SUMMER TRAINING REPORT ON DRILLING

RIG AND ITS EQUIPMENTS (2022)

Department of Mechanical Engineering

SUBMITTED BY: - SUBMITTED TO: -

TANMAY JOSHI Mr. Raju Kumar,
B.Tech (Mechanical Eng.) (DGM) Mechanical,
Dr. B.R. Ambedkar National Institute Drilling Services, Frontier Basin,
of Technology ONGC Dehradun, Uttarakhand
Jalandhar, Punjab

1|Page
 CERTIFICATE

This is to certify that TANMAY JOSHI pursuing Bachelor of

Technology in Mechanical Engineering from Dr. B.R.
Ambedkar National Institute of Technology, Jalandhar,
Punjab, has successfully completed Virtual summer training in
Oil and Natural Gas Corporation Limited, Dehradun from
01/07/2022 to 15/08/2022 at Drilling Services, Frontier Basin,
ONGC Dehradun under the supervision of Mr. Raju Kumar,
DGM (Mechanical), Frontier Basin, Dehradun. His
performance has been satisfactory and has shown keen interest to
understand the subject assigned. This document is a bonafide
testimony of the training undergone and works carried out by him
in this course. He has also submitted a copy of project report after
successful completion of the training.

Date:
Mr. Raju Kumar
DGM (Mechanical)
Drilling Services, Frontier Basin

2|Page
ONGC, Dehradun

ACKNOWLEDGEMENT

First of all, I want to thank Mr. Raju Kumar, Deputy General

Manager (DGM) of the Mechanical Engineering Department
at ONGC Dehradun, for being my guide and mentor for the
training. Throughout my training, he has been a constant source
of resources and knowledge for me. I am grateful to him for
providing me the necessary guidelines and in-depth knowledge of
the “Mechanical Equipment used in the Drilling Rigs.”

I want to express my sincere thanks to the ONGC Dehradun

administration for allowing me to attend this fantastic training.

I would like to thank all my professors at Dr. B.R. Ambedkar

National Institute of Technology, Jalandhar who taught me the
principles and basics of Mechanical Engineering, which helped
me to perform the project assigned to me by Frontier Basin
ONGC, Dehradun.

Without the support and guidance of the above personnel, this

training cannot be completed with this vast experience about
working and facts of drilling rigs at ONGC.

3|Page
 ABSTRACT
The presented report shows an overview of mechanical
equipments of drilling rigs and their maintenance.

It gives an outline about drilling rigs, its classification and all the
systems including their main components. It also includes the
operations which are undergone to extract oil and natural gas
from wells.

This report also covers brief information about auxiliary elements

of a drilling rig like drill bits, drilling fluid. It includes
classification, properties and functions of the drilling fluid.

It also shows various methods used for maintenance of the

drilling rigs.

4|Page
 INDEX
Sr. No. Description Page No.
1. ONGC 6-7
2. Drilling Rig 8-13
3. Power System 14-15
4. Hoisting System 16-25
4.1. Crown Block
4.2. Derrick
4.3. Travelling Block
4.4. Hook
4.5. Drawworks
5. Rotating System 26-32
5.1. Swivel
5.2. Rotary Table
5.3. Kelly Spinner
5.4. Independent Rotary Drive
5.5. Pipe Spinner

6. Drill Bits 33-37

7. Circulating System 38-54
7.1. Mud Pump
7.2. Shale Shaker
7.3. Desander
7.4. Desilter
7.5. Mud Agitator
7.6. Degasser
7.7. Drilling Fluids
8. Air Control System 55-58
8.1. Compressor
8.2. Supercharger
9. Well Control System 59-62
9.1. Accumulator
9.2. Blowout Preventer
10. Cementing and Casing 63-65
11. Maintenance of Drilling Rig and its Equipment 66-67
12. Conclusion 68

5|Page
 13. References 69

OIL AND NATURAL GAS CORPORATION

(ONGC)
Oil and Natural Gas Corporation (ONGC) is an Indian government-owned
crude oil and natural gas corporation. It was founded on 14 August 1956 by
Government of India. It is the largest oil and gas exploration and production
company in the country and produces around 70% of India's crude oil
(equivalent to around 57% of the country's total demand) and around 84% of its
natural gas. Its registered office is in New Delhi. It is under the ownership of
Ministry of Petroleum and Natural Gas, Government of India.

In a survey by Government of India for fiscal year 2019–20, ONGC was ranked
as the largest profit-making PSU in India. It is ranked 7th among the Top 250
Global Energy Companies by Platts. ONGC has a unique distinction of being a
company with in-house service capabilities in all areas of Exploration and
Production of oil & gas and related oil-field services. Winner of the Best
Employer award, this public sector enterprise has a dedicated team of around
28,500 professionals who toil round the clock in challenging locations.
ONGC is involved in exploring for and exploiting hydrocarbons in 26
sedimentary basins of India and owns and operates over 11,000 kilometres of
pipelines in the country. Its international subsidiary ONGC Videsh currently has
projects in 17 countries. ONGC has discovered 7 out of the 8 producing Indian
Basins, adding over 7.15 billion tonnes of In-place Oil & Gas volume of
hydrocarbons in Indian basins.

6|Page
ONGC supplies crude oil, natural gas, and value-added products to major Indian
oil and gas refining and marketing companies. Its primary products crude oil
and natural gas are for the Indian market. The market cap of ONGC is one of
the best among PSUs in India. ONGC is the biggest wealth creator in the
country. This public sector enterprise operates with 14 seismic crews, manages
262 onshore production installations, 268 offshore installations, 69 drilling (plus
37 hired) and 54 work-over rigs (plus 25 hired), owns and operates more than
25,500 kilometres of pipeline in India, including 4,500 kilometres of sub-sea
pipelines.
Subsidiaries of ONGC are ONGC Videsh Limited (OVL), Hindustan Petroleum
Corporation Limited (HPCL), ONGC Mangalore Petrochemicals Limited, and
ONGC sports. Along with these subsidiaries ONGC is having some joint
ventures also like ONGC Tripura Power Company, ONGC Petro Additions
Limited.

7|Page
 DRILLING RIG
A drilling rig is an integrated system that drills wells, such as oil or water wells,
in the earths subsurface. Drilling rigs can be massive structures housing
equipment used to drill water wells, oil wells, or natural gas extraction wells, or
they can be small enough to be moved manually by one person and such are
called augers. The term "rig" therefore generally refers to the complex
equipment that is used to penetrate the surface of the Earth's crust. Drilling rigs
can sample subsurface mineral deposits, test rock, soil, and groundwater
physical properties, and also can be used to install sub-surface fabrications, such
as underground utilities, instrumentation, tunnels or wells. Drilling rigs can be
mobile equipment mounted on trucks, tracks or trailers, or more permanent land
or marine-based structures (such as oil platforms, commonly called 'offshore oil
rigs' even if they don't contain a drilling rig).
Small to medium-sized drilling rigs are mobile, such as those used in mineral
exploration drilling, blast-hole, water wells and environmental investigations.
Larger rigs are capable of drilling through thousands of metres of the Earth's
crust, using large "mud pumps" to circulate drilling mud (slurry) through the
drill bit and up the casing annulus, for cooling and removing the "cuttings"
while a well is drilled. Hoists in the rig can lift hundreds of tons of pipe. Other
equipment can force acid or sand into reservoirs to facilitate extraction of the oil
or natural gas; and in remote locations there can be permanent living
accommodation and catering for crews (which may be more than a hundred).
Marine rigs may operate thousands of miles distant from the supply base with
infrequent crew rotation or cycle.
In early oil exploration, drilling rigs were semi-permanent in nature and the
derricks were often built on site and left in place after the completion of the
well. In more recent times drilling rigs are expensive custom-built machines that
can be moved from well to well. Some light duty drilling rigs are like a mobile
crane and are more usually used to drill water wells. Larger land rigs must be
broken apart into sections and loads to move to a new place, a process which
can often take weeks.
An automated drill rig is an automated full-sized walking land-based drill rig
that drills long lateral sections in horizontal wells for the oil and gas industry.
ADRs are agile rigs that can move from pad to pad to new well sites faster than
other full-sized drilling rigs.

