Pressure Analysis and Oil Well Study

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Pressure Analysis Of Hydraulic Power Pack Used In Coil Tubing And Study Of Oil Development Well
PROJECT ADVISOR
Engr. Zahid Suleman Butt

(Asst. Professor)
ISSUING COMPANY
SPRINT OIL AND GAS SERVICES

AUTHORS Aamir Raza Muhammad Umer Saad Arshad Muhammad Imran 07-ME-47 07-ME-87 07-ME-141 07-ME-149
Department Of Mechanical Engineering University Of Engineering And Technology Taxila

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Pressure Analysis Of Hydraulic Power Pack Used In Coil Tubing And Study Of Oil Development Well
A dissertation submitted as a part of the degree program required for BSc In MECHANICAL ENGINEERING
By
Aamir Raza Muhammad Umer Saad Arshad Muhammad Imran 07-ME-47 07-ME-87 07-ME-141 07-ME-149
ISSUING COMPANY SPRINT OIL AND GAS SERVICES
Internal Examiner
Asst. Prof Zahid Suleman Butt
External Examiner
Department Of Mechanical Engineering University Of Engineering And Technology Taxila

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DEDICATION
Dedicated with great respect to, Our beloved parents Who at every stage of their Life sacrificed and Endeavored for our Well being and progress, and Encourage us in every field of life
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ACKNOWLEDGEMENT
All praise and thanks to ALLAH Al-mighty who gave us valor and vigor for successfully completion of such a momentous project. No book is the result of Authors only; it includes also the precious contribution of others, which pave the patch of triumph and immortality to the book. Same is true for this thesis work.
The effort embodies in this manuscript attained its present form under the vibrant and skillful leadership of Engr. Zahid Suleman Butt (Asst Professor) who made it all possible for us.
Heartfelt thanks are extended to Mr. Sami Ullah (HSE Officer CCDC), Mr. Affnan Ahmed Dar (Technical Engineer SPRINT OIL), Mr. Fakhar (Senior Operator SPRINT OIL), Mr. Javed Iqbal (Executive Engineer SPRINT OIL), Mr. Atta Ullah (Senior Operator SPRINT OIL). Their thorough guidance led us successful development of our final year project.
They encouraged us to prepare this project and enabling us to eradicate the errors and augment the program. We also thank Mr. Zahoor Mohyuddin (OGDCL), Mr. Asif Anjum (MOL), Mr. Ali Arshad (CAMERON), and MR. NOUMAN ARSHAD (SNGPL).
We find no words in our grasp to articulate our gratitude and profound obligation to our treasured and affectionate parents, who always remembered us in their prayers and as such we always deem them as divine source of inspiration.
Authors
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ABSTRACT
Oil is the most important and basic requirement in todays world as it is the key source of energy. Ever since the dawn of industrial age oil industry has become the most critical part for the development of any industry or nation. It is also the key factor which affects the prices and as a result the economy of any country. We have seen in the past century that the most developed nations are those which are leading in the race of Black Gold (OIL). Oil exploration has taken dramatic changes over the past few decades. Off shore exploration has seen extreme turns and oil wells and fields are being built in the most hostile of the environments. In engineering works we often come cross certain set of problems with our process or equipment which cause bottle necking, limiting the performance of the process or the efficiency of the equipment. De-bottle necking is performed to increase the efficiency of the equipment. Keeping this in mind we selected this project Pressure analysis of hydraulic power pack and study of an oil exploratory well the topic of our final year project. In the first part the true suggestions were provided to the Sprint Oil and Gas Company as a reference for future modifications nature and working of any oil exploratory well and rig was studied to understand this typical and most important industry. After sound knowledge of the working of a rig we came to the second part of our project which was basically an industrial problem. The problem is a concern for all service providers giving Coil Tubing Services to Oil drilling companies in Pakistan. As a part of this project experimentation was performed on the Coil Tubing unit in order to determine the main causes of the faults occurring. Through study and experimentation we were enable to diagnose and analyze the problem and solve it. A new intermediate and modified circuit was designed on AUTOCAD 2006 while solutions and.
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TABLE OF CONTENTS
Chapter#1 INTRODUCTION TO OIL AND GAS WELL..................... 1
1.1 INTRODUCTION ................................................................................................................................. 1 1.2 HISTORY ............................................................................................................................................. 1 1.3 CREATION AND LIFE OF A WELL ........................................................................................................ 2 1.3.1 1.3.2 1.3.3 1.3.4 1.3.5 PLANNING ......................................................................................................................... 2 DRILLING ........................................................................................................................... 3 COMPLETION..................................................................................................................... 4 PRODUCTION .................................................................................................................... 4 ABANDONMENT ............................................................................................................... 5
1.4 TYPES OF WELLS ................................................................................................................................ 5
Chapter#2
DRILLING OF OIL AND GAS WELLS .............. 8
2.1 INTRODUCTION ................................................................................................................................. 8 2.2 DRILL BITS IN MECHANICAL DRILLING............................................................................................... 8 2.2.1 TYPES OF DRILL BITS .............................................................................................................. 8 2.3 THE DRILLING FLUID .......................................................................................................................... 9 2.3.1 DRILLING FLUID MAJOR FUNCTIONS .................................................................................... 9 2.3.2 THE DRILLING FLUID PREPARATION AREA ............................................................................ 9 2.4 CASING AND CEMENTING ............................................................................................................... 10 2.4.1 2.4.2 CASING ............................................................................................................................ 10 CEMENTING .................................................................................................................... 10
2.5 RIG ................................................................................................................................................... 11 2.5.1 DRILLING RIG BACKGROUND .............................................................................................. 12 2.5.2 EVALUATING AND SELECTING RIGS .................................................................................... 12 2.6 DRILLING RIG CLASSIFICATION ........................................................................................................ 13 2.7 TYPES OF DRILLING RIGS: ................................................................................................................ 14 2.8 THE ROTARY DRILLING RIG: ............................................................................................................. 14 2.8.2 OPERATIONS IN A DRILLING RIG: ........................................................................................ 15 2.9 THE RIG CREW ................................................................................................................................. 19
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Chapter#3
WELL COMPLETION .....................................21
3.1 INTRODUCTION ............................................................................................................................... 21 3.2 COMPLETION ................................................................................................................................... 21 3.3 Well Completion Activities: ............................................................................................................. 21 3.3.1 CONDUCTING DRILL STEM TEST .......................................................................................... 21 3.3.2 SETTING PRODUCTION CASING........................................................................................... 21 3.3.3 INSTALLING PRODUCTION TUBING ..................................................................................... 22 3.3.4 STARTING PRODUCTION FLOW ........................................................................................... 22 3.3.5 BEAM PUMPING UNITS ....................................................................................................... 22 3.4 TYPES OF COMPLETION ................................................................................................................... 22 3.4.1 BAREFOOT COMPLETION .................................................................................................... 23 3.4.2 OPENHOLE COMPLETION .................................................................................................... 23 3.4.3 CASED HOLE COMPLETION ................................................................................................. 24 3.5 COMPLETION COMPONENTS: ......................................................................................................... 24 3.6 PERFORATING AND STIMULATING.................................................................................................. 27 3.6.1 ACIDIZING ............................................................................................................................ 27 3.6.2 FRACTURING ....................................................................................................................... 28 3.6.3 ACIDIZING AND FRACTURING (Combined Method) ............................................................ 28 3.6.4 NITROGEN CIRCULATION .................................................................................................... 28
Chapter#4
WELL TESTING ................................................29
4.1 INTRODUCTION ............................................................................................................................... 29 4.2 TYPES OF WELL TESTS ..................................................................................................................... 29 4.2.1 DRILL STEM TEST: ................................................................................................................ 29 4.2.2 POTENTIAL TEST: ................................................................................................................. 30 4.2.3 BOTTOM-HOLE PRESSURE TEST: ......................................................................................... 30 4.2.4 TRANSIENT PRESSURE TESTING: ......................................................................................... 30 4.2.5 PRODUCTIVITY TESTS: ......................................................................................................... 30 4.2.6 ROUTINE PRODUCTION TESTS ............................................................................................ 30 4.2.7 BOTTOMHOLE TEMPERATURE DETERMINATION: ............................................................ 31 4.2.8 WATER ANALYSIS: ............................................................................................................... 31
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Chapter#5
.......33
5.1 INTRODUCTION ............................................................................................................................... 33 5.2 PRESSURE ANALYSIS OF HYDRAULIC POWER PACK ........................................................................ 34 5.2.1 EXPLANATION OF PROBLEM ............................................................................................... 35 5.2.2 CRITICALITY OF THE PROBLEM ............................................................................................ 35 5.3 WORKING AND RESEARCH PHASES ................................................................................................. 35 5.4 TESTING OF EQUIPMENT................................................................................................................. 36 5.4.1 FUNCTIONAL TESTING OF PUMP ........................................................................................ 36 5.4.2 PULL TEST ............................................................................................................................ 37
Chapter#6 ...................................................................................................41
6.1 COIL TUBING .................................................................................................................................. 41 6.1.1 INTRODUCTION .............................................................................................................................. 41 6.1.2 HISTORY............................................................................................................................... 42 6.1.3 COIL TUBING EQUIPMENT .................................................................................................. 44 6.1.4 WELL AND PRESSURE CONTROL EQUIPMENT .................................................................... 50 6.1.5 COIL TUBING APPLICATIONS ............................................................................................... 52 6.2 DRILLING.......................................................................................................................................... 56 6.2.1 Directional Wells ................................................................................................................. 56 6.2.2 Non-Directional Wells ......................................................................................................... 56 6.2.3 Overbalanced Coil Tubing Drilling ....................................................................................... 57 6.2.4 Underbalanced Coil Tubing Drilling..................................................................................... 57 6.3 PIPELINE APPLICATIONS: ................................................................................................................. 57 6.3.1 LAND BASED ........................................................................................................................ 57 6.3.2 OFF SHORE .......................................................................................................................... 58 6.3.3 VELOCITY STRINGS .............................................................................................................. 58 6.4 CIRCUIT USED IN POWER PACK ....................................................................................................... 58 6.4.1 OPEN LOOP SYSTEM ............................................................................................................ 58 6.4.2 COMPONENTS OF OPEN LOOP CIRCUIT.............................................................................. 61
Chapter#7
ANALYSIS AND DIAGNOSIS......................63

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7.1 INTRODUCTION ............................................................................................................................... 63 7.2 METHOD OF ANALYSIS .................................................................................................................... 63 7.2.1 DESIGN FEATURES ............................................................................................................... 63 7.2.2 MODIFICATIONS .................................................................................................................. 64 7.2.3 MAINTENANCE .................................................................................................................... 64 7.2.4 USAGE ................................................................................................................................. 65
Chapter#8
DATA ACCUMULATION ................................66
8.1 PUMPS ............................................................................................................................................. 66 8.1.1 WORKING ............................................................................................................................ 66 8.1.2 ADVANTAGES VANE TYPE PUMPS....................................................................................... 67 8.1.3 DISADVANTAGES OF VANE TYPE PUMPS ............................................................................ 67 8.1.4 APPLICATIONS OF VANE TYPE PUMPS ................................................................................ 67 8.1.5 PUMP SPECIFICATIONS CHART ........................................................................................... 68 8.2 COOLING FLUID AND COOLING MECHANISM ................................................................................. 68 8.2.1 Measures Taken During Operation ..................................................................................... 68 8.2.2 USAGE ................................................................................................................................. 69 8.2.3 DESCRIPTION ....................................................................................................................... 69 8.2.4 FEATURES AND BENEFITS .................................................................................................... 69 8.2.5 APPLICATIONS ..................................................................................................................... 70 8.2.6 RESULT: ............................................................................................................................... 72 8.3 HYDRAULIC CIRCUITS ...................................................................................................................... 72 8.3.1 BASIC PROBLEMS ................................................................................................................ 72 8.3.2 OPEN LOOP SYSTEMS .......................................................................................................... 72 8.3.3 CLOSED LOOP SYSTEM ........................................................................................................ 73 8.3.4 COMPARISON BETWEEN OPEN AND CLOSED LOOP CIRCUIT ............................................. 74 8.3.5 CIRCUIT DIAGRAMS............................................................................................................... 75 8.4 COOLING TANK ................................................................................................................................ 82 8.4.1 CAPACITY OF THE TANK ...................................................................................................... 82 8.4.2 RESULT ................................................................................................................................ 83 8.5 ASSEMBLY OF PUMPS ..................................................................................................................... 83 8.5.1 INTRODUCTION ................................................................................................................... 83
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8.5.2 PARALLEL COMBINATION OF PUMPS ................................................................................. 83 8.5.3 SERIES COMBINATION OF PUMPS ...................................................................................... 84 8.5.4 CIRCUIT CONFIGURATION ................................................................................................... 84 8.5.5 ASSEMBLY AND USE OF THE PUMPS INSTALLED ................................................................ 85 8.5.6 RESULTS:.............................................................................................................................. 86 8.6 HEAT EXCHANGER .......................................................................................................................... 86 8.6.1 INTRODUCTION ................................................................................................................... 86 8.6.2 BASIC PROBLEM .................................................................................................................. 87 8.6.3 SOLUTION ............................................................................................................................ 87 8.7 MAINTENANCE ................................................................................................................................ 88 8.7.1 PREVENTIVE MAINTENANCE ............................................................................................... 89 8.7.2 FREQUENCY MAINTENANCE ............................................................................................... 89 8.7.3 EXPLANATION...................................................................................................................... 90 8.7.4 RESULTS............................................................................................................................... 90 8.8 MODIFICATION ................................................................................................................................ 90 8.9 RESULTS DEDUCED......................................................................................................................... 91
Chapter#9
SOLUTION AND SUGGESTIONS .........94
9.1 INTRODUCTION ............................................................................................................................... 94 9.2 COOLING TANK ................................................................................................................................ 94 9.2.1 SOLUTION ............................................................................................................................ 95 9.3 MAINTENANCE ............................................................................................................................... 95 9.3.1 SOLUTION ............................................................................................................................ 95 9.4 CIRCUIT USED .................................................................................................................................. 95 9.4.1 INTRODUCTION ................................................................................................................... 95 9.4.2 ADVANTAGES OF THIS CIRCUIT ........................................................................................... 96 9.4.3 SOLUTION ............................................................................................................................ 97 9.5 MODIFIED CIRCUIT .......................................................................................................................... 98 9.5.1 CONSTRUCTION .................................................................................................................. 99 9.5.2 ADVANTAGES .................................................................................................................... 100 9.5.3 SOLUTION .......................................................................................................................... 100 9.6 SUGGESTIONS ............................................................................................................................... 101
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TABLE OF FIGURES
Figure 1: Drag Bit .................................................................................................................................................. 8 Figure 2: Rolling Bit.............................................................................................................................................. 8 Figure 3: Drag Bit .................................................................................................................................................. 8 Figure 4: Diamond Bit ......................................................................................................................................... 9 Figure 5: PPL Rig ADHI Oil Field .................................................................................................................. 12 Figure 6: Components Of Oil Rig .................................................................................................................. 15 Figure 7: Coil Tubing Being Rigged Up ...................................................................................................... 16 Figure 8: Circulation System.......................................................................................................................... 18 Figure 9: Electric Generators at PPL Rig ................................................................................................... 19 Figure 10: Christmas Tree at PPL Rig ........................................................................................................ 25 Figure 11: Potential & Associated Tests.................................................................................................... 31 Figure 12: Pull Test Being Performed ........................................................................................................ 38 Figure 13: Function Test Being Performed .............................................................................................. 39 Figure 14: Coil Tubing Trailer ....................................................................................................................... 44 Figure 15: Tubing Reel ..................................................................................................................................... 45 Figure 16: Injector Head.................................................................................................................................. 46 Figure 17: Hydraulic Power Pack ................................................................................................................ 47 Figure 18: Coil Tubing Control Cabin ......................................................................................................... 49 Figure 19: Coil Tubing Plastic deformation Points ............................................................................... 51 Figure 20: Coil Tubing Blow Out Preventer ............................................................................................. 51 Figure 21: Block Diagram of Open Loop Circuit..................................................................................... 59 Figure 22: Schematic of Open Loop Circuit .............................................................................................. 59 Figure 23: Vane Type Installed In Power Pack ....................................................................................... 66 Figure 24: Schematic of Open loop Circuit ............................................................................................... 73 Figure 25: Schematic of Closed Loop Circuit ........................................................................................... 73 Figure 26: BOP Hydraulic Circuit on Power Pack.................................................................................. 76 Figure 27: Auxiliary Circuit On Power Pack ............................................................................................ 77 Figure 28: Priority, Reel & Over-rider Hydraulic Circuit On Power Pack .................................... 78 Figure 29: Injector Hydraulic Circuit in Power Pack............................................................................ 79 Figure 30: Hydraulic Reservoir in Power Pack ...................................................................................... 82 Figure 31: Head Vs Flow Rate-Parallel Combination ........................................................................... 83 Figure 32: Head Vs Flow Rate-Series Combination .............................................................................. 84 Figure 33: Heat Exchanger in Power Pack ............................................................................................... 86 Figure 34: Intermediate circuit connected with an ECM .................................................................... 97 Figure 35: Un-Modified Circuit ..................................................................................................................... 98 Figure 36: Modified Circuit ............................................................................................................................ 99 [xii]
TABLE OF TABLES
Table 1: Function Of Hydraulic Power Pack ............................................................................................ 48 Table 2: Coil Tubing Applications ................................................................................................................ 53 Table 3: Advantages Of Open loop system ............................................................................................... 61 Table 4: Features and Advantages of Cooling Fluids ........................................................................... 70 Table 5: Properties of Mobile DTE 26 ........................................................................................................ 71 Table 6: Comparison between Swatch and Vane Type Pumps ........................................................ 75 Table 7: Hydraulic Pumps Specifications ................................................................................................. 79 Table 8: Key Of Above Circuit ........................................................................................................................ 80
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INTRODUCTION TO OIL AND GAS WELLS
Chapter#1
1.1 INTRODUCTION
INTRODUCTION TO OIL AND GAS WELL
Wood and coal were used to heat and cook with, while whale oil was used for light. The black, smelly, thick liquid is referred to as tar or rock oil was only seen as a substance to avoid. When the whaling industry hunted the sperm whale almost to extinction and the Industrial Revolution needed a fuel to run generators and engines, a new source of energy was needed. In the search for new products, it was discovered that from crude oil or petroleum, kerosene could be extracted and used as a light and heating fuel. Petroleum was in demand at the end of the 1800's. Early oil pioneers noted that oil could be found near oil seeps. As drilling equipment was developed in the 1800's, searching for water and salt, oil finders decided to drill for oil. As drilling started, they recognized that the rocks gave them clues to where the oil was trapped. They noted that sedimentary rocks, especially sandstones, would contain the black liquid. An oil well is a term for any perforation through the Earth's surface designed to find and release both petroleum oil and gas hydrocarbons. Since the turn of 20th century, rotary drilling has been a dominant technique for well production in the oil and gas industry.
1.2 HISTORY
Oil wells are drilled in China up to 800 feet deep using bits attached to bamboo poles in 347 A.D. From the 9th century, oil fields were exploited in the area around modern Baku, Azerbaijan, to produce naphtha for the petroleum industry of the medieval Islamic world. These fields were described by Al-Masudi in the 10th century, and by Marco Polo in the 13th century, who described the output of those oil wells as hundreds of shiploads. When Marco Polo in 1264 visited the Azerbaijani city of Baku, on the shores of the Caspian Sea, he saw oil being collected from seeps. He wrote that "on the confines toward Geirgine there is a fountain from which oil springs in great abundance, in as much as a hundred shiploads might be taken from it at one time." Shallow pits were dug at the Baku seeps in ancient times to facilitate collecting oil, and handdug holes up to 35 meters (115 feet) deep were in use by 1594. These holes were essentially oil wells, which makes Baku the first true field. Apparently 116 of these wells in 1830 produced 3,840 metric tons (about 28000 barrels) of oil. In 1849, Russian engineer F.N. Semenov used a cable tool to drill an oil well on the Apsheron Peninsula, ten year before Colonel Drake's 1

famous well in Pennsylvania. Also, offshore drilling started up at Baku at Bibi-Eibat field near the end of the 19th century, about the same time that the "first" offshore oil well was drilled in 1896 at Summerland field on the California Coast. The earliest oil wells were drilled percussively by hammering a cable tool into the earth. Soon after, cable tools were replaced with rotary drilling, which could drill boreholes too much greater depths and in less time. The record-depth Kola Borehole used non-rotary mud motor drilling to achieve a depth of over 12 000 meters (38,000 feet). Until the 1970s, most oil wells were vertical (although different methodology and mechanical imperfections cause most wells to deviate at least slightly from true vertical). However, modern directional drilling technologies allow for strongly deviated wells which can, given sufficient depth and with the proper tools, actually become horizontal. This is of great value as the reservoir rocks which contain hydrocarbons are usually horizontal, or sub- horizontal; a horizontal wellbore placed in a production zone has more surface area in the production zone than a vertical well, resulting in a higher production rate. The use of deviated and horizontal drilling has also made it possible to reach reservoirs several kilometers or miles away from the drilling location (extended reach drilling), allowing for the production of hydrocarbons located below locations that are either difficult to place a drilling rig on, environmentally sensitive, or populated.
1.3 CREATION AND LIFE OF A WELL

