SUMMER INTERNSHIP REPORT

Project report
On
“Comprehensive study on Artificial lift and production
optimization”
Submitted by

Nupur Tripathi Rajat Pareta

Harshad Kapuriya Ayush. D patel
Saniya Mirza Hasmita Kadavla
Ravi Rathod Priyank Vagadiya
Rohan Patel Gadhiya Naimish J

Mentor (Name and signature)

Mr Kshitij Vijayvargia

EE, Production

ONGC, Ankleshwar Asset

pg. 1
 CERTIFICATE OF COMPLETION

This is to certify that Ms Nupur Tripathi, student of B.tech Sem VII (Petroleum
engineering), Pandit Deendayal petroleum University has successfully
completed the project titled “ Comprehensive study on Artificial lift and
production optimization” from Ankleshwar asset, Oil and Natural Gas
Corporation Ltd.

Duration of the project work- 24th July, 2020 to 7th September 2020

Mentor

Mr Kshitij Vijayvargia

EE, Production

ONGC, Ankleshwar Asset

pg. 2
 ACKNOWLEDGEMENT

We would like to take this opportunity to express our gratitude to Mr Kshitij

Vijayvargia (EE, Production) who has contributed and extended their valuable
assistance and time in the completion of this virtual internship and helping us in
making the best use of the given opportunity.

We would like to show our gratitude and regards to Ankleshwar Asset for
allowing us to do virtual summer internship despite COVID-19 pandemic.

We would also like to thank Career and Development cell at PDPU for giving us
this opportunity.

pg. 3
ABOUT ONGC

Oil and Natural Gas Corporation Limited (ONGC) was founded on 14 August 1956
by Government of India, which currently holds a 68.94% equity stake. ONGC is an
Indian multinational oil and gas company headquartered in Dehradun,
Uttarakhand, India. It is a Public Sector Undertaking (PSU) of the Government of
India, under the administrative control of the Ministry of Petroleum and Natural
Gas.
Vision

To be global leader in integrated energy business through sustainable growth,

knowledge excellence and exemplary governance practices.

Mission

 World Class
 Dedicated to excellence by leveraging competitive advantages in
R&D and technology with involved people.
 Imbibe high standards of business ethics and organizational values.
 Abiding commitment to safety, health and environment to enrich
quality of community life.
 Foster a culture of trust, openness and mutual concern to make
working a stimulating and challenging experience for our people.
 Focus on domestic and international oil and gas exploration and
production business opportunities.
 Create growth opportunities and maximize shareholder value.
 Dominant position in Indian petroleum sector and enhance India's
energy availability

pg. 4
 1. ONGC GROUP

Figure-1-ONGC group

OVL: ONGC Videsh Limited (OVL) is the international arm of ONGC. It was
rechristened on 15 June 1989. It currently present in 17 countries across 5
continents with a balanced portfolio of 36 hydrocarbon properties, worth over USD
24.5 billion. Its oil and gas production reached 8.92 MMT of O+OEG in 2016. It’s
share of O+OEG production overseas assets is nearly 13% of India‘s production.
ONGC holds 100% stake in ONGC Videsh Limited.

MRPL: Mangalore Refinery and Petrochemicals Limited (MRPL) is an oil refinery at

Mangalore and is a subsidiary of ONGC, set up in 1988. The refinery has a versatile
design with high flexibility to process crudes of various API gravity and with high
degree of automation. MRPL has a design capacity to process 15 million metric tons
per annum and is the only refinery in India to have two hydrocrackers producing
premium diesel (high cetane). It also has a Polypropylene unit with a capacity of
4,40,000 MT/annum. It is also the only refinery in India to have two CCRs producing
unleaded petrol of high octane. It has the unique distinction of processing more
than 61 crudes, light to heavy/ sour to sweet with 24 to 46 API gravity.

pg. 5
OMPL: ONGC Mangalore Petrochemicals Limited (OMPL) a green field
petrochemicals project, is promoted by Oil and Natural Gas Corporation Ltd (ONGC)
India's Most Valuable Public Sector Enterprise and Mangalore Refinery and
Petrochemicals Limited (MRPL) a subsidiary of ONGC.

OMPL was incorporated on 19th December 2006. MRPL holds 51% and ONGC holds
49% of equity share capital of OMPL.OMPL has become a direct subsidiary of MRPL
w.e.f 28th February 2015. In view of MRPL holding 51% stakes in OMPL.

OPaL: ONGC Petro additions Limited (OPaL), a multi-billion joint venture company
was incorporated in 2006, as a Public Limited Company under the companies Act,
1956, promoted by Oil and Natural Gas Corporation (ONGC) and co-promoted by
GAIL and GSPC. OPaL is setting up a grass root mega Petrochemical project at Dahej,
Gujarat in PCPIR/SEZ. The complex's main Dual Feed Cracker Unit has the capacity
to produce 1100 KTPA Ethylene, 400 KTPA Propylene and the Associated Units
consists of Pyrolysis Gasoline Hydrogenation Unit, Butadiene Extraction Unit and
Benzene Extraction Unit. The Polymer plants of OPaL has 2X360 KTPA of
LLDPE/HDPE Swing unit, 1X340 KTPA of Dedicated HDPE and 1x340 KTPA of PP. All
the major contracts have been awarded and the construction is in full swing.

OTPC: ONGC Tripura Power Company Ltd (OTPC) is a joint venture which was
formed in September 2008 between ONGC, Infrastructure Leasing and Financial
Services Limited and the Government of Tripura. It is developing a726.6 MW CCGT
thermal power generation project at Palatana in Tripura which will supply electricity
to the power deficit areas of the north eastern states of the country.

1. Operation

ONGC's operations include conventional exploration and production, refining and

progressive development of alternate energy sources like coal-bed methane and
shale gas. The company's domestic operations are structured around 11 assets
(predominantly oil and gas producing properties), 7 basins (exploratory properties),
2 plants (at Hazira and Uran) and services (for necessary inputs and support such as
drilling, geo-physical, logging and well services).

pg. 6
 2. Production

It is India's largest oil and gas exploration and production company. It

contributes 70% of oil and oil equivalent gas of the country with 49.47 MMTOE
[1]. ONGC Natural gas production is 21.18 BCM (2016).

