Internship Report 2010

Umar Rasheed
Petroleum Engineer

Acknowledgment
I am also extremely thankful to Mr. Zahid Abbas (F.M Fimkassar Oil Field), Mr. Munir Awan (Reliever to F.M), Mr. Muhammad Arif (I/C Production) & Mr. Muhammad Ashfaq, who are constant source of inspiration for me. I am grateful to OGDCL and UET Lahore for providing me opportunity to learn the practical aspects of Oil & Gas industry. I take this opportunity to acknowledge with gratitude, all the team members of FIMKASSAR OIL FIELD, OGDCL specially Mr. Zahid Abbas , Mr. Munir Awan , Mr. Muhammad Arif & Mr. Muhammad Ashfaq Ahmed.

Preface
Engineering is always completed by the unification of theoretical knowledge and Practical field experience. For this reason, Field internship plays vital role in polishing an Engineer. Technical and management skills are very important for the Fresh Graduates and internships provide a golden opportunity to enhance and practice all types of skills. The aim of writing this report is to express the Seven week experience, which I gained here at Fimkassar Oil Field.

Table of contents
1. OGDC 2. Introduction to Fimkassar oil field 3. Social Welfare Programs 4. Well # 1 5. Well # 2 6. Well # 3 7. Well # 1-A 8. Well # 4 9. Surface Facilities 10. Present Status for Enhancement of Crude Production 11. Intro to Chak Naurang oil field 12. Yard 1 13. Yard 2 14. Yard 3 15. Yard 4 16. Yard 5 17. Technical assignments 18. Economical View 19. HSEQ 4 7 8 9 12 15 18 18 19 20 26 26 26 28 28 29 30 58 61

OGDCL
Company History:
To revive exploration in the energy sector the Government of Pakistan signed a long-term loan Agreement on 04 March 1961 with the USSR, whereby Pakistan received 27 million Rubles to finance equipment and services of Soviet experts for exploration. Pursuant to the Agreement, OGDC was created under an Ordinance dated 20th September 1961. The Corporation was charged with responsibility to undertake a well thought out and systematic exploratory program and to plan and promote Pakistan's oil and gas prospects. A number of donor agencies such as the World Bank, Canadian International Development Agency (CIDA) and the Asian Development Bank provided the impetus through assistance for major development projects in the form of loans and grants. OGDC's concerted efforts were very successful as they resulted in a number of major oil and gas discoveries between 1968 and 1982. Toot oil field was discovered in 1968 which paved the way for further exploratory work in the North Thora, Sono, Lashari, Bobi, Tando Alam & Dhodak oil/condensate fields and Pirkoh, Uch, Loti, Nandpur and Panjpir gas fields which are commercial discoveries that testify to the professional capabilities of the Corporation. The financial year 1989-90, was OGDC's first year of self-financing. It was a great challenge for OGDC. Prior to 23 October 1997, OGDCL was a statutory Corporation, and was known as OGDC (Oil & Gas Corporation). It has been incorporated as a Public Limited Company w.e.f. 23 October 1997 and is now known as OGDCL (Oil & Gas Development Company Ltd.). In December 2006, the Government of Pakistan divested a further 10% of its holding in the company. The Company is now listed on the London Stock Exchange since on December 06, 2006.

Vision:
To be a leading multinational Exploration and Production Company.

Mission:
To become the leading provider of oil and gas to the country by increasing exploration and production both domestically and internationally, utilizing all options including strategic alliances. To continuously realign ourselves to meet the expectations of our stakeholders through best management practices, the use of latest technology, and innovation for sustainable growth, while being socially responsible. The Name Of Producing Fields Contained In North, Center, And South Areas Are North Fields The nine fields are producing in the northern area of Pakistan. Bhal Syedan, Chak Naurang,Dakhni, Fimkassar, Kal, Missa Keswal, Rajian, Sadkal and Toot. The seven gas fields are producing in the central area of Pakistan, Dhodak, Loti, Nandpur, Panjpir, Pirkoh, Qadir pur and Uch. The fifteen fields are producing in northern areas of Pakistan, Bobi, Buzdar, Daru, Hundi, Kunar, Lashari Center, Lashari Soutj, Missan, Palli,Pasahki,Sari, Sono, Tando Allah Yar, Tando Alam, and Tobra Distinguished Feature
First heavy oil field development in OGDC. Only and lonely commercial development of sour gas field in Pakistan. Gas sale through SSGCL pipeline specifically laid down for BP (ext UTP) fields. First refinery gas in Pakistan yielding complex array of refined products. First successful water injection field of OGDC and 2nd after Dhurnal in Pakistan. first dry gas revenue generation fields as well as first discoveries of OGDC. Successful installation of sucker rod pump .First in north for OGDC. Gas recycling through Gas Cap for maximum recovery of oil. A well was drilled to tap the attic oil of lashari Center fileld. No decline in production from SML formation under natural depletion.

Center Fields South Fields

Field
Chak Naurang Dakhni Daru Dhodak Fim kassar Hundi / Sari Kal Kunnar Lashari Loti

Missa kesswal Missan Nandpur/ Panjpir Palli Pasahki Pirkoh Qadirpur Rajian Sadkal Sono Tando Allah Yar Tando Alam Toot Uch

Hydro carbons discovered in eight (08) reservoirs (Khewra to murree). The one well field is draining some of its up dip potential through jet pump. Very low btu gas fields became commercial first time in Pakistan. 1st typical one well field of OGDC producing(not discovered) in south area. Shares the same Horst block with kunnar but oil production is marvelous. First recovery in center for OGDC. Maximum well drilled in a single field by OGDC. Highest ranked OGDC field in terms of revenue generation. A main breakthrough in 3D seismic acquisition technology is applied first time ever in Pakistan to map Rajian structure. A complex thrust fault bounded structure has been delineated in to at least five compartment /blocks in Sadkal field. The successful workovers of recompletion and jet pumps installations made the hydrocarbons recovery up to 60% from Sono field. A thick gas condensate column over laying an oil rim. Provided breakthrough in south to OGDC. First major oil discovery that provided the foundation for further development of OGDC. Biggest dry gas field being used for power generation.

FIMKASSAR OIL FIELD

Location:
The Fimkassar Oil Field is located in the Chakwal District of the Punjab Province approximately 95 km South West of Islamabad.

Potwar Basin: The Potwar Basin has been actively explored for hydrocarbon since 1870 and first success came in 1914 when Attock Oil Company discovered oil at Khaur. The Dhulian, Joyamir and Balkassar field are then discovered by the same company in 1918, 1943 and 1945 respectively. In 1978 Amoco was granted the exploration license in the Northern Potwar. In 1982, the concession was granted to the Occidental of Pakistan, who discovered oil from the Eocene formations and later from Paleocene and Permian horizons. Similarly OGDCL was also granted exploration license in the Northern Potwar Deformed Zone (NPDZ), where it drilled several exploratory, appraisal as well as development wells successively History:
It was discovered in 1980 by Gulf Oil Company, but the production rate was not good enough for commercial production of the Field. Even after Stimulation it had poorly produced around 10 to 20 barrels per day. Then they surrender their lease. OGDCL carried-out further Geological and Seismic studies. FMK # 1 was side-tracked and drilled down to 3,081 meters with a horizontal displacement of 250 meters. The well was completed in Sakessar Formation with an initial flow rate of 4,100 BOPD Oil and 4 MMSCFD Gas in October 1989. FMK # 2 was drilled and completed in 1990 and put on regular production in October 1990. The Initial Oil and Gas flow rates were 1,600 BOPD and 1.4 MMSCFD respectively. The reservoir Sakessar FMK # 1 went below the bubble point pressure during March 1993 and therefore Water Injection was planned. FMK # 3 was drilled and completed in Sakessar Formation for this purpose. Pilot Water Injection in Sakessar Formation through FMK # 3 was started on 4th March 1996. After injecting water at a rate of 10,080 barrels per day for a period of 3 months and increase in well head flowing pressure from 380-700 Psi and oil production 2060-3560 BOPD of FMK # 1 as on 30th June 1998.

