energy audit report-rig-e-1400 s-3 rig - oilweb · 2013-05-29 · energy audit of rig e-1400 s-3,...

OF

Conducted By

(EASTERN REGION)

2, Gariahat Road South, Dhakuria

Kolkata – 700 068

Ph: 033 – 2414 5092, 2414 5088, 2414 5094;

Telefax: 033 – 2414 5091

e-mail: [email protected]

Website: http://www.pcra.org

Energy Audit of Rig E-1400 S-3, Oil India Ltd.

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Petroleum Conservation Research Association – Eastern Region


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RELEVANT INFORMATION

1 Name and address of the Industry M/s. Oil India Ltd.

Duliajan

Dist: Dibrugarh,

Assam– 786602

2

Name & Contact no. Installation Manager Mr. Rajib Baruah, Drilling-In-charge

9435038739 (M)

3 PCRA Team Members Mr. A.K. Mallick, Jt. Dir., PCRA, ER

Mr. D. Dutta, Jt. Dir., PCRA, ER

4 Period of Audit

Dec’2012

5 Total Estimated Fuel Oil (HSD)Requirement by

DGs / year

(considering 3 nos. site operation in a year)

582 KL

7 Specific Power Consumption

65.21 Ltrs. / Hour of engine running

9 Total Estimated Fuel Oil Cost

Rs. 291 Lakhs

10 Saving potential (HSD)/ Year

50.1 KL

11 Saving potential in % of Estimated Annual Fuel

Consumption

8.6%


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INDEX

Sec.

No.

Title

Page

1.0 Executive Summary

5

2.0 Summary of anticipated savings and

investment 8

3.0 Introduction

9

4.0 Total connected Load

17

5.0 Study of Fuel Consumption per unit drill depth

18

6.0 Study of DG Sets

26

7.0 Illumination Study 60


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1.0 Executive Summary:

1.1 Connected load and captive power generation capacity

Total connected DC load for the Rig operations is 4.113 MW and that of AC load is

0.880MW. Hence, total connected electrical load is 4.99 MW.

Total captive power generation capacity by 4 nos. DGs are 3.4MW. The normal operating

load or peak operating demand load is catered by single or joint operation by three nos.

DGs.

1.2 Study of fuel consumption per hour of engine running:

After analyzing the data for the entire drilling operation, we have derived that the

Fuel (diesel) Consumption = 65.52 Ltrs. / Hour of engine running

1.3 Study of load on DGs:

A detailed study reveals that during the drilling operations, the DGs were operated at part load. The

range of this part load varies from 4% to 39% in most of the operating days. The peak loads on DGs

have never crossed 50% and observation says, load on each of the four DGs were between 40% to

50% only for 3 to 4 days of entire drilling operations.

The derived average specific fuel consumption in relation to the present operating condition is 278

gm/kWh. The reason behind this higher specific fuel consumption is part load operation of the DGs.

Study of gen-set at different % loading along with load curve (actual vis-à-vis theoretical) is

shown here.


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DG Loads for S-3 Rig for one complete Drilling operation from 04 / 03 /12 to 12/05/12 with

a depth of 2690 meters

Hence, we have recommended the following:

Recommendation-1: Rationalize DG operations to ensure the load on DGs above 50% with

existing on line generators.

Total savings per drilling well = 16.7KL x Rs. 50,000 /KL = Rs.8,35,000/-

Considering 3 nos. drilling wells completed by a rig in a year


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Annual savings = Rs.8,35,000 x 3 = Rs.25,05,000/-

Recommendation-2:

The existing D399 engines may be replaced by energy efficient engines like D-3512B.

This is likely to result in saving of Rs. 2297529/- for one drilling well of 2960Mtrs completed in 70

days.

Considering 3 nos. of wells drilled by a rig in a year, total saving envisaged is Rs. 68.93 lacs

annually.

Recommendation-3:

Install a gen-set of lower capacity (KVA as required) to cater auxiliary AC load. This will

help in reducing the running hours of bigger DG Sets on low load condition and result in

substantial savings apart from increasing the life of the rig engines.

Since, many a times, it is a usual practice to operate necessary AC connected load

during the drilling operations. It is very difficult to rationalize the load with existing

higher size (1215 KVA) DGs when the load requirement is very low. Hence, it is justified

to install a smaller size DG to cater the AC-load as and when required. It is advisable to

use the lower capacity gen-set during production testing / waiting for allied services

etc. when only auxiliary and lighting load is required. [(Note: Such practice is

prevalent at the Rig of M/s. JAY BEE Energy (P) Ltd. The model of the Rig is DZ 315/9-S

and nominal drill depth of which is 3000 – 5000M).They have installed a 400 KVA DG of

VOLVO PENTA make.]

Recommendation-4:

Study of Illumination:

The Rig unit is using 66 nos. 36/40 W Fluorescent Tube light. At present context, it is

not energy efficient and use of T-5 FTL in place of 36 W FTL will produce more

illumination with lower energy input.

Hence, we recommend to replace all the 36/40 W FTLs with energy efficient T-5 lamps

with improvement in the lux level.

The implementation of above recommendations will give a savings of Rs.62550/- per

year with an investment of Rs.29,700/- and pay back of 6 months.


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2.0 Summary of anticipated savings and investment

Sl No Area of Savings

Savings