Introductions Geology lec ( 2 )

The geologic understanding of the pay and the surrounding formations plays an important part in the design of well completions and stimulations. The brief introduction given here will only give a glimpse of the subject matter in the field. This treatment of geology is very simplistic; reference articles and books are available for every segment.
The type of formation, composition, strength, logging basics, leakoff sites and other parameters may be available from a detailed geologic investigation. This information is useful for pay zone identification, fluid and additive selection, longevity of fluid contact, and selecting casing points.
There are several major classifications of rocks of interest to the petroleum industry: sandstones, carbonates (limestone and dolomite) evaporites, and shales are only the major groups. Several others, such as mudstones, siltstones and washes, are subdivisions of the major classifications.
Sandstones are predominately silicon dioxide and may have various amounts of clay, pyrite, calcite, dolomite or other materials in concentrations from less than 1 % to over 50%. Sandstone formations are generally noted for being a collection of grains. The grain size may range from very small, silt sized particles (5 microns) to pea size or larger. The grains fit together to form a matrix that has (hopefully) some void space between the particles in which oil or other fluids may accumulate. The grains are usually held together by a cement that may be clay, silica, calcite, dolomite, or pyrite. Some cementation of the grains is critical for formation strength; however, excess cementation reduces porosity and permeability.
Sands are deposited in a variety of depositional environments that determine the initial sedimentkock properties. The depositional environment is simply what type of surroundings and forces shaped the deposits. In the following descriptions of depositional environment, the energy level is labeled as either high or low depending upon the level of force that accompanied the deposition of the sediments. High energy deposits are those with sufficient wind or current to move large pieces of debris while low energy is sufficient to move only the smaller particles. The importance of energy is described later.
Common depositional environments are:

1. Deltas - These mouth of river deposits provide some of the larger sandstone deposits. Because of the enormous amount of natural organic material swept down the river systems, the deltas are also rich in hydrocarbons. Quality of the reservoir rock deposits may vary widely because of the wide variations in the energy level of the systems.
2. Lagoonal deposits - May be regionally extensive along the shores of ancient seas. Lagoonal deposits are low energy deposits that are hydrocarbon rich. Permeability may vary with the energy and amount of silt.
3. Stream beds - A moderate to low energy deposit with some streaks of high energy along the fast flowing parts of the streams. Stream beds are known to wander extensively and chasing these deposits with wells requires very good geologic interpretation, plus a lot of luck. The deposit volumes are also limited and frequently deplete quickly.
4. Deep marine chalks - These are often the most massive deposits available, built up at the bottom of ancient seas by the death of millions of generations of plankton-sized, calcium fixing organisms. They can be very consistent, thick deposits. Natural fracturing is common.
5. Reefs - These formations were built in the same manner as the reefs of today, by animals that take calcium from the sea water and secrete hard structures. Because of the cavities remaining from the once living organisms, reefs that have not undergone extensive chemical modification are among the most permeable of the carbonate deposits

6. Dunes - The effects of desert winds on the sands have a shaping effect that can be seen in the arrangement of the grains. These deposits may be massive but are usually lower energy. Permeability may vary considerably from top to bottom.
7. Alluvial fan - Zones of heavy water run-off such as from mountains are extremely high energy runoffs. Common constituents of these formations may range from pebbles to boulders and cementation may be very weak. Formations such as the granite washes are in this classification.
8. Flood plains - Occur along lower energy rivers and form during flood stages when the rivers overflow the banks and spill into adjacent low areas. Flood plain deposits are mostly silt and mud.

The level of energy with each type of deposit can be visualized by their modern depositional counterparts.
The importance of energy is in the sorting of the grains and the average size of the grains. As seen in the description of permeability in the preceding section, a rock with larger grains and the absence of very small grains leads to high permeability. When small grains are present, the permeability is much lower. When there is a mixture of the very large and very small grains, such as in some alluvial fans, the permeability can be very low. The extent of grain differences in a formation is termed the “sorting”, with well sorted formations having similar sized grains and poorly sorted formations showing a very wide size range.
The events that happen after the deposit is laid down are also factors in well completions and may have a devastating effect on reservoir engineering. Some of these forces are active for a short period in geologic time such as faulting and salt domes, and others like salt flows and subsidence, are active during the productive life of the well. The faulting, folding and salt movement make some reservoirs difficult to follow. Continuous forces are often responsible for formation creep in open holes, spalling, and casing sticking and collapse problems. Although these geologic movement factors cannot be easily controlled, the well completion operations can be modified to account for many of them, if the problems
are correctly identified early in the project life.
Chemical modifications also influence the reservoirs, though much less drastically than the uplift forces of a salt dome, for example. Most carbonates (not including the reefs) are laid down by accumulation of calcium carbonate particles. Limestone may recrystallize or convert to dolomite by the addition of magnesium. Because the limestone is soluble in ground water and very stable (resistant to collapse), the limestones are often accompanied by locally extensive vugs or caverns which form from ground water flow. Recrystallization or modification by the water as is flows through the rock may also lead to a decrease in porosity in some cases.
When dolomite forms, a chemical process involving the substitution of magnesium for part of a calcium in the carbonate structure generally shrinks the formation very slightly, resulting in lower microporosity but slightly higher porosity through the vugs or the natural fracture systems. Other types of dolomitization are possible. The carbonates are marked by a tendency towards natural fractures, especially dolomite. The chalk formations may be almost pure calcium carbonate, are reasonably soft (low compressive strength) and may have very high porosities on the order of 35-45%, but relatively low permeabilities of less than, typically, 5 md.
The third formation of interest is shale. These formations are laid down from very small particles (poor sorting) that are mixed with organic materials. The organic material is often in layers, pools, or ebbs.
The shales may accumulate in deep marine environments or in lagoonal areas of very low energy resulting in almost no large particles being moved. The shales are marked by high initial porosity and extremely low permeability. Shales often serve as a seal for permeable formations. The shales are also extremely important, since they are the source for the oil that has been generated in many major plays. Oil leaves the shale over geologic time and migrates into the traps formed in sandstones, limestones and other permeable rocks.
The evaporites are deposits that are formed by the evaporation of water. Deposits such as anhydrite are usually accumulations of dried inland seas and serve as extensive local geologic markers and sealing formations. They are extremely dense with almost no porosity or permeability.
When a deposit of oil and gas is found, it usually has its origins elsewhere and been trapped in a permeable rock by some sort of a permeability limiting trap. The trapping mechanism is too extensive to be covered in a short explanation on geology, but the major traps are outlined in the following paragraphs.

1. Trapping by a sealing formation is common and accounts for some major fields. These occurrences, called unconformity traps, are where erosion has produced a rough topography with peaks and valleys. Like the rolling terrain of the surface, most formations are rarely flat; they have high and low points and may have a general rise in a direction. If an extensive sealing formation is laid down in top of the sandstone (or other pay), and the sand is exposed to migrating oil from a lower source over geologic time, the oil will accumulate in the higher points of the pay and trend “uphill” toward the point where the hill drops off or another sealing event stops the migration. Tracking these deposits is best accomplished with as complete a structural map as can be constructed. These maps of the formations highs and lows compiled from seismic and drilling data indicate the better places to drill a well -- small wonder that the maps are among the most closely guarded secrets of an oil company.

2. Faulting is an event that shifts a large block of the formation to a higher or lower position. The misalignment of the zones often provides contact with sealing formations and traps the hydrocarbon. There are several types of faulting depending on the action and movement of the rock. In areas of extensive tectonic plate movements, faulting may be extensive.

3. Folding is an uplift or a drop of part of the formation where the breaks associated with faults do not occur. The formation maintains contact with itself, although it may form waves or even be turned completely over by the event. Complete turnover is seen in the geologic overthrust belts and accounts for the same formation being drilled through three times in one well, with the middle contact upside down. Vertical wells directly on the fold will  penetrate the formation horizontal to the original plane of bedding. Although these wells offer increased local reservoir quantity when they are productive, the problems with directional permeability and sweep in a flood are often substantial.

4. Salt domes cause uplift of the formation and result in numerous small or large fields around their periphery. Faulting is often very wide spread. Brines in these areas are frequently saturated or oversaturated and evaporated salt formations, stringers and salt-fill in vugs are common. Because of the uplift of some formations from deeper burial, the productive formations may be over pressured.

5. Stratigraphic traps (permeability pinchouts) are a change in the permeability of a continuous formation that stops the movement of oil. These deposits are very difficult to observe with conventional seismic methods. This effect, combined with a sealing surface to prevent upward movement of fluid forms numerous small reservoirs and a few massive ones. Permeability pinchout may also explain poor well performance near the seal. Laminated beds with permeable sands sandwiched between thin shales are a version of the pinchout or stratigraphic trap. These deposits may be locally prolific but limited in reservoir and discontinuous. Linking the sands is the key to production.
The age of a formation is dated with the aid of fossils which are laid down with the matrix. The age of a formation is important to know if the formation has a possibility of containing significant amounts o hydrocarbon. In most cases, very old formations such as the pre-Cambrian and Cambrian contain very little possibility for hydrocarbons unless an uplift of the structure has made the formation higher than an oil-generating shale, and oil has migrated into a trap inside the formation.


