Page | 1

LIST OF CONTENTS
LIST OF FIGURES
ABSTRACT
1. INTRODUCTION
2. PLANT DESIGN CAPACITY
3. PRODUCTION RATE
4. RAW MATERIAL TYPE & QUALITY
5. QUALITY PARAMETERS
6. PROCESS FLOW DIAGRAM
7. PROCESS DESCRIPTION OF REFINERY
CRUDE &CONDENSATE STORAGE
CRUDE CHARGING & PREHEATING
CRUDE DESALTER UNIT
CRUDE FURNACE
ATMOSPHERIC CRUDE COLUMN
INDIVIDUAL DRAW OUT SECTION
8.GAS COLLECTING STATION
9.WELL CONTROL TECHNIQUES
10.WELL CONTROL EQUIPMENTS
11.CLASSIFICATION OF BLOW OUTS
12.IMPACT OF BLOWOUTS
13.BLOWOUT CONTROL EQUIPMENT
14.BLOWOUT CONTROL PROCEDURES

Page | 1
 Page | 2

LIST OF FIGURES

ACKNOWLEDGEMENT

Page | 2
 Page | 3

It would not have been possible without the kind support of many individuals in the
course of completion of this project. I would like to extend my sincere thanks to all
of them.

I am very thankful to my project guide Shri.Y.N.Rao for his support , guidance,

inspiring collaboration , his very sincere efforts to impart me with skills essential for
chemical engineers and also for his insightful suggestions.

I would like to express my gratitude towards , for approving and allowing me to

carry out the project work.

I thank especially who supervised me through out my stay which lead to the success
of my internship.

Finally my sense of gratitude would be incomplete without acknowledging the efforts

of Our Programme director ,Prof. P. V. N. RAO ,Faculty advisor Prof. K. V. RAO and
Head of the Department , Shri. L. VINOD BABU, to encourage me to take up this
intern.

VANKAYALA PADMA SRI PRAGNA

(13021A2527)

INTRODUCTION

Page | 3
 Page | 4

The O.N.G.C. Krishna-Godavari (K.G.) Project operates around the Krishna-

Godavari Basin in the inland as well as in the offshore area.
The corporation felt need for a refinery in the state for the following reasons:
It would help save substantial transportation cost of crude oil , which was earlier being
sent to VIZAG refinery.

1) To minimize safety hazards otherwise involved in long distance

transportation.
2) To ensure uninterrupted availability of the petro products.
3) To help decongest roads in the region by minimizing vehicular movement.

The corporations plan to set up a refinery bore fruit on September 3,2001 by the
inauguration of MINI-REFINERY at Tatipaka, Nagaram Village in East Godavari district
of Andhra Pradesh.

The Mini-Refinery is the first of its kind in Asia, a RELOCATABLE SKID MOUNTED
UNIT and is set up in a very compact area of 350m*150m and houses the sophisticated
Distributed Control System (D.C.S.) for the process dynamics control.

PLANT DESIGN CAPACITY:

The unit normal capacity will have 1500barrels per day (bpd) with feed corresponding to
CASE-1 and CASE-2. The maximum capacity will have 2000bpd. The minimum capacity
will have 1000bpd.
Page | 4
 Page | 5

CASE-I: CRUDE-30% CONDENSATE-70%

CASE-2: CRUDE-70% CONDENSATE-30%

PRODUCTION RATE(TPD):

NAPTHA 97.248 80.712

KEROSENE 74.208 74.496
DIESEL 46.128 37.776
RCO (L.S.H.S.) 32.352 63.576

TOTAL 249.94TPD 256.56TPD

LOSS 2.76TPD 1.74TPD

Page | 5
 RAW MATERIAL - TYPE & QUALITY

The raw material is PARAFINNIC-BASE TYPE CRUDE categorized as LIGHT

CRUDE OIL.
QUALITY PARAMETERS:

PHYSICAL PROPERTIES:

PARAMETER Case-I Case-2

Viscosity at 400C 1.78cst 2.544cst

Temperature 46.5oC 42.58oC

Sulphur 0.02% by weight 0.021% by weight

Salts 4ptb 3.75ptb

Reid vapor pressure 5.2psi -------

Pour point -6oC 21oC

Metals-Vanadium <1ppm 0.01ppm

Metals-Iron <0.5ppm 6.83ppm

Metals- Nickel <1ppm 0.39ppm

Density at 15oC 0.795g/cc 0.812g/cc

Carbon residue 0.45% by weight 0.38% by weight

PROCESS FLOW DIAGRAM
Fig-1PROCESS DESCRIPTION

The refinery processes a normal quantity of 1500bpd of crude and condensate

with a maximum processing capacity of 2000bpd.

CRUDE & CONDENSATE STORAGE:

Crude/condensate is brought from nearby fields through tankers. It is stored in storage
tanks, one of 5000KL capacity and two of 1000KL capacity.

5000KL CRUDE

1000Kl CRUDE

1000Kl CONDENSATE

They are mixed in the desired ratio and fed to the preheater by pump.