Social Welfare Program

Construction of free medical dispensary Free Medicines for Locals 97 Two Class Rooms with verandah for Govt. Elementary Boys School Fimkassar Since 1997. Electrical Water Coolers for Rs. 54000. Mini Bus Hired for Pick and Drop for Local Students Services of a Lady Doctor for Rs. 18000 per month Since Nov 2006 Note Books Pencils, Sharpener, Scales, Bags, erasers for students

Proposed Social Welfare Schemes Construction of 2 class rooms, 3 toilets, and 8 ceiling fans for Govt. Girls Primary School, Fimkassar for 1.68 million rupees. Construction of classrooms, boundary wall and toilets for Govt. Elementary Boys School Fimkassar. Rs. 2 million. Construction of approximately 1 km metal road with side drainage nala. 3.27 million

Well # 1
Well Tech Data Summary Spud-in Date Spud-in Date No. of DST Run CSD TD PBTD Completion Tubing size and grade Minimum ID Completion Type Completion Fluid SG Mule Shoe SG X-mass Tree 21-08-1980 (Gulf Oil) 13-04-1989 (Side Tracked by OGDC) 03 7 casing/ liner shoe @ 2888 m 3081 m 3081 m 14-09-1998 3 N-80 56 mm Open (Single string) 1.37 Mule shoe @ 2781.465 1.002 3 1 16 x 1000 psi Cameron

Other Information @ 30th June 2010 Water Cut 89.2% (calculated from told liquid and oil rates at field) Gas Rate 333 Mscfd Liquid Rate 1800 BPD (Oil rate: 195 bpd) Wellhead Pressure 130~180 psig @ 30th June 2010 Separators 3 Horizontal (2 under operation) Processing Gas is processed for marketing and power generation

Well Completion Profile

No .
1
2

DEPT H M

LENGT HM ---

OD mm ---

ID mm ---

DESCRIPTION Tubing Hanger: 3 1/2" CSHyD (BxB) Cross Over : 3-1/2" NKEL (P) 9.3 Lbs/Ft. x 3-1/2" CSHyD (P) 10.3 Lbs/Ft. Cross Over : 3-1/2" NKEL (B) 9.3 Lbs/Ft. x 3-1/2" CSHyD (P) 10.3 Lbs/Ft. Pup Joint : 3-1/2" CSHyD 9.3 Lbs/Ft. Tubing Joints : 3 1/2'' CS Hyd
9.3 Lbs/Ft.

306 M
4 5

2
20"

---

0.1

95

76

3 4 5

0.58 1.52 2736.22 2737.13 2756.26 2759.21 2760.28 2763.14 2763.4 2765.07 2765.26 2765.47 2768.6 2768.97 2772.05

0.48 0.94 2734.7 0.91 19.13 2.95 1.07 2.86 0.255 1.68 0.18 0.21 3.12 0.25 3.18

99 89 89 113 89 82 139 114 138 115 127 89 73 81 73

75 75 75 70 75 61 83 82 85 100 62 58 62 56 62

1602 M

13 3/8"

6
8

SSD Tubing Joints: 2 Nos.3 1/2'' CS

Hyd.

9 5/8" 9

7 8 9 10 11 12 13

10
11 11

10 12

Seal Assy: P # 442-34-7276 P. B . PKR: P # 08415-058280-01-63 Seal Bore Extension Coupling: P # 02-4300-02-1161 Mill Out Extension: P# 0184643-49 Casing Sub: P# 294-69-2518 Seating Nipple : P# 44 - 5 0 Perforated Pipe: P# 457 - 43 798 Seating Nipple - R - Type: P#801-57-2252 Spacer Tube x 1/2 Mule Shoe X-Mass Tree: 3 1/16" Cameron Rating: 10000 Psi.

13

14

15

14
16

15
17 2644.16 M

16 17

7"

2783 M
OPEN HOLE

TD=3081 M

Top connection:

10

Gas Flow Diagram of Fimkassar

Gate #2

W/Shop

Seprator FMK#2

Drip

Plant SepratorFMK#1

Knock out vessel

Gas Gen Set

Gate # 1

A portion of gas produced from FMK01 is sold to Lime Kiln at 25 psi.

Stock Tanks at FMK01

11

Well # 2
Well Tech Data Summary Spud-in Date 06-02-1990 No. of DST Run 01 till 11-10-2005 CSD 7 casing/ liner shoe @ 2889 m TD 3075 m PBTD 2943 m Completion 02-10-1990 Tubing size and grade 3 N-80 9.3 lbs/ft Minimum ID 56 mm Completion Type Open (Single string, permanent completion) Completion Fluid SG 1.37 Mule Shoe Mule shoe @ 2851.278 m PKR setting Depth 2842 m Formation Chorgali Perforated Interval 2943-2889 m 1ST Survey BHSIP 5208 psi @ 29-09-1990 st 1 Survey BHSIT 239 F @ 29-09-1990 Water Production Start 06-12-1992 Initial Rate qw 4.67% Chlorides 4090 ppm SG 1.007 X-mass Tree 3 1 16 x 1000 psi Cameron Completion fluid type Mud Completion fluid S.G 1.37 Other Information @ 04-07-2010 Wellhead Pressure = 130psi Wellhead Temperature = 90 F Production from FMK02 through choke manifold is transported to FMK01 site through steel pipelines. Production Casing Size Grade Weight per foot Threads 7 N-80 32 Lbs/ft NA

12

Well Completion Profile

HOLE CONSTRUCTION OF FMK # 02

40 M

20 " CSG SHOE

1500 M

13 3/ 8" CSG SHOE

2405 M

9 -5 / 8" CSG SHOE

2889 M

7" CSG SHOE PBTD 2943M

3075 M 6" OPEN HOLE

13

4 5 6 402m 20 " CSG 13 3/8" CSG 7

WELL COMPLETION DIAGRAM # 2

NO DEPTH
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 0 0

DESCRIPTION
ROTARY TABLE DIFFEENCE 3 1/8" *10,000PPSI CAMERON X-MASS T.

1500m

8 9 5/8" CSG 9 2405m

11

11"*7 1/16" TUB. HEAD SPOOL 0 3 1/2" 9.3PPF CS HYD TUB HANGE 5.86 X-OVER CS 3 1/2" P*P 6.33 PUP JOINT 3 1/2" 9.3 PPF CS HYD 4 JTS 11.88 3 1/2" 10.3 PPF TUB CS HYD N -80 2819.59 SSD 3 1/2" 9.3PPF CS HYD BAKER 2821.4 2 JTS 3 1/2" 10.3PPF TUB 2840.37 BAKE 3 1/2" CS HYD SEAL ASSY 2844.25 BAKER 7" DB PACKER 2841.48 BAKER SEAL BORE EXT. P*P 2844.34 CONNECTING SUB B*B 2844.6 2846.28 MILL OUT EXTENSION P*P CASING SUB 2846.46 F SETTING NIPPLE 2846.75

2849.87 2850.24 2850.97

2 7/8" NU P*B PERFORATED PIPE 2 JTS R SEATING NIPPLE 2 7/8" NU (B) * 1/2 MULE SHOE.

10 13

12

19

14 15 16

00 0 00 0

17

18

19

7" CSG 2889m 2943m 2955.5m cement CaCO3 Plug 3075m 6" open hole

14

Well # 3
Water Injection Well

Background: After putting FMK # 1 on regular production the production reached to 4100 BOPD in 1990. Since the reservoir was highly under saturated therefore rapid decline in the reservoir pressure occurred. In March 1993 the reservoir went below bubble point when it had produced 3.9 MMSTB of oil at 600 psi. In order to maintain the pressure above bubble point water injection was designed for Sakessar

formation.

