Submitted to: Submitted by:R.P.GUPTA SIDDHARTH JAINSE (Mech.) ME(II Yr)TEL BHAVAN, ONGC COER, ROORKEE

PREFACE

This training report pertains to the industrial training that I have

undergone at ONGC, Dehradun as a part of curriculum of B.Tech

(Mechanical Engineering). The purpose of this training is to expose the

trainees with actual practical experience. I have learned much from the

professional managers and engineers with whom I was placed for

training work. Justification can not be done to whatever I have learnt

during this period within in a few pages but still I have tried my best to

cover as much as possible in this report.

Acknowledgement

“Knowledge is incomplete without implementing it in practical terms.”

With this view I would like to say that I am highly obliged to Mr.V.P

Singh for providing me an opportunity to work under his proper

guidance and support to complete my seminar report on “Mechanical

Equipments equipped on Land Drilling Rig.”

I am thankful to him for providing me the ample opportunities to raise

my confidence level and providing knowledge about certain areas of my

field about I was, otherwise ignorant.

At last I would like to say thanks to all those invisible hands, which

were indirectly linked with my project and helped me in successful

completion of my project.

Siddharth Jain

(M.E IV year)

Certificate

It is certified that Siddharth Jain (Roll no. 08060104107), a student of

COER, Roorkee has successfully completed the project in Mechanical

Equipments Equipped on Land Drilling Rig under my guidance

during the summer training period w.e.f 04/06/2010 to 09/07/2010.

During the period, his attitude towards learning was excellent and found

him very sincere to work/project assigned to him.

I wish him all the best in his future endeavor and a bright future ahead.

Mr. R.P. Gupta SE (Mech.)

Technical Services Tel Bhavan, ONGC

CONTENTS

Introduction

History

Company Overview

ONGC Vision

ONGC Mission

Institutes

ONGC Offices

Technical Services

Drilling rig

Vital Equipments On Drilling Rig

Mud Handling Equipments

Pumps

Power Packs

Drilling Equipments

Summer Training Tour

Introduction

Oil and Natural Gas Corporation Limited (ONGC) (incorporated on June 23,

1993), previously known as Oil & Natural Gas Commission, is an Indian

public sector petroleum company. It is a Fortune Global 500 company, and

contributes 77% of India's crude oil production and 81% of India's natural gas

production. It is the highest profit making corporation in India. It was set up as a

commission on August 14, 1956. Indian government holds 74.14% equity stake

in this company.

ONGC is engaged in exploration and production activities. It is involved in

exploring for and exploiting hydrocarbons in 26 sedimentary basins of India. It

produces about 30% of India's crude oil requirement. It owns and operates more

than 11,000 kilometers of pipelines in India. Until recently (March 2007) it was

the largest company in terms of market cap in India.

ONGC is the only fully–integrated petroleum company in India, operating

along the entire hydrocarbon value chain:

One of the Navratana companies of India.

Holds largest share of hydrocarbon acreages in India.

Contributes over 78 per cent of Indian’s oil and gas production.

About one tenth of Indian refining capacity.

Created a record of sorts by turning Mangalore Refinery and

Petrochemicals Limited around from being a stretcher case for referral to

BIFR to the BSE Top 30, within a year.

History

Foundation:

In August 1956, the Oil and Natural Gas Commission was formed. Raised from

mere Directorate status to Commission, it had enhanced powers. In 1959, these

powers were further enhanced by converting the commission into a statutory

body by an act of Indian Parliament. Major functions of ONGC according to this

provision were to plan, promote, organize and implement programs for the

development of petroleum resources and the production and sale of petroleum

and its products.

1960-1990:

Since its foundation stone was laid, ONGC is transforming India’s view towards

Oil and Natural Gas by emulating the country’s limited upstream capabilities into

a large viable playing field. ONGC, since 1959, has made its presence noted in

most parts of India and in overseas territories. ONGC found new resources in

Assam and also established the new oil province in Cambay basin (Gujarat). In

1970 with the discovery of Bombay High (now known as Mumbai High), ONGC

went offshore. With this discovery and subsequent discovery of huge oil fields in

the Western offshore, a total of 5 billion tonnes of hydrocarbon present in the

country was discovered. The most important contribution of ONGC, however, is

its self-reliance and development of core competence in exploration and

production activities at a globally competitive level.

Post-1990:

Post 1990, the liberalized economic policy was brought into effect, subsequently

partial disinvestments of government equity in Public Sector Undertakings were

sought. As a result, ONGC was re-organized as a limited company and after

conversion of business of the erstwhile Oil & Natural Gas Commission to that of

Oil and Natural Gas Corporation Ltd in 1993, 2 percent of shares through

competitive bidding were disinvested. Further expansion of equity was done by 2

percent share offering to ONGC employees. Another big leap was taken in

March 1999, when ONGC, IOC (Indian Oil Corporation) and Gas Authority of

India Ltd.(GAIL) agreed to have cross holding in each other’s stock.

