.

STUDENTS INDUSTRIAL WORK EXPERIENCE SCHEME (SIWES)

TRAINING PROGRAMME

AT

500LEVEL

AUGUST 2018– DECEMBER 2018

DEDICATION

I dedicate this report to my lover and friend the Lord Jesus Christ who is the
source of my strength. Also, to my family especially my grandmother who has
been there all the way and to my lovely supervisors at PTI who in their various
quota showed me the reality of life.

ACKNOWLEDGEMENT

My greatest appreciation goes to God almighty for his blessing, courage and wisdom to
complete my industrial training.

I would like to express my profound gratitude and special thanks to all the staff of
Petroleum and Geosciences Department for their support, encouragement, consistent
advice, useful suggestion and constructive criticism. Mr Esabunor O.N.R my supervisor,
Mr Uti and Mrs Irabor.I offer my sincere appreciation for the learning opportunities
provided.

Special appreciation goes to my grandmother Mrs Elizabeth.O. Zini, your moral and
financial support, prayers and encouragement over the years are much appreciated and
duly noted.

I am extremely grateful to my fellow industrial trainees; Michael, Silver, Domino, Mark,

Tejiri, Euphoria and the others. Your solidarity, coherence and unanimity will ever be in
memory.
 ABSTRACT

Students industrial work experience Scheme (SIWES) is one of the industrial

training fund (ITF) program. Design to give Nigerian Students studying
occupationally related course in higher institution the experience that would
supplement their theoretical learning. Students industrial work experience Scheme
(SIWES) is also established to facilitate the full realization and mandatory skill
acquisition and proper training programmes designed to expose students to the
industrial workplace environment in their respective discipline during the course
of study.

This report gives insight to the experience I gained during my Internship

program at Petroleum Training Institute.

Chapter one of this report talks entirely about Petroleum Training Institute.
Starting with Brief history of Petroleum Training Institute, it’s departments and a
short note on Petroleum and Geosciences Department. Also, it covers the various
workshops and laboratories in the Petroleum and Geosciences Department.

Chapter two of this report Introduces the workshops: drilling workshop,

production workshop and production laboratories and their operations.
 Chapter three of this report covers the various analysis and experiments carried
out in the laboratories with their various procedures and calculations.

Chapter four of this report covers the experience gained, conclusion and the
appropriate recommendation.

TABLE OF CONTENT

CERTIFICATION

DEDICATION

ACKNOWLEDGEMENT

ABSTRACT

LIST OF FIGURES

CHAPTER ONE: INTRODUCTION

1.1. STUDENT INDUSTIAL WORK EXPERIENCE SCHEME

1.2. PETROLEUM TRAINING INSTITUTE

1.3. PETROLEUM AND GEOSCIENCES DEPARTMENT

CHAPTER TWO: OPERATIONS AND ANALYSIS.

2.1. DRILLING WORKSHOP/RIG.

2.1.1. ROTATING SYSTEM.

2.1.2. HOISTING SYSTEM.

2.1.3. POWER SYSTEM.

2.1.4. BLOWOUT PREVENTION SYSTEM.

2.1.5. CIRCULATING SYTEM.

2.1.6. TUBULAR HANDLING EQUIPMENT.

2.2. PRODUCTION WORKSHOP/ FLOWSATTION.

2.2.1 WELLHEAD.

2.2.2. SEPERATORS AND HEAT TREATERS.

2.2.3. TANKS AND METERING.

2.2.4. PATH OF FLOW IN FLOW STATION.

CHAPTER THREE: PRODUCTION LABORATORY.

3.1 DRILLING MUD / FLUID.

3.2 FUNCTIONS OF DRILLING MUD

3.3 MUD ENGINEER.

3.4 EXPERIMENTS/ ANALYSIS.

3.4.1. CRUDE OIL TEST: BS&W.

3.4.2 CENTRIFUGE METHOD.

3.4.3. HYDROMETER METHOD

3.4.3. RELATIVE DENSITY.

3.5 EMULSION

3.5.1. EMULSION TEST.

3.6. MUD FORMULATION & ANALYSIS.

3.6.1 pH TEST.

3.6.2. FLUID LOSS CONTROL TEST.

CHAPTERFOUR: CONCLUSION AND REFERENCE

 CHAPTER ONE
1. 1 INTRODUCTION
The Students Industrial Work Experience Scheme (SIWES) is the accepted skills training
programme which forms part of the approved minimum academic standard in various
degree programmes for all the Nigerian universities. The scheme is aimed at bridging the
gap existing between the theory and the practice of engineering, sciences, agriculture,
medical sciences, environmental technology, technical education, science education and
other professional educational programmes in the Nigerian tertiary institutions. This
programme was established by Federal Government of Nigeria in the year 1973, and is
jointly managed by the Industrial Training Fund (ITF) and National University
Commission (NUC).

However, it is on this note that I secured an internship placement with the Petroleum
Training Institute for a period of six months. This report covers a practical knowledge of
mud preparation, characterization and beneficiation. It also entails practical knowledge
on crude oil analysis, surface production and well drilling technology.

Objectives of SIWES
• Provide an avenue for students in institutions of higher learning to acquire
industrial skills in their courses of study.
 • Prepare students for the industrial work situations they are to meet after
graduation.

• Expose students to work methods and techniques in handling equipment and

machinery that may not be available in their institutions.

• Provide students with opportunity to apply their knowledge in real work situation
thereby bridging the gap between theory and practice.

• Make the transition from school to the world of work easier, and thereby enhance
student’s contacts for later job contracts and for job placements.

• Enlist and strengthen employer’s involvement in the entire educational process

and prepare students for employment after successful graduation.

