Lecture 4 Tbt 2 Hoisting Systems And Pipe Handling Systems

Drilling and Workover Systems Bohr und Workover Anlagen Dr.-Ing. Opeyemi Bello Institute of Petroleum Engineering, TU Clausthal

Literatures  Applied Drilling Engineering - Bourgoyne Jr., Chenevert, Millheim, Young Jr.

 A Primer of Oilwell Drilling - Paul Bommer

 Drilling Practices Manual. Second Edition - Preston L.Moore  Petroleum Engineering Handbook: Drilling Engineering - Lake, L.W (Ed.) 

Petroleum Engineering Handbook for the Practical Engineering

- Mohammed A. Mian  Well Engineering and Construction - Hussain Rabia  Handouts, Technical Papers, etc. Dr.-Ing. Opeyemi Bello Institute of Petroleum Engineering, TU Clausthal

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Lecture Module: Things to know

 Classes:

14:00 – 17:00 pm

 Grading:

20% Homework 80% Examination

 Schedule:

Dr.-Ing. Opeyemi Bello Institute of Petroleum Engineering, TU Clausthal

Thursdays @ Raum 125 ExxonMobil Hörsaal

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Lecture Module: Things to know

Dr.-Ing. Opeyemi Bello Institute of Petroleum Engineering, TU Clausthal

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Course Content  Lecture 1: Fundamentals  Lecture 2: Well Construction and Introduction to Drilling Rigs  Lecture 3: Rig Power Systems  LECTURE 4: HOISTING SYSTEMS AND PIPE HANDLING SYSTEMS

 Lecture 5: Rotating Systems and Circulation Systems  Lecture 7: Wellbore Control Systems (BOPs)  Lecture 8: Fishing Operations and Workover Systems  Lecture 9: HTHP Drilling and Geothermal Drilling  Lecture 10: Basic Data Management in Drilling & Workover Systems Dr.-Ing. Opeyemi Bello Institute of Petroleum Engineering, TU Clausthal

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Lecture 3: Rig Power System Revision 1.

What is a mechanical drilling rig?

2.

What is an electric drilling rig?

3.

Name the three key main components of drilling rigs powered by rig power system

4.

What is the difference between the old rigs and modern rigs?

5.

What is the difference between a motor and a generator engine in terms of energy transfer?

6.

What is the role(s) of the Power Management System (PMS)?

7.

List out the mechanical power transmission of a mechanical rig system?

8.

Mention the 5 out of 6 key attributes to look for when selecting generator sets for a modern drilling rig.

9.

From the below graph, which motor characteristic is better and why? What does the two parameters, η and T represent?

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Lecture 3: Rig Power System Revision

T

T

η

η Diesel Engine

AC-Motor

T

T

η DC-Motor Dr.-Ing. Opeyemi Bello Institute of Petroleum Engineering, TU Clausthal

η Steam Engine WS 2016/2017 - Drilling and Workover Systems (Bohr und Workover Anlagen)

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Lecture 4: Hoisting Systems and Pipe Handling Systems  4.1 HOISTING SYSTEMS  4.1.1 Hoisting System Overview  4.1.2 Hoisting System Components  4.1.3 Brake System Types and Principle  4.1.4 Drilling Hoisting Systems: A look into new Concept

 4.2

PIPE HANDLING SYSTEMS

 4.2.1  4.2.2

Basic Information about Drill Pipe

 4.2.3  4.2.4

Tool Joint Damages and Causes

 4.2.5

Automatic Pipe Handling System

Dr.-Ing. Opeyemi Bello Institute of Petroleum Engineering, TU Clausthal

Tool Joints and Makeup Process

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Lecture 4: Hoisting Systems and Pipe Handling Systems  4.1  4.1.1  4.1.2  4.1.3  4.1.4

Dr.-Ing. Opeyemi Bello Institute of Petroleum Engineering, TU Clausthal

HOISTING SYSTEMS Hoisting System Overview Hoisting System Components Brake System Types and Principle Drilling Hoisting Systems: A look into new Concept

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4.1.1 Hoisting System Overview  Definition





Hoisting System is the system used on a drilling rig to perform all lifting activities on the rig.

o

These activities include the lowering and lifting of necessary equipment in or out of the hole as rapidly as is economically possible

o

This system is the main component that performs the drilling operation by either lifting or lowering the casing or drill pipes to drill and finally complete the well.

o

The principal items of equipment that are used in the hole are drill string, casing, and miscellaneous instruments such as logging and hole deviation instruments

Functionality of the hoisting system:

o o o



Tripping: casing, drillstring and measuring devices Rate of penetration compensation Weight on bit (WOB) control

The major components of the hoisting system are:

o

Derrick and substructure, block & tackle system, drawworks and drilling line

Dr.-Ing. Opeyemi Bello Institute of Petroleum Engineering, TU Clausthal

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4.1.1 Introduction to Hoisting System 

In addition, making a connection (process of adding a new joint of drill pipe), and making a trip (removing the drill string from the hole to change a porting of the downhole equipment) are the two regular tasks that need to be done by the hoisting system.

After GFZ-OSG-L.Wohlgemuth

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4.1.2 Hoisting System Components 

The principal components of HS consist of:

o o o o o o o o o o

Derrick and Substructure Drawworks Fast line Dead line Dead line anchor Crown block Travelling block

Hook Supply reel and other miscellaneous hoisting equipment such as elevators and weight indicators

Hoisting System for a Drilling Rig Source: Hossain, Al-Mejed (2015): Fundamentals of Sustainable Drilling Engineering

Dr.-Ing. Opeyemi Bello Institute of Petroleum Engineering, TU Clausthal

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4.1.2 Hoisting System Components  Derrick

      

The derrick is the steel structure part of a rig. Derrick/Mast provides the necessary height and support to lifts loads in and out of the well. The derrick stands above the derrick floor. It is the stage where several surface drilling operations occur. The derrick must be strong enough to support: the hook load, deadline and fast line loads, pipe setback load and wind loads. Derricks are rated by the API according to their height (2, 3, or 4 joints) and their ability to withstand wind and compressive loads. The greater the height of the derrick, the longer the section of pipe that can be handled. The most commonly used drill pipe is between 27-30 feet. The compressive load of a derrick is the sum of the strengths of the four legs. Each leg is considered as a separate column and its strength is calculated at the weakest section.

Dr.-Ing. Opeyemi Bello Institute of Petroleum Engineering, TU Clausthal

Four Legged Derrick Structure

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4.1.2 Hoisting System Components  Derrick



The wind load is specified in two ways, namely with or without pipe setback based on API derricks. The wind load can be calculated as: 𝑊𝑤 = 0.004 ∗ 𝑉 2 Where 𝑊𝑤 = Wind load (lbf/ft²) V = Wind velocity (mph)



Assuming the system has a frictionless pulley, the total compressive load on a derrick can be calculated using the following formula:

𝑊𝐷 =

𝑛+2 ∗ 𝑊ℎ𝑙 𝑛

Derrick/ Mast of the Hoisting System Source: Hossain, Al-Mejed (2015): Fundamentals of Sustainable Drilling Engineering

Where 𝑊𝐷 = Total compressive load on derrick (lbf) 𝑊ℎ𝑙 = Hook load (lbf) n = Number of drilling lines through the travelling block Dr.-Ing. Opeyemi Bello Institute of Petroleum Engineering, TU Clausthal

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4.1.2 Hoisting System Components  Derrick



The load imposed on the derrick (𝑊𝐷 ) is greater than the hook load. Therefore, using the fast line and dead line tension, the derrick load can also be calculated by:

𝑊𝐷 = 𝑊ℎ𝑙 + 𝑇𝑓 + 𝑇𝑑 𝑇𝑓 = Tension in the fast line [lbf]