The creation and life of a well can be divided up into five segments:
1.3.1
Planning Drilling Completion Production Abandonment

PLANNING
Effective least cost drilling, or optimization, begins with good well planning. Every well is not a wild cat. Other wells in the area of interest can be a good source of information for a drilling project. Well planning includes these three areas of interest: 1. Cost per foot of the drilling system. 2. Character of the formation to be penetrated. 3. Character of producing formation. Cost per foot is the ultimate indicator of drilling success. Drilling system is selected according to the expected depth of the producing zone. Cable tool drilling system is preferable in many 2

shallow-producing areas. Rotary rig is used for deeper wells. Optimum size of the drilling rig must be determined. Several factors enter into the selection of the rig, including casing requirement, bit size and type, nature of formation, speed and safety of operation and geological characteristics.
1.3.2 DRILLING
The well is created by drilling a hole 5 to 30 inches (13 76 cm) diameter into the earth with an oil platform which rotates a drill bit. After the hole is drilled, a steel pipe (casing) slightly smaller than the hole is placed in the hole, and secured with cement. The casing provides structural integrity to the newly drilled wellbore in addition to isolating potentially dangerous high pressure zones from each other and from the surface. With these zones safely isolated and the formation protected by the casing, the well can be drilled deeper (into potentially moreunstable and violent formations) with a smaller bit, and also cased with a smaller size casing. Modern wells often have 2-5 sets of subsequently smaller hole sizes drilled inside one another, each cemented with casing. To drill the well, The drill bit, aided by the weight of drill string and drill collars above it, breaks up the earth. Drilling fluid (aka "mud") is pumped down the inside of the drill pipe and exits at the drill bit and aids to break up the rock, keeping pressure on top of the bit, as well as cleaning, cooling and lubricating the bit. The generated rock "cuttings" are swept up by the drilling fluid as it circulates back surface outside the drill pipe. The fluid then goes through "shakers" which strain the cuttings from the good fluid which is returned to the bit. Watching for abnormalities in the returning cuttings and volume of returning fluid are imperative to catch "kicks" (when the pressure below the bit is more than that above, causing gas and mud to come up uncontrollably) early. The pipe or drill string to which the bit is attached is gradually lengthened as the well gets deeper by screwing in several 30-foot (10 m) joints of pipe at surface. Usually joints are combined into 3 joints equaling 1 stand. Some smaller rigs only use 2 joints and newer rigs can handle stands of 4 joints. This process is all facilitated by a drilling rig which contains all necessary equipment to circulate the drilling fluid, hoist and turn the pipe, control down hole pressures, remove cuttings from the drilling fluid, and generate onsite power for these operations.

1.3.3 COMPLETION
After drilling and casing the well, it must be 'completed'. Completion is the process in which the well is enabled to produce oil or gas. In a cased-hole completion, small holes called perforations are made in the portion of the casing which passed through the production zone, to provide a path for the oil to flow from the surrounding rock into the production tubing. In open hole completion, often 'sand screens' or a 'gravel pack' is installed in the last drilled, uncased reservoir section. These maintain structural integrity of the wellbore in the absence of casing, while still allowing flow from the reservoir into the wellbore. Screens also control the migration of formation sands into production tubular and surface equipment, which can cause washouts and other problems, particularly from unconsolidated sand formations in offshore fields. After a flow path is made, acids and fracturing fluids are pumped into the well to fracture, clean, or otherwise prepare and stimulate the reservoir rock to optimally produce hydrocarbons into the wellbore. Finally, the area above the reservoir section of the well is packed off inside the casing, and connected to the surface via a smaller diameter pipe called tubing. This arrangement provides a redundant barrier to leaks of hydrocarbons as well as allowing damaged sections to be replaced. Also, the smaller diameter of the tubing produces hydrocarbons at an increased velocity in order to overcome the hydrostatic effects of heavy fluids such as water. In many wells, the natural pressure of the subsurface reservoir is high enough for the oil or gas to flow to the surface. However, this is not always the case, especially in depleted fields where the pressures have been lowered by other producing wells, or in low permeability oil reservoirs. Installing smaller diameter tubing may be enough to help the production, but artificial lift methods may also be needed. Common solutions include down hole pumps, gas lift, or surface pump jacks. The use of artificial lift technology in a field is often termed as "secondary recovery" in the industry. Many new systems in the last ten years have been introduced for well completion. Multiple packer systems with frac ports or port collars in an all in one system have cut completion costs and improved production, especially in the case of horizontal wells. These new systems allow casings to run into the lateral zone with proper packer/frac port placement for optimal hydrocarbon recovery.
1.3.4 PRODUCTION
The production stage is the most important stage of a well's life, when the oil and gas are produced. By this time, the oil rigs and work over rigs used to drill and complete the well have moved off the wellbore, and the top is usually outfitted with a collection of valves called a wellhead. These valves regulate pressures, control flows, and allow access to the wellbore in case further completion work is needed. From the outlet valve of the wellhead, the flow can 4

be connected to a distribution network of pipelines and tanks to supply the product to refineries, natural gas compressor stations, or oil export terminals. As long as the pressure in the reservoir remains high enough, the wellhead is all that is required to produce the well. If the pressure depletes and it is considered economically viable, an artificial lift method mentioned in the completions section can be employed. Workovers are often necessary in older wells, which may need smaller diameter tubing, scale or paraffin removal, acid matrix jobs, or completing new zones of interest in a shallower reservoir. Such remedial work can be performed using workover rigs also known as pulling units to pull and replace tubing, or by the use of a well intervention technique called coiled tubing. Enhanced recovery methods such as water-flooding, steam flooding, or CO2 flooding may be used to increase reservoir pressure and provide a "sweep" effect to push hydrocarbons out of the reservoir. Such methods require the use of injection wells (often chosen from old production wells in a carefully determined pattern), and are used when facing problems with reservoir pressure depletion, high oil viscosity, or can even be employed early in a field's life. In certain cases depending on the reservoir's geomechanics reservoir engineers may determine that ultimate recoverable oil may be increased by applying a water-flooding strategy early in the field's development rather than later. Such enhanced recovery techniques are often called "tertiary recovery".
1.3.5 ABANDONMENT
When the well no longer produces or produces so poorly that it is a liability, it is abandoned. In this process, tubing is removed from the well and sections of well bore are filled with cement to isolate the flow path between gas and water zones from each other, as well as the surface. Completely filling the well bore with cement is costly and unnecessary. The surface around the wellhead is then excavated, and the wellhead and casing are cut off, a cap is welded in place and then buried.
1.4 TYPES OF WELLS

Oil wells come in many varieties. By produced fluid, there can be wells that produce oil, wells that produce oil and natural gas, or wells that only produce natural gas. Natural gas is almost always a byproduct of producing oil, since the small, light gas carbon chains come out of solution as it undergoes pressure reduction from the reservoir to the surface, similar to uncapping a bottle of soda pop where the carbon dioxide effervesces. Unwanted natural gas can be a disposal problem at the well site. If there is not a market for natural gas near the wellhead it is virtually valueless since it must be piped to the end user. Until recently, such unwanted gas was burned off at the well-site, but due to environmental concerns this practice 5

is becoming less common. Often, unwanted (or 'stranded' gas without a market) gas is pumped back into the reservoir with an 'injection' well for disposal or re pressurizing the producing formation. Another solution is to export the natural gas as a liquid. In locations such as the United States with a high natural gas demand, pipelines are constructed to take the gas from the well-site to the end consumer. Another obvious way to classify oil wells is by land or offshore wells. There is very little difference in the well itself. An offshore well targets a reservoir that happens to be underneath an ocean. Due to logistics, drilling an offshore well is far more costly than an onshore well. By far the most common type is the onshore well. These wells dot the Southern and Central Great Plains, Southwestern United States, and are the most common well in the Middle East. Another way to classify oil wells is by their purpose in contributing to the development of a resource. They can be characterized as: Production wells are drilled primarily for producing oil or gas, once the producing structure and characteristics are determined Appraisal wells are used to assess characteristics (such as flow rate) of a proven hydrocarbon accumulation Exploration wells are drilled purely for exploratory (information gathering) purposes in a new area Wildcat wells are drilled based on a large element of hope, in a frontier area where little is known about the subsurface. In the early days of oil exploration in Texas, wildcats were common as productive areas were not yet established. In modern times, oil exploration in many areas has reached a very mature phase and the chances of finding oil simply by drilling at random are very low, and much more effort is placed in exploration and appraisal wells. At a producing well site, active wells may be further categorized as: Oil producers producing predominantly liquid hydrocarbons, but mostly with some associated gas. Gas producers producing almost entirely gaseous hydrocarbons. Water injectors injecting water into the formation to maintain reservoir pressure or simply to dispose of water produced with the hydrocarbons because even after treatment, it would be too oily and too saline to be considered clean for dumping overboard, let alone into a fresh water source, in the case of onshore wells. Frequently water injection has an element of reservoir management and produced water disposal.

Aquifer producers intentionally producing reservoir water for re-injection to manage pressure. This is in effect moving reservoir water from where it is not as useful to where it is more useful. These wells will generally only be used if produced water from the oil or gas producers is insufficient for reservoir management purposes. Using aquifer produced water rather than sea water is due to the chemistry. Gas injectors injecting gas into the reservoir often as a means of disposal or sequestering for later production, but also to maintain reservoir pressure.
DRILLING OF OIL AND GAS WELLS Chapter#2

2.1 INTRODUCTION
Drilling is a process of making a hole, by penetrating in the producing formation for research of hydrocarbons. It is necessary to drill a hole to obtain crude oil and natural gas from under the earth's surface. Engineers make this hole using a rotary drilling rig.
DRILLING OF OIL AND GAS WELLS
2.2 DRILL BITS IN MECHANICAL DRILLING

For mining and construction and Depending on the soil condition different drill bits are utilized. There are three main categories: soft, medium and hard formation bits. Soft formation rock bits are used in unconsolidated sands, clays, soft limestone, red beds and shale, etc. Medium formation bits are used in calcites, dolomites, lime-stones, and hard shale, while hard formation bits are used in hard shale, calcites, mudstones, cherty lime stones and hard and abrasive formations.
2.2.1 TYPES OF DRILL BITS
There are three general types of drill bits. These are: 1. Drag type 2. Rolling type 3. Diamond type
2.2.1.1 DRAG BITS
Drag bits have no moving parts and drill by the shoveling action of their blades on the encountered formation. Their water courses are placed such that the drilling fluid is directed on the blades, keeping them clean. Bits of this type were once widely used for drilling soft, sticky formations, but in recent years have been largely replaced by rolling cutter types.
2.2.1.2 ROLLING BITS:
3: Figure 1: Drag Bit
The first successful rolling cutter bit was designed by Howard R. Huges in 1909. This bit, with subsequent improvements, allowed the rotary method to compete with the cable tool in hard formations which are un-drillable with drag bits. The bits designed for soft formation have relatively long, wide spaced teeth with interruption in the pattern. Tooth length, spacing and pattern are balanced to obtain the fastest penetration rate with
Figure 2: Rolling 8 Bit

minimum of the balling between teeth. Cones of bit are offset, i.e., the cone axes do not intersect at a common point. This offset imparts a drag bit action to the teeth as the bit is rotated. Bits designed for harder formations have successively shorter, more closely spaced teeth (allowing higher loading) and diminishing cone offset which reaches zero on the hardest formation types.
2.2.1.3 DIAMOND BITS:
Diamond bits drill by a scraping, drag-bit action of the stone which protrude from a steel matrix. Their use is justified in many areas where their long life and the consequent reduction in trip time afford sufficient advantage to offset the higher bit cost. Diamond bits are normally used in hard formations.
Figure 4: Diamond Bit
2.3 THE DRILLING FLUID

Drilling fluid often called as scientific mud due to its frequent monitoring and testing required in order maintaining optimum conditions in the well bore as different formations are encountered from the surface hole drilling up to target depth and well completion. The major properties of mud are; Viscosity Gel Strength Density
2.3.1 DRILLING FLUID MAJOR FUNCTIONS
Transport drilled cuttings to the surface. Control subsurface formation pressures. Keep the cuttings in suspension in the annulus when circulation is stopped. Cool and lubricate the hit and drill stem. Clean the bottom of hole below bit during drilling. Supports the well bore walls.
2.3.2 THE DRILLING FLUID PREPARATION AREA
The area generally includes: Mud House Steel Mud Pits/Tank Storage shed for additives. Steel containers that facilitate the handling of drilling fluid at the surface.

Mixing Hopper Chemical Mixing Barrel Bulk Storage Bins Water Tank Device used to rapidly add additives to the drilling fluid. Device used to add chemicals to the drilling fluid. Large bins used to facilitate the handling of additives used in large quantities. Storage container for water in preparation area. Water wells are drilled in some locations, i.e. arid area. A large earthen pit used to hold cutting wastes from well bore, and sometimes excess fluid.
Reverse Pit
2.4 CASING AND CEMENTING

Casing and cementing procedures have grown more sophisticated in recent years. As wells are drilled deeper in search of new oil reservoirs, casing and cementing procedures have been to handle the severe conditions encountered at greater depths
2.4.1 CASING
Casing is strong steel pipe used in an oil well to ensure a pressure-tight connection from the surface to the oil or gas reservoir. Casing in an oil well serves at least seven important functions: To prevent cave-in or washout of the hole; To prevent contamination of freshwater stads by fluid from lower zones; To exclude water from the producing formation; To confine production to the well bore; To provide a means of controlling well pressure; To permit installation of artificial lift equipment for producing the well; To provide a flow path for producing fluids
2.4.2 CEMENTING
After the casing string is run, the next task is cementing the casing in place. An oil-well cementing service is usually called in for this job although, as when casing is run, the rig crew is available to lend assistance. Cementing service companies stock various types of cement and have special transport equipment to handle this material in bulk. Bulk-cement storage and handling equipment is 10

moved out to the rig, making it possible to mix large quantities of cement at the site. The dry cement is gradually added to the hopper, and jet of water thoroughly mixes with the cement to make slurry. Special pumps pick up the cement slurry and send it up to a valve called a cementing head (also called a plug container) mounted on the topmost joint of casing that is hanging in the mast or derrick a little above rig floor. Just before the cement slurry arrives, a rubber plug (called the bottom plug) is released from the cementing head and precedes the slurry down the inside of casing. The bottom plug stops or seats in the float collar, but continued pressure from cement pumps opens a passageway through the bottom plug. Thus, the cement slurry passes through the bottom plug and continues on down the casing. The slurry then flows out through the opening in the guide shoe and fills up the annular space between the outside of the casing and wall of the hole. A top plug, which is similar to the bottom plug except that it is solid, is released as the last of cement slurry enters the casing. The top plug follows the regaining slurry down the casing as displacement fluid (usually salt water or drilling mud) is pumped in behind the top plug. Meanwhile, most of the cement slurry flows out of casing and into the annular space .By the time the top plug seats on or bumps the bottom plug in the float collar, which signals the cementing pump operator to shut down the pumps, the cement is only in the casing below the float collar and in the annular space. Most of the casing is full of displacement fluid. After the cement is run, a waiting time is allowed to allow the slurry to harden. This period of time referred to as waiting on cement or simply WOC. After the cement hardens, tests may be run to ensure a good cement job, for cement is very important. Cement supports the casing, so the cement should completely surround the casing; this is where centralizers on the casing help. If the casing centered in the hole, a cement sheath should completely envelop the casing. Also, cement seals off formations to prevent fluids from one formation migrating up or down the hole and polluting the fluids in another formation, For example cement can protect a freshwater formation (that perhaps a nearby town is using as its drinking water supply) from saltwater contamination. Further, cement protects the casing from the corrosive effects that formation fluids (as salt water) may have on it. After the cement hardens and tests indicate that the job is good, the rig crew attaches blowout prevent stack to the top of casing. The BOP stack is pressure-tested, and drilling is resumed.
2.5 RIG
It is an apparatus or machinery fitted up for a purpose, with a derrick complete with an engine house and other equipment necessary for operation i.e. used for boring and afterwards pumping an oil. 11

2.5.1 DRILLING RIG BACKGROUND
The first operation probably occurred when member of one of the earlier civilization cleaned out a spring with a pointed stick or other crude tool. As it became necessary to drill deeper, the spring pole was developed. It is interesting to note that the original drilling method was to impact the formation with a pointed object. To great extent, this is the same principle used in modern roller bits. The cable tool rig gradually evolved and still in use in some of areas. The
Figure 5: PPL Rig ADHI Oil Field
rotary rig was truly a new innovation in drilling equipments and techniques. It involved drilling by a rotating, scrapping and crushing action as compared to the reciprocating, pounding and crushing action of cable tool method. The drilling applied a greater horsepower at the bit so hole could be drilled faster. The rotary rig and rotary drilling techniques were continuously improved, evolving into new modern rigs capable of drilling deeper.
2.5.2 EVALUATING AND SELECTING RIGS
When selecting a rig to drill a well, the age and the conditioning of rig, as well as its depth capability, must be evaluated and considered. Drilling rigs are called by the name of manufacturer of the draw works. The mast usually has a load capacity in excess of the rated depth capacity of the draw works. The pumps must have sufficient hydraulic horsepower to pump at the depth that can be drilled by the draw works under standard sized-hole condition.
12

When selecting a rig to drill a well, one of the first items to be checked is the depth capacity of the overall rig to ensure it has capacity to drill the well. This includes all of the basic components of the rig. One of the best methods is to check with other operators who have used other rigs.
2.6 DRILLING RIG CLASSIFICATION