Formation Sequences and Layering
Formations are almost never homogeneous from top to bottom. There is a considerable amount of variation, even in a single formation, between permeability and porosity when viewed from the top of the zone to the bottom. When formations are interbedded with shale streaks, they are referred to as a layered formation. The shale streaks, often laid down by cyclic low energy environments, may act as seals and barriers and form hundreds or thousands of small isolated reservoirs within a pay section  Many times, the layering is too thin to be spotted by resistivity or gamma ray logs. When a formation is known to be layered, the completion requirements change. Perforating requirements may rise from
four shots per foot to 16 shots per foot, and in many cases, small fracturing treatments may prove very beneficial even in higher permeability formations.

Action plan 4 teachers free download learning English





Learn English with BBC World Service
BBC World Service broadcasts radio programmes for learners and teachers of English. Many programmes include
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Many of the radio programmes are accompanied by printed material, including free information sheets and booklets. These
support materials are based on the content of the radio programmes and also contain additional background information
on the subjects covered. Action Plan for Teachers is one of three new booklets from BBC World Service. The other two are
The Mediator, which uses authentic material to present and explain the language used in the news and broadcast media
and which is of particular interest to anyone pursuing a career in the media, and The Business, which is a self-help guide
to essential business concepts - from entrepreneurship to globalisation - that includes practical help on how to get ahead.
The BBC World Service’s Learning English website is a comprehensive online resource for both learners and teachers of
English. Material from the radio programmes plus information on many topics associated with English language learning can
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© British Broadcasting Corporation 2000
Action Plan for Teachers
Written by: Callum Robertson and including some material adapted from the English One to One teacher’s book written
by Richard Acklam.
Edited by: Tim Moock
Illustrated by: Tania Lewis at Doodlebugs, except for page 30 illustrated by Tim Moock.
Cover images: top and bottom © British Broadcasting Corporation, middle © The British Council
About the authors
Callum Robertson
has worked in English Language teaching since 1986. He has taught in Japan, China and Denmark as well as in the UK. He
is a teacher trainer and writer, producer and presenter for BBC World Service. He has a degree in Drama from the Univeristy
of Hull and the RSA Dip. TEFLA.
Richard Acklam
is a freelance ELT teacher, teacher trainer and textbook writer. He has worked in Cairo, Paris and London and has an MA
(TEFL) from the Uni versity of Reading.

Contents

Introduction 1
Planning
Pre-planning 2
• What should go into an English language lesson? 2
• What is a lesson plan? 3
• Why is planning important? 4
• Do you need to plan if you have a course book? 5
• What are the principles of planning? 5
Planning a lesson 7
• Aims and concepts 7
• Contexts and marker sentences 7
• Starting a lesson 8
• Presenting new language 9
• Controlled practice 10
• Freer (less controlled) practice 11
• Finishing the lesson 13
Action
Methodology 14
• Use of the mother tongue 14
• Eliciting 14
• Board work 15
• Drilling 15
• Pronunciation 17
• Organising student practice 18
• Exploiting listening and reading texts 19
Technology 21
• Overhead projectors 21
• Tape recorders 22
• Radio 24
• Television and video 26
• Computers and the internet. 28
Activities 30
• Warmers 30
• Presentation techniques 32
• The Phonemic Char t 37
Glossary 38

Who is Muhammad that is followed by more than one billion Muslims





Who is Muhammad that is followed by more than one billion Muslims


Is he a venerable scientist?


Is he a popular prince?


Is he a sophisticated Prime Minister ?


Is he a fair king?


The answer is

No


He is greater than all of those


He is the Messenger of Allah

Muhammad received the message from Allah 1400 years ago to call all mankind to follow the true path, no matter where or when; no matter if white or black, his message is for all.

His message is the last and the lasting one, no messenger will come after him, he is the last Messenger.


Who is Muhammad?

Is he a terrorist, as said by the Western media, or is he the brave warrior who won most of his battles against the enemies of Islam, or is he the genius who resolved all cases and troubles between the tribes.

He is the one who protected our Rights.


He protected men's, women's and children rights


He protected the relations between neighbors


He established the relationship between Muslims and Non-Muslims .


He organized the relationship between the members of the family showing the duties towards the parents


He prevented injustice and called for justice, love, togetherness and cooperation for the best.


He called for helping the needy, visiting the patients, love and exchanging advises between people.


He prohibited bad manners such as steeling, lying, and murdering .

He is the one who changed our lives and manners to the best .


A Muslim doesn't steal

A Muslim doesn't lie

A Muslim doesn't drink alcohol.

A Muslim doesn't commit adultery

A Muslim doesn't chea

A Muslim doesn't kill innocent people

A Muslim doesn't harm his neighbors

A Muslim obeys his parents and helps them

A Muslim is kind to young and elderly people, to women and to weak people.

A Muslim doesn't torture humans or even animals

A Muslim loves his wife and takes care of his children and show mercy towards them until the last day of his life.

A Muslim's relationship towards his children never stops even when they become adults



He is Muhammad (PBUH)

Did you know why all Muslims love Muhammad (PBUH)?

Did you know what does Muhammad mean for Muslims?

Every Muslim loves Muhammad (peace be upon him) more than himself and more than everything in his life.

Before judging a person be neutral and:

1-Listen to this person, and follow his doings.

2-Compare his ideas and teachings with what is acceptable to the mind and heart.

3-If you think that his thoughts are right, compare them with his doings; is he applying his teachings?

4-If he is applying his teachings and sayings, so he is for sure right and one must believe him.

At the end you will get a clear answer for all confusing questions and you will know for sure :

who Muhammad really is

Christian breaks down crying after Yusuf Estes answer to his question!!

Christian breaks down crying after Yusuf Estes answer to his question





This is our Prophet the Messenger of Islam

This is our Prophet After this they say he is bad

Hear from us not hear about us

First, our Prophet Mohammed  loves you and we also love and we hope that you will enter Paradise


Introduction: Basic Well Completion Concepts lec ( 1 )


Porosity
Porosity is the fraction of the total volume of the rock that is pore (non rock) space or void and not made of solid pieces of the formation. It will be filled with a gas, water or hydrocarbon or two or more at the same time. Porosity will range from a high of 40-50% in some marginally consolidated chalk formations to a low of near zero in some of the evaporites (anhydrite). The average porosity of producing reservoirs ranges from about 515% in limestones or dolomites, 10-25% in sandstones and over 30% in many of the chalk formations. In most unconsolidated formation, porosity depends upon the grain size distribution; not on the absolute size of the grain itself. Porosity can be in the order of 35-40% if all grains are close to the same size, but in most cases where a wide range of grain sizes are available, the porosity will be between 15-25%. Severe cases of formations with mixtures of large and very small grains may have porosities less than 15%.
Lower porosities, such as 10% or less, are usually the result of chemical modification of the pore structure, i.e., recementation, precipitation of additional minerals, or leaching and reprecipitation. In some cases, the very consolidated sandstones with overgrowth of quartz may have porosities down to near zero. Geologists further subdivide porosity into several descriptive classifications that help engineers describe the flow of fluids through the formation and into the wellbore. The major classifications are briefly described in the following paragraphs.
  1.  Matrix porosity or intergranular porosity - the porosity between the grains of the formation.
  2.  Vug porosity - porosity in the solution chambers that may range from a tenth of a    millimeter to voids larger than a basketball.
  3.  Fracture porosity - the void space created within the walls of an open natural fracture.
  4.  Micro porosity - the voids between the clay platelets or particles. Although a large micro porosity
may exist, production of fluids from them is often difficult since the fluids are usually held by
strong cohesive forces.
The matrix porosity is referred to as the primary porosity and most other porosities are secondary. Usually, the pore space described by natural fractures and vugs are produced or swept very early (flush production) and their continuing use becomes as a conductive pathway to the wellbore. Long term production rate estimates are usually based upon the reserves in the matrix except in very large fields where solution porosity (vugs) is very extensive. Porosity values derived from neutron or sonic logs are usually used alone with other log information and well observations to establish whether a section of rock is “pay.” Although the use of porosity in this manner is common, it can also be very misleading. Obviously, porosity is not a “stand along” value for establishing the quality of ‘pay.” Shales, for example, have porosities of 30% or more but lack the conductive pathways (permeability) to make them economic except where fractured gas-rich shales
exist in massive sections. The location and type of porosity has a great affect on the performance of a well. Relying totally on a log derived porosity, especially in a carbonate, may provide unexpected low production or may result in missing productive intervals. The occurrence of lime muds, a low porosity deposit common within limestones may isolate porosity and result in much lower effective porosities than reported with a log. Fossils, 
Saturation