𝑇𝑑 = Tension in the dead line [lbf]

In particular situation, the total derrick load is not distributed equally over all four derrick legs due to the placement of drawworks. The table below shows that tension in the fast line is distributed over only two of the derrick legs (A & C) and the dead line affects only D. Load on each derrick leg Load source

Total load

Leg A

Leg B

Leg C

Leg D

𝑊ℎ𝑙

𝑊ℎ𝑙 /4

𝑊ℎ𝑙 /4

𝑊ℎ𝑙 /4

𝑊ℎ𝑙 /4

Fast Line

𝑇𝑓

𝑇𝑓 /2

-

𝑇𝑓 /2

-

Dead Line

𝑇𝑑

-

-

-

𝑇𝑑

(𝑊ℎ𝑙 /4) + (𝑇𝑓 /2)

𝑊ℎ𝑙 /4

(𝑊ℎ𝑙 /4) + (𝑇𝑓 /2)

𝑊ℎ𝑙 4 + 𝑇𝑑

Hook Load

Total load on each derrick leg Dr.-Ing. Opeyemi Bello Institute of Petroleum Engineering, TU Clausthal

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4.1.2 Hoisting System Components  Substructure

    

The space below the derrick floor is called the Substructure.

The height of the substructure should be enough to accommodate the wellhead and BOPs. At about 3/4 of the height of the derrick is located a platform called “monkey board”. This platform is used to operate the drillstring stands during trip operations. During drillstring trips, the stands are kept stood in in the mast, held by “fingers” in the derrick rack near the monkey board

substructure after Macini, 2005

Dr.-Ing. Opeyemi Bello Institute of Petroleum Engineering, TU Clausthal

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4.1.2 Hoisting System Components  Drawworks



 



Drawwork is the large winch on the rig which is used to raise or lower the drill string into the well. The drawworks consists of a large revolving drum, around which a wire rope called drilling line is spooled. The drum is connected to an electric motor and gear system. The driller controls the drawworks with a clutch and gearing system when lifting equipment out of the well and a brake (friction and electric) when lowering equipment into the well. The principal functions are: o

To lift drill string, casing, or tubing string, or to pull in excess of these string loads to free stuck pipe

o

To lower drill string, casing string, or tubing string into the borehole

o

Transmit power from the prime movers to the rotary drive sprocket to drive the rotary table

o

Transmit power to the catheads for breaking out and making up drill string, casing and tubing string

The principal parts of the drawworks are the drum, the drum brakes, transmission, and cathead.

Dr.-Ing. Opeyemi Bello Institute of Petroleum Engineering, TU Clausthal

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4.1.2 Hoisting System Components  Drawworks



It is composed of a wire rope drum, mechanical and hydraulic brake, the transmission and the cathead.

o

o

Drum: is housed in the drawworks and transmits the torque required for hoisting and braking. It also stores the drilling line required to move the traveling block the length of the derrick The cathead is a shaft with a lifting head that extends on either side of the drawworks and has two major functions. It is used in making up and breaking out tool joints in the drill string. It is also used as a hoisting device for heavy equipment on the drill floor

Catheads. Source: NOV

Dr.-Ing. Opeyemi Bello Institute of Petroleum Engineering, TU Clausthal

AC Electric Gear Driven Drawworks. Source: NOV

DC Chain Driven Drawworks. Source: NOV

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4.1.2 Hoisting System Components  Drawworks: Gear-driven drawworks

After GFZ-OSG-L.Wohlgemuth

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4.1.2 Hoisting System Components  Drawworks Sand reel

Drill line

Main drum

Hydromatic brake Spinning cathead

Drillers console

Manual brakes Kingland Global Petroleum, Inc. (2015): Drilling Rig Components

Dr.-Ing. Opeyemi Bello Institute of Petroleum Engineering, TU Clausthal

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4.1.2 Hoisting System Components  Drawworks: Efficiency Factor, E The input power to the drawworks is calculated by taking into account the efficiency of the chain drives and shafts inside the drawworks. The efficiency factor E is given by the following equation: 𝐾 1 − 𝐾𝑛 𝐸= 𝑛 1−𝐾

Where K is sheave and line efficiency per sheave K = 0.9615 is in common use.

Dr.-Ing. Opeyemi Bello Institute of Petroleum Engineering, TU Clausthal

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4.1.2 Hoisting System Components  Example A rig must hoist a load of 300,000 lbf. The drawworks can provide an input power to the block and tackle system as high as 500 hp. Eight lines are strung between the crown block and traveling block. Calculate: 1. The static tension in the fast line when upward motion is impending 2. The maximum hook horsepower available. 3. The maximum hoisting speed

4. The actual derrick load 5. The maximum equivalent derrick load 6. The derrick efficiency factor

Dr.-Ing. Opeyemi Bello Institute of Petroleum Engineering, TU Clausthal

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4.1.2 Hoisting System Components  Solution 1. The static tension in the fast line when upward motion is impending

𝐸=

𝐾 1−𝐾𝑛 𝑛 1−𝐾

=

0.96151 1−0.961518

= 0.844

8 1−0.96151

2. The maximum hook horsepower available.

𝑃ℎ = 𝐸. 𝑃𝑖 = 0.844 𝑥 500 = 421 hp 3. The maximum hoisting speed

𝑉𝑏 =

𝑃ℎ 𝑊

=

421 𝑥 33000 300,000

= 46.3 ft/min

4. The actual derrick load

𝐹𝑑 =

1+𝐸+𝐸 𝑛 𝐸𝑛

𝑊=

Dr.-Ing. Opeyemi Bello Institute of Petroleum Engineering, TU Clausthal

1+0.844+0.8448 0.844 𝑥 8

300, 000 = 382, 090 lbf

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4.1.2 Hoisting System Components  Solution 5. The maximum equivalent derrick load

𝐹𝑑𝑒 =

𝑛+4 W 𝑛

=

8+4 8

300,000 = 450,000 lbf

6. The derrick efficiency factor

𝐸𝑑 =

𝐹𝑑 𝐹𝑑𝑒

=

382,090 450,000

Dr.-Ing. Opeyemi Bello Institute of Petroleum Engineering, TU Clausthal

= 84.9 %

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4.1.2 Hoisting System Components  Drilling line



The drilling is a wire rope made up of strands wound around a steel core.

o

 

The drilling line is of the round strand type with Lang’s lay. The drilling line has a 6x19 construction with Independent Wire Rope Core (IWRC)

o

 

Each strand contains a number of small wires wound around a central core

6 strands and each strand containing 19 filler wires

A typical wire rope construction: 6x19 classification according to API Spec 19A

The size of the drilling line varies from ½ "to 2 ". The drilling line is reeved round the crown block and travelling block sheaves with the end line going to an anchoring clamp called "Dead Line Anchor”

Drilling Line and its Cross Section. Source: Mid-America Rigging L.L.C. (2015

Dr.-Ing. Opeyemi Bello Institute of Petroleum Engineering, TU Clausthal

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4.1.2 Hoisting System Components  Drilling line- The pulley Principle B

A

C

D P

P

P =W

  

P

P = 1/ 2W

P

P = 1/ 2W

P = 1/ 4W

A pulley transfers a force along a rope without changing its magnitude. In Figure A, there is a force on the rope that is equal to the weight of the object. This force or tension is the same all along the rope. For a simple pulley system, the force is equal to the weight. The pulley in figure B is moveable. The rope end attached to the upper bar and the end held by the person is supporting the weight, so each side carries only half the weight. So the force needed to hold up the pulley is 1/2 the weight.

Dr.-Ing. Opeyemi Bello Institute of Petroleum Engineering, TU Clausthal

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4.1.2 Hoisting System Components  Fast Line



 

The drilling line coming from the drawworks, called fast line, goes over a pulley system mounted at the top of the derrick (called the crown block) and down to another pulley system called the traveling block.

