Eni Corporate University

Titolo: LIBYA – DRILLING & COMPLETION ENGINEER

Codice corso: RPWA004B

DRILLING RIGS
LIBYA ENABV TRAINING PROJECT

Edizione a cura di : Eni Corporate University

COPY FOR DIDACTICAL USE

Cod.: IPE044-E-P-A01 REV.: 001 DEL: 10/11/2006 N. TOT. PAG.: 463

Libya ENABV Training Project Drilling Rigs

INDEX

01. INTRODUCTION ........................................................................................................................ 9

1.1 DEFINITION ........................................................................................................................... 9
1.2 RIG TYPES............................................................................................................................. 9
02. ON-SHORE RIGS..................................................................................................................... 10
2.1 DUTY .................................................................................................................................... 10
2.2 TYPES TRANSPORT.......................................................................................................... 11
- CONVENTIONAL RIG .......................................................................................................... 11
- FAST MOVING RIG ............................................................................................................. 12
- HELI-RIG .............................................................................................................................. 12
2.3 DRILLING RIG MAIN SYSTEMS.......................................................................................... 13
- HOISTING & ROTATION SYSTEM...................................................................................... 13
- POWER GENERATION SYSTEM........................................................................................ 13
- MUD CIRCULATING SYSTEM ............................................................................................ 14
- WELL CONTROL SYSTEM.................................................................................................. 14
03. RIG SITE .................................................................................................................................. 15
3.1 RIG SITE .............................................................................................................................. 15
- Dimensions and Safety......................................................................................................... 15
- Lay-out Examples ................................................................................................................. 17
- Civil Works on Location ........................................................................................................ 19
3.2 CELLAR DIMENSIONS ........................................................................................................ 20
3.3 WASTE PIT DIMENSIONS................................................................................................... 21
04. SUBSTRUCTURE .................................................................................................................... 22
4.1 FUNCTION ........................................................................................................................... 22
4.2 SUBSTRUCTURE LOAD and DIMENSIONS....................................................................... 23
4.3 TYPES AND CHARACTERISTICS ...................................................................................... 24
4.4 RIG UP SYSTEMS ............................................................................................................... 25
- SWING UP - PYRAMID ........................................................................................................ 25
- SWING LIFT - BRANHAM .................................................................................................... 26
- SLING SHOT DRECO .......................................................................................................... 27
4.5 INSPECTIONS ..................................................................................................................... 27
05. DERRICK.................................................................................................................................. 28
5.1 CONCEPTUAL DESIGN ...................................................................................................... 28
5.2 TYPES AND CHARACTERISTICS ...................................................................................... 29
- DERRICK ............................................................................................................................. 29
- MAST.................................................................................................................................... 32
- RAM RIG .............................................................................................................................. 35
5.3 RIGGING UP ........................................................................................................................ 37
5.4 DRILLING LOADS ................................................................................................................ 42
- Calculation of Drilling Loads at Crown Block ........................................................................ 42
- Definition of Gross Nominal Capacity ................................................................................... 45
5.5 INSPECTION........................................................................................................................ 46
06. DRAWWORKS ......................................................................................................................... 47
6.1 FUNCTION ........................................................................................................................... 47
6.2 TYPES AND CHARACTERISTICS ...................................................................................... 48
6.3 MAIN SYSTEMS................................................................................................................... 52
a - Main Drum ......................................................................................................................... 53
b - Catheads ........................................................................................................................... 53
c - Stationary Brake ................................................................................................................ 54
d - Auxiliary brake / dynamic brake........................................................................................ 57
6.4 POWER CALCULATION ...................................................................................................... 61
6.5 INSPECTIONS ..................................................................................................................... 61
07. CROWN BLOCK....................................................................................................................... 62
7.1 FUNCTION ........................................................................................................................... 62
7.2 TYPES AND CHARACTERISTICS ...................................................................................... 63

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7.3 INSPECTIONS ..................................................................................................................... 64

08. TRAVELLING BLOCK .............................................................................................................. 67
8.1 FUNCTION ........................................................................................................................... 67
8.2 TYPES AND CHARACTERISTICS ...................................................................................... 67
8.3 INSPECTIONS ..................................................................................................................... 71
- Periodic inspections.............................................................................................................. 71
- Frequency of Periodic Inspections........................................................................................ 71
- API Recommended Practice 8B ........................................................................................... 72
- Dimensional Inspection ........................................................................................................ 73
- NDT Inspection..................................................................................................................... 75
09. HOOK ....................................................................................................................................... 76
9.1 FUNCTION ........................................................................................................................... 76
9.2 TYPES AND CHARACTERISTICS ...................................................................................... 77
Standard Hook ........................................................................................................................ 77
Unitized Hook ......................................................................................................................... 79
Combination Travelling Block and Hook ................................................................................. 80
9.3 INSPECTIONS ..................................................................................................................... 81
- API Recommended Practice 8B ........................................................................................... 82
- Dimensional Inspection ........................................................................................................ 83
- NDT Inspection..................................................................................................................... 85
10. DRILLING LINE ........................................................................................................................ 87
10.1 DRILLING LINE STRUCTURE ........................................................................................... 87
10.2 TYPES AND CHARACTERISTICS .................................................................................... 90
10.3 DRILLING LINE REEVING ................................................................................................. 92
10.4 DEADLINE ANCHOR ......................................................................................................... 94
10.5 SAFETY FACTOR .............................................................................................................. 94
10.6 DRILLING LINE WEAR ...................................................................................................... 97
SLIP AND CUT TON-MILES CALCULATION ........................................................................ 97
SLIP AND CUT ..................................................................................................................... 102
11. POWER GENERATION SYSTEMS ....................................................................................... 106
11.1 TYPES OF POWER GENERATORS ............................................................................... 106
FOR MECHANICAL RIGS .................................................................................................... 106
FOR ELECTRIC RIGS.......................................................................................................... 109
12. DIESEL ELECTRIC POWER GENERATION SYSTEM ......................................................... 115
12.1 DIESEL ENGINES............................................................................................................ 115
12.2 POWER GENERATORS .................................................................................................. 117
- DC GENERATORS ............................................................................................................ 117
- AC GENERATORS ............................................................................................................ 119
12.3 DC ENGINES ................................................................................................................... 122
12.4 AC ENGINES.................................................................................................................... 125
12.5 ENGINE CONTROLS ....................................................................................................... 126
- Current Control Panel......................................................................................................... 126
- Driller Control Panel ........................................................................................................... 128
12.6 SCR SYSTEM .................................................................................................................. 129
13. PNEUMATIC SYSTEM........................................................................................................... 131
13.1 FUNCTIONS..................................................................................................................... 131
13.2 CHARACTERISTICS........................................................................................................ 133
13.3 APPLICATIONS................................................................................................................ 134
14. ROTARY TABLE & MASTER BUSHING............................................................................... 135
14.1 FUNCTIONS..................................................................................................................... 135
14.2 DIMENSIONS AND CHARACTERISTICS ....................................................................... 137
14.3 TYPES OF ROTARY TABLE............................................................................................ 140
14.4 TYPES OF MASTER BUSHINGS .................................................................................... 141
14.5 TYPES OF CASING BUSHINGS ..................................................................................... 143
15. KELLY & DRIVE BUSHING.................................................................................................... 144
15.1 FUNCTION AND TYPES.................................................................................................. 144

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15.2 DIMENSIONS (HEXAGONAL KELLY) ............................................................................. 145

15.3 DRIVE BUSHING ............................................................................................................. 146
- Kelly Bushing...................................................................................................................... 146
- Roller Assembly.................................................................................................................. 146
15.4 OPERATION..................................................................................................................... 147
16. UPPER & LOWER KELLY VALVES....................................................................................... 148
16.1 FUNCTION ....................................................................................................................... 148
16.2 DIMENSIONS ................................................................................................................... 149
- Upper Kelly Cock ................................................................................................................ 149
- Lower Kelly Cock ................................................................................................................ 150
17. SWIVEL HEAD ....................................................................................................................... 151
17.1 FUNCTION ....................................................................................................................... 151
17.2 TYPES AND CHARACTERISTICS .................................................................................. 152
17.3 CONTROLS...................................................................................................................... 153
18. TOP DRIVE ............................................................................................................................ 155
18.1 FUNCTION ....................................................................................................................... 155
18.2 TYPES AND CHARACTERISTICS .................................................................................. 156
- Top Drive National Oilwell .................................................................................................. 156
- Top Drive VARCO .............................................................................................................. 157
18.3 TOP DRIVE COMPONENTS............................................................................................ 162
18.4 INSPECTIONS ................................................................................................................. 174
19. RIG FLOOR MUD MANIFOLD ............................................................................................... 175
19.1 FUNCTION ....................................................................................................................... 175
19.2 TYPES .............................................................................................................................. 175
19.3 COMPONENTS ................................................................................................................ 177
1. Rotary Hose and Vibrator Hose ........................................................................................ 177
2. Mud Valve......................................................................................................................... 178
3. Quick Unions .................................................................................................................... 180
4. Pressure Readings ........................................................................................................... 181
20. MUD PUMPS.......................................................................................................................... 182
HIGH PRESSURE MUD PUMPS ............................................................................................. 182
20.1 PRINCIPLES .................................................................................................................... 182
20.2 NOMENCLATURE............................................................................................................ 183
20.3 TYPES AND CHARACTERISTICS .................................................................................. 186
20.4 ACCESSORIES................................................................................................................ 188
20.5 FLOW RATE AND EFFICIENCY CALCULATION............................................................ 192
20.6 POWER AND EFFICIENCY CALCULATION ................................................................... 192
LOW PRESSURE MUD PUMPS (Centrifugal Pump)............................................................... 193
20.7 FUNCTION ....................................................................................................................... 193
20.8 NOMENCLATURE............................................................................................................ 195
20.9 PUMP PERFORMANCE CURVES .................................................................................. 196
21. MUD MIXING SYSTEM .......................................................................................................... 198
21.1 FUNCTION ....................................................................................................................... 198
21.2 MIXING EQUIPMENT....................................................................................................... 199
21.3 BULK STOCK SYSTEM ................................................................................................... 204
- SILOS ................................................................................................................................. 204
- SURGE TANK .................................................................................................................... 207
22. MUD PITS............................................................................................................................... 208
22.1 GENERAL......................................................................................................................... 208
22.2 TYPES .............................................................................................................................. 210
22.3 ACCESSORIES................................................................................................................ 211
a. Valves (suction, butterfly, dump, equalizing) .................................................................... 211
b. Agitators (hydraulic, mechanical)...................................................................................... 214
23. PIPE SIZING........................................................................................................................... 219
23.1 INTRUDUCTION .............................................................................................................. 219
23.2 FRICTION LOSSES ......................................................................................................... 220

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- Friction Losses for Different Pipe Size................................................................................ 220

