STUDENT INDUSTRIAL INTERNSHIP PROGRAMME JUNE 2009 - JANUARY 2010
AT
PETRONAS CARIGALI SDN BHD PMO, PCSB PENINSULAR WELL INTEGRITY ENGINEERING DEPARTMENT
NUR KHAIRINA BINTI KOSNON 9066 PETROLEUM ENGINEERING PROGRAM
VERIFICATION STATEMENT
I hereby verify that this report was written by Nur Khairina Binti Kosnon (I/C no: 881104-01-5040) and all the information regarding this company and the projects
involved are NOT confidential.
-----------------------------(Supervisor)
Name
:
Designation
:
Host Company
: Petronas Carigali Sdn. Bhd.
Date
:
ii
VERIFICATION STATEMENT
I hereby verify that this report was written by Nur Khairina Binti Kosnon (I/C no: 881104-01-5040) and all the information regarding this company and the projects
involved are NOT confidential.
-----------------------------(Supervisor)
Name
:
Designation
:
Host Company
: Petronas Carigali Sdn. Bhd.
Date
:
ii
EXECUTIVE SUMMARY University Technology Petronas, UTP was established with objectives of producing well-rounded graduates who possess technical competence, lifetime learning capacity, critical thinking, communication and behavioral skills, business acumen, practical aptitude and solution synthesis ability. In order to achieve these objectives, undergraduate students undergo industrial internship program. By that, students have the opportunity to gain knowledge and experience from different types of industrial practitioners. The Industrial Internship Program is a compulsory exercise where every student is required to complete thirty (32) weeks of training in a multinational or any designated company.This Industrial Internship Final Report summarizes all the activities done by the author during the (32) weeks period of the st
Industrial Internship Program at PETRONAS Carigali Sdn. Bhd. started on 1 June th
2009 until 7 January 2010. The final report is divided into 3 main parts. The introduction is briefly focusing on the host company background, which is PETRONAS Carigali Sdn. Bhd., the objectives and the scope of works during the Industrial Internship Program. The body section is focused on the details of the main activities and projects involved. The last part will contain on subjective matters such as lessons learnt and experience gained, discussion and recommendations to the Host Company and the Internship Unit. Conclusion and references also provided by the end of the report.
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ACKNOWLEDGEMENT I would like to take this opportunity to thank all parties involved in making the internship programme a great educational session and a great success. Honorably thanking PETRONAS Carigali Sdn Bhd (PCSB) and Industrial Internship Training Program committee at Universiti Teknologi Petronas (UTP) for giving me this chance to learn and experience a real working culture and environment in the industry and for all their support and integrity which played an ultimate roll in the success of training. I would like to thank the following for their respective professionalism and contribution to the program.
•
Mrs Noriani Noriani Yati, Manager Well Integrity Integrity Engineering Department
•
Mr.Shahrizal Hasyim, Senior Well Services Engineer, Plant Supervisor
•
Mr Hairi Razak,Well Sevices Engineer, Mentor 1
•
Mr. Rohaizat Ghazalli, Well Services Engineer, Mentor 2
•
Mrs Mazlin Idris, UTP Supervisor
•
All staff in Well Integrity Engineering Department
Heartfelt appreciation goes to lecturers and UTP staff, which have spend time to provide additional support and advice throughout the training. Last but not least to all my fellow trainees, friends and my family who have been giving me courage and advice throughout this course in order to complete my Industrial Training
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TABLE OF CONTENTS Verification Statement…..……………………………………………………….….ii Executive Summary…………………………………………………..……............iii Acknowledgement…...………………………………………………….………….iv Table of Contents…………………………………………………………………...v List of Illustrations………………………………………………………...............vii 1.
INTRODUCTION......................... INTRODUCTION............................................... ............................................ ............................................. .......................... ... 1
1.1.
INDUSTRIAL INDUSTRIALI NTERNSHIP ............................................ .................................................................. ......................... ... 1
1.2.
HOST COMPANY HOST COMPANY OVERVIEW OVERVIEW ......................................... ................................................................ ....................... 2 1.2.1. PETRONAS ............................................ ................................................................... ....................................... ................ 2 1.2.2. PETRONAS Carigali Sdn. Bhd ............................................. ..................................................... ........ 3 1.2.3. Peninsular Well Integrity Integrity Engineering Engineering Dep (PWE)................... (PWE) ...................... ... 4
1.3. 2.
SCOPE OF SCOPE OF WORK WORK ............................................ .................................................................. ........................................ .................. 6
TRAINING AND ACTIVITIES ........................ ............................................. .......................................... ........................... ...... 7
2.1 ROUTINE 2.1 ROUTINE ACTIVITIES ........................................... ................................................................. ........................................ .................. 7 2.1.1. Database .......................................... ................................................................ ............................................. ....................... 7 2.1.2. Inspection of packages and equipments........................................ ........................................ 8 2.2.ATTENDED FORMAL TRAINING ........................................... ............................................................... ....................11 2.2.1. Geowell Warehouse (Slick line) ............................................. .................................................. ..... 11 2.2.2. Schliumberger Wireline Testing Acquisition (WTA)................... (WTA) ...................17 2.2.3. Dowell Schlumberger (Coiled Tubing) ....................................... ....................................... 23 2.3.OFFSHORE VISIT 2.3.OFFSHORE VISIT E XPOSURE ........................................... ................................................................. ........................ .. 26 2.3.1. Duyong Platform ........................................... ................................................................. .............................. ........ 26 2.3.2. Production facilities…………………………………………………27 2.3.3 Inter - rig rig to Duyong Alpha……………………………………….... Alpha………………………………………....29 29 2.4.SPECIAL TOPIC............................................. ................................................................... ............................................ ........................ .. 22 2.4.1. Static Gradient Survey Survey (SGS) interpretation interpretation .............................. .............................. 22 2.4.2. Overview ........................................... .................................................................. .......................................... ................... 22 2.4.3. Conclusion ............................................ .................................................................. ...................................... ................ 24 3.