The fast line is spooled onto the drawworks hoisting drum. It is called fast line because it moved quickly as the traveling block moved up and down the derrick.

 Dead line

  

In the context of lift systems, a dead line is that part of a drilling line that is attached to a fixed anchor point and does not move through a pulley or other mechanical device. The drilling line from the crown block sheave to the anchor. This end of the drilling line was called the dead line because it was secured to the deadline anchor. Is the last line of tackle (Block tackle is the assembly of crown block, traveling block and drilling line).

Dr.-Ing. Opeyemi Bello Institute of Petroleum Engineering, TU Clausthal

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4.1.2 Hoisting System Components  Fast Line and Dead Line



The force in the fast line (𝐹𝑓 ) and in the dead line (𝐹𝑑 ) to hold the hook load in a frictionless system can be determined with the following formula:

𝐹𝑓 = 𝐹𝑑 =

 



𝑊ℎ 𝑛

𝐹𝑓 = 𝐹𝑑 = Force to hold the hook load [lbs] 𝑊ℎ = The weight of the traveling block plus the weight of the drill string suspended in the hole [tons] 𝑛 = number of drilling lines between the crown block and traveling block

Drilling Line – Traveling Block – Crown Block. Source: Heriot-Watt University (2012): Overview of Drilling Operations

Dr.-Ing. Opeyemi Bello Institute of Petroleum Engineering, TU Clausthal

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4.1.2 Hoisting System Components  Fast Line and Dead Line

 

There is however inefficiency in any pulley system. Exemplary efficiency factors are shown in the table on the right side. So, the force on the drilling line and therefore on the fast line will then be: 𝐹𝑓 =



𝑊ℎ 𝐸∗𝑛

The load on the dead line is not a function of the inefficiency because it is static.

Efficiency Factors for the Drilling Line

Dr.-Ing. Opeyemi Bello Institute of Petroleum Engineering, TU Clausthal

Number of Lines (n)

Efficiency (E)

6

0.874

8

0.842

10

0.811

12

0.782

14

0.755

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4.1.2 Hoisting System Components  Dead Line Anchor





 

a device to which the deadline is attached, securely fastened to the mast or derrick substructure

The dead line anchor grips one end of the drilling line and keeps it from moving. It is a strong, rugged device that the crew bolts to the substructure of the rig. Besides anchoring the drilling line, the anchor also serves as a mount for the weight indicators sensing device. The weight indicator, which is on the console of the driller, shows the actual hook load and how much weight is on the bit. Hook load is the weight hanging on the hook. Weight on the bit is how much drill stem weight is pressing on the bit. Dead Line Anchor. Source: Davis (2013): The Blocks and Drilling line

Dr.-Ing. Opeyemi Bello Institute of Petroleum Engineering, TU Clausthal

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4.1.2 Hoisting System Components  Traveling Block



   



a diamond-shaped block containing a number of sheaves which is always less than those in the crown block.

With or without a top drive, the blocks and the drilling line are central to the hoisting system. Rigs use to block. One is the traveling block. The driller moves the traveling block up and down the derrick between the crown block and the rig floor. Blocks are giant pulleys that have a high strength wire-rope drilling line running between the traveling and the crown block. The traveling block is a pulley system that gives great mechanical advantage to the action of the wire rope drilling line, enabling the drill string or casing to be lifted out of or lowered into the wellbore. Average weight of a traveling block: 5,500 lb (2,5 tons) up to 44,000 lb (20 tons).

Dr.-Ing. Opeyemi Bello Institute of Petroleum Engineering, TU Clausthal

Traveling Block and Drilling Line. Source: NOV

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4.1.2 Hoisting System Components  Traveling Block and Topdrive Systems





Compared to conventional rotary drilling rigs, top drive systems allow drilling faster and safer, with far less instances of stuck drill pipe.

Traveling Block

Top drives hang below, and travel with, the traveling block and rotate the drill pipe from the top of the string, as opposed to using a rotary table and Kelly drive Top Drive

Traveling Block and Top Drive. Source: Bolton Oilfield Services LLC (2015

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4.1.2 Hoisting System Components  Crown Block

  



The crown block is at the top of the derrick. The crown block is the fixed set of pulleys (called sheaves) located at the top of the derrick or mast, over which the drilling line is threaded. The sheaves and bearings are interchangeable with those of matching travelling block.

Crown Block. Source: teficopetro.com

Average weight of a traveling block: 5,000 lb (2,5 tons) up to 22,000 lb (20 tons)

Crown Block. Source: welldrillingbasicinfo.wordpress.com

Dr.-Ing. Opeyemi Bello Institute of Petroleum Engineering, TU Clausthal

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4.1.2 Hoisting System Components  Hook

   



The hook is a large, hook-shaped device from which the elevator bails or the swivel is suspended. It turns on bearings in its supporting housing. It is a high-capacity J-shaped equipment used to hang various other equipment, particularly the swivel and Kelly, the elevator bails or top drive units. The hook is attached to the bottom of the traveling block and provides a way to pick up heavy loads with the traveling block. The hook is either locked (the normal condition) or free to rotate, so that it may be mated or decoupled with items positioned around the rig floor, not limited to a single direction.

The hook load is the total force pulling down on the hook. This total force includes the weight of the drill string in air, the drill collars and any ancillary equipment, reduced by any force that tends to reduce that weight.

Dr.-Ing. Opeyemi Bello Institute of Petroleum Engineering, TU Clausthal

Hook. Source: thai.alibaba.com

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4.1.3 Brake System Types and Principle  Definition: Brake System



  

A brake system for a drawworks includes a hydraulically actuated band brake system having a backup spring actuator for emergency stops. The system also includes a caliper disc brake system for emergency stops. The disc brake system includes a rotor directly mounted to the drum barrel and a pair of spring actuated caliper assemblies. Brakes are mechanical devices that inhibit motion, speed control or stopping a moving object or preventing its motion. Brakes are generally applied to rotating axles or wheels. On the drilling rig, bakes are a very important tool to run the drawworks. Brakes on the drawworks are used to permit the driller to control the speed and motion of the drilling line in order to lift or lower the drill string.

Dr.-Ing. Opeyemi Bello Institute of Petroleum Engineering, TU Clausthal

Brake for Drawworks. Source: Pickett Oilfield (2015): Baylor Elmagco 7040 Eddy Current Brake

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4.1.3 Brake System Types and Principle  Brake System Types Drawwork Brake

A uxilia r y Brake

W a ter B r a k e ( H ydr a ulic B r a k e)

Ma in B r a k e ( St a t iona r y)

Elect r ic Brake

Dr.-Ing. Opeyemi Bello Institute of Petroleum Engineering, TU Clausthal

Mecha nica l Brake

- H ydr a ulica ssisted Brake

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4.1.3 Brake System Types and Principle  Auxiliary Brake System

  

An auxiliary brake is a device that supplements the mechanical brake. It permits the lowering of heavy hook loads safely at reduced rates without incurring appreciable brake maintenance. There are two types of auxiliary brakes;

o o 

Hydromatic brake system

Electrodynamic brake system

In both models, work is converted to heat, which is dissipated through liquid systems.

Drilling Rig Auxiliary Brake. Source: torlinservices.com

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4.1.3 Brake System Types and Principle  Auxiliary Brake – Hydromatic / Hydrodynamic brake system

   

The hydromantic brake is mounted on the end of the drawworks shaft of the drilling rig. The hydromantic brake acts as an auxiliary brake to the mechanical brake when the drill string is being lowered into the well. The breaking action in the hydromatic brake is accomplished by means of a runner or impeller turning in a housing filled with water. The hydrodynamic brake is built somewhat like a centrifugal pump using water to provide a cushioning effect, rather than pumping and producing pressure.