1.2 BRIEF HISTORY OF PETROLEUM TRAINING INSTITUTE

Petroleum Training Institute (PTI) in Effurun, Delta State was established in 1973 by the
federal government of Nigeria as a prerequisite for the membership in the organization of
petroleum exporting countries (OPEC) to train indigenous middle-level manpower to
meet the labour force demands of the oil and gas industry in Nigeria and the west African
sub region. It awards general welding certificates, ND (National Diploma) and HND
(Higher National Diploma) certificates.

The institute is headed by the Principal and CEO Professor Sunny Iyuke, who last served
at the University of Witwatersrand (Johannesburg), before returning to Nigeria to head
the Institute.

VISION

To become the leading oil and gas technology institute in Africa.

MISSION
To provide competent technological manpower through quality training, research, and
consultancy for the petroleum and allied industries.

DEPARTMENTS IN PETROLEUM TRAINING INSTITUTE

• Petroleum and Natural Gas Processing (PNGPD)

• Industrial Safety and Environmental Technology(ISET)
• Petroleum Marketing and Business Studies(PMBS)
• Petroleum Engineering and Geo-sciences(PEG)
• Electrical Engineering (EED)
• Welding and offshore Technology(DWOT)
• Mechanical Engineering (MED).

1.3 PETROLEUM ENGINEERING AND GEOSCIENCES (PEG)

The Petroleum Engineering and Geosciences Department is one of the Departments that
came on stream at the inception of the Petroleum Training Institute (PTI) in 1975.Since
then it has trained Technicians and Technologists for the Nigerian Oil/Gas and Allied
Industries .These were produced specifically for Production and Drilling operations.
Furthermore in 1992, a Diploma Program in Mineral Resources Engineering Technology
was established.

Engineering is about innovation and creativity and as such the Diploma programs offered
by the Department of Petroleum Engineering and Geosciences prepares individuals for a
range of careers offering the following certification:

ND - PETROLRUM ENGINEERING TECHNOLOGY.

HND - PETROLRUM ENGINEERING TECHNOLOGY.

ND – MINERAL, RESOURCES ENGINEERING TECHNOLOGY.

The programs, all of which are fully accredited by NBTE are designed to develop
personal and transferable skills which are particularly attractive to employers such as:

• The ability to develop problem-solving strategies.

 • A creative approach.

• Team-working skills.

• Entrepreneurship.

• The ability to analyse data.

• The ability to communicate and present information.

Each is a four semester program that would serve as a spring board to launch a career in
Petroleum Engineering Technology and related disciplines .The courses offered by the
Department range from specialized petroleum engineering technology topics such as
Drilling, Production and Reservoir Engineering to Mineral mining Engineering and Oil
Exploration Technology.

In our efforts to provide relevant and effective technical training for the personnel in the
Oil/Gas and Allied Industries .The Institute has a functional Demonstration ground to
ensure that our training programs are as close as possible to actual industrial situation
.The Demonstration ground has the following facilities :

• A Training Rig

• A Mini flow Station

• Mineral Processing Ball Mill.

• Drill Sim 6000, Test Sim 5000 and Coil –tubing 5000 simulators.

The department laboratories and workshops are:

• Production Laboratories 1 & 2.
• Exploration Laboratories 1 & 2.
• Production Workshop.
• Drilling Production.

SAFETY REGULATIONS
One of the key imperative is health, safety and environment (HSE), the condition of
being protected from harm or other non-desirable objects. As we all know safety comes
first, which is very vital in any establishment or organization. It is expected that we
follow the safety rules to avoid accidents and explosion happening in the laboratory. The
code of practice applies to all work to be carried out in all the laboratories, it must
therefore be adhered to the following:

CODE OF PRATICE

• Smoking, eating (including chewing gums) and drinking are prohibited

• Safety glasses must be worn at all times

• Long hair must be tied back

• Appropriate footwear must be worn within the laboratory

• All chemicals must be properly disposed in appropriate waste bins

• When handling toxic and corrosive chemicals disposable gloves must be worn at
all times

• Laboratory coats must be worn at all times and properly fastened

• Toxic chemicals and highly flammable solvents are to be dispensed in the fume
cupboard

In every organisation there is an avenue for safety meeting, this is to educate the workers
on the need to work safely .At PTI drilling/Production Workshop it is a mandatory task to
always go to the rig with your personal protecting equipment (PPE).

CHAPTER TWO
2.0 Operation and Analysis.

During the period of my internship at the Petroleum Training Institute, I was assigned to
various workshops and laboratories under the Petroleum and Geosciences Department.
These workshops were basically on drilling operations and surface production, on the
other hand the laboratories were concentrated on mud formulation and additives, clay
beneficiation, crude oil analysis, enhanced oil recovery experiment using foreign and
local materials and much more. With the knowledge and training acquired ,I can fit in the
crude oil production process .It should be noted that the primary objective of crude oil
production process is to efficiently produce crude oil in commercial quantity with the
least possible cost while considering workers safety.

2.1 Drilling Workshop.

On arrival at the drilling workshop, Mr Uti the interns supervisor at the drilling workshop
gave us a brief talk on the rotary drilling rig and its systems .The rotary drilling rig is a
machine used for making conduit (hole) in the earth’s subsurface that is economical and
environmentally safe .The various systems which are Rotating system, Hoisting System,
Power System, Blow Out prevention system and Circulating system were properly
explained as we carried out operations on them using the PTI demonstration rig.

2.1.1 Rotating system

Rotating component is the equipment responsible for rotating the drill string .It consists
of the swivel, Kelly bushing, master bushing and rotary table.

• Swivel is a mechanical device that is hung from the hook of the travelling block
to support the weight of the drill string and allows it to rotate freely. It provides
connection for the rotary hose as well as passageway for the flow into the drill
stream.

• Kelly spinner is a pneumatically controlled device mounted below the swivel to

spin the Kelly to make up tool joints when making connections.