LESSON LEARNED AND EXPERIENCES GAINED ................................ ................................ 25
3.1.
TEAMWORK AND INDIVIDUAL AND INDIVIDUAL ACTIVITIES ..................................... ..................................... 26 26
3.2.
LEADERSHIP AND LEADERSHIP AND MANAGEMENT MANAGEMENT SKILLS SKILLS ....................................... ....................................... 26
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4.
3.3.
SAFETY TRAINING AND AWARENESS ................................................26
3.4.
PROBLEMS AND CHALLENGES ENCOUNTERED ............................ 26
DISCUSSION AND RECOMMENDATIONS............................................... 29
4.1.
UNIVERSITI TEKNOLOGI PETRONAS ................................................29
4.2.
PETRONAS CARIGALI SDN. BHD. .......................................................42
5.
CONCLUSION ................................................................................................. 43
6.
REFERENCES.................................................................................................. 44
7.
APPENDICES ............................................................................................... I-VI
7.1.
APPENDIX A: TRAINING SCHEDULE ................................................... I
7.2.
APPENDIX B: TIMETABLE TRAINING PROGRAMME ........................ II
7.3.
APPENDIX C: EXAMPLE OF MAWOP CALCULATIONS .................... IV
7.4.
APPENDIX D: WELLBORE SKETCHES ................................................. V
7.5.
APPENDIX E: TRAINING/ VISIT PICTURE GALLERY ......................... VI
vi
LIST OF ILLUSTRATIONS
FIGURES
TABLES
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1. INTRODUCTION 1.1. INDUSTRIAL INTERNSHIP The Industrial Internship is coordinated by the Industrial Committee of UTP to achieve the objectives of UTP establishment in producing well-rounded graduates. In order to produce well-rounded graduates, UTP is responsible to provide the undergraduate students with adequate theoretical knowledge as well as structure a program for them to undergo a practical work. This Industrial Internship carries 16 credit hours and last for 32 weeks. It is generally to equip the students with technical competence, practical aptitude as well as communication and behavioral skills. Apart from that, it also helps to enhance the relationship between UTP and the industry including private and government sectors. The following is the main objectives of this Industrial Internship. •
To integrate the theoretical knowledge learned with practice
•
To introduce and familiarize the students with working culture and industrial practices
•
To give opportunity for students to work with industrial practitioners
•
To develop and enhance students’ personal ability and skills in work ethics, communication and management.
•
To expose students to potential employers
•
To acquaint UTP students with industries and their programs.
\
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1.2. BACKGROUND OF THE HOST COMPANY
1.2.1 PETRONAS PETRONAS, short for Petroliam Nasional Bhd, is Malaysia's national petroleum corporation established on 17 August 1974. Wholly-owned by the Government, the corporation is vested with the entire oil and gas resources in Malaysia and is entrusted with the responsibility of developing and adding value to these resources. Since its incorporation PETRONAS has grown to be an integrated international oil and gas company with business interests in more than 30 countries. As at end of March 2003, the PETRONAS Group comprised 82 wholly owned subsidiaries, 24 partly owned outfits and 47 associated companies.
The Group is engaged in a wide spectrum of petroleum activities, including upstream exploration and production of oil and gas to downstream oil refining; marketing and distribution of petroleum products; trading; gas processing and liquefaction; gas transmission pipeline network operations; marketing of liquefied natural gas; petrochemical manufacturing and marketing; shipping; automotive engineering; and property investment.
PETRONAS Vision: •
A leading Oil and Gas Multinational of Choice
PETRONAS Mission: •
We are a business entity
•
Petroleum is our core business
•
Our primary responsible is to develop and add value to this national resource
•
Our objective is to contribute to the well being of the people and the nation.
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PETRONAS Shared Values •
Loyalty - Loyal to Nation and Corporation
•
Professionalism - Committed, Innovative and Proactive and Always Striving for Excellence
•
Integrity - Honest and Upright
•
Cohesiveness - United in Purpose and Fellowship.
1.2.2 PETRONAS Carigali Sdn. Bhd(PCSB) PETRONAS Carigali Sdn Bhd (PCSB) is a wholly owned subsidiary of PETRONAS and it was incorporated on May 11, 1978. The PCSB's vision is to be a multinational exploration and production company of choice, creating value through continuous improvement and growth. Nowadays, the company has been rapidly expanded its operations locally and internationally. PCSB’s operation in Malaysia is divided into three production divisions (see figure 1), which are Peninsular Malaysia Operations (PMO), Sabah Operations (SBO) and Sarawak Operations (SKO). The PMO’s operation is based at PETRONAS Office Complex in Kertih, about 110 km of south Kuala Terengganu. The PMO’s operation started in April 1984 with the commencement of gas production from the Duyong gas field, the first field owned and developed by PCSB. Its operations start to grow with the production of Dulang oil field in 1991. Effective April 1, 1995, PCSB took the operatorship of 5 producing oil fields, known as PM-9 (see figure 2) from Exxon Mobil Exploration Production Malaysia Incorporated (EMEPMI). With this acquisition, PMO became the largest production division in PCSB. The takeover of PM9 also posed a greater challenge to PMO in managing bigger and more complex operations with matured fields and aging facilities. PCSB, PMO is headed by Mr. Abu Fitri Abd Jalil and there are 11 departments heading by him which are Human Resource, Regional Planning, Health, Safety and Environment, Administration, Finance, Performance Improvement, Supply Chain Management, Maintenance Engineering, Production, Reliability & Integrity and Well Integrity Engineering.
