Engineering Practice with Oilfield and Drilling Applications

Although specific requirements and considerations must be incorporated into an engineering design for petroleum drilling and production, the approach for developing a successful solution is the same across many engineering disciplines. Engineering Practice with Oilfield and Drilling Applications helps readers understand the engineering design process while demonstrating how basic engineering tools can be applied to meet the needs of the oil and petroleum industry.

Divided into three parts, the book opens with an overview of best practices for engineering design and problem solving, followed by a summary of specific mechanical design requirements for different modes of power generation, transmission, and consumption. The book concludes with explanations of various analytical tools of design and their application in vibration analysis, fluid mechanics, and drilling systems. Throughout the book, clearly written chapters present traditional tools of engineering mechanics, various mathematical models and methods of solution, key references and background information, and more. Featuring hundreds of figures and a wealth of real-word examples from the petroleum industry, this practical reference:

• Presents a systematic process for developing an engineering design
• Illustrates the application of engineering tools during all stages of design
• Discusses key specifications and considerations for pressure vessels and drilling rigs
• Explains concept evaluation, visualization of a system and its subsystems, implementing feedback from test results, finalizing a design, and presenting manufacturing drawings

Drawn from the author's decades of academic and industrial experience, Engineering Practice with Oilfield and Drilling Applications is the perfect textbook for undergraduate and graduate students in Engineering programs, as well as a highly useful reference for mechanical engineers new to the petroleum industry.

