Drilling Engineering – PE 311 Rotary Drilling System

1. Drilling Engineering – PE 311 Rotary Drilling System

2. General Information Instructor: Tan Nguyen Class: Tuesday & Thursday Time: 11:00 AM - 12:15 PM Room: WIER 129 Office: MSEC 372 Office Hours: Tuesday & Thursday 2:00 – 4:00 pm Phone: ext-5483 E-mail: tcnguyen@nmt.edu

3. Required Materials Applied Drilling Engineering – Adam T. Bourgoyne – SPE Textbook OR Fundamentals of Drilling Engineering – Robert Mitchell & Stefan Miska – SPE Textbook. Class notes PowerPoint slides

4. Grading Homework: 20% Quizzes: 20% Midterm exam: 30% Final: 30%

5. Movie http://www.youtube.com/watch?v=DniNIvE69SE&feature=related

6. Main Rig Components

7. Main Rig Components 1. Power System 2. Hoisting System 3. Fluid Circulating System 4. Rotary System 5. Well Control System 6. Well Monitoring System

8. Main Topics in Drilling Rotary drilling Drilling fluids Drilling hydraulics Drilling bits Directional drilling Formation and fracture pressure Cements Casing design Tubing design Other topics: under balance drilling, cutting transport, etc.

9. Steps To Drill an Oil/Gas Well 1. Complete or obtain seismic, log, scouting information or other data. 2. Lease the land or obtain concession. 3. Calculate reserves or estimate from best data available. 4. If reserve estimates show payout, proceed with well. 5. Obtain permits from conservation/national authority. 6. Prepare drilling and completion program. 7. Ask for bids on footage, day work, or combination from selected drilling contractors based on drilling program. 8. If necessary, modify program to fit selected contractor equipment.

10. Steps To Drill an Oil/Gas Well 9. Construct road, location/platforms and other marine equipment necessary for access to site. 10. Gather all personnel concerned for meeting prior to commencing drilling (pre-spud meeting) 11. If necessary, further modify program. 12. Drill well. 13. Move off contractor if workover unit is to complete the well. 14. Complete well. 15. Install surface facilities. 16. Analysis of operations with concerned personnel.

11. Drilling Rig A drilling rig is a machine which creates holes (usually called boreholes) in the ground. Drilling rigs can be massive structures housing equipment used to drill water wells, oil wells, or natural gas wells, or they can be small enough to be moved manually by one person. Rotary table drive: rotation is achieved by turning the kelley at the drill floor. Top drive: rotation and circulation is done at the top of the drill string, on a motor that moves in a track along the derrick.

12. Drilling Rig Drilling rig preparing rock blasting Water well drilling rig

13. Drilling Rig Oil drilling rig onshore Rotary table drive Oil drilling rig onshore Top drive

14. Drilling Rig Rotary Table drive Drilling Top Drive Drilling

15. Drilling Rig An advantage of a top drive is that it allows the drilling rig to drill longer sections of a stand of drill pipe. A rotary table type rig can only drill 30’ sections of drill pipe while a top drive can drill 90-feet drillpipe. Therefore, there are fewer connections of drill pipe and hence improving time efficiency.

16. Drilling Rig While the bit cuts the rock at the bottom of the hole, surface pumps are forcing drilling fluids down the hole through the inside of the drill pipe and out the bit. This fluid lubricates and removes cuttings. The fluid (with the cuttings) then flows out the center of the drill bit and is forced back up the outside of the drill pipe onto the surface of the ground where it is cleaned of debris and pumped back down the hole. This is an endless cycle that is maintained as long as the drill bit is turning in the hole. In generally, there are four main systems of a rotary drilling process including: Rig power system, hoisting system, drill string components, and circulating system.

17. Rig Power System The power generated by the power system is used principally for five main operations: (1) rotating, (2) hosting, (3) drilling fluid circulation, (4) rig lighting system, and (5) hydraulic systems. However, most of the generated power is consumed by the hoisting and fluid circulation systems. In most cases these two systems are not used simultaneously, so the same engines can perform both functions. Rig power system performance characteristics generally are stated in terms of output hoursepower, torque, and fuel consumption for various engine speeds. The following equations perform various design calculations:

18. Rig Power System

19. Rig Power System P – shaft power developed by engine, hp Qi – heat energy consumed by the engine, hp Et – overall power system efficiency w – angular velocity of the shaft, rad/min; w = 2pN with N is the shaft speed in RPM T – output torque, ft-lbf Wf – volumetric fuel consumption, gal/hour H – heating value of diesel, 19,000 BTU/lbm rd – density of diesel, 7.2 lbm/gal 33,000 – conversion factor, ft-lbf/min/hp (1) (2) (3)

20. Rig Power System

21. Rig Power System Example 1.1. A diesel engine gives an output torque of 1740 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: Angular velocity: w = 2pN = 2p(1200) = 7,539.84 rad/min The power output: Heat energy consumed by the engine: Overal efficiency:

22. Hoisting System The function of the hoisting system is to get the necessary equipment in and out of the hole as rapidly as is economically possible. The principal items of equipment that are used in the hole are drillstring, casing, and miscellaneous instruments such as logging and hole deviation instruments. The major components of the hoisting system are: the derrick, the block and tackle system, the drawworks, miscellaneous hoisting equipment such as hooks, elevators, and weight indicator.