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Figure PCSB, PMO Operations
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1:
1.2.3 Peninsular Well Integrity Engineering Department (PWE) Well Integrity Engineering Department (PWE) is a new department born after re-organization exercise in 2006. Previously, we were known as Well Services fraternity and resided under Sub-surface Engineering (PTS1) section of Technical Services Department (PTS). PWE’s Mission : To be a resource centre for PMO in providing strategic technical solution in well integrity engineering and services towards operational excellence. PWE’s Vision : To be a custodian in PCSB, governing technical solutions in well integrity engineering and services.
The department is headed by a manager, and anchored by three (3) sections namely PWE 1 for operation section, PWE 2 for planning section and last but not least PWE 3 which is for technical support section. Below is the organization chart of PWE department. The job scope of each of the sections is as below: PWE - Operation Section • Lead execution operations on all Well Integrity activities. • Manage daily operations and contractors performance. • Interface SSI team and operations authority during work execution. • Lead new technology implementation. • Prepare/review work program and procedures for all Well Integrity activities.
PWE - Planning Section • Strategies Well Integrity work program and budget. • Strategize implementation plan on Well Integrity activities. • Contract holder for all Well Integrity contractors. • Focal point for management reporting on Well Integrity activities. • Focal point for Well Integrity database management.
PWE - Technical Support Section
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• Custodian for regional Well Integrity Management. • Provide technical support and consultancy on Well Integrity activities. • Review safety related procedures for Well Integrity activities. • Lead Well Integrity special projects or abnormal operations. • Custodian for new technology implementation.
1.3 SCOPE OF WORK During 8 months for the industrial training in Peninsular Well Integrity Department, there are several involvements, formal Well Intervention training programme, familiarization at offshore and also assignments that have been allocated to trainee in order to get better knowledge, further understanding on the roles and responsibility of Well Integrity Engineers. There are two main involvements during internship which are completing database of the weekly activity well intervention update for each field and wellwork summary for well intervention operation in each month. Other than that, acrivity of inspection package and equipment is done routinely if there is any new job will be operated. The objective of these database is to perform an assessment to determine opportunities for improvements in PWE Department in relation to operational performance. Besides that, the purposes of inspections are to ensure that all the equipments that will be sent to offshore follow Carigali’s standards by the service providers.
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For formal well intervention training program, there are t hree course of training such slickline training at Geowell warehouse, wireline training at Schlumberger Wireline Testing Acquisition (WTA) and Dowell Schlumberger for Coiled Tubing training. Familiarization at offshore was conducted after completing safety training course which is Malaysia Basic Offshore Safety and Emergency Training (MBOSET). The objective of the offshore familiarization is for exposure on actual working environment in well intervention jobs. Last but not least, there are assignement and and case study involved to assisting engineers such as Static Gradient Survey (SGS) and Flowing Gradient Survey (FGS) interpretation.
2.
TRAINING AND ACTIVITIES 2.1 ROUTINE ACTIVITY The objective of routine activity is to familiarize with the routine job of well
services engineer such as database for weekly well intervention activity update and well work summary. Furthermore, other routine activity is such as do inspection for package and equipment. Seems like this activity quit simple and easy, however it gave good impact to me. By doing this activity, it help me to understand more about well intervention and its tools, equipment and equipments 2.1.1 Database a) Weekly well intervention activity update This task is completed by summarize the daily operation report that we got everyday by email or fax from contractor or supervisor in offshore. These reports contained the type of wireline operation in each well. By doing this task, it can give me information about the standard procedure for conducting wireline operation and also tools used during the operation. If there is any problem during the operation, engineer has to decide what to do next. We can see the solution of the problem by 7
reading the daily operation report. Below is the example of weekly well intervention activity update of Angsi field. It consisted of date of operation, platform name, well number, type of job, and summary of activities. This is important for engineers to make a review on condition of each well.
Figure 2 : Sample of weekly activity well intervention updated
b) Wellwork summary This task is to be completed at the end of every month to make revision on wireline operation along that month. Just like weekly activity well intervention update, this wellwork summary is much simpler. It also consisted of date of operation, platform name, well number, type of job, and summary of activities. By doing this, we can know the performance of each field during the month.
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Figure 3 : Sample of Wellwork summary
2.1.2 Inspection of tools and equipment The inspection of tools and equipment is really important to ensure all the t ools and equipment follows the specification that has been highlighted by Carigali before its mobilization to offshore and to ensure that the service provider follows the requirements mobilization of the package based on contract.
There are several
inspection that I able to inspect with engineers such as inspection on Tecwel Well Leak Detector (WLD) , BJ engineering (Inject Safe), Dimension Bid - Multi Pulsed Neutron-Neutron (MPNN). The details of the inspection will be explained below : 1. Tecwell - Well Leak Detector (WLD) The Well Leak Detector (WLD) from TecWel is designed to identify the exact location of a leak points (WLD). The Well Leak Detector (WLD), a cased hole logging tool developed by TecWel, detects and locates leakage in a wellbore with a depth accuracy of a few inches. Any oil, gas, water or multiphase fluid leak can be detected with rates from as small as 0.02 liter/min (or 0.004 GPM) and upwards. Also multiple leaks in a wellbore can be detected. 9
Basic Principle
Energy caused by turbulent flow across the leak will generate low current out of crystal sensor and being amplified and finally being processed in DSP which creates the signature of the leaking. The leak must be kept active by maintining a differential pressure.
