Tiffin School Team BP 2009/2010

Striking Oil
Recovery and Separation of Hydrocarbons
Biranavan Sivapuratharasu Ian Sipin Ben Davies Niall Ahmad Mr D N Macleod Neil King Michael Bailey Christopher Royle

Acknowledgements We would like to thank the following individuals, for helping our project become what it is now: Mr D N Macleod, our EES coordinator and mentor, whom we owe this very project to. Thank you for allowing us to participate in the scheme, as well as organizing trips and helping fill in gaps in our project. Mr Neil King, Mr Michael Bailey and Mr Christopher Royle, our link engineers, who were all key to ensuring that we were constantly on the right track on the project, as well as touring us around BP Sunbury and coming to Tiffin School to help with any problems. Thank you for giving your free time to help us grow in our engineering intelligence. BP, who helped us by sponsoring our scheme, as well as letting us tour around their Sunbury facility. The EDT, who gave us this amazing, once in a lifetime opportunity to gain more knowledge in the field of engineering. Our friends and family, for their unending support.

Contents Page 4 Team Profile 5 Terms of Reference (Task set by BP) 6 Background of British Petroleum 7 Overview of the Situation 8 Project Brief 9 Project Objectives 10 Gantt Chart for Project Planning and Reference 11 Formation of Oil and Gas 12 The Drilling Process 14 Flowchart of the Drilling Process 15 Formation of the Casing 18 Removal of Drill Cuttings 20 Three Phase Separation 23 Pre-Workshop Planning and Research 28 Residential Workshop Planning 29 Residential Workshop Day 1 32 Residential Workshop Day 2 34 Residential Workshop CAD Report 36 Residential Workshop Conclusion 37 Environmental and Economical Concerns 38 Final Conclusions 40 Bibliography

Team Profile Biranavan Sivapuratharasu A year 12 student at Tiffin School and currently studying Mathematics, Further Mathematics, Physics and Design Technology. He is a member of the school basketball team and enjoys playing other sports such as football. He has been playing the Karnatic (Indian) violin for ten years now at a relatively high standard.

Ian Sipin He aspires to read Mechanical Engineering at university, and is currently taking Mathematics, Further Mathematics, Physics and Chemistry at AS Level. He studies at Tiffin Grammar School in Kingston. He enjoys Music, Drama and MUN debate and he is a capable student, particularly in Mathematics and Physics.

Ben Davies He is currently studying Mathematics, Physics, Chemistry and German. He aspires to become an electrical / chemical engineer, and hopes to study Physics or Engineering at Cambridge or at Imperial College. He is particularly interested in how large machines or mechanisms work, and also in making prototypes of mechanisms.

Niall Ahmad He is currently in year 12 at Tiffin School, studying Mathematics, Physics, Chemistry and English. He has taken part in a wide variety of activities from learning to play the guitar, to acting in large scale school productions. He is hoping to go into some field of engineering but is particularly interested in scientific areas such as biomedical engineering.

Terms of Reference (Task Set by BP)

Striking Oil - Recovery and Separation of Hydrocarbons For more than a century, petroleum geologists have been looking for oil all over the world, the early discoveries were those that were most accessible both in geographical location and in terms of depth beneath the Earths surface. As these fields are depleted and to continue providing for the worlds ever increasing energy demands, exploration must turn to deeper higher pressure oil and gas fields. These challenges can only be overcome with new advances in drilling and processing technology in order to get the hydrocarbons out of the ground and to the worlds markets. Once the reservoir fluids are brought up through the well to the processing facilities, the first stage is the separation of the oil, gas and water, this is achieved by the gravity separation in a vessel. The ability to do this and the speed at which it occurs has massive implications on the daily oil and gas production of the facility. As a very valuable commodity in the world today, ensuring a high oil production rates from your well is crucial to your business success. Part 1 Investigate the drilling process, how the drill cuttings are removed, the forming of the casing, how break through into the reservoir is achieved and fluids are lifted up to the surface. Part 2 To investigate the separation process of the fluids from the reservoir once brought above the surface and fed into a vessel. Determine what mixture of fluids you get from the well and methods used to separate them.

Key aspects of the project Oil and gas formation - Understand the key aspects of oil and gas formation under the ground and methods for locating it beneath the earths surface. Oil drilling - Investigate how drilling for oil and gas is carried out, identify how a well is completed in terms o f drilling into the reservoir itself, initiating the flow of oil and lifting it to the surface. Oil and gas separation Investigate the method of oil and gas separation, research and analyze the different equipment used and make a recommendation on the optimum piece of equipment for a three phase separation for use on a mobile offshore unit (boat). Lab work - Build a model to demonstrate at least one method of how to drill into a pressurised liquid reservoir and enclose the released fluid safely and without dispersal to the atmosphere or external environment. Lab work - Successfully model a vessel containing a 3 phase mixture (gas, water and oil), and carry out investigation into separation of the mixture to reflect processes used in the oil & gas industry.

