Drilling Engineering

Lecture 1

3/8/2023 B Riachi 1

Introduction to drilling engineering

• Introduction
• History of oil well drilling
• The life-cycle of a field or reservoir and the role of the drilling
engineer in each phase
• Drilling rig organization
• Drilling contracts
• Personnel on a rig crew and personnel at the rig site
• Drilling rigs
• Offshore vessels – special topic

3/8/2023 B Riachi 2
 Introduction

• The term drilling indicates the whole complex of operations

necessary to construct wells of circular section applying
excavation techniques.
• To drill a well it is necessary to carry out simultaneously the
following actions (drilling process):
- to overcome the resistance of the rock, crushing it into small
particles;
- to remove the rock particles, while still acting on fresh
material;
- to maintain the stability of the walls of the hole;
- to prevent the fluids contained in the drilled formations from
entering the well.
3/8/2023 B Riachi 3

Introduction

• This can be achieved by using rotary drilling rigs which are the
ones operating today in the field of hydrocarbons exploration
and production.
• In rotary drilling, the rock is bored using a cutting tool called
the bit, which is rotated and simultaneously forced against
the rock at the bottom of the hole by a drill string consisting
of hollow steel pipes of circular section screwed together.

3/8/2023 B Riachi 4
 https://www.youtube.com/watch?v=JjGXsLWcwI0

3/8/2023 B Riachi 5

Introduction

• The cuttings produced by the bit are transported up to the

surface by a drilling fluid, usually a liquid (mud or water), or
else a gas or foam, circulated in the pipes down to the bit and
thence to the surface.
• The rotation is transmitted to the bit from the surface by a
device called the rotary table or, in the modern rigs, by a top
drive motor with the rotary table as backup; additional
rotation can be added by downhole motors located directly
above the bit.

3/8/2023 B Riachi 6
 Introduction

• After having drilled a certain length of hole, in order to

guarantee its stability it has to be cased with steel pipes,
called casings, joined together by threaded sleeves.
• The space between the casing and the hole is then filled with
cement slurry to ensure a hydraulic and mechanical seal.
• The final depth of the well is accomplished by drilling holes of
decreasing diameter, successively protected by casings,
likewise of decreasing diameter, producing a structure made
up of concentric tubular elements.

3/8/2023 B Riachi 7

History of oil well drilling

The earliest known oil wells were drilled in China during the
6th century. Using drill bits attached to bamboo poles, they
dug wells about 800 ft (240 m) deep. Oil produced was
transported via bamboo pipelines and was used for early
lighting and heating applications.

3/8/2023 B Riachi 8
 Effects from the Industrial Revolution lead to an increased
demand for a cheaper, more efficient fuel than coal. This
demand led to Colonel Edwin Drake’s famous 1859 discovery
of oil in Pennsylvania, which marked the first commercial well
drilled in North America.
The first modern wells were drilled by using a ‘cable-tool’
system that was raised and dropped to the earth percussively
to create a wellbore

3/8/2023 B Riachi 9

Offshore drilling began in 1897, just 38 years after Col. Edwin

Drake drilled the first well in 1859. H.L. Williams is credited
with drilling a well off a wooden pier in the Santa Barbara
Channel in California. He used the pier to support a land rig
next to an existing field.
Five years later, there were 150 “offshore” wells in the area.
By 1921, steel piers were being used in Rincon and Elwood
(California) to support land-type drilling rigs

3/8/2023 B Riachi 10
 The year 1901 is marked for what is often identified as the
most famous and influential oil well drilled in the Spindletop
Oilfield located in South East Texas. The success of this oilfield
influenced the introduction and popularity of the rotary
drilling system, which became the globally accepted preferred
method of drilling.
Parallel to the entry of the rotary drilling system, other key
technologies were developed, such as the introduction of the
derrick/drawworks system, the tricone drill bit, and the first
recorded use of drilling mud.

3/8/2023 B Riachi 11

The first truly offshore MODU was the Mr. Charlie (1954),
designed and constructed from scratch by Ocean Drilling and
Exploration Co. (ODECO). The Mr. Charlie was a purpose-built
submersible barge built specifically to float on its lower hull
to location and, in a sequence of flooding the stern down,
ended up resting on the bottom to begin drilling operations.

3/8/2023 B Riachi 12
3/8/2023 B Riachi 13

Vertical drilling is considered the traditional drilling method

for accessing reservoirs directly beneath the surface. Once the
only method of extracting oil and gas, vertical drilling has
become a less common method of drilling due to the
advancement of horizontal and directional drilling
technologies
Today, vertical wells are mostly used during the exploratory
phase in evaluating the potential of new oil and gas zones

3/8/2023 B Riachi 14
 As the 20th century came to an end, technology was quickly
evolving, paving the way for more precise drilling capabilities
through the use of directional or steerable drilling
equipment. Wells are considered horizontal when they
approach a drilling angle 85-90˚ from vertical.
Horizontal drilling, also called directional drilling, facilitates an
increase of production volumes from a single wellbore by
accessing a larger surface area of an oil and gas zone.