- Friction Losses for Valves and Connections....................................................................... 224
24. TRIP TANK ............................................................................................................................. 225
24.1 DESCRIPTION ................................................................................................................. 225
24.2 DIMENSIONS ................................................................................................................... 226
24.3 CONFIGURATION............................................................................................................ 227
25. SOLIDS REMOVAL SYSTEM ................................................................................................ 229
26. DEGASSER............................................................................................................................ 245
26.1 FUNCTIONS..................................................................................................................... 245
26.2 PRINCIPLES .................................................................................................................... 245
26.3 DEGASSER TYPES ......................................................................................................... 246
- MANUFACTURERS ........................................................................................................... 246
- DEGASSER SYSTEM for H2S PRESENCE ...................................................................... 248
26.4 INSTALLATION CRITERIA .............................................................................................. 249
27. DRILL PIPE ............................................................................................................................ 250
27.1 PHYSICAL DATA FOR STEEL DRILL PIPE .................................................................... 250
DRILL PIPE .......................................................................................................................... 250
DRILL PIPE BODY ............................................................................................................... 252
TOOL JOINT......................................................................................................................... 254
27.2 DRILL STEM DESIGN CALCULATIONS ......................................................................... 261
BODY STRESS .................................................................................................................... 261
TOOL JOINT STRESS ......................................................................................................... 267
27.3 DRILL PIPE CODE IDENTIFICATION ............................................................................. 270
27.4 DRILL PIPE INSPECTIONS ............................................................................................. 271
27.5 DRILL PIPE BRITTLE FOR H2S ..................................................................................... 272
28. HEAVY WALL DP & DRILL COLLARS .................................................................................. 273
28.1 HEAVY WALL DRILL PIPE .............................................................................................. 273
28.2 DRILL COLLARS.............................................................................................................. 276
- DRILL COLLAR TYPES ..................................................................................................... 276
- DRILL COLLAR CHARACTERISTICS ............................................................................... 277
- BENDING STRENGTH RATIO CALCULATION ................................................................ 279
- DRILL COLLAR THREADS FEATURES............................................................................ 281
28.3 DRILL STEM SUBS.......................................................................................................... 282
28.4 LIFT SUBS........................................................................................................................ 284
28.5 INSPECTIONS ................................................................................................................. 284
29. PIPE HANDLING TOOLS....................................................................................................... 286
29.1 DEFINITIONS ................................................................................................................... 286
29.2 ELEVATOR LINKS (BALES) ............................................................................................ 287
29.3 SLIPS................................................................................................................................ 290
MANUAL SLIPS.................................................................................................................... 290
AUTOMATIC POWER SLIPS ............................................................................................... 297
29.4 ELEVATORS .................................................................................................................... 298
- ELEVATORS for DP - DC Manual...................................................................................... 298
- ELEVATORS for DP - DC Remoted controlled .................................................................. 300
- ELEVATORS for DP & DC (with variable size bushings) ................................................... 301
- ELEVATORS for DC........................................................................................................... 301
- ELEVATORS for Casing..................................................................................................... 303
- ELEVATORS for DP-DC-CASING & TUBING.................................................................... 305
- SINGLE JOINT ELEVATORS ............................................................................................ 306
29.5 TONGS ............................................................................................................................. 306
SPINNING WRENCHES....................................................................................................... 306
TONGS for DP - DC & CASING Manual.............................................................................. 308
TONGS for DP - DC & CASING Automatic ......................................................................... 310
SPINNING & TORQUE Combination Wrench ..................................................................... 310
29.6 PIPE RACK....................................................................................................................... 312
29.7 FINGERBOARD ............................................................................................................... 312

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29.8 PICK UP & LAY DOWN MACHINE .................................................................................. 313

29.9 CSG STABBING BOARD ................................................................................................. 313
30. DIVERTER.............................................................................................................................. 314
30.1 FUNCTION ....................................................................................................................... 314
30.2 TYPICAL CONFIGURATION............................................................................................ 314
- Diverter Installations ........................................................................................................... 317
30.3 TYPES AND CHARACTERISTICS .................................................................................. 318
30.4 INSPECTIONS ................................................................................................................. 319
31. ANNULAR PREVENTER........................................................................................................ 320
31.1 FUNCTION ....................................................................................................................... 320
31.2 FUNCTIONING PRINCIPLES .......................................................................................... 322
31.3 TYPES AND CHARACTERISTICS .................................................................................. 323
- CAMERON BOP................................................................................................................. 323
- HYDRIL BOP ...................................................................................................................... 325
- SHAFFER BOP .................................................................................................................. 330
31.4 INSPECTIONS ................................................................................................................. 331
32. RAM PREVENTER................................................................................................................. 332
32.1 FUNCTION ....................................................................................................................... 332
32.2 DATA ................................................................................................................................ 334
32.3 TYPES AND CHARACTERISTICS .................................................................................. 336
- CAMERON RAMS BOP ..................................................................................................... 336
- HYDRIL RAMS BOP .......................................................................................................... 343
- SHAFFER RAMS BOP ....................................................................................................... 347
- SHAFFER BOP Rams ........................................................................................................ 352
32.4 INSPECTIONS ................................................................................................................. 353
33. BOP CONTROL SYSTEM...................................................................................................... 354
33.1 FUNCTION ....................................................................................................................... 354
33.2 RESPONSE TIMES.......................................................................................................... 355
- ACCUMULATORS CAPACITY........................................................................................... 355
33.3 MAIN COMPONENTS ...................................................................................................... 357
- ACCUMULATOR UNIT....................................................................................................... 358
- DRILLER CONTROL PANEL ............................................................................................. 364
SECONDARY CONTROL PANEL (Remote)........................................................................ 364
33.4 ACCUMULATOR OPERATIONS ..................................................................................... 365
33.5 INSPECTIONS ................................................................................................................. 366
34. INSIDE BOP ........................................................................................................................... 367
34.1 FUNCTION ....................................................................................................................... 367
34.2 TYPES OF INSIDE BOP .................................................................................................. 368
DROP-IN VALVE .................................................................................................................. 368
FLOAT VALVE...................................................................................................................... 370
GRAY FLOAT VALVE .......................................................................................................... 371
SAFETY VALVES ................................................................................................................. 372
35. KILL & CHOKE LINES and VALVES...................................................................................... 374
35.1 FUNCTION ....................................................................................................................... 374
- KILL & CHOKE LINES........................................................................................................ 374
- KILL & CHOKE VALVES .................................................................................................... 377
- TYPICAL LINES CONSTRUCTION ................................................................................... 379
35.2 TYPICAL ASSEMBLY ...................................................................................................... 381
35.3 INSPECTIONS ................................................................................................................. 383
35.4 MANUAL VALVES & REMOTE CONTROLLED VALVES ............................................... 383
- Gate Valve Cameron Type "FL" ......................................................................................... 383
- Cameron Manual Valve FLS .............................................................................................. 384
- Cameron Manual Valve FLS-R........................................................................................... 385
- Hydraulic Actuator for Cameron Valve ............................................................................... 386
36. CHOKE MANIFOLD & MUD GAS SEPARATOR ................................................................... 387
36.1 CHOKE MANIFOLD ......................................................................................................... 387

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- CHOKE MANIFOLD FUNCTION........................................................................................ 387

- TYPICAL CHOKE MANIFOLD ASSEMBLY ....................................................................... 388
- CHOCKE MANIFOLD COMPONENTS .............................................................................. 389
- CHOKE MANIFOLD INSPECTIONS .................................................................................. 393
36.2 MUD GAS SEPARATOR.................................................................................................. 394
- MUD GAS SEPARATOR FUNCTION ................................................................................ 394
- TYPES OF MUD GAS SEPARATORS............................................................................... 395
- MUD GAS SEPARATOR INSPECTIONS .......................................................................... 396
37. INSTRUMENTATION ............................................................................................................. 397
37.1 FUNCTION ....................................................................................................................... 397
37.2 PARAMETERS ................................................................................................................. 397
37.3 SENSORS AND INDICATORS ........................................................................................ 398
37.4 INTERFACE (Panels, Consoles) ...................................................................................... 405
37.5 INTEGRATED SYSTEMS ................................................................................................ 406
38. SOUND PROOFING............................................................................................................... 411
38.1 GENERAL......................................................................................................................... 411
38.2 SONOURUS SOUCES ON A LAND RIG ......................................................................... 411
38.3 SOUND PROOFING......................................................................................................... 412
39. WINTERIZATION SYSTEM.................................................................................................... 414
39.1 GENERAL......................................................................................................................... 414
39.2 COMPONENTS ................................................................................................................ 414
39.3 SOME OF THE MAIN DATA ............................................................................................ 417
40. H2S MONITORING & PROTECTION .................................................................................... 418
40.1 GENERAL......................................................................................................................... 418
40.2 MONITORING SYSTEMS ................................................................................................ 419
- FIXED MONITORING SYSTEM ......................................................................................... 419
- PORTABLE MONITORING SYSTEMS .............................................................................. 421
40.3 BREATHING APPARATUS PROTECTION SYSTEM...................................................... 422
- FIXED SYSTEM'S COMPONENTS ................................................................................... 422
- CYLINDERS RECHARGING SYSTEM .............................................................................. 422
- DISTRIBUTION SYSTEM .................................................................................................. 424
BREATHING APPARATUS .................................................................................................. 425
41. SAFETY EQUIPMENT ........................................................................................................... 427
41.1 PERSONAL PROTECTIVE EQUIPMENT ........................................................................ 427
- General Personal Protective Equipment............................................................................. 427
- Personnel Protective means............................................................................................... 427
41.2 EMERGENCY WASHING STATION ................................................................................ 428
41.3 ESCAPE - EVACUATION - RESCUE .............................................................................. 428
ESCAPE SLIPWAY .............................................................................................................. 431
41.4 OMNIDIRECTIONAL FOGHORN..................................................................................... 431
41.5 PERSONNEL LIFTING DEVICE ...................................................................................... 432
41.6 FIRE FIGHTING SYSTEM................................................................................................ 432
41.7 SAFETY DEVICES ........................................................................................................... 434
42. COMUNICATION SYSTEMS ................................................................................................. 435
42.1 COMMUNICATIONS ........................................................................................................ 435
42.2 OFFSHORE RIGS INTERCOMMUNICATION SYSTEM ................................................. 435
42.3 LAND RIG REQUIREMENTS........................................................................................... 436
43. JACK UP RIG ......................................................................................................................... 437
43.1 DESCRIPTION ................................................................................................................. 437
43.2 JACK UP TYPE ................................................................................................................ 440
- 150-250 ft Nominal water depth ......................................................................................... 440
- 300-350 ft Nominal water depth ......................................................................................... 441
- 400-450 ft Nominal water depth ......................................................................................... 442
44. JACK UP POSITIONING ........................................................................................................ 443
44.1 POSITIONING .................................................................................................................. 443
44.2 MAX WATER DEPTH....................................................................................................... 445

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44.3 PRELOAD......................................................................................................................... 447

44.4 PUNCH THROUGH.......................................................................................................... 449
45. SUBMERSIBLE RIGS ............................................................................................................ 451
45.1 SWAMP BARGE............................................................................................................... 451
45.2 POSTED BARGE ............................................................................................................. 451
46. TENDER DRILLING RIGS...................................................................................................... 453
46.1 TENDER SHIP TYPE ....................................................................................................... 453
46.2 TENDER JACK UP TYPE ................................................................................................ 454
46.3 TENDER SEMI TYPE....................................................................................................... 455
47. SELF CONTAINED DRILLING RIGS ..................................................................................... 456
47.1 SELF CONTAINED DRILLING RIGS ............................................................................... 456
47.2 JACKET RIG IN THE ADRIATIC SEA .............................................................................. 457
48. SUPPLY VESSELS ................................................................................................................ 458
48.1 TYPES of SUPPLY VESSELS ......................................................................................... 458
49. DRILLING RIGS IN CASPIAN SEA........................................................................................ 460

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01. INTRODUCTION

INDEX

1.1 DEFINITION
1.2 RIG TYPES

1.1 DEFINITION

Drilling rigs: equipment and tool used for

- DRILLING
- RE-DRILL OR RE-ENTRIES
- WORKOVERS

1.2 RIG TYPES

a. On-shore Drilling b. Off-shore Drilling

- Conventional b1. Bottom sea supported
- Fast Moving - Submersible -Swamp
- Heli-transportable - Barge
- Jack-Up
- Platform rig
- Self contained
- Tender assisted
b2. Floater
- Semi-sub
- Drilling ship

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- Maximum Operating Water Depth

Bottom sea supported

- Platform rig (150 - 200 m)
- Jack-Up (150 m)

Floater
- Semi-sub and Drilling ship (Anchored) (1000 - 1500 m)
- Semi-sub and Drilling ship (Dynamic pos.) (3000 m)

02. ON-SHORE RIGS

INDEX

2.1 DUTY
2.2 TYPES
- Conventional rig
- Fast Moving rig
- Heli-rig

2.3 DRILLING RIG MAIN SYSTEMS

- HOISTING & ROTATION SYSTEM
- POWER GENERATION SYSTEM
- MUD CIRCULATING SYSTEM
- WELL CONTROL SYSTEM

2.1 DUTY

ENI E&P divides the rig type in five main levels depending on HP and nominal maximum depth
with 5" DP.

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ENI Classification
DUTY I II III IV V
DRAWWORKS HP 700 1000 1500 2000 3000
MAX DEPTH WITH 5” DP 2500 3500 4500 5500 More
m m m m

2.2 TYPES TRANSPORT

- CONVENTIONAL RIG

Land rigs work on dry land. They are the most common rigs.

- Conventional Land Rig - Conventional Land Rig for Cold Zone

- Winterized land rig - Conventional Land Rig for Desert Zone

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- FAST MOVING RIG

They usually have low power and belong to - duty I e II of ENI E&P classification.
They are dimensioned for: shallow wells, workover and abandonment.
Their main advantage is their capability to rig up, move, and rig down quickly and easily.

Fast Moving Land Rig G-200 Soilmec

This rig handles stands of range III drill pipe (completely automatic racking system)
- Fast moving rig example
- P/U and rotary system
- Racking system

Fast Moving Rig Example - Land Rig: Fast Moving Trailer Mounted

- HELI-RIG

Land rig type heli-transported

Not very common.

