Upload
hadung
View
223
Download
2
Embed Size (px)
Citation preview
Pr ince Mo hammad Bin Fahd Univers it y
C o l l e g e o f E n g i n e e r i n g
Department of Mechanical Engineering
Internship Report
at
Halliburton Company
at
Boots and Coots Department
R e p o r t i n g P e r i o d :
[16/06/2012 - 08/08/2012]
S u b m i t t e d b y :
[ G h a z i K . A l A r f a j ]
[ 2 0 0 7 0 0 6 7 7 ]
[ s u b m i s s io n d a t e ( 1 5 / 0 9 / 2 0 1 2 ) ]
Mechanical Engineering Department
Summer 2012
1
Abstract
As an engineering student at Prince Mohammad bin Fahd University, or any other
university around the globe we are required to fulfill a summer training program or as we call
it in the university, internship, upon graduation. The purpose of the internship is to apply
what I learned during our educational life at the university in the working environment. I
selected Halliburton Services Company to be my destination for the training because the
knowledge they gives us as summer trainees, weather by taking safety courses or by letting us
monitor and involving us a bit while they are performing their job.
2
Acknowledgments
It is always a pleasure to thank and gratitude the people behind my success at
Halliburton Services Company, Boots & Coots Department for their sincere guidance I
received to imply my theoretical skills in engineering. Firstly, I would like to thank Dr. Omar
Ouda, the charged instructor of the internship program for his positive and effective advices
prior working. Secondly, I would like to thank Eng. Ali Alabdrab Alnabi, the industry
supervisor for his great guidance and effort he gave us. Finally, I apologize to all other
unnamed who helped me in various ways to have a good training and knowledge about the
working environment.
3
Table of Content
Page
Abstract 1
Acknowledgments 2
Table of contents 3
List of Figures 4
Main Text 5
Introduct ion 6
The Company 7
Activities and responsibilities 7
Major tasks or projects 12
Conclusion 13
References 14
Appendix A: Industry Supervisor Report 15
Appendix B: Student Log Sheet 18
Appendix C: Student Feedback Form 20
Progress Technical Reports 23
4
List of Figures
Figure Number and Name Page
Figure 1: The Training Courses Cards I obtained 7
Figure 2: PPE (The Personal Protection Equipment) 7
Figure 3: BOP (Blow Out Preventure) 7
Figure 4: Fluid End 10
Figure 5: CTU (Coiled Tubing Unit) 10
5
Main Text
In this section I will post the training schedule for the 8 weeks I spend at the
company:
Week Task
1 HR Introduction
2 Safety Courses
3 Coiled Tubing Shop: Redress BOP and Stripper
4 Coiled Tubing Shop: Bottom Hole Assembly (BHA)
5 Coiled Tubing Shop: HT-400 Pump
6 Coiled Tubing Shop: N2 Equipment
7 Coiled Tubing Shop: Coiled Tubing Unit
8 Coiled Tubing Shop: Software (IFS)
This training schedule looks the same as the Student Log Sheet, because the supervisor filled
the sheet at the beginning of the training in order to follow his training program, and be able
to know what task I should follow each week.
6
Introduction
Boots &Coots Department in Halliburton consider as the newest and one of the main
departments at the company. Boots & Coots merges with Halliburton in 2010, which is why
it is consider as new. The main goal of this internship is to gain experience of what I learned
in collage, as well as understand the department main functions. This report will explain the
following, the company, activities and responsibilities, and the major tasks or projects.
The Company
Halliburton founded in 1919. It is consider one of the largest oil services companies,
which serve the upstream industry. The company has more than 70,000 employees in almost
80 countries. In the 1940s, Halliburton was one of the first oil service companies that sign
contracts with Saudi Aramco back then. Halliburton consists of two main divisions: Drilling
and Evaluation; and the Completion and production, where the Boots & Coots fall under it.
Boots & Coots as I mentioned before merges with Halliburton in 2010. Nevertheless, Boots
& Coots was a separate company from Halliburton where it founded during the 1978. Boots
& Coots helped during the Gulf War in 1991, by controlling nearly 700 oil well fires that
ignited by the Iraqi soldiers.
