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INDUSTRIAL TRAINING (2018)

ONGC SIVASAGAR, ASSAM

Submitted by
Ajay Kumar
B.Tech (3rd YEAR)
DEPARTMENT OF MECHANICAL ENGINEERING
GALGOTIAS COLLEGE OF ENGINEERING & TECHNOLOGY
GREATER NOIDA-201301
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ACKNOWLEDGMENT

On the very outset of this report, I would like to take this opportunity to express
my sincere and heartfelt gratitude to all those who have been instrumental in
making this summer training successful for me. Without their active guidance,
help, cooperation & encouragement, it would not have been possible to walk
over this vast ocean of knowledge and technicality.

I am obligated to Oil and Natural Gas Corporation Limited (O.N.G.C) Assam Asset
for giving me this opportunity to undergo this summer training of one month
(June 20, 2017 to July 19, 2017).

I would like to convey my sincere thanks to Mrs. Ruprekha Boruah, Manager

(HR), RTI for showing her kindness and faith upon me.

I am deeply indebted to my training mentor Shri Rituraj Sahu, DY.SE (M) for his
valuable guidance and support.

I also give sincere thanks to Mr. L.Gogoi, Dy SE(M),CMS &Mr. J.N. Saikia SE(M)
CMS, for giving their valuable time and sharing their knowledge.

I also extend my gratitude towards Mr. Jalal Hussain, ONGC without the help of
whom it would not have been possible for me to undergo this training.

My heartiest thanks to all the floor in-charges of the Central Workshop who not
only allowed me to visit their respective shops but also guided me through the
internship with lots of invaluable advice and information. Last but not the least
I am also grateful to all the employees of drilling services who directly or
indirectly assisted at various stages of the training.

Thanking You

Ajay Kumar
B.Tech (3rd YEAR )
Department of Mechanical
Engineering, G. C. E. T. Greater Noida
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ABSTRACT

Theory of any subject is important but without its practical knowledge it

becomes useless, particularly for technical students. A technical student
cannot become a perfect engineer for without practical understanding of his
branch and his subjects, hence training provides a golden opportunity for all
the technical students to interact with the working environment. This report
is an insight of the training I have undergone for a month from 05th June to 05th
July, 2017 in drilling services, ONGC Sivasagar. It has given me the knowledge
and experience of oil industry. To prepare this report I have repeatedly visited
the Central Workshop and also gone to the Drilling Rigs of ONGC and also had
wide interaction with the workers and supervisors and went through the reading
materials provided by ONGC.

The Report includes a brief introduction of oil industry, role of ONGC, brief
description about the processes ONGC has to go through during the production
of crude oil, details of equipment running on drill rigs and brief outline of Central
Workshop, Sivasagar which is captive workshop of ONGC catering to overhauling
need and repair of drilling equipment.

In course of preparing this report I have enhanced my knowledge about industry

especially oil industry and I have realized the importance of team work and
dedication to achieve goals under tough working conditions.
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CONTENTS

Topic Page Number

1. A Brief Introduction of ONGC 5 – 9

& ONGC Assam Asset

2. DRILLING FLUID SERVICES 10 – 11

3. PROCESS OF OIL 12
EXPLORATION

4. OIL RIG SYSTEM 13 - 18

5. MAINTENANCE PRACTICE 19

6. OPERATION OF DRILLING 19 - 22
RIGS & RIG EQUIPMENT

7. POWER PRODUCING 22 - 28
EQUIPMENT

8. COMPRESSORS 29 - 31

9. HOISTING EQUIPMENT 31 - 33

10.ROTATING EQUIPMENT 34

11.MUD HANDLING 35 - 38
EQUIPMENT

12.KELLY DRIVE & BOP 39 - 40

13.CONCLUSION 41
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Oil and Natural Gas Corporation

Oil and Natural Gas Corporation (ONGC) is an Indian multinational oil and
gas company headquartered in Dehradun, Uttarakhand, India. It is a Public
Sector Undertaking (PSU) of the Government of India, under the administrative
control of the Ministry of Petroleum and Natural Gas. It is India's largest
oil and gas exploration and production company. It produces around 77% of
India's crude oil (equivalent to around 30% of the country's total demand) and
around 62% of its natural gas. ONGC was founded on 14 August 1956 by
Government of India.It is involved in exploring and exploiting hydrocarbons
in 26 sedimentary basins of India, and owns and operates over 11,000
kilometers of pipelines in the country. Its international subsidiary ONGC Videsh
currently has projects in 17 countries. ONGC went offshore in early 70's
and discovered a giant oil field in the form of Bombay High, now known as
Mumbai High. This discovery, along with subsequent discoveries of huge oil and
gas fields in Western offshore changed the oil scenario of the country.
Subsequently, over 5 billion tonnes of hydrocarbons, which were present in the
country, were discovered. At present ONGC produces 1.2 million barrels of oil
per day.
ONGC Group of Companies comprises of
1. Oil and Natural Gas Corporation Limited (ONGC - The Parent Company)
2. Overseas E&P: ONGC Videsh Limited (OVL – a wholly owned subsidiary of
ONGC), ONGC
Nile Ganga BV (ONG BV - a wholly owned subsidiary of OVL), ONGC Amazon
Alaknanda Ltd. (OAAL) etc.
3. Mangalore Refinery and Petrochemicals Limited (MRPL - a subsidiary of
ONGC).
4. Value-Chain: OPAL, OMPL etc.
5. Services: OMESL, Pawan Hans Helicopters Ltd., etc.
6. SEZ: MSEZ, DSL.
7. Power: OTPC.
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HISTORY OF ONGC