Preface xxi

Nomenclature xxiii

Part I Engineering Design and Problem Solving 1

1 Design and Problem Solving Guidelines 3

Design Methodology 3

Market Analysis 5

Operational Requirements 5

Product Development 6

Government Procurement Procedure 6

Petroleum Industry Procedure 6

Design Specifications 7

Specification Topics 7

Performance Requirements 7

Sustainability 7

Codes and Standards 8

Environmental 8

Social Considerations 9

Reliability 9

Cost Considerations 10

Aesthetics 10

Product Life Cycle 10

Product Safety and Liability 11

Engineering Ethics 11

Creating Design Alternatives 12

Tools of Innovation 12

Patents 13

Reference Books and Trade Journals 13

Experts in a Related Field 13

Brainstorming 13

Existing Products and Concepts 13

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Concurrent Engineering 14

Feasibility of Concept 14

Evaluating Design Alternatives 14

Evaluation Metrics 15

Scoring Alternative Concepts 15

Starting the Design 16

Design for Simplicity 16

Identify Subsystems 17

Development of Oil and Gas Reservoirs 17

Design of Offshore Drilling and Production Systems 18

Connection of Subsystems 19

Torsion Loading on Multibolt Patterns 19

Make-Up Force on Bolts 21

Preload in Drill Pipe Tool Joints 24

Shoulder Separation 26

Possible Yielding in the Pin 26

Make-Up Torque 28

Bolted Brackets 29

Welded Connections 30

Torsion Loading in Welded Connections 30

Attachments of Offshore Cranes 32

Quality Assurance 33

Engineering Education 34

Mission Statement 34

Academic Design Specifications 34

Design of the Academic Program 35

Outcomes Assessment 35

Saturn – Apollo Project 35

Notes 36

References 36

2 Configuring the Design 37

Force and Stress Analysis 37

Beam Analysis 39

Shear and Bending Moment Diagrams 40

Bending Stresses 45

Beam Deflection and Boundary Conditions 47

Shear Stress in Beams 48

Midpoint 50

Composite Cross Sections 52

Material Selection 54

Mechanical Properties of Steel 54

Use of Stress–Strain Relationship in a Simple Truss 57

Statically Indeterminate Member 59

Modes of Failure 62

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Material Yielding 62

Stress Concentration 62

Wear 63

Fatigue 63

Stress Corrosion Cracking 69

Brittle Fracture 69

Fluid Flow Through Pipe 70

Continuity of Fluid Flow 70

Bernoulli’s Energy Equation (First Law) 71

Reynolds Number 71

Friction Head for Laminar Flow 72

Turbulent Flow Through Pipe 72

Senior Capstone Design Project 74

Pump Selection 74

Required Nozzle Velocity 74

Nozzle Pressure 74

Pump Flow Rate Requirement 75

Vibration Considerations 77

Natural Frequency of SDOF Systems 80

Location of Center of Gravity 84

Moment of Inertia with Respect to Point 0 84

Springs in Series, Parallel 84

Deflection of Coiled Springs 85

Free Vibration with Damping 86

Quantifying Damping 86

Critical Damping in Vibrating Bar System 88

Forced Vibration of SDOF Systems with Damping 89

Nonlinear Damping 93

Vibration Control 93

Other Vibration Considerations 94

Transmissibility 94

Vibration Isolation 95

Commonality of Responses 96

Application of Vibration Absorbers in Drill Collars 96

Natural Frequencies with Vibration Absorbers 97

Responses to Nonperiodic Forces 100

Dynamic Load Factor 102

Packaging 103

Vibrations Caused by Rotor Imbalance 105

Response to an Imbalanced Rotating Mass 105

Synchronous Whirl of an Imbalanced Rotating Disk 106

Balancing a Single Disk 109

Synchronous Whirl of Rotating Pipe 109

Stability of Rotating Pipe under Axial Load 110

Balancing Rotating Masses in Two Planes 112

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Refining the Design 113

Manufacturing 113

Manufacturing Drawings 114

Dimensioning 114

Tolerances 115

Three Types of Fits 116

Surface Finishes 117

Nanosurface Undulations 118

Machining Tools 119

Lathes 119

Drill Press 119

Milling Machines 120

Machining Centers 120

Turning Centers 120

References 121

Part II Power Generation, Transmission, Consumption 123

3 Power Generation 125

Water Wheels 125

Fluid Mechanics of Water Wheels 125

Steam Engines 127

Steam Locomotives 128

Power Units in Isolated Locations 130

Regional Power Stations 131

Physical Properties of Steam 131

Energy Extraction from Steam 132

First Law of Thermodynamics – Enthalpy 132

Entropy – Second Law 132

Thermodynamics of Heat Engines 133

Steam Turbines 135

Electric Motors 136

Internal Combustion Engines 137

Four Stroke Engine 137

Two Stroke Engines 138

Diesel Engines 139

Gas Turbine Engines 139

Impulse/Momentum 141

Energy Considerations 142

Engine Configurations 142

Rocket Engines 144

Rocketdyne F-1 Engine 144