8|Page
 Classification of Drilling Rigs
There are different types of drilling Rigs available nowadays which allows the
operator to choose the best Rig according to their requirement and conditions.
The classification of Drilling Rigs are as follows --
1. On the basis of power used: -
 Mechanical —This type of rig uses torque converters, clutches, and
transmissions powered by its own engines, often diesel is used.
 Electric — In this type of rigs, the major items of machinery are driven
by electric motors, usually with power generated on-site using internal
combustion engines.
 Hydraulic — This type of rig primarily uses hydraulic power for its
functioning.
 Pneumatic — The rig is primarily powered by pressurized air.
 Steam — This type of rig uses steam-powered engines and pumps.
2. On the basis of pipe used: -
 Cable — A cable is used to raise and drop the drill bit.
 Conventional —In this type, the rig uses metal or plastic drill pipe of
varying types.
 Coil tubing — When rig uses a giant coil of tube and a downhole drilling
motor then it is said to be coil tubing.
3. On the basis of height: -
Rigs are differentiated by height based on how many connected pipes they are
able to stand in the derrick when needing to temporarily remove the drill pipe
from the hole. Typically, this is done when changing a drill bit or when logging
the well.
 Single — It can pull only single drill pipes. The presence or absence of
vertical pipe racking "fingers" varies from rig to rig.
 Double — It can hold a stand of pipe in the derrick consisting of two
connected drill pipes, called a "double stand".
 Triple — It can hold a stand of pipe in the derrick consisting of three
connected drill pipes, called a "triple stand".
 Quadri — It can store stand of pipe in the derrick composed of four
connected drill pipes, called a "quadri stand".

9|Page
4. On the basis of method of rotation or drilling method: -
 No-rotation includes direct push rigs and most service rigs
 Rotary table —The rotation is achieved by turning a square or hexagonal
pipe also called Kelly at drill floor level.
 Top drive — The rotation and circulation is done at the top of the drill
string, on a motor that moves in a track along the derrick.
 Sonic — Primarily vibratory energy are used to advance the drill string
 Hammer — It uses rotation and percussive force.
5.On the basis of the position of derrick: -
 Conventional — derrick is vertical
 Slant — derrick is slanted at a 45-degree angle to facilitate horizontal
drilling
Another classification of types of Rigs are based on their location. They are: -
 Onshore Rigs:
I. Conventional
II. Mobile
 Offshore Rigs:
I. Floating
a) Semi- submersible
b) Drill ship
II. Bottom supported
a) Jack up
b) Fixed Platform

10 | P a g e
 Drilling Rig Equipments

The Equipments in the drilling Rig as shown in the figure are:-

1.Mud Tank 2. Shale Shakers
3.Suction Line 4. Mud Pump

11 | P a g e
5.Power Source 6. Hose
7.Draw-Works 8. Standpipe
9.Kelly Hose 10. Goose-Neck
11.Travelling Block 12. Drill Line
13.Crown Block 14. Derrick
15.Monkey Board 16. Drill Pipe
17.Setback 18. Swivel
19.Kelly Drive 20. Rotary Table
21.Drill Floor 22. Bell Nipple
23.BOP (annular) 24. BOP(pipe ram )
25.Dill String 26. Drill Bit
27.Well-head 28. Flow-line

12 | P a g e
 Drilling Rig Subsystems

There are mainly six subsystems of Drilling Rig. These systems are:
• The Power System
• The Hoisting System
• The Rotary System
• The Circulation System
• The Well Control System (Blowout Prevention System)
• The Air control system

13 | P a g e
 POWER SYSTEM
Drilling rig and their support vessels in the case of barge and floating vessels,
have high power requirements. Some of the equipment requiring power includes
the draw-works, mud pumps, rotary system, and life-support system. The power
loading may be continuous or intermittent. The power system on a drilling rig
usually consists of a prime mover as the source of raw power and some means
to transmit the raw power to the end-use equipment. The prime movers used in
the current drilling industry are diesel engines. Steam boilers are rarely used in
present operations due to the difficulty in transporting the boilers and the fact
that greater widespread knowledge of diesel units exists among crewmen.
Historically, coal was used to generate the power for drilling rigs; however,
modern drilling rigs use other sources of fuel. Typically, modern rigs are now
run using an internal combustion engine with diesel or lease fuel. Diesel oil is a
petroleum-based fuel that is a product of the distillation process. If the rig is
running in a developed field, then the field may have a small on-site refinery
that is used to distil the diesel fuel. If the rig is drilling an exploration, appraisal,
or delineation well, then the fuel will need to be delivered from an external
source and stored on-site.

14 | P a g e
Raw power is transmitted via one of the following systems:
 mechanical drive
 direct current (DC) generator and motor
 alternating current (AC), silicon-controlled rectifier (SCR), direct current
(DC) motor
The most widely used system on new rigs or large marine rigs is the AC-SCR
system. The mechanical horsepower requirements for the prime movers must be
determined from an evaluation of the loads and the overall system efficiency.
Mechanical Drive Systems. Most early drilling rigs used a mechanical drive
system to transmit power from the engines to the operating equipment such as
the draw-works and pumps. The drive system consists of gears, chains, and
belts. The compound device attached to the engine shafts combines the output
of two engines.
Torque converters are attached to the shafts to increase the range of output
rpm's and also to improve engine life by absorbing equipment-induced power
train shock loads. Efficiency drops off at high torques, but the converter has a
useful range of approximately 2:1 multiplication at efficiency factors of 0.75—
0.85. The chief advantage of the converter is the ability to accelerate loads
rapidly and give reasonable constant horsepower output over the most efficient
2: 1 speed range.

15 | P a g e
HOISTING SYSTEM

16 | P a g e
Hoisting System is the system used on a drilling rig to perform all lifting
activities on the rig. These activities basically include the lowering and lifting of
necessary equipment in or out of the hole. 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 major components of a
Hoisting System are derrick, block & tackle system, drawworks and
miscellaneous hoisting equipment like elevators, hooks and weight indicator.
The hoisting system is comprised of :-
 The Crown Block
 The Mast/Derrick
 The Traveling Block
 The Hook
 The Draw-works
 The Drilling Line

17 | P a g e
 CROWN BLOCK
A crown block is the stationary section of a block and tackle that contains a set
of pulleys or sheaves through which the drill line (wire rope) is threaded or
reeved and is opposite and above the traveling block. The combination of the
traveling block, crown block and wire rope drill line gives the ability to lift
weights in the hundreds of thousands of pounds. On larger drilling rigs, when
rising and lowering the derrick, line tensions over a million pounds are not
unusual.
The use of a crown block and traveling block greatly enhances the power of the
oil derrick. The position of the pulleys allows the cables to withstand
tremendous levels of force, and helps workers drill deeper and extract more oil.
Without a crown block, the oil derrick would require much thicker and stronger
cables. It would also require a more powerful and substantial pumping system
to operate successfully. The use of the block and tackle system provides a high
degree of leverage to lift and lower the hoisting drum in order to maximize
productivity and efficiency.

18 | P a g e
 DERRICK

The derrick (or mast) provides the structural support for the hoist system. It
must be capable of supporting the entire load on the system including the
weight of the drill string (accounting for buoyancy effects) and any frictional
forces.
The derrick is a metallic structure which has four supporting legs resting on a
square base. It is erected on a substructure which supports the rig floor and the
rotary table and provides work space on the rig floor.

19 | P a g e
The derrick and its substructure always support the weight of the drillstem. The
drillstem is suspended by the traveling block and drilling line, the entire load
rests on the derrick. Whenever it is suspended from the crown block or resting
in the rotary table. The height of the derrick does not affect its load-capacity,
but it can limit the length of drill pipe sections that can be pulled out of the hole
for many reasons (ex: changing drill bit). This is because the crown block must
be sufficiently elevated above the rig floor.