Consequently the Government sold off 10 per cent of its share holding in ONGC

to IOC and 2.5 per cent to GAIL. With this, the Government holding in ONGC

came down to 84.11 per cent. In 2002-03 ONGC took over Mangalore Refinery

and Petrochemicals Limited (MRPL) from Birla Group and announced its

entrance into retailing business. ONGC also went to global fields through its

subsidiary, ONGC Videsh Ltd. (OVL). ONGC has made major investments in

Vietnam, Sakhalin and Sudan and earned its first hydrocarbon revenue from its

investment in Vietnam.

Company Overview

Global Ranking:

ONGC ranks as the Numero Uno Oil & Gas Exploration & Production

(E&P) Company in the world, as per Platts 250 Global Energy Companies

List for the year 2008 based on assets, revenues, profits and return on

invested capital(ROIC).

ONGC ranks 20th among the Global publicity-listed Energy Companies as

per “PFC Energy 50” (Jan 2008).

ONGC is the only company from India in the Fortune Magazine’s list of

the World’s Most Admired Companies 2007.

Occupies 152nd rank in the “Forbes Global 2000” 2009 list (up 46 notches

than last year) of the elite companies across the world, based on sales,

profits, assets and market valuation during the last fiscal year. In the terms

of profit, ONGC maintains its top rank from India.

ONGC ranked 335th position as per Fortune Global 500 - 2008 list, up from

369th position last year, based on revenues, profits, assets and shareholder’s

equity. ONGC maintains top rank in terms of profits among seven

companies from India in the list.

Represents INDIA’S Energy Security:

ONGC has single-handedly scripted India’s hydrocarbon saga by:

Establishing 6.66 billion tonnes of In-place hydrocarbon reserves with

more than 300 discoveries of oil and gas, in fact, 6 out of 7 producing

basins have been discovered by ONGC: out of these In-place hydrocarbons

in domestic acreages, Ultimate Reserves are 2.36 Billion Metric tonnes

(BMT) of Oil plus Oil Equivalent Gas (O+OEG).

Cumulatively producing 788.273 Million Metric Tonnes (MMT) of crude

and 463 Billion Cubic Meters (BCM) of Natural Gas, from 111 fields.

ONGC has bagged 85 of 162 Blocks (more than 50%) awarded in the 6

rounds of bidding, under the New Exploration Licensing Policy (NELP) of

the Indian Government.

ONGC’s wholly- owned subsidiary ONGC Videsh limited (OVL) is the

biggest Indian multinational, with 44 Oil and Gas projects (7 of them

producing) in 18 countries, namely , Vietnam, Sudan, Russia, Iran, Iraq,

Myanmar, Libya, Cuba, Nigeria, Columbia, Nigeria Sao Tome JDZ, Egypt,

Brazil, Congo, Turkmenistan, Syria, Venezuela and United Kingdom. OVL

has committed overseas investment of over 5 billion US dollars.

INDIA’S Most Vulnerable Sector Enterprise:

Ranked as the most respected Public Enterprise in India in 2007 “Business

World Survey, with 19th position in the league of the most respected Indian

Corporate(s).

Rated “Excellent” in MOU Performance Rating for 2006-07 by the

Department of Public Enterprise, Ministry of Heavy Industries in Public

Sector, GOI.

Oil Industry Safety Directorate (OISD) has selected Ahmedabad Asset and

MRPL for the year 2006-07 (as number one in Group-4 category ( Oil &

Gas Assets) and Second in Group-1 Refinery category respectively).

Topped the visibility metrics in Indian Oil and Gas Sector and the only

PSU in the top 10 list of Indian Corporate newsmakers.

“Golden Peacock Global Award 2007 for Excellence in Corporate

Governance 2007”, for the 3rd consecutive time, conferred by World

Council for Corporate Governance.

Bagged the coveted winner’s trophy of the maiden “Earth Care Award for

excellence in climate change mitigation and adoption” under the category

of GHG mitigation in the small, medium and large enterprises.

Conferred with “Infraline Energy Excellence Award” for its service to the

Nation in the Oil & Gas Exploration & Production category.

Bestowed with “Amity Award for Excellence” in Cost Management.

Pioneering Efforts:

ONGC is the only fully-integrated petroleum company in India, operating

along the entire hydrocarbon value chain:

Holds largest share of hydrocarbon acreage in India.

Contribute over 80 per cent of Indian’s oil and gas production.

About one tenth of Indian refinery capacity.

Created a record of sorts by turning Mangalore Refinery and Petrochemical

Limited around from being a stretcher case for referral to BIFR to the BSE

Top 30, within a year.

Interest in LNG and product transportation business.

Competitive Strength:

All crudes are sweet and most (76%) are light, with sulphur percentage

ranging from 0.02-0.10, API gravity range 26°-46° and hence attract a

premium in the market.

Maximum number of Exploration Licenses, including competitive NELP

rounds. ONGC has bagged 85 of the 162 Blocks (more than 50%) awarded

in the 6 rounds of the bidding, under the New Exploration Licensing Policy

(NELP) of the Indian Government.

ONGC owns and operates more than 15,000 kilometres of pipelines in

India, including nearly 3,800 kilometres of sub-sea pipelines. No other

company in India operates even 50 per cent of this route length.

