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1. 228rpm lee eer 500ton Transmission e eet 10 5 1 If the primary gear mesh backlash exceeds 0 030 inch Or the secondary gear mesh backlash exceeds 0 040 inch Excessive gear wear or bearing failure may be indicated A 10 hp 1800rpm AC motor drives two hydraulic pumps and powers the hydraulic system A fixed displacement pump drives the lube oil system motor A variable displacement pump provides hydraulic power for the AC motor brakes powered rotation head remote actuated IBOP pipe backup clamp cylinder link tilt and counterbalance system INSPECTING THE UPPER MAI NSHAFT LI NER e Remove the wash pipe assembly e Check the upper main shaft liner for erosion caused by leaking wash pipe packing and replace the liner if erosion is found e The poly pack seal must also be replaced whenever the upper stem liner is replaced e Grease the poly pack seal and clean the main shaft bore before re installing e Make sure the O ring of the seal is facing down when the seal is installed on the liner GREASE POINTS Ac Be AC motor Sl no Description drilling blower Hydraulic pump motor motor y ou Number of S i motors Black pearl 01 EP2 grease 4points 4points 2points 02 Gees 3months 3months 3months interval 03 Capacity 400hp Shp 10hp 04 RPM 3600RPM 1800rpm 8gpm 3 5gpm t Ge PROW h
2. m LA HYDROMECHANI CAL SHUTOFF SWITCH SAFETY SYSTEM The hydro mechanical shutoff device gives protection to engine due to low lub oil pressure high coolant temperature and engine over speed The shutoff valve has also manual control to stop the engine The fuel rack shutoff will move the rack to the fuel off position with either low oil pressure or high coolant temperature Both the fuel rack and inlet air shutoffs will activate when the engine speed exceeds the setting speed setting speed 18 of rated speed rated speed or if the manual control is used The fuel rack shutoff will reset automatically but the inlet air shutoff must be manually reset Oil pump pressure 250psi Oil pressure at the start of the rack circuit 110psi Oil pressure at the start of the air inlet circuit 15psi Rack sequence valve maintain rack circuit oil pressure of 110psi SENSING PARAMETERS Low speed low lub oil pressure sensing valve activate at minimum oil pr of 20psi v High speed low lub oil pressure sensing valve activate at minimum oil pr of 30 psi Thermostatic pilot valve activate at the water temperature of 99 Y Over speed sensing valve activate at the speed of 1180 rpm At approximately 70 of engine full load speed the oil pressure protection changes from the low speed range to the high speed range OVER SPEED FAULT PRESSURE LOW OIL PRESSU
3. Low transmission High transmission Low clutch 19 83X 282 264 rpm 19 83X451 103rpm High clutch 37 43 X282 243 rpm 37 43X451 388rpm V Rotary counter shaft speeds 282 rpm amp 451 Rotary counter shaft RPM Output shaft R c Rpm Low 43 37 X 243 282 High 43 37 X 388 451 VI Rotary input rpm 494 789 Rotary input RPM R c shaft Rotary input Rpm Low 35 20 X 282 494 High 35 20 X 451 789 VII Rotary turntable rpm 129 205 Rotary table RPM ROTARY PINION TURNTABLE RPM LOW 20 77 X 494 129 HIGH 20 77 X 789 205 Cathead RPM Low clutch Cat head Rpm Low 39 21 X 64 119 High 39 21 X 103 191 MAIN DRUM SIZE 1 Drum size 28 x 52 2 Drum brake 50 x 10 3 Low amp High clutches Air flexes 38VC1200 4 Rotary clutch Airflex24VC650 5 Sand reel clutch Airflex24CB500 CLUTCH SPECI FI CATI Maximu Clutch m Minimi Minimum Sl n Rig E1400 Description drum size allowable allawabla allowable O equipment dia x wear on di dia lining width drum thickness dia Draw works low 38 VC x S 38 3 16 O1 amp high 1200 ene 37x 13 16 3 8 clutches Rotary 24 x i 24 1 8 02 24VC650 6 5 1 8 23 x 7 8 5 32 03 Sandreel 24CB500 24 x 5 RECOMMENDED MAXIMUM HOOK LOADS IN TONNES WITH 12 LINES Transmission Clutches
4. 8 and Natural Gas Corporation Limited ay Cauvery Asset Karaikal RIG EQUIPMENT MANUAL Compiled By K Chelladurai December 2006 SE DS and Natural Gas Corporation Limited Cauvery Asset FOREWORD The manual Rig Equipment Manual contains voluminous technical information about Rig Equipment This technical information is of much use to field engineers for day to day operation and maintenance of Rig Equipment I hope this manual will certainly help the engineers to uncover hidden potential enhance their talent skill and confidence level for collective success of the team Employees would always aspire to find a better and more efficient way to work By making use of this manual the user can update his her technical knowledge and skills to face challenges I am sure this special issue on Rig Equipment Manual being brought out by Shri CHELLADURAI SE MECH at a very appropriate time will enlighten the engineers about the operation and maintenance of equipment with high spirit I wish him great success ANIL J OHARI GGM Asset Manger PREFACE The manual Rig Equipment Manual is prepared and compiled for field engineers and their team members This manual is for better understanding about the system functions safe operations and upkeep of equipment The main objective of compiling this manual is to motivate the field personnel for professional advancement and also for safe and
5. THERMAL VALVE 1 6 PRESSURE REGULATOR SRICHON 7 INSTRUMENT PANEL 0088 MNMUM PRESSURE BLOWDOWN vu __ SAFETY VALVE MECEVERISUMP MAIN OIL FILTER SULUCON CONTROL ON Olt LEVEL SIGHT GEASS FLEXMASTER COUPLING PRIME MOVER RETURN LINE pu AIR END OR COMPRESSOR UNIT BARING OIL FR 9 DL VALVE SCREW COMPRESSOR HOUSING d J bet en SHAR FEMALE ROTCR AERE SEAL T E TL Ep GEAR 3 BEL BEARINGS DRIVEN GEAR 4 TRARINGS MALE ROTOR TURE AIR OL MIX IPRESSED AIR OUTLET COM COOLING AND LUBRICATION SYSTEM AIR COOLED VERSION 1 Air Cooled Oil Cooler 10 Return Line Oil Sight Glass 2 Air Cooled After Cooler 11 Return Line 3 Cooling Fan Motor 12 Bearing Oil Filter 4 Minimum Pressure Valve 13 Orifice 5 Receiver Tank 14 Discharge Check Valve 6 Terminal Check Valve 15 Oil Stop Valve 7 Terminal Check Valve 16 Main Oil Filter 8 Air End 17 Flexible Hose 9 Return Oil Strainer Screw compressor has the following components and systems Air end compressor unit Air inlet system Air discharge system Cooling and lubrication system Control system Electrical system Safety system N O Un BR HL Instrument panel AIR INLET SYSTEM It consists of a dry type air filter a restriction gauge and an air inlet valve T
6. O Hoisting system e Brake system a Lubrication system Cooling system D gt ga Pneumatic control system a Driller s console Driller s console is an integral part of draw works It consists of electrical and pneumatic circuits and valves The main functions of driller s console are to integrate all electrical and pneumatic circuit in a single platform and facilitate the driller to operate and control varies activities of drilling operation by standing in a convenient place without much difficulties b PRIME MOVER DC motors Are prime movers of Draw works Convert electrical energy input to mechanical energy Provide mechanical energy input to the draw works Suitable to variable speed requirement of draw works C TRANSMISSION SYSTEM The transmission system consists of motor input shaft drive output shaft drive low clutch drive and high clutch drive rotary counter shaft drive and sand reel shaft drive etc The purpose of transmission system is to provide variable speed and torque to main drum cathead and rotary according to their speed and load requirement Particularly the combination of a set of sprockets of the input and output shafts with low or high clutches provide a variable torque and speed to main drum shaft for proper function The power flow diagram along with speeds calculations are illustrated in this chapter to understand about draw works transmission system
7. The after cooler removes some of the heat from the compressed air of turbochargers This inlet air temperature is lowered to the engine coolant temperature The exhaust manifolds are water shielded to avoid heat radiation to the engine body and inlet manifold NOTE If the intake air temperature increases by 1 degree then exhaust temperature will increase by 3 degrees FUEL SYSTEM Quick starts in cold weath er with glow plug in pre combustion chamber Use plow plug heater for spe cified time then start diesel Separate Fuel Injection Camshaft Low Pressure Fuel Manifold Fuel injector capsules can Fuel Control Rack Regulated by Governor be changed easily and quickly although it s Individual Fuel Injection Pump seldom required Capsule Fuel Injection Valve SCHEMATIC OF FUEL SYSTEM 1 Fuel transfer pump inlet line 6 Fuel tank 2 Fuel priming pump 7 Fuel transfer pump outlet line 3 Fuel passage 8 Fuel transfer pump 4 Inlet from tank 9 Fuel filter housing 5 Fuel return line 10 Fuel injection pump housing FUEL SYSTEM The basic function of the fuel system is to supply the fuel to the cylinders in the right quantity at the right time and at right pressure to atomize thoroughly Fuel produces the power in a diesel engine when it is atomized and mixed with hot air in the combustion chambers Pressure caused by the piston risings in the cylinders causes a rapid temperature increase When fuel
8. e An external lubrication system is provided for lubrication of gears and bearings e The axial clearance of main bearing is between 0 004 to 0 006 Couplings are greasing lubricated EP2 Grade of oil HP140 e Oil capacity is 30 liters e High lubrication temperature 180 F Oil pressure 1 8 kg mm to 2 5 kg mm e Input shaft dia 3 94 inches e Input shaft keyway 1 x 3 4 inches Output shaft dia 3 94 inches e Output shaft keyway 1 x 3 4 inches Weight of gear box unit 1000 kgs OPERATI ONAL SPARES Part name Part no Quantity 01 Coupling chain rotary half 2 96948 1 0614 1 02 Coupling chain trans half 2 96948 1 0613 1 03 Chain ANSI 200H 1 X 18P R1022 1 04 Hose assy 45 171 898 1 05 Quick release valve 06 000 391 1 06 Air flex clutch 20VC600 06 001 882 1 07 Hose assy 45 171 799 1 08 Flex hose assy 45 171 775 1 TRANSMISSION SI no Input shaft ou Low gear High gear 01 Input speed 1100rpm 1240rpm 566rpm 02 Gear ratio 1 767 1 1 1 128 03 Rated input IHP 600 1000 04 Stall torque Ft Ib 5000 7000 lt OW Check the flexible gear coupling for
9. High Intermediate 321 1 30 000 54 High 499 83 500 37 V Rotary counter shaft speeds 186 rpm 296 rpm and 461 rpm Output shaft rom High clutch rpm ROTARY COUNTER SHAFT RPM Output shaft R c Rpm Low 36 39 X 201 186 Intermediate 36 39 X 321 296 High 36 39 X 499 461 VI Rotary input rpm 307 488 760 ROTARY INPUT RPM R c shaft Rotary input Rpm Low 33 20 X 186 307 Intermediate 33 20 X 296 488 High 33 20 X 461 760 VII Rotary turntable rpm 80 126 197 ROTARY RPM Rotary pinion Turntable Rpm Low 20 77 X 307 80 Intermediate 20 77 X 487 126 High 20 77 X 760 197 Sand reel drum gt Used for hoisting amp lowering of tool required for directional drilling Sand reel shaft gt Giving power to sand reel drum spinning and break out catheads Capacity 16000 Its Wire line 9 16 Clutch 24 CB 500 Catheads Spinning makeup cathead is used for tightening drill pipes gt Break out cathead is used for breaking drill pipes CATHEAD RPM Low clutch Cat head Rpm Low 36 21X47 81 Intermediate 36 21 X 75 129 High 36 21 X 117 201 AI RFLEX CLUTCHES Clutch De Maximum S Minimum 51 drum Minimum Rig E760 allowable allowable no equip Desc size Wear an allowable lining dia drum dia thickness width Draw _ works low 32 VC 32 x 5 01 amp high
10. Normally open position Solenoid valve Normally closed 09 Normally closed position Solenoid valve NOTE Moisture and impurities are worst enemy of pneumatic valves and its system function It leads to fast worn out of moving parts malfunctions and system failure and ultimately increase maintenance cost Therefore moisture free air is must for proper functions of pneumatic valves and its system Air dryer function is must for pneumatic system of drilling rigs Important specifications Run out for Brake drum 0 25 mm Run out for clutch drum 0 4mm Alignment between sprocket 0 8 mm Slackness of chain 0 089 End float of main drum shaft 12 mm Clearance between clutch and drum 1 5 mm Operating temperature 80 C Sprocket surface hardening thickness 10 12 mm Fixed end at low clutch side VV ON ON Y ON ON V Floating end at high clutch side IMPORTANT POI NTS TO REMEMBER Y All shafts are supported on self aligning spherical roller bearings except high and low clutch drum sprocket They are non adjustable heavy duty straight roller bearings Y The draw works shafts are provided with tapered end provision for quick removal of all end members on the shafts 32VC 1000 constriction type air clutch is used for maximum heat dissipation required in the rugged use of drum clutches v Interlock system is provided in the draw works pneumatic circuit to avoid accidental engage
11. healthy work practice It is useful not only to maintenance engineers but also to operators for developing technical skills and knowledge about functions of equipment for safe operation I hope this manual is of much use to field engineers and they make use of it I wish them all the best with my heartiest pleasure This manual has been thoroughly revised incorporated with more information and edited a second time I wish to acknowledge the assistance that I have taken in preparing and compiling this manual from various textbooks manuals training course materials experience etc It is a pleasure to express my thanks and gratitude to all those authors and publishers I am especially thankful to Shri Anil Johari GGM Asset Manager Shri Khanna DGM D HDS and Shri Sivakolundu M DS for their encouragement and cooperation in bringing out this manual I am grateful to my family members for their active cooperation for completion of this manual K Chelladurai SE MECH DS TRAINING HELPS ENCOURAGE THE BEST AND DEVELOP THE REST ABSTRACT BHEL make E 760 and E 1400 series of deep drilling rigs are deployed at different locations of Cauvery asset Karaikal for drilling activities These Rigs are having drilling capacities of 3600mts and 4900mts respectively These Rigs are equipped with CAT D399 Engines BPCL Mud Pumps ELGI and KHOSLA make Screw and Reciprocating Compressors Ingersoll Rand Ai
12. x6x14 57 01 Flow Gpm S 500 500 5 500 2000 500 1500 100 320 1500 5200 02 Deliver Feet 165 205 1 95 80 65 55 110 80 jac ion 03 Speed Rpm 1150 1150 1750 1750 1750 04 Hp 50 75 25 60 17 35 2 7 5 Se EH 05 60 80 30 70 20 40 3 10 ion 06 Feet 3 5 15 3515 420 4 20 07 Suctio Inch n end 8 8 3 8 8 dia 08 Deliver Inch y end 6 6 2 6 6 dia 09 o 45 65 45 65 25 50 45 55 45 55 10 Casing Mate body CI CS CI CS cics Gives eiyes 11 es T CS SS CS SS cs ss CS SS CS SS 12 Stuffin Mate g box rial CI CI CI CI CI bushes 13 Glands d CI CI CI CI CI E T 55416 55416 55416 55416 55416 15 Shaft Mate s5416 58416 55416 55416 55416 sleeve rial 3 CUMMINS ENGINE RATING FOR GENSET APPLI CATI ON ENGINE MODEL BHP 1500 RPM KW KVA NTC 495 G 154 100 125 NT 743 G 205 128 160 NTA 855 G 306 200 250 These values are calculated at 0 8 P F and Volts 440 N K Series T Turbocharger A After cooler G Gen set application P Production application C Construction application I MPORTANT PARAMETERS Maximum coolant temperature 95 C Normal engine oil pressure at 105 C 3 to 7 kg cm at rate rpm 1 to 2 kg cm at low idle pH value should be between 8 5 to 10 ENGI NE EXHAUST The engine exhaust is a good indicator of engine operation and performance
13. 0213 541 40 8 03 40 x 40 0 010 0 015 381 36 8 04 40 x 20 0 014 0 012 310 910 36 8 05 60 x 60 0 0075 0 0092 234 30 5 06 60 x 40 0 009 0 0077 200 406 31 1 07 80 x 80 0 0055 0 007 178 31 4 08 80 x 40 0 007 0 0055 140 460 35 6 09 100 100 0 0045 0 0055 140 30 3 10 120 x 120 0 0037 0 00146 117 30 9 11 150 x 150 0 0026 0 0041 105 37 4 DIFFERENCE BETWEEN SQUARE amp RECTANGULAR MESHES Square mesh Rectangular mesh Remove more solid Remove less solids Shorter life Longer life of Opening area is less of opening area is high GPM capacity is lower in the given GPM capacity is higher in the shale shaker given shale shaker FACTORS INFLEUNCE THE VI BRATI 1 The shaft should rotate toward discharge end of shale shaker i e toward waste pit 2 Correct belt tension is to be maintained for proper vibration 3 Vibration mount is flexible enough to permit vibration of basket 4 Fly weight must be tightened position in the shaft for proper vibration 5 Adequate motor rpm is also influence the vibration of shale shaker basket DO Y Do all the checks necessary for proper vibration of shale shaker before and after running Avoid excess greasing DO T Don t run the shale shaker without safety guard Avoid excess greasing of bearing FACTORS INFLEUNCE THE VIBRATION LMS 1 Fly weight must be tight position in
