Pr ince Mo hammad Bin Fahd Univers it y

C o l l e g e o f E n g i n e e r i n g

Department of Mechanical Engineering

Internship Report

at

Halliburton Company

at

Boots and Coots Department

R e p o r t i n g P e r i o d :

[16/06/2012 - 08/08/2012]

S u b m i t t e d b y :

[ G h a z i K . A l A r f a j ]

[ 2 0 0 7 0 0 6 7 7 ]

[ s u b m i s s io n d a t e ( 1 5 / 0 9 / 2 0 1 2 ) ]

Mechanical Engineering Department

Summer 2012

1

Abstract

As an engineering student at Prince Mohammad bin Fahd University, or any other

university around the globe we are required to fulfill a summer training program or as we call

it in the university, internship, upon graduation. The purpose of the internship is to apply

what I learned during our educational life at the university in the working environment. I

selected Halliburton Services Company to be my destination for the training because the

knowledge they gives us as summer trainees, weather by taking safety courses or by letting us

monitor and involving us a bit while they are performing their job.

2

Acknowledgments

It is always a pleasure to thank and gratitude the people behind my success at

Halliburton Services Company, Boots & Coots Department for their sincere guidance I

received to imply my theoretical skills in engineering. Firstly, I would like to thank Dr. Omar

Ouda, the charged instructor of the internship program for his positive and effective advices

prior working. Secondly, I would like to thank Eng. Ali Alabdrab Alnabi, the industry

supervisor for his great guidance and effort he gave us. Finally, I apologize to all other

unnamed who helped me in various ways to have a good training and knowledge about the

working environment.

3

Table of Content

Page

Abstract 1

Acknowledgments 2

Table of contents 3

List of Figures 4

Main Text 5

Introduct ion 6

The Company 7

Activities and responsibilities 7

Major tasks or projects 12

Conclusion 13

References 14

Appendix A: Industry Supervisor Report 15

Appendix B: Student Log Sheet 18

Appendix C: Student Feedback Form 20

Progress Technical Reports 23

4

List of Figures

Figure Number and Name Page

Figure 1: The Training Courses Cards I obtained 7

Figure 2: PPE (The Personal Protection Equipment) 7

Figure 3: BOP (Blow Out Preventure) 7

Figure 4: Fluid End 10

Figure 5: CTU (Coiled Tubing Unit) 10

5

Main Text

In this section I will post the training schedule for the 8 weeks I spend at the

company:

Week Task

1 HR Introduction

2 Safety Courses

3 Coiled Tubing Shop: Redress BOP and Stripper

4 Coiled Tubing Shop: Bottom Hole Assembly (BHA)

5 Coiled Tubing Shop: HT-400 Pump

6 Coiled Tubing Shop: N2 Equipment

7 Coiled Tubing Shop: Coiled Tubing Unit

8 Coiled Tubing Shop: Software (IFS)

This training schedule looks the same as the Student Log Sheet, because the supervisor filled

the sheet at the beginning of the training in order to follow his training program, and be able

to know what task I should follow each week.

6

Introduction

Boots &Coots Department in Halliburton consider as the newest and one of the main

departments at the company. Boots & Coots merges with Halliburton in 2010, which is why

it is consider as new. The main goal of this internship is to gain experience of what I learned

in collage, as well as understand the department main functions. This report will explain the

following, the company, activities and responsibilities, and the major tasks or projects.

The Company

Halliburton founded in 1919. It is consider one of the largest oil services companies,

which serve the upstream industry. The company has more than 70,000 employees in almost

80 countries. In the 1940s, Halliburton was one of the first oil service companies that sign

contracts with Saudi Aramco back then. Halliburton consists of two main divisions: Drilling

and Evaluation; and the Completion and production, where the Boots & Coots fall under it.

Boots & Coots as I mentioned before merges with Halliburton in 2010. Nevertheless, Boots

& Coots was a separate company from Halliburton where it founded during the 1978. Boots

& Coots helped during the Gulf War in 1991, by controlling nearly 700 oil well fires that

ignited by the Iraqi soldiers.