Used where there are not roads (bush, forest)

- Transport by helicopter
All parts are dimensioned to be transported by
helicopter.

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2.3 DRILLING RIG MAIN SYSTEMS

There are 4 main systems on a drilling rig:

- HOISTING & ROTATION SYSTEM

- POWER GENERATION SYSTEM
- MUD CIRCULATING SYSTEM
- WELL CONTROL SYSTEM

- HOISTING & ROTATION SYSTEM

1. MAST & SUBSTRUCTURE

2. CROWN BLOCK

3. TRAVELLING BLOCK

4. TOP DRIVE

5. ROTARY TABLE

6. DRAWWORKS

7. DRILLING LINE

8. DEADLINE ANCHOR

- POWER GENERATION SYSTEM

AC-DC POWER GENERATION STATION

EXAMPLE

1. GENERATORS

2. CONTROL PANELS

3. TRANSFORMER

4. DC MOTOR

5. DIGITAL DRILLER CONSOLE

6. MOTOR CONTROL CENTER

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- MUD CIRCULATING SYSTEM

1. MUD PITS

2. MUD MIXING HOPPER

3. MUD PUMPS (HI AND LOW

PRESSURE)

4. SHAKERS

- WELL CONTROL SYSTEM

1. RIG FLOOR MUD

MANIFOLD

2. INSIDE BOP

3. BOP STACK

4. CHOKE & KILL LINES

5. CHOKE & KILL MANIFOLD

6. BOP ACCUMULATOR

7. BOP CONTROL MANIFOLD

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03. RIG SITE

INDEX
3.1 RIG SITE
Dimensions and Safety
Lay-out examples
Civil works on location
3.2 CELLAR DIMENSIONS
3.3 WASTE PIT DIMENSIONS

3.1 RIG SITE

- Dimensions and Safety

- Dimensions
Rig site dimensions depend on different factors:
- Place (village, mountain, desert, forest)
- Local laws and regulations
- Rig type
- Drilling programme and risks (H2S, HP/HT, etc.)
- Water supply (water well, river, trucks with pits, etc.)
- Operating and economical factors

- Safety
For the safety of the people, the rig and the environment, some aspects must be considered in the
project phase:

- rig must be positioned following the main wind direction; above all if H2S is foreseen;

- Emergency escape roads must be prepared in different direction;

- Different access way must be prepared in case the main road is inaccessible (i.e. Blow-
out);

- Observe minimum distance between equipments according to laws and regulations.

- Standard references
European Directive 94/9/EC (ATEX 95)
"Equipment indended for use in potentially esplosive atmophere"

API RP 500
"Recommended Practice for Classification of Locations for Electrical Installations at Petroleum
Facilities Classified as Class I, Division I and Division 2"

API RP 49
" Recommended practice for drilling and well servicing operations involving hydrogen sulfide" Third
Edition

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API RP-49 Standard rig site

- Example of Hazardous area classification - Plans

Minimum distances according to Italian and European laws.

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- Lay-out Examples

- Minimum Lay Out for G125 Rig

- Example of Massarenti 7000 Lay Out

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- Example of 3 Well Cluster for 2000 HP Rig

- Example of Lay Out for 3000 HP Rig

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- Civil Works on Location

- Example of Civil Works On Location

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3.2 CELLAR DIMENSIONS

- Cellar breadth

Cellar breadth is usually decided with the Rig

Contractor, considering well head, BOP and
substructure. The cellar is usually cased in
concrete to avoid collapse with the weight of
the rig.

- Cellar depth

Cellar depth depends on substructure height, BOP and well head dimensions.

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3.3 WASTE PIT DIMENSIONS

Waste pit dimensions must take into account:

- Total mud volume
- Total cuttings volume
- Cuttings treatment (on location or transported)
- Estimated drilling time.
- Weather conditions.

Waste Pits And Treatment Layout example

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04. SUBSTRUCTURE

INDEX
4.1 FUNCTION
4.2 SUBSTRUCTURE LOAD and DIMENSIONS
4.3 TYPES AND CHARACTERISTICS
4.4 RIG UP SYSTEMS
"SWING UP" - PYRAMID
"SWING LIFT" - BRANHAM
"SLING SHOT" - DRECO
4.5 INSPECTIONS

4.1 FUNCTION

The substructure has the function

of supporting the drawworks,
rotary table, stands of DP and
derrick. The top side is generally
called the rig floor.

Substructure are made following

API STD 4E or 4F regulations.
There is usually a plate mounted
on the substructure identifying its
main characteristics.

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- API Plate

A - NAME OF THE BUILDER

B - ADDRESS

C - API STANDARD (ie API 4F)

D - SERIAL NUMBER

E - HEIGHT (ft)

F - MAXIMUM STATIC LOAD OF ROTARY TABLE

G - MAXIMUM SETBACK STATIC LOAD

4.2 SUBSTRUCTURE LOAD and DIMENSIONS

- Substructure Load

A Derrick or mast weight

B Rig Floor and equipment
C Maximum load of pipe that can be set back in the derrick
D Maximum hook load

- Dimensions
Substructure dimensions are proportional to the rig power.

PYRAMID Dimensions

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4.3 TYPES AND CHARACTERISTICS

- Substructure Types
Land rigs are made for frequent Rig Up, moving and Rig Down.
This is the main reason why different substructure types have been developed.

Two main types

- Type Box on Box
- Type: High Floor Substructure

- Type Box on Box

Different modules or
boxes are positioned to
raise the rig floor.

The numbers of boxes

depends on the height
required to install the
wellhead and BOP stack.

- Type: High Floor Substructure

These have been developed to accommodate

higher BOP stacks and wellheads.

Although each builder has their own model, they all

have the following characteristics:

Enables the drawworks and derrick to be rigged up

at ground level, eliminating the need for big cranes;
Uses the rig's drawworks to raise the floor and
derrick (some models use hydraulic pistons).

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4.4 RIG UP SYSTEMS

- "SWING UP" - PYRAMID
- "SWING LIFT" - BRANHAM
- "SLING SHOT" - DRECO

- SWING UP - PYRAMID
Drawwork lifts the mast, the substructure and the complete rig floor.

Only 2 main lifts are required

- 1st lift to pick up mast and part of rig floor

- 2nd lift to pick up draw work and aft part of rig floor.

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- SWING LIFT - BRANHAM

- Position of lifting cables

- 1st PHASE: A-frame positioning
- 2nd PHASE : Lifting the Mast
- 3rd PHASE : Lifting the Drawworks

Lifting Cables - Scheme 1st A-frame Positioning - Scheme

2nd Lifting the Mast - Scheme 3nd Lifting the Drawworks - Scheme

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- SLING SHOT DRECO

Dedicated hydraulic pistons to lift derrick, substructure and complete rig floor.

Lifting sequence

- Beginning - After 3 minutes - After 6 minutes - After 9 minutes

4.5 INSPECTIONS

Periodical inspections

Substructure, derrick and lifting equipment must have periodical inspections, (every six months)
following the builder's instructions and the API regulations:

API RP 4G ed API RP 54.

International Organization for Standardization (ISO)

ISO 13534.

ENI rules ask also a complete re-certification of the derrick/mast every 5 years.

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05. DERRICK

INDEX

5.1 CONCEPTUAL DESIGN

5.2 TYPES AND CHARACTERISTICS
- DERRICK
- MAST
- RAM RIG
5.3 RIGGING UP
5.4 DRILLING LOADS
- Calculation of Drilling Loads at Crown Block
- Definition of Gross Nominal Capacity
5.5 INSPECTION

5.1 CONCEPTUAL DESIGN

- Derricks

Derricks and Masts consist of a steel framework with a

square or rectangular cross-section.
Their purpose is to support the hoisting equipment and
rack the tubulars while tripping.

The number of joints in a stand (single-double-triple) that

the rig can pull is dependent on the height of the derrick.

- Manufacturer Specifications

Derricks are manufactured in accordance with API 4F or

related ISO (International Organization for
Standardization) 13626 draft.

This specifications covers the design, manufacture, and

use of derricks, portable masts, crown block assemblies
and substructures.

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- Nameplate Information

Derricks built within API/ISO specs must have a specification nameplate attached in a visible place
containing the following information:

a. MANUFACTURER’S NAME.
b. PLACE OF CONSTRUCTION.
c. STANDARD ADOPTED (ex. API 4F).
d. SERIAL NUMBER.
e. HEIGHT ( ft ).
f. MAXIMUM STATIC HOOK LOAD ( lbs) FOR STATED NUMBER OF LINES TO TRAVELLING BLOCKS.
g. MAX. RATED WIND VELOCITY (Knots) WITH RATED CAPACITY OF PIPE RACKED.
h. EDITION OF THE API SPEC. USED
I. GUYING DIAGRAM (when applicable)

j. The following note: “CAUTION: ACCELERATION OR IMPACT, ALSO SETBACK AND WIND LOADS
WILL REDUCE THE MAXIMUM RATED STATIC HOOK LOAD CAPACITY.”k. LOAD DISTRIBUTION
DIAGRAM.

l. GRAPH PLOTTING MAX. ALLOWABLE STATIC HOOK LOAD VERSUS WIND VELOCITY.
m. MAST SETUP DISTANCE FOR MAST WITH GUY LINES.

5.2 TYPES AND CHARACTERISTICS

There are 3 different types of derricks:

- DERRICK
- MAST
- RAM RIG

- DERRICK
Pyramidal steel framework with square or rectangular cross section assembled as fixed structure.

- API Definition
A semipermanent structure of square or rectangular cross-section having members that are
latticed or trussed on all four sides.

This unit must be assembled in the vertical or operation position, as it includes no erection
mechanism. It may or may not be guyed.

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- Derrick dimensions

Table 1 - Derrick Sizes and General Dimensions

A - The vertical distance from the top of the base plate to the bottom of the Crown Block support
Beam.

B - The distance between heel to heel of adjacent legs.

C - The window opening measured in the clear and parallel to the center line of the derrick side
from top of base plate.

D - The smallest clear dimension at the top of the derrick that would restrict passage of crown
block.

E - The clearance between the horizontal header of the gin pole and the top of the crown support
beam.

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Derrick Types

Derrick are normally used on

Offshore rigs and can be divided into
categories:

- Stationary Derrick
Derrick used on offshore fixed
structures

- Dynamic Derrick
Heavyweight derrick used on floating
rigs subjected to marine stress.

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Installation on Dynamic Derrick mounted on

offshore floating unit DS SAIPEM 10000

- MAST

A Mast is a steel framework with square or rectangular cross-section comprised of multiple

sections assembled together.

Mast are normally used on land rigs; they are rarely used on offshore rigs.

Most masts have one side open (window side), while others have both the front and rear side open
(full view).

Generally masts are assembled on the ground in horizontal position and are raised using the
drawworks. Some masts use telescopic sections and are assembled in vertical (boot strap).

- API Definition
3.16 mast: A structural tower comprised of one or more sections assembled in a horizontal
position near the ground and then raised to the operating position.

If the unit contains two or more sections, it may be telescoped or unfolded during the erection
procedure.

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Mast Types

There are 2 different types of masts for land drilling and service rigs:

- STATIONARY BASE
- WITH GUY LINES

Stationary Base With Guy Lines

- Pyramid Mast sizes table

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Example of MAST with GUY LINES

Example 1 Example 2

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- RAM RIG

The RAM RIG is a new concept used to hoist

the drill string.

The Drawwork and the drilling line are replaced

with a system of hydraulic pistons and rams.
Ram rigs can be used with singles or stands,
depending on the height of the derrick.

They have only recently been developed and

are not yet classified within API/ISO Specs

- Hydraulic System

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- Semisub Ram Rig Sketch

- Ram Rig System Scheme

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5.3 RIGGING UP

- Conventional Mast (Land rig)

Erection sequence

- Phase 1

- Phase 2

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- Vertical Mast (offshore Rig)

Boot Strap sequence:

- First

- Second - Final

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- Trailer Mounted Rig

Rigging Up Sequence of a Trailer Mounted Rig

- a) Deploying of substructure base

- b) Anchoring of trailer to substructure base
- c) Extension of the telescopic sections
- d) Installation of the hydraulic rams
- e) Anchoring the mast to the substructure
- f) Raising the mast in vertical position
- Final Position

a) Deploying of substructure base

- b) Anchoring of trailer to substructure base

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- c) Extension of the telescopic sections

- d) Installation of the hydraulic rams

- e) Anchoring the mast to the substructure

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- f) Raising the mast in vertical position - Final Position

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5.4 DRILLING LOADS

- Forces on the Derrick

Derricks are subjected :

- Weight of the derrick itself

- Wind load
- Stress induced by Floating hull motion
(for floating vessels)
- Horizontal component load of the drill string
when racked back
- Hoisting load

The first 3 forces are considered in the structural design of the derrick.