CRUDE CHARGING & PRE-HEATING:

Crude/Condensate from the storage tanks is pre-heated by two systems of heat
exchangers (Hair-Pin Type).
In the first system of pre-heating Crude/Condensate is made to exchange heat
with Kerosene, Diesel and RCO (L.S.H.S./cold) product streams in the respective
three heat exchangers. The crude is preheated to the optimum temperature
requirement of 1190C.
In the second system of crude pre-heating, allowing it to exchange heat with
Kerosene Circulating Reflux (CR), RCO product (hot) and Diesel Circulating Reflux
streams, pre-heating of crude occurs.
Crude/Condensate mixture, which 0
initially enters at 35oC into this pre-heating
system, leaves the system at 210 C.
 Fig-2

CRUDE DE-SALTER UNIT:

The feed to desalter is heated to 119 oC and water is injected at a rate of 4% to 7%
of the feed volume by desalter water pump into the crude charge line upstream of
the mixing valve. The desalter produces desalted crude of 1.0 ptb(max) salt
content by single stage dual field electrical process.
Salt in the crude gets dissolved in the wash water and forms an emulsion. The
emulsion is broken by a high potential electric field(16000-35000 V) across a desalter
to coalesce the drops of salty water. The water phase is controlled by Interphase level
controller. Brine leaving desalter is sent to effluent treatment plant.

Fig-3
CRUDE FURNANCE:
The desalted
o
crude from the desalter unit is further heated up to a temperature
of 220 C by successive heat exchangers where in kerosene circulating reflux at
185 oC , Diesel circulating reflux at 254 oC and RCO product at 320oC
respectively is used as heating medium. The heated crude is fed into the
furnace. By this operation, the Crude gets partially vaporized, gaining a
temperature of 330oC.
The furnace is fired with fuel gas (NATURAL GAS) controlled by the Coil
Outlet Temperature Controller (C.O.T.) that is cascaded with a pressure controller
on the fuel gas line.
Along with Crude/Condensate mixture feed, de-mineralized (D.M.) water form the
boilers in the form of saturated steam is also superheated in the furnace for routing it
to the crude column and also the strippers.

Fig-4

ATMOSPHERIC CRUDE COLOUMN:

The Crude Column operates at Atmospheric pressure and fractionates the Crude
Oil into Naphtha, Superior Kerosene Oil (Kerosene), Diesel and Low Sulphur
Heavy Stock (L.S.H.S./R.C.O.) products. This column is provided with forty-nine
(49) trays. Partially vaporized steam form the furnace enters the column on the tray
number-44 from the top. The region between the 43 rd and 44th trays is the
FLASHING ZONE. The significance of Flashing Zone is that it is the zone (of
length 2.5m) wherein the partially vaporized (85%vapor-15% liquid) Crude feed
(entering the column at pressure of 2.5kg/cm2) by difference in pressure of column
(0.8kg/cm2) separates out into vapor and liquid components.
Fig-5

Atmospheric crude column Temperature range(0C)

Sections

Tower overhead 108 111

Heavy naphtha draw 126 129

Kerosene draw 178 181

Diesel draw 265 271

Bottoms 325 344

EFFLUENT TREATMENT PLANT OPERATION
The process effluent Oily Water Sump (O.W.S.) generated at Tatipaka Refinery &
G.C.S. is collected through a system of underground pipe network and is brought to the
OWS pit. Mainly suspended solids, biological oxygen demand, phenolic compounds
and chemical oxygen demand contaminate the effluent. Then a transfer pump through
oil catcher to waste water treatment pump available in the plant transfers the effluent.
The oil catcher utilizes the density differences between oil and water, thus separating
oil. The oil in water will attain a constant rising velocity when the resistance to motion
caused by the water is equal to the rising force created by the density difference. In the
oil catcher, the oil floats on the surface and gets periodically removed by slotted pipe
skimmer mechanism.
The process effluent from oil catcher is brought to the receiving sump where alkali is
added to adjust the pH of the effluent. The neutralized effluent is then taken to the
primary clarifier to achieve primary settling and thus removing part of the suspended
solids. The objective of treatment by clarifier is to remove readily settle able solids and
thus to reduce the suspended solids content. Primary clarifier is used as a preliminary
step in the further processing of the wastewater. The clarified effluent from sump is
taken for biological treatment.
The settled sludge form clarifier is taken to sludge sump for further processing. The
treated effluent is injected to the dry wells and part of it is used for Green-Belt
Development around the Plant.
Report of Effluent Treatment Plant:

Characteristic Perm. limit IS- Perm. Limit Achievement

2490 CPCB

PH (ppm) 5.5-9.0 5.5-9.0 8.4-8.7

C.O.D.(mg/l) 250 100 88

B.O.D.(mg/l) 30 30 30

Oil + Grease 10 10 4

Phenols 1 1 -nil-

INDIVIDUAL DRAW-OUT SECTIONS

 OVERHEAD SECTION:

The overhead vapor from the crude column at 114 oC is withdrawn under pressure
control and is condensed and cooled in overhead condenser to 55oC.
The condenser utilizes cooling water as the cooling medium. This condensed
overhead product separates out as hydrocarbons and water in the overhead
accumulator. Water is withdrawn from the boot under level control and sent to the
Effluent Treatment Plant for treatment.
Part of the unstabilized Naphtha from the accumulator is pumped under level
cascaded flow control by crude column overhead pumps to naptha stabilizer and the
rest is sent back to the Crude column as reflux.
Crude column top temperature & reflux controller sets reflux demand. A Split Range
Pressure Control maintains the column overhead pressure by controlling fuel gas
make-up and vapor to flare.
HEAVY NAPHTHA SECTION:

Heavy Naphtha is withdrawn as side product from tray#11 of the crude column at a
temperature of 144oC under level control of Side-Stripper bottom.
Light ends in the Heavy Naphtha Steam are stripped in Heavy Naphtha Side-
Stripper using superheated steam. Stripped vapours routed back to tray#9 of the
crude column.
The bottom product, Heavy Naphtha is pumped by gear pumps and cooled in the
Heavy Naphtha Cooler using cooling water. It is mixed with Stabilized Naphtha in
the Naphtha Storage Tanks.
KEROSENE SECTION:

Kerosene (as Superior Kerosene Oil, S.K.O.) is withdrawn as a side product form
chimney tray, which receives liquid from tray#22 of the crude column at a
temperature of 186.7oC under level control of Side-Stripper bottom. Light ends in the
Kerosene stream are stripped in the Kerosene side stripper using super heated LP
steam.
Stripped vapours are sent back to tray#19 of the crude column. The hot bottom
product of Kerosene Stripper is pumped by gear pumps, under flow control to the
crude pre-heating train to exchange heat with Crude in Crude/Kerosene exchanger.
The Kerosene product gets cooled to 60oC in the preheat train and further cooled in
Kerosene product Cooler to 40oC using cooling water. The cooled product is stored is
stored in Kerosene Storage Tanks.
DIESEL SECTION:

Diesel is withdrawn as a side product from tray#35 of the Crude column at a

temperature of 290oC under level control of Side-Stripper bottom. Light ends in the
Diesel stream are stripped in the Diesel Side-Stripper using superheated steam. Stripped
vapors are sent back to the tray#32 of the crude column. The hot bottom of the Diesel
Stripper is pumped by Diesel Product gear pumps under flow control to the Crude pre-
heating train to exchange heat with the Crude in the Crude/Diesel Exchanger. The
Diesel product gets cooled to 53oC in the preheat train and further cooled in Diesel
Product Cooler to 40oC using cooling water. The cooled product is stored in Diesel
Storage Tanks.

LOW SULPHUR HEAVY STOCK SECTION:

Stripped RCO at a temperature of 330oC is withdrawn from the bottom of the Crude
column under level control cascaded with flow control. It is pumped R.C.O. centrifugal
pumps to the crude pre-heat train. This hot R.C.O. exchanges heat with Crude in
Crude/RCO (hot) exchanger and Crude/RCO (cold) exchanger and in turn gets cooled
to a temperature of 110oC in this pre-heating section. RCO is sent to the Storage Tanks
provided with Steam Heating Coils to avoid R.C.O. congealing.

CIRCULATING REFLUXES:

In order to maximize the heat recovery and balance the tower loading, heat is
removed by way of Circulating Refluxes (pump around) from Kerosene and
Diesel Sections.
Kerosene Circulating Reflux (C.R.) is withdrawn from the Crude Column at
186.7oC. It is pumped by Kerosene centrifugal pumps to the crude pre-heating
section where it exchanges heat with Crude in Crude/Kerosene C.R. exchanger.
The Kerosene C.R. is routed back to the Crude Column. A flow controller
controls the C.R. draw rate.
Diesel Circulating Reflux (C.R.) is withdrawn from the Crude column at 250oC.
It is pumped by Diesel C.R. centrifugal pumps to the Crude preheat section
where it exchanges heat with the crude in the Crude/Diesel C.R. exchanger. The
Diesel C.R. is routed back to the Crude column. A flow controller controls the
C.R. draw rate.
CHEMICAL DOSING FACILITIES:

The following Chemical Dosing Facilities make up for the UNIT PROCESSES in the
Refinery:

1) AMMONIA:

Pumps to Crude column Overhead and Reflux lines pump 2-5% solution
of Ammonia in service water.

2) De-EMULSIFIER:

Pumps to Crude line pump de-emulsifier solution upstream of the De-Salter.

3) CORROSION INHIBITOR:

Diluted Corrosion Inhibitor (3% solution) is properly mixed with Diesel

and is injected by pumps to control Corrosion due to presence of water
in this line.
NAPHTHA STABILIZER:

The unstabilized Naphtha from the Overhead Naphtha Accumulator of the Crude
column is stabilized by removal of light ends in the Naphtha Stabilizer Column. The
light ends are recovered as fuel gas and stabilized Naphtha at 168 oC is obtained from the
bottom of the column under level control. The necessary heat to the vertical reboiler
(Thermosyphon Reboiler) is provided by Diesel Circulating Reflux under temperature
control of the Naphtha Stabilizer bottom. The stabilized Naphtha is further cooled in
using cooling water and sent to Storage Tanks.