7

Figure 1

Figure 2

Figure 3

Activities and Responsibilities

The beginning of the internship journey starts when I arrived to the company at the

first day when I arrived to the company. At that day we were involve in a two days

introduction about the company, as well as how long it has been in the region. On my third

day, I introduced to the supervisor who was assign to give me

instructions on the work that is perform, and introducing me to the

management of the department as well. The following week, was the

beginning of the actual training, where I was assign to take four different

courses before I proceed to work.

After that, I received the PPEs, the Personal Protective Equipment

from  the  department  so  I  can  start  to  work  and  learn  about  the  company’s  

different equipment. The PPE consists of, a helmet, safety glasses, a

coverall, a pair of gloves, and a pair of safety boots. In addition to that,

the supervisor told me about their safety roles. One of the main important roles he told me

about is the JSA form, the Job Safety Analysis, where I should read it

carefully and understand what problems I might find and then sign it. This

form is also includes a work permits so I can be eligible to work. The

following activity, I introduce to the basic equipment they have, the BOP

or as it called the Blow Out Preventer. I had a chance to be involved in

seeing its parts, and assemble them in the unit. After the assembly, we did a pressure test on it

to make sure it meets the company standards.

8

The following task was involving in the Nitrogen Equipment. On that particular day, I

was involved in replacing a non-working booster pump in the nitrogen-converting unit. After

we were done with the replacement, we have done a test to make sure that things are running

smoothly. The next activity was about the BHA, Bottom Hole Assembly, each tool to be

fitted to the coil tubing is consist of:

1. External or internal connector to fit the tube with the tool.

2. A MHA (motor head assembly) that is include a wafer check valve to prevent fluid to

come back.

3. A rupture disc to prevent excesses pressure.

4. A nozzle to increase the velocity and the pressure.

5. A SurgicFrac, this will gives more life for the selected tool because it stands very high

corrosive materials.

6. Knuckle joint, to give the nozzle flexibility to move, or a hydraulic knuckle joint,

where it kicks off while pumping.

The next task was about learning about the HT-400 pump, and its component. The

usage of the HT-400 is to deliver different fluids downhole. Typically, the pump consists of

two main ends, power end, and fluid end.

9

Power End Components:

1. Case and drive gears: It divides into two main parts, right- and left-hand sides.

2. Crankshaft: Heat-treated steel forgings used to manufacture crankshafts. All

cranks are the same, even for left- and right-hand units.

3. Connecting Rods: Connecting rods made from aluminum forgings. The

identical rods internally drilled to provide lubrication to the crosshead pins.

4. Crossheads: Crosshead bodies are made of heat-treated steel alloy castings.

They fitted with replaceable; high leaded bronze shoes on both top and

bottom.

5. Lubrication: an internal crescent gear-type pump driven off the end of the

worm gear pressurizes standard self-contained power end lubrication system.

6. Cooling: The HT-400 Pump cooled with radiator-type coolers that provide

high cooling capacity.

Fluid End Components:

1. Chambers: The fluid end constructed from three separate

but identical forged and heat-treated chambers. Fluid ends

can supply any of five plunger sizes and each size can fit to

the standard power end without alteration of either fluid or

power end.

Figure 4

d

10

Figure 5

2. Valves and valves sets: Fluid ends are fitted with replaceable, carburized

valves and seats. Most of the valve assembly parts are interchangeable

between suction and discharge ports within a given size and some are even

interchangeable between sizes.

3. Lubrication: A separate lubrication system supplies lubricant to the fluid end

package.

The next activity I learned was the Coiled Tubing Unit, CTU. The CTU usually

contains the following equipment or parts:

1. Injectors: As the name refers, it used to

move coiled tubing into the well, and at the

same time, it seals off the tubing, making a

pressure-tight connection. The injectors

have roller chain and gripper blocks to hold tubing in place and injecting it

into the BOP (Blow Out Preventer) mounted on the top of the well. The size of

these injectors based on its maximum pull capacity. For instant, 30K means it

can pulls up to 30,000 lb.

2. The Guiding Arches: The tubing guiding arches mount on top of the injector

and does its part in guiding tubing into the well too. The design and the radius

of each arch are typical with all job set-ups and condition.