As the well was

produced below bubble point the production data showed no increase in the gas production or any increase in GOR as was expected. The stabilized W.H.F.P below

bubble point and no increased gas production showed that the gas instead of moving in the reservoir tended to move upward in the reservoir due to fractures forming a gas cap. Water injection was started in FMK # 3 in the Sakessar formation in 1996 with initial injection rate of 10,000 BOWD. FMK # 1 responded to the water injection responded after 3.5 months increasing the W.H.F.P from 380 to 725 psi. Production increased from 2055 to 3833 BOPD. Early Water Break Through: The water breakthrough occurred in early 1997 earlier than predicted. Till date the cumulative water injected is 20.75 MMBBls. The water produced is 4.62MMBBLS. The water produced is 22.62% of injected water.

15

Well Technical Data Summary Spud-in Date 27-03-1994 No. of DST Run 01 CSD 7 casing/ liner shoe @ 3214 m TD 3261 m PBTD 3214 m Completion 16-06-1995 Tubing size and grade 4 & 3 N-80 Minimum ID 68 mm Completion Type Perforated Completion Fluid SG 1.40 Mule Shoe Mule shoe @ 2998.46 PKR setting Depth 2985 m Formation Sakessar Perforated Interval 3150 3180 m ST 1 Survey BHSIP 2390 psi @ 31-08-1995 1st Survey BHSIT 283 F @ 31-08-1995 Water Injection Start 04-03-1996 Initial Rate qw 8600 barrels per day Chlorides 85 ppm SG 1.002 Wellhead Pressure 1800 psi @ 05-07-2010 Injection System Facilities Tank Capacity Safe Capacity Number of Tanks Total Water Inj in 23 hrs Total water inj in 1 hr Diesel Consumption Water/Diesel Tanks 87.67 m3 = 87667 ltr 79.03 m3 = 79033 ltr 2 for Water and 1 for Diesel 210755 ltr/d = 1325.5 bbl 9163 ltr/ hr 15 mm/day (23 hrs) = 649 ltr/23 hr = 28~29 ltr/hr varies from engine to engine

Water from a canal; 10 km away from the wellsite, is pumped to an open pond at wellsite, from this pond water is pumped to water tanks through filters. From tanks water is pumped through triplex pumps at desired rate and pressure to inject into the reservoir.

16

HOLE CONSTRUCTION OF FMK # 03

402 M

20 " CSG SHOE

1745 M

9 5/8" LINER TOP

1849 M

13 3/ 8" CSG SHOE

3090 M

9 -5 / 8" LINER SHOE

3214 M

7" CSG SHOE PBTD = 3261 M

17

Lay out Fimkassar Well no. 3 (Injection Well)

Entrance Well Operator cabin
Water to be injected

Entrance

Well no. 3

Triplex Pump

Triplex Pump

Triplex Pump

Filtered Water

Filtered Water

Filters

Pump

Water Storage
From Nindral Village

Diesel

Well # 1A
Well Tech Data Summary At Fimkassar O.G.D.C.L. has drilled another well in 2003. But unfortunately this well came out to be non productive and no oil or gas was conceived from it. Some technical details are listed as follows Spud in Date 13-04-1989 Total Depth 3450 m There is also problem that instead of oil or gas a large amount of water came into the wellbore and company was unable to restrict this water in the formation so it was decided to let this water come to surface, in this regard surface assembly was installed and water is being produced. But unfortunately this water is not suitable for usage because of presence of Sulphur in it that is why it is also discarded along the water of well no. 1 & 2.

Well # 4
Well Technical Data Summary Spud-in Date 29-07-2003 No. of DST Run 08 CSD 7 casing/ liner shoe @ 2833 m TD 3450 m PBTD 3439 m Abandoned 06-12-2004 Bottom CMT plug 2680 m Top CMT plug 68 m Reason for Plugging Un-productive as result of 8 DSTs

Surface Facilities:
Surface facilities at FIMKASSAR Oilfield consist mainly of 1st stage and 2nd Stage Separators for Well # 1 and a single stage separator for well # 2. Other than that Water injection Pumps are also working 24 hrs at well # 3.The layout of Surface facilities is shown in fig

18

Mixed Flow from well # 1 (W.H.F.P 90-100 psi 150 deg F) passes through Choke Manifold and enters 1st stage (40-50 psi & 140 deg F). Water is drained and Oil and Gas are sent in to 2nd Stage separator (30 psi & 135 deg F). Water is drained to Flare pit and oil sent to storage Tanks. Gas thorough the knockout drum is sent to the gas generator at site and partially for the Utility for the residential colony at 70 psi. Extra gas is flared. The water cut for Well # 1 is approximately 410 bbls/day with Oil and gas productions being 140 bbls/day and 0.2 MMSCF respectively. Mixed flow from Well # 2 (W.H.F.P 140-130 psi 85 deg F) passes through choke Manifold and enter Separator # 1(40-50 psi and 80 deg F). Water is drained to flare pit while oil is sent to storage tanks. Gas separated is 1st passed through a scrubber to remove condensate and water vapors and sent to residential colony. Water cut for well # 2 is 90 bbls/day with Oil and gas productions being 0.10 MMSCF. There are 4 storage tanks of approximately 6000 bbl capacity Production from Well # 1 and 2 is stored in Tank # 1 and Tank # 3. Oil from tank # 3 is than shifted to Tank # 4 for dispatch. After every three days the Oil is stored in the other 2 Tanks and water is drained from Tank # 1 and Tank # 3. It is the case for Tank # 4 and Tank # 3. Water is drained from storage tanks in three stages to remove any Oil contents that may remain in the water. First from Tanks to Pit # 1 and Pit # 2. Water is than pumped to the flare pit where further removal of sluge takes place the water underneath is drained in next pit and than in the rivulet. Four centrifugal pumps are used to dispatch Oil from the Storage tanks to the Bowers to Attock oil refinery. FMK # 3 is a water injection well. Water is injected at 2000 psi at an injection rate of 2000 bbls/day. FMK 1A is oozing water well producing uncontrollable water (7500 bbls/d) from annulus and tubing at the same time. This water (51 deg C) is drained in the nearby rivulet.

19

This is required to maintain a retention time that will enable the Oil gas and water to separate completely. An inappropriate Retention time will either cause oil carry over with gas or gas carried over with oil. A reciprocating air compressor coupled with electric motor provides instrument air at 70 psi. This pressure is further reduced according to the requirement of the equipment by regulators. The Liquid control Valve (LCV) comprises of a floater which is directly in contact with the Liquid in the Separator. The Floater governs the movement of the outlet pressure of instrument air in the wizard box.

Chemical Injection:
Anti-scaling chemicals are injected in FMK # 1. To prevent scaling of pipelines which could result in complete blockage of the pipeline and hence loss in production. Demulsifying chemicals are injected in FMK # 1 and 2 fluids to reduce water in oil emulsion, which hampers proper separation of the fluids in the separators. For chemical injection in production lines chemical injector pumps are used. The amounts of chemical to be injected depend upon the flow rate of the fluid.

Present Status for Enhancement Of Crude Oil of Fimkassar Oil Field

All efforts are being made to enhance crude oil. Our production target set by management for the fiscal year 2009-09 was 300 bbls/day. Some modification has been made in process system to enhance crude oil. From these efforts, crude oil production enhanced from 325 bbls/day to 360 bbls/day and still maintaining. Well #1 production has about 86% water. Scale inhibitor is being used to minimize deposition of scales in production lines. Although, we are using scale inhibitor but mostly crude lines has been choked with the passage of time. Decision has been made that all crude lines will dismantle after six month and remove scale. Practice in Vogue. Separators & Well Area

20

Well # 01 is being continuously monitored and observed that mostly scale occurred in before choke because scale inhibitor was injecting after choke. Due to scale depositions that cause increase in back pressure and decrease in flow. To get rid of it, instrument flange was arranged and fitted before adjustable choke. Connections for scale inhibitor were made with the instrument flange. After this modification, upon continuous monitoring, observed an increase of about 25 bbls/day of crude oil.

Well # 1 crude line towards separator choked due to scale deposition. This line has been replaced by laying new line.

