fimkasar oil field report

Internship Report 2010

Umar Rasheed Petroleum Engineer

1

Acknowledgment

I am also extremely thankful to Mr. Zahid Abbas (F.M Fimkassar Oil Field), Mr. Munir Awan

(Reliever to F.M), Mr. Muhammad Arif (I/C Production) & Mr. Muhammad Ashfaq, who are

constant source of inspiration for me.

I am grateful to OGDCL and UET Lahore for providing me opportunity to learn the practical

aspects of Oil & Gas industry. I take this opportunity to acknowledge with gratitude, all the team

members of FIMKASSAR OIL FIELD, OGDCL specially Mr. Zahid Abbas , Mr. Munir Awan ,

Mr. Muhammad Arif & Mr. Muhammad Ashfaq Ahmed.

2

Preface

Engineering is always completed by the unification of theoretical knowledge and Practical field

experience. For this reason, Field internship plays vital role in polishing an Engineer.

Technical and management skills are very important for the Fresh Graduates and internships

provide a golden opportunity to enhance and practice all types of skills.

The aim of writing this report is to express the Seven week experience, which I gained here at

Fimkassar Oil Field.

3

Table of contents

1. OGDC 4

2. Introduction to Fimkassar oil field 7

3. Social Welfare Programs 8

4. Well # 1 9

5. Well # 2 12

6. Well # 3 15

7. Well # 1-A 18

8. Well # 4 18

9. Surface Facilities 19

10. Present Status for Enhancement of Crude Production 20

11. Intro to Chak Naurang oil field 26

12. Yard 1 26

13. Yard 2 26

14. Yard 3 28

15. Yard 4 28

16. Yard 5 29

17. Technical assignments 30

18. Economical View 58

19. HSEQ 61

4

OGDCL

Company History:

To revive exploration in the energy sector the Government of Pakistan signed a long-term loan

Agreement on 04 March 1961 with the USSR, whereby Pakistan received 27 million Rubles to

finance equipment and services of Soviet experts for exploration. Pursuant to the Agreement,

OGDC was created under an Ordinance dated 20th September 1961. The Corporation was

charged with responsibility to undertake a well thought out and systematic exploratory program

and to plan and promote Pakistan's oil and gas prospects.

A number of donor agencies such as the World Bank, Canadian International Development

Agency (CIDA) and the Asian Development Bank provided the impetus through assistance for

major development projects in the form of loans and grants. OGDC's concerted efforts were very

successful as they resulted in a number of major oil and gas discoveries between 1968 and 1982.

Toot oil field was discovered in 1968 which paved the way for further exploratory work in the

North

Thora, Sono, Lashari, Bobi, Tando Alam & Dhodak oil/condensate fields and Pirkoh, Uch, Loti,

Nandpur and Panjpir gas fields which are commercial discoveries that testify to the professional

capabilities of the Corporation.

The financial year 1989-90, was OGDC's first year of self-financing. It was a great challenge for

OGDC.

Prior to 23 October 1997, OGDCL was a statutory Corporation, and was known as OGDC (Oil

& Gas Corporation). It has been incorporated as a Public Limited Company w.e.f. 23 October

1997 and is now known as OGDCL (Oil & Gas Development Company Ltd.).

In December 2006, the Government of Pakistan divested a further 10% of its holding in the

company. The Company is now listed on the London Stock Exchange since on December 06,

2006.

5

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

Mission:

To become the leading provider of oil and gas to the country by increasing exploration and

production both domestically and internationally, utilizing all options including strategic

alliances.

To continuously realign ourselves to meet the expectations of our stakeholders through best

management practices, the use of latest technology, and innovation for sustainable growth, while

being socially responsible.

Field Distinguished Feature

Chak Naurang First heavy oil field development in OGDC. Dakhni Only and lonely commercial development of sour gas field in Pakistan. Daru Gas sale through SSGCL pipeline specifically laid down for BP (ext UTP)

fields. Dhodak First refinery gas in Pakistan yielding complex array of refined

products. Fim kassar First successful water injection field of OGDC and 2nd after Dhurnal in

Pakistan. Hundi / Sari first dry gas revenue generation fields as well as first discoveries of

OGDC. Kal Successful installation of sucker rod pump .First in north for OGDC. Kunnar Gas recycling through Gas Cap for maximum recovery of oil. Lashari A well was drilled to tap the attic oil of lashari Center fileld. Loti No decline in production from SML formation under natural depletion.

The Name Of Producing Fields Contained In North, Center, And South Areas Are

North Fields The nine fields are producing in the northern area of Pakistan. Bhal Syedan, Chak Naurang,Dakhni, Fimkassar, Kal, Missa Keswal, Rajian, Sadkal and Toot.

Center Fields The seven gas fields are producing in the central area of Pakistan, Dhodak, Loti, Nandpur, Panjpir, Pirkoh, Qadir pur and Uch.

South Fields The fifteen fields are producing in northern areas of Pakistan, Bobi, Buzdar, Daru, Hundi, Kunar, Lashari Center, Lashari Soutj, Missan, Palli,Pasahki,Sari, Sono, Tando Allah Yar, Tando Alam, and Tobra

6

Missa kesswal Hydro carbons discovered in eight (08) reservoirs (Khewra to murree).

Missan The one well field is draining some of its up dip potential through jet pump.

Nandpur/ Panjpir Very low btu gas fields became commercial first time in Pakistan. Palli 1st typical one well field of OGDC producing(not discovered) in south

area. Pasahki Shares the same Horst block with kunnar but oil production is

marvelous. Pirkoh First recovery in center for OGDC. Maximum well drilled in a single

field by OGDC. Qadirpur Highest ranked OGDC field in terms of revenue generation. Rajian A main breakthrough in 3D seismic acquisition technology is applied

first time ever in Pakistan to map Rajian structure. Sadkal A complex thrust fault bounded structure has been delineated in to at

least five compartment /blocks in Sadkal field. Sono The successful workovers of recompletion and jet pumps installations

made the hydrocarbons recovery up to 60% from Sono field. Tando Allah Yar A thick gas condensate column over laying an oil rim. Tando Alam Provided breakthrough in south to OGDC.

Toot First major oil discovery that provided the foundation for further development of OGDC.

Uch Biggest dry gas field being used for power generation.

7

FIMKASSAR OIL FIELD

Location:

The Fimkassar Oil Field is located in the Chakwal District of the Punjab Province approximately

95 km South West of Islamabad.

Potwar Basin:

The Potwar Basin has been actively explored for hydrocarbon since 1870 and first success came

in 1914 when Attock Oil Company discovered oil at Khaur. The Dhulian, Joyamir and

Balkassar field are then discovered by the same company in 1918, 1943 and 1945 respectively.

In 1978 Amoco was granted the exploration license in the Northern Potwar. In 1982, the

concession was granted to the Occidental of Pakistan, who discovered oil from the Eocene

formations and later from Paleocene and Permian horizons. Similarly OGDCL was also granted

exploration license in the Northern Potwar Deformed Zone (NPDZ), where it drilled several

exploratory, appraisal as well as development wells successively

History:

It was discovered in 1980 by Gulf Oil Company, but the production rate was not good enough for

commercial production of the Field. Even after Stimulation it had poorly produced around 10 to 20

barrels per day. Then they surrender their lease.

OGDCL carried-out further Geological and Seismic studies. FMK # 1 was side-tracked and

drilled down to 3,081 meters with a horizontal displacement of 250 meters. The well was completed in

Sakessar Formation with an initial flow rate of 4,100 BOPD Oil and 4 MMSCFD Gas in October 1989.

FMK # 2 was drilled and completed in 1990 and put on regular production in October 1990. The Initial

Oil and Gas flow rates were 1,600 BOPD and 1.4 MMSCFD respectively.

The reservoir Sakessar FMK # 1 went below the bubble point pressure during March 1993 and

therefore Water Injection was planned. FMK # 3 was drilled and completed in Sakessar Formation for

this purpose. Pilot Water Injection in Sakessar Formation through FMK # 3 was started on 4th March

1996. After injecting water at a rate of 10,080 barrels per day for a period of 3 ½ months and increase in

well head flowing pressure from 380-700 Psi and oil production 2060-3560 BOPD of FMK # 1 as on 30th

June 1998.

8

Social Welfare Program

Construction of free medical dispensary

Free Medicines for Locals „97

Two Class Rooms with verandah for Govt. Elementary Boys School Fimkassar Since

1997.