3. The Reel: Basically, reels used to winding and unwinding coiled tubing; store

the tubing for transport to location; and keep the tubing in good working

11

condition. In addition to that, reels also provide tension during coil tubing

operations.

4. Coiled tubing power pack: The function of this power pack is to provide all of

the power and fluid controls necessary to operate a coiled tubing unit.

5. Control House: As its name refers, the control house is the operational nerve

center of any coiled tubing unit. Usually it is mounting at the front side of the

trailer after the reel and before the truck driver cabin; the control house could

lifted hydraulically above the reel for better view during the coiled tubing

operations.

The last activity I have done was learning about software used at the department in order to

perform their required job. Their software is called IFS, InSite For Simulation. The software

main functions are:

1. Monitoring, which include:

Pressure Monitoring.

Rate Monitoring; whether it is flow rate or anything else.

Density Monitoring.

Volume Monitoring.

Speed Monitoring.

Weight Monitoring.

Depth Monitoring.

12

2. Control that do the followings:

Controlling Pumps.

Controlling Blenders.

Controlling Coiled Tubing jobs.

Controlling Nitrogen jobs.

3. Analysis, which is used to analysis the data gathered by the software.

The operation of this software like any other software in the universe, where it needs inputs

such as, sensors, and cables to carry out the signals; after then, converting them in a sort of

out puts for the user.

Major Tasks or Projects

The main task was exciting and has lots of information. It is the BOP pressure test. As

the policy of the company requires performing either pressure or function tests depending on

the type of equipment they will perform the test, in this case a BOP 15K type (Can hold up to

15,000+ psi). Prior the test I had to look at the JSA, Job Safety Analysis and sign on it, and

sign a copy of a job permit in order to start. In order to pass that test we had to repeat the test

twice because a leakage that was occurs in the lower stack of the BOP. After fixing this leak,

we did a retest on the next day, and we hold a pressure of 15,280 psi for 10 minutes. What I

observe is that a drop of the pressure was occurring with an amount of 1 psi every 3 second

which is acceptable for us to pass. After the 10 minutes was gone we passed the test with a

total pressure of 15,070 psi.

13

Conclusion

In conclusion, it was a great opportunity to join Halliburton Company during the

summer training period. Training at Halliburton, Boots & Coots Department was beneficial

and related to my major as a mechanical engineering student as well as it is not related to my

major, somehow petroleum engineering. I had a great knowledge in my field at the company

since the supervisor offered me a copy of the Coiled Tubing Introductory Book. At the end, I

would love to recommend the student to do training at Halliburton or any other company to

obtain much knowledge and to expos to the working environment.

14

Reference

1. Eng. Ali Alabdrab Alnabi, Boots & Coots Engineer.

2. Eng. Ernesto Bustamante, Senior Engineer at Boots & Coots.

3. Halliburton Coiled Tubing I Workbook.

23

Prince Mohammad Bin Fahd Universi ty

C o l l e g e o f E n g i n e e r i n g

Department of Mechanical Engineering

Internship Report

at

Halliburton Company

at

Boots and Coots Department

R e p o r t i n g P e r i o d :

[16/06/2012 - 27/06/2012]

S u b m i t t e d b y :

[ G h a z i K . A l A r f a j ]

[ 2 0 0 7 0 0 6 7 7 ]

[ s u b mi s s i o n d a t e ( 2 9 / 0 6 / 2 0 1 2 ) ]

Mechanical Engineering Department

Summer 2012

24

Summary

The first week at Halliburton Company was mainly about introducing us as students about the company and its policies. At the end of this week we were introduced to our supervisors and our departments, and signing our contracts. Our second week was mainly about four different coerces we have to take. The third week was about  the  department’s  equipment at the department yard.