- Calculation of Drilling Loads at Crown Block

Cases

Case 1: Suspended load

The load on the support is equal to the weight

being hung.

Case 2a : Static Load

Drilling load is at rest, hoisted by

the Drawworks over a single
sheave on the Crown Block

The load on the drawworks is equal

to the weight being hung from the
crown sheave.

The crown supports both the drilling

load and drawworks tension, so the
force supported is double the
weight being hung.

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Case 2b : Dynamic Load

Drilling load is in motion, hoisted by

the Drawworks over the single
sheave on the Crown Block

The load on the drawworks is equal

to the weight being hung from
crown sheave PLUS frictions.

The crown block supports both the

drilling load and the drawworks
tension PLUS frictions, so the force
supported in more than the weight
being hung.

Case 3: Drilling load is in motion

Drilling load is in motion, hoisted by

the Drawworks through a series of
sheaves on the Crown and
Travelling Blocks

The load supported by the Crown

Block is the sum of the load
supported by each of the lines.

In this example with 3 lines, the

load supported by Crown block is
1500 kg

The load supported by the Drawworks is the drilling load divided by the number of lines on the
traveling block.
In this example the force required by the drawworks to hoist a weight of 1000 kg is reduced by
by using a travelling block with one sheave.

The series of sheaves in Crown-Travelling Blocks system reduces the load necessary to hoist a
weight.

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- Series of sheaves and Lines

- Load Supported by the Drawworks

The series of sheaves in Crown-Travelling Blocks system reduces the load necessary to hoist a
weight. The load supported by the drawworks is related to the number of lines installed on the
Travelling Block.

- Example:

In this case the travelling block has 4 shieves

and 8 lines. The crown block has 5 shieves
and 10 lines ( 8 lines from the travelling block +
Fastline and Dead line.)

Applying a Drilling Load of 120 ton,

The load on each line is: 120 / 8 = 15 ton

The load at the crown block is:

15 x 10 = 150 ton

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- Definition of Gross Nominal Capacity

- Gross Nominal Capacity

Gross nominal capacity is defined as the MAXIMUM STATIC LOAD with a stated number of
drilling lines.
API regulation takes in consideration only the capability for hoisting the drill string.

- Calculation of GNC for Mast

In a MAST the maximum load to the crown block(Gross Nominal Capacity) is calculated as
follows:

with:
GNC = Gross Nominal capacity;
n = lines number
SHL = Maximum static Hook Load.

Example of Load distribution on a Mast

- Calculation of GNC for Derrick

In a DERRICK the maximum load applied at the crown block (Gross Nominal Capacity) is equally
divided on its 4 legs and its calculated as follows:

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with:
GNC = Gross Nominal Capacity
n = Lines number
SHL = Maximum static Hook Load

Example of Load distribution on a Derrick

5.5 INSPECTION

- Periodic inspections

The API applicable references are:

API RP 4G and API RP 54 (chapt. 9.2 and 9.3). and the Manufacturer's recommendations.

ENI policy is more strict and requires the API Category IV inspection (as per API RP 4G) every 5
years instead of 10.

Mast/derricks and substructures on mobile offshore drilling units or fixed platforms are exempted
from the requirements of a Category IV inspection.

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06. DRAWWORKS

INDEX
6.1 FUNCTION
6.2 TYPES AND CHARACTERISTICS
6.3 MAIN SYSTEMS
- Main Drum
- Catheads
- Stationary Brake (Main brake)
- Auxiliary brake
6.4 POWER CALCULATION
6.5 INSPECTIONS

6.1 FUNCTION

- Drawworks Functions

The Drawworks is one of most important

equipment on drilling rig.

The unit supplies the hoisting power, the

drawworks spools the drilling line as pipe is
run into and pulled out from the well.

The drilling line spools out under gravity

and is reeled in by an electrical or diesel
engine.

Schematic Draw

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- Manufacture specifications

The Drawworks is built in according to specifications in API 7K or related ISO (International

Organization for Standardization) 14693.

Drawworks

6.2 TYPES AND CHARACTERISTICS

Depending on the engines on the rig, the drawworks can be either:

- MECHANICAL
- ELECTRICAL

- MECHANICAL
Diesel engines are directly connected (compounded) to the drawwork by chain.
This system is still in use for small Drilling Rigs (under 1500 HP), but is no longer used on
medium-Hi powered rigs( 1500 & 3000 HP).

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- ELECTRICAL
Electrical system are normally used today on land rigs and is the only system in use on offshore
rigs. The drawworks are generally connected to 1000 HP D.C. engines, although A.C. engines are
now being used as well.

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- Connection Drawworks-Engines

The connection between the drawworks and the engines can be either:

- CHAIN DRIVEN
- GEAR DRIVEN

ELECTRIC TYPE (Chain-Driven)

ELECTRIC TYPE (Gear-Driven)

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- Technical Data

Mechanical Type (Technical Data)

Electric Type (Technical Data)

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6.3 MAIN SYSTEMS

a - Main Drum
b - Catheads
c - Stationary Brake (Main brake)
d - Auxiliary brake

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a - Main Drum

- Main Drum Diameter

The diameter of the main drum is a function of
the diameter of the drilling line being used.

It is preferable to have the drum as large as

possible to reduce the number of wraps and the
bending of the cable.

- Drum Length
The length of the drum is a function of the
distance between Crown block and
Drawworks.

- Fleet Angle
To reduce the wear on the drilling line, it is good
practice to keep the angle alpha under 2
degrees.
(see pictures)

b - Catheads

- Spinning line and Breakout Cathead

Catheads are winches with pneumatic

clutch and are mounted on the
extremity of the secondary drum of
the drawworks.

The make up cathead is located

beside the driller's console and the
break-out cathead is located on the
opposite side of the driller's console.

The catheads apply the pulling force

on the hand tongs connections.
- Model 16 Spinning line Cathead
- Model 16 Breakout Cathead

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- Employment scheme

For safety reasons and convenience their employment comes supplanted from the dedicated
equipments.

c - Stationary Brake

- Band Brake

- Disk Brake

- Regenerative Brake System

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- Band Brake

- Description (parts)
- BRAKE HANDLE
- LEFT BAND
- RIGHT BAND
- BALANCE BAR

- Braking action
Braking action is activated by pushing the Brake handle down towards the floor.
Through a strength multiplier system, the braking force is transmitted on the balance bar, then
to the brake bands, and finally to the two drums on either side of main drum.
Heat produced by the braking action is dissipated through the circulating water cooling system.

- Disk Brake

Depending of the size the drawworks, there are 2 to 4 hydraulically-actuated calipers.

In addition to these main calipers, each disc brake system has 2 dedicated calipers (normally
closed) that are used as the emergency and parking brake.

These calipers are actuated by an independent hydraulic system.

Disk brakes can be mounted on Drawworks that was originally equipped with band brake.

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- Advantages
The advantages are:
- Greater braking capability
- Emergency braking system
- Possibility of Remote control
- Significant noise reduction during drilling

- Use

Disk Brake is a
development of the
band brake, due to
the necessity to
handle heavier loads

- Performance
Comparison
diagram of 3
brake
combinations

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- Regenerative Brake System

- New generation of drawworks

The newest generation of drawworks (4000-5000 HP), mounted on ultradeep offshore rigs, have a
direct drive transmission system, permanently connecting the drawworks to the motors.

When the travelling block descends in the derrick, the motors turns in the opposite direction,
producing an opposite current and hence a braking action.

- NOTE: This braking system, is not able to hold, when the motors are rest, hence the need for
emergency and parking the disk brake system.

Regenerative Brake System

d - Auxiliary brake / dynamic brake

The function of the auxiliary brake is to assist the main braking system during rapid descent of the
blocks with heavy string weights. The auxiliary brake prevents the overheating and premature
wear of main brakes.

Types:
- Hydrodynamic Brake
- Elettromagnetic Brake

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- Hydrodynamic Brake

That system is still in use on small drawworks.

However, on medium-Hi powered drawworks,
this system has been replaced by the
Electromagnetic brake.

- Description

The Hydrodynamic brake

consisting of two box with a
rotor pressed onto the main
drive shaft and two stators.

When the main shaft rotates

the rotor drags water against
the two stators, producing a
braking action.

Braking capability can be

regulated by increasing or
decreasing the water levels in
the "Hydraulic Brake box".

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- Hydrodynamic Brake

The electromagnetic brake consists of a stator with coil, two magnetic poles and a rotor pressed
onto the main drive shaft.

When the driller activates the brake control, a magnetic field is produced by 4 electromagnetic
coils mounted concentrically inside the drum.

By varying the amount of current to these stationery coils, the driller can control the amount of
braking torque applied to the rotating drum.

- "Baylor" brakes

The use of electromagnetic brake began with diesel-electric rigs. Almost all drawworks today are
equipped with "Baylor" brakes.
Baylor Brakes are manufactured in 5 standard sizes for nominal drilling depths up to 30.000feet.

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- Braking force

The diagram shows the values of

braking force as a function of rpm of the
drawworks shaft.
Notice how the electromagnetic brake is
also effective at low speeds.

Braking Force Diagram

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6.4 POWER CALCULATION

WORK = Force x Step

POWER= Force x Pooh velocity

- Hook Power Ph = Hook Power (HP)

Ve = Pooh velocity (m/s)
P = Weight on Hook (kg)

- Drawwork Power F = Pull to Fast line equal to:

P (Weigh on Hook) / N (Number of lines)

Vf = fast line velocity equal to:

Ve * = 2 R n (rpm drawwork shaft)

E= Efficiency of sheaves. This value (empiric)

provided by API in function of number of
lines.

6.5 INSPECTIONS

- Periodic inspections
The API applicable references are:

API RP 7L and API RP 54 (chapt. 9.4 and 9.5).

and the Manufacturer's recommendations.

ENI policy requires the API Category IV

inspection (as per API RP 7L) every 5 years.

Drawwork Inspection

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07. CROWN BLOCK

INDEX
7.1 FUNCTION
7.2 TYPES AND CHARACTERISTICS
7.3 INSPECTIONS

7.1 FUNCTION

- Crown block definition

The Crown Block is a fixed set of pulleys

(called sheaves) located at the top of the
derrick or mast, over which the drilling line is
threaded.

The companion blocks to these pulleys are

the travelling blocks. By using two sets of
blocks in this fashion, great mechanical
advantage is gained, enabling the use of
relatively small drilling line to hoist loads
many times heavier than the cable could
support as a single strand.

- Sheave characteristics
The number of sheaves on the two Blocks
(Crown and Travelling ) can range from 5 to
8 and is a function of the Hoisting system
capability.

The rating of the Crown Block must be

higher than the Travelling Blocks.

The diameter and the groove of sheaves

depends on the diameter of drilling line in
use. This values are established by the
builder based the recommendations of API
RP 9B.

The ratio of sheaves diameter to drilling line Crown Block

diameter should be between 30-40.

- API specifications

The Crown Block, Travelling Block and the Hook are built in accordance with API specifications
8A or 8C.

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7.2 TYPES AND CHARACTERISTICS

- Groove size

The groove on the sheaves must be same

size as the diameter of drilling line used to
provide the right support. (Fig. 77)

A groove to wide will flatten the drilling

line, while a groove to narrow will cause
high friction and excessive wear on the
drilling line.

Groove (Fig. 77)

- Typical Derrick Crown Block

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7.3 INSPECTIONS

- Periodic inspections

The Crown Block, as with all Hoisting equipment, must have periodic inspections according to the
builder's recommendations and API RP 8B.

ENI procedures stipulate that the Crown Block be certified every 5 years, in addition to the
mandatory periodic inspections.

- Frequency of Periodic Inspections

The frequency of periodic inspections is:

- Daily
- Monthly
- Semi-annual
- Annual
- Five-year

- Table: Periodic Inspection and Maintenance Categories and Frequencies

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- API Recommended Practice 8B

CATEGORIES
Category I
Observation of equipment during operation for indications of inadequate performance.

Category II
Category I inspection, plus further inspection for corrosion; deformation; loose or missing
components; deterioration; proper lubrication; visible external cracks; and adjustment.