Best In Class Infrastructure Facilities:

Onshore:

Production Installation – 240

Pipeline Network (km) – 15,800

Drilling Rigs – 70

Work Over rigs – 74

Seismic Units – 29

Logging Units – 32

Engineering Workshops – 2

Virtual Reality Centre – 5

Regional Computer Centre – 5

Offshore:

Well Platforms – 147

Well-cum-Process Platforms – 32

Process Platforms – 13

Drilling Rigs – 29

Pipeline Network (km) – 4,500

Offshore Supply Vessels – 55

Special Application Vessels – 4 (including 2 MSV)

Seismic Vessels – 1

ONGC VISION

 “To be global leader in integrated energy business through

sustainable growth, knowledge excellence and exemplary governance

practices.”

Diversification of energy sources, technology in understand Cost Classification

and above all finding new ways of energy wherever it is to meet the ever growing

demand of the country.

Strategic Vision: 2001-2020:

To focus on core business of E&P, ONGC has set strategic objectives of:

Doubling reserves (i.e. accreting 6 billion tonnes of O+OEG)

Improving average recovery from 28 per cent to 40 per cent.

Tie-up 20 MMTPA of equity hydrocarbon from abroad.

The focus of management will be to monetise the assets as well as to assetise the

money.

A new mission on golden jubilee by Dr.A.P.J. Abdul Kalam the

than President of India:-

“He suggest ONGC to give world leadership in management of energy sources,

exploration of energy resources , diversification of energy sources, technology in

underground Coal Gasification and above all finding new ways of tapping energy

wherever it is, to meet the ever growing demand of the country.”

ONGC MISSION

1. World Class Company:

“Making the nation energy independent before 2030”.

Dedicated to excellence by leverage competitive advantage in R&D

and technology with involved people.

Imbibe high standards of business ethics and organizational values.

Abiding commitment to health, safety and environment to enrich

quality of community life.

Foster a culture of trust, openness and mutual concerns to make

working a stimulating and challenging experience for our people.

Strive for customer delight through quality products and services.

2. Integrated in Energy Business:

Focus on domestic and international oil and gas exploration and

production business opportunities.

Provide value linkage in other sector of energy business.

Create growth opportunities and maximize shareholder value.

3. Dominant Indian Leadership:

Retain dominant position in leadership in Indian petroleum sector and

enhance India’s energy availability.

Institutes

ONGC has institutionalized research and development in the oil & gas, and

related sectors and established separate institutions to undertake specific

activities in key areas of exploration, drilling, reservoir management, production

technology, ocean engineering, safety and environment protection in the form of

9 independently managed R&D centers. These institutes are also supported by

regional laboratories.

These R & D institutes with experienced and highly qualified manpower support

exploration and production activities of ONGC.

List of Institutes  

GEOPIC: Geodata Processing and Interpretation Centre

KDMIPE: Keshav Deva Malaviya Institute of Petroleum Exploration

IDT: Institute of Drilling Technology

IEOT: Institute of Engineering and Ocean Technology

IMD: Institute of Management Development

INBIGS: Institute of Biotechnology & Geotectonics Studies

IOGPT: Institute of Oil & Gas Production Technology

IPSHEM: Institute of Petroleum Safety, Health & Environment

Management

IRS: Institute of Reservoir Studies.

ONGC OFFICES

Technical Services 

With a modest beginning in the year 1982 as the Department of Equipment

Management the section over the years has evolved as full fledged service

provider responsible for effective and efficient life cycle management of

equipment in ONGC.

 Its Corporate Office is situated at Vth Floor, B S Negi Bhawan, Tel

Bhawan, ONGC, Dehradun, Uttarakhand, India.

Core Activities

Equipment Management

Technical Audit

Quality Assurance

IMPETUS Project

School of Maintenance Practice

Energy Management

 

Equipment Management (EM):

Its Office is situated at Vth Floor, B S Negi Bhawan, Tel Bhawan, ONGC,

Dehradun, Uttarakhand, India.

Sub Groups under EM:

Standardization Group (ISO 9001: 2000 certified)

Policy Formulation Group

Capital & Idle Equipment Monitoring Group

Failure Analysis Group

CWS Monitoring Group

Technology & Web Monitoring Group

 

  Technical Audit(TA):

Technical Audit was instituted in ONGC in 1985-86 to complement the

monitoring control set up within the organization with a view to effectively

organize life cycle of the equipment / system.

Technical Audit offices are ISO 9001:2000 certified and are situated at each and

every strategic location of ONGC.

Its Corporate Office is situated at Vth Floor, B S Negi Bhawan, Tel Bhawan,

ONGC, Dehradun, Uttarakhand, India.

Corporate Energy Cell (CEC):

Energy Conservation cell in ONGC established in the year 1988. Energy cell

offices are ISO 9001:2000 certified and are situated at each and every strategic

location of ONGC.

Its Corporate Office is situated at Vth Floor, B S Negi Bhawan, Tel Bhawan,

ONGC, Dehradun, Uttarakhand, India.

 

Quality Assurance Department (QAD):

QAD established in 1967 as 'Directorate of Inspection & Equipment'. From

initial 2 divisions, today QAD has well distributed network at 15 strategic

locations.

