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SUMMER INDUSTRIAL TRAINING

AT ONGC ANKLESHWAR

DEEPAK CHANDAK-13EJIME032 SUBMITTED TO-


JODHPUR INSTITUTE OF ENGINEERING HOD- M R BAID
AND TECHNOLOGY(CO ED,MECHANICAL) (MECHANICAL)
OIL AND NATURAL GAS CORPORATION
INDUSTRY- OIL AND GAS
HEADQUARTER- TEL BHAVAN, DEHRADUN, UTTRAKHAND
CHAIRMAN & MD- DINESH KUMAR SARAF
OWNER- GOVERNMENT OF INDIA
PRODUCTS- PETROLEUM, NATURAL GAS, AND OTHER
PETROCHEICALS.
ABOUT ONGC
VISION STATEMENT
“to give world leadership in management of energy source, exploration of
energy sources, diversification of energy sources, technology in Underground
Coal Gasification, and above all, finding new ways of tapping energy
wherever it is, to meet the ever-growing demand of the country”

33,560 7.1 BILLION TONNES OF


HYDROCARBONS (TILL
EMPLOYEES NOW)

11 ASSETS(OIL & GAS)


7 BASINS(EXPLORATORY) ONGC 11,000 KMS OF PIPE -
LINES OVER COUNTRY
2 PLANTS(OIL REFINING)
PRODUCTS- CRUDE OIL,
GAS, LPG, NAPTHA, C2-C3
SERVICES (DRILLING, WELL AND OTHER HYDRO-
SERVICES, LOGGING, ) CARBON’S PRODUCTS
ABOUT ONGC ANKLESHWAR ASSET
• STARTED IN 1960, PRODUCTION STARTED IN 1961.
• SITUATED AT ANKLESHWAR, BHARUCH, GUJRAT.
HAS 4 FIELDS OF OIL
-ANKLESHWAR(1960, well depth~1100m)
-GANDHAR(1984, well depth~3200m) HAS VARIOUS
HAS MORE THAN -JAMBHUSAR(1999, well depth~3800m)
6000 WELLS DEPARTEMENTS
-DAHEJ(2005, well depth~3500m) LIKE DRILLING,
DRILLED TILL
FISHING, LOGGING,
DATE & MORE CASING, MATERIAL,
THAN 300 INTRUMENTATION,
ACTIVE WELLS ANKLESHWAR SURFACE etc..
ASSET, ONGC
OUTSOURCING FOR
HAS 11 GGS (GGS VARIOUS SERVICES
1-7, GGS DAHEJ, LIKE DIECTIONAL
GGS JOLWA, GGS HAS 7 NO. OF OIL RIGS:- DRILLING, FISHING,
DABKA, GGS 2 MOBILE RIGS(CWX, M-450) DRILLING, WORK-
GANDHAR), 1 CTF 4 ELECTRICAL( E-1400-3, E- SHOP SERVICES FOR
1 CPF, 1 MPH 1400-7, E-760, E-2000) MACHINES etc..
1 VFD(EV-2000-2)
FORMATION OF OIL
PROCESS OF FORMATION OF OIL IN EARTH

LIVING
ORGANISM
1. E.g. PLANTS AND ANIMALS.

2. BURIED UNDER LAYER DEAD


OF SOIL. BODIES

BIOPOLYMER 3. DUE TO FORMATION OF MORE


SOIL LAYERS.
4. DUE TO HEAVY ROCKS
GEOPOLYMER
HIGH TEMPRETURE & (KEROGEN)
PRESSURE.
BITUMEN 5.HIGH TEMPRETURE & PRESSURE
UNDER ROCKS FOR LONG TIME.
6.THE CONVERSION PRO- PETROLEUM
CESS OVER YEARS. FOSSIL FUELS
PROCESS OF OIL PRODUCTION

DATA FROM SATELLITE SEISMIC SURVEYS

RIG MOVING,BUILDING & LEVELLING

THE CHRISTMAS TREE DRILLING PROCESS


DRILLING RIG

A Rig is a complete Mechanical machine that consist of the structure and the
machines that were used for drilling of oil well.
DRILLING PROCESS
Rig moving / Rig The drilling process
Readying of drilling
building starts that includes
location (surface
If a free rig is there in mud circulation,
leveling, water
nearby area then rig casing, cementation,
sources, pipeline
moving & rig building inert of drill pipes,
setup etc).
else only rig building. fishing etc.

