SUMMER INDUSTRIAL TRAINING

DEEPAK CHANDAK-13EJIME032JODHPUR INSTITUTE OF ENGINEERING AND

TECHNOLOGY(CO ED,MECHANICAL)

AT ONGC ANKLESHWARSUBMITTED TO-HOD- M R BAID(MECHANICAL)

OIL AND NATURAL GAS CORPORATIONINDUSTRY- OIL AND GASHEADQUARTER- TEL BHAVAN, DEHRADUN, UTTRAKHANDCHAIRMAN & MD- DINESH KUMAR SARAFOWNER- GOVERNMENT OF INDIAPRODUCTS- PETROLEUM, NATURAL GAS, AND OTHER PETROCHEICALS.

ABOUT ONGC

“to give world leadership in management of energy source, exploration of energy sources, diversification of energy sources, technology in Underground Coal Gasification, and above all, finding new ways of tapping energy wherever it is, to meet the ever-growing demand of the country”

VISION STATEMENT

ONGC

33,560 EMPLOYEES

11 ASSETS(OIL & GAS)7 BASINS(EXPLORATORY)2 PLANTS(OIL REFINING)

SERVICES (DRILLING, WELL SERVICES, LOGGING, )

7.1 BILLION TONNES OF HYDROCARBONS (TILL

NOW)

11,000 KMS OF PIPE -LINES OVER COUNTRY

PRODUCTS- CRUDE OIL, GAS, LPG, NAPTHA, C2-C3

AND OTHER HYDRO-CARBON’S PRODUCTS

ABOUT ONGC ANKLESHWAR ASSET • STARTED IN 1960, PRODUCTION STARTED IN 1961.• SITUATED AT ANKLESHWAR, BHARUCH, GUJRAT.

ANKLESHWAR ASSET, ONGC

HAS 4 FIELDS OF OIL-ANKLESHWAR(1960, well depth~1100m)-GANDHAR(1984, well depth~3200m)-JAMBHUSAR(1999, well depth~3800m)-DAHEJ(2005, well depth~3500m)

HAS 11 GGS (GGS 1-7, GGS DAHEJ, GGS JOLWA, GGS DABKA, GGS GANDHAR), 1 CTF1 CPF, 1 MPH

HAS 7 NO. OF OIL RIGS:-2 MOBILE RIGS(CWX, M-450)4 ELECTRICAL( E-1400-3, E-1400-7, E-760, E-2000)1 VFD(EV-2000-2)

HAS MORE THAN 6000 WELLS DRILLED TILL DATE & MORE THAN 300 ACTIVE WELLS

HAS VARIOUS DEPARTEMENTS LIKE DRILLING, FISHING, LOGGING, CASING, MATERIAL, INTRUMENTATION, SURFACE etc..

OUTSOURCING FOR VARIOUS SERVICES LIKE DIECTIONAL DRILLING, FISHING, DRILLING, WORK-SHOP SERVICES FOR MACHINES etc..

FORMATION OF OIL PROCESS OF FORMATION OF OIL IN EARTH

1. E.g. PLANTS AND ANIMALS.

2. BURIED UNDER LAYER OF SOIL.

3. DUE TO FORMATION OF MORE SOIL LAYERS.4. DUE TO HEAVY ROCKS HIGH TEMPRETURE & PRESSURE. 5.HIGH TEMPRETURE & PRESSURE UNDER ROCKS FOR LONG TIME.6.THE CONVERSION PRO- CESS OVER YEARS.

LIVING ORGANISM

DEAD BODIES

BIOPOLYMER

GEOPOLYMER (KEROGEN)

PETROLEUMFOSSIL FUELS

BITUMEN

PROCESS OF OIL PRODUCTION

DATA FROM SATELLITE SEISMIC SURVEYS

RIG MOVING,BUILDING & LEVELLING

THE CHRISTMAS TREE DRILLING PROCESS

DRILLING RIG

A Rig is a complete Mechanical machine that consist of the structure and the machines that were used for drilling of oil well.

DRILLING PROCESS

Readying of drilling location (surface leveling, water sources, pipeline setup etc).

Rig moving / Rig buildingIf a free rig is there in nearby area then rig moving & rig building else only rig building.

The drilling process starts that includes mud circulation, casing, cementation, inert of drill pipes, fishing etc.

Various simultaneous processes takes place such as mud cleaning, data handling of well like temp. pressure etc, maintenance of various machines etc.

When it is get to know that oil starts coming, the rig is removed and ‘The Christmas Tree’ is placed there in place for oil production.

A continuous care is taken of well data like pressure, temp., gas from mud after drilling, the required depth of drilling etc.

THE DRILLING PROCESS (INSIDE VIEW)

Major Drilling Equipment

Divided Into Following Categories:

–Hoisting Equipment (used for raising and and lowering of drill pipes)–Rotary Equipment (used to give rotary power to drill bit for cutting action)–Circulating Equipment (for circulation of mud)

Hoisting Equipment

1. Draw worksOne of the major drilling equipment on the rig

Raises or lowers drill string, casing and other equipment in well

TRAVELLING BLOCK HOOK

CROWN BLOCK

Rotating equipments

SWIVEL TOP DRIVE SYSTEM

SWIVEL IS CONNECTED BETWEEN DRILL PIPE AND HOOK TOP DRIVE SYSTEM IS USED TO DRIVE THE WHOLE ROTARY SYSTEM

MUD CIRCULATION SYSTEM

TYPES OF DRILL BITS

MILLED TOOTH BITUSED FOR CUTTINGOF UPPER LAYER OF SAND (GENERALLYUPTO 400-700 m.)

