GIDEN Ilhami

Bakkalaurea Thesis

Derricks

Supervised by: Approval date:

Prof. Kessler 4th February 2005

Date: 29/12/2011

Table of Contents

Table of Contents.................................................................................................................2 List of Figures......................................................................................................................3 Abstract................................................................................................................................4 Introduction..........................................................................................................................5 Essay....................................................................................................................................6

1 History.............................................................................................................................................6 2 Historical Derricks in Europe...........................................................................................................12

2.1 Salzgitter-Gullivermast..................................................................................................................................12 2.2 EIKOMAG Four-Pole-Derrick......................................................................................................................13 2.3 Trauzl-W-Mast..............................................................................................................................................15

3 Steel Derrick..................................................................................................................................16 4 Cantilever Mast (Jack-knife Mast)...................................................................................................18

4.1 Lee C. Moore Mast.......................................................................................................................................19 4.2 Newer Mast Designs.....................................................................................................................................20 4.3 Standard-Full-View-Mast (System Ideco)........................................................................................................23 4.4 Elevated-Full-View-Mast................................................................................................................................25 4.5 Kwik-Lift-Mast (mainly workover rigs) ............................................................................................................25 4.6 Helicopter Rig...............................................................................................................................................25 4.7 Duallift Mast .................................................................................................................................................27 4.8 Mobile rigs ...................................................................................................................................................27 5.1 Application Range.........................................................................................................................................30 The regulations of this standard are valid for stationary and portable rigs, its segments and foundation, which are used to install and maintain production wells and van also be used as storage. Guy lines and the anchoring belong to the units.30 5.2 Terms..........................................................................................................................................................30 5.3 Various Loads..............................................................................................................................................31

5 Standard DIN 411 for rigs...............................................................................................................30

- Irregular hook load The irregular hook load includes the regular hook load plus the wind load during irregular operation...........................................................................................................................31 - Stress due to the power swivel The torque, which should be made by the power swivel, has to be considered........................................................................................................................................31

5.4 Load Combinations.......................................................................................................................................32 5.5 Scope and Details of the Static Proof..............................................................................................................33 5.6 Sign with load capacity..................................................................................................................................33 6.1 Summary.....................................................................................................................................................34 6.2 Future outlook..............................................................................................................................................35

6 Conclusions...................................................................................................................................34

References.........................................................................................................................37

List of Figures

Derricks

Abstract

At first I tried to mention that derricks are not an invention of the 19th century. Therefore I wrote a little bit about the former history of derricks. For that I wrote about the first people who had built a derrick, which were the Chinese not for oil or gas but for salt and the Egyptians used drilling to break large stones, which they used to build their pyramides. The next step, which I made, was the place where the development did not stop till today. This development began in the USA in middle of the 19th century. The first derricks were made of wood then the materials were changed into steel. The development in Europe was always some decades after the USA. I gave some examples for Austrian and German development, but the developments in Europe ended and later most of the derricks, which were built in Europe, were constructed under license of the US types. After the history I tried to explain the difference between derricks and masts. Then I gave some examples of different masts and tried to explain why these developments were necessary, for example the helicopter rigs, which can be disassembled into light parts which can be transported by a helicopter or the desert rambler with large tires which can roll in the sand without sinking. In the end of my essay I tried to explain some standards and some explanations in standards, which are usually in central Europe. The last thing I made was to write a conclusion with a future outlook.

Author: GIDEN Ilhami

Page: 4

Derricks

Introduction

My first goal is to tell something about the history of derricks, which people began with drilling and why did they do that. The next thing I want to do is to find out the history about modern drilling and in my case how the people did managed it with the derrick. Another goal of mine is to find out which materials the people used. Then I want to look at the development of different types and which types survived and which types died out. The next thing I want to do is to compare the two big parts of the world where the oil was/is very important: The USA and Europe. How was the development in these two continents and especially in central Europe? How is this development today? Do now exist types of both continents or has one of these continents won this competition. The second goal after the history is to find out which types were built and why they had been built. Which differences exist/existed between the different types? Is there anything which is always the same or are the different types completely different? Then I want to find out if there are any standards. And if yes what do they include? These are many questions and I hope I can find the answers and write them down here and I hope also that anybody who read my essay know something about derricks.

