I had the opportunity to visit an onshore drilling rig of ONGC and had done a project on "Mud Circulation System and Mud handling Equipments in a drilling Rig". I got introduced to various drilling activities, mud tanks, mud handling equipments, mud pumps, solid removal system and other control equipments. I learnt and saw how oil and gas is extracted from the earth crust at 3km depth.

1. PROJECT REPORT
ON
VOCATIONAL WINTER TRAINING
WITH
M/S OIL AND NATURAL GAS CORPORATION LTD.
MBA BASIN, KOLKATA
BY
RAHUL ROY
STUDENT
DEPT. OF MECHANICAL ENGINEERING
JADAVPUR UNIVERSITY, KOLKATA

2. ONSHORE OIL RIG

3. A REPORT ON
PROJECT
“MUD CIRCULATION SYSTEM
&
MUD HANDLING EQUIPMENTS
IN A DRILLING RIG”
TRAINNING WITH: M/S ONGC LTD., MBA BASIN, KOLKATA
TRAINNING VENUE : ONGC Office, 3Rd Floor, Technopolis Building,
Block-BP4,Sector-V, Salt Lake, Kolkata-91
INSTALLATION VISITED:DRILLING RIG-BI2000-1
TRAINNING PERIOD :4th January 2016 to 3rd February 2016
Submitted to
Mentor
Shri. CHAMPAK MITRA
DGM (Mech) , Section : TA & EA
ONGC, MBA Basin-Kolkata
By
RAHUL ROY
Student
Dept. of Mechanical Engineering,
Jadavpur University, Kolkata

4. ACKNOWLEDGEMENT
The success of any task lies upon the efforts made by a person but it cannot be
achieved without co-operation of others. I would like to thankmy mentor and guide Shri
Champak Mitra, DGM(M) (Section TA & EA) for giving me the opportunity of doing General
Training and Project work as a special subject and this provided me such a wonderful
platform to represent myself as a mechanical engineering student.
I express my gratitude to Champak Sir for his guidance. It is due to his
encouragement, valuable guidance and direction for this project work, which would not be
finished without his help.
I convey my gratitude to Dr. Anupam Kumar, GM(C)-HES for his guidance and
arrangement for such an important and fabulous rig visit. I am indebted to
ShriDiptenduMaitra Sir, DGM(M)-HSE for sharing his knowledge and guiding us to fulfill
our training.
I am really thankful to ShriShyamalDe,CE(D)-DIC and his crew employees of rig
BI2000-1 who have guided me in this path step by step during my rig visit and have made
my path really simple to get through.
I am thankful to M/S ONGC and our project in-charge who give us opportunity to do
this work.
Rahul Roy,
Student, Dept.of Mechanical Engg.
Jadavpur University, Kolkata
Date: / / 2016

5. PREFACE
INTRODUCTION OF ONGC
Oil and Natural Gas Corporation Limited (ONGC) is an Indian multinational oil and
gas company headquartered in Dehradun, Uttarakhand, India. It is a Public Sector
Undertaking (PSU) of the Government of India, under the administrative control of the
Ministry of Petroleum and Natural Gas. It is India's largest oil and gas exploration and
production company. It produces around 69% of India's crude oil (equivalent to around
30% of the country's total demand) and around 62% of its natural gas.
On 31 March 2013, its market capitalization was INR 2.6 trillion (US$48.98 billion),
making it India's second largest publicly traded company. In a government survey for FY
2011-12, it was ranked as the largest profit making PSU in India.[5] ONGC has been ranked
357th in the Fortune Global 500 list of the world's biggest corporations for the year 2012.
It is ranked 22nd among the Top 250 Global Energy Companies by Platts.
ONGC was founded on 14 August 1956 by Government of India, which currently
holds a 68.94% equity stake. It is involved in exploring for and exploiting hydrocarbons in
26 sedimentary basins of India, and owns and operates over 11,000 kilometers of pipelines
in the country. Its international subsidiary ONGC Videsh currently has projects in 17
countries. ONGC has discovered 6 of the 7 commercially producing Indian Basins, in the
last 50 years, adding over 7.1 billion tonnes of In-place Oil & Gas volume of hydrocarbons
in Indian basins. Against a global decline of production from matured fields, ONGC has
maintained production from its brownfields like Mumbai High, with the help of aggressive
investments in various IOR (Improved Oil Recovery) and EOR (Enhanced Oil Recovery)
schemes. ONGC has many matured fields with a current recovery factor of 25-33%. Its
Reserve Replacement Ratio for between 2005 and 2013, has been more than one. During
FY 2012-13, ONGC had to share the highest ever under-recovery of INR 494.2 million (an
increase of INR 49.6 million over the previous financial year) towards the under-
recoveries of Oil Marketing Companies (IOC, BPCL and HPCL).
HISTORY
During pre-independence, the Assam Oil Company in the North-Eastern and Attock
Oil company in North-Western part of undivided India were the only oil companies
producing oil in the country. The major part of Indian sedimentary basins was deemed to
be unfit for development of oil and gas resources.
After independence, the Government realized the importance of oil and gas for rapid
industrial development and its strategic role in defense. Consequently, while framing the
Industrial Policy Statement of 1948, the development of the hydrocarbon industry in the
country was considered to be of utmost necessity.