21

Newly Laid Lines

Modification in the separator lines has been made for ensuring smooth operations. All sharp bends/elbows have been removed to minimize scale deposition, which also caused scale deposition.

22

Production Field Terminologies X-mass Tree: It is a combination of valves which controls the pressure at surface. Master Valves: Valves which are used in sever operating operations. Wing Valves: Wing valves are used to divert the flow in one of the two wings of the x-mass tree. Inner and outer wing valves are used to protect the valves in sever operating operations. Swab Valves: Used to isolate the tubing pressure from the environment

23

Manifold: It is a combination of valves which divert the flow in the required direction. Choke: Choke is used to control the production rate it may be fixed or adjustable. Back Pressure Valve: BPV Installed on the tubing hanger to stop the flow of well to surface. Crossovers: Used to make connection between tubing of different diameters. Tubing Head: Tubing head accommodates the tubing hanger. Perforated Tubing: Tubing having equidistant holes to get the production from the formation. Separators: A device used to segregate different fluids from the mixture. Its working principle is gravity, centrifugal force and effect of baffles also perforated plates or screen. Double Barrel Knock-out Bottle: Type of separator used to separate condensate oil and water from gas. Threads: There are a number of thread connections available in tubing and pipelines. Few of them are discussed below: 1. CS Hydrill 2. PH-6 3. EUE 4. VAM 5. NKEL CS-Hydrill: It has three edges with eight square threads between the edges.

24

PH-6: It is same as CS hydril but with six threads between the three edges. In this type hreads are thicker than the previous type so the space between the threads is less. EUE: These type of threads are used in pipes, they are triangular in shape pointed outwards and continues. VAM: These are same as EUE threads but square in shape. They are also continues throughout. NKEL: These are also square in shape with long collar in the start.

25

Chak Naurang Oil Field

Location of Field
This is one of the northern oil field centrally controlled by Fimkassar Oil field. The Chak Naurang Oil Field is located in Distt. Chakwal and is 20 KM from Chakwal and 85 KM from Islamabad.

History of Field
The Field was discovered in June- 1986 and came on regular production from July-1987. Chak Naurang is a joint venture with M/S. POL. OGDCL & POL shares are 85 % and 15 % respectively. In this Oilfield a total of 05 Nos. of Wells were drilled. At present only two Wells are producing.

CNG # 1A
Chak Naurang Well # 01-A was drilled down to a target depth of 2687 meters on 26.06.1986 and completed on 20.08.1986.

All the prospecting zones were tested. Khewra and Tobra formation produced Oil of 18-19 API gravity to surface at the average rate 15-30 BOPD. This well has been put on artificial lift (through sucker rod pumping system) since 25-05-1990 and initial oil flow rate was 100-110 BOPD. Present oil production is 10-15 BOPD

Tool Yard
Shed 1: Auto/Local Store This tool shed contains tyres, gyres, clutches and other auto spare parts. Their description here is not thought to be necessary. Shed 2: Production Store Some of the tools available in the production shed are enlisted below Sr# Name/Description 1 2 3 4 5 6 7 8 9 10 11 Pressure Relief v/v 4 Oil well level Control INST Back Pressure v/v Wrench Back pressure Packing (dual) Tubing Hanger Seal ring for type H Back pressure v/v Plug 1 v/v Removal plug v/v removal Gas ket ring Bull plug 4 elbow 26

12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50

O Ring RIDGID Nu-clear Thread Cutting Tool, Contents: Mineral Oil. Not to be used as Lubricator Tester MOHM Model. HIOKI PHILIPS Battery Charger BW Technologies. O2 Sensor BW Technologies, Multi Gas Detector. Detects CO, H2S, LEL, O2 Rototherm Instrumentation and Control Halliburton Non-Elastomer, Tubing Retrievable Safety v/v (TRSV) Bentley, Thermocouple Instruments Schlumberger 3 Safety V/v sleeve W/collet ( for SSSV) S-seal OD type HNBR FMC Technologies, Pressure Gauge F/H2S & CO2 SVC Tubing Anchor Bestolife PTC Thread Sealer. Net Wt. 43 lbs/bucket ILEX TFE-20 Thread sealing compound Snap in spring Lift Rod Hook Millout Extension Packer Wash pipes BWD Wireline Set, PERMA Service 7 Packer Wireline Tubular Jar Bellows Assy (assembly) R. Stabbing guide 3 Bourdon Tube Fisher Control Company, Repair Kit Relay Body Assy Diaphragm Union cross Ball v/v 2 RTJ600 Bowen Spang Link, used on Jar Pomy Rods 7 Dual Completion Packer 2 Type C Gliding SSD 2 Type L Multiple acting Indicator Orifice OTS Position#2 Key locator Mandrel Assy Prong pulling Mandrel Selecting Locking 27

51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68

Orifice Plate 6x Flow Bean Tungsten Carbide 28/64, 32/64, 48/64, 64/64 Air Hose Assy Hydro Sub 2 with ball Pilot Assy HP Inline Safety System Bean Flow 16/64, 20/64, 24/64, 28/64, 32/64, 48/64, 64/64 Cross Over 4 CS Pup Joint 2 CS Box Pin Mule Shoe Guide Dual Completion for 9 Casing, 5x6 Millout Extension Baker Perforated Spacer Tube 2x10 polish rod 11 long KRT Seal Assy Seal bore Extension X Over 5 3 Pup Joint 10.3 lb/ft 2 Pup Joint 56.50 lb/ft 2 Pup Joint 5 lb/ft

Shed 3 Chemical Store Sr# 1 2 3 4 5 6 7 8 9 10 11 Chemical Sodium Acid, PURON*F Disodium Pyrophosphate Mud Chemical PFExtend (Bentonite Extender) PPTA Pure Terephthalic Acid No. 7 APIIC, SETTIPALLI PAC Polyanionic cellulose, Regular Grade (PAC-R) API Non treated Bentonite Non-treated Bentonite API 13A. Sec. 10 Refined Sodium Bicarbonate EN-CMC-HV Black Magic SFT (Sacked Fishing Tools) OPC Ordinary Portland Cement. Clinker 95%, gypsum 5%. 28 days strength 6500 psi Net Weight 250 kg/sack 40x25 kg/stack 1050 kg 25 kg/sack 25 kg/sack 1000 kg/stack (Gross 1015 kg) 100 lb/sack 25 kg/sack 875 kg/stack 998 kg/sack (Gross 1025 kg) 20 bags to a Metric Ton

28

Shed 4 Cement/CMT Additive Sr.# 1 2 3 4 5 6 7 8 9 10 11 Description Retarder D 13 Tuned Spacer E+ Temperature Retarder D 800 Dispersant D 065 TIC*D 065, Sodium polynaphthalene sulfonate 60~100% Cement Friction Reducer CFR-3. Made in Germany Cement Retarder HR-15 FL-198. Source of Chemical: USA. Source of Finished Chemical: Singapore Oil well Cement, Class G Grade HSR API Spec 10A Single Trip 5:1, Safe working Load 1500 kg PolyCarb Film Foam Antifoam Agent D 047, Polypropylene Glycol 60-100% Shed 5: Chemical Store Sr.# Brand and Description 1 2 3 4 5 6 ICI Pakistan. Light Soda Ash. Net Wt. 50 kg/sack OGDCL Pakistan. Hydrogen sulphide Scavenger (Zinc Carbonate). Net Wt. 30x25 kg = 500 kg/stack, Gross 520 kg/stack Saw Dust Net Wt. 250 kg/sack Itehad Chemicals Pakistan. Caustic Soda Flakes ICL. 971% pure. Net Wt. 25 kg/sack KCl Potassium Chloride Sacks China Petroleum Drilling Fluid Co. KPAM Net Wt. 75010 kg, Gross Wt. 77515 kg Weight 50 lbs/sack

50 lb/sack 50 lb/sack 50 lb/sack 1.5 Metric Ton/sack 25 kg/sack 25 ltr/ container Net Wt. 19 kg Gross 20.4 kg

