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ENGINEERING
LECTURE 1
J. JAYA BHARATHI,
ASST.PROFESSOR
DEPARTMENT OF CHEMICAL ENGINEERING
KONGU ENGINEERING COLLEGE, PERUNDURAI
1
INDUSTRIES IN INDIA
2
OIL AND NATURAL GAS - FROMATION
3
4
5
6
7
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OIL AND GAS SECTOR – AN INTRODUCTION
10
NEED FOR ENERGY
11
12
13
14
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16
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OIL AND GAS SECTOR – TOP PLAYERS
18
19
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Bharat Petroleum Hindustan Oil Exploration
Corporation Ltd (BPCL) Company Ltd (HOEC)
Essar Oil
22
OIL AND NATURAL GAS ENGINEERING
23
CAREER OPPORTUNITIES
storage.
Carry out the above processes in an environmentally benign manner.
24
RESARCH AREAS
26
PETROLEUM - INTRODUCTION
Petroleum industry
Plays vital role in the industrialization and urbanization.
Helps meeting the basic needs of the mankind through
supplying energy for domestic purposes, for industrial
purposes, for transport sectors .
Its products are used as feed stock for the fertilizer, synthetic
fiber industry, synthetic rubber polymers, intermediates
explosive agrochemicals, dye, etc.
PETROLEUM - HISTORY
Petroleum was formed several million years ago from organic matter
of marine deposits in a deficiency of oxygen (anaerobic conditions).
Selective bacterial attack destroyed proteins and carbohydrates,
leaving fats to accumulate as oil reserves, hence the name fossil fuel.
Today it stands as the largest single industry in the world with a doubling
time of 10-15 years.
From the early days where oil seepage at ground level was used to
indicate an oil field, exploration methods have progressed to a highly
scientific stage.
30
CONSTITUENTS OF CRUDE PETROLEUM
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CONSTITUENTS OF CRUDE PETROLEUM
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CONSTITUENTS OF CRUDE PETROLEUM
33
CONSTITUENTS OF CRUDE PETROLEUM
The aromatic hydrocarbons
They tend to burn with a sooty flame, and many have a sweet aroma.
Some are carcinogenic.
Asphalts
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COMPOSITION CRUDE PETROLEUM – BY WEIGHT
Composition by weight
Composition by weight
Element Percent range
Carbon 83 to 87% Hydrocarbon Average Range
36
OIL REFINING
37
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REFINERY PRODUCTS
Crude petroleum must be separated into numerous products to
achieve maximum economic return.
Gas Fraction:
Light Ends
This fuel, as an energy source for piston engine and gas turbines,
is formulated to meet the engine combustion requirements.
40
REFINERY PRODUCTS
Residues:
Intermediate Distillates:
Lubricants
◦ Heavy fuel oils
Asphalt
◦ Diesel oils
Fuel oil
◦ Gas oil
Road oils
Heavy Distillates:
Greases
◦ Mineral oil
Petroleum coke (used for
◦ Flotation and frothing oil
aluminum plant electrodes)
◦ Waxes
Petrolatum
◦ Lubricating oil
By-products: detergents, ammonia,
sulfur and derivatives
41
TYPES OF CRUDE OILS
Crude oil quality is measured in terms of
◦ density (light to heavy) and
◦ sulfur content (sweet to sour).
Density:
Classified by the American Petroleum Institute API .
API gravity is defined based on density at a temperature of 15.6
ºC.
Higher API gravity – lighter crude
Light crude - an API gravity of 38 degrees or more
Heavy crude - an API gravity of 22 degrees or less
Medium crude - an API gravity between 22 and 38 degrees.
Sweet crude is commonly defined as oil with a sulfur content of
less than 0.5%, while sour crude has a sulfur content of greater
than 0.5%.
TYPES OF CRUDE OILS
Brent Blend
Brent Blend is a light, sweet North Sea crude with an API gravity
of approximately 38 and a sulfur content of approximately 0.4%.
Brent Blend is used for pricing around two-thirds of the crude
traded internationally.
45
What’s in a barrel of crude?
47
OIL AND NATURAL GAS
ENGINEERING
LECTURE 2
Petroleum
A natural, yellow-to-black, flammable, liquid
hydrocarbon found beneath the earth’s surface
The word Petroleum is coined from two latin words
Petra meaning rock and Oleum meaning oil .