Oil and Natural Gas Corporation Ltd, leading Natural Oil Gas Corporation
company of India Oil and Natural Gas Corporation, ONGC was set up in 1956
with significant contribution in industrial and economic growth of the country,
ONGC is leading Natural Oil Company of India engaged mainly in exploration,
development and production of crude oil, natural gas and some value added
products.
ONGC was subsequently converted into a public limited company in
June’93 following new liberalized economic policy adopted by the Govt of India
in July 1991 sought to deregulate and delicense the core sector (including
petroleum sector) with partial disinvestment of Govt. Equity in Public Sector
undertakings and under measures. ONGC is India’s largest producer of crude oil,
natural gas and LPG. ONGC India also produces other value added petroleum
products such as NGL, C2-C3, Aromatic Rich Naphtha and Kerosene.
Internationally. Its wholly owned subsidiary ONGC Videsh Limited has a
number of existing and upcoming interests in selected oil patches ONGC
including development of a large gas field discovered by it in Vietnam offshore.
During March 1999 ONGC, Indian Oil Corportion (IOC) a downstream giant and
Gas Authority of India Limited (GAIL), the only gas marketing company, agreed
to have crossholding in each other’s stock to pave the way for long term strategic
alliance amongst themselves, both for the domestic and overseas business
opportunites in the energy value chain.
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ONGC, ASSAM ASSET

ONGC started production in Assam Asset in 1957 and spudded the first wild Cat
act at Disangmukh in 1957. Based on the results of geo-scientific surveys, drilling
of Rudrasagar prospect was taken up in 1960, which proved to be commercially
viable hydrocarbon accumulation. Subsequent by, Lakwa field was discovered in
1964 and Geleky field in 1968. The continued search for oil and gas led to the
discovery of many other small fields such as Demulgaon, Lakhmani,
Changmaigaon, Laiplingaon, etc. The fields of the asset are Rudrasagar, Geleky
and Lakwa. The fields are in Sivasagar district of Assam. The installation of these
fields located within a radius of about 50km from the cities of Sivasagar and
Nazira. The headquarter of Assam Asset is situated at Nazira and Sivasagar is the
district headquarter. The Assam Asset of ONGC produced 1.4 unit of crude oil
and 367.63 mm^3 of gas during 2004-2005.
_________________________

Statistics:
Onshore
• Production Installations: - 240 • Seismic Units: - 29
• Logging Units: - 32 • Engineering Workshops: - 2
• Virtual Reality Centre: - 5 • Regional Computer Centre: - 5

• Pipeline Network (km):- 15,800 • Drilling Rigs: - 70

• Work Over rigs: - 74

Offshore
• Well Platforms: - 147 • Well-cum-Process Platforms: - 32
• Process Platforms: - 13 • Drilling Rigs: - 29
• Pipeline Networks (km):- 4,500 • Offshore Supply Vessels: - 55
• Special Application Vessels: - 4 (including 2 MSV)
• Seismic Vessels :- 1
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ONGC ASSAM CENTRAL WORKHOP

The Central Workshop of ONGC Assam is situated in Sivasagar. It is the largest

workshop in North-East India. During my training period, I have visited these
workshops for an avg. of 3-4 days each. The various maintenance practices of
both drilling and production are done here. It has 9 shops which help in repairing
the damaged parts of different equipment of drilling and production. The
various shops are:

 Tubular Repair Shop: The worn out threads of drilling pipes and threads
for newer ones are cut in this shop with the help of lathes.
 Heavy Equipment Repair Shop: The function of this shop is to-
 Repair Draw-works
 Repair Mud Pumps
 Repair Blow Out Preventer
 Sonoscopy Shop: This shop performs following functions-
 Inspection of suspected pipes
 Repair of usable pipes with low damage
 Compressor and Transmission Shop: Its functions are-
 Inspection of Compressors
 Repair of defected compressors
 Machining Shop: It performs the various machining works with the help
of lathes.
 Diesel Engine Shop: It performs the following functions-
 Inspection of diesel engines
 Repair or replacement of the various damaged
parts.
 Electrical Shop: It performs the following functions-
 Repair of damaged motors
 Repair of damaged alternators
 Fabrication Shop: it performs following functions with the help of
welding-
 Manufacture of Mud Tanks
 Repair of Rigs
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 Testing Shop: Various instruments are tested here.