29

Technical Assignments
1. Piping Layout 2. Layout Fmk01 3. Layout Of Field 4. Separators 5. Pressure vs. Time Behavior of FMK03 6. Triplex plunger PUMP CALCULATION 7. Water sprinkler System/ Water Disposal 8. Liquid Holdup

30

Well no. 1

Well no. 2

FMK01 PIPING LAYOUT

Mix Fluid

6 2 1st stage 1

To Pit 1st stage Mix Fluid 1 6 Sale Gas Line

2nd stage

Power House Knock out vessel 2 7/8 To Colony

PLANT

Kitchen

FIMKASSAR WELL 01 LAYOUT PLAN

Water Pit Pit ( Water with mixed oil) Building Masjid Security Check Point Bowser Filling Point Water Gun Horizontal Separator Vertical Separator Fire Extinguisher Water Tank StockTanks Demulsifier Injector

Power House (Fuel: Gas) Gas Discharge Point Diesel Tank (Fuel for Oil Pumping) Electric Pumps for Bowzer Filling Diesel Engine Elec Pump Ctrl Fire Brigade Truck Stand Well (FMK#1) Choke Water Sprinkler Control

FIMKASSAR OIL FIELD LAY OUT PLAN

<= CHAKBAILI KHAN ROAD

FMK WELL # 2

FMK WELL # 1

OGDCL
FREE DISPENSARY

OGDCL RESIDENTIAL COLONY

3 KM

LPG RECOVERY PLANT & ADMIN BLOCK

2,5 KM

FMK # 3 WATER INJECTION WELL

<= CHAKWAL-MANDRA ROAD

FILLING POINT

DHUDIAL

Types of Separators
Three basic types of separators are widely used for gas-liquid separation. (1) Vertical Separator (2) Horizontal Separator and (3) Horizontal Double-Barrel.

Each has specific advantages, and selection is usually based on which one will accomplish the desired results at the lowest cost. Separators (Two Phase Configuration shown) consists of the following: A= Vessel, B= Skid or Saddles, C= Monarch Turbulence Diverter, E= Vortex Breakers, Separators (Three Phase Configuration shown) consists of the following: A= Vessel, B= Skid or Saddles, C= Inlet Diverter, D= Distribution Baffle, E= Monarch Coalescing Pack, F= Foam Breaker, G= Vortex Breakers, 31

H= Oil Sump and Weir, I= Mist Eliminator, J= Sand Jetting

Stage Separation

At fimkassar plant sepration used is done in two stages and in one stage seprator as well as the wellhead pressure and temprature of well stream obtained from well no 1 is higher that is the reason this is seprated by two stage seprator as in fig 1.
1 2 3

Storage Tanks

Fluid from
well

Seprators arrangement for well No 1

Well stream from well no 2 is of low pressure and temprature and is seprated in sigle stage as shown in fig.1 only one seprator is used in that case.

32

Separators at FMK01

33

Injection Time vs. Injection Pressure graph:

Water injection in well no.3 is carried out by triplex pumps. They are stopped for 1 hour a day to give rest to mechanical parts and routine maintainence check. This particular time period in which engines are stopped is called make up time. We have plotted a graph between injection pressure and time during make up and after make up to get a tren of pressure decrease and rise respectively. pressure decrease and rise respectively.

Time Pressure
TIME 09:45 09:55 10:05 10:15 10:25 10:35 10:45 10:55 11:00 PRESSURE 2000 1800 1700 1600 1500 1400 1300 1300 1300

After Makeup Time when injection was restarted at 11:00 am then the values were TIME 11:00 11:02 11:05 11:08 11:20 11:32 11:42 12:05 12:15 12:37 12:47 PRESSURE 1400 1500 1600 1700 1750 1800 1800 1800 1850 1900 1900

34

Time Vs Pressure (Make up Time)

2400 2200 2000 1800 1600 1400 1200 1000

35

Calculation of Water Injection Pump Efficiency: (WELL NO. 3)

Water at well no.3 is injected by the help of triplex plunger pump. Its the calculation of the efficiency of the pump both theoretically & physically. Theoretical Method: Circumference of Plunger Radius of Plunger = 11 in = = /2 = 11/2 3.14 = 1.75 in Number of Plungers =3

Stokes per minutes (Plunger) = 86 Length of Plunger Volume of plunger = 6 in = (/4) (d2 l) = 57.8 in3 Volume of 3 plunger = 3 57.8 = 173.2 in3

Volume injected per minute = Volume of Pluger Stokes per minute = 173.2 86 = 14890 in3 / min Conversion Factor Volume injected per minute = 6.7375 = 14890/6.7375 =2210 BPD Physical Method: In this method we physically calculated the discharge of the tanks after taking dips with the help of dip rods by a time interval of 15 mins.

36

Average Difference

= 2857.92 ltrs /15min = 2857 4 23 /159 = 1653.7 BPD

Pump Efficiency

= Output / Input = 1653.7/ 2210 = 74.8 %

37

WATER Sprinkler System

Produced water from Fimkassar field is set to dispose using a sprinkler system. This system worked on the principle of forced evaporation system. Literature is reviewed and calculations are done for system efficiency.

WHAT IS EVAPORATION?
Evaporation is a type of vaporization of a liquid that occurs only on the surface of a liquid. The other type of vaporization is boiling, that instead occurs on the entire mass of the liquid. Evaporation is also part of the water cycle. Or The transformation of water liquid to water gas (or vapor) by energy from heat or air movements.

How Evaporation occurs?

Evaporation occurs only on the surface of a liquid. The other type of vaporization is boiling, that instead occurs on the entire mass of the liquid. Evaporation is also part of the water cycle. Evaporation is a type of phase transition; it is the process by which molecules in a liquid state(e.g. water) spontaneously become gaseous (e.g. water vapor). Generally,

evaporation can be seen by the gradual disappearance of a liquid from a substance when exposed to a significant volume of gas. Vaporization and evaporation however, are not entirely the same processes.

What is the Theory behind Evaporation?

For molecules of a liquid to evaporate, they must be located near the surface, be moving in the proper direction, and have sufficient kinetic energy to overcome liquid-phase intermolecular forces. Only a small proportion of the molecules meet these criteria, so the rate of evaporation is limited. Since the kinetic energy of a molecule is proportional to its temperature, evaporation proceeds more quickly at higher temperatures. As the faster-moving molecules escape, the 38

remaining molecules have lower average kinetic energy, and the temperature of the liquid thus decreases. This phenomenon is also called evaporative cooling. This is why

evaporating sweat cools the human body. Evaporation also tends to proceed more quickly with higher flow rates between the gaseous and liquid phase and in liquids with higher vapor pressure. Three key parts to evaporation are heat, humidity and air movement.

What are the factors that affect the rate of evaporation?

Concentration of the substance evaporating in the air: If the air already has a high concentration of the substance evaporating, then the given substance will evaporate more slowly. Concentration of other substances in the air: If the air is already saturated with other substances, it can have a lower capacity for the substance evaporating. Concentration of other substances in the liquid (impurities) If the liquid contains other substances, it will have a lower capacity for evaporation. Oil.. Wind velocity: If fresh air is moving over the substance all the time, then the concentration of the substance in the air is less likely to go up with time, thus encouraging faster evaporation. Inter-molecular forces: The stronger the forces keeping the molecules together in the liquid state, the more energy one must get to escape. Pressure:

39

Evaporation happens faster if there is less exertion on the surface keeping the molecules from launching themselves. Surface area: A substance which has a larger surface area will evaporate faster as there are more surface molecules which are able to escape. Temperature: If the substance is hotter, then its molecules have a higher average kinetic energy, and evaporation will be faster. Density: The higher the density, the slower a liquid evaporates. An Example from daily life: When clothes are hung on a laundry line, even though the ambient temperature is below the boiling point of water, water evaporates. This is accelerated by factors such as low humidity, heat (from the sun), and wind. In a clothes dryer, hot air is blown through the clothes, allowing water to evaporate very rapidly. Working Principle of an Evaporator: The solution containing the desired product is fed into the evaporator and passes a heat source. The applied heat converts the water in the solution into vapor. The vapor is removed from the rest of the solution and is condensed while the now concentrated solution is either fed into a second evaporator or is removed. The evaporator as a machine generally consists of four section: The heating section contains the heating medium, which can vary. Steam is fed into this section. The most common medium consists of parallel tubes but others have plates or coils. 40

The concentrating and separating section removes the vapor being produced from the solution. The condenser condenses the separated vapor, then The vacuum or pump provides pressure to increase circulation.

