PETE 355: Drilling Engineering

Rig Design/Rig Selection

PETE 355: Drilling Engineering

Office hours: TR 10:00 am – 11:30 am

or
anytime my office door is open
 PETE 355: Drilling Engineering
Recommended literature:

• Robert F. Mitchell and Stefan Z. Miska: Fundamentals

of Drilling Engineering, Society of Petroleum
Engineers, Richardson, TX, 2011.
• Adam Bourgoyne et al.: Applied Drilling Engineering,
Society of Petroleum Engineers, Richardson, TX, 1986.
• J.J. Azar and G. Robello Samuel: Drilling Engineering,
PennWell, 2007
• Halliburton Redbook, available on Halliburton website
or Richardson computer labs.
• Schlumberger iHandbook, available on Schlumberger
website or Richardson computer labs.
PETE 355: Drilling Engineering
Lecture Topics Covered:

• The drilling rig, terminology, drilling fluids

• Drilling problems and solutions
• Wellbore hydraulics and design of circulation system
• Casing design procedures; collapse, burst, tension
• Abnormal pressure/Fracture gradient prediction
• Well control
• Well design for safety and efficiency
• Design of primary and secondary cementing jobs
• Directional drilling, torque & drag
• Offshore drilling
• Innovative drilling methods: MPD/UBD/Dual gradient
PETE 355: Drilling Engineering
Simple Things You MUST Know
Displacement of
pipe
Capacity of pipe

Capacity of
pipe
Ap  d 2

4
d2
1 ft
d1 Capacity of annulus

Aa  d 2
2 d1
2

4

d Displacement of pipe

As 
4
d 1
2
d2 
Simple Things You MUST Know - Example
 (do2-di2)/1029.4 = bbl/ft, d is inches

▪ 42 gallons per bbl

▪ 5.615 cu ft per bbl
▪ 7.48 gal per cu ft

 What is the daily water volume increase

needed to drill 17 ½” hole at the rate of
1500 feet per day?
Simple Things You MUST Know - Example
 What is the daily water volume increase
needed to drill 17 ½” hole at the rate of
1500 feet per day?
• Seepage losses of 25%
• Dilution losses of 25%

 How much water will need to be supplied

on an hourly basis?
 A) 5 bbls/hr B) 10 bbls/hr C) 20 bbls/hr D) 30
bbls/hr
What is the total capacity of 10,000 ft of 5”
OD, 19.50 lb/ft drillpipe (ID = 4.276”)?

Total capacity = capacity factor x total length

Total capacity = 4.2762 /1029.4*10000
Total Capacity = 177.6 bbls
What is the total displacement of 10,000 ft of
5” OD, 19.50 lb/ft drillpipe?
Total Displ. = Displ. Factor x total length
Total Displ. = (52-4.2762) /1029.4*10000
= 0.00652*10000

Total Displacement = 65.2 bbls

or 0.59 bbls per Stand*

*Stand=90’ (3 joints of 30’ together)

Triplex mud pump: single-acting design

Pump Factor = 3 * /4 dL2 LS EV/(231 * 42)

 Example 1
Compute the pump factor in units of barrels per stroke
for a triplex pump having 6.5-in. liners, 12-in. strokes,
and a volumetric efficiency of 96%.
Solution:

pump factor  3   6.52 12  0.96
4
pump factor  1,146.8 in.3 / stroke
1 U .S . gallon  231 in.3 and 42 U .S . gallon  1 U .S . barrel
in.3 gal bbl
1,146.8  3

stroke 231 in. 42 gal
pump factor  0.1182 bbl / stroke
 Example 2
Compute the pump rate in units of gallons per minute if
pump speed is 80 stk/min.
Solution:

Flow rate = Pump Factor * Strokes/min

bbl stks
= 0.1182  80
stk min

= 9.456 bbl/min = 397.15 gal/min

Pump Rate ≈ 400 gal/min

 Example 3
Compute the time necessary to pump the cuttings
generated at the bottom of the hole up to the surface.

Hole: 8.5” 14”

DP: 5” OD 7”
Depth: 6,000’
Pump: Example 1
Pump velocity: 100 stk/min

8.52 - 52
capacity factor = = 0.046 bbl / ft
1029.4
Annular total capacity = 0.046 ´ 6, 000 = 275 bbl
flowrate = 0.1182 bbl / stk ´100 stk / min = 11.8 bbl / min
275 bbl
Dt = @ 23 min
11.8 bbl / min
Simple Things You MUST Know
• Hydrostatic Pressure
 Pressure= 0.052 x MW x Vertical Depth
• Example
 Your casing shoe at 15000’ needs to be
tested to 17 ppg. Your MW is 12.5 ppg.
What surface pressure will be needed to
test the shoe?