The Central Workshop is basically divided into 4 major shops:

 DIESEL ENGINE SHOP:

Diesel engines are repaired over here. This shop includes a fuel injection lab.
This shop also carries out trouble shooting and periodical inspection of diesel
engines.

 HEAVY EQUIPMENT REPAIR SHOP:

This shop repairs heavy equipments like draw works, mud pumps. Rotary
table, testing of BOP.

 COMPRESSOR and TC(TORQUE CONVERTOR) SHOP:

Here the reapir and maintenance of various compressors takes place. TC

Shop includes repair of Allison transmission system.

 MACHINE SHOP:

Machine shop is equipped with various laths, drilling machines, milling

machines, boring machines, etc.

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Drilling Fluid Services

Drilling Fluid Section includes following Services :-

 It includes engineering fluid services that are appropriately matched with

well providing chemicals for cuttings separation and crude production.
 Transportation and Logistic Services related to chemicals and equipment
for drilling.
 In Drilling Fluid Engineers, experts and technician are the pillars of this
section and help in technical support.

The main objective of Drilling Fluid Engineers and this section is produce drilling
muds to remove cutting and control the formation pressure. The composition of
the drilling fluid changes from depth to depth and conditions. So drilling fluid
engineers main aim is to make drilling easier and better by making appropriate
drilling fluids.

DRILLING TECHNIQUES

Straight Hole Drilling:-

In straight hole drilling, the well bore is vertical and deviates by no more than 3
degrees anywhere along the well bore, and the bottom of the well deviates by
no more than 5 degrees from the starting point of the well bore at the drilling
platform. With straight hole drilling, the drill bit may be deflected if it contacts
fault zones or dipping beds of hard rock layers.

Directional and Horizontal Drilling:-

Directional drilling (also termed slant drilling) involves the drilling of a curved
well to reach a target formation. Directional drilling is employed when it is not
possible, practicable, or environmentally sounds to place the drilling rig directly
over the target area. Directional drilling is especially useful for offshore
locations. With directional drilling, it may take several thousand feet for the well
to bend from drilling vertically to horizontally.
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DRILLING FLUIDS

Any liquid or gaseous fluid or a mixture of fluids and solids (solid as suspension,
emulsions of liquids, mixtures of gases and solids) used in operations to drill
boreholes into the earth may be called a Drilling Fluid. It is used in almost every
oilfield drilling operation to remove the cutting generated (rock drilled) from the
well bore by maintaining the formation pressure.

Functions of Drilling Fluids

i. Remove cuttings from the wells.
ii. Control formation temperature.
iii. Suspend and release cuttings.
iv. Seal Permeable formation.
v. Maintain Wellbore Stability.
vi. Minimize formation damage.
vii. Cool, lubricate and support the bid and drilling assembly.
viii. Transmit hydraulic energy to the tools and Bits.
ix. Ensure adequate formation evaluation.
x. Corrosion control.
xi. Facilitate cementing and completion.
xii. Maintain impact on environment.
.
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PROCESS OF OIL EXTRACTION

The three principal processes in which ONGC is engaged are: exploration,

drilling and extraction of oil and natural gas. We are not going into details of oil
exploration and extraction in this report as it is out of our scope. Oil drilling is
what we will be focusing on which is also called the back-bone of any oil industry.
The task of finding oil is assigned to geologists, whether employed directly by an
oil company or under contract from a private firm. Their task is to find the right
conditions for an oil trap -- the right source rock, reservoir rock and entrapment.
Once the legal issues have been settled, the crew goes about preparing the land:
1. The land is cleared and leveled, and access roads may be built.
2. Because water is used in drilling, there must be a source of water
nearby. If there is no natural source, they drill water well.
3. They dig a reserve pit, which is used to dispose of rock cuttings and
drilling mud during the drilling process, and line it with plastic to protect
the environment. If the site is an ecologically sensitive area, such as a
marsh or wilderness, then the cuttings and mud must be disposed
offsite -- trucked away instead of placed in a pit.