7
Figure 1
Figure 2
Figure 3
Activities and Responsibilities
The beginning of the internship journey starts when I arrived to the company at the
first day when I arrived to the company. At that day we were involve in a two days
introduction about the company, as well as how long it has been in the region. On my third
day, I introduced to the supervisor who was assign to give me
instructions on the work that is perform, and introducing me to the
management of the department as well. The following week, was the
beginning of the actual training, where I was assign to take four different
courses before I proceed to work.
After that, I received the PPEs, the Personal Protective Equipment
from the department so I can start to work and learn about the company’s
different equipment. The PPE consists of, a helmet, safety glasses, a
coverall, a pair of gloves, and a pair of safety boots. In addition to that,
the supervisor told me about their safety roles. One of the main important roles he told me
about is the JSA form, the Job Safety Analysis, where I should read it
carefully and understand what problems I might find and then sign it. This
form is also includes a work permits so I can be eligible to work. The
following activity, I introduce to the basic equipment they have, the BOP
or as it called the Blow Out Preventer. I had a chance to be involved in
seeing its parts, and assemble them in the unit. After the assembly, we did a pressure test on it
to make sure it meets the company standards.
8
The following task was involving in the Nitrogen Equipment. On that particular day, I
was involved in replacing a non-working booster pump in the nitrogen-converting unit. After
we were done with the replacement, we have done a test to make sure that things are running
smoothly. The next activity was about the BHA, Bottom Hole Assembly, each tool to be
fitted to the coil tubing is consist of:
1. External or internal connector to fit the tube with the tool.
2. A MHA (motor head assembly) that is include a wafer check valve to prevent fluid to
come back.
3. A rupture disc to prevent excesses pressure.
4. A nozzle to increase the velocity and the pressure.
5. A SurgicFrac, this will gives more life for the selected tool because it stands very high
corrosive materials.
6. Knuckle joint, to give the nozzle flexibility to move, or a hydraulic knuckle joint,
where it kicks off while pumping.
The next task was about learning about the HT-400 pump, and its component. The
usage of the HT-400 is to deliver different fluids downhole. Typically, the pump consists of
two main ends, power end, and fluid end.
9
Power End Components:
1. Case and drive gears: It divides into two main parts, right- and left-hand sides.
2. Crankshaft: Heat-treated steel forgings used to manufacture crankshafts. All
cranks are the same, even for left- and right-hand units.
3. Connecting Rods: Connecting rods made from aluminum forgings. The
identical rods internally drilled to provide lubrication to the crosshead pins.
4. Crossheads: Crosshead bodies are made of heat-treated steel alloy castings.
They fitted with replaceable; high leaded bronze shoes on both top and
bottom.
5. Lubrication: an internal crescent gear-type pump driven off the end of the
worm gear pressurizes standard self-contained power end lubrication system.
6. Cooling: The HT-400 Pump cooled with radiator-type coolers that provide
high cooling capacity.
Fluid End Components:
1. Chambers: The fluid end constructed from three separate
but identical forged and heat-treated chambers. Fluid ends
can supply any of five plunger sizes and each size can fit to
the standard power end without alteration of either fluid or
power end.
Figure 4
d
10
Figure 5
2. Valves and valves sets: Fluid ends are fitted with replaceable, carburized
valves and seats. Most of the valve assembly parts are interchangeable
between suction and discharge ports within a given size and some are even
interchangeable between sizes.
3. Lubrication: A separate lubrication system supplies lubricant to the fluid end
package.
The next activity I learned was the Coiled Tubing Unit, CTU. The CTU usually
contains the following equipment or parts:
1. Injectors: As the name refers, it used to
move coiled tubing into the well, and at the
same time, it seals off the tubing, making a
pressure-tight connection. The injectors
have roller chain and gripper blocks to hold tubing in place and injecting it
into the BOP (Blow Out Preventer) mounted on the top of the well. The size of
these injectors based on its maximum pull capacity. For instant, 30K means it
can pulls up to 30,000 lb.