Author: GIDEN Ilhami

Page: 5

Derricks

Essay

1 History

Author: GIDEN Ilhami

Page: 6

Derricks

Figure 1: Peter Wilson (left) Local Druggist, Colonel Edwin L Drake (right) (1861) If you do not count picks and shovels, two drilling techniques have been available since people first began making holes in the ground: cable-tool drilling and rotary drilling. Both methods originated a very long time ago. Over 2000 years ago, for instance the Chinese drilled wells with primitive yet efficient cable tool rigs, because they were looking for salt. (They were still using similar rigs as late as the 1940s.) Two quarry rocks for the pyramids, the ancient Egyptians drilled holes using hand-powered rotating bits. They drilled several holes in a line and stuck dry wooden pegs in the holes. They then saturated the pegs with water. The swelling wood split the stone along the line made by the holes. The next time when we hear about derricks is about the mid 19th century where in the USA the first derricks of wood-frame construction were built. The materials were beam and building timber. Most of the derricks were only one time to use for another well it was necessary to build another derrick. There was a lot of difference in the construction and how the dimensions were chosen. Only the floor which was like a square and the top were the same in all cases. The power unit was either in a machine room or not but in all cases built next to the derrick. At that period the most famous wood-frame derrick was the one of Colonel Drake 1859 in Titusville (Pennsylvania) because he was the first one who found oil with a well in the USA. This was the beginning of the oil era in the USA and the rest of the world. Introducing the mud percussion drilling where the rope was replaced by drill pipes the disadvantage of the derricks with a lower height became obvious. At bit-changes there was no possibility to let the drill pipes in stands (2 or 3 pipes are connected) in the derrick. This disadvantage became more clearly to recognize by using the rotary drilling system at the beginning of the 20th century. The cable-tool drilling system were used by Colonel Drake at the Oil Creek site. Such rigs feature a cable to which workers attach a sharply pointed bit. Workers also attach heavy weights called jars above the bit. Rig machinery lifts the cable, the bit, and the weights, and then drops them. The falling bit strikes the ground with a heavy blow. It punches its way into the rock. Repeated lifting and dropping makes the bit drill. Cable tool drilling is very efficient in hard-rock formations such as those Drake and others drilled in Pennsylvania. From time to time, however, workers have to stop drilling, pull the bit from the hole, and remove the pieces of rock, or cuttings, the bit makes. If the crew fails to bail the cuttings, the cuttings will obstruct the bits progress. What is more, cable-tool drilling is not suitable for soft-rock formations, as soft-rock fragments tend to close around the bit and wedge it in the hole. The rotary drilling system was found in England in 1844, where the first rotary table and rotary swivel were used. This system was used only for water or salt wells at first. A rotary drilling rig turns, or rotates, the bit on bottom to drill, or make hole. Crew members attach the bit to the end of a length of pipe. By adding more pipe, they lower the bit to the bottom of the hole. With the bit on bottom, the driller starts rotating it. Some of the weight of the pipe is allowed to press down on the bit. The weight causes the bits cutters to bite into the formation rock. Instead of being a chisel, a rotary bit has several rows of metal teeth or diamond cutters. As the bits teeth or cutters rotate over the formation, they gouge or scrape the rock away.

Author: GIDEN Ilhami

Page: 7

Derricks

Figure 2: Cable-tool drilling rig

Author: GIDEN Ilhami

Page: 8

Derricks

Figure 3: An early (about 1916) rotary drilling rig; the rotary machine is in the foreground to the right. After about 50 years in 1900 Anthony Lukas, who had been born in Austria, used the rotary drilling system to drill an oil reservoir in Spindletop (Beaumont/Texas) and helped this system on the road to success, caused by a spectacular blow out known as the Spindletop Gusher.

Figure 4: Spindletop, 10 th October 1901

Author: GIDEN Ilhami

Page: 9

Derricks

"Black Gold" erupted from this well near Beaumont, Texas to a height greater than 50 meters on January 10th, 1901. It was not brought under control for 9 days, losing one million barrels of oil in the process. A device now called a "Christmas Tree" was invented on the spot to control the flow of oil. Christmas trees are now commonplace in the industry to prevent just such an occurence. An estimated 850,000 barrels of oil was lost. By today's standards, that's a loss of about $17,000,000. Of course, given the huge amount of oil which glutted the market after this discovery, the price of oil dropped from $2 to $.03 per barrel. Similarly to the period in 1860 in Titusville the happenings in Spindletop ended in an oil-rush. Spindletop was full of people who were looking for oil and woods of wood-frame derricks were founded. In 1903 at the Boiler Avenue were most of the drilling activities of the whole state of Texas. Daily blow outs were to register and it was not possible to avoid fire, because of the wood-frame derricks where the wood was covered with oil and so the fire could not been stopped.

Figure 5: Spindletop 1903

Author: GIDEN Ilhami

Page: 10

Derricks

The scene at figure 3 illustrates the densest drilling in Texas. By 1903, more than 400 wells had been drilled on the dome. The wood-frame derricks were some decades in action because they were cheap to build at the well site and no transport to another location was necessary.

Figure 6: Rigging up a wooden Derrick

While in the USA the wood-frame derricks had been changed with steel derricks from 1910 in Europe the wood-frame derricks were still in use of the oil companies. In Germany for example wood-frame derricks were in action till 1935. Remarkable are some constructions from Germany and Austria which brought diversity into the landscape of derricks for several years.