6. Until 1955, private oil companies mainly carried out exploration of hydrocarbon
resources of India. Assam Oil Company was producing oil at Digboi, Assam (discovered in
1889) and the Oil India Ltd. (a 50% joint venture between Government of India and
Burmah Oil Company) was engaged in developing two fields Naharkatiya and Moran in
Assam.
In 1955, Government of India decided to develop the oil and natural gas resources
in the various regions of the country as part of Public Sector development. With this
objective, an Oil and Natural Gas Directorate was set up in 1955 under the then Ministry of
Natural Resources and Scientific Research. The department was constituted with a nucleus
of geoscientists from the Geological survey of India.
ONGC went offshore in early ’70s and discovered a giant oil field in the form of
Bombay High, now known as Mumbai High.
BROAD FUNCTIONS
Ø It produces 77 percent of India’s domestic petroleum and 81 percent of its natural
gas.
Ø Stacking of released locations and handling over a drilling rig and oil mining.
Ø Preparation of GTO (Geological Technical Order) and other related technical data.
Ø Planning ,improvising and inventory control of casting, wellheads, floating
equipments, centralizers etc.
Ø Collection of subsurface geological data during drilling.
Ø Monitoring of day-to-day drilling operations for healthy/timely well completion.
PRODUCT DETAILS
ONGC has the following product profile:
1. CRUDE OIL
2. PETROLEUM
3. GAS OIL
4. KERO/JET
5. MS/NAPHTHA
6. PETROCHEMICALS
VISION STATEMENT:To be a world class Oil and Natural Gas Company integrated in energy
business with dominant Indian leadership and Global Presence.

7. ONSHORE OIL RIGS

8. DRILLING RIG
&
DRILLING ACTIVITIES
In ONGC, drilling is done in Onshore and in Offshore in search and extraction of
subsurface oil and natural gas.
I had the opportunity to visit a drilling rig BI2000-1 under MBA Basin, Kolkata,
which is a onshore drilling installation.
A drilling rig is a massive structure combined with high mast and a number of
machines used to extract oil and gas.
TYPES OF DRILLING RIG :
Ø Exploratory drilling – To establish commercially viable oil and gas reserves.
Ø Development drilling- To exploit already proven reserves.
Drillings are done in
Ø On-Shore (on Land by portable drilling rig)
Ø Off-Shore (inside sea) by floating ship and jack up rig
Here, we will discuss about land rig:
A drilling rig is a machine that creates holes in the earth sub-surface. 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 and
are called augers. Drilling rigs can sample sub-surface mineral deposits, test rock, soil and
groundwater physical properties, and also can be used 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' even if they don't
contain a drilling rig). The term "rig" therefore generally refers to the complex of
equipment that is used to penetrate the surface of the Earth's crust.
A location to drill is selected through seismic survey by Geophysical party of ONGC.
Geologist then interprets these data and if probability of hydrocarbon exists the site is
released for drilling.
The Civil Engineering sector prepares the site and makes the infrastructure and
approach road. The drilling rig consisting of mast, structures, machineries, store items etc.
are then transported to the drill site mounted on trailers and trucks. Rig crew(drilling,
Mechanical, Electrical engineers, chemist etc.) reaches the site. In site Rig Building is done
i.e. mast is erected , machineries are installed and other infrastructures are mobilized.

9. ONSHORE RIG:
OFFSHORE RIG:

10. Once ready, the drilling is started. The drill bit attached at the bottom of drill pipe is
rotated and lowered to earth surface. By self-weight it hits the surface and goes on
penetrating. The cuttings are lifted by high viscous circulating fluid (mud), pumped
through the drill pipe and nozzles on rotating drill bit. The mud is prepared by adding
chemicals with water and is recirculated. This mud, once returned to the surface, is passed
through different mud handling equipments that separates even the finest silt particles.
Thereafter, it is further treated to maintain the viscosity and pumped to well. After
1stphase of drilling(26”) the Conductor casing pipe(20”) is lowered. On top, the Well Head
is attached to casing pipe and at the bottom the casing is supported by cement,placed in
annulus (between hole and casing pipe).Likewise subsequent 2nd, 3rd,4th phases of
drilling/casings are done each up to the predetermined depth.Cementation in annulus is
done to prevent leakage of oil/gas from earth surface.All casing pipes are hung from the
wellhead.
During drilling, geologist collects cutting samples from return mud from well and
checks possibility of hydrocarbon. If positive, the depth at which the sample is found is
noted.Once drilling is complete, the well is surveyed by looking for traces of hydrocarbon.
Next 3-1/2” Tubing is lowered inside 5-1/2” casing, hanged from wellhead and
supported at bottom by a packer set in annulus for isolation. On top of wellhead Christmas
Tree is placed which connects tubing and annulus through different valves. Next,
perforation tool is lowered and the tubing and casing pipe both are perforated at the
desired depth. Oil and gas from inside Formation comes out with high pressure. But this
pressure is controlled by high viscous mud column maintained inside tubing and annulus.
Orifices of different sizes are placed inside the Christmas tree and valves are opened in a
controlledmanner to extract Oil and Gas from well.
The flow rate of oil and gas is then observed and measured to find the capacity of
the reservoir. If the reserve is commercially viable the pipeline is made to the
refinery/user for commercial approach. Oil/Gas/wax (surfed from well) is separated in a
station called GGS and unutilied gas is flredup.Part of the gas may be used in gas
engine/turbine to produce power for use by installation. From GGS oil and gas are pumped
to refinery/users through separate pipelines.
DRILLING RIG