2. The Guiding Arches: The tubing guiding arches mount on top of the injector
and does its part in guiding tubing into the well too. The design and the radius
of each arch are typical with all job set-ups and condition.
3. The Reel: Basically, reels used to winding and unwinding coiled tubing; store
the tubing for transport to location; and keep the tubing in good working
11
condition. In addition to that, reels also provide tension during coil tubing
operations.
4. Coiled tubing power pack: The function of this power pack is to provide all of
the power and fluid controls necessary to operate a coiled tubing unit.
5. Control House: As its name refers, the control house is the operational nerve
center of any coiled tubing unit. Usually it is mounting at the front side of the
trailer after the reel and before the truck driver cabin; the control house could
lifted hydraulically above the reel for better view during the coiled tubing
operations.
The last activity I have done was learning about software used at the department in order to
perform their required job. Their software is called IFS, InSite For Simulation. The software
main functions are:
1. Monitoring, which include:
Pressure Monitoring.
Rate Monitoring; whether it is flow rate or anything else.
Density Monitoring.
Volume Monitoring.
Speed Monitoring.
Weight Monitoring.
Depth Monitoring.
12
2. Control that do the followings:
Controlling Pumps.
Controlling Blenders.
Controlling Coiled Tubing jobs.
Controlling Nitrogen jobs.
3. Analysis, which is used to analysis the data gathered by the software.
The operation of this software like any other software in the universe, where it needs inputs
such as, sensors, and cables to carry out the signals; after then, converting them in a sort of
out puts for the user.
Major Tasks or Projects
The main task was exciting and has lots of information. It is the BOP pressure test. As
the policy of the company requires performing either pressure or function tests depending on
the type of equipment they will perform the test, in this case a BOP 15K type (Can hold up to
15,000+ psi). Prior the test I had to look at the JSA, Job Safety Analysis and sign on it, and
sign a copy of a job permit in order to start. In order to pass that test we had to repeat the test
twice because a leakage that was occurs in the lower stack of the BOP. After fixing this leak,
we did a retest on the next day, and we hold a pressure of 15,280 psi for 10 minutes. What I
observe is that a drop of the pressure was occurring with an amount of 1 psi every 3 second
which is acceptable for us to pass. After the 10 minutes was gone we passed the test with a
total pressure of 15,070 psi.
13
Conclusion
In conclusion, it was a great opportunity to join Halliburton Company during the
summer training period. Training at Halliburton, Boots & Coots Department was beneficial
and related to my major as a mechanical engineering student as well as it is not related to my
major, somehow petroleum engineering. I had a great knowledge in my field at the company
since the supervisor offered me a copy of the Coiled Tubing Introductory Book. At the end, I
would love to recommend the student to do training at Halliburton or any other company to
obtain much knowledge and to expos to the working environment.
14
Reference
1. Eng. Ali Alabdrab Alnabi, Boots & Coots Engineer.
2. Eng. Ernesto Bustamante, Senior Engineer at Boots & Coots.
3. Halliburton Coiled Tubing I Workbook.
23
Prince Mohammad Bin Fahd Universi ty
C o l l e g e o f E n g i n e e r i n g
Department of Mechanical Engineering
Internship Report
at
Halliburton Company
at
Boots and Coots Department
R e p o r t i n g P e r i o d :
[16/06/2012 - 27/06/2012]
S u b m i t t e d b y :
[ G h a z i K . A l A r f a j ]
[ 2 0 0 7 0 0 6 7 7 ]
[ s u b mi s s i o n d a t e ( 2 9 / 0 6 / 2 0 1 2 ) ]
Mechanical Engineering Department
Summer 2012
24
Summary
The first week at Halliburton Company was mainly about introducing us as students about the company and its policies. At the end of this week we were introduced to our supervisors and our departments, and signing our contracts. Our second week was mainly about four different coerces we have to take. The third week was about the department’s equipment at the department yard.
