Engineering Practice with Oilfield and Drilling Applications

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 vii 0005157525.3D 7 21/7/2021 12:18:06 PM 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 viii Contents 0005157525.3D 8 21/7/2021 12:18:06 PM 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 Contents ix 0005157525.3D 9 21/7/2021 12:18:06 PM 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 x Contents 0005157525.3D 10 21/7/2021 12:18:06 PM 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 0005157525.3D 11 21/7/2021 12:18:06 PM 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 xii Contents 0005157525.3D 12 21/7/2021 12:18:06 PM 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 0005157525.3D 13 21/7/2021 12:18:06 PM 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 xiv Contents 0005157525.3D 14 21/7/2021 12:18:06 PM 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 0005157525.3D 15 21/7/2021 12:18:07 PM 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 xvi Contents 0005157525.3D 16 21/7/2021 12:18:07 PM 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 0005157525.3D 17 21/7/2021 12:18:07 PM 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 xviii Contents 0005157525.3D 18 21/7/2021 12:18:07 PM 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 0005157525.3D 19 21/7/2021 12:18:07 PM Microcantilever Sensors 588 Simulation Model 588 Molecular and Elastic Potential Energies 591 References 592 Index 000