INSERT BIT USED FOR CUTTINGOF ROCKS AND SAND(DEPTH UPTO 1200m.)

POLYCRYSTALLINEDIAMOND COMPACT DRILL BITUSED FOR CUTTING OF HARD FORMATION OR ROCKS (DEPTH 1000m. AND ABOVE).

CASING & CEMENTATION PROCESS Casing is large diameter pipe that is assembled and inserted into a recently

drilled section of a bore hole and typically held into place with cement. The following casing intervals are typically used in an oil or gas well:• Conductor casing• Surface casing• Intermediate casing (optional)• Production casing The basic principle of cementing operations is the displacement of cement

slurry down the casing, tubing or drill pipe to a pre-specified point in the well. The main functions of primary cementation are:-• To bond and support the casing.• Protecting the casing from corrosion.• To restrict fluid movements between formations.• Protecting the casing from shock loads during drilling of next zone.• Sealing off problematic zone

TYPES OF CASING

COST ANALYSIS OF DRILLING RIG E-1400-7

Drilling Cost

Operating Cost Man PowerDiesel Cost

Well CostMud cost

Casing cost Drill bit cost Out sourcing

costCementing cost

Maintenance Cost

OPERATING COSTNet operating cost included two types of cost:

• Man power cost (assuming man power cost as a fixed cost)• Variable cost

It includes:

Diesel cost Mud cost Casing Cost Drill Bit Cost Out Sourcing Cost Cementing Cost Maintenance cost

DIESEL COST Total available engines at the drilling site:4 nos • Based on the operational requirement engines are

started. Sometimes operation are carried out with 3 or 4 engines or sometimes by one or two engines

• Diesel consumption is approx. 7000 liters per day (it includes diesel consumption of all the engines)

• Net diesel consumption is 7000*30*3 (per well) = 630000 liters

• Diesel cost is Rs.58.84 per liter.• Total diesel cost is 630000*58.84 = Rs.3,70,69,200

2.WELL COST1. MUD COST• Mud is the mixture of water, bantonite clay, thinner and lubricating oil.• Its cost is around Rs.70 per liter.• And 150000 liters of mud is used for drilling of a well of around 3000 meters depth.• So total mud cost is 150000*70 = Rs.1, 05, 00,000.2. CASING COST• Cost of conductor casing is Rs. 3667.05 per meter.

So total cost of conductor casing is = 3667.05*200 = Rs. 7,33,410 • Cost of intermediate casing is Rs. 2015.31 per meter.

So total cost of intermediate casing is = 2015.31*1600 = Rs. 32,24,494• Cost of production casing is Rs. 1311.51 per meter.

So total cost of production casing is = 1311.51*3233 = Rs. 42,40,139• Total casing cost = 81, 98, 043 or approx. 82 lakhs.

3. DRILL BIT COST Generally two types of drilling bits are used1. Fixed cutter and tri conical roller2. PDC (Poly Crystalline Diamond Compact) bit

Cost of fixed cutter and tri conical roller is 15 lakhs per bit.Cost of PDC is around 50 lakhs per bit.One well consumes around one TCR and one PDC bit.Total drill bit cost = Rs. 65 lakhs.

4. OUT SOURCING COSTOut sourcing means giving specific job to any private industry. For example: - Jindal, Schlumberger and CAIRN etc.For directional drilling ONGC out sources the job to different companies.Cost of out sourcing is around 2 crore.

5. CEMENTING COST

TOTAL CEMENTING COST= Rs. 1954533 = 20 lacs.

3. Maintenance cost

• The maintenance budget of ONGC per year for 6 drilling rigs is around 50 crore.

• Each rig drills average 5 wells per year.• So maintenance cost per well is around 1.67 crore.

TOTAL DRILLING COST

• Operating Cost = 3.70 crore• Well Cost = 4.72 crore• Maintenance Cost = 1.67 crore• Total cost = 10.09 = 10 crore

SITE VISITS The rigs that we have visited:• CARDWELL-10• M-450• E-760-5• E-2000-2• E-1400-7 GGS (Group Gathering Station) CTF (Central Tank Farm) MPH (Main Pump House)

PRODUCTION

• From 1 GGS around 1000 m^3/day liquid (oil +water) is sent to CTF.

• And oil production in CTF from 1 GGS is around 150m^3/day

• LPG production per day is around 10 to 15 tones.

• Naptha production per day is around 20 tones.

After summer training at ONGC ankleshwar,I have known about the process of oil well drillingfrom starting to finish, at the Ankleshwar fieldand Gandhar field. We also visited GGS, CTFand MPH. we also conducted one project work,

“COST ANALYSIS OF DRILLING RIG E1400-7”.

CONCLUSION

THANK YOU