Types of evaporators
1. Flash Evaporator 2. Rotary evaporator 3. Centrifugal evaporator 4. Natural/forced circulation evaporator 5. Falling film evaporator 6. Rising film evaporator 7. Plate evaporator 8. Multiple-effect evaporators 9. Vacuum Evaporator Flash evaporation: Flash or partial evaporation occurs when a saturated liquid stream undergoes a reduction in pressure by passing through a throttling valve or other throttling device. This process is one of the simplest unit operations. If the throttling valve or device is located at the entry into a pressure vessel so that the flash evaporation occurs within the vessel, then the vessel is often referred to as a flash drum. If the saturated liquid is a single-component liquid (e.g. liquid propane or liquid ammonia), a part of the liquid immediately "flashes" into vapor. Both the vapor and the residual liquid are cooled to the saturation

41

temperature of the liquid at the reduced pressure. This is often referred to as "auto-refrigeration" and is the basis of most conventional vapor compression refrigeration systems. If the saturated liquid is a multi-component liquid (e.g. a mixture of propane, iso-butane and normal butane), the flashed vapor is richer in the more volatile components than is the remaining liquid. BLEVE: BLEVE is an acronym for boiling liquid expanding vapor explosion. This is a type of explosion that can occur when a vessel containing a pressurized liquid is ruptured. Such explosions can be extremely hazardous.)

A BLEVE can occur even with a non-flammable substance such as water, liquid nitrogen, liquid helium or other refrigerants or cryogens, and therefore is not usually considered a type of chemical explosion. Rotary evaporator: A rotary evaporator is a device used in chemical laboratories for the efficient and gentle removal of solvents from samples by evaporation. Design: The main components of a modern rotary evaporator are: A motor unit which rotates the evaporation flask or vial containing sample. A vapor duct which acts both as the axis for sample rotation, and as vacuum-tight conduit for the vapor being drawn off of the sample. A vacuum system, to substantially reduce the pressure within the evaporator system. 42

A heated fluid bath, generally water, to heat the sample being evaporated. A condenser with either a coil through which coolant passes, or a "cold finger" into which coolant mixtures like dry ice and acetone are placed. A condensate-collecting flask at the bottom of the condenser, to catch the distilling solvent after it re-condenses. A mechanical or motorized mechanism to quickly lift the evaporation flask from the heating bath.

Application: Rotary evaporation is most often and conveniently applied to separate "low boiling" solvents which are solid at room temperature and pressure such as n-hexane. However, careful application also allows removal of a solvent from a sample containing a liquid compound if there is minimal co-evaporation (azeotropic behavior), and a sufficient difference in boiling points at the chosen temperature and reduced pressure. Solvents with higher boiling points such as water (100 C at standard atmospheric pressure, 760 torr), dimethylformamide (DMF, 153 C at the same), or dimethylsulfoxide (DMSO, 189 C at the same), can also be evaporated if the unit's vacuum system is capable of sufficiently low pressure. Centrifugal evaporator: A centrifugal evaporator is a device used in chemical and biochemical laboratories for the efficient and gentle evaporation of solvents from many samples at the same time, and samples contained in microtitre plates. If only one sample required evaporation then a rotary evaporator is most often used. The most advanced modern centrifugal evaporators not only concentrate many samples at the same time, they eliminate solvent "bumping" (sample loss by violent boiling) and can handle solvents with boiling points of up to 220 C. This is more than adequate for the modern high throughput laboratory.

43

Natural/forced circulation evaporator: Natural circulation evaporators are based on the natural circulation of the product caused by the density differences that arise from heating. In an evaporator using tubing, after the water begins to boil, bubbles will rise and cause circulation, facilitating the separation of the liquid and the vapor at the top of the heating tubes. The amount of evaporation that takes place depends on the temperature difference between the steam and the solution. Falling film evaporator: This type of evaporator is generally made of long tubes (48 meters in length) which are surrounded by steam jackets. The uniform distribution of the solution is important when using this type of evaporator. The solution enters and gains velocity as it flows downward. This gain in velocity is attributed to the vapor being evolved against the heating medium, which flows downward as well. This evaporator is usually applied to highly viscous solutions so it is frequently used in the chemical, food, and fermentation industry. Rising film (Long Tube Vertical) evaporator: In this type of evaporator, boiling takes place inside the tubes, due to heating made (usually by steam) outside the

same. Submergence is therefore not desired; the creation of water vapor bubbles inside the tube creates an ascensional flow enhancing the heat transfer coefficient. This type of evaporator is therefore quite efficient, Plate evaporator: Plate evaporators have a relatively large surface area. The plates are usually corrugated and are supported by frame. During evaporation, steam flows through the channels formed by the free spaces between the plates. The steam alternately climbs and falls parallel to the concentrated liquid. The steam follows a co-current, counter-current path in relation to the liquid. The concentrate and the vapor are both fed into the separation stage where the vapor is sent to a

44

condenser. Plate evaporators are frequently applied in the dairy and fermentation industries since they have spatial flexibility. Multiple-effect evaporators: Unlike single-stage evaporators, these evaporators can be made of up to seven evaporator stages or effects. The energy consumption for single-effect evaporators is very high and makes up most of the cost for an evaporation system. Putting together evaporators saves heat and thus requires less energy. Adding one evaporator to the original decreases the energy consumption to 50% of the original amount. Adding another effect reduces it to 33% and so on.. The number of effects in a multiple-effect evaporator is usually restricted to seven because after that, the equipment cost starts catching up to the money saved from the energy requirement drop. There are two types of feeding that can be used when dealing with multiple-effect evaporators. Forward feeding: takes place when the product enters the system through the first effect, which is at the highest temperature. The product is then partially concentrated as some of the water is transformed into vapor and carried away. It is then fed into the second effect which is a little lower in temperature. The second effect uses the heated vapor created in the first stage as its heating source (hence the saving in energy expenditure). The combination of lower temperatures and higher viscosities in subsequent effects provides good conditions for treating heat-sensitive products like enzymes and proteins. In using this system, an increase in the heating surface area of subsequent effects is required. Backward feeding: In this process, the dilute products are fed into the last effect with has the lowest temperature and is transferred from effect to effect with the temperature increasing. The final concentrate is collected in the hottest effect which provides an advantage in that the product is highly viscous in the last stages so the heat transfer is considerably better.

45

Vacuum evaporation: Vacuum evaporation is the process of causing the pressure in a liquid-filled container to be reduced below the vapor pressure of the liquid, causing the liquid to evaporate at a lower temperature than normal. Although the process can be applied to any type of liquid at any vapor pressure, it is generally used to describe the boiling of water by lowering the container's internal pressure below standard atmospheric pressure and causing the water to boil at room temperature. Vacuum evaporation is also a form of physical vapor deposition used in

the semiconductor, microelectronics, and optical industries and in this context is a process of depositing thin films of material onto surfaces. Such a technique consists of pumping a vacuum chamber to pressures of less than 10 - 5 torr and heating a material to produce a flux of vapor in order to deposit the material onto a surface. The material to be vaporized is typically heated until its vapor pressure is high enough to produce a flux of several Angstroms per second by using an electrically resistive heater or bombardment by a high voltage beam. Forced Evaporation System

46

What is Forced Evaporation System? The sprinkler system works on the principle of forced evaporation in which a pump is used to suck the produced water from the pit and sprays through the nozzles causing the water to form fine mist on the surface of nozzle. The nozzles cause the water to atomize (the conversion of a vaporized sample into atomic components) into very small droplets into the atmosphere. The performance of the system is greatly dependent on atmospheric conditions like temperature, humidity and wind. How do misting systems work? Water is forced through small diameter pipes or hoses to tiny nozzles which release the water in such a fine mist that it appears almost fog like. The droplets are so small most of them will evaporate instantaneously and effectively lower the temperature around us 15-20 degrees. This phenomenon is called flash evaporation.
Water Sprinkler system at Fimkassar oil field Well # 1:

Water Sprinkler system has been improvised at Fimkassar Oil Field Well No. 1 for the disposal of produced water. Equipment: 1 centrifugal pump of capacity 200gpm Delivery line of pump is connected to 6" header of length . On this header, 12 connections have been made of Pipes of Size 1". Length of each pipe is 10, at the end of GI Pipes, spray nozzles have been fitted. 12 Spray nozzles are installed which are in operation for the last 8 Months. Maximum capacity of each nozzle is 1 gpm.