There are many types and designs of drilling rigs, with many drilling rigs capable of switching or combining different drilling technologies as needed. Drilling rigs can be described using any of the following attributes: BY POWER USED Human - percussion is performed by pulling a rope over a pulley or a lever and rotary action (if any) by one or more workers, in manual well drilling. Electric - the rig is connected to a power grid usually produced by its own generators and uses electric motors to drive individual components such as draw works, mud pumps and rotary tables. Mechanical - the rig uses torque converters, clutches, and transmissions powered by its own engines, often diesel Hydraulic - the rig primarily uses hydraulic power Pneumatic - the rig is primarily powered by pressurized air BY PIPE USED Cable - a cable is used to raise and drop the drill bit or drill string Conventional - uses metal or plastic drill pipe of varying types Coil Tubing - uses a giant coil of tube and a down hole drilling motor BY HEIGHT Single - can drill only single drill pipes, has no vertical pipe racks (most small drilling rigs) Double - can store double pipe stands in pipe racks Triple - can store stands composed of three pipes in the pipe rack (most large drilling rigs) Quad - can store stands composed of four pipes in the pipe rack
BY METHOD OF ROTATION OR DRILLING METHOD No rotation includes direct push rigs and most service rigs Rotary table - rotation is achieved by turning a square or hexagonal pipe (the Kelly) at drill floor level. 13

Top-drive - rotation and circulation is done at the top of the drill string, on a motor that moves along the derrick. Sonic - uses primarily vibratory energy to advance the drill string BY POSITION OF DERRICK Conventional - derrick is vertical Slant - derrick is at an angle (this is used to achieve deviation without an expensive down hole motor)
2.7 TYPES OF DRILLING RIGS:

Rotary rigs Electric rigs Diesel electric
2.8 THE ROTARY DRILLING RIG:

The rotary drilling rig uses a drill bit to cut through the earth and create a hole. As the hole gets deeper, pipe is added to the drill bit to allow it to dig further. These lengths of drill pipe form the drill string. This pipe is connected to an engine that turns the drill bit to cut the hole. The rotary rig operates the same as a hand-held electric drill. The electric drill has a motor that turns the drill bit and sufficient weight must be applied to keep the drill in contact with the bottom of the hole. 2.8.1 COMPONENTS OF A DRILLING RIG The different components of rig are shown in figure 6; 1. Crown Block and Water Table 2. Cat-line Boom and Hoist Line 3. Drilling Line 4. Monkey-board 5. Traveling Block 6. Top Drive 7. Mast 8. Drill Pipe 9. Doghouse 14
Figure 6: Components Of Oil Rig
2.8.2 OPERATIONS IN A DRILLING RIG:
There are four main operations in a drilling rig: Hoisting Rotating Circulating Power
15

The hoisting system is used to raise and lower pipe in and out of the hole and to support the drill string to control the weight on the drill bit during drilling.
2.8.2.1 Hoisting System
The hoisting system consists of the derrick, traveling and crown blocks, the drilling line, and the draw works. The drilling rig uses a derrick to support the drill bit and pipe .The derrick is a steel tower that is used to support the traveling and crown blocks and the drill string.
Figure 7: Coil Tubing Being Rigged Up
There may be no more identifiable symbol of the oil and gas industry than the derrick on a drilling rig. The crown and traveling blocks are a set of pulleys that raise and lower the drill string. The crown block is a stationary pulley located at the top of the derrick. The traveling block moves up and down and is used to raise and lower the drill string. These pulleys are connected to the drill string with a large diameter steel cable. The cable is connected to a winch or drawworks. The drawworks contains a large drum around which the drilling cable is wrapped. As the drum rotates one way or the other, the drilling cable spools on or off the drum and raises or lowers the drill string. 2.8.2.2 Rotating Equipment The rotating equipment turns the drilling bit. This equipment consists of the swivel, the kelly, the rotary table, the drill pipe, the drill collars, and the bit. The swivel is attached to the 16

bottom of the traveling block and permits the drill string to rotate. The kelly is a square or hexagonal shaped section of pipe that is attached to the swivel. The kelly fits in matching slot in the rotary table. As the rotary table turns the kelly is also turned. The movement of the kelly rotates the drill string and the drill bit. Drilling pipe is round steel tubes about 30 feet long with a diameter of from 4 to 5 inches. The drill collars are used to add weight on the bit. Drill pipe has threaded connections on each end that allow the pipe to be joined together to form longer sections as the hole gets deeper. The drilling bit is used to create the hole. Drilling bit sizes range from six inches to three feet in diameter. The most common drill bits are roller cone bits and diamond bits. Roller cone bits have three cones containing rows of teeth. The cones rotate on bearings and turn as the drilling bit rotates. The teeth cut and crush the rock to create the hole. The bit also contains small nozzles that spray drilling fluids to remove the rock fragments from the bottom of the hole. Diamond bits have a single fixed head that contains many small diamonds. As the bit turns the diamonds cut the rock. Diamond bits also have nozzles to wash away the broken pieces of rock. Different drilling bits are used depending on the type of rock that is encountered.
2.8.2.3 Circulating System
The drilling operation uses fluids to reduce friction and remove rock fragments or cuttings. The circulating system pumps these drilling fluids down the hole, out of the nozzles in the drilling bit, and returns them to the surface where the debris is separated from the fluid. Drilling fluid is also knows as drilling mud because of its characteristic brown color. The drilling mud is mixed in tanks. The mud is pumped through a hose to the swivel, down the Kelly, and into the drill pipe. The mud goes down the drill string and out of the drilling bit nozzles. The mud carries the cuttings from the bottom of the hole to the surface in the space between the outside of the drill string and the inside of the hole. The cuttings are separated from the mud in a vibrating screen called a shale shaker. The cuttings are trapped on the screen and the mud passes through the screen into the mud pits. The circulating pumps pick up this clean mud and send it back down the hole. The cuttings are collected in a plastic-lined pit for disposal. Drilling mud is a mixture of water, clay, and special minerals and chemicals. Drilling mud removes cuttings from the hole and cools and lubricates the drilling bit. Mud also maintains pressure in the hole to keep fluids in the formation from entering the hole and producing a gusher of oil on the surface.
17
Figure 8: Circulation System
2.8.2.4 Power Generation System
A drilling rig needs power to operate the circulating, rotating, and hoisting systems. This power comes from two or more diesel engines. Power is transmitted to the drilling rig from either generators that provide electricity or mechanical drivers that use a series of pulleys and belts to transmit power from the engines to the components that require the power.
18
Figure 9: Electric Generators at PPL Rig
2.9 THE RIG CREW

Drilling is usually done by a service company or drilling contractor. The drilling crew is composed of a tool pusher, a driller, a derrick man, a motorman and several roughnecks and roustabouts. The tool pusher, the location supervisor for the drilling contractor, is usually a senior, experienced individual who has worked his way up through the ranks of the drilling crew positions. His job is largely administrative, including ensuring that the rig has sufficient materials, spare parts and skilled personnel to continue efficient operations. The driller is the supervisor of the rig crew. The driller is responsible for the efficient operation of the rig site as well as the safety of the crew. He typically has many years of rig site experience and has worked his way up from other jobs. While the driller must know how to perform each of the jobs on the rig, his or her role is to supervise the work and control the major rig systems. The driller operates the pumps, draw works, and rotary table via the drillers 19

console-a control room of gauges, control levers, rheostats, and other pneumatic, hydraulic and electronic instrumentation. The driller also operates the draw works brake using a longhandled lever. Hence, the driller is sometimes referred to as the person who is "on the brake. The derrick man is in charge of the mud-processing area during periods of circulation. The derrick man also measures mud density. The derrick man reports to the tool pusher, but is instructed in detail by the mud engineer on what to add to the mud, how fast and how much. His other job is to handle pipe in the derrick while pulling out or running into the hole. One of the rig crew members who gets his name from the fact that he works on a platform attached to the derrick or mast, typically 85 ft [26 m] above the rig floor, during trips. In a typical trip out of the hole, the derrick man wears a special safety harness that enables him to lean out from the work platform (called the monkey board) to reach the drill pipe in the center of the derrick or mast, throw a line around the pipe and pull it back into its storage location (the fingerboards) until it is time to run the pipe back into the well. In terms of skill, physical exertion and perceived danger, a derrick man has one of the most demanding jobs on the rig crew. Some modern drilling rigs have automated pipe-handling equipment such that the derrick man controls the machinery rather than physically handling the pipe. In an emergency, the derrick man can quickly reach the ground by an escape line often called the Geronimo line. The motorman is responsible for maintenance of the engines. While all members of the rig crew help with major repairs, the motorman does routine preventive maintenance and minor repairs. A roughneck is a low-ranking member of the drilling crew. The roughneck usually performs semiskilled and unskilled manual labor that requires continual hard work in difficult conditions for many hours. A roustabout is any unskilled manual laborer on the rig site. A roustabout may be part of the drilling contractor's employee workforce, or may be on location temporarily for special operations. Roustabouts are commonly hired to do the peripheral tasks, ranging from cleaning up location to cleaning threads to digging trenches to scraping and painting rig components. The operator is the company that serves as the overall manager and decision-maker of a drilling project. Generally, but not always, the operator will have the largest financial stake in the project. As far as the drilling contractor and service companies are concerned, the designated operator is paying for the entire operation, and the operator is responsible for recouping some of that expense from the partners.
20
WELL COMPLETION
Chapter#3
3.1 INTRODUCTION
WELL COMPLETION
Once the design well depth is reached, the formation must be tested and evaluated to determine whether the well will be completed for production, or plugged and abandoned. To complete the well production, casing is installed and cemented and the drilling rig is dismantled and moved to the next site. If no further pre-production servicing is needed, the Christmas tree is installed and production begins.
3.2 COMPLETION
Completion is the process of making a well ready for production (or injection). This principally involves preparing the bottom of the hole to the required specifications, running in the production tubing and its associated jewellery and perforating and stimulating as required. Sometimes, the process of running in and cementing the casing is also included.
3.3 Well Completion Activities:

Well completion activities include the following. Conducting Drill Stem Test Setting Production Casing Installing Production Tubing Starting Production Flow Beam Pumping Unit
3.3.1 CONDUCTING DRILL STEM TEST
To determine the potential of a producing formation, the operator may order a drill stem test (DST). The DST crew makes up the test tool on the bottom of the drill stem, and then lowers it to the bottom of the hole. Weight is applied to the tool to expand a hard rubber sealer called a packer. Opening the tool ports allows the formation pressure to be tested. This process enables workers to determine whether the well can be produced.
3.3.2 SETTING PRODUCTION CASING
Production casing is the final casing in a well. It can be set from the bottom to the top. Sometimes a production liner is installed. This casing is set the same as other casings, then cemented in place
21
WELL COMPLETION
3.3.3 INSTALLING PRODUCTION TUBING
A well is usually produced through tubing inserted down the production casing. Oil and gas is produced more effectively through this smaller-diameter tubing than through the largediameter production casing. Joints of tubing are joined together with couplings to make up a tubing string. Tubing is run into the well much the same as casing, but tubing is smaller in diameter and is removable. The steps for this activity are: Tubing elevators are used to lift tubing from the rack to the rig floor. The joint is stabbed into the string, which is suspended in the well, with air slips. Power tongs are used to make-up tubing. This process is repeated until tubing installation is complete. The tubing hanger is installed at the wellhead.
New technology allows tubing to be manufactured in a continuous coil, without joints. Coiled tubing is inserted into the well down the production casing without the need for tongs, slips, or elevators, which takes considerably less time to run.
3.3.4 STARTING PRODUCTION FLOW
Production flow is started by washing in the well and setting the packer. Washing in means to pump in water or brine to flush out the drilling fluid. Usually this is enough to start the well flowing. If not, then the well may need to be unloaded. This means to swab the well to remove some of the brine. If this does not work the flow might be started by pumping high- pressure gas into the well before setting the packer. If the well does not flow on its own, well stimulation or artificial lift may need to be considered.
3.3.5 BEAM PUMPING UNITS
If the well doesn't produce adequately, a beam pumping unit may be installed. There are four basic types of beam pumping units. Three involve a walking beam, which seesaws to provide the up and down reciprocating motion to power the pump. The fourth reciprocates by winding a cable on and off a rotating drum. The job of all four types is to change the circular motion of an engine to the reciprocating motion of the pump. The pump units are brought in disassembled on trucks and off-loaded onsite. The many parts of the pump unit include large heavy metal pieces that need to be assembled.
3.4 TYPES OF COMPLETION

The most common types are briefly explained here:
22
WELL COMPLETION
3.4.1 BAREFOOT COMPLETION
This type is the most basic, but can be a good choice for hard rock, multi-laterals and under balance drilling. It involves leaving the productive reservoir section without any tubular. This effectively removes control of flow of fluids from the formation; it is neither suitable for weaker formations which might require sand control, nor for formations requiring selective isolation of oil, gas and water intervals. However, advances in interventions such as coiled tubing and tractors means that barefoot wells can be successfully production logged, zonal isolation of the toe-end can be achieved (e.g. cemented off), and sidetracks can readily be drilled from within the barefoot section.
3.4.2 OPENHOLE COMPLETION
This designation refers to a range of completions where the tubular across the production zone are not cemented in place. Openhole completions have seen significant uptake in recent years, and there are many configurations, often developed to address specific reservoir challenges. There have been many recent developments which have boosted the success of openhole completions, and they also tend to be popular in horizontal wells, where cemented liners are more expensive and technically more difficult. The common options for openhole completions are; 1) Pre-holed liner (also often called pre-drilled liner). The liner is prepared with multiple small drilled holes, and then set across the production zone to provide wellbore stability and an intervention conduit. Pre-holed liner is often combined with openhole packers, such as swelling elastomers, mechanical packers or external casing packers, to provide zonal segregation and isolation. It is now quite common to see a combination of pre-holed liner, solid liner and swelling elastomer packers to provide an initial isolation of unwanted water or gas zones. Multiple sliding sleeves can also be used in conjunction with openhole packers to provide considerable flexibility in zonal flow control for the life of the wellbore. This type of completion is also being adopted in some water injection wells, although these require a much greater performance envelope for openhole packers, due to the considerable pressure and temperature changes that occur in water injectors. Open hole completions (in comparison with cemented liners) require better understanding of formation damage, wellbore clean-up and fluid loss control. A key difference is that perforating penetrates through the first 6-18inches (15-45cm) of formation around the wellbore, whilst openhole completions require the reservoir fluids to flow through all of the filtrate-invaded zone around the wellbore and lift-off of the mud filter cake. Many openhole completions will incorporate fluid loss valves at the top of the liner to provide well control whilst the upper completion is run. There are an increasing number of ideas coming into the market place to extend the options for openhole completions; for example, 23
WELL COMPLETION
electronics can be used to provide a self- opening or self-closing liner valve. This might be used in an openhole completion to improve clean-up, by bringing the well onto production from the toe-end for 100 days, then self-opening the heel-end. Inflow control devices and intelligent completions are also installed as openhole completions. Pre-holed liner may provide some basic control of solids production, where the wellbore is thought to fail in aggregated chunks of rubble, but it is not typically regarded as a sand control completion. 2) Slotted liner can be selected as an alternate to pre-holed liner, sometimes as a personal preference or from established practice on a field. It can also be selected to provide a low cost control of sand/solids production. The slotted liner is machined with multiple longitudinal slots, for example 2mm x 50mm, spread across the length and circumference of each joint. Recent advances in laser cutting means that slotting can now be done much cheaper to much smaller slot widths and in some situations slotted liner is now used for same functionality and sand control screens. 3) Open hole sand control is selected where the liner is required to mechanically hold-back the movement of formation sand. There are many variants of openhole sand control, the three popular choices being stand-alone screens, openhole gravel packs (also known as external gravel packs, where a sized sand 'gravel' is placed as an annulus around the sand control screen) and expandable screens. Screen designs are mainly wire-wrap or premium; wire-wrap screens use spiral-welded corrosion-resistant wire wrapped around a drilled base pipe to provide a consistent small spiral gap (such as 0.012inch, termed 12 gauge). Premium screens use a woven metal cloth wrapped around a base pipe. Expandable screens are run to depth before being mechanically swaged to a larger diameter. Ideally, expandable screens will be swaged until they contact the wellbore wall.
3.4.3 CASED HOLE COMPLETION
This involves running casing or a liner down through the production zone, and cementing it in place. Connection between the well bore and the formation is made by perforating. Because perforation intervals can be precisely positioned, this type of completion affords good control of fluid flow, although it relies on the quality of the cement to prevent fluid flow behind the liner. As such it is the most common form of completion.
3.5 COMPLETION COMPONENTS:

The upper completion refers to all components from the bottom of the production tubing upwards. Proper design of this "completion string" is essential to ensure the well can flow properly given the reservoir conditions and to permit any operations as are deemed necessary for enhancing production and safety. 24
WELL COMPLETION
Christmas tree
Figure 10: Christmas Tree at PPL Rig
This is the main assembly of valves that controls flow from the well to the process plant (or the other way round for injectors) and allows access for chemical squeezes and well interventions Tubing hanger This is the component, which sits on top of the wellhead and serves as the main support for the production tubing. Production tubing Production tubing is the main conduit for transporting hydrocarbons from the reservoir to surface (or injection material the other way). It runs from the tubing hanger at the top of the wellhead down to a point generally just above the top of the production zone.
25
WELL COMPLETION
Downhole safety valve This component is intended as a last resort method of protecting the surface from the uncontrolled release of hydrocarbons. It is a one way valve, which allows fluids to flow down, but not up, when closed. It is placed as far below the surface as is deemed safe from any possible surface disturbance including cratering caused by the wipeout of the platform. Annular safety valve On wells with gas lift capability, many operators consider it prudent to install a valve, which will isolate the annulus for the same reasons a DHSV may be needed to isolate the production tubing in order to prevent the inventory of natural gas downhole from becoming a hazard as it became on Piper Alpha. Side pocket mandrel This is a welded/machined product which contains a 'side-pocket' alongside the main tubular conduit. The side pocket, typically 1" or 1" diameter is designed to contain gas lift valve, which allows hydrocarbon gas from the annulus to be injected into the flow stream. Electrical submersible pump This device is used for artificial lift to help provide energy to drive hydrocarbons to surface if reservoir pressure is insufficient. Landing nipple This is a receptacle to receive wire line tools. It is also a useful marker for depths in the well, which can be difficult to accurately determine. Sliding sleeve The sliding sleeve is hydraulically or mechanically actuated to allow communication between the tubing and the 'A' annulus. They are often used in multiple reservoir wells to regulate flow to and from the zones. Production packer The packer isolates the annulus between the tubing and the inner casing and the foot of the well. This is to stop reservoir fluids from flowing up the full length of the casing and damaging it. It is generally placed close to the foot of the tubing, shortly above the production zone.
26
WELL COMPLETION
Downhole gauges This is an electronic or fiber optic sensor to provide continuous monitoring of downhole pressure and temperature. Gauges use a 1/4" control line clamped onto the outside of the tubing string to provide an electrical or fiber optic communication to surface. Perforated joint This is a length of tubing with holes punched into it. If used, it will normally be positioned below the packer and will offer an alternative entry path for reservoir fluids into the tubing in case the shoe becomes blocked, for example, by a stuck perforation gun. Formation isolation valve This component, placed towards the foot of the completion string, is used to provide two way isolation from the formation for completion operations without the need for kill weight fluids. Their use is sporadic as they do not enjoy the best reputation for reliability when it comes to opening them at the end of the completion process. Centralizer In highly deviated wells, this component may be included towards the foot of the completion. It consists of a large collar, which keeps the completion string centralized within the hole. Wire line Entry Guide This component is often installed at the end of the tubing (the shoe). It is intended to make pulling out wireline tools easier by offering a guiding surface for the tool-string to re-enter the tubing without getting caught on the side of the shoe.
3.6 PERFORATING AND STIMULATING