11. DRILLING FLUID-MUD SYSTEM
The Drilling Fluid System commonly known as “Mud System” consists of
mud and mud handling equipments.
Drilling fluid is a fluid used to drill bore holes into the earth. Often used
while drilling Oil and Natural Gas wells in site for exploration and exploitation of
oil/gas wells. Drilling fluid is known as mud. It is to be circulated in the well at
required parameters to maintain healthy well. It is very essential to maintain
effective and optimum parameters of mud for successful drilling and completion
of well. Drilling fluid is a mixture of clays and chemicals and water, pumped down
the drill pipe to lubricate and cool the drilling bit and to flush out the drilled
cuttings from wellbore.
Mud is prepared by adding chemical powder like Barite/Bentoniteetc.with
water. Mud helps lift cuttings that are crushed by the drill bit and carry out of
well to the surface. If cuttings are not lifted properly the drill bit/pipe may get
stuck. This mud is recirculated after removal of cuttings and chemical treatment.
SOLID CONTROL IN MUD
Failure of the mud to meet its design functions can prove extremely costly
in terms of materials and time, and can also jeopardise the successful completion
of the well and may even result in major problems such as stuck pipe, kicks or
blowouts.Effective solid control ie. Conditioning of mud is done to lower
maintenance cost, avoiding excessive chemical treatment and maintaining mud
systems volume will decrease the chance of equipment failure, unnecessary high
mud costs, hole and drilling problems.

12. DRILLING FLUID FUNCTIONS
The drilling fluidplays several functions in the drilling process. The most
important functions of drilling mud are as follows:
1. To balance and control surface pressure through hydrostatic head.Mud
controls sub-surface pressures by providing hydrostatic pressure greater than
the formation pressure. This property depends on the mud weight which, in turn,
depends on the type of solids added to the fluid making up the mud.
2. To pickup and transport drilled cuttings, unwanted solids and caving to
the surface. Mud removes the drilled cuttings from the hole. The removal of
cuttings depends on the viscous properties called "Yield Point" which influences
the carrying capacity of the flowing mud and "gels" which help to keep the
cuttings in suspension when the mud is static. The flow rate of mud is also critical
in cleaning the hole.
3. To cool, clean and lubricate the drill bit and drillpipe.
4. To support walls of the well bore. Mud prevents the walls of the hole
from caving in ie. collapsing. This function is provided by the formation of a stable
mud cake on the walls of the wellbore, somewhat like plastering the walls of a
room to keep them from flaking.
5. To suspend the cuttings and weighing material when circulation is
stopped (gelation). This property is provided by gels and low shear viscosity
properties.
6. To prevent or minimise damage to the formations penetrated by having
minimum fluid loss into the formation.
7. To assist in the gathering of the maximum information from the
formations being drilled.
8. To suspend the weight of the drill string and casing by buoyancy. Mud
releases the drilled cuttings at the surface.
9. To minimise the swelling stresses caused by the reaction of the mud with
the shale formations. This reaction can cause hole erosion or cavings resulting in
an unstable wellbore. Minimisation of wellbore instability is provided by the
"inhibition" character of the drilling mud.

13. PROPERTIES OF DRILLING FLUIDS
A) DENSITY (SPECIFIC GRAVITY)
Density is defined as weight per unit volume. It is expressed either in ppg
(lbs gallons) or pound per cubic feet (lb/ft3) OR kg/M^3 or gm./cm^3 or
compared to the weight of an equal volume of water as specific gravity. Density is
measured with a mud balance.
B)VISCOSITY
Viscosity is defined as the resistance to flow. Its unit is centipoise.
C)GEL STRENGTHIt is the measure of gelling or thixotropic property of mud under
static conditions is generally reported in pounds per hundred square feet.

14. TYPES OF DRILLING FLUID
Three types of drilling mud are in common use:
Ø Water-based mud
Ø Oil-based mud
Ø Synthetic-based fluids
Ø Gas-based fluids
Water Base Mud
This fluid is the mud in which water is the continuous phase. This is the
most common drilling mud used in oil drilling.The main disadvantage of using
water based mud is that the water in these muds causes instability in shales.
Oil Base Mud
This drilling mud is made up of oil as the continuous phase mainly Diesel
oil. Oil-based muds are used for many reasons, including increased lubricity,
enhanced shale inhibition, and greater cleaning abilities with less viscosity. Oil-
based muds also withstand greater heat without breaking down.
Synthetic based Mud
Synthetic-based fluid is a mud where the base fluid is a synthetic oil. This is
most often used on offshore rigs because it has the properties of an oil-based
mud, but the toxicity of the fluid fumes are much less than an oil-based fluid.
This type of mud is important when men work with the fluid in an enclosed space
such as an offshore drilling rig.
Gas based fluids
There are four main types of gas-based fluids: Air, Mist, Foam, Aerated
Drilling Fluid
The following are the important mud properties, which contributes to the
character of the mud. These properties must be monitored regularly to show
trends, which can be used to ascertain what is happening to the mud whilst
drilling.
Ø Mud weight or mud density.
Ø Funnel Viscosity.
Ø Plastic Viscosity (PV).
Ø Gel Strengths.
Ø Yield Point.
Ø Fluid Loss and Filter Cake.

