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.
Table of Contents
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
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
Neutral Axis 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
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 A 84
Springs in Series, Parallel 85
Deflection of Coiled Springs 86
Free Vibration with Damping 86
Quantifying Damping 87
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
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
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
Notes 150
References 150
4 Power Transmission 151
Gear Train Transmission 153
Water Wheel Transmission 153
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 Equation 185
Acceleration Equation 185
Velocity Analysis 186
Acceleration Analysis 187
Geneva Mechanism 188
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 196
Cam with Pivoted Follower 196
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 233
Squeeze Film with Recess 233
Squeeze Film Under a Washer 234
Spherical Squeeze Film 235
Nonsymmetrical Boundaries 236
Application to Wrist Pins 237
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 254
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
Note 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
Physical Properties of Drill Pipe 279
Selecting Drill Pipe Size and Grade 281
Select Pipe Grade for a Given Pipe Size 281
Determine Maximum Depth for Given Pipe Size and Grade 282
Roller Cone Rock Bits 283
Polycrystalline Diamond Compact (PDC) Drill Bits 283
Natural Diamond Drill Bits 284
Hydraulics of Rotary Drilling 285
Optimized Hydraulic Horsepower 285
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 316
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
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 Newton’s 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
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 403
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
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
Surface Deflections of Thick-Wall Cylinders 447
Thick Wall Cylinder Enclosed by Thin Wall Cylinder 448
Thick Wall Cylinder Enclosed by Thick Wall Cylinder 448
Elastic Buckling of Thin Wall Pipe 449
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 482
Internal Pressure 483
Applied Torque 483
Bending Moment 483
Failure of Ductile Materials 484
Visualization of Stress at a Point 485
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
Experimental Modal Analysis 532
Modal Response to Nonperiodic Forces 535
Natural Frequencies of Drillstrings 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
Elliptical Conduit 545
Rectangular Conduit 546
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
Drilling Hydraulics 554
Power Demands of Downhole Motors 556
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
Microcantilever Sensors 588
Simulation Model 588
Molecular and Elastic Potential Energies 591
References 592
Index 593