Background of British Petroleum British Petroleum, more commonly known as BP, is one of the worlds largest energy companies. BP started in 1901 and found its first oil in 1908 in a rugged part of Persia. Since then the company has grown to flourish amongst the oil industry and is now a fundamental part of society as we know it. The discovery in Persia was the end of a very difficult period for the company. From 1901 1908, no oil was found in the Persian lands. Nevertheless, George Reynolds instructed his men to keep drilling, while William DArcy (the founder of the project) was on the verge of losing all his fortune. On 26th May 1908, a fountain of oil spewed out into the dawn sky, and BP was in business. The company inspired by this success, continued the hard work and progressed well, under Lord Stratacona, Lord Charles Greenway, John Cadman, the three executives. During this time, there were not a huge number of vehicles. Once again, the company was on the verge of bankruptcy they had a great deal of oil, but did not have a market to sell the oil to. BP had courted the Royal Navy as a potential customer for a very long time, but the navy was not interested. In 1914, war on the Western Front was on the brink of breaking out and the army was in need of fuel. Winston Churchill entrusted the task upon BP and the once again the company were relieved of bankruptcy. The company flourished as the number one fuel provider for the army and continued to grow significantly.
Willian DArcy

George Reynolds

Not long after the First World War, cars started becoming popular in the streets of Europe and BP had found a new market. BP began to spread around the West and became a major competitor to Shell. During the Second World War, Britain was in a great shortage of fuel and fuel became rationed. As a solution to the problem, oil from all the leading brands (BP, Shell, etc.) went into a common pool into generic fuel. BP became a crucial part of the war effort and was central for the success of the Allies. The major oil companies lost a lot during the war, but slowly rebuilt to what they are today. Since 1908 till 1945, BP had been relying on Persian (Iranian) oil reserves. This was starting to run out, BP needed to go searching. BP searched far and wide and found many reserves across the globe. It found oil in the Atlantic, the North Sea, Alaska, and of course in the Middle East. Today, BP is focused on providing its customers with fuel for transportation, energy for heat and light, retail services and petrochemicals products for everyday items.

Pipeline in Alaska

BP today is split into three major sectors: Exploration and Production, Refining and Marketing, and BP Alternative Energy. The BP group operates across six continents, and their products and services are available in more than 100 countries.

Overview of the Situation Oil has been searched for and sought after all over the world for over a century, for its value as an essential resource and commodity. The earliest oil reservoirs discovered were the easiest to access and the closest to the surface. However, as all the early oil wells have depleted, petroleum geologists must now explore deeper down, in less accessible areas. Some reservoirs of oil which originally werent economically viable to harvest are now being exploited as the number of oil wells decreases. Many problems arise from drilling deeper, which can be made more awkward if the drilling site is hard to access. These problems can only be overcome through use of better drilling and processing to get the oil out of the ground. The oil, of course, does not come straight out of the ground in its pure form. It is mainly a mixture of crude oil, water, and gas which needs to be separated before it can be used. The method of separation is very simple it is left to separate in a vessel under gravity. However, the speed at which you can get the oil out of the mixture must be as fast as possible to keep the oil production rate high.

BP Thunder Horse - USA

BP Andrew - UK

Project Brief The project consists of three main elements: Research, Recommendation and Modelling. Research There are three main aspects of oil drilling that need to be researched for the project: Oil and Gas Formation, Oil Drilling methods and Three Phase Separation methods. Oil and Gas Formation - Explain how oil and gas are formed under the ground - Explain the methods of locating it under the Earth's Surface Oil Drilling - Investigate the Drilling Process - Explain the meaning of 'Drill Cuttings' and how they are removed - Explain the forming of the casing - Explain how fluids are lifted to the surface Three Phase Separation - Explain the method of separating the fluids from the reservoir - Investigate the different types of separation apparatus This investigation is vital to presenting key information to engineers and their superiors, for use as data for future ventures. Recommendation As part of the research for three phase separators, one aspect is to investigate the different methods of separation for a three phase solution containing oil, water and gas. The project must delve into the different types of apparatus for separating oil, gas and water. After analyzing the different types of separators and giving a full description of each one, recommendations must be made to the engineers for which one to use as a separator design on their boat. Modelling One objective is to investigate, through the practical work, the drilling process and the separation process, then to build a model which can demonstrate how a pressurized liquid reservoir can be drilled, and the released liquid to be safely contained, without any leakage or spillage. This report also requires the construction of a model vessel which can successfully separate a 3-phase mixture (gas, water and oil). This practical work is key to showing executives the basics of oil drilling, and is useful to the link engineers as a visual representation of breakthrough into a pressurized reservoir.

Project Objectives

1) Oil and Gas Formation: - Explain how oil and gas are formed under the ground - Explain the methods of locating it under the Earth's Surface 2) Drilling: - Investigate the Drilling Process - Explain the meaning of 'Drill Cuttings' and how they are removed - Explain the forming of the casing - Explain how fluids are lifted to the surface 3) Oil and Gas Separation: - Explain the method of separating the fluids from the reservoir - Investigate the different types of separation apparatus - Recommend a suitable separator for use Practical Investigation: - Model the process of drilling into a pressurized chamber - Model the separation of a vessel containing a 3 part mix of Oil, Gas and Water

Using the specification obtained from the link engineers, we constructed a list of objectives to make planning straightforward. This allows us to regularly check our work and relate it back to our list of objectives to ensure that the project is completed as per specification. Constraints Time: As there is a time limit to research and make the model for the investigation, time constraints for project components must be set. In addition, there are deadlines to meet for the project and report to be done successfully to be shown to link engineers and teachers. Tools: Although there are a variety of tools in the workshop available, there is always a limit which may slow the project down and/or may need a change of plans / ideas. Materials: There is a very good source of materials and availability is high. Nevertheless, there isnt an endless supply of materials for the project due to environmental and economical issues. Skill: Despite having a number of experts on hand to aid the project, there is a limit to what can be done with the technology and skill available. Cost: Cost is always important to consider. The project must use as little money as possible so that the project is cost-effective.

Gantt chart for Project Planning and Reference

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Formation of Oil and Gas The formation of oil and gas started millions and millions of years ago. As life on earth passed away and got buried, their remains got covered under layers of mud and rock. As sea organisms died, their remains sank to the bottom of the seabed. Layers of partially decomposed matter formed on the surface and this is how the formation of oil and gas began. Layers of sediment cover the layers of partially decomposed matter as more and more organisms die. As more and more layers get added to the process, the initial layers are tightly packed under immense pressure. Over time, beneath the hundreds of layers under the sea bed, kerogen is formed. Kerogen is mixture of organic chemical compound that makes up a portion of the organic matter in sedimentary rocks. It contains a complex range of hydrocarbon molecules.