3/8/2023 B Riachi 15

3/8/2023 B Riachi 16
 Life cycle of oil and gas fields or reservoirs

• Exploration Stage
• Appraisal Stage
• Development Stage
• Plateau Stage
• Decline Stage
• Abandonment Stage

3/8/2023 B Riachi 17

Life cycle of oil and gas fields or reservoirs

3/8/2023 B Riachi 18
 Exploration phase

9 Exploration geologist and geophysicist (amongst others)

generate locations for future exploration prospects
9 Once exploration prospects are generated, Drilling Engineers
work with the exploration geologists to develop the drilling
proposal for any Exploration Wells
9 Exploration wells are wells which are drilled with an objective
of proving or disproving the presence of commercial
hydrocarbon accumulations “wildcat well”

3/8/2023 B Riachi 19

Exploration phase

9 Once a drilling proposal is generated and approved, the

drilling engineer coordinates with drilling companies, service
companies, suppliers, and manufactures for all of the
equipment required by the well (off-the shell equipment)
9 Only after the required equipment is onsite (long lead time
equipment) and all permits are in hand drilling operations can
begin

3/8/2023 B Riachi 20
 Appraisal Phase

During this phase of the life-cycle, a rig schedule is typically

developed with input from most asset team members, but
most notably the drilling engineer(s), the development
geologist(s), and the reservoir engineer(s)

3/8/2023 B Riachi 21

Development phase

During the development phase, wells are drilled with the

primary objective of hydrocarbon production

3/8/2023 B Riachi 22
 Exploration versus development

• A well is classified as a wildcat well if its purpose is to discover

a new petroleum reservoir.
• In contrast, the purpose of a development well is to exploit a
known reservoir.
• Usually the geological group recommends wildcat well
locations, while the reservoir engineering group recommends
development well locations, the drilling engineering group
makes the preliminary well design and cost estimates for the
proposed well

3/8/2023 B Riachi 23

Plateau phase

9 At the Plateau Stage of production, the facility capacity is

constant over time.
9 During this phase, the drilling rig is often used for activities
other than drilling.

3/8/2023 B Riachi 24
 Decline Phase

9 At the later period of production, the well capacity is

bottleneck, and it is referred to as the decline stage of
production. The well capacity is tied to the reservoir pressure
which is continually decreasing with time
9 At some point in time, the reservoir management options can
no longer keep production at the facilities capacity, and the
field production rate will eventually go into decline.
9 During this stage, reservoir management activities are still
performed, but with the objective of arresting the decline
rate, not keeping the facilities fully utilized.

3/8/2023 B Riachi 25

Abandonment Stage

Finally, at some finite, non-zero production rate, the revenues

generated by the oil and gas sales can no longer support the
costs of the operations, and the field must be abandoned (see
figure, next slide)

3/8/2023 B Riachi 26
3/8/2023 B Riachi 27

3/8/2023 B Riachi 28
 Drilling contract types

There are many contract types used in the oil and gas
industry, but two of the more common contract types are
the Day-Rate Contract and the Turnkey Contract. Of these
two contract types, the Day-Rate contract is the more
common contract.
In a Day-Rate contract, the drilling engineers for the operating
company design the well, and the operating company leases
the drilling rig, its personnel, and routine supplies at a fixed
daily rate (Day Rate) from the drilling contractor

3/8/2023 B Riachi 29

Drilling contract type

Typically, the day rate accounts for approximately one half of

the costs required to drill the well.
The Total Daily Cost required to drill a well is referred to as
the Spread Rate.
For onshore, it will be < 100,000 $/day, and for deepwater
offshore Gulf of Mexico, it can be very high—up to 600,000 to
800,000 $/day (values are from 2010). The number of days
will be a function of depth.

3/8/2023 B Riachi 30
 Example of actual day rates

Transocean signed a contract in December 2018 with Chevron

to provide drilling services. The contract is for one rig, will
span five years and is worth $830 million.

The effective day rate for the rig is $455,000

3/8/2023 B Riachi 31

Rig personnel

• Drilling Contractor Personnel (Land Rigs)

• Drilling Contractor Personnel (Offshore Rigs)
• Operating Company Personnel
• Service Company Personnel

3/8/2023 B Riachi 32
 Drilling Contractor Personnel(Land Rigs)

‰ Tool pusher
‰ Drilling crew:
Driller
Derickman
Skilled technicians
Roughneck
Roustabout

3/8/2023 B Riachi 33

Tool pusher: He is the drilling company employee in charge of

all drilling and non-drilling operations occurring on and
around the drilling rig
Driller: He is the drilling company employee in charge of
drilling operations and supervision of a drilling crew
Derrickman: a person working at the top of the Derrick of a
drilling rig who is manually moving and handling Drillpipe