Author: GIDEN Ilhami

Page: 11

Derricks

2 Historical Derricks in Europe

2.1 Salzgitter-Gullivermast
At the beginning of the 1950s Salzgitter-Maschinen AG introduced one of the most interesting two-legged-pole-mast called Gullivermast in the market. Special features of the Gullivermast are: Two steel poles with an outside diameter of ca. 1 m and a wall thickness of 5 mm Each pole exists of three parts, which are connected like a flange On the top the poles are connected to each other with a crown block A-shaped

Inside the poles are: Ladders to reach the monkey board and the crown block Mud standpipe Tong counterweights Electric wiring for the electric lighting

The mast pole bearings are situated on the substructure: In the mast pole base bearings, an eccentric bushing is installed which makes it possible to adjust the travelling block into the borehole centre Both mast legs are supported by two slanted braces, which are attached in the lower section of the mast. The whole mast is tilted slightly to the front.

The Gullivermast has a platform, which can be moved between 3,5 m and 12m above the drill floor with an electric hoist on a square guide rail. The guide rail is mounted on the right mast pole (described from the pipe rack). On this platform it is possible to drive to the top end of the drill pipe and guide it during the make up. The construction of the Gullivermast was obviously influenced of the lightweight and pole constructions of airplane design. It was an interesting type of a full view mast but later it had been replaced by new types.

Author: GIDEN Ilhami

Page: 12

Derricks

Figure 7: Gullivermast

2.2 EIKOMAG Four-Pole-Derrick

Another fascinating German construction of the 1950s was the Four-Pole-Derrick built in Coproduction by SANDER and EIKOMAG. It was a Full-View-Mast in steel lightweight construction. The mast was built for crown loads from 300 t or 625 t. For this derrick the four legs are characteristic. They have a squared cross section of 1,2 m x 1,2 m and are built in a framework design. Every pole consists of five framework segments (10 m in length).

Author: GIDEN Ilhami

Page: 13

Derricks

The Four-Pole-Derrick is a further development of the classical steel derrick. The assembling of this derrick was in vertical position. Special raising masts, like the ones at the assembly of a Steel derrick, were in use. Later on mobile cranes were in use to assembly these derricks. The EIKOMAG-Derrick was built for large hook loads but it was not a standardized construction.

Figure 8: EIKOMAG Derrick 1961, height: 54 m

Author: GIDEN Ilhami

Page: 14

Derricks

2.3 Trauzl-W-Mast
Again in the 1950s TRAUZL developed a Full-View-Mast in Austria, which had a unique structure worldwide.

Figure 9: Raising up the Trauzl-W-Mast

The raising procedures of the Trauzl-W-Mast: The mast is mounted right and left onto the substructure in a horizontal position The upper parts of the legs are inserted telescopically into the lower parts of the legs. Turning points of the legs what means the mast pole bearings are situated on the substructure The legs are folded upwards by a corresponding spooling device onto a raising frame, which is centrally mounted on the drilling floor. Then the upper segments are drawn out telescopically

During the raising procedures the legs of the mast built a W with the raising frame. This is the reason for the W in the name of this derrick. The construction of the Trauzl-W-Mast did not prove in practice because this mast needed a lot of space during the raising procedure, which could not be used during the drilling process. However, the raising procedure itself was tricky.

Author: GIDEN Ilhami

Page: 15

Derricks

3 Steel Derrick
The Steel Derrick was introduced in 1910 the first time. In 1926 it was standardized by the API (= American Petroleum Institute) and started to spread all over the world in the 1930s. The most common types of Steel Derricks were those ones in which a drill string which consisted of three drill pipes could be set back. Other systems e.g. with lower heights were seldom because there was only the possibility to set two drill pipes back which ended up in very long round trip periods. Other systems were the ones with a large construction height (178 ft and 189 ft) where four drill pipes could be set back, but these ones also did not survive because four drill pipes were very difficult to handle. Originally the Steel Derricks stood directly on concrete foundations. The blow out control equipment and the flange connections were placed in the cellar and so dit not need any space at the surface. Soon the construction of this cellar especially in the swamp regions of the USA e.g. in the Gulf Coast became difficult and expensive. But it did not take a long time a simple solution was found. The solution was to put the derrick on a substructure to get some space. Then it was possible to put the blow out control equipment and the flange connections to there and there was no need to build a real cellar. This development was also very useful for the mud pumping system. The bell nipple won on height because the rig floor was elevated. This was the reason why it became possible to use mud tanks which were installed on the foundation instead of earth tanks. This was the beginning for the modern mud technology. Due to the development of the Steel Derrick and its corresponding substructure, a very important part of history in the development of rotary drilling was written. - Now it was possible to drill several wells with just one derrick - The derrick, the substructure and all other parts were transported from on location to the other - Now a better fire protection existed caused by the construction material steel - The wind working surface was reduced to one thirds - The load capacity of Steel Derricks was easier to calculate than that of the old wooden derricks, which made it possible to make a more accurate rig selection

Author: GIDEN Ilhami

Page: 16

Derricks

Figure 10: Raising up a Steel Derrick

Author: GIDEN Ilhami

Page: 17

Derricks

4 Cantilever Mast (Jack-knife Mast)

Figure 11: Model of triple jack-knife-mast

In the oil industry the development of derricks and masts was rather simultaneously. Previously the wooden derricks were left if the well had been successful. Later this fact was useful for so called workover jobs, because no had to be build again. But nearly each time Steel Derricks were dismantled after the drilling job. So the question was how the workover jobs could be done. At first, steel tower constructions, which were similar to the Steel derricks in their conception, were used. The steel tower constructions were much lighter than the Steel derricks and they had no substructure. The next step was to create a construction, which was easy to transport and also easy to build up. These constructions consisted of two mast poles (legs) and these ones can be regarded as the precursor of the Full-View-Mast. Some of these light constructions were mobile and had telescopic masts.