• Kelly is the heavy steel square or hexagonal member that is suspended from the
swivel through the rotary table and connected to the topmost joint of drill pipe to
turn the drill stem as the rotary table turns .It has a hole drilled through the middle
that permits fluid to be circulated into the drill stem and up to the annulus or vice
versa. The Kelly goes through the Kelly bushing, which is driven by the rotary
table.
• Top drive is a hydraulically powered device on the drilling rig and is located at
the swivel place. It allows the drill stem to spin and facilitate the process of
drilling a borehole. Top drive means a power swivel, which directly from the drill
string without the need for a Kelly and rotary table.

• Kelly bushing is a device that fits into a part of rotary table called master
bushing, transmits torque to the Kelly and simultaneously permits vertical
movement of the Kelly to make hole. The Kelly bushing as Kelly is square or
hexagonal and has an inside profile matching the Kelly’s outside profile with
slightly larger dimensions so that the Kelly can freely move up and down inside.

• Master bushing is a tool that fits into the rotary table of a drilling rig to
accommodate the slips and drive the Kelly bushing so that the rotating motion of
the rotary table can be transmitted to the Kelly.

• Rotary table is section of the drill floor used to turn the drill stem. It has a
bevelled gear arrangement to create the rotational motion and opening into which
bushings are fitted to drive and support the drilling assembly.

The rotary table consist of the bowl insert, rotary deck, rotary housing, rotary
drive and pinion drive shaft. The rotary table helps rotate the bottom hole
assembly(BHA) by the use of Kelly bushing which are two types ;square drive
and pin drive .The square drive goes into the bowl insert and it’s narrowed so that
it sits properly in the bowl inserts. On the other hand, the pin drive has pins by
which it’s locked into the master bushing that has four holes .The Kelly is
attached to the Kelly bushing and the drill string, drill pipe, drill collar and bit is
attached to the Kelly. As the rotary table rotates mechanically, the Kelly bushing
is rotated as well the Kelly and the drill string .This in turn helps to cut through
the formation.
OPERATION
I and the fellow interns carried out tripping out of hole and tripping in hole operation.
While tripping out, slips were used to suspend the pipe from falling into the hole. The
Kelly is broken off and kept in the rat hole while pipes to make up are kept in the mouse
hole and rested on the monkeyboard .During this process ,the Kelly bushing is removed
and an elevator is used which helps to suspend the drill pipe. The elevator has a
compartment that enables you to attach it to the travelling block via the travelling hook.
The reversal of the above outlined process is tripping in operation.

2.1.2 .Hoisting System.

It is used to perform all lifting activities on the rig and helps in lowering or raising
equipment into or out of the well. It consists of drawworks, crown blocks, travelling
blocks, travelling block hook, deadline anchor, and supply reel, drilling line (deadline and
fastline), derrick and substructure.

• Drawworks is the main component of the hoisting system and is used to transmit
power from prime movers to the hoisting drum that lifts drill string, casing or
tubing string out of and to lower it back into the borehole. They consist of a large
diameter steel spool, brakes, a power source and assorted auxiliary devices. The
primary function of the drawworks is to reel out and to reel in the drill line, a
large diameter wire rope, in a controlled manner. The speeds for hoisting the drill
string could be changes by driller via integrated gear system.

• Crown block is fixed assembly of sheaves (single or double) with a wire rope
drilling line running between it and is located at the top of the derrick or mast and
over which the drilling line is threaded. It is used to change the direction of pull
from the drawworks to the travelling block.

• Travelling block and hook combination is used to safely and efficiently raise or
lower tools and equipment in the well. It is the set of sheaves or pulleys through
which the drill line (wire rope) is threaded or reeved, is opposite the crown block
and enabling heavy loads to be lifted out of or lowered into the wellbore. Hook is
located beneath the travelling block and is used to pick up and secure the swivel
and Kelly.
 • Deadline anchor is usually bolted on the substructure and is the equipment that
holds down the deadline part of the wire rope. It provides weight measurement
and secure deadlines.

• Supply reel is a spool that stores the unused portion of the drill line.

• Drill line is the wire rope used to support the drilling tools. It is threaded or
reeved through the travelling block and crown block to facilitate the lowering and
lifting of the drill string into and out of the borehole. Drill line then damped to the
rig floor by the deadline anchor.

2.1.3. Power System.

The power generated by the power system is used for five main operations such as
rotating, hoisting, drilling fluid circulation, rig lighting and hydraulic systems. It is
important to note that the most of the generated power is consumed by the hoisting and
drilling fluid circulation systems. Internal combustion engine (mostly diesel) connected
to electric generators or turbine is the source of power on the rig. Some rotary rigs can
use electricity directly from power lines.

The electrical power generators are driven by diesel powered internal combustion engines
(prime movers). Electricity is then supplied to electric motors connected to the
drawworks, rotary table and mud pumps. The rig may have, depending on its size and
capacity, up to 4 prime movers, delivering more than 3000 horsepower(hp) is an old, but
still widely used, unit of power in the drilling industry.

Older rigs used steam power and mechanical transmission systems but modern drilling
rigs use electric transmission since it enables the driller to apply power more smoothly,
thereby avoiding shock and vibration. The drawworks and the mud pumps are the major
users of power on the rig, although they are not generally working at the same time.
OPERATION.

I and my fellow interns carried out maintenance operation on the prime movers and
generators. We primed the prime movers (2); by adding water to the carburettor and also
took the batteries out to charge them up. I and my fellow interns also joined the
technicians in fixing the generator. Finally we were shown how to turn on the prime
movers (simultaneously since PTI rig have two prime movers) and how it powers the
entire rig.