3. Global Ranking

Leading international business journal Forbes has published its much awaited
Global 2000 list of the world's biggest public companies for 2016. It has ranked
ONGC, 3rd largest in India and 220 worldwide. Forbes ranks the world's most
powerful and large companies on the basis of their revenue, profits, assets and
market value.

Net profit after Tax (2016): 16,004 crores

Total staff strength: 33560 as on 1st August, 2015

pg. 7
OVERVIEW OF ANKLESHWAR ASSET

ONGC’s Ankleshwar Asset is operating oil and gas fields since 1960. The first exploratory well
Ankleshwar -1 was spudded by ONGC in the Asset on February 25, 1960 with Russian Rig
Uralmarshi – 5D. This was the first commercially producing oil well of ONGC. Various fields
under Ankleshwar Asset and their year and nature of discovery are shown below.

Table 1: Discoveries of oil and gas fields

/structures
Sr. Year of
Field Nature of Discovery
Number ; Discovery
1 Ankleshwar 1960 Oil and Gas
2 Olpad 1962 Free Gas
3 Kosamba 1963 Oil and Gas
4 Hazira 1969 Free Gas
5 Dabka 1970 Oil and Gas
6 S.W. Motwan 1974 Oil and Gas
7 Bhandut 1976 Oil and Gas
8 Matar 1977 Oil and Gas
9 Sisodra 1978 Oil and Gas
10 W. Motwan 1978 Oil and Gas
11 Gajera 1978 Free Gas and Condensate
12 Dahej 1980 Free Gas and Condensate
13 Kudara 1981 Oil and Gas
14 Gandhar 1983 Oil and Gas
15 Pakhajan 1985 Oil and Gas
16 S. Malpur 1987 Oil and Gas
17 Elao 1988 Free Gas
18 Nada 1988 Oil and Gas
19 Andada 1989 Oil and Gas
20 Palej 1990 Oil and Gas
21 Kim 1991 Oil and Gas
22 Jambusar 1991 Oil and Gas
23 N. Sarbhan 1999 Oil and Gas
24 Katpur 2001 Free Gas and Condensate
25 Degam 2003 Oil and Gas

pg. 8
The establishment of Ankleshwar oil field dates back to late fifties, and the production started
in 1961. The first oil well drilled was Vasundhara which was put on production by Hon. Mr.
Pandit Jawaharlal Nehru.
It is the largest onshore asset of ONGC. It makes second highest profit after Mumbai High.
Major Oil & Gas fields are:
 Ankleshwar Field (found in 1960)
 Gandhar Field (found in1984)
In addition 21 satellite Oil & Gas fields have been discovered around the main
fields.Ankleshwar Asset is divided into 4 areas:
 Area 1 (Ankleshwar, Motwan, Sisodra, Andada )
 Area 2 (Kosamba, Kim, Olpad, Elao)
 Area 3 (Gandhar, Dahej, Pakhajan)
 Area 4 (Nada, Jambusar, Dabka, Sarbhan, Degam)

ANKLESHWAR FIELD
Ankleshwar fields have anticlinal structure. It is intersected by 7 faults. Northern part has 3-
7° dip and southern part has 10-30° dip. Ankleshwar has nearly 340 wells and production
started in1962.Two important formations are Hazad and Ardol.
Hazad has S1 – S4 sand.
Ardol has S6 – S12 sand.
Presently, the age of this asset is more than 50 years and still continuously providing oil and
gas. At present, the production is declined to about 800 m3 per day. The field has 8 GGS, one
CTF, one GCS and one water injection plant.
Till now around 380 wells have been drilled.
A nearby structure was drilled in 1975 named after the village Motwasisodra. This structure
was put on production in 1979. 28 oil wells and 16 gas wells have been drilled in this area.
Oil wells are connected are to the oldest GGS but wells producing gas have been connected
to a separate GCS near Motwan village to produce about 8 lakhs m3/day.
A new LPG plant was commissioned in 1986 with a capacity of 140 tonnes per day.

pg. 9
“Group gathering station (GGS) is the place where the oil/liquid and gas gather from the
various wellsof particular field where various process conducted such as separation,
storage, compress in same case and most important supply of water/gas to the injection
well to do the enhance oil recovery (EOR)”.

Crude is separated here in the form of the gas, oil and the water. Separated gas is sent to
the Central Tank Farm (CTF) for the further treatment. And separated gas sent to the Gas
compression station (GCP), through where the gas sent to the Gas collection station (GCS),
where at desired pressure the gas is compressed for further application.Now the water is
sent to the Effluent Treatment Plant (ETP).

 Main working of GGS :-

1. Gather the produced petroleum product from the various wells.
2. Separation of the petroleum product as phase separator (liquid & gas).
3. Supply of the separated gas to the further treatment through pips.
4. Storage of the liquid (oil & water).
5. Supply of the liquid to do further treatment.
6. Compression of the produced gas or lean gas in same cases.
7. Supply of the compressed gas for the gas lift if there is requirement.
8. Other facilities like operating room, generator, pumps and most important fire
resisting facilities.

 Main equipment in GGS:-

1. Separator
2. Storage tanks
3. Generator
4. Compressor
5. Scrubber

Majority of wells in ankleshwar have implemented Gas Lift and some of the wells are
equipped with Sucker Rod Pumps (SRPs).

The wells in Ankleshwar are at a depth of 1800 to 2000 meters. Most of the wells are
vertical while some of them are directional. In Gandhar field the wells have a depth of 2800
to 3000 meters. Majority of wells in ankleshwar are equipped with Gas Lift while some of
them are equipped with Sucker Rod Pumps.

pg. 10
Sucker Rod Pumps cannot be used in highly deviated wells because in deviated wells they
increase wear and tear and require high operating power and because of this a larger SRP
unit is required for deviated wells. Hence SRPs are not used frequently in deviated wells.
The immaculate usage of SRPs is in vertical wellswith heavy crude oil.

Gas Lift is opted only if the gas to be used has feasible availability. Gas lift can be used at
higher depths and for highly deviated wells.

Ankleshwar field has a gas lift pressure of 30 kg/cm2 and Gandhar field has a gas lift
pressure of 110 kg/cm2.