The fraction of pore space containing water is called the water saturation and usually denoted by an Sw. The remaining fraction of the pore space that contains oil or gas is called hydrocarbon saturation Sh. The simple balance sh = 1 - Sw accounts for all of the pore space within a rock. In almost every porous formation, there is at least a small amount of water saturation. Usually when the sediments were laid down, the matrix materials were dispersed in water. As the hydrocarbon entered the porous formation, water was displaced from many of the pores, although the displacement process is not efficient enough to move all the water. This displacement process, whether it was oil displacing
water over geologic time, or water displacing oil during water drive or water flooding, results in a lower saturation of the fluid being displaced. If a very large amount of the driving fluid is displaced, the quantity of the initial fluid reaches a point, usually a few percent of the pore space, where it cannot be reduced further. This level of fluid is the irreducible saturation of that fluid. Therefore, an irreducible water saturation, S,,,i, is the saturation of water in the core that cannot be removed by migration of hydrocarbon. This water or oil, Soil may be trapped in the small pores, held by high capillary attraction, or bound to clays as a surface layer or in the clay lattice.
Permeability

Permeability, denoted by a lower case k, is a measure of the conductance of the formation to flow of a fluid. The higher the permeability, the easier it is (takes less driving pressure) for a fluid to flow through the rock matrix. The “law” was originally derived by a French engineer named d’Arcy to account for the flow of water through sand filters. The original permeability concept used darcies as a unit of measurement, but most productive formations will be between 0.001 md (1 md = 0.001 darcy) and 1000 millidarcies (1 darcy). Permeability depends on the absolute grain size of the rock, how well the sediments are sorted, presence of fractures, and how much chemical modification has occurred in the matrix. Flowing and bound fluid properties also affect the permeability. Large-grained sediments with a minimum of fine particles (large, open pores) usually have high permeabilities whereas very
fine-grained sediments with small pores have lower permeabilities. Porosity does not always relate directly to permeability. Materials such as shales and some chalks may have very high porosities but low permeability because of lack of effective connection of the pores.
Permeability to oil, water and gas may be different because of viscosity differences and other influences such as wetting and the issue of the thickness of the liquid coating on the pore wall. Oil wet formations are usually thought to be less permeable to the flow of water than water wet formations because the molecular thickness of the oil coating is thicker than that of water. This leaves less pore space for fluids flow. When more than one phase exists in the pore, relative permeability relationships govern the flow.
Relative Permeability
The effects of relative permeability explain many of the problems involved in formation damage and reduction of flow from a formation, either on initial production or after treating with a material which severely oil wets the formation. As will be pointed out in the chapter on formation damage, problems with relative permeability include a significant drop in permeability to the saturating fluid as trace amounts of a second, immiscible phase are introduced in the flowing liquid. Reductions of up to 80% of initial permeability are common when saturation of an immiscible phase is increased from zero to approximately 20 or 25%. It is this significant reduction in permeability that explains much of the damage behind overtreatment with an oil-filming chemical, such as an oil-based drilling mud, or the use of highly absorptive surfactants or solvents. The surface of the rock also plays an important part since the charge of a surfactant controls the attraction to a particular formation face. It must be remembered that severe wettability problems such as the absorption of cationic materials onto sandstones and the absorption of anionic materials onto limestones can play a significant role in permeability reduction. The reduction from this coating or wetting may be severe and can be long-lasting, depending on the tenacity of the coating. Matrix cleanup of this type of wetting is imperative to fully restore the flow capacity of the formation.
Cleanup of this type of damage must take into account both the stripping of the relative permeability influencing layer and the type of rock surface to which it is adsorbed.
Natural Fractures
Natural fractures are breaks in the fabric of the rock caused by a wide variety of earth forces. These natural fractures may have widths of a few thousandths of an inch to a tenth of an inch or more. Natural fractures generally have a common direction that corresponds to forces generated by a significant geologic event in the area such as folding, faulting, or tectonic forces. Where solution etching or cementation forces are active, the fractures may be widened into extensive vugs with permeabilities of hundreds of darcies or filled completely with precipitated minerals. Stylolites or gouge filled fractures are examples of these behaviors. Natural fractures influence flush production or high initial production rate that diminishes quickly after bringing on a new well or the start of flow in a well that has been shut-in. Although they serve as conductive pathways for oil or gas production, they also will transmit water at a much faster rate than the formation matrix, leading to early breakthrough of water or other type floods and sweep problems in reservoir engineering.
Reservoir Pressure
The pressure that the reservoir fluids exert on the well at the pay zone is the reservoir pressure. In single pay completions with little or no rat hole (extra hole below the pay), the reservoir pressure is the bottom hole pressure, BHP. The initial reservoir pressure is the pressure at the time of discovery. Flowing bottom hole pressure is pressure exerted as the result of a drawdown (differential pressure produced by flowing the well). Shut-in pressure is the stable pressure reached after the well has been shut in long enough to come to equilibrium. Shut-in pressures are often quoted as a function of time. The initial pressure is usually a function of depth of burial but may be modified by other forces at the
time of burial or at a later time. Driving pressure may be supplied by a number of mechanisms depending upon the characteristics of the oil and the surrounding geologic and physical forces. The general types of reservoir drive forces (to the limit of general interest in well completions) are:
    1. Solution gas drive - a volumetric displacement where all the driving energy or pressure is supplied by gas expansion as the pressure is reduced and the gas comes out of solution. In reservoirs “above the bubble point”, all the gas is dissolved in the oil and there is no free gas. In these reservoirs, there may be a volume change of the oil as the pressure drops and gas breaks out of solution. Reservoir pressure decreases with fluid withdrawals.
    2. Gas Cap - a volumetric displacement where the oil is “below the bubble point”, i.e., there is free gas or gas saturation in the pores and there may be a gas cap. Reservoir pressure decreases with fluid withdrawals.
   3. Water drive -water influx into the reservoir from edge, bottom or water injection wells can provide very consistent drive pressure to a reservoir. Like the oil, the water moves through the most permeable pathways of the formation towards the pressure drop produced by removal of fluids. The water pushes part of the oil in front, entering some of the pores and displacing the oil. Oil production continues long after the breakthrough of water at the producing well since the formation may contain a number of streaks that have permeability differences an order of magnitude or more. Reservoir pressure may remain the same or drop with fluid withdrawals, depending upon how fast the incoming water replaces the withdrawn fluids.
   4. Reservoir compression through compaction in poorly consolidated, high porosity reservoirs is also a “method” of supplying driving energy but it usually generates serious problems in the reservoir. In these reservoirs, which may often be initially over pressured, the reservoir fluids are aoverburden load supporting element. Withdrawal of the fluids requires the matrix of the formation to support more of the load from the overlying sediments (overburden). In some poorly consolidated or weak formations, the matrix compresses under the load, leading to lower porosity and a continued pressure on the remaining fluids. Although this is a definite form of pressure maintenance, when the porosity is decreased, the permeability also is reduced. Compaction of the pay in massive sections may also lead to subsidence of several feet at the surface -- a critical problem for some offshore rigs and sea level land fields.
   5. Pressure maintenance or sweep projects using water or gas are our methods of increasing recovery. These processes come with many of the same advantages and limitations as their natural counterparts.
Pressures
To a workover engineer, pressure can be a powerful tool or a nightmare. The difference is in how pressure control is handled. The following "short list" of pressures and pressure related terms presents an idea of what and how pressures are important to the workover.
     1. Reservoir Pore Pressure - The pressure of the reservoir fluids, often expressed as a gradient in psilft. The initial reservoir pressure is the pressure at the time of discovery. Fluid withdrawals from a reservoir are made by lowering the pressure in the wellbore. The flow of fluids toward the low pressure creates zones of lower pressure or pressure gradients extending into the reservoir. The reservoir pressure can only be measured at the wellbore in a new well or in a well that has experienced complete buildup.
     2. Flowing Bottom Hole Pressure -This pressure is measured at the productive zone during flow. A value of flowing bottom hole pressure is usually reported with a flow rate or a choke setting. A change in the flow rate will change the flowing bottom hole pressure.
     3. Drawdown - Drawdown is the pressure differential set by the difference of the reservoir pressure and the flowing bottom hole pressure.
     4. Flowing Tubing Pressure - A surface measurement of the pressure in the tubing, prior to the choke, at a particular flow rate. It is equal to the flowing bottom hole pressure minus the hydrostatic pressure exerted by the fluids in the tubing. Because of entrained gas production and gas breakout as the well is produced, it is rarely possible on liquid/gas producers to accurately calculate the flowing bottom hole pressure from the flowing wellhead pressure. Only when the composition of the fluid in the tubing is known can the down hole pressure be calculated.
      5. Shut-in Surface Pressure - Any pressure measured at the surface immediately after a well is shut-in will change as bottom hole pressure builds up toward reservoir pressure and the fluids in the tubing come to an equilibrium. Surface measured shut-in pressures are useful in some buildup tests to assess the productivity of a well.
     6. Productivity Index - The productivity index is a measurement of well flow potential. It is a term generated from a delivery plot of flow rate and pressure from a particular well. It is commonly expressed as a potential flow rate per pressure drop such as barrels per day per psi. By multiplying the PI by the intended drawdown, a flow rate of the well can be predicted. The PI is established by test on the well. It changes with time.
     7. Fracture Breakdown Pressure - A measurement of what pressure is required to hydraulically fracture the rock. The breakdown pressure is usually attained from drilling data, breakdown tests, or fracture stimulations. It is usually expressed as a gradient of pressure per unit of formation depth such as psi/ft.
    8. Fracture Extension Pressure -The pressure necessary to extend the fracture after initiation. Like fracture breakdown pressure, it is relevant to a particular well or field.
    9. Friction Pressure - When fluids are flowed at high rates through a conduit, there is a resistance to flow caused, at least partly, by friction of the fluids at the boundaries of the conduit and by turbulence (mixing) of the fluids. Whether the conduit is pipe or a fracture, friction represents a back pressure. Friction is expressed as pressure at a rate for a unit length of a particular conduit.
    10. Bubble Point Pressure - In a reservoir that contains an undersaturated oil, there will be no gas cap. As the pressure is drawn down, the solution gas will break out of solution. Because of relative permeability and saturation concerns, the occurrence of reaching the bubble point usually coincides with a drop in production.
Pressure Differential
Pressure differential is probably the most important pressure during drilling, completion, workover and production. The differential pressure between the wellbore and the formation dictates which direction fluids will move and at what rate they will move. Additional controls such as reservoir permeability and native and injected fluid viscosity also have an affect, as does the presence of solids in the wellbore fluid when the pressure differential is toward the formation. In general, drilling pressure differential should be as low as possible to minimize formation damage and the amount of fluid invasion from wellbore fluids. However, during any drilling, completion or workover operation, the pressure differential must be toward the wellbore (higher pressure in the wellbore than in the reservoir) when well flow is not wanted. Maintaining pressure differential is the same as maintaining well control. Certain conditions, such as intentional or accidental swabbing caused by swab cups or large-diameter tools, can create low pressures at the bottomhole, even with a column of high pressure fluid above the swab or tool. It is the rate of movement and the diameter difference between the object in the hole and the inside of the hole itself that determine the swab or underbalance loads. Each step of a drilling, completion or workover operation, particularly when tools or  equipment are removed from the hole, should be examined to determine if swab loads can unbalance the pressure differential and swab fluids into the wellbore. During production, pressure differential toward the wellbore is essential for fluid flow. Columns of standing liquids, excessive backpressures or large amounts of solids in the fluids in the wellbore will
act as a check valve, severely limiting production flow into the well. The study of pressure differential and pressure drop is commonly done using a nodal analysis program. These programs compute pressure drops and backpressures on a system, and help identify
those points that may be bottlenecks to good production practices. There are many instances of wells, some even with large-diameter tubing where the tubing has been found to be a “choke” on the production from the well. Changing out the tubing to a larger size in many cases has doubled production from a high capacity well.
Well Temperature
The reservoir at static conditions has a shut-in or reservoir temperature that is characteristic of the depth times the geothermal gradient for that area. A 13,000 ft deep reservoir in one part of the world may have a bottom hole temperature of 1 6OoF, while a similar depth reservoir in a hotter geothermal area may be 360°F.
As the well flows, the bottom hole temperature will drop depending on the type and amount of gas and the pressure drop. The cooling is produced by the expansion of gas. Temperature reductions low enough to freeze water may form ice or “hydrates” in some gas wells while wells with a smaller ratio of gas to liquids will flow hot to surface.