Hydromatic Auxiliary Brake. Source: http://www.parmacbrake.com/function1.html

Dr.-Ing. Opeyemi Bello Institute of Petroleum Engineering, TU Clausthal

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4.1.3 Brake System Types and Principle  Auxiliary Brake – Hydromatic / Hydrodynamic brake system







 

The operating principle is to convert the mechanical energy produced by lowering a load into heat by means of a rotor that is made to rotate by the draw works drum. The amount of mechanical energy that can be absorbed depends on the rotation speed and on the volume of water circulating in the working chamber.

In order to adapt the deceleration to the load, the driller regulates the level of water in a small tall surge tank located in the water cooling circuit. The tank adjusts the amount of fluid in the brake and varies the braking torque. The system is reliable and requires very little maintenance, Major drawbacks: it provides little braking at slow speeds and regulation is too inflexible. As a result, its use is confined to lightweight drilling rig.

Dr.-Ing. Opeyemi Bello Institute of Petroleum Engineering, TU Clausthal

Hydromatic Auxiliary Brake. Source: PARMAC

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4.1.3 Brake System Types and Principle  Auxiliary Brake – Electrodynamic brake system

 



The electrodynamic brake is a device mounted on the drawworks shaft of a drilling rig. The electrodynamic brake (sometimes referred to as magnetic brake) serves as an auxiliary to the mechanical brake when the drillstring is lowered into the well.

The braking effect in an electrodynamic brake is achieved by means of the interaction of electric currents with magnets, with other currents, or with themselves.

Eddy Current Brakes. Source: NOV

Dr.-Ing. Opeyemi Bello Institute of Petroleum Engineering, TU Clausthal

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4.1.3 Brake System Types and Principle  Brake Types – Eddy Current Brake System









Disc (conductive)

Eddy current brakes basically consist of a rotating disc (made of conductive material) and permanent magnet. As the disc spins in the constant magnetic field generated by the permanent magnet, is conductive properties induce eddy currents. The Lorentz forces from these currents in turn slow down the disc.

Permanent magnet

The eddy current brake is widely applied as the auxiliary brake for drawworks.

The brakes generate extreme heat during operation. Normally water is used as a cooling medium. Principle Eddy Current Brake. Source: Littmarck (2013): Simulating Eddy Current Brakes

Dr.-Ing. Opeyemi Bello Institute of Petroleum Engineering, TU Clausthal

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4.1.3 Brake Types and Principle  Brake Types – Eddy Current Brake System (after Catalin Teodoriu)



Design and functionality

o o 

Control units are able to regulate the energizing current automatically by RPM or torque

Operating modes

o o o 

The control is possible with an energizing current (with the help of potentiometer)

constant energizing current constant RPM constant torque

Different characteristic lines

o o

Torque - RPM – line Power - RPM - line

Dr.-Ing. Opeyemi Bello Institute of Petroleum Engineering, TU Clausthal

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4.1.3 Brake Types and Principle  Hydraulic Brakes vs. Eddy Current Brakes Overview Brake Characteristics ( after Catalin Teodoriu)

Characteristics

Hydraulic brake

Eddy current brake

Characteristic line

High braking moments can only be realized with a high drum rotation

At a certain RPM the braking moment becomes constant

RPM working area

Can not brake a load to a point where it is nearly stopping

Needs RPM to brake

Reliability

No problems

Electric and electrical control systems Additional cooling

Wear of the main brake

Higher

Smaller

Costs

Low

High

Dr.-Ing. Opeyemi Bello Institute of Petroleum Engineering, TU Clausthal

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4.1.3 Brake System Types and Principle  Brake Types – Main Brake (Mechanical)

 

A mechanical brake is a device used to slow or stop a turning shaft. It usually uses a brake shoe and brake drum that fits around the shaft. The brake is activated by levers or rods that are directly attached to it. 1

4 2

1

Brake bands

2

Adjusting hold down

3

Equalizing yoke

4

Brake lever

3 Schematic of the Main Brake. Source:

Dr.-Ing. Opeyemi Bello Institute of Petroleum Engineering, TU Clausthal

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4.1.3 Brake System Types and Principle  Brake Types – Main Brake (Mechanical)

4

1

4 3

1

2 Source: rigworks.ca

Source: Rigworks Oilfield Solutions Inc. (2015)

1

Drillers brake level

2

Magnification linkage

Dr.-Ing. Opeyemi Bello Institute of Petroleum Engineering, TU Clausthal

3

Equalizing beam

4

Anchored end (adjustable to set into position)

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4.1.3 Brake System Types and Principle  Brake Types – Main Brake (Mechanical)

Source: broncomfg.com

Dr.-Ing. Opeyemi Bello Institute of Petroleum Engineering, TU Clausthal

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4.1.4 Drilling Hoisting Systems: A look into new concept  Modern hoisting designs



In rig construction two new designs have been introduced apart from the conventional hoisting system. The two systems presented here are:

o o 



Ram Rig

Rack and Pinion Rigs

The Ram Rig is based on hydraulic cylinders as actuator powered by hydraulic power in a closed loop system. It is used for offshore operations. Rack and pinion rigs have a direct drive, thus no drill line. These types of rigs are mainly used onshore. Hoisting System of Rack and Pinion Rigs. Source: KazPetroDrilling (2013)

Dr.-Ing. Opeyemi Bello Institute of Petroleum Engineering, TU Clausthal

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4.1.4 Drilling Hoisting Systems: A look into new concept  The Ram Rig Hoisting System

 

  



The ram rig concept makes mechanical brakes and clutches obsolete, since hoisting and lowering of the load is controlled solely by the closed loop hydraulics. Hoisting is done by two hydraulic cylinders called rams instead of conventional drawworks and derricks.

The hoisting lines are parallel, fixed length, wires with one end anchored at the drill floor, and the other end at the top drive. The travelling distance and the speed of the top drive is twice that of the rams. The maximum stroking velocity of the rams is 1 m/s, allowing the Top Drive to travel 2 m/s. The powering of the ram rig is done by means of a central hydraulic power Unit with 8 to 14 pumps of equal capacity. Any of the pumps can give a full hoisting force. The pumps are powered by constant speed AC motors. Ram Rig Hoisting System. Source: Offshore Job Guide (2015)

Dr.-Ing. Opeyemi Bello Institute of Petroleum Engineering, TU Clausthal

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4.1.4 Drilling Hoisting Systems: A look into new concept  The Ram Rig Hoisting System - Closed loop hydraulic system, after Jan Artymiuk

   

A closed loop hydraulic system normally consists of a rotating motor and a pump, forming a hydraulic transmission. The oil returning from the motor feeds the pump and the motor speed control is performed solely by varying the output of the pump. The pump varies the output and suction side by regulating the displaced oil per revolution of the pump. A good example of the conventional closed loop system is the hydraulic top drive. In the case of the cylinder based hoisting system, the motor of the transmission is replaced by a differential cylinder acting as an actuator.

Dr.-Ing. Opeyemi Bello Institute of Petroleum Engineering, TU Clausthal

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4.1.4 Drilling Hoisting Systems: A look into new concept

The main elements of the RamRig hoist assembly, showing the: - Yoke (A) - Dolly (B) - Top drive (C) - Equalizer assembly (D) - Lifting wires (E) and - Ram cylinders (F) RamRig new rig offshore concept

Dr.-Ing. Opeyemi Bello Institute of Petroleum Engineering, TU Clausthal

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4.1.4 Drilling Hoisting Systems: A look into new concept  The Ram Rig Hoisting System: Benefits (after Jan Artymiuk)

 20-30% reduction in weight compared to conventional rig  Lowered center of gravity (CoG)  Reduced rig footprint compared to conventional rig

 Improved employee safety  Reduced noise  Reduced manning when drilling crews become familiar with the operations

 Designed for: o Drilling,

Under balanced drilling, Slim hole drilling, Work over, Well intervention, Snubbing operations, Re-entry.

o

Replaces: Conventional drilling rig, Hydraulic work over units, Snubbing units and Coil tubing units.