47

Suction Pump Sediment Filteration Pressure Gauge

Flare/Water Pit

Nozzles

Valves

GI Pipes

Sprinkler system at Fimkassar oil field Well # 1

48

Sprinkler Rate Calculation

OIL & GAS DEVELOPMENT COMPANY LIMITED FIMKASSAR OIL FIELD

Water Sprinkler System

No. of Nozzles Nozzle Pressure Pipe Pressure Pump Pressure Losses Elevation Pump Efficiency 12 12 psi 100 psi 244 psi 118.5943 0 67.29% Pump Information Pressure 25 362.5943 Capacity 30 132.086 bar psi cu.m/hr GPM

K-factor 0.949 x (for TF nozzles) 0.5 Nozzle outFlow 3.287432 GPM Total outFlow 39.44919 GPM

Unit Conversion 1 bar 1 cu.m/hr

14.503774 psi 4.4028675 GPM

Note: Nozzle Pressure is selected by the experimental observation of pressure response on shuting each nozzle (one at a time)
Petroleum Engineer UET Dated: 01-08-10

Alternate & Future Recommendations:

Installing Water Treatment Plant will be an additional step towards companys social welfare program. (Agricultural and drinking purposes). Re-Injection into the reservoir. (After proper treatment) Keeping in view the current economic status of this field and land availability construct more pits to enhance solar evaporation OR expand sprinkler system to opposite side of the same pit to increase flash evaporation process.

49

Liquid Holdup
Problem Description: Initially well FMK01 was flowing at relatively constant rate of 1450 bpd & WHFP of 100160 psi for a sufficient long time owing to Injection at FMK03 @ 2000 bwpd (till constant). On 27/07/10 @ 1800 hrs well started cease to flow, WHFP decreased to 7080 psi, and water cut to 8081%. Actions Taken: Under such conditions crew and admin at field decided to reduce choke size in order to stabilize/increase the production rate. As a result of some surges and reduced Choke size production rate increased. Reasons as told by Field Personnel FM, Muhammad Munir Awan: Gas was the main source of energy in the reservoir that was lifting oil to the wellhead, now the gas potential to lift oil has decreased causing liquid to load up in the well. I/C Prod. Muhammad Arif: The well cease to flow due to the build up of water column in the well which exerts backpressure on the formation thus forbidding reservoir to flow into the well.

Literature Review
Liquid Holdup is defined as the fraction of an element of pipe that is occupied by the liquid at some instant. That is (1)

Evidently, if the volume element is small enough the liquid holdup will be either zero or one. It is necessary to be able to determine liquid holdup to calculate such things as mixture density, actual gas and liquid velocities, effective viscosity and heat transfer. In the case of fluctuating flows, such as slug flow, the liquid holdup at a point changes periodically and is taken as the time-averaged value. Experimentally the value of liquid holdup may be measure by several methods for example; 50

Resistivity or Capacitance Probes Nuclear Densitometers Trapping a segment of the flow stream between quick-closing valves and measuring the volume of trapped liquid.

Analytically liquid holdup value cant be calculated. Correlation exists that are widely used for HL value calculation. These correlations are functions of gas and liquid properties, flow pattern, pipe diameter and pipe inclination. In preceeding discussion we will develop a correlation for the HL determination. Density All fluid flow equations require the availability of density value. Calculation of denity changes with changing temperature and pressure. The liquid comprising of oil and water have density calculated by assuming no slippage between oil and water phases as = + (2) Where, L o w fo fw = density of liquid, pcf = density of oil, pcf = density of water, pcf = fractional flow of oil = frational flow of water

Fractional Flow of oil is defined as below, similarly for water. = (3) +

51

Calculation of density of gas/liquid mixture flow requires the knowledge of liquid holdup. Three equations for two-phase density have been used by various investigators of two phase flow. = + (4) = + (5)
2 2 = + (6)

Equationa (4) is used for determine the pressure gradient due to elevation change. Equation (5) is used when no-slippage is assumed. Equation (6) is used when friction loss term and Reynolds number is required. Velocity Many two-phase flow correlations are based on a variable called superfacial velocity. The superfacial velocity of a fluid is defined as the velocity of that phase would exhibit if it flowed through the total crossectional area of the pipe alone. The superfacial gas velocity is calculated from: =

The actual area through which the gas flows is reduced to HgA by the presence of the liquid. Therefore the actual gas velocity is calculated from the following formula. =

Where A is the pipe area. The superfacial and Actual liquid velocities are similarly calculated from: 52

Since HL and Hg are less than one, the actual velocities are greater than the superfacial velocities. The two-phase or mixture velocity is calculated based on the total in-situ flow rate from the equation. + = +

As it has been stated previously, the gas and liquid phases may travel at different velocities in the pipe. Some investigators prefer to evaluate the degree of slippage and thus the liquid holdup by determining a slip velocity s . The slip velocity is defined as the difference between the actual gas and liquid velocities by: = =

Using the previous definitions for the various velocities, alternate forms of the equations for no-slip and actual liquid holdup are: =

and + 2
2

+ 4

1 2

Identifiation of Flow Pattern The manner in which the two phases are distributed in the pipe significantly affects other aspects of two-phase flow, such as slippage between phases and the pressure gradient. The flow regime or flow pattern is a qualitative description of the phase distributon. In gas-liquid, vertical, upward flow, four flow regimes are now generally agreed upon in the two-phase flow 53

literature: bubble, slug, churn, and annular flow. These occur as a progression with increasing gas rate for a given liquid rate. (for detailed description of these flow regimes reader is advised to go through the literature). The flow regime in gas-liquid vertical flow can be predicted with a flow regime map, a plot relating flow regime to flow rates of each phase, fluid properties, and pipe size. One such map that is used for flow regime determination is that of Duns and Ros (1963), shown in figure 7-10. The Duns and Ros map correlates flow regime with two dimensionless numbers, the liquid and gas velocity numbers, Nvl and Nvg, defined as

= 1.938

= 1.938

Where,

sl , sg = superfacial velocities of liquid and gas, fps l go = density of liquid (defined previously ), pcf = interfacial tension of gas-oil, dynes/cm

54

Figure: Duns and Ros map 1 Correlating Velocity Number with Flow regime

Production History Illustrating the Well Problem

FWHP (psi) BOPD 200 180 160 140 120 100 80 60 40 20 0 Choke Size (xx/64") WCT WHFT (deg. F) Gas Rate (mmscfd) 1 0.9 0.8 0.6 WCT, Gas Rate 0.7

Choke size reduced from 50 to 40/64"

0.5 0.4 0.3 0.2 0.1 0

55

Figure: Possible flow regimes that can occur in vertical, multiphase flow.