If inflow inside the wellbore from the reservoir is more and outflow from the wellbore to
the surface is less, then oil gets accumulated inside the wellbore. Inflow performance curve
cannot be shifted unless reservoir properties are changed which can be achieved using
stimulation jobs. Using ALT outflow performance curve can be shifted.

INFLOW PERFORMANCE RELATIONSHIP (IPR): The inflow performance of a well represents

the ability of that well to give fluids into the wellbore for a given drawdown. The
productivity of a well depends on the type of reservoir and the drive mechanisms along
with reservoir pressure, permeability, etc. The Inflow Performance curve (a Cartesian plot
of bottom-hole flowing pressure versus surface flow rate) is one of the diagnostic tools
used by Petroleum engineers to evaluate the performance (maximum potential) of a
flowing well. The equation that describes this curve is the Inflow Performance Relationship
(IPR). This equation can be determined both theoretically and empirically. In day to day
variations IPR remains constant.

According to Vogel‘s Equation:

OUTFLOW PERFORMANCE Tubing size is very important in gas lift design in order to
operate at the maximum stable rate. Too small tubing will result in excessive friction losses.

pg. 11
However, too large tubing will cause unstable flow and heading, particularly if well
productivity begins to decline.

This can only be corrected (partially) by increased volumes of lift gas. To assist in optimizing
tubing design the appropriate two phase vertical flow correlations together with good
quality fluid property PVT data, must be used. An increase in water cut may result in a
reduction in PI due to relative permeability affects. This will also increase the density of the
produced fluid, and simultaneously reduce the gas-liquid ratio to the detriment of vertical
lift.

To assess the long term completion requirements the effect of water breakthrough and PI
reduction should be taken into account during initial design. (Using the long term forecast
for wells.)

Low wellhead back-pressure is also of prime importance, as it allows increased drawdown

and enhances the efficiency of gas lift, and hence productivity. Higher backpressure also
results in closer valve spacing and shallower injection.

It is strongly recommended that gas lift systems are operated with minimum back pressure
at the wellhead. After knowing the well potential, we have to design the outflow system in
such a way so that to exploit the inflow. Outflow pressure or tubing intake pressure
depends on the following parameters:-

 Tubing diameter

 Depth

 Water cut

 Gas Liquid Ratio

 QL(liquid flow rate)

 THP(tubing head pressure) Tubing intake pressure is defined as the pressure required at
the bottom of the tubing to lift a particular amount of liquid through a specific tubing size,
from a specific depth, with a definite water cut & GLR against a specific tubing head
pressure. This pressure is specific to a particular condition as mentioned above and it
change with changes in any of the parameters

Thus, we must design outflow system in such a way that for lifting a specific quantity of
liquid the tubing intake pressure should be equal to flowing bottomhole pressure at which
the well would deliver the same quantity of liquid into the wellbore. The intersection point
of IPR and outflow curves will give the operating point for the well

pg. 12
PARAMETERS AFFECTING IPR AND TPR TUBING SIZE SELECTION - One of the most
important components in the production system is the tubing string. As much as 80% of
(the total pressure loss in an oil well can occur in moving the fluids from the bottom of the
hale to the surface. A common problem in well completion design is to select a tubing size
based on totally irrelevant criteria, such as what size tubing is on the pipe rack or what size
has been installed in the past. The tubing size selection should be made before a well is
drilled, because the tubing size dictates the casing size which dictates the hole size.

Tubing too small will restrict the production rate because of excessive friction lass, while
tubing too large will cause a well to load up with liquids and die. A common problem that
occurs in completing large capacity wells is to install very large tubing to be safe.

This often results in increased flowing life for the wells as the reservoir pressure declines
and the wells begin to load. As tubing size is increased. the frictional losses decreases,
which results in a lower pwf and therefore larger Inflow. However, as the tubing size is
further increased the well

FLOWLlNE SIZE EFFECT If a well is producing into a flowline, the wel1head pressure is equal
to the sum of the separator pressure and the pressure drop in the flowline, assuming there
is no wellhead choke. A common cause of low producing capacity in many wells, especially
for wells with long flowlines, is the excessive flowline pressure drop.

pg. 13
EFFECT OF GLR As production continues for a longer period of time, the gas saturation will
increase and occupies larger pores thereby reducing oil saturation.

EFFECT OF GAS INJECTION The purpose of injecting gas into the tubing is to decrease the
density of the flowing gas liquid mixture and therefore, increase the requires flowing BHP.
However, as the gas rate is increased, the fluid velocity and therefore, the friction losses
also increase. A point will eventually be reached such that the friction losses increase more
than the density or Hydrostatic losses decrease with an increase in gas rate.

pg. 14
EFFECT OF PERFORATION DENSITY Since the perforation pressure drop is a function of the
number of perforations open, as well as production rate, a different inflow curve would
exist [or each perforating density. As the number of perforations is increased. a point will
eventually be reached such that the perforation pressure drop is negligible, and, therefore,
a further increase in perforating density would be useless.

Since the perforation pressure drop is a function of the number of perforations open, as
well as production rate, a different inflow curve would exist for each perforating density. As
the number of perforations is increased. a point will eventually be reached such that the
perforation pressure drop is negligible, and, therefore, a further increase in perforating
density would be useless.

pg. 15
Nodal analysis The objective of systems analysis is to combine the various components of
the production system for an individual well to estimate production rates and optimize the
components of the production system.