Fluid Properties
The composition of the fluid in the formation, at various points in the tubing and at the surface have major affects on the performance of the well and the selection of production equipment. The following terms are required knowledge to describe the fluid and their changing nature.
.
1. Gas-oil-ratio, GOR, the amount of free gas associated with the oil production. The gas may ordinarily be in solution or free gas as in a reservoir with a gas cap. When the gas volume is expressed as a function of the total liquids, the value is the gas-liquid-ratio, GLR. Wells with GLRs above 8000 are considered gas wells, while those with a GOR less than 2000 are labeled oil wells. The wells in between 2000 and 8000 are combination wells. The actual GOR value is usually measured at the surface, its value downhole changes with pressure.
2. Water-oil-ratio, WOR, is the amount of water being produced in ratio to the oil production.
3. Bubble point refers to the pressure that a free gas phase will form in an undersaturated oil. The significance is the addition of another phase that, most likely, will lower the relative permeability.
4. Dew point is the pressure and temperature at which the light hydrocarbon gases, Cs-C,, begin to condense into a liquid. The addition of another phase will lower relative permeability.
5. Cloud point is the temperature in an oil system where paraffin crystals appear (cj8 + fraction begins to solidify).
6. Pour point is the temperature below which the oil will no longer pour.
High Temperature and High Pressure Wells
Wells with pressures over 0.6 psi/ft and temperatures over 300°F are often referred to as HTHP wells
or high temperature, high pressure wells. These wells account for less than 1% of the total wells
drilled, but may cost 5% or more of the total expenditures for drilling and completions. The risk, reward
and cost can all be very great in these types of wells. Very special workover and completion operations
are necessary to adequately complete and produce these wells.

FUNCTIONS OF A DRILLING FLUID lec ( 1 )

There are a number of functions of a drilling fluid. The more basic of these are listed below:
1. Balance formation pressure
2. Carry cuttings and sloughings to the surface
3. Clean beneath the bit
4. Cool and lubricate bit and drill string
5. Seal permeable formations
6. Stabilize borehole
7. Corrosion control

In addition to these functions, there are several other functions with which the drilling fluid should not interfere:
1. Formation evaluation
2. Completion operations
3. Production operations

Clearly, these lists of functions indicate the complex nature of the Clearly, these lists of functions indicate the complex nature of the role of drilling fluids in the drilling operation. It is obvious that compromises will always be necessary when designing a fluid to carry out these functions, which in some cases require fluids of opposite properties. The most important functions in a particular drilling operation should be given the most weight in design of the drilling fluid.
Many of these functions are controlled by more than one mud property and should be discussed in more detail.

Pressure Control

 The density of drilling fluid must be such that the hydrostatic pressure exerted by the mud column will prevent flow into the wellbore. This is the first requirement of any drilling fluid and it must be provided for before considering any other mud property or function.
 The equation for calculating hydrostatic pressure is:
Hydrostatic Pressure, psi = (depth, ft.)(mud weight, lb./gal)(0.052) Pressure control would be rather simple if it consisted only of balancing the hydrostatic and formation pressures in the static condition. However, pressure is required to cause a fluid to flow This pressure is dissipated in frictional losses along the entire flow path.
Consequently, the total pressure at any point in a circulating system is the sum of the hydrostatic pressure at that point and in the circulating pressure drop from that point to the exit point.
Under normal circulating conditions, the pressure at any given point in the hole is the sum of the hydrostatic pressure at that point and the circulating pressure drop from that point to the flow line. An example of circulating pressures at various points in the system is seen in
Figure 1.

When pipe is run into the hole, the pipe displaces fluid, causing it to flow up the annulus. This is analogous to circulating the fluid and pressure calculations can be made in the same manner. When pipe is being pulled from the hole, the mud falls under its own weight to fill the void volume left by the pipe. The mud flowing down the annulus under gravity develops a flowing pressure drop that subtracts from the hydrostatic pressure. The total pressure at any point in the annulus is the hydrostatic minus the flowing pressure drop from the surface to that point in the annulus.

Figure 2

 illustrates pressure profiles under swab, static, or surge conditions. The difference in total pressure at any depth between the hydrostatic and swab or surge lines is the pressure drop caused by pipe movement.
Obviously, if a formation pressure is greater than the wellbore pressure under swab conditions, the formation fluid will flow into the well when the pipe is pulled. If the fracture pressure of a formation is less than the pressure at that depth under surge conditions, the
formation will be fractured while running the pipe and lost circulation will occur. These factors must be taken into account when establishing the required density of a mud.