14. 1000 10 3 16 13 16 3 8 clutches Rotary amp Sand reel 24 CB v clutches 500 SE EXAMPLE 32VC1000 Original drum diameter 32 00 inches Minimum allowable drum dia is 32 00 3 16 31 13 16 38VC 1200 Original drum diameter 38 00 inches Minimum allowable drum dia is 38 00 3 16 37 13 16 Air flex CB and VC clutches are simple in design and construction rugged self adjusting shock absorbing and do not require any lubrication The torque arm is the drum radius not a reduced radius as in plate clutches The tube under the influence of compressed air expands about 0 12 3mm The tube distributes the clamping pressure evenly around the full circle and across the entire drum width This is an efficient method of transmitting torque Centrifugal force acting on the friction shoes when the clutch is rotating forces the friction shoes off the drum surface quickly Centrifugal force also helps to force air from the tube As friction surfaces wear the tube expands further and compensates for the wear Normal friction surface wear will not reduce the torque capacity The tube is constructed to work within the normal wear limits without requiring additional air pressure to achieve full clutch torque The dampening quality of neoprene is constantly reducing the effects of torsional vibration The tube is also able to flex sufficiently to operate misaligned parallel or angularly Air is an easy medium to control Flow rates an
15. 7 is neutral 6 to 8 is neutral PH value 6 5 to1 progressively more acidic attack on ferrous metal Avoid keeping coolant this range pH value 8 to 14 progressively more alkaline attack on non ferrous materials Avoid keeping coolant above pH11 3 Desired range is between 8 to 10 5 EFFECT OF SULFUR IN ENGINE PERFORMANCE During the combustion process sulfur dioxide SO and sulfur trioxide 03 are formed These oxides of sulfur combine with the water vapor formed acid during combustion This acid accelerates corrosive wear in the engines body components and increases the chance of early engine failure Hence sulphur is the silent enemy of the engine Oil has an affinity for oxygen at high temperature This tendency leads to oxidation of oil at higher temperature and increase the viscosity Due to oxidation the longer the oil is used more the viscosity of oil High viscous oil is not desirable for better lubrication Viscosity is a measure of resistance to oil flow Oil that is too viscous will have excessive resistance to flow at low temperature Alkaline additives called buffers are used to prevent corrosive wear on engine parts caused by acids The alkalinity of oil is referred to as TBN The higher the oil s TBN the greater is its capacity to neutralize acids Caterpillar recommends that the TBN of new oil is to be 20 times as great as the percent of sulfur in the fuel being used Corrosive wear can occur in any engine on
16. A smoky exhaust may be due to a poor grade of fuel dirty air cleaner overhauling due or poor mechanical condition 4 FUEL SPECIFICATIONS AND THEIR USAGES CETANE NUMBER The cetane number refers to the property of igniting the fuel easily If the fuel is at a high cetane number the fuel can ignite easily It can then ignite at a low temperature If the cetane is low the temperature required to ignite the fuel is high This is not desirable Also if the cetane number is low there is a possibility for the fuel to knock A high cetane number ensures that the fuel will ignite and burn immediately after the fuel is injected SI no Properties 1 It is a mixture of butane and propane gases 2 It 15 liquefied under normal ambient LPG temperature and moderate pressure 01 222 3 It is clean burning non poisonous 222 dependable high calorific value fuel 4 Very low sulphur content 5 It is mainly used as a domestic fuel 6 It is also widely used in industries where very fine degree of temperature control is required 1 It is used as fuel in spark ignition engines 02 ait Motor 2 It is mainly used in two stroke and four stroke iri engines of automobiles 3 It is a highly refined fuel and possesses good anti knock and volatility characteristics with appropriate stability ATF 1 It is a highly refined transparent fuel having aviation extremely good oxidation and
17. H 2 X 78 X Singlex Rotary Counter shaft 1 I 2 X 108 X Doublex Rotary Chain 1 g COOLI NG SYSTEM Cooling water for brakes Brakes Gpm Psi Drum brake 35 50 75 ECB 50 50 75 h DRAWWORKS PNEUMATIC SYSTEMS AND ITS FUNCTI Draw works is a most important and critical equipment of drilling rig Understanding about draw works mechanism and pneumatic system will give us better idea about operation and maintenance The pneumatic circuit specially prepared for easy understanding about various lines valves and flow path of the circuit is given below One can easily identify the fault by tracing line or valve or working component by understanding the circuit The functions of each valve are also given for understanding about working principle and important for draw works safety Each valve is important and most significant for smooth and successful operation of draw works The operator can operate and control the draw works through pneumatic control valves mounted on the driller s console TWIN STOP DIAGRAMMATIC CIRCUIT MAIN AIR SUPPLY BRAKE OVER RIDE VALVE AIR SUPPLY NORMALLY OPEN EXHAUST NORMALLY CLOSED MAIN SUPPLY VALVE BRAKE SET VALVE MAIN BRAKE EXHAUST CYLINDER LOW CLUTCH HIGH CLUTCH Twin stop is a simple pneumatic control device to limit the travel of the hook block in both directions i e between derrick floor and crown block The ci
18. Low High Low 295 168 High 99 64 IMPORTANT PARAMETERS Sl no Description Capacity measures 1 LUB OIL SS220 230 Its 2 OIL PR ON GAUGE 20 50 psi 3 BRAKE COOLING WATER D W 35 gpm 4 COOLING WATER ECB 50 gpm 5 WATER PR ON GAUGE 50 75 psi AIR PR TRANSMISSION 75 psi CLUTCHES AIR PR LOW amp HIGH CLUTCHES 150 psi 8 AIR PR SANDREEL CLUTCH 90 110 psi AIR PR ROTARY CLUTCH 90 110 psi 10 BRAKE LEVER HEIGHT 710 810 mm 11 GUIDE ROLLER CAP 3 2 mm NOTE 1 All bearings are grease lubricated Chains and sprockets are oil lubricated 2 3 Oil changing period 6months 4 Avoid excess greasing CHAIN SPECI FI CATI ON Sl no Description Chain Location Quantity in nos 1 X 114 X A Input chain 2 Triplex B 2 X 46 X Triplex High Transmission 1 2 X 56 X Triplex Low Transmission 1 D 2 X82X Triplex High clutch 1 2 X 98 X Triplex Low Clutch 1 F 2 X 82 X Single CAT Head 1 G 2 X 88 X Doublex Rotary Counter shaft 1 H 2 X 112X Doublex Rotary drive 1 INDEPENDENT ROTARY DRIVE XI The main purpose of installing the independent rotary drive system in the drilling rig E1400 19 is to eliminate the drive from draw works to rotary table to save energy The draw works function is not required during drilling operation The independent rotary drive system consists of DC mo
19. PUMP The pressure pulsation in the pumps is due to 1 Loss of effective suction head 2 Fluid or hydraulic knocking 3 Reduction of volumetric efficiency 4 Discharge line vibration SUCTION Fluid knocking is closely related to insufficient suction head The degree of such fluid knocking depends on the conditions of the pump suction Fluid knock causes metal fatigue and therefore should be avoided The mud tanks should be arranged to keep the suction line filled the suction line should be short and straight a pulsation dampener should be provided to reduce hydraulic hammer and a supercharging pump may be needed SUPERCHARGI NG 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 PULSATI ON DAMPENER A pulsation dampener absorbs discharge pressure variations and thus reduces peak pressures and permits smoother volumetric pump output This action in turn minimizes vibrations in the discharge line and rotary hose and gives a more constant flow rate through bit nozzles The dampeners should be installed as near to the pump as possible Nitrogen charging pressure in the dampener must be held to the manufacturer s recommendation PRESSURE RELIEF VALVE A pressure relief valve should be installed in the discharge line immediately next to the pum
20. advantage which permits extremely heavy loads to be hoisted with a relative low line pull at the reeving mechanism the draw works drum However to gain this advantage additional wire line is placed in service and the elevating rate of the traveling block must be reduced or the wire line reeving must be accelerated CALCULATION FOR REEL THE ROPE Traveling block s travelling distance pulling the stand 90 feet The draw works has to reel with 6 sheaves in travelling block 1080 feet 90 x 12 1080 SPEED CACULATION OF SHEAVES VV VV ON ON ON ON VV ON ON V v jul No of sheaves in the crown block 6 No of sheaves in the travelling block 5 If the guide pulley speed of crown block 1000rpm The fast end pulley speed of travelling 9 10 x 1000 900 The second pulley speed of crown block 8 10 900 720 The second pulley speed of travelling block 7 10 x 720 504 The third pulley speed of crown block 6 10 x 504 302 4 The third pulley speed of travelling block 5 10 x 302 4 151 20 The fourth pulley speed of crown block 4 10 x 151 2 60 48 The fourth pulley speed of travelling block 3 10 x 60 48 18 14 The fifth pulley speed of crown block 2 10 x 18 14 3 63 The fifth pulley speed of travelling block 1 10 x 3 623 0 36 The last pulley speed of crown block 0 10 x 0 36 0 Hook Pulling and absorbing load shoc
21. choked 3 We cannot change the capacity or head by definite maximum amount of head for a particular speed 3 We can change the head capacity without changing 02 constant RPM RPM by increase or degrease the suction and 4 We can change the delivery pipe capacity by increasing rpm 5 We can change the pressure by changing cylinder liner Losses due to slip problem of losses due to slip 03 leakage in passage may or leakage in passage occur 04 The water flow is pulsating There is continuous liquid flow There is high initial and Low initial and maintenance 05 maintenance cost costs No continuous supervision Maintenance is difficult and required requires constant attention They are large in size and They are compact and 06 oblique in disposition symmetrical design They are better suited for They are efficient for heads upto 07 hob heads over 60m 0 single stage Mostly viscous liquids suitable for pumping cold and clean water 08 Efficiency is as high as 85 Efficiency is 60 Power absorbed by a pump is almost directly proportional to discharge rate However this relationship is true only for radial discharge centrifugal pumps MUD PUMPS The main component of fluid circulating equipment for rotary drilling is mud pump It provides the driving force that sends the fluid through the route that must travel The
22. hot flame will pass through gap and seat will cut the portion of valve is called valve cutter VALVE DROP Valve drop occurs due to over speed of the engine due to the failure of lock spit ring that allow the valve to drop inside the cylinder cause damage to cylinder head piston liner crankshaft and even cylinder block Increase in 1 C of inlet air temperature will increase the temperature of 3 Backlash of accessory drive gear is 0 001inch permissible Maxi Blow 2 of H20 when using H20 manometer Maxi Blow by of New engine 1cft hr rated hp of new engine Exhaust temperature 540 Injection Mixing Burning Gives power Power loss due to 1 Delay in injection of fuel 2 Delay in mixing of fuel and air 3 Delay in burning of fuel Total volume Swept volume clearance volume Total volume BDC Compression ratio Compressed volume TDC Valve opening pressure 2500psi Nozzle injection pressure 15000psi 82 Nozzle hole size 5 micron 83 Number of holes in a nozzle 7 DO Y Daily physical checks are required before and after starting the engine to identify any abnormality that will help us to rectify the problem Ze Breather line is to be connected to outside canopy to avoid fumes enter into fins of radiator x Ensure all the safety systems are in working condition S Ensure the radiator cap is fitted and the cooling system
23. overload etc Check the causes and correct it Too much ply in the sprocket is due to bearing clearance worn out retainer plate or bolt looseness in the retainer plate Check and correct it If required add to or remove shims from retainer plate to arrest ply 9 Keep 2psi air supply to electrical panel of driller s console to prevent inflammable gas enters into it to avoid fire 10 Daily physical checks are required before and after starting the equipment to identify any abnormality that will help us to rectify the problem in time 11 Set kick off rollers in place to avoid damages to casing rope and brake drum 12 Set brake band guide rollers to maintain uniform gap between brake drum and shoes to avoid touching of brake shoes in the top due to gravity Improper setting of rollers will allow the shoes to warn out unevenly DON T 1 Avoid excessive greasing of bearings It overheats the bearings and also damages the seals of bearings 2 Don t inflate the clutch without having the friction drum in place as this may cause permanent damage to the clutch actuating element 3 Don t run the draw works on load with less thani20psi operating pressure of compressed air in the clutches It is unsafe for operation 4 Don t bypass the crown o matic by removing cam from the device This leads to severe accident 5 Don t run the draw works without cooling water Brake will not work properly 6 Don t run the draw
24. ratio Unit Injection Pc nozzl Pc noz Pc noz Unit Unit 09 injecto method e zle zle injector injector r i6 Type of Electron Electro Electro Electron Electron Electro governing ic nic nic ic ic nic 1215h 1576h 11 Power 610hp 912hp 860hp 1321hp 1200 1200 1200 1200 1200 1200 12 Speed rpm rpm rpm rpm rpm rpm Cetane 13 35 35 35 40 40 40 number Inlet Inlet Inlet Inlet Inlet Inlet 0 015 0 015 g 0 020 Tappet 0 015 0 020 0 020 Exhau Exhau Exhau clearance Exhaust Exhaust Exhaust st st st 0 035 0 040 0 040 0 035 0 035 0 040 is Crank shaft 0 13 to end play 0 89mm T Turbocharged TA Turbocharged after cooled STA Series turbocharged after cooled PARAMETERS Sl no Parameters D379 D398 D399 Air pressure for 100 to 100 to 100 to 01 starter 150psi 150psi 150psi Jacket water temp normal 02 75 to 90 C 75 to 90 C 75 to 90 C range 03 Maxi Oil temp 110 C 110 C 110 C Maxi Inlet air 04 temp 115 C 115 C 115 Maxi Exhaust 05 temp 540 C 540 C 540 C 45 to 70psi 45 to 7Opsi 45 to 70psi Most Most Most Engine oil 06 apropriate59 apropriate56 apropriate56 pressure to 66 to 63 to 63 07 Fuel pressure 20 to30PSI 20 to30PSI 20 to30PSI Allowable pressure 08 difference across 12 to 15psi 12 to 15psi 12 to 15psi oil filter Minimum jacket T water temp for 32 32 32 st
25. shaft Forged Steel Forged Steel Steel Backed Al Steel Backed Al 13 Bearing Cam shaft alloy alloy Cast alloyed Gray Cast alloyed Gray 14 Cylinder Block iron iron Wet Wet Cast iron Cu Cr Mo Cast iron 15 Cylinder Liners type alloy hardened alloy harden Al Casting or Al Casting or 16 Oil pan welded Steel welded Steel Cast alloyed Gray Cast alloyed Gray 17 Cylinder head iron iron 18 Exhaust valve stem Steel Steel 19 Exhaust valve head Cr Ni Mo alloy Cr Ni Mo alloy 20 Seat insert Ni Alloy Casting Ni Alloy Casting 21 Intake valve stem Steel Steel 22 Intake valve head Cr Ni Mo alloy Cr Ni Mo alloy 2 PNEUMATIC SYSTEMS COMPRESSED Fluid power system using air as medium for developing transmitting controlling and utilizing power is called pneumatic system Compressed air is an important energy source for controlling and operating the Drilling Rig Equipment The compressed air an energy transfer medium connects the operator with mechanical equipment for better control and faster operation Air prosperities mainly influence the controlling systems The compressed air must be properly treated before sending into pneumatic components systems Air as a source of energy is more flexible to use at a time for different applications in the Rigs It is capable of taking over a large number of functions in the Rig Pneumatic system as compared to other power sources is low cost to produce easy to handle ea