After the land has been prepared, several holes must be dug to make way for
the rig and the main hole. A rectangular pit, called a cellar, is dug around the
location of the actual drilling hole. The cellar provides a work space around the
hole, for the workers and drilling accessories. The crew then begins drilling the
main hole, often with a small drill truck rather than the main rig. The first part
of the hole is larger and shallower than the main portion, and is lined with a
large-diameter conductor pipe.
Additional holes are dug off to the side to temporarily store equipment -- when
these holes are finished, the rig equipment can be brought and set up.
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RIG COMPONENTS
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OIL RIG SYSTEM

Once the equipment are at the site, the rig is set up. Here are the major systems
of a land oil rig:

Fig: Anatomy of an oil rig

Power system
large diesel engines - burn diesel-fuel oilto provide the main
source of power
 electrical generators- powered by the diesel engines to
provide electrical power
Mechanical system - driven by electric motors
 hoisting system - used for lifting heavy loads; consists of a
mechanical winch (draw works) with a large steel cable spool,
a block-and-tackle pulley and a receiving storage reel for the
cable
 rotary-table/turntable - part of the drilling apparatus
Rotating equipment - used for rotary drilling
 swivel - large handle that holds the weight of the drill string;
allows the string to rotate and makes a pressure-tight seal on
the hole
 kelly - four- or six-sided pipe that transfers rotary motion to
the turntable and drill string
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 turntable or rotary table - drives the rotating motion using

power from electric motors

 drill string - consists of drill pipe (connected sections of about 30 ft

/ 10 m) and drill collars (larger diameter, heavier pipe that fits
around the drill pipe and places weight on the drill bit)
 drill bit(s) - end of the drill that actually cuts up the rock; comes in
many shapes and materials (tungsten carbide steel, diamond) that
are specialized for various drilling tasks and rock formations

Casing - large-diameter concrete pipe that lines the drill hole, prevents the hole
from collapsing, and allows drilling mud to circulate.
Circulation system - pumps drilling mud (mixture of water, clay, weighting
material and chemicals, used to lift rock cuttings from the drill bit to the surface)
under pressure through the Kelly, rotary table, drill pipes and drill collars
 pump - sucks mud from the mud pits and pumps it to the drilling
apparatus
 pipes and hoses - connects pump to drilling apparatus
 mud-return line - returns mud from hole
 shale shaker - shaker/sieve that separates rock cuttings from the
mud
 shale slide - conveys cuttings to the reserve pit
 reserve pit - collects rock cuttings separated from the mud
 mud pits - where drilling mud is mixed and recycled
 Mud-mixing hopper - where new mud is mixed and then sent to the
mud pits.

Drill-mud circulation system

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Functions and uses of drill mud-

 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 facilitates easy penetration of drill bit for faster drilling. It facilitates easy
removal of solid and gas by solid control equipment.
 It buoyancy the casing and drilling string.
 It protects the drilling string and casing pipes from tubular corrosion.
 It handles contaminate/ harmful like H2S.
 It facilitates removal of gas at the surface.
 It removes cutting particles from bottom of the hole.
 It keeps the drill bit in cool condition to enhance drill bit life.
 It keeps cutting particles in suspension.

Derrick - support structure that holds the drilling apparatus; tall enough to allow
new sections of drill pipe to be added to the drilling apparatus as drilling progresses
Blowout preventer - high-pressure valves (located under the land rig or on the
sea floor) that seal the high-pressure drill lines and relieve pressure when
necessary to prevent a blowout (uncontrolled gush of gas or oil to the surface,
often associated with fire)

Fig: Mud circulation in the hole

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Oil drilling
The crew sets up the rig and starts the drilling operations. First, from the starter hole,
they drill a surface hole down to a pre-set depth, which is somewhere above where
they think the oil trap is located. There are five basic steps to drilling the surface hole:

1. Place the drill bit, collar and drill pipe in the hole.
2. Attach the Kelly and turntable and begin drilling.
3. As drilling progresses, circulate mud through the pipe and out of the bit to
float the rock cuttings out of the hole.
4. Add new sections (joints) of drill pipes as the hole gets deeper.
5. Remove (trip out) the drill pipe, collar and bit when the pre-set depth
(anywhere from a few hundred to a couple-thousand feet) is reached.

Once they reach the pre-set depth, they must run and cement the casing -- place
casing-pipe sections into the hole to prevent it from collapsing in on it. The casing pipe
has spacers around the outside to keep it centered in the hole.

The casing crew puts the casing pipe in the hole. The cement crew pumps cement
down the casing pipe using a bottom plug, cement slurry, a top plug and drill mud. The
pressure from the drill mud causes the cement slurry to move through the casing and
fill the space between the outside of the casing and the hole. Finally, the cement is
allowed to harden and then tested for such properties as hardness, alignment and a
proper seal.