Oil and gas are formed under the numerous layers of sediment, in the right temperature and pressure. As the oil and gas reservoirs get bigger and bigger over time, the oil displaces the water and the gas displaces the oil. We now have natural separation underground, although the oil and gas are not in their pure forms. The oil rests beneath the sedimentary rock and the gas is in the porous rock above. Sedimentary rock makes up less than a third of the world oil and gas make up less than 1% of this. This shows how limited we are in our sources for crude oil and gas.

Locating Oil and Gas Reservoirs It is very difficult to locate where exactly beneath the surface the reservoirs are. Seismic surveys are carried in attempt to locate them. Shocks are sent down and geotherms (receivers) record the rebound waves or echoes. It uses ultrasonic technology to tell us how deep the rock is below the surface. On land, shocks are created by explosions, dropping weights or vibrations. In the sea, compressed air is used to create the shock. Drilling is the only method that can provide a certain location for a reservoir.

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The Drilling Process There are two parts to the drilling process. The first is to dig an exploration well and the second is to drill appraisal wells. Exploration wells are drilled for the contractor to be sure that there is a reservoir in the suspected location. The drilling rig is placed over the assumed reservoir and the drilling starts. The rotating bits cuts through the rock and hopefully into a reservoir. The bits turn at the end of a long string of pipes.
Shape of a typical drill bit

This multipart fits into a turn table on the surface of the rig. The turn table is then rotated, to give the bits the rotating action. The bits of rock cut (drill cuttings) by the bit need to removed from the well as quickly as possible or they will jam the drill bits, resulting in a lot of extra cost and time. A fluid called MUD is sent down with the drill bit to remove the bits of rock from the well. Every thirty feet, the drilling string needs to be lengthened this is repeated approximately three hundred times during the drilling process. The hole being drilled must be cased, using a steel pipe this is lowered into the ground to line the sides of the well. It is then cemented into place. On top of the bore hole, a blowout preventer is fitted to take care of the change in pressure. This is a safety precaution made to ensure that not all is lost if there is an accident. Without a blowout preventer, the process would not work and it is very difficult to repair the damage it is almost always necessary for the whole process to be started again. Every now and again the drill bit needs to be changed it may have worn out or a different shaped bit may be required if the drill comes across harder or softer rock. The pipes are brought to the surface and the bit is changed. The process is known as a round trip it can take hours. Eventually, the drilling breaks through into the rock structure and fragments are brought up to the surface to be examined for traces of oils. Samples are taken to the laboratory and the go through a series of tests to analyse for oil traces. A common test is to put the sample under UV light. Oil is yellowy under UV light, so a clear answer can be found. If there is evidence of oil, appraisal wells need to be drilled to find the full extent of the reservoir. Appraisal wells are the second part to the drilling process. Appraisal wells are additional wells drilled after a discovery, to confirm the size of a hydrocarbon deposit. The first appraisal is drilled on one side of the dip in the horizontal plane. It attempts to find water beneath the oil and gas. Sometimes more than one well may need to be drilled to locate where exactly the water is, as this will mark one

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end of the reservoir. The second appraisal is then drilled on the other side of the dip, once again to find the water. More than one well may need to be drilled to locate this other side. After the two sides of the reservoir have been found, more wells are perpendicular to the profile range of oil. This will make it clear where the oil reservoir is in the x, y and z directions. Production drilling in the sea is a bit more difficult and expensive. The platform must be standing on the seabed to get a stable work environment and the drilling must be centralised. The rest of the drilling process is the same as drilling on land, but a lot more care needs to be taken, because it is hard to make adjustments in the sea. To make the most productive and successful drilling the exploration and initial appraisal wells must be positioned as far apart from each other as possible. This is known as directional drilling new technology has enabled contractors to drill horizontally through the ground and change direction within the ground. This is a very big advantage as it is often necessary for oil companies to extract oil from thousands of feet beneath the seabed.

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Flowchart of the Drilling Process

Formation of Oil

Seismic Survey

Drilling rig is placed over the assumed reservoir

Drilling starts - Rotating bits (At the end of a long string of pipes) cut into the rock

Bits of rock are removed from the well using a fluid known as mud

Pipes are lengthened numerous times to drill deeper and deeper. Drill bits are also changed occasionally.

A sample of rock structure is brought back to the surface to be examined for oil

The first apprasial well is drilled, on onse side of the reservoir, to find the water

The second apprasal well is drilled, on the other side of the reservoir, to find the water

More appraisal wells are drilled to find the full profile range of the oil

The platform for production drilling can now be centralised and the drilling for oil can begin.