2.1.4. BLOWOUT PREVENTION SYSTEM.

Blowouts are the most feared occurrence on a drilling rig because they can result in
injury or death to personnel, loss of equipment(including the entire rig),loss of valuable
oil and/or gas and damage to adjacent property. Blowouts can occur when well kicks are
not properly controlled. Kicks occur when abnormal pressures enter the wellbore. The
blowout prevention system comprises of two components basically: Blowout preventer
stack and the accumulator. When a kick occurs, the blowout prevention method is the
secondary defence mechanism .It involves shutting in the well with the annular preventer
which has a rubber seal that helps to close over the pipe until the kick is bled out .During
an emergency kick, the ram preventer is used whose functions depends on the ram piece
in it. Usually a shear-blind ram is used which cuts the pipe and closes over the hole
blocking the fluid from coming to the surface.

The blowout preventer is made up of the Annular preventer, Ram preventer, Drilling
spool and the Casing head. The annular preventer is considered as universal preventer as
it can close all sizes of hole and pipe. The annular preventer is the topmost part of the
BOP stack .The Ram preventer is the second part of the BOP stack. The Ram preventer
has four types; the pieces fixed into the ram differentiates it into pipe ram, shear ram,
blind ram and variable bore ram (VBR). The pipe ram is used to for different sizes of
pipe where the size of the pipe determines the ram to be used (6” pipe requires 6” pipe
ram).The shear ram is used to cut the pipe. The blind ram is used to shut in the hole that
does not have a pipe in it. The VBR can be used for pipes of different sizes as it has the
ability to adjust to the size of the pipe. The VBR is now commonly used instead of the
pipe, shear and blind ram.

The Drilling spool is the third component of BOP stack, it consist of the kill line and
choke line. The kill line is used to bleed out kick when it occurs after the annular ram is
shut in. The choke line is used to supply drilling fluid into the wellbore when the drilling
bit nozzles are blocked. The kill line has a choke line has a check valve that does not
permit backflow. The drilling spool also known as spacer.

The last component of the BOP stack is the casing head which is a flange welded to the
casing.

The accumulator or koomey unit is the opening and closing unit of the blowout
prevention system. It’s situated at a reasonable distance from the rig to allow access in
times of emergency where the driller’s console can’t be used. The accumulator is
powered by compressed air which is gotten from the air tank (the compressor close to the
koomey unit compresses air and sends to the air tank). The blowout preventer closes
within 3mins. The accumulator has nitrogen bottles that helps in storing compressed
nitrogen and has a diaphragm. The accumulator helps in opening and closing of the BOP
through the presence of hydraulics from turbulent to laminar flow. The BOP is connected
to the accumulator through hose (in which the hydraulics flows through to the BOP). The
accumulator has a console at its front that enables you to make the desired change.

2.1.5. CIRCULATING SYSTEM.

This is the rig equipment responsible for the movement of drilling fluid within the well as
well as solids removal incurred by the drilling fluid .Normally, the circulation would start
from the mud pits or tanks that are located besides the rig. Powerful pumps force the
drilling through the surface high-pressure connections to a set of valves called pump
manifold, located at the derrick floor. Then, the fluid goes up the rig within a pipe called
standpipe to approximately1/3 of the height of the mast. From there, the drilling fluid
flows through a flexible high-pressure rotary hose to the top of the drill string. The
flexible hose allows the fluid to flow continuously as the drill string moves up and down
during normal drilling operations. The fluid enters in the drill string through a piece of
equipment called swivel located at the top of the Kelly. The swivel permits the rotating
the drill string while the fluid is pumped through the drill string, In wellbore, the drilling
fluid then flows down the rotating drilling string and jets out through the nozzles in the
drill bit at the bottom of the hole. Drilling fluid carrying the drilled cuttings and flows out
through the center of the drill bit and is forced back up the outside of the ground where it
is cleaned and circulated back to the well. The cleaning process starts from the shale
shaker, which is basically a vibrating screen. This will remove the larger particles, while
allowing the residue to pass into settling tanks. The finer material can be removed using
other solids removal equipments such as desander and desilter. If the mud contains gas
from the formation,it will be passed through a degasser that separates the gas from the
liquid mud. Having passed through all mud processing equipment, the mud is returned to
the mud pits or tanks for recycling.

The principal components of the drilling fluid circulation system are as follows :

• Mud pump is a large, high pressure and high –volume pump used to circulate the
drilling fluid down the drill pipe and out of the annulus on an oil rig. It could be
double acting duplex(2 cylinder) pump, which has four pumping actions per pump
cycle or single acting triplex (3 cylinder) with three pumping actions per pump
cycle whose pistons or plungers travel in replaceable liners and are driven by a
crankshaft by an engine or motor.

• Pump manifold is an arrangement of piping and valves that receives during fluid
from mud pumps and transmits the drilling fluid to the succeeding circulating
component. It is designed to control, distribute and monitor drilling fluid flow.

• Stand pipe is the vertical rigid pipe rising along the side of the derrick or mast,
which joins mud pump manifold to the rotary hose.

• Drill string is the mechanical assemblage connecting the rotary drive on the
surface to the drilling bit on bottom of the wellbore.

• Mud return line or flow line is the large diameter metal pipe and is the
passageway of the drilling fluid as it comes out of the well.

• Shale shaker is the primary solids-removing device with one or more vibrating
screens which is used to remove cuttings from the circulating fluid for reuse.
Screens while mud fluid flows on top of it. The liquid phase with solids which are
smaller than the wire mesh pass through the screen as well as larger solids are
retained on the screen and eventually fall to the screen and eventually fall to the
special container and can be disposed in an environmentally friendly manner.
• Desilter is also a centrifugal device for removing free particles of silt from the
drilling fluid. Comparing with desander, its design incorporates a greater number
of smaller cones which allow removing smaller diameter particles than a desander
does.