Testing of Oil
Drilling continues in stages: They drill, then run and cement new casings, then drill again.
When the rock cuttings from the mud reveal the oil sand from the reservoir rock, they may
have reached the final depth. At this point, they remove the drilling apparatus from the hole
and perform several tests to confirm this finding:

 Well logging - lowering electrical and gas sensors into the hole to take
measurements of the rock formations there
 Drill-stem testing - lowering a device into the hole to measure the pressures, which
will reveal whether reservoir rock has been reached
 Core samples - taking samples of rock to look for characteristics of reservoir rock
Once they have reached the final depth, the crew completes the well to allow oil to flow into
the casing in a controlled manner. First, they lower a perforating gun into the well to the
production depth. The gun has explosive charges to create holes in the casing through which
oil can flow. After the casing has been perforated, they run a small-diameter pipe (tubing)
into the hole as a conduit for oil and gas to flow up the well. A device called a packer is run
down the outside of the tubing. When the packer is set at the production level, it is expanded
to form a seal around the outside of the tubing. Finally, they connect a multi-valved structure
called a Christmas tree to the top of the tubing and cement it to the top of the casing. The
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Christmas tree allows them to control the flow of oil from the well. Once the well is
completed, they must start the flow of oil into the well. For limestone reservoir rock, acid is
pumped down the well and out the perforations. The acid dissolves channels in the limestone
that lead oil into the well. For sandstone reservoir rock, a specially blended fluid containing
proppants (sand, walnut shells, aluminum pellets) is pumped down the well and out the
perforations. The pressure from this fluid makes small fractures in the sandstone that allow
oil to flow into the well, while the proppants hold these fractures open. Once the oil is flowing,
the oil rig is removed from the site and production equipment is set up to extract the oil from
the well.

Extraction of Oil
After the rig is removed, a pump is placed on the well head

Fig: Pump on an oil well

In the pump system, an electric motor drives a gear box that moves a lever. The
lever pushes and pulls a polishing rod up and down. The polishing rod is attached to a
sucker rod, which is attached to a pump. This system forces the pump up and down,
creating a suction that draws oil up through the well.

In some cases, the oil may be too heavy to flow. A second hole is then drilled into the
reservoir and steam is injected under pressure. The heat from the steam thins the oil
in the reservoir, and the pressure helps push it up the well. This process is called
enhanced oil recovery.
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MAINTENANCE PRACTICE

Utilization of various kind of the state-of-the-art equipment to carry-on the drilling and
extraction process requires regular maintenance of the rig equipment so that they can
re-used with maximum efficiency. Moreover, such equipment wear out in long run and
are subject to stress and load while carrying out the operation, therefore it is very
necessary to carry out repair and upkeep work for increasing productivity, which is the
main goal of any organization. Thus, Maintenance department for maintenance, repair
and upkeep of the rig equipment used in oil drilling work, is the gargantuan functioning
department of ONGC Ltd. Upcoming sections gives the detail information of the
various department of maintenance workshop of this highly esteemed organization
and the equipment being repaired here.

OPERATIONS OF DRILLING RIGS AND RIG

EQUIPMENT

Assam asset of ONGC owns and operates 17 drilling rigs in the region. These
rigs do exploratory and development wells in Lakwa, Gelekey and Rudrasagar
(RDS) fields in Sivasagar district of Assam. These Rigs are named as
1. E-1400-1 2. E-1400-2
3. E-1400-4 4. E-1400-6
5. E-1400-13 6. E-1400-21
7. E-2000-4 8. E-2000-6
9. E-2000-9 10. E-3000-1
11. F-4900 12 F-6100-1
13. ARMCUE-1 14. BI-1500
15. EV-2000-3 16. EV-2000-4
17. EV-2000-5
A drilling rig is a machine which creates holes in the earth sub-surface. Oil and
natural gas drilling rigs are used not only to identify geologic reservoirs but also
to create holes that allow the extraction of oil or natural gas from those reservoirs.
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The various components of a typical onshore drilling rig can be listed as:
Mud tank, 2.Shale shakers, 3.Suction line (Mud pump), 4.Mud pump, 5.Motor or power source,
6.Vibrating hose, 7.Draw-works, 8.Standpipe, 9.Kelly hose, 10.Goose-neck, 11.Traveling
block, 12.Drill line, 13.Crown block, 14.Derrick, 15.Racking board (Monkey board), 16.Stand
(of Drill pipe), 17.Setback (floor), 18.Swivel, 19.Kelly drive, 20.Rotary table, 21.Drill floor,
22.Bell nipple, 23. & 24.Blow-out preventer (BOP), 25.Drill string, 26.Drill bit, 27.Casing
head, 28.Flow line.
The Deep drilling range of rigs developed by Bharat Heavy Electricals Limited (BHEL) can
be classified as:

Rig Model: E-760

1. E- Electric Drive
2. Draw-works power rating : 1000 HP
3. Maximum Drilling Depth : 3600 m

Rig Model: E-1400

1. E- Electric Drive
2. Draw-works power rating : 1400 HP
3. Maximum Drilling Depth : 4900 m

Rig Model: E-2000/EV-2000

1 .E- Electric Drive

2.Draw-works power rating: 2000 HP
3. Maximum Drilling Depth: 6100 m
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Rig Model: E-3000

1. E- Electric Drive
2. Draw-works power rating : 3000 HP
3. Maximum Drilling Depth : 9000 m

Rig Equipment can be classified into following five categories:

1. Power producing equipment

2. Hoisting equipment
3. Rotating equipment
4. Fluid circulating equipment
5. Auxiliary equipment

1. Power producing equipment

1. Power packs
2. Compressors

2. Hoisting equipment

1. Draw works
2. Crown block
3. Traveling block
4. Hook
5. Air winch

3. Rotating equipment

1. Rotary table
2. IRD
3. Top Drive System
4. Swivel

4. Fluid circulating and conditioning equipment

1. Mud pumps
2. Hopper
3. De-sander
4. De-silter
5. Shale shaker
6. De-gasser
7. Mud agitator
8. Mud mixture
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5. Auxiliary equipment

1. Water pumps
2. Diesel lifting pump
3. Welding transformer
4. Lighting

POWER PRODUCING EQUIPMENT

Power Packs

ONGC Drilling Rigs are mainly powered by Caterpillar make D399 and 3512 model engines.
These engines are the source of power to the Drilling Rig Equipment. Hence engines are
considered to be heart of the Rig.
Rig Model Number of Power Packs
E-760 3
E-1400 4
E-2000 4
E-3000 6

Most of the rigs of ONGC are running on AC-SCR electrical system wherein power packs
(Diesel engine with alternator) run 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 (SCR). This DC input is required for variable speed drive motors (DC motors)
of mud pumps and draw works. AC is required for all other constant.

AC motors used at rigs are squirrel cage induction motors which are constant speed device. It
cannot operate for any length of time at speeds below those shown on the nameplate without
danger of burning out.

Srpm = (120 x F)xP

Srpm = synchronous revolutions per minute.

120 = constant
F = supply frequency (in cycles/sec) generally 50Hz
P = number of motor winding poles i.e. 2, 4, 6, 8, 10
Based on above formula , AC motors work on following speeds.
number of synchronous
motor revolutions per
winding minute
poles
2 3000
4 1500
6 1000
8 750
10 600
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Caterpillar Engine:

Engine Model: D399 Engine Rated RPM: 1000RPM

Engine Rated HP: 1010HP No. of Cylinders: 16

Caterpillar D399 Engine

Engine Model: 3512

Engine Rated RPM: 1200 rpm
Engine Rated HP: 1020 HP
No. of Cylinders: 12
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Caterpillar 3512 Engine

Diesel Engine:
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.

(A) 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 results in 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 than1psi then the filter element needs replacement. 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.
AIR SYSTEM Functions:
• To supply air for complete combustion of fuel.
• To remove exhaust gases out of engine.
• Air supplied at the combustion chamber should be sufficient: 1 lt of fuel
needs 12,500 lt of air containing for completion.
• Combustion
• Clean air
• Cool air: Air at high temperature is thin and contain less Oxygen.
• Dry air
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FUNCTION OF THE COMPONENTS OF AIR SYSTEM:-

1. Air cleaner/Air filter: Air is not vital for any life form on Earth but also
important for today’s state of art diesel engines. An average Heavy Duty Diesel
truck engine requires between 3650-5600 gallons (13,000-20,000 litres) of air to
burn just one litre of fuel. However this air is polluted with all kinds of
combinations such as fumes, dust, smog and other particles. Like temperature
and humidity, these particles are not always visible to the eye but are harmful to
the engine. They diminish the purity of air and can lead to severe damage of all
engines components. So, air filter required to purify this air. To properly perform
its function of reducing wear and extending engine life filter 100% of the pre-
combustion air to remove as much contaminate of any and every particle size as
it can lead to a very high final efficiency. REQUIREMENTS and
IMPORTANCE of Air Cleaner Elements and Housing:

AIR CLEANER ELEMENT:

? Filters the air passing the combustion chamber.
? Allows sufficient air due for cleaning.
? Tough paper element to withstand moisture.
AIR CLEANER HOUSING:
? Perfect sealing to prevent dust entry
? Easy removal of heavy dust particles collected. Hump hose leads the
purified air from cleaner to turbo charger by connecting housing and section
pipe.

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. The standard turbocharger is made up of a shaft with a turbine wheel on one
end and a compressor wheel on the other end.

These turbine and compressor wheels are covered by a housing.

 26

The exhaust gases from the engine enter the turbine housing through the
inlet port. At that point, the thermal energy of the exhaust gas is converted
into kinetic energy because of the constriction in the turbine. Consequently,
the turbine is driven by kinetic energy. As the turbine wheel and compressor
wheel share the same shaft the compressor wheel rotates at the same speed
as the turbine wheel. Consequently, the compressor wheel draws in air and
compresses it, then the air passes through the outlet port and supplies the
engine with oxygen.

Such turbocharged systems need an intercooler because the air heats up when it
is compressed. So the intercooler cools down the hot air, coming from the
compressor, ensuring that more oxygen reaches the engine. This makes the engine
much more efficient.
 27

Furthermore, a valve known as the waste gate carries exhaust gas away from the
turbine when too much exhaust gas is produced by the engine. So it limits the
rotational speed of the turbine wheel and consequently the compressor wheel so
that the turbocharger won’t be damaged.