Your mud pump is rated to 3,000 psi. What do you do?

Simple Things You MUST Know
• Force = Pressure x Area = psi x in2 =
lbf

• Example
 Your choke manifold is rated to 10,000 psi
and has a 2” threaded bull plug on one
side. How much force is acting on this bull
plug at maximum pressure?

Area =(/4) (d2)=3.14 in2

Force = 3.14 x 10000 = 31,400 lbf
Oil Well Classification
Wildcat
• Aim is to discover a new
petroleum reservoir
• Geological group usually
recommends locations

Development
• Aim is to exploit a known
reservoir
• Reservoir engineering group
usually recommends locations
Rotary Drilling Rigs
Organization
Classification
 Typical Drilling Organization for a Well Drilled
on a cost-per-day basis
Final authority
rests with the
Operator

Makes the on-

site decisions
concerning the
rig operation and
personnel

Makes the on-

site decisions
concerning the
well
Classification of Rotary Drilling Rigs
Classification of Rotary Drilling Rigs
The Rotary Drilling
Process
Primary Systems on a Rig
The major rig components
that need to be designed
and sized for the purpose of
rig selection are:
• Power requirements
• Derrick capacity and
substructure
• Hoisting
• Rotating equipment
• Circulating system
• Tubular goods
• Well control
Primary Systems on a Rig
• Power
• Hoisting
• Fluid-Circulating
• Rotary
• Well Control
• Well Monitoring
 Primary Systems on a Rig

• Power
• Hoisting
• Fluid-Circulating
• Rotary
• Well Control
• Well Monitoring
• Modern rigs are powered by internal-combustion diesel
engines which are used to generate electricity. The
most widely used system is AC - DC (alternating-current
generator – direct-current motor)

• Most rig power is consumed by the hoisting and fluid

circulation systems. Fortunately, these two systems are
not used simultaneously  same engines for both
functions

• Total power requirements range:

1,000 hp 6,000 hp
Power system performance characteristics:
• Output horsepower

• Torque

• Fuel consumption at various engine speeds

Overall power system efficiency, Et

output power
Et 
total heat energy consumed by the engine
 Engine
horsepower
output

Output Power = angular

velocity * output torque Power = load F * hoisting velocity
HEATING VALUE OF VARIOUS FUELS

Fuel Density Heating Value

Type (lbm/gal) (Btu/lbm)

diesel 7.2 19,000

gasoline 6.6 20,000
butane 4.7 21,000
methane --- 24,000
Example (1.1 in FDE)
A diesel engine gives an output torque of 1,740 ft-
lbf at an engine speed of 1,200 rpm. If the fuel
consumption rate was 31.5 gal/hr, what is the
output power and overall efficiency of the engine?

Solution: The angular velocity, w , is given by

w= 2 (1,200) = 7,539.8 rad/min

The power output can be computed as follows:

7,539.8 (1,740) ft - lbf/min
P w T   397.5hp
33,000 ft - lbf/min /hp
Since the fuel type is diesel, the density is 7.2
lbm/gal and the heating value H is 19,000
Btu/lbm (Table 1.1). Thus, the fuel consumption
rate w f is:
 1 hour 
w f  31.5 gal/hr (7.2 lbm/gal)  
 60 minutes 
wf = 3.78 lbm/min.
 Example 1 cont’ed
The total heat energy consumed by the
engine is given by:
Qi = w f H
3.78 lbm/min 19,000Btu/lbm  779 ft - lbf/Btu 
Qi 
33,000 ft - lbf/min/hp

Qi = 1,695 HP
 Example 1 cont’ed

Thus, the overall efficiency of the engine at 1,200

rpm given by

P 397.5
Et    0.234 or 23.4%
Qi 1,695.4
 Primary Systems on a Rig

• Power
• Hoisting
• Fluid-Circulating
• Rotary
• Well Control
• Well Monitoring
Hoisting System

All rights reserved © 2008 PETEX® (Petroleum Extension Service), The

University of Texas
Hoisting System: Block and Tackle
Crown
block

Fast line Dead line

Traveling
block

to drawworks to anchor
 Hoisting System: Block and Tackle
Considering the ideal system, with no friction in the sheaves:

W
Fd Fs  F f 
n
Ff
W
n
W W
n n
W W
n n
W
n
Fs Fd  W  Fs  F f
hook power W
W E 
drawworks anchor input power F f n
E 1
Mechanical Advantage M = W/Ff
M=n
Hoisting System: Block and Tackle
Fd