Electrical Water Coolers for Rs. 54000.

Mini Bus Hired for Pick and Drop for Local Students

Services of a Lady Doctor for Rs. 18000 per month Since Nov 2006

Note Books Pencils, Sharpener, Scales, Bags, erasers for students

Proposed Social Welfare Schemes

Construction of 2 class rooms, 3 toilets, and 8 ceiling fans for Govt. Girls Primary

School, Fimkassar for 1.68 million rupees.

Construction of classrooms, boundary wall and toilets for Govt. Elementary Boys School

Fimkassar. Rs. 2 million.

Construction of approximately 1 km metal road with side drainage nala. 3.27 million

9

Well # 1

Well Tech Data Summary

Spud-in Date 21-08-1980 (Gulf Oil)

Spud-in Date 13-04-1989 (Side Tracked by OGDC)

No. of DST Run 03

CSD 7” casing/ liner shoe @ 2888 m

TD 3081 m

PBTD 3081 m

Completion 14-09-1998

Tubing size and grade 3½” N-80

Minimum ID 56 mm

Completion Type Open (Single string)

Completion Fluid SG 1.37

Mule Shoe ½” Mule shoe @ 2781.465

SG 1.002

X-mass Tree 3 1 16 x 1000 psi Cameron

Other Information @ 30th

June 2010

Water Cut 89.2% (calculated from told liquid and oil rates at field)

Gas Rate 333 Mscfd

Liquid Rate 1800 BPD (Oil rate: 195 bpd)

Wellhead Pressure 130~180 psig @ 30th

June 2010

Separators 3 Horizontal (2 under operation)

Processing Gas is processed for marketing and power generation

10

Well Completion Profile

No

.

DEPT

H

M

LENGT

H M

OD

mm

ID

mm DESCRIPTION

1 --- --- --- Tubing Hanger: 3 1/2"

CSHyD (BxB)

2 --- 0.1 95 76

Cross Over : 3-1/2" NKEL (P)

9.3 Lbs/Ft. x 3-1/2" CSHyD (P)

10.3 Lbs/Ft.

3 0.58 0.48 99 75

Cross Over : 3-1/2" NKEL

(B) 9.3 Lbs/Ft. x 3-1/2"

CSHyD (P) 10.3 Lbs/Ft.

4 1.52 0.94 89 75 Pup Joint : 3-1/2" CSHyD 9.3

Lbs/Ft.

5 2736.22 2734.7 89 75 Tubing Joints : 3 1/2'' CS Hyd

9.3 Lbs/Ft.

6 2737.13 0.91 113 70 S S D

7 2756.26 19.13 89 75 Tubing Joints: 2 Nos.3 1/2'' CS

Hyd.

8 2759.21 2.95 82 61 Seal Assy: P # 442-34-7276

9 2760.28 1.07 139 83 P. B . PKR: P # 08415-05-

8280-01-63

10 2763.14 2.86 114 82 Seal Bore Extension

11 2763.4 0.255 138 85 Coupling: P # 02-4300-02-11-

61

12 2765.07 1.68 115 100 Mill Out Extension: P# 01-

84643-49

13 2765.26 0.18 127 62 Casing Sub: P# 294-69-2518

14 2765.47 0.21 89 58 Seating Nipple : P# 44 - 5 – 0

15 2768.6 3.12 73 62 Perforated Pipe: P# 457 - 43 –

798

16 2768.97 0.25 81 56 Seating Nipple - R - Type:

P#801-57-2252

17 2772.05 3.18 73 62 Spacer Tube x 1/2 Mule Shoe

* X-Mass Tree: 3 1/16" Cameron

Rating: 10000 Psi.

Top connection:

1

5

4

3

2

6

7

8

9

13

11

10

20"306 M

1602 M 13 3/8"

9 5/8"

2644.16 M

OPEN HOLE

2783 M

TD=3081 M

7"

14

15

16

17

11

10

12

11

Gas Flow Diagram of Fimkassar

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

Stock Tanks at FMK01

Seprator FMK#2

SepratorFMK#1

Gas Gen

Set

Drip

Gate # 1

Knock out

vessel

Plant

W/Sh

op

Gate

#2

12

Well # 2


Spud-in Date 06-02-1990

No. of DST Run 01 till 11-10-2005


TD 3075 m

PBTD 2943 m


Tubing size and grade 3½” N-80 9.3 lbs/ft

Minimum ID 56 mm

Completion Type Open (Single string, permanent completion)


Mule Shoe ½” Mule shoe @ 2851.278 m

PKR setting Depth 2842 m

Formation Chorgali

Perforated Interval 2943-2889 m

1ST

Survey BHSIP 5208 psi @ 29-09-1990

1st Survey BHSIT 239 F @ 29-09-1990

Water Production Start 06-12-1992

Initial Rate qw 4.67%

Chlorides 4090 ppm

SG 1.007

X-mass Tree 3 1 16 x 1000 psi Cameron

Completion fluid type Mud

Completion fluid S.G 1.37

Other Information @ 04-07-2010

Wellhead Pressure = 130psi

Wellhead Temperature = 90 F

Production from FMK02 through choke manifold is transported to FMK01 site through steel

pipelines.

Production Casing

Size 7”

Grade N-80

Weight per foot 32 Lbs/ft

Threads NA

13

Well Completion Profile

40 M 20 " CSG SHOE

1500 M 13 3/ 8" CSG SHOE

2405 M 9 -5 / 8" CSG SHOE

2889 M 7" CSG SHOE

PBTD 2943M

3075 M

6" OPEN HOLE

HOLE CONSTRUCTION OF FMK # 02

14

NO DEPTH6 1 0

402m 3 0

4 5.86

5 6.33

1500m 6 11.88

7 2819.59

8 8 2821.4

9 2840.37

10 2844.25

9 11 2841.48

12 2844.34

13 2844.6

14 2846.28

15 2846.46

16 2846.75

17 2849.87

18 2850.24

19 2850.97

13

15

3075m 6" open hole

2889m

2943m cement

2955.5m

CaCO3 Plug

16

7" CSG

17

18

19

2405m BAKER SEAL BORE EXT. P*P

CONNECTING SUB B*B

11

MILL OUT EXTENSION P*P

CASING SUB

F SETTING NIPPLE

2 7/8" NU P*B PERFORATED PIPE 2 JTS

12

R SEATING NIPPLE

2 7/8" NU (B) * 1/2 MULE SHOE.

BAKER 7" DB PACKER

13 3/8"

CSG

11"*7 1/16" TUB. HEAD SPOOL

3 1/2" 9.3PPF CS HYD TUB HANGE

7X-OVER CS 3 1/2" P*P

PUP JOINT 3 1/2" 9.3 PPF CS HYD 4 JTS

3 1/2" 10.3 PPF TUB CS HYD N -80

SSD 3 1/2" 9.3PPF CS HYD BAKER

9 5/8" CSG

2 JTS 3 1/2" 10.3PPF TUB

BAKE 3 1/2" CS HYD SEAL ASSY

2 0 3 1/8" *10,000PPSI CAMERON X-MASS T.

WELL COMPLETION DIAGRAM # 2

5

20 " CSG

DESCRIPTIONROTARY TABLE DIFFEENCE

4

10

14

0 0 00 0 0

4

15

Well # 3

Water Injection Well

Background:

After putting FMK # 1 on regular production the production reached to 4100 BOPD in

1990. Since the reservoir was highly under saturated therefore rapid decline in the reservoir

pressure occurred. In March 1993 the reservoir went below bubble point when it had produced

3.9 MMSTB of oil at 600 psi. In

order to maintain the pressure

above bubble point water injection

was designed for Sakessar

formation. As the well was

produced below bubble point the

production data showed no increase

in the gas production or any

increase in GOR as was expected.

The stabilized W.H.F.P below

bubble point and no increased gas

production showed that the gas instead of moving in the reservoir tended to move upward in the

reservoir due to fractures forming a gas cap.

Water injection was started in FMK # 3 in the Sakessar formation in 1996 with initial

injection rate of 10,000 BOWD. FMK # 1 responded to the water injection responded after 3.5

months increasing the W.H.F.P from 380 to 725 psi. Production increased from 2055 to 3833

BOPD.

Early Water Break Through:

The water breakthrough occurred in early 1997 earlier than predicted. Till date the

cumulative water injected is 20.75 MMBBls. The water produced is 4.62MMBBLS. The water

produced is 22.62% of injected water.