Dr.-Ing. Opeyemi Bello Institute of Petroleum Engineering, TU Clausthal

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4.1.4 Drilling Hoisting Systems: A look into new concept  The Rack and Pinion Rig Hoisting System

   

The main concept of the rack and pinion technology is to replace the drawworks, drill line, blocks and tackle with a linear, direct driven hoisting system. This leads to the use of a closed mast construction containing the entire hoisting system. Supplementing a modern drilling operation, the rack and pinion rig contains an AC-driven top drive system. To offer a safe and „hands-free” drilling operation, a fully automated pipe handling system is used.

Terra Invader Rack and Pinion Rig: Source: Herrenknecht AG (2015): TERRA INVADER RACK & PINION DEEP DRILLING RIG

Dr.-Ing. Opeyemi Bello Institute of Petroleum Engineering, TU Clausthal

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4.1.4 Drilling Hoisting Systems: A look into new concept  The Rack and Pinion Rig Hoisting System, after Artymiuk

 



A turning wheel in the bottom of the mast makes the rack modules turn so that the (non driven) dead side is vertically opposite of the load side. The pinions driven by the reduction gearboxes and the drive motors engage with the rack elements on the (driven) load side, making the rack move upwards for hoisting and downwards (around the turning wheel) for lowering. Advantages of the rack and pinion system:

 Mobilization time is reduced as the rig has fewer 

 

truck loads A faster rig up and a higher automation level can be realized Improved employee safety Can reduce the operational cost and improve the well performance

Dr.-Ing. Opeyemi Bello Institute of Petroleum Engineering, TU Clausthal

Rack and Pinion Rig Hoisting Systems. Source: Artymiuk (2006): A new concept drilling hoisting systems rigs

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Dr.-Ing. Opeyemi Bello Institute of Petroleum Engineering, TU Clausthal

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Lecture 4: Hoisting Systems and Pipe Handling Systems  4.2 PIPE HANDLING SYSTEMS  4.2.1 Basic Information about Drill Pipe  4.2.2 Tool Joints and Makeup Process  4.2.3

Tool Joint Damages and Causes

 4.2.4  4.2.5

Components used in Connection Process

Dr.-Ing. Opeyemi Bello Institute of Petroleum Engineering, TU Clausthal

Automatic Pipe Handling System

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4.2.1 Basic Information about Drill Pipe 

The components of drillstring:

o o o 



Drill pipe Drill collar Accessories including: Stabilizers, HWDP, Reamers, which are included in the drill string

Typical dimensions of a 10.000 ft (3050 m) drill string would be: Component

Outside Diameter

Length

Drill pipe

5 in.

(12,7 cm)

9400 ft

Drill collar

9 ½ in.

(24,13 cm)

600 ft

Drill bit

12 ¼ in.

(31,12 cm)

The main functions of a drill string are:

o o o

To suspend the bit To transmit rotary torque from the Kelly to the bit To Provide a conduit for circulating drilling mud Drill String Components. Source: Tricon Drilling Solutions Pty Ltd

Dr.-Ing. Opeyemi Bello Institute of Petroleum Engineering, TU Clausthal

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4.2.1 Basic Information about Drill Pipe  Drill Pipe

 

 



The drill pipe is the major component of the drill string. It generally constitutes 90-95 % of the entire length of the drill string. The taller the rig structure, the longer the drill pipe sections that can be strung together.

A drill pipe is a seamless pipe with threaded connections, known as tool joints. At one end of the pipe there is the box. At the other end of the pipe is known as the pin.

The wall thickness of the outer diameter of the tool joints must be larger than the wall thickness of the main body of the drill pipe to accommodate the threads.

Drill Pipe and Tool Joint. Source: petroleumsupport.com

Dr.-Ing. Opeyemi Bello Institute of Petroleum Engineering, TU Clausthal

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4.2.1 Basic Information about Drill Pipe  Drill Pipe Selection



The standard dimensions for the drill pipe are specified by the American Petroleum Institute (API). Single pipe segments are available in three API length ranges, where range 2 is the most common. Drill Pipe API range length

API Range



Length [ft]

1

18-22

2

27-30

3

38-45

The drill pipe is also manufactured in a variety of outside diameters, and weights which assuming a specific gravity for steel of 490 lb/ft³, is a reflection of the wall thickness of the drill pipe

Dr.-Ing. Opeyemi Bello Institute of Petroleum Engineering, TU Clausthal

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4.2.1 Basic Information about Drill Pipe  Drill Pipe Selection Dimensions of Drill pipe

Size (OD) [in.]

Weight [lb/ft]

Size (ID) [in.]

2 3/8

6.65

1.815

2 7/8

10.40

2.151

3 1/2

9.50

2.992

3 1/2

13.30

2.764

5

15.50

4.602

5

16.25

4.408

5

19.50

4.276

5 1/2

25.60

4.000

5 1/2

21.90

4.776

5 1/2

24.70

4.670

Dr.-Ing. Opeyemi Bello Institute of Petroleum Engineering, TU Clausthal

Drill pipe Material Grades

API Grade

Minimum Yield Stress (psi)

Minimum Tensile Stress (psi)

Yield Stress/Tensile (ratio)

D

55,000

95,000

0.58

E

75,000

100,000

0.75

X

95,000

105,000

0.70

G

105,000

115,000

0.91

S

135,000

145,000

0.93

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4.2.1 Basic Information about Drill Pipe  Drill Pipe Selection



Selecting the right drill pipe for the job is as important as any other part of the drill string and allows saving time and money.

 Aspects which need to be considered while choosing the drill pipe: a. Location and operational considerations - Kind of well - Well profile - Formations to drill through - Drill method used - Depth of the well - Flow rate - Store capacity on rig - Handling equipment - Operation conditions (Temp., Pressure,...) b. Financial considerations - In long term need, purchasing the drilling equipment can be cheaper than renting it. - But renting the drill pipe can have benefits: Wider selection of pipes, no worry about inspection,…

c.

Quality

-

important to choose a drill pipe that is manufactured to the API or other standards.

Dr.-Ing. Opeyemi Bello Institute of Petroleum Engineering, TU Clausthal

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4.2.1 Basic Information about Drill Pipe  Weight of a Drill Pipe



Assuming we ignore the extra weight of the pin and box of the pipe, its weight can be easily calculated by: 𝑾𝒆𝒊𝒈𝒉𝒕 𝒊𝒏 𝒂𝒊𝒓 = 𝑳𝒆𝒏𝒈𝒕𝒉 𝒙 𝑾𝒆𝒊𝒈𝒉𝒕 𝒑𝒆𝒓 𝒇𝒆𝒆𝒕  Example: What is the weight in air of a joint (30ft) of 5” OD and ID = 4,602 in.? 𝑾𝒆𝒊𝒈𝒉𝒕 𝒊𝒏 𝒂𝒊𝒓 = 𝟑𝟎 𝒇𝒕 𝒙 𝟏𝟓. 𝟓



𝒍𝒃 = 𝟒𝟔𝟓 𝒍𝒃𝒔 𝒇𝒕

The calculated weight is the so called „Weight in air“. If we use a water-based mud or a oilbased mud, we need to consider that there is a lifting power, buoyancy. So, the „Wet Weight“ is: 𝑊𝑒𝑡 𝑊𝑒𝑖𝑔ℎ𝑡 = 𝑊𝑒𝑖𝑔ℎ𝑡 𝑖𝑛 𝑎𝑖𝑟 𝑥 𝐵𝑢𝑜𝑦𝑎𝑛𝑐𝑦 𝑓𝑎𝑐𝑡𝑜𝑟  Example: What is the wet weight of this joint of drill pipe when immersed in a drilling fluid with a density of 12 ppg? 𝑊𝑒𝑡 𝑊𝑒𝑖𝑔ℎ𝑡 = 𝟒𝟔𝟓 𝒍𝒃𝒔 𝒙 𝟎. 𝟖𝟏𝟕 = 𝟑𝟖𝟎 𝒍𝒃𝒔

Dr.-Ing. Opeyemi Bello Institute of Petroleum Engineering, TU Clausthal

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4.2.1 Basic Information about Drill Pipe  Drill Collar

  



A dill collar is a heavy steel tube with a much larger diameter and generally smaller inner diameter. The drill collars therefore have a significantly thicker wall than a drill pipe. A number of dill collars may be used between the bit and the drill pipe.