Category III
Category II inspection, plus further inspection which should include NDE of exposed critical
areas and may involve some disassembly to access specific components and identify wear
that exceeds the manufacturer's allowable tolerances.

Category IV
Category III inspection, plus further inspection where the equipment is disassembled to the
extent necessary to conduct NDE of all primary load carrying components as defined by
the manufacturer.

FREQUENCY
The owner or user of the equipment should develop his own schedule of inspections based
on experience, manufacturer's recommendations, and consideration of one or more of the
following factors:
- environment; - testing;
- load cycles; - repairs;
- regulatory requirements; - remanufacture
- operating time;

As an alternative the owner or user may use Table 1.

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- Example of Dimensional
Inspection

a. scheme
b. Measures and Methods

The Drilling Contractors must have

a sheave gauge to carry out the
checks and measurements to
evaluate wears.

- Example of NDT Inspection

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08. TRAVELLING BLOCK

INDEX
8.1 FUNCTION
8.2 TYPES AND CHARACTERISTICS
8.3 INSPECTIONS

8.1 FUNCTION

The Travelling Block is a set of sheaves

(pulleys) that move up and down in the derrick.

The drilling line is threaded (reeved) over the

sheaves on the crown and through the sheaves
in the travelling block. This provides a great
mechanical advantage to the drilling line,
enabling it to lift heavy loads of pipe and casing.

The number of the pulleys used on the two

Blocks can vary from 5 to 8, providing a variable
capacity to the Hoisting system.

Travelling Block

- Manufacture Specifications
The diameter and groove of the pulleys depends on the dimensions of the drilling line to be used.
These values are determinated by manufacturer in accordance with API RP 9B.
The ratio of sheave diameter to drilling line should be between 30-40:1.
The travelling blocks is built in accordance with API Spec. 8A and 8C.
The reference standards adopted by ENI is: ISO 13535

8.2 TYPES AND CHARACTERISTICS

\
- Groove size

The size of the groove should be the same as

the diameter of drilling line in order to provide
the proper support.

A pulley groove too large could flatten the

drilling line and a groove too small can cause
high friction and excessive wear on the drilling
line.

Groove

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Standard Type

- Standard Travelling Block

- Dimensional characteristics

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Unitized

- Scheme and Nomenclature

- Unitized Type

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Combination With Hook

- Scheme and Nomenclature

- Combination Travelling Block

Combination Travelling Block - Scheme Combination Travelling Block

Maritime Travelling Block

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8.3 INSPECTIONS

- Periodic inspections
The Travelling Block, as with all Hoisting equipment, must inspected according to the
manufacturers recommendations and API RP 8B or related ISO (International Organization for
Standardization) 13534.

ENI policy requires the Category IV inspection (as per API RP 8B and ISO 13534) every 5 years.

- Frequency of Periodic Inspections

The frequency of periodic inspections is:
- Daily
- Monthly
- Semi-annual
- Annual
- Five-year

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- API Recommended Practice 8B

- CATEGORIES
Category I
Observation of equipment during operation for indications of inadequate performance.

Category II
Category I inspection, plus further inspection for corrosion; deformation; loose or missing
components; deterioration; proper lubrication; visible external cracks; and adjustment.

Category III
Category II inspection, plus further inspection which should include NDE of exposed critical
areas and may involve some disassembly to access specific components and identify wear
that exceeds the manufacturer's allowable tolerances.

Category IV
Category III inspection, plus further inspection where the equipment is disassembled to the
extent necessary to conduct NDE of all primary load carrying components as defined by
the manufacturer.

- FREQUENCY
The owner or user of the equipment should develop his own schedule of inspections based
on experience, manufacturer's recommendations, and consideration of one or more of the
following factors:
- environment; - testing;
- load cycles; - repairs;
- regulatory requirements; - remanufacture.
- operating time;

As an alternative the owner or user may use Table 1.

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- Dimensional Inspection
- Dimensional Inspection 1

- Dimensional Inspection 2

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- Dimensional Inspection 3

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- NDT Inspection

- NDT Inspection 1

- NDT Inspection 2 - NDT Inspection 3

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09. HOOK

INDEX
9.1 FUNCTION
9.2 TYPES AND CHARACTERISTICS
9.3 INSPECTIONS

9.1 FUNCTION

- Description

Attached to the bottom of the travelling blocks,

the hook is required to hang the swivel and kelly
(for drilling), and the elevator bales (for tripping
pipe and casing).

Hook

- Manufacture Specifications

The Hook blocks is built in accordance with API

Spec. 8A or 8C.

The reference standards adopted by ENI is:

ISO13534 / 13535"

Hook

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9.2 TYPES AND CHARACTERISTICS

Standard Hook

- Structure and components

The hook is composed of 2 parts: upper and

lower.

The upper part has a spring that absorbs the

bouncing action when tripping pipe.

The lower part allow the hook to rotate

facilitate different operations. It can also be
locked to avoid undesired rotation, such as
when tripping.

Standard Hook

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- Nomenclature

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- BJ Model

BJ Model 5750 Dynaplex hook, equipped

with high-volume hydraulic snubber and
optional hook positioner that automatically
rotates elevator into correct position for
derrikman.

Unitized Hook

- Untized Hook - Untized scheme

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Combination Travelling Block and Hook

- Travelling Block and Hook - Combination scheme

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- Example of National Hook Blocks

9.3 INSPECTIONS

- Periodic inspections
The Hook, as with all Hoisting equipment, must be inspected according to the manufacturer's
recommendations and API RP 8B.

ENI procedures stipulate that the hook must be re-certified every 5 years, in addition to the
required periodic inspections.

- Frequency of Periodic Inspections

The frequency of periodic inspections is:
- Daily
- Monthy
- Semi-annual
- Annual
- Five-year

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- API Recommended Practice 8B

- CATEGORY
Category I
Observation of equipment during operation for indications of inadequate performance.

Category II
Category I inspection, plus further inspection for corrosion; deformation; loose or missing
components; deterioration; proper lubrication; visible external cracks; and adjustment.

Category III
Category II inspection, plus further inspection which should include NDE of exposed critical
areas and may involve some disassembly to access specific components and identify wear
that exceeds the manufacturer's allowable tolerances.

Category IV
Category III inspection, plus further inspection where the equipment is disassembled to the
extent necessary to conduct NDE of all primary load carrying components as defined by
the manufacturer.

- FREQUENCY
The owner or user of the equipment should develop his own schedule of inspections based
on experience, manufacturer's recommendations, and consideration of one or more of the
following factors:
- environment; - testing;
- load cycles; - repairs;
- regulatory requirements; - remanufacture.
- operating time;

As an alternative the owner or user may use Table 1.

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- Dimensional Inspection

- Bail and Bolts

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- Housing Inspection - Cam Ring Inspection

- Hook Stem Inspection - Hook and Lower Locking Arm Inspection

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- NDT Inspection

- Bail and Bolts NDT Inspection - Housing NDT Inspection

- Cam Ring Z1 NDT Inspection - Cam Ring Z2 - Z4 NDT Inspection

- Hook and Lower Locking Arm NDT Inspection - Link Ears NDT Inspection

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10. DRILLING LINE

INDEX
10.1 DRILLING LINE STRUCTURE
10.2 TYPES AND CHARACTERISTICS
10.3 DRILLING LINE REEVING
10.4 DEADLINE ANCHOR
10.5 SAFETY FACTOR
10.6 DRILLING LINE WEAR
- SLIP AND CUT TON-MILES CALCULATION
- SLIP AND CUT
10.7 DRUM

10.1 DRILLING LINE STRUCTURE

- Drilling line choice

The factors to consider in the drilling line

choice are:

Diameter
Breaking strength
Flexibility
Elasticity
Corrosion strength
Abrasion resistance
Distortion strength

The drilling line shall be in compliance with:

API 9A and API RP 9B.

Drilling line

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- Wire rope

Wire rope is an intricate network of close

tolerance, precision made steel wires, much on
the order of a machine, where each part has a
job to do.

Wire Rope is composed three parts:

- the CORE,
- the STRAND and
- the WIRE.

API 9A defines drilling lines with abbreviations

in function of:

Type of core (Steel or fiber)

Number of strands
Number of wires per strand

Wire rope

- CORE
The center wire of the drilling line can be one of
two types:

FIBER CORE: Either of natural fiber such as

sisal or man-made fiber such as polypropylene.

WIRE ROPE CORE: Steel wire

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- LAY: Direction

The first element in describing lay is the

DIRECTION the strands lay in the rope -
Right or Left.
When you look along the rope, strands of
a Right Lay rope spiral to the right. Left
Lay spirals to the left.

The second element describing lay is the

relationship between the direction the
strands lay in the rope and the direction
the wires lay in the strands. In regular Lay,
wires are laid opposite the direction the
strands lay in the rope.

In appearance, the wires in Regular Lay

are parallel to the axis of the rope.

In Lang Lay, wires are laid the same

direction as the strands lay in the rope and
the wires appear to cross the rope axis at
an angle.

a) RIGHT REGULAR LAY

b) LEFT REGULAR LAY LAY
c) RIGHT LANG LAY
d) LEFT LANG LAY
e) RIGHT ALTERNATE LAY

- LAY: Length of the Rope Axis

The third element in describing lay is

that one rope lay is length the rope
axis which one strand uses to make
one complete helix around the core.

For API 9A regulations one rope lay

is usually
7 to 8 times the nominal diameter.

Drilling line nominal diameter measurement

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- Nomenclature Example

1" x 5000' 6 x 19 S PFR RRL IPS IWRC

1" = Diameter of Line

5000' = Length of Line
6' = Number of Strands per Line
19 = Number of Wires per Strand
S = Seale Pattern; Seale All layers contain the same number of wires.

PRF = Preformed Strands are helically formed into the final shape.
RRL = Right Regular Lay
IPS = Improved Plow Steel with breaking strength between 1770 and
1960 MPa.
IWRC = Independent Wire Rope Core

10.2 TYPES AND CHARACTERISTICS

- Table: Typical sizes and Constructions of Wire Rope for Oilfield Service

Typical sizes

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- Classification Example

Abbreviations

EIPS = Extra Improved Plow Steel

FC = Fiber Core
FS = Flattened Stand
FW = Filler Wire
IPS = Improved Plow Steel
IWRC = Indipendent Wire Rope Core
LL = Left Lay
NPF = Non Pre-Formed
PF = Pre-Formed
PS = Plow Steel
RL = Right Lay
S = Seale
WS = Warrington Seale

- Nominal Strength of Drilling Line (API 9A)

Drilling Line 6 x19 Bright or Drawn Galvanized, independent Wire Rope Core

Nominal Strength

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10.3 DRILLING LINE REEVING

- Total length of drilling line

Depending on the height of the derrick and the

number of lines to be strung, the total length of
drilling line can vary from 650 to 1750 feet.

- Heavy wear

Heavy wear occurs in 3 localized areas:

1. Where the drilling line makes contact with

the crown block and the travelling block
sheaves

2. The position of the drilling line on the

sheaves when the slips are set and pulled

1. 3. The position on the drum where each

wrap of the drilling line crosses over the
layers below Reeving

- Typical Reeving Diagram

Typical Reeving Diagram for

14-Line String-Up With

8-Sheave Crown Block and

7-Sheave Travelling Block: Left

Hand Reeving

(See Arrangement no. 1 in

Table 3)

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Table 3: Recommended Reeving Arrangements

- Method of Attaching Clips for lifting operations

Figure 6: Correct Method

Figure 7: Incorrect Methods
- Table: Attachment of Clip

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10.4 DEADLINE ANCHOR

- Deadline Anchor
The deadline anchor provides for the attachment of the Martin Decker weight indicator and can be
either on the drilling floor or underneath the floor in the substructure.

- Anchor Size
The anchor must be least 15 times the diameter of the drilling line.

Deadline Anchor - Anchor Size

10.5 SAFETY FACTOR

- Design factor

where
B = Nominal Strength
W = Weight (fast line side)

- "Design factor" of the main equipment:

Minimum
Design Factor
Cable tool-line 3
Stand line 3
Rotary drilling line 3
Hoisting service other than rotary drilling 3
Mast raising and lowering line 2.5
Rotary drilling line when setting casing 2
Pulling on stuck pipe and similar infrequent 2
operations

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- Fast Line pull calculations (API RP 9B)

- CASE A

Fast Line pull calculations

- Fast Line Table

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- Design Factor calculations

i.e.: Drilling line 1 3/8" EIPS

n: Number of lines 10
Pg: Total load 400.000 lb (181.4 tonne)
R: Sheave efficiency x 10 lines= 0.811
B: Nominal strength 87.1 ton

Pg 181.4
W = ----------- = ------------ = 22,3 tonne
n x Rc 10 x 0.811

B 87.1
Design Factor DF = ------ = ------- = 3.9
W 22.3

Tool Pusher Manual Safety factor

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10.6 DRILLING LINE WEAR

- Drilling line Wear

In working the line, heavy wear occurs

a few localized sections: where the
rope makes contact with the travelling
block sheaves, the crown block
sheaves and the drum.