26. the compression stroke both valves will be closed Valve clearance is measured with a feeler gauge put between the rocker arm and the valve stem tip Check the tappet clearance in the inlet valve upto 0 015inch and exhaust valve tappet clearance upto 0 035inch and adjust accordingly IMPORTANT POI NTS TO REMEMBER Y Inlet valve diameter is greater than exhaust valve diameter to allow more air into combustion chamber in a given time Y Exhaust valve tappet clearance is more than inlet valve tappet clearance to accommodate expansion of exhaust valve stem due to high temperature Y The timing of the fuel injection pump is correct when the timing pin goes into the notch in the camshaft and no 1 piston is on top center compression stroke With No 1 cylinder on compression stroke Counterclockwise rotation Viewed from flywheel 0379 0398 0399 Valves Cylinders Cylinders Cylinders Exhaust 1 4 5 8 1 4 5 6 9 12 1 2 3 4 5 6 8 9 Intake 1 2 3 6 1 3 6 7 10 12 1 2 7 8 11 12 13 14 With No 1 cylinder on exhaust stroke Counterclockwise rotation Viewed from flywheel Valves D379 D398 D399 Cylinders Cylinders Cylinders Exhaust 2 3 6 7 2 3 7 8 10 11 7 10 11 12 13 14 15 16 Intake 4 5 7 8 2 4 5 8 9 11 3 4 5 6 9 10 15 16 NUMBERING OF CYLINDER 16 ek 12 5 2 6 XS os 399ENGINES D398 ENGINE L 0379 ENGINES ll ee 27205 5 s 1 ro mmTrz lt m
27. the shaft for proper vibration 2 Fly weight must be rotate in the opposite direction in both the motors of a basket 3 Spring tension shock mount must be adequate for proper vibration 4 Slope angle is also to be maintained in the discharge end as per instruction of OEM 2 DESANDER The de sander is used in the mud system for the purpose of removing sand size particles It is the second stage of solids removal program for weighted mud A centrifugal pump should be used to feed desander with mud This pump delivers smooth even flows to the hydro cyclones for separation of desand particles The pressure of feed should be 4 x mud weight Low pressure will cause poor separation and high fluid loss High pressure will cause high rates of hydro cyclone wear The cones should operate with a spray discharge for maximum efficiency Do not operate hydro cyclone with a rope discharge De sander cones have an internal diameter of 6 to 12 inches They have the advantage of handling large volumes per single cone but they do not remove coarse and fine particles Desanders operate efficiently with lower pressures than small cones Usually 30 35 psi is required for desander to function properly Total head of about 70 80feet is normally provided The unit should be kept normally 6 to 10 feet above the desander pump Pressure is the critical factor in obtaining maximum efficiency in desander and desilting with cone shaped centrifuges If the
28. the vessel The vacuum pump suck gas air from the vessel and create the negative pressure of about 8 to 15 inches of mercury 3 2 to 6 psi depending upon the weight of the mud to be raised into the unit The mud enters near the top of the horizontal vessel and flows along a section of large pipe that is closed at its far end The top of the pipe is sliced away in a horizontal plane so that the mud can spill over the sides and down an inclined plane extending the full length of the feed pipe and sloping downward As the mud streams down the inclined plane the vacuum in the vapor space causes the gases to leave the mud and to be withdrawn from the tank by the vacuum pump The degassed mud back to its normal weight flows to the bottom of the vessel for exit The mud flows from the bottom of the vessel through the tube at the left of the machine which is a downspout into the second mud tank A hydraulically operated jet is located in this downspout Mud at high velocity is pumped through this jet to lower the mud pressure here below the mud pressure in the degasser In this way the mud is made to flow from the degasser in spite of the vacuum in it Meter drilled Commercial speed x 30 4 Drilling days Meter age drilled x 30 4 CY Cle Speeds e EE Rig building drilling production testing ADVANTAGES OF MAINTAINING THE QUALITY MUD FOR MECHANICAL EQUIPMENT SUUS Re e 595
29. thermal stability 03 turbine fuel with a very low pour point 2 Application fuel for jet and turbo propelled aircrafts 04 HSD high 1 Application fuel for medium and high speed speed engines above 750 R P M diesel HF HSD 1 HF HSD meets the same specification as 05 high flash normal HSD except that it has a flash point of high speed 66 c minimum against 329 for normal HSD diesel 2 Sulphur percentage is limited to max of 1 3 Application It is specially recommended for use in diesel engines for naval applications and merchant navy 06 LSHF HSD 1 It is similar to HF HSD except that sulphur low sulphur percentage is limited to 0 2 This is specially high flash recommended for use in certain diesel engines high speed for naval applications and merchant navy diesel Where low sulphur fuel is recommended 07 LDO light 1 LDO is a blend of distillate fuel with a small diesel oil proportion of residual primarily recommended for slow speed diesel engines operating below 750 rpm 2 Application Agriculture marine furnaces and boilers 5 DI FERENT SIZE AND RANGE OF PRESSURE GAUGES USED IN THE DRILLING RIGS 51 of Applicati Dial Range Thread Moun No the on size size ting equipme Of gauge Pipe nt pan el 01 Lub oil pr 2 to 10 NPT Pipe 2 pump kg cm 02 Mud Lub oil pr 4 0
30. to 10 Yo NPT Pipe 2 pump kg cm 03 Mud MP line pr 4 0 to 350 2 NPT Pipe 2 pump kg cm 04 De silter Input pr 2 O to 80psi Pipe 1 05 De silter Input pr 4 Oto 80psi 12 Pipe 1 06 De gasser Ve pr 4 Oto 30 NPT Pipe 2 0 to 30 07 De sander Input 4 to 10 Yo NPT Pipe 2 kg cm 08 Air tank Air pr 6 0 to 20 Yo NPT Pipe 1 kg cm 09 Air dryer Air pr 6 to 14 V4 Pipe 2 kg cm 10 Air dryer Regulator 2 to 7 14 NPT Pipe 1 pr kg cm 11 Air Air pr 2 to 16 V4 1 receiver kg cm tank 6 PNEUMATIC VALVES OF DRAW WORKS SEN BHEL Part Wabco Part Sl no Description Location NiffnBer Number Rotary oi Valve HC 2 Gees n 196615 3 P52518 3 SX 0022 cat head 02 Valve H 2 Ex SPINNING cat 06 000 085 50925 2 Drum 3 96615 3 03 Valve 2HA 2 low high 0029 P59335 Neutral 3 96615 3 04 Valve 2HA 1 0030 59331 3 96615 3 05 Valve 2 1 Sandreel 0030 P59331 Cat shaft 3 96615 3 06 Valve 2HA 1 0030 P59331 2410 brake G H Bear 08 Valve 2HA 2Z Kelly spinner 09 ioco D W 06 000 811 PD2 31 9820 10 Relay valve D W 06 000 662 P55162 RUCK release Lewd 9 eenegen 2529853 valve clutch 12 Quick release Rotary 06 000 391 _ valve clutch 13 Quick release Cat head _ _ valve Quick release Sandree
31. toughing the dial stem on the flywheel body radially as well as face at point A as shown in figure Rotate the crankshaft either clockwise or anticlockwise but follow only one direction till complete the alignment Take reading at point A B C and D Add remove the shims from alternator base and tight foundation bolts till the reading comes close to permissible limits given below While taking face reading at points A B C and D push the crankshaft towards radiator end so as to take actual reading of the alignment ALTERNATOR ENGINE CRANKSHAFT RADIAL C 0 015 0 38 mm 0 008 0 003 ACTUATOR SETTING Model EG 3P Control system 2301 FUNCTION OF ACTUATOR The actuator s terminal shaft output position is directly proportional to the input signal to the actuator i e current The main element of the actuator is an electro hydraulic transformer which controls flow to and from the power piston through the action of a polarized solenoid The piston of the actuator shaft is proportional to the input current to the solenoid coil controlling the hydraulic pilot valve plunger v The flow oil to and from the power piston is controlled by the pilot valve plunger Y The actuator normally goes to minimum fuel position if the electric signal is stopped ACTUATOR ELECTONIC CONTROL SYSTEM Y S Be X 575 205 The output signal of the 2301 electric control is a leve
32. 0 to P of o X E 01 shaker 2000 a 4 6x8x 13 40 to 1500 12 30 35 02 Desander 250 1200rp m 6x8x 13 71 03 10 to 40 1500 200rp 4 35 45 m 4 MUD CLEANER Mud cleaner is used in the solid control system to effectively remove drilled solids from weighted mud without excessive loss of barite and fluid Mud cleaner is a combination of desilting hydro cyclones and a very fine mesh vibrating screen to remove drilled solids while returning valuable mud additives and liquids back to the active system 5 MUD AGI TATOR The agitator is a right angle gearbox having a set of gears with speed reduction ratio of 25 1 It has to rotate in the clockwise direction when viewed from its top The agitator is powered by electric motor receives and transmits energy to impeller for stirring mud The impeller keeps the mud in movement continuously to prevent gels from forming and maintaining weighing material in suspension 6 MUD GUN The mud gun is used in the mud system to stir the mud and thus avoid gel formation Mud gun stands should be positioned around the mud pits so that the entire area can be stirred Mud guns are usually connected to a manifold and supplied with mud from a pump operated for that specific purpose The mud gun streams are directed at a particular position in the mud pit and produce a swirling or rolling action Mud guns are quite use
33. 1 The thermostat valve starts opening at 82 C and full opening at 92 C opening size 0 375 62 Oil is required for cooling turbocharger from 578 C engine exhaust temperature to 115 C engine maximum operating temperature 63 Inlet air must be cooled down to increase density so as to accommodate more oxygen molecules inside the cylinder for better combustion 64 Factors that control combustion 1 Volume of air compressed 2 Type of fuel used 3 Amount of fuel mixed with the air 65 CRANKSHAFT Induction hardening of crankshaft is up to 150 thou 67 3 25 mm from the outer surface Two times under sizing is permissible 25 thou 25thou Minimum hardness is required for remaining service of the engine is 100 thou The crankshaft is to be discarded beyond 50 thou undersize 66 Change of RPM requires adjustment at two points 1 Rack setting 2 Lifter setting Oil change period depends on sulphur presence in the lub Oil and load TBN 20 x sulphur presence in the fuel 20 x 0 5 10 Oil should be changed if TBN comes down less than 50 Sulphur content in the fuel water produce sulphuric acid which is Corrosive in nature 68 High injection pressure to reach high fuel penetration 69 Fuel dilution 4 is normal 70 74 72 73 74 75 76 77 78 79 80 81 VALVE CUTTER There is a small gap between valve and valve seat during power stroke due to carbon deposit etc the
34. 150psi Receiver sump capacity 100ltrs Oil fill capacity 24ltrs Normal operating temperature 80 C VV VV VV VV WV Temperature switch shutdown at 116 C Pump dealing with air vapours and gases are called Blowers in small sizes and Compressors in bigger sizes WORKING PRINCIPLE OF SCREW COMPRESSOR The screw compressor is a positive displacement type It has two rotors housed in a cast iron casing called stator One of the rotors is called male rotor and other one is called female rotor The male rotor has four asymmetrical lobes piston that run helically along the rotor length and female rotor too has six similar helical flutes cylinder These two rotors rotate in conjunction with each other inside the casing Drive is usually provided to male rotor through a set of gears Air is admitted at one end of the rotors where the matching lobe and flute first come into mesh as the rotors turn Continued rotation brings the line of mesh past the air inlet port and then the air in the flute of the female rotor is confined by the lobe of the male rotor and stator housing Compression now occurs as the rotors turn further At that time the far end of the compression pocket turns towards the discharge port and air flows out in the system Lubricating oil is injected into the compressor in large quantities mixes directly with the air as the rotors turn compressing the air BASIC FUNCTION OF LU
35. 38mm Relief valve 25 above the 25 above the rated 17 pressure rated working working pressure of setting pressure of liner liner size size 18 Serving period 6 months 3000 to 5000operating hours 19 Oil capacity of 85 gal 322litres sump 20 Operating 90 F to 180 F 32 C to 82 C temperature Note A850 PT A Series 850 HP P Pump amp T Triplex A1100PT A Series 1100HP P Pump amp T Triplex DISCHARGE VOLUME CALCULATI ON The load on the piston rod determines pressure ratings which is the product of the pressure multiplied by the area of the piston exposed to fluid pressure The size of the liner limits the allowable discharge pressure regardless of speed Area of piston x Length of stroke x Number of pistons Gal Rev Gal per Min Gal per Rev x rpm GPM x PSI Hydraulic horse power hhp Where P Delivery pressure in psi Q Fluid pumped in gpm Hhp Volumetric efficiency x Mechanical efficiency 90 x 80 72 prime mover output power THE SALIENT FUTURES OF MUD PUMPS Mud pump is designed for heavy duty service The extreme volume pressure capabilities of this pump are developed in an all welded steel power frame Double row spherical self aligning roller bearings Support both crankshaft and pinion shaft with straight roller bearings employed in the connectin
36. BRICATING OIL 1 As a coolant it takes away the heat of compression 2 Seals the leakage paths amongst the rotors and housing 3 Acts as a lubricating film between the rotors allowing one rotor to directly drive the other without a metal to metal contact 4 Lubricates the bearings and gears PRINCI PLE OPERATION The air aspirated through the air filter is compressed in the screw compressor driven by an electric motor The injected oil removes the compression heat generated This internal cooling makes possible very low compression end temperatures Under normal conditions the compression end temperature amounts to approx 80 C Oil and air are separated by the in line 3 stage oil separator The separated oil is cooled in the oil cooler and is returned to the injection point via the micro filter This oil circulation circuit operated solely by the pressure differential does not require any oil pump The compressed air liberated from oil in the oil separating cartridge except for a very small amount of residual oil is passed to the air after cooler via the minimum pressure non return valve The combined minimum pressure non return valve downstream of the oil separator maintains a minimum pressure for safe supply of oil to the compressor The temperature of the compressed air at the unit discharge side is lowered to within a few degrees above ambient temperature by the air after cooler which is fitted as a standard m
37. CS NO US It helps to enhance the useful service life of Mud pump expendables It helps to eliminate cavitations problems of pumps It helps to maintain volumetric efficiency of the pump It helps to save the power Erosion problem can be minimized Acid corrosion of mud handlings can be avoided Main component like fluid end centrifugal pump housing and impeller can be saved from mud cut Life of equipment can be extended Man power usage can be reduced Down time can be eliminated Consumption of spares can be minimized Money can be saved PUMPS Pump is purely a mechanical device which raises the energy level of various fluids by converting the kinetic energy imparted by its prime mover into hydraulic energy Pumps can be broadly classified into three types a Centrifugal pump dynamic non positive displacement type b Rotary pump positive displacement pump c Reciprocating pump positive displacement pump CENTRIFUGAL PUMPS Centrifugal pumps employ centrifugal force for pumping liquids Liquid coming in at the centre of the impeller is picked up by the vanes and accelerated to a high velocity by the rotation of the impeller and thrown out by centrifugal force into an annular channel or volute and the discharge Centrifugal pumps are normally used for pumping water and liquids Law of centrifugal pump N Hoo 2 PooN Higher specific speed higher efficiency high head high flow is economi