Dynamic
analysis Ff T1 T2 T3 T4 Tn
Fs

W
drawworks anchor
traveling block
going up: Ff>T1>T2>T3>……>Tn=Fs=Ff en
going down: Ff<T1<T2<T3<……<Tn=Fs=Ff e-n

where e = sheave efficiency

Hoisting System: Block and Tackle
Dynamic analysis
Traveling Block Drawworks Derrick
 1  W  1  e   1 
Fs  e  1  n  Ff  Fs  1  n  2  e 
Up
W  e  
e  1  en  Fd   e 
e 1 1 e
Down W

Fs  1  e n Ff 
W  e n 1  e 
Fd 
 
Fs  2  e  e n 1
1 e 1  en 1 e

Indicates dead line tension

times n as the hook load,
neglecting friction
Hoisting System: Block and Tackle
System Efficiency

hook power W
E 
input power F f n
Dynamic W
E
analysis n  W  (1  e)
e  (1  e n )
e  (1  e n )
E
n  (1  e)

See FDE Table 1.1 for K = 1/e = 1.04

Hoisting System: Example
A rig must hoist a load of 400,000 lbf. Ten lines are
strung between the crown block and traveling block.
Consider e = 0.97

a) Calculate the dynamic tension in the fast line.

b) What value do you read at the weight indicator?
Solution.
a) The tension in the fast line is given by:

W  1  e  400,000  1  0.97 
Ff  

e  1 e n

0.97  1  0.9710  
F f  47,114 lbf (How much would it be in a
frictionless system?)
Hoisting System: Example
Solution (cont.)

b) The tension in the dead line is given by:

Fs  F f  e n

Fs  47,114  0.9710
Fs  34,743 lbf

The reading at the weight indicator is 347,430 lbf.

The driller must be aware that the real load is

greater than that he reads at the weight indicator
(13% error in this example)
Hoisting System: Drilling Line wire
core
Strands and Construction
1. Wires are the basic building blocks of
wire rope strand
2. They lay around a "center" in a Wire
specified pattern in one or more layers rope
to form a strand
3. The strands lay around a core to form
a wire rope
4. The strands provide all the tensile
strength of a fiber core rope and over
90% of the strength of a wire rope with
an independent wire rope core
(IWRC).
Hoisting System: Design Considerations

1. Determine the deepest hole to be

drilled,
2. Determine the worst drilling loads or
casing loads,
3. Use these values to select the
drilling line, the derrick capacity, and
the drawworks power requirements
Hoisting System: Derrick capacity and Substructure
There are two types of derricks:
Standard Derrick: is a bolted structure that
must be assembled part by part, usually
used on offshore platforms

Mast or Portable Derrick:

This type is pivoted at its base and is
lowered to the horizontal by the use of
drawworks after completing the well
and the rig is ready to move to another
location
Hoisting System: Derrick capacity and Substructure
The derrick provides the
necessary height and mast
support to lift loads in
and out of the well

The derrick and

substructure must be
strong enough to
support the hook load, substructure
deadline and fast line
loads, pipe setback and
wind loads
Hoisting System: Drilling Line capacity
A design factor is used to determine the
minimum tensile strength required for the
drilling line. This design factor, DF, may be
calculated as follows:

nomin al strength of wire rope (lbf )

DF =
fast line load (lbf )

Min Design Factors:

Drilling/Tripping 3
Casing Running 2
 Hoisting System: Drawworks capacity
1. As a rule of thumb, the drawworks should have 1 HP
for every 10 ft to be drilled. Hence for 20,000 ft well,
the drawworks should have 2,000 HP.

2. A more rigorous way of calculating the horsepower

requirements is as follows:

W ´ vtb
drum power output = Ff ´ v fl =
E
where,

Ff is the fast line load, W is the hook load, vfl is the fast line velocity,
vtb is the traveling block velocity , and E is the block & tackle
efficiency
Hoisting System: Drawworks capacity
Example: A rig must hoist a load of 500,000 lbf
at a velocity of 120 ft/min. Ten lines are strung
between the crown block and traveling block.
Considering that the mechanical efficiency of
the drawworks is equal to 88% and FDE Table
1.1, determine:

1. The output power at the drawworks’ drum

2. The drawworks’ motor power required
e = 0.96
 Hoisting System: Drawworks capacity
Solution:
Power at drum = (W x vtb) / (E x 33,000)
= (500,000 x 120) / (0.811 x 33,000) = 2,242 HP
Since, table
Power at drum = motor power x mechanical efficiency
then,
2,242 = motor power x 0.88,
Motor power = 2,242 / 0.88 = 2,548 HP