The function of drill collars are:

o o o 

To provide enough weight on bit To keep the drill string in tension To provide stiffness in the bottom hole assembly, BHA for directional control

Drill collars have a large wall thickness that the connection threads can be machined directly onto the body of the collar.

Dr.-Ing. Opeyemi Bello Institute of Petroleum Engineering, TU Clausthal

Drill Collar and Threads. Source: hunting-intl.com

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4.2.2 Tool Joints and Makeup Process  Tool Joint

   

Tool joints are located at each end of a length of drill pipe to provide the screw thread for connecting the joints of pipe together. Notice that the only seal in the connection is the shoulder/shoulder connection between the box and the pin. The strength of a tool joint depends on the cross sectional area of the box and the pin. Today, tool joints are flash-welded onto the pipe. A hard material is welded onto the surface of the tool joint to protect it from abrasive wear as the drill string is rotated in the well. Tool Joint. Source: oilngasdrilling.com

Tool Joint. Source: http://oil_en_ru.academic.ru/21964/tool_joint

Dr.-Ing. Opeyemi Bello Institute of Petroleum Engineering, TU Clausthal

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4.2.2 Tool Joints and Makeup Process  Tool Joint- Pin End Component

Source:drillingformulas.com

Dr.-Ing. Opeyemi Bello Institute of Petroleum Engineering, TU Clausthal

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4.2.2 Tool Joints and Makeup Process  Tool Joint

  

It should be noted that the inner diameter of the tool joint is less than the inner diameter of the pipe. The size of the tool joint depends on the size of the drill pipe but various sizes of tool joints are available. Common tool joints for a 4 ½ inch drill pipe are Size [in.]

Type

OD [in.]

ID [in.]

TPI

TAPE

Thread Form

4½

API REG

5½

2¼

5

3

V..040

4½

Full Hole

5¾

3

5

3

V..040

4½

NC 46

6

3¼

4

2

V..038R

4½

NC 50

6 1/8

3¾

4

2

V..038R

4½

H 90

6

3¼

3½

2

90° V..050 * TPI = Threads per Inch

Dr.-Ing. Opeyemi Bello Institute of Petroleum Engineering, TU Clausthal

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4.2.2 Tool Joints and Makeup Process  Tool Joint

 

Tool joint boxes usually have a 18 degree tapered shoulder, and pins have 35 degree tapered shoulders.

Tool joints are subjected to the same stresses as drill pipe, but also have to face additional problems:

o o o 

When pipe is being tripped out the hole, an elevator supports the string weight underneath the shoulder of the tool joint The threaded pin end is often left exposed Frequent engagement of pins and boxes can damage the threads

Tool joint life can be substantially extended if connections are greased properly when the connection is made-up and a steady torque is applied.

Dr.-Ing. Opeyemi Bello Institute of Petroleum Engineering, TU Clausthal

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4.2.2 Tool Joints and Makeup Process  Tool Joints - Construction Characteristic Internal and External Upset (e.g. Drill pipe)

External Upset (e.g. Drill pipe)

Internal Upset (e.g. Drill collar)

Internal and External Upset

Dr.-Ing. Opeyemi Bello Institute of Petroleum Engineering, TU Clausthal

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4.2.2 Tool Joints and Makeup Process

Dr.-Ing. Opeyemi Bello Institute of Petroleum Engineering, TU Clausthal

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4.2.2 Tool Joints and Makeup Process  Makeup a Connection

    

The term make up describes the process of tightening a connection of drill pipes or to assemble a system of equipment. To make a connection means to screw another joint of drill pipe to the drill string while drilling a well. In case of a rotary table system, the next joint of pipe is stored in the mouse hole on the drill floor. It is added to the drill string below the Kelly. As an approximate value, a connection is made every 30 ft. (9.1 m) while drilling a well with a rotary table, Kelly bushing, etc. If a top drive is used, a connection is made every 90 ft. (27.4 m) with three joints of drill pipe.

Makeup a Connection. Source: Source: osha.gov

Dr.-Ing. Opeyemi Bello Institute of Petroleum Engineering, TU Clausthal

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4.2.2 Tool Joints and Makeup Process (after Dr. Koppe)  Makeup a Connection

   

When two joints of pipe are being connected the rig tongs must be engaged around the tool joints (and not around the main body of the drill pipe). The greater wall thickness of the tool joint can sustain the torque required to make up the connection. When drilling ahead the top of the Kelly will eventually reach the rotary table (this is known as Kelly down). At this point a new joint of pipe must be added to the string in order to drill deeper.

Drillpipe Make Up. Source: drillingformulas.com

Dr.-Ing. Opeyemi Bello Institute of Petroleum Engineering, TU Clausthal

Pipe connection with application of dope. Source: osha.gov

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4.2.2 Tool Joints and Makeup Process (after Dr. Koppe)  Adding a Pipe – Making a Connection



 



When the bit has drilled the equivalent of the pipe, the drill string must be lengthened by screwing a new joint of pipe onto the bottom of the Kelly. During drilling, the crew places a joint of pipe in the mousehole, located near the rotary table. The driller engages the drawworks to hoist the drillstring to the first length of the drill pipe under the Kelly. The crew puts the slips in place and the Kelly can be unscrewed since the drill string is supported by the rotary table. Mud circulation stops.

B A

Preparing the make up. Source: Klempa et. Al (2015)

Dr.-Ing. Opeyemi Bello Institute of Petroleum Engineering, TU Clausthal

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4.2.2 Tool Joints and Makeup Process (after Dr. Koppe)  Adding a Pipe – Making a Connection







Then, the crew screws the Kelly to the box end of the length of drill pipe in the mousehole. The pipe is screwed and made up in the mousehole.

The driller hoists the drill pipe with the drawworks. Once the new joint of pipe has been screwed and made up on the drill string, the driller resumes drilling fluid circulation.

A B

C

The crew places the Kelly bushing back in the rotary table and drilling can be resumed.

Make Up Connection. Source: Klempa et. Al (2015)

Dr.-Ing. Opeyemi Bello Institute of Petroleum Engineering, TU Clausthal

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4.2.2 Tool Joints and Makeup Process (after Dr. Koppe)  Farr’s Formula

   



Pipe connections are a basic component part of the drill string, and the entire security of the wellbore depends upon the makeup process and the reliability of the tool joint performance. The quality of the assembly process decides whether a connection between two drill pipe is adequate or not. It is affected by the performance of the thread compound. Standards have been developed to define minimum thread compound properties and their performance, because of a wide variety of thread compounds. In general, the API standards for tool joints and the makeup process are based on the Farr´s Formula (1957).

Farr´s Formula describes that stress distribution and makeup torque do correspond. The formula helps to fulfill a adequate make up procedure by calculating the optimum make up torque.