38. PT series mud pumps are horizontal triplex single acting piston pumps These pumps will provide a uniform flow over a wide pressure volume range to meet any drilling requirement within its size capability These pumps are categorized by the input HP rating Detailed specifications of M S BHEL M S BPCL make mud pumps are given below SI no Description Model A850PT Model A1100PT 01 Rated in horse 850HP at 160RPM 1100 at 150RPM power Pump size 72 x 9 9 72 x 10 10 stroke 02 piston dia x stroke single single acting stroke acting horizontal horizontal Standard 5 5 2 6 62 Sa ae 03 piston size 7 amp 7 i men 72 04 Gear ratio 4 48 1 4 48 1 05 Rated working 5000psi 5000psi pressure delivery 06 Rated working 250psi 250psi pressure suction 07 Testing 10000psi 10000psi pressure delivery 08 Testing 500psi 500psi pressure suction 09 Suction pipe 8 8 diameter 10 Delivery pipe 5 5 diameter 11 Weight 34669165 17000kg 12 Cross head 0 015 to 0 025 0 40 to 0 60mm clearance 13 Crankshaft 0 05 to 0 06 1 25 to 1 50mm end play 14 Pinion shaft 0 05 to 0 06 1 25 to 1 50mm end play 15 Cross head pin 0 000 to 0 000 to in cross head 0 003 interference 0 075mm interference fit fit 16 Jackshaft 0 01 to 0 015 0 25 to 0
39. RE oRAIN ot ENGINE O11 PRESSURE OVER SPEED NORMAL OPERATION ap Al eil Pet HIGH OIL PRESSURE LOW OIL PRESSURE DRAIN OIL 4 st N HMSO SYSTEM COMPONENTS Selector valve 10 Low speed oil protection 11 valve Start up override valve 12 Diverter valve orifice 13 Engine oil pressure orifice 14 Speed sensing valve spool 15 Diverter valve 16 Rack shutoff actuator 17 Thermostatic pilot valve 18 High speed oil protection valve Emergency manual shutoff valve Air inlet shutoff actuator Air inlet sequence valve Pilot operated two way valve Rack sequence valve Air inlet shutoff valve Oil pump Oil pressure relief valve HYDRAMECHANICAL PROTECTIVE SYSTEM TO RIGHT HAND FROM LEFT HAND AIRINLETSHUTOFF AIR INLET SHUTOFF Ee THERMOSTATIC RACK PILOT VALVE ENGINE OIL 7 Pise mA X PRESSURE n M lis z ENGINE H DIVERTER VALVE Fh OIL PUMP DRAIN ENGINE OIL m 3 EMERGENCY TWO WAY MANUAL bd DRAIN SUPPLY Se E ae Ki Sp W AMA L VALVE START UP SHUTOFF d OVERRIDE DRAIN TA 9 fix AIR d SNE NSUMP OVERFLOW SUPPLY ENGINE AND ALTERNATOR ALI GNMENT Set the dial gauge stand on the alternator shaft near flywheel or flywheel housing Fix two dial gauges on the stand and set the dial gauge at zero by
40. a Limited Operation and maintenance manual Hindustan powerplus Operation and maintenance manual Elgi Equipment Limited Operation and maintenance manual Khosla Pnuematic Selection operation amp maintenance of pumps NPC The reciprocating pump second edition Miller Kricker Mud equipment manual George S Oremsby amp Walter Liljestrand Lubricant manual 1OC Lubricants manual HPCL Course material FTI Operation and maintenance manual TDS VARCO Operation and maintenance manual ID BHEL
41. acity 750 KW Motor speed 1080 rpm Draw works speed ratio 16 875 1 The draw works is powered with two DC motors of 1000 hp each Either one or both of these motors can be put into operation at a time The additional motor is only for standby operation Draw works is the heart of the drilling operation without which no work can be performed on the derrick floor It requires more care and maintenance due to involvement of different mechanisms rugged use severity and frequency of operation More over it doesn t have any standby Draw works consists of Prime mover Transmission system Hoisting system Brake system Lubrication system Cooling system zl OD HL Pneumatic control system 1 PRIME MOVER DC motors Are prime movers of Draw works Convert electrical energy input to mechanical energy Provide mechanical energy input to the draw works Suitable to variable speed requirement of draw works 2 TRANSMISSION OF 1400 DRAW WORKS A ing 3 gi f i Chey 1 2 3 SPEED CALCULATION I Input shaft speed 28 51x1080rpm 593 rpm II Output shaft speed 282 rpm amp 451 rpm III Low clutch speeds 64 rpm amp 103 rpm IV High clutch speeds 243 rpm amp 388rpm Low Transmission 20 42 X 593 282rpm High transmission 19 25 X 593 451rpm
42. al pressure in the oil separator exceedsi5psi then change the element Compressor should run in the right direction as per arrow mark in the air end Frequent loading and unloading of compressor is due to air cooler puncture or blow down valve malfunction or line leakage or more consumption of air Causes to be checked and rectify the problem Top up oil up to mark Ensure safety systems are in place Check the direction of rotation as per arrow mark DON T Y Don t allow to run the compressor with reverse rotation The compressor may cease immediately Don t allow to run the compressor with overheating problem Don t allow to run the compressor with excess differential pressure of oil HOISTING SYSTEM OF RIG E 760 1 DRAW WORKS Model E760 Draw works capacity 1000 hp Motor capacity 750 kw 1000 hp Motor speed 1000 rpm Draw works speed ratio 21 3 1 The draw works is powered with two DC motors of 1000 hp each Either of these motor can be put into operation at a time The additional motor is only for standby operation Draw works is the heart of the drilling operation without which no work can be performed on the derrick floor It requires more care and maintenance due to involvement of different mechanisms rugged use severity and frequency of operation More over it doesn t have any standby Draw works consists of Driller s console Dm mover Transmission system
43. and water is burning inside the combustion chamber PURPLE SMOKE If engine operates in the vicinity of hot springs or in surroundings with high sulphur content it will cause purple smoke from the exhaust this is very dangerous and harmful for the engine BARELY VISIBLE HAZE When the engine operates the exhaust can be seen as a clear haze against any background this means combustion is perfect and all systems are working as per the design and the engine is in the best operating condition SCHEDULE OIL SAMPLE The atomic absorption spectrophotometer measures the engine wear particles in suspension in the used oil Y Infrared analysis to determine the condition of used lube oil The IR test compares a used oil sample against a new oil sample This test can measure the presence of additional sulfur products and soot as well as oil oxidation Each oil sample should be taken when the oil is hot and well mixed VALVE LASH ADJUSTMENT Two revolutions are required for completing the tappet settings Putting the engine in one of two positions can do the adjustments of valves mentioned against the particular position Turn the flywheel in the direction of engine rotation anticlockwise rotation when viewed from flywheel until No 1 piston is at top center on the compression stroke as indicated by the flywheel housing pointer Align the TDC1 timing mark for the engine with the timing pointer on the flywheel housing On
44. appens due to rate of fuel injection Liner projection limits are given in the service manual What would be the effect of an excessive liner projection Liner flange crack Static injection timing in an engine is achieved by timing the FIP with the 1 cylinder TDC Which is not a test performed on an injector nozzle for deciding its serviceability Valve opening pressure test tip leakage test injection pressure testv Normal operating fuel pressure in PSI 30 psi Glow plugs are provided for facilitating starting in cold temperature Nozzles of D399 are Capsule type Transfer pump is mounted of the engine front right side In a D399 how many lifters are there in the fuel injection pump 16nos Bore amp stroke of the engine is 6 25 X 8 D399 Engine has number of camshafts one D399 Engine has Main bearings 9nos D399 Engine has number of connecting rods 16nos D399 Engine has Thrust plates 2nos rear side Crankshaft Thrust plate in D399 Engine is positioned rear Pistons of D399 Engine are made of alloy of Aluminium 0399 Engine crankshafts can be ground twice 25 thou 25 thou D399 Engine has Camshaft bushings 9nos Magnetic pickup is provided in flywheel housing 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 Actuator Model on D399 Engine is EG3P D399 Engine pistons have Piston Rings 3nos D399 Engine line
45. arting engine Clearance 0 022 0 022 0 022 between 10 To To To magnetic pickup 0 030 inch 0 030 inch 0 030 inch and flywheel gt Thermostat valve starts open at 82 gt Thermostat valve completely open 92 C gt Thermostatic pilot valve in the HMSO circuit opens at 99 C and shutoff the engine OIL PAN CAPACITY IN LI TERS Sl no Capacity D379 D398 D399 01 Engine crank case in Its 189 246 416 Engine coolant 257 422 530 02 including radiator 03 Low idle rpm 600 600 600 Valve lash Inlet 0 015inch 0 015inch 0 015inch 04 Exhaust 0 035inch 0 035inch 0 035inch METALLURGY OF ENGINE COMPONENTS Sl no Description D398 D399 54 Flywheel Cast iron Cast iron 02 Flywheel housing Cast iron Cast iron 03 Crank shaft Forged steel Forged steel T Main bearing Crank Steel backed Al Steel backed shaft alloy alloy 05 EE Cast bronze Cast bronze bearing a tonio bean Steel backed Al Steel backed Al alloy alloy Hardened steel Hardened steel 07 Wrist pin bearing alloy alloy Steel backed Steel backed 08 Bushing bronze bronze Cu Si Al Alloy Cu Si Al Alloy Piston 09 casting casting Cr Carbide top amp Cr Carbide top amp Piston ring Chrome plated Chrome plated 10 compression Ni Resistance Ni Resistance 11 Piston ring oil Chrome plated Chrome plated 12 Cam
46. aust air from the twin stop braking system and supply air simultaneously to Draw works clutch valve If the brake set valve is in the set position or the cam valve is in the tripped position the brake will get engaged as soon as the over ride valve is released In normal operation the brake set valve is moved from set position When the over ride valve is depressed and system is reset LOW amp HIGH CLUTCH DIAGRAMATIC CIRCUIT NC LOW NC HIGH ze PNEUATIC SYSTEM OF E760 D WORKS WORKING PRINCIPLES DRAW WORKS PNEUMATIC SYSTEM The low high clutch valve normally closed in the neutral position mounted on the driller s console receives compressed air from main valve of twin stop The moment driller engages the low clutch valve the air from low clutch valve passing into low clutch interlock valve This low clutch interlock valve normally open position immediately allows the same air to low clutch relay valve for pilot operation This air operates the low relay valve to open its port which in turn allows the main air supply through check valve to low clutch for operation A small quantity of air is immediately pass on to high clutch interlock valve to close the high clutch airline passage to prevent accidental engagement of high clutch at the same time The interlock valve acting as a safety valve prevents simultaneous engagement of both the clutch at a time While disengaging the low clutch valve th
47. cal ROTARY PUMP A rotary pump consists of a fixed casing containing gears gerot vanes pistons lobe and screws It operates with minimum clearance in such a way that a positive displacement of liquid occurs with each rotation of the drive shaft Rotary pumps are normally used for lubricating machinery and hydraulic application GEROTER PUMP No slippage Itis used for instrumentation and automotive system GEAR PUMP Slippage is more Itis used to pump the high viscous fluid like lubricant oil Uniform flow so pulse is less VANE PUMP Balance is also a problem v Y Y Non uniform flow v RECI PROCATI NG PUMPS Pulse is more due to eccentricity of shaft Slippage is less compare to gear pumping Reciprocating pump employs a piston in a cylinder positively displacing a given volume of fluid for each stroke It is normally used in ONGC for pumping high viscous fluids like mud and crude oil Differences between positive and non positive displacement pumps Sl no Positive displacement pump reciprocating pumps Roto dynamic pumps centrifugal pumps 01 It runs at slow speed It runs at high speed 1 The discharge volume does not change with variations delivery head 2 The delivery pressure 1 discharge volume decreases with increase in delivery head 2 They can develop a may rise dangerously if the delivery pipe is
48. d pressures are variable within wide ranges The air flex CB clutch torque capacity is directly proportional to the air pressure applied up to the maximum air pressure permissible Permissible misalignment is indirectly proportional to the air pressure The VC clutch is suitable for applications at higher air pressures than the CB model Within the design limits the clutch will transmit full torque at the same air pressure regardless of the amount of wear Air expands the actuating tube uniformly engaging the 360 friction surface at maximum diameter to provide greatest operating torque The actuating air tube automatically compensates for friction shoe wear eliminating the need for adjustment centrifugal force and release springs assure total disengagement of the friction shoes from the drum the moment the air is expelled Lubrication is not required The torque developed is proportional to the applied air pressure By limiting the applied pressure the element will act as a torque limiting device and provide overload protection To accomplish regulated or cushioned engagement of the element a flow control valve is installed with restricted flow to element and free flow away from element When the friction material has worn down approximately two thirds of its original thickness friction linings must be replaced in complete sets not few at a time The number preceding letters VC in the element size designates the original drum diameter in i
49. e air to pilot operation of low relay valve is stopped immediately and main supply port to low clutch is cutoff Now the check valve allows the small quantity of air to vent from low clutch supply line Because of this there will be pressure different before and after quick release valve Now the quick release valve quickly acts and vents the low clutch air to atmosphere The same principle will follow while engaging high clutch The symbols and functions of pneumatic valves are given elaborately for easy understanding Draw work pneumatic system consists of v Signal components Valves Controlling components Valves v Working part air motors clutches brakes cylinders etc TYPE OF VALVES BW N Directional control valve Non return valve Pressure control valve Flow control valve Shut off valve The various types of valves are used in the pneumatic system to control regulate and direct the flow of compressed air according to operational requirement VARIOUS TYPES OF PNEUMATIC VALVES AND THEIR FUNCTI ONS Sl no Description Functions 01 Directional control valve On off function 02 Over ride valve Cracking pressure 03 Relief valve Limiting pressure 04 Pressure reducing valve Reducing pressure 05 Flow control valve Regulate flow 06 Check valve Permits flow of air in one direction 07 Shuttle valve Permits flow of air in two direction Normally open u 08
50. ecessary to ensure oil supply to them almost immediately after the engine starts A choked air cleaner can also cause a vacuum in the suction side of the compressor wheel leading to leakages in the seals of the turbocharger and allowing oil to be thrown into the intake manifold causing more lubricating oil consumption and blue exhaust smoke Hence timely changing of air cleaner element is paramount important not only for long life of turbocharger but also for engine life NOTE All turbocharged engines must be idled for 3 5 min time immediately after startup and before shutdown This ensures lubrication and cooling of the bearing shaft seals and bearing housing etc It helps us to increase turbocharger operating life AIR INLET AND EXHAUST SYSTEM EXHAUST GAS INLET AIR COMPRESSED AIR WATER T 5429 AIR INLET AND EXHAUST SYSTEM Exhaust manifolds 6 Left cylinders Right cylinders 7 Turbocharger turbine wheels Diffuser plate 8 Left turbocharger impeller Right turbocharger impeller 9 After cooler Exhaust elbow INTAKE AIR TEMPERATURE Air molecules expand at high temperature occupies the areas with less density This less density hot compressed air provides inadequate quantity of oxygen molecules to the cylinders It is not enough for complete combustion of fuel in the cylinders and increases the exhaust temperature Hence high intake air temperature of the engine is undesirable for proper combustion