THE TRAVELLING BLOCK

The traveling block, crown block and drilling line are used to connect the
derrick with the drill string to be lowered into or pulled out of the hole. During
drilling operations, this drill string usually composed of the drill pipe, heavy
weight drill pipe, drilling jar, drill collars and drill bit. The drilling line passes
from the drawworks to the top of the derrick. From there, it is sheaved between
the crown block and traveling block to give an eight, ten or twelve-line

20 | P a g e
suspension. It is then clamped to the rig floor by the deadline anchor. The
drilling line wears evenly as it is used; it has to be Cut-off time to time. The cut-
off procedures are related to ton-miles of service. The ton-mile unit is calculated
as the drill line moves a one-ton load a distance of one mile, and then the line
receives one ton-mile of usage.
Lowering, lifting, and controlling the drill string in deep well bores generally
requires an extraordinarily robust hoist arrangement. These hoists usually
consist of a crown block mounted in a fixed position at the top of the well
derrick and a traveling block at the bottom of the fall of rope. The traveling
block is a multi-sheave device, generally featuring between four and six
individual sheaves. These sheaves are flat disks with a deep groove machined
around their circumference. When grouped together, as they are in the traveling
block, they are collectively referred to as a pulley. The function of the sheaves
is to allow the drill line ropes to pass through the block with minimal friction. In
the case of a traveling block, four or more sheaves are used to spread the
considerable loads carried by the block.

Mechanical advantages provided by Crown Block and Travelling Block:

21 | P a g e
 THE HOOK
Hook is the 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 total force pulling down on the hook includes the weight of the drill string
in air, the drill collars and any auxiliary equipment, reduced by any force that
tends to reduce that weight. Some forces that might reduce the weight include
friction along the wellbore wall and importantly buoyant forces on the drill
string caused by its immersion in drilling fluid

22 | P a g e
 DRAWWORKS
A draw-works is the primary hoisting machinery that is a component of a rotary
drilling rig. Its main function is to provide a means of raising and lowering the
traveling blocks. The draw works is the power control center of the rig. The
principal component of the draw works is a hoisting drum on which the drilling
line is spooled. There is an assembly of a rotating drum, a series of shafts,
clutches, chains and gears for changing speed and for reversing. It also contains
the main brake for stopping the drilling line. The drilling line is wound a
number of times around the drum, the end of the line then passes on the crown
and travelling block.

The wire-rope drilling line winds on the drawworks drum and extends to the
crown block and traveling blocks, allowing the drill string to be moved up and
down as the drum turns. The segment of drilling line from the draw-works to
the crown block is called the "fast line". The drilling line then enters the sheaves
of the crown block and it makes several passes between the crown block and
traveling block pulleys for mechanical advantage. The line then exits the last
sheave on the crown block and is fastened to a derrick leg on the other side of
the rig floor. This section of drilling line is called the "dead line".

23 | P a g e
A modern draw-works consists of five main parts: the drum, the motor(s), the
reduction gear, the brake, and the auxiliary brake. The motors can be AC or
DC-motors, or the draw-works may be connected directly to diesel engines
using metal chain-like belts. The number of gears could be one, two or three
speed combinations. The main brake, usually operated manually by a long
handle, may be friction band brake, a disc brake or a modified clutch. It serves
as a parking brake when no motion is desired. The auxiliary brake is connected
to the drum, and absorbs the energy released as heavy loads are lowered. This
brake may use eddy current rotors or water-turbine-like apparatus to convert the
kinetic energy of the moving load to heat and dissipate it.
Drawworks comprised of the following:
1. Prime Mover: The power source or prime mover consists of one to four
or more diesel engines producing up to several thousand horsepower. Usually,
the diesel engines are connected to electric generators. The generated electrical
power is then sent to AC or DC motors that operate the draw-works. An
advantage of an AC driven draw-works is the internal braking capability of the
AC motor. DC motors are limited to roughly 1200 rpm and require shifting
transmissions to achieve the correct speed for different conditions.
2. Transmission system: A gearbox transfers energy from the motor(s) to
the winch or spool. Larger rigs may have more gears in the draw-works
transmissions. Torque converters used in draw-works are intended to absorb
shocks in the system and to multiply the input torque. Torque converters are
used in conjunction with internal combustion prime movers when these engines
are used directly to drive the draw-works.
3. Pneumatic system: The recommended air pressure for proper clutch
engagement is 120 to 150 psi. Pressure regulating valves should be regularly
serviced to regulate the pressure to avoid Clutch slippage in case of low
pressure as well as Clutch damage in case of higher pressure. All the air valves
including the Inter lock valves, pilot valves, Quick release Valves must be
checked and serviced at regular intervals to prevent accidental dual clutch
engagement, less air to clutch /more time lag in engagement and delayed
disengagement respectively.
4. Brake system: Brakes control the speed of the drill line while it is being
reeled out or lowered. They also stop and hold the line. The braking system is in
constant use during a round trip up and down the bore. The main brake of a
draw-works is a mechanical friction brake. Since using friction brakes for

24 | P a g e
extended periods will create excessive heat, an auxiliary brake is often used to
slow and control movement allowing the mechanical brake to stop and hold.
5. Cooling system: Brake cooling water of OEM recommended quality
which is approximately 85 GPM at 50-75 psi should be ensured to minimize
scaling in the water pathway inside the Draw works. Scaling affect heat
dissipation leading to malfunctioning of Mechanical Brake.
6. Lubrication System: Lube oil level should be checked daily. Proper
chain lubrication should be ensured through regular checks to avoid Galling, or
friction wear. It is caused by improper lubrication that allows metal to rub off
between the chain pin and the bushing. It generally occurs in low-speed chain
because of poor lubrication, but it can occur in high-speed chains too with the
best lubrication methods in use.

25 | P a g e
 ROTATING SYSTEM
The rotary system includes all of the equipment used to achieve bit rotation. It
causes the drill bit to rotate at the bottom of wellbore. The working principle of
rotation system is the Kelly, which is connected to the drill pipe drove by the
rotary table and then the whole drilling string can be rotated for drilling. Wells
are drilled by the pipe & bit rotation; therefore it is very important to have an
efficient rotation system.

26 | P a g e
The Rotary system consists of:
 Swivel
 Rotary Table
 Rat hole
 Kelly
 Rotary Hose
 Kelly Bushing
 Drill String
 Master Bushing
 Drill Bit
 Independent rotary device
 Mouse hole

SWIVEL
A Swivel is a mechanical device used on a drilling rig that hangs directly under
the traveling block and directly above the kelly drive, that provides the ability
for the Kelly (and subsequently the drill string) to rotate while allowing the
traveling block to remain in a stationary rotational position (yet allow vertical
movement up and down the derrick) while simultaneously allowing the
introduction of drilling fluid into the drill string. It is designed to allow rotation
of the drill string beneath it conveying high volumes of high-pressure drilling
mud between the rig's circulation system and the drill string.

27 | P a g e
The function of the swivel is to:
• Hold the weight of the drill string on the hoisting system,
• Allow rotation of the drill string below it,
• Allow passage of the drilling fluid from the circulation system to the drill
string, bottom hole assembly, and drill bit of the rotary system

ROTARY TABLE
A rotary table is a mechanical device on a drilling rig that provides rotational
force to the drill string to facilitate the process of drilling a borehole. Rotary
speed is the number of times the rotary table makes one full revolution in one
minute. The rotary table is also called a turntable. Most rotary tables are chain
driven. These chains resemble very large bicycle chains. The chains require
constant oiling to prevent burning and seizing.

28 | P a g e
Virtually all rotary tables are equipped with a rotary lock'. Engaging the lock
can either prevent the rotary from turning in one particular direction, or from
turning at all. This is commonly used by crews in lieu of using a second pair of
tongs to makeup or break out pipes. The rotary bushings are located at the
center of the rotary table. These can generally be removed in two separate
pieces to facilitate large items, i.e. drill bits, to pass through the rotary table.
The large gap in the center of the rotary bushings is referred to as the "bowl"
due to its appearance. The bowl is where the slips are set to hold up the drill
string during connections and pipe trips as well as the point the drill string
passes through the floor into the wellbore.

29 | P a g e
 Fig. Rotary Table of a drilling rig

KELLY SPINNER
Kelly Spinner is a mechanical device used for rotating the Kelly. It is typically
pneumatic. It is a relatively low torque device, useful only for the initial makeup
of threaded tool joints. It is not strong enough for proper torque of the tool joint
or for rotating the drill string itself. The Kelly spinner has largely replaced the
infamous spinning chains, which were responsible for numerous injuries on the
rig floor. A Kelly spinner is a well-known tool for making up a joint of drill
pipe by application of a fixed amount of torque.