 QAD has obtained accreditation for ISO 9001:2000

Its Corporate Office is situated at Shed No-8, Tel Bhawan, ONGC,

Dehradun, Uttarakhand, India, PIN- 284003.

 IMPETUS:

Project IMPETUS (Implementing Maintenance & Procurement Efforts through

Upgraded Systems) was initiated by ONGC in 1999 as a result of a

benchmarking study conducted by M/s A.T. Kearney Limited, the renowned

international Consultant having international exposure on Maintenance Best

Practices and Procurement processes. The aim of Project IMPETUS is to

improve upon the operational efficiency and assets utilization.

  Its Office is situated at Vth Floor, Bengal Chemical Bhawan, ONGC,

502, Veer Savarkar Road, Prabhadevi, Mumbai, India PIN-400025.

School of Maintenance Practices (SMP):

This institutes in ONGC was established in Nov 2003, and since then has been

nurtured as a Center of Excellence. SMP is the only technology driven learning

hub on maintenance practices in hydrocarbon industry, in this part of the globe.

It is situated at Makarpura Road, Vadodara, Gujarat, India.

Drilling Rig

A drilling rig is a machine which creates holes (usually called boreholes) and/or

shafts in the ground. Drilling rigs can be massive structures housing equipment

used to drill water wells, oil wells, or natural gas extraction wells or they can be

small enough to be moved manually by one person. They sample sub-surface

mineral deposits, test rock, soil and groundwater physical properties, and to

install sub-surface fabrications, such as underground utilities, instrumentation,

tunnels or wells. Drilling rigs can be mobile equipment mounted on trucks, tracks

or trailers, or more permanent land

or marine-based structures (such as

oil platforms, commonly called

'offshore oil rigs'). The term "rig"

therefore generally refers to the

complex of equipment that is used

to penetrate the surface of the

earth's crust.

Drilling rigs can be:

Small and portable, such as those used in mineral exploration drilling,

water wells and environmental investigations.

Huge, capable of drilling through thousands of meters of the Earth's crust.

Large "mud pumps" circulate drilling mud (slurry) through the drill bit and

the casing, for cooling and removing the "cuttings" while a well is drilled.

Hoists in the rig can lift hundreds of tons of pipe. Other equipment can

force acid or sand into reservoirs to facilitate extraction of the oil or mineral

sample; and permanent living accommodation and catering for crews which

may be more than a hundred. Marine rigs may operate many hundreds of

miles or kilometres offshore with infrequent crew rotation.

Petroleum drilling industry

Petroleum drilling rig capable of drilling thousands of feet.Oil and Natural Gas

drilling rigs can be used not only to identify geologic reservoirs but also to create

holes that allow the extraction of oil or natural gas from those reservoirs.

Primarily in on shore oil and gas fields once a well has been drilled, the drilling

rig will be moved off of the well and a service rig ( a smaller rig ) that is purpose

built for completions will be moved on to the well to get the well on line. This

frees up the drilling rig to drill another hole and streamlines the operation as well

as allowing for specialization of certain services, ie. completions vs. drilling.

Vital Equipments on Drilling Rig

The equipment associated with a rig is to some extent dependent on the type of

rig but typically includes at least some of the following items:

1. Mud tank2. Shale shakers3. Suction line (mud pump)4. Mud pump5. Motor or power source6. Vibrating hose7. Draw-works8. Standpipe9. Kelly hose

10. Goose-neck11. Traveling block12. Drill line13. Crown block14. Derrick15. Monkey board16. Stand (of drill pipe)17. Pipe rack (floor)18. Swivel19. Kelly20. Rotary table21. Drill floor22. Bell nipple23. Blowout preventer (BOP) Annular24. Blowout preventers (BOPs) Pipe ram & Blind ram25. Drill string26. Drill bit27. Casing head

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

mud guns

Are performing their function to prepare and conditioning the mud and

also keep the mud parameters well within the limits during drilling operations.

Purpose:

To prevent the mud for drilling a healthy well

To remove solid and gas from mud

To maintain the required parameters

To avoid mud wastages.

To keep weighing materials in suspension and avoid gel formation.

To aids reduction in consumption of mud pump expandable.

Drilling fluid:

The liquid drilling fluid is called drilling mud. It may be gas or liquid or

combination of both. It should have 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 based drilling fluid has these

properties. It is basically a mixture of water, barite, bentonite and some chemical

additives.

Barite:

It increases the density of mud (4.2 times more than water).

Bentonite:

Filtration control and increase the yield point.

Oil mud:

It is used when

The bottom hole temperature is high

Drilling in high pressure zone

Instability of well

Smaller dia well

Deep well

Production formation is water sensitive.

Functions of drilling 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 removes cutting particles from bottom of the hole.

It keeps the drill bit in cool condition and enhances drill bit life.

Solid Control Equipment

Hopper system:

Mud hopper is used for mixing dry material with drilling fluid. Hopper system

consists of centrifugal pumps and hoppers with jets. It is the first stage of mud

handling system. The centrifugal pump charger the water/drilling fluid into the

hopper through jet, which acts like venture creates vacuum and suck the dry

material along with it.