Author: GIDEN Ilhami

Page: 18

Derricks

The principle of all Jack-knife masts do not depend on the producer but is always the same. The derricks are assembled horizontally on the floor and then raised up by the drawworks. Most of the modern types can be used freestanding way what means that there is no necessary to use bracing lines. The lines which can be found on the rig are only guy lines, which mean that they compensate the wind load capacities. A difference exists in the way the derricks are raised up and how the mast weights are diverted onto the substructure. We make the difference of two general types of rising up: - To pull up the mast over an A-frame - To push up the mast with raising legs Lee C. Moore System Ideco System

There are again two types of difference with the Lee C. Moore System according to the diversion of the mast forces: Masts which need the A-frame to divert the mast forces.

In this construction the mast has only two mast pole bases on the averted side of the drawworks. The second support surface is the A-frame the mast, when it is raised, leans on it. Masts which need the A-frame just as a reversing point in the raising process.

These masts have four legs and can stand on their own legs. The system of the freestanding four base mast has been used from OILWELL and EMSCO. All other companies use the concept of the two base mast, what means that this system is usually to find more often. Since 1947 the Jack-knife masts have been standardized from the API. Other criteria to make a different of Jack-knife masts are: Masts, which stand directly on the foundation steel frame Masts, which are elevated up to the substructure during the raising process

4.1 Lee C. Moore Mast

The first Jack-knife mast did not appear on the market until the 1930s. The first company who introduced this mast was the company of Lee C. Moore, which built already 1907 a Steel Derrick, what means that this company was a pioneer of the oil business. The Lee C. Moore Jack-knife mast was assembled on the floor horizontally and then it was raised up over the A-frame with the drawworks. This mast already looked like a modern Jackknife mast. The raising process of the Lee C. Moore is illustrated in the next page. First the well site has to be leveled out and the friable soil removed. Then the base beams, their extensions (raising legs), and the drawworks substructure have to be mounted according to the assembly drawing on the floor logs. The drawworks, the engines, and the guide rails have to be installed and mounted onto the substructure. The travelling block and the hook are placed into a certain distance of the well. The mast has to be assembled according to the assembly drawings. The drilling line has to be reeved

Author: GIDEN Ilhami

Page: 19

Derricks

from the deadline anchor, over the first wire-line sheave, over and through the crown block and the travelling block, then over the sheaves on the rear side of the mast to the main drum. The brace line, mounted just underneath the monkey board, holds back the mast at the end of the raising procedure. The pull line runs over a balance sheave, which hangs on the hook, and winding up the pull line raises the mast. The use of the brace line prevents the mast from falling against the A-frame in the end. The mast is attached with bolts to the A-frame. Then the pull lines are loosened, lowered with the travelling block, and fastened with slings to the drawworks substructure. Afterward the bolt connection between the base frame and the drawworks substructure is disabled. Then, by slowly winding up the drilling line, the drawworks are lifted onto the drilling floor level and fastened with bolts.

4.2 Newer Mast Designs

After the special constructions, which were meant before from German and Austrian producers, was no other development in Europe for any mast construction. The Europeans just bought licences from designs of the USA and rebuilt it. In the 1970s newer mast constructions were developed. These ones could be moved more easily, because it was possible the parts into smaller ones. This made it possible that no heavy flatbed trailers were necessary anymore. Also Jack-knife masts were developed, which could be moved on dollies (mainly folded but also erected). Nowadays only freestanding masts are in use and their stability allows such a procedure in suitable landscapes. In the middle of the 1960s began the exploration of gas reservoirs. Then it was necessary to build the substructure higher because the larger safety armatures (BOP-stacks = blow-out preventer stacks) needed more space (i.e. Helmerich & Payne Inc., Tulsa planned built 25 new derricks between 1998 and 2003 with a substructure height of about 8,3 m). A construction called insert-structure became popular again The mast legs were positioned as low as possible to divert the loads directly into the foundation This was the reason why the masts became larger The insert-structure made it possible to install the biggest BOP-stacks

These necessaries were the reason why a new mast the so called Raised-Floor-Mast was built. The mast leg points are situated on the main frame, which is positioned directly on the foundation. The rig floor is build between the mast legs. The mainframe boxes support it and this structure allows the heaviest casings and drill pipe loads to be absorbed. This solution is up to now the optimum for the required function of drilling rigs. A total load of up to 1000 tons is possible.