2
Petroleum – Properties & Products
Petroleum or hydrocarbons are a mixture of
Solids
Liquids
Semisolids and
Gases
These occur naturally in the rocks and are loosely called as
MINERAL FUELS also.
Chemically it is a mixture of Hydrogen and Carbon with
minor amounts of nitrogen, oxygen, sulphur as impurities.
3
Chemical Composition of Oil and Gas
(% by Weight)
4
Petroleum
6
Types of Petroleum
2.Natural Gas ( Petroleum gas) :
Natural gas is composed of lighter paraffin hydrocarbons
(hydrocarbons of the methane series) – the most abundant being
methane gas (CH4).
7
Types of Petroleum
Inorganic Theory
Berthelot (1860) & Dmitri Mendeleev (1902):
Overtime the layers on the sea floor became rich in the fossil remains
of previous life
Organic Matter
The composition of the organic matter strongly influences whether the
organic matter can produce coal, oil or gas.
Basic components of organic matter in sediments
•• PROTEINS
•• CARBOHYDRATES
•• LIPIDS Fats •• LIPIDS Fats
•• LIGNIN
All of these + Time + Temperature +
Pressure = KEROGEN
Transformation in to Petroleum
Thermal maturation processes (decay, heat, pressure) slowly
converted the organic matter into oil & gas over periods of millions of
geologic years.
Clay & silt are carried together with the dead organic remains &
deposited under deltaic, lacustrine & marine conditions to form Source
rocks.
Structural traps,
Stratigraphic traps and
Combination traps.
Most reservoir contain water also along with oil and gas.
Sedimentation:
Process that cause mineral and/or organic particles (detritus) to
settle and accumulate .
Sediment:
Particles that form a sedimentary rock by accumulating are called Sed
iments.
They are formed by weathering and erosion in a sources area .
They are then transported to the place of deposition by water, mass
movement
Source rock
A type of rock which contains organic matter and is capable to generate
the hydrocarbons.
•• Best example of source rock is shale.
Source Rocks - Organic Matter
Carrier beds - Oil on the move
Reservoirs exist anywhere from the land surface to 30,000 ft below the
surface and are a variety of shapes, sizes and ages.
Conventional Vs Unconventional Reservoirs
Petroleum Reservoir (Contd…)
Reservoir Rocks
A reservoir rock is a rock that is capable of storing a fluid.
There are two requirements for any reservoir rocks.
I. Porosity – sufficient void space available to contain the
petroleum
II. Permeability – interconnection of void spaces, ability of
petroleum to flow through the voids.
Traps
Traps are underground rock formation that blocks the movement of
petroleum and causes it to accumulate in a reservoir that can be
exploited.
The oil is accompanied always by water and often by natural gas; all are
confined in a porous and permeable reservoir rock
The natural gas, being lightest, occupies the top of the trap and is
underlain by the oil and then the water.
A layer of impermeable rock, called the cap rock, prevents the upward
or lateral escape of the petroleum.
The part of the trap actually occupied by the oil and gas is called the
petroleum reservoir.
Sandstone trap Fissured lime
stone trap
Traps
Types of Traps
Types of traps based on their geological characteristics
• Structural trap
• Stratigraphic trap
• Combinational trap
Structural traps
Structural traps are formed as a result of changes in the structure of
the subsurface due to processes such as folding and faulting etc.
EXPLORATION OF PETROLEUM
LECTURE 4
EXPLORATION OF PETROLEUM
Exploration refers to discovering new crude oil and gas fields, drilling
wells and bringing the products to the surface.
Crude oil, which had naturally seeped to the surface, was collected for
use as medicine, protective coatings and fuel for lamps.
Natural gas seepage was recorded as fires burning on the surface of
the earth.
Until 1859 that methods of drilling and obtaining large commercial
quantities of crude oil were not developed.
EXPLORATION CONTD…
Crude oil and natural gas are found throughout the world, beneath
both land and water, as follows:
In early days oil seepage at ground level was used to indicate an oil
field.
Exploration methods have progressed to a highly scientific stage.
There are three (3) primary methodologies used to find
hydrocarbons in the subsurface:
Geophysical,
Wildcatting.
GEOPHYSICAL SURVEYS
Geophysical techniques used for petroleum exploration utilize
equipment to measure such things as:
Electrical currents,
Gravitational and magnetic anomalies,
Heat flow,
Geochemical relationships, and
Density variations
from deep within the earth.