In cased hole completions (the majority of wells), once the completion string is in place, the final stage is to make a connection between the wellbore and the formation. This is done by running perforation guns to blast holes in the casing or liner to make a connection. Modern perforations are made using shaped explosive charges, similar to the armor-penetrating charge used on antitank rockets (bazookas). Sometimes once the well is fully completed, further stimulation is necessary to achieve the planned productivity. There are a number of stimulation techniques.
3.6.1 ACIDIZING
This involves the injection of chemicals to eat away at any skin damage, "cleaning up" the formation, thereby improving the flow of reservoir fluids. Acid can also be used to clean the wellbore of some scales that form from mineral laden produced water. 27
WELL COMPLETION
3.6.2 FRACTURING
This means creating and extending a fracture from the perforation tunnels deeper into the formation increasing the surface area for formation fluids to flow into the well as well as extending past any possible damage near the wellbore. This may be done by either injecting fluids at high pressure (hydraulic fracturing), injecting fluids laced with round granular material (proppant fracturing) or using explosives to generate a high pressure and high speed gas flow (TNT or PETN up to 1,900,000 Psi) and (propellant stimulation up to 12,000 Psi).
3.6.3 ACIDIZING AND FRACTURING (Combined Method)
This involves use of explosives and injection of chemicals to increase acid-rock contact.
3.6.4 NITROGEN CIRCULATION
Sometimes, productivity may be hampered due to the residue of completion fluids, heavy brines, in the wellbore. This is particularly a problem in gas wells. In these cases, coiled tubing may be using to pump nitrogen into the bottom of the hole to circulate out the brine.
28
WELL TESTING Chapter#4

4.1 INTRODUCTION
The efficiency and performance of gas and oil wells is of great importance. Some kind of tests must be made to determine the performance of gas and oil well. There are many types of tests performed on the well out of which some are of great importance. Some of the tests are very simple and some are very complicated. It is very important that the test be done very accurately since well test data document the performance of well and the reservoir in which test is completed.
WELL TESTING
4.2 TYPES OF WELL TESTS

There are many types of well tests performed by lease operators, well testers, etc. Some of the important tests performed are listed below Drill stem test Potential test Bottom-hole pressure test Transient pressure testing Productivity test Routine production tests Bottom-hole temperature determination Water analysis
A brief explanation of these tests is given below

4.2.1 DRILL STEM TEST:
When a well is being drilled, a drill-stem test is often run on a formation of unknown formation to determine if formation contains oil, gas, water or combination of the three. This procedure requires special tools and packers to be run on the drill pipe to isolate the interval to be tested. The fluid is permitted to flow through the formation, through the tester to the drill pipe. The fluid entering is trapped by a stem of valves in the tester so that it may be withdrawn from well with the drill pipe for checking. If formation pressure is sufficient to cause flow through the surface, a sustained flow through the drill pipe will provide a measure of productive captivity of the interval tested. The result show the bottom-hole shut-in pressure, bottom-hole flowing pressure, bottom-hole temperature and the type of fluid the well might be capable of producing. The results of drill-stem test will determine if a casing string should be run to complete the well as a producing well or the well is a dry-hole.
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WELL TESTING
4.2.2 POTENTIAL TEST:
A potential test is a measurement of production of oil and gas that will be produced in a 24 hour period under certain fixed conditions. This test is made on each newly completed well. Information from these tests is used to establish the producing rate of the well.
4.2.3 BOTTOM-HOLE PRESSURE TEST:
A bottom hole pressure test is a measure of pressure of the well taken at a special depth or at midpoint of the producing interval. The purpose of this test is to measure the pressure in the zone in which the well is completed. In making this test a specially designed pressure gage is lowered into the well to a selected depth where the pressure is recorded by the gage. The gage is then pulled to the surface and taken from the well to observe and record the pressure. There are certain variations in the test including flowing bottom-hole pressure test and shut-in bottom-hole test. These shutin tests also give the information of fluid levels in the shut-in well.
4.2.4 TRANSIENT PRESSURE TESTING:
Transient pressure testing plays an important role in reservoir management. Bottom-hole pressures are calculated under various flowing and shut-in conditions. The information thus obtained can be used in modeling the reservoir, predicting its performance and optimizing production alternatives in order to achieve maximum economic recovery of reserves.
4.2.5 PRODUCTIVITY TESTS:
These tests are performed on both oil and gas wells and include well potential and bottom-hole tests. The first procedure in conducting a well production test is to measure the shut in bottomhole pressure; the pressure might be called as static pressure or reservoir pressure. At each stabilized rate of production the bottom-hole flowing pressure is measured. This data provide an estimate of maximum flow of fluid to be expected from the well. The main pieces of equipment necessary for making potential and associated tests are a part o the normal tank battery. The separator and the tank cannot be used for operating operations while a test is being conducted. Oil from the test and measured in the tank while gas is measured with an orifice meter.
4.2.6 ROUTINE PRODUCTION TESTS
daily productions of oil, gas and water. These tests can be conducted with various items of equipment ranging from simple tank measuring equipment to a fully automated test facility. When a computerized system is used, the valve operation is upon computer command and the results are automatically transmitted by the computer Routine operation tests are performed monthly to inform the well operator for any changes in the
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WELL TESTING
Figure 11: Potential & Associated Tests 4.2.7 BOTTOMHOLE TEMPERATURE DETERMINATION:
This test is made in conjunction with the bottom-hole pressure test and is used to obtain the temperature of the well at the bottom of the well on a wire line. After the thermometer is removed, the temperature at the desired depth is read from the instrument. Temperature tests are sometimes useful in locating leaks in the pipe above the producing zone. These are also used to determine weather the gas valves are operating and the location of top and bottom cement in newly cemented wells.
4.2.8 WATER ANALYSIS:
The oil industry has used water analysis for many years for formation identification, compatibility studies, water quality control and evaluation of pollution problems. The end use of water analysis should determine the sampling procedure, analytical procedure and data presentation. In some cases the only concern is whether or not a particular substance is present or not. A reliable water analysis is very important as it is the first step in solving scale or pollution problems. Casing leaks in producing wells can be detected using results of water analysis. Water analyses are often used to identify the source of water produced with oil and gas.
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Chapter#5
5.1 INTRODUCTION
Sprint Oil & Gas Services is a well services and testing company founded in 2003. It is a multinational company operating in countries like Dubai, Pakistan, Iraq and Libya etc. Its head office is located in Dubai and Pakistan branch is located in services where I-10 Islamabad with 2 ware houses and work shop. Sprint Oil and Gas Services is dedicated to provide safe, cost effective technical solutions and services to the oil and gas industry in its core specialties. Sprint provides services in oil and gas sector in following areas,

Coiled Tubing Services Nitrogen Services Primary and Remedial Cementing Services Stimulation Services Surface Testing Filtration
Sprint Coiled tubing operations often requires large pulling capacity. These operations include pumping fluids, kicking off wells, clean-outs, running tools, cementing, stimulation and hanging off velocity string tubing. Coiled Tubing units are designed to operate in a wide range of ambient conditions. Especially hot weather environment. The CT units are ideal for Nitrogen kickoff, fishing, stimulation and cementing through coiled tubing applications to a depth of 17500 feet. Sprint Oil & Gas Services provides stimulation services and systems for treating both limestone and sandstone formations. The latest systems including Diverting Acid (NDA), Non-Damaging Diverting Acid (NDA-S), Organic and Alcoholic Acids (ORA, AHCL and AHF) and Non Acid Based Scale Removal systems (Sulf CLEAN and Carbo CLEAN) allow treating any type well impairment. Our Horsepower capability allows stimulating HP zones at high injection rates to provide efficient fluids diversion as well as pumping treatments at higher then frac gradient (Hydraulic Fracturing). Treatment rate up to 20 bpm and 10000 psi can be safely and efficiently handled. Filtration applications are used for filtering of fresh water, sea water, brine water, aquifer 33

water, brackish water, calcium chloride and calcium bromide, brine and other fluids. This can be achieved easily by filtration of all fluids introduced to the well. Sprint has vast experience and a proven track record in this field. Sprint Oil & Gas Services also provides nitrogen pumping services for several well applications including:

Nitrogen Lifting Energizing fluids Foam diversion
Sprint has four coil tubing units to perform coil tubing applications. We can distinguish between these on the basis on the bases of hydraulic system on which these are operating. One unit works on closed loop system and two on modified open loop system. The last one on which we are assigned project works on open loop system. This system has the problem of heat gain and pressure drop in both its pump and hydraulic circuitry. In Pakistan major coil tubing service providing companies were Schlumberger, Sprint, Wheatherford. But know Sprint oil and gas services is well known for its coil tubing operations and companies like OGDCL which posses their own C.T. equipment prefer contracting Sprint for their jobs.
5.2 PRESSURE ANALYSIS OF HYDRAULIC POWER PACK

The second phase of our project is the problem verification and rectification of the hydraulic power pack system used in the coil tubing equipment. The project is issued to us by SPRINT OIL AND GAS SERVICES, multinational oil and gas services providing company. Our main concern was to first rectify the causes of these problems through detailed study and experimentation and then rectify them and in the end suggest the best possible solution keeping in mind the overall expenses, Pakistans climate and such that the maintenance or modification does not disturb the job schedule of other units. The unit we worked on was unit 4 the latest unit in the Sprint inventory. The problem consists of two parts Pressure drops in the circuit. Heat gains and the excessive raise in temperature of the cooling fluid. In order to tackle this problem we have divided our project into four phases of study and experimentation. The sequence of this report is in accordance with the phases of work we performed. 34

According to the design manual the pressure limitations were defined but in practical use and as found during function testing the pressure drops occurring were about 2000 psi. The drops in pressure are also the main reason for the increased temperatures but not the only reason of the fluid as well as the overall system.
5.2.1 EXPLANATION OF PROBLEM
Coil tubing equipment utilizes a hydraulic power delivery system known as hydraulic power pack. Its main purpose as discussed earlier is to deliver hydraulic power to the injector, to pumps auxiliary equipment reel and other parts and it also energizes a pneumatic pump embedded in the system. The pressure drop occurs at the pump manifold of the power pack and thus the decreased pressure in received by the different equipments that are attached to it through sets of pumps. As the pressure decreases at the outlet of pump the lost pressure is converted as a form of heat energy and gain in pressure at other ends like valves thus some times causing them to approach the fracture pressure. Thus the problem had to be instantly dealt with. The losses are calculated through two methods Pull test Function test
5.2.2 CRITICALITY OF THE PROBLEM
As stated above the pressure drop of 2000 psi brought some devastating results to the equipments performance and safety. Decreased efficient and performance of the equipment. Safety issues when performing operations like acid treatment. Increased cost of cooling. Increased cost in pressurizing of the equipment. Increase in external temperature causing conflicts with the safety aspects. Frequent maintenances required
5.3 WORKING AND RESEARCH PHASES

In order to understand the problem and solving it we divided our work into three main phases to maintain a step by step analysis technique and the layout of the report is according to the phases of work we adopted. The description of these working phases is summarized below. 35

PHASE 1: Complete and thorough study of the C.T process, equipment, parts and construction. PHASE 2: Study and experimentation to determine the problem and analyzing the possible solutions on the unit in Sprint yard located in services road I-10 Islamabad. PHASE 3: Applying these solutions on the unit and giving the best possible suggestions to the Sprint team for future maintenance or modification purposes.
5.4 TESTING OF EQUIPMENT

5.4.1 FUNCTIONAL TESTING OF PUMP
Pumping is the process of adding kinetic and potential energy to fluid for the purpose of moving it from one place to another through a pipe or a duct and providing and transmitting fluid power to any place. Efficiency drop is expected over time due to deposits in the blades of pump. Function testing of pumps would reveal the existing discharge of a pump which can be compared with designed value of discharge of a pump. By calculating discharge of a pump we can easily calculate efficiency of a pump as;
We can measure the discharge of a pump by following methods; Tank Filling Method Installation Of Online Flow Meter Ultrasonic Flow Measurement
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Tank Filling Method Flow measurement can be measured by putting the discharge side of a pump in a container whose dimensions are measured accurately. By noticing the difference between the specified levels gives the volume which is divided by time in which that graduated tank is filled gives us discharge of the pump. The internal readings of the tank should be preferably taken from the design drawings. Installation Of An On-line Flow meter If the application to be measured is going to be critical and periodic then the best option would be to install an on-line flow meter which can get rid of the major problems encountered with other types. Ultrasonic Flow Meter Operating under Doppler Effect principle these meters are non-invasive, meaning measurements can be taken without disturbing the system. Scales and rust in the pipes are likely to impact the accuracy. Ensure measurements are taken in a sufficiently long length of pipe free from flow disturbance due to bends, tees and other fittings. The pipe section where measurement is to be taken should be hammered gently to enable scales and rusts to fall out. For better accuracy, a section of the pipe can be replaced with new pipe for flow measurements. RESULTS OF FUNCTION TESTING Function testing was performed by discharge method and found that the total loss in the pressure was about 2000psi the decrease in this pressure disrupts all of the operations like it lowers the pulling capacity of the injector nozzle to 66%. Thus the pressure losses calculated are around 2000 psi.
5.4.2 PULL TEST
Pull test is a test in which we measure the pulling capacity of the pulling unit attached to our system in this case the injector nozzle. The injector nozzle of unit 4 is capable of a pulling capacity of up to 60000 lb. Pull test was performed to measure the pulling capacity to the injector as the next job the unit was planned for required a load of approx 55000 lb to be lifted when in full depth. So the pull test of injector nozzle of our unit was performed. Pull test was performed such that loads were continuously added and pulled by the injector nozzle. It was noticed that the injector nozzle fails to pull load after 40000 lb. certain text book modifications
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were made to the equipment to increase its pulling capacity and the pulling capacity was increased to 43000 lb. There are many reasons of decrease in pulling capacity of injector nozzle. There can be a leakage or worn out seal or resistance to flow in injector circuit or it could be a decrease in pumping capacity of a pump rather than decrease in pulling capacity of injector. But after extensive testing and taking the Function test as a reference of pump it was concluded that it is the pump which has caused decrease in pulling capacity of injector as its efficiency was measured to be only 60-66%. Decrease in efficiency = 33%
Figure 12: Pull Test Being Performed
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SPRINT OIL AND GAS SERVICES CONCLUSION