- Slipping and cutting drilling line

For this reason there is the procedure

of SLIPPING AND CUTTING
DRILLING LINE
Cut is done every 2 - 4 slipping.

Slipping new rope through the system

shifts the drilling line through these
critical wear areas and distributes the
wear more uniformly along the length of
the rope

Extreme positions in the operations of run and

pool out of hole

SLIP AND CUT TON-MILES CALCULATION

SLIP AND CUT TON MILES CALCULATIONS AS PER API RP9B

- Work Done During Round-Trip

The only complicated part of a cut-off

procedure is the determination of how
much work has been done by the wire
rope.

Methods such as counting the number

of wells drilled or keeping track of days
between cuts are not accurate because
the loads change with the depth and
with different drilling conditions.

For an accurate record of the amount of

work done by a drilling line, it's
necessary to calculate the weight being
lifted and the distance it is raised and
lowered. In engineering terms, work is
measured in foot-pounds.

On a drilling rig the loads and distance

are so great that we use "ton-miles".
One Ton-mile equals 10,560,000 foot-
pounds.

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- Work Done During Reaming

With reaming after drilling the stand

Without reaming after drilling the
stand

- Work Done During

Drilling with Top Drive (with
stands)

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- Work Done During CSG

The ton-miles of work done in setting

casing would be one-half the ton-miles
done in making a round trip if the weight of
the casing were the same as the weight of
the drill pipe.

- CHARTS EXAMPLE

Charts example from which it's possible deduce the unitary weigh of the various tubular of BHA
(Bottom Hole Assembly)

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a) Effective Weight of Pipe in Drilling Fluid

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b) Effective Weight of Drill Collars in Drilling Fluid

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SLIP AND CUT

- Slip and Cut the drilling line

Every contractor follows a programme,

depending on the kind of rig, wire rope,
drawwork, etc, to calculate when to slip and
cut the drilling line.

IADC tool Pusher's manual

- Recommended Cutoff Lengths

Length of drilling line to be cut following the API RP 9B regulations.

Table: Recommended Cutoff Lengths

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- Ton miles for 1 " drilling line suggest by IADC

1. Do not accumulate more than 3700

ton-miles between cuts, even on the first
cut of a new line.

2. So long as less than 3700 ton-miles

have been accumulated, a cut may be
made anytime it is convenient. To
determine the length to cut, refer to the
above table or calculate so that your
"ton-miles per foot cut" is constant
(length to cut = T - M since last cut
25.0).

3. This program is based upon a goal of

25.0. Any attempt to improve rope
service by increasing the ton-mile goal
should not be made until one entire
drilling line (requiring no long cuts) has
been used following this particular
program.

IADC tool Pusher's manual

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10.7 DRUM

- Drum size
Total length of drilling
line depends on the
drum size.
Sometimes it's
enough to put a new
standard drum with
the new drilling line.

For some rigs the new

drilling line must be
passed in the
dedicated Rig drum
with different
dimensions.

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- Service Life
Relationship Between Rotary-Line Initial Length and Service Life

Graph: Rotary-Line Initial Length and Service Life

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11. POWER GENERATION SYSTEMS

INDEX

11.1 TYPES OF POWER GENERATORS

- FOR MECHANICAL RIGS
- FOR ELECTRIC RIGS
ELECTRIC POWER GENERATION
- DC electric generator
- AC electric generator
- Rigs connected to Power Distribution Net

11.1 TYPES OF POWER GENERATORS

- FOR MECHANICAL RIGS

- FOR ELECTRIC RIGS

FOR MECHANICAL RIGS

- Diesel engines
Power for mechanical rigs is developed by diesel engines connected directly to the load
(drawworks, mud pumps, etc).

Power for the lighting system and small loads (like mud agitators, shakers, etc) comes from a
dedicated electric generator.

- Example of a typical rig

In this example of a typical rig, 3 diesel engines drive the drawworks, pumps and rotary table
through a gear transmission system.

Typical rig

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- Mechanical rig Lay-Out

Mechanical rig Lay-Out with distribution compound for rotary table, mud pumps and drawworks.

Mechanical Rig Lay Out

- Connection Engine - Drive shaft

There are 2 devices used on a mechanical system to connect the engine and the drive shaft:
- HYDRAULIC COUPLER
- TORQUE CONVERTER

Hydraulic Coupler Torque Converter

The devices are beneficial since they can absorb strains on the system such as those present
when starting the engines.

The Hydraulic coupler provides a smooth transfer of power by absorbing mechanical strains.

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The Torque converter, in addition to functioning as a hydraulic coupler, also operates as a gear
shifter by regulating torque variations.

- Hydraulic Coupler

Oil position when the hydraulic Oil position when the hydraulic Oil position when the hydraulic
coupling has stopped coupling is on starting phase coupling has assumed a constant
speed

- Torque Converter

Fluid movement inside the torque converter

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Direct connections between motors and torque Indirect connections between motors and torque
converter converter

FOR ELECTRIC RIGS

ELECTRIC POWER GENERATION

- DC electric generator
DC-DC Drives
Ward-Leonard DC-DC drives on drilling rigs usually consist of a diesel engine coupled to a DC
generator operating at a constant speed.

The output of the generator is controlled by varying its shunt field excitation.

These systems are dedicated to a single purpose. Any load changes caused by drilling activity are
supplied immediately by the motor. The engine and generator rarely interfere with other rig
functions.

The engine and DC generator must have adequate capacity to supply full load and accelerating
current under all load conditions over the operating speed range.

- AC electric generator

AC-DC drives
- Silicon Controlled Rectifier (SCR)
Ward Leonard DC-DC drives have been replaced lately with a Silicon Controlled Rectifier (SCR)
systems. In these systems, AC generator power is converted to DC voltage eliminating the need
for a dedicated generator for each drilling function.
AC loads do not need dedicated generators since they are connected directly to the AC generator.

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- Power distribution examples

Typical electrical one-line diagram of a land rig system

Offshore Rig - Power distribution

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- Jack Up Power Distribution.

AC-AC drives

The AC-AC system is the latest generation of power distribution.

Generators and all loads (drawwork, pumps, etc) are AC.

- Variable Frequency Drives

Because N= f x 120 / P

where: f = voltage frequency Hz

P = number of machine poles
N = shaft speed , rpm

Variable Frequency Drives can convert the fixed voltage and frequency into variable voltage and
frequency to power AC motors at variable speed.

- Benefits of an AC system
AC motors do not have brushes and therefore create no sparks (beneficial in hazardous areas).
Less maintenance.

Can reverse drawworks and rotary table by reversing phase sequence.

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Lighter and smaller (GE 752 DC weights 7200 lbs and GEB-AC 6300 lbs).

- Rigs connected to Power Distribution Net

Power supply at MT for civil and industrial users is 20.000 Volts.
Transformers reduce tension to 600 V.
Variable Frequency drivers change frequency from 50Hz to 60Hz if on the rig are installed AC
loads manufactured as per American standards.
SCR system supplies DC power to DC loads.
Emergency generator automatically starts in case of Main power supply interruptions

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Rig connected to Power Supply

Rig connected to Power Supply with Variable Frequency Drives

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- How much electrical power does a rig need ?

Classification of Electric Drilling Rigs

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12. DIESEL ELECTRIC POWER GENERATION SYSTEM

INDEX

12.1 DIESEL ENGINES

12.2 POWER GENERATORS
- DC GENERATORS
- AC GENERATORS
12.3 DC ENGINES
12.4 AC ENGINES
12.5 ENGINE CONTROLS
- Current Control Panel
- Driller Control Panel
12.6 SCR SYSTEM

12.1 DIESEL ENGINES

- Characteristics
Diesel engines are characterized by their low speed of operation, limited speed range, relatively
low maintenance and general availability.

The selection of diesel engines to drive electric generators is obvious because their similar
operating speeds allow direct coupling, the torque and horsepower of both are compatible, and
control of engine-generator speeds allows relatively easy control of generator output power.

Fuel is usually diesel but also methane could be used.

Diesel Engines

- Caterpillar Engines
Caterpillar engines are the most commonly used engines because of their reliable operation.
Some rigs today still use D-399 TA engines, even though they are no longer being produced.

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Performance

Dimension Data

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12.2 POWER GENERATORS

- DC GENERATORS

- Characteristics
DC generator are very similar to a DC motor, different only in their winding and commutator.

- Speed Control System

Diesel engines coupled to a DC generator work at constant speed.
Generator output power is regulated by changing the current field.

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- Speed and Torque of DC motor

1. Torque load imposed on the diesel engine shaft by te the DC generator

TG = KG IFG IA

where
KG = DC Generator machine constant
IFG = DC Generator field current, amperes
IA = DC Generator/DC motor armature current, amp

2. Armature voltage applied to DC motor terminals

VA = E - IA RAG- VBG volts DC

where
E = Generated DC voltage
RAG = DC Generator armature resistane, ohms
VBG = DC Generator brush drops, volts

3. Speed of DC motor

VA - IA RAM - VBM’
NM = ⎯-⎯-⎯-⎯-⎯-⎯-⎯- KM’ rmp
IFM

where
RAM = DC motor armature resistance, ohms
VBM = DC motor brush drop, volts
IFM = DC motor field current, amperes
KM’ = motor constant

4. Torque developed by DC motor

\\TM = KM IFM IA ft-lb

where
KM = DC motor constant

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- AC GENERATORS

Generators used on drilling rigs are generally synchronous three phase 600 V.

Typical DC Generator - Example (SR4 Generator)

- Example (SR4 Generator)

It is essential to have a properly designed base for diesel electric power modules used on drilling
rigs.
Misalignment between engine and generator can cause vibration and shorten the life of couplings
and bearings. Caterpillar has designed a base which provides a build-in three-point mounting
system.

The engine and generator are mounted by Caterpillar on this base and aligned to exacting
tolerances at the factory. These power modules will maintain alignment during most rig moves.

- Components
The AC generator consists of:

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- Rotor

- Stator

- Field Excitation

The poles are on

the rotor.

- Frequency
Frequency (Hz) depends on the number of poles and Rotor speed

PN
Hz = --------
120

P = number of poles
N = rotor speed (rpm)

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- Apparent Power and Real power

Vector diagram
demonstrates the effect of
power factor correction. The
kVA burden of the
generators is lessened by
adding leading kVARS,
which in turn allows the
system to perform up to its
full kW potential.

APPARENT POWER = (Kva): REACTIVE POWER = (Kvar): REALE POWER = (Kw)

where F = angle between where Φ = angle between

where Vl = line voltage (V) current and voltage current and voltage
Il = line current (A) cos Φ = power factor

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12.3 DC ENGINES

DC motors are commonly

used in the oilfield because of
their flexibility to control RPM
and torque.

- Components and
Models

Manufacturers (mainly
GE) produce models at
600, 800, 1000,1200 HP
with maximum speed of
1000 and 1200 RPM.

Drilling Motor GE-752 components

- Use
Dc motors are mainly used for the:
DRAWWORK, MUD PUMPS, ROTARY TABLE and TOP DRIVE.

On Offshore rigs they are also used for the:

PROPELLERS, ANCHOR CHAIN WINCHES, CEMENT UNIT and JACKING CONTROLS.

These motors develop a lot of heat. Cooling is achieved with air coming from a non-hazardous
area.

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- Types: SHUNT and SERIES

There are 2 main types of DC motors:

SHUNT and SERIES

The final selection between them is

mainly economical.

- Torque-speed of DC Shunt Motor

- Torque-speed of Series Motor

DC motors in series often go into

overspeed at light loads.

Torque-speed of DC Shunt Motor Torque-speed of Series Motor

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Example of Top Drive Dc Motors Top Drive DC motor Characteristics

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12.4 AC ENGINES

- AC motors

AC motors are replacing DC

motors due to the Variable
Frequency Drives technology.