Background

During this summer internship, my actual journey started on 16/06/2012. We introduced to our supervisor Ali as I stated before in the summary on Wednesday in the first week at the company. The contact details of the supervisor as  well  as  the  department’s  training schedule will be presented at the appendix at the end of this progress technical report. The second week at the company was at the department. During the first three days, Saturday, Sunday, and Wednesday, we took some required courses in their training facility, as it appear in the appendix, and we received completion cards. The remaining days, Monday, and Tuesday, were off-days since our supervisor gave us these days because he was out in the field.  During  the  third  week,  we  learned  about  the  department’s  equipment  at  the  department  yard on Saturday. In the following day, we introduced to one of their equipment in detail. That part was the BOP, Blowout Preventer, I learned about their deferent types 10k and 15k. The one I was learning about is the 15k (15-kpsi) type. I learned about its deferent components, the parts inside it, and its usage. I will explain this part in the progress.

Progress

The  planed  work  was  about  learning  about  the  BOP’s  components,  which  are,  Quad  Slips, and the Campy Rams. Quad is the first four parts on each side of the BOP. Campy is the two parts on each side of the BOP as what you will see in the picture. BOP used as an emergency  device  to  control  the  downhole  pressure.  The  BOP’s  parts  are  consist  of,  blinds, shear or cutter, slips, and pipe close, one on each side in the Quad Slips region. The Campy Rams region consist of Blind/ Shear or cutter as one part, and slips/ pipe close as another part. I help the operators during the assembly of these parts in the BOP. After our lunch break, we run a pressure test to test the BOP if it can hold a 15-kpsi pressure for 10 minutes as the company policy to check for any potential leaks. One main problem I faced is memorizing the deferent parts and component of the BOP. On Tuesday, we ran a last test in front of the shell company man to see our testing result in order to ship it out for work at Shell Company. Unfortunately, after we run the test several times leaks occurs after we

25

passed 4 minutes approximately, and we had to adjust the equalizer of the BOP. After we adjust the equalizer we fixed the pressure at 15,280-psi for 10 minutes with 1-psi drop at every 3 seconds which considered acceptable. Finally it passed the test with holding a pressure at approximately 15,070-psi for 10 minutes after the dropping out.

Plans

What I will do during the upcoming week is following up with the supervisor’s  schedule and instructions.

26

Appendices

I. Supervisor’s  Contact  Details:

27

II. The Department Training Schedule:

Week Task

1 HR Introduction

2 Safety Courses

3 Coiled Tubing Shop

Redress BOP and Stripper

4 Coiled Tubing Shop

Bottom Hole Assembly (BHA)

5 Coiled Tubing Shop

Learn about HT-400 Pump

6 Coiled Tubing Shop

Learn about N2 Equipment

7 Coiled Tubing Shop

Learn about Coiled Tubing Unit

8 Coiled Tubing Shop

Learn about Software

III. Courses Completion Cards:

28

IV. Photos:

1. BOP Parts: Notice the parts I mentioned before, from top to bottom, Blinds, Shears or Cutter, Slip, Pipe Close, these will be in the Quad region. And the Last two parts are, Blind/ Shear or Cutter, and Slip/ Pipe Close, in the Campy region.

2. BOP Before Assembly: Notice the two regions, the Quad first four components on the top, and the Campy, which are the last two components on the bottom.

3. BOP After Assembly: Same as I mentioned above, but this is after assembly.

29

Prince Mohammad Bin Fahd Universi ty

C o l l e g e o f E n g i n e e r i n g

Department of Mechanical Engineering

Internship Report

at

Halliburton Company

at

Boots and Coots Department

R e p o r t i n g P e r i o d :

[30/06/2012 - 11/07/2012]

S u b m i t t e d b y :

[ G h a z i K . A l A r f a j ]

[ 2 0 0 7 0 0 6 7 7 ]

[ s u b mi s s i o n d a t e ( 1 3 / 0 7 / 2 0 1 2 ) ]

Mechanical Engineering Department

Summer 2012

30

Summary

The third week at Halliburton Company was mainly about introducing us as summer trainee students about the Bottom Hole Assembly or as commonly we name it as BHA. Our fourth week supposed to be about HT-400 Pump but since the pumps were not availably in the yard, I was introduced to the Nitrogen Equipment.