Author: GIDEN Ilhami

Page: 20

Derricks

Raising up the mast finished

Raising up the substructure with hydraulic hoists

Author: GIDEN Ilhami

Page: 21

Derricks

Building up the substructure finished Figure 12: Jack-Knife-Mast with raised floor system; System DRECO, Type Slingshot

In newer mast constructions the drawworks are generally placed on the substructure. Therefore solutions had to be found how the drawworks could be elevated onto the substructure. Therefore some different constructions were designed: PYRAMID patented a system where the drawworks are placed onto the drawworks base frame, which is mounted behind the main base frame. During holding the drawworks in this position the mast is erected. After this process the drawworks with the base frame, where the drawworks are mounted, are lifted up by the winches, which are situated in front of the rig. In the second method of PYRAMID the drawworks, which are mounted on the frame, are lifted up with extern winches to the level of the rig floor. Then the mast is being erected by the installed drawworks. In the so called BIG DADDY system (Lee C. Moore) no external winches are necessary. At this system at first the mast is being lifted up with the drawworks. Then the drawworks pull up themselves.

Author: GIDEN Ilhami

Page: 22

Derricks

4.3 Standard-Full-View-Mast (System Ideco)

Author: GIDEN Ilhami

Page: 23

Derricks

Figure 13: IDECO Full-View-Mast Full-View-masts have generally an A-shape. The mast is lifted up by the drawworks and supported at the front by two legs. Special advantages: The driller has a very good visibility to the monkey man and the hook The drill floor is empty, what means that various sizes of drawworks can be used Free space around the catheads, and the support beams are mounted in the front Big stability by due to the wide support distances Massive framework construction Easy assembly and disassembly The rope stays reeved in the pulleys during the transport Different possibilities of transport Mounted to skids and movable with fold legs Transport of disassembled simple parts

Erecting the Standard-Full-View-Mast 1. Preparation: The mast is laid onto wooden beams next to the mast foot chock. For high mast substructures it has to be considered that the lower side of the mast does not overlap with the tracks of the guide ramp. Otherwise it could become necessary to lift the masthead a bit higher. In case the two guide rolls are not exactly in the centre of the guide rail, the masthead has to be moved horizontally (not with the drawworks lift). 2. Pulling up the mast to the mast foot jack: The travelling block and the hook are situated as near as possible to the front traverse braces of the substructure so that the bail for the erecting ropes can be fastened easier in the hook. The hook is bound with a wire sling onto the substructure and the foot rolls of the T-1 sections have to be on the rails of the guide ramp. The upper end of the guide ramp has to be lifted up with lifting spindles so much that it is allowed to the mast hinge bolts to slide into the slots of the mast foot chock. After the reefing of the blocks, it is possible to lift up the mast (the head end lies on the transport vehicle) onto the guide ramps by winding up the drum rope. By lowering the guide ramps the mast hinge bolts are inserted into the slot. Afterwards the bracings of the mast foot chock are unfolded and secured with bolts. 3. Checks before the erecting: The mast has to be in a horizontally position or above, if it lies on the crown frame. The guy lines have to be attached to the crown block frame in the provided bails. The erecting lines have to have to be mounted on the bail and the bail on the hook. The erecting line has to cross the dead line above. Erecting lines have to be lubricated and in a good condition. The dead line anchor, the raising legs and the monkey board have to be installed in a right way. On the mast no loose objects (like bolts, tools, etc.) are allowed. All bolts have to be secured by split-pins or other safety devices. The drillometer has to function without any problems.

Author: GIDEN Ilhami

Page: 24

Derricks

4. Process of erecting the mast: The mast has to be pulled up slowly and in a regular way by the drawworks. It is necessary to pay attention to the loose guy lines, if they are in the right order. At the beginning of the erecting of the mast the dead line runs horizontally with a longer lever arm, which is the reason why the drillometer shows 1.4 times more forces than in reality. If the vertical position is reached, the four locks close automatically. The two locking spindles are used and braced now. The erecting lines have to run inside the mast by pulling them all the way up together and bound to the mast. The guy lines have to be braced with the anchors at an angle of 45.

4.4 Elevated-Full-View-Mast
This mast is very similar to the Standard-Full-View-Mast. The difference is that the ElevatedFull-View-Mast has a larger substructure to be able to use larger preventer systems.

4.5 Kwik-Lift-Mast (mainly workover rigs)

Kwik-Lift-Masts exist in heights between 24,2 m (74) and 36,75 m (112). They can be mounted on a Drive-In, Back-In, Single Trailer and Dual Trailer Rambler. Advantages of the Kwik-Lift-Mast: Good sight from the floor to the crown Transportable from well to well with all lines strung (in one piece) Raised and lowered by multistage hydraulic rams Possibility of telescoping the mast The racking platform is able to vary the length due to the pipe length Substructure is built for capacity from 150 t up to 275 t The crown block is adaptable for dual-speed-operations High torsion-stiffness; for slim-holes and hard workover-jobs

4.6 Helicopter Rig

When the demand for lighter rigs began, this was for remote places like a jungle or off-shore, a new type of rigs was developed. This one should be able to be transported with helicopters, what means that they should be light. These rigs can be assembled into parts which are lighter than 2 t. Then these parts can be transported by helicopters into the working area.