3/8/2023 B Riachi 34
 Drilling Contractor Personnel(Offshore Rigs)

‰ Offshore Installation Manager OIM, is the chief executive on

the offshore installation
‰ Tool pusher … (same as onshore)
‰ Barge master The Barge Master (and his crew) is responsible
for all marine operations that occur on a Mobile Offshore
Drilling Unit (MODU).
‰ Chief mechanic, Chief electrician, Camp boss

3/8/2023 B Riachi 35

Operating Company Personnel

‰ Drilling Superintendent: He is the operating company

employee in charge of drilling operations. The drilling
superintendent typically works in a field office away from the
rig site and supervises simultaneous drilling operations of
multiple wells
‰ Wellsite Personnel
Company man
Wellsite geologist: Well Log Operations ; Logging while drilling
(LWD), Measurement while Drilling (MWD) includes logging
equipment on the Bottom-Hole Assembly (BHA), Mud
Logging. N.B well logs are records of geological data versus
depth used by geologists to evaluate a well.

3/8/2023 B Riachi 36
 Service Company Personnel

‰ Drilling Fluids Engineer or “Mud Man”

‰ Cement Engineer
‰ Logging Engineer
‰ Well Test Engineer
‰ Well Completions and Stimulation Engineers
Typically the role of a completions engineer is assigned to a
production engineer.
The term “mud” is used in oil and gas well drilling because
historically the most common water-based drilling fluids were
mixtures of water and finely ground, bentonite clays which, in
fact, are mud.

3/8/2023 B Riachi 37

Drilling Rigs

Rotary Rig

3/8/2023 B Riachi 38
 Onshore rig, desert location

3/8/2023 B Riachi 39

Onshore rig, Arctic location

3/8/2023 B Riachi 40
 Classification of Drilling Rigs

9 Onshore Drilling Rigs

o Cable Tool Rigs
o Rotary Rigs
(Conventional Rotary /Rotary Table /Kelly Drive) Rig
Top-Drive Rig

9 Offshore Drilling Rigs (MODU and Fixed)

o Jack-Up Rig
o Semi-Submersible Rig MODU
o Drill Ships
o Drilling Rigs on Fixed Production Platform s

3/8/2023 B Riachi 41

Classification of rigs

Up to 500 m

3/8/2023 B Riachi 42
 Cable tool drilling rigs

Cable tool rigs had their origins in the percussive drilling

techniques used by ancient Chinese and Persian civilizations
and are of historic importance because,
Colonel Edwin Drake used a cable tool rig to drill for oil in
Titusville, PA in 1859. This event is considered to be the
beginning of the modern oil and gas industry

3/8/2023 B Riachi 43

1-Crown Block
2-Bull Wheel
3-Walking Beam
4-Temper Screw
5-Drilling Line
6-Casing Head
7-Cellar
8-Drilling Tools
9-Calf Wheel
10-Casing Line
11-Pittman
12-Crank
13-Band Wheel
14-Sand Reel
15-Sand or Bailing Line
16-Belt House
17-Engine
18-Engine House
19-Headache Post
20-Lazy Bench

3/8/2023 B Riachi 44
 Rotary rigs (1900)

The Rotary System is one of the major systems on the drilling

rig and is where the torque is applied

Classification by the location on the rig of the Rotary System

9 Conventional rotary table / Kelly Drive rig
9 Top-drive rotary rig

3/8/2023 B Riachi 45

Conventional rotary table rig

The conventional rotary table rig applies torque to the drill

string and drill bit through a series of mechanical devices that
sit on the rig floor. These are:
Kelly
Kelly bushing
Master bushing
Rotary table (or turn table)

3/8/2023 B Riachi 46
1.Mud Pit
2.Shale Shaker
3.Suction Line
4.Mud Pumps
5.Engine-Generator Sets
6.Vibration Dampening Hose
7.Draw Works 8.Stand Pipe
9.Rotary Kelly Hose
10.Goose Neck
11.Traveling Blocks
12.Cat Line Boom and Hoist Line
13.Crown Blocks
14.Derrick
15.Monkey Board
16.Drill Pipe
17.Substructure
18.Swivel
19.Kelly
20.Turn Table
21.Rat Hole
22.B.O.P. Stack
23.Annular Blowout Preventer
24.Ram Blowout Preventer
25.Drill String 26.Drill Bit
27.Conductor Casing
28.Diverter
3/8/2023 Line B Riachi 47

Rotary table

The rotary table is the device that is connected to the main

power system of the rig (usually through a chain and gear
system).
The rotary table imparts the rotation (torque) to the master
bushing, kelly bushing, kelly, drill string, and drill bit.

3/8/2023 B Riachi 48
 Mouse hole

3/8/2023 B Riachi 49

Drill string

The drill string is made up of (30-foot) joints of drill pipe.