Shale shaker:

Shale shaker is the first piece of solid control equipment on surface mud tanks to

remove large particles coming out of the drilling well. It should be located above

the sand trap of 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 rotates towards the discharge end of the screen.

Shale shaker mesh weaves:

1. Plain square weaves

2. Rectangular opening

3. Plain notch weaves

4. Twilled square weaves

Desander:

It is used in the mud system for the purpose of removing sand size particles. It is

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× (mud weight). Low pressure will cause poor separation and

high fluid loss. High pressure will cause 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-silter:

It is used in the mud system for the purpose of removing silt particles. It is the

third 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 materials of sand size, a high %age of

solids larger than 10-20 microns, and decreasing %age of materials down 2-3

microns. Total desilting of the mud in drilling can cut drastically on mud pump

wear, hole problems, bits, time required to drill a hole, water and chemicals

required for mud treatment.

Mud cleaner:

It is used in the solid control system to effectively remove drilled solids from

weighted mud without excessive loss of barite and fluid.

It 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.

Mud agitator:

It is a right angle gear box 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.

Mud guns:

It is used in the mud system to stir the mud and thus avoid gel operation. Mud

gun stands should be positioned around the mud pits so that the entire area can be

stirred. It should be connected to a manifold and supplied with mud from a pump

operated for that specific purpose. The mud streams are directed at a particular

position in the mud pit and produce a rolling action. These are quite useful to mix

floating last circulation material and carry it below the mud surface, where it is

wetted and picked by a main mud pump to be pumped into the well.

Purpose of using mud agitators:

1. To prevent weighing material from dropping out of suspension during the

slow travel of mud through the pits

2. To break up gel strength mud

3. To reduce the apparently viscosity of mud and permit gas bubbles to escape

in minor gas cutting

4. To promote good mixing of mud when a get hopper is used to add weighing

material or clay to the system

Degasser:

It removes the entrained gas from the gas cut mud coming out of driller 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.

It is normally kept just after shale shaker to remove gas from mud before the

desander pump handling the mud to avoid cavitations problems.

Drawworks:

A draw-works is the primary hoisting machinery that is a component of a rotary

drilling rig. Its main function is to provide a means of raising and lowering the

traveling blocks. The wire-rope drilling line winds on the drawworks drum and

extends to the crown block and traveling blocks, allowing the drill string to be

moved up and down as the drum turns. The segment of drilling line from the

draw-works to the crown block is called the "fast line".

Blow Out Preventers:

A blowout preventer is a large valve or series of valves that can seal off an oil or

natural gas well being drilled or worked on. The term "BOP" (an initialism rather

than spoken as a word, i.e- pronouned 'B' 'O' 'P') is used in oilfield vernacular. If

underground pressure forces oil or gas into the wellbore, operators can close the

valve remotely (usually via hydraulic actuators) to forestall a blowout, and regain

control of the wellbore.

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.

Rotary pump:

It is a positive-displacement pump that consists of vanes mounted to a rotor that

rotates inside of a cavity. In some cases these vanes can be variable length and/or

tensioned to maintain contact with the walls as the pump rotates. It was invented

by Charles C. Barnes of Sackville, New Brunswick who patented it on June 16,

1874.It consists of a fixed casing containing gears, gerot, vanes, pistons, lobes

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 used for lubricating machinery and hydraulic application.

Reciprocating pumps:

Reciprocating-type pumps use a piston and cylinder arrangement with suction

and discharge valves integrated into the pump. Pumps in this category range from

having simplex one cylinder; to in some cases quad four cylinders or more. Most

reciprocating-type pumps are duplex (two) or triplex (three) cylinder.

Furthermore, they are either single acting independent suction and discharge

strokes or double acting suction and discharge in both directions. The pumps can

be powered by air, steam or through a belt drive from an engine or motor.

Centrifugal pumps:

A centrifugal pump is a rotodynamic pump that uses a rotating impeller to

increase the velocity of a fluid. Centrifugal pumps are commonly used to move

liquids through a piping system. The fluid enters the pump impeller along or near

to the rotating axis and is accelerated by the impeller, flowing radially outward

into a diffuser or volute chamber, from where it exits into the downstream piping

system. Centrifugal pumps are used for large discharge through smaller head.

Mud pumps:

The main component of fluid circulating equipment for rotary drilling is mud

pump. It provides the drilling force that sends the fluid through the route that

must travel.

Features of mud pumps:

It is designed for heavy duty service. The extreme volume pressure capabilities

of this pump are develop in an all welded steel power frame. Double row

spherical self aligning roller bearings, support both crank shaft and pinion shaft,

with straight roller bearing employed in the connecting rod at crank and cross

ends. Crossheads are operating on replaceable upper and lower shoes in

renewable shim adjustable guides. The dual lubricating system is design to

provide constant trouble free operation. The three fully interchangeable and

individually replaceable L shaped fluid cylinders afford easy 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. The bull gear

is attached to the crankshaft; the crankshaft turns to give a back and forth motion

to the connecting rod the connecting rods are linked to the crossheads. The

crossheads are connected to the piston rods and impart back and forth,

reciprocating, motion to the rods.