• Degasser is device designed to remove air, methane, hydrogen sulphide (H2 S),
carbon dioxide (CO 2 ) and other gases from drilling fluids and allow it to be reused
continuously. It helps to reduce the risk of explosions and other dangers during
the drilling process.

• Mud pit is an excavated earthen-walled pit and is used only to store used or waste
drilling fluid and cuttings.

• Mud tank is an open-top steel container with possibility to observe the

consistency of drilling fluid and monitor it level in the tanks. It is used as a
reserve store for the drilling fluid.

• Tubular and tubular handling equipment. Tubular consist of the following

equipments:

• Drill pipe is the longest section of the drill string and is heavy hot-rolled, pierced
and seamlessly tubing .It connects the surface equipment with the bottom hole
assembly and the bit is used to rotate the bit and for drilling fluid circulation.

• Drill collar is thick-walled, heavy and large diameter steel tube placed between
the drill pipe and the bit in the drill stem to provide weight on the bit. It can be
 cylindrical spiral shape and is threaded at both ends (male and female) to allow
multiple drill collars to be joined above the bit assembly.

• Heavy weight drill pipe is thick-walled tube and is used as transition pipe
between drill collar and drill pipe. In high-angled and horizontal wellbore, it is
used in lieu of drill collars.

• Subs are short component of the drill string, threaded piece of pipe used to adapt
parts of the drilling string that cannot otherwise be screwed together because of
difference in thread size or design.

2.1.6. Tubular handling equipment is made of the following equipment:

• Elevator clamps that grip a stand of casing, tubing, drill pipe or drill collars so
that the stand or joint can be lifted and lowered into the wellbore opening of the
rotary table. The elevators are connected to the travelling block by means if bails,
which are solid steel bars with eyes at both sides. Elevator could be side door,
centre latch or single joint types.

• Elevator links is device designed to support the elevators and attach them to the
hook.

• Slips are a wedge – shaped piece of metal with teeth or other gripping elements
that supports and transmits the weight of the drill string to the rotary table and are
used to hold the pipe in place as well as to prevent pipe from slipping down inti
the borehole. Different types of slips are used during oil well drilling such as drill
pipe, drill collar or casing slips.
 • Safety clamp is a mechanical device used on tubulars above the slips and is used
to keep parts of the tool string from falling down the wellbore if other safety
measures fail.

• Tongs are large wrenches used to make or break out tubular. It must be used in
opposing pairs-make up or breakout tongs to make or break connection.

• Drill pipe spinner is a pneumatically operated device usually suspended on the

rig floor used to make fast connections and spin off of drill pipe.

• Iron roughneck is a pneumatically operated machine that replaces the functions

performed by the Kelly spinner, drill pipe spinner and tongs and is used to
connect and disconnect tubular.

Drill bits are cutting tools used to create cylindrical holes. Bits are located at the bottom
of the drill string and are suited for particular conditions, such as formation, which is to
be drilled .These are three different types of bit designs, such as:

• Roller cone bits with milled tooth or tungsten carbide insert (TCI) could have
2-6 cone-shaped steel devices that are free to turn as the bit rotates.

• Fixed cutter bits could be drill bit or core bit. The first one could be
polycrystalline diamond compact bit (PDC-bit),surface set diamond bit and
impregnated diamond bit. It consists of bit bodies and cutting elements
integrated with the bit bodies and do not have moving parts.

• Hybrid bits combine both rolling cutter and fixed cutter elements.

If the drilling bit needs to be changed, the whole string of pipe must be raised to the
surface.
Parts of the Bit.

• Shank- threaded part of the bit.

• Bit lug- the part that houses the cone.

• Bit cone-the part that houses the teeth.

• Bit nozzle- the circulating element.

2.2. Production Workshop/Flow Station.

An oil production plant (sometimes called an oil terminal) is a facility which performs
processing of production fluids production fluid from oil wells in order to separate out
key components and prepare them for export. This distinct from oil deport, which does
not have processing facilities. There are three components of surface production
equipment:

• 2.2.1. Wellhead

The wellhead is the equipment at the surface that provides support for the tubulars
inside the well, a pressure seal between the tubulars, and a means of controlling
production from the well. Typically, the wellhead consists of a casing head for
each casing string, a tubing head, and a Christmas tree. For each string of pipe in
the well, casing or tubing, some means of support and pressure sealing must be
provided which are mainly casing hanger and tubing hanger. This is the function
of the casing and tubing heads. The casing head annular valve allows one to flow
in gas into the annulus between the tubing and the inner diameter of the casing.
The tubing head annular valve allows one to flow in gas into the tubing where we
need to reduce gas to reduce the viscosity of the fluid in the tubing. The Christmas
tree provides the necessary valving and chokes to control the production from a
well capable of flowing. For a well that is being pumped, the Christmas tree is
replaced by the wellhead equipment that accommodates the pumping operation.

The valves are wing valve, master valve and swab valve. The wing valve allows
the flow of fluids from the Christmas tree to the strings; long string (lima) and
short string (serial). The wing valve of the long string is usually lower than that
of the short string. The master valve allows the flow of fluids from the reservoir to
the surface. The master valve of the Christmas tree is shut in when the reservoir is
 to be shut down permanently while the wing valve is shut when the reservoir is
temporarily shut down. The type of valve used in the Christmas tree is the non-
throttling valve. For a well that is being pumped, the Christmas tree is replaced by
wellhead equipment that accommodates the pumping operation.

A choke is provided to control the rate of production from the well in addition to
the tubing wing valve, which provides for a complete shut off of the production.
The choke can be either fixed or variable in size. The choke is nothing more than
a small orifice, usually from 1/8 to 3/4 in. in diameter that restricts the flow rate.

• 2.2.2. Separators and Heat Treaters.