30 | P a g e
Use of a Kelly spinner can significantly reduce the time required for the joint
makeup operation and the potential of spark formation and lost fingers in
comparison to spinning chains previously employed. Kelly spinners typically
comprise a geared mandrel having suitable pipe connections at each end. The
mandrel is installed in the string between a derrick swivel and a Kelly joint. A
motor then turns the mandrel which in turn spins the Kelly joint to make up a
new joint on the Kelly opposite end. In some circumstances, it is not desirable
to insert the spinner mandrel in the drill string due to space limitations. In such
instances, the spinner mandrel can be removed and the ring gear of the spinner
is attached directly to a swivel stem.
A Kelly spinner, comprises of:
 An adjustable sleeve concentric with the central opening receiving a stem
of a derrick swivel, the sleeve having an outer diameter surface with axial
stops affixed thereto.

31 | P a g e
  A clamp disposed adjacent the sleeve outer diameter surface in abutment
with the axial stops, the clamp including a hub member and an associated
flange member for locking the sleeve to the swivel stem;
 A generally cylindrical locking ring assembly disposed in an annular slot
formed between the outer diameter surface of the sleeve, the flange
member and the hub member, the ring assembly including dual axially-
split ring members having complementary axially angled surfaces;
 A ring gear attached to the clamp;
 A drive gear mounted in rotational engagement with the ring gear;
 A generally cylindrical housing having a central opening

INDEPENDENT ROTARY DRIVE

The independent rotary drive system consists of a drive to the rotary table by an
independent motor through a single speed transmission. By installing the
system, the drive to the rotary table from the draw works is eliminated. An
emergency sprocket provided on the system gives a provision to use Draw
works drive in case of emergencies for a temporary failure or a required service
of the motor. This drive from the draw works is for emergency only, hence drip
type lubrication for the chain is provided.

PIPE SPINNER
32 | P a g e
Pipe spinner used to rotate a drill pipe during connection thereof to a drill string
or during division of the drill string into individual pipes, the aim has been to
reduce the time and damage on the threaded connections (the pin-and-box
joints) in the screwing/unscrewing operations.

The spinner comprises a pair of hydraulically actuated gripping jaws each

provided with a power-driven, endless silent chain for spinning a drill pipe
section into or out of threaded engagement with a drill string and a hydraulic
system for operating the same. The spinner is operatively connected to a pair of
conventional pipe tongs having a lever arm and articulated jaws connected
thereto. The tong jaws have an open position for receiving the drill pipe section,
a latch position in which the jaws engage in non-gripping relation about the pipe
and a pipe gripping position in which the jaws grippingly engage the pipe. A
hydraulic ram is mechanically connected between the spinner and tongs and in
hydraulic circuit with the spinning chain drive to effect automatic shifting of the
tongs jaws from the latched position to the pipe gripping position.

DRILL BITS
33 | P a g e
The drill bit is an important component in the drill string. The bit drills the rock
in many mechanisms. The drilling bit is selected according to the formation to
be drilled. The bit performance is related to several operating parameters like
weight on bit, revolution per minute, mud properties and hydraulic efficiency.
When the bit is pulled out of the hole, the level of damage on the bit must be
carefully recorded. The system followed to evaluate the bit is called the IADC
dull grading system which is designed to facilitate the damage grading. An
accurate grading can contribute effectively in bit selection in future operations.
There are two main types of drilling bits:
i. Roller cone bits
ii. Fixed cutter bits
1.Roller cone bits
They are also called tri-cone bits. The cutting structures are mounted on three
rolling cones and all these cones are attached to main bit body. There are two
main types of tri-cone bits:
a) Mill tooth bits
These types of bits have steel teeth which are milled on the cones. The size and
shape of teeth vary according to the formation to be drilled. In soft formation,
the teeth are long and slender, where in hard formation the teeth are short and
broad.

Mill Tooth Bits

b) Insert bits

34 | P a g e
In these types of bits, the teeth are not milled into the cones, instead of that,
tungsten carbide inserts are pressed into the cones. These technics make the bits
much harder and can last longer when drilling through hard formation. The size
and shape of teeth also depend on the formation to be drilled, the teeth can be
long and chisel shapes in soft formation, and for hard formation can be short
and round shapes.

Insert bits

2.Fixed cutter bits

Fixed cutter bit has no moving parts; the cutting structures and bit body rotate as
one part. The main types of these bits are: PDC (polycrystalline diamond
compact), TSP (thermally stable PDC) and diamond bits.
a) TSP Drilling Bits
It was noticed that the bonding materials are the weakest part of the cutter.
Under the high temperature at the bottom while drilling, the bonding materials
lose their strength. The TSP bits are composed with same artificial diamond
without using the bonding materials.

35 | P a g e
 TSP Drilling Bits
b) The PDC Drilling Bits
This type of bits can be used for different formations from soft to hard. The
PDC bit has cutters which consist of a layer of artificial diamond
(polycrystalline diamond). Using a high pressure, high temperature technique
the polycrystalline diamond is bonded on layer of cementer tungsten carbide.
The cutter is self-sharpening because the sharp crystals are exposed
continuously as each layer wears or disappears.

PDC drill bit

36 | P a g e
The polycrystalline diamond is bonded to studs of tungsten carbide, which are
then pressed into holes on the head of the bit. The cutters are placed in a helical
pattern on the face of the bit. This combination results to a cutter which has
wear resistance and hardness of diamond, and also impact resistance and
strength of tungsten carbide. The bit body is forged with same high steel used to
make the cones of the tri-cone bits, and in order to reinforce the bit against fluid
erosion, the face of the bit is coated by a layer of tungsten carbide.
PDC bit design:
The PDC bit has an important advantage if it is compared with the tri-cone bit;
it has no moving parts like bearings or cones which they have to be fished in
case of failure.
The PDC bit shears the formation rather than crushing or gauging the formation
as do the tri-cone bit. The PDC bit has longer life and extended gauge with
tungsten carbide wears pads which help to maintain gauge. The concave shape
of bit's face permits the cutters to drill the rock simultaneously, and also
increasing bit stabilization and decreasing the potential for deviation.
The cleaning action of the bottom of the hole and the cutters are performed by
the jet nozzles which vary in number and size. They are located in such manner
to increase the quality of cleaning.
Diamond Drilling Bits:
The natural diamond bits are used to drill through very hard abrasive formation.
This type of bits was developed from mining industry. The main advantages of
this type of bits are their longevity, reduced number of run bits and tripping
time to get to the next casing point.

Natural diamond Drilling Bits

There are also some drawbacks of using a natural diamond bits. The slow rate
of penetration is one of the main down sides of using this kind of bits. The

37 | P a g e
diamonds are set into a steel body; roughly two thirds of the cutter length is
embedded into the bit head which can cause easy balled bits in soft formation,
for this reason the natural diamonds bits are used for hard, abrasive formations.
The natural diamond bits require relatively high RPM and moderate WOB.
High hydraulic horsepower is not a major requirement, so the jet nozzles are not
used. The drilling fluids flow through orifices then by flow channels cut into the
bit head to promote cutter cooling and cleaning.

38 | P a g e
 CIRCULATING SYSTEM
The circulation system on the rig is the system that allows for circulation of the
Drilling Fluid or Mud down through the hollow drill string and up through the
annular space between the drill string and wellbore. It is a continuous system of
pumps, distribution lines, storage tanks, storage pits, and cleansing units that
allow the drilling fluid to fulfil its primary objectives.
Drilling fluid is mixed in the mud pits and pumped by the mud pumps through
the swivel, through the blow out preventer (not part of the circulation system)
down the hollow drill pipe, through holes (Jet Nozzles) in the bit, up the annular
space between drill pipe and wellbore (where it lifts the rock cuttings), to the
surface, through the Solids Control Equipment (Shale Shaker, Desander, and
Desilter), and back to the mud pits.

From the mud pumps, the drilling fluid goes to the swivel, through the blow out
preventer, and down the hollow drill string and bottom-hole assembly. The
drilling fluid then goes through jet nozzles in the drill bit; at which point, it
begins its return to the surface. The drilling fluid travels up the annular space

39 | P a g e
between the drill pipe and the wellbore, picking up and carrying the drill
cuttings up the hole.