Necessity of examining flow through system The flow of reservoir fluids from the
subsurface reservoir to the stock tank or sales line requires an understanding of the
principles of fluid flow through porous media and well tubulars. As the fluid moves through
the production system, there will be an associated pressure drop to accompany the fluid
flow. This pressure drop will be the sum of the pressure drops through the various
components in the production system. Because of the compressible nature of the fluids
produced in oil and gas operations, the pressure drop is dependent on the interaction
between the various components in the system. This occurs because the pressure drop in a
particular component is not only dependent on the flow rate through the component, but
also on the average pressure that exists in the component. As a result, the final design of a
production system requires an integrated approach, since the system cannot be separated
into a reservoir component or a piping component and handled independently. The amount
of oil and gas produced from the reservoir to the surface depends on the total pressure
drop in the production system, and the pressure drop in the system depends on the
amount of fluid flowing through the system. Consequently, the entire production system
must be analyzed as a unit or system.

pg. 16
Individual pressure drops can be divided into yet additional pressure drops to account for
restrictions, subsurface safety valves, tubing accessories, etc. Systems analysis is based on
the concept of continuity. At any given point in the production system, there is a particular
pressure and production rate associated with that point for a set of conditions. If there is
any change in the system, then there will be an associated change in pressure and/or
production rate at that same point. This concept allows the production system to be
divided at a point of interest for evaluation of the two portions of the system. This
evaluation determines the conditions of continuity of pressure and production rate at the
division point, which is the estimated producing condition for the system being evaluated.
The approach provides the flexibility to divide the production system at any point of
interest within the system to evaluate a particular component of the system. The most
common division points are at the wellhead or at the perforations, either at the reservoir
sandface or inside the wellbore. The terminal ends of the system will be the reservoir on
the upstream end of the system and the separator at the downstream end of the system or
the wellhead if a wellhead choke controls the well. The components upstream of the
division point or node comprise the inflow section of the system, while the components
downstream of the node represent the outflow section. Once the system is divided into
inflow and outflow sections, relationships are written to describe the rate-pressure
relationship within each section.

The flow rate through the system is determined once the conditions of continuity are
satisfied:

 Flow into the division point equals flow out of the division point

pg. 17
 The pressure at the division point is the same in both inflow and outflow sections of the
system

Typical applications include:

 Estimation of flow rates

 Selection of tubing size

 Selection of flowline size

 Selection of wellhead pressures and surface choke sizing

 Estimation of the effects of reservoir pressure depletion

Identification of flow restrictions Other typical applications are

 Sizing subsurface safety valves

 Evaluating perforation density

 Gravel pack design

 Artificial lift design

 Optimizing injection gas-liquid ratio for gas lift

 Evaluating the effects of lower wellhead pressures or installation of compression

 Evaluating well stimulation treatment

pg. 18
WELL STIMULATION SERVICES

Fig – Well Stimulation Service Provider

The role of Stimulation techniques is well acknowledged for augmenting and

sustaining hydrocarbon production from varied nature of reservoirs. However, it
requires a detailed technical understanding and analysis of the problem(s) for
planning an effective treatment for wells which in turn require trained specialists of
various disciplines.

 To fulfill the stimulation needs of the Western Onshore fields of ONGC,

Central Stimulation Team (CST) was established in 1975 at Mayur Bhavan,
Ahmedabad, which was later renamed as Well Stimulation Services (WSS)
Ahmedabad in 1982.
 To cater the increasing stimulation needs of different onshore Assets and
Basins, the following WSS onshore work centres were subsequently
established.
1. Sivasagar, Assam Asset (1983)
2. Narsapur, Rajahmundry Asset(1985)
3. Karaikal, Cauvery Asset(1990)
4. Gandhar, Ankleshwar Asset(1995)
5. CBM, Bokaro (2003)
6. Jorhat, Assam & Arakan Basin (2005)
7. Another WSS work centre is being established at Tripura Asset shortly which
would initially have the facilities for carrying out Acid jobs & Nitrogen / Coil
Tubing Jobs.

pg. 19
 Fig – Flow Diagram of ONGC WSS services.

COILED TUBING UNIT

In the oil and gas industries, coiled tubing refers to a very long metal pipe, normally 1 to
3.25 in (25 to 83 mm) in diameter which is supplied spooled on a large reel. It is used for
interventions in oil and gas wells and sometimes as production tubing in depleted gas wells.
Coiled tubing is often used to carry out operations similar to wire-lining. The main benefits
over wireline are the ability to pump chemicals through the coil and the ability to push it
into the hole rather than relying on gravity. Pumping can be fairly self-contained, almost a
closed system, since the tube is continuous instead of jointed pipe.

For offshore operations, the ‘footprint' for a coiled tubing Operation is generally
larger than a wireline spread, which can limit the number of installations where
coiled tubing can be performed and make the Operation costlier.

The tool string at the bottom of the coil is often called the bottom hole assembly
(BHA). It can range from something as simple as a jetting nozzle, for jobs involving
pumping chemicals or cement through the coil, to a larger string of logging tools,
depending on the operations.

pg. 20
Coil tubing has also been used as a cheaper version of work-over operations. It is
used to perform open hole drilling and milling operations. it can also be used to
fracture the reservoir, a process where fluid is pressurised to thousands of psi on a
specific point in a well to break the rock apart and allow the flow of product.

APPLICATION OF CTU

1. Circulation

The most typical use for coiled tubing is circulation or Deliquification. A

hydrostatic head (a column of fluid in the well here) may be inhibiting flow of
formation fluids because of its weight (the well is said to have been killed). The
safest (though not the cheapest) solution would be to attempt to circulate out
the fluid, using a gas, frequently nitrogen (Often called a 'Nitrogen Kick‗). By
running coiled tubing into the bottom of the hole and pumping in the gas, the
kill fluid can be forced out to production. Circulating can also be used to clean
out light debris, which may have accumulated in the hole.

2. Nitrogen Pumping

The liquid nitrogen is pumped through a triple-stage cryogenic pump at a specified

rate into an expansion chamber that allows the nitrogen to absorb heat from the
environment and vaporize into a dry gas. The gas is then displaced out of the
expansion chamber and into the treatment piping at the required surface pressure
to perform the prescribed job.