Figure 4 : 2D principle od Well Leak Detector 2. BJ Engineering – Inject Safe InjectSafe SCSSV technology is applied to well Angsi E-06L which had a problem with the SCSSV control line. The inspection for this tool had been done in BJ warehouse. Below is the explaination of the InjectSafe SCSSV. The 3.500 ISSCSSV-R InjectSafe SCSSV Restire is a capillary controlled,wireline retrievable, flat flapper,equalizing or non-equalizing, subsurface safety valve rated for 5000 psi and 10000 psi working pressures. This system is deployed when conventional wireline valve applications are not possible. This system provides capillary hydraulic control of a wireline retrievable surface controlled sub-surface safety valve to maintain “fail safe” control over the well if some catastrophic surface or subsurface event were to occur. The system is deployed in wells where the subsurface Tubing Retrievable Safety Valve (TRSV) is no longer operational as aresult of a hydraulic control system failure,eliminating the use of a conventional wireline retrievable surface controlled sub-surface safety valve.
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Figure 5 : Insert Valve
3. Dimension Bid – Multi Pulsed Neutron-Neutron (MPNN) The MPNN is a memory pulsed neutron logging tool which measures the capture cross-sections of the formation and borehole. These tools are often referred to as cased hole resistivity tools due to the correlation between the sigma log and the resistivity log from the open hole. The MPNN can run using either slickline or coiled tubing, and provides better porosity estimates in gas filled boreholes. The MPNN is also better for identifying gas/water contacts. The MPNN provides high-quality data at a fraction of the cost, thereby making reservoir monitoring in remote locations or complex wellbores more economically feasible. This tool will be used in Resal well which was gas well.
Figure 6: Memory Pulsed Neutron Neutron (MPNN)
2.2 ATTENDED FORMAL TRAINING The purposes of attended formal training are to familiarization on the scope of Wireline which are Slick line, e-line and coiled tubing used in well intervention. Other than that, Well intervention training is really useful in order to familiarize with 11
the scope, objective and deliverables from each of the Well intervention method. Also, exposure to be familiar with the planning, execution and post job process involve during well intervention job.
2.2.1.
Geowell Warehouse (Slick line)
Wireline is a method used to convey downhole equipment or tools in and out of the wells under pressure. The principle of wireline is that, any downhole tools or equipment to be run into a well must acquire fishing neck and all its dimensions and drawings must be logged. The slickline or solidline is made up of a single strand wire. There are three common sizes of slickline which are: 0.108”for soft job, 0.125”for heavy job and 0.140” for fishing job. Wireline toolstring is the assembly that is run downhole to perform a specific operation. The toolstring is run; retrieved and manipulated by upward and downward movement of the wire, which is raised and lowered by the wireline winch at the surface.. Thus, it is important for PWE Engineers to be familiarized with the toolstring assembly so as to know its usage, and functions. This can help choosing the right tool when planning for any well intervention job. A typical wireline toolstring is shown below:
Figure 7: Typical tool string assembly
Rope Socket
Function: Connection between slickline to other downhole tools. Features: Commonly used: Tear Drop •
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•
•
Stem
Knot tied to allow rope socket to break at a predetermined pull Weak point allows separation and retrieval of wire downhole
Function: • •
To provide additional weight to the toolstring. Increase impact force delivered by the jars by increasing weight of downhole tool
Features: Normally available in 2ft, 3ft, and 5ft.
Roller stem
Function: Used for work on deviated wells, Used in wells with paraffin, asphaltine etc. on the tubing internal walls. Allows the stem to roll down the tubing wall and hence, cut down the friction incurred when using regular stem. • •
•
Jar
Function: Act as downhole hammer Provide impact foce to operate, set and retrieve downhole equipment • •
Features: Activated by hand or winch movement Blind box Function: Used when heavy downward jarring is required to dislodge a fish or push a tool down the hole. Features: It is flat on the bottom and hardened to reduce wear and damage. 13
Kick over tool
Function: Required to run and pull valves and accessories into and from SPMs and perform the following functions: - locates the mandrel - orientates the valve or pulling tool to the correct position - Laterally offsets the valve or pulling tool into position over the pocket.
Knuckle jar
Functions: Allows angular movement in deviated wells. Features: Constructed of a special ball and socket design Useful when light jarring is required. • •
Table 1: Down hole tools for slick line Furthermore, Data Acquisition System provided by Geowell which cover the function of Electronic Memory Recorder to record pressure and temperature is also include during the training. Basically, there are two common survey job done by Operation Engineers which are Static Gradient Survey and Flowing Gradient Survey. The following describes each of these gradient surveys. Electronic Tools : 1. Pressure and Temperature Gauge ( Gauge ) 2. Memory Production Logging Tools ( MPLT) 3. Multi-finger Imaging Tools ( MIT ) 4. Down-Hole Shut In Tools ( DHSIT
Pressure Temperature Gauge: To down hole pressure and temperature for reservoir monitoring and production forecast.
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Figure 8 : Electronic Memory Recorder (EMR) Gauge
Static Gradient Survey(SGS) While conducting SGS, pressure is measured at different depths in the well while the well is shut in. The well is usually shut in for a sufficient time to allow the pressure to stabilize before starting the SGS. A pressure from static gradient survey is used to: •
To determine the fluid distribution in the well bore. This information is required for pressure correction and locating the depth for the operating gas lift valve.
•
To calculate the middle perforation and datum pressure.
Flowing Gradient Survey (FGS) The flowing gradient survey involves measuring flowing pressure at different depth in the well while the well is flowing. The well must have been flowed at sufficient time for flowing pressure to stabilize. It can be done during run in hole (RIH) or pull out of hole (POOH). The result of FGS can be use for:
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•
To determine appropriate correlation for modeling flow along the well bore.
•
To determine the gaslift optimization
•
To determine the flowing pressure at mid perforation (Pwf)
The following figure shows total vertical depth against pressure graph for both Static gradient and flowing gradient survey. Based on the static gradient curve, it indicate the level of properties in the wellbore which Gas Oil Contact (GOC) because of different density or pressure gradient between oil and gas. Compare with flowing gradient survey which shows the performance of gas lift manderal at second Side Pocket Manderal (SPM#2). The purpose of gas lifting is to lighten up oil that can increase production by reduce the density and pressure gradient of oil.
