Oil and Natural Gas Corporat ion Limited

Cauvery Asset, Karaikal

RIG EQUIPMENT MANUAL

Compiled By

K.Chelladurai December 2006 SE (M), DS

FOREWORD

The manual “Rig Equipm ent Manual” contains voluminous technical

information about Rig Equipment. This technical information is of much

use to field engineers for day-to-day operation and maintenance of Rig

Equipment. I hope this manual will certainly help the engineers to

uncover hidden potential, enhance their talent, skill and confidence level

for collective success of the team. Employees would always aspire to find

a better and more efficient way to work. By making use of this manual,

the user can update his/her technical knowledge and skills to face

challenges. I am sure this special issue on “Rig Equipm ent Manual”

being brought out by Shri. K. CHELLADURAI , SE ( MECH) at a very

appropriate time will enlighten the engineers about the operation and

maintenance of equipment with high spirit.

I wish him great success.

ANI L JOHARI

GGM-Asset Manger

PREFACE

The manual “Rig Equipm ent Manual” is prepared and compiled for field

engineers and their team members. This manual is for better

understanding about the system functions, safe operations and upkeep of

equipment. The main objective of compiling this manual is to motivate

the field personnel for professional advancement, and also for safe and

healthy work practice. It is useful not only to maintenance engineers but

also to operators for developing technical skills and knowledge about

functions of equipment for safe operation. I hope this manual is of much

use to field engineers and they make use of it. I wish them all the best

with my heartiest pleasure. This manual has been thoroughly revised,

incorporated w ith m ore inform at ion and edited a second time.

I wish to acknowledge the assistance that I have taken in preparing and

compiling this manual from various textbooks, manuals, training course

materials, experience etc. It is a pleasure to express my thanks and

gratitude to all those authors and publishers.

I am especially thankful to Shri. Anil Johari, GGM- Asset Manager,

Shri. A.K. Khanna, DGM ( D) - HDS and Shri. T.R. Sivakolundu, CE

( M) , DS for their encouragement and cooperation in bringing out this

manual.

I am grateful to my family members for their active cooperation for

completion of this manual.

K.Chelladurai

SE (MECH), DS

“TRAI NI NG HELPS TO ENCOURAGE THE

BEST AND DEVELOP THE REST”

ABSTRACT

BHEL make E-760 and E-1400 series of deep drilling rigs are deployed

at different locations of Cauvery asset, Karaikal for drilling activities.

These Rigs are having drilling capacities of 3600mts and 4900mts

respectively. These Rigs are equipped with CAT D399 Engines; BPCL Mud

Pumps, ELGI and KHOSLA make Screw and Reciprocating Compressors,

Ingersoll Rand Air Winches, Top Drive, Independent Drive etc. This

manual mainly describes various functions of equipment and their

importance to the drilling activities. It is presented in the most compact

and lucid form. It will enhance confidence level of an individual for proper

operations and maintenances of equipment with out any difficulties. It will

also help engineers to enhance problem-solving capabilities and ensure

safety of personnel and equipment. Various important parameters are

also given in this manual for better diagnosis and to eliminate the

problems forthwith.

This manual is prepared and compiled based on the problems faced by

field technicians, engineers and operators of the rigs. Of course, it must

be very useful to them.

CONTENTS

CHAPTER DESCRI PTI ON PAGES

1 CLASSI FI CATI ON OF DRI LLI NG RI G

EQUI PMENT 0 1 - 0 2

2 POW ER PRODUCI NG EQUI PMENT 0 3 - 3 7

3 PNEUMATI C SYSTEMS 3 8 - 5 4

4 HOI STI NG SYSTEM OF RI G E- 7 6 0 5 5 - 8 9

5 HOI STI NG SYSTEM OF RI G E- 1 4 0 0 9 0 - 1 0 2

6 MUD HANDLI NG EQUI PMENT 1 0 3 - 1 1 4

7 PUMPS 1 1 5 - 1 2 7

8

GENERAL I NFORMATI ONS RELATED

W I TH DRI LLI NG RI GS

1 2 8 - 1 3 5

CLASSI FI CATI ON OF DRI LLI NG RI G EQUI PMENT

RI G MODEL: E- 7 6 0

E- Electric drive.

760- Draw works power rating in kW/1000HP.

Maximum drilling depth: -------3600 mts

Drill pipe size-------41/2"

Maximum load carrying capacity: ---190tonnes

RI G MODEL: E- 1 4 0 0

E- Electric drive.

1400- Draw works power rating in HP (1400HP).

Maximum drilling depth: -------4900 mts

Drill pipe size-------41/2"

Maximum load carrying capacity: ---190tonnes

Rig equipment can be divided into five categories.

Power producing equipment.

Hoisting equipment

Rotating equipment.

Fluid circulating equipment

Auxiliary equipment

1. Power producing equipment

Power packs

Compressors

2. Hoisting equipment

Draw works

Crown block

Traveling block

Hook

Air winch

3. Rotating equipment

Rotary table

IRD

Top Drive System

Swivel

4. Fluid circulating and conditioning equipment

Mud pumps

Hopper

De-sander

De-silter

Shale shaker

De-gasser

Mud agitator

Mud mixture

5. Auxiliary equipment

Water pumps

Diesel lifting pump

Welding transformer

Lighting

I .POW ER PRODUCI NG EQUI PMENT

1 . POW ER PACKS

ONGC Drilling Rigs are mainly powered by Caterpillar make D399

model engines. These engines are the source of power to the Drilling Rig

Equipment. Hence engines are considered to be heart of the Rig. Each Rig

of E760 Model having three power packs and E1400 Model having four

power packs. These power packs can be put into operation individually

and parallels with common bus bar provision. These power packs produce

mainly AC current. Part of the AC is converted into DC with help of silicon

control rectifier. This DC input is required for variable speed drive motors

of mud pumps and draw works. AC is required for all other constant RPM

motors.

CATERPI LLAR ENGI NE Engine model: ------------ D399

Engine rated RPM ------- 1000RPM

Engine rated HP -------- 1010HP

The inlet air, fuel, lubrication and cooling systems are the most

important and critical part of four stroke diesel engines. If all these

systems are maintained properly, the engine’s reliability, availability and

optimum performance are ensured. The details of each function are

elaborately given below for better understanding about engine for proper

operation and maintenance.