(B) 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 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.
 28

(C)LUBRICATION SYSTEM:

Oil is the blood of an engine. The lubricating oil has to perform several basic functions during
engine operation.
1. Clean
2. Cool
3. Seal
4. Lubricate
5. Support and
6. Protect.

(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
o
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.
 29

COMPRESSORS
A gas compressor is a mechanical device that increases the pressure of a gas by reducing its
volume. It is used to convert mechanical energy into gas energy by means of compressing air
at desired working pressure.

Compressed air is needed to carry energy for work at different locations/ areas/equipment.

GENERAL APPLICATION OF PNEUMATIC SYSTEM:-

 Power application
 Process application
 Control application

APPLICATION IN RIG:-

Power application
Ex: starting of engine, engaging clutches

Control application
Ex: driller’s console

APPLICATION OF COMPRESSED AIR IN DRILLING RIG EQUIPMENT:-

 Main power pack engines

 Draw works
 Rotary table
 Air winch
 BOP
 Kelly spinner
 Pipe spinner
 Purging of electrical panel in driller’s console
 Cellar pit cleaning
 Air horn
 Cleaning of casing pipe and drill pipe

TYPES OF COMPRESSORS:-

POSITIVE DISPLACEMENT
 Screw compressor
 Reciprocating compressor

DYNAMIC TYPE
 Centrifugal compressor
 30

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 LUBRICATING 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. It lubricates the bearings and gears.

PRINCIPLE OF 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 degrees 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.
 31

HOISTING EQUIPMENT
Draw-works:
A draw-works is the primary hoisting machinery that is a component of a rotary drilling rig.
Its main function is to provide a means of raising and lowering the traveling blocks. The wire-
rope drilling line winds on the draw-works drum and extends to the crown block and traveling
blocks, allowing the drill string to be moved up and down as the drum turns. The segment of
drilling line from the draw-works to the crown block is called the “fast line”.
The drilling line then enters the sheaves of the crown block and is makes several passes between
the crown block and traveling block pulleys for mechanical advantage. The line then exits the
last sheave on the crown block and is fastened to a derrick leg on the other side of the rig floor.
This section of drilling line is called the “dead line”

A modern draw-works consists of five main parts: the drum, the motor(s), the reduction
gear, the brake, and the auxiliary brake. The motors can be AC or DC-motors, or the
draw-works may be connected directly to diesel engines using metal chain-like belts.
The number of gears could be one, two or three speed combinations. The main brake,
usually operated manually by a long handle, may be friction band brake, a disc brake or
a modified clutch.
It serves as a parking brake when no motion is desired. The auxiliary brake is connected
to the drum, and absorbs the energy released as heavy loads are lowered. This brake
 32

may use eddy current rotors or water-turbine like apparatus to convert to heat the kinetic
energy of a downward-moving load being stopped.
Power catheads (winches) located on each side provide the means of actuating the tongs used
to couple and uncouple threaded pipe members. Outboard catheads can be used manually with
ropes for various small hoisting jobs around the rig.

The draw-works often has a pulley drive arrangement on the front side to provide turning power
to the rotary table, although on many rigs the rotary table is independently powered.

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. Moreover it doesn’t have any standby.

Crown Block

A crown block is the stationary section of a block and tackle that contains a set of pulleys or
sheaves through which the drill line (wire rope) is threaded or reeved and is opposite and above
the traveling block. The combination of the traveling block, crown block and wire rope drill
line gives the ability to lift weights in the hundreds of thousands of pounds. On larger drilling
rigs, when rising and lowering the derrick, line tensions over a million pounds are not unusual.

 It is a stationary pulley assembly mounted on the top of derrick (or) mast to provide
leverage point.
 The function of sheaves is to guide and support the drilling line as it passes through
the blocks.
 The number of sheaves in a block is determined by the weight to be supported.
 33

Travelling Block

A traveling block is the freely moving section of a block and tackle that contains a set of
pulleys or sheaves through which the drill line (wire rope) is threaded or reeved and is opposite
(and under) the crown block (the stationary section).

 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 holds 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.

Hook

 It is a device used for pulling and absorbing load shock 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.
 34

ROTATING EQUIPMENT
Rotary Table

A rotary table is a mechanical device on a drilling rig that provides clockwise (as viewed from
above) rotational force to the drill string to facilitate the process of drilling a borehole. Rotary
speed is the number of times the rotary table makes one full revolution in one minute (rpm).

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 itsdrill-string load and also provides a centering effect for the turntable because
of the angular contact between the ball bearing and its race.