Production and Exportation

Refining

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The Formation of the Casing Oil drilling is not a simple process. It involves very high pressures and large volumes of liquids, gases and some solids. It is also done very deep into the surface so we have less control. For these reasons a casing is produced to secure the borehole once it has been dug and, to ensure nothing can escape the borehole, it is usually lined with cement. Casing consists of a pipe with a large diameter. It operates periodically throughout the drilling process starting with the surface casing, intermediate casing, and ending with production string which takes place during well completion. It is assembled and inserted into a recently drilled section of a borehole and typically held into place with cement. Casing that is cemented in place aids the drilling process in several ways including the prevention of contamination of the fresh water well zones, which are zones of land containing natural water which can be useful us. Besides providing a smooth internal bore for installing production equipment, the casing also prevents unstable upper formations from caving-in and sticking the drill string or forming large caverns. This type of casing has several other benefits which include: - Giving a stronger upper foundation to use high-density drilling fluid allowing drilling to continue deeper. - Isolating different zones containing a range of pressures or fluids (zonal isolation). - Sealing off high pressure zones from the surface, avoiding potential for a blowout A slightly different metal string, called production tubing, is often used without cement in the smallest casing of a well completion to contain production fluids and convey them to the surface from an underground reservoir. In the planning stages of a well a drilling engineer, usually with input from geologists and others, will pick strategic depths at which the hole will need to be cased in order for drilling to reach the desired total depth. This decision is often based on subsurface data such as formation pressures, strengths, and makeup, and is balanced against the cost objectives and desired drilling strategy. With the casing set depths determined, hole sizes and casing sizes must follow. The hole drilled for each casing string must be large enough to easily fit the casing inside it, allowing room for cement between the outside of the casing and the hole. Also, the inside diameter of the first casing string must be large enough to fit the second bit that will continue drilling. Thus, each casing string will have a subsequently smaller diameter. The inside diameter of the final casing string (or penultimate one in some instances of a liner completion) must accommodate the production tubing and associated hardware such as packers, gas lift mandrels and subsurface safety valves. Casing strings are supported by casing hangers that are set in the wellhead, which later will be topped with the Christmas tree. The wellhead usually is installed on top of the first casing string after it has been cemented in place.

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Typically, a well contains multiple intervals of casing successively placed within the previous casing run. The following casing interval is typically used in an oil or gas well: - Conductor casing - Surface casing - Intermediate casing (optional) - Production casing - Production liner The conductor casing serves as a support during drilling operations, to flowback returns during drilling and cementing of the surface casing, and to prevent collapse of the loose soil near the surface. It can normally vary from sizes such as 18" to 30". The purpose of surface casing is to isolate freshwater zones so that they are not contaminated during drilling and completion. Surface casing is the most strictly regulated due to these environmental concerns, which can include regulation of casing depth and cement quality. A typical size of surface casing is 13 inches. Intermediate casing may be necessary on longer drilling intervals where necessary drilling mud weight to prevent blowouts may cause a hydrostatic pressure that can fracture deeper formations. Casing placement is selected so that the hydrostatic pressure of the drilling fluid remains between formation pores and fracture pressures. The final interval is production casing. As with the casing intervals described above, the production casing string extends to the surface where it is hung off. As the smallest casing, it will former the outer boundary of the 'A' annulus, which may involve it being used for gas lift and well kills. A typical size is 9 inches. In order to reduce cost, a liner may be used which extends just above the shoe (bottom) of the previous casing interval and hung off downhole rather than at the surface. It may typically be 7", although many liners match the diameter of the production tubing. Few wells actually produce through casing, since producing fluids can corrode steel or form deposits such as asphaltenes or paraffins and the larger diameter can make flow unstable. Production tubing is therefore installed inside the last casing string and the tubing annulus is usually sealed at the bottom of the tubing by a packer. Tubing is easier to remove for maintenance, replacement, or for various types of workover operations. It is significantly lighter than casing and does not require a drilling rig to run in and out of hole; smaller "pulling units" are used for this purpose. Cementing is performed by circulating a cement slurry through the inside of the casing and out into the annulus through the casing shoe at the bottom of the casing string. In order to precisely place the cement slurry at a required interval on the outside of the casing, a plug is pumped with a displacement fluid behind the cement slurry column, which "bumps" in the casing shoe and prevents further flow of fluid through the shoe. This bump can be seen at surface as a pressure spike at the cement pump. To prevent the cement from flowing back into the inside of the casing, a float collar above the casing shoe acts as a check valve and prevents fluid from flowing up through the shoe from the annulus. Once they reach the pre-set depth, they must run and cement the casing -- place casing-pipe sections into the hole to prevent it from collapsing in on itself. The casing pipe has spacers around the outside to keep it centered in the hole.

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New Drilling Technologies The U.S. Department of Energy and the oil industry are working on new ways to drill oil, including horizontal drilling techniques, to reach oil under ecologically-sensitive areas, and using lasers to drill oil wells. The casing crew puts the casing pipe in the hole. The cement crew pumps cement down the casing pipe using a bottom plug, a cement slurry, a top plug and drill mud. The pressure from the drill mud causes the cement slurry to move through the casing and fill the space between the outside of the casing and the hole. Finally, the cement is allowed to harden and then tested for such properties as hardness, alignment and a proper seal.

Diagram of Casing

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Removal of Drill Cuttings Drill cuttings is the term given to all the loose material created by the drill, mainly the small pieces of rock that are sheared off by the action of the drill bit. The cuttings themselves vary in size, and depending on the rocks being drilled through, vary from fine sand to coarse sand, and occasionally stones. Common rocks that make up cuttings include sand, shale, chalk, clay, granite, hematite (iron ore) and silt. Drill cuttings are a large problem during the drilling process, as they obstruct the drill bit, slowing down drilling, and decreasing the working life of the drill bit, both of which increase production costs. They must be cleared from the drilling site in order to reach the oil in the minimum amount of time. This is a difficult task to carry out, as the drilling site is many kilometres below ground, and so the cuttings must be lifted to the surface to be removed, whilst the drill is still in operation to minimise drilling time until the oil is reached. The problem of clearing the cuttings from the shearing site has been solved by using drilling fluid. The cuttings are cleared from the shearing site through several stages: - During drilling, drilling fluid is pumped through the centre of the drill pipe, which then exits through perforations in the drill tip to the drilling site, where the cuttings are created.
Diagram showing the drill cutting removal process using mud

- The viscosity of the drilling fluid is high enough to suspend the drill cuttings, so that the cuttings do not settle at the bottom of the shaft, which could potentially cause a blockage.