Dr.-Ing. Opeyemi Bello Institute of Petroleum Engineering, TU Clausthal

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4.2.2 Tool Joints and Makeup Process (after Dr. Koppe) Farr’s Formula

𝑴𝟎 = 𝑨 ∗ 𝝈𝟎 ∗

𝑹𝒑 𝑷 + ∗ 𝝁 + 𝑹𝒔 ∗ 𝝁 𝟐𝝅 𝒄𝒐𝒔𝜷

𝑀0

-

Optimum and recommended make up torque

𝐴

-

Critical area of the pin and box (Tool Joint)

𝜎0

-

Optimum and recommended stress at the critical area

𝑃 2𝜋

-

P = Thread pitch: it is a constant value

𝑅𝑃

-

Pitch radius: As a reference it helps to approximate the tapered thread

𝛽

-

Half flank angle: wear can change the flanks in make up or breakout operations

𝜇

-

Coefficient of friction: it is defined to be 0.08 for API thread compounds

𝑅𝑠

-

Averaged shoulder radius: it is not constant due to the shoulder design and manufacturing process

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4.2.3 Tool Joint Damages and Causes  Drill Pipe Failure

  



It is not uncommon for the drill pipe to undergo tensile failure while drilling. When this happens, drilling has to stop and the drill string must be pulled out from the well. The part of the string below the point of failure will be left in the borehole when the upper part is retrieved. The retrieval of the lower part of the string is a very difficult and time consuming operation. Stresses are also induced by vibration, abrasive friction and bouncing the bit off bottom.

Pipe Failure (fatigue). Source: Vallourec

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4.2.3 Tool Joint Damages and Causes (after Dr. Koppe)  Drill Pipe Failure

 

The failure of a drill string can be due to excessively high stresses and/ or corrosion. The drill pipe is exposed to the following stresses:

o o

o

Tension: Weight of the suspended drill string exposes each tool joint to several thousand pound of tensile load Torque: During drilling, rotation is transmitted down the string. Cyclic Stress Fatigue – The wall of the pipe is exposed to compressive and tensile forces

Cyclic Stress Fatigue. Source: drillingformula

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4.2.3 Tool Joint Damages and Causes (after Dr. Koppe)  Tool Joint Damage



Tool Joint damage normally occurs due to one of the following reasons:

o o o

Wear Mechanical failure (for example: side forces impose lateral loading) Corrosion

Dr.-Ing. Opeyemi Bello Institute of Petroleum Engineering, TU Clausthal

Tool Joint Damage (after Teodoriu Catalin)

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4.2.3 Tool Joint Damages and Causes (after Dr. Koppe)  Tool Joint Damage



The shoulder is the only seal in a tool joint connection. Washouts occur if the connection is not tightened properly.

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4.2.3 Tool Joint Damages and Causes (after Dr. Koppe)  Tool Joint Damage

Shoulder is the only seal

Dr.-Ing. Opeyemi Bello Institute of Petroleum Engineering, TU Clausthal

Channel

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4.2.3 Tool Joint Damages and Causes (after Dr. Koppe)  Drill Pipe Damage due to Corrosion



Corrosion of the drill string in a water-based mud is primarily due to dissolved gases, dissolved salts and acids in the wellbore, such as:

o o o o

Oxygen Carbon dioxide Dissolved Salts

Hydrogen sulphide

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4.2.3 Tool Joint Damages and Causes (after Dr. Koppe)  Wrong Makeup Process

 

Even one wrong make up connection decreases the load capacity and the overall performance of the operation.

An insufficient make up process causes damage and produces:

o o o

Fatigue

53% of wrong make up connections show this effect

Twist-off

38% of wrong make up connections show this effect

Shoulder separation

9% of wrong make up connections show this effect causes washout

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4.2.3 Tool Joint Damages and Causes – Summary 

Twistoff

o 

Parting

o



Pipe-parting failure occurs when the induced tensile stress exceeds the pipe-material ultimate tensile stress. This condition may arise when pipe sticking occurs and an overpull is applied in addition to the effective weight of suspended pipe in the hole above the stuck point

Collapse and burst

o 

Pipe failure as a result of twistoff occurs when the induced shearing stress caused by high torque exceeds the pipe-material ultimate shear stress

Pipe failure as a result of collapse or burst is rare; however, under extreme conditions of high mud weight and complete loss of circulation, pipe burst may occur

Fatigue

o o

o

Drillstring fatigue failure is the most common and costly type of failure in oil/gas and geothermal drilling operations. The combined action of cyclic stresses and corrosion can shorten the life expectancy of a Drillpipe by thousand folds Cyclic stresses are induced by dynamic loads caused by drillstring vibrations and bending-load reversals in curved sections of hole and doglegs caused by rotation

Pipe corrosion occurs during the presence of O2, CO2, chlorides, and/or H2S

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4.2.3 Tool Joint Damages and Causes – Summary

 Drillpipe Failure prevention 

Fatigue failures can be mitigated by:

o o

o o

minimizing induced cyclic stresses and insuring a noncorrosive environment during the drilling operations Cyclic stresses can be minimized by controlling dogleg severity and drillstring vibrations. Corrosion can be mitigated by corrosive scavengers and controlling the mud pH in the presence of H2S. The proper handling and inspection of the drillstring on a routine basis are the best measures to prevent failures

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4.2.4 Components used in Connection Process (after Dr. Koppe)  Pipe Slips

 

 



While a make up connection is performed on the rig floor, the drill pipe hangs suspended in the so called pipe slips on the rotary table. Slips support the entire weight of the drill string while the new joint can be added.

The slips are constructed as a collection of metal wedges, hinged together to form a circular shape around the drill pipe. On the inside surface, the slips normally has replaceable steel teeth that grips the pipe.

The outsides of the slips are tapered and meet a similar taper on the drill floor

Rotary Slips. Source: Nov.com

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4.2.4 Components used in Connection Process (after Dr. Koppe)  Pipe Slips

 

After the pipe slip is placed around the drill pipe, it is lowered so that the teeth on the inside grip the pipe and the slips are pulled down. After work is completed, the drill string is raised, thereby unlocking the gripping action. The slips are then lifted away.

Rotary Slips. Source: Nov.com

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4.2.4 Components used in Connection Process  Types of Slips

Drill Collar Slips (DCS). Source: Nov.com

Drillpipe Slip. Source: dhoiltools.com

Dr.-Ing. Opeyemi Bello Institute of Petroleum Engineering, TU Clausthal

Casing Slips. Source: Nov.com

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4.2.4 Components used in Connection Process (after Dr. Koppe)  Rig Tongs

   

Tongs are very large tools used on a derrick to tighten and loosen the drill pipes and collars etc. Imagine a pair of grips that are at least 5 feet long and are tensioned by a winch operated by the driller on an oil rig floor. Most times a chain is used first to do the initial tightening of the pipe joint but tongs are needed for the final pinch up torques need to keep the joint tight. Types of tong:

o o o o

Breakout tong

Makeup tong Chain tong Power tong

Rig Tong. Source: Keystoneenergytools..com

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4.2.4 Components used in Connection Process  Rig Tongs

Torque = Force x Length of the tong Where Torque in ft-lb Force in lb Length of the tong in ft Force is perpendicular to the tong length

Rig Tong. Source: drillingformulas.com

Manual Tongs. Source: nov.com

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4.2.4 Components used in Connection Process (after Dr. Koppe)  Breakout Tongs and Makeup Tong

 

Two large wrenches (tongs) are used to make up or to break a connection. To make up a connection two tongs are used and operated be the roughnecks:

o o

 



The breakout tong The makeup tong

Both tongs are usually connected by a chain to their respective catheads. The makeup cathead is usually on the drillers side of the drawworks. To make a connection the makeup tong is put above, and the breakout tong below the connection.