Atlas Booster Engine 144

Gas Dynamics Within Rocket Engines 145

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Rocket Dynamics 146

Energy Consumption in US 147

Solar Energy 148

Hydrogen as a Fuel 149

Hydroelectric Power 149

Wind Turbines 149

Geothermal Energy 149

Atomic Energy 150

Biofuels 150

References 150

4 Power Transmission 151

Gear Train Transmission 154

Water Wheel Transmission 154

Fundamental Gear Tooth Law 154

Involute Gear Features 154

Gear Tooth Size – Spur Gears 156

Simple Gear Train 158

Kinematics 158

Worm Gear Train 159

Planetary Gear Trains 160

Compound Gear Trains 161

Pulley Drives 162

Rope and Friction Pulleys 162

Belted Connections Between Pulley Drives 164

Fundamentals of Shaft Design 166

Shear Stress 167

Stress Analysis of Shafts 170

Twisting in Shafts Having Multiple Gears 171

Keyway Design 172

Mechanical Linkages 173

Relative Motion Between Two Points 173

Absolute Motion Within a Rotating Reference Frame 175

Scotch Yoke 177

Slider Crank Mechanism 178

Velocity Analysis 179

Acceleration Analysis 180

Four-Bar Linkage 181

Velocity Analysis 183

Acceleration Analysis 183

Three-Bar Linkage 184

Velocity Analysis 185

Acceleration Analysis 185

Velocity Analysis 186

Acceleration Analysis 187

Contents xi

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Geneva Mechanism 187

Flat Gear Tooth and Mating Profile 189

Cam Drives 191

Cam Drives – Linear Follower 191

Velocity Analysis 191

Acceleration Polygon 193

Cam with Linear Follower, Roller Contact 194

Velocity Analysis – Rotating Reference Frame 195

Acceleration Analysis – Rotating Reference Frame 195

Velocity Analysis – Ritterhaus Model 196

Acceleration Analysis – Ritterhaus Model 197

Cam with Pivoted Follower 197

Velocity Analysis 197

Acceleration Analysis 198

Power Screw 198

Hydraulic Transmission of Power 199

Kinematics of the Moineau Pump/Motor 202

Mechanics of Positive Displacement Motors 203

References 208

5 Friction, Bearings, and Lubrication 209

Rolling Contact Bearings 209

Rated Load of Rolling Contact Bearings 210

Effect of Vibrations on the Life of Rolling Contact Bearings 213

Effect of Environment on Rolling Contact Bearing Life 216

Effect of Vibration and Environment on Bearing Life 217

Hydrostatic Thrust Bearings 220

Flow Between Parallel Plates 220

Fluid Mechanics of Hydrostatic Bearings 222

Optimizing Hydrostatic Thrust Bearings 224

Pumping Requirements 224

Friction Losses Due to Rotation 225

Total Energy Consumed 226

Coefficient of Friction 227

Squeeze Film Bearings 228

Pressure Distribution Under a Flat Disc 228

Comparison of Pressure Profiles 230

Spring Constant of Hydrostatic Films 231

Damping Coefficient of Squeeze Films 231

Other Shapes of Squeeze Films 232

Squeeze Film with Recess 232

Squeeze Film Under a Washer 234

Spherical Squeeze Film 235

Nonsymmetrical Boundaries 236

Application to Wrist Pins 237

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Thick Film Slider Bearings 240

Slider Bearings with Fixed Shoe 240

Load-Carrying Capacity 243

Friction in Slider Bearings 243

Coefficient of Friction 244

Center of Pressure 244

Slider Bearing with Pivoted Shoe 245

Frictional Resistance 246

Coefficient of Friction 246

Exponential Slider-Bearing Profiles 247

Pressure Distribution for Exponential Profile 247

Pressure Comparison with Straight Taper Profile 248

Load-Carrying Capacity 249

Pressure Distribution for Open Entry 249

Exponential Slider Bearing with Side Leakage 250

Hydrodynamic Lubricated Journal Bearings 253

Pressure Distribution Around an Idealized Journal Bearing 254

Load-Carrying Capacity 257

Minimum Film Thickness in Journal Bearings 258

Friction in an Idealized Journal Bearing 259

Petroff’s Law 259

Sommerfeld’s Solution 260

Stribeck Diagram and Boundary Lubrication 261

Regions of Friction 261

Comparison of Journal Bearing Performance with Roller Bearings 263

Journal Bearing 263

Roller Contact Bearing (See Footnote 1) 263

Ball Bearing (See Footnote 1) 264

References 264

6 Energy Consumption 267

Subsystems of Drilling Rigs 267

Draw Works in Drilling Rigs 269

Block and Tackle Hoisting Mechanism 270

Spring Constant of Draw Works Cables 270

Band Brakes Used to Control Rate of Decent 270

Rotary Drive and Drillstring Subsystem 272

Kelly and Rotary Table Drive 272

Friction in Directional Wells 272

Top Drive 273

Drillstring Design and Operation 275

Buoyancy 276

Hook Load 277

Definition of Neutral Point 277

Basic Drillstring: Drill Pipe and Drill Collars 279

Contents xiii

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Physical Properties of Drill Pipe 279