51. er cooled through a stuffing box ic 10 9 tg Water Jacket Brake Drum Brake Drum BRAKE BAND BHEL DRAW WORK 711 TO 815 FLOOR LEVEL DRAW WORKS BRAKE USTMENT A Using special wrench attached to inside of front guard adjust nuts 1 on dead end of each band until brake lever sets at desired height usually 711 to 813 from end of handle to floor B Clearance between end of equalizer and stop should be 3mm on each side if one side is higher than the other Loosen the adjusting nut on the high side and tighten nut on the low side on equivalent to 3mm clearance re adjust stop screws when clearance exceed With brake set tighten all stop screws 2 until they just touch band then back screws off one turn this is equivalent to 3mm clearance re adjust stop screws when clearance exceed D Anchored at one end E The other end is actuated by lever mechanism that tightens the bands around the rims Brake blocks gt Are mounted on the inside of the bands gt Contact the rotating rime when the brake is engaged LEVER SM gt Force the bands to close on the twining rims gt The large angle of wrap and width of brake lining provides for a large contact area between the brake lining and brake flanges m D 1 Elmagco It acts as a retarder It slows input speed But it will not bring the input speed to a complete stop NN Normal
52. for proper functions of pneumatic systems DRY AND CLEAN AIR Free from all contaminants and having gt 78 of nitrogen molecules gt 21 of oxygen molecules and gt 01 of other gases What is compressed air How achieve it Pressurized atmospheric air is called compressed air Compressor is converting mechanical energy into gas energy by means of compressing air at desired working pressure Why compressed air is needed Compressed air is needed to carry energy for work at different locations areas equipment GENERAL APPLICATION OF PNEUMATIC SYSTEM gt Power application gt Process application gt Control application APPLICATION IN RIG gt Power application Ex starting of engine engaging clutches gt Control application Ex driller s console TYPE OF VALVES 1 Directional control valve 2 Non return valve 3 Pressure control valve 4 Flow control valve 5 shut off valve The various types of valves are used in the pneumatic system to control regulate and direct the flow of compressed air according to operational requirement VARIOUS TYPES OF PNEUMATIC VALVES THEIR FUNCTIONS Sl no Description Functions 01 Directional control valve On off function 02 Over ride valve Cracking pressure 03 Relief valve Limiting pressure 04 Pressure reducing valve Reducing pressure 05 Flow control valve Regulate flow 06 Check valve Permits flow of air i
53. ful to mix floating lost circulation material and carry it below the mud surface where it is wetted and picked up by the main mud pump to be pumped into the well The purpose of using mud agitators mud guns To prevent weighting material from dropping out of Suspension during the slow travel of mud through the pits Y To break up gel strength mud To reduce apparent viscosity of mud and permit gas bubbles to escape in miner gas cutting To promote good mixing of mud when a jet hopper is used to add weighting material or clay to the system DEGASER Degasser removes entrained gas from the gas cut mud coming out of drilling hole It is necessary to maintain gas free mud to avoid cavitations problems of mud handling pumps for their optimum performance and also to control specific gravity of mud to maintain hydrostatic pressure of the well Degasser is normally kept just after shale shaker to remove gas from the mud before the desander pump handling the mud to avoid cavitations problem Mud enters the degasser through an 8 riser pipe at the right end of the vessel The suction port of the vacuum pump mounted on the top of the unit connected to left end of the vessel through pipes and three way valve The three way valve again connected to a floater The floater functions depend on mud level inside the vessel which will open or close the three way valve to the atmosphere and thus controls vacuum inside
54. g rods at crank and crosshead ends Crossheads are cast ductile iron operating on replaceable upper and lower shoes in renewable shim adjustable guides The connecting rods are two piece design which permits separate installation of connecting rods into pump and in frame assembly of connecting rods to crankshaft The dual lubrication system is designed to provide constant trouble free operation The cascade oiling system will temporarily provide lubrication even in the event of oil pump failure The three fully interchangeable and individually replaceable L shaped fluid cylinders afford easy maintenance For time saving and convenience the piston rods are threaded two piece construction which quickly disassemble to facilitate removal of pistons without disturbing the liner Valves and valve seats are removed and replaced thru individual valve covers This pump incorporates all features contributing to low cost trouble free maintenance WORKING PRINCIPLE OF MUD PUMP The chain driven sprocket from the power source is attached to the pinion shaft and causes it to turn a smaller gear The pinion drives a larger gear i e bull gear The bull gear is attached to the crankshaft the crankshaft turns to give a back and forth motion to the connecting rods The connecting rods are linked to the crossheads The crossheads are connected to the piston rods and impart back and forth or reciprocating motion to the rods PULSATIONS EFFECT OF
55. haft 19 Cross head clearance is to be checked and adjusted once in six month 20 Pre charge pressure of nitrogen in the hydril chamber is 1 3 of mud pumps discharge pressure or maximum up to 1000psi PRE CHARGE PRESSURE OF HYDRIL BALOON sino Mud pump discharge pressure in psi Hydril pressure in psi 01 1500 350 02 2500 500 03 3000 700 04 4000 900 05 5000 1000 NOTE Pre charge pressure of hydril is not less than 20 of expected maximum delivery pressure ADVANTAGES OF RUNNING THE PUMP AT LOW SPEED Infinite life could be expected at zero pump speed and zero life at infinite speed due to abrasive wear of expendables of reciprocating pumps is exponential not linear Speed of the pump produce wear and shorten parts life The detrimental effect on parts life and efficiency of pump at 1 High speed 2 Short stroke 3 High discharge pressure 4 Low suction pressure Fast speeds and short stroke result in high stroke reversal rate is a major cause of wear in reciprocating pumps handling abrasive liquids If pump speed is reduced to half of rated speed parts life improvement more than doubles longer stroke length contributions to greater parts life are effective because they decrease stroke reversal rate At reduced speed for equal output results in significant cost savings from increases in the expected life of expendable pump parts The piston speed below 200 fpm generally provides
56. he butterfly type air inlet valve directly controls the amount of air intake into the air end in response to the operation of the silicon control DISCHARGE SYSTEM The compressor discharges the compressed air oil mixture through a discharge check valve into the combination receiver sump The discharge check valve prevents air in the receiver from returning to the compression chamber after the machine has been shut down RECEIVER SUMP It has got three main functions 1 Acts as the primary oil separator 2 Serves as the compressor oil sump 3 Houses for oil separator element Oil collected at the bottom of the separator is return to the compressor by a pressure difference between the separator and the compressor inlet The pressure drop across the separator element shows more than 15psi the separator element needs replacement MINIMUM PRESSURE VALVE A minimum pressure valve is located at the downstream of the separator just above the sump assures a minimum receiver pressure of 3 4kg cm during all conditions This pressure is necessary for proper air oil separation and to assure proper oil circulation in the system CHECK VALVE It is located after minimum pressure valve to prevent compressed air in the service line from bleeding back into the receiver on shutdown and during operation of the compressor in an unload condition PRESSURE RELI EF VALVE It is located at the wet side of the separator It will
57. he turbocharger compressor side seal fails there will be traces of oil in the air filter Turbocharger shaft end play specifications 0 004inch to 0 006inch 5 Oil cooler is responsible for cooling oil The temperature difference across outlet and inlet of the radiator is 7 to 11 C Pressurized cooling system is provided to increase the boiling temp of water The working pressure of D399 cooling system is 7psi 9 Engine trips at a temperature setting of 99 C 10 11 12 13 14 15 Thermostat starts opening at 82 Thermostatic pilot valve is responsible for the tripping of the engine when there is overheating A fuel will detonate less if it has higher self ignition temperature An injection timing retard 5 in a diesel engine will cause high boost Cetane number is determined by comparing the performance of diesel oil with the mixture of cetane and alpha methyl naphthalene Excess quantities of sulfur in diesel pave the way to formation of corrosive acids 16 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 If one cylinder of a diesel engine receives more fuel than the others then for that cylinder the exhaust temperature will be high If the intake air temperature of IC engine increases its efficiency will decrease In a diesel engine combustion processes the shift from controlled combustion to uncontrolled combustion h
58. igh low speed Sl SCH Description lubricator Hydraulic fluid Servo mesh Servo system OFON grade SP320 HLP 46 02 Quantity 15gal 57 Its 25gal 95lts s 20 to 4 0 o 03 Operating temperature 200 F maxi 10 to 85 C 04 Oil change interval 6months 6months 05 Replacement of oil filter 3months 3months P N 111013 1 P N 114416 1 CONSUMABLES Consumable parts Part number Quantity 01 Tong Dies 16401 2 4 02 Stabilizer Front 118368 1 03 Stabilizer Rear 118367 1 04 Guide Arm Stabbing 76442 2 Guide Flippers 05 Wash Pipe Standard 30123289 1 Wash Pipe Tungsten Up Coated High Pressure MUS 1 Wash Pipe Assembly 07 Standard 30123290 08 Wash Pipe Assembly 30123290 High Pressure 1000 09 Wash Pipe Packing Kit 3 standard use with wash pipe 123289 30123290 10 Wash Pipe Packing Kit 3 High Pressure use with wash pipe 123289 TC only 30123290 PK 1 11 Hydraulic Oil Filter 114416 1 12 Gear Oil Filter 111013 1 13 Brake Pads KHOLA COMPRESSORS MODEL SESH1 155 v v v v v v S Stationary E Electrical driven S Screw H High pressure application 1 Single stage MODEL TDSH1275 v v v v v v T Transferable D Diesel engine driven S Screw type compressor H High pressure application 1 Single stage 155 Capacity cubic feet per minute 275 Capacity c
59. in a better way This will help the operator to select the suitable transmission for lifting load and maintenance crew to diagnoses the problem in a systematic way TRANSMISSION SYSTEM MOTOR 1000RPM 21 a Wl KA ag Joy d 422 RPM RP ORT OUTSHEFT ij CAT SHAFT wins om m d rt LO a 02 123 WO 2 499 1 REALI Cen i p A F Ett DRUM SHAFT ei LO H 04 20 Mi X Sen H 117 9 RICSHAFT RN LO 186 AV vg 197 T 0 SPEED CALCULATI I Input shaft speed 27 64X1000rpm 422 rpm II Output shaft speed 201 rpm 321 rpm 499 rpm OUTPUT SHAFT RPM at 1000 RPM of Motor Low Transmission 20 42 X 422 201 Intermediate 19 25 X 422 321 High Transmission 26 22 X 422 499rpm III Low clutch speeds 47 rpm 75 rpm 117 rpm IV High clutch speeds 201 rpm 321 rpm 499 rpm DRUM SPEED Transmission Low clutch High clutch Low 18 77 X 201 247 rpm 36 36 X 201 201 rpm Intermediate 18 77 X 321275 rpm 36 36 X 321 321 rpm High 18 77 X 499 117 rpm 36 36 X 499 499 rpm HOOK LOAD CAPACITY Drum Transmission Speed 10 lines 10 lines in clutch clutch in Ibs tonnes Low 47 4 18 000 190 Low Intermediate 75 3 35 000 152 High 117 2 99 000 136 Low 201 2 12 000 96
60. ing in HP 1400 Maximum drilling depth 4900 mts Drill pipe size 41 2 v v v v Maximum load carrying capacity 190tonnes Rig equipment can be divided into five categories VV ON ON WV Power producing equipment Hoisting equipment Rotating equipment Fluid circulating equipment Auxiliary equipment 1 Power producing equipment Power packs Compressors 2 Hoisting equipment Draw works Crown block Traveling block gt Hook gt Air winch 3 Rotating equipment gt Rotary table gt IRD gt Top Drive System gt Swivel 4 Fluid circulating and conditioning equipment gt Mud pumps Hopper De sander De silter Shale shaker De gasser Mud agitator VV ON ON Y Mud mixture 5 Auxiliary equipment gt Water pumps gt Diesel lifting pump gt Welding transformer gt Lighting I POWER PRODUCING EQUIPMENT 1 POWER PACKS ONGC Drilling Rigs are mainly powered by Caterpillar make D399 model engines These engines are the source of power to the Drilling Rig Equipment Hence engines are considered to be heart of the Rig Each Rig of E760 Model having three power packs and E1400 Model having four power packs These power packs can be put into operation individually and parallels with common bus bar provision These power packs produce mainly AC current Part of the AC is converted into DC with help of silicon control rectifier This DC in
61. is pressurized XN Top up lubricant in engine oil sump preferably upto middle of dip stick in between low and high mark DON T Y Do not operate the engine with safety system bypass Don toperate the engine without radiator cap Y Don trun the engine with abnormal smoke Don t run the engine with overload Don t run the engine with under load for long time Don t run the engine with idle condition for more than 15minutes Don t run the engine with overheating problem Don t run the engine with mechanical noise Don t run the engine with air cleaner element choking condition that lead to failure of turbocharger seal SPECI FI CATI ON SI Model Model Model Model Model Model Description No D379B D398B D399 3508 3512 3516 Year of 01 1961 1962 1967 1981 1981 1981 production Bore in inch 6 25 6 25 6 25 6 7 6 7 6 7 02 Bore in 158 8 158 8 158 8 170 170 170 mm Stroke in 8 8 8 7 5 7 5 7 5 inch 03 Stroke in rta 203 2 203 2 203 2 190 190 190 Cylinder v 8 12 Popes Wes Vado Ns 04 arrangeme nt 60 60 60 60 60 60 Four Four Four Four Four Four 05 Engine stroke stroke stroke stroke stroke stroke type TA TA TA TA TA TA Valve per 06 2 2 2 4 4 4 cylinder Displaceme 07 1964 2945 3927 2105 3158 4210 nt in cubic inches 32 2 48 3 64 4 34 8 51 8 69 1 In liters Compressio 08 IS I 1551 151 13 1 37i 13 1 n
62. is injected the fuel air mixture ignites and the energy of the fuel is released to force the pistons downward and turn the crankshaft A perfect fuel would burn completely leaving no residue or smoke products However there is no perfect fuel CETANE NUMBER Cetane number is a measure of the ignition quality of a fuel Y Higher cetane rating assures ease of starting in most conditions POUR POINT The pour point of a fuel is an indication of the minimum temperature at which the fuel will flow CLOUD POI NT Y The cloud point is the temperature at which some of the heavier paraffin components wax in the fuel start to form crystals This wax can plug the filter NOTE Heat changes the volumetric efficiency of fuel resulting in a 1 power loss for each 6 C above 38 C CATERPILLAR FUEL SPECI FI CATI SI Requirement Preferred Permissible no Cetane no for 01 pre combustion 35 minimum 35minimum engine Cetane no direct 02 injection engine 40minimum 40minimum Water amp 03 sediment 0 1 max 0 5max 04 Pour point 10 F below ambient temperature Not higher than ambient 05 Cloud point temperature 06 Sulfur 0 5 max 0 5 max C LUBRICATION SYSTEM Oil is the blood of an engine The lubricating oil has to perform several basic functions during engine operation T Clean Cool Seal Lubricate Support and Protect NOTE During engine star