In completed wellbores that are critically under-pressured or liquid-sensitive,

nitrogen pumped at high rates can be used to transport solids up the annulus and
out of the wellbore. The solids removal mechanism within the wellbore is directly
dependent upon the annular velocity of the nitrogen returns. If the nitrogen pump
rate is interrupted during the cleanout program, all solids being transported up the
annulus will immediately fall back. Of equal concern are the tremendous erosional
effects on the production tube, CT, and surface flow tee or flow cross that will occur
at the rates needed to maintain solids transport up the annulus. Because of the
difficulty to safely execute this type of cleanout program, solids removal programs
using nitrogen should be considered as a last resort option.

pg. 21
 Fig – Nitrogen Advantages

3. COIL TUBING DRILLING

A relatively modern drilling technique involves using coiled tubing instead of
conventional drill pipe. This has the advantage of requiring less effort to trip
in and out of the well (the coil can simply be run in and pulled out while drill
pipe must be assembled and dismantled joint by joint while tripping in and
out).
An additional advantage is that the coiled tubing enters the hole via a
stripper, mounted on the injector, which provides a hydraulic seal around the
coil. This offers well control capabilities beyond those normally possible with
drill pipe, and gives the ability to drill underbalanced.
Instead of rotating the drill bit by using a rotary table or top drive at the
surface, it is turned by a downhole MUD MOTOR, powered by the motion of
drilling fluid pumped from surface.

pg. 22
 4. PRODUCTION

Coiled tubing is often used as a production string in shallow gas wells that produce
some water. The narrow internal diameter results in a much higher velocity than
would occur inside conventional tubing or inside the casing. This higher velocity
assists in lifting liquids to surface, liquids which might otherwise accumulate in the
well bore and eventually "kill" the well.

The coiled tubing may be run inside the casing instead or inside conventional tubing.
When coiled tubing is run inside of conventional tubing it is often referred to as a
"velocity string" and the space between the outside of the coiled tubing and the
inside of the conventional tubing is referred to as the "micro annulus". In some
cases, gas is produced up into the micro annulus. Coiled tubing umbilical can convey
hydraulic submersible pumps, electric submersible pumps and jet pumps into wells
for both permanent deliquification schemes and service applications.

5. SAND WASHING WITH FOAM

Foam may be recognized as low pressure gradient fluid with sand carrying capacity.
Foam is gas in water emulsion comprising of 65% to 95% gas. Ideally the gas is
nitrogen. The foam at surface is generated by pumping liquid consisting mainly
about 99% water and 1%surfactant and gas. The atomizer acts as a foam generator.
Rheological properties and foam quality are affected by pressure and temperature.
Choke will maintain back pressure to maintain foam quality.

COMPONENTS OF CTU

1. Coil Tubing:

Generally large coils of low alloy carbon sheet steel are used as coil tubes. ASTM
A606 Type 4 & ASTM A607 are most commonly used as CTs. These are thermo-
mechanically rolled.

2. Tubing Reel:

The tubing reel is located on the unit itself. It is supported in axle and is driven
by a hydraulic chain drive. The inner end of the coil tube has a high pressure inlet
safety valve before it is connected to the reel.

pg. 23
 3. Injector:

The injector is the heart of CTU which is installed directly on the well head or drill
string, and is the means by which the tubing is lowered, maneuvered and hoisted in
the well. A load cell is located at the bottom of the injector head. This hydraulic
device is connected to the operator‘s control panel to monitor tubing weight PD –
14 Technology & Application of Acidisation, Sand Control and Coiled Tubing.

4. Stuffing Box:

The stuffing box is the primary sealing mechanism for isolating well bore fluids while
under static or dynamic operating conditions. Hydraulic pressure acting on a piston
actuates it. The piston compresses a polyurethane element, which makes a seal
around the CT. This element, called a stripper rubber, allows the CT into and out of
a live well, providing complete pressure control. Generally stuffing box is mounted
above the BOP and below the injector head. 24

5. Blow Out Preventer (BOP):

A blowout preventer (BOP) contains wellbore pressure. Its main function is to

prevent well fluids from escaping into the atmosphere. A CT BOP is designed
specifically for CT operations. BOP is a critical part of CTU and PD – 14 Technology
& Application of Acidisation, Sand Control and Coiled Tubing.

6. Control Console, the power pack & crane:

The coiled tubing control cabin is situated to provide a clear view of both the well
head & injector and the tubing reel.

pg. 24
 Fig – CTU UNIT

NITROGEN ACTIVATION

PRINCIPLE

The nitrogen gas is circulated into the production conduit to displace liquids and
reduce the hydrostatic pressure created by the fluid column hence, nitrogen lifting
is a common technique used to initiate production, generally a coiled tube is utilised
but it can be directly injected via the annulus.

The nitrogen is selected for the purpose because nitrogen possesses certain
properties which are given in the figure below:

pg. 25
 Fig – Nitrogen Properties

This technology used in case back pressure to formation have to be reduced, formed
by killing fluid or drilling mud presented in a well after drilling of workover
operations. Those jobs are done for stimulation of kick-off in oil and gas wells.

pg. 26
 Figure-9 – Annulus Space Created between Casing and CT

Equipment Involved
Cryo Vessel (storage) (with pumps if not a pumping unit and a heat exchanger)
Coiled Tubing Unit (If required)

Operation

1. Cryo vessel is prepared and is filled with nitrogen (Liquid state Low T at
about -196oC at 1 atm pressure)
2. The units are then mobilised to the site.
3. The connections are made with the pump outlet to the annulus of the well.
4. At first the connection is tested by pressurising the line.
5. Now the annulus valve is opened and pumping begins.
6. Liquid nitrogen is sucked from the tank by a Boost pump (Centrifugal pump)
then it is supplied to a triplex pump where it is pressurised more to
reduce the temperature then the nitrogen flows to the heat exchanger
(With hot water) and the temperature increases and this high-pressure gas
is pumped in the annulus.
7. The tubing valve is open for the well fluids to come out if present.
pg. 27
 8. The nitrogen pressurises the bottom hole as the pressure builds up the
nitrogen expands to 700 times the original volume and lifts the present well
fluids.
9. The outlet of the fluids is controlled and the fluids coming out are examined.
10. After completion of the job connections are opened and the units are
demobilised back to the base.

GAS LIFT

MANDREL

OIL LIFT WITH GAS

Fig-10

pg. 28
Advantages of Gas Lift

 High degree of flexibility and design rates.

 Subsurface equipment are wire line retrievable.
 Handles sandy conditions well
 Surface wellhead equipment requires minimal space
Disadvantages of Gas Lift

 Needs high-pressure gas well or compressor.

 Single well application may be uneconomical.
 Performance dependent on fluid viscosity.