Once liquids are brought to the surface, the oil, gas, and water must be separated
for ease of measurement and transportation. A separator is a vessel used to
separate liquid from gas. In some cases, the liquid may be additionally separated
into individual oil and water streams.

A heat treater is simply a separator that is designed to separate primarily oil from
water. Heating of the mixture normally speeds up and improves the separation
process. It is simply a separator in which a firetube has been placed to heat the
liquid mixture as it enters the vessel. Several processes are usually used in the
separation which are; gravity setting, centrifugal force, impingement, electrostatic
precipitation, filtration and heat.

The design of a particular separator depends on the nature of the flow stream to be
separated. For a gas well, the separator usually separates a small amount of liquid
from the gas. In an oil well, the separation may involve a small amount of gas for
the amount of liquid. In general, the well stream separator must separate the
mostly liquid fluids from the mostly gas fluids .In addition, it must separate liquid
hydrocarbon from liquid water and remove most of the entrained liquid mist from
the gas.
 To accomplish the separation, the separator is usually designed to control and
dissipate the well stream flowing energy. Once gas and liquid velocities are slow
enough, gravity causes the liquid to settle and the gas to rise. The size of the
vessel must be such that adequate time is allowed for this settling to occur before
the fluid leaves the separator. If water is to be separated from oil, then the liquid
residence time depends on the volume of the fluid being handled and the specific
gravity of the two liquids. Many times, a mist extractor composed of vanes, mesh
pads, or a cyclonic passage is used to remove residual liquid droplets from the gas
stream.

There are three types of separators; vertical, horizontal and spherical. Horizontal
separator are found in both the single and double tube design.

• 2.2.3. Tanks and Metering.

Tanks must be provided to hold both oil and water for shipping or disposal.
Usually, at least two oil tanks are used, one for shipping and one for filling. The
tanks are of two types; fixed roof and floating roof. The volume of oil being
shipped is sometimes determined by simply measuring the height of the fluid in
the tank, or “strapping” the tank. Many of the more modern production facilities
have lease automatic custody transfer (LACT) units installed. These stations
continuously measure the flow into the shipping point and periodically sample the
product being shipped so that oil gravity, temperature, pressure, and water content
are known. The metering in this case is done with a positive displacement meter.
The tanks are protected by a bond –wall so as to contain spillage. It also has a
manhole that allows a person in during maintenance, a lightening system, and a
hand ray.

The measurement of gas is usually done with an orifice meter. For a given meter,
the gas flow rate depends on the pressure on both sides of the orifice and the
temperature of the gas. These pressures and temperatures are normally recorded
on a circular chart. This chart is later used to determine the total gas flow over a
particular time period. Many installations today have digital flow calculating and
recording devices installed at the meter. These installations have proven to be
accurate and they provide for the telemetering of the flow information from a
remote installation.

OPERATIONS.

I and the fellow interns were given a first-hand demonstration on the process of
changing the orifice plate of the orifice meter. The orifice meter has orifice plate
of different sizes which is determined by the size of pipeline and the pressure of
gas being flowed. The orifice meter consist of the seal at the upper and lower
region of the meter, equalizing and build up valve .When changing the orifice
plate, the equalizing valve is always opened to ensure that there is no pressure
build up in any section of the orifice meter. The orifice plate has an inlet and
outlet; with the outlet having a groove on it. When changing the orifice plate, the
inlet of it faces the inflow direction of the fluid while the outlet follows the
outflow direction of fluid. A chart is used to record the result with a clock and two
pointers one with red and the other with blue.

Also we the interns and company trainees were given the opportunity to change
the beam size of the Christmas tree. A downvalve attached to the flowline string
was shut down and the wing valve of the Christmas tree was bled of any stored
fluid before the beam was changed. The person changing the beam stands at the
side of the choke to avoid coming in contact with compressed fluid pressure.

Finally we carried out maintenance activities on the Christmas tree. The valves
were removed and greased to allow for easy movement during the regulation
process. Corrosion control activities were also done by us as we painted the
pipelines of the flow station after scrubbing away the rust.

2.4. PATH OF FLOW IN FLOW STATION.

The fluid flows from the reservoir to the surface through the wellhead, tubing
head and Christmas tree. On getting to the surface, the fluid goes through the
wing valve to the two dual strings (long and short string) of the flow station to the
choke manifold system; Hp, Lp and Test manifold. From the manifold system
flows to the bypass line; Hp, Lp and Test manifold which has the Instrumentation
line or pneumatic line that is used to monitor the flow of fluids in the entire flow
station. The Instrumentation line is connected to the contromatic unit which is
used to monitor flow automatically. The bypass line is connected to the separators
accordingly: Hp, Lp and Test separator. The separator uses baffles to reduce the
pressure of the fluid as part of the separating process. Finally the separators are
connected to the surge tanks and from there it leaves to the terminal where are
transferred from the flow station the Group Gathering Facility (GGF).
 3.0 CHAPTER THREE.

3.1. Production Laboratory.

Drilling Mud/Fluid.

We cannot talk about mud without mentioning clay. There are basically four types of clay
which are: Illite, Kaolinite, Vermiculite, and smectite clay. For drilling mud we are
concerned with smectite as it swells in contact with water. The mineral bentonite falls
under such and it was first found in France, Font Benton and it was named bentonite.
America discovered in Wyoming and it was named Wyoming bentonite. It is formed
from weathering volcanic ash. It has some exceptional properties: when stirred into
water, it demonstrates a so-called thixotropic reaction. It reacts as a fluid when
mechanically stressed. However, it hardens in quiescent condition because its viscosity
increases.

In geotechnical engineering, drilling fluid, also called drilling mud, is used to aid the
drilling of boreholes into the earth. Often used while drilling oil and natural gas wells and
on exploration drilling rigs, drilling fluids are also used for much simpler boreholes, such
as water wells.