The column is provided with a Stub-In Exchanger to condense the overhead vapor.
Water is used as the cooling medium and water flow is controlled by column top
temperature control. The Off-gas from the top of the column is sent to the fuel gas
system. Column pressure is controlled by a pressure control provided on the fuel gas
line.
The various flow streams and their flow rates are as follows:

Normal flow streams Flow rates(m3/hr)

Crude feed 13.2

Desalter wash water 0.8

Crude column reflux 10.03

Heavy naphtha product 1.6

Kerosene product 3.9

Kerosene CR 12.75

Diesel product 2.3

Diesel CR 18.5

RCO product 3.0

Stabilizer light naphtha 3.75

 GAS COLLECTING STATION
Fig-6
LP AND HP HEADERS:
Liquid and Gas mixture which is coming from different wells are diverted to two headers,
namely a LP header and a HP header depending upon the amount of liquid and gas which
are measured by the pressure gauge. The mixture from LP header is directly sent into the
bath heater while the mixture from HP header is sent into the HP separator.

HP SEPARATOR:
The mixture from HP header whose pressure is greater than 40 kg is sent into HP separator
for separation of liquid and gas. The gas which is separated in this will have a pressure as per
the requirement of GAIL (Gas Authority Of India).This gas is sent into the filter separator
where the further separation process takes place and the gas is sent to GAIL. The liquid
which is present is sent to the bath heater.

LP SEPARATOR:
The mixture from bath heater is sent into LP separator. Here the separated liquid is sent into
heater treater while the separated gas which is having a low pressure is used in 3 ways:

To local consumers.

Inplant use.
If the consumer extracts lesser gas, to handle the back pressure, to nullify it, the gas is
diverted to the flare.Also, depending on the quantity of gas left at low pressure, it is sent to
the compressor, is compressed to 45 kg pressure and sent to the GAIL line.

BATH HEATER:

The mixture which is coming from LP header and the liquid from HP header is heated in this
unit. A chemical called DEMULSIFIER is added to this mixture before entering into the bath
heater so as to break the emulsions present in the mixture. Then the mixture is sent into LP
separator.
HEATER TREATER:
The separated liquid which is coming from LP separator is introduced into this. A chemical
called DEOILER is added to this liquid mixture before entering into heater treater so as to
make the liquid mixture to form two different layers namely oil and effluent water. The
separated oil is directly sent to the storage tank. The effluent water is sent to the
ETP(Effluent Treatment Plant) for treatment of water.

RECIPROCATING COMPRESSOR:
To meet the requirements of GAIL the low pressure gas having a pressure of less than 10 kg
is compressed here to around 45 kg and sent to the GAIL line through filter separator.

OIL STORAGE TANK:

The oil which is separated in heater treater and the oil from oil sump in the ETP unit is
stored in these storage tanks. There are two tanks each of 1000 m 3 are available to store this
oil. A new tank of 1000 m3 is under construction.

FILTER SEPARATOR:
The high pressure gas which is coming from the HP separator and the compressed gas
which is coming from the compressor unit is filtered in this unit before finally sending it to
GAIL line.

KNOCK OUT DRUM:

The low pressure gas from the LP separator is sent into this unit where any residual liquid
present is knocked out from the gas. This gas is now used in three ways as mentioned above.
Effluent Treatment Plant (ETP)
From the storage tank the produced water enters to the wash tank. In this tank water wash is
done for produced water and in this tank we maintain retention time of 24hours then pre-
settling of oil takes place. Now the effluent is sent into TPI(tilted plate interception),where
we get maximum oil recovery is obtained because oil particles entrained at the plates which
are tilted at the angle of 45degrees.now the produced oil is sent into sump tank and the
remaining effluent water is sent to flash mixture. Now we add poly aluminium chloride and
de -oiler in flash mixture. It is sent to flocculation tank and there it is sent to DAFT(dissolved
air flotation tank).Air is dissolved in water and is released in DAFT.oil is collected in the tank
and the remaining EFFLUENT WATER is sent to the DMF(DUAL MEDIA FILTER).In this
DMF suspended solids are removed and the oil obtained is sent to oil sump and the effluent
water having the characteristics of

Inlet designed parameters

Oil and grease 300 ppm

TSS 100 mg/lt
PH 5.5 to 9

Outlet parameters

Oil and grease < 10 ppm

TSS < 40 mg/lt
PH 6.5 8.5

With these outlet parameters, the effluent water is injected into the abandoned wells
ETP process flow diagram

Fig-7
1.Tilted Plate Interceptor

Tilted Plate interceptor (TPI) provide economical and effective removal of oil and solids from
wastewater by gravity, in a smooth, efficient automatic flow. With thousands of installations
in operation, this proven design has no moving parts and provides consistent operating results
for simple and better separation. The configuration and number of plates of the units provide
enough effective area for free oil removal down to 15 ppm with greater than 60 micron
removal.

Fig-8
2.FLOCCULATOR
Flocculation, in the field of chemistry, is a process wherein colloids come out of
suspension in the form of floc or flake, either spontaneously or due to the addition of a
clarifying agent. The action differs from precipitation in that, prior to flocculation, colloids
are merely suspended in a liquid and not actually dissolved in a solution

Fig-9

Chemicals added:
Three dosing chemicals are added and mixed in the incoming effluent before the dissolved air
floatation unit

Alum dosing for coagulation

Alkali dosing for ph correction

Poly electrolyte for de-oiling

2.Dissolved Air Floatation Tank (DAFT)

Dissolved Air Flotation is widely used for separating solids, fats, oil, and grease from a
waste stream. In the process, pressurized water is saturated with dissolved air and is
discharged into a flotation vessel. The microscopic air bubbles attach to solids and float them
to the surface, forming a sludge blanket. A scraping assembly skims the sludge off the
surface of the water and into a sump.