63. it lubricates seals and cools the rotors and the compression chamber As the discharge temperature rises above preset temperature due to heat of compression the thermal valve begins to close and a portion of the oil then flows to the cooler for cooling From the cooler the oil passes to compressor unit through filters NOTE The pressure in the receiver sump causes flow of oil from the high pressure area in the sump to an area of lower pressure in the compressor unit BEARING FILTER It has a replacement element and an integral pressure by pass valve When the pressure drop exceeds 5 kg cm the filter needs servicing OIL STOP VALVE The oil stop valve prevents oil flow to compressor when the compressor is shut off When the compressor is operating the oil stop valve is held open by the pilot pulse from the air end allowing a free flow of oil from the receiver sump to the air end On shut of the air end pressure gets reduced significantly causing the oil stop valve to close and cut off oil supply to air end IMPORTANT POINTS TO REMEMBER Tf lub oil is coming out from the suction air filter of the compressor while stopping the compressor then it is the failure of oil stop valve change it DO v v v Overheating of compressor may be due to insufficient oil in the sump or oil cooler choke or cooling motor fan failure or thermostat valve failure etc check the causes and rectify problem If differenti
64. k developed by drilling operation The hook is suspended from the travelling block to grasp the various pieces of equipment components needed for drilling operation and round trip The hook has swivel and position locks The hook cushions the weight of the drill pipe so that tool joint threads are not damaged in making up or breaking out of the pipe Hook prevents from twisting of wire ropes in the travelling block 6 Swivel Swivel joints two parts to pivot freely The rotation of drill string begins with swivel The swivel prevents torque transmits to sheave block system Its basic functions are BW N TO support load To allow drill stem to rotate TO Support wash pipe and gooseneck to Provide a connection for the rotary hose to drill string allow drilling fluid into the Kelly and drill string MODEL gt Y WV PC300 Load capacity 300tons 41 2 drill pipe Fluid passage 31 2 Oil sump capacity 59 liters SWIVEL WLLL 2 GOOSENECK d 7 d KS nre QW PACKING HOUSING W PACKING RADIAL ROLLER AND ROLLER THRUST BEARING UPPER 011 SEAL AMEN 2 Gal UPPER WEAR HOUSING y WA pK cum 75 Vj CH ROLLER f ARING aL LOWER WEAR SLEEVE Dowel Pin WASHPIPE ASSEMBLY Ensure that the nose of the socket head dog nose screw is fully engaged in the groove of the lo
65. l 14 valve clutch 4 96611 3 15 Rotor seal Low clutch 0010 16 Rotor seal High clutch 06 001 857A Rotary 06 001 857A _ 17 Rotor seal clutch Sandreel 4 96614 3 18 Rotor seal clutch 0078 19 Check valve D W 06 000 667 P55026 20 Pressure Air supply 06 000 940 regulator Transmission 21 valve 2HA 2 Gear shifter Crown o 22 Cam valve matie 2412 G H Bear 23 Shuttle valve 2413 G H Bear matic 24 Main valve Sons 2669 G H Bear matic 25 Check valve nos 2467 G H Bear matic 26 Over nae 2411 valve matic Brake 27 D W 2414 G H Bear cylinder main 28 Air Cylinder Rotary Brake 06 001 264 29 Aircylinder L9 drum 06 001 264 drive 30 Air cylinder Transmission 06 010 083 31 Air cylinder Neutral 960012264 brake 32 Valve Rotary brake 06 000 561 33 Transmission Transmission TP5 2049 PD20045 valve valve 34 Air cylinder Transmission 06 000998 35 Rotor seal COLD 06 001855 clutch 36 Relay valve P57431 a7 es PD20000 0020 valve PD20000 0098 valve end kit Over ride 39 3014 GH Main valve 40 crown o 3013 GH matic Cylinder Air brake OE975102000 54 1 85 0131 41 BIBILOGRAPHY Hoisting Equip Operation and maintenance manuals BHEL Operation and maintenance manual Caterpillar USA Operation and maintenance manual Cummins I ndi
66. l of voltage that determines the actuator terminal shaft position required to maintain a particular load on engine The voltage is always same polarity Electrical control must produce voltage at the lead terminals for actuator during cranking is equal to 4 Volts Resistance between leads is 30 to 40 Ohms Higher resistance is an indication of bad actuator Coil current is 20 to 160 ma Coil resistance is 30 to 35 Ohms Actuator should have 50 ma at high idle While staring the engine the actuator initially draw the current about 30 to 45ma Actuator draws maximum current on load is upto160ma VI SUAL INSPECTON A GOVERNOR LI NKAGE CHECKS a b h Linkage must move freely without binding and backlash Ensure full travel available to fuel off as well as fuel on positions Ensure joints are not in loose condition Ensure ball joints are pivot freely Oil pressure minimum at cranking speed 345psi at cold start 22 and 115psi at hot start 85 C Oil pressure at pressure tap at rated speed is 400psi MAGNETIC PICKUP The magnetic pickup to flywheel ring gear tooth clearance is 0 56 to 0 85mm Tight the magnetic pickup to touch the flywheel and loose it by turning 2 round anticlockwise direction This is approximately 0 56 to 0 85mm IMPORTANT POINTS TO REMEMBER After cooler is responsible for cooling air 2 Turbocharger boost pressure is measured at inlet manifold 3 If t
67. lds the elevators during round trip The selection of travelling block depends on its load carrying capacity required for drilling operation The sheaves are precision balanced and operate on heavy duty roller bearings The large diameter center pin is made of heat treated high carbon steel It is designed for maximum rigidity and strength Easily removable strong steel plates are provided for safety lt S Grease is to be done judicially as per maintenance schedule Ply is to be checked during every rig building to see any abnormality Groove diameter is to be measured for wear out limit Ensure safety guards are in place and secured DON T Don t keep the travelling block in the floor to avoid foreign particles entry MODEL AND CAPACITY OF TRAVELLI NG Gl Description Unit Capacity Capacity 01 Model Tons 350 500 02 Load capacity Tons 350 500 03 Sheaves Nos 5 6 04 Outside dia of sheaves Inches 42 50 1 or 05 Wire line size Inches 1 13 8 06 Center pin diameter Inches 8 10 07 Overall width Inches 27 31 08 Overall height Ft in 6 11 8 83 4 Distance center to 09 Ft in 28 3074 top 10 Weight Pounds 8500 12830 The mechanical advantage in lifting a specific load is proportional to the number of lines in contact with the traveling block i e the number of lines in and out of the traveling block It is this mechanical
68. ly after sulfuric acid has formed Engine temperature is an important factor in the creation of sulfuric acid The exhaust gas containing sulfur oxides must combine with water to form sulfuric acid Therefore the engine should operate above dew point temperature to minimize acid formation Low engine operating temperatures provide ideal conditions for sulphuric acid condensation High humidity levels in combustion air supply the water necessary to form acid Another factor that determines the quantity of acid formed is the amount of fuel used during an oil change interval During combustion the fuel s sulfur is converted to sulfur oxides Naturally the more fuel consumed during an oil change interval the more sulfur oxides are available to form acids FACTORS AFFECTING ACID FORMATI ON 1 Fuel sulfur content 2 Engine temperature combustion air humidity 3 Fuel consumption 4 Clean oil addition INDICATORS OF CORROSIVE WEAR Increased oil consumption Crankcase blow by in blow by Blue exhaust smoke Acid attacks cylinder liners piston rings exhaust valve guides and other engine parts When enough corrosive wear has taken place you will probably notice increased oil consumption more blow by and vapor in the crankcase Blue exhaust smoke may also occur as a result of acid attacks E EXHAUST SYSTEM REQUI REMENTS The exhaust system of an engine plays an important part in the overall perfo
69. ly the ECB is used during running in operation f LUBRICATION SYSTEM 1 Bearings are grease lubricated 2 Chains and sprockets are oil lubricated 3 Oil changing period gt 6 MONTHS or condition of oil 4 Avoid excess greasing oil LUBRICATION OF DRAW WORKS IMPORTANT PARAMETERS Changing Type of Grade Capacity greasing Psi lubrication period 6 month All chains 55220 6005 condition 20 50 lubrications gallon of oil All bearings including EP2 toggling lithium Daily system weekly water grease stuffing box Sl no Description Capacity measures 1 LUB OIL SS220 230 Its 2 OIL PR ON GAUGE 20 50 psi 3 BRAKE COOLING WATER D W 35 gpm 4 COOLING WATER ECB 50 gpm 5 WATER PR ON GAUGE 50 75 psi 6 AIR PR TRANSMISSION CLUTCHES 75 psi 7 AIR PR LOW amp HIGH CLUTCHES 150 psi 8 AIR PR SANDREEL CLUTCH 90 110 psi 9 AIR PR ROTARY CLUTCH 90 110 psi 10 BRAKE LEVER HEIGHT 710 810 mm 11 GUIDE ROLLER CAP 3 2 mm CHAIN SPECI FI CATI ONS 61 Description Chain Location Quantity in nos A 1 2 X 116 X Input chain 2 Triplex B 2 X 46 X Doublex Intermediate 1 2 56 X Doublex Low Transmission 1 D 2 X 48 X Doublex High Transmission 1 E 2 X 76 X Doublex High Clutch 1 F 2 X 92 X Doublex Low Clutch 1 G 2 X 76 X Singlex CAT Head 1
70. made up of steel casting internally ribbed to give maximum strength with minimum weight It supports the bearings and act as oil path enclosure 10 Wash pipe assembly is also another important part of swivel which needs to be greased once in round trip DO 1 AA Keep the swivel always in the vertical position in the specially fabricate platform Disconnect the Kelly from the swivel while transportation Top up proper oil up to the mark Clean the breather to vent the gases from the swivel oil sump Daily physical checks are to be done before and after starting the equipment to identify any abnormality that will help us to rectify the problem DON T Don t fill up oil full of housing The oil will expand due to temperature raise during operation and pressure buildups inside the housing ultimately damage the oil seal Don t lift the swivel with Kelly in the horizontal position because the bearings of swivel will not take horizontal loads Don t keep the swivel in the slanting position It damages the bearings Rotary hose is rotating with swivel is the failure of swivel bearing Don t allow to run further without rectification of problems ROTARY TABLE Rotary table supports the weight of any pipe or casing run into or from the hole It provides rotary motion to the drill string via Kelly to drill bit The main bearing completely supports the turntable and its drill s
71. ment of both clutches at a time Transmission clutches are spline type and air shifted from the driller s position The spline type clutch has been provided the transmission system to obtain minimum backlash and reduce impact or shock loads as compared to the jaw type clutch Y Fan type spray nozzles are provided the draw works lubrication system The self energizing type 306 main brake system is provided in the E760 draw works This has high ratio of brake rim diameter to drum spool diameter for maximum braking effect v Clutch shifting is completely air controlled from the driller s console The draw works will ordinarily be moved in three pieces main sections rotary countershaft section and motor skid Y An adequate supply of cooling water is essential for satisfactory brake performance Proper lubrication and adjustment are essential to long bearing life Taper roller bearings may be adjusted by shim removal between the bearing retainer and sprocket of each shaft Spherical roller bearings require no adjustment Straight roller bearings under drum shaft sprockets require no adjustment Y Friction shoes with replaceable linings should be replaced when the d friction material has worn down approximately 2 3 of its original thickness DO 1 If the low or high clutch is continuously engaging with drum while the pneumatic valve low high is off position then it is the failure of valve
72. n one direction 07 Shuttle valve Permits flow of air in two direction 08 aue Normally open position 09 per Normally closed position solenoid valve CHECK VALVE Bees DIRECTIONAL CONTROL VALVE 2 2 WAY 3 2 WAY APPLICATION OF COMPRESSED AIR IN DRILLING RIG EQUI PMENT Main power pack engines Draw works Rotary table Air winch BOP Kelly spinner Pipe spinner Purging of electrical panel in driller s console gt Cellar pit cleaning gt Air horn gt Cleaning of casing pipe and drill pipe AIR FLOW DIAGRAM OF DRILLING RIG come 1 Co 6 E 22 recerver 23 TANK 1 E RECEIVER ey TANK A POWER e DRAW WORKS Co KELLY SPINNER AIR WINCH 29 c PIPE SPINNER CELLAR e CLEANING AND OTMER PURPOSE TYPES OF COMPRESSORS POSITIVE DISPLACEMENT Screw compressor Reciprocating compressor DYNAMIC TYPE Centrifugal compressor COMPRESSOR Drilling Rigs are equipped with two types of compressors for utility service in drilling operations of Cauvery Asset They are M S ELGI make screw and reciprocating compressors and M S khosla make screw compressors ELGI SCREW COMPRESSOR Model SR12100LH SR12 12series 100 HP of motor LH low and high pressure application Free air delivery 250CFM 7 08M MIN Working pressure 10 5kg cm
73. nches d HOISTING SYSTEM The E760 Draw works is equipped with an engineered drum 25 in diameter by 4934 long The drum is provided with Lebus grooving system for reeving the wire rope This draw works is engineered to fully load the capacity of 1 wire line and when using this size line it will provide for 8 lines reeving with no more than three layer spooling on the drum Drum gt Drum size dia by length 25 X 49 34 Drum brake dia by width 46 X10 Number of speed Drum Forward 6 Rotary Forward 3 gt Lebus groove are for spooling of 1 1 4 wire line Accommodates 8 line reeving and three layers spooling on the drum e DRAW WORKS BRAKE SYSTEM Large diameter drum barrel with 10 x 46 water circulating type brake rims bolted to drum Full wrap single point adjusted fully equalized brake bands to deliver extra self energizing effort BRAKE It is a device by means of which artificial frictional resistance is applied to a moving rotating body in order to retard or stops the motion of a body Exterior band type brakes which consists of gt Hoisting drum gt pair of brakes gt Brake blocks gt Lever mechanisms Hoisting drum gt With steel brake rims at each end gt It will be slowed stopped when the brakes are applied gt The rims of hoisting drum provide the braking surface for the brake blocks gt Brake flanges are wat
74. on t run the pump without coolant for piston and liner Don t run the pump with mud leakage from tell tale holes Don t run the mud pump without supercharger GENERAL INFORMATIONS RELATED WITH DRILLING RIGS 1 TECHICAL SPECIFICATIONS OF BEACON WEIR MAKE WATER PUMPS SI no Operating Units of Model Model Model parameters parameters BWC DOB DOC 50 80 80 100 100 125 01 Flow rate M hour 30 25 35 02 Flow rate Liters min 500 417 583 03 Flow rate Gallons min 110 91 7 128 3 04 Delivery head Meters 100 75 85 05 Delivery Kg cm 10 7 5 8 5 pressure 06 Delivery psi 142 107 121 pressure 07 Operating speed rpm 3000 1460 1470 08 BHP obtained hp 27 4 13 7 22 2 09 MHP hp 60 30 50 recommended 10 NPSH required meters 4 6 5 6 3 8 11 Suction end mm 80 100 125 12 Delivery end mm 50 80 100 13 efficiency 40 50 49 14 Casing body material Cast iron Cast iron Cast iron 15 impeller material Cast iron Cast iron Cast iron 16 Stuffing box material Cast iron Cast iron Cast iron bushes 17 Glands material Cast iron Cast iron Cast iron 18 Shafts material EN 8 EN 8 EN 8 19 Shaft sleeves material Mild Mild steel Mild steel steel 2 TECHNI CAL SPECIFICATION OF MISSION MAGNUM PUMPS Sino Param Unit Model Model Model Model Model eter 8 x 8 x 8 x 8 x18 6 x14 6 x12 5 6 x10 6 x12