Background
During this summer internship, my actual journey started on 16/06/2012. We introduced to our supervisor Ali as I stated before in the summary on Wednesday in the first week at the company. The contact details of the supervisor as well as the department’s training schedule will be presented at the appendix at the end of this progress technical report. The second week at the company was at the department. During the first three days, Saturday, Sunday, and Wednesday, we took some required courses in their training facility, as it appear in the appendix, and we received completion cards. The remaining days, Monday, and Tuesday, were off-days since our supervisor gave us these days because he was out in the field. During the third week, we learned about the department’s equipment at the department yard on Saturday. In the following day, we introduced to one of their equipment in detail. That part was the BOP, Blowout Preventer, I learned about their deferent types 10k and 15k. The one I was learning about is the 15k (15-kpsi) type. I learned about its deferent components, the parts inside it, and its usage. I will explain this part in the progress.
Progress
The planed work was about learning about the BOP’s components, which are, Quad Slips, and the Campy Rams. Quad is the first four parts on each side of the BOP. Campy is the two parts on each side of the BOP as what you will see in the picture. BOP used as an emergency device to control the downhole pressure. The BOP’s parts are consist of, blinds, shear or cutter, slips, and pipe close, one on each side in the Quad Slips region. The Campy Rams region consist of Blind/ Shear or cutter as one part, and slips/ pipe close as another part. I help the operators during the assembly of these parts in the BOP. After our lunch break, we run a pressure test to test the BOP if it can hold a 15-kpsi pressure for 10 minutes as the company policy to check for any potential leaks. One main problem I faced is memorizing the deferent parts and component of the BOP. On Tuesday, we ran a last test in front of the shell company man to see our testing result in order to ship it out for work at Shell Company. Unfortunately, after we run the test several times leaks occurs after we
25
passed 4 minutes approximately, and we had to adjust the equalizer of the BOP. After we adjust the equalizer we fixed the pressure at 15,280-psi for 10 minutes with 1-psi drop at every 3 seconds which considered acceptable. Finally it passed the test with holding a pressure at approximately 15,070-psi for 10 minutes after the dropping out.
Plans
What I will do during the upcoming week is following up with the supervisor’s schedule and instructions.
26
Appendices
I. Supervisor’s Contact Details:
27
II. The Department Training Schedule:
Week Task
1 HR Introduction
2 Safety Courses
3 Coiled Tubing Shop
Redress BOP and Stripper
4 Coiled Tubing Shop
Bottom Hole Assembly (BHA)
5 Coiled Tubing Shop
Learn about HT-400 Pump
6 Coiled Tubing Shop
Learn about N2 Equipment
7 Coiled Tubing Shop
Learn about Coiled Tubing Unit
8 Coiled Tubing Shop
Learn about Software
III. Courses Completion Cards:
28
IV. Photos:
1. BOP Parts: Notice the parts I mentioned before, from top to bottom, Blinds, Shears or Cutter, Slip, Pipe Close, these will be in the Quad region. And the Last two parts are, Blind/ Shear or Cutter, and Slip/ Pipe Close, in the Campy region.
2. BOP Before Assembly: Notice the two regions, the Quad first four components on the top, and the Campy, which are the last two components on the bottom.
3. BOP After Assembly: Same as I mentioned above, but this is after assembly.
29
Prince Mohammad Bin Fahd Universi ty
C o l l e g e o f E n g i n e e r i n g
Department of Mechanical Engineering
Internship Report
at
Halliburton Company
at
Boots and Coots Department
R e p o r t i n g P e r i o d :
[30/06/2012 - 11/07/2012]
S u b m i t t e d b y :
[ G h a z i K . A l A r f a j ]
[ 2 0 0 7 0 0 6 7 7 ]
[ s u b mi s s i o n d a t e ( 1 3 / 0 7 / 2 0 1 2 ) ]
Mechanical Engineering Department
Summer 2012
30
Summary
The third week at Halliburton Company was mainly about introducing us as summer trainee students about the Bottom Hole Assembly or as commonly we name it as BHA. Our fourth week supposed to be about HT-400 Pump but since the pumps were not availably in the yard, I was introduced to the Nitrogen Equipment.