The breakout tong is fixed, and the driller pulls on the makeup cathead until the connection is tight. Makeup and Breakup Tongs. Source: Schlumberger

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4.2.4 Components used in Connection Process  API Standards (after Dr. Koppe & Dr. Catalin Teodoriu)



API standards define the tool joint make up, but these recommendations do not consider:

o o o o 

Axial forces during makeup Grease property changes

Large bending moments Damaged Tool joints

The height, in which the tool joint connection is performed, depends on the angle between the breakout and makeup tong. A 90° angle leads to a connection process higher above the floor

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4.2.4 Components used in Connection Process (after Dr. Koppe)  Chain Tong

 

A chain tong is a type of pipe wrench used for handtightening various threaded connections around the rig site. It consists of a handle, a set of gripping die teeth, a length of flat chain and a hooking slot where the chain may be adjusted to fit the pipe.

Crew using chain tongs. Source: Schlumberger

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4.2.4 Components used in Connection Process (after Dr. Koppe)  Power Tong

   

Today, the most recommended tong is the so called power tong also referred to as pipe spinner. The first power tongs were used in the 1940s (they were air driven).

Nowadays, power tongs replace the conventional spinning chain and make up tongs in normal operations. However, the old tools are still available on the market for direct use or as a back up in case of a mechanical failure.

Hydraulic power tong. Source: nov.com

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4.2.4 Components used in Connection Process (after Dr. Koppe)  Power Tong



   



Power tongs have fundamental advantages:

o o o

Higher reliability Higher safety standard

High efficiency and quality

Many drill pipe failures can be attributed to improperly made up joints. Power tongs reduce this failure. Many of the personnel hazards associated with drilling are related directly to the spinning and torqueing up operations. The power tong consists of a series of gears inside a housing powered by a small engine. Power tongs are air or hydraulic driven from a throttle handle.

These tongs are reversible and have two speeds:

o o

High speed for makeup Low speed for breakout Power Tong

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4.2.4 Components used in Connection Process  Power Tong Components – Pipe Spinner

Drill Pipe Spinner. Source: controldrillingservice.com

Pipe Spinner. Source: International Association Of Drilling Contractors (2015)

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4.2.4 Components used in Connection Process  Fingerboard





The fingerboard is the working platform halfway up the derrick or mast. It allows storing drill pipes and drill collars in an orderly fashion during trips out of the hole. The platform consists of a small section where the derrick man can work, and several steel fingers with slots in between that can keep the tops of the drill pipe.

Fingerboard. Source: smst.nl

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4.2.5 Automatic Pipe Handling System (after Dr. Koppe)  Early Pipe Connection Methods

    

Adoption of the rotary drilling rig put new demands on the roughnecks working the rigs. Early roughnecks applied torque to the connections by hand with pipe wrenches. Today, the crew uses hydraulic wrenches called power tongs for pipe connections. But even if the risk was lowered, both methods invited hand injuries. The invention of the top drive allows making and breaking connections with little participation of the rig crew

Dr.-Ing. Opeyemi Bello Institute of Petroleum Engineering, TU Clausthal

Pipe Connection

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4.2.5 Automatic Pipe Handling System  Automatic Pipe Handling Systems

 

 

Recently, several companies have been marketing automated pipe handling systems. These systems are designed to pick up drill pipe segments from the storage rack, position them over the borehole, and apply torque to connect them. The pipe handler that comes with every rig increases safety and saves time. It is automatic and assistance is needed.

no

Weatherford Iron derrick man drilling pipe handling robot (yellow) with red gripper. The pipes are stacked in precise rows separated by steel.

roughneck

Iron Roughneck from National Oilwell Varco. Source: nov.com

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4.2.5 Automatic Pipe Handling System (after Dr. Koppe)  Conventional Method



Lifting the drill pipes or stands step by step with manual work

 Modern Technology

  

Lifting the drill pipes or stands with a Pipe Handling System PHS will be operated from the driller’s cabin Advantages:

 High performance  Increased safety  High availability  Decreased manual work

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4.2.5 Automatic Pipe Handling System (after Dr. Koppe)  Column Racker



  

A column rack is an automated system of arms on a column that can be a fixed rotating machine or a traveling and rotating machine. Usually it consists of a single guide and single gripping hoist arm and has a primary function of tripping the pipe without the intervention of human labor. Various modes and versions exist to facilitate standbuilding off-line, riser tailing, riser tripping, and casing tripping. These systems are prevalent on offshore rigs where the lateral stand loads are too high for typical manual operations by a derrick man.

Smart Colum Racker. Source: axiom.us.com

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4.2.5 Automatic Pipe Handling System (after Dr. Koppe)  Column Racker



Three fingerboard designs are common for a column racker:

o

The star fingerboard:



o

The X-Y fingerboard:



o

There the column is a fixed rotating design and the arms place the pipe in a radial fashion

It is like the traditional left-hand, right hand fingerboard with the exception that each stand is locked in place with a remotely controlled finger latch

The parallel fingerboard:



There all the fingers point towards well center and the racker travels in front of the set back rotating 180 degrees to present the tubular stand at well center

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4.2.5 Automatic Pipe Handling System

After GFZ-OSG-L.Wohlgemuth

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4.2.5 Automatic Pipe Handling System

After GFZ-OSG-L.Wohlgemuth

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4.2.5 Automatic Pipe Handling System (after Dr. Koppe)  Pipe Handling Systems



Horizontal to vertical pipe transfer arm:

o o



A device designed to transition pipes between a horizontal or angled presentation and a vertical position in a mousehole or at well center The machine is usually integrated into a V-door

Pipe handling Boom:

o o

An arm-based machine that usually transitions drill pipe from the horizontal to the vertical position in a single motion. It is usually rotated around a fixed pivot point in the sub structure and is mostly used in land rig applications

Dr.-Ing. Opeyemi Bello Institute of Petroleum Engineering, TU Clausthal

Pipe Transfer System. Source: International Association Of Drilling Contractors (2015)

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4.2.5 Automatic Pipe Handling System (after Dr. Koppe)  Pipe Handling Systems - Vertical Racking System



 



A vertical racking system is a pipe racking system. It can be manufactured for any rig and any application. This machine optimizes the racking/setback capacity and flexible regarding alternative installations. Consists of two racking arms, that can be fixed in a single or dual column.

Vertical Pipe Handling. Source: nov.com

Advantages of a vertical racking system:

 High setback on racking speed  Wide handling range (Drill pipe

and drill

collar)

 Suitable for any derrick or mast  Fully remote control  High safety standard Vertical Racking System. Source: drillingcontractor.org

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4.2.5 Automatic Pipe Handling System (after Dr. Koppe)  Pipe Handling Systems – Horizontal Pipe Handling

  

 

The pipe deck conveyor is a horizontal pipe handling tool. It is well proven for transfer of drill pipes, collars and casing from the pipe deck to the well center or back. For optimal handling performance, the conveyor is equipped with a tail-in and tail-out function for guiding the pipe over the drill floor.

In addition, the conveyor has a feeding table for easier pipe handling. Advantages are:

 High racking capacity  High safety standard  Wide handling range  Fully remote control

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4.2.5 Automatic Pipe Handling System  Pipe Handling Systems – Horizontal Pipe Handling

NOV's latest Horizontal Pipe Handling System Dr.-Ing. Opeyemi Bello Institute of Petroleum Engineering, TU Clausthal

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Lecture 4: Hoisting Systems and Pipe Handling Systems: Learning Milestones In this lecture, you should have learnt to:  Understand hoisting system and components  Understand the brake system, the types and principles  Have a knowledge of drilling hoisting system new concept

 Idea about drill pipe and selection  Tool joints and makeup procedures  Components used in connection process  Knowledge of automatic pipe handling system

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