The three main categories of drilling fluids are: water-based muds (WBs), which can be
dispersed and non-dispersed; non-aqueous muds, usually called oil-based muds (OBs);
and gaseous drilling fluid, in which a wide range of gases can be used. Along with their
formatives, these are used along with appropriate polymer and clay additives for drilling
various oil and gas formations.

The main functions of drilling fluids include providing hydrostatic pressure to prevent
formation fluids from entering into the well bore, keeping the drill bit cool and clean
during drilling, carrying out drill cuttings, and suspending the drill cuttings while drilling
is paused and when the drilling assembly is bought in and out of the hole. The drilling
fluid used for a particular job is selected to avoid formation damage and to limit
corrosion.

3.2. Functions of the Mud in the Wellbore.

• Remove cuttings from well.

• Suspend and release cuttings.

• Control formation pressures.

 • Seal permeable formations.

• Maintain wellbore stability.

• Minimizing formation damage.

• Cool, lubricate, and support the bit and drilling assembly.

• Transmit hydraulic energy to tools and bit.

• Ensure adequate formation evaluation.

• Control corrosion (in acceptable level).

• Facilitating cementing and completion.

• Minimize impact on environment.

Chemical Additives.

Broad classes of water-based drilling- fluid additives are in use today such as;

Weighting Agents: The most important weighting additive in drilling fluids is barium
sulphate (BaSO4). Barite is a dense mineral comprising barium sulphate. The specific
gravity of barite is at least 4.20g/cm3 to meet API specifications for producing mud
densities from 9 to 19Ibm/gal.

Fluid-Loss-Control Additives: Clays, dispersants, and polymers such as starch are

widely used as fluid-loss control additives. Sodium montmorillonite (bentonite) is the
primary fluid loss control in most waterbased drilling fluids.

Thinners or Dispersants: Although the original purpose in applying certain substances

called thinners was to reduce flow resistance and gel development, the modern use of
dispersants is to improve fluid loss control and reduce filter cake thickness. Dispersants
are chemical materials that reduce the tendency of the mud to coagulate into a mass of
particles or floc cells. Quebracho is an example.

Lost – Circulation Materials: In mud parlance, losses of whole drilling fluid to

subsurface formation are called lost circulation. Circulation in a drilling well can be lost
into a highly permeable sandstones, natural or induced formation fractures, and
cavernous zones; such a loss is generally induced by excessive drilling-fluid pressures.
Commonly used materials include fibrous materials (such as wood fibre, cotton fibre,
mineral fibre,) granular material (such as nutshell).
Surfactants or Surface Active Agents: A surface-active agent is a soluble organic
compound that concentrates on the surface boundary between two dissimilar substances
and diminishes the surface tension between them. They are commonly used in the oil
industry as additives to water based drilling fluid to change the colloidal state of the clay
from that of dispersion to one f controlled flocculation.

Various other additives. There are a plethora of other additives for drilling fluids. Some
are used for pH control- that is chemical reaction control (inhibit or enhance) and drill
string corrosion mitigation. There are bactericides used in starch-laden fluids (salt mud in
particular) to kill bacteria. There are corrosion inhibitors, especially H 2 S scavengers.
There are defoamers to knock out foaming agents and foaming to enhance foaming.
There are also lubricants for torque and drag reduction as well as pipe freeing agents for
when a drill string is stuck.

3.3. Mud Engineer.

A person responsible for testing the mud at a rig and for prescribing mud treatments to
maintain mud weight, properties and chemistry within recommended limits. The mud
engineer works closely with the rig supervisor to disseminate information about mud
properties and expected treatments and any changes that might be needed. The mud
engineer also works with the derrickman, who is charged with making scheduled
additions to the mud during his work period.

3.4. Experiments/ Analysis.

3.4.1. Crude Oil Test.

Basic sediment and water (BS&W) is a technical specification of certain impurities in

crude oil. When extracted from an oil reservoir, the crude oil will contain some amount
of water and suspended solids from the reservoir formation. The particulate matter is
known as sediment or mud. The water content can vary greatly from field to field, and
may be present in large quantities in older fields. The bulk of the water and sediment is
usually separated at the field to minimize the quantity that needs to be transported. The
residual content of these impurities is measured as BS&W. Oil refineries may either buy
crude to a certain BS&W specification or may alternatively have initial crude oil
dehydration or desalting process units that reduce the BS&W to acceptable limits.
Methods used in determining BS&W are centrifuge method, distillation method; also
called dean and stark method and karl firsher method also called titration method.

3.4.2. Procedure for Centrifuge Method (BS&W).

• Agitate sample to homogenise.

• Pour in 10ml of the sample into the centrifuge tube and put into the centrifuge
jacket.

• Fix in the crank and start cranking for 5mins at 500rpm. (When using the manual
centrifuge machine.)

To get the volume of the impurity;

× =%

Methods of Determining Specific Gravity and API Gravity.

• The Hydrometer Method.
• The Relative Density Method.

3.4.3 Procedure for Specific Gravity using Hydrometer Method.

• Agitate the sample to homogenise.

• Pour the sample into 3/4 of the measuring cylinder.

• Use a thermometer to check for the temperature.

• Dip the hydrometer into the measuring cylinder to get the

reading.
Using the formula:

= ± 4×ΔT (0.74 – 0.84)

=± 3.5×ΔT (0.84 – 0.94

API Gravity Determination.

API= ˗ 131.5

Crude Oil API classification.

• Heavy oil: 10 - ≤20.

• Intermediate: 20 - ≤29.

• Light: 30 - ≤50.

• Condensate: 52

• Procedure for Relative Density.

• Take the weight of the empty density bottle.
 • Take the weight of the density bottle and water.

• Take the weight of density bottle and crude oil.