15. DRILLING FLUID CIRCULATION
The principle components of the mud circulation system are:
Ø Mud Handling Equipments
o Mud pumps
o Super ChargerPumps
Ø Contaminant/Solid removal equipments(Solid Control)
o Shale Shaker,
o Degasser
o Centrifugal Pumps
o Hydroclones
o Desander& Desilter
o Mud Cleaner
Ø Mud Treatment or Mixing equipments
o Mud Mixing Pumps
o Mud Mixing Hopper
o Mud Agitators
o Mud Guns
Ø Mud pits and tanks
o Settling tanks
o Mixing tanks or Suction tanks)
Ø Mud Swivel
Ø Flow Lines
Ø Drill pipe/Drill String
Ø Casing
Ø Drill Bit-Types
Ø Blow Out Preventor (BOP)

16. Mud circulation system can be summarized in the following steps:
• Drilling fluid/mud is forced to circulate in the hole at various pressures
and flow rates depending on hole size/depth/well condition.
• Mud is prepared in mud mixing hopper, where various additives and
weighing materials are mixed with water. Mud is stored in steel tanks(mud
pits).
• The mud pumps suck the mud from the mud pits. The mud is pressured up
to the required mud pressure value. From the mud pumps the mud is
pushed through the stand pipe (a pipe mounted at the derrick), the rotary
hose (flexible connection that allows the fed of the mud into the vertically
moving drill string), via the swivel into the drill string
• Inside the drill string, (Kelly, drill pipe, drill collar) the mudflows down to
the bit where it is forced through the nozzles to act against the bottom of
the hole.
• From the bottom of the well the mud rises up the annuli (drill collar, drill
pipe) and the mud line (mud return line), which is located above the BOP.
• From the mud line the mud is fed to the mud cleaning system consisting of
shale shakers, settlement tank, de-sander and mud cleaner/ de-silter. After
cleaning the mud, the circulation circle is closed when the mud returns to
the mud pit.
MUD CIRCULATING SYSTEM

17. MUD HANDLING EQUIPMENTS
Rig sizing must incorporate mud-handlingequipments as theseequipments
determine the speed of drilling and the quality of hole drilled.
The equipments includeare :Mud Pumps, Super Charger and Mud Mixing
Pumps,Mud Agitators, Mud Guns, Shale Shakers, Degasser,Centrifuges,
Desander,Mud Cleaner or Desilters, Mud Tanks(Mud Pits) etc.
MUD HANDLING EQUIPMENTS

18. MUD PUMPS
The heart of the circulating system is the mud pump. A mud pump is a
reciprocating piston/plunger device designed to circulate drilling fluid under
high pressure (up to 7,500 psi (52,000 kPa) ) down the drill string and back up
the annulus depending upon the hole depth and condition.
Function :
• To circulate drilling fluid through well.
• Displacement of cement.
• Pressure Testing of casing.
Classification :
• Single acting pump.
• Double acting pump.
It is mainly called reciprocating positive displacement pumps (PDP).
Advantages of the reciprocating PDP when compared to centrifugal pumps are:
Ø ability to pump fluids with high abrasive solids contents and with large
solid particles,
Ø easy to operate and maintain,
Ø sturdy and reliable,
Ø ability to operate in a wide range of pressure and flow rate.
PDP are composed of two major parts, namely:
Power end:It converts rotation of drive shaft to reciprocating motion of the
pistons. It receives power from motor or engines and transforms the rotating
movement into reciprocating movement using a crosshead crank gear
mechanism. The efficiency (Em) of the power end, that is the efficiency with
which rotating mechanical power is transformed in reciprocating mechanical
power is of the order of 90%.
Fluid end:Itconverts the reciprocating power into pressure and flow rate. It
consists of valves, pistons and liners. These are high wear items and can be
replaced quickly. The efficiency (Ev) of the fluid end (also called volumetric
efficiency), that is, the efficiency that the reciprocating mechanical power is
transformed into hydraulic power, can be as high as 100%.
Rigs normally have two or three PDPs.
During drilling of shallow portions of the hole, when the diameter is
large,the two PDPs are connected in parallel to provide the highest flow rate

19. necessary to clean the borehole. Large piston of diameter of about 7” is required
for drilling.
As the borehole deepens, less flow rate and higher pressure is required.
Hence, a smaller diameter piston of 5” is used.
The great flexibility in the pressure and flow rate is obtained with the
possibility of changing the diameters of the pair piston–liner. Normally only one
PDP is used while the other is in standby or in preventive maintenance.
To reduce severe vibration caused by the pumping process, these pumps
incorporate both a suction and discharge pulsation dampner. These are
connected to the inlet and outlet of the fluid end.
The flow rate depends on the following parameters:
• Stroke length, liner diameter, rod diameter,pump speed N (normally given
in strokes/minute), volumetric efficiency (Ev) of the pump.
• The pump factor (Fp) is defined as the total volume displaced by the pump
in one stroke.
The pump used by ONGC at the drill site is single-action triplex pump.
Triplex PDPs, due to several advantages, (less bulky, less pressure fluctuation,
cheaper to buy and to maintain, etc.,) has taking place of the duplex PDPs in both
onshore and offshore rigs.
TRIPLEX PUMPS:
A basic triplex pump consists of three nos. piston liner Assy. mechanism.
Each piston reciprocates inside a cylinder(liner). The pump is single acting as it
pumps fluid on the forward stroke.
Pump liners fit inside the pump cavity and these affect the pressure rating
and flow rate from the pump.
The size of the pump is determined by the length of its stroke and the size
of the liner.
Due to the reciprocating action of the PDPs, the output flow rate of the
pump presents a “pulsation”.These pulsations are detrimental to the surface and
down hole equipment .To decrease the pulsation, surge dampeners are used at
the output of each pump.