Figure 9: Total Vertical Depth against pressure for SGS and FGS
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Memory Production Logging Tools ( MPLT) : Production logging provides the information that enables the diagnosis of well problems. Some examples of problems that can be identified are: •
Water entry location
•
Non-performing perforations
•
Channeling behind casing
•
Tubing,Packer or casing leak
Figure 10 : MPLT
Multi-finger Imaging Tools ( MIT ) : To used to detect the corrosion and scale deposition through the wells.
•
24 finger – 1.75” to 4.5” Range
•
40 finger – 3.0” to 7.5” Range
•
60 Finger – 4.5” to 9 5/8” Range
Figure 11 : MIT
Down-Hole Shut In Tools ( DHSIT ) : To obtain sufficient Build-up and Drawdown data with eliminating the well bore storage in order to get accurate skin, permeability and boundary analysis.
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Down Hole Shut-in Tool Application : •
PBU and IFO
•
Multi-zone test
•
Interference tests
Figure 12: DHSIT
2.2.2. Schliumberger Wireline Testing Acquisition (WTA) Electric line is used for well logging involving deploying sensory tools designed to provide some information about the properties of the well. Electric line can be subdivided into open hole operations and cased hole operations. However, PMO do not use all the E-line tools. We commonly use five tools, which are Reservoir Saturation Tool(RST), Production Logging Tool(PLT), Mechanical Plug Back Tool(MPBT), Perforating Gun, and Propellant Stimulation. The details about all the five tools will be discussing later. These are the comparison between slick line and e-line: E-line
Slick line
Electric power is supplied from surface equipment to perform the measurements.
Survey tools is run with memory gauge and the power is supplied by battery.
Mainly used to evaluate and measure reservoir performance.
Mainly used to manipulate well’s accessories such as SSD, nipple, GLM.
Survey results can be monitored real-time.
Survey results will only be downloaded once the gauge is out at the surface.
Table 2: Comparison between Slick line and e-line
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Cable Wireline cable is used for electrical, depth and mechanical connection. The wireline cable is divided into two types which are monocable and heptacable
Monocable Construction A monocable has one conducting wire, protected by insulation, a jacket and two layers of armor (left). The armor layers wind in opposing directions, so that a twist that opens one layer will tighten the other layer. A coaxial cable is a monocable with a coaxial shield between the insulation and the jacket (center). A heptacable has seven conductors (right).
Heptacable
The heptacable has filler strands to give it a rounder shape and an interstitial filler to prevent air pockets and to make the core more rigid. A jacket and the two armor layers complete the outer layers. Conductor 1 here has a green jacket to distinguish the conductors when making connections.
Table 3 : Type of E-line cable 19
Reservoir Saturation Tool (RST)
Figure 13 : Reservoir Saturation Tool RST is a nuclear tool with different logging modes. The purpose of RST is to provide unique data from cased well to help production and reservoir engineers :
‐
To locate bypassed oil
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To detect waterflood fronts
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To fine tune formation evaluation
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To monitor production profiles
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Basic Sequences :
‐
Tools generate neutron
‐
Neutrons interact with the formation, the borehole and tool creating gamma rays
‐
Tools detect gamma ray swith two detectors ( Near and Far)
‐
Figure 14 : Neutron interacted
Production Logging Tool (PLT)
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Saturation computed
Production Logging Tool is used when in production mode to get production split ratio and also the high water zone. It can be used to temperature survey
Production Logging Applications : ‐ Evaluation ‐ Production profile distribution ‐ Zonal productivity ‐ Monitoring ‐ Production profile change ‐ Fluid type changes : Water or Gas breakthrough ‐ Diagnosis ‐ Source of high GOR or water cut ‐ Detection of leaks or crossflow ‐ Production Enhancement ‐ Data of workover planning ‐ Completion and treatment effectiveness
Figure 15 : PLT application
Figure 16 : Standard Production Service Platform
Production Logging Interpretation 22
•
Single phase : determination of downhole profile and interpretation of downhole data is straight forward
‐
Tools used : Flow meter- to calculate total flowrate Temperature – fluid entries, flow behind pipe Pressure – well performance
•
Multiphase flow : phenomena like hold up, slippage velocity and phase segregation complicates the flow behavior.
‐
Tools used (additional) : Gradiomanometer – Fluid mixture density eProbes (PFCS or DEFT) – water hold up oProbes (GHOST) – gas hold up
Mechanical Plug Back Tool (MPBT) Purpose : Water Shut Off – Isolating lower perforated zone MPBT features • •
Figure 17 : Mechanical Plug Back Tool •
•
Through tubing Minimum 500psi differential pressure rating without cement and working temperature up to 340 F. Anchors center plug & tool even in horizontal well. Plugs are drillable.
Perforating Gun Perforation in the context of oil well refers to a hole punched in the casing, or liner of well to connect it to the reservoir.
Figure 18: Perforating gun method
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Propellant for stimulation A propellant is a material that is used to move an object by applying a motive force. Involves a chemical reaction. Common chemical propellants consist of a fuel, like gasoline, jet fuel , rocket fuel and an oxidizer.
Propellant application :
‐
Method used to produce fractures that bypassed the damaged zone which was created by the perforation.
‐
The technique is used to increase or restore the rate which fluids can be produced from the formation.
‐
The surface area of the formation exposed to the borehole is increased.