Normally the mud density will be run slightly higher than required to balance the formation pressure under static conditions. This allows for a safety margin under static conditions and offsets the same amount of negative swab pressure. If the swab effect is still greater
than the overbalance, it must be reduced by slower pipe pulling speeds. This is necessary because further increases in mud density would cause problems in the areas of lost circulation, decreased penetration rates, and differential pressure sticking. The hole must
be filled when pulling pipe to replace the volume of the pipe.
Otherwise, the reduction in hydrostatic pressure will allow the well to flow.
By the same token, if the surge or the circulating pressure drop causes the total pressure to exceed the fracture pressure of a formation, the pipe running speed or the circulating rate must be decreased enough to prevent fracturing from occurring. When it becomes impossible to meet minimum and maximum pressure requirements at realistic pipe moving speeds or circulating rates, it is time to case the hole.
There are at least two different ways of calculating the annular pressure loss while circulating a mud. One method is to measure or predict the mud flow properties under downhole conditions and knowing the circulation rate and hydraulic diameter, calculate
directly the annular pressure drop.
This method has several weaknesses. First, an accurate knowledge of the flow properties of the mud is usually not available. This is especially true of water-base muds, which tend to gel with time when static in the hole and gradually decrease in viscosity when sheared. Such a mud may have a considerably higher gel strength and yield point initially after breaking circulation than under normal circulating conditions. Annular pressure drop calculations using flow line measurements of mud properties will yield pressure losses that
are less than actual when the mud is gelled downhole.
A second problem with annular pressure drop calculations is in knowing the hole diameter. If the hole is washed out, the pressure drop will be less than calculated; if a filter cake is deposited, the diameter will be decreased and the pressure drop greater than calculated. We are normally faced with estimating the average hole diameter in order to calculate pressure drop. The clearance between pipe and hole is very critical to pressure drop when this clearance is small. For this reason we need an accurate estimate of hole size around the drill collars. Fortunately, this is the part of the hole that should be least washed out and has the thinnest filter cake. A third factor that leads to inaccuracy in annular pressure drop
calculations is how well the pipe is centered in the hole. Our calculation procedure assumes perfect centering. This is usually not the case. The pressure drop in the annulus is greatest when the pipe is centered and is least when the pipe is lying against the wall.
This means that we tend to calculate a pressure drop which is higher than actual.
In general, this method of determining annular pressure loss is accurate for oil muds, which are not susceptible to temperature elation and which tend to keep the hole in gage. The method is not so accurate for water muds and especially for those which have high
gel strength at bottom hole temperature.
A second and more accurate method for determining annular pressure losses employs the use of an accurate standpipe pressure measurement. The pressure drop down the drill string and through the bit can be accurately calculated with a Reed Slide Rule and
subtracted from the standpipe pressure. The difference is the pressure drop up the annulus. This method is also quite useful while breaking circulation and until "bottoms up" has been obtained. During this period, the flow properties of the mud downhole are unknown and changing rapidly. This makes the direct calculation of annular pressure drop quite inaccurate. After breaking circulation, the annular pressure drop will decrease for a period of time. This is due to "shearing down" the gel structure of the mud. However, the shear rate in the annulus is not high  enough to break all flocculation bonds and the “bottoms up” mud will
remain abnormally high in viscosity. As this mud becomes cooler, as it is circulated up the hole, the viscosity will begin to increase. When the “bottoms up” mud is somewhere in the upper half of the hole, the pressure drop may begin increasing. If the circulation rate is not
decreased, a pressure drop greater than that required to initiate circulation may occur.
A detailed analysis of pressure drop calculations is given in Appendix A. Remember that these are calculations and the answers are only as good as the input data. Always try to determine how the most probable errors in the input data will affect your answer and how this will affect the drilling operation.

Hole Cleaning 

The ability to lift particles of various sizes out of the hole is one of
the most important functions of a drilling fluid. This is the only way
that the rock which is drilled or which sloughs from the wall is
carried out of the hole. In a 121/4-inch hole, about 130 pounds of
earth material must be removed for every foot of hole drilled. In fast
drilling an enormous amount of drilled cuttings are entering the mud
system. The mud circulation rate must be high enough to prevent an
excessive increase in mud density or viscosity.
Drilling a 12 ¼-inch hole at 3 feet per minute while circulating a 9
lb./gal mud at 10 bbl/min will result in a mud density increase in the
annulus to 9.5 lb./gal. If the drilled solids are fine and further
dispersed into the mud, a substantial increase in viscosity will result.
The combination of these two effects may cause the equivalent
circulating density of the mud in the annulus to exceed the fracture
gradient and cause loss of circulation. The circulation rate can be
increased to minimize the increase in density and viscosity due to
the influx of solids, but this will also cause an increase in equivalent
circulating density. If this ECD is also higher than fracture gradient,
then the drilling rate must be decreased.
It is possible, for short periods of time, to obtain such high drilling
rates in soft shales that cuttings cannot be wet and dispersed fast
enough to prevent them from sticking together and forming "balls" or
"slabs". For this reason, it is necessary to watch not only the long
time average drilling rate but also the instantaneous rates. A
procedure for calculating annular mud density increase due to drilled
solids influx is given in Appendix A.
Another, more common type of carrying capacity problem is the
ability of the fluid to lift the cuttings or sloughings and carry them out
of the hole. This problem is often difficult to detect because some of
the smaller cuttings come out while the larger ones remain in the
hole. If the hole is beginning to slough, the amount of shale coming
across the shaker will appear to be normal, but large amounts may
be collecting in the hole. Sometimes the appearance of the cuttings
will indicate poor hole cleaning. If the cuttings are rounded, it may
indicate that they have spent an undue amount of time in the hole.
The condition of the hole is usually the best indicator of hole
cleaning difficulty. Fill on bottom after a trip is an indicator of
inadequate cleaning. However, the absence of fill does not mean
that there is not a hole cleaning problem. Large amounts of cuttings
may be collecting in washed-out places in the hole. Drag while
pulling up to make a connection may also indicate inadequate hole
cleaning. When the pipe is moved upward, the swab effect may be
sufficient to dislodge cuttings packed into a washed-out section of
the hole. The sudden dumping of even a small amount of material is
often enough to cause severe drag or sticking.
Hole cleaning is a more severe problem in high-angle holes than in
vertical holes. It is not only more difficult to carry the cuttings out of
the hole, but they need to settle only to the low side of the hole
before causing problems. Consequently, more attention should be
paid to hole cleaning requirements in directional holes.
The ability of a fluid to lift a piece of rock is affected first by the
difference in density of they rock and the fluid. If there is no
difference in densities, the rock will be suspended in the fluid and
will move in a flow stream at the same velocity as the fluid. As the
density of the fluid is decreased, the weight of the rock in the fluid is
increased and it will tend to settle. The shear stress of the fluid
moving by the surface of the rock will tend to drag the rock with the
fluid. The velocity of the rock will be somewhat less than the velocity
of the fluid. The difference in velocities is usually referred to as a
slip velocity. The shear stress that is supplying the drag force is a
function of shear rate of the fluid at the surface of the rock and the
viscosity of the mud at this shear rate. A number of other factors
such as wall effects, inter-particle interference, and turbulent flow
around the particles make exact calculations of slip velocity
impossible. However, equations for estimating slip velocities are
shown in Appendix G. These equations give a rough idea of the size
range that can be lifted under a given set of conditions.
In general, hole cleaning ability is enhanced by the following:
1. Increased fluid density
2. Increased annular velocity
3. Increased YP or mud viscosity at annular shear rates.
It should be noted that with shear thinning fluids it is sometimes
possible to decrease annular velocity, increase the yield point, and
also increase the hole cleaning. This is done in order to minimize
hole erosion. Where viscosity is sufficient to clean the hole, the
annular velocity should be maintained below that for turbulent flow in
order to minimize annular pressure drop and hole erosion. This, of
course, is not possible when drilling with clear water where high
velocities and turbulent flow are usually necessary to clean the hole.
annular velocity should be maintained below that for turbulent flow in
order to minimize annular pressure drop and hole erosion. This, of
course, is not possible when drilling with clear water where high
velocities and turbulent flow are usually necessary to clean the hole.

Cleaning Beneath
the Bit

Cleaning beneath the bit appears to require mud properties almost
opposite from those required to lift cuttings from the hole. In this
case we want the mud to have as low a plastic viscosity as possible.
Since the fluid shear rates beneath the bit are at least 100-fold
greater than in the annulus, it is possible to have low viscosities at
the bit and sufficient viscosity in the annulus to clean the hole. A
mud that is highly shear-thinning will allow both functions to be
fulfilled. Flocculated mud and some polymer muds have this
characteristic.
Since cleaning beneath the bit relates to penetration rate, all other
factors that relate to penetration rate (such as density, hydraulics,
etc.) should be considered simultaneously.

Cooling and
Lubricating

Cooling and lubricating the bit and drill string are done automatically
by the mud and not because of some special design characteristic.
Muds have sufficient heat capacity and thermal conductivity to allow
heat to be picked up down hole, transported to the surface, and
dissipated to the atmosphere.

The process of
circulating cool mud
down the drill pipe
cools the bottom of the
hole. The heated mud
coming up the annulus
is hotter than the earth
temperature near the
surface and the mud
begins to heat the top
part of the hole. This
causes the
temperature profile of
the mud to be different
under static than
under circulating
conditions, as shown
in Figure 3.