- Advantages of AC Motors over DC Motors

AC motors:
- do not have any
brushes and therefore
do not produce sparks
(critical in hazardous
area)
- require less
maintenance
- enable the drawworks
and rotary table to be
reversed by reversing
the phase sequence.
- are lighter and smaller
- can operate a twice
the speed

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12.5 ENGINE CONTROLS

- Current Control Panel

The functions of the power Control Unit include:

- CONTROL
- PROTECTION
- MEASUREMENT OF ELECTRICAL PARAMETERS

- Control function

Voltage regulator:
Output tension is monitored and regulated. When two or more generators are in parallel,
the voltage regulators sense voltage and current to maintain equal voltages and minimize
circulating current between generators.

Speed regulator:
Regulates engine speed by adjusting the fuel flow. As the load increases, the speed
momentarily decreases, creating a speed "error" in the governor. This error causes the fuel
rack to adjust for more engine fuel and return to the original speed.

Synchronizer :
Allows the generators to work in parallel at the same phase sequence, frequency and
voltage.

- Protection function

Circuit Breaker:
Protection against short circuits and overloads.

Reverse Power Protection:

Prevents current for circulating between generators.

Power Limit:
Prevents engine generator overload. Total power delivered from AC bus is monitored
electronically and compared to the capacity available.

Ground Fault Detection:

Monitors whether electrical machines and cables are connected to the ground.

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- Electric parameters measurements

Panel - Meters Breakers and Switch

Components

- motor control center

- feeder breakers
- generator breakers
- synchronizing
control
- power conversion
panels
- engine control panel
- ground detection
module

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- Driller Control Panel

- Driller Control Panel - Indicators and Switch

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12.6 SCR SYSTEM

- SCR (Silicon-Controlled Rectifier)

Semiconductors SCR (Silicon-

Controlled Rectifier) convert AC
power in to DC power.

- SCR Circuit

An SCR is a rectifier, it blocks power in its

reverse direction and allows power to
conduct in the forward direction.

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- Waveform

- Speed Command

Once an electrical
system is put into
service, the driller's
primary control is the
drilling control console.

Load speed is increased

to the desired level by
manual adjustment of
the throttles.

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13. PNEUMATIC SYSTEM

INDEX
13.1 FUNCTIONS
13.2 CHARACTERISTICS
13.3 APPLICATIONS

13.1 FUNCTIONS

Compressed air is used in many applications on a drilling rig.

- Diesel engine start up

- Drawworks air friction
- Safety device (Crown -O- Matic)
- Instrumentation
- BOP control panel
- Spinning wrench, kelly spinner
- Various servomechanisms (Top drive, valves, etc).

General Plan
- Two-stage air compressor
. Air intake filter
- Air tank
. Safety valve
. Drain valve
- Regulators
- Manifold

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General Plan

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13.2 CHARACTERISTICS

ATLAS COPCO

SERIE GA
POWER 30- 200
HP

Max press 125

psi

Rate 30 m3 for
min

Z series Rotary Screw

Compressors for 100 %

oil-free air Vibrationless,
compact, trouble-free.

Available engineered for

the oil industry, the Z
compressor provides
absolutely clean air with
vibrationless running,
compact design, low
weight an long, trouble-
free service life.

It has air or water cooling

and can also be fitted for
seawater cooling.

The Z has versatility of pressure from low throught high. Drive is also versatile - electric motor,
turbine or diesel engine.

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13.3 APPLICATIONS

- Air Pressure Testing Pump - Driller's Air Operated Control Panel

- Submersible Pump - Air Remote Control System
- Air Pump - Crown o Matic
- Air Winch - Pit Level System (air operated)

- Air Pressure Testing Pump - Submersible Pump

- Air Pump - Air Winch

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14. ROTARY TABLE & MASTER BUSHING

INDEX
14.1 FUNCTIONS
14.2 DIMENSIONS AND CHARACTERISTICS
14.3 TYPES OF ROTARY TABLE
14.4 TYPES OF MASTER BUSHINGS
14.5 TYPES OF CASING BUSHINGS

14.1 FUNCTIONS

- Rotary Table
Before the TOP DRIVE introduction, the rotary table had two main functions:
1. Transmit rotation to the BHA through the Kelly Bushing.
2. Collect and support the weight of all the tools to RIH .

With the invention of the TOP DRIVE, the rotary table is only used for the second function.

Rotary Table

- Master Bushings
The master bushings and bushing adaptors enable the rig to handle all different types and
sizes of tubulars (DP. Csg, DC, etc).

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Scheme and Nomenclature

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14.2 DIMENSIONS AND CHARACTERISTICS

Rotary Table from API 7K

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- Master Bushing from API 7K

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- Rotary Table "IDECO"

- Rotary Table "NATIONAL OILWELL"

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14.3 TYPES OF ROTARY TABLE

The Rotary Table can run off independent motor or can be coupled with the drawworks.

The independent motor can either be

- electrical (most common) or
- hydraulic

Rotary table with electrical motor Rotary tables with hydraulic motor

Rotary tables with hydraulic motor were designed specifically for a TOP DRIVE.
They:
- Run at reduced rotary speed.
- Are smaller and cheaper.

Can stay in the locked position with hydraulic pressure.

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14.4 TYPES OF MASTER BUSHINGS

- MPCH 37 " and 49 " - VARCO MSPC for 20 ½" to 27 ½"

This MASTER BUSHING has been
dimensioned for floating rigs. It can be pulled
from Rotary table also when BHA is in the well.

Master Bushing Handling

- API Insert Bowl
N1 -2 - 3 allow in RT diameters from
2 3/8" to 13 3/8".

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- INSERT BOWLS (VARCO)

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14.5 TYPES OF CASING BUSHINGS

- Casing Bushing
Casing bushing are set inside the Rotary table instead of master bushing for big CSG size.
- CU and CUL models are integrals,
- CB model is split in two.

Table: Master Bushing - Casing Bushing

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15. KELLY & DRIVE BUSHING

INDEX
15.1 FUNCTION AND TYPES
15.2 DIMENSIONS (HEXAGONAL KELLY)
15.3 DRIVE BUSHING
15.4 OPERATION

15.1 FUNCTION AND TYPES

- Function
The function of the Kelly is to transmit rotation and torque to the drilling bottom hole assembly.

- Types (Hexagonal kelly - Square kelly)

Kellys are manufactured as square or hexagonal.

- Square kelly - Hexagonal kelly

The most common is the hexagonal kelly, which
No more utilized offers maximum surface contact with the Kelly
Bushing.

Standard lengths are:

40 ft for onshore and
54 ft for offshore.

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15.2 DIMENSIONS (HEXAGONAL KELLY)

- Hexagonal kelly data from API 7

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15.3 DRIVE BUSHING

- Kelly Bushing

Kelly Bushing Assembly Kelly Bushing Roller Section

- Roller Assembly

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15.4 OPERATION

- Kelly & Kelly Bushing Inside Rat hole - Kelly Bushing in Working Position

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16. UPPER & LOWER KELLY VALVES

INDEX
16.1 FUNCTION
16.2 DIMENSIONS
- Upper Kelly Cock
- Lower Kelly Cock

16.1 FUNCTION

- Kelly valves

Kelly valves are manually operated valves

run above and below the kelly to shut off
back-flow in the drill stem in the case of a
kick.

- Upper Kelly Cock

- Lower Kelly Cock

The valves are manually operated with a

dedicated wrench.

This is a limit for a quick intervention.

The Top drive system has eliminated this

with remove control operated valves.

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16.2 DIMENSIONS

- Upper Kelly Cock

Upper Kelly Cock - Size Table

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- Lower Kelly Cock

Lower Kelly Cock - Size Table

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17. SWIVEL HEAD

INDEX

17.1 FUNCTION
17.2 TYPES AND CHARACTERISTICS
17.3 CONTROLS

17.1 FUNCTION

The Swivel head has 3 main functions:

- Bears the string load

- Enables string rotation

- Allows circulation

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17.2 TYPES AND CHARACTERISTICS

- "IDECO" swivel

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- "NATIONAL OILWELL" swivel

17.3 CONTROLS

- Manufacturer and API RP 8A

Swivel must be checked and inspected as per the manufacturer's recommendations and API RP
8A.

ENI procedures require a complete re-certification every 5 years.

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- Inspection guide

1. Check for Wear

2. Check for Cracks
3. Check for Wear and Cracks
4. Refer to "Disassembly Inspection"

Inspection of Rotary Swivel

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18. TOP DRIVE

INDEX

18.1 FUNCTION
18.2 TYPES AND CHARACTERISTICS
18.3 TOP DRIVE COMPONENTS
18.4 INSPECTIONS

18.1 FUNCTION

- Introduction
Oil well drilling with a rotary table, kelly drive
bushing and 45 ft of kelly was the industry
standard for years.

TOP DRIVE has been one of the better

innovations in the oil field in the last few years

- Main functions and advantages

Top drive system has 3 main functions:

1. Perform all normal hoisting requirements

2. Rotate the drill string
3. Enable circulation through the drill string

Most rigs today are equipped with top drive.

Advantages:
Possibility to drill stands of pipe rather than single
Ability to back-ream while pooh
Contains remote-controlled Inside BOP , that can be operated at distance from the rig floor

- Manufacture specifications
Top Drive is built in accordance with API Spec. 8A and 8C.
The reference standards adopted by ENI is: ISO 13535

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18.2 TYPES AND CHARACTERISTICS

- Top Drive National Oilwell

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- Top Drive VARCO

- Characteristics of Top Drive VARCO

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- TDS-3A Output Curves - TDS-3H Output Curves

- TDS-4H Output Curves - TDS-5 Output Curves

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- TDS-5H Output Curves

Features of Top Drive VARCO

- Features IDS-1 TDS-4H TDS-4S TDS-6S

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- Features TDS-10SA TDS-11SA

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- Features TDS-8SA

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18.3 TOP DRIVE COMPONENTS

- Top Drive Components - Nomenclature

Top Drive Components

1. Counterbalance System
2. Guide Dolly Assembly
3. Motor Housing & Swivel Assembly
4. Pipe Handler
5. Top Drive Control System
6. Top Drive Auxiliary Tools

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1. Counterbalance System

A Counterbalance system offsets

the weight of the TDS and provides
a soft landing when TDS stabs into
or out of the joint when making a
connection.

This prevents damage to the tool

joint threads.
To do this, Hydraulic cylinder
connect the Swivel Bail and the
elevator ear portion of the hook
body.

- Components

2. Guide Dolly Assembly

3. Motor Housing & Swivel

Assembly

4. Pipe Handler

5. Top Drive Control System

6. Top Drive Auxiliary Tools

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2. Guide Dolly Assembly

The Guide Dolly assembly transmits the

drilling torque reaction to the Guide Rails
and can provide a method for setting the
entire unit aside for maintenance or to allow
rig operation without the TDS if necessary.

3. Motor Housing & Swivel Assembly

Consists of:

a. Integrated swivel & wash pipe

b. Drilling Motor & Brake

c. Transmission Pinions

d. Rotating Head

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a. Integrated Swivel & Wash Pipe

The Integrated Swivel is a bearing assembly

that allows transfer of the rotating load to the
lifting components.

- The Swivel Wash pipe is a rotating seal that

allows mud to flow to the rotating drill string.

Working pressure is usually 5000 or 7500 psi.

b. Drilling Motor & Brake

DC drilling motor used is essentially the same as those used elsewhere on a drilling rig to power
the drawworks, mud pumps and rotary table, with same modifications:

1. A double ended armature shaft is provided to permit the attachment of an air brake.
2. Special bearings are installed to allow the motor to operate in a vertical orientation.

The shaft extension on the commutator end of the motor is used to attach an Airflex 16VC600 air
brake that with 90 psi air pressure gives 35.000 ftlbs brake torque.

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Drilling Motor & Brake

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c. Transmission Gear
Depends on the model of TDS
- Transmission Gear: Two speeds
- Transmission Gear: One speed

- Transmission Gear: Two speeds - Transmission Gear: One speed

- Example of Torque data of Varco Top Drive

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d. Rotating head

The rotating head allows the pipe handler to

rotate on the Top Drive.

It can be locked in 2 positions:

180 and 360.

- Rotating head - draw 1

- Rotating head - draw 2

Rotating head - draw 1 Rotating head - draw 2

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4. Pipe Handler

The pipe handler has 2 main function:

- Tripping 93 foot stands

- Providing torque for make up and

break out of connections (at any height
in the derrick)

The main components are:

a. Link Adapter
b. Safety valves and Actuator
c. Torque Wrench
d. Link Tilt
5. Top Drive Control System
6. Top Drive Auxiliary Tools

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a. Link Adapter

The link adapter transfers the hoisting

loads to the drive stem.