Gas lift system is now broadly classified into 2 categories depending upon the duration of
lift gas being injected into the tubing:

a. Continuous gas lift

b. Intermittent gas lift

1. Continuous Gas Lift

The basic principle underlying the natural flow and continuous gas lift is same. The only
difference between them is the source of gas. In the case of natural flow, gas comes into the
wellbore along with oil or in the dissolved condition in the oil whereas in the latter case, the
gas is conveyed down the hole and is injected into the oil body. That is why Continuous gas
lift can be seen as an extension of the self-flow period of oil well.

The basic principle of Continuous flow gas lift is to inject the gas in the oil body at some
predetermined depth at a controlled rate to aerate the oil column above it and as a result
increasing drawdown on the formation. This has the result of increasing the well GLR. When
the GLR is increased the density of oil column gets reduced to a point where a flowing bottom
hole pressure at a desired rate of production is sufficient to lift the oil to the surface.

Continuous gas lift system should be employed when well moderate to high reservoir
pressure and PI. Continuous gas lift characteristically provides high volume of oil production
thus; oil is produced continuously from the well. This method is only applicable to wells
having a lower than optimum natural GLR, and a reservoir pressure high enough to sustain
the desired flow rate. Gas injection is done at a slow rate and continuously. Because of this
reason, the port size of the gas lift valve is smaller in comparison with port sizes of the gas
lift valves for intermittent gas lift.
pg. 29
It is also generally intended and the accepted practice that in the continuous gas lift, only one
valve will be accomplishing the gas injection work and that this valve should be as deep as
possible as per the available normal gas injection pressure. This valve is termed as
operating valve. The valves above it is used to unload the well to initiate the flow from
reservoir and are called ―unloading valve. As the unloading through the unloading valves
continues, the upper unloading valve gets closed once the gas injection begins through next
lower valve. By the time the gas injection commences through the operating valves all
unloading valves are in closed condition and the injection continues through the operating
valve. In case there is disruption in gas injection, the well will be loaded. So, when gas lift is
resumed, the well is required to be unloaded with unloading valves.

Fig 11 – Continuous Gas Lift

2. Intermittent Gas lift

In intermittent gas lift sufficient volume of gas at the available injection pressure is injected
as quickly as possible into the tubing under a liquid column and then the gas injection is
stopped. The gas expands and in this process it displaces the oil on to the surface. So, the
assistance of flowing bottomhole pressure is not required when the gas displaces the oil.
Static bottomhole pressure, flowing bottomhole pressure, and productivity index of the well
govern the fluid accumulation in the tubing.

In this system, a pause or idle period is provided, when no gas injection takes place. In this
period the well is allowed to buildup the level of liquid which depends upon he reservoir
pg. 30
pressure and PI of the well. Then again next gas injection cycle is initiated to lift oil. In this
manner, as the name suggests, intermittent gas lift works on the principle of intermittent
injection of gas in a regular cycle. It is to be noted that in the cycle the injection time should
be as short as possible. A large volume of gas should be injected quickly underneath the oil
slug as a result the oil slug above the point of gas injection will acquire the terminal velocity(
maximum velocity) within shortest possible time, which would minimize the liquid fallback in
the tubing string. Less fluid fallback will not only increase production but also help reduce the
paraffin accumulation problem in the tubing, if oil is paraffinic in nature.

For injecting large amount of gas, bigger port size gas lift valves are required. That is why gas
lift valves having port sizes 1/2‖, 7/16‖, 3/8‖, or 5/16‖ are preferred. In intermittent gas lift
application, two different injection flow rates are considered. One is the normal gas
injectionrate( called day rate) required for a well on per day basis and other is the
instantaneous gas injection rate, commonly called per minute demand rate of gas injection.
It helps to minimize the injection gas breakthrough the oil slug and arrests liquid fall back to
a desired extent. Similar to continuous gas lift, a number of gas lift valves are also installed in
the intermittent gas lift well. The last valve is located as deep as possible (conventionally last
valve is just above the top of perforations). At every cycle, the injection of gas takes place
through this valve first and as such, it is also termed as operating valve. The upper valves may
or may not operate, when the liquid slug crosses the valve during its upward travel. If the
upper valve opens as the slug crosses the valve, the additional gas further arrests the liquid
fall back and thus results in more oil production. In the light of above discussion it can be
comprehended that. Intermittent gas lift system should be deployed when the well has a
poor PI and low reservoir pressure.

pg. 31
 Fig 12 – Intermittent Gas Lift

Gas Lift Valves (GLVs)

A gas lift valve is analogous to a downhole pressure regulator. The surface areas of the gas
lift valve exposed to tubing and casing pressures. So, in response to casing or tubing
pressure the gas lift valves open, which allows injection gas to enter the production string
to lift fluid to the surface.

There are two types of Gas lift valves:

1. Casing Pressure Operated Gas Lift Valve :-

Casing pressure operated gas lift valves operate predominantly with the pressure of casing.

pg. 32
Figure13- Casing operated Gas Lift Valve

2. Tubing Pressure Operated Gas Lift Valve :-

Fluid operated gas lift valve

Figure14 : Tubing
operated Gas Lift Valve

pg. 33
HYDRAULIC FRACTURING

 Hydraulic fracturing is the process of pumping fluid into a wellbore at an injection rate
that is too high for the formation to accept without breaking. During injection the
resistance to flow in the formation increases, the pressure in the wellbore increases to
a value called the break-down pressure, that is the sum of the in-situ compressive
stress and the strength of the formation. Once the formation “breaks down,” a
fracture is formed, and the injected fluid flows through it. From a limited group of
active perforations, ideally a single, vertical fracture is created that propagates in two
"wings" being 180° apart and identical in shape and size. In naturally fractured or
cleated formations, it is possible that multiple fractures are created and/or the two
wings evolve in a tree-like pattern with increasing number of branches away from the
injection point.
 If fluid is pumped into a well faster than the fluid can escape into the formation,
inevitably pressure rises, and at some point, something breaks. Because rock is
generally weaker than steel, what breaks is usually the formation, resulting in the
wellbore splitting along its axis as a result of tensile hoop stresses generated by the
internal pressure. However, in general, the wellbore breaks—i.e., the rock fractures—
owing to the action of the hydraulic fluid pressure, and a “hydraulic” fracture is
created. Because most wells are vertical and the smallest stress is the minimum
horizontal stress, the breakdown results in a vertical, planar parting in the earth. The
breakdown and early fracture growth expose new formation area to the injected fluid,
and thus the rate of fluid leaking off into the formation starts to increase. This growth
continues to open more formation area. However, although the hydraulic fracture
tremendously increases the formation flow area while pumping, once pumping stops
and the injected fluids leak off, the fracture will close and the new formation area will
not be available for production. To prevent this, measures must be taken to maintain
the conductive channel. This normally involves adding a propping agent to the
hydraulic fluid to be transported into the fracture. When pumping stops and fluid flows
back from the well, the propping agent remains in place to keep the fracture open and
maintain a conductive flow path for the increased formation flow area during
production. The propping agent is generally sand or a high strength, granular
substitute for sand.