Fig-10

3.Dual Media Filter (DMF)

These filters are widely used in the facilities, where the material contains suspended particles,
turbidity and iron The filter "media" start with fine sand on the top and then graduating
coarser sand in a number of layers followed by gravel on the bottom, in gradually larger
sizes. The top sand physically removes particles from the water. The job of the subsequent
layers is to support the finer layer above and provide efficient drainage. Since it is a dual
media filter in ONGC two mediums are observed with the top one being sand and the bottom
one being the anthracite.
WELL CONTROL TECHNIQUES
KICK
It is defined as an influx or flows of formation fluid into the well bore & can occur any time
the formation fluid pressure is greater than the pressure exerted by the mud hydrostatic in the
well bore.

BLOWOUT
It is an uncontrolled flow of formation fluid at the surface or sub surface from the well bore.
A Blow-out is the result of an uncontrolled kick.

PRIMARY WELL CONTROL

During normal drilling operations the hydrostatic pressure of drilling fluid is greater than the
pressure of the fluids in the formation. The maintenance of sufficient hydrostatic head exerted
by drilling fluid to hold back the formation fluid pressure is termed as Primary Well
Control.

SECONDARY WELL CONTROL

If due to any reason hydrostatic pressure in the well bore falls below the formation pressure,
formation fluid may enter in the well bore & if so happens, the primary control may be
temporarily lost and a proper use of blow out preventers & kill procedures will provide
Secondary well control, or in other words secondary well control involves detection & safe
handling of kicks so as to re-establish primary well control.

TERTIARY WELL CONTROL

It involves the techniques used to control a blow-out once the primary & Secondary Control
are lost. This primarily involves a re-establishment of the secondary control system such as :
the well bore conduit, well head & BOP equipment & subsequently establishing the Primary
Control.

PRESSURE

The term pressure is defined as force exerted per unit area. The field unit for pressure is psi.
Various pressure terms used in well control are discussed below:

Hydrostatic Pressure

It is the pressure exerted by a static column of fluid by virtue of its density. Or it can be
termed as the pressure due to static effect of a fluid column. It depends on the vertical height
(TVD) of the column and the density of the fluid.

Depth TVD(M ) x Mud density (gm/cc)

Hydrostatic pressure (kg/cm) =

10
Hydrostatic pressure (psi) = Depth-TVD (ft.) x Mud Density (ppg) x 0.052

Bottom Hole Pressure ( BHP )

It is defined as sum total of all pressures i.e. static , surface as well as dynamic pressures that
are being exerted at the bottom of the hole :

BHP = Hydrostatic Pressure + Surface Pressure Dynamic Pressure

Dynamic pressures are exerted by either due to fluid movement (Annular pressure losses) or
pipe movement in the well bore (Swab/ Surge pressure).
 WELL CONTROL EQUIPMENTS

BLOWOUT PREVENTERS:
When primary well control has been lost, it becomes necessary to seal the well to prevent
Blowout ( i.e. uncontrolled flow of formation fluids). The equipment that seals the well is
called BLOWOT PREVENTER ( BOP ). These are basically of two types:

1 ANNULAR BOP
2 RAM BOP
NORMAL BOP HOOK UP AT DRILLING RIGS
BOP CONTROL UNIT
BOP control unit consists of accumulator bottles, a reservoir tank, charging system to pump
hydraulic fluid into accumulator bottles, pressure regulating valves, an operating manifold,
pressure relief valve. The purpose of BOP control unit is to provide pressurized hydraulic
fluid that will promptly operate the blowout preventer.
CLASSIFICATION OF BLOWOUTS

BLOW-OUTS

TYPE OF SOURCE ENVIRONMENTNATURE OF ERUPTION

SEVERITY OPERATION

GAS ONSHOREUNDER GROUND CLASS-I CLASS-II CLASS-III CLASS-IV CLASS-V

DRILLING
OIL SURFACE WITH FIRE OR WITHOUT
OFFSHORE WORK-OVER
STEAM (GEO-THERMAL) UNDER-GROUND SURFACED WITH CRATER PRODUCTION PLAT

IMPACTS OF BLOWOUTS
NATURAL RESOURCES
Blowouts considerably drains the hydrocarbon from the reservoir whether it may be oil or
gas. It mainly depends upon duration of blowout, the flow area and reservoir pressures.
History tells the cased well blow outs blows for longer periods comparatively than open hole
blowouts.

CONTROL EXPENDITURE
A well control event ranges from minor to very significant. It involves huge amounts of
expenditure, for hiring the experts, procurement / hiring of control equipment,
compensations, logistics support, public evacuation, relief camps etc. More the duration and
severity needs more expenditure.

ORGANIZATION IMPACTS
The losses a company suffers from major well control event cannot be measured totally in
monetary value. The cost of control figure never includes intangible loss like productivity
loss etc due to deployment of regular personnel for control operations.There is always a
physiological tool. Company morale suffers because all the people involved must shoulder
the part of the blame. A major event can impact the financial statement of even the largest
corporations. Many recent events have demonstrated public companies stock prices can be
adversely affected by major well control event. Damage to the good will of the company is
no exception for this.