16

Well Technical Data Summary


No. of DST Run 01


TD 3261 m

PBTD 3214 m


Tubing size and grade 4½” & 3½” N-80

Minimum ID 68 mm

Completion Type Perforated


Mule Shoe ½ Mule shoe @ 2998.46

PKR setting Depth 2985 m

Formation Sakessar

Perforated Interval 3150 – 3180 m

1ST

Survey BHSIP 2390 psi @ 31-08-1995

1st Survey BHSIT 283 F @ 31-08-1995

Water Injection Start 04-03-1996

Initial Rate qw 8600 barrels per day

Chlorides 85 ppm

SG 1.002

Wellhead Pressure 1800 psi @ 05-07-2010

Injection System Facilities

Water/Diesel Tanks

Tank Capacity 87.67 m3 = 87667 ltr

Safe Capacity 79.03 m3 = 79033 ltr

Number of Tanks 2 for Water and 1 for Diesel

Total Water Inj in 23 hrs 210755 ltr/d = 1325.5 bbl

Total water inj in 1 hr 9163 ltr/ hr

Diesel Consumption 15 mm/day (23 hrs) = 649 ltr/23 hr = 28~29 ltr/hr

varies from engine to engine

Water from a canal; 10 km away from the wellsite, is pumped to an open pond at wellsite, from

this pond water is pumped to water tanks through filters. From tanks water is pumped through

triplex pumps at desired rate and pressure to inject into the reservoir.

17

402 M 20 " CSG SHOE

1745 M 9 5/8" LINER TOP

1849 M 13 3/ 8" CSG SHOE

3090 M 9 -5 / 8" LINER SHOE

3214 M 7" CSG SHOE

PBTD = 3261 M

HOLE CONSTRUCTION OF FMK # 03

Lay out Fimkassar Well no. 3 (Injection Well)

Entrance Entrance

Water Storage

Pump

Filt

ere

d W

ate

r

Filt

ere

d W

ate

r

Die

sel

Wel

l O

per

ator

cabin

Tri

ple

x

Pu

mp

Tri

ple

x

Pu

mp

Tri

ple

x

Pu

mp

F

ilte

rs

Well no. 3

Water to be injected

From Nindral Village

18

Well # 1A


At Fimkassar O.G.D.C.L. has drilled another well in 2003. But unfortunately this

well came out to be non productive and no oil or gas was conceived from it. Some

technical details are listed as follows

Spud in Date 13-04-1989

Total Depth 3450 m

There is also problem that instead of oil or gas a large amount of water came into

the wellbore and company was unable to restrict this water in the formation so it was

decided to let this water come to surface, in this regard surface assembly was installed

and water is being produced. But unfortunately this water is not suitable for usage

because of presence of Sulphur in it that is why it is also discarded along the water of

well no. 1 & 2.

Well # 4

Well Technical Data Summary


No. of DST Run 08


TD 3450 m

PBTD 3439 m

Abandoned 06-12-2004

Bottom CMT plug 2680 m

Top CMT plug 68 m

Reason for Plugging Un-productive as result of 8 DSTs

Surface Facilities:

Surface facilities at FIMKASSAR Oilfield consist mainly of 1st stage and 2nd

Stage

Separators for Well # 1 and a single stage separator for well # 2. Other than that Water injection

Pumps are also working 24 hrs at well # 3.The layout of Surface facilities is shown in fig

19

Mixed Flow from well # 1 (W.H.F.P 90-100 psi 150 deg F) passes through Choke

Manifold and enters 1st stage (40-50 psi & 140 deg F). Water is drained and Oil and Gas are sent

in to 2nd

Stage separator (30 psi & 135 deg F). Water is drained to Flare pit and oil sent to storage

Tanks. Gas thorough the knockout drum is sent to the gas generator at site and partially for the

Utility for the residential colony at 70 psi. Extra gas is flared. The water cut for Well # 1 is

approximately 410 bbls/day with Oil and gas productions being 140 bbls/day and 0.2 MMSCF

respectively.

Mixed flow from Well # 2 (W.H.F.P 140-130 psi 85 deg F) passes through choke

Manifold and enter Separator # 1(40-50 psi and 80 deg F). Water is drained to flare pit while oil

is sent to storage tanks. Gas separated is 1st passed through a scrubber to remove condensate and

water vapors and sent to residential colony. Water cut for well # 2 is 90 bbls/day with Oil and

gas productions being 0.10 MMSCF.

There are 4 storage tanks of approximately 6000 bbl capacity Production from Well # 1

and 2 is stored in Tank # 1 and Tank # 3. Oil from tank # 3 is than shifted to Tank # 4 for

dispatch. After every three days the Oil is stored in the other 2 Tanks and water is drained from

Tank # 1 and Tank # 3. It is the case for Tank # 4 and Tank # 3.

Water is drained from storage tanks in three stages to remove any Oil contents that may

remain in the water. First from Tanks to Pit # 1 and Pit # 2. Water is than pumped to the flare pit

where further removal of sluge takes place the water underneath is drained in next pit and than in

the rivulet.

Four centrifugal pumps are used to dispatch Oil from the Storage tanks to the Bowers to

Attock oil refinery.

FMK # 3 is a water injection well. Water is injected at 2000 psi at an injection rate of

2000 bbls/day.

FMK 1A is oozing water well producing uncontrollable water (7500 bbls/d) from annulus

and tubing at the same time. This water (51 deg C) is drained in the nearby rivulet.

20

This is required to maintain a retention time that will enable the Oil gas and water to

separate completely. An inappropriate Retention time will either cause oil carry over with gas or

gas carried over with oil.

A reciprocating air compressor coupled with electric motor provides instrument air at 70

psi. This pressure is further reduced according to the requirement of the equipment by regulators.

The Liquid control Valve (LCV) comprises of a floater which is directly in contact with

the Liquid in the Separator. The Floater governs the movement of the outlet pressure of

instrument air in the wizard box.

Chemical Injection:

Anti-scaling chemicals are injected in FMK # 1. To prevent scaling of pipelines which

could result in complete blockage of the pipeline and hence loss in production. Demulsifying

chemicals are injected in FMK # 1 and 2 fluids to reduce water in oil emulsion, which hampers

proper separation of the fluids in the separators.

For chemical injection in production lines chemical injector pumps are used. The

amounts of chemical to be injected depend upon the flow rate of the fluid.

Present Status for Enhancement Of Crude Oil of Fimkassar Oil Field

All efforts are being made to enhance crude oil.

Our production target set by management for the fiscal year 2009-09 was 300 bbls/day.

Some modification has been made in process system to enhance crude oil. From these efforts,

crude oil production enhanced from 325 bbls/day to 360 bbls/day and still maintaining.

Well #1 production has about 86% water. Scale inhibitor is being used to minimize

deposition of scales in production lines. Although, we are using scale inhibitor but mostly crude

lines has been choked with the passage of time. Decision has been made that all crude lines will

dismantle after six month and remove scale. Practice in Vogue.

Separators & Well Area

21

Well # 01 is being continuously monitored and observed that mostly scale occurred in

before choke because scale inhibitor was injecting after choke. Due to scale depositions that

cause increase in back pressure and decrease in flow. To get rid of it, instrument flange was

arranged and fitted before adjustable choke. Connections for scale inhibitor were made with the

instrument flange.

After this modification, upon continuous monitoring, observed an increase of about 25

bbls/day of crude oil.

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

by laying new line.

22

Newly Laid Lines

Modification in the separator lines has been made for ensuring smooth operations. All sharp

bends/elbows have been removed to minimize scale deposition, which also caused scale

deposition.

23

Production Field Terminologies

X-mass Tree:

It is a combination of valves which controls the pressure at surface.

Master Valves:

Valves which are used in sever operating operations.

Wing Valves:

Wing valves are used to divert the flow in one of the two wings of the x-mass tree. Inner and

outer wing valves are used to protect the valves in sever operating operations.

Swab Valves:

Used to isolate the tubing pressure from the environment

24

Manifold:

It is a combination of valves which divert the flow in the required direction.

Choke:

Choke is used to control the production rate it may be fixed or adjustable.

Back Pressure Valve: BPV

Installed on the tubing hanger to stop the flow of well to surface.

Crossovers:

Used to make connection between tubing of different diameters.

Tubing Head:

Tubing head accommodates the tubing hanger.

Perforated Tubing:

Tubing having equidistant holes to get the production from the formation.

Separators:

A device used to segregate different fluids from the mixture. Its working principle is gravity,

centrifugal force and effect of baffles also perforated plates or screen.