Swivel

A Swivel is a mechanical device used on a drilling rig that hangs directly under the traveling
block and directly above the Kelly drive, that provides the ability for the Kelly (and
subsequently the drill string) to rotate while allowing the traveling block to remain in a
stationary rotational position (yet allow vertical movement up and down the derrick) while
simultaneously allowing the introduction of drilling fluid into the drill string.
Swivel joins two parts to pivot freely. The rotation of drill string begins with swivel. The swivel
prevents torque transmission to sheave block system.

Its basic functions are:

1. To support load
2. To allow drill stem to rotate
3. To support wash pipe and gooseneck
 35

4. To provide a connection for the rotary hose to drill string.

5. To allow drilling fluid into Kelly and drill string.

MUD HANDLING EQUIPMENT

Mud is considered to be the blood of the well. Mud parameters are necessarily to be maintained
well within allowable parameters to drill a healthy well.
Mud system is one of the most important elements of drilling rig. Mud system consists of mud
mixing, mud cleaning and mud 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.

MUD HOPPER

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.
 36

SHALE SHAKERS

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 shale shaker (i.e. towards the waste pit).

DE-SANDER

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 de-sander with mud. This pump delivers
smooth; even flows to the hydro cyclones for separation of de-sand 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. De-sanders operate efficiently with lower pressures than small cones.
Usually 30-35 psi is required for de-sander to function properly. Total head of about
 37

70- 80 feet is normally provided. The unit should be kept normally 6 to 10 feet above
the de-sander pump.

DE-SILTER

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 de-silter with mud. This pump delivers smooth, even flow to the hydro cyclones
for separation of de-silting particles.

Good de-silters 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
de-silting of the mud in drilling can cut down drastically on mud pump wear the hole problems,
bits, time required to drill the hole, water and chemicals required for mud treatment.

MUD AGITATOR

The agitator is a right angle gearbox 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 that
receives and transmits energy to impeller for stirring mud.
 38

DE-GASSER

Degasser removes entrained gas from the gas cut mud coming out of drilling hole.

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 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. Some of the Manufacturers
are- Mission Magnum, Kirloskar, BHEL and BPCL.

KELLY DRIVE

A Kelly drive refers to a type of well drilling device on an oil or gas drilling rig that
employs a section of pipe with a polygonal (three-, four-, six-, or eight-sided) or splined
outer surface, which passes through the matching polygonal or splined Kelly (mating)
bushing and rotary table.
 39

This bushing is rotated via the rotary table and thus the pipe and the attached drill
string turn while the polygonal pipe is free to slide vertically in the bushing as the
bit digs the well deeper.

When drilling, the drill bit is attached at the end of the drill string and thus the
Kelly drive provides the means to turn the bit (assuming that a down-hole motor
is not being used).

Rotation is transferred to the Kelly and connected drill string through a special
device called the Kelly bushing, which when fitted into the master bushing
transmits torque to the Kelly and simultaneously permits vertical movement of
the Kelly to make hole. The Kelly bushing can be shaped to fit the rotary opening
or have pins for transmitting torque. A Kelly bushing may also be called the drive
bushing.

Vertical movement of the Kelly during rotation is facilitated by rollers in the

Kelly bushing that engage and turn the square or hexagonal sides passing through
the Kelly bushing and roll to allow axial motion when turning to the right or
drilling.
 40

BLOW OUT PREVENTER (BOP)

A blowout preventer is a large, specialized valve or similar mechanical device,

usually installed redundantly in stacks, used to seal, control and monitor oil and
gas wells. Blowout preventers were developed to cope with extreme erratic
pressures and uncontrolled flow (formation kick) emanating from a well reservoir
during drilling. Kicks can lead to a potentially catastrophic event known as a
blowout. In addition to controlling the down-hole (occurring in the drilled hole)
pressure and the flow of oil and gas, blowout preventers are intended to prevent
tubing (e.g. drill pipe and well casing), tools and drilling fluid from being blown
out of the wellbore (also known as bore hole, the hole leading to the reservoir)
when a blowout threatens. Blowout preventers are critical to the safety of crew,
rig (the equipment system used to drill a wellbore) and environment, and to the
monitoring and maintenance of well integrity; thus blowout preventers are
intended to provide fail-safety to the systems that include them.

The term BOP (pronounced B-O-P, not “bop”) is used in oilfield vernacular to
refer to blowout preventers.
 41

CONCLUSIONS:

My days at Central Workshop, Sivasagar has given provided me lots

of information regarding the practical field of applied engineering. In this
span of time limit, I ave learned about practical working and work situation
of ONGC Ltd. By the study and observation of various techniques used at
CMS, Sivasagar.

ONGC is a very large industry and plays a very important role in

development of this region. ONGC, Central Workshop, Sivasagar has been
contemplating on maintaining all the safety and environmental norms in
every sphere of work life.

I am pleased to express my heartful thanks to all the engineers,

technicians and other employees in different units for their kind help and
excellent co-operation.

BIBLIOGRAPHY

1. Rig Equipment manual and other reading material provided by ONGC.

2. Wikipedia and other related sites like BHEL site.