- The drilling fluid is continuously pumped, and the fluid with the drill cuttings is carried by the fluid pressure to the surface through the drill shaft. - However, drilling fluid is usually highly toxic to the environment, and difficult to handle. Therefore it is easier to handle the cuttings if they are separated from the fluid. This also means that the separated drilling fluid can be re-used. - The used fluid is then passed through machinery which separates the cuttings from the fluid, known as shale shakers, before being re-used, stored, or modified. Shale shakers consist of vibrating screens that the used drilling mud is passed through, in order to separate the cuttings from the drilling fluid. Used drilling fluid is passed through these vibrating screens, and cutting particles get collected by the mesh whilst the fluid passes through. The vibration of the mesh moves cuttings across and off the screen, where they can be collected, stored and further processed. Generally, an equal amount of fluid as cuttings gets removed during this process.

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Often, two shale shakers are used in series on the fluid. The primary shakers contain coarse mesh screens, which can only remove larger drill cuttings. The secondary shakers use much finer screens, to remove the rest of the finer cuttings from the fluid. However, the finest particles such as silt can easily pass through the gaps in the mesh. In order to retain the maximum effectiveness of the Used Drilling Fluid being processed at a shale shaker used fluid, it is usually passed through further shale shakers and centrifuges to remove even finer solids and ensure maximum purity of the fluid. If the fluid being used is particularly expensive to produce, so that further reclamation of the fluid from the cuttings is economically viable, then the cuttings are further processed by a cuttings dryer. The dryer produces dry powdery cuttings which can then be disposed of. Modifications are generally on the viscosity of the fluid. The fluid pressure has to be increased as the drill goes deeper, so viscosity must be slightly reduced, so that the fluid is still able to flow. The Drilling Fluid itself is also known as mud or drilling mud. It is a complex mixture of different chemicals, which determines the properties of the mud. One particularly useful property of mud is that it is a thixotropic substance; it becomes a semi-solid gel when stationary. This ensures that the cuttings do not settle in the fluid, causing blockages, when A centrifuge at a plant stationary during maintenance or replacing of drill parts. A mud engineer is responsible for all aspects of the fluid, from its composition to its modification. The mud engineer also inspects the produced cuttings and tests for the presence of hydrocarbons in the mud coming out. The engineer can then modify the mud to pump down the drill accordingly, usually changing the viscosity. The viscosity of the mud is very important, as the underground pressure causes the mud to become more viscous the deeper it travels. If the mud becomes too viscous, there is a chance of it solidifying and causing pipe blockages. The drilling mud also fulfils a variety of other tasks, as well as clearing drill cuttings from the cutting site. It also: - Seals any cracks in the formed casing - Cools and supports the drill - Lubricates the machinery - Prevents the newly-drilled uncased section from collapsing

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Three Phase Separation The fluids received from the exploration well are in three phases that consist of liquid hydrocarbons, gas hydrocarbons and water. The liquid oil and the water are immiscible, and so this means that large amounts of the mixture can be separated in a simple fashion. When allowed to set, the oil automatically separates from the water, and the oil naturally floats to the top, and this drives the design and concept of three phase separation. When this mixture is first received from the ground, it will exist as an emulsion with gas mixed in. Emulsion which is the state when the two immiscible liquids are mixed to such an extent that it is impossible to tell the two apart, and which takes time to separate. Over time, this emulsion phase will get smaller, and the oil and the water will gradually settle out. The oil will form a layer on top, the water will stay at the bottom, and the emulsion phase will exist in between, with any remnant gas particles quickly escaping out of the mixture and above the liquid. Separation Technique

Diagram of the liquid phases

Mixture flows into separator

Gas escapes liquid upwards

Mixture is allowed to settle into oil, emulsion and water phases

Oil flows over a weir, located above the emulsion and water phases, into a separate compartment

Oil flows out via a valve located in its separate compartment

Water flows out via a valve located at the bottom of the separator

Gas escapes via a valve located at the top of the separator

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This flowchart describes the simple process of separating a three phase mixture. The above process is independent of the separator design; the concept is used for all designs. Separator Design There are many types of separators used in industry. We are mainly interested in a separator that allows the three phase solution to disperse out into its different phases the quickest, as well as a separator that can be integrated into a boat.

Schematic of a Horizontal Separator

Here is a schematic of a horizontal separator fitted with an interface level controller and a weir. The interface level controller on the left controls the water and oil level with the water out valve. It senses the interface between the oil emulsion and the water. Using this data, it can control the valve at the bottom to open and close, to allow the liquid level to rise and fall. This allows the right level for the oil to flow over the weir into the next compartment, therefore separating the oil and water. The inlet diverter on the left of the schematic is used to direct the oil and water mixture below the oil and water interface. This allows the oil to steadily rise to the top, and leave water down at the bottom. This is a typical separator that is most commonly used in the industry. It allows for quick and accurate three phase separation, using interface level controllers and a weir.

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Schematic of a Bucket and Weir Separator

Here is a schematic of a bucket and weir three phase separator. This design uses two weirs to separate the two phases. It uses a bucket design and this allows the exclusion of an interface level controller and only utilizes a simple float to calculate the level control valves. This controls the levels of the liquid in the vessel to separate the liquids using the weirs. The two types of separators have no real impact on the speed or accuracy of separation. The design concepts are very similar, there are only minor changes between the two sets of apparatus. Conclusion The two separators are near identical, but the bucket and weir separator utilizes a simpler method of separation, without the need of an interface level controller. This simplicity is a small difference between the two separators, but distinguishes it as a better piece of apparatus. Therefore, we recommend that BP use a bucket and weir separator design for a three phase separator.