The maximum mud temperature when circulating is cooler than the
geothermal bottom-hole temperature. The point of maximum
circulating temperature is not on bottom but about a third of the way
up the hole. These facts are important to remember when attempting
to predict mud behavior downhole. A mud additive which is not
completely stable at the geothermal bottom-hole temperature may
perform adequately at the circulating temperatures. If flocculation
due to temperature begins to occur during circulation, as evidenced
by increases in yield point and gel strength at the flow line, then we
can be assured that severe gelation will occur as the mud heats up
after circulation is stopped.
In addition to cooling the well bore, the circulating mud also removes
frictional heat and supplies a degree of lubrication. Cooling is
especially important at the bit where a large amount of heat is
generated. Sufficient circulation to keep the temperature below a
critical point is essential in using a diamond bit.
Lubrication is a very complex subject and especially as it applies to
the drilling operation. If a mud does not contain a great deal of
abrasive material such as sand, it will supply lubrication to the drill
string simply because it is a fluid that contains solids that are softer
than the pipe and casing. Attempts to improve this basic lubricating
quality of a mud are usually ineffective and expensive. Probably far
greater benefits can be realized by keeping the abrasive content of a
mud as low as possible.
Hole symptoms such as excessive torque and drag, which are often
associated with the need for a lubricant in the mud, are often caused
by other problems such as bit or stabilizer balling, key seats, and
poor hole cleaning. Sometimes materials sold as lubricants relieve
these symptoms, but not as cheaply or effectively as a more specific
solution to the problem.
The success or failure of a lubricant is related to its film strength in
relation to the contact pressure at the surface being lubricated. If the
lubricating film is "squeezed out", then the lubricant has apparently
failed. A material that appears to be a good lubricant in a test at low
contact pressure may fail in actual application due to higher contact
pressures, higher rotating speed, etc. The only good test of a
lubricant is under the exact conditions that exist where lubrication is
desired. Unfortunately, these conditions are not known downhole.
Lubrication should not be confused with attempts to reduce
differential pressure sticking. These are two different problems.
Additives sold as lubricants will probably do very little to relieve
differential pressure sticking if used in the concentrations
recommended for lubrication.




MATERIALS lec ( 3 )

1. INTRODUCTION
This chapter covers the most commonly used materials of construction
for piping systems within a process plant.
The two principal international codes used for the design and
construction of a process plant are ASME B31.3, Process Piping, and
the ASME Boiler and Pressure Vessel Code Sections.
Generally, only materials recognized by the American Society of
Mechanical Engineers (ASME) can be used as the ‘‘materials of
construction’’ for piping systems within process plants, because they
meet the requirements set out by a recognized materials testing body, like
the American Society of Testing and Materials (ASTM).
There are exceptions, however; the client or end user must be satisfied
that the non-ASTM materials offered are equal or superior to the ASTM
material specified for the project.
The Unified Numbering System (UNS) for identifying various alloys is
also quoted. This is not a specification, but in most cases, it can be crossreferenced
to a specific ASTM specification.
1.1. American Society of Testing and Materials
The American Society of Testing and Materials specifications
cover materials for many industries, and they are not restricted to the
process sector and associated industries. Therefore, many ASTM
specifications are not relevant to this book and will never be referred to
by the piping engineer.
We include passages from a number of the most commonly used
ASTM specifications. This gives the piping engineer an overview of the
specifications and scope in one book, rather than several ASTM books,
which carry specifications a piping engineer will never use.
It is essential that at the start of a project, the latest copies of all the
relevant codes and standards are available to the piping engineer.
All ASTM specification identifiers carry a prefix followed by a
sequential number and the year of issue; for example, A105/A105M-02,
Standard Specification for Carbon Steel Forgings for Piping Applications,
breaks down as follows:
A ¼ prefix.
105 ¼ sequential number.
M means that this specification carries metric units.
02 ¼ 2002, the year of the latest version.
Official title ¼ Standard Specification for Carbon Steel Forgings for Piping
Applications.
The complete range of ASTM prefixes are A, B, C, D, E, F, G, PS, WK;
however, the piping requirements referenced in ASME B31.3, which is
considered our design ‘‘bible,’’ call for only A, B, C, D, and E.
The requirements of an ASTM specification cover the following:
. Chemical requirements (the significant chemicals used in the production
and the volumes).
. Mechanical requirements (yield, tensile strength, elongation, hardness).
. Method of manufacture.
. Heat treatment.
. Weld repairs.
. Tolerances.
. Certification.
. Markings.
. Supplementary notes.
If a material satisfies an ASTM standard, then the various characteristics
of the material are known and the piping engineer can confidently use the
material in a design, because the allowable stresses and the strength of
the material can be predicted and its resistance against the corrosion
of the process is known.
1.2. Unified Numbering System
Alloy numbering systems vary greatly from one alloy group to the
next. To avoid confusion, the UNS for metals and alloys was developed.
The UNS number is not a specification, because it does not refer to the
method of manufacturing in which the material is supplied (e.g., pipe
bar, forging, casting, plate). The UNS indicates the chemical composition
of the material.
An outline of the organization of UNS designations follows:

In this chapter, the ASTM specification is the most common reference in
the design of process plants. Extracts from a number of the most
commonly used ASTM specifications are listed in the book, along
with the general scope of the specification and the mechanical
requirements.
For detailed information, the complete specification must be referred
to and the engineering company responsible for the design of the plant
must have copies of all codes and standards used as part of their
contractual obligation.
1.3. Manufacturer’s Standards
Several companies are responsible for inventing, developing, and
manufacturing special alloys, which have advanced characteristics that
allow them to be used at elevated temperatures, low temperatures, and in
highly corrosive process services. In many cases, these materials were
developed for the aerospace industry, and after successful application,
they are now used in other sectors.
Three examples of such companies are listed below:
. Haynes International, Inc.—high-performance nickel- and cobalt-based
alloys.
. Carpenter Technology Corporation—stainless steel and titanium.
. Sandvik—special alloys.
1.4. Metallic Material Equivalents
Some ASTM materials are compatible with specifications from other
countries, such as BS (Britain), AFNOR (France), DIN (Germany), and
JIS (Japan). If a specification from one of these other countries either
meets or is superior to the ASTM specification, then it is considered a
suitable alternative, if the project certifications are met.
1.5. Nonmetallic Materials
In many cases, nonmetallic materials have been developed by a major
manufacturer, such as Dow Chemical, ICI, or DuPont, which holds the
patent on the material. This material can officially be supplied only by
the patent owner or a licensed representative.
The patent owners are responsible for material specification, which
defines the chemical composition and associated mechanical characteristics.
Four examples of patented materials that are commonly used in
the process industry are as follows:
. Nylon, a polyamide, DuPont.
. Teflon, polytetrafluoroethylene, DuPont.
. PEEK, polyetheretherketone, ICI.
. Saran, polyvinylidene chloride, Dow.
Certain types of generic nonmetallic material covering may have several
patent owners; for example, patents for PVC (polyvinyl chloride) are
owned by Carina (Shell), Corvic (ICI), Vinoflex (BASF), and many
others. Each of these examples has unique characteristics that fall into
the range covered by the generic term PVC. To be sure of these
characteristics, it is important that a material data sheet (MDS) is
obtained from the manufacturer and this specification forms part of the
project documentation.
2. MATERIALS SPECIFICATIONS
Listed below are extracts from the most commonly used material
specifications referenced in ASME B31.3.
ASTM, A53/A53M-02 (Volume 01.01), Standard
Specification for Pipe, Steel, Black and Hot-
Dipped, Zinc-Coated, Welded and Seamless
Scope.
1.1 This specification covers seamless and welded black and hot-dipped
galvanized steel pipe in NPS 1⁄8 to NPS 26 (DN 6 to DN 650) for the
following types and grades:
1.2.1 Type F—furnace-butt welded, continuous welded Grade A.
1.2.2 Type E—electric-resistance welded, Grades A and B.
1.2.3 Type S—seamless, Grades A and B.
Referenced Documents
ASTM
A90/A90M, Test Method for Weight [Mass] of Coating on Iron and Steel
Articles with Zinc or Zinc-Alloy Coatings.
A370, Test Methods and Definitions for Mechanical Testing of Steel
Products.
A530/A530M, Specification for General Requirements for Specialized
Carbon and Alloy Steel Pipe.
A700, Practices for Packaging, Marking, and Loading Methods for Steel
Products for Domestic Shipment.
A751, Test Methods, Practices, and Terminology for Chemical Analysis of
Steel Products.
A865, Specification for Threaded Couplings, Steel, Black or Zinc-Coated
(Galvanized) Welded or Seamless, for Use in Steel Pipe Joints.
B6, Specification for Zinc.
E29, Practice for Using Significant Digits in Test Data to Determine
Conformance with Specifications.
E213, Practice for Ultrasonic Examination of Metal Pipe and Tubing.
E309, Practice for Eddy-Current Examination of Steel Tubular Products
Using Magnetic Saturation.
E570, Practice for Flux Leakage Examination of Ferromagnetic Steel
Tubular Products.
E1806, Practice for Sampling Steel and Iron for Determination of Chemical
Composition.
ASC Acredited Standards Committee X12.
ASME
B1.20.1, Pipe Threads, General Purpose.
B36.10, Welded and Seamless Wrought Steel Pipe.
Military Standard (MIL)
STD-129, Marking for Shipment and Storage.
STD-163, Steel Mill Products Preparation for Shipment and Storage.
Fed. Std. No. 123, Marking for Shipment (Civil Agencies).
Fed. Std. No. 183, Continuous Identification Marking of Iron and Steel
Products.
American Petroleum Institute (API)
5L, Specification for Line Pipe.
Methods of Manufacture. Open hearth (OH), electrofurnace (EF), basic
oxygen (BO).
Chemical Requirements. Refer to ASTM A53/A53M.
Mechanical Requirements. These are extracted from ASTM A53/A53M:




ASTM, A106-02a (Volume 1.01), Standard
Specification for Seamless Carbon Steel Pipe
for High-Temperature Service
Scope. This specification covers seamless carbon steel pipe for hightemperature
service (Note: It is suggested that consideration be given to
possible graphitization) in NPS 1⁄8 –NPS 48 inclusive, with nominal
(average) wall thickness as given in ANSI B 36.10. It is permissible to
furnish pipe having other dimensions provided such pipe complies with all
other requirements of this specification. Pipe ordered under this
specification is suitable for bending, flanging, and similar forming
operations and for welding.Whenthe steel is to be welded, it is presupposed
that a welding procedure suitable to the grade of steel and intended use or
service is utilized (Note: The purpose for which the pipe is to be used should
be stated in the order. Grade A rather than Grade B or Grade C is the
preferred grade for close coiling or cold bending. This note is not intended
to prohibit the cold bending of Grade B seamless pipe).
Referenced Documents
ASTM
A530/A530M, Specification for General Requirements for Specialized
Carbon and Alloy Steel Pipe.
E213, Practice for Ultrasonic Examination of Metal Pipe and Tubing.
E309, Practice for Eddy-Current Examination of Steel Tubular Products
Using Magnetic Saturation.
E381, Method of Macroetch Testing, Inspection, and Rating Steel Products,
Comprising Bars, Billets, Blooms, and Forgings.
A520, Specification for Supplementary Requirements for Seamless and
Electric-Resistance-Welded Carbon Steel Tubular Products for High-
Temperature Service Conforming to ISO Recommendations for Boiler
Construction.
E570, Practice for Flux Leakage Examination of Ferromagnetic Steel
Tubular Products.
ASME
B36.10, Welded and Seamless Wrought Steel.
Methods of Manufacture. Open hearth (OH), electrofurnace (EF), basic
oxygen (BO).
Chemical Requirements. Refer to from ASTM A106/A106M.
Mechanical Requirements. These are extracted from ASTM A106/
A106M:




ASTM, A126-95 (2001) (Volume 01.02), Standard
Specification for Gray Iron Castings for Valves,
Flanges, and Pipe Fittings
Scope. This specification covers three classes of gray iron for castings
intended for use as valve pressure retaining parts, pipe fittings, and flanges.
Referenced Documents
ASTM
A438, Test Method for Transverse Testing of Gray Cast Iron.
A644, Terminology Relating to Iron Castings.
E8, Test Methods for Tension Testing of Metallic Materials.
A48, Specification for Gray Iron Castings.
Sizes. Varies.
Heat Treatment. Refer to ASTM A126/A126M.
Welding Repair. For repair procedures and welder qualifications, see
ASTM A488/A488M.
Chemical Requirements. Refer to ASTM A126/A126M.
MechanicalRequirements. Theseare extractedfromASTMA126/A126M:

WHAT IS A PIPING MATERIAL ENGINEER lec ( 1 )

This chapter explains briefly the role of the piping engineer, who is
responsible for the quality of piping material, fabrication, testing, and
inspection in a project and the major activities such engineers are
expected to perform. This individual can be employed by either the EPC
(engineering, procurement, and construction) contractor or the operator/
end user.
1.1. Job Title
The piping engineer, the individual responsible for creating the project
piping classes and the numerous piping specifications necessary to
fabricate, test, insulate, and paint the piping systems, is titled either the
piping material engineer or the piping spec(ification) writer.
1.2. Job Scope
Whatever the title, the piping material engineer (PME) is a very
important person within the Piping Design Group and should be

dedicated to a project from the bid stage until the design phase has been
completed. He or she should also be available during construction and
through to mechanical completion.
The lead piping material engineer, the individual responsible for all
piping engineering functions, usually reports directly to the project lead
piping engineer, and depending on the size of the project, the lead piping
material engineer may be assisted by a number of suitably qualified
piping material engineers especially during the peak period of the
project. This peak period is early in the job, while the piping classes are
being developed and the first bulk inquiry requisitions are sent out to
vendors.
1.3. The Piping Material Engineer’s
Responsibilities
The piping material engineer’s responsibilities vary from company to
company. Here is a list of typical functions that he or she is expected to
perform:
. Develop the project piping classes for all process and utility services.
. Write specifications for fabrication, shop and field testing, insulation, and
painting.
. Create and maintain all data sheets for process and utility valves.
. Create a list of piping specials, such as hoses and hose couplings, steam
traps, interlocks.
. Create and maintain data sheets for these piping special (SP) items.
. Assemble a piping material requisition with all additional documents.
. Review offers from vendors and create a technical bid evaluation.
. Make a technical recommendation.
. After placement of a purchase order, review and approve documentation
from vendors related to piping components.
. When required, visit the vendor’s premises to attend kickoff meetings, the
testing of piping components, or clarification meetings.
. Liaise with the following departments: Piping Design and Stress, Process,
Instrumentation, Vessels, Mechanical, Structural, Procurement, Material
Control.
1.4. Qualities of an Engineer
Not only is it essential that a piping material engineer be experienced
in several piping sectors, such as design, construction, and stress, he or
she must also be a good communicator, to guarantee that everyone in the
piping group is aware of the materials of construction that can be used
for piping systems.
The PME must also have a basic understanding of other disciplines
having interface with the piping, such as mechanical, process,
instrumentation, and structural engineering. He or she should also be
aware of the corrosion characteristics of piping material and welding
processes necessary for the fabrication of piping systems. Both corrosion
and welding engineering are specialist subjects, and if the PME has any
doubts, he or she must turn to a specialist engineer for advice.
1.5. Experience
There is no substitute for experience, and the piping material engineer
should have strengths in several sectors and be confident with a number
of others disciplines, to enable the individual to arrive at a suitable
conclusion when selecting material for piping systems.
Strong areas should include piping design layout and process
requirements. Familiar areas should include the following:
. Corrosion.
. Welding.
. Piping stress.
. Static equipment.
. Rotating equipment.
. Instruments.

PIPING MATERIAL ENGINEER’S
ACTIVITIES
Outlined here are the principal activities of a piping material engineer.
These are listed in chronological order as they would arise as a project
develops from preliminary to detailed design.

2.1. Development of the Project Piping Classes
All process plants have of two types of principal piping systems:
process (primary and secondary) piping systems and utility piping
systems.
Process piping systems are the arteries of a process plant. They receive
the feedstock, carry the product through the various items of process
equipment for treatment, and finally deliver the refined fluid to the
battery limits for transportation to the next facility for further
refinement. Process piping systems can be further divided into primary
process, which is the main process flow, and secondary process, which
applies to the various recycling systems.
Utility piping systems are no less important. They are there to support
the primary process, falling into three groups:
. Support—instrument air, cooling water, steam.
. Maintenance—plant air, nitrogen.
. Protection—foam and firewater.
There are other utility services such as drinking water.
Piping Classes. Each piping system is allocated a piping class, which lists
all the components required to construct the piping. A piping class
includes the following:
. Process design conditions.
. Corrosion allowance.
. List of piping components.
. Branch table.
. Special assemblies.
. Support notes.
Both process and utility piping systems operate at various temperatures
and pressures, and the following must be analyzed:
. Fluid type—corrosivity, toxicity, viscosity.
. Temperature range.
. Pressure range.
. Size range.
. Method of joining.
. Corrosion allowance.
After analyzing these characteristics, process and utility piping systems
can be grouped into autonomous piping classes. This allows piping
systems that share fundamental characteristics (pipe size range, pressure
and temperature limits, and method of joining) to be classified
together.
This standardization or optimization has benefits in the procurement,
inspection, and construction phases of the project. Too little optimization
increases the number of piping classes, making the paperwork at all
stages of the project difficult to handle and leading to confusion,
resulting in mistakes. Too much optimization reduces the number of
piping classes, however, as the piping class must satisfy the characteristics
of the most severe service and use the most expensive material. This
means that less-severe services are constructed using more-expensive
material, because the piping class is ‘‘overspecified.’’ It is the
responsibility of the piping material engineer to fine-tune this
optimization to the benefit the project.
A typical oil and gas separation process plant may have 10 process
piping classes and a similar number of utility piping classes. Morecomplex
petrochemical facilities require a greater number of piping
classes to cover the various process streams and their numerous
temperature and pressure ranges. It is not uncommon for process plants
such as these to have in excess of 50 process and piping classes.
2.2. Writing Specifications for Fabrication, Shop
and Field Testing, Insulation, and Painting
It is pointless to specify the correct materials of construction if the
pipes are fabricated and erected by poorly qualified labor, using bad
construction methods and inadequate testing inspection, insulation, and
painting.
The piping material engineer is responsible for writing project-specific
narratives covering these various activities to guarantee that they meet
industry standards and satisfy the client’s requirements. No two projects
are the same; however, many projects are very similar and most EPC
companies have corporate specifications that cover these subjects.
2.3. Creating All Data Sheets for Process
and Utility Valves