Background

This report will explain the entire process of what I learned about the Bottom Hole Assembly and the Nitrogen Equipment. Let me explain the Bottom Hole Assembly at the beginning. Bottom Hole Assembly is a component of a drilling rig. Alternatively, I can explain it as the end tool of the coiled tube, as what I introduced to the Hydrablast Tool. On the other hand, the Nitrogen is used to pressurize to well to increase the production of the well such as, the concept of the perfume bottle.

Progress

The period of 30/06/2012 to 04/07/2012 is the Bottom Hole Assembly or mainly the Hydroblast Tool:

I was introducing to this tool as a part of my training schedule. This tool is assembled at the end of the coiled tube, and it is used for different purposes such as, cleaning the well, or pumping Nitrogen to pressurize the well for better production. After I was introduce to this tool, and we saw the cleaning process, the disassembly and the assembly process of this tool we ran a test on this tool to see if it can handle a pressure of 2014 psi at a rate of 2.4 barrel per minutes (bpm) without leakage. During the test I was monitoring the screen for any up normal conditioned that may occurs.

The period of 07/07/2012 to 11/07/2012 is the Nitrogen Equipment:

I was introduced to the Nitrogen equipments on that week. I saw the tank that they refrigerate the Nitrogen at (-320 degrees Fahrenheit). In addition to that, I saw the pumping device that they use to pump the Nitrogen into the well. I understand the concept behinds pumping the Nitrogen into the well. I understood that the process of that is based on the heat transfer or closely as the heat exchangers. The whole process goes by having a pump that will suck the liquid Nitrogen, and while the Nitrogen leaving the tank it goes into tubing lubes to exchange some heat of the atmosphere with the heat of the Nitrogen to heat up the Nitrogen a little before it gets into the pumping device. After that, the Nitrogen will be circulated around the

31

exhaust to gain additional heat from the exhaust gases. After it takes that additional heat it will circulate one more time around the hydraulic devices to gain more heat from the hydraulic devices before it turns into its gases state to pump it throw the booster pump into the well. During this learning process, I saw a test run on the Nitrogen equipment to see how it actually runs.

Plans

What  I  will  do  during  the  upcoming  week  is  following  up  with  the  supervisor’s schedule and instructions.

32

Appendices

I. Photos:

1. Hydrablast Tool: It is located at the far left of the picture (The White Lined Area).

2. Connection Cables I helped in connecting to the measurements devices in order to read the readings.

3. The monitors on the left I was assigned to monitor to see the readings of the tool.

33

Prince Mohammad Bin Fahd Universi ty

C o l l e g e o f E n g i n e e r i n g

Department of Mechanical Engineering

Internship Report

at

Halliburton Company

at

Boots and Coots Department

R e p o r t i n g P e r i o d :

[14/07/2012 - 25/07/2012]

S u b m i t t e d b y :

[ G h a z i K . A l A r f a j ]

[ 2 0 0 7 0 0 6 7 7 ]

[ s u b mi s s i o n d a t e ( 2 6 / 0 7 / 2 0 1 2 ) ]

Mechanical Engineering Department

Summer 2012

34

Summary

The fifth week at Halliburton Company was mainly about introducing us as summer trainee students about the HT-400 Pump after the delay because of the availability of the pump at the yard. Our sixth week is about the Coiled Tubing Unit or as it called CTU.

Background

This report will explain what I learned about the HT-400 Pump and the Coiled Tubing Unit. During this report, I will go over the HT-400 and the main usages for it. On the other hand, I will talk about the Coiled Tubing Unit and its components.

Progress

The period of 14/07/2012 to 18/07/2012 is the HT-400 Pump:

I was introducing to the HT-400 Pump as a part of my training schedule. This pump used to deliver fluids downhole. Typically, the HT-400 Pump has two ends, power end components, and the fluid end components, as I will explain as follow:

Power End Components:

1. Case and drive gears: It divides into two main parts, right- and left-hand sides.

2. Crankshaft: Heat-treated steel forgings used to manufacture crankshafts. All cranks are the same, even for left- and right-hand units.

3. Connecting Rods: Connecting rods are made from aluminum forgings. The identical rods are internally drilled to provide lubrication to the crosshead pins.

4. Crossheads: Crosshead bodies are made of heat-treated steel alloy castings.

They are fitted with replaceable, high leaded bronze shoes on both top and bottom.