The classification of type of surface equipment includes the following: Type of Surface Equipment
Explanation
Drum Skid
Function: Stores and protects the E-line string
Power Pack
Function: Provides the hydraulic power to operate the E-line unit and pressure control equipment All power packs will include the following major equipments:
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Logging Cabin
Contains all controls and instruments necessary to allow the E-line operation to be run from one control station Function: 1) Control and monitor the operation of all the E-line operating functions 2) Control and monitor the operation of well pressure control equipment 3) Monitor and record the principle well and E-line parameters, Ex: Voltage supplied to E-line 4) Monitor real time logging using E-line
Table 4: Type of surface equipments for e-line
2.2.3. Dowell Schlumberger (Coiled Tubing) The objectives of Coiled tubing training is to Familiarization on Coiled Tubing Surface Equipment, Coiled Tubing Pressure Control Equipment, Bottom Hole Assembly and to familiarization with common jobs conducted using coiled tubing. Coiled Tubing unit is the package of equipment required to run a coiled tubing operation. Four basic components are required: 1. The coiled tubing reel to store and transport the coiled tubing string 2. The injector head to provide the tractive effort to run and retrieve the coiled tubing string 3. The control cabin from which the equipment operator controls and monitors the operation 4. The power pack that generates the necessary hydraulic and pneumatic power required by the other components. The dimensions and capacities of the coiled tubing unit components determine the size and length of coiled tubing string that can be used on the unit. Pressurecontrol equipment (PCE) is incorporated into the equipment to provide the necessary control of well pressure fluid during normal operating conditions and contingency situations requiring emergency control.
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The classification of type of surface equipment includes the following: Type of Surface Explanation Equipment Injector Head Provides effort and traction necessary to run and retrieve the CT string into and out of a wellbore. The Injector head also guides and supports the CT string Function:
Coil Tubing Reel
1) Safely pull, push and hold the CT string into and out of a wellbore 2) Weight indicator mounted 3) Depth system mounted – At least two independent sensors are typically required on every CT operation, such as one reel mounted and one injector head mounted system. 4) Stripper mounted- Stripper secures the injector head to the pressure control stack. Function: Safely store and protect the CT string. Features: 1) Swivel and manifold to enable fluids to be pumped through tubing string while the reel drum rotates. All reels should have a valve fitted as close as practical to end of CT string. This valve can be closed in the event of a swivel seal failure while the CT is being run, thereby isolating the contents of the string.
2) Level wind assembly for accurate and even spooling of reels onto the drum. 3) Tubing measurement accessories for depth measurements. Depth measurements are important for correlation with open log. 4) Tubing Lubrication Equipment CT Power Pack
Function: Provides the hydraulic power to operate the coil tubing unit (CTU) and pressure control equipment, ex: BOP system. All power packs will include the following major equipments:
Engine Hydraulic Pumps Pressure Control Valves Hydraulic Reservoir Filters and Strainers 26
Control Cabin
Contains all controls and instruments necessary to allow the CT operation to be run from one control station Function: Control and monitor the operation of all the
CTU operating functions Control and monitor the operation of well pressure control equipment Monitor and record the principle well and CT parameters of wellhead pressure, circulating pressure, tubing weight at the injector head and tubing depth.
Table 5: Type of surface equipments for Coiled tubing
Besides that, There are several common jobs conducted using Coiled tubing such as Nitrogen kick off, zonal isolation, wellbore fill removal and acidizing. Thus, It is important to learn the job application of coiled tubing so that we will know the suitable well intervention job to overcome any problem occurs in well. Squeeze cementing
Process of forcing cement slurry, under pressure, through perforations or holes in the casing or liner. This is done to permanently block the intrusion of undesirable fluids to the wellbore. In oil wells, this is done to reduce excessive water or gas production, which limits downstream separation or process capacity.
Nitrogen lift
The use of nitrogen gas circulated into the production conduit to displace liquids and reduce the hydrostatic pressure created by the fluid column. Nitrogen lifting is a common technique used to initiate production on a well following workover or overbalanced completion.
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Wellbore Fill Removal
Fill removal operations are conducted to: a) Restore full productivity of the well b) Improve access for running/retrieving tool c) Maintenance of wellbore below perforation
Table 6: Common jobs conducted by Coiled Tubing unit
2.3 OFFSHORE VISIT EXPOSURE th
On 8 of October 2009, Well Integrity Department had given golden opportunity to trainees to go offshore. The platform that had been visited is Duyong. The objectives of the visit are as below: . To gain experience and get opportunity to see the real work in platform To familiarize the work procedure in offshore To gain knowledge about surface facilities, and improve my understanding
regarding the well intervention job
2.3.1 Duyong Platform History of Duyong’s platform
The first PCSB’s platform in Terengganu which built in 1983
This platform start produced in 1984
Duyong Platforms division
Duyong-Alpha platform (DDP-A)
Duyong-Bravo platform (DDP-B)
Duyong-Charlie platform (DDP-C)
Living Quarters platform (LQ)
Central Processing Platform (CPP)
Gas Compression Platform (GCP)
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Process Flow Diagram of Duyong Production
Figure 19 : Central Processing Platform (CPP) 2.3.2 Production facilities Slug Catcher : A slugcatcher is a vessel with sufficient buffer volume to store the largest slugs expected from the upstream system. The slugcatcher is located between the outlet of the pipeline and the processing equipment. The buffered liquids can be drained to the processing equipment at a much slower rate to prevent overloading the system.
Seperator : A device used to separate entrained gas from production liquids. Surface processing facilities generally use gas separators to render the liquids safe for further processing or disposal. Gas-separation equipment is also used in downhole applications, such as the protection of pumping equipment against gas lock by separating and redirecting free gas at the pump suction or inlet.
Scrubber : A device to remove dirt, water, foreign matter, or undesired liquids that are part of the gas flowstream. Air can be used to absorb water; also an oil bath might be useful to remove dust, dirt or other liquids. A scrubber is used to protect downstream rotating equipment or to recover valuable liquids from gas .
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Compressor : A device that raises the pressure of air or natural gas. A compressor normally uses positive displacement to compress the gas to higher pressures so that the gas can flow into pipelines and other facilities.