Double Barrel Knock-out Bottle:

Type of separator used to separate condensate oil and water from gas.

Threads:

There are a number of thread connections available in tubing and pipelines. Few of them are

discussed below:

1. CS Hydrill

2. PH-6

3. EUE

4. VAM

5. NKEL

CS-Hydrill:

It has three edges with eight square threads between the edges.

25

PH-6:

It is same as CS –hydril but with six threads between the three edges. In this type hreads are

thicker than the previous type so the space between the threads is less.

EUE:

These type of threads are used in pipes, they are triangular in shape pointed outwards and

continues.

VAM:

These are same as EUE threads but square in shape. They are also continues throughout.

NKEL:

These are also square in shape with long collar in the start.

26

Chak Naurang Oil Field

Location of Field

This is one of the northern oil field centrally controlled by Fimkassar Oil field. The Chak

Naurang Oil Field is located in Distt. Chakwal and is 20 KM from Chakwal and 85 KM from Islamabad.

History of Field

The Field was discovered in June- 1986 and came on regular production from July-1987. Chak

Naurang is a joint venture with M/S. POL. OGDCL & POL shares are 85 % and 15 % respectively. In

this Oilfield a total of 05 Nos. of Wells were drilled. At present only two Wells are producing.

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

completed on 20.08.1986.

All the prospecting zones were tested. Khewra and Tobra formation produced Oil of 18-19 API

gravity to surface at the average rate 15-30 BOPD. This well has been put on artificial lift

(through sucker rod pumping system) since 25-05-1990 and initial oil flow rate was 100-110

BOPD. Present oil production is 10-15 BOPD

Tool Yard

Shed 1: Auto/Local Store

This tool shed contains tyres, gyres, clutches and other auto spare parts. Their description here is

not thought to be necessary.

Shed 2: Production Store

Some of the tools available in the production shed are enlisted below

Sr# Name/Description

1 Pressure Relief v/v 4”

2 Oil well level Control INST

3 Back Pressure v/v

4 Wrench Back pressure

5 Packing (dual) Tubing Hanger

6 Seal ring for type H Back pressure v/v

7 Plug 1½” v/v Removal

8 ½” plug v/v removal

9 Gas ket ring

10 Bull plug

11 4” elbow

27

12 „O‟ Ring

13 RIDGID Nu-clear Thread Cutting Tool, Contents: Mineral Oil. Not to be used as

Lubricator

14 Tester MOHM Model. HIOKI

15 PHILIPS Battery Charger

16 BW Technologies. O2 Sensor

17 BW Technologies, Multi Gas Detector. Detects CO, H2S, LEL, O2

18 Rototherm Instrumentation and Control

19 Halliburton Non-Elastomer, Tubing Retrievable Safety v/v (TRSV)

20 Bentley, Thermocouple Instruments

21 Schlumberger 3½ Safety V/v sleeve W/collet ( for SSSV)

22 S-seal OD type HNBR

23 FMC Technologies, Pressure Gauge F/H2S & CO2 SVC

24 Tubing Anchor

25 Bestolife PTC Thread Sealer. Net Wt. 43 lbs/bucket

26 ILEX TFE-20 Thread sealing compound

27 Snap in spring Lift Rod Hook

28 Millout Extension Packer

29 Wash pipes

30 BWD Wireline Set, PERMA Service

31 7” Packer

32 Wireline Tubular Jar

33 Bellows Assy (assembly)

34 R. Stabbing guide 3½”

35 Bourdon Tube

36 Fisher Control Company, Repair Kit

37 Relay Body Assy

38 Diaphragm

39 ⅜” Union cross

40 Ball v/v 2” RTJ600

41 Bowen Spang Link, used on Jar

42 ¾” Pomy Rods

43 7” Dual Completion Packer

44 2⅞ Type C Gliding

45 SSD 2⅞ Type L

46 Multiple acting Indicator

47 Orifice OTS

48 Position#2 Key locator Mandrel Assy

49 Prong pulling

50 Mandrel Selecting Locking

28

51 Orifice Plate 6”x⅛

52 Flow Bean Tungsten Carbide 28/64”, 32/64”, 48/64”, 64/64”

53 Air Hose Assy

54 Hydro Sub 2⅞” with ball

55 Pilot Assy HP Inline Safety System

56 Bean Flow 16/64”, 20/64”, 24/64”, 28/64”, 32/64”, 48/64”, 64/64”

57 Cross Over 4½” CS

58 Pup Joint 2⅜” CS Box Pin

59 Mule Shoe Guide

60 Dual Completion for 9⅝” Casing, 5”x6 Millout Extension

61 Baker Perforated Spacer Tube 2⅞”x10

62 polish rod 11‟ long

63 KRT Seal Assy

64 Seal bore Extension

65 X Over 5”

66 3½ Pup Joint 10.3 lb/ft

67 2⅞ Pup Joint 56.50 lb/ft

68 2⅜ Pup Joint 5 lb/ft

Shed 3 Chemical Store

Sr# Chemical Net Weight

1 Sodium Acid, PURON*F Disodium Pyrophosphate 250 kg/sack

2 Mud Chemical – PF”Extend” (Bentonite Extender) 40x25 kg/stack

3 PPTA Pure Terephthalic Acid 1050 kg

4 No. 7 APIIC, SETTIPALLI 25 kg/sack

5 PAC Polyanionic cellulose, Regular Grade (PAC-R) 25 kg/sack

6 API Non treated Bentonite 1000 kg/stack

(Gross 1015 kg)

7 Non-treated Bentonite API 13A. Sec. 10 100 lb/sack

8 Refined Sodium Bicarbonate 25 kg/sack

9 EN-CMC-HV 875 kg/stack

10 Black Magic SFT (Sacked Fishing Tools) 998 kg/sack

(Gross 1025 kg)

11 OPC Ordinary Portland Cement. Clinker 95%, gypsum 5%.

28 days strength 6500 psi

20 bags to a Metric Ton

29

Shed 4 Cement/CMT Additive

Sr.# Description Weight

1 Retarder D 13 50 lbs/sack

2 Tuned Spacer E+

3 Temperature Retarder D 800

4 Dispersant D 065 TIC*D 065, Sodium polynaphthalene sulfonate

60~100%

50 lb/sack

5 Cement Friction Reducer CFR-3. Made in Germany 50 lb/sack

6 Cement Retarder HR-15

7 FL-198. Source of Chemical: USA. Source of Finished

Chemical: Singapore

50 lb/sack

8 Oil well Cement, Class „G‟ Grade HSR API Spec 10A

Single Trip 5:1, Safe working Load 1500 kg

1.5 Metric Ton/sack

9 PolyCarb 25 kg/sack

10 Film Foam 25 ltr/ container

11 Antifoam Agent D 047, Polypropylene Glycol

60-100%

Net Wt. 19 kg

Gross 20.4 kg

Shed 5: Chemical Store

Sr.# Brand and Description

1 ICI Pakistan. Light Soda Ash. Net Wt. 50 kg/sack

2 OGDCL Pakistan. Hydrogen sulphide Scavenger (Zinc Carbonate).

Net Wt. 30x25 kg = 500 kg/stack, Gross 520 kg/stack

3 Saw Dust Net Wt. 250 kg/sack

4 Itehad Chemicals Pakistan. Caustic Soda Flakes ICL. 97±1% pure. Net Wt. 25 kg/sack

5 KCl Potassium Chloride Sacks

6 China Petroleum Drilling Fluid Co. KPAM Net Wt. 750±10 kg, Gross Wt. 775±15 kg

30

Technical Assignments

1. Piping Layout

2. Layout Fmk01

3. Layout Of Field

4. Separators

5. Pressure vs. Time Behavior of FMK03

6. Triplex plunger PUMP CALCULATION

7. Water sprinkler System/ Water Disposal

8. Liquid Holdup

FMK01 PIPING LAYOUT

Power House

Kn

ock

ou

t

ves

sel

Kit

chen

6”

Mix

Flu

id

Well no. 1 Well no. 2

To Pit

6” Sale Gas Line

1’’

Mix

Flu

id

2’’

1’’

1st stage

1st stage

2nd

stage

PLANT

To Colony

2 7/8’’

FIMKASSAR WELL 01 LAYOUT PLAN

Water Pit Power House (Fuel: Gas)

Pit ( Water with mixed oil) Gas Discharge Point

Building Diesel Tank (Fuel for Oil Pumping)

Masjid Electric Pumps for Bowzer Filling

Security Check Point Diesel Engine Elec Pump Ctrl

Bowser Filling Point Fire Brigade Truck Stand

Water Gun Well (FMK#1)

Horizontal Separator Choke

Vertical Separator Water Sprinkler Control

Fire Extinguisher

Water Tank

StockTanks

Demulsifier Injector

<= CHAKBAILI KHAN ROADFMK WELL # 2

FMK WELL # 1FILLING POINT

OGDCLRESIDENTIAL COLONY

<=

CH

AK

WA

L-M

AN

DR

A R

OA

D

FIMKASSAR OIL FIELDLAY OUT PLAN

FMK # 3WATER INJECTION WELL

OGDCLFREE DISPENSARY

LPG RECOVERY PLANT& ADMIN BLOCK3 KM

DH

UD

IAL

2,5 KM

31

Types of Separators

Three basic types of separators are widely used for gas-liquid separation.