These joints are connected as doubles (two joints) or triples
(three joints) and racked and stored onto the side of the
derrick as stands of drill pipe depending on the specifications
of the rig.
hollow steel tubing is followed by a bottom hole assembly
BHA, and a drill bit

3/8/2023 B Riachi 50
 Drill pipe

On a conventional rotary table rig, drill pipe is added to the

drill string, one joint at a time. The next joint of drill pipe to be
added to the drill string is temporarily stored in the
mousehole on the rig floor.

3/8/2023 B Riachi 51

Top-drive rig (1990s)

A top-drive rig applies torque to the drill string and drill bit
with a motor mounted on the traveling block of the derrick.

Advantages over conventional: The improved efficiencies

coming from a top-drive is that an entire 90-foot stand (or
triple) of drill pipe can be connected to the drill string rather
than a single 30-foot joint. This is because the top-drive can
go to the full height of the derrick using the traveling block to
connect to the entire stand of drill pipe.

3/8/2023 B Riachi 52
1.Crown Block and Water Table
2.Catline Boom and Hoist Line
3.Drilling Line 4.Monkeyboard
5.Traveling Block 6.Top-drive
7.Mast 8.Drill Pipe
9.Doghouse 10.Blowout Preventer
11.Water Tank 12.Electric Cable Tray
13.Engine Generator Sets 14.Fuel Tanks
15.Electric Control House 16.Mud Pump
17.Bulk Mud Components Storage
18.Mud Pits 19.Reserve Pits
20.Mud Gas Separator
21.Shale Shaker 22.Choke Manifold
23.Pipe Ramp 24.Pipe Racks
25.Accumulator

3/8/2023 B Riachi 53

https://youtu.be/XEV6Cg70c74

3/8/2023 B Riachi 54
3/8/2023 B Riachi 55

Mobile Offshore Drilling Units MODU

Mobile Offshore Drilling Units (or MODUs) used for offshore

drilling:
¾ Jack-up rig
¾ Semi-Submersible rig
¾ Drill ship

3/8/2023 B Riachi 56
 Jack-up drilling rig

A jack-up drilling rig is a rig with three or more (typically

three) retractable legs that can be used to jack the rig up
above the wave action of the water surface
¾ It is towed (or self-propelled) to the well’s surface location
¾ It can be used in water depths of up to 400 ft of water; and
can be used to drill wells to a Total Depth (TD) of 30,000 –
35,000 ft
¾ It can be used to drill exploration, appraisal, or development
wells.

3/8/2023 B Riachi 57

3/8/2023 B Riachi 58
3/8/2023 B Riachi 59

Semi-submersible drilling rig

A semi-submersible drilling rig is a rig with multiple pontoons

that are used to keep the rig floating while drilling.
¾ It uses a system of thrusters for dynamic positioning of the rig
while drilling and is considered the most stable drilling rig for
offshore drilling.
¾ It can be used to drill wells in water depths up to 9,500 ft and
is capable of drilling wells to a TD of 30,000 – 35,000 ft.
¾ For lower water depth, the rig is anchored to the sea floor

3/8/2023 B Riachi 60
3/8/2023 B Riachi 61

3/8/2023 B Riachi 62
 Jack-up versus semisubmersible

3/8/2023 B Riachi 63

Drill ship

A drill ship is a sea-going ship that is specifically modified to

perform deep water drilling operations
¾ Drill ship is used for deep water drilling in regions with little
onshore logistical support.
¾ It can typically store large quantities of supplies which allows
for its use in drilling exploration wells in more remote regions.
¾ In addition, drill ship can be used to drill appraisal, and
development wells in oil or gas fields beneath deep water
surface locations.
¾ They are anchored or dynamically controlled when drilling

3/8/2023 B Riachi 64
3/8/2023 B Riachi 65

Production quarters and drilling platforms

In addition to the Mobile Offshore Drilling Units, offshore

drilling can be performed off of large Production, Drilling, and
Quarters Platforms.
Example Hibernia Platform (1997), 185 people

3/8/2023 B Riachi 66
3/8/2023 B Riachi 67

3/8/2023 B Riachi 68
 Drilling platforms for deep water

3/8/2023 B Riachi 69

Hibernia facts

• Hibernia is jointly owned by six different companies:

ExxonMobil Canada (33.125%), Chevron Canada (26.875%),
Suncor (20%), Canada Hibernia Holding Corporation (8.5%),
Murphy Oil (6.5%), Statoil Canada (5%).
• The platform stands 224 meters high. That’s half the height of
the New York Empire State building, and 33 meters taller than
the Calgary Tower.
• At peak production, Hibernia can produce 220,000 barrels of
oil a day.