75. on the driller s console This valve partially supplies air to pilot operated relay valve which needs to repaired replaced or Clutch shoes retainer springs tension is also to be checked for clutch release if required change the spring If releasing of air from the clutch is delayed then cleaning is to be done on the quick release valve diaphragm If clutch slips on load it may be due to less air pressure malfunction of interlock valve or relay valve Check and correct fault accordingly a If tracking or delay in disengagement of catheads then check the malfunctions of cathead operating valve or of quick release valve b If tracking is in the catheads spring tension is more in the just bottom of the cathead This needs to be adjusted c If cathead is not taking full load it is due to inadequate air pressure or spring tension The air pressure must be checked and ensured110psi or adjust the spring tension if required If the brake cylinder is continuously engaging position then malfunction of main valve or wrong air line connection in the crown o matic circuit Check and correct it If braking effect is less it is due to unequal 3setting of brake bands Set the brake bands by keeping equal gap in both sides of the equalizer beam but not counting number of threads in the eyebolts Frequent failures of chains are due to misalignment starvation of lubricant shear of shear pins looseness of chain
76. p Its primary purpose is to protect the pump when the discharge line another part of the hydraulic system or bit nozzle becomes plugged IMPORTANT POINTS TO REMEMBER 1 When the pump alignment is achieved it should be reinforced by shear blocks or dowel pins 2 Single acting pumps require a flooded or charged suction for proper performance A net positive suction pressure as provided by an adequate centrifugal charging pump will aid in the filling of the fluid cylinders and reduce the erratic operation caused by cavitations Generally the charging pump should have a capacity equal to 1 times that of the triplex pump 3 The suction line should be as short as possible and the fluid velocity should not exceed 3 feet second Maintain the lowest possible velocity and the lowest possible pump speed to provide for maximum pump performance 4 A suction stabilizer is recommended installed as close as possible to the pump inlets 5 Installed a discharge pulsation dampener as close to the pump as possible 9 10 11 12 13 14 15 16 Installed a pressure relief valve ahead of any valve in the discharge line It must be set at a pressure not greater than 25 above the rated working pressure of the pistons or plungers being used The pump is designed for clockwise rotation of the crankshaft when viewed from the right hand side Right or left hand side is determined by standing at the powe
77. pressure is not sufficient solids do not separate well from the mud If there is too much pressure the service life of the units is drastically reduced Most desander operates at about 35 psi and most desilters at 45 psi The most common causes of internal wear are excessive pump pressure to the cone unit and closer of the apex to such an extent that separated solids cannot escape thus plugging the opening and preventing further separation 3 DESILTER The de silter is used in the mud system for the purpose of removing silt particles It is the third and final stage of solids removal program for weighted mud A centrifugal pump should be used to feed desilter with mud This pump delivers smooth even flow to the hydro cyclones for separation of desilting particles Good desilters properly operated reject all material of sand size a high percentage of solids larger than 10 20 microns and decreasing percentages of materials down to 2 3 microns Total desilting of the mud in drilling can cut down drastically on mud pump wear hole problems bits time required to drill the hole water and chemicals required for mud treatment NOTE For maximum removal efficiency the discharge from the apex opening should be in the form of a spray rather than a rope discharge Particle Handling Working ee Pump Temp size in capacity pressure EE size Size eratu 5 Description micron in gpm in psi r Shale 25
78. proper lubrication Check for the concentric clearance between the clutch drum and clutch Check for proper functioning of the lubrication system for the transmission Ensure proper seating of the skid and tightening of bolts Check and verify the clearance between the two sprockets of the chain coupling i e 3 5 0 5 Check and ensure proper lubrication to the transmission Ensure adequate air supply to clutch for effective function of brake system DON T Don t apply excessive torque on rotary It may leads to failure of rotary table The maximum allowable current for maximum torque on rotary table is 500 ampere TOP DRIVE SYSTEM The main purpose of installing the top drive system in the drilling rig E1400 09 is to eliminate the drive from draw works to rotary table to swivel to drill string during drilling operation to save energy It will also help us to reduce manual activities in the derrick floor and facilitate quicker and faster pipe connection to save time MODEL TDS 11SA TDS Top Drive System 11 11 Model S Swivable Assembly IMPORTANT POINTS REMEMBER Maximum operating pressure of hydraulic system is up to 3000psi Maximum operating pressure of Pneumatic system is 150psi Power requirement 700KVA Maximum capacity of each motor 400 hp each x 2 800HP el e 37500 ft Ib 800hp Maximum speed at full power
79. proportionally more trouble free hydraulic performance for all pump type and size The mechanical efficiency of single action triplex pump is 90 and double acting duplex pump 85 In order to experience maximum savings both pumps should be operated at equal rpm Advantage of low speed 1 Extended parts life 2 Reduced mechanical maintenance 3 Lower parts replacement costs Better to operate both mud pumps in equal rpm to enhance service life of expandable and the life of the pump itself DO Y Wc CN lt Top up oil up to tip stick mark preferably middle of low and high mark Drain the water from trap Safety valve pressure setting must be 20 more than maximum delivery pressure of liner used in the pump Check the mud pump rotation It should be clock wise direction when viewed from right hand side Ensure both suction and delivery valves are open condition before starting the pump Check the nitrogen pressure in the hydril and ensure within the limit Delivery line must be anchored properly to avoid accident DON T Don t run the mud pump with reverse rotation Don t run the mud pump without proper setting of pressure relief valve Don t run the mud pump without checking of oil level in the sump as there is no safety system for stopping the pump due to starvation of oil Don t run the mud pump without opening suction and delivery line valves Don t run the pump without nitrogen pressure D
80. put is required for variable speed drive motors of mud pumps and draw works AC is required for all other constant RPM motors CATERPILLAR ENGINE Engine model D399 Engine rated RPM 1000RPM Engine rated HP 1010HP The inlet air fuel lubrication and cooling systems are the most important and critical part of four stroke diesel engines If all these systems are maintained properly the engine s reliability availability and optimum performance are ensured The details of each function are elaborately given below for better understanding about engine for proper operation and maintenance AIR INDUCTION SYSTEM The maximum power developed by a diesel engine largely depends upon the cubic capacity of the engine and the engine s ability to receive the maximum amount of cool clean fresh and dry air for complete combustion of fuel Restriction of air if any in the air induction system result improper burning or unburned fuel goes to exhaust in the form of black smoke causing power loss overheating problem and high exhaust temperature The purpose of using an air filter is to remove harmful dirt and impurities from the air rushing into the engine The dry type air filter is the most efficient type of air filter and its efficiency is around 99 5 wet type filter efficiency is 93 5 In case the pressure difference across air filter element shows more thanipsi then the filter element needs replacemen
81. r Winches Top Drive Independent Drive etc This manual mainly describes various functions of equipment and their importance to the drilling activities It is presented in the most compact and lucid form It will enhance confidence level of an individual for proper operations and maintenances of equipment with out any difficulties It will also help engineers to enhance problem solving capabilities and ensure safety of personnel and equipment Various important parameters are also given in this manual for better diagnosis and to eliminate the problems forthwith This manual is prepared and compiled based on the problems faced by field technicians engineers and operators of the rigs Of course it must be very useful to them CONTENTS CHAPTER DESCRI PTI ON PAGES 1 CLASSI FICATION OF DRILLING RIG 01 02 EQUIPMENT 2 POWER PRODUCING EQUIPMENT 03 37 3 PNEUMATIC SYSTEMS 38 54 4 HOISTING SYSTEM OF RIG E 760 20592 5 HOI STI NG SYSTEM OF RIG E 1400 RUE EM 6 MUD HANDLI NG EQUIPMENT 7 PUMPS 115 127 GENERAL INFORMATIONS RELATED 8 WI TH DRILLING RI GS 128 135 CLASSI FICATION OF DRILLING RIG EQUIPMENT RIG gt VV ON WV RIG MODEL E 760 E Electric drive 760 Draw works power rating in kW 1000HP Maximum drilling depth 3600 mts Drill pipe size 41 2 Maximum load carrying capacity 190tonnes RIG MODEL E 1400 E Electric drive 1400 Draw works power rat
82. r end and looking toward the fluid end Reverse rotation may be detrimental to the unit The filling of oil may be accomplished by removing the breather on top of the crankcase If lubricant gets contaminated change it immediately Maintain the temperature of lubricant within range Change the filter cartridge when the lubricant is changed Change the filter cartridge when the pressure across filter increases 15psi Clean the magnetic filter once each month Clean the lubricant strainer once each month Tell tale holes are provided in the valve chambers Any leakage past the valve cover gasket will be discharged through these openings If leakage is detected immediately tighten the valve cover or replace the gasket otherwise fluid cutting or a wash out will occur If leakage occurs replace the wiper rings immediately and if necessary replace the crosshead extension The sealing inner lip of the first wiper ring installed in the diaphragm housing must be directed inward toward the power frame to keep the lubricant from being carried out of the crank case the crosshead extension The sealing lip of the second wiper rings two numbers installed in the diaphragm housing must be directed outward toward the fluid end to wipe foreign material from the extension rod 17 Daily train water contaminant from trap 18 The jackshaft assembly is provided to drive lubricating oil pump as well as manual rotation of cranks
83. r has Rings and Bands three and one respectively Air pressure required to start D399 Engine is 110psi Each cylinder head has valves as 2 INLET AND 2 EXHAUST Speed of crankshaft with respect to the camshaft is TWICE Centre main journal of D399 engine has oil hole true Rotation of Engine as viewed from flywheel is anti clockwise true Cooling system in D399 engine is pressurized true Normal operating Oil pressure in PSI 60 Breather is located at Vee Crankcase explosion relief valve is located at inspection covers Pressure regulating valve is provided between the oil pump and oil cooler true Oil filter relief valve regulates oil to oil filters true Pistons are lubricated by the oil from the cooling jets Rear gears get oil from the turbocharger drain true Temperature difference across oil cooler is 7 C Oil change interval has to be increased if the sulphur in the fuel is more false What percentage of oil cooler cores can be blocked if they are found to be leaking without affecting cooling system 7 When Engine is running at low idle speed what is the pressure at which low oil pressure shutdown takes place 20psi When an engine is running at rated speed What is the pressure at which low oil pressure shutdown takes place 30PSI Oil in the Exhaust generally denotes turbocharger seal failure true 59 The purpose of keeping pre combustion chamber is to burn low quality fuel 60 6
84. rcuit diagram specially prepared for better understanding about working principles of various controlling valves easy identification of various lines and find out the problem during fault Two cam lobes are to be fixed with respect to the device position of hook block When either of the cam valve opens and sends a set pilot pressure to the main supply valve through the shuttle valve in the cam enclosure This pressure blocks air supply to clutch valve and releases air to actuate the brake cylinder and engage the brake Another source of set pilot pressure is the brake set valve mounted on the control panel emergency brake In the normal position the set pilot pressure is blocked and down stream pressure exhausted allowing free travel of the block In the set position i e engaged position emergency brake valve the set pilot pressure is passed to the main supply valve through shuttle valve to actuate the brake cylinder piston The shuttle valve allows only one set pressure either from cam valve or brake set valve emergency valve provided in the driller s console Both the cam and brake set valves receive air supply through over ride valve which can be mounted either on the control panel or on the floor As the over ride valve is actuated the air supply to both these valves is blocked and downstream pressure is exhausted At the same time an over ride pilot pressure goes to the main supply valve causing it to block air to and exh
85. re is high drilling in high pressure zone instability of the well smaller dia well deep well and production formation is water sensitive v v v v v v v v v v v PRI MARY FUNCTION OF DRILLI NG FLUID It prevents formation fluids from entering into the well bore It prevents the formation from falling into the well bore It keeps the well in good and healthy condition It keeps cutting particles in suspension It removes cutting particles from bottom of the hole It keeps the drill bit in cool condition to enhance drill bit life It facilitates removal of gas at the surface It handles contaminate harmful like H2S It protects the drilling string and casing pipes from tubular corrosion It buoyancy the casing and drilling string It facilitates easy removal of solid and gas by solid control equipment It facilitates easy penetration of drill bit for faster drilling 1 SHALE SHAKER Shale shaker is first piece of solids control equipment on surface mud tanks to remove large particles coming out from the drilling well It should be located above the sand trap on the first mud tank in the surface system The discharge from the screens should be directed to a waste area and the clean fluid should return to the sand trap The shaker s shaft should rotate toward the discharge end of the screen g factor determine shale shaker life g factor Stroke x RPM 7040 g is less than 3 for conven
86. release sump pressure if the sump pressure exceeds 2 5kg cm more than that of compressor working pressure HIGHER PRESSURE SHUTDOWN SWITCH The purpose of compressor is to shutdown the compressor at 2kg cm more than that of working pressure It prevents the pressure relief valve from opening under routine conditions thereby preventing oil loss through the pressure relief valve A temperature switch will also shutdown the compressor if the discharge temperature reaches116 C BLOW DOWN PRESSURE SWITCH It senses service line pressure when the line pressure reaches a pre set valve pressure switch signals the solenoid valve to unload the machine BLOW DOWN VALVE Blow down valve vents sump pressure to the atmosphere during unloading and shut off SILI CON CONTROL Regulates the amount of air required to the compressor through air intake manifold of the air end This regulation is determined by the amount of air being used in the service line THERMAL VALVE It regulates the temperature of oil getting into the air end by by passing the same to oil cooler in case the temperature of oil exceeds preset value COMPRESSOR COOLING amp LUBRI CATI ON SYSTEM Oil flows from the bottom of the receiver sump to the thermal valve The thermal valve is fully open when the oil temperature is below preset temperature The oil passes through the thermal valve main filter bearing filter and to the compressor unit where