20. TRIPLEX MUD PUMP
MUD PUMP SPECIFICATIONS:
Ø VOLUMETRIC EFFICIENCY:Drilling mud contains little air and is slightly
compressible. Hence the piston moves through a shorter stroke than
possible before reaching discharge pressure. As a result the volumetric
efficiency is 95% for triplex pumps.
Ø PUMP FACTOR: As the triplex mud pump consists of three single–action
piston cylinders, drilling mud is pumped through the forward movement of
the piston in cylinder. For a triplex pump the pump factor(Fp) is:
Here, dLis diameter of piston cylinder
LS is length of piston cylinder
EV is volumetric efficiency
Ø PUMP FLOW RATE: The flow rate is given as
where N is the pump speed given is strokes/min.
Ø PUMP POWER: The pumps convert mechanical power into hydraulic
power.The pressure differential in the piston Δp times the area A of the
piston gives the force by which the piston moves. The velocity v of the fluid
is equal to the flow rate q divided by the area A.
Hence, flow rate q= A.v and PH = (Δp.A).v

21. SUPER CHARGER PUMP
Centrifugal pumps are used to supercharge mud pumps and providing fluid
under pressure to solids control equipment and mud mixing equipment.
This type of pump uses an impeller for the movement of fluid rather than a
piston reciprocating inside a cylinder.
Centrifugal pumps are used to transport fluids by the conversion of
rotational kinetic energy to the hydrodynamic energy of the fluid flow. The
rotational energy typically comes from an engine or electric motor. The fluid
enters the pump impeller along or near to the rotating axis and is accelerated by
the impeller, flowing radically outward into a diffuser or volute chamber (casing),
from where it exits.
Common uses include pumping air, water, mud, chemical, sewage,
petroleum and petrochemical pumping. The reverse function of the centrifugal
pump is a water turbine converting potential energy of water pressure into
mechanical rotational energy.
Image of Centrifugal Pump

22. SOLIDS REMOVAL SYSTEM
Fine particles of inactive solids are continuously added to mud during
drilling.
• These solids increase the density of the fluid and
• Also due to its friction pressure drop, but
• do not contribute to the carrying capacity of the fluid.
• The amount of inert solids must be kept as low as possible.
Mud is made up of fluid (water, oil or gas) and solids (bentonite, barite).
The aim of any efficient solids removal system is
• to retain the desirable components of the mud system
• by separating out and discharging the unwanted drilled solids and
contaminants.
Solids in drilling, classified by specific gravity, is divided into two groups:
• High Gravity Solids (H.G.S.) sg = 4.2
• Low Gravity Solids (L.G.S.) sg = 1.6 to 2.9
The solids content of a drilling fluid will be made up of a mixture of high
and low gravity solids.
High gravity solids (H.G.S) are added to fluids to increase the density, e.g.
barites, and low gravity solids (L.G.S) enter the mud through drilled cuttings
and should be removed by the solids control equipment.
Mud solids are also classified according to their size in units called microns
(μ).
Particle size is important in drilling muds for the following reasons:
• The smaller the particle size, the more pronounced the affect on fluid
properties.
• The smaller the particle size, the more difficult it is to remove it or control
its effects on the fluid.

23. SOLIDS CONTROL EQUIPMENT
Solids contaminants and gas entrapped in mud can be removed from mud
in four stages:
Ø Screen separation: Scalper screens, Shale shakers and mud cleaner screens.
Ø Settling separation in non-stirred compartments: Sand traps and settling
pits.
Ø Removal of gaseous contaminants: By vacuum degassers or similar
equipment
Ø Forced settling: By the action of centrifugal devices and hydro cyclones
(desanders, desilters and micro-cones) , Mud cleaners and centrifuges.
SCHEMATIC OF SOLID CONTROL SYSTEM

24. SHALE SHAKER
Shale Shakers: The type of mud (i.e. oil-based or water-based) determines
the type of the shaker required and the motion of the shaker. Deep holes require
more than the customary three shakers.
Shale shakers are the primary solids separation tool on a rig. Itcan
effectively remove up to 80% of all solids from a drilling fluid. After returning to
the surface of the well, the used drilling fluid flows directly to the shale shakers
where it begins to be processed.
A Shale shaker consists of a series of trays with sieves or screens that
vibrate to remove cuttings from circulating fluid in rotary drilling operations. The
size of the openings in the sieve is selected to match the size of the solids in the
drilling fluid and the anticipated size of cuttings.
ISOMETRIC VIEW OF SHALE SHAKER
Removal procedure:
• Mud laden with solids passes over the vibrating shaker
• where the liquid part of mud and small solids pass through the shaker
screens and
• drill cuttings collect at the bottom of the shaker to be discharged.