Selecting Drill Pipe Size and Grade 281

Select Pipe Grade for a Given Pipe Size 282

Determine Maximum Depth for Given Pipe Size and Grade 283

Roller Cone Rock Bits 283

Polycrystalline Diamond Compact (PDC) Drill Bits 284

Natural Diamond Drill Bits 284

Hydraulics of Rotary Drilling 286

Optimized Hydraulic Horsepower 286

Field Application 288

Controlling Formation Fluids 290

Hydrostatic Drilling Mud Pressure 290

Annular Blowout Preventer 290

Hydraulic Rams 292

Casing Design 293

Collapse Pressure Loading (Production Casing) 295

Burst Pressure Loading (Production Casing) 295

API Collapse Pressure Guidelines 297

Plastic Yielding and Collapse with Tension 297

Summary of Pressure Loading (Production Casing) 298

Effect of Tension on Casing Collapse 298

Tension Forces in Casing 300

Design of 95=8 in. Production Casing 302

Design Without Factors of Safety 302

Directional Drilling 306

Downhole Drilling Motors 306

Rotary Steerable Tools 307

Stabilized Bottom-Hole Assemblies 308

Power Units at the Rig Site 310

References 310

Part III Analytical Tools of Design 313

7 Dynamics of Particles and Rigid Bodies 315

Statics – Bodies in Equilibrium 315

Force Systems 315

Freebody Diagrams 318

Force Analysis of Trusses 318

Method of Joints 319

Method of Sections 319

Kinematics of Particles 320

Linear Motion 320

Rectangular Coordinates 321

Polar Coordinates 322

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Velocity Vector 325

Acceleration Vector 325

Curvilinear Coordinates 325

Navigating in Geospace 328

Tracking Progress Along a Well Path 328

Minimum Curvature Method 329

Dogleg Severity 331

Projecting Ahead 332

Kinematics of Rigid Bodies 333

Rigid Body Translation and Rotation 333

General Plane Motion 334

Dynamics of Particles 335

Units of Measure 335

Application of the Second Law 336

Static Analysis 336

Dynamic Analysis 337

Work and Kinetic Energy 337

Potential Energy 339

Drill Bit Nozzle Selection 341

Impulse–Momentum 342

Impulse–Momentum Applied to a System of Particles 343

Mechanics of Hydraulic Turbines 345

Performance Relationships 349

Maximum Output of Drilling Turbines 350

Dynamics of Rigid Bodies 351

Rigid Bodies in Plane Motion 352

Translation of Rigid Bodies 354

Rotation About a Fixed Point 354

Center of Gravity of Connecting Rod 355

Mass Moment of Inertia of Connecting Rod 356

General Motion of Rigid Bodies 356

Dynamic Forces Between Rotor and Stator 359

Interconnecting Bodies 361

Gear Train Start-Up Torque 361

Kinetic Energy of Rigid Bodies 363

The Catapult 364

Impulse–Momentum of Rigid Bodies 364

Linear Impulse and Momentum 365

Angular Impulse and Momentum 365

Angular Impulse Caused by Stabilizers and PDC Drill Bits 368

Accounting for Torsional Flexibility in Drill Collars 369

Interconnecting Bodies 370

Conservation of Angular Momentum 371

References 374

Contents xv

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8 Mechanics of Materials 375