Once the drilling fluid reaches the surface, it goes through the mud return line to
the gas-mud separator and the solids control equipment. The shale shaker is
where the large cuttings from the returning drilling fluid are removed. The shale
shaker is a set of vibrating mesh screens that allow the mud to pass through
while filtering out cuttings of different size at screen screen mesh sizes. A Mud
logger or a Well-Site Geologist may be stationed at the shale shaker to analyse
the cuttings to determine the lithology of the rock and the depth within the
Stratigraphic Column at which the well is currently being drilled.
The drilling fluid then passes through the Desander and Desilter. These are
hydrocyclones which use centrifugal forces to separate the smaller solids from
the drilling fluid. The drilling fluid is then sent through a degasser to remove
any gas bubbles that have been picked up during the circulation. These gasses
may include natural gas from the subsurface or air acquired during the solids
control. Typically, the degasser is a piece of equipment that subjects the drilling

40 | P a g e
fluid to slight vacuum to cause the gas to expand for extraction. The drilling
fluid is then returned to the mud pit to start the circulation process over again.
The circulation system is comprised of:
• The Mud Pumps
• The Rotary Hose
• The Mud Return Line
• The Shale Shaker
• The Choke Manifold
• The Mud Gas Separator
• The Degasser
• The Reserve Pit
• The Mud Pits
• The Desander
• The Desilter
• The Mud Discharge Line
• The Bulk Mud Components Storage
• The Mud House
• The Water Tank

41 | P a g e
 MUD PUMP
A mud pump is a large pump used to move heavy drilling fluid, known as mud,
within a hole when drilling for oil. The pump circulates the mud by pushing it
down into the hole and then moving it back up again. Mud pumps are
reciprocating pumps, meaning that they use oscillating pistons or plungers to
displace the fluid.

A mud pump is a single acting pump, so the fluid will move in only one
direction. A hole, or well, is drilled into the ground, and the mud is pushed by
the mud pump down piping to the bottom of the hole. The pressure then forces
the mud up the annulus, or the space that surrounds the piping. Used drilling
fluid is pumped back up to the surface, where it is cleaned and purified using
special machines such as the shale shaker.
The "mud" used in drilling for oil consists of emulsified water or oil, clay and
chemicals. For safety reasons, it is tailor-made to the particular chemical
conditions of the drilling. Its purpose is to float rock cuttings out of the hole,
clean the bottom of the hole and cool the drilling equipment. It also acts as the
initial barrier in case of a blowout by resisting the pressure from any fluid
within the rock that might enter the well.
Most modern mud pumps are triplex-style pumps, which have three cylinders.
Older oil rigs, or those in developing countries, might still use duplex pumps
that have only two cylinders. Some newer pumps have as many as six cylinders.

42 | P a g e
A mud pump is a crucial piece of machinery in the process of drilling for oil.
On a drilling rig, the process of drilling begins by using a rotating drill to bore a
hole in the ground. After a hole has been drilled, a pipe is inserted into the well
in order to ensure that it maintains its shape and structure. Within that casing, a
smaller drill bit is used to drill deeper, and another pipe, known as casing, is
placed in that hole. It is common for up to five holes, each slightly smaller than
the next, to be bored when drilling for oil.
As the drill cuts the rock, the mud pump moves those cuttings up the well. The
rock cuttings are put through a "shaker" that removes them from the mud. The
mud is then reused by the mud pump. This process continues until the well is
drilled to its full depth.

The normal mud pump consists of two main sub-assemblies, the fluid end and
the power end. The fluid end produces the pumping process with valves,
pistons, and liners. Because these components are high-wear items, modern
pumps are designed to allow quick replacements of these parts.
To reduce severe vibration caused by the pumping process, these pumps
incorporate both a suction and discharge pulsation dampener. These are
connected to the inlet and outlet of the fluid end.
The Power end converts the rotation of the drive shaft to the reciprocating
motion of the pistons. In most cases a crosshead crank gear is used for this.
A mud pump is composed of many parts including mud pump liner, mud pump
piston, modules, hydraulic seat pullers, suction valve and discharge valve with
their seats, pulsation dampeners.
There are two main parameters to measure the performance of a mud pump:
Displacement and Pressure. Displacement is calculated as discharged litres per
43 | P a g e
minute, it is related with the drilling hole diameter and the return speed of
drilling fluid from the bottom of the hole, i.e. the larger the diameter of drilling
hole, the larger the desired displacement. The pressure size of the pump depends
on the depth of the drilling hole, the resistance of drilling fluid through the
channel, as well as the nature of the conveying drilling fluid. The deeper the
drilling hole and the greater the pipeline resistance, the higher the pressure
needed.
Single-acting pumps usually operate at a volumetric efficiency of about 95
percent. If fluid is supplied under positive pressure by supercharging pumps, the
efficiency of a single-acting pump may reach 98 percent. The volumetric output
of a double-acting pump is usually about 90 percent.
The volumetric efficiency of a pump is not a constant. It can be affected by
discharge pressure, pump operating speed, suction line design, fluid aeration,
and mechanical wear. High discharge pressures promote leakage and
compression of the fluid, thereby reducing volumetric efficiency. High piston
speeds, combined with poorly designed suction lines, can cause knocking when
fluid cannot enter the pump fast enough to maintain a full cylinder. Knocking
causes very rapid mechanical wear. The efficiency of suction lines can be
greatly reduced by solids accumulation. Solids accumulation is sometimes
indicated by a temperature difference between the top and bottom of the suction
line. Suction lines should be as large, short, and straight as possible. Aeration of
the drilling fluid causes an increase in compressibility, with a corresponding
drop in volumetric efficiency. This can sometimes be seen as a decrease in
pump pressure combined with a slight increase in pump rate.
A drop in pump efficiency which is not attributable to the above causes may be
the result of leakage past worn valves or seals, indicating that maintenance is
required. The bulk rate of fluid flow is equal to the volumetric output of the
pump.
Pulsation in Mud Pumps
Pulsations and/or pressure surges are caused by the action of the reciprocating
pistons in the mud pumps. In single-acting triplex pumps, each forward stroke
of the piston displaces a certain amount of the fluid into the discharge cross
based on the pump’s filling efficiency (suction condition). This drilling mud
surges through the discharge valve under high pressure (discharge condition),
creating over shoot pressures (energy/ wave) as a result of instantaneous
changes in flow velocity caused by both fluid compression and valve opening
delays. This pulsation energy (wave) travels at the speed of sound through the

44 | P a g e
fluid mud until it first reaches the conventional gas charged dampener placed on
the pump cross.
The role of pulsation dampeners is to absorb the mud pump’s pressure surges
(changes in flow velocity), creating a steady-state (non-surging) flow of mud
under more-or-less constant pressure, which lessens wear on the hose (and other
mud system components).

45 | P a g e
 SHALE SHAKER
Shale shakers are considered by most of the drilling industry to be the most
important device in the solid control system as the performance of the
successive equipment directly relates to the cleanliness of the treated drilling
fluid.