Author: GIDEN Ilhami

Page: 25

Derricks

Two main arguments exist for designing a helicopter rig: Minimize the hours for assembling, disassembling and the time of preparing the flight with the helicopter Reduction of helicopter flights by using a highly engineered module concept

To ensure that the transport is optimal, corresponding transport-containers are in use. Example of a helicopter rig (MSH 2000 Ideco): Up to 7000 m depth Up to 360 t hook load Eight diesel engines deliver 3000 hp Drawworks has Four-speed steps and 1600 hp input power 20 x 46 3/16 drawworks drum and 1 1/8 rope with 10 reevings Two brake drums 50 x 10 at the main drum (possible to transport in one unit) Two hydraulic brakes (Parmac 342A) give the needed braking power Three mud pumps (each with 500 hp input power). Two of them get their power by the compound and one has an independent drive with two diesel engines.

Author: GIDEN Ilhami

Page: 26

Derricks

Figure 14: Helicopter Mast

4.7 Duallift Mast

Duallift masts are vertically free standing constructions, which are telescopic, built for high hook loads and high wind forces. These ones have not any guy lines. The Duallift Masts can be erected either by hydraulics or by the drawworks (dependent of the type). These masts are generally used as offshore-workover-rigs. On the single piece substructure, the drawworks, machines, masts and the rotary table are mounted on a skid. They can be moved on the substructure and can be placed exactly above the well. It is possible to save up to 40% of time with the dual-speed-system during the trip action.

4.8 Mobile rigs

4.8.1 Trailer Rambler

On wheels (trailer) mounted for easy transport Rig is transportable in three units

- Trailer for drawworks and drive engines - Trailer for Duallift mast with the block and tackle system - Trailer for the substructure Possibility to telescope the mast twice, to make the mast smaller Drawworks and rotary table are chain driven

4.8.2 Desert Rambler

The IDECO Desert Rambler for drilling or workover is a large Dual Trailer rig with the drawworks and engines carried on one trailer and the mast and substructure carried on the other trailer. This Rambler Rig can be furnished with the IDECO H-725, H-900 or H-1200 mechanical or electric drawworks and the KM 127-430 VM or the KM 136-525 VM Duallift Mast. The dimensions of the Desert Rambler restrict its use to off highway locations. This Rambler Rig is normally furnished with large sand tires for use in desert locations.

Author: GIDEN Ilhami

Page: 27

Derricks

- Figure 15: Desert Rambler Rig

Author: GIDEN Ilhami

Page: 28

Derricks

4.8.3 Drive-In Rambler Rigs

Advantages: Spots easily and quickly at the well, requires little driver experience Eliminates overhang of mast in front of driver on highway Meets critical highway regulations for weight distribution and overhang Suitable for quick rod and tubing service involving fast rig-up

Figure 16: Drive-In Rambler Rig IDECO 4004

4.8.4 Back-In Rambler Rigs

Advantages: Suitable for shallow drilling, workover, as well as rod and tubing work Short turning radius provides easy spotting in restricted turning areas The drivers cabin does not get dirty because the well is on the rear part of the well The larger loading areas make the transport of longer tools and auxiliaries possible Wheels located well back from cellar or around wet well site

Author: GIDEN Ilhami

Page: 29

Derricks

Figure 17: Back-In Rambler Rig

5 Standard DIN 411 for rigs

5.1 Application Range

The regulations of this standard are valid for stationary and portable rigs, its segments and foundation, which are used to install and maintain production wells and van also be used as storage. Guy lines and the anchoring belong to the units.

This standard does not include the machines and the movable parts during operations except the ropes.

5.2 Terms

5.2.1 Derrick
The derrick is the part of the rig, which carries mainly the hoist, the corresponding hook loads and the pipes. The difference between derrick and mast that the hook load is more central and the bigger base of the derrick.

Author: GIDEN Ilhami

Page: 30

Derricks

5.2.2 Mast
The difference lies in the hook load axis, which is different from the mast axis and that of the assembly. Normally masts are assembled in a horizontally position and then they are erected and if necessary and if possible telescoped.

5.2.3 Crown
The crown is the upper part of the hoist

5.2.4 Substructure
The substructure diverts all loads into the foundation or the ground. It can also be used as a foundation. As far as the portable units serve this function, they are also seen as substructure.

5.3 Various Loads

5.3.1 Dead load

The dead load of all parts (mast of derrick, drill floor) has to be considered in all static calculations. We assume that the dead load is located in the crown.

5.3.2 Working load

Hook load in the calculations we use the static hook load. The hook load is the force on the hook of the travelling block, the weight of the travelling block and the weight of the moving line (in the lowest position of the hook). Its direction is from the centre of the crown block to the centre of the rotary table. A difference between regular hook load and irregular hook load exists: - Regular hook load The regular hook load is the static hook load, what includes the pipe weights and wind load in regular operation - Irregular hook load The irregular hook load includes the regular hook load plus the wind load during irregular operation - Stress due to the power swivel The torque, which should be made by the power swivel, has to be considered - Stress through the pull line, dead line and any guy line The load components from the pull line, dead line and any guy line have to be considered. But it is important to pay attention to the right direction of the forces.