Pulsation effect of 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 super charging pump may be needed.

Supercharging:

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.

Pulsation dampener:

It absorbs discharge pressure variations thus reduces peak pressure and permits

smoother volumetric pump output. This action in turn minimizes vibrations in the

discharge line and the 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:

It should be installed in the discharge line immediately next to the pump. Its

primary purpose is to protect the pump when the discharge line, another part of

the hydraulic system or bit nozzle becomes plugged.

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 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 reduce

to half to 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

saving from increases in the expected life of expendable pump parts. The piston

speed below 200rpm generally provides proportionally more trouble free

hydraulic performance for all pump type and sizes.

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

Power Packs

Drilling rig are mainly powered with caterpillar make D399 model engines.

Engines are considered to be heart of the rig. These power packs can be put into

operation individually and parallel as well with common bus bar provision.These

power packs AC current.Part of AC is converted into DC silicon control rectifier.

This DC input is required for variable speed derive motors of mud pumps and

draw works.AC is required for all other constant rpm motors.

Working System:

Induction air 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 improper burning or

unburned fuel goes to exhaust in form of black smoke (improper burning of

diesel fuel) causing power loss,overheating 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.

Turbocharger:

The purpose of turbocharger is to charge more air into the engine cylinders.It

helps the engine to get more power by burning more fuel in a given time.Waste

going exhaust gas drives the turbocharger.The turbocharger increases the

pressure 3 to 4 times more than atmospheric pressure called boost pressure.The

turbocharger speed can varry between 70000 to 85000rpm.

The two turbochargers provide a cross blowing.These results in minimum air

flow restriction in the after cooler and assure equal quantities of air to each bank

of cylinders.The full floating bearings manufactured from an

alloy of copper-tin-lead are a critical lubrication point indicator.It is necessary to

ensure oil supply to them almost immediately after the engine starts.

Intake air temperature:

High air intake temperature is undesirable for proper combustion. Air molecules

expand at high temperature reduce the oxygen for combustion and increase

exhaust temperature. The after cooler removes some of the heat. The inlet air

temperature is lowered to a temperature near that of the engine coolent. If the

intake air temperature increases by one degree then exhaust temperature will

increase by three degree.

Fuel system :

The basic function of the fuel system is to supply the fuel in right quantity,at the

right time and at the right pressure to atomize thoroughly. Fuel produces power

in a diesel engine when it is atomized and mixed with hot air in the combustion

chamber.Pressure caused by the piston rising in the cylinder 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 piston 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:

It is a measure of the ignition quality of the fuel. Higher cetane rating assures

ease of starting in most conditions.

Pour point:

It is an indication of the minimum temperature at which the fuel will flow.

Cloud point:

It is the temperature at which some of the heavier paraffin (wax) in the fuel start

to form crystals.This wax can plug the filter.

Lubrication System:

Oil is the blood of an engine. The lubricating oil has to perform several basic

functions during engine operations.

1. Clean

2. Cool

3. Seal

4. Lubricate

5. Support

6. Protect

Cooling System:

The cooling system is basically a heat regulating system. It maintains the

temperature of the coolant by dissipiating 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 tolerences.

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.

Safety System(Hydromechanical Shutoff Switch):

It gives protection for low oil pressure, high coolant temperature and engine over

spends. The shutoff also has a 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

coolant temperature. Both the fuel rack and inlet air shutoffs will activate when

the engine over 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:250 psi

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:110psi

Sensing parameters:

1. Low speed low lubricating oil pressure sensing valve activate at minimum oil

pressure of 20 psi.

2. High speed low lubricating oil pressure sensing valve activate at minimum oil

pressure of 30 psi.

3. Thermostatic pilot valve activate at the water temperature of 99°C.

4. Over speed sensing valve activate at the speed of 1180rpm. At approximately

70% of engine full load speed, the oil pressure protection changes from low

speed range to high speed range.

Drilling Equipments

Drill String:

A drill string on a drilling rig is a column, or string, of drill pipe that transmits

drilling fluid (via the mud pumps) and torque (via the kelly drive or top drive) to

the drill bit. The term is loosely applied as the assembled collection of the drill

pipe , drill collars, tools and drill bit. The drill string is hollow so that drilling

fluid can be pumped down through it and circulated back up the annulus (the

void between the drill string and the formation).

Drill string components:

The drill string is typically made up of 4 sections:

Bottom hole assembly (BHA)

Transition pipe, which is often heavyweight drill pipe (HWDP)

Drill pipe

Drill stem subs

Each section is made up of several components, joined together using special

threaded connections known as tool joints.

Bottom hole assembly (BHA):

The BHA is made up of a drill bit which is used to break up the rock formations,

drill collars which are heavy, thick-walled tubes used to apply weight to the drill

bit, and drilling stabilizers which keep the drilling assembly centered in the hole.

The BHA may also contain other components such as a downhole motor, Rotary

Steerable System, measurement while drilling (MWD), and logging while

drilling (LWD) tools.