3/8/2023 B Riachi 70
 Hibernia facts

• Hibernia is located in the Jeanne d’Arc Basin, 315km east of St

John’s, Newfoundland and Labrador, Canada, in a water depth
of 80m
• The platform sits atop an enormous gravity base
structure (GBS) that sits on the ocean floor. The GBS is
specially designed to withstand the impact of sea ice and
icebergs, and can hold 1.3 million barrels of crude oil in its 85-
metre high caisson.
• The word “Hibernia” is Latin for “Ireland” and has been a
commonly used name for ships plying the North Atlantic
Ocean.

3/8/2023 B Riachi 71

https://www.youtube.com/watch?v=1nnSYlwesrk

In the end of this lecture we suggest you to watch a video

about the construction of massive oil platform - the
Appomattox

3/8/2023 B Riachi 72
 Offshore Vessels

Offshore vessels are ships that specifically serve operational purposes such as oil
exploration and construction work on the oceans. There are a variety of offshore
vessels, which not only help in exploration and drilling of oil but also for providing
necessary supplies to the excavation and construction units located on the oceans

3/8/2023 B Riachi 73

The Three translational Ship Motions The Three Rotational Ship Motions
1. Heaving (Vertical translation – Z-axis) 1. Yawing (Vertical rotation – Z-axis)
2. Swaying (Transverse translation – Y-axis) 2. Rolling (Longitudinal rotation – X-axis)
3. Surging (Longitudinal translation – X-axis) 3. Pitching (Transverse rotation – Y-axis)

3/8/2023 B Riachi 74
 In action, the depth of the vessel in the water (draft) and the distance above
the water (freeboard) are important factors.

Beam is the widest part of the vessel

Depth of hull = draft + freeboard

3/8/2023 B Riachi 75

Ship drive train

The purpose of the propulsion system on a ship is to convert fuel energy into
useful thrust to propel the ship

BHP – “Brake Horsepower” is the power output of the engine. It is called “brake”
because engines are tested by applying a mechanical load to the shaft using a brake
BHP = T x ω
SHP – “Shaft Horsepower” is equal to the Brake Horsepower minus any mechanical
losses in the reduction gear. The reduction gear reduces the RPM (revolutions per
minute) of the engine to an efficient propeller speed. Reduction gears are very large,
heavy, and expensive.

3/8/2023 B Riachi 76
 DHP – “Delivered Horsepower” is the power delivered to the propeller

THP – “Thrust Horsepower” is the power from the propeller thrust, equal to the
product of the speed of advance and the thrust generated by the propeller

EHP – “Effective Horsepower” is the power required to move the ship’s hull at a
given speed in the absence of propeller action. It is equal to the product of the
resistance of a ship and the speed of the ship
EHP = Rt x V

3/8/2023 B Riachi 77

Propulsive Efficiency

Common values of propulsive efficiency / propulsive coefficient (PC) typically

range from 55% to 75%.

3/8/2023 B Riachi 78
 Model testing has determined that a ship has an EHP of 30,000 HP at a speed of 19
knots. Assuming a propulsive efficiency of 70%, what SHP is required to be installed
to achieve 19 knots?

A total of 42,860 horsepower (43,000 HP) should be installed to achieve a speed of

19 knots.; 1 HP = 735.5 = 736 W (metric horsepower; (745.7 = 746 W) imperial HP

Once a value of shaft horsepower has been determined, various combinations of prime
movers can be considered based on power produced, weight, fuel consumption, etc for
installation in the ship.
A “prime mover” is another term for an engine or motor (i.e. a source of mechanical
power). Common prime mover types include steam turbines, gas turbines engines, diesel
engines, and electric motors.
3/8/2023 B Riachi 79

Environmental forces that influence offshore vessels include:

(1) Wind force,
(2) wave force, and
(3) current force.

The wind force on an offshore vessel is calculated using the relationship:

In this equation, Fw is the wind force lbf,

Vw is the wind velocity in knots,
Ch is the height coefficient,
Cs is the shape coefficient,
and A is the projected area of all exposed surface in square feet.
The shape coefficients and height coefficients can be estimated from the tables
below:

The knot equal to one nautical mile per hour

Equal 1.852 km/h (approximately 1.151 mph or 0.514 m/s)
The ISO standard symbol for the knot is kn
3/8/2023 B Riachi 80
3/8/2023 B Riachi 81

The current force is calculated from the equation:

Fc is the current drag force lbf,

Vc is the velocity of the current,
Cs is the drag coefficient and is the same as the wind coefficient,
and A is the projected area of all exposed surfaces in square feet.