In order to find the decrease in efficiency of the equipment and pressure losses we performed the above mentioned Pull and Function tests. As a result we found that the system was now operating at 60-66% efficiency and the drop in efficiency was about 33%. Our project is based on study and experimentation to minimize this efficiency drop and increase the performance and lifetime of the equipment.
Figure 13: Function Test Being Performed
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6.1 COIL TUBING
6.1.1 INTRODUCTION
Coiled Tubing (CT) has been defined as any continuously-milled tubular product manufactured in lengths that require spooling onto a take-up reel, during the primary milling or manufacturing process. The tube is nominally straightened prior to being inserted into the wellbore and is recoiled for spooling back onto the reel. Tubing diameter normally ranges from 1 in. to 3.25 in, and single reel tubing lengths in excess of 30,000 ft. have been commercially manufactured. Common CT steels have yield strengths ranging from 55,000 PSI to 120,000 PSI. In the Oil and Gas Industries, coiled tubing refers to metal piping, normally 1" to 3.25" in diameter, used for interventions in oil and gas wells and sometimes as production tubing in depleted gas wells, which comes spooled on a large reel. Coiled tubing is often used to carry out operations similar to wire lining. The main benefits over wire line are the ability to pump chemicals through the coil and the ability to push it into the hole rather than relying on gravity. However, for offshore operations, the 'footprint' for a coiled tubing operation is generally larger than a wire line spread, which can limit the number of installations where coiled tubing can be performed and make the operation more costly. A hydraulic power pack, or prime mover, controlled from a console in a central control cabin drives the injector head to deploy and retrieve coiled tubing. The large storage reel also applies back-tension on the tubing. The continuous tubing passes over a goose-neck and through an injector head before insertion into a wellbore through well-control equipment that typically consists of a stuffing box, or pack off, riser and blowout preventer (BOP) stack on top of the wellhead. This process is reversed to retrieve and spool coiled tubing back onto the reel The global oil and gas industry is using coiled tubing for an ever-increasing array of well intervention projects. Coiled tubing offers a number of operational and economic advantages, including: live well intervention, elimination of well kill and potentially damaging heavy-weight kill fluids, reduced operational footprint, horizontal intervention, and the ability to intervene without a rig. These advantages have led to the development of truly fit-for-purpose coiled tubing systems from the industrys largest provider of coiled tubing well intervention solutions. While the initial development of coiled tubing was spurred by the desire to work on live wellbores, speed and economy have emerged as key advantages for application of CT. In addition, the relatively small footprint and short rig-up time make CT even more attractive for drilling and workover applications. Some of the key benefits associated with the use of CT technology are as follows: 41
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Safe and efficient live well intervention Rapid mobilization and rig-up Ability to circulate while RIH/POOH Reduced trip time, resulting in less production downtime Reduced crew/personnel requirements Cost may be significantly reduced Coiled tubing can also be fitted with internal electrical conductors or hydraulic conduits, which enables down hole communication and power functions to be established between the BHA and surface. In addition, modern CT strings provide sufficient rigidity and strength to be pushed/pulled through highly deviated or horizontal wellbores. This enables successful execution of down hole operations that would be impossible to perform with conventional wire line approaches, or would be cost prohibitive if performed by jointed-pipe.
6.1.2 HISTORY
The development of coiled tubing as we know it today dates back to the early 1960's, and it has become an integral component of many well service and workover applications. While well service/ workover applications still account for more than 75% of CT use, technical advancements have increased the utilization of CT in both drilling and completion applications. Prior to the Allied invasion in 1944, British engineers developed and produced very long, continuous pipelines for transporting fuel from England to the European Continent to supply the Allied armies. The project was named operation "PLUTO", an acronym for "Pipe Lines Under The Ocean", and involved the fabrication and laying of several pipelines across the English Channel. Most of the lines were fabricated from 40ft joints of 3 inside diameter 0.212 wall thickness steel pipes welded together to form 4000ft sections. The successful fabrication , spooling and deployment of 23 pipelines ranging from 30 to 70 miles provided the foundation for additional technical developments that eventually led to the tubing strings used today by the CT industry. In 1962, the California Oil Company and Bowen Tools developed the first fully functional CT unit, for the purpose of washing out sand bridges in wells. The first injector heads operated on the principle of two vertical, contra-rotating chains. This design is still used in the majority of CT units today. The stripper was a simple, annular-type sealing device that could be hydraulically activated to seal around the tubing at relatively low wellhead pressures. The tubing string used for the initial trials was fabricated by butt-welding 50 ft. sections of 1 3/8 in. OD pipe into a 15,000 ft. string and spooling it onto a reel with a 9 ft. diameter core. The units 42
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9ft dia storage reel included hub with rotating fluid swivel to allow continuous pumping down the coil tubing. However low yield-strength steels and the numerous end-to-end, or butt, welds required to fabricate continuous tubing could not with stand repeated bending cycles and high tensile loads. Weld failures, equipment breakdowns and fishing operations to retrieve lost coiled tubing caused operators to lose confidence in this technique. Throughout the late 1960's and into the 1970's, both Bowen Tools and Brown Oil Tools continued to improve their designs to accommodate CT up to 1 in. OD. By the mid-1970's, more than 200 of the original-design CT units were in service. CT strings were also undergoing significant improvements during this period. Through the late 1960's, CT services were dominated by tubing sizes of 1 in. and less, and relatively short string lengths. Tubing diameter and length were limited by the tubing mechanical properties and currently available manufacturing processes. Early CT operations suffered many failures due to the inconsistent quality of the tubing and the numerous butt welds required to produce a suitable string length. However, by the late 1960's, tubing strings were being milled in much longer lengths with fewer butt welds per string. The late 1970s and early 1980s represented a turning point for coiled tubing, which up to that time was milled, or formed, in 1,500-ft [457-m] sections. In 1978, improved manufacturing quality and continuous milling allowed fabrication of OD pipe. In 1980, Southwestern Pipe introduced 70,000-psi high-strength, low-alloy (HSLA) steel for coiled. In 1983, Quality Tubing Inc. began using 3,000-ft [914-m] sheets of Japanese steel to reduce the number of required welds by 50%. Later in the 1980s, Quality Tubing introduced bias welding to eliminate butt welds. This process involved cutting flat steel strips diagonally to enhance coiled tubing strength to enhance coiled tubing strength and spirally around the tube. In addition, a better understanding of coiled tubing fatigue enabled improvements in reliability and pipe performance. In 1990, the first string of 2-in. coiled tubing was milled for a permanent well completion. Today, coiled tubing is manufactured from steel with high yield strengths of 90, 100, 110 and 120 ksi as well as corrosion- resistant alloys. Higher strength steel, larger diameters and the need to reduce costs were key factors behind the CT revolution of the1990s, and subsequently accounted for the extraordinary increase in concentric, or through-tubing, well-intervention work.
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Figure 14: Coil Tubing Trailer
Today it's common for CT strings to be constructed from continuously milled tubing that can be manufactured with no butt welds. In addition, CT diameters have continued to grow to keep pace with the strength requirements associated with new market applications. It's not unusual for CT diameters of up to 2 7/8 in. to be readily available for routine use. It's clear the CT industry has continued to make technical advancements that have opened new market applications for the technology. This progress has served to make CT an even more appealing solution for its early market applications.
6.1.3 COIL TUBING EQUIPMENT
Coil tubing generally consists of six basic equipments. 1. Tubing Reel 2. Injector Head & Gooseneck 3. Power Pack. 4. Control Cabin. 5. Well Control Equipment. Stuffing Box (Stripper, Pack off). Blow-Out Preventers (BOP). 44
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6.1.3.1. TUBING REEL
Coiled tubing is stored on a drum that is supported on a shaft and mounted on a skid frame. A bi-directional hydraulic motor directly driving the reel via roller chain and sprockets or by a gear drive system rotates the reel. The drive system has dual function: when running in hole (RIH), the motor acts as a constant-torque brake, enabling back tension to be held on the pipe and while pulling out of hole (POOH), more tension is applied to enable efficient spooling of the pipe onto the drum. The reel will have a brake mechanism to prevent accidental rotational movement when it is required. The reel drive system should produce enough torque to provide the required tension to the coiled tubing to bend the coiled tubing over the gooseneck and onto the reel. This tension provided by the reel on the coiled tubing unit between the reel and injector is commonly referred to as reel back-tension. The tension requirements thus reel motor drive systemincreases exponentially with coiled tubing diameter because of the Figure 15: Tubing Reel increased load/weights required. The tubing is spooled on/off the drum using a hydraulically raised & lowered level wind assembly. The level wind allows for travel along an adjustable diamond lead screw and is powered by rotation of the reel itself and incorporates a floating tubing guide to allow for height adjustments. A manual override facility is incorporated to allow for compensation of spooling errors. The reel is equipped with a rotating joint (swivel) to allow pumping through the coiled tubing while the reel is rotating; this rotating joint is flange mounted on to the reel shaft.
6.1.3.2. COILED TUBING INJECTOR HEAD
The injector head is the heart of the coiled tubing unit. This piece of equipment allows the coiled tubing to be injected (snubbed) and retrieved from the wellbore. The coiled tubing is gripped between contoured blocks, which are carried by two sets of double row contra-rotating chains. The injector operates on the friction drive principle. The injector speed and direction are controlled through the use of bi-directional hydraulic motors that provide the force for the injector. Hydraulic motors are used to drive the gripper block and chains by turning the chain 45
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drive sprockets. Different configurations are available with up to four motors driving the upper and lower sprockets. The hydraulic counter balance system provides dynamic braking when hydraulic pressure is released. Many injector motors have built in hydraulically released mechanically actuated brakes that automatically lock when there is loss off hydraulic pressure to the motor. Separate external manual mechanical brakes are also used on older injector heads. It is important that correct tension of the drive chains be maintained to prevent either crushing the tubing or letting it slip due to poor grip.
Figure 16: Injector Head
The chains and their motor and gearbox drive system are mounted in a sub frame, one side of which is hinged. The opposite lower side can rest on a hydraulic load cell, which is connected to the weight indicator in the control cab. The forces exerted by the action of the drive system and the tubing weight are all applied along the centerline of the tubing and cause the sub frame to pivot; the resulting deflection measuring direct force or load acting on hydraulic load cell bladder . Individual hydraulic load cells will measure either pipe-heavy (positive weight) or pipelight (negative weight, less than zero, snubbing). Another type of weight indicator is an electric strain gauge model. This type of weight indicator measures the applied load by strain gauges, with output signals in mAmps (4-20mA) or Volts (05 V), which are converted in the cab to measure applied loads tension (pulling) or compression (snubbing). The load is defined as the tensile or compressive force in the coiled tubing just above the stripper. It is one of the most important measurements used in the operation of a coiled tubing unit. Load may be effected by several parameters other than the hanging weight of the coiled tubing, including wellhead pressure, stripper friction, reel backtension , gooseneck alignment and the density of the fluids inside and outside the coiled tubing.
6.1.3.3. GOOSENECK
To complete the injector head package there is a tubing roller guide or gooseneck positioned on top off the injector head. The gooseneck aids in supporting, straightening and aligning the coiled tubing as it comes off the work reel and into the gripper blocks on the injector. This is done by a series of contoured rollers and cages that contain the coiled tubing as it travels over 46
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the gooseneck. The gooseneck base should also pivot or be flared at reel facing end, to enable for spooling across a work reel as the coiled tubing travels along the width of the drum. The gooseneck is designed with a nominal radius of curvature appropriate to the coiled tubing size; the radius needs to be at least 48 times the coiled tubing OD. This is to enable the maximization of coiled tubing life and thus reduce the effect of fatigue. Common gooseneck sizes are: 72, 96 and 120(183 cm, 243cm and305cm).
6.1.3.4. COIL TUBING POWER PACK
The most common type of power pack is diesel driven skid/trailer unit made up of a system of hydraulic pumps, hydraulic pressure control circuits, hydraulic tanks and accumulators to enable the efficient operation of the coiled tubing package. Power packs are built in many different configurations depending on the operating environment e.g. Electric Units, Zone 2 Certified, Sound Proof, Wet Units trailer tractor driven etc. The type of injector driven generally Figure 17: Hydraulic Power Pack classifies power pack as, 1-Standard open loop power pack 2-High pressure open loop power pack 3-Closed loop power pack 1-STANDARD OPEN LOOP POWER PACK The standard open loop injector drive circuit utilizes a fixed displacement double vane pump and a 4-wayvalve. The valve is a pressure compensating directional control valve that controls the speed and direction of the injector motors. The system is capable of operating at 3,000 psi. (20,684 k Pa) and works on the principle of oil going from the tank, through the pump and valves and to the injector motors; oil returns through a filter and air cooler into the hydraulic tank . 2-HIGH PRESSURE OPEN LOOP POWER PACK The high pressure open loop injector drive circuit utilizes a load sensed, variable displacement, pressure compensated piston type pump. The system is capable of operating at 5,000 psi. (34,473 k Pa) and works on the principle of oil going from the tank, through the pump and valves and to the injector motors; oil returns to the pump inlet (supercharging the pump) after 47
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passing through a filter and heat exchanger. A pressure relief valve in there turn line ensures oil that is not required by the pump is routed back to the tank; an advantage of this system, is that less heat is generated. 3-CLOSED LOOP POWER PACK The closed loop injector circuit utilizes a bi-direction, variable displacement pressure compensated piston pump. The pump actually comprises of three pumps: main pump, charge pump and servo pump (shifts the swash-plate for directional control). The system is capable of operating at 5,000 psi. (34,473 k Pa) and is a less complicated system when compared to the high-pressure open loop system. The system works on the principle of oil going from the tank, through the pump and valves and to the injector motors; oil returns through a filter and goes directly back to the pump inlet. A charge pump and auxiliary flushing circuit are always present to replenish fluid that leaked from the high pressure elements into the pumps case and to add cool oil into the low side of the loop to stabilize the oil temperature Hydraulic Circuit Injector Flush Reel Level wind BOP Auxuillary Functions Runs the injector Flushes The Injector(Closed loop pumps only) Runs the reel Runs the level wind Runs the BOP Runs the power hose reel, crane , winch etc
Table 1: Function Of Hydraulic Power Pack
5. COILED TUBING CONTROL CABIN The control cabin fully allows the operation and control of all functions of the coiled tubing unit from within the cabin. The typical unit is hydraulically elevated for better operator vision. The control panel incorporates: Injector controls Reel controls Dual stripper packer controls 48
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BOP controls Auxiliary shear seal BOP controls Hydraulic circuit pressure gauges Weight indicator Coiled tubing internal pressure Wellhead pressure - WHP Data Acquisition unit Remote power pack control
Figure 18: Coil Tubing Control Cabin
The unit is fully insulated with a heater for cold climates and space for air conditioning unit in warm climates .All necessary hoses to control and operate the Injector Head, BOPs, Power Pack and Tubing Reels are incorporated on hydraulically powered reels on the front of the skid. 49
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6.1.4 WELL AND PRESSURE CONTROL EQUIPMENT
Coiled tubing well and pressure control equipment is designed to allow for safe well intervention on a live/ pressurized well. The stuffing box and BOP are considered a Primary barrier for well control purposes, STUFFING BOX The stuffing box is the primary sealing mechanism for isolating/containing wellbore fluids while coiled tubing is under static or dynamic operating conditions. The stuffing box is attached to the bottom of the injector head by means of a flange connection or retaining pins. Operation of the stuffing box is by means of hydraulic pressure acting on a piston, which compresses a polyurethane element (stripper rubber) forming a seal around the coiled tubing. The packing elements are positioned between sets of brass bushing sand may incorporate Non-Extrusion Rings between bushings and stripper element. There are two main stuffing box designs, Top loading Side door BLOW OUT PREVENTERS The BOP is the primary safety apparatus designed to prevent the uncontrolled release of wellbore hydrocarbons and is usually flanged on top off the wellhead. A coiled tubing BOP is designed specifically for coiled tubing operations. The BOP consists of several pairs of rams, with each pair of rams having a specific function. 1. Blind rams isolate and seal against open hole when there is no tubing in the BOP. 2. Shear or Cutter rams have cutting blades to shear the coiled tubing and wire, if stiff-wire line. A Booster cylinder may be incorporated in the ram system to aid in shearing larger diameter or heavy wall coiled tubing. 3. Slip rams hold the coiled tubing to prevent it from being pushed out of the well or from falling down the well. Note Interrupted Slip Inserts are recommended to prevent undue marking of the tubing in event of use of rams. 4. Tubing or Pipe rams form a pressure seal around the coiled tubing to isolate well bore and contain pressure.
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Figure 6.5: Coil Tubing Plastic deformation Points Figure 19: Coil Tubing Plastic Deformation Points
AUXILIARY WELL CONTROL EQUIPMENT Auxiliary well control equipment includes, Hydraulic Quick Lathes Annular BOPs Tool String Development System
Figure 20: Coil Tubing Blow Out Preventer
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BOTTOM HOLE ASSEMBLIES A key element of most coiled tubing jobs is the type of tool or combination of tools that are needed to bring about a desired result. The tools covered has been categorized as follows Connectors Valves Disconnects Locators Centralizers & Stabilizers Wash Tools Down hole Separator Impact Tools Shifting Tools Stiff Wire line Tools Fishing Tools Specialty Tools
6.1.5 COIL TUBING APPLICATIONS
The use of coiled tubing for oil and gas well service operations has increased significantly over the past 10 years. There are numerous applications of coil tubing. The applications of coil tubing are as,
6.1.5.1 WORKOVER AND COMPLETION
CT is routinely used as cost-effective solution for numerous workover applications. A key advantage of CT in this application is the ability to continuously circulate through the CT while utilizing CT pressure control equipment to treat a live well. This avoids potential formation damage associated with well killing operations. The ability to circulate with CT also enables the use of flow-activated or hydraulic tools. Other key features of CT for workover applications include the inherent stiffness of the CT string. This rigidity allows access to highly deviated/horizontal wellbores, and the ability to apply significant tensile or compression forces
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down hole. In addition, CT permits much faster trip times as compared to jointed pipe operations. OVERVIEW OF SELECTED WORKOVER APPLICATIONS PUMPING APPLICATIONS 1- Removing sand or fill from a wellbore 2- Fracturing/acidizing a formation 3- Unloading a well with nitrogen 4- Gravel packing 5- Pumping slurry plugs 6- Scale removal (hydraulic) 7- Cutting tubular with fluid MECHANICAL APPLICATIONS 1- Setting a plug or packer 2-Fishing 3-Perforating 4-Logging 5-Scale Removal 6-Drilling 7-Running completion
Table 2: Coil Tubing Applications 6.1.5.2 FISHING
Coiled tubing is used to convey fishing tool to deliver jarring action in longer horizontal wellbore configurations. When fishing on coiled tubing for devices stuck in hole, hydraulic jars are typically used as means of providing impact force to free the device. The drawback is that the pipe must be cycled over the gooseneck multiple times to fire and reset the jar. Down hole vibration technology places impact energy right where the device is stuck and frees it quickly, even from deep or deviated wells. Most types of conventional spears and overshot can be conveyed on coiled tubing. These include standard basket and spiral-type overshot, kelo sockets, mousetrap over shots, and releasing spears. However, these types of tools cannot be released conventionally because coiled tubing cannot be rotated. If these tools are run on coiled tubing and the fish cannot be retrieved after latching the overshot, a hydraulic disconnect farther up the tool string must be activated. This leaves additional tools in the hole. To avoid this situation, it is advisable to run hydraulic releasing spears and overshot before running conventional types of spears and overshot when fishing using coiled tubing.
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6.1.5.3 FRACTURING /ACIDIZING A FORMATION
This CT application has experienced significant growth in recent years, and provides several advantages versus conventional formation treatment techniques. In particular, CT provides the ability to quickly move in and out of the hole (or be quickly repositioned) when fracturing multiple zones in a single well. CT also provides the ability to facture or accurately spot the treatment fluid to ensure complete coverage of the zone of interest. When used in conjunction with an appropriate diversion technique, more uniform treating of long target zones can be achieved. This is particularly important in horizontal wellbores. At the end of the formation treating operation, CT can be used to remove any sand plugs used in the treating process, and to lift the well to be placed on production. One of the earlier concerns with CT fracturing was the erosion effects that occur when proppant is pumped during the fracturing operation and the resulting impact on CT string life. An ultrasonic thickness (UT) gauge is now used on location to measure CT thickness during the job. Data from these UT measurements can be used to adjust the CT fatigue models, and to accurately monitor remaining CT string life.
6.1.5.4 UNLOADING A WELL WITH NITROGEN
The process of using CT to unload a well with nitrogen is a quick and cost-effective method used to regain sustained production. A typical field scenario consists of a wellbore that has developed a fluid column with sufficient hydrostatic pressure to prevent the reservoir fluid from flowing into the wellbore. Displacement of some of this wellbore fluid with nitrogen reduces the hydrostatic head, and this reduction of BHP allows the reservoir fluid to again flow naturally into the wellbore. If the wellbore conditions are suitable (pressure, fluid phase mixture and flow rate), production will continue after nitrogen pumping ceases. There are numerous benefits associated with the use of CT for a nitrogen kickoff operation. The rate and depth of the nitrogen injection can be adjusted to fit a wide range of field conditions. The procedure also provides a ready source of uncontaminated production fluid samples (oil, formation water). And, the procedure is extremely simple from an operational standpoint, as only a small amount of equipment and a limited number of field personnel are necessary.
6.1.5.5 SAND REMOVAL OR FILFORM A WELL BORE
The removal of sand from well bore is the most common coil tubing operation performed in the field. The process has several names including sand washing, sand cleanout, sand jetting and file removal. The objective of this is to remove the accumulation of solid particles in the well bore. The material will act to impede fluid flow and reduce well productivity. In many cases coil tubing is the only viable mean of fill removal from well bore. The fill include the formation of sand or fines, proppant flow back or fracture operation screen out and gravel pack failures The 54
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typical procedure involved in this application is to circulate a fluid through the CT while slowly penetrating the fill with an appropriate jetting nozzle attached to the end of the CT string. This action causes the fill material to become entrained in the circulating fluid flow, and is subsequently transported out of the wellbore through the CT/production tubing annulus. Where consolidated fill is present, the procedure may require the assistance of a downhole motor and bit or impact drill. An alternative fill removal approach is to pump down the CT/production tubing annulus and allow the returns to be transported to surface within the CT string. This procedure, called reverse circulation, can be very useful for removing large quantities of particulate, such as frac sand, from the wellbore..
6.1.5.6 LOGGING
Logging is the process of measuring and taking values while the well is being drilled. There are several electronic, acoustical, mechanical or radioactive devices which are use to perform logging of the well , to measure and record certain characteristics or events while the well is being drilled or any other operation being performed in the well. Acoustical logging is the process of recording the acoustic characteristics of subsurface formations, based on the time required for a sound wave to travel a specific distance through rock. The rate of travel depends on the composition of the formation, its porosity, and its fluid content. It is also called sonic logging. Radioactive Logging is the recording of the natural or induced radioactive characteristics of subsurface formations. A radioactivity log, also known as a radiation log or a nuclear log, normally consists of two recorded curves: a gamma ray curve and a neutron curve. Both help to determine the types of rocks in the formation and the types of fluids contained in the rocks. Mud Logging is a continuous examination of the drilling fluid circulating in the wellbore for the purpose of discovering evidence of oil or gas regardless of the quantities entrained in the fluid. When this service is utilized, a portable mud logging laboratory is set. Deploying logging tools on coiled tubing is one of the more innovative uses of coiled tubing. Installing logging cable inside the coiled tubing allows tools to be deployed into highly deviated wells and permits a variety of remedial functions, including: Cement bond logging in highly deviated wells Production logging to determine water entry points in highly deviated wells Open hole logging in deviated air-drilled wells that need pressure control Single-trip under-balanced perforating with long gun strings. Setting plugs and packers in deviated wells with pinpoint depth control.
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6.2 DRILLING
Coiled tubing drilling has been utilized on a commercial basis for many years, and can provide significant economic benefits when applied in the proper field setting. In addition to potential cost advantages, Coil Tubing Drilling can provide the following additional benefits: Safe and efficient pressure control Faster rig up/rig down Faster tripping time (150+ ft/min) Reduced environment impact Smaller footprint and weight Less personnel
6.2.1 Directional Wells
This type of CTD application utilizes an orienting device in the bottom hole assembly (BHA) to control the wellbore trajectory as desired. CTD for this application can include new wells, extensions, side-tracks through existing completions, horizontal drain holes, or side-tracks where the completions are pulled. However, the primary use of CTD for directional wells is to directionally drill into new reservoir targets from existing wellbores. Directional drilling with CT has some fundamental differences compared to conventional rotary drilling techniques. One of the basic differences is the need for an orienting device to control the well trajectory, since CT cannot rotate. Orienting devices control hole direction by rotating a bent housing to a particular orientation or controls the side loading at the bit to push the assembly in a particular direction. A steering tool is used to measure inclination, azimuth, and tool face orientation. Two basic types of steering tools are used for directional drilling with CT, Electric steering tools and Mud pulse tools. In addition to orientation and steering devices, some Bottom Hole Assemblies utilized for CTD are equipped with additional measurement tools, including gamma ray, casing collar locator, accelerometers etc.
6.2.2 Non-Directional Wells
Non-directional wells represent the largest CTD application, and these are defined as a well that lacks down hole tools to control direction, inclination and/or azimuth. Much of the CTD work performed to date involved shallow gas well, but it has also been used for shallow water injection wells and for "finishing" operations. A primary advantage that CTD provides in this application is the speed of the rig up/down operation, and the continuous rate of penetration. The majority of this CTD work has been performed with hole sizes less than 7 in., but hole sizes up to 13 3/4 in. have been successfully drilled. 56
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6.2.3 Overbalanced Coil Tubing Drilling
As with conventional well drilling operations, the drilling fluid is used for controlling subsurface pressure and the CTD drilling fluid systems are typically smaller versions of conventional systems. Conventional well control principles apply except that the CT string limits the fluid flow rate and the frictional pressure loss varies with the ratio of tubing on/off the reel.
6.2.4 Underbalanced Coil Tubing Drilling
CTD is ideal for these underbalanced applications because of its inherent well control system. For finishing operations, a conventional rig is used to drill to the top of the reservoir and casing is run. From this point, CTD is utilized to drill into the reservoir with underbalanced drilling techniques. This technique attempts to leverage the respective strengths of both drilling approaches. Conventional drilling can be faster (less expensive) in the large diameter, unproductive up hole drilling intervals, while underbalanced CTD is faster (less expensive) in the producing interval. CTD is also better suited to deal with the pressure/produced hydrocarbons from the productive interval.
6.3 PIPELINE APPLICATIONS:

CT can be used as an effective tool for numerous pipeline applications, including: Transportation of inspection tools Removing organic deposits and hydrate plugs Removing sand or fill Placing a patch or liner to repair minor leaks Setting temporary plugs
6.3.1 LAND BASED
Land-based Coil Tubing operations in pipelines are similar to Coil Tubing operations in horizontal wellbores with a few notable exceptions. First, the injector head must supply all the force required to Run In Hole with the Coil Tubing. The lack of a vertical Coil Tubing section means that none of the Coil Tubing weight is available to push on the Coil Tubing ahead of it. Second, the injector head must be oriented horizontally at the entrance to the pipeline. This requires a special mounting frame and an injector that will operate efficiently while lying on its side. Finally, the injector head will be required to snub the Coil Tubing into the pipeline during the entire Run in hole operation, and thus the weight measuring device (weight cell) must be configured for accurate measurement of snubbing forces.
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6.3.2 OFF SHORE
CT operations in pipelines from an offshore platform are similar to operations in extended reach wellbores that kickoff at a shallow depth. The primary difference is that the path of the CT between the injector and the conduit on the sea floor may include several short radius bends. These bends impart a high drag force, and increase the snubbing force requirement on the CT injector. Since the injector may have to snub the CT into the pipeline during most of the RIH phase of the operation, the CT weight measuring device (weight cell) must be configured for accurate snubbing force measurement.
6.3.3 VELOCITY STRINGS
The use of velocity strings is a common practice, especially in depleted gas wells. The objective of this permanent installation is to decrease the available production surface area within the wellbore such that the produced gas has sufficient energy to carry any produced liquids to surface. Small diameter (OD < 2 in.) velocity strings are often constructed from used CT work strings. A downhole hydraulic simulator is often used to estimate the performance of the string over a range of expected operating conditions. This modeling can help design a velocity string that maximizes well production. However, for these depleted wells, the choice of CT size and installation hardware may be heavily dependent on the price/availability of used CT strings.
6.4 CIRCUIT USED IN POWER PACK

The type of hydraulic circuit used in any hydraulic system is a key factor to find the response of a system over some extended period of time. There are two types of basic circuits used in the power pack system. Hydraulic circuit is basically the assembly and the path given to the specific fluid to move in the circuit. Open loop system Closed loop system The type of circuit used by Sprint Oil and Gas are Open loop systems. Many companies use closed loop systems but both have their respective advantages and disadvantages.
6.4.1 OPEN LOOP SYSTEM
In open loop systems the pump draws fluid from a storage tank or reservoir and then discharges it to a directional control valve, which is used to select up, down or neutral. Flow from this valve goes to the motor and back to tank (up or down) or goes directly back to the tank when in neutral. In this system as flow is from tank to tank, so in each cycle the pump has to cover the friction head as well as static head.
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Figure 21: Block Diagram of Open Loop Circuit
Open loop configuration overcomes the problems associated with closed loop systems as dynamic braking is accomplished by means of a motor control or counterbalance valve, which is normally fitted directly to the hydraulic motor. The energy of lowering the load at a controlled speed is converted into heat in the hydraulic fluid by forcing it to flow through a small orifice at high pressure, so the prime mover plays no role in dynamic braking. This means the prime mover need not be sized based on the potential full power requirements of the three primary crane motions. For this reason, a failure of the prime mover cannot and will not result in loss of control of the load. If the prime mover is a diesel engine, it is not necessary to run it at high speed. Full-rated loads, on both the boom and the hook, can be lowered under full control with the engine operating at idle speed.
Figure 22: Schematic of Open Loop Circuit
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Hydrostatic transmissions for earth moving machines, such as for track loaders, are often equipped with a separate inch pedal that is used to temporarily increase the diesel engine rpm while reducing the vehicle speed in order to increase the available hydraulic power output for the working hydraulics at low speeds and increase the tractive effort. The function is similar to stalling a converter gearbox at high engine rpm. The inch function affects the preset characteristics for the 'hydrostatic' gear ratio versus diesel engine rpm.
ADVANTAGES
1. The pump can be utilized for any other hydraulic function in an easy way. 2. The oil after flowing through the whole circuit comes back to tank, so cooling is relatively easily achieved due to excess exchange of oil flow. 3 As oil temperatures are easily controlled so the lifetime for the transmission is increased. 4. A hydraulic line rupture cannot cause the load to drop because load holding is performed between the hydraulic motor pistons and the spool in the counterbalance valve. This means that the fluid conductors are not critical components in this type of system. 5. It is very easy to filter the hydraulic fluid because the fluid passes through the tank whenever a hoist is in operation. This makes it practical to filter the oil on a continuous basis by means of a separate fluid conditioning circuit. 6. Neutral creep in the pump swash plate servo cannot cause the crane to move unintentionally because the directional control valve will divert any unexpected flow directly to tank as long as the control handles are centered.
7. It is also very easy to cool the hydraulic fluid by means of a large oil cooler fitted in the fluid conditioning circuit. This overcomes the overheating problem common with closed loop systems.
8. As in open loop systems there are minimum leakages so, there in no need for leakage flow and extra flush flow to be supplied by the charge pump to the system.
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9. There is no need that to lower the system pressures to keep the temperature of to a minimum value.
Table 3: Advantages Of Open loop system
6.4.2 COMPONENTS OF OPEN LOOP CIRCUIT
The basic components of open loop hydraulic systems are as follows, Hydraulic pump (Normally vane type pump is used) Control Valves (Valves to control the flow such as directional control valves etc) Actuators (Actuators to actuate our commands such as hydraulic motors, hydrostatic transmission, brakes, hydraulic cylinders) Reservoirs Accumulator Hydraulic Fluid Filters Tube, Pipes and Hoses Seals, Fittings and Connections
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PHASE-II Chapter#7 ANALYSIS AND DIAGNOSIS
7.1 INTRODUCTION
In this part of our work maximum work was accomplished on the unit by frequent visits to the sprint yard. This part mainly concerns with the determination of the problem and locating its possible solution. As the main research was divided into three main phases similarly we devised a simple method to cover all the possible routes that could affect the equipments performance in any regard. Thus the method of analysis used is described below.
7.2 METHOD OF ANALYSIS

The complete analysis of the problem and the solution requires identification and study of four basic parameters, DESIGN FEATURES MODIFICATIONS MAINTENANCE USAGE
The performance of the machine part can be easily determined by theoretically calculating it through given parameters. But the theoretical values are always greater than practical values. Once the equipment is designed it is made to give the maximum possible efficiency keeping in mind all the laws and principles but as the machine is applied to some work its efficiency some times decreases after some time or certain problems start to raise. The trouble shooting of these problems require first a schematic study of them. The study and experimentation performed is described below according to the pattern they were performed.
7.2.1 DESIGN FEATURES
Design features are the most important factors affecting the performance. While studying the design features of the system it is considered that the system was designed after exhausting hundreds of man hours on the research phase but it was found that the unit was custom made for the use in Pakistan thus design features were also given importance. 63
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Following are the design factors which are studied Pumps Assembly of pumps Types of cooling method used Types of cooling fluid used Layout of the fluid lines. Cooling tank capacity Heat exchanger Type of hydraulic circuit used
7.2.2 MODIFICATIONS
Modifications are occasionally made to the original design to support any new work or perform any new task but some times these modifications dont support the equipment in the long run thus they have to be studied. Types of modifications studied are Recent in-house modifications Onsite modifications Spare parts used
7.2.3 MAINTENANCE
Maintenance is the key aspect of any equipment especially when it has moving parts. Excessive use of the machine without proper maintenance periods or frequency maintenance being done the equipment starts to malfunction as slung starts depositing friction comes into action and also that un cleaning of filter causing vibrations. Following maintenance histories were concerned Preventive maintenance Frequency maintenance Maintenance being missed due to work on rig
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7.2.4 USAGE
Overworking the unit with skipped modifications can be very harmful to the system and cause problems like leakages over heating etc. an interesting factor was also discovered during the study that any equipment when subjected to multiple operators can have problems due to different tackling techniques of the operators. Following usage criteria where studied Working hours Multiple operators
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EQUIPMENT STUDY Chapter#8 DATA ACCUMULATION
EQUIPMENT STUDY
Working on the second phase of the project our main concern was to collect all the possible data and governing factors of the process. Coil tubing is basically powered by hydraulic oil which pressurizes the equipment. Thus our main concern started with the study of the pumps. All of the equipment was studied and the following data was accumulated
8.1 PUMPS
Pumps are the pumping devices which are used to push the fluid in the required direction. It displaces or moves a fluid by physical or mechanical action. Pumps have different types and applications accordingly. Pump type which will be discussed in this report is VANE TYPE PUMP. As it is the pump used in the open loop hydraulic power pack.
Figure 23: Vane Type Installed In Power Pack
Vane Type Pump is a positive displacement pump that consists of vanes mounted to a rotor that rotates inside a cavity. In some cases these vanes can be of variable length and tensioned to maintain contact with the wall as the pump rotates.
8.1.1 WORKING
1. A slotted rotor is eccentrically supported in a cycloidal cam. The rotor is located close to the wall of the cam so a crescent-shaped cavity is formed. The rotor is sealed into the cam by two side plates. Vanes or blades fit within the slots of the impeller. As the rotor rotates (yellow arrow) and fluid enters the pump, centrifugal force, hydraulic pressure, and/or pushrods push
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the vanes to the walls of the housing. The tight seal among the vanes, rotor, cam, and side plate is the key to the good suction characteristics common to the vane pumping principle. 2. The housing and cam force fluid into the pumping chamber through holes in the cam (small red arrow on the bottom of the pump). Fluid enters the pockets created by the vanes, rotor, cam, and side plate. 3. As the rotor continues around, the vanes sweep the fluid to the opposite side of the crescent where it is squeezed through discharge holes of the cam as the vane approaches the point of the crescent (small red arrow on the side of the pump). Fluid then exits the discharge port.
8.1.2 ADVANTAGES VANE TYPE PUMPS
Advantages of vane type pumps are as follows, Handles thin liquids at relatively higher pressures Compensates for wear through vane extension Sometimes preferred for solvents, LPG Can run dry for short periods Can have one seal or stuffing box Develops good vacuum
8.1.3 DISADVANTAGES OF VANE TYPE PUMPS
Disadvantages of vane type pumps are as follows, Can have two stuffing boxes Complex housing and many parts Not suitable for high viscosity Not good with abrasives
8.1.4 APPLICATIONS OF VANE TYPE PUMPS
Aerosol and Propellants Aviation Service - Fuel Transfer, Deicing Auto Industry - Fuels, Lubes, Refrigeration Coolants Bulk Transfer of LPG and NH3 67
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Alcohols Refrigeration - Freons, Ammonia
8.1.5 PUMP SPECIFICATIONS CHART
The specifications of the pumps used in the equipment are as follows:

1.
DENISON HYDRAULIC PUMP VANE TYPE DUAL ACTING Priority pump (2200psi-2500psi) (flow rate = 12 GPM) Over-ridder pump (2500 psi) (flow rate = 27 GPM)
2.
DENISON HYDRAULIC PUMP VANE TYPE SINGLE ACTING Injector high pump (3000psi-3200psi) (flow rate = 60 GPM) DENISON HYDRAULIC PUMP VANE TYPE DUAL ACTING injector low pump (3000psi-3200psi) (flow rate = 30-35 GPM) reel pump (2500psi) (flow rate = 27 GPM) DENISON HYDRAULIC PUMP VANE TYPE DUAL ACTING Auxiliary pump (500psi-2500psi) (flow rate = 27 GPM) Blow out preventer pump (2700psi-3000psi) (flow rate = 12 GPM)
3.
4.
8.2 COOLING FLUID AND COOLING MECHANISM

The cooling oil used for cooling and lubrication purposes in the hydraulic power pack is DTE 26. There is a wide range of varieties to choose from for this purpose. The main reasons for the use of this cooling oil are described below. All the hydraulic power packs for both open and closed loop systems use DTE 26 cooling oil. At about 205f it changes to foam like substance loosing all its cooling and lubricating abilities. So cooling is very important so as to maintain the temperature below or up to 195f. Operation up to 190f is considered safe but beyond that serious measure should be instantly taken to avoid any sort of accident.
8.2.1 Measures Taken During Operation
Instantly shutting of the injector high and low pumps Sprinkling water externally through pipes on the heat exchanger, pumps and cooling tank Increase in temperature can cause the cooling fluid to change to a foamy liquid thus no cooling or lubrication will be provided to the equipment causing a dry run and thus in turn can cause major accidents. 68
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8.2.2 USAGE
The recommended oil change frequency given by the vendor is 2000 working hours. After this period oil change must be provided with cleaning of shieves and filters with the frequency of 15 days. But it was found while looking into the maintenance log that cooling oil changes have not been taking place at the given time period and a delay of some times 500 hours also occurred during a job that was being performed in Marree gas field. This is also a reason of the heat gains that occur in the equipment.
8.2.3 DESCRIPTION
Mobil DTE 20 Series oils are supreme performance anti-wear hydraulic oils designed to satisfy a wide range of hydraulic equipment requirements. They provide long oil/filter life and optimum equipment protection reducing both maintenance costs and product disposal costs. They were developed in conjunction with the major builders to meet the stringent requirements of severe hydraulic systems using high pressure, high output pumps as well as handling the critical requirements of other hydraulic system components such as close clearance servo-valves and the high accuracy numerically controlled (NC) machine tools. These products meet the most rigorous performance requirements of a wide range of hydraulic system and component manufacturers using various multi-metallurgy designs allowing a single product with outstanding performance characteristics. The DTE 20 Series oils are formulated with high quality base oils and a super-stabilized additive system that neutralizes the formation of corrosive materials. They are designed to work with systems operating under severe conditions where high levels of antiwear and film strength protection are needed, yet they are formulated to work where non-antiwear hydraulic oils are generally recommended.
8.2.4 FEATURES AND BENEFITS
The Mobil DTE 20 Series hydraulic oils provide outstanding oxidation resistance allowing extension of oil and filter change intervals. Their high level of anti-wear properties and excellent film strength characteristics result in exceptional equipment performance that not only results in fewer breakdowns but helps improve production capacity. Their controlled demulsibility permits the oils to work well in systems contaminated with small amounts of water yet readily separate large amounts of water. 69
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FEATURES
Anti wear
ADVANTAGES AND POTENTIAL BENIFITS
Reduces wear Protects systems using various metallurgy Maintains performance features even under severe Quality Reserve service conditions and extended drain intervals. Improved system cleanliness. Provides long oil and equipment life. Oxidation Stability Extends filter life. Prevents internal hydraulic system corrosion. Reduces Corrosion Protection negative effects of moisture in systems. Provides corrosion protection of multi-metallurgy component designs. One product can replace several Meets a Wide Range of equipment Minimizes inventory requirements requirements. Reduced potential for product misapplication Reduces foaming and its negative effects. Air Separation Characteristics Protects systems where small quantities of moisture Water Separation are present Readily separates larger quantities of water Reduces system deposits and sludging. Keep Clean Properties
Table 4: Features and Advantages of Cooling Fluids 8.2.5 APPLICATIONS

Hydraulic systems critical to deposit build-up such as sophisticated Numerically Controlled (NC) machines, particularly where close clearance servo-valves are used. Where small amounts of water are unavoidable. Applications where sludges and deposits form with conventional products. In systems containing gears and bearings. Systems requiring a high degree of load-carrying capability and anti-wear protection. Applications where thin oil-film corrosion protection is an asset such as systems where small amounts of water are unavoidable. Machines employing a wide range of components using various metallurgy.
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TYPICAL PROPERTIES
Mobile DTE 20 21 Series ISO Grade Viscosity 10 ASDM D 445 cSt @ 40 C cSt @ 100 C Viscosity Index, ASTM D 2270 Specific Gravity @ 15.6 C/15.6 C, ASTM D 1298 Copper Strip Corrosion, ASTM D 130, 3 hrs @ 100 C Rust Characteristics Proc B, ASTM D 665 Pour Point, C, ASTM D 97 Flash Point, ASTM D 92 10 2.74 98 0.845
22 22 21 4.5 98 0.865
24 32 31.5 5.29 98 0.871
25 46 44.2 6.5 98 0.876
26 68 71.2 8.53 98 0.881
27 100 95.3 10.9 98 0.887
28 150 142.8 14.28 98 0.895
1B
1B
1B
1B
1B
1B
1B
Pass
Pass
Pass
Pass
Pass
Pass
Pass
-30
-30 200 -
-27 220 12
-27 232 12
-21 236 12
-21 248 12
-15 276 12
C, 174
FZG 4-Square Load Support, DIN 51354, Fail Stage Foam Sequence I, 20/0 II, III, ASTM D 892 , ml
20/0
20/0
20/0
20/0
20/0
20/0
Table 5: Properties of Mobile DTE 26
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8.2.6 RESULT:
From the above discussion we conclude that DTE 26 is the best cooling oil for this kind of operation and there is no problem with the type of cooling fluid used. DTE 26 is exceedingly effective when working on Potohar exploration region in Pakistan.
8.3 HYDRAULIC CIRCUITS