Sound waves are generated downward into the earth's crust which
reflect off various boundaries between different rock strata.
Seismic survey
Seismic surveys
The frequency generated penetrates the earth's crust. The echoes
are detected by electronic devices called geophones.
The geophones receive the reflected sound waves and the data are
recorded on magnetic tape.
The tape is printed to produce a two-dimensional graphic
illustrating the subsurface geology.
Animation
Offshore surveys
Conducted in a slightly different manner.
Boats tow cables containing hydrophones in the water, which is
similar to geophones on land.
Sound waves use to be created by dynamite, but this method killed a
variety of sea life.
dynamite
The most acceptable method today is to generate sound waves using
pulses of compressed air which creates large bubbles that burst
beneath the water surface creating sound.
The sound waves travel down to the sea floor, penetrate the rocks
beneath, and return to the surface where they are intercepted by the
hydrophones.
Processing and illustration is the same as the dry land method.
Analysis
In this type of survey, sound waves are sent into the earth where they
are reflected by the different layers of rock.
The time taken for them to return to the surface is measured as a
function of time.
This measurement reveals how deep the reflecting layers are; the
greater the time interval, the deeper the rock layer.
This technique also can determine what type of rock is present
because different rocks transmit sound waves differently.
The most sophisticated seismic surveys are three-dimensional (3-D).
The recorded data is processed by computer and the results are a
detailed, 3-D picture of the formations and structures below the
surface.
Advantages
1/28/2018
METHODS OF DRILLING
1. Auger drilling
2. Percussion rotary air blast drilling (RAB)
3. Air core drilling
4. Cable tool drilling
5. Reverse circulation (RC) drilling
6. Diamond core drilling
7. Direct push rigs
8. Hydraulic rotary drilling
9. Sonic (vibratory) drilling
1/28/2018
INTRODUCTION
Mineral Lease:
It is the legal ownership to the right to drill for oil and natural gas.
1/28/2018
INTRODUCTION
Power Used: The power used for drilling may vary from 250 to
2000 bhp, a heavy duty mud pump needs around 700 bhp.
Rotary system: It is used to rotate the drill string and therefore the
drill bit, on the bottom of the borehole.
DRILLING OPERATION
Casing:
Completing a well and preparing for production of oil involves
insertion of a casing which comprises of one or more strings of
tubing.
The casing provides
A permanent wall to the borehole,
Prevents cave-in,
Blocks off unwanted water, oil or gas from another formation,
Provides a return passage for the Mud stream and
Provides control of the well during production.
1/28/2018
DRILLING OPERATION
Used to circulate the drilling fluid or mud down the drill string, up
the drill string to the borehole annulus and for carrying the drill
cuttings from the mouth of the bit to the surface.
The mud is mixed and conditioned in the mud pits and then
circulated down hole by large pumps.
DRILLING OPERATION
Mud Pumping
Mud is pumped through the mud
pumps to the top of the drill string
and mud then goes through the
string to the bottom.
At the bottom, mud passes through
the bit and then up the annulus,
carrying the drill cuttings to the
surface.
Before mud enters to the mud pit,
the solids are removed from it by
vibrating screens.
DRILLING OPERATION
Recovery of oil
When a well is first opened recovery is generally by natural flow,
forced by the pressure of the gas or fluids that are contained within
the reservoir.
At the beginning, there may be a chance of flush, hence at this stage,
well should be carefully controlled.
There are several ways which serve to drive out the petroleum fluids
from the formation to the surface, through the well.
The drives are classified as either
Natural flow (primary recovery) or
Applied flow (improved oil recovery).
1/28/2018
COMPONENTS OF DRILLING RIG
DRILL BIT
The bit is the main critical
item of a drilling operation.
Traveling block,
Crown block
The main function is to connect the supporting derrick with the load
of pipe to be lowered into or withdraw from the hole.
TRAVELLING BLOCK
The Kelly is used to transmit rotary motion from the rotary table
to the drill string while allowing the drill string to be lowered or
raised during rotation.