Transition pipe:

Heavyweight drill pipe (HWDP) is used to make the transition between the drill

collars and drill pipe. The function of the HWDP is to provide a flexible

transition between the drill collars and the drill pipe. This helps to reduce the

number of fatigue failures seen directly above the BHA. A secondary use of

HWDP is to add additional weight to the drill bit.

Drill pipe:

Drill pipe makes up the majority of a drill string. A drill string is typically about

15,000 feet (4.6 km) long for an oil or gas well vertically drilled onshore in the

United States and may extend to over 30,000 feet (9.1 km) for an offshore

deviated (non-vertical) well.

Drill stem subs:

Drill stem subs are used to connect drill string elements.

Drill line:

In a drilling rig, the drill line is a multi-thread, twisted wire rope that is threaded

or reeved through the traveling block and crown block to facilitate the lowering

and lifting of the drill string into and out of the wellbore.

On larger diameter lines, tension strengths over a million pounds are possible

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

Kelly Drive:

A kelly drive refers to a type of well drilling device on an oil 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. 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 downhole motor is not

being used).

Kelly:

The kelly is the polygonal tubing and the kelly bushing is the mechanical device

that turns the kelly when rotated by the rotary table. Together they are referred to

as a kelly drive. The upper end of the kelly is screwed into the swivel, using a

left-hand thread to preclude loosening from the right-hand torque applied below.

The kelly typically is about 10 ft (3 m) longer than the drill pipe segments, thus

leaving a portion of newly drilled hole open below the bit after a new length of

pipe has been added ("making a connection"), and the drill string has been

lowered until the kelly bushing engages again in the rotary table.

Kelly Hose:

The kelly hose is the flexible, high-pressure hose connected from the standpipe to

a gooseneck pipe on a swivel above the kelly and allows the free vertical

movement of the kelly while facilitating the flow of the drilling fluid.

Traveling block:

A Traveling block is the free 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 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 raising and lowering the derrick, line tensions over a million

pounds are not unusual.

Swivel:

A swivel is a connection that allows the connected object, such as a gun or chair,

to rotate horizontally and/or vertically. A common design for a swivel is a

cylindrical rod that can turn freely within a support structure. The rod is usually

prevented from slipping out by a nut, washer or thickening of the rod. The device

can be attached to the ends of the rod or the center. Another common design is a

sphere that is able to rotate within a support structure. The device is attached to

the sphere. A third design is a hollow cylindrical rod that has a rod that is slightly

smaller than its inside diameter inside of it. They are prevented from coming

apart by flanges. The device may be attached to either end.

Drill bits:

Drill bits are cutting tools used to create cylindrical holes. Bits are held in a tool

called a drill, which rotates them and provides torque and axial force to create the

hole. Specialized bits are also available for non-cylindrical-shaped holes.

SUMMER TRAINING

TOUR

During my training period, I visited following institutes of ONGC

Subir Raha Oil Museum

IDT (Institute of Drilling Technology)

KDMIPE (Keshav Das malviya Institute Of Petroleum Exploration)

ONGC Subir Raha Oil Museum:

During my visit to ONGC Subir Raha Oil Museum in Tel Bhavan, I came to

know about the development of oil drilling techniques & ONGC.

This is the building where K.D.Malviya held office as the first chairman of

ONGC. It has seen struggle of early pioneers, to traverse ONGC to become the

most valuable company of India in five decades.It has come up in Patiala house

without disturbing the orginal architecture. All development blend with natural

surroundings.

Museum detour

Ground Floor:

The ground floor of the museum depicts the search for oil and history of oil

industry.

Foucault’s pendulum-the theme exhibit depicting rotation of earth

Oil and its properties-the concept of hydrocarbons, main constituents of

crude oil

Formation of oil-generation, maturation, migration and entrapment of oil &

gas

Continental drift and plate tectonics

World oil history-a computer kiosk gives the details of world history of oil

in an intractive mode

Indian oil history-ihe first oil well in Digboi with its oil sample

Five decades of ONGC-the history of ONGC can be seen through an

intrective history seeker

Oil exploration & drilling-various methods of exploration, drilling

technology

Geological and geophysical exploration

Geo-data processing and interpretation and oil well logging

Offshore jack up drilling rig

Different part of drilling rig

Rotary drilling-functional model

Production technology- the section on production explains the primary and

secondary methods of oil production

First floor:

The exhibits depicts the journey of crude oil after it surfaces, and the arduous

process till it enters every aspect of life as a refined product.

Transportation

Offshore engineering

Pipeline laying and maintenance

Science of refining including treating and blending-functional models-

interactive exhibits

A panoramic view of ONGC’s MRPL Refinery

Usages of oil &gas-crude to crayons

Retailing and distribution network of ONGC

IT in ONGC

Crises management, speaking well and ONGC patent inclinometer

Safety and environmental management in ONGC

ONGC-a responsible corporate citizen

Overseas arm-ONGC Videsh Limited(OVL)

ONGC group of companies at the stroke of fifty

This museum is expected to leave the visitors, young or old satisfied and

enriched with knowledge of petroleum-the liquid gold

Institute of Drilling Technology (IDT)

During my visit to Institute of Drilling Technology (IDT), Dehradun I came to

know about the drilling technology used in ONGC.