3/8/2023 B Riachi 82
3/8/2023 B Riachi 83

Theory of propellers
Momentum theory (Rankine, Froude, Betz, Dryewiecki)

3/8/2023 B Riachi 84
 Controllable pitch propeller

3/8/2023 B Riachi 85

Aerodynamics of propellers
blade element theory (Prandtl, Glauret, Joukowski)

Thrust
L- lift Torque
D- drag Power
Efficiencies

3/8/2023 B Riachi 86
 Drilling Engineering

Lecture 2

B Riachi 1

Drilling Rig Systems

• Power System
• Hoisting System
• Rotary System
• Circulation System
• Well Control System (Blowout Prevention System)

B Riachi 2
 Rotary table
Mud pumps
Drawworks
…

B Riachi 3

B Riachi 4
 Equipment items

B Riachi 5

The Power System

A power system is needed to run the machines driving the

main components of the rig and it is provided by diesel
engines, diesel-electric engines; (Steam and gas power plants)

Power is transferred from the engines (power plants) to the

different rig systems by belts, chains, gears and drive shafts on
a mechanical rig, or by generated DC / AC electrical power on
an electric rig and it is distributed to the rotary table, mud
pumps, drawworks, air compressors, and many other
machinery

B Riachi 6
 Mechanical rig hookup

B Riachi 7

Mechanical drives

Gear drive Chain drive and Belt drive are three mechanisms widely used in
power transmission.

Belt and chain drives: The power output from an engine in the form of
torque delivered by the crankshaft or axle is transferred to another rotating
body such as an axle or a wheel using closed loop of chain or belt.

B Riachi 8
Belt Drive

B Riachi 9

B Riachi 10
B Riachi 11

B Riachi 12
B Riachi 13

B Riachi 14
B Riachi 15

B Riachi 16
Belt length

Choose nearest standard length from special catalogues

Recalculate distance between centers

Wrap angle

B Riachi 17

Chain Drive

B Riachi 18
 B Riachi 19

Gears and gear transmission

B Riachi 20
 Spur gears are used to transmit rotary Helical gears are used to transmit motion
motion between parallel shafts. between parallel or nonparallel shafts.

B Riachi 21

Bevel gears are used to transmit rotary Worm gears ets are used to transmit
motion between intersecting shafts rotary motion between nonparallel and
nonintersecting shafts.

B Riachi 22
B Riachi 23

B Riachi 24
B Riachi 25

B Riachi 26
 B Riachi 27

Ball Bearing

B Riachi 28
B Riachi 29

B Riachi 30
 Types of roller bearings:(a) straight roller; (b) spherical roller,
thrust; (c) tapered roller,thrust; (d) needle; (e) tapered roller; ( f )
steep-angle tapered roller.

B Riachi 31

Thrust Ball Bearings (Chevalier)

B Riachi 32
 Needle + Thrust Ball Bearings

B Riachi 33

Shaft and housing shoulder diameters dS and dH should

be adequate to ensure good bearing support.

B Riachi 34
 Bearing lubrication

The purposes of an antifriction-bearing lubricant may be

summarized as follows:
• To provide a film of lubricant between the sliding and rolling
surfaces
• To help distribute and dissipate heat
• To prevent corrosion of the bearing surfaces
• To protect the parts from the entrance of foreign matter
Either oil or grease may be employed as a lubricant. The
following rules may help in deciding between them.

B Riachi 35

Lubrication cont’d

Use Grease When Use Oil When

1. The temperature is not over 1. Speeds are high.
200°F. 2. Temperatures are high.
2. The speed is low. 3. Oil tight seals are readily
3. Unusual protection is employed.
required from the entrance 4. Bearing type is not suitable
of foreign matter. for grease lubrication.
4. Simple bearing enclosures 5. The bearing is lubricated
are desired. from a central supply which
5. Operation for long periods is also used for other
without attention is desired. machine parts.

B Riachi 36
 Lubricating methods (Grease)

Ball bearings – double raw Tapered roller bearings

B Riachi 37

Lubricating methods (oil)

Normal lubrication Forced circulation

B Riachi 38
 Bearing Mounting

A common bearing mounting An alternative bearing mounting

B Riachi 39

Shaft – gear – bearing mounting

B Riachi 40
B Riachi 41

B Riachi 42
 Hydraulic, Mechanical, Electrical Powers

Hydraulic power Ph = Q ΔP
Mechanical power Pm = T x ω; ω = 2 π n / 60; (Pm = F V)
Electric power Pe = U x I
Example for a pump Pm = Ph / ηp = Q ΔP/ηp
Pe = Pm/ηe
Electric motor required power to drive mechanical systems
such as pumps … AC motors offer longer life, lighter weight,
less maintenance, and lower cost than a DC motor.
AC generators: 3-phase synchronous

B Riachi 43

Electric generators and motors

Apparent power
S = 3 Iph x Vph

Real power
P = S x cosφ

Star connected load

Vph = VL / √3
Iph = IL

Delta connected load

Iph = IL / √3
Vph = VL

In both cases
S = √3 IL x VL

Power factor
Cosφ = 0.85 – 0.95 B Riachi 44
 Star and Delta connections

Vph = VL / √3
Iph = IL / √3
?V Iph = IL
380 V Vph = VL

B Riachi 45

Gear Box Design

Pin x ηm = Pout , Pin = Tin x ωin, Pout = Tout x ωout

MP Np = 6000 rpm
Gear ratio
Pump shaft i= Np/Nm
Bearings
Driven gear
Lubrication system
pressurized
EM Nm = 3000 rpm