Select a motor with 3,000 hp rating

 Primary Systems on a Rig

• Power
• Hoisting
• Fluid-Circulating
• Rotary
• Well Control
• Well Monitoring
Circulating System for liquid drilling fluid
Major function: remove the
rock cuttings from the hole as
drilling progresses

Mud pumps: use reciprocating

positive-displacement pistons.
Why?
• Ability to move high-solids-content
fluids
• Ability to pump large particles
• Ease of operation & maintenance
• Reliability
• Wide range of pressure x flowrate
(changing liner diameter)
 Overall efficiency of a mud pump

Pump overall efficiency = Em x Ev

Em = mechanical efficiency (power-end efficiency)

Ev = volumetric efficiency (actual flowrate/theoretical flowrate)

Most manufacturer’s tables rate pumps

using Em = 90% and Ev = 100%
 pressure flowrate

PRESSURE ( psi) ´ FLOWRATE ( gpm)

HHP ( hp) =
1, 714
 Primary Systems on a Rig
• Power
• Hoisting
• Fluid-Circulating
• Rotary
• Well Control
• Well Monitoring
Rotary System Power Requirement
The rotary power requirement is usually
small when compared to the hoisting and
fluid-circulating power requirements.
As a rule of thumb, the rotary horsepower
requirement is usually between 1.5 to 2
times the rotary speed, depending on the
hole depth.
Hence for rotary speed of 200 RPM, the
power requirement is about 400 HP.
Rotary System Power Requirement
A more rigorous way to calculate the rotary
horsepower is given by:
2  N  T
P w T 
33,000
where,
P = rotary power, hp
N = pipe velocity, rpm
T = pipe torque, ft-lbf

For highly deviated wells, torque/rotary power

requirements must be closely calculated using
available computer programs
 Primary Systems on a Rig
• Power
• Hoisting
• Fluid-Circulating
• Rotary
• Well Control
• Well Monitoring
 Well Control System: Blowout preventer (BOP)
Equipment installed on
Blind shear
ram the wellhead or
Casing shear wellhead assemblies to
ram contain wellbore fluids
Pipe ram either in the annular
space between the
Pipe ram casing and the tubulars,
Pipe ram
or in an open hole
during well drilling,
completion, and testing
operations. (API RP 96)
Well Control System: BOP pressure requirement
The working pressure of the BOP must be greater
than the Maximum Anticipated Surface Pressure
(MASP). BOPs are rated by API as 3M (3000 psi),
5M, 10M and 15M. For HPHT wells, BOPs are
either 15M or 20M

MASP is a design load that represents the

maximum internal pressure that may occur at the
surface within each hole interval during the
construction of the well. The internal pressure is
typically defined by either an applied pressure or a
reservoir pressure (subtracting the hydrostatic
fluid/gas column).
Well Control System: BOP working pressure
Most Operators determine MASP as the minimum value based
on the two following situations:

1. Underground blowout occurring below the casing shoe while

a gas kick is circulated out. MASPfas is calculated as equal
to the fracture pressure at the shoe) less the hydrostatic
pressure of a column of gas (gradient multiplied by true
vertical depth) to surface.

1. Well is completely full of gas. MASPgts is calculated as

equal to the reservoir BHP less the hydrostatic pressure of a
column of gas (gradient times true vertical depth) to surface.

MASP = min (MASPfas , MASPgts)

Well Control System: BOP working pressure
Frac-at-Shoe, Gas-to-Surface
MASPfas MASPgts
Pressure

Pfract

BHPmax
 Well Control System: Example
MASP
MASPfas is equal to

0.052*(15 - 2)*10,000 =
6,760 psi
rgas = 2 ppg
10,000’
13,000’

MASPgts is equal to

0.052*(9 - 2)*13,000 =
rfrac = 15 ppg
4,732 psi

rpore = 9 ppg Select a BOP with

5,000 psi WP
 Primary Systems on a Rig
• Power
• Hoisting
• Fluid-Circulating
• Rotary
• Well Control
• Well Monitoring
• Safety and efficiency require constant well
monitoring to detect problems quickly

Driller’s cabin at rig Operator’s Drilling

Engineering office
Control System & Drilling Instrumentation
Depth
Penetration rate
Hook load

Weight on bit

Rotary speed

Rotary torque

Pump pressure

Pump rate

Pit level

Mud properties
Directional drilling data
ETC.
Last Slide