Author: GIDEN Ilhami

Page: 31

Derricks

- Wheel frictions in the crown Horizontal forces and torques due to the frictions of the wheels has to be considered. If the losses cannot be defined exactly, it is necessary to assume a friction of 2,5% for each wheel - Stress due to the pipe stack The whole weight of the pipes can be seen as an evenly distributed surface load onto the plan surface. The horizontal component of slanted pipes in an inconvenient position has to be taken in account. The footprint of drill collars on the drill floor has to be proved in the static calculations - Rotary table load The force applied in the borehole centre on the substructure, has to be at least of the same value as the regular hook load, even if the rotary table load is smaller. Pipe forces, which are applied at the same time, also have to be considered. Other stresses Floor sections, which are free, have the following loads: - Drill floor 25 kN single-load for inconvenient positions or 5 kN/m, whereas the worse condition must be taken - The monkey board, crown floor, catwalks and other floors have 1,5 kN single-load in inconvenient positions - Stairs 3,5 kN/m or 1,5 kN single-load in inconvenient positions whereas the worse case must be taken - Rails They have a given load of 0,3 kN in horizontal direction - Wind loads The calculation of wind load is done according to DIN 1055 part four. The values for impact pressure can be taken from the following table. The wind surface for the selected pipes belong to the largest pipe stack - Regular operation The impact pressure q = 0,05 kN/m (means wind velocities about v = 9 m/s) - Irregular operation At irregular loads the impact pressure can have q = 0,3 kN/m (means wind velocities about 22 m/s) - Rig shut down According to DIN 1055 part 4 or for rigs smaller than 60 m the impact pressure q = 1,0 kN/m (means wind velocities about 40 m/s) and for offshore rigs q = 1,65 kN/m (means wind velocities about 51 m/s) - Erecting case During the erection of masts q = 0,05 kN/m (means wind velocities about 9 m/s) and for derricks q = 0,10 kN/m (means wind velocities about v = 13 m/s)

5.4 Load Combinations

Regular operation

The regular hook load has to be combined with all stresses like dead load, pull line forces, dead line forces, guy line forces, wheel friction on crown, stress due to pipe stacks, and wind as according to regular operation. The loads according to other stresses have to be taken in account for the various floors. For the substructure in regular operation also the loads have to be combined with the single-load stresses due to pipe stacks and rotary table and catching loads as well. Irregular operation

For the irregular operation the wind loads have to be taken according to the irregular operations. - Rig shut down The wind loads according to rig shut down have to be combined with all inconvenient loads. Hook loads are not included.

Author: GIDEN Ilhami

Page: 32

Derricks

Erecting case Use of auxiliaries

During the erecting of the mast the dead loads of moving parts are multiplied with the factor 1,1

If auxiliaries like hook loads, the power swivel, the crane arm and the pipe floor are in use, the effect has to be checked closely

5.5 Scope and Details of the Static Proof

General - The calculations must be made by using the general rules of technology according to the standards.

For the calculation of the framework calculations, like pressure rods, the DIN 4114 part 1 and for the buckling safety of the corner beams the DIN 4114 part 2 is used Required safety For static calculations according to theory of the 1st order:

The required safeties of the steel and aluminium components must be shown by comparing the calculated stresses with the allowed stresses. The allowed stresses for these materials are listed in DIN 1050 and in DIN 4113. The allowed stresses during assembly are listed in DIN 1050. For ropes the minimum force to break is to find in DIN 5881 part 1 and part 2. The rope safety factor against the breakage has to be: 3,3 times for driving ropes during operation 2,5 times for an irregular case 2,1 times for an erecting line 2,5 times for guy lines

Rigs need a tilt safety of at least 1,5. Guy lines and wind lines can be used for calculating the tilt safety, if they have all of this three requirements: Thickness of at least 10 mm The anchoring has to have at least the factor 1,5 times more than the expected rope forces They have to be pre-stressed with a third of the expected rope force or at a maximum of 10 kN

For static calculations according to theory of the 2nd order according to DIN 4114 part: In case of a 1,5 stress condition (according to chapter 5,3 Various Loads) the safety of the steel construction against yield has to be 1,0 and 2,0 against breakage.

5.6 Sign with load capacity

On a very clear and visible place of the rig a sign with the loads capacity has to be mounted. The given carrying capacity of the derrick or mast is the static hook load.