The Institute of Drilling Technology (IDT) was set up in 1978 at Dehradun.

Located in the picturesque valley of Doon between the green Shivaliks and the

lower Himalayas, it is engaged in relentless effort in R&D and has rendered

excellent services in the area of oil and gas well drilling technology. Over the

years, the Institute has emerged as a premier R&D centre in South East Asia,

capable of providing advance technical knowledge through training and offering

plausible solution to field problems.

The Institute with highly qualified and experienced scientists and engineers

carries out applied research in all facets of drilling related activities to achieve

technical excellence in R&D efforts and assimilation of emerging technologies.

In IDT, I saw a drilling rig model NAT-55. My mentor told me how the drilling

rig works.

Drilling Technology:

Technological schemes for deep wells

Optimized design and engineered well plans including directional/horizontal

wells

Drilling complication diagnostics and solutions

Bit selection for improving drilling efficiency

Consultancy study on techno-economics

On the job consultancy and monitoring

Research and Development Lab:

The infrastructure for applied R&D has been developed with the state-of-the-art

equipment and machines to achieve qualitative experimental results. Focus of

R&D is directed towards drilling technology, drilling fluid engineering and

cementation and cementing materials to meet challenges of drilling industry. The

technologists and scientists provide solutions to the down hole drilling problems,

improving design of the systems and thereby contributing towards the

development of excellent, efficient and cost effective operations.

Cementation & Cementing Lab:

Special cement slurries for enlarged hole of BUA-1

Low temperature cement slurry for DUA-B

Design of micro fine cement slurry for squeeze cementation

Thixotropic cement slurry for loss prone areas of Neelam field and KG Basin

Light weight slurries for low fracture gradient formations

Corrective measures for cementation failure in Gandhar and Neelam fields

Formulation of guidelines for placement of cement plugs for deep side

tracking jobs

Development of software for centralizer placement

Pre and post cement job simulation by computer aided software

Optimization of cement slurry design under simulated down hole condition

KDMIPE :

During my visit to Keshav Deva Malaviya Institute of Petroleum

(KDMIPE), Dehradun. I went to service block in KDMIPE and saw a Central

AC and Generator room and my mentor told me about its principle (refrigeration

cycle) and its working.

The Keshava Deva Malaviya Institute of Petroleum Exploration (KDMIPE),

located at Dehradun in the picturesque Doon valley, was set up in 1962 as a

research and training institute. The institute continues to be the country's premier

centre for basic and applied research in petroleum exploration. It caters to the

search needs of ONGC's operating regions in the field of geosciences for

petroleum exploration, and development of alternate sources of energy.

Refrigeration cycle:

In the refrigeration cycle, a heat pump transfers heat from a lower temperature

heat source into a higher temperature heat sink. Heat would naturally flow in the

opposite direction. This is the most common type of air conditioning.

A simple stylized diagram of the refrigeration cycle: 1) condensing coil,

2) expansion valve, 3) evaporator coil, 4) compressor.

Central air conditioning:

Central air conditioning, commonly referred to as central air or air-con,is an air

conditioning system which uses ducts to distribute cooled or dehumidified air to

more than one room, or uses pipes to distribute chilled water to heat exchangers

in more than one room, and which is not plugged into a standard electrical

outlet.Central air conditioning performs like a regular air conditioner but has

several added benefits:

When the air handling unit turns on, room air is drawn in from various parts

of the building through return-air ducts. This air is pulled through a filter

where airborne particles such as dust and lint are removed. Sophisticated

filters may remove microscopic pollutants as well. The filtered air is routed

to air supply ductwork that carries it back to rooms. Whenever the air

conditioner is running, this cycle repeats continually.

Because the central air conditioning unit is located outside the home, it

offers a lower level of noise indoors than a free-standing air conditioning

unit.

UPS:

2x250 KVA

415 V

PCI Make

Redundant ups system with 352 number Ni-Cd Alkaline battery bank HBL make

to meet critical load like data acquisition center, labs etc.

Generator Room:

It supplies electricity to KDMIPE campus.

AC Generator-4

Kirloskar Electric Co. Ltd.

Bangalore, India

Specification:

Type-Turbocharged after cooled (TA)

KVA-1000

Volts-415

Amps-1392

ExtnN-86V

Extn-2.7A

Coolant temp-40°C

PF-0.8

Hz-50

Conn.-STAR

PH-3

Rating-S1 to BS: 2613-1970

Measured at 150 altitude and 29°C

Transformer:

Cromptons Greaves Ltd (Bombay, India)

KVA-1000

Volts-110000-H.V

-415-L.V

Amps.-52.5-H.V

-1391.2-L.V

Phase-3

Type of Cooling-OMAN

Frequency-50Hz

Impedance Volts-5.09%

Weight:

Core and Winding Weight-1490Kg

Oil Weight-730Kg

Total Weight-3380Kg

Oil-830Litre

Year of Manifacturing-1987

References

www.ongcindia.com

www.ongcreports.net

www.google.com

www.wikipedia.org

ongc publications

- ongc reports

- museum booklet