PUBLIC HAZARDS
The potential hazard to the people and environment cannot be over emphasized. Many
blowouts have significantly threatened the well-being of the people, animals and ecosystem
associated with the event. Sometimes people may have to be evacuated due to H 2S explosion
etc. But as on today loss of life in general population due to out of control oil wells is nil.
However the possibility of tragedy in the minds of those associated with well control
operations cannot be over ruled.

POLLUTION
The problem of pollution due to oil spill is very serious for oil well blowout whereas noise
pollution is predominant in case of gas well blowout. Local effects like temperature rise,
damage to vegetation, release of unburned gases like carbon monoxide are more significant
with oil fire incidents like Kuwait oil fires of about 700 wells at a time are rare but may cause
a considerable damage to the environment.
BLOW OUT CONTROL EQUIPMENT
The Blowout control equipment can be classified as below.

A. FIRE FIGHTING EQUIPMENT

B. DEBRIS REMOVAL EQUIPMENT

C. CAPPING EQUIPMENT

D. SPECIAL EQUIPMENT

A. FIRE FIGHTING EQUIPMENT

1. Fire Fighting Pumps

Fig-11

In Blowout conditions high volumes of water is to

be sprayed on and around the well for cooling,
prevention of ignition and personnel protection.
For this, Fire Fighting Pumps with a discharge of
2000 to 4000 GPM are used. Generally, these
Pumps are centrifugal pumps driven by diesel
engine mounted on skid.

2. Fire Fighting Monitors

Fire Fighting Monitors will be used to direct the
flow of water delivered by the Fire Fighting Pumps
on and around the Blowout Well. Generally, 4 to
6 Monitors are used in Blowout Control
Operations. Fire Monitors are :-

a. Water Monitors

b. Hydro-foam Monitors

c. Hyro-chem Monitors (shown in figure)

Fig-12

d. Fog Monitors
3.Monitor Piping & Fire Hoses

Fig-13 Fig-14

Fire Fighting Monitors are connected to Fire Pumps through Light weight aluminium pipes or
flexible light weight synthetic hoses with quick unions like storz connections. In Blowout
Control Operations, Hoses of 4 to 6 dia are used.

4. Ksoks / Heat Shields

Ksoks are used to install fire fighting monitors and provide a

protective shield for the monitor operations. Both fixed type
and foldable are available.

Fig-15

5.DCP Units

This equipment is specially built to inject the Dry Chemical in the pressurized flow for
effective Fire Control of Massive Gas Fires. Each Unit consists of two containers of capacity
3 Tons each and Nitrogen Battery to charge the Containers to 30 Kg/cm 2 Pressure. These are
skid mounted units built with one Hydro-Chem Monitor of 6000 GPM and one only 4 Dry
Chemical Monitor. Huge DCP Units of 6000 Kg capacity with 6 to 10 Monitors are
available to use while huge blowouts with fire.
 Fig-16

B. DEBRIS REMOVAL EQUIPMENT

Debris Removal Equipment play an important role in clearing the surrounding area of the
well to facilitate the approach for carrying out well capping operations.

1.Athey Wagon

Also called All Purpose Capping Vehicle

(ACV). It is a vital piece of equipment used for
Blowout Control Operations like Debris
Removal, Explosive Operations, Hydraulic
Cutting, Stinging, Capping etc. Accessories
like Winch (Hydraulic or Pneumatic), Hooks
are used with Athey Wagon. It is simple boom
of around 60 length mounted on a track.

Fig-17

2.Bull Dozer
Bull Dozer Model D-8 (CAT) or equivalent with 50 Ton draw bar pull capacity is
generally used in Blowout Control Operations to make suitable approach to the
well, to facilitate the operations of Athey Wagon.

Fig-18
3.Oxylance Cutting System or Magna Rods
These are used for quick cuts on debris for easy removal.
These are generally 6 to 10 length so that cuts can be made
from distance.

The OXYGEN
Cutting torch is a
self-consuming
cutting tool used in
heavy industry for a
variety of
applications. Using
only pure Oxygen
for fuel, the torch
will reach temperatures of 7,000 degrees
Fahrenheit. The tool will cut most ferrous and non ferrous metals as well as concrete and
refractory. Benefits over conventional cutting methods include cutting speed and the ability
to cut thick and rusty metals.

Fig-19

Standard Sizes

1/2" (.540) 13.7mm

5/8" (.625) 15.8 mm
11/16" (.675) 17.1 mm
1" (.922) or 1.050
(.922) - 2.34 cm
(1.05) - 2.67 cm
Standard Length is 10'6" - 3.2m
End Finish: Plain End, Quick Connect, Threaded and Coupled

CUTTING TORCH SHIELD- REGULATING VALVE

Applications
Opening Tap Holes, Cutting Refractory Brick, Skulls, and
Slag Removing Solidified Material from debris, Demolition,
Concrete Removal.
 C.CAPPING EQUIPMENT
1.Abrasive Cutters

a)Halliburton Cutters

b)Jet Edge Cutters

2.Pneumatic Cutters (Porta Lathe Cutters)

3.Casing Clamps

4.Capping Stack

5.Smoke Stack

6.Stinger

ABRASIVE CUTTERS

1.Halliburton Hydra Jet Cutter

This type of external abrasive jet cutting system is designed to severe well heads, BOPs, Drill
pipe, Casing, Flanges even in fire condition. This system consists of high pressure jet nozzles
(3/16 dia) fixed to a tracking system powered by Hydraulic unit. Water with 1 to 1.5 ppg of
abrasive concentration pumped through nozzles with the help of external pumping unit at the
rate of 1.75 to 2 bpm. Pressure required to make the cut is 8000 to 11000 PSI.