The 4 torque arrestors avoid the elevator

rotation and shift 2 ft when the elevators
touch the rig floor.

b. Safety valves & Actuator

There are 2 safety valves on a TDS:

One manual and one remote controlled.

- VARCO remote operated safety valve

- HYDRIL remote operated safety valve

- Kellyguard Valve actuator

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c. Torque Wrench

The torque wrench has a clamping Jaw

for standard tool joints from 5 " to 7 3/8".
Different size can also be handled.

- Torque Wrench Assembly

- Torque Wrench Control manifold

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Torque Wrench - Assembly

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d. Link Tilt

The link tilt allows the elevators to move off of

well center to pick up a joint from the
mousehole.
It also helps the derrickman to handle pipe more
easily

5. Top Drive Control System

- Scheme: Top Drive Control system - Control panel

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6. Top Drive Auxiliary Tools

- Wireline Adapter tool

- TV camera system

It's a system with one or more

cameras installed at different level
of Derrick to allow the driller to
monitor the operations .

18.4 INSPECTIONS

TOP DRIVE system, as with traditional hoisting equipment, must be checked and inspected
periodically as per the manufacturer's recommendations and API RP 8B or related ISO
(International Organization for Standardization) 13534.
ENI policy requires the Category IV inspection (as per API RP 8B and ISO 13534) every 5 years.

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19. RIG FLOOR MUD MANIFOLD

INDEX
19.1 FUNCTION
19.2 TYPES
19.3 COMPONENTS
- Rotary Hose and Vibrator Hose
- Mud Valve
- Quick Unions
- Pressure Readings

19.1 FUNCTION

- Description
The mud manifold is composed of
pipes and valves.
It connects the high pressure mud
pumps to the injection head in order
to circulate the drilling mud down
the DP.

There are several outlets on the

mud manifold to connect pressure
transducer.

This allow the crew to monitor the

"stand pipe pressure"

19.2 TYPES

- Single Stand Pipe - Dual Stand Pipe

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- Dual Stand Pipe

5000 psi w.p. for
Land Rig

- Dual Stand Pipe 7500 psi w.p. for Land Rig

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19.3 COMPONENTS

1. Rotary Hose and Vibrator Hose

2. Mud Valve
3. Quick Unions
4. Pressure Readings

1. Rotary Hose and Vibrator Hose

Definitions (API 7K)

- Rotary drilling hose

Rotary drilling hose is used as the flexible

connector between the top of the standpipe and
the swivel that allows for vertical travel.

It is usually used in lengths of 45 ft (13.7 m) and

over.

- Rotary vibrator hoses

Rotary vibrator hoses are used as flexible

connectors
between the mud pump manifold and the
standpipe manifold to accommodate alignment
and isolate vibration.

They are usually used in lengths of 30 ft (9.2 m)

or less.

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Rotary Vibrator and Drilling Hose

Dimensions and Pressures

2. Mud Valve

- Features
A gate valve uses a closing mechanism
different than a ball valve. In the gate valve a
blank plate is positioned across the flow path to
halt fluid flow.

When the valve is opened, the plate is moved

in a manner such that a section of the plate
containing an orifice is positioned across the
flow path which thus allows fluid movement
through the orifice.

Gate and seat are easy changeable for re-

dressing.

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- Use and Connections Type

Valve dimension should be proportional to the flux speed. 20 ft/s (6 m/s) to limitate the wear.
Valves connections could be flanged, welded or threaded.
API rules are against threaded connections since 2" 5000 psi w.p.
ENI policy is against threaded connections on the mud manifold.

- Drawing, working pressure, dimensions

Nominal dimensions are referred to the nominal gauge of the line connected to the valve.
Most commons size are : 2 -3- 4- 5 -6 inch.
Working pressures are: 1.000, 2.000, 3.000, 5.000, 7.500 psi.

-Example of Valve component and assembly

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3. Quick Unions

- Red Nut Blue Sub

These unions are available in 1 thru 4 inch 10,000-psi and 5

and 6 inch 7,500-psi NSCWP.
These unions also have a resilient nitrite seal ring (5-inch and 6-
inch have nitrile o-ring).

They are made from alloy steel and are used primarily by
service companies in applications such as cementing, fracturing
and acidizing.

Designed for high-pressure systems, including

truck-mounted systems, Fig 1002 unions also are
available as non-pressure seal unions, and in butt-weld.

Sch. 160 or XXH, or prepped for sour gas service.

- Figure 1002; WP Use and Features

10,000 psi (960 bar) cold working pressure

5- and 6-inch sizes butt weld only

Recommended service: Cementing, fracturing, acidizing, testing,

and choke-and-kill lines

Features
- Replaceable, lip-type seal provides primary seal, protectors
secondary metal-to-metal seal, minimizes flow turbulence.
- O-ring seal on 5- and 6-inch sizes
- Available for sour gas service: 7,500 psi (517 bar) cold working
pressure

- Figure 1202: WP Use and Features

15,000 psi (10034 bar) cold working pressure

Recommended service: Especially designed for sour gas service

Features

- Meets National Association of Corrosion Engineers Standard

MR-01-75 and American Petroleum Institute RP-14E.
- Head-treated components 100 percent tested for hardness
- Fluoroelastomer seal rings

- Pipes
- Quick Unions Pipes
- Quick Unions Pipes Use
- Quick Unions Pipes Fittings

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4. Pressure Readings

- Pressure gauge

- Pressure transducers

- Provides quick, accurate check on mud pump

operation; helps detect washed out drill pipe or bit
nozzle problems
- Indicator gauges can be mounted in the weight
indicator box, driller's console, or locally on the
mud pump
- Full 360 dial calibration for maximum pinter
movement; shows the smallest pressure changes.
- Fluid filled gauge has large easy-to-read 6" dial
face and high pressure damper adjust.
- Rugged E17-152 Diaphragm Protector mounts
with 2" NPT sb
- Hose lengths to 50 feet are standard; longer
legths available in some pressure ranges.

Standard Capacity include:

------------------------------------------------
3,000 5,000 6,000 10,000 and 15,000 psi
------------------------------------------------
210 350 420 700 and 1,00 kg/cm2
------------------------------------------------
21 35 42 70 100 MPa
------------------------------------------------

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20. MUD PUMPS

INDEX

HIGH PRESSURE MUD PUMPS

20.1 PRINCIPLES
20.2 NOMENCLATURE
20.3 TYPES AND CHARACTERISTICS
20.4 ACCESSORIES
20.5 FLOW RATE AND EFFICIENCY CALCULATION
20.6 POWER AND EFFICIENCY CALCULATION
LOW PRESSURE MUD PUMPS (Centrifugal Pump)
20.7 FUNCTION
20.8 NOMENCLATURE
20.9 PUMP PERFORMANCE CURVES

HIGH PRESSURE MUD PUMPS

20.1 PRINCIPLES

- Duplex Pump / Triplex pump

Hi-pressure mud pumps:

In a Duplex Pump the

piston discharges mud on
one side of the piston and at
the same time takes mud in
on other side.

In a Triplex pump the

piston discharges mud only
when it moves forward in
the liner.

In the Oilfield, duplex

pumps have been replaced
by triplex pumps.

Triplex pumps of the same

power, are smaller and
lighter than duplex pumps.

They also provide an

uniform flow.

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20.2 NOMENCLATURE

Pistons are moved with a shaft by

an electrical engine or a diesel
engine.

The pump is divided in 2 parts:

- POWER END

- FLUID END

POWER END

- POWER END Schematic 1

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- POWER END Schematic 2

- POWER END Schematic 3

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FLUID END

- FLUID END Schematic 1

- FLUID END Schematic 2 - Fluid end type " L"

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20.3 TYPES AND CHARACTERISTICS

Performance Data

- NATIONAL OILWELL 10-P-130

- NATIONAL OILWELL 12-P-160

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- NATIONAL OILWELL 14-P-220

- Type P Mud Pump Specification and Dimensions

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20.4 ACCESSORIES

- Pulsation Dampeners
- Pressure Relief Valve (Safety Valve)
- Pump Stroke Counter

Accessories

Pulsation Dampeners

- Function

Alternating movement of the

pistons produces an irregular flux
(See right).

Pulsation dampener reduces

vibrations of pumps and lines
(See right).

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- Installation examples

- Pulsation dampener on discharge line - Pulsation dampener on suction line

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- PULSATION DAMPENER HYDRIL TYPE K

- Characteristics

Pulsation Dampeners are

usually installed on discharge
line.

It is a bottle with a diaphragm

inside and pre-charged with
Nitrogen at maximum 1000
psi.

It absorbs pressure variations,

reduces peak pressures,
permits slightly higher pump
output and increases discharge
line life.

- Movement and Components

- Diaphragm movement during - Diaphragm section - Diaphragm

operation

- Pressure Relief Valve

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- Installation and Primary Purpose

A pressure relief valve must be installed in

the discharge line immediately beyond the
pump.

Its purpose is primarily to protect the pump and

discharge line against extreme pressures that
might occur when a bit becomes plugged.

Pressure Relief Valve - Installation

- Use of the Relief Valve

The relief valve should be used to limit the pressure in accordance with the pump manufacturer's
rating for a given liner size.

Pressure Relief Valve Safety Valves

- Scheme

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20.5 FLOW RATE AND EFFICIENCY CALCULATION

- Theoretical Flowrate

where

Pt = theoretical flow rate (l/min)

D = Liner diameter in mm
L = Length of stroke in mm
Vliq = Output volume per stroke
SPM = strokes per minute

- Efficiency
Real flow rate must be calculated with the pump efficiency, which varies according to the state of
the valves, the supercharging and the type of fluid.

In the best case it is 0.98 for a supercharged triplex pump.

Usually a normal average is between 0.95 - 0.97

20.6 POWER AND EFFICIENCY CALCULATION

- Hydraulic Power Calculation

where
Pt = Real Flow rate (theoretical flow rate x efficiency)
HHP = Hydraulic power in HP
P = output pressure in kg/cm2

- Mechanical Horse Power :

- Efficiency Real flow rate must be calculated with the pump efficiency.
Usually efficiency is between E = 0.95 - 0.97

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LOW PRESSURE MUD PUMPS (Centrifugal Pump)

20.7 FUNCTION

- Centrifugal pumps

Centrifugal pumps have an important role on drilling rigs.

They are used to:

- Feed the degasser, desander desilter, mud cleaner, trip tank
- Supercharge mud pumps
- Mix mud
- Transfer mud

- Mix mud - Transfer mud

- Primary purpose

The primary purpose of the centrifugal

precharge pump is to keep the mud
pump from being starved by
maintaining a positive pressure in the
suction line.

Total head doesn't change depending

by type and weight fluid.

It changes only the final pressure.

Mud Pumps

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- Total head and Output pressure

Total head stays the same. Output pressure changes

- Pressure gage readings - Pressure gage and Mud weight

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20.8 NOMENCLATURE

Mud Pumps – Section

Casing Pedestal

Rotation

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20.9 PUMP PERFORMANCE CURVES

- Performance Curve 1

- Performance Curve 2

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- Performance Curve 3

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21. MUD MIXING SYSTEM

INDEX

21.1 FUNCTION
21.2 MIXING EQUIPMENT
21.3 BULK STOCK SYSTEM
- SILOS
- SURGE TANK

21.1 FUNCTION

- Use of Mud Mixing Equipment

The mud mixing equipment is used Mud Mixing System

to accomplish the following:

- Prepare and mix mud

- Maintain mud weight and

properties while drilling the well.

Mud mixing must be done at the

highest pump rate, to avoid
decantation and grumes of the solid
part (barite, bentonite, polymers,
etc).

NOTE: event of a kick

The mud mixing system must enable

personnel to mix as much mud as
required, as fast as possible, in the
event of a kick.

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21.2 MIXING EQUIPMENT

Mud mixing system includes:

- Centrifugal pumps
- Funnel with nozzle and Venturi pipe
- Charging hopper

Centrifugal pump must have:

- a flow rate of about 3000-3200 liters/min and

- a total head of 70 - 75 ft.

Mixing Equipment

Funnel with Venturi Pipe

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Pressure and speed profile

- Pressure losses in downstream pipes

Pressure losses in downstream pipes must be less than 50% of the total pressure.
- Mixing Chamber Pressure Vs System Back Pressure
- Feed Rate Vs Venturi Back Pressure
- Discharge pressure Vs Sacks per Minute Barite

Mixing Chamber Pressure Vs System Back Pressure

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