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Pre-Workshop Planning and Research Practical Investigation Objectives - Model the process of drilling into a pressurized chamber - Model the separation of a vessel containing a 3 part mix of Oil, Gas and Water Modelling the Drilling Process Aim The main aim of modelling the drilling process is to show how breakthrough into a pressurised oil reservoir is achieved, and how the oil, water and gas are siphoned up to the surface without being dispersed into the atmosphere. Method We have researched the method used by the oil industry to encapsulate the three phase solution obtained in the drilling process. They encase the drill with a concrete tube that goes into the oil reservoir, therefore allowing both the prevention of oil escape into the surroundings, as well as allowing oil rigs to siphon up the three phase solution successfully. We will model this by using a tube attached to a pressurized chamber, and we will use a drill bit with an extender to drill through this pressurized chamber, therefore showing how breakthrough into this reservoir is achieved and how the oil is trapped and allowed to be brought to the surface.

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Prototype A-1 was our first concept idea for the practical. The advantage of using this method of investigation was that it was simple and displayed the concept of drilling into an oil reservoir successfully. It was cheap and easy to make, and it would only need a small amount of work to build. The disadvantage of using this was that a garden pot, even if it resembled the rock barrier between the surroundings and the oil reservoir, was one use only, and it would be hard to drill through it by hand without breaking the pot. Also, a garden pot would be difficult to pressurise. In addition, we would only be able to do one run through per garden pot, which makes it very difficult to observe. We then drafted a second concept:

Prototype A-2 was built upon the flaws of the first prototype, as well as help received by our link engineers. We decided to integrate the oil reservoir into the acrylic tube, and this would give a view of both above and inside the oil reservoir. Also, we decided instead of pressurizing the reservoir with a bike pump, we would use a simple liquid displacement pump in the form of a 4 litre plastic container, which we could squeeze to simulate a pressurized environment, and link it to the main tube. In addition we would manually hand drill through the reservoir crust for more control over the rig. We will also use a circular piece of foam board to drill through, and this way, we can create several circular foam boards so we can repeat the demonstration several times. So we finalized measurements for the model

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Materials Required - Clear acrylic tube (500mm height, 100mm outer diameter, 3mm thickness) - Plaster moulded base for tube - 2x 15mm push fit pipe connectors - 2x 15mm plastic pipe - 15mm inner diameter plastic hose - Metal jubilee clips - 15mm push fit plastic tap with matching washer and nut - Garden Stones - 4 Litre plastic drinks container - 30mm thick foam board - Black Food Colouring - Beaker Analysis and Evaluation The model will be a successful representation of drilling through the pressurized oil reservoir and extracting the three phase mixture using a casing (a concrete tube connecting the reservoir and the oil rig above surface. We will film the demonstration with one member of the team putting pressure into the liquid displacement apparatus (4 litre drink container), and one member drilling into the through the cap rock (foam board) into the reservoir. By using the model, we will then show the method of drilling into a pressurized oil reservoir, and extracting the oil.

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Pre Workshop Preparation Before the Residential Workshop, We decided it would be best to prepare the tube for assembly and testing early to give us more time to test in the workshop. Here is a list of actions we took before the workshop: - Cut the acrylic tube and sand down the edges - Create a base for the tube - Drill holes at the top and the bottom of the tube - Attach connectors to the holes

A picture of the prepared tube, attached to the base with connectors fixed at the top and bottom of the tube.

Modelling the Three Phase Separation Aim The aim of modelling the three phase separation of two mixed immiscible liquids and a gas is vital to understanding the method of separating the two substances successfully. The mixture is made up of crude oil and water, and the aim is to observe how the two substances behave when the mixed together. Method We will use a simple method to observe the separation of two immiscible liquids. We will have a 4 litre plastic container with a mixture of vegetable oil and water, and we will observe how the two liquids behave when it is physically shaken and mixed to reflect the state of the liquid obtained when the actual three phase mixture enters a separator.

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Materials Required - Clear Plastic 4 Litre Drinks container - 1 Litre of Vegetable Oil - 1 Litre of Water - 2 Litres equivalent of Air Analysis and Evaluation By observing the separation of these three substances, we will gain a better understanding of how a three phase separator (as shown in the research) works.

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Residential Workshop Planning By the end of the residential workshop, we should have achieved the following goals: - Construct and assemble the model for drilling into a pressurized oil reservoir - Assemble a model for showcasing how to separate a three phase mixture - Model the process of drilling into the pressurized chamber - Model the separation of a three phase mixture in a separator - Construct a CAD drawing of the drilling model We will have 2 days of pure workshop time, and we will split the tasks as follows Day 1 Objectives - Send Engineer Chris Royle to shop for extra parts - Cut out foam board circles to fit into tube - Assemble drill model - Use a silicon sealant to seal off gaps in tube - Assemble pressurizing chamber and attach to tube - Finish CAD drawing on drilling model Day 2 Objectives - Assemble all parts of the drilling rig - Video and demonstrate the model in action - Mix oil and water in a plastic tube and observe separation Summary After the 2 days, we should have a completed model for the drilling rig and successfully video and model it in action, observe the separation of two immiscible liquids, and finish a CAD drawing of the drilling rig model. Health and Safety Concerns Health and Safety is a pressing issue, especially in a workshop environment. We need to wear lab coats and goggles when handling equipment, and we need to be supervised by a university workshop assistant at all times to ensure maximum safety of the group. Prior to the workshop, we were given health and safety documents used in Tiffin School, and we read through the guidelines thoroughly. Risk assessments were carried out before the workshop, control measures were put into place with all hazards in the workplace identified. This ensured our groups maximum health and safety.