Driving gear Motor shaft

B Riachi 46
 Example of calculation 1

Given: a chemical pump Q = 200 L/s, Δp = 100 bar; ηp = 0.75;

np = 6000 rpm is driven by an EM through a GB with ηm =
0.97. determine:
Ph = Q Δp =
Pout = Pm = Ph/ηp =
Pm = T ω = T 2πn/60
Torque on the pump shaft, Tout =

Energy balance: Pin x eff = Pout

Tin Nin 0.97 = Tout Nout
Torque on the motor shaft, Tin =

GB ratio i = Np / Nm =

B Riachi 47

Example of calculation 2

Elec - G 3phase ηe = 0.95; cos Φ = 0.85; Vph = 380 V, f = 50

Hz; nb of poles = 2, P = 100 kW
• S = P/cosΦ =
• S = 3 Iph x Vph =
• Star connection Iph =
• Delta connection Iph =

f = n p/120

B Riachi 48
 Example of calculation 3

In a gas turbine drive 300 kW power is transmitted using a pair of double

helical gear. The pinion speed is 2950 rpm and that of the gear is about
816.5 rpm.

Determine GB ratio, Tin, Tout, Pout (GB efficiency 0.96)

B Riachi 49

Example of calculation 4
Calculation of shaft diameter

Shear stress due to torsion

• τmax = Tmax x R/ Ip
Solid shaft diameter
• D shaft = (Tmax/ 0.2 x [τ])^1/3

Allowable stress determination

• [σ] = Yield stress / Factor od safety = σy/FS
• [τ] = ½ [σ]

Example ; Yield stress = 400 Mpa, FS = 4, Tmax = 100 N.m

B Riachi 50
 Polar Moment of Inertia

If the shaft has a solid circular cross section, the polar

moment of inertia J can be determined using an area element
in the form of a differential ring or annulus having a thickness
dr and circumference 2πr, Fig. 5–4. For this ring, dA = 2πr dr,
and so

J = (π x d^4)/32
B Riachi 51

Polar moment of hollow shaft

If a shaft has a tubular cross section, with inner radius ci and

outer radius co, its polar moment of inertia J

B Riachi 52
Engines and power plants calculations

B Riachi 53

B Riachi 54
B Riachi 55

B Riachi 56
B Riachi 57

B Riachi 58
2-5 Determine the daily cost of running a diesel engine to power a duplex
pump under the following conditions:

Theoretical flow rate = 313.3 gpm

Delivery pressure = 1000 psi
Volumetric efficiency = 90%
Mechanical efficiency = 85%
Diesel engine: efficiency = 50%
Diesel oil: weight = 7.2 lb/gal
Heating value = 19000 BTU/lb
Cost = $1.15/gal

B Riachi 59

B Riachi 60
 B Riachi 61

Student work ( 10 – 15 pages)

team of 2- 3 students
Gear box
Belt drive
Chain drive
Bearings
Shafts

Examples: top drive, draw work, rotary table, air compressor,

mud pump

B Riachi 62
 The Hoisting System

It is the set of equipment necessary for handling any

material inside the well (drill string and the casing);
It consists of a structural part (derrick/mast, and
substructure), the complex of the crown and travelling
block, the drawworks (hoist) and the drilling line;
The substructure is the supporting base for the derrick,
the drawworks and the rotary table, and constitutes the
working floor for operations, or drilling floor.

B Riachi 63

Hoisting system for a kelly drive rig

B Riachi 64
 Derrick / Mast

The derrick/mast (A portable derrick capable of being erected

as a unit, as distinguished from a standard derrick, which
cannot be raised to a working position as a unit) provides the
structural support for the hoist system.
It must be capable of supporting the entire load on the system
including the weight of the drill string (accounting for
buoyancy effects) and any frictional forces.

B Riachi 65

Derrick and Mast structures

B Riachi 66
 B Riachi 67

The drawworks

The drawworks of the hoisting system is a winch that reels the

drilling line in or out causing the traveling block to move up or
down. The drawworks is the component of the hoisting
system that consumes energy from the power system. The
drum on the drawworks is grooved to accommodate a specific
size drilling line

B Riachi 68
 Dead line anchors

Dead Line Anchor: anchors the last line coming from the
crown block and also stores drilling line on a reel. This allows
new lengths of line to be fed into the system to replace the
worn parts of the line that have been moving on the pulleys
of the crown block or the travelling block.
The worn parts are regularly cut and removed by a process
called: Slip and Cut Practice. Slipping the line, then cutting it
off helps to increase the lifetime of the drilling line

B Riachi 69

Braking system

Modern rigs use both a mechanical brake and an

electromagnetic brake. The braking system is an integral part
of the drilling process because it is used to control
the Weight-on-Bit (WOB) during drilling.
The two most important drilling parameters within
the Driller‘s control to maximize the Rate of Penetration (ROP)
are the weight-on-bit and the rotational speed of the rotary
system.