When it is get to A continuous care Various simultaneous


know that oil starts is taken of well processes takes place
coming, the rig is data like pressure, such as mud cleaning,
removed and ‘The temp., gas from data handling of well
Christmas Tree’ is mud after drilling, like temp. pressure
placed there in place the required depth etc, maintenance of
for oil production. of drilling etc. various machines etc.
THE DRILLING PROCESS (INSIDE VIEW)
Major Drilling Equipment
Divided Into Following Categories:

–Hoisting Equipment (used for raising and and


lowering of drill pipes)
–Rotary Equipment (used to give rotary power to
drill bit for cutting action)
–Circulating Equipment (for circulation of mud)
Hoisting Equipment
1. Draw works
One of the major drilling equipment on the rig
Raises or lowers drill string, casing and other equipment in well
CROWN BLOCK

TRAVELLING BLOCK HOOK


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

SWIVEL TOP DRIVE SYSTEM


MUD CIRCULATION SYSTEM
TYPES OF DRILL BITS

MILLED TOOTH BIT INSERT BIT POLYCRYSTALLINE


USED FOR CUTTING USED FOR CUTTING DIAMOND COMPACT
OF UPPER LAYER OF OF ROCKS AND SAND DRILL BIT
SAND (GENERALLY (DEPTH UPTO 1200m.) USED FOR CUTTING OF
UPTO 400-700 m.) HARD FORMATION OR
ROCKS (DEPTH 1000m.
AND ABOVE).
CASING & CEMENTATION PROCESS
 Casing is large diameter pipe that is assembled and inserted into a recently
drilled section of a bore hole and typically held into place with cement.
The following casing intervals are typically used in an oil or gas well:
• Conductor casing
• Surface casing
• Intermediate casing (optional)
• Production casing
 The basic principle of cementing operations is the displacement of cement
slurry down the casing, tubing or drill pipe to a pre-specified point in the
well.
 The main functions of primary cementation are:-
• To bond and support the casing.
• Protecting the casing from corrosion.
• To restrict fluid movements between formations.
• Protecting the casing from shock loads during drilling of next zone.
• Sealing off problematic zone
TYPES OF CASING
COST ANALYSIS OF DRILLING RIG E-1400-7

Drilling Cost

Well Cost Maintenance


Operating
Cost
Cost
Mud cost
Man Power Casing cost
Diesel Cost Drill bit cost
Out sourcing cost
Cementing cost
OPERATING COST
Net operating cost included two types of cost:

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


• Variable cost

 It includes:

 Diesel cost
 Mud cost
 Casing Cost
 Drill Bit Cost
 Out Sourcing Cost
 Cementing Cost
 Maintenance cost
DIESEL COST
 Total available engines at the drilling site:4 nos
• Based on the operational requirement engines are
started. Sometimes operation are carried out with 3 or
4 engines or sometimes by one or two engines
• Diesel consumption is approx. 7000 liters per day (it
includes diesel consumption of all the engines)
• Net diesel consumption is 7000*30*3 (per well) =
630000 liters
• Diesel cost is Rs.58.84 per liter.
• Total diesel cost is 630000*58.84 = Rs.3,70,69,200
2.WELL COST
1. MUD COST
• Mud is the mixture of water, bantonite clay, thinner and lubricating oil.
• Its cost is around Rs.70 per liter.
• And 150000 liters of mud is used for drilling of a well of around 3000 meters depth.
• So total mud cost is 150000*70 = Rs.1, 05, 00,000.
2. CASING COST
• Cost of conductor casing is Rs. 3667.05 per meter.
So total cost of conductor casing is = 3667.05*200 = Rs. 7,33,410
• Cost of intermediate casing is Rs. 2015.31 per meter.
So total cost of intermediate casing is = 2015.31*1600 = Rs. 32,24,494
• Cost of production casing is Rs. 1311.51 per meter.
So total cost of production casing is = 1311.51*3233 = Rs. 42,40,139
• Total casing cost = 81, 98, 043 or approx. 82 lakhs.
3. DRILL BIT COST
 Generally two types of drilling bits are used
1. Fixed cutter and tri conical roller
2. PDC (Poly Crystalline Diamond Compact) bit
Cost of fixed cutter and tri conical roller is 15 lakhs per bit.
Cost of PDC is around 50 lakhs per bit.
One well consumes around one TCR and one PDC bit.
Total drill bit cost = Rs. 65 lakhs.

4. OUT SOURCING COST


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

5. CEMENTING COST

TOTAL CEMENTING COST= Rs. 1954533 = 20 lacs.


3. Maintenance cost
• The maintenance budget of ONGC per year for 6 drilling rigs
is around 50 crore.
• Each rig drills average 5 wells per year.
• So maintenance cost per well is around 1.67 crore.

TOTAL DRILLING COST


• Operating Cost = 3.70 crore
• Well Cost = 4.72 crore
• Maintenance Cost = 1.67 crore
• Total cost = 10.09 = 10 crore
SITE VISITS
 The rigs that we have visited:
• CARDWELL-10
• M-450
• E-760-5
• E-2000-2
• E-1400-7
 GGS (Group Gathering Station)
 CTF (Central Tank Farm)
 MPH (Main Pump House)

PRODUCTION
• From 1 GGS around 1000
m^3/day liquid (oil +water) is
sent to CTF.
• And oil production in CTF from 1
GGS is around 150m^3/day
• LPG production per day is around
10 to 15 tones.
• Naptha production per day is
around 20 tones.
CONCLUSION
After summer training at ONGC ankleshwar,
I have known about the process of oil well drilling
from starting to finish, at the Ankleshwar field
and Gandhar field. We also visited GGS, CTF
and MPH. we also conducted one project work,

“COST ANALYSIS OF DRILLING RIG E1400-7”.


THANK YOU