(1) Vertical Separator

(2) Horizontal Separator and

(3) Horizontal Double-Barrel.

Each has specific advantages,

and selection is usually based

on which one will accomplish

the desired results at the lowest

cost.

Separators (Two Phase

Configuration shown) consists

of the following:

A= Vessel,

B= Skid or Saddles,

C= Monarch Turbulence Diverter,

E= Vortex Breakers,

Separators (Three Phase Configuration shown) consists of the following:

A= Vessel,

B= Skid or Saddles,

C= Inlet Diverter,

D= Distribution Baffle,

E= Monarch Coalescing Pack,

F= Foam Breaker,

G= Vortex Breakers,

32

H= Oil Sump and Weir,

I= Mist Eliminator,

J= Sand Jetting

Stage Separation

At fimkassar plant sepration used is done in two stages and in one stage seprator as well

as the wellhead pressure and temprature of well stream obtained from well no 1 is higher that is

the reason this is seprated by two stage seprator as in fig 1.

1 2 3

Storage

Tanks

Fluid from

well

Seprators arrangement for well No 1

Well stream from well no 2 is of low pressure and temprature and is seprated in sigle

stage as shown in fig.1 only one seprator is used in that case.

33

Separators at FMK01

34

Injection Time vs. Injection Pressure graph:

Water injection in well no.3 is carried out by triplex pumps. They are stopped for 1 hour a day to

give rest to mechanical parts and routine maintainence check. This particular time period in

which engines are stopped is called make up time. We have plotted a graph between injection

pressure and time during make up and after make up to get a tren of pressure decrease and rise

respectively.

pressure decrease and rise respectively.

Time Pressure TIME PRESSURE

09:45 2000

09:55 1800

10:05 1700

10:15 1600

10:25 1500

10:35 1400

10:45 1300

10:55 1300

11:00 1300

After Makeup Time when injection was restarted at 11:00 am then the values were

TIME PRESSURE

11:00 1400

11:02 1500

11:05 1600

11:08 1700

11:20 1750

11:32 1800

11:42 1800

12:05 1800

12:15 1850

12:37 1900

12:47 1900

35

1000

1200

1400

1600

1800

2000

2200

2400

Time Vs Pressure(Make up Time)

36

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

Water at well no.3 is injected by the help of triplex plunger pump. It‟s the calculation of the

efficiency of the pump both theoretically & physically.

Theoretical Method:

Circumference of Plunger = 11 in

Radius of Plunger = 𝑟 = 𝑐/2𝜋

= 11/2 × 3.14 = 1.75 in

Number of Plungers = 3

Stokes per minutes (Plunger) = 86

Length of Plunger = 6 in

Volume of plunger = (π/4) × (d2 × l)

= 57.8 in3

Volume of 3 plunger = 3 × 57.8 = 173.2 in3

Volume injected per minute = Volume of Pluger × Stokes per minute

= 173.2 × 86 = 14890 in3 / min

Conversion Factor = 6.7375

Volume injected per minute = 14890/6.7375

=2210 BPD

Physical Method:

In this method we physically calculated the discharge of the tanks after taking dips with the help

of dip rods by a time interval of 15 mins.

37

Average Difference = 2857.92 ltrs /15min

= 2857 × 4 × 23 /159

= 1653.7 BPD

Pump Efficiency = Output / Input

= 1653.7/ 2210

= 74.8 %

38

WATER Sprinkler System

Produced water from Fimkassar field is set to dispose using a sprinkler system. This system

worked on the principle of forced evaporation system. Literature is reviewed and calculations are

done for system efficiency.

WHAT IS EVAPORATION?

Evaporation is a type of vaporization of a liquid that occurs only on the surface of a liquid. The

other type of vaporization is boiling, that instead occurs on the entire mass of the liquid.

Evaporation is also part of the water cycle.

Or

The transformation of water liquid to water gas (or vapor) by energy from heat or air

movements.

How Evaporation occurs?

Evaporation occurs only on the surface of a liquid. The other type of vaporization is boiling, that

instead occurs on the entire mass of the liquid. Evaporation is also part of the water cycle.

Evaporation is a type of phase transition; it is the process by which molecules in

a liquid state(e.g. water) spontaneously become gaseous (e.g. water vapor). Generally,

evaporation can be seen by the gradual disappearance of a liquid from a substance when exposed

to a significant volume of gas. Vaporization and evaporation however, are not entirely the same

processes.

What is the Theory behind Evaporation?

For molecules of a liquid to evaporate, they must be located near the surface, be moving in the

proper direction, and have sufficient kinetic energy to overcome liquid-phase intermolecular

forces. Only a small proportion of the molecules meet these criteria, so the rate of evaporation is

limited. Since the kinetic energy of a molecule is proportional to its temperature, evaporation

proceeds more quickly at higher temperatures. As the faster-moving molecules escape, the

39

remaining molecules have lower average kinetic energy, and the temperature of the liquid thus

decreases. This phenomenon is also called evaporative cooling. This is why

evaporating sweat cools the human body. Evaporation also tends to proceed more quickly with

higher flow rates between the gaseous and liquid phase and in liquids with higher vapor pressure.

Three key parts to evaporation are heat, humidity and air movement.

What are the factors that affect the rate of evaporation?

Concentration of the substance evaporating in the air:

If the air already has a high concentration of the substance evaporating, then the given substance

will evaporate more slowly.

Concentration of other substances in the air:

If the air is already saturated with other substances, it can have a lower capacity for the substance

evaporating.

Concentration of other substances in the liquid (impurities)

If the liquid contains other substances, it will have a lower capacity for evaporation.

Oil…..

Wind velocity:

If fresh air is moving over the substance all the time, then the concentration of the substance in

the air is less likely to go up with time, thus encouraging faster evaporation.

Inter-molecular forces:

The stronger the forces keeping the molecules together in the liquid state, the more energy one

must get to escape.

Pressure:

40

Evaporation happens faster if there is less exertion on the surface keeping the molecules from

launching themselves.

Surface area:

A substance which has a larger surface area will evaporate faster as there are more surface

molecules which are able to escape.

Temperature:

If the substance is hotter, then its molecules have a higher average kinetic energy, and

evaporation will be faster.

Density:

The higher the density, the slower a liquid evaporates.

An Example from daily life:

When clothes are hung on a laundry line, even though the ambient temperature is below the

boiling point of water, water evaporates. This is accelerated by factors such as

low humidity, heat (from the sun), and wind. In a clothes dryer, hot air is blown through the

clothes, allowing water to evaporate very rapidly.

Working Principle of an Evaporator:

The solution containing the desired product is fed into the evaporator and passes a heat source.

The applied heat converts the water in the solution into vapor. The vapor is removed from the

rest of the solution and is condensed while the now concentrated solution is either fed into a

second evaporator or is removed.

The evaporator as a machine generally consists of four section:

The heating section contains the heating medium, which can vary. Steam is fed into this section.

The most common medium consists of parallel tubes but others have plates or coils.

41

The concentrating and separating section removes the vapor being produced from the solution.

The condenser condenses the separated vapor, then

The vacuum or pump provides pressure to increase circulation.

Types of evaporators 1. Flash Evaporator

2. Rotary evaporator

3. Centrifugal evaporator

4. Natural/forced circulation evaporator

5. Falling film evaporator

6. Rising film evaporator

7. Plate evaporator

8. Multiple-effect evaporators

9. Vacuum Evaporator

Flash evaporation:

Flash or partial evaporation occurs when a saturated

liquid stream undergoes a reduction in pressure by

passing through a throttling valve or other throttling

device. This process is one of the simplest unit

operations. If the throttling valve or device is located at

the entry into a pressure vessel so that the flash

evaporation occurs within the vessel, then the vessel is

often referred to as a flash drum.