Pig : A device with blades or brushes inserted in a pipeline for cleaning purposes. The pressure of the oil stream behind pushes the pig along the pipeline to clean out rust, wax, scale and debris. These devices are also called scrapers.
2.3.3 Inter-rig to Duyung Alpha th
On 13 of October, we had a permission from Platform Superintendent, Mr Che Wan Faizal to go to Duyong-B platform which were having drilling job there. I had a chance to transfer to the boat by basket and got the experienced to visit a RIG, Jack Up Rig.(JUR). There were some job that i able to see in the A-01 well,which is set bridge plug by E-line and workover. The details of the job will be explained below.
Figure 21 :Drilling Rig ENSCO 52 (Jack Up Rig)
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Jack-ups are used for most of the offshore exploration drilling world-wide
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This rig has spud cans or tanks mounted on the base of the legs
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These are usually round and are equipped with a jetting system to allow them to be jetted into the sea bed.
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Additional jetting systems are installed on he top of the spud cans to allow the can to be pulled out of the formation should penetration into the sea bed be too great
Draft Plan at Well A-01
1. Cut the tubing at 2227m-MDDF by using Power Cutter (E-line) 2. Set Bridge Plug at 185m-MDDF by using CPST(E-line) 3. Nipple down X-mas tree 4. Nipple up Blow Out Preventer (BOP) 5. Workover 6. Start drilling
Figure 22 : Power Cutter-Cut the tubing
E-line – Set Bridge Plug Problem :
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X-mas Tree cannot be nipple down because the SSSV is not functioning
Solution :
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Set bridge plug using Casing Packer Setting Tool (CPST) above SSSV to be the second barrier
Casing Packer Setting Tool (CPST) Provides a reliable method of deploying plugs and packers in the wellbore during completion, isolation, or abandonment .
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Workover – Pull out the tubing For the last day in the rig, i had a chance to see how the tubing had been pulled out of the hole. They used Spear as the picture below. The depth of the tubing is 2227mMDTHF. It took about two days to complete the job.
Figure 23 : Spear
2.4 SPECIAL
TOPIC
:
STATIC
GRADIENT
SURVEY
(SGS)
INTERPRETATION 2.4.1. Introduction Static Gradient Survey (SGS) interpretation is important to know the pressure and temperature gradient tracking, static Bottom Hole Pressure (BHP) and Bottom Hole Temeperature (BHT) monitoring and fluid level inside the tubing. This interpretation is done by Services Company before. The cost for this interpretation is quit high. However, in this year, PWE department had decided that the interpretation will be done by all the engineers in PWE department to make cost saving as we know that our economic is in crisis right now. This decision make proud of PWE department because engineers can enhance their capability, knowledge and skills as what contractor done. However, this training also gives me big opportunity to get very precious knowledge that has the same level with the engineers.
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2.4.2. Detail of SGS Interpretation The details about this training are as below. Objectives of this training: •
Increase internal workforce capability by enhancing the departmental scope of work.
•
Estimated cost saving for interpretation of RM 2.88 million within 5 years contact period (RM 3062.5 X 939 strings).
Why SGS & FGS Data Required Static Gradient Survey (SGS)
Flowing Gradient Survey (FGS)
Static BHP & BHT monitoring
Flowing BHP & BHT monitoring
Pressure & temperature gradient tracking
Measure flow gradient (above & below injection points)
FL inside tubing
Cooling effect detection (point of injection, leaking tubing, valve or mandrel) PI determination
Table 7: Differences between Slickline and E-line Data Requirement 1. From Reservoir Management (SSI). - Datum depth. - Reservoir pressure gradient. - Stationary depth which include time for each stop. - Advise on total well shut-in time (for modified SGS). 2. PWE Existing Data. - Well schematic. - Well survey data. 3. Data delivered from contractor to PWE (after job). - Total job sequence & well intervention report during t he job. - Raw data (in .txt & .rec).
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Interpretation tool •
Standard template for interpretation is ready to be utilized by PWE group.
•
Software (PPS Smartview) available.
How to interpret? 1. Paste Well schematic diagram and well survey data inside the standard template. 2. Convert raw data received (using PPS Smartview) for upper and bottom gauge into excel format and paste into "ASCII sheet" - Refer to Guide#1 3. Fill up job event (from Operator) into the "working sheet". Take note on "offdepth" contributed by wireline equipment - Refer to Guide#2 4. Fill up Gradient Survey sheet with using the reference on gradient stop period and pressure and temperature data (for upper and bottom gauge) taken from ASCII sheet - Refer to Guide#3 5. Convert all grad. stop (initially in MD) to TVD with using TVD calculation sheet - Refer to Guide#4 6. Note: Each sheet are linked each other. Never attempt to edit any of the box which contain the formula. 7. All data in "interpretation sheet" will automatically generated once all the sheet before it is completely fill (except for datum depth and reservoir gradient) - Refer to Guide#5 8. The most trickiest part in SGS interpretation are the graph plot where the fluid gradient shall be properly distributed before generate the graph - Refer to Guide#6 Pressure and temperature graph plot for each gauge (to observe data quality from each gauge) using PPS smartview – Reference#7
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Guideline for Graph Plot procedure: 1. Identify pressure gradient at each grad stop. Note: Type of fluid for each depth determine based on the following range: - 0.01 psi/ft - 0.09 psi/ft : Gas - 0.30 psi/ft – 0.39 psi/ft : Oil - 0.40 psi/ft – 0.49 psi/ft : Water 2. Plot different graph for each fluid distribution (number of Pressure line requirement may different depending on the well fluid condition e.g. water, oil, gas) – for upper and bottom gauge. 3. Plot temperature trending for each gauge.
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2.4.3. Conclusion As for the conclusion, this interpretation makes contribution most in cost saving for PWE department. For only one interpretation, it cost almost RM3000. It gives a big opportunity to me to contribute in cost saving in my host company. In future, with my knowledge and capability in this interpretation, could make me easier to get a job in any services company.