25. MECHANISM:
§ The shale shaker removes
the coarse solids (cuttings)
generated during drilling.
§ It constitutes of one or more
vibrating screens in the range
of 10 to 150 mesh over which
the mud passes before it is
fed to the mud pits.
§ Eccentric heavy cylinders
connected to electric motors
vibrate the screens.
§ The vibration promotes an
efficient separation without
loss of fluid.
STRUCTURE:
Shale shakers consist of the following :
Ø Hopper
Ø Feeder
Ø Screen Basket
Ø Basket Angling Mechanism
Ø Vibrator
Ø Shaker Frame
SHALE SHAKER

26. DEGASSER
A degasser is a device, used in drilling, to remove gasses from drilling fluid,
which could otherwise form bubbles. Presence of gas in mud may cause harm to
human beings and increases risk of fire hazards. Further these gas or air bubbles
burst inside mud pump liner-piston/valve Assy and causes pitting of metal body
parts/wear and leakage.For a small amount of entrained gas in a drilling fluid, the
degasser can play a major role of removing small bubbles that a liquid film has
enveloped and entrapped. In order for it to be released and break out the air and
gas such as methane, H2S and CO2 from the mud to the surface, the drilling fluid
must pass degassing technique.
The degasser removes gas from the gas cut fluid by creating a vacuum in a
vacuum chamber.
Ø The fluid flows down an inclined flat surface as a thin layer.
Ø The vacuum enlarges and coalesce the bubbles.
Ø Degassed fluid is draw from chamber by a fluid jet located at the discharge
line.
PROCEDURE:
Gas entrapped in mud must be removed in order to maintain the mud
weight to a level needed to control down hole formation pressures.
Gas is removed from mud using a vacuum degasser. It is a simple equipment
containing a vacuum pump and a float assembly.
Ø The vacuum pump creates a low internal pressure, which allows gas-cut
mud to be drawn into the degasser vessel, and it then flows in a thin layer
over an internal baffle plate.
Ø The combination of low internal pressure and thin liquid film causes gas
bubbles to expand in size, rise to the surface of the mud inside the vessel
and break from the mud.
Ø As the gas moves toward the top of the degasser it is removed by the
vacuum pump.
Ø The removed gas is routed away from the rig and is then either vented to
atmosphere or flared.

27. DEGASSER SCHEMATIC
CENTRIFUGAL PUMP
Centrifugal pumps uses an impeller, sucks mud from mud tanks and pumps
fluid under pressure to solids control equipments like desander, desilter, mud cleaner,
hydroclone etc.This mud under pressure enters into the cones of the desander/desilter
tangentially and creates vortex motion.Thus heavier cuttings accumulated at the
periphery of the cones discharge through bottom of the cones and purified mud
accumulated centrally comes through top of the cone to mud tanks.

28. HYDROCLONE
Desanders and Desilters are hydro cyclones and work on the principle of
separating solids from a liquid by creating centrifugal forces inside the hydro-
cyclone.A hydrocyclone is a device to classify, separate or sort particles in a liquid
suspension based on the ratio of their centripetal force to fluid resistance. This
ratio is high for dense (where separation by density is required) and coarse
(where separation by size is required) particles, and low for light and fine
particles.
Hydrocyclones are simple devices with no internal moving parts. They are
classified according to the removed particle size as Desanders (cut point in the
40–45μm size range) Desilters (cut point in the 10–20μm size range).
At the cut point of a hydrocyclone 50% of the particles of that size is
discarded.
PROCEDURE:
Mud is injected tangentially
into the hydrocyclone.
Ø The resulting
centrifugal force
drives the solids to
the walls of the
hydrocyclone and
finally discharges
them from the apex
with a small volume of
mud.
Ø The fluid portion of
mud leaves the top of
the hydrocyclone as
an overflow and is
then sent to the active
pit to be pumped
downhole again.

29. DESANDER&DESILTER
Desanders and Desilters are solid control equipment with a set of hydro
cyclones that separate sand and silt from the drilling fluids in drilling rigs.
Desanders are installed on top of the mud tank following the shale shaker and the
degasser, but before the desilter. Desander removes the abrasive solids from the
drilling fluids which cannot be removed by shakers. Normally the solids diameter
for desander to be separated would be 45~74μm, and 15~44μm for desilter.
A centrifugal pump is used to pump the drilling fluids from mud tank into
the set of hydro cyclones.
DESANDERS:
Ø The primary use of desanders is in the top hole sections when drilling with
water based mud to help maintain low mud weights.
Ø Desanders should be used if the sand content of the mud rises above 0.5%
to prevent abrasion of pump liners.
Ø It should never be used with oil based muds, because of its very wet solids
discharge.
DESILTER:
Ø It removes particles that can not be removed by the desander.
Ø Desilters, in conjunction with desanders, should be used to process low
mud weights used to drill top hole sections.
Ø If it is required to raise the mud weight this must be done with the
additions of barites, and not by allowing the build up of low gravity solids.
Ø It should never be used with oil based muds.

30. MUD CLEANER
Ø A mud cleaner is a desilter unit in which the underflow is further processed
by a fine vibrating screen, mounted directly under the cones.
Ø Inert solids in weighted fluid (drilling fluid with weight material like barite,
iron oxide, etc.)cannot be treated with hydro cyclones alone because the
particle sizes of the weighting material are within the operational range of
desanders and desilters.
Ø The mud cleaner separates the low density inert solids (undesirable) from
the high density weighting particles.
MUD CLEANER

31. MUD TREATMENT AND MIXING EQUIPMENT
Drilling fluid is usually a suspension of clay(sodium Bentonite)in water.
Higher density fluids can be obtained by adding finely granulated (fine sand to
silt size) barite. Various chemicals or additives are also used in different
situations. Water base fluids are normally made at the drill site. Hence, mixing
equipments are required for this purpose.
MIXING EQUIPMENTS:
Image of Centrifugal Pump
MUD MIXING PUMP
Centrifugal pump uses an impeller and is used to pump fluid ( mud /water) to
mud mixing equipment ( Mud Hopper) for preparation/treatment of mud.
It is a centrifugal pump used to prepare mud drill water sucked by this
pump is passed through the venture placed below the mud mixing hopper.
Chemicals poured through hopper is sucked in venture.
In other hand,the mud mixing pump act as a supercharge pump and can be
used to pump mud back into the desilt tank. Pumping clean mud back into
the desilt tank also agitates the sludge at the bottom of the tank which makes it
easier to clean out. It helps to control the mud weight and is constantly
recirculated resulting in cleaner drilling fluid.