Weight of Crude Oil= Weight of density bottle and crude oil –

Weight of empty density bottle.

Weight of Water= Weight of density bottle and water– Weight of

empty density bottle.

Relative Density=

3.5. Emulsion.
Emulsions are mostly caused by the presence of emulsifiers (such as
asphaltenes, Iron and certain cations). Improper well completion such as
failure to clean the well after cementation, the cement washes into the
formation and mixes with the oil to form emulsions. Sometimes emulsions
are not formed at the reservoir, they are formed as a result of vigorous
agitation during transportation to the surface.
Surfactants such as separol are used to separate the emulsion and the
separator does the final separation.
3.5.1 Procedure For Emulsion Test.
• Take 100ml of the crude oil & mix with 100ml of toluene in a beaker.

• Add a demulsifier to the mixture.

 • Put the mixture in a waterbath and heat to the temperature present in
the field (storage tank) for 30mins to 1hr.

• Then take it to the centrifuge machine and spin to get the emulsion

separated to the bottom of the tube.

All these test are done; BS&W, Specific gravity and API gravity, and

Emulsion test so as;

• To determine the commercial viability of a given well.

• For the safety of the producing equipment.

• To determine the productivity of each well on a daily basis.

3.6Mud Formulation and Analysis.

350 ml of water is used to formulate drilling mud in the laboratory + either:

• 350 ml + 17g of clay –Low Viscous mud.

• 350 ml + 21g of clay –Medium Viscous Mud.

• 350 ml +24.5g of clay – High viscous mud.

This process gives a laboratory barrel of drilling mud. In the rig, a filed

barrel of drilling mud is formed and 10% of the cost of drilling a well is

spent on mud.

3.6.1 pH Test.
The pH test is carried out to determine the alkalinity of the mud as it helps
in controlling corrosion and enhancing or inhibit chemical reaction. Sodium
hydroxide is the basic pH enhancer.
Apparatus/Materials.
Bentonite clay, pH paper, Water, Multimixer, Beakers and local pH
enhancer such as Cow bone, Rock salt and Egg shell.
Procedure.
• Formulate 24.5g of clay with 350ml of water using the multimixer
(blank no additive).
• Formulate 24.5g of clay with 350ml of water using the multimixer,
with the additive cow bone (0.2g to 1g).

• Formulate 24.5g of clay with 350ml of water using the multimixer,

with the additive rock salt (0.2g to 1g).

• Formulate 24.5g of clay with 350ml of water using the multimixer,

with the additive egg shell (0.2g to 1g).

• Test for the pH of all samples using pH paper for a week to observe
the effect of the pH enhancer.

Result.

The pH of the blank sample was observed to be 8 while the sample

with the additives were observed to be 9.5 to 10 as it increases
progressively on a daily basis.

3.6.2. Fluid Loss Control Test.

In carrying out drilling operation in a site, there is a need of drilling
fluid to be pumped into the wellbore via the drill string, with the
purpose of taking out the cuttings generated by the drill bit while
crushing the formation.

However, during this process of the drill mud carrying the cutting
from hole to the surface, the loss of the drilling mud into the
formation which has an adverse effect to the formation, contributing
to the fact that it is not economical in terms of financial cost.
 Apparatus/Materials.
Corn starch (grinded), Cassava starch (grinded), Potato starch
(grinded), Beaker, Filter Press, Nitric acid, Multimixer.

Procedures.
• Insert the cartage and then tape onto the filter press.

• Set the pressure gauge to be 100psi.

• Pour the sample (additives + mud) into the sample cup and hook it up
to the filter press.

• Place the beaker underneath the sample cup.

• Set a particular and desired duration of time.

• Loosen the nut on the cup sample so as to permit flow of the fluid that
could be lost with the given time.

• Then take the measurement of fluid loss volume.

• Remove the filter cake.

• With aid of Vernier calliper, measure the thickness of the filter cake.

Table.
Sample 1.

Material. Quantity. Water. Nitric Acid.

Cassava starch. 50g 10ml 5ml

Corn starch. 50g 10ml 5ml

Potato starch. 40g 10ml 5ml

Sample 2.

Material. Quantity. Water. Nitric Acid.

Cassava starch 50g 5ml 5ml

Corn starch 50g 5ml 5ml

Result.
From the size (thickness) of the filter cake, the drilling mud can be used to
control filter loss in the formation.

Other types of test carried out in the Laboratories by us interns were the
Rheology test, sand content test.
 4.0 CHAPTER FOUR.
RECOMMENDATION.
The Student Industrial Work Experience Scheme is a great platform
provided by the Federal Government of Nigeria to breach the gap between
the academic world and the industries. However provision should be made
the Federal Government in fixing students to various companies and
institutions just as we have the NYSC scheme of Nigeria. Furthermore the
Federal government and the companies and institutions involved should put
into consideration the remuneration of the interns during the period of the
internship.

CONCLUSION.
In conclusion the Student Industrial Work Experience Scheme was a huge
success for me. The experience for me was amazing as it beats my
expectation. I was brought face to face with the beauty of my Course
Petroleum Engineering as I was exposed constantly to field operations and
analysis. The exposure to field operators during their short courses at PTI
was a stunner for me as it gave me a new and better perspective of the Oil
and Gas sector.
Indeed internship for me was a success as it gave a redefinition to a lot of
things for me.

REFERENCES.
• https://www.researchgate.net/publication/32298741 Petroleum-Extraction-
Engineering.

• http://www.iado.org/safety- meeting-topics/blowout-prevention.

• http://en.m.wikipedia.org/wiki/oil_production plant.

• http://www.advancedsciencenews.com/bentonite-drilling mud.

• http://www.glossary-oilfield.slb.com.en/Terms/m/mud engineer.aspx.

• http://en.m.wikipedia.org/wiki/Drilling fluid.