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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

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

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 Hrsaal

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

Lecture Module: Things to know

Dr.-Ing. Opeyemi Bello


Institute of Petroleum Engineering, TU Clausthal

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

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

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

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,
and T represent?

Dr.-Ing. Opeyemi Bello


Institute of Petroleum Engineering, TU Clausthal

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

Lecture 3: Rig Power System Revision

Diesel Engine

AC-Motor

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

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

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

Components used in Connection Process


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

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

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

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.

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

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.

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:

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

Dr.-Ing. Opeyemi Bello


Institute of Petroleum Engineering, TU Clausthal

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

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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

Dr.-Ing. Opeyemi Bello


Institute of Petroleum Engineering, TU Clausthal

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

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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

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

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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:
= 0.004 2
Where
= Wind load (lbf/ft)
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:

+2

Derrick/ Mast of the Hoisting System


Source: Hossain, Al-Mejed (2015): Fundamentals of
Sustainable Drilling Engineering

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

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

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4.1.2 Hoisting System Components


Derrick

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

= + +
= Tension in the fast line [lbf]

= 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

/4

/4

/4

/4

Fast Line

/2

/2

Dead Line

( /4) + ( /2)

/4

( /4) + ( /2)

4 +

Hook Load

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

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

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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

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

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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

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

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

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

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

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

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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.

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

Dr.-Ing. Opeyemi Bello


Institute of Petroleum Engineering, TU Clausthal

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

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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

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

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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:
1
=
1

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

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

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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

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

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4.1.2 Hoisting System Components


Solution
1. The static tension in the fast line when upward motion is impending

1
1

0.96151 10.961518

= 0.844

8 10.96151

2. The maximum hook horsepower available.

= . = 0.844 500 = 421 hp


3. The maximum hoisting speed

421 33000
300,000

= 46.3 ft/min

4. The actual derrick load

1++

Dr.-Ing. Opeyemi Bello


Institute of Petroleum Engineering, TU Clausthal

1+0.844+0.8448
0.844 8

300, 000 = 382, 090 lbf

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

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4.1.2 Hoisting System Components


Solution
5. The maximum equivalent derrick load

+4
W

8+4
8

300,000 = 450,000 lbf

6. The derrick efficiency factor

382,090
450,000

Dr.-Ing. Opeyemi Bello


Institute of Petroleum Engineering, TU Clausthal

= 84.9 %

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

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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.

The drilling line is of the round strand type with


Langs lay.
The drilling line has a 6x19 construction with
Independent Wire Rope Core (IWRC)

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 "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

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

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4.1.2 Hoisting System Components


Drilling line- The pulley Principle
B

D
P

P =W

P = 1/ 2W

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

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

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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

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

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4.1.2 Hoisting System Components


Fast Line and Dead Line

The force in the fast line ( ) and in the dead


line ( ) to hold the hook load in a frictionless
system can be determined with the following
formula:

= =

= = Force to hold the hook load [lbs]


= The weight of the traveling block plus
the weight of the drill string suspended in the
hole [tons]
= 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

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

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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:
=

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)

0.874

0.842

10

0.811

12

0.782

14

0.755

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

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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

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

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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

Dr.-Ing. Opeyemi Bello


Institute of Petroleum Engineering, TU Clausthal

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

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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

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

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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

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

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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

Dr.-Ing. Opeyemi Bello


Institute of Petroleum Engineering, TU Clausthal

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

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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

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

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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

Brake bands

Adjusting hold down

Equalizing yoke

Brake lever

3
Schematic of the Main Brake. Source:

Dr.-Ing. Opeyemi Bello


Institute of Petroleum Engineering, TU Clausthal

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44

4.1.3 Brake System Types and Principle


Brake Types Main Brake (Mechanical)

4
3

2
Source: rigworks.ca

Source: Rigworks Oilfield Solutions Inc. (2015)

Drillers brake level

Magnification
linkage

Dr.-Ing. Opeyemi Bello


Institute of Petroleum Engineering, TU Clausthal

Equalizing beam

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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46

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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47

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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48

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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50

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.

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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51

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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52

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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54

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 in.

(24,13 cm)

600 ft

Drill bit

12 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]

18-22

27-30

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/ft, 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

15.50

4.602

16.25

4.408

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)

55,000

95,000

0.58

75,000

100,000

0.75

95,000

105,000

0.70

105,000

115,000

0.91

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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60

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:
=
Example: What is the weight in air of a joint (30ft) of 5 OD and ID = 4,602 in.?
= .

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:
=
Example: What is the wet weight of this joint of drill pipe when immersed in a drilling
fluid with a density of 12 ppg?
= . =

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 inch drill pipe are
Size [in.]

Type

OD [in.]

ID [in.]

TPI

TAPE

Thread
Form

API REG

V..040

Full Hole

V..040

NC 46

V..038R

NC 50

6 1/8

V..038R

H 90

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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66

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

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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72

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


Farrs 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
Farrs Formula (1957).

Farrs 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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73

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


Farrs Formula

+
+

Optimum and recommended make up torque

Critical area of the pin and box (Tool Joint)

Optimum and recommended stress at the critical area

P = Thread pitch: it is a constant value

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

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

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

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

Dr.-Ing. Opeyemi Bello


Institute of Petroleum Engineering, TU Clausthal

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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

Dr.-Ing. Opeyemi Bello


Institute of Petroleum Engineering, TU Clausthal

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75

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

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

Dr.-Ing. Opeyemi Bello


Institute of Petroleum Engineering, TU Clausthal

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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.

Dr.-Ing. Opeyemi Bello


Institute of Petroleum Engineering, TU Clausthal

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78

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

Parting

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

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

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


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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

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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 drillers 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:

The star fingerboard:

The X-Y fingerboard:

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


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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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Dr.-Ing. Opeyemi Bello


Institute of Petroleum Engineering, TU Clausthal

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Dr.-Ing. Opeyemi Bello


Institute of Petroleum Engineering, TU Clausthal

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