32. MUD MIXINGHOPPER
Mud hopper:The mixing hopper allows adding powder substances and
additives in the mud system. The hopper is connected to a Venturi pipe.
Mud is circulated by centrifugal pumps and passes in the Venturi at high
speed, sucking the substance into the system.
MUD MIXING HOPPER
Mud mixing hoppers are widely used in HDD(horizontal directional
drilling) and oil gas drilling for bentonite mixing. Mud mixing unit is combination
of drilling mud hopper and centrifugal pumps, its mixing force comes from the
centrifugal pump.
The mud mixing hopper also called a jet mixing hopper, in which materials
are put into the circulating mud system. The mud hopper is powered by a
centrifugal pump that flows the mud at high velocity through a venturi nozzle
(jet) below the conical-shaped hopper. Dry materials are added through the mud
hopper to provide dispersion, rapid hydration and uniform mixing. Liquids are
sometimes fed into the mud by a hose placed in the hopper. The mud mixing unit
can be delivered with an integrated Venturi-type mud mixer to provide fast,
easier and more effective mixing of fluids and powders.

33. MUD AGITATOR
It is used in surface mud systems to agitate & mix suspended solids in mud
to suspend solids and maintain homogeneous mixture throughout the system. A
mechanical agitator is driven by an explosion-proof motor, coupled to a gear
box that drives the impeller shaft. The impellers (turbines) transform mechanical
power into fluid circulation or agitation. The objective is to obtain a uniform
suspension of all solids.
Ø Mud agitator or blender: They are located in the mud tanks to homogenize
the fluid in the tank. Theyhelp to keep the various suspended material
homogeneously distributed in the tank by forcing to radial and whirl
motions of the fluid in the tank.
MUD AGITATOR

34. MUD GUN
They are mounted in gimbals at the side of the tanks, allow aiming a
mud jet to any point in the tank and help to homogenize the properties of
two tanks, and spread liquid additives in a large area of the tank.
Centrifugal pumps power the mud guns.
MUD GUN
MUD PITS &TANKS
A mud tank in a drilling rig,is an open-top container, typically made of steel,
to store drilling fluid. Based on functions, mud tanks include metering tank,
circulating tank, chemical tank, aggravating tank, precipitating tank, storing tank,
etc.
Mud Pit: The number and size of pit is determined by size and depth of hole.
Other factors include: size of rig and space available, especially on offshore
rigs.The size of a mud pit is usually 8-12 ft.wide,20-40 ft.long and6-12 ft.high.
Function of mud tank:
Ø The main function of mud tank is storage, because the worked drilling
fluids must be stored to the next separation or to the next recirculation, or
to be reused.
Ø They contain a safe excess (neither to big nor to small) of the total volume
of the borehole. In the case of loss of circulation, this excess will provide the
well with drilling fluid while the corrective measures are taken.
Ø The tanks will allow enough retaining time so that much of the solids
brought from the hole can be removed from the fluid.
Ø The number of active tanks depends on the hole volume( current depth of
the hole)
(Bypasses allow isolating one or more tanks.)

35. Description of mud tank:
§ The tanks (3 or 4 – settling tank, mixing tank(s), suction tank) are made of
steel sheet. The mud tank top surfaces and the passage are covered with
slipping resistant steel plate and linearity netted steel plate (soak zinc
processed).
§ A tank is sectioned off into compartments. A compartment may include a
settling tank, sometimes called a sand trap, to allow sand and other solids
in the drilling fluid to precipitate before it flows into the next compartment.
Other compartments may have agitators, which are large fan blades stirring
the fluid to prevent its contents from precipitating.
§ Mud handling equipments (scalper, shale shaker, desander, mud cleaner
etc.) are installed on mud tanks. Super charger pumps attached to active
pits feeds mud pump suction. Mud mix pumps attached to mixing tank
sucks mud/water and feeds to hopper and returns back to mixing tank.
MUD SWIVEL
Mud Swivel is attached from Travelling Block accommodates Kelley
(screwed to M/Swivel) at bottom. Mud Swivel is connected with high press Mud
hose to pump in Mud ( from mud pump ) to the well through Kelley –Drill pipe-
Drill bit. Bottom of Mud Swivel rotates with Kelley – Drill pipe.