pg. 34
Aim
 Increase the flow rate of oil and/or gas from low-permeability reservoirs
 Increase the flow rate of oil and/or gas from wells that have been damaged
 Connect the natural fractures and/or cleats in a formation to the wellbore
 Decrease the pressure drop around the well to minimize sand production
 Enhance gravel-packing sand placement
 Decrease the pressure drop around the well to minimize problems with asphaltine
and/or paraffin deposition
 Increase the area of drainage or the amount of formation in contact with the wellbore
 Connect the full vertical extent of a reservoir to a slanted or horizontal

Candidate Selection
Critical parameters Reservoir parameters
 Formation permeability  A thick pay zone
 The in-situ stress distribution  Medium to high pressure
 Reservoir fluid viscosity  In-situ stress barriers to minimize vertical
 Skin factor height growth
 Reservoir pressure  Either a low-permeability zone or a zone
 Reservoir depth that has been damaged (high skin factor)
 The condition of the wellbore

Developing Data Sets

Controlled data Measured data critical data

 The well completion  Formation depth  In-situ stress profile
details  Formation permeability  Formation permeability
 Treatment volume  In-situ stresses in the pay  Fluid-loss characteristics
 Pad volume zone  Total fluid volume
 Injection rate  In-situ stresses in the pumped
 Fracture fluid viscosity surrounding layers  Propping agent type and
 Fracture fluid density  Formation modulus amount
 Fluid-loss additives  Reservoir pressure  Pad volume
 Propping agent type  Formation porosity  Fracture fluid viscosity
 Propping agent volume  Formation  Injection rate
compressibility  Formation modulus
 Reservoir thickness

pg. 35
Fracking Fluid

 Typically, a mixture of water, proppants and chemicals is pumped into the rock or coal
formation. There are, however, other ways to fracture wells. Sometimes fractures are
created by injecting gases such as propane or nitrogen, and sometimes acidizing occurs
simultaneously with fracturing. Acidizing involves pumping acid (usually hydrochloric
acid), into the formation to dissolve some of the rock material to clean out pores and
enable gas and fluid to flows more readily into the well.

 Some studies have shown that more than 90% of fracking fluids may remain
underground. Used fracturing fluids that return to the surface are often referred to as
flowback, and these wastes are typically stored in open pits or tanks at the well site
prior to disposal.

 Water plays an important role in the fracturing fluid composition. A huge amount of
fresh water supply is thus required for a hydrofracturing job, which restricts its use in
areas where fresh water is unavailable. In such cases other ways for fracturing are
employed. A typical composition of fracturing fluid is shown in the figure, where

pg. 36
 different additives are added to the water at different stages for the desired properties
of the frac fluid. Acids are used to clean the formation, crosslinker is used to increase
the viscosity and thus the proppant carrying capacity. A typical gallant is also used for
achieving desired viscosity of frac fluid. Other chemical additives such as corrosion
inhibitor, clay control, iron control, etc.

Process of HF:

The placement of hydraulic fracturing treatments underground is sequenced to

meet the particular needs of the formation. Each oil and gas zone is different and
requires a hydraulic fracturing design tailored to the particular conditions of the
formation. Therefore, while the process remains essentially the same, the sequence
may change depending upon unique local conditions. It is important to note that not
all of the additives are used in every hydraulically fractured well; the exact “blend”
and proportions of additives will vary based on the site-specific depth, thickness and
other characteristics of the target formation.

Acid stage:

pg. 37
 Consisting of several thousand gallons of water mixed with a hydrochloric acid
or mud acid. This serves to clear cement debris in the wellbore and provide an open
conduit for other frac fluids by dissolving carbonate minerals and opening fractures
near the wellbore.

Minifrac Test:

Refer to pre-frac operations conducted in the well on the same day as the
main stimulation operation. These pumping operations are carried on up to full-scale
pump rates with cross-linked fluid without proppant. The purpose is to determine or
confirm certain information that had to be assumed for the design of the treatment
and if necessary, we can modify the slurry parameter and pumping rate. The
information that can be obtained from a minifrac are:

o Closure pressure and time

o Near wellbore pressure losses
o Fluid leak-off
o Rate of pressure loss due to leak-off to the formation using cross-linked fluid

Pad stage:

Consisting of approximately cross-linked fluid without proppant material. The

pad stage fills the solution, opens the fracture in formation and helps to facilitate the
flow and placement of proppant material.

Main flush:

Which may consist of several sub stages of water combined with proppant
material (generally -20 & +40 mesh size). This stage may collectively use several
hundred thousand gallons of water. Proppant material may vary from a finer particle
size to a coarser particle size throughout this sequence.

Post flush, Flow back and cleaning with N2

Consisting of clean the tubing with reverse wash. Then, after 4 to 5 hours the
frac fluid is being braked to the viscosity of 10 cp with breaker and flow back the fluid
and do N2 job for cleaning perforation and fracture.

pg. 38
HOC (Hot Oil Circulation)
Circulation of Hot Oil from the wellbore to remove wax deposition. Wax deposition reduces
production rate so this technique is generally applicable to maintain optimum production
rate by removing this wellbore mechanical damage. In simple case Hot Oil is circulated from
tubing to the annulus but in case of the packer applied at the bottom between tubing and
casing this simple circulation cannot be obtained hence by adding CTU artificial annulus can
be created and circulation can be obtained. While if SRP type artificial lift is present then due
to the NRV at the bottom of sucker rods simple circulation cannot be obtained hence reverse
circulation is required. In reverse circulation, Hot Oil is injected from annulus and return to
surface from tubing. Temperature of Hot Oil is maintained about 85°C or more than that
because at this temperature wax are soluble in Oil. Weather also effect to the solubility of
wax and temperature transmission via Oil. Hence in winter PPD (Pour Point Depression) has
to be added with Oil. It maintains low deposition temperature so even at the low
temperature transmission wax will remain soluble in Oil. Amount of fluid or slug that is
injected in the wellbore is selected based upon the annulus and tubing sizes.