56

Precautions/Solutions to Liquid Holdup Start up a well quickly to avoid losing the gas dissolved in the oil. Avoid slowly shutting in a well. A quick shut-in will reduce the liquid hold-up. Leave the well shut-in for an extended period of time to allow water to diffuse back into the reservoir, to promote gas dissolution into the oil and to allow the local reservoir pressure to build. Larger diameter tubing is required in the initial life of the well but later on as the reservoir potential declines hold-up can be high in larger diameter tubing then it is necessary to re-optimize the system with smaller diameter tubing. Consider some form of intermittent or kick-off artificial lift scheme (for Offshore wells). Use a conventional artificial lift method.

Sizing production tubing requires economic assessment. A reservoir simulation (numerical, decline curve or material balance) will be required to integrate reservoir performance and reservoir pressure. Pressure traverse means the relationship of pressure with depth. Pressure traverse curves are used to evaluate the well performance, pressure drop calculations in the piping and to optimize the production system. However we have performed a calculation using Standard Tubing Performance (Pressure traverse) Curves (Well Performance, Curtis H. Whitson) in order to evaluate well performance in following three Scenarios. FWHP = 150 psi, Tubing Size = 2.875, GLR = 180 scf/bbl, FOPR = 200 bpd, BHP = 2750 psi FWHP = 150 psi, Tubing Size = 3.5, GLR = 180 scf/bbl. FOPR = 200 bpd, BHP = 2900 psi FWHP = 100 psi, Tubing Size = 3.5, GLR = 364 scf/bbl, FOPR = 140 bpd, BHP = 2464 psi

57

Economical View Gas Crude Oil Revenue Revenue (Rs.

(Rs. Millions) 45.142 54.720 55.733 54.941 48.508 34.371 33.717 25.249 31.561 28.640 Millions) 0.500 0.578 0.569 0.595 0.582 0.665 0.921 0.827 0.942 0.929

Months Jul-08 Aug-08 Sep-08 Oct-08 Nov-08 Dec-08 Jan-09 Feb-09 Mar-09 Apr-09

Total BOE
8528.5 10105.6 10198.0 10618.8 10221.0 10923.8 10858.5 9721.7 11283.9 11103.0

Total Revenue
(Rs. Millions) 45.642 55.298 56.302 55.536 49.089 34.976 34.313 25.783 32.170 29.570

Total Expenditure Cost Per bbls. Rs. (Rs. Millions)

9.397 7.591 10.551 7.810 8.072 7.752 6.337 6.431 6.858 6.951 1102 751 1035 735 790 710 584 660 608 626

Total

412.582

7.108

103563

419

78

58

OI L & GA S D EV ELOP M EN T COM P A N Y LI M I TED F I M K A SSA R OI L F I ELD R EV EN U E / EX P EN D I TU R E A N D COST P ER B B L

100000.000 Crude Oil Revenue (Rs. Millions) Gas Revenue (Rs. Millions)

Total BOE

Total BOE

Rs. (Millions) / BBLS

1000.000 Total Revenue (Rs. Millions) Total Expenditure (Rs. Millions) Cost Per bbls. Rs.

Cost Per bbl Rs. Crude oil Rev. /Total Rev. Rs. Millions Total Exp. Rs. Millions

10.000

0.100 Jul-08 Aug-08

Gas Rev. Rs. Millions

Sep-08 Oct-08 Nov-08 Dec-08 Jan-09 Feb-09 Mar-09 Apr-09

Months

OI L & GA S D EV ELOP M EN T COM P A N Y LI M I TED F I M K A SSA R OI L F I ELD

R e v e n u e / Ex p e n d i t u r e a n d Co s t P e r b b l
60.000 1200

Revenue Rs. Million

50.000 1000 Revenue (Rs. Millions) 40.000 800 Expenditure (Rs. Millions)

Revenue / Expenditure

30.000

600

Cost Per bbl Rs.

Cost Per bbls. Rs.

10.000

200

0.000 Jul-08 Aug-08 Sep-08 Oct-08 Nov-08 Dec-08 Jan-09 Feb-09 Mar-09 Apr-09

Months

Cost Per bbl

20.000

Expenditure Rs. Million

400

59

OI L & GA S D EV ELOP M EN T COM P A N Y LI M I T ED

F I M K A SSA R OI L F I ELD
M ON TH LY GA S P R OD U CTI ON / SA LE W .E.F JU LY -2 0 0 8 TO A P R I L-2 0 0 9
14.000

12.000

10.000

GAS PROD SALE GAS

MMSCF

8.000

6.000

4.000

2.000

0.000 Jul-08 Aug-08 Sep-08 Oct-08 Nov-08 Dec-08 Jan-09 Feb-09 Mar-09 Apr-09

MONTHS

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HSEQ (Health Safety Environment and Quality Policy)

According to the rules assigned by HSE, PPE is provided to employs. Without PPE no one is allowed to work in yard. PPE includes Hard hat Safety shoes Safety glasses Appropriate clothing (coverall) Hand gloves This is minimum PPE requirement, in maximum PPE mask, and ear plugs are included. Emergency assembly point and procedure is guided to every visitor, employ and inspection team. In case of emergency everyone has to gather at a common point called Muster point. There are also first aid boxes and emergency showers provided at fix points in case of emergency. First aid box must not contain any medicine, because some medicines can be allergic to someone. Personal Lift Capacity A person is not allowed to lift more than 22 kg. Safety lifting procedure should be used in lifting weight. Do not put weight on our back; try to lift by putting weight on thighs rather than on back bone. In case of heavier weights, fork lifter is used. Care should be taken while lifting equipment with fork lifter. Do not stand under the forks of lifter. Plug should be inserted in forks leg while lifting, so that weight should not fall. Avoid Jokes There should be no horse play and physical jokes. Other Safety Requirements No smoking inside accommodation Alarm systems and mustering points for office and yards 61

Waste management responsibility House keeping Emergency situations and contact at location Designated smoking areas, no Alcohol and drugs, Mobile phone and over speeding and safety belts.

12 Life saving Rules

Work Permit Gas Tests Lockout-Tag out Confined Space System Override Safety Harness Suspended Loads Designated Smoking Areas No Alcohol & Drug Mobile Phone & over Speeding Safety Belt Journey Management

Prompt Cure for Chemical (Acid/alkali) base Burnt Keep on washing affected part with cold, clean and excess of water Remove the affected clothe from the corresponding part In case Eyes are affected by the chemical splash 1. Dip your face in water and keep on blinking your eyes 2. Use Eye wash lotion 3. Come under the nearby water tap and wash your eyes properly. Repeat this process for atleast 20 minutes. In case Skin is affected by the chemical 62

1. Wash properly the affected part with fresh water 2. Ask someone else to wash your affected part with water 3. Remove the affected clothe from your body 4. Place the affected part under a water tap. As a precaution, consult any doctor later on.

In case theyre swallowed Swallowing them by mistake may cause vomiting and bad digestion. Possibly affect these organs 1) respiraFire Extinguishing
System

Carbon Dioxide Extinguisher (5 kg) Where to use: 1. Open the seal and press the lever by hand. 2. Grip the pipe from the recommended portion. 3. Direct the stream towards flame. 4. Prevent touching the gas exhaust pipe. Precautions: Try extinguishing the fire according to air direction. Foam Type Extinguisher (10 litres) Where to use: Used for initial stage fire of oil along with wood, paper and cloth. How to use: Open and erect the hose pipe. Grip the nozzle with left hand and from right hand fully open the mixture valve by rotating it anticlockwise. Laid it down horizontally using handle and immediately open the control valve in opposite direction. Point the stream of liquid foam to the flame origin. 63

If fire is eradicated immediately place the extinguisher in vertical direction (former position) so that remaining gas is exhausted.

Precautions: 1. Wash twice after using fire extinguisher. 2. It is dangerous to use it on electrical wiring and equipments. Water Pipe Extinguisher (10 litres) Where to use: Used for solid fire (paper, wood, cloth, rubber, husk etc.) 1. Keep extinguisher vertical 2. Remove safety pin 3. Fully press the handle 4. Point the exiting foamy stream towards flames. 5. Never use on electric wires 1. Never hang on wall immediate after use, instead place it on the floor. 2. Ask the concerned authority to Refill it.

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