SCHEMATIC OF ABRASIVE JET CUTTER

Fig-20

ROTATION POINT

CUTTING ATTACHING FLANGE TO

TARGET ATHEY WAGON BOOM

PIVOT POINT

JET NOZZLES HYDRAULIC

MOTOR
HIGH PRESSURE ABRASIVE
SLURRY

CUTTIN
TARGE

DOZE
R
HYDRAULIC CONTROL
LINES FROM POWER PACK
TO MOTORS AND WINCH

ATHEY POWE
PACK PUMP
PUMP BLENDE
 APPLICATION
* To cut and remove the damaged
equipment from the Blowing well
with or without fire.
* Cut and
remove the
debris from
the
surroundings
of the well to
facilitates access to the well
mouth.
(HALLIBURTON MAKE)
SPECIFICATIONS
Fig-21
External Pumping System
Pumping Discharge : 4 Barrels / Minute

Pumping Pressure : 7000 9000 PSI

Sand Feeding : 1 PPG

Sand Type : 30/40 mesh frac. Sand

2. Jet Edge Cutter

It is self contained mobile machine which will

develop 36,000 PSI of water pressure. It contains
Hydraulic Pumps by 250 HP diesel engine,
Intensifier, Hopper system, Jet Nozzle .

Nozzle Size : 0.5 to 0.7 mm

Discharge Rate : 3-4 GPM

App, Nozzle Velocity : 2000 ft. / Sec. Fig-22

Applications :-To cut casing strings, well heads, studs, valves etc. It cannot be used in fire.

3. Pneumatic Cutters or Porta Lathe Cutters

These are used during final stages of

capping to make fine cut on casing
pipes where capping head, slip and
seal assembly are to be installed.
Different sizes of cutters for different
pipes from 3 to 30 are available.
 Fig-23

4.Casing Clamps

Set of Casing Clamps used to install

capping heads, slip and seal assembly. 2
Nos. of casing clamps and hydraulic jacks
are used to set capping head, slip and seal Fig-24
assembly in required position.
30

5.Smoke Stack or Venturi Tube

Smoke stack is single pipe used to increase the height of

flow to facilitate working on the well during capping
operations. Also there are tubes and nozzles for spraying
the water into the flow.

APPLICATIONS
To shift the flame front and facilitate to work on the well
head in well blowing condition.

Fig-25

6.Capping Stack
Capping Stack consists of capping head, various spools as per
requirement with necessary attachments, set of BOPs.

Spools : Spacer Spool, Drilling Spool, X over

Spool

BOPs : In capping generally, slip rams, pipe

rams and blind rams are used.
7.Stinger
Fig-26

Stinger is used as temporary valve while killing the blowing well. It can be used, either in
single blowing condition or with fire. It can be successfully used in relatively low pressures
and for small flow areas.
 TO WELL

LOW-TORQUE
VALVE

PUMPING LINE LOADING LINE

8.Junk Shot Manifold

Facilitates adding of leak seal materials in to the pumping line so that sealing materials seal
the leaking valves and flanges etc. Pumping line should be below the leakage.Particularly
useful in stinger operations. Fig-27

D.EQUIPMENT FOR SPECIAL OPERATIONS

1.Snubbing unit

2.Hot Tapping Tool

3.Freezing

4.Relief Well
1.Snubbing Unit
The basic snubbing unit is the
mechanical or hydraulic
machine used to generate push,
pull, and torsional forces on the
work string for accomplishing
specific tasks in subject well.
The three most commonly used
types of snubbing units are the
Hydraulic Jack, Hydraulic long
stroke, and the mechanical Rig
Assist(conventional) unit.

The snubbing unit plays

important role in regaining the
well control after blowout
control (capping) operations are
over. This helps in entering and
exiting the well in a live
condition (pressurized).

Fig-28

Long Stroke Hydraulic Snubbing Unit

 2.Hot Tapping Tool

Hot tapping tool is used to relieve the pressures trapped

in pipes or any other vessels. This equipment consists
of Saddle, Hot tapping(drill) tool, Isolation valve,
Pump In or bleed off valve etc.

The slight variation of Hot Tapping tool is used for

Valve drilling to bleed off pressures due to stuck gates
of hi-pressure valves. The Valve drilling and Hot
Tapping tools are integral part of the pressure control HOT TAP TOOL

equipment. Both are often required to regain control of

wells where malfunction of the pressure control
equipment occurred. Hot tapping is useful procedure
when no other option is available. These operations can VALVE
SADDLE

Be accomplished in pressures of more than 10000 Psi.

Bothe these operations require expertise and most safe Fig-29
precautions.

3.Freezing

Fig-30

Freezing involves forming an ice plug from liquid to isolate the bottom pressure. After
bentonite solutions is pumped in to the place and frozen. Dry ice or nitrozen is used around
the outside diameter for freezing. Requires lot of skill and experience.
BLOW OUT CONTROL PROCEDURES:
Blowout control procedures mainly in to three steps

1.Preliminary operations to make approach and make workable conditions for capping well.