If the saturated liquid is a single-component liquid

(e.g. liquid propane or liquid ammonia), a part of the

liquid immediately "flashes" into vapor. Both the vapor

and the residual liquid are cooled to the saturation

42

temperature of the liquid at the reduced pressure. This is often referred to as "auto-refrigeration"

and is the basis of most conventional vapor compression refrigeration systems. If the saturated

liquid is a multi-component liquid (e.g. a mixture of propane, iso-butane and normal butane), the

flashed vapor is richer in the more volatile components than is the remaining liquid.

BLEVE:

BLEVE is an acronym for boiling liquid expanding vapor explosion. This is a type

of explosion that can occur when a vessel containing a pressurized liquid is ruptured. Such

explosions can be extremely hazardous.)

A BLEVE can occur even with a non-flammable substance such as water, liquid nitrogen, liquid

helium or other refrigerants or cryogens, and therefore is not usually considered a type

of chemical explosion.

Rotary evaporator:

A rotary evaporator is a device used in chemical laboratories for the

efficient and gentle removal of solvents from samples by evaporation.

Design:

The main components of a modern rotary evaporator are:

A motor unit which rotates the evaporation flask or vial containing sample.

A vapor duct which acts both as the axis for sample rotation, and as vacuum-tight conduit

for the vapor being drawn off of the sample.

A vacuum system, to substantially reduce the pressure within the evaporator system.

43

A heated fluid bath, generally water, to heat the sample being evaporated.

A condenser with either a coil through which coolant passes, or a "cold finger" into

which coolant mixtures like dry ice and acetone are placed.

A condensate-collecting flask at the bottom of the condenser, to catch the distilling

solvent after it re-condenses.

A mechanical or motorized mechanism to quickly lift the evaporation flask from the

heating bath.

Application:

Rotary evaporation is most often and conveniently applied to separate "low boiling"

solvents which are solid at room temperature and pressure such as n-hexane. However, careful

application also allows removal of a solvent from a sample containing a liquid compound if there

is minimal co-evaporation (azeotropic behavior), and a sufficient difference in boiling points at

the chosen temperature and reduced pressure.

Solvents with higher boiling points such as water (100 °C at standard atmospheric

pressure, 760 torr), dimethylformamide (DMF, 153 °C at the same), or dimethyl-

sulfoxide (DMSO, 189 °C at the same), can also be evaporated if the unit's vacuum system is

capable of sufficiently low pressure.

Centrifugal evaporator:

A centrifugal evaporator is a device used in chemical and biochemical laboratories for the

efficient and gentle evaporation of solvents from many samples at the same time, and samples

contained in microtitre plates. If only one sample required evaporation then a rotary evaporator is

most often used. The most advanced modern centrifugal evaporators not only concentrate many

samples at the same time, they eliminate solvent "bumping" (sample loss by violent boiling) and

can handle solvents with boiling points of up to 220 °C. This is more than adequate for the

modern high throughput laboratory.

44

Natural/forced circulation evaporator:

Natural circulation evaporators are based on the natural circulation of the product caused by

the density differences that arise from heating. In an evaporator using tubing, after the water

begins to boil, bubbles will rise and cause circulation, facilitating the separation of the liquid and

the vapor at the top of the heating tubes. The amount of evaporation that takes place depends on

the temperature difference between the steam and the solution.

Falling film evaporator:

This type of evaporator is generally made of long tubes (4–8 meters in length) which are

surrounded by steam jackets. The uniform distribution of the solution is important when using

this type of evaporator. The solution enters and gains velocity as it flows downward. This gain in

velocity is attributed to the vapor being evolved against the heating medium, which flows

downward as well. This evaporator is usually applied to highly viscous solutions so it is

frequently used in the chemical, food, and fermentation industry.

Rising film (Long Tube Vertical) evaporator:

In this type of evaporator, boiling takes place inside the tubes, due

to heating made (usually by steam) outside the

same. Submergence is therefore not desired; the creation of water

vapor bubbles inside the tube creates an ascensional flow

enhancing the heat transfer coefficient. This type of evaporator is

therefore quite efficient,

Plate evaporator:

Plate evaporators have a relatively large surface area. The plates are usually corrugated and are

supported by frame. During evaporation, steam flows through the channels formed by the free

spaces between the plates. The steam alternately climbs and falls parallel to the concentrated

liquid. The steam follows a co-current, counter-current path in relation to the liquid. The

concentrate and the vapor are both fed into the separation stage where the vapor is sent to a

45

condenser. Plate evaporators are frequently applied in the dairy and fermentation industries since

they have spatial flexibility.

Multiple-effect evaporators:

Unlike single-stage evaporators, these evaporators can be made of up to seven evaporator

stages or effects. The energy consumption for single-effect evaporators is very high and makes

up most of the cost for an evaporation system. Putting together evaporators saves heat and thus

requires less energy. Adding one evaporator to the original decreases the energy consumption to

50% of the original amount. Adding another effect reduces it to 33% and so on..

The number of effects in a multiple-effect evaporator is usually restricted to seven

because after that, the equipment cost starts catching up to the money saved from the energy

requirement drop.

There are two types of feeding that can be used when dealing with multiple-effect

evaporators.

Forward feeding: takes place when the product enters the system through the first effect, which

is at the highest temperature. The product is then partially concentrated as some of the water is

transformed into vapor and carried away. It is then fed into the second effect which is a little

lower in temperature. The second effect uses the heated vapor created in the first stage as its

heating source (hence the saving in energy expenditure). The combination of lower temperatures

and higher viscosities in subsequent effects provides good conditions for treating heat-sensitive

products like enzymes and proteins. In using this system, an increase in the heating surface area

of subsequent effects is required.

Backward feeding: In this process, the dilute products are fed into the last effect with has the

lowest temperature and is transferred from effect to effect with the temperature increasing. The

final concentrate is collected in the hottest effect which provides an advantage in that the product

is highly viscous in the last stages so the heat transfer is considerably better.

46

Vacuum evaporation:

Vacuum evaporation is the process of causing the pressure in a liquid-filled container to

be reduced below the vapor pressure of the liquid, causing the liquid to evaporate at a lower

temperature than normal. Although the process can be applied to any type of liquid at any vapor

pressure, it is generally used to describe the boiling of water by lowering the container's internal

pressure below standard atmospheric pressure and causing the water to boil at room temperature.

Vacuum evaporation is also a form of physical vapor deposition used in

the semiconductor, microelectronics, and optical industries and in this context is a process of

depositing thin films of material onto surfaces. Such a technique consists of pumping a vacuum

chamber to pressures of less than 10 - 5

torr and heating a material to produce a flux of vapor in

order to deposit the material onto a surface. The material to be vaporized is typically heated until

its vapor pressure is high enough to produce a flux of several Angstroms per second by using an

electrically resistive heater or bombardment by a high voltage beam.

Forced Evaporation System

47

What is Forced Evaporation System?

The sprinkler system works on the principle of forced evaporation in which a pump is

used to suck the produced water from the pit and sprays through the nozzles causing the water to

form fine mist on the surface of nozzle. The nozzles cause the water to atomize (the conversion

of a vaporized sample into atomic components) into very small droplets into the atmosphere.

The performance of the system is greatly dependent on atmospheric conditions like

temperature, humidity and wind.

How do misting systems work?

Water is forced through small diameter pipes or hoses to tiny nozzles which release the

water in such a fine mist that it appears almost fog like. The droplets are so small most of them

will evaporate instantaneously and effectively lower the temperature around us 15-20 degrees.

This phenomenon is called flash evaporation.

Water Sprinkler system at Fimkassar oil field Well # 1:

Water Sprinkler system has been improvised at Fimkassar Oil Field Well No. 1 for the disposal

of produced water.

Equipment:

1 centrifugal pump of capacity 200gpm

Delivery line of pump is connected to 6" header of length ….΄

On this header, 12 connections have been made of Pipes of Size 1".

Length of each pipe is 10΄, at the end of GI Pipes, spray nozzles have been fitted.

12 Spray nozzles are installed which are in operation for the last 8 Months.

Maximum capacity of each nozzle is 1 gpm.