There are basically two types of hydraulic circuits. 1. Open Loop Systems 2. Closed Loop Systems
8.3.1 BASIC PROBLEMS
Open loop ( decrease in efficiency of pumps ) Closed loop ( raise in temperature ) The decrease in the efficiency of the pumps is caused mainly due to the fact in the open loop circuit as the fluid at the end of the loop drops in the tank thus every time a new loop starts the pump has to over come friction head and static head. Thus the working of every pump is increased even if the operation being performed does not require the continuous use of that pump. Like during cementing operation the pump of BOP pump no longer exists but as it is also mounted on the same shaft of the engine it operates and thus has to over come both the static and the kinetic heads and thus after certain time of operation wear causes the efficiency of the pumps to decrease but in the case of closed loop circuit where Swatch plate pumps are used and the out put from the circuit does not fall into the tank and goes directly to the input of the pump the pump only has to over come the friction head not the static head. As we know that the static head is very high as compared to the friction head thus pump has to perform very little work when not operating on load conditions thus minimizing the wear factor and increasing the efficiency of the pump. But the main disadvantage of this type of circuit is that as fluid no longer falls into the tank where as in the case of open loops losses most of its heat in the reservoir thus increase in temperature is a common problem in the closed loop circuit. In order to compensate for this increased temperature a bigger cooling tank is required and a bigger heat exchanger thus increasing the cost of the closed loop circuit power packs.
8.3.2 OPEN LOOP SYSTEMS
In open loop systems the pump draws fluid from a storage tank or reservoir and then discharges it to a directional control valve, which is used to select up, down or neutral. Flow from this valve goes to the motor and back to tank (up or down) or goes directly back to the tank when in neutral. In this system as flow is from tank to tank, so in each cycle the pump has to cover the friction head as well as static head. Open loop configuration overcomes the 72
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problems associated with closed loop systems as dynamic braking is accomplished by means of a motor control or counterbalance valve, which is normally fitted directly to the hydraulic motor. The energy of lowering the load at a controlled speed is converted into heat in the hydraulic fluid by forcing it to flow through a small orifice at high pressure, so the prime mover plays no role in dynamic braking. This means the prime mover need not be sized based on the potential full power requirements of the three primary crane motions.
Figure 24: Schematic of Open loop Circuit
For this reason, a failure of the prime mover cannot and will not result in loss of control of the load. If the prime mover is a diesel engine, it is not necessary to run it at high speed. Full-rated loads, on both the boom and the hook, can be lowered under full control with the engine operating at idle speed.
Figure 25: Schematic of Closed Loop Circuit 8.3.3 CLOSED LOOP SYSTEM
In closed loop systems the pump draws fluid from a storage tank or reservoir and then connects the motor outlet directly to pump inlet. o keep up pressure on the low pressure side.
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8.3.4 COMPARISON BETWEEN OPEN AND CLOSED LOOP CIRCUIT
In open loop systems as the fluid passes through the hydraulic tank in each cycle of operation, so it get the chance to exchange hot incoming fluid with the previously present cold fluid which helps in decreasing the temperature of oil being used. But all this is achieved at the expense of requiring greater amount of work from the pump as in this system pump has to cover the static head as well in addition to friction head, due to this reason greater pressure losses are resulted in case of open loop systems. In case of closed loop system, exit from the motor is connected directly to the pump, so in this case the pump has to cover only static head. But as the fluid has not got the chance to get cool by entering in the reservoir so there are large heat generation problems in case of closed loop systems. In closed loop systems for achieving high pressures, there must be a flush value assembled in the circuit in order to exchange much more flow than the basic leakage flow from the pump and the motor, for increased cooling and filtering. Due to this leakage flows and extra flows must be supplied to the system through charging pump. But in open loop no extra pump is required. As there is decrease in pressure in open loop systems on the other hand there exists a problem of heat gain in closed loop systems. So one preference should be made by considering the environmental conditions and economics of the system. Close loop systems are very expensive than open lop but they provide higher efficiencies as compared to the open loop. But there is a lot heating problems in Pakistan as in Pakistan there is extreme working conditions. So in order to avoid high temperatures open loop systems should be preferred because they can easily cover the heating problems at the expense of small decrease in efficiency. The hydraulic systems in Sprint Units are using vane type pumps in open loop systems, and swatch type pump in close loop systems.
8.3.4.1 Vane Type Pumps
Vane type pumps consist of vanes or slots in rotor. When rotor turns, centrifugal force pushes the vanes out to reach the casing, where they trap and propel fluid. Sometimes springs also pushes the vanes outward. When vanes reach the return side they are pushed back into the rotor by the casing. Fluid escapes through channels or grooves in the casing. Vane type pumps are used in open loop systems.
8.3.4.2 Swatch Plate Pump
Swatch plate pumps have a rotting cylinder containing pistons. A spring pushes the piston against the stationery swatch plate, which sits at an angle to the cylinder. The piston sucks the fluid during half revolution and pushes the fluid out during other half. The greater the plate slants, further the piston moves, more the fluid they transfer. Swatch plate pumps can be designed with fixed or variable displacement arrangements. 74
EQUIPMENT STUDY VANE TYPE PUMPS

1. It is a positive displacement pump. 2. It is normally used in open loop systems.
SWATCH PLATE PUMPS
1. It is a positive displacement pump. 2. It is commonly employed in closed loop systems. 3. The oil after flowing through the whole 3. Oil doesnt flow through reservoir during circuit comes back to tank, so cooling is cycle of its operation, excess cycling increases relatively easily achieved due to excess the temperature of system drastically. exchange of oil flow. 4. As oil temperatures are easily controlled 4. Due to excess increase in temperature, so the lifetime for the transmission is lifetime for transmission is decreased. increased. 5. In order to control the direction of flow 5. Swatch plate provides the additional feature directional control valves is used. of controlling the fluid flow rate and direction of flow. 6. Vane type pumps can easily be employed 6. Swatch plate pumps are difficult to use. in any circuit. 7. The ECM (Electronic Control Module) for 7. The ECM (Electronic Control Module) for vane type pumps is easy to design. Swatch plate pumps is complex to design. 8. Long service intervals. 8. Relatively short service life because of heating problems. 9. Can easily be attached and switched on. 9. Difficult to attach and use. 10. Low energy consumption. 10. Comparatively high energy consumption.
Table 6: Comparison between Swatch and Vane Type Pumps
8.3.4.3 COMPONENTS OF HYDRAULIC CIRCUIT
The basic components of open loop hydraulic systems are as follows, Hydraulic pump (Normally vane type pump is used) Control Valves (Valves to control the flow such as directional control valves etc) Actuators (Actuators to actuate our commands such as hydraulic motors, hydrostatic transmission, brakes, hydraulic cylinders) Reservoirs Accumulator Hydraulic Fluid Filters Tube, Pipes and Hoses
8.3.5 CIRCUIT DIAGRAMS
For analysis the circuit we first draw the circuit diagrams. The circuit diagrams were developed by extensive line tracing me. In this technique we study the circuit completely and draw the 75
EQUIPMENT STUDY
lines, their inputs and outputs and draw a hydraulic circuit or modal which gives us complete knowledge of the flow.
8.3.5.1 BOP HYDRAULIC CIRCUIT ON POWER PACK
Figure 26: BOP Hydraulic Circuit on Power Pack
Explanation The BOP pump (12GPM) take suction from hydraulic tank through strainer, it delivers flow through relief valve (2700Psi-3000Psi), adjusted by knob on relief valve. The flow goes to the Accumulators and Hose (28) through check valve and further to control cabin for its functions. There is a high pressure needle valve located in the high pressure flow line, when the needle valve is open all the flow goes back to the tank through filter, and when the needle valve is closed the flow of oil to the tank stops and starts pressure build up to operate different BOP rams. The function of check valve is that that the flow did not came in reverse when the power pack is off
8.3.5.2 AUXILIARY CIRCUIT ON POWER PACK
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Figure 27: Auxiliary Circuit On Power Pack
Explanation The auxiliary (27GPM) take suction from hydraulic tank through strainer, it delivers flow through relief valve if ball valve is closed on panel adjusted by knob on relief valve. The flow goes to the hose reel motor for its operation. The control panel consists of a high pressure ball valve which has two positions i.e. load and vent. When this valve is at vent/open all flow goes back to the hydraulic tank through a manifold without any pressure, when the valve is at load/closed position the oil flow stops towards the tank and is diverted to the relief valve.
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8.3.5.3 PRIORITY, REEL AND OVER-RIDER HYDRAULIC CIRCUIT ON POWER PACK
Figure 28: Priority, Reel & Over-rider Hydraulic Circuit On Power Pack
Explanation The Hydraulic pump takes suction from hydraulic tank through strainer, it delivers flow through relief valve if ball valve is closed on panel, and pressure is adjusted by knob on relief valve. The flow goes to the main hose panel and further to control cabin for its functions. The control panel consists of a high pressure ball valve which has two positions i.e. load and vent. When this valve is at vent/open all flow goes back to the hydraulic tank through a manifold without any pressure, when the valve is at load/closed position the oil flow stops towards the tank and is diverted to the relief valve.
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Pump description Priority pump Reel pump Over-rider pump
Flow rate(Gal/min) 12GPM 27GPM 27GPM
Pressure limitation(PSI) 2200-2500 2500 2500
Hose Description 48 27 29
Table 7: Hydraulic Pumps Specifications 8.3.5.4 INJECTOR HYDRAULIC CIRCUIT ON POWER PACK
Figure 29: Injector Hydraulic Circuit in Power Pack
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Hydraulic tank
Ball valve Pressure gauge
Strainer
Hydraulic Pump
Relief valve
Oil cooler
Table 8: Key Of Above Circuit
Hydraulic filter
Explanation There are two pumps used for injector drive circuit i.e. Inj. Low pump and Inj. High pump. Both the pumps take suction from the hydraulic tank through strainer and deliver a flow of oil to their respective relief valve. The relief valve set pressure for injector is 3000Psi to 3200Psi and the rest of oil goes back in to the tank, there are two hoses (35 & 36) connected before the flow goes to the relief valve. Both the hoses (35 & 36) are also connected with a 3-way control valve in control cabin; the control valve is used to select the pump flow (Low, medium, High). A main relief valve is also located after both the relief valves of pumps. Hydraulic pressure of 30003200Psi acts at the inlet of main relief valve. Hose (34) is connected with the main relief valve through which the injector pressure is controlled from the control cabin. When shifting the control valve in control cabin in to Low pump position, the flow (30GPM) of oil through Hose (36) to the tank stops and the flow goes to the relief valve of injector low pump and then the flow goes to the main relief valve. Also the flow of high pump is drained to the tank through Hose (35) When shifting the control valve to medium position, the flow (60GPM) of oil through hose (35) to the tank stops and the flow go to the relief valve of injector high pump and then the flow goes to the main relief valve. Also the flow of low pump is drained to the tank through Hose (36).
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Similarly when the control valve is shifted to high position then the flow to the tank from both the pumps stops and both the pumps flow (90GPM) go through their respective relief valves to the main relief valve.
There are five control valves in this injector drive circuit on power pack which are, 1. Relief valve (The relief valve is used to relief the extra pressure in the circuit/system) 2. Direction Control valve (The direction control valve changes the direction of fluid flow according to requirements) 3. Flow Control valve (The Flow control valve controls the fluid flow direction) 4. Full Flow valve (The full flow valve is attached to the oil cooler and all the drain hoses are connected with the full flow valve) 5. Pilot valve (The pilot valve is operated by pilot pressure and transfers the pilot pressure to the direction control valve and flow control valve with respect to requirement) The Hoses (31 & 32) are connected to the menson-tenson valve in control cabin and further connected to the pilot valve. When the control valve in control cabin is operated, a pilot pressure acts on the spool of pilot valve. The pilot valve then operates the direction control valve and flow control valve according to requirement and flow of oil goes from direction control valve in to the injector main hoses. Also the return of injector motor will came back through the other main hose and then through the flow control goes back in to the tank.
8.3.5.5 RESULT
After drawing the circuit diagrams and studying them we come to know that the major problem with all the circuits is that they have to over come the static head as well thus causing the following problems Wear of the equipment even when running in no load condition Power input is very high as compared to similar closed loop circuit Capacity and performance decrease exponentially with the passage of time Thus changes in design of the circuit are to be made in order to decrease the pressure efficiency drop problem and the heat gain problem.
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8.4 COOLING TANK
The hydraulic tank is located on the top of hydraulic pump where hydraulic oil is placed. There are strainers in the hydraulic tank which provides clean oil to the pump. Also a temperature gauge is located on the tank which shows the hydraulic temperature. The temperature of hydraulic oil should not exceed from 190F. The hydraulic oil level should be with in 2 from the top of gauge.
Figure 30: Hydraulic Reservoir in Power Pack
The cooling tank holds the cooling oil so that it can be utilized. When the pumps start they drive oil from the tank according to there flow rates and then according to the loop it returns back to the tank know to determine the total capacity of the tank so that the total capacity of the tank can be calculated.
8.4.1 CAPACITY OF THE TANK
Capacity of the tank is approx. 120 Gallons. About 110 gallons of cooling fluid can be accumulated in the tank. CAPACITIES OF THE PUMPS Priority pump Over-ridder pump Injector high pump injector low pump reel pump Auxiliary pump Blow out preventer pump (flow rate = 12 GPM) (flow rate = 27 GPM) (flow rate = 60 GPM) (flow rate = 30-35 GPM) (flow rate = 27 GPM) (flow rate = 27 GPM) (flow rate = 12 GPM)
Total capacity of the pumps: 12+27+60+30+27+27+12 = 195 Gallons required per minute 82
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According to our calculations we know that the tank should hold 195 gallons but it holds only 110 gallons. It is visible from our calculations that the capacity of the tank is not according to our requirement thus cooling oil does not has enough time in the tank to loose its heat and cool down. Thus the problem of heating of cooling fluid mainly arises due to the fact that the capacity of the tank is low and as a result the oil can not loose all of its heat. Every pump has its own time of the circuit flow and thus the time of flow per pump is different and can be easily calculated by the given formula. Thus by calculating the time of flow per circuit we can calculate the bottle necking pump. Bottle necking pump there fore governs the flow of the circuit. Once the bottle necking pump we can shut of other pumps and thus lower the heat gain problem.
8.4.2 RESULT
The results of our calculations show that the size of the tank needs to be increased current dimensions of the tank do not meet our requirements. The revised tank dimensions will be given in the solutions phase of our project.
8.5 ASSEMBLY OF PUMPS

8.5.1 INTRODUCTION
Pumps are assembled in two basic combinations. The discharge and the pressure head both are affected by the type of the combination used in the circuit. Types of pump assemblies Parallel combination of pumps Series combination of pumps
8.5.2 PARALLEL COMBINATION OF PUMPS
In parallel combination of pumps the flow rates are added and the pressure head remains the same.
Figure 31: Head Vs Flow Rate-Parallel Combination
Centrifugal pumps in parallel are used to overcome larger volume flows than one pump can handle alone. For two identical pumps in parallel the flow rate will double (moving from 1 to 2) 83
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compared to a single pump if head is kept constant. In practice the combined head and volume flow moves along the system curve as indicated from 1 to 3. If one of the pumps in parallel or series stops, the operation point moves along the system resistance curve from point 3 to point 1 - the head and flow rate are decreased.
8.5.3 SERIES COMBINATION OF PUMPS
When two (or more) pumps are arranged in serial, their resulting pump performance curve is obtained by adding their head at same flow rate as indicated in the figure below.
Figure 32: Head Vs Flow Rate-Series Combination
Centrifugal pump in series are used to overcome larger system head loss than one pump can handle alone. For two identical pumps in series the head will be twice the head of a single pump at the same flow rate. With constant flow rate the combined head moves from 1 to 2. In practice the combined head and flow rated moved along the system curve to 3. If one of the pumps stops, the operation point moves along the system resistance curve from point 1 to point 2 head and flow rate are decreased. Series operation of single stage pumps is seldom encountered - more often multistage centrifugal pumps are used.
8.5.4 CIRCUIT CONFIGURATION
For our circuit parallel combination of pumps is with only one air driven pneumatic pump in series with the other pumps. The pneumatic pump is known as charging pump and used for charging purposes at the start up of the power pack. This mixed combination of the pumps compensate for both the pressure head required and the flow rate required. Basically the flow rate was our main requirement thus parallel combination of pumps is most effective. 84
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8.5.5 ASSEMBLY AND USE OF THE PUMPS INSTALLED
1.
DENISON HYDRAULIC PUMP VANE TYPE DUAL ACTING

PRIORITY PUMP (2200PSI-2500PSI) (FLOW RATE = 12 GPM)
REEL BRAKE
INJ BRAKE
CHAIN TENSION
CHAIN TRACTION
MONSUN TISON
CABIN JACKS
OVER-RIDDER PUMP (2500PSI) OVER RIDDER
(FLOW RATE = 27 GPM)
2.
DENISON HYDRAULIC PUMP VANE TYPE SINGLE ACTING

INJECTOR HIGHPUMP (3000PSI-3200PSI) INJ PRESSURE FLOW RATE = 60 GPM)
3.

INJECTOR LOWPUMP (3000PSI-3200PSI) REEL PUMP (2500PSI) FLOW RATE =27 GPM
FLOW RATE =30-35 GPM INJ PRESSURE CT REEL LEVE L WIND
4.