All valves used within a process plant must have a dedicated valve
data sheet (VDS). This document is, effectively, the passport for the
component, and it must detail the size range, pressure rating, design
temperature, materials of construction, testing and inspection procedures
and quote all the necessary design codes relating to the valve.
This VDS is essential for the efficient procurement and the possible
future maintenance of the valve.
2.4. Creating a List of Piping Specials and Data
Sheets

A piping system generally comprises common components such as
pipe, fittings, and valves; however, less common piping items may be
required, such as strainers, hoses and hose couplings, steam traps, or
interlocks. This second group, called piping specials, must carry an SP
number as an identifying tag.
The piping material engineer must create and maintain a list of SP
numbers that makes the ‘‘special’’ unique, based on type, material, size,
and rating. This means that there could be several 2 in. ASME 150,
ASTM A105 body strainers with the same mesh.
As with valves, each piping special must have its own data sheet, to
guarantee speedy procurement and future maintenance.
2.5. Assembling Piping Material Requisition
with All Additional Documents

When all the piping specifications have been defined and initial
quantities identified by the Material Take-off Group, the piping material
engineer is responsible for assembling the requisition packages.
The Procurement Department will break the piping requirements into
several requisitions, so that inquiry requisitions can be sent out to
manufacturers or dealers that specialize in that particular group of
piping components.
. Pipe (seamless and welded)—carbon and stainless steel.
. Pipe (exotic)—Inconel, Monel, titanium.
. Pipe fittings (seamless and welded)—carbon and stainless steel.
. Valves gate/globe/check (small bore, 11⁄2 in. and below)—carbon and
stainless steel.
. Valves gate/globe/check (2 in. and above)—carbon and stainless steel.
. Ball valves (all sizes)—carbon and stainless steel.
. Special valves (all sizes)—non-slam-check valves, butterfly valves.
. Stud bolting—all materials.
. Gaskets—flat, spiral wound, ring type.
. Special piping items (SPs)—strainers, hoses, hose couplings, sight glasses,
interlocks, and the like.
To get competitive bids, inquiries will go out to several manufacturers
for each group of piping components, and they will be invited to offer
their best price to satisfy the scope of supply for the requisition. This
includes not only supplying the item but also testing, certification,
marking, packing, and if required, shipment to the site.
2.6. Reviewing Offers from Vendors and Create
a Technical Bid Evaluation

Many clients have an ‘‘approved bidders list,’’ which is a selection of
vendors considered suitable to supply material to the company. This
bidders list is based on a track record on the client’s previous projects
and reliable recommendations.
Prospective vendors are given a date by which they must submit a
price that covers the scope of supplies laid out in the requisition. The
number of vendors invited to tender a bid varies, based on the size and
complexity of the specific requisition.
To create a competitive environment, a short list of between three and
six suitable vendors should be considered, and it is essential that these
vendors think that, at all times, they are bidding against other
competitors. Even if, sometimes, vendors drop out and it becomes a
‘‘one-horse race’’ for commercial and technical reasons, all vendors must
think that they are not bidding alone.
All vendors that deliver feasible bids should be evaluated, and it is the
responsibility of the piping material engineer to bring all vendors to the
same starting line and ensure that they are all offering material that
meets the specifications and they are ‘‘technically acceptable,’’ sometimes
called ‘‘fit for purpose.’’

Some vendors will find it difficult, for commercial or technical reasons,
to meet the requirements of the requisition. These vendors are deemed
technically unacceptable and not considered further in the evaluation.
The piping material engineer, during this evaluation, creates a bid
tabulation spreadsheet to illustrate and technically evaluate all vendors
invited to submit a bid for the requisition.
The tabulation lists the complete technical requirements for each item
on the requisition and evaluates each vendor to determine if it is technically
acceptable.
Technical requirements include not only the materials of construction
and design codes but also testing, certification, and painting. Nontechnical
areas also are covered by the piping material engineer, such as
marking and packing. The delivery, required on site (ROS) date, is
supplied by the Material Control Group as part of the final commercial
negotiations.
The Procurement Department is responsible for all commercial and
logistical aspects of the requisition, and the Project Services Group
determines the ROS date and the delivery location. It is pointless to
award an order to a manufacturer that is technically acceptable and
commercially the cheapest if its delivery dates do not meet the
construction schedule.
When this technical bid evaluation (TBE) or technical bid analysis
(TBA) is complete, with all technically acceptable vendors identified,
then it is turned over to the Procurement Department, which enters into
negotiations with those vendors that can satisfy the project’s technical
and logistical requirements.
After negotiations, a vendor is selected that is both technically acceptable
and comes up with the most competitive commercial/logistical offer. The
successful vendor is not necessarily the cheapest but the one that
Procurement feels most confident with in all areas. What initially looks to
be the cheapest might, at the end of the day, prove more expensive.
2.7. After Placement of a Purchase Order,
Reviewing and Approving Documentation
Related to All Piping Components


The importance of vendor documentation after placement of an order
must not be underestimated. It is the vendor’s responsibility to supply
support documentation and drawings to back up the material it is
supplying. This documentation includes an inspection and testing plan,
general arrangement drawings, material certification, test certificates,
and production schedules.
All this documentation must be reviewed by the piping material
engineer, approved and signed off, before final payment can be released
to the vendor for the supply of the material.
2.8. Vendor Visits
The piping material engineer may be required to visit the vendor’s
premises to witness the testing of piping components or attend clarification
meetings.
Certain piping items are more complex than others, either because of
their chemical composition and supplementary requirements or their
design, size, or pressure rating. In these cases, the relevant purchase
order requires a greater deal of attention from the piping material
engineer to ensure that no complications result in incorrect materials
being supplied or an unnecessary production delay.
To avoid this, the following additional activities should be seriously
considered:
. A bid clarification meeting to guarantee that the prospective vendor fully
understands the requisition and associated specification.
. After the order has been placed, a preinspection meeting to discuss
production, inspection, and quality control.
. Placing the requisition engineer in the vendor’s facilities during critical
manufacturing phases of the job to ensure that the specifications are
understood.
. Placing an inspector in the vendor’s facilities, who is responsible for the
inspection and testing of the order and coordinates with the piping
material engineer in the home office to guarantee that the specifications
are understood and being applied.
The first two are low-cost activities and should be a formality for most
purchase orders, the last two are more-expensive activities and should be
considered based on the complexity of the order or the need for long lead
items.
No two requisitions are the same, and a relatively simple order with a
new and untried vendor may require more consideration than a complex
order with a vendor that is a known quantity. The decision to make
vendor visits also relates to the size of the inspection budget, which might
not be significant enough to support ‘‘on-premises’’ personnel during the
manufacturing phase.
Remember that if the wrong material arrives on site, then the replacement
cost and the construction delay will be many times the cost of
on-premises supervision.
If the items concerned are custom-made for the project or they have
long lead times (three months or more), then on-premises supervision
should be seriously considered.
2.9. Bids for New Projects
All the preceding are project-related activities; however, the piping
material engineer may also be required to work on bids that the company
has been invited to tender by clients. This is preliminary engineering, but
the work produced should be accurate, based on the information provided
in a brief form the client. The usual activities are preliminary piping
classes, basic valve data sheets and a set of specifications for construction,
inspection, and painting.
A piping material engineer will either be part of a project task force
dedicated to one job or part of a corporate group working on several
projects, all in different stages of completion. Of these two options, the
most preferable is the former, because it allows the PME to become more
familiar with the project as it develops.
The role of a piping material engineer is diverse and rewarding, and
there is always something new to learn. A project may have the same
client, the same process, and be in the same geographical location, but
because of different personnel, a different budget, purchasing in a
different market, or a string of other factors, different jobs have their
own idiosyncrasies. Each one is different.
The knowledge you learn, whether technical or logistical, can be used
again, so it is important that you maintain your own files, either digital
or hard copies, preferably both.
Whether you work for one company for 30 years or 30 companies for
1 year, you will find that the role of PME is respected within the
discipline and throughout the project.
As a function, it is no more important than the piping layout or piping
stress engineer; however, its importance must not be underestimated.
The pipe can be laid out in several different routings, but if the material
of construction is wrong, then all the pipe routes are wrong, because the
material is ‘‘out of spec.’’