Author: GIDEN Ilhami

Page: 33

Derricks

The following details must be shown on the sign: Producer Type Date of construction Regular hook load in kN with the reeving type Irregular hook load in kN with the reeving type Corresponding rope diameter and rope strength

6 Conclusions

6.1 Summary
Now the essay ended and I think that I found many answers to my questions and I hope that you get also the answers you looked for. In the following I will try to make a summary of the essay and then a future outlook. At first I tried to mention that derricks are not an invention of the 19th century. Therefore I wrote a little bit about the former history of derricks. For that I wrote about the first people who had built a derrick, which were the Chinese not for oil or gas but for salt. The next step, which I made, was the place where the development did not stop till today. This development began in the USA in middle of the 19th century. The first derricks were made of wood then the materials were changed into steel. The development in Europe was always some decades after the USA. I gave some examples for Austrian and German development, but the developments in Europe ended and later most of the derricks, which were built in Europe, were constructed under license of the US types. After the history I tried to explain the difference between derricks and masts. Then I gave some examples of different masts and tried to explain why these developments were necessary, for example the helicopter rigs, which can be disassembled into light parts which can be transported by a helicopter or the desert rambler with large tires which can roll in the sand without sinking. In the end of my essay I tried to explain some standards and some explanations in standards, which are usually in central Europe.

Author: GIDEN Ilhami

Page: 34

Derricks

6.2 Future outlook

It is possible that some very special derricks will be built with very special advantages. For example a subsidiary of ExxonMobil wants to build a very special rig in a very dangerous environment at the Sakhalin Island (Russia), which is placed in the north of Japan. Outside the temperatures will drop to 40 C and they try to create a shirt-sleeve environment. Due to the remote location and difficult logistics for acquiring equipment and materials, quality assurance takes on a much more significant meaning. Sakhalin Island is in a very seismically active location, lying in a region where four of the earths tectonic plates converge just south of Sakhalin, near Japan. Russias worst earthquake, measuring 7,5 in the Richter scale, occurred on Sakhalin Islands north end in May 1995. ExxonMobil says the significant design features of the land drilling rig for Sakhalin should allow it to survive serious seismic activity without catastrophic collapse of the mast or rig structure.

Figure 18: Rig cross section Other examples are slant drilling rigs produced by Precision Drilling Corp. The rigs history, currents statistics, and operator demand indicate that they are competitive with conventional cantilever doubles, telescoping doubles, and singles. The rigs have drilled wells that vary considerably in type, depth, and other characteristics. A Precision Drilling engineer Ron Isinger said: One key advantage to starting a well at a sharp incline is the reduction of wellbore build rate from vertical to horizontal during the drilling of very shallow horizontal wells.

Author: GIDEN Ilhami

Page: 35

Derricks

Figure 19: A Slant-Hole Drilling Rig A very futuristic mast was presented in November 2004 by DrillTec. This new structure has a mast which has a height of 22 m in a closed rectangular structure twice supported from the rear. This mast is placed on a substructure, which has a height of three containers. DrillTec promises that this new type of derricks is the ultimate one. They say that it can do anything much faster, very silent, highly automated,...

Figure 20: Futuristic mast design by DrillTec In the next years we will see if the promises become true or if another technique will become the leader derrick in the oil industry.

Author: GIDEN Ilhami

Page: 36

Derricks

References

Erdlmaschinen und Pipelinebau, Institut fr Montanuniversitt Leoben, p.1 ff: Bohrgerste

Frdertechnik

und

Konstruktionslehre,

Drilling and Production Fundamentals, Institut fr Frdertechnik und Konstruktionslehre, Montanuniversitt Leoben, p.7 ff: Derrick Fundamentals of Drilling Technology and Economics, John L. Kennedy; PennWell Publishing Company Tulsa, Oklahoma, USA; p.29 ff: Types of Rigs A PRIMER OF OILWELL DRILLING (Fifth edition) by Ron Baker, published by PETROLEUM EXTENSION SERVICE; The University of Texas at Austin, Texas, USA; 1996: p. 1 ff: 1 Introduction: Drakes Well and Spindletop; p. 5 ff: 2 Cable-Tool Versus Rotary Drilling; p.29 ff:7 The Drill Site; p.37 ff: 8 Moving Equipment to the Site; p. 47 ff: 9 Rigging Up Oil & Gas Journal, week of Jan. 7, 2002, p.78 f: Challenging wells require greater rig capabilities, enabling technologies Oil & Gas Journal, week of June 17, 2002, p.41 ff: Extreme conditions, extended-reach wells govern land-rig design for Sakhalin Oil & Gas Journal, week of Feb. 26, 2001, p.86 ff: PLCs, hydraulics improve slant rig shallowdrilling operations Erdl Erdgas Kohle, Nov. 2004, p.408 f: Das etwas andere Tiefbohrgert: DrillTec prsentiert neues Bohranlagenkonzept Parker Drilling Co. http://www.pnig.jaslo.pl/pl_07rig.html http://www.c-pic.org/collections.htm http://servisni.mnd.cz/en/milestones.html http://www.pe.tu-clausthal.de/AGBalck/vorlesung/server/energ2001/ http://www.texacohistory.com/Photos/Spindletop.JPG http://www.drilshop.com/hallfame/wellsite.html

Author: GIDEN Ilhami

Page: 37