87. rmance and efficiency of diesel engines as like the air fuel cooling and lubrication system does It minimizes exhaust back pressure and reduces noise EXHAUST SMOKE Exhaust smoke is the best indicator for the operating condition of engine BLACK SMOKE Block smoke indicates improper burning of diesel fuel inside the combustion chamber If air is less or diesel is more it causes improper burning of diesel and therefore black smoke Ex If air filter is choked the amount of air needed for the amount of diesel sprayed will not be available for combustion leading to improper burning of diesel which comes out of the exhaust as carbon particles or block smoke WHITE SMOKE When water vaporizes inside the combustion chamber it comes out in the form of white smoke from the exhaust Ex If the cylinder head is cracked or if the nozzle adapter is broken it causes water to enter the combustion chamber and leads to white smoke BLUISH SMOKE When lubricating oil burns inside the combustion chamber engine will emit bluish smoke Lubricating oil can enter the combustion chamber through the piston rings and liner from the turbocharger seal from the valve guides and if the oil level is kept more than full mark on the dipstick Note Turbocharger seal failure normally occurs due to air filter choke GRAY OR ASH COLOUR SMOKE Gray or ash colour smoke is a combination of bluish and white smoke This means both engine oil
88. sy to maintenance and better for safety It liberates man from repetitive manual activities in the derrick floor With introduction of pneumatic system in the rig the operators activities are Integrated and synchronized with various equipment by standing at one place Pneumatic system is more effective medium for continuous operation over a long period at a faster rate ADVANTAGE OF AIR OVER HYDRAULIC FLUI D Available in plenty Compressible Easily storable Transportable Insensitive to temperature No risk of explosion and fire hence it is safe Clean and non pollutant VON ON ON ON ON ON WV Fast expandable gt Suitable for high speed operation gt Learnable technology gt Easy to operate gt Low cost energy Why dry and clean compressed air is necessary for pneumatic system Atmospheric air contains Nitrogen Oxygen Carbon dioxide Water vapor Other gases like neon Dust VV VV ON ON WV Smoke Compressed air should be free from all contaminant for better and efficient operation of pneumatic system and its component It also helps the component for longer life NOTE Compressor having the capacity of 3 m min at 7 5 bar produces 40 liters of water per day Problems in pneumatic system due to contamination of Corrosion Pressure losses Increase the tool wear Faults in pneumatic controls Delay in response time VV VV ON WV Expensive down time Dry air is absolute necessary
89. t The two turbochargers of CAT engine D399 provide a cross air blowing to inlet manifolds These results in minimum air flow restriction due to long bend pipe in the after cooler and assure equal quantities of air to each bank of cylinders The after cooler removes the heat from the compressed air as it passes through after cooler to increase the density TURBOCHARGER The purpose of turbocharger is to charge boost more air into the engine cylinders It helps the engine to provide more power by burning more fuel in a given time The waste going exhaust gas drives the turbocharger without any extra input The turbocharger increases the pressure of inlet manifold air 3 to 4 times more than atmospheric pressure is called boost pressure With turbocharged engines there is small time lags between the Engine speeds throttle and boost pressure of turbocharger This results black smoke during starting and acceleration of engine The turbocharger speed can vary between 70000 to 85000 rpm Turbo compressor performance is sensitive to the presence of dirt and other deposits Bearing design and precise balancing of the whole rotating assembly are of paramount importance in ensuring a long life for the unit Allowing deposits to build up on the compressor wheel can cause wheel imbalance seal damage and ultimately jammed The full floating bearings manufactured from an alloy of copper tin lead are a critical lubrication point It is n
90. tion in the jet or pipe or jet dia is more the venture effect will not be there to carry away the dry mixture along with pressurized water of the centrifugal pump hopper pump So problem are to be identified fand corrective action needs to be done for proper function of hopper SOLID CONTROL EQUI PMENT 1 Shale shaker 2 Degasser Desander 3 4 Desilter 5 Mud agitator 6 Mud guns The purpose of solid control equipment is TO prepare the mud for drilling of a healthy well To remove solid and gas from mud TO maintain the required parameters To avoid mud wastage by recycling To keep weighing material in suspension and avoid gel formation It aids reduction in consumption of mud pump expandable It aids saving of energy CON KRW Mr It aids saving of well cost DRILLING FLUID The liquid drilling fluid is called drilling mud It may be gas or liquid or combination of both The drilling fluid should have the lowest viscosity possible at the bottom of the hole to achieve maximum chip removal and high viscosity in the annular to keep the cutting particles in suspension Water base drilling fluid has these properties It is basically a mixture of water barite bentonite and some chemical additives BARITE Increase the density of mud 4 2 times more than water BENTONITE Filtration control and increase yield point OIL MUD It is used when the bottom hole temperatu
91. tional shale shaker Higher the g factor greater the solid separation Very high g factor reduce the life of screen 9 co thrust CAPACITY LIMIT OF SHALE SHAKER 1 Solid capacity limit maxi quantity of solid to be removed 2 Liquid capacity limit maxi discharge volume is to be able handle while considering minimum screen size SHALE SHAKER Sl no Mud weight Screen size Single Dual tandem tandem 01 20 3000 6050 02 30 2650 3650 03 1 20 40 2270 4540 04 50 1892 Lpm 3785 05 60 1514 Lpm 3028 Lpm CLASSIFICATION OF PARTICLES SI ZE SI no Particle size in micron Classification 01 2000 Coarse 02 250 to 2000 Intermediate 03 74 to 250 Medium 04 44 to 74 Fine 05 2 to 44 Ultra fine 06 to 2 Colloidal SIZE OF SOLIDS AND SHALE SHAKER SCREEN Sl no Screen size Removal of solids in microns 01 12 x 12 1540 02 14 x 14 1230 03 16 x 16 1020 04 18 x 18 920 05 20 x 20 765 06 40 x 40 320 07 60 x 60 250 08 80 x 80 177 09 100 x 100 149 SHALE SHAKER MESH WEAVES 1 Plain Square weaves 2 Rectangular opening 3 Plain notch weave 4 Twilled square weave err opening Sl no Meshsize Wire dia in inch area inches micron 01 20 x 20 0 017 0 033 838 43 6 02 30 x 30 0 012 0
92. to the ring gear from which it drips continuously to the turntable ball bearing guided by a trough Backlash between the teeth of the pinion and the ring gear is adjusted by means of the lower ball race shims To increase backlash add shims To decrease backlash remove shims This backlash should vary between 0 025 in to 0 035 in Clearance between the hold down ring and the hold down ring bushing should be adjusted by a series of tests First install an excessive numbers of hold down ring shims Then remove the shims until a slight drag is felt while rotating the turntable by hand Add one 0 015in shims for proper running clearance DO 1 2 Do greasing of all points as per maintenance schedule judicially Daily physical checks before and after running of equipment for any abnormality will help us to rectify the problem Clean the breather to vent the gases from the oil sump and avoid labyrinth seal damage due to pressure buildup inside the oil sump Align the mast center to rotary bore center to avoid one side track which will damage the rotary DON T Y Don allow to engage the rotary lock for pipe breaking It leads to accident and damage the rotary table Y Don t allow to keep the heavy weights on the top cover of rotary table It will bend and touch the rotating member of the rotary table HOISTING SYSTEM OF E 1400 DRAW WORKS E 1400 Model E1400 Draw works capacity 1400 hp Motor cap
93. tor clutch gear box assembly and couplings for connections The motor 4903CX is coupled to the transmission RT2010D by a flexible gear coupling and the transmission is connected to the rotary pinion shaft through a chain coupling The braking is provided by the arrangement of a brake drum and an air flex clutch 20VC600 The drum is mounted on the motor adapter and the clutch is assembled over the drum The clutch is made stationary by bolting it to the clutch carrier and the carrier is bolted to the transmission skid Separate lub Oil pump is provided with gear assembly for forced lubrication IRD is mounted on an independent skid MODEL RT2010D Where R Rotary T Transmission 2 No of speed forward no of speed 2 No of speed reverse 10 1000hp D Location of input shaft down IMPORTANT POINTS TO REMEMBER e By installing the IRD the drive to the rotary table from the draw works is eliminated e Drive to rotary table by an Independent D C motor through a 2 speed transmission system i e a gear box e The braking is provided by the arrangement of a brake drum and air flex clutch model 20 VC 600 e The clearance between the two sprockets of the chain coupling is 3 5 0 5 e The gears in these units single helical type and operate parallel axes e The high or low speed output is selected by the engagement of spline clutch for which an external lever is provided
94. tring load and also provides a centering effect for the turntable because of the angular contact between the ball bearing and its race ROTARY TABLE CROSS SECTION A Nominal diameter of rotary hole 2712 E Table size 44 Sl no Description 20 271 37 01 Capacity tons 320 465 650 02 Speed rpm maxi 500 500 500 03 Oil pan capacity liter 23 32 45 IMPORTANT POINTS TO REMEMBER 1 Hold down ring serve as a steadying bearing absorbs upward thrusts develop through turntable And provide oil return to the oil reservoir in the base and prevents the escape of any oil from the oil bath system 2 Labyrinth seals at both top and bottom of the turntable protect the oil bath from contamination from outside foreign matter 3 A flexible seal ring attached to the bottom of the hold down ring prevents mud from entering the system in case of a well kick or a blow out The flexible lip of the ring bends upward under the force of a stream of mud forming an effective seal The pinion shaft inner bearings are tapered roller type and are located at the pinion end of the pinion shaft They absorb radial and thrust loads as well as maintain proper tolerance between the pinion and ring gear A spherical roller outer bearing at the sprocket end of the pinion shaft absorbs the radial load transmitted through the drive sprocket The rotating pinion dipping into the reservoir carries oil
95. tup the pre lubrication pump is activated by compressed air and sends oil into the engine lubrication system until there is a low oil pressure of approximately 3psi is developed mainly the turbocharger line The pressure sensing switch in the vee of the engine closes the air to pre lub Pump and allows the air to the motor to be activated for starting the engine Oil pressure regulating valve is the first component in the engine body to receive oil from the oil pump This valve controls the maximum pressure of the engine oil in the lubrication system D COOLING SYSTEM The cooling system is basically a heat regulating system It maintains the temperature of the coolant by dissipating the excess heat to atmosphere so as to keep the engine at normal operating temperature Normal operating temperature ensures the best fuel economy peak engine performance and also keeps engine parts within the designed working tolerances Temperature regulator controls the coolant flow to the radiator to regulate the temperature in the cooling system The temperature difference between jacket water and radiator is 7 to 11 C The small vent line on the top of the outlet of the housing is connected to the inlet of the water pump The cooling water pressure is approximately 7psi when the engine is on load pH VALUE pH value is the inverse of log concentration of H ion pH value range is 1 to 14 pH gt 7 basic pH 7 acidic alkalic pH value
96. ubic feet per minute v Less than 7 kg cm low pressure application More than 7 kg cm high pressure application SWIVEL Model PC425 Load capacity 425 tons Y Drill pipe size 41 2 Y Fluid passage 31 2 Y Oil sump capacity 191 2 Gallons XI V TRAVELLI NG BLOCK Capacity 500Tons No of sheaves 6 Out side diameter of sheaves 42 Wire size 13 8 Centre pin dia 10 Re ON 52552 47005 Clevis bar pin dia 5 MUD HANDLING EQUIPMENT Mud is considered to be the blood of the well Mud parameters are necessarily to be maintained well within the allowable parameters to drill a healthy well Mud system is one of the most important elements of a drilling rig Mud system consists of mud mixing mud cleaning and agitating Mud processing and reconditioning equipment like mud hopper shale shaker degasser de sander de silter mud agitators and mud guns are performing their functions to prepare and conditioning the mud and also keep the mud parameters well within the limit during drilling operations HOPPER SYSTEM Mud hopper is used for mixing dry materials with the drilling fluid Hopper system consists of centrifugal pumps and hoppers with jets It is the first stage of mud handling system The centrifugal pump charge the water drilling fluid into the hopper through jet which acts like a venturi creates vacuum and suck the dry materials along with it NOTE If any abstrac
97. wer spacer The wash pipe nut and the packing box have left handed threads Slide the wash pipe nut and the packing box together for installation Hand pack all seals with multipurpose lithium based or high temperature moly based grease completely filling the void IMPORTANT POINTS REMEMBER 1 The main body of the swivel is supported in the housing by the main bearing and is stabilized by the auxiliary thrust bearing above and radial bearing below 2 Main bearing carries the drill string load It is of the full apex tapered roller type 3 The auxiliary bearing located just above main bearing maintains precise centering of the rotating body in the swivel housing and also absorbs upward thrust forces It is a heavy duty combination straight radial roller and roller thrust type 4 Radial bearing located just below the main bearing in the housing centers the rotating body in the housing The bearing is of the straight roller type 5 Bearings are oil lubricated and they are continually submerged in the oil 6 Oil seals prevent escape of oil and entrance of drilling fluid or other foreign matter Oil seals are grease lubricated and to be greased daily Breather is to be kept clean and obstruction free to avoid pressure buildup in the body due to heat expansion of oil Failure to this may result in oil leakage at the housing oil seal which is weakest part of swivel body 9 The swivel housing is
98. works without ensuring adequate lubrication of chains 7 Don t lift the load with ineffective brake system 3 Crown block gt Itis a stationary pulley assembly mounted on the top of derrick or mast to provide leverage point gt The function of sheaves is to guide and support the drilling line as it passes through the blocks gt The number of sheaves in a block is determined by the weight to be supported MECHANICAL ADVANTAGE CROWN BLOCK GUIDE PULLEY A7 a SS 4 FAST END PULLEY e Ed D 4 Nd lt E I L E Www TRAVELLING BLOCK Z DEAD END 7 TOTAL WEIGHT 120 Tons No of Incoming and Outgoing wire rope from Travelling block 8 Lines Power requirement of Draw works to hoist 120Tonsweight 120 8 15 Tons Mechanical advantage Total weight Traveling block hook swivel 100 tons Kelly drill pipe drill collar bit No of lines incoming outgoing from traveling block 10 Therefore hoisting line load 100 10 10 ton Note Sheave blocks allow the hoisting line load to be reduced 4 Travelling block v Y S The pulley block moving inside the derrick is called travelling block The travelling block moves up and down between derrick floor and near to crown block on the line The travelling block carries the hook that supports the drill string during drilling and its elevator bails that ho

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