Shale shakers are the primary solids separation tool on a rig. After returning to
the surface of the well the used drilling fluid flows directly to the shale shakers
where it begins to be processed. Once processed by the shale shakers the
drilling fluid is deposited into the mud tanks where other solid control
equipment begins to remove the finer solids from it. The solids removed by the
shale shaker are discharged out of the discharge port into a separate holding
tank where they await further treatment or disposal.
46 | P a g e
Shale Shakers consists of the following parts:
1. Hopper
2. Feeder
3. Screen Basket
4. Basket Angling Mechanism
5. Vibrator
1. Hopper: The Hopper, commonly called the "base" serves as both a platform
for the shaker and collection pan for the fluid processed by the shaker screens,
also known as "underflow". The hopper can be ordered according to the needs
of the drilling fluid, aka "mud" system. It can come in different depths to
accommodate larger quantities of drilling fluid as well as have different ports
for returning the underflow to the mud system.
2. Feeder: The Feeder is essentially a collection pan for the drilling fluid before
it is processed by the shaker, it can come in many different shapes and sizes to
accommodate the needs of the mud system. The most commonly used feeder is
known as the weir feeder, the drilling fluid enters the feeder usually through a
pipe welded to the outside wall near the bottom of the feeder tank, it fills the
feeder to a predetermined point and like water flowing over a dam the mud
(drilling fluid) spills over the weir and onto the screening area of the shaker.
This method of feeding the shaker is most widely used due to its ability to
evenly distribute the mud along the entire width of the shaker allowing for
maximum use of the shaker's screening deck area.
3. Screen Basket: Also known as the screen "bed" it is the most important part
of the machine, it is responsible for transferring the shaking intensity of the
machine, measured in "G's", while keeping the "shaking" motion even
throughout the entire basket. It must do all that while holding the screens
securely in place, eliminating drilled solids bypass to the hopper and allowing
for easy operation and maintenance of the machine. Different brands of shakers
have different methods of fulfilling these demands by using specialized screen
tensioning apparatus, rubber seals around the screens, basket reinforcement to
limit flex, rubber Float Mounts rather than springs, rubber Deck seals and
selective vibrator placement
4. Basket Angling Mechanism: The shaker basket must be capable of changing
its angle to accommodate various flow rates of drilling fluids and to maximize

47 | P a g e
the use of the shaker bed; this is where the angling mechanism plays an
important part. The drilling fluid flowing over the shaker bed is designated into
two categories:
Pool: The area of the screening deck that consists mostly of drilling fluid with
drilled cuttings suspended within it.
Beach: Is the area where the fluid has been mostly removed from the cuttings
and they begin to look like a pile of solids.
As a rule of thumb the Beach and pool are maintained at a ratio of 80% pool
and 20% beach, this of course can change depending on the requirements of
cutting dryness and flow rates.
There are various angling mechanisms currently in use which vary from
hydraulic to pneumatic and mechanical, they can be controlled from either one
side of the shaker or must be adjusted individually per side. Mechanical angling
mechanisms can be very dependable often requiring less maintenance but
usually take more time to operate than their hydraulic or pneumatic counterparts
whereas the hydraulic/pneumatic angling mechanisms are much faster to
operate and require less a physical means of operation.
5. Vibrator: This is the device which applies the vibratory force and motion
type to the shaker bed. A vibrator is a specialized motor built for the purpose of
vibrating, while containing an electric motor to provide the rotary motion it uses
a set of eccentric weights to provide an omnidirectional force. To produce the
proper linear motion a second, counter rotating, vibrator is added in parallel to
the first. This is what gives us the linear motion, "high G" shaking of the basket.

48 | P a g e
 DESANDER
Desander is a hydrocyclone device that removes the large drill solids from the
whole mud system. The desander should be located downstream of the shale
shakers and degasers, but before the desilters or mud cleaners. A volume of
mud is pumped into the wide upper section of the hydrocyclone at an angle
roghly tangent to its circumference. As the mud flows around and gradually
down the inside of the cone shape, solids are separated from the liquid by
centrifugal forces. The solids continue around and down until they exit the
bottom of the hydrocyclone and are discarded. The cleaner and lighter density
liquid mud travels up through a vortex in the centre of the hydrocyclone, exits
through the piping at the top of the hydrocyclone and is then routed to the mud
tanks and the next mud- cleaning device, usually a desilter.

49 | P a g e
 DESILTER
A Desilter is a hydroclone that is used to remove sand particles which have a
grain size of 20 microns or less. Hydroclones operate on the basis of centrifugal
force such that the mud with smaller particles is returned to the active system
while the larger particles are discarded. The usual size of a desilter is 6 inches
and above, however, the most common size is 10 inches.
A hydrocyclone much like a desander except that it’s design incorporates a
greater number of smaller cones. As with the desander, it’s purpose is to remove
unwanted solids from the mud system. The smaller cones allow the desilter to
efficiently remove smaller diameter drill solids than a desander does. For that
reason the desilter is located downstream from the desander in the surface mud
system.

Fig. Desilter

50 | P a g e
 MUD AGITATOR
A Mud Agitator is used in surface mud systems to suspend solids and maintain
homogeneous mixture throughout the system. A mechanical agitator is driven
by an explosion-proof motor, coupled to a gear box that drives the impeller
shaft. The impellers (turbines) transform mechanical power into fluid
circulation or agitation. The objective is to obtain a uniform suspension of all
solids.
Drilling mud agitator is a device mounted on mud tank for agitating the drilling
mud to prevent the drilled cuttings and fine solids from sedimentation. Nearly
every large compartment of mud mixing and storage tank should be equipped
with mud agitators to maintain the proper properties of drilling mud that will
pump back to the borehole.
Types of agitator impellers:
• Radial Flow Impeller: A radial flow created by the impellers wherein the
circulation is predominantly horizontal.
• Axial Flow Impeller: An axial flow created by the impellers wherein the
circulation is predominantly axial fluid movement.

51 | P a g e
 Fig. Mud Agitator

Mud agitators are used are used for the purpose of prevention of weighting
material from dropping out of suspension during the slow travel of mud through
the pits. To breakup gel strength mud and to reduce the apparent viscosity of
mud and permit gas bubbles to escape in miner gas cutting. Also to promote
good mixing of mud when a jet hopper is used to add weighting material or clay
to the system.

DEGASSER
A degasser is a device used in drilling to remove gasses from drilling fluid
which could otherwise form bubbles. For a small amount of entrained gas in a
drilling fluid, the degasser can play a major role of removing small bubbles that
a liquid film has enveloped and entrapped. In order for it to be released and
break out the air and gas such as methane, H2S and CO2 from the mud to the
surface, the drilling fluid must pass through a degassing technique, and it can be
accomplished by the equipment called a degasser, which is also a major part of
mud systems.

52 | P a g e
Types of Degasser:
1. Vacuum Tank Degasser:- Vacuum Type is the most common form of
degasser. It can be horizontal, vertical or round vessel. A vacuum action
is created to pull in the gas cut mud. When the liquid enters the tank it
will flow and be distributed to a layer of internal baffle plates designed
for the mud to flow in thin laminar film and is exposed to a vacuum that
forces the gas to escape and break out of the mud. The vacuum pump
moves the escaping gas from the vessel discharging it to the rig's flare or
environmental control system.

2. Atmospheric Degasser:- This type of degasser processes mud by

accelerating fluid through a submerged pump impeller and impinging the
fluid on a stationary baffles to maximize surface and thus enable escaping
gas vent to atmosphere.

DRILLING FLUIDS
53 | P a g e
Drilling fluid, also called drilling mud, is used to aid the drilling of boreholes
into the earth. Often used while drilling oil and natural gas wells and on
exploration drilling rigs, drilling fluids are also used for much simpler
boreholes, such as water wells. One of the functions of drilling mud is to carry
cuttings out of the hole.

The three main categories of drilling fluids are:

1. Water-based muds : which can be dispersed and non-dispersed;
2. Non-aqueous muds: usually called oil-based muds (OBs); and
3. Gaseous drilling fluid: In which a wide range of gases can be used. Along
with their formatives, these are used along with appropriate polymer and
clay additives for drilling various oil and gas formations.
The main functions of drilling fluids include providing hydrostatic pressure to
prevent formation fluids from entering into the well bore, keeping the drill bit
cool and clean during drilling, carrying out drill cuttings, and suspending the
drill cuttings while drilling is paused and when the drilling assembly is brought
in and out of the hole. The drilling fluid used for a particular job is selected to
avoid formation damage and to limit corrosion.
On a drilling rig, mud is pumped from the mud pits through the drill string,
where it sprays out of nozzles on the drill bit, thus cleaning and cooling the drill
bit in the process. The mud then carries the crushed or cut rock ("cuttings") up
the annular space ("annulus") between the drill string and the sides of the hole
being drilled, up through the surface casing, where it emerges back at the
surface. Cuttings are then filtered out with either a shale shaker or the newer