AUXALIARY PUMP (500PSI-2500PSI). HOSE REEL FLOW RATE = 27 GPM
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BLOW OUT PREVENTOR PUMP (2700PSI-3000PSI) BOP FLOW RATE = 12 GPM
8.5.6 RESULTS:
Through our study we have found out that the pump configuration is not the factor which is affecting our efficiency or the factor through which we can increase our head at the current situation.
8.6 HEAT EXCHANGER

8.6.1 INTRODUCTION
Heat exchanger is a device that facilitates the exchange of heat between two fluids that are at different temperatures while keeping them from mixing with each other. Heat exchangers are commonly used in wide variety of applications, from heating and air conditioning systems in a household to a chemical and power processing and power production in plants. Heat exchangers differ from mixing chambers in a way that they dont allow the fluids involving to mix. In Sprint coil tubing unit on which we are assigned project is using Shell & Tube heat exchanger for cooling of the oil used in the system. Shell & Tube heat exchangers are built of round tubes mounted on large cylinder shells with the tube axis parallel to that of shell.
Figure 33: Heat Exchanger in Power Pack
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The shell and tube heat exchange provide the comparatively large ratio of heat transfer area to volume and weight. It provides the surface in a form which is relatively easy to construct in a sizes and which is mechanically rugged enough to withstand normal shock fabrication stresses and normal operations. There are many modifications of the basic configuration, which can be used to solve special problems. The shell and tube heat exchanger can be reasonably easily cleaned and those components most subject to failure (gaskets and tubes) can be easily replaced. Finally good design methods exist, and the expertise and shop facilities for the successful design and construction of Shell & Tube heat exchanger are available throughout the world.
8.6.2 BASIC PROBLEM
The actual purpose of heat exchanger used in power pack of Sprint Unit is to cool the oil which gets heated after circulation through the circuit. As Pakistan environmental conditions are harsh and the heating problem is the primary factor in decreasing the efficiency of the whole circuit. According to our analysis the heat exchanger installed in unit is of low capacity, its capacity should be increased for efficient and effective cooling of oil. One another factor of prime importance is of fouling. Fouling is actually the deposits of extraneous materials on the heat transfer surfaces during the lifetime of the heat exchanger. Whatever the cause or exact nature of the deposit, additional resistances to heat transfer is introduced and the operational capability of the heat exchanger is correspondingly reduced. In many cases, the deposit is heavy enough to significantly interfere with fluid flow and increase the pressure drop required to maintain the flow rate through the exchanger. Another factor which could also be a problem is that excessive clearance is created in between plated due to the corrosion.
8.6.3 SOLUTION
In order to cool the oil efficiently, we need to remove all those problems which have caused the drop in cooling efficiency of heat exchanger. So the first step was to minimize the fouling effect as it has great impact on cooling capacity and efficiency of heat exchanger. A marked increase in pressure drop and/or reduction in performance usually indicate cleaning is necessary. The unit should first be checked for air or vapor binding to confirm that this is not the cause for the reduction in performance. So to minimize the effect of fouling heat exchanger should be gone through the proper maintenance and all those extraneous deposits should be removed. In order to increase the cooling capacity of the heat exchanger installed on the Sprint Unit one suggestion is to increase the size of fan which is being used to cool the oil. Another most time demanding task is to increase the length of coil of oil used in heat exchanger. By increasing the length of coil we can provide greater length of coils to be cooled, thus providing greater surface 87
EQUIPMENT STUDY
area for heat transfer, thus more efficient the cooling of oil. The pressure drops in heat exchanger can be given as,
Pt = Tube side pressure drop (N/m) Np = Number of tube side passes = 1 jf = Tube dimensionless friction factor = 0.004 L = Length of tube = 1m f = Tube side fluid density = 996 kg/m ut = Tube side velocity = 1 m/s m = 0.25 as laminar Similarly heat transfer in the exchanger should be maximum so that our cooling in more effective. Heat transfer can be given as,
Where: Ao = Outside area of tube (m) Ai = Inside area of tube (m) Tm = Mean temperature difference Uo = Overall heat transfer coefficient on outer area Ui = Overall heat transfer coefficient on inner area (kW/ m C)
8.7 MAINTENANCE
The maintenance of any unit is very critical to its performance any unmaintained equipment is more likely to be defected or loose efficiency after a some period of operation. This is the reason maintenance periods of every part is predefined and the schedule must be strictly followed. There are two main types of maintenances performed in Sprint Preventive maintenance Frequency maintenance
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8.7.1 PREVENTIVE MAINTENANCE
Preventive maintenance is the type of maintenance in which equipment is thoroughly checked and inspected time again even when there is no problem in the working of the equipment in order to ensure its proper working especially when any job has to be performed in the coming days. Preventive maintenance is a good technique and prevents many troubles that might arise during the operation on any well.
8.7.2 FREQUENCY MAINTENANCE
Frequency maintenance is the type of maintenance in which inspection and maintenance operations are performed on the equipment after a specified period of time. That time is known as the frequency of that part. For instance if the vendors specifies that oil filters are to cleaned or changed after every 15 days then the frequency is 15days and this type of maintenance is known as frequency maintenance. The major difference between preventive and frequency maintenance is that preventive maintenance is performed when the unit is not working in the field it can be in the yard or a stand by at field. But in the case of frequency maintenance even if the unit is working on the field the client party is informed of the frequency maintenance period and the unit is stopped for that work even if it is rigged up.
The three main type of maintenances performed on the units of Sprint are as follows,
MR 1 The MR 1 of power pack must be done according to MR 1 form MR 2 The MR 2 of Power pack includes MR 3 The MR-3 of engine should be done after 40,000Hrs/7 years Engine oil should be changed after every 250Hrs/6-months of operation Gear oil should be changed after every 2500Hrs of operation Hydraulic oil should be changed after every 2000Hrs of operation
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8.7.3 EXPLANATION
MR or maintenance request 1 includes the basic maintenances of the unit which include cleaning greasing and degreasing of the parts. Complete inspection before or after any job and acting accordingly is any fault is located. MR 2 can be graded as frequency maintenance in which oil changes cooling fluid changes are taken care of and the third MR 3 is the over hauling of the Detroit diesel engine after 7 years. On units 4 MR 1 and 2 have been performed but MR 3 has not been performed yet.
8.7.4 RESULTS
According to our research as mentioned earlier MR 2 is not performed on time which is technically the most critical of the all. Cooling oil changes are to be done every 2000 operating hours but it is delayed to 2200 to 2300 hours when the unit is rigged on any well. This is causes the cooling fluid to loose its cohesive bonds and loose their cooling abilities in turn. The cooling fluid starts to turn foamy. So we can confidently conclude that the MR 2 being performed not on time is one of the major reasons for the drop in efficiency and heat gains.
8.8 MODIFICATION
Modifications are the changes made to the original design in order to increase its efficiency, correct any fault or any other reason. Modifications are often done to debottleneck any equipment or process which has reached its optimum man can not produce any further quantity. Thus modifications are a regular part of the equipments life. The equipment under consideration Coil Tubing Unit 4 has been subjected to several minor modifications which were often made on site or in yard. During job it is necessary to keep the equipment running in the safest way possible so that the work does not get disturbed, when faults occur it is best to trouble shoot them man move on with the work in order to get the job done on time. Minor modifications like adjustment of the valves or replacement or leaked or cracked seals with temporary sealing equipment was done on site but as soon as the equipment is returned to the yard these temporary modifications are again replaced by installing the vendor specified part or equipment. Great care is taken by Sprint as only vendor specified spares are used on the equipment. Modifications are made to improve the performance of any equipment but some times these performance increasing measures can turn out to be dangerous or trouble some for the equipment or process in the long run. According to our study we found that no major modifications were made to the equipment which could have effected the equipment. Complete logs of maintenance and 90
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modifications were maintained for future references or for use of any other operator. By the study of these logs we found the no such modifications were to the equipment which could have disturbed the performance of the equipment.
8.9
RESULTS DEDUCED
Phase 2 was concerned with the accumulation of data man testing. The two tests described earlier which are Function Test and Pull Test both were also a part of our experimental study during phase 2. After the completion of this phase all of the faults in the design features which we are to give the solution of are summarized below. COOLING TANK ( capacity of the tank was not fulfilling our requirement) HEAT EXCHANGER ( size and rating of heat exchanger was not fulfilling the requirement) HYDRAULIC CIRCUIT ( the circuit used was a source of problem thus it is to be modified) MAINTENANCE ( MR 2 maintenance was not being performed on time )
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PHASE-III Chapter#9 SOLUTION AND SUGGESTIONS
9.1 INTRODUCTION
In the third part of our project is concerned with giving the best possible solutions and suggestions to the company keeping in mind that our solutions must be economically beneficial and be effective in the long run. Many solutions can be formulated to the given problem like using a closed loop circuit or purchasing a new hydra unit of using swatch plate pumps in the open loop with a combination of pressure relief valves but these solutions are expensive and time consuming. The change in pumps for vane type to swatch plate will be very expensive as swatch plate pumps are very expensive and the entire power pack will have to be opened and rebuilt by welding. It is take about 2 3 months on this modification at least with 1 month on testing the new system and time for getting safety approvals by concerning authorities. Thus we are mainly concerned with only the solutions which are practical.
9.2 COOLING TANK

As discussed earlier cooling tank capacity in low and needs to be increased to about 150 Gallons. We cannot increase the length or width of the tank as length and with of the tank are limited by the dimension of the trailer it is installed on. Thus increasing the length or width of the cooling tank would require a new orientation of the tank on the trailer. We have a ease in the height as the control cabin which is installed in the centre of the trailer and is 3 feet higher than the tank. Thus we have a allowance in the height up to 3 feet. Now capacity of the tank = 110 Gallons Requirement of the tank = 150 170 gallons Volume of the tank = 4 feet Dimensions = length * width * height = 4 * 1 * 1 = 4 New dimensions Keeping length and with same New height 1.5foot 94
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Volume = 4 * 1 * 1.5 = 6 New capacity = 6 * 1 / 0.035 = 169 Gallons
9.2.1 SOLUTION
By only increasing the height of the tank by 0.5 feet we can increase the capacity to 170 gallons. Thus our solution and suggestion in to increase the height of the tank as it a maximum of 1 day job in the yard and can be economically performed. As a result an increased capacity of the tank will allow greater time for the cooling oil to stay in the tank and loose heat thus greatly decreasing the problem of heat gains. Our cooling fluid temperature will then stay maintained in a range to 170-180 f.
9.3 MAINTENANCE
Another draw back that we located was that when the unit was rigged up the maintenances such as MR 2 are often delayed. One of the main causes of equipment performance to decrease in carelessness in the maintenance of the equipment. The cooling oil should be replaced after every 2000 working hours and no delay should be accepted on this part.
9.3.1 SOLUTION
Even though proper logs are maintained such skips of maintenance does occur some time thus it is recommended that soft wares like MAXIMO should be used to increase the performance of the equipment and the personal. I f maximo or other soft wares are not to be used then a system of check and balance should be improved, the logs should be fort nightly checked and sighed by the concerning superiors and complete reports should be provided of weekly jobs to the safety officer and the concerned superiors.
9.4 CIRCUIT USED

9.4.1 INTRODUCTION
As discussed in phase 2 the biggest problem lies in the circuit which is being used in the CTU. It is an open loop which comes with the problem of efficiency and pressure drops after some years of operation. But we can also not use closed circuit as in closed circuit the problem of heat gains is very high and in the climatic conditions of Pakistan where the temperature in some fields exceeds 50c it is not favorable to use a closed loop circuit. We have made an effort to eliminate this problem of circuit by utilizing the incentives we had in the closed loop and applying some in our open loop making an intermediate circuit which specifies the properties of closed loop without giving its disadvantages. 95
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The intermediate circuit designed specially for this unit is a very simply design formed to be attached to the existing unit not destroying any of the circuit or existing route. According to this design the old circuit is embedded with a new line. As we can see that the fluid after leaving the output of the pump through a relief valve falls in the tank. We can give a line from that initial pipe leading the fluid to the tank and make it the input of the pump. As the fluid moves from the relief valve instead of falling in the tank it will move towards the pump suction and thus the pump will only have to overcome the friction head thus decreasing the use of the pump in no load condition significantly and minimizing the pressure drops and decrease in the efficiency. Any pressure regulatory valve can be installed at the input of the pump line which should not be operated by a binary function electrical circuit. It should facilitate opening closing partial opening and partial closing of the valve. The partial opening of the valve is required because some cooling fluid is required after every loop because some amount of the cooling oil is lost while lubricating the parts and can not be recovered thus after every few fluid circuits some amount of oil is required from the tank which can be again easily provided by the use of pressure regulatory valve when the pressure of the cooling fluid drops by a certain amount the p.r.v partially would open and allow sufficient amount of oil to enter the circuit and compensate for the lost oil. This assembly of the valves can be attached or controlled by a very simple circuit board and can be controlled from the control room. The intermediate circuit is given below
9.4.2 ADVANTAGES OF THIS CIRCUIT
Load on the pumps will significantly decrease and causing reduced wear and increased performance and efficiency and prolonged life time The circuit does not require any high tech electronic circuits or coding as required by the latest modal units The transition from the existing to the new circuit will be highly simply, inexpensive and replaceable 4 5 days of work is required for complete installation and testing. It minimizes the problems of cost and wear and the increase in the size of the cooling tank will also minimize heat gain thus making this a very efficient circuit.
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9.4.3 SOLUTION
Thus using an intermediate circuit will decrease the loads on the pump when the operation is not being done on the respective pump. This will eliminate the static head which is very high as compared to dynamic or friction head. The eliminating the static head reducing the work load on the pumps and the power required by the pumps.
Figure 34: Intermediate circuit connected with an ECM
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9.5 MODIFIED CIRCUIT
As our main objective is to eliminate the static head of the pumps when working on no load condition, we can also achieve this goal by slightly modifying the existing circuit by adding a new vane type pump in the circuit which is used to take the load of the entire static heads of pumps.
Figure 35: Un-Modified Circuit
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Figure 36: Modified Circuit 9.5.1 CONSTRUCTION
According to this new assembly the discharge of this new pump which we call as by-pass pump is given at the suctions of the previously existing pumps of the circuit. let us suppose that when the equipment is turned on the pumps 1, 2 and 3 are not to be used and pumps 4, 5, 6 and 7 are to be used always for any operation being performed on the CTU. In this case the ball valves located at the suctions of the pumps 1, 2and 3 will be closed so that the pumps can not take any suction from the reservoir. As the by-pass pump will operate it will take its suction 99
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from the reservoir and after adding pressure energy will deliver the fluid to the suctions of the pumps 1, 2 and 3. The flow rate of the charging pump is kept the sum of the flow rates of the individual pumps but the pressure of the charging pump is kept low. The by-pass pump can be operated by the case engine giving the same shaft power or it can be provided with additional power source. When the operation starts the entire static head is lifted by the by-pass pump and the pumps on the circuit only have to accommodate the friction head. Now let us consider a case in which any one of these 3 pumps is to be operated and the remaining 2 are to be operated under no load conditions. In this condition the ball valve of pump which needs to be no load condition for the job is opened. The ball valve at its suction from the reservoir is opened and at the same time the valve connecting the discharge line of the by-pass pump and the suction of the pump is closed. In this condition the pump 3 is allowed to take the fluid from the cooling tank and flow through the circuit as in normal working condition. By the use of such a by-pass pump when operating in no load condition the power required decreases significantly and the wear of the pumps in the circuit also decrease exponentially. With the decrease in the wear and the temperature gains the performance and the efficiency of the pumps installed in the circuit is increased where as the by-pass pump used will wear a lot quicker and its efficiency will decrease but as it does not operate any equipment thus the efficiency of the equipment will remain unchanged. Thus we can say that charging pump is basically a sacrificial pump used in the circuit. As this by-pass pump is installed away from the main hydraulic circuit any overhauling or changes that might be required on the pump will not require any disturbance in the hydraulic circuit and even in case of its failure the equipment can be operated on the actual pumps p1, 2 and 3 with out obstruction in the operation of the Coil Tubing Equipment.
9.5.2 ADVANTAGES
Decrease in pressure drops Increase in efficiency of the equipment Decreased wear of the pumps Increased life of the pumps
9.5.3 SOLUTION
If the above mentioned intermediate circuit is not to be used then an additional sacrificial pump in the circuit is to be added which would take the suctions heads for no load condition. 100
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9.6 SUGGESTIONS
The entire study, analysis and diagnosis helped us to identify the faults and enabled us to give the solutions. Following are the suggestions given to the Sprint team as a reference for future modifications. The pressure and efficiency drop and the heat gains of the hydraulic power pack can be easily tackled by using the above mentioned intermediate circuit or modified circuit along with a renewed cooling tank with an increased height of 0.5 feet, heat exchanger of a bigger size and increased no of tubes and finally the preventive and frequency maintenances being very carefully performed on time. This would ensure us an efficiently working power pack and coil tubing equipment thus increasing the performance and the life of the equipment.
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APPENDICES
102
HYDRAULIC SYMBOLS
103
104
105
REFERENCES
BOOKS 1-Advanced Oil Well Drilling Engineering by Dr. Bill (10th Edition). 2-Applied Drilling Engineering By Adam T. Bourgoyne, Jr. Keith, K. Millhein, Martin Ecen Evert, FS Young Jr 3-Drilling Engineer Workbook By Baker Huges 4-Introduction To Oil And Gas Production By American Petroleum Society 5-ICOTA Handbook By International Coil Tubing Association 6- Dictionary For The Petroleum Industry (2nd Edition) By The University Of Texas 7-Coil Tubing Equipment Manual By D-SR-005 Baker Hughes Publication Date:0101-1996 8-Coil Tubing Unit 4 Manual Sprint Oil And Gas Services
WEBSITES www.energyeficencyasia.org www.google.com/hydraulic circuits/open loop systems http://www.free-ed.net/free-ed/MechTech/hydraulics01/default.asp http://hydraulicspneumatics.com/200/FPE/IndexPage.aspx http://www.slb.com
Bibliography
[1] Dr. Bill, Advanced Oil Well Drilling Engineering., vol. 10. [2] Jr. Keith, K. Millhein, Martin Ecen Evert, FS Young Jr Adam T. Bourgoyne, Applied Drilling Engineering.
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Auton Villa: United, 2003, vol. 2nd. [3] Baker Hughes, Drilling Engineering Workbook. Toronto, 2003, vol. 8th. [4] International Coil Tubing Association, ICOTA Handbook., 2008. [5] University Of Texas, Dictionery For Petroleum Engineering. Texas: Alpha Thames Ltd, 2004, vol. 2nd. [6] Anthony Espaceto, Fluid Dynamics For Engineering.: Tata McGrawhill, vol. 1st. [7] Mohammad Z. Abdullah, Zanial Alimuddin Zoeb Hussian, Basic Fluid Mechanics And Hydraulic Machines. Hyderabad: BS Publishers, 2008, vol. 1st. [8] Terry, Fluid Machinery:Performance, Analysis And Design, 2nd ed. Washington DC., U.S.A: LLC Press, 1999.
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Pressure Analysis and Oil Well Study

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Pressure Analysis and Oil Well Study

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Engr. Zahid Suleman Butt

SPRINT OIL AND GAS SERVICES

Department Of Mechanical Engineering University Of Engineering And Technology Taxila

ISSUING COMPANY SPRINT OIL AND GAS SERVICES

Department Of Mechanical Engineering University Of Engineering And Technology Taxila

1.4 TYPES OF WELLS ................................................................................................................................ 5

DRILLING OF OIL AND GAS WELLS .............. 8

WELL COMPLETION .....................................21

WELL TESTING ................................................29

ANALYSIS AND DIAGNOSIS......................63

DATA ACCUMULATION ................................66

SOLUTION AND SUGGESTIONS .........94

INTRODUCTION TO OIL AND GAS WELLS

INTRODUCTION TO OIL AND GAS WELL

INTRODUCTION TO OIL AND GAS WELLS

1.3 CREATION AND LIFE OF A WELL

Planning Drilling Completion Production Abandonment

INTRODUCTION TO OIL AND GAS WELLS

INTRODUCTION TO OIL AND GAS WELLS

INTRODUCTION TO OIL AND GAS WELLS

1.4 TYPES OF WELLS

INTRODUCTION TO OIL AND GAS WELLS

INTRODUCTION TO OIL AND GAS WELLS

DRILLING OF OIL AND GAS WELLS Chapter#2

DRILLING OF OIL AND GAS WELLS

2.2 DRILL BITS IN MECHANICAL DRILLING

3: Figure 1: Drag Bit

DRILLING OF OIL AND GAS WELLS

Figure 4: Diamond Bit

2.3 THE DRILLING FLUID

2.3.2 THE DRILLING FLUID PREPARATION AREA

DRILLING OF OIL AND GAS WELLS

2.4 CASING AND CEMENTING

DRILLING OF OIL AND GAS WELLS

DRILLING OF OIL AND GAS WELLS

Figure 5: PPL Rig ADHI Oil Field

DRILLING OF OIL AND GAS WELLS

2.6 DRILLING RIG CLASSIFICATION

DRILLING OF OIL AND GAS WELLS

2.7 TYPES OF DRILLING RIGS:

2.8 THE ROTARY DRILLING RIG:

DRILLING OF OIL AND GAS WELLS

Figure 6: Components Of Oil Rig

2.8.2 OPERATIONS IN A DRILLING RIG:

DRILLING OF OIL AND GAS WELLS

Figure 7: Coil Tubing Being Rigged Up

DRILLING OF OIL AND GAS WELLS

DRILLING OF OIL AND GAS WELLS

Figure 8: Circulation System

2.8.2.4 Power Generation System

DRILLING OF OIL AND GAS WELLS

Figure 9: Electric Generators at PPL Rig

2.9 THE RIG CREW

DRILLING OF OIL AND GAS WELLS

3.3 Well Completion Activities:

3.3.1 CONDUCTING DRILL STEM TEST

3.4 TYPES OF COMPLETION

3.5 COMPLETION COMPONENTS:

Figure 10: Christmas Tree at PPL Rig

3.6 PERFORATING AND STIMULATING

WELL TESTING Chapter#4