B Riachi 70
 B Riachi 71

Hoisting system design

The procedure for carrying out hoisting design calculations are

as follows:
Determine the deepest hole to be drilled
Determine the worst drilling loads or casing loads
Use these values to select the drilling line, the derrick capacity
and in turn the derrick

B Riachi 72
 Static Derrick Loading SDL

Static derrick loading (SDL) = fast-line load + hook load + dead-

line load (1)
Referring to Figure and for a system consisting of four lines
supporting the hook load, then under static conditions:
Fast- line load (FL) = Hook load /4
Dead-line load (DL) = Hook load /4
Then SDL = HL/4 + HL + HL/4 = 3/2 HL

B Riachi 73

Static Derrick Loading SDL

For N lines, the static derrick load is given by:

SDL = ((N+2) / N) HL (2)
Where N = number of lines strung to travelling block, HL =
hook load = W

B Riachi 74
 Efficiency of the hoisting system (EF)

Hoisting operation: Friction between the wire rope and sheaves

reduces the efficiency of the hoisting system. The efficiency
factor (EF) during hoisting operation (pulling out of hole) is given
by:
EF = K (1 – KN) / N (1 – K) (3)
Where K – line efficiency per sheave
FL = HL / (N x EF) (4)
DL = HL x KN / (N x EF) (5)
The design factor DF = σ / FL (6),
Where σ – strength of wire rope in lb

B Riachi 75

Efficiency of the hoisting system (EF)

Lowering operation:
EF = K x KN (1 – K) / (1 – KN) (7)
FL = W KN (1 – K) /N (1 – KN) (8) ?

B Riachi 76
 Power requirements of the drawworks

As a rule of thumb, the drawwork should have 1 HP for every

10 ft to be drilled. Hence for a 20,000 ft well, the drawwork
should have 2000 HP. A more rigorous way of calculating the
horse power requirements is to carry out the following
calculations:

B Riachi 77

Power requirements of the drawworks

9 Velocity of fast-line load (Vf)

Vf = N x VL (9)
Where VL = velocity of travelling block
9 Power output at drum (P)
P = FL x Vf (10)
P = HL x VL / EF (11)
9 Motor power (PM)
PM = P/ηm (12)
HP = PM / 33000 (13) motor horsepower
i = nMotor / nDrum (14) gear ratio

B Riachi 78
 Drilling line design consideration

9 Ton-miles of the drilling line

The amount of work done need to be calculated to determine
when to change the drilling line.
Work done in round trip operations (Tr)

B Riachi 79

M = mass of travelling assembly (lb)

Ls = length of each stand (ft)
D = hole depth (ft)
We = effective weight per foot (or master) of drill pipe in mud
C = (L x Wdc - L x Wdp) x BF
Wdc = weight of drill collars in air
Wdp = weight of drill pipe in air
L = length of drill collars
BF = Buoyancy factor

B Riachi 80
 Work done during drilling operations: In drilling a length of
section from d1 to depth d2 the work done is given by:

9 hole is drilled only once without any reaming; Td = 2(T2 – T1)

9 hole is drilled with one time reaming: Td = 3 (T2 – T1)
9 hole is drilled with two times reaming: Td = 4 (T2 – T1)

B Riachi 81

What is reaming?

Like drill bits, reamers also remove material from the place
on which they are used. However, reamers remove
significantly less material than drill bits. The primary purpose
of reaming is simply to create smooth walls in an existing hole
Drilling
Coring
Reaming

B Riachi 82
Casing Ton-Miles calculation

Wcs = effective weight per unit length of casing in mud

Ls = length of casing joint
M = mass of travelling assembly (lb)
D = hole depth (ft)

B Riachi 83

B Riachi 84
 B Riachi 85

Evaluation of the total service

and cut-off practice
9 Portions of the drilling line on the crown and travelling blocks
sheaves and on the hoisting drum, carry the greatest amount
of work and are subjected to a great deal of wear and tear.
9 These parts must be cut and removed at regular times
otherwise the drilling line will fail by fatigue. The process is
called "slip and cut practice". The length of line to be cut is
calculated as follows:
Length of drum laps = number of laps x drum circumference =
number of laps x π x D
Where D = drum diameter

B Riachi 86
Recommended cut-off lengths in terms of drum laps and derrick
height for a design factor = 5, Courtesy of API

B Riachi 87

B Riachi 88
B Riachi 89

B Riachi 90
B Riachi 91

B Riachi 92
B Riachi 93

B Riachi 94
Drilling solved problems

Lecture 2

2
3

4
5

6
7

8
 9

10
11

12
13

14
15

16