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3. LESSON LEARNED AND EXPERIENCES GAINED 3.1. TEAM WORK AND INDIVIDUAL ACTIVITIES For most of the tasks undertaken during the internship, the author has experienced and observed the significance of teamwork in accomplishing any of them. In completing departmental initiatives, all the trainees had faced many challenges, especially due to time-constraint. It is without a doubt that without teamwork, and the selfless attitude to ’lend a hand’ when needed, most of the tasks may not have been completed accordingly. For any project embarked by PCSB, a group of engineers from different background disciplines will be assigned to dedicatedly involve in completing all undertakings related to carry out the project. This group of engineers will need to work out the best solution in executing the project. Engineers from the PWE would also assist in providing all required information, as well as sharing experiences, which are acquired through lessons learned to attain the best and practical solution in the execution of the project. Each engineer must also have a sense of responsibility in completing the tasks assigned, as their jobs are interrelated. Therefore, failure to accomplish one’s job may contribute to the failure of the whole team members in the project’s execution.
3.2. LEADERSHIP AND MANAGEMENT SKILLS
Leadership skills can only be developed through practices. Throughout this industrial placement, the author had observed how managers, lead engineers, and other personnel handle various staffs with different needs and temperament. In order to understand the staffs’ needs as well as to meet the predetermined objectives of jobs or project-related matters, all leading personnel should be able to communicate and approach them wisely in ensuring the staffs perform their responsibilities efficiently. When working in an environment that requires various duties and responsibilities to be performed, time and self-management would determine one’s performance. An individual who can prioritize his works and has a sense of urgency in doing them would able to manage his time and works well.
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3.3. SAFETY TRAINING AND AWARENESS Throughout this Industrial Internship, trainees have been exposed to safety related matter and awareness to ensure that trainees have profound knowledge on safety related-matters as parts of PCSB engineers’ working scope involves activities in hazardous environment. Safety awareness is essential in order to avoid any fatalities or injuries to personnel, when performing their duties. For this reason, each personnel would be informed on safety-related matters to inculcate safety awareness among the personnel and to educate them on potential hazards existing in the working area. For personnel that go to offshore, they are required to attend safety briefing before boarding the helicopter and again on the arrival at the platform.. All of these were done to ensure that “Safety First” at all the time and especially at the workplace. During the plant visits, visitors are compulsory to attend the plant safety briefing. The safety briefing mainly covers the safety guidelines and procedures, which have been structured, based on the OSHA Act 314/1994. The most valuable safety training when attended the Combined Safety Course and Underwater Helicopter Escape training at Terengganu Safety Training Centre. During the training, trainee has been exposed to the safety equipments that can be used when we are faced to the fire or when the room was filled with smoke .
2.3.
PROBLEMS & CHALLENGES ENCOUNTERED
Throughout the industrial internship program, I had some problems and challenges to be faced such as, the expectations from the engineers in Well Integrity department from student that comes from Petroleum Engineering background was very high. They expect us to be fast learning in PE job scope since we are in same background. and knowing the basic Petroleum Engineering course. Other than that, working with different gender workers made me difficult to work in comfort condition at the early phase. However, I faced the challenges very well. From their expectation, made me to be fast learner and made revision on Petroleum Engineering subject that I have learned and also I am able to adapt the working style in oil and gas industry throughout the 8 months working experiences very well.
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4. DISCUSSION AND RECOMMENDATIONS The Industrial Internship Training has proven to be very beneficial to undergraduate trainees, in providing them with sufficient knowledge, experiences and a general overview of working environment, specifically related to engineering disciplines. Nonetheless, there are still rooms that the author has identified to be improved. 4.1. UNIVERSITI TEKNOLOGI PETRONAS a) UTP’s own Internship Website UTP internship unit should take an initiative to develop a dedicated website where undergraduate trainees undergoing internship and host company can have online communication directly with the internship unit. The website may also include materials for students who will undergo internship training to refer to.
b) Training Budget UTP should allocate budget for undergraduate trainees to acquire own Personal Protective Equipment (PPE) for site visits purposes, or tasks which require trainees to be stationed in plant or operation site.
c) Introduction Session Prior to Internship Program It is suggested that UTP can initiate a collaboration with Host companies to have an induction session on internship program, that is on what to expect as an undergraduate begin the internship ‘journey’. The introduction session does not has to be by all host companies, but rather by selected companies that UTP has deemed as able to provide ‘a bird’s eye view’ on their operation.
4.2. PETRONAS CARIGALI SDN. BHD. a) Field jobs For the benefits of undergraduate trainees, the host company could provide more opportunities for them to have field jobs, so as to provide better understanding, concerning engineering discipline of interest. The trainees may also contribute by assisting engineers in the execution of tasks related.
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5. CONCLUSION The Internship Programme has achieved all UTP’ objective such as exposing to industrial practices and integrating theories with practical work. During the 32 weeks of internship with PETRONAS Carigali Sdn. Bhd., the author has been exposed to instrumentation and control though attachment to the Well Integrity Engineering Department.
Experience and knowledge are the two main elements that the author feels really appreciate during the internship. The combination of technical and non-technical skills has provided an opportunity for the author to be prepared for the real working life culture. The understanding about working environment is not only limited to Carigali’s work scope but also to other parties like vendor, consultants, contractors and subcontractors.
Personal skill development formed part of the training. Interaction with various people from the company and corporate level has enhanced communication skills while working with personnel of all levels promotes teamwork and leadership.
PETRONAS Carigali Sdn. Bhd. has given a good exposure to the students about instrumentation and control application in oil and gas industry. PETRONAS Carigali Sdn. Bhd. objectives were met throughout the entire training and student’s personal goals were met beyond expectation.
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