above the formation pressure.
* Working Press Systems: 2000,3000,5000,10000,15000 psig.
Well Control System...