KELLY AND ITS COMPONENTS
SWIVEL
Swivel is a mechanical device that simultaneously
Suspend the weight of the drill string,
Provide for rotation of the drill string beneath it while keeping the
upper portion stationary, and
Permit high-volume flow of high-pressure drilling mud from the
fixed portion to the rotating portion without leaking
J. JAYA BHARATHI,
ASST.PROFESSOR
DEPARTMENT OF CHEMICAL ENGINEERING
KONGU ENGINEERING COLLEGE, PERUNDURAI
1/28/2018
INTRODUCTION
1/28/2018
INTRODUCTION
Mineral Lease:
It is the legal ownership to the right to drill for oil and natural gas.
1/28/2018
INTRODUCTION
Power Used: The power used for drilling may vary from 250 to
2000 bhp, a heavy duty mud pump needs around 700 bhp.
Rotary system: It is used to rotate the drill string and therefore the
drill bit, on the bottom of the borehole.
DRILLING OPERATION
Casing:
Completing a well and preparing for production of oil involves
insertion of a casing which comprises of one or more strings of
tubing.
The casing provides
A permanent wall to the borehole,
Prevents cave-in,
Blocks off unwanted water, oil or gas from another formation,
Provides a return passage for the Mud stream and
Provides control of the well during production.
1/28/2018
DRILLING OPERATION
Used to circulate the drilling fluid or mud down the drill string, up
the drill string to the borehole annulus and for carrying the drill
cuttings from the mouth of the bit to the surface.
The mud is mixed and conditioned in the mud pits and then
circulated down hole by large pumps.
DRILLING OPERATION
Mud Pumping
Mud is pumped through the mud
pumps to the top of the drill string
and mud then goes through the
string to the bottom.
At the bottom, mud passes through
the bit and then up the annulus,
carrying the drill cuttings to the
surface.
Before mud enters to the mud pit,
the solids are removed from it by
vibrating screens.
DRILLING OPERATION
Recovery of oil
When a well is first opened recovery is generally by natural flow,
forced by the pressure of the gas or fluids that are contained within
the reservoir.
At the beginning, there may be a chance of flush, hence at this stage,
well should be carefully controlled.
There are several ways which serve to drive out the petroleum fluids
from the formation to the surface, through the well.
The drives are classified as either
Natural flow (primary recovery) or
Applied flow (improved oil recovery).
1/28/2018
COMPONENTS OF DRILLING RIG
DRILL BIT
The bit is the main critical
item of a drilling operation.
Traveling block,
Crown block
The main function is to connect the supporting derrick with the load
of pipe to be lowered into or withdraw from the hole.
TRAVELLING BLOCK
The Kelly is used to transmit rotary motion from the rotary table
to the drill string while allowing the drill string to be lowered or
raised during rotation.
KELLY AND ITS COMPONENTS
SWIVEL
Swivel is a mechanical device that simultaneously
Suspend the weight of the drill string,
Provide for rotation of the drill string beneath it while keeping the
upper portion stationary, and
Permit high-volume flow of high-pressure drilling mud from the
fixed portion to the rotating portion without leaking
J. JAYA BHARATHI,
ASST.PROFESSOR
DEPARTMENT OF CHEMICAL ENGINEERING
KONGU ENGINEERING COLLEGE, PERUNDURAI
1/28/2018
Oil Recovery
Oil recovery refers to the processes by which crude oil is
extracted from beneath the Earth’s surface.
Oil recovery can be categorized into three phases:
Primary oil recovery
Secondary oil recovery
Tertiary oil recovery
Primary oil recovery
Water flooding
VideoVideos\The Phases of Oil
Recovery -- So Far.mp4 1
Tertiary Oil Recovery
Thermal Recovery:
Involves the introduction of heat such as the injection of steam to
Lower the viscosity, or thin, the heavy viscous oil, and
Improve its ability to flow through the reservoir.
Thermal techniques account for over 40 percent of U.S. EOR
production, primarily in California.
Thermal recovery
Enhanced Oil Recovery
Gas Injection:
Uses gases such as natural gas, nitrogen, or carbon dioxide (CO2)
The gases expand in a reservoir to push additional oil to a
production wellbore.
Gases dissolve in the oil to lower its viscosity and improves its
flow rate.
Gas injection accounts for nearly 60 percent of production in the
united states.
Enhanced Oil Recovery
Chemical Injection:
Involve the use of long-chained molecules called polymers to
increase the effectiveness of waterfloods.