48

Sprinkler system at Fimkassar oil field Well # 1

Nozzles

Sediment Filteration

Suction Pump

Pressure Gauge

Flare/Water Pit

Valves GI Pipes

49

Sprinkler Rate Calculation

Alternate & Future Recommendations:

Installing Water Treatment Plant will be an additional step towards company‟s social

welfare program. (Agricultural and drinking purposes).

Re-Injection into the reservoir. (After proper treatment)

Keeping in view the current economic status of this field and land availability construct

more pits to enhance solar evaporation OR expand sprinkler system to opposite side of

the same pit to increase flash evaporation process.

No. of Nozzles 12

Nozzle Pressure 12 psi Pressure 25 bar

Pipe Pressure 100 psi 362.5943 psi

Pump Pressure 244 psi Capacity 30 cu.m/hr

Losses 118.5943 132.086 GPM

Elevation 0

Pump Efficiency 67.29% Unit Conversion

1 bar 14.503774 psi

K-factor 0.949 1 cu.m/hr 4.4028675 GPM

x (for TF nozzles) 0.5

Nozzle outFlow 3.287432 GPM

Total outFlow 39.44919 GPM

Petroleum Engineer UET Dated: 01-08-10

Note: Nozzle Pressure is selected by the experimental observation of pressure response on

shuting each nozzle (one at a time)

OIL & GAS DEVELOPMENT COMPANY LIMITED

Pump Information

FIMKASSAR OIL FIELD

Water Sprinkler System

50

Liquid Holdup

Problem Description: Initially well FMK01 was flowing at relatively constant rate of 1450 bpd

& WHFP of 100160 psi for a sufficient long time owing to Injection at FMK03 @ 2000 bwpd

(till constant). On 27/07/10 @ 1800 hrs well started cease to flow, WHFP decreased to 7080

psi, and water cut to 8081%.

Actions Taken: Under such conditions crew and admin at field decided to reduce choke size in

order to stabilize/increase the production rate. As a result of some surges and reduced Choke size

production rate increased.

Reasons as told by Field Personnel

FM, Muhammad Munir Awan: Gas was the main source of energy in the reservoir that was

lifting oil to the wellhead, now the gas potential to lift oil has decreased causing liquid to load

up in the well.

I/C Prod. Muhammad Arif: The well cease to flow due to the build up of water column in the

well which exerts backpressure on the formation thus forbidding reservoir to flow into the well.

Literature Review

Liquid Holdup is defined as the fraction of an element of pipe that is occupied by the liquid at

some instant. That is

𝐻𝐿 =𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝐿𝑖𝑞𝑢𝑖𝑑 𝑖𝑛 𝑎 𝑃𝑖𝑝𝑒 𝐸𝑙𝑒𝑚𝑒𝑛𝑡

𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑡𝑕𝑒 𝑃𝑖𝑝𝑒 𝐸𝑙𝑒𝑚𝑒𝑛𝑡 ⋯⋯⋯⋯ (1)

Evidently, if the volume element is small enough the liquid holdup will be either zero or one. It

is necessary to be able to determine liquid holdup to calculate such things as mixture density,

actual gas and liquid velocities, effective viscosity and heat transfer. In the case of fluctuating

flows, such as slug flow, the liquid holdup at a point changes periodically and is taken as the

time-averaged value.

Experimentally the value of liquid holdup may be measure by several methods for example;

51

Resistivity or Capacitance Probes

Nuclear Densitometers

Trapping a segment of the flow stream between quick-closing valves and measuring the

volume of trapped liquid.

Analytically liquid holdup value can‟t be calculated.

Correlation exists that are widely used for HL value calculation. These correlations are functions

of gas and liquid properties, flow pattern, pipe diameter and pipe inclination. In preceeding

discussion we will develop a correlation for the HL determination.

Density

All fluid flow equations require the availability of density value. Calculation of denity changes

with changing temperature and pressure. The liquid comprising of oil and water have density

calculated by assuming no slippage between oil and water phases as

𝜌𝐿 = 𝜌𝑜𝑓𝑜 + 𝜌𝑤𝑓𝑤 ⋯⋯⋯⋯ (2)

Where, L = density of liquid, pcf

o = density of oil, pcf

w = density of water, pcf

fo = fractional flow of oil

fw = frational flow of water

Fractional Flow of oil is defined as below, similarly for water.

𝑓𝑤 =𝑞𝑤

𝑞𝑤 + 𝑞𝑜 ⋯⋯⋯⋯ (3)

52

Calculation of density of gas/liquid mixture flow requires the knowledge of liquid holdup. Three

equations for two-phase density have been used by various investigators of two phase flow.

𝜌𝑠 = 𝜌𝐿𝐻𝐿 + 𝜌𝑔𝐻𝑔 ⋯⋯⋯⋯ (4)

𝜌𝑛 = 𝜌𝐿𝜆𝐿 + 𝜌𝑔𝜆𝑔 ⋯⋯⋯⋯ (5)

𝜌𝑘 =𝜌𝐿𝜆𝐿

2

𝐻𝐿+

𝜌𝑔𝜆𝑔2

𝐻𝑔⋯⋯⋯⋯⋯ (6)

Equationa (4) is used for determine the pressure gradient due to elevation change.

Equation (5) is used when no-slippage is assumed.

Equation (6) is used when friction loss term and Reynolds number is required.

Velocity

Many two-phase flow correlations are based on a variable called superfacial velocity. The

superfacial velocity of a fluid is defined as the velocity of that phase would exhibit if it flowed

through the total crossectional area of the pipe alone.

The superfacial gas velocity is calculated from:

𝜐𝑠𝑔 =𝑞𝑔

𝐴

The actual area through which the gas flows is reduced to HgA by the presence of the

liquid. Therefore the actual gas velocity is calculated from the following formula.

𝜐𝑔 =𝑞𝑔

𝐴𝐻𝑔

Where A is the pipe area.

The superfacial and Actual liquid velocities are similarly calculated from:

53

𝜐𝑠𝐿 =𝑞𝐿

𝐴 ; 𝜐𝐿 =

𝑞𝐿

𝐴𝐻𝐿

Since HL and Hg are less than one, the actual velocities are greater than the superfacial velocities.

The two-phase or mixture velocity is calculated based on the total in-situ flow rate from

the equation.

𝜐𝑚 =𝑞𝐿 + 𝑞𝑔

𝐴= 𝑣𝑠𝐿 + 𝑣𝑠𝑔

As it has been stated previously, the gas and liquid phases may travel at different

velocities in the pipe. Some investigators prefer to evaluate the degree of slippage and thus the

liquid holdup by determining a slip velocity s . The slip velocity is defined as the difference

between the actual gas and liquid velocities by:

𝜐𝑠 = 𝜐𝑔 − 𝜐𝐿 =𝜐𝑠𝑔

𝐻𝑔−

𝜐𝑠𝐿

𝐻𝐿

Using the previous definitions for the various velocities, alternate forms of the equations

for no-slip and actual liquid holdup are:

𝜆𝐿 =𝜐𝑠𝐿

𝜐𝑚

and

𝐻𝐿 =𝜐𝑠 − 𝜐𝑚 + 𝜐𝑚 − 𝜐𝑠

2 + 4𝜐𝑠𝜐𝑠𝐿 1 2

2𝜐𝑠

Identifiation of Flow Pattern

The manner in which the two phases are distributed in the pipe significantly affects other

aspects of two-phase flow, such as slippage between phases and the pressure gradient. The “flow

regime” or flow pattern is a qualitative description of the phase distributon. In gas-liquid,

vertical, upward flow, four flow regimes are now generally agreed upon in the two-phase flow

54

literature: bubble, slug, churn, and annular flow. These occur as a progression with increasing

gas rate for a given liquid rate. (for detailed description of these flow regimes reader is advised to

go through the literature).

The flow regime in gas-liquid vertical flow can be predicted with a flow regime map, a

plot relating flow regime to flow rates of each phase, fluid properties, and pipe size. One such

map that is used for flow regime determination is that of Duns and Ros (1963), shown in figure

7-10. The Duns and Ros map correlates flow regime with two dimensionless numbers, the liquid

and gas velocity numbers, Nvl and Nvg, defined as

𝑁𝜐𝑙 = 1.938 𝜐𝑠𝑙 𝜌𝑙

𝜍𝑔𝑜

4

𝑁𝜐𝑔 = 1.938 𝜐𝑠𝑔 𝜌𝑙

𝜍𝑔𝑜

4

Where, sl , sg = superfacial velocities of liquid and gas, fps

l = density of liquid (defined previously ), pcf

go = interfacial tension of gas-oil, dynes/cm

55

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

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1

0

20

40

60

80

100

120

140

160

180

200

WC

T, G

as R

ate

Production History Illustrating the Well Problem

FWHP (psi) Choke Size (xx/64") WHFT (deg. F)

BOPD WCT Gas Rate (mmscfd)

Choke size reduced from 50 to 40/64"

56

Figure: Possible flow regimes that

can occur in vertical, multiphase

flow.