2.Capping the well

3.Killing the well

1.Preliminary Operations :-
Most of the Blowouts are associated with plenty of Debris around the well. To bring the
flowing well in to control the first step is to clear the debris and make approach to the well.
During carrying out these operations higher volumes of water is to be sprayed in and around
the well with the help of high discharge water pumps and water monitors for cooling,
prevention of ignition and for personnel protection. Hence abundant supply of water is to be
ensured.

Various types of earth moving equipment, Athey Wagon or ACV, Mag rods or Oxygen cutting
system play major role in carrying out these operations. Probably this is most time
consuming part of Blowout Control.

2.Capping Operations :-
Once approach and workable conditions are made Capping Operation to be carried out.
Capping is the placement of competent pressure control device on to the Blowout Well so that
Pressure integrity is required. Capping stack which is used to cap the well must withstand
maximum anticipated surface pressure (MASP). MASP is maximum shut-in pressure plus
externally applied pressure with a safety factor of 1.25.

WELL KILLING METHODS

The main principle involved in all well killing methods is to keep bottom hole pressure
constant. The various kill methods are as follows:

a) Drillers Method

b) Wait and Weight Method

3.3 DRILLER'S METHOD

In Driller's method the killing of a well is accomplished in two circulations

In first circulation the influx is removed from the well bore using original mud density.
 In second circulation the kill mud replaces the original mud and restores the primary control of
the well.

Formulae required :

SIDPP (kg/cm) X 10

a) Kill Mud Weight (gm/cc) = Old Mud Weight + -----------------------------

(gm/cc) TVD (ft)

b) Initial Circulating Pressure (ICP) = SIDPP(kg/cm) + KRP (kg/cm)

Kill mud weight (gm/cc)

c) Final Circulating Pressure (FCP) = ---------------------------------- KRP(kg/cm)

Original mud weight (gm/cc)

Drill string volume( ltrs.)

d) Surface to bit Strokes = -----------------------------------

Pump output (ltrs/stroke)

Open hole annulus volume (ltrs)

e) Bit to shoe Strokes = --------------------------------------

Pump output (ltrs/stroke)

Annulus Volume (ltrs)

f) Bit to surface Strokes = ------------------------------------

 Pump output (ltrs/stroke)

3.3.1 Killing Procedure( Drillers Method )

In this method the well is killed in two circulations.

First Circulation
a Bring the pump up to kill speed in steps of 5 SPM, gradually opening the choke
holding casing pressure constant.
b When the pump is up to kill speed, maintain drill pipe pressure constant .
c) Circulate out the influx from the well maintaining drill pipe pressure constant.

d) When the influx is out, stop the pump reducing the pump speed in steps of 5 SPM ,

gradually closing the choke, maintaining casing pressure constant. Record pressure,
SIDPP and SICP should be equal to original SIDPP.

Note : In case recorded SIDPP & SICP are equal but more than original SIDPP value, it
indicates trapped pressure in wellbore. Whereas if SICP is more than original SIDPP, it
indicates that some influx is still in the wellbore.

Second Circulation
a) Line up suction with kill mud.

b) Bring the pump up to kill speed in steps of 5 SPM, gradually opening the choke,
holding casing pressure constant.

c) When the pump is at kill speed, pump kill mud from surface to bit, maintaining casing
pressure constant.

d) Pump kill mud from bit to surface, maintaining drill pipe pressure constant equal to
FCP.

e) When the kill mud reaches surface, stop the pump reducing the pump in steps of 5
SPM , gradually closing the choke maintaining casing pressure constant. Record
pressures, SIDPP and SICP both should be equal to zero.

Open & observe the well. Add trip margin before resuming normal operation .

3.4 WAIT AND WEIGHT METHOD

In Wait and Weight method well is killed in one circulation using kill mud.
 In this method operations are delayed (wait) once the well is shut in, while a sufficient
volume of kill (weight) mud has been prepared. As the kill mud is pumped to the bit the
hydrostatic pressure in the Drill Pipe increases, this causes the drill pipe pressure to fall.
At the same time, influx which is on its way up the annulus expands continuously and
gains volume / height, thereby causing the hydrostatic pressure in annulus to fall and
casing pressure to rise. Because of this , for maintaining BHP constant a calculated step
down plan for the drill pipe pressure must be used while pumping the kill mud from
surface to the bit .

3.4.1 Killing Procedure ( Wait and Weight Method )

a) Line up suction with kill mud.

b) Bring the pump up to kill speed in steps of 5 SPM, gradually opening the choke,
holding casing pressure constant.

c) When the pump is at kill speed, pump kill mud from surface to bit, maintaining drill
pipe pressure as per step down schedule( during this step drill pipe pressure will fall
from ICP to FCP ).

d) Pump kill mud from bit to surface, maintaining drill pipe pressure constant equal to
FCP.

e) When the kill mud reaches surface, stop the pump reducing the pump speed in steps
of 5 SPM , gradually closing the choke maintaining casing pressure constant. Record
pressures, SIDPP and SICP both should be equal to zero.

Open & observe the well. Add trip margin before resuming normal operation .