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Residential Workshop Day 1 The first day will mainly be focused on construction and assembly of the two models. Here is the day plan for each of the four members: Biranavan Create a CAD diagram of the drilling model Ian, Ben and Niall Cut out foam board circles to fit the tube Assemble drill model Use silicon sealant to seal off gaps in the model Connect liquid displacement chamber (4 litre drinks bottle) to bottom of tube

Biranavan hard at work on the CAD drawing

First drawing of the tube, a work in progress

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Cutting foam board circles to fit inside the tube as perfectly as possible without allowing any gaps was difficult. We first took a scrap piece of cylindrical metal which was larger than the size we needed for the tube. We then cut this metal accurately to make it just slightly larger than the tube. We used this template and drew circles around the foam board. Using the metal cylinder, we placed it on top of a foam board circle and then proceeded to the sanding machine, where we accurately sanded the circles until it just fit into the tube, allowing pressure build up for our model.

Cutting the cylindrical piece of metal to slightly larger than the tube.

After cutting rough circles from the foam board using a band saw, we placed the cylinder on top again

Niall sanding the foam disc into the perfect size

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After assembling the tube and fitting all the parts together, we noticed that since the connectors were produced to fit flat surfaces and it was fitted onto a curved tube, there were gaps making pressure build up impossible. Using the help of our link engineer, we were advised to use silicon sealant, a water proof sealant, which could cover up the gaps between the connector and the tube, as well as the base and the tube.

Ben and Engineer Chris Royle patching up the gaps between the connector and the tube

Assembling parts together and finishing applying sealant to any remaining gaps

Summary Today was a productive day. We completed every task we set out to do. We had a finished water tight model which we can test out tomorrow and video for the demonstration. The tube was assembled and the pressurizing chamber was yet to be finished. Tomorrow, we will take the drinks container, and drill a hole in the cap to create an air tight connection between the tube and the 4 litre container, so that one of us can press down on it to create pressure. After the container is prepared and connected to the tube, we can model the process of drilling into a pressurized chamber. On the CAD drawing, Biranavan had successfully completed an extremely accurate depiction of the model. All in all, it was a successful and productive day.

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Residential Workshop Day 2 We had already finished assembling the drilling rig the day before. The sealant had dried and we had water tested the apparatus to check for any leaks. Since there was none, we started preparing the model by putting the Japanese garden rocks at the bottom of the tube. We then put the cylindrical foam board we had cut the day before and pressed it down just above the rocks to simulate the cap rock. We connected the 4 litre drinks container to the bottom of the tube, and filled it with water mixed with black water colouring to simulate oil. We then took a video of our demonstration several times.

Image of the model before breakthrough of the cap rock

Image of the model after breakthrough of the cap rock

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As seen on the photos of the video, the model proved to be a tremendous success. It was an exciting and informative simulation of breakthrough into a pressurized oil reservoir. The three phase separation demonstration was difficult to process due to our third workshop day being cut short. Instead, as a last minute resort, we opted to use a small glass and fill it with 30% oil and 30% water, stir it and take images and observations of the behaviour of the liquids. We took the following images:

Before Separation (After liquids were mixed)

After Separation

As seen, the oil and water separated quickly, however it left an emulsion phase that we had researched. In addition, we observed that air bubbles formed inside the phases, an interesting observation which may lead us to believe that complete separation of three phases might not be as complete as originally thought. Air bubbles in the liquid could simulate how gaseous hydrocarbons could be trapped within the liquid phases below. Summary Today was a very productive day. We had completed and tested the drilling apparatus, and we had modelled breakthrough very successfully. The CAD diagram was finalized with Biranavan and he had created a report on it. Our short demonstration of the three phase separation was informative, and gave us insight into the behaviour of the phases through practical work. It was yet another successful, informative and productive day, and a good conclusion to the research we obtained, giving us a visual representation of what we had learned only through secondary sources.

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Residential Workshop CAD Drawing

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Residential Workshop - Conclusion The residential workshop was a great asset to the project. We were able to use the Universitys excellent mechanical engineering workshop to get some of the components prepared for the model. The facilities were great and it was an enlightening experience. Biranavan worked with one of the CAD engineers to produce the drawing, and he gained a lot of knowledge by doing so. Main Objectives - Construct and assemble the model for drilling into a pressurized oil reservoir We had created an excellent model for drilling into the pressurized oil reservoir. It was crafted well, and was water tight. The model itself was visually pleasing, since using the clear acrylic tube allowed us to see the actual breakthrough into the pressurized chamber. - Assemble a model for showcasing how to separate a three phase mixture We had assembled a smaller model to what we had intended, but still obtained substantial information. - Model the process of drilling into the pressurized chamber We had taken a video of the model in action successfully. The breakthrough into the pressurized chamber was a spectacle to say the least, and it allowed us to glimpse what it would look like in reality in model form. - Model the separation of a three phase mixture in a separator We had modelled the separation of the two immiscible liquids in our smaller model of the three phase separator. Observing the behaviour of the two immiscible liquids and the emulsion phase allowed us to understand the use of the three phase separator and to witness what property of the two liquids allowed the said separator to achieve the end goal first hand. - Construct a CAD drawing of the drilling model As seen, Biranavan did an excellent job at creating an accurate drawing of the model, including dimensions and a report giving a full description of the model. Conclusion The residential workshop helped us achieve the main objectives we drafted in the beginning of the project, and also allowed the project to come full circle, by giving us a visual representation of our research.