Stress Transformation 376

Theory of Stress 377

Normal and Shear Stress Transformations 377

Maximum Normal and Maximum Shear Stresses 378

Mohr’s Stress Circle 381

Theory of Strain 383

Strain Transformation 384

Mohr’s Strain Circle 386

Principal Axes of Stress and Strain 386

Generalized Hooke’s Law 388

Theory of Plain Stress 388

Orientation of Principal Stress and Strain 389

Theory of Plain Strain 391

Pressure Vessel Strain Measurements 391

Analytical Predictions of Stress and Strain 391

Strain in the Spherical Cap 393

Conversion of Strain Measurements to Principal Strains and Stresses 393

Beam Deflections 396

Cantilever Beam with Concentrated Force 397

Cantilevered Beam with Uniform Load 398

Simply Supported Beam with Distributed Load 399

Statically Indeterminate Beams 400

Multispanned Beam Columns 402

Large Angle Bending in Terms of Polar Coordinates 402

Bending Stresses in Drill Pipe Between Tool Joints 405

Application to Pipe Bending in Curved Well Bores 408

Multispanned Beam in Terms or Polar Coordinates 410

Pulling Out of the Well Bore 410

Columns and Compression Members 411

Column Buckling Under Uniform Compression 411

Columns of Variable Cross Section 415

Tubular Buckling Due to Internal Pressure 416

Effective Tension in Pipe 417

Buckling of Drill Collars 418

Combined Effects of Axial Force and Internal/External Pressure 420

Buckling of Drill Pipe 420

Bending Equation for Marine Risers 424

Unique Features of the Differential Equation of Bending 424

Effective Tension 426

Buckling of Marine Risers 426

Tapered Flex Joints 429

Equation of Bending 430

Parabolic Approximation to Moment of Inertia 430

Solution to Differential Equation 432

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Example Calculation 433

Application to Marine Risers 435

Torsional Buckling of Long Vertical Pipe 435

Boundary Conditions 436

Both Top and Bottom Ends Pinned 438

Simply Supported at Both Ends with no End Thrust 440

Force Applied to Lower End 441

Effect of Drilling Fluid on Torsional Buckling 442

Lower Boundary Condition Fixed 442

Operational Significance 442

Pressure Vessels 443

Stresses in Thick Wall Cylinders 443

Stresses in Thin-Wall Cylinders 444

Stresses Along a Helical Seam 444

Interference Fit Between Cylinders 445

Thin-Wall Cylinders 445

Thick Wall Cylinder Enclosed by Thin Wall Cylinder 447

Elastic Buckling of Thin Wall Pipe 450

Bresse’s Formulation 450

Application to Long Cylinders 451

Thin Shells of Revolution 452

Curved Beams 455

Location of Neutral Axis 455

Stress Distribution in Cross Section 456

Shear Centers 460

Unsymmetrical Bending 464

Principal Axis of Inertia 464

Neutral Axis of Bending 468

Bending Stresses 470

Beams on Elastic Foundations 471

Formulating the Problem 472

Mathematical Solution 473

Solution to Concentrated Force 474

Radial Deflection of Thin Wall Cylinders Due to Ring Loading 475

Formulation of Spring Constant 476

Equation of Bending for Cylindrical Arc Strip 477

Reach of Bending Moment 480

Bending Stress in Wall of a Multi Banded Cylinder 480

Criteria of Failure 482

Combined Stresses 483

Internal Pressure 483

Applied Torque 483

Bending Moment 483

Failure of Ductile Materials 484

Visualization of Stress at a Point 485

Contents xvii

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Pressure Required to Yield a Cylindrical Vessel 486

Failure of Brittle Materials 487

Mode of Failure in Third Quadrant 489

References 489

9 Modal Analysis of Mechanical Vibrations 491

Complex Variable Approach 491

Complex Transfer Function 493

Interpretation of Experimental Data 493

Natural Frequency 494

Damping Factor 494

Spring Constant 495

Mass 495

Damping Coefficient 495

Two Degrees of Freedom 495

Natural Frequencies and Modes of Vibration 495

SDOF Converted to 2-DOF 497

Single Degree of Freedom 497

Two Degrees of Freedom 498

Other 2-DOF Systems 499

Undamped Forced Vibrations (2 DOF) 500

Undamped Dynamic Vibration Absorber 502

Base and Absorber Pinned Together 503

Multi-DOF Systems – Eigenvalues and Mode Shapes 507

Flexibility Matrix – Stiffness Matrix 508

Direct Determination of the Stiffness Matrix 511

Direct Determination of the Mass Matrix 512

Amplitude and Characteristic Equations 512

Parameters Not Chosen at Discrete Masses 514

Lateral Stiffness of a Vertical Cable 515

Building the Damping Matrix 516

Modal Analysis of Discrete Systems 516

Orthogonal Properties of Natural Modes 517

Proportional Damping 518

Transforming Modal Solution to Local Coordinates 519

Free Vibration of Multiple DOF Systems 520

Free Vibration of 2 DOF Systems 521

Suddenly Stopping Drill Pipe with the Slips 522

Critical Damping of Vibration Modes 524

Forced Vibration by Harmonic Excitation 526

Complex Variable Approach 526

Harmonic Excitation of 3 DOF Systems 527

Modal Solution of a Damped 2-DOF System 529

General Complex Variable Solution 530

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Experimental Modal Analysis 532

Modal Response to Nonperiodic Forces 535

Natural Frequencies of Drill Strings 536

References 538

10 Fluid Mechanics 541

Laminar Flow 541

Viscous Pumps 541

Force to Move Runner 543

Capillary Tubes 544

Flow Through Noncircular Conduits 545

Unsteady Flow Through Pipe 547

Hydraulics of Non-Newtonian Fluids 551

Hydraulics of Drilling Fluids 551

Pressure Loss Inside Drill Pipe 551

Pressure Loss in Annulus 552

Oil Well Drilling Pumps 552

Example of Drilling Hydraulics 554

Power Demands of Downhole Motors 557

Performance of Positive Displacement Motors (PDM) 557

Application of Drilling Turbines 560

Hydraulic Demands of Drilling Motors – Turbines 561

Fluid Flow Around Vibrating Micro Cantilevers 562

Mathematical Model 563

Fluid Pressure Formulation 564

Fluid Velocity Formulation 565

References 566

11 Energy Methods 569

Principle of Minimum Potential Energy 569

Stable and Unstable Equilibrium 569

Stability of Floating Objects 570

Stability of a Vertical Rod 572

Rayleigh’s Method 573

Multiple Degrees of Freedom 574

Structure Having Two Degrees of Freedom 574

Analysis of Beam Deflection by Fourier Series 576

Concentrated Load 577

Distributed Load 577

Axially Loaded Beam (Column) 578

Principle of Complementary Energy 579

Engineering Application 580

Castigliano’s Theorem 582

Chemically Induced Deflections 588

Contents xix

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Microcantilever Sensors 588

Simulation Model 588

Molecular and Elastic Potential Energies 591

References 592

Index 000

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