Use of detergent-like surfactants to help lower the surface tension
that often prevents oil droplets from moving through a reservoir.
These techniques are less preferred for their
Relatively high cost and
Unpredictability of its effectiveness.
EOR-Polymer Flooding
J. JAYA BHARATHI,
ASST.PROFESSOR
DEPARTMENT OF CHEMICAL ENGINEERING
KONGU ENGINEERING COLLEGE, PERUNDURAI
1/28/2018
Life cycle of oil wells
The creation and life of a well can be divided up into five segments:
Planning
Drilling
Completion
Production
Abandonment
Completion
After drilling and casing the well, it must be 'completed'.
Completion is the process in which the well is enabled to produce
oil or gas
Completion
Tubing
In many wells, the natural pressure of the subsurface reservoir is
high enough for the oil or gas to flow to the surface.
This is not always the case, especially in depleted fields where the
pressures have been lowered by other producing wells, or in low
permeability oil reservoirs.
Installing a smaller diameter tubing may be enough to help the
production, but artificial lift methods may also be needed.
Well Simulation
Sometime, petroleum exists in a formation but is unable to flow
readily into the well because the formation has very low
permeability.
Acidizing or fracturing done used to improve the permeability
near the wellbore.
Acidizing
It is done if the formation is composed of rocks that dissolve upon
being contacted by acid, such as limestone or dolomite.
Acidizing operation basically consists of pumping from 50 to 1000
gallons of acid down the well.
The acid travels down the tubing, enters the perforations, and
contacts the formation.
Acidizing
Continued pumping forces the acid into the formation
where it produces channels.
Channels will provide a way for the formation’s oil or
gas to enter the well through the perforations.
Fracturing
Production
The production stage is the most important stage of a well's life.
The oil rigs and work over rigs used to drill and complete the well
have moved off the wellbore.
The top of the well is usually outfitted with a collection of valves
called a Christmas tree or production tree.
These valves regulate pressures, control flows, and allow access to
the wellbore in case further completion work is needed.
From the outlet valve of the production tree, the flow can be
connected to a distribution network of pipelines and tanks to supply
the product to refineries, natural gas compressor stations, or oil
export terminals.
Christmas Tree
A collection of valves called a Christmas tree is installed on the
surface at the top of the casing hanger.
As the well’s production flows up the tubing, it enters the christmas
tree.
So, the production can be controlled by opening or closing valves on
the christmas tree.
Christmas Tree
Production
J. JAYA BHARATHI,
ASST.PROFESSOR
DEPARTMENT OF CHEMICAL ENGINEERING
KONGU ENGINEERING COLLEGE, PERUNDURAI
Oil Platform
Marine(offshore) Land(onshore)
Self - Tendered
Contained
Environmental
and Regulatory
Issues
Onshore
Drilling Industry
Innovation
Rig in Short
Supply
Portable Security
Power Concerns
Requirements
8
Source: Contango Analysis
Confident
Land Rigs
As the name implies, these rigs are primarily used to drill oil wells on
land.
There are various sizes depending on application.
Land Rigs
Conventional rigs
Mobile rigs
Portable mast
Land Rig
Conventional:
Land Rig
Mobile:
Environmental
and Regulatory
Issues
Offshore
Drilling Industry
Innovation
Rig in Short
Supply
Portable Security
Power Concerns
Requirements
14
Source: Contango Analysis
Confident
Offshore Vs Onshore
Type of the drilling platform - A major difference between
onshore and offshore.
In offshore drilling the drill pipe must pass through the water
column before entering the seafloor or lake.
Jack up
Jack-ups
Used for most of the offshore exploration drilling world-wide.
Shallower offshore oil deposits that don't warrant a permanent
platform.
Exploration is performed using self-elevated, jack-up rigs in water less
than about 300 feet deep.
Jack-up has a floating hull with retractable legs which can be jacked
down to the sea bed.
Hull can be lifted until it is clear off the sea surface.
The legs support the hull.
In shallow and relatively calm waters the Jack up has the advantage of
being able to leave a free standing well with a surface completion once
it is finished.
Semi-Submersibles
This type of rig does not contact the lake floor but floats partially
submerged and is held in place through a number of anchors.
In areas where water depths exceed 100m and heavy weather can be
expected, then semi-submersibles must be used
Drill ships
Drill ships are used to drill the well in deep water ( up to 7000 ft ).