54 | P a g e
shale conveyor technology, and the mud returns to the mud pits. The mud pits
let the drilled "fines" settle; the pits are also where the fluid is treated by adding
chemicals and other substances.
The returning mud can contain natural gases or other flammable materials
which will collect in and around the shale shaker / conveyor area or in other
work areas. Because of the risk of a fire or an explosion if they ignite, special
monitoring sensors and explosion-proof certified equipment is commonly
installed, and workers are trained in safety precautions. The mud is then
pumped back down the hole and further re-circulated. After testing, the mud is
treated periodically in the mud pits to ensure there are the desired properties that
optimize and improve drilling efficiency, borehole stability, and other
requirements, as listed below.
Some other functions of drilling fluids are:-
 Suspend and release cuttings
 Remove cuttings from well
 Control formation pressures
 Seal permeable formations
 Maintain wellbore stability
 Minimizing formation damage
 Cool, lubricate, and support the bit and drilling assembly
 Transmit hydraulic energy to tools and bit
 Control corrosion (in acceptable level)
 Ensure adequate formation evaluation
 Facilitate cementing and completion
 Minimize impact on environment
Water-based drilling mud most commonly consists of bentonite clay (gel) with
additives such as barium sulfate (barite), calcium carbonate (chalk) or hematite.
Various thickeners are used to influence the viscosity of the fluid, e.g. xanthan
gum, guar gum, glycol, carboxymethylcellulose, polyanionic cellulose (PAC),
or starch. In turn, deflocculants are used to reduce viscosity of clay-based muds;
anionic polyelectrolytes (e.g. acrylates, polyphosphates, lignosulfonates (Lig) or
tannic acid derivates such as Quebracho) are frequently used. Red mud was the
name for a Quebracho-based mixture, named after the color of the red tannic
acid salts; it was commonly used in the 1940s to 1950s, then was made obsolete
when lignosulfonates became available. Other components are added to provide
various specific functional characteristics as listed above.

55 | P a g e
Some other common additives include lubricants, shale inhibitors, fluid loss
additives (to control loss of drilling fluids into permeable formations). A
weighting agent such as barite is added to increase the overall density of the
drilling fluid so that sufficient bottom hole pressure can be maintained thereby
preventing an unwanted (and often dangerous) influx of formation fluids. Also,
use of silica and clay nanoparticles for high pressure high temperature (HPHT)
invert emulsion based muds, and observed their positive effect on the rheology
of the drilling mud.

AIR CONTROL SYSTEMS

The Air Control system manages the compressor and variable speed fan
controls to maintain a constant pressure and temperature on the system with a
simple interface. This automated Compressor control system matches the
volume of air created to the volume being consumed by modulating the
positioning of the inlet control valve. The valve position is controlled by an
attached cylinder. The compressor sump pressure indicates whether the
compressor needs to make more or less air to match the consumption. The
control system is capable of artificially lowering the pressure below system
demand, or lowering the volume below potential with operator overrides.
The compressor control system monitors engine load and reduces the
compressor volume as necessary to prevent the engine from shutting down due
to being overloaded.
Some of the components of air control system are:
• Supercharger
• Compressor

56 | P a g e
 COMPRESSOR
A compressor is a mechanical device that increases the pressure of a gas by
reducing its volume. An air compressor is a specific type of gas compressor.
Compressors are similar to pumps: both increase the pressure on a fluid and
both can transport the fluid through a pipe. As gases are compressible, the
compressor also reduces the volume of a gas. Liquids are relatively
incompressible; while some can be compressed, the main action of a pump is to
pressurize and transport liquids.
Many compressors can be staged, that is, the fluid is compressed several times
in steps or stages, to increase discharge pressure. Often, the second stage is
physically smaller than the primary stage, to accommodate the already
compressed gas without reducing its pressure. Each stage further compresses
the gas and increases its pressure and also temperature.

57 | P a g e
A positive displacement compressor is the system which compresses the air by
the displacement of a mechanical linkage reducing the volume (since the
reduction in volume due to a piston in thermodynamics is considered as positive
displacement of the piston).
Put another way, a positive displacement compressor is one which operates by
drawing in a discrete volume of gas from its inlet then forcing that gas to exit
via the compressor's outlet. The increase in the pressure of the gas is due, at
least in part, to the compressor pumping it at a mass flow rate which cannot pass
through the outlet at the lower pressure and density of the inlet.

Reciprocating compressors use pistons driven by a crankshaft. They can be

either stationary or portable, can be single or multi-staged, and can be driven by
electric motors or internal combustion engines. Small reciprocating compressors
from 5 to 30 horsepower (hp) are commonly seen in automotive applications
and are typically for intermittent duty. Larger reciprocating compressors well
over 1,000 hp (750 kW) are commonly found in large industrial and petroleum
applications.

58 | P a g e
Rotary vane compressors consist of a rotor with a number of blades inserted in
radial slots in the rotor. The rotor is mounted offset in a larger housing that is
either circular or a more complex shape. As the rotor turns, blades slide in and
out of the slots keeping contact with the outer wall of the housing.[1] Thus, a
series of increasing and decreasing volumes is created by the rotating blades.
Rotary Vane compressors are, with piston compressors one of the oldest of
compressor technologies.

SUPERCHARGER
A supercharger is an air compressor that increases the pressure or density of air
supplied to an internal combustion engine. This gives each intake cycle of the
engine more oxygen, letting it burn more fuel and do more work, thus
increasing the power output. Power for the supercharger can be provided
mechanically by means of a belt, shaft, or chain connected to the engine's
crankshaft. Common usage restricts the term supercharger to mechanically
driven units; when power is instead provided by a turbine powered by exhaust
gas, a supercharger is known as a turbocharger or just a turbo - or in the past a
turbosupercharger.

59 | P a g e
There are two main types of superchargers defined according to the method of
gas transfer: positive displacement and dynamic compressors. Positive
displacement blowers and compressors deliver an almost constant level of
pressure increase at all engine speeds (RPM). Dynamic compressors do not
deliver pressure at low speeds; above a threshold, speed pressure increases
exponentially.
Centrifugal supercharging pumps increase suction line pressure. The increased
pressure produces higher pump volumetric output and allows higher-speed
operation, smoother discharge pressure, and other advantages.

WELL CONTROL SYSTEM

(BLOWOUT PREVENTION SYSTEM)
The Well Control System or the Blowout Prevention System on a drilling rig is
the system that prevents the uncontrolled, catastrophic release of high-pressure
fluids (oil, gas, or salt water) from subsurface formations. These uncontrolled
releases of formation fluids are referred to as Blowouts. Due to the explosive
nature of oil and gas, any spark on the surface can result in the ignition of the
fluids and an explosion on the rig.

60 | P a g e
The blowout preventers are the principal piece of equipment in the well control
system and are operated hydraulically; pressurized fluids are used to operate
pistons and cylinders to open or close the valves on the BOP. The Accumulators
are used to store pressurized, non-explosive gas and pressurized hydraulic fluid
to run the hydraulics systems on the rig. The accumulators store enough
compressed energy to operate the blowout preventers even if the Power System
of the rig is not operating.
The well control system is comprised of:
• The Accumulator
• The Blowout Preventer

ACCUMULATOR
An accumulator or Koomey unit is a unit used to hydraulically operate Rams
BOP, Annular BOP, HCR and some hydraulic equipment. There are several of
high pressure cylinders that store gas (in bladders) and hydraulic fluid or water
under pressure for hydraulic activated systems. The primary purpose of this unit
is to supply hydraulic power to the BOP stack in order to close/open BOP stack
for both normal operational and emergency situation. Stored hydraulic in the
system can provide hydraulic power to close BOP’s in well control operation,
therefore, kick volume will be minimized. The accumulator should have

61 | P a g e
sufficient volume to close/open all preventers and accumulator pressure must be
maintained all time.