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Environmental and Economical Aspects There are many environmental factors concerned with the use of oil and the production processes involved with oil. Firstly, oil is a non-renewable fuel. A non-renewable resource is a natural resource which cannot be produced, re-grown, regenerated, or reused. Crude oil is a fossil fuel; it is a flammable liquid consisting of a complex mixture of hydrocarbons of various molecular mass and other organic compounds. As has been mentioned previously, the petroleum industry is involved in exploration, extraction, refining and distribution. This costs a huge sum of money, which is rapidly increasing. The need for crude oil over the globe is immense it is not only needed for fuel but it is also hugely necessary as a raw material for other chemical products, such as pharmaceuticals, solvents, plastics, etc.
Fossil fuel burning

A BP wind farm

The majority of the worlds crude comes from the Middle Eastern countries. However, these key sources are swiftly running out and the world is near crisis in terms of energy needs. The world needs other sources of energy, which are just as valuable as crude oil, but renewable. BP Alternative Energy is investing in new ways of providing energy from innovative new solar and wind businesses to advanced biofuels and clean energy technologies, such as the capture and storage of carbon dioxide from the traditional fossil fuels. A major problem with crude oil is that it creates a lot of global warming when it burns. When crude oil burns, it releases carbon dioxide, which causes the greenhouse effect. The greenhouse effect is when the Earths atmosphere acts like a thermal blanket over the Earth. The shorter wavelength radiation from the Sun can pass through the atmosphere; but the longer wavelength radiation which rebounds of the surface is trapped within the atmosphere. The Earth is becoming too The greenhouse effect warm; this is causing the sea levels to rise along with many other serious problems. Cutting back on our fossil fuel usage will reduce the greenhouse gases and help save the planet. The economical crisis and the running out of crude oil have made a huge impact on the economy. The fuel prices have increased hugely; in fifteen years, the price of unleaded petrol has risen from 54 pence to an astonishing 113 pence. This is affecting the lives of a lot of people that own vehicles. If we found an alternate source of energy to fuel our cars, we would not be having this problem as a society. The energy A solar power car source is likely to be cheaper and better for the atmosphere than a fossil fuel base. A renewable energy source which is as successful as crude oil will solve the situation in all areas it would not cause the greenhouse effect, it would be reused and it would be cheaper.

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Final Conclusions The objectives of the project are in bold as follows: 1) Oil and Gas Formation: - Explain how oil and gas are formed under the ground - Explain the methods of locating it under the Earth's Surface Summary: - Thousands of years ago, living organisms (plants and animals) died and sank to the bottom of the sea. - These dead carbon based organisms decomposed at the bottom of the sea floor. - Sediment settled on top of the decomposed matter, forming layers. - Under right pressure and temperature conditions, carbon compounds formed hydrocarbons (Oil and Gas), forming reservoirs. - Locating oil reservoirs requires seismic surveys, and exact location of the reservoir is done through drilling and excavating, and analysing rock samples obtained. Conclusion: The research objectives concerning the formation and location of oil and gas reservoirs were met successfully. 2) Drilling: - Investigate the Drilling Process - Explain the meaning of 'Drill Cuttings' and how they are removed - Explain the forming of the casing - Explain how fluids are lifted to the surface Summary: - A detailed flowchart depicting the process of drilling is shown on Page 14 on the report. - Drill cuttings are rock debris obtained through drilling through rock, and are a natural occurrence in any drilling. A fluid known as mud is circulated down the casing and back to bring cuttings to the surface. - Casing is formed in several stages, the hole is drilled downwards, and the drill is brought up, and the hole is lined with cement, and is done again in a cycle until the drill reaches the reservoir. - Fluids are lifted up due to the pressure of the reservoir up the casing. Conclusion: The research objectives concerning drilling reservoirs were met successfully. 3) Oil and Gas Separation: - Explain the method of separating the fluids from the reservoir - Investigate the different types of separation apparatus - Recommend a suitable separator for use Summary: - The fluids lifted from the surface is made up of liquid and gas hydrocarbons and water. - Three phase separation is done in a separator, which uses the property of the two immiscible liquids automatic separation to separate the three phases

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- The recommendation of a suitable three phase separator is a bucket and weir separator, shown below:

Schematic of a Bucket and Weir Separator

- The advantages to a bucket and weir separator is cost, since it only uses a simple float to determine the liquid levels, and doesnt require a liquid interface controller. It is also a simpler separator. Conclusion The research objectives concerning three phase separation were met successfully, and a suitable separator schematic was recommended. Practical Investigation: - Model the process of drilling into a pressurized chamber - Model the separation of a vessel containing a 3 part mix of Oil, Gas and Water Conclusion The modelling objectives were completed successfully Overall Project Conclusion Overall, all the criteria set by the engineers were met successfully. All research, modelling and recommendation objectives were achieved, and the report was successful and completed all tasks. Overall Team Conclusion The team performed superbly on all fronts. We completed the project report before the deadline, and all team members were supportive and all contributed equally to the project. Problems such as arranging meetings were difficult, since team members were very busy with other activities, but when meetings were set, full attendance was always there. Organisation was not an obstacle, and deadlines concerning different parts of the report were all met. A job well done.

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Bibliography www.odec.ca/.../2006/smit6d2/oilgasformation.png www.jamstec.go.jp/.../observe/seabed.html http://pmsuppliercn.en.ec21.com/Tricone_Bit_TCI_Bit_Rock--3558604_3558852.html www.globalization101.org/.../oil_production Surrey University work site www.jamstec.go.jp/.../vol5/vol5_2.html http://oilrigjobsinfo.com/153/roustabout-jobs-explained/ http://www.oilrig-photos.com/picture/number101.asp http://www.allamericanpatriots.com/news_topics/gas_prices?page=5 reference.findtarget.com/search/oil%20refinery/ www.emt-india.net/.../Petroleum.htm www.hope4volgograd.com/?paged=2 www.visco-vn.com/Major_Projects.aspx http://www.alibaba.com/product/energyptc-11710682-11053496/Saudi_Light_Crude_Oil.html http://www.school-for-champions.com/chemistry/hydrocarbon.htm http://earthsci.org/mineral/energy/gasexpl/refine.html http://www.kurion.co.uk/vacuum_distillation_2.html www.iocltech.com/thermal.html

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