57

Precautions/Solutions to Liquid Holdup

Start up a well quickly to avoid losing the gas dissolved in the oil.

Avoid slowly shutting in a well. A quick shut-in will reduce the liquid hold-up.

Leave the well shut-in for an extended period of time to allow water to diffuse back into

the reservoir, to promote gas dissolution into the oil and to allow the local reservoir

pressure to build.

Larger diameter tubing is required in the initial life of the well but later on as the

reservoir potential declines hold-up can be high in larger diameter tubing then it is

necessary to re-optimize the system with smaller diameter tubing.

Consider some form of intermittent or kick-off artificial lift scheme (for Offshore wells).

Use a conventional artificial lift method.

Sizing production tubing requires economic assessment. A reservoir simulation (numerical,

decline curve or material balance) will be required to integrate reservoir performance and

reservoir pressure.

Pressure traverse means the relationship of pressure with depth. Pressure traverse curves are used

to evaluate the well performance, pressure drop calculations in the piping and to optimize the

production system.

However we have performed a calculation using Standard Tubing Performance (Pressure

traverse) Curves (“Well Performance”, Curtis H. Whitson) in order to evaluate well performance

in following three Scenarios.

FWHP = 150 psi, Tubing Size = 2.875”, GLR = 180 scf/bbl, FOPR = 200 bpd, BHP = 2750 psi

FWHP = 150 psi, Tubing Size = 3.5”, GLR = 180 scf/bbl. FOPR = 200 bpd, BHP = 2900 psi

FWHP = 100 psi, Tubing Size = 3.5”, GLR = 364 scf/bbl, FOPR = 140 bpd, BHP = 2464 psi

58

Economical View

Months

Crude Oil

Revenue

(Rs. Millions)

Gas

Revenue

(Rs.

Millions)

Total

BOE

Total

Revenue (Rs. Millions)

Total

Expenditure (Rs. Millions)

Cost Per

bbls. Rs.

Jul-08 45.142 0.500 8528.5 45.642 9.397 1102

Aug-08 54.720 0.578 10105.6 55.298 7.591 751

Sep-08 55.733 0.569 10198.0 56.302 10.551 1035

Oct-08 54.941 0.595 10618.8 55.536 7.810 735

Nov-08 48.508 0.582 10221.0 49.089 8.072 790

Dec-08 34.371 0.665 10923.8 34.976 7.752 710

Jan-09 33.717 0.921 10858.5 34.313 6.337 584

Feb-09 25.249 0.827 9721.7 25.783 6.431 660

Mar-09 31.561 0.942 11283.9 32.170 6.858 608

Apr-09 28.640 0.929 11103.0 29.570 6.951 626

Total 412.582 7.108 103563 419 78

59

OI L & GA S DEV ELOP M EN T COM P A N Y LI M I TED

FI M KA SSA R OI L FI ELD

REV EN UE / EX P EN DI TURE A N D COST P ER BBL

0.100

10.000

1000.000

100000.000

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

Months

Rs. (M

illi

on

s)

/ B

BL

S

Crude OilRevenue (Rs.Millions)

Gas Revenue (Rs.Millions)

Total BOE

Total Revenue (Rs. Millions)

Total Expenditure (Rs. Millions)

Cost Per bbls. Rs.

Gas Rev. Rs.

Millions

Total Exp. Rs.

Millions

Crude oil Rev. /Total Rev. Rs.

Millions

Cost Per bbl

Rs.

Total BOE


FI M KA SSA R OI L FI ELD

0.000

10.000

20.000

30.000

40.000

50.000

60.000


Months

Re

ve

nu

e /

Ex

pe

nd

itu

re

0

200

400

600

800

1000

1200

Re v e n u e / Ex p e n d it u r e a n d Co s t P e r b b lC

os

t P

er

bb

l

Revenue (Rs. Millions)

Expenditure (Rs. Millions)

Cost Perbbls. Rs.

Expenditure Rs.

Million

Cost Per bbl Rs.

Revenue Rs. Million

60


FI M KA SSA R OI L F I ELD

M ON TH LY GA S P R OD U CTI ON / SA LE

W.E.F JU LY -2 0 0 8 TO A P R I L-2 0 0 9

0.000

2.000

4.000

6.000

8.000

10.000

12.000

14.000


MONTHS

MM

SC

F

GAS

PROD

SALE

GAS

61

HSEQ (Health Safety Environment and Quality Policy)

According to the rules assigned by HSE, PPE is provided to employs. Without PPE no one is

allowed to work in yard. PPE includes

Hard hat

Safety shoes

Safety glasses

Appropriate clothing (coverall)

Hand gloves

This is minimum PPE requirement, in maximum PPE mask, and ear plugs are included.

Emergency assembly point and procedure is guided to every visitor, employ and

inspection team. In case of emergency everyone has to gather at a common point called Muster

point. There are also first aid boxes and emergency showers provided at fix points in case of

emergency. First aid box must not contain any medicine, because some medicines can be allergic

to someone.

Personal Lift Capacity

A person is not allowed to lift more than 22 kg. Safety lifting procedure should be used in

lifting weight. Do not put weight on our back; try to lift by putting weight on thighs rather than

on back bone. In case of heavier weights, fork lifter is used.

Care should be taken while lifting equipment with fork lifter. Do not stand under the

forks of lifter. Plug should be inserted in forks leg while lifting, so that weight should not fall.

Avoid Jokes

There should be no horse play and physical jokes.

Other Safety Requirements

No smoking inside accommodation

Alarm systems and mustering points for office and yards

62

Waste management responsibility

House keeping

Emergency situations and contact at location

Designated smoking areas, no Alcohol and drugs, Mobile phone and over speeding and

safety belts.

12 Life saving Rules

Work Permit

Gas Tests

Lockout-Tag out

Confined Space

System Override

Safety Harness

Suspended Loads

Designated Smoking Areas

No Alcohol & Drug

Mobile Phone & over Speeding

Safety Belt

Journey Management

Prompt Cure for Chemical (Acid/alkali) base Burnt

Keep on washing affected part with cold, clean and excess of water

Remove the affected clothe from the corresponding part

In case Eyes are affected by the chemical splash

1. Dip your face in water and keep on blinking your eyes

2. Use Eye wash lotion

3. Come under the nearby water tap and wash your eyes properly.

Repeat this process for atleast 20 minutes.

In case Skin is affected by the chemical

63

1. Wash properly the affected part with fresh water

2. Ask someone else to wash your affected part with water

3. Remove the affected clothe from your body

4. Place the affected part under a water tap.

As a precaution, consult any doctor later on.

In case they’re swallowed

Swallowing them by mistake may cause vomiting and bad

digestion. Possibly affect these organs 1) respiraFire Extinguishing

System

Carbon Dioxide Extinguisher (5 kg)

Where to use:

1. Open the seal and press the lever by hand.

2. Grip the pipe from the recommended portion.

3. Direct the stream towards flame.

4. Prevent touching the gas exhaust pipe.

Precautions: Try extinguishing the fire according to air direction.

Foam Type Extinguisher (10 litres)

Where to use: Used for initial stage fire of oil along with wood, paper and cloth.

How to use:

Open and erect the hose pipe.

Grip the nozzle with left hand and from right hand fully open the mixture valve by

rotating it anticlockwise.

Laid it down horizontally using handle and immediately open the control valve in

opposite direction.

Point the stream of liquid foam to the flame origin.

64

If fire is eradicated immediately place the extinguisher in vertical direction (former

position) so that remaining gas is exhausted.

Precautions:

1. Wash twice after using fire extinguisher.

2. It is dangerous to use it on electrical wiring and equipments.

Water Pipe Extinguisher (10 litres)

Where to use: Used for solid fire (paper, wood, cloth, rubber, husk etc.)

1. Keep extinguisher vertical

2. Remove safety pin

3. Fully press the handle

4. Point the exiting foamy stream towards flames.

5. Never use on electric wires

1. Never hang on wall immediate after use, instead place it on the floor.

2. Ask the concerned authority to Refill it.

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