There are 4 main components of the Koomey unit as follows:

• Accumulators
• Pumping system
• Manifold system
• Reservoir tank

BLOWOUT PREVENTER
A blowout preventer (BOP) is a specialized valve or similar mechanical device,
used to seal, control and monitor oil and gas wells to prevent blowouts, the
uncontrolled release of crude oil or natural gas from a well. They are usually
installed in stacks of other valves.
62 | P a g e
Blowout preventers were developed to cope with extreme erratic pressures and
uncontrolled flow (formation kick) emanating from a well reservoir during
drilling. In addition to controlling the down hole (occurring in the drilled hole)
pressure and the flow of oil and gas, blowout preventers are intended to prevent
tubing (e.g. drill pipe and well casing), tools and drilling fluid from being blown
out of the wellbore (also known as bore hole, the hole leading to the reservoir)
when a blowout threatens.
The primary functions of a blowout preventer system are to:
 Confine well fluid to the wellbore.
 Provide means to add fluid to the wellbore.
 Allow controlled volumes of fluid to be withdrawn from the wellbore.
 “Kill” the well (prevent the flow of formation fluid, influx, from the
reservoir into the wellbore).
 Seal the wellhead (close off the wellbore).
BOPs come in two basic types:
1. Ram Blowout preventer: A ram-type BOP is similar in operation to a
gate valve, but uses a pair of opposing steel plungers, rams. The rams
extend toward the centre of the wellbore to restrict flow or retract open in
order to permit flow. The inner and top faces of the rams are fitted with
packers (elastomeric seals) that press against each other, against the
wellbore, and around tubing running through the wellbore. Outlets at the
sides of the BOP housing (body) are used for connection to choke and kill
lines or valves.

Fig. Ram Blowout Preventer

2. Annular Blowout preventer: An annular-type blowout preventer can close
around the drill string, casing or a non-cylindrical object, such as the Kelly.
Drill pipe including the larger-diameter tool joints (threaded connectors) can be
"stripped" (i.e., moved vertically while pressure is contained below) through an

63 | P a g e
annular preventer by careful control of the hydraulic closing pressure. Annular
blowout preventers are also effective at maintaining a seal around the drill pipe
even as it rotates during drilling. Annular preventers are generally not as
effective as ram preventers in maintaining a seal on an open hole. Annular
BOPs are typically located at the top of a BOP stack, with one or two annular
preventers positioned above a series of several ram preventers.

Fig. Annular Blowout Preventer

CEMENTING AND CASING

The cement is used as a sealing material while drilling an oil and gas well.
Pumping cement behind the casing provides a barrier to the fluids flow from or
into the formation, and bonds the casing to the formation. This is called a
primary cement job. Cement is also pumped for other reasons like sealing off
perforated casing or plugging zones.
Once a well has been drilled, if it is to become a production well, the well must
undergo completion. While drilling a well cut through the rock formations and
allows drilling engineers to reach the reservoir below, the raw sides of the well
cannot support themselves. Similar to the bones of your spine protecting the
spinal cord, casing is tubing that is set inside the drilled well to protect and
support the wellstream.

64 | P a g e
In addition to providing stabilization and keeping the sides of the well from
caving in on themselves, casing protects the wellstream from outside
contaminants, as well as any fresh water reservoirs from the oil or gas that is
being produced.
Also known as setting pipe, casing a well involves running steel pipe down the
inside of a recently drilled well. The small space between the casing and the
untreated sides of the well is filled with cement to permanently set the casing in
place.
Casing a Well
The casing is fabricated in sections, or joints, that are usually about 40 feet long
and screwed together to form longer lengths of casing, called casing strings.
Each end of the casing joint has male threads that are protected by cap called a
thread protector until the casings are ready to be jointed. Then, a collar or
coupling, composed of a short cylindrical steel pipe that is slightly larger in
diameter than the joints and also has female threads, is used to connect the two
male joint ends. A thread compound is used on the two ends to ensure a tight
seal.
Casing is run from the rig floor, connected one joint at a time by casing
elevators on the traveling block and stabbed into the previous casing string that
has been inserted into the well. Hanging above the drill floor, casing tongs
screw each casing joint to the casing string.

65 | P a g e
Casing is run into the well and officially landed when the weight of the casing
string is transferred to the casing hangers, which are located at the top of the
well and use slips or threads to suspend the casing in the well.
A rounded section of pipe with an open hole on the end, a guide shoe is
connected to the first casing string to guide the casing crew in running the
casing into the well. Additionally, the outside of the casing has spring-like
centralizers attached to them to help position in casing string in the center of the
well.
After running the casing and before the cementing the well, a used drill bit is
inserted into the well via a drill string, and drilling fluid is then circulated for a
certain amount of time to remove any remaining cuttings from the well. Also,
wall scratchers are dispatched into the well to remove any filter cake that may
have formed on the sides of the well.
A cement slurry is then pumped into the well and allowed to harden to
permanently fix the casing in place. After the cement has hardened, the bottom
of the well is drilled out, and the completion process continues.

66 | P a g e
Casing Programs
Sometimes the well is drilled in stages called a casing program. Here, a well is
drilled to a certain depth, cased and cemented, and then the well is drilled to a
deeper depth, cased and cemented again, and so on. Each time the well is cased,
a smaller diameter casing is used.
The widest type of casing is called conductor pipe, and it usually is about 30 to
42 inches in diameter for offshore wells and 16 inches in diameter for onshore
wells. The next size in casing string is the surface casing, which can run several
thousand feet in length.
In some wells, protection or intermediate casing is run to separate challenging
areas or problem zones, including areas of high pressure or lost circulation.
The last type of casing string that is run into the well, and therefore the smallest
in diameter, is the production or oil string. The oil string is run directly into the
producing reservoir.
Cementing
Cementing is performed by circulating a cement slurry through the inside of the
casing and out into the annulus through the casing shoe at the bottom of the
casing string. In order to precisely place the cement slurry at a required interval
on the outside of the casing, a plug is pumped with a displacement fluid behind
the cement slurry column, which "bumps" in the casing shoe and prevents
further flow of fluid through the shoe. This bump can be seen at surface as a
pressure spike at the cement pump. To prevent the cement from flowing back
into the inside of the casing, a float collar above the casing shoe acts as a check
valve and prevents fluid from flowing up through the shoe from the annulus.

67 | P a g e
 MAINTENANCE OF DRILLING RIG
AND ITS EQUIPMENTS
Since the Drilling Rigs Works on highly toxic and dusty area, therefore
maintenance of RIG and its equipment’s are very necessary, to increase the
efficiency and productivity of the RIG and its components. Therefore the
maintenance can be performed in following ways:
1. Preventive Maintenance.
2. Predictive Maintenance.
3. Corrective Maintenance.
Preventive Maintenance:
These maintenances can be done by performing some tasks daily, weekly and
monthly. Greasing of the rig, “to get all of the dirt out of the bearings and keep
them clean”. Changing filters, Belt tightening, Oil changes, and by performing
some task which can increase life of equipment, and helps it runs more
efficiently.
Benefits of Preventive Measurement:
 It increases life of equipment
 Reduces failure and breakdown
 Reduces costly down time
 Decreases cost of replacement
Predictive Maintenance:

68 | P a g e
These are the techniques that help determine the condition of in-service
equipment in order to predict when maintenance should be performed. Primary
goal is to minimize disruption of normal system operations, while allowing for
budgeted, scheduled repairs. Vibration Analysis, Infrared Thermography, Oil
Analysis, and Visual Inspection are some tasks that are performed while
predictive maintenance.
Benefits of Predictive maintenance are:
 It provides increased operational life,
 Results in decrease of down time,
 Allows for scheduled down time,
 Allows for money to be budgeted for repair,
 Lowers needs for expensive parts inventory.
Corrective Maintenance:
It includes the repair of equipment or machinery in order to bring it back to itS
original operating condition. Some points which should be taken under
consideration while performing the corrective maintenance are:
 Original OEM parts should be used,
 Installation of the part should be done as per manufacturer’s
specifications,
 While maintaining the machinery part no shortcuts should be taken,
 Installation and repairing should be done very correctly.

69 | P a g e
 CONCLUSION

The Virtual internship at the ONGC, Dehradun gave me a lot of knowledge and
other memorable experiences. It has provided me exposure to how the drilling
operation is being performed at ONGC. In training, my mentor's videos and
animations play a crucial role in understanding the mechanisms of various
components and their design structures along with their operations.
After this training, my interest towards drilling technology has increased and I
am looking forward to gain more and more knowledge and experiences.

70 | P a g e
 REFERENCES
 Wikipedia: - https://en.wikipedia.org/wiki/Drilling_rig
 https://www.glossary.oilfield.slb.com/
 https://www.e-education.psu.edu
 https://www.drillingcourse.com/
 google Photos
 ONGC website
 YouTube

71 | P a g e