23. Derrick The function of the derrick is to provide the vertical height required to raise sections of pipe from or lower them into the hole. Derricks are rated according to their height and their ability to withstand compressive and wind loads. The greater the height of the derrick, the longer the section of pipe that can be handled. The most commonly used drillpipe is between 27-30 feet. To provide working space below the derrick floor for pressure control valves called blowout preventer, the derrick usually is elevated above the ground level by placement on a substructure.

24. Making a Trip http://www.youtube.com/watch?v=5f3STxhzICQ http://www.osha.gov/SLTC/etools/oilandgas/drilling/trippingout_in.html#

25. Making a Trip

26. Making a Connection / Tripping In Making a mouse hole connection

27. Making a Connection / Tripping In Stabbing the Pipe Single Added. Ready to Drill Moving Kelly to Single in Mousehole

28. Tripping Out Use Elevators for tripping Put Kelly in Rathole

29. Tripping Out

30. Block and Tackle Block and tackle is comprised of the crown block, the travelling block, and the drilling line. The principal function of the block and tackle is to provide a mechanical advantage which permits easier handling of large loads.

31. Machenical Advantage (4) The mechanical advantage M of a block and tackle is defined as the ratio of the load supported by the traveling block, W, and the load imposed on the drawworks, Ff.

32. Pully A pulley transfers a force along a rope without changing its magnitude. In Figure a, there is a force (tension) on the rope that is equal to the weight of the object. This force or tension is the same all along the rope. For this simple pulley system, the force is equal to the weight, as shown in the picture. The mechanical advantage of this system is 1!. In the Figure b, the pulley is moveable. As the rope is pulled up, it can also move up. Now the weight is supported by both the rope end attached to the upper bar and the end held by the person! Each side of the rope is supporting the weight, so each side carries only half the weight. So the force needed to hold up the pulley in this example is 1/2 the weight! Now the mechanical advantage of this system is 2.

33. Pully c d b a

34. Block and Tackle (5) Without friction between the block and the tackle, the mechanical advantage is given by Equation (1.5) tells us the ideal mechanical advantage is equal to the number of lines. For frictionless between the block and tackle, the power efficiency is given by In general, the power efficiency can be calculated (6) (7)

35. Block and Tackle (8) The load applied to the derrick, Fd, is the sum of the hook load, W, the tension in the dead line, Fs, and the tension in the fast line, Ff: The total derrick load is not distributed equally over all four derrick legs. Since the drawworks is located on one side of the derrick floor, the tension in the fast line is distributed over only two of the four legs. Also, the dead line affects only the leg to which it is attached. If E > 0.5, the load on leg A is greatest of all four legs. Since if any leg fails, the entire derrick also fails, it is convenient to define a maximum equivalent derrick load, Fde, which is equal to four times the maximum leg load.

36. Block and Tackle Maximum equivalent derrick load: (9)

37. Drawworks The drawworks is a complicated mechanical system with many functions: To lift drill string, casing, or tubing string, or to pull in excess of these string loads to free stuck pipe. Provide the braking systems on the hoist drum for lowering drill string, casing string, or tubing string into the borehole. Transmit power from the prime movers to the rotary drive sprocket to drive the rotary table Transmit power to the catheads for breaking out and making up drill string, casing and tubing string.

38. Drawworks

39. Drawworks

40. Efficiency Factor, E The input power to the drawworks is calculated by taking into account the efficiency of the chain drives and shafts inside the drawworks. The efficiency factor E is given by the following equation: Where K is sheave and line efficiency per sheave; K = 0.9615 is in common use.

41. Example 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 500 hp. Eight lines are strung between the crown block and traveling block. Calculate: 1. The static tension in the fast line when upward motion is impending 2. The maximum hook horsepower available. 3. The maximum hoisting speed 4. The actual derrick load 5. The maximum equivalent derrick load 6. The derrick efficiency factor

42. Example • The static tension in the fast line when upward motion is impending • 2. The maximum hook horsepower available. • Ph = Epi = 0.844 x 500 = 420.5 hp • 3. The maximum hoisting speed • 4. The actual derrick load • 5. The maximum equivalent derrick load • 6. The derrick efficiency factor