Background
This report will explain the entire process of what I learned about the Bottom Hole Assembly and the Nitrogen Equipment. Let me explain the Bottom Hole Assembly at the beginning. Bottom Hole Assembly is a component of a drilling rig. Alternatively, I can explain it as the end tool of the coiled tube, as what I introduced to the Hydrablast Tool. On the other hand, the Nitrogen is used to pressurize to well to increase the production of the well such as, the concept of the perfume bottle.
Progress
The period of 30/06/2012 to 04/07/2012 is the Bottom Hole Assembly or mainly the Hydroblast Tool:
I was introducing to this tool as a part of my training schedule. This tool is assembled at the end of the coiled tube, and it is used for different purposes such as, cleaning the well, or pumping Nitrogen to pressurize the well for better production. After I was introduce to this tool, and we saw the cleaning process, the disassembly and the assembly process of this tool we ran a test on this tool to see if it can handle a pressure of 2014 psi at a rate of 2.4 barrel per minutes (bpm) without leakage. During the test I was monitoring the screen for any up normal conditioned that may occurs.
The period of 07/07/2012 to 11/07/2012 is the Nitrogen Equipment:
I was introduced to the Nitrogen equipments on that week. I saw the tank that they refrigerate the Nitrogen at (-320 degrees Fahrenheit). In addition to that, I saw the pumping device that they use to pump the Nitrogen into the well. I understand the concept behinds pumping the Nitrogen into the well. I understood that the process of that is based on the heat transfer or closely as the heat exchangers. The whole process goes by having a pump that will suck the liquid Nitrogen, and while the Nitrogen leaving the tank it goes into tubing lubes to exchange some heat of the atmosphere with the heat of the Nitrogen to heat up the Nitrogen a little before it gets into the pumping device. After that, the Nitrogen will be circulated around the
31
exhaust to gain additional heat from the exhaust gases. After it takes that additional heat it will circulate one more time around the hydraulic devices to gain more heat from the hydraulic devices before it turns into its gases state to pump it throw the booster pump into the well. During this learning process, I saw a test run on the Nitrogen equipment to see how it actually runs.
Plans
What I will do during the upcoming week is following up with the supervisor’s schedule and instructions.
32
Appendices
I. Photos:
1. Hydrablast Tool: It is located at the far left of the picture (The White Lined Area).
2. Connection Cables I helped in connecting to the measurements devices in order to read the readings.
3. The monitors on the left I was assigned to monitor to see the readings of the tool.
33
Prince Mohammad Bin Fahd Universi ty
C o l l e g e o f E n g i n e e r i n g
Department of Mechanical Engineering
Internship Report
at
Halliburton Company
at
Boots and Coots Department
R e p o r t i n g P e r i o d :
[14/07/2012 - 25/07/2012]
S u b m i t t e d b y :
[ G h a z i K . A l A r f a j ]
[ 2 0 0 7 0 0 6 7 7 ]
[ s u b mi s s i o n d a t e ( 2 6 / 0 7 / 2 0 1 2 ) ]
Mechanical Engineering Department
Summer 2012
34
Summary
The fifth week at Halliburton Company was mainly about introducing us as summer trainee students about the HT-400 Pump after the delay because of the availability of the pump at the yard. Our sixth week is about the Coiled Tubing Unit or as it called CTU.
Background
This report will explain what I learned about the HT-400 Pump and the Coiled Tubing Unit. During this report, I will go over the HT-400 and the main usages for it. On the other hand, I will talk about the Coiled Tubing Unit and its components.
Progress
The period of 14/07/2012 to 18/07/2012 is the HT-400 Pump:
I was introducing to the HT-400 Pump as a part of my training schedule. This pump used to deliver fluids downhole. Typically, the HT-400 Pump has two ends, power end components, and the fluid end components, as I will explain as follow:
Power End Components:
1. Case and drive gears: It divides into two main parts, right- and left-hand sides.
2. Crankshaft: Heat-treated steel forgings used to manufacture crankshafts. All cranks are the same, even for left- and right-hand units.
3. Connecting Rods: Connecting rods are made from aluminum forgings. The identical rods are internally drilled to provide lubrication to the crosshead pins.
4. Crossheads: Crosshead bodies are made of heat-treated steel alloy castings.
They are fitted with replaceable, high leaded bronze shoes on both top and bottom.