36. FLOW LINES
Mud from Mud Pits are sucked by supercharger and mud pumps and is
pumped into the well through drill pipes and drill string.Back from well,due to
high pressure of mud, this mud with contaminants/solids rises up through
annulus to the well head and flows,through flow channels to solid control
equipments and tanks( Settling Tanks). From these tanks this purified mud flows
down , through mud pipes,to mud pit tanks. Where it is stored. From here this
mud/water is sucked through mud pipes and pumped to hopper for mud
treatment /mud preparation and returns to mud pit for recirculation to well.
DRILL PIPE/DRILL STRING
Drill pipe, is hollow, thin-walled, steel or aluminium alloy piping that is
used on drilling rigs. It is hollow to allow drilling fluid to be pumped down the
hole through the bit and back up the annulus. It comes in a variety of sizes,
strengths, and wall thicknesses.
FUNCTIONS:
• Rotation of the drill pipe and bit causes the bit to drill through the rock.
• It is used to transmit torque and hydraulic horse power at the bit.
CASING
Casing is a large diameter pipe that is assembled and inserted into a
recently drilled section of a borehole and typically held into place with cement.
PURPOSE OF CASING:
Casing that is cemented in place, aids the drilling process in several ways:
• Prevent contamination of fresh water well zones.
• Prevent unstable upper formations from caving in and sticking the drill
string or forming large caverns.
• Provides a strong upper foundation to use high-density drilling fluid to
continue drilling deeper.
• Isolates different zones, that may have different pressures or fluids - known
as zonal isolation, in the drilled formations from one another.
• Seals off high pressure zones from the surface, avoiding potential for a
blowout
• Prevents fluid loss into or contamination of production zones.

37. • Provides a smooth internal bore for installing production equipment.
Casing design for each size is done by calculating the worst conditions that
may be faced during drilling and production. Mechanical properties of designed
pipes such as collapse resistance, burst pressure, and axial tensile strength must
be sufficient for the worst conditions.
DRILL BIT
Drill bits are cutting tools used to remove material to create holes, almost
always of circular cross-section. Drill bits come in many sizes and shape and can
create different kinds of holes in many different materials. In order to create
holes drill bits are attached to a drill, which powers them to cut through the
workpiece, typically by rotation. The drill will grasp the upper end of a bit called
the shank in the chuck.
Drill bits are used in oil and gas industry to produce wellbores in the earth’s
crust by the rotary drilling method for the discovery and extraction of
hydrocarbons such as crude oil and natural gases. Subsurface formations are
broken apart mechanically by cutting elements of the bit by scraping, grinding or
localized compressive fracturing. The cuttings produced by the bit are most
typically removed from the wellbore and continuously returned to the surface by
the method of direct circulation.
TYPES OF BIT
MILLED TOOTH BIT INSERT BIT PDC BIT
BLOW OUT PREVENTOR (BOP)

38. A blowout preventer (BOP) is a large, specialized valve or similar
mechanical device, used to seal, control and monitor oil and gas wells to prevent
blowout, the uncontrolled release of crude oil and/or natural gas from well. They
are usually installed redundantly in stacks.
The term BOP (pronounced B-O-P, not "bop") is used in oilfield vernacular
to refer to blowout preventers. The abbreviated term preventer, usually prefaced
by a type (e.g. ram preventer), is used to refer to a single blowout preventer unit.
A blowout preventer may also simply be referred to by its type (e.g. ram).
Two categories of blowout preventer are most prevalent: ram and annular.
BOP stacks frequently utilize both types, typically with at least one annular BOP
stacked above several ram BOPs.
Blowout preventers are used on land wells, offshore rigs, and subsea wells.
Land and subsea BOPs are secured to the top of the wellbore, known as the
wellhead.
FUNCTIONS:
The primary functions of a blowout preventer system are to:
• Confine well fluid to the wellbore
• Provide means to add fluid to the wellbore
• Allow controlled volumes of fluid to be withdrawn from the wellbore
• Regulate and monitor wellbore pressure
• Center and hang off the drill string in the wellbore
BLOWOUT PREVENTER
CHEMICAL COMPOSTION OF PETROLEUM

39. Petroleum (L. petroleum, from early 15c. "petroleum, rock oil" (mid-14c. in
Anglo-French), from Medieval Latin petroleum, from Latin: petra: "rock" + oleum:
"oil".[1][2][3]) is a naturally occurring, yellow-to-black liquid found in geological
formations beneath the Earth's surface, which is commonly refined into various
types of fuels.
Petroleum is a mixture of naturally occurring organic compounds within
the earth that contain hydrogen, carbon, and oxygen. It is found beneath the
earth’s surface in geological formations.
FRACTIONAL CATEGORISATION
ADVANTAGES OF ALTERNATE SOURCE OF ENERGY
Ø Limited availability of fossil fuels

40. Ø Hazardous impact of fossil fuels on the environment.
Ø Global warming- Increase of the average temperature of the earth. As the
earth is getting hotter, disasters like hurricanes, draughts and floods are
becoming rampant phenomenon.
Ø There is continuous growth of energy requirement.
Ø More than 25% of the primary energy needs of our country are met
through imports.
Ø Energy security of the country.
CONCLUSION
Henceforth, we can save our non-renewable resources of energy by using
solar energy, wind energy, etc. At a large scale which will also aid in making our
environment pollution free as of result of which our economy will become
competitive in world and we will have the sustainable development of our society
and countr

41. BIBLIOGRAPHY
Books:
Ø Drilling technology in non-technical language
Ø Drilling Engineering
Ø Well completion Design
Websites:
Ø www.google.com
Ø www.scribd.com
Ø www.wikipedia.org
Ø www.slideshare.net
Ø www.learntodrill.com
Ø www.mud-tech.com
Magazines
Ø Drilling Contractor
Ø Drilling Today
Ø GeoDrilling International
Others
Ø ONGC official presentation and word documents
Ø Schlumburger oil field glossary
Ø Information collected from the site visit of ONGC
Submitted By
RAHUL ROY
Student, Dept. of Mechanical Engineering,
Jadavpur University, Kolkata
Date: / / 2016