Effect of wax deposition in pipes:

Crystallization of waxes in crude oils leads to non-Newtonian flow characteristics, including
very high yield stresses that are dependent on time and the shear and temperature histories
of the fluid.
This crystallization may cause three problems:
o High viscosity, which leads to pressure losses
o High-yield stress for restarting flow

pg. 39
 o Deposition of wax crystals on surfaces
Wax precipitation-induced viscosity increases and wax deposition on pipes are the primary
causes of high flowline pressure drops. In turn, these pressure losses lead to low flow rates
that make conditions for wax deposition more favorable. In extreme cases, pumping
pressure can exceed the limits of the system and stop flow entirely. A related problem is
the high-yield stress for restarting flow.

1. HOC (Hot Oil Circulation) Unit:

The main purpose of HOC Unit was to heat the oil and circulate further in order to carry out
the opeartion. Two oil tanks each of capacity 3 �3 were present to store the oil which was
taken from oil tanker. Two diesel tanks were installed besides providing fuel to heat the oil.
Oil tanks were connected to circulation pump at the bottom which helped in circulation of
oil to burner unit. Burner unit heated the oil at 80℃. Triplex pump was present at the end
to circulate oil. It can be done by direct injection of hot oil from HOC unit or can be done
along with the CTU.

2. OIL TANKER

An oil tanker with capacity of 12 �3 was kept to circulate oil to HOC Unit. The oil was of
high API gravity loaded from nearby GGS.

3. CTU (Coil Tubing Unit) [Alternative]

A Coil Tubing Unit with tubing assembly of 2500 m was used in the operation. It was in kept
in hold with nearly 1000 psi tension pressure in order to keep the tubing in control. A
gooseneck assembly was present to keep the tubing in turning condition at the top. An
injector with chain assembly was present which helped in RIH and POOH of the tubing.
Small annular BOP was present with four rams (pipe ram, shear ram, blind shear ram and
slip(annular)ram) which could provide assistance at the time of uncontrolled pressure of
the well. It could be operated hydraulically as well as manually. Sewage (nipple type) was
fixed at the top of christmas tree to join BOP with it. Cross overs with square threads (Vam
threads) were used to join two different assemblies. The size of the tubing was 114 inches
with capacity of 2.5 �3. The whole unit was hydraulically operated. The power of the the
whole unit was gained from diesel of the truck. A crane was also present to move and
assemble the parts.

pg. 40
Acidization Job

 Acidizing Basics Acidizing involves pumping acid into a wellbore or geologic

formation that is capable of producing oil and/or gas.

 The purpose of any acidizing is to improve a well’s productivity or injectivity. There

are three general categories of acid treatments: acid washing; matrix acidizing;
fracture acidizing.

 In acid washing, the objective is simply tubular and wellbore cleaning. Treatment
of the formation is not intended. Acid washing is most commonly performed with
hydrochloric acid (HCl) mixtures to clean out scale (such as calcium carbonate),
rust, and other debris restricting flow in the well. Matrix and fracture acidizing are
both formation treatments.

 In matrix acidizing, the acid treatment is injected below the formation fracturing
pressure. In fracture acidizing, acid is pumped above the formation fracturing
pressure.
 The purpose of matrix or fracture acidizing is to restore or improve an oil or gas
well’s productivity by dissolving material in the productive formation that is
restricting flow, or to dissolve formation rock itself to enhance existing, or to create
new flow paths to the wellbore.

 Two key factors dominate the treatment selection and design process when
planning an acid job; formation type – carbonate, sandstone, or shale, and
formation permeability – the ability of fluid to flow through the formation in its
natural state. Formation type determines the type(s) of acid necessary and
formation permeability determines the pressure required for pumping the acid into
the formation.

 In lower permeability formations the acid cannot be pumped into the formation
matrix as readily, but is pumped through existing or induced fractures at higher
pumping pressures. If the pumping pressure is above that which will part or
fracture the formation, the treatment is called “fracture acidizing” (or “acid
fracturing”).
 There is not an absolute value of formation permeability that separates matrix and
fracture acidizing, however the range of values where this may typically occur is
between 0.1 millidarcies and 10 millidarcies, depending on the case specific
situation. There are two subsets of fracture acidizing. The first type is performed as
pg. 41
 a preliminary step in a hydraulic fracturing operation, such as in shale or extremely
low permeability sandstone or carbonate formations. In this case, acid (HCl or
HCl/HF blend) is pumped ahead of the fluid carrying the proppant that will hold the
fractures open once the pump pressure is released. The purpose of the acid job in
this case is to provide the cleanest possible formation face to enable easier fracture
creation and maximize the performance of the proppant once it is placed. The
second type is a fracture acid job, primarily applicable in carbonate formations,
where the acid is pumped alone or following a fracturing fluid stage – with the
intent of creating new or opening existing fractures, and dissolving formation
material to create irregular facture surfaces that create new flow paths or enhance
existing flow paths into the wellbore when the fractures close.

 When acidizing, the acid is chemically consumed and neutralized as the target
material is dissolved. In carbonate formations the reaction is relatively simple and
occurs in a single step. The hydrochloric acid (HCl) reacts with the carbonate to
form a salt, carbon dioxide, and water. When acidizing sandstones with HF the
reactions are more complex, occurring in three stages. In the primary stage, the
mud acid reacts with the sand, feldspar and clays to form silicon fluorides and
aluminium fluorides. In the secondary stage the silicon fluorides can react with clay
and feldspar to release aluminium and silicon precipitates, however with proper
design, formation of these damaging precipitates, which can restrict flow of oil or
gas through the formation, can be avoided. In the final stage the remaining
aluminium fluorides react until all the remaining acid is consumed.

pg. 42