5. Lubrication: an internal crescent gear-type pump driven off the end of the

worm gear pressurizes standard self-contained power end lubrication system.

6. Cooling: The HT-400 Pump cooled with radiator-type coolers that provide high cooling capacity.

35

Fluid End Components:

1. Chambers: The fluid end constructed from three separate but identical forged and heat-treated chambers. Fluid ends can supply any of five plunger sizes and each size can fit to the standard power end without alteration of either fluid or power end.

2. Valves and valves sets: Fluid ends are

fitted with replaceable, carburized valves and seats. Most of the valve assembly parts are interchangeable between suction and discharge ports within a given size and some are even interchangeable between sizes.

3. Lubrication: A separate lubrication

system supplies lubricant to the fluid end package. The period of 21/07/2012 to 25/07/2012 is the Coiled Tubing Unit:

I introduced to the Coiled Tubing Unit on that week. The Coiled Tubing Unit components are as follow (From the back of the trailer to the front):

1. Injectors: As its name means, it is used to moves coiled tubing into the well, and at the same time, it seals off the tubing, making a pressure-tight connection. The injectors have roller chain and gripper blocks to hold tubing in place and injecting it into the BOP

36

(Blow Out Preventer) mounted on the top of the well. The size of these injectors are based on its maximum pull capacity, for example, 30K which means it can pulls up to 30,000 lb.

2. The Guiding Arches: The Tubing guiding arches mount on top of the injector and does its part in guiding tubing into the well too. The design and the radius of each arch are typical with all job set-ups and conditions.

3. The Reel: Basically, reels are used to winding and unwinding coiled tubing; store the tubing for transport to the location; and keep the tubing in good working conditions. In addition to that, reels also provide tension during coil tubing operations.

4. Coiled Tubing Power Pack: The power pack provides all of the power and fluid controls necessary to operate a coiled tubing unit.

5. Control House: As its name implies, the control house is the operational nerve center of any coiled tubing unit. Usually it is mounting at the front side of the trailer after the reel and before the truck driver cabin. The control house could lift hydraulically above the reel for better view during the coiled tubing operations.

Plans

What  I  will  do  during  the  upcoming  week  is  following  up  with  the  supervisor’s  schedule and instructions, which I will be lift with the software, that are used in the department to perform the jobs are required.

37

Prince Mohammad Bin Fahd Universi ty

C o l l e g e o f E n g i n e e r i n g

Department of Mechanical Engineering

Internship Report

at

Halliburton Company

at

Boots and Coots Department

R e p o r t i n g P e r i o d :

[28/07/2012 - 08/08/2012]

S u b m i t t e d b y :

[ G h a z i K . A l A r f a j ]

[ 2 0 0 7 0 0 6 7 7 ]

[ s u b mi s s i o n d a t e ( 0 9 / 0 8 / 2 0 1 2 ) ]

Mechanical Engineering Department

Summer 2012

38

Summary

The seventh week at Halliburton Services Company was mainly about introducing us as summer trainee students about the software are using at the department in order to perform there required jobs.

Background

This report will explain what I learned about the Boots and Coots Software, and deeply the IFS Software.

Progress

The period of 28/07/2012 to 01/08/2012 is the IFS Software:

I was introducing to the InSite For Simulation Software or as it called (IFS). The software main functions are:

1. Monitoring, which include:

Pressure Monitoring.

Rate Monitoring; whether it is flow rate or anything else.

Density Monitoring.

Volume Monitoring.

Speed Monitoring.

Weight Monitoring.

Depth Monitoring.

2. Control that do the followings:

Controlling the Pumps.

Controlling the Blenders.

Controlling the Coiled Tubing jobs.

39

Controlling the Nitrogen jobs.

3. Analysis, which is analysis the data gathered by the software.

The operation of this software is basically as any other software in the universe. This program will need inputs such as, sensors, and cables to carry out the signals. After so, this program will give us the outputs based on the different inputs it takes.

Plans

What I will do during the upcoming week after completing the required training during the eight weeks is gathering up with the supervisor and collects the evaluation form. In addition, getting the supervisor feedback during my training weeks.