5. Lubrication: an internal crescent gear-type pump driven off the end of the
worm gear pressurizes standard self-contained power end lubrication system.
6. Cooling: The HT-400 Pump cooled with radiator-type coolers that provide high cooling capacity.
35
Fluid End Components:
1. Chambers: The fluid end constructed from three separate but identical forged and heat-treated chambers. Fluid ends can supply any of five plunger sizes and each size can fit to the standard power end without alteration of either fluid or power end.
2. Valves and valves sets: Fluid ends are
fitted with replaceable, carburized valves and seats. Most of the valve assembly parts are interchangeable between suction and discharge ports within a given size and some are even interchangeable between sizes.
3. Lubrication: A separate lubrication
system supplies lubricant to the fluid end package. The period of 21/07/2012 to 25/07/2012 is the Coiled Tubing Unit:
I introduced to the Coiled Tubing Unit on that week. The Coiled Tubing Unit components are as follow (From the back of the trailer to the front):
1. Injectors: As its name means, it is used to moves coiled tubing into the well, and at the same time, it seals off the tubing, making a pressure-tight connection. The injectors have roller chain and gripper blocks to hold tubing in place and injecting it into the BOP
36
(Blow Out Preventer) mounted on the top of the well. The size of these injectors are based on its maximum pull capacity, for example, 30K which means it can pulls up to 30,000 lb.
2. The Guiding Arches: The Tubing guiding arches mount on top of the injector and does its part in guiding tubing into the well too. The design and the radius of each arch are typical with all job set-ups and conditions.
3. The Reel: Basically, reels are used to winding and unwinding coiled tubing; store the tubing for transport to the location; and keep the tubing in good working conditions. In addition to that, reels also provide tension during coil tubing operations.
4. Coiled Tubing Power Pack: The power pack provides all of the power and fluid controls necessary to operate a coiled tubing unit.
5. Control House: As its name implies, the control house is the operational nerve center of any coiled tubing unit. Usually it is mounting at the front side of the trailer after the reel and before the truck driver cabin. The control house could lift hydraulically above the reel for better view during the coiled tubing operations.
Plans
What I will do during the upcoming week is following up with the supervisor’s schedule and instructions, which I will be lift with the software, that are used in the department to perform the jobs are required.
37
Prince Mohammad Bin Fahd Universi ty
C o l l e g e o f E n g i n e e r i n g
Department of Mechanical Engineering
Internship Report
at
Halliburton Company
at
Boots and Coots Department
R e p o r t i n g P e r i o d :
[28/07/2012 - 08/08/2012]
S u b m i t t e d b y :
[ G h a z i K . A l A r f a j ]
[ 2 0 0 7 0 0 6 7 7 ]
[ s u b mi s s i o n d a t e ( 0 9 / 0 8 / 2 0 1 2 ) ]
Mechanical Engineering Department
Summer 2012
38
Summary
The seventh week at Halliburton Services Company was mainly about introducing us as summer trainee students about the software are using at the department in order to perform there required jobs.
Background
This report will explain what I learned about the Boots and Coots Software, and deeply the IFS Software.
Progress
The period of 28/07/2012 to 01/08/2012 is the IFS Software:
I was introducing to the InSite For Simulation Software or as it called (IFS). The software main functions are:
1. Monitoring, which include:
Pressure Monitoring.
Rate Monitoring; whether it is flow rate or anything else.
Density Monitoring.
Volume Monitoring.
Speed Monitoring.
Weight Monitoring.
Depth Monitoring.
2. Control that do the followings:
Controlling the Pumps.
Controlling the Blenders.
Controlling the Coiled Tubing jobs.
39
Controlling the Nitrogen jobs.
3. Analysis, which is analysis the data gathered by the software.
The operation of this software is basically as any other software in the universe. This program will need inputs such as, sensors, and cables to carry out the signals. After so, this program will give us the outputs based on the different inputs it takes.
Plans
What I will do during the upcoming week after completing the required training during the eight weeks is gathering up with the supervisor and collects the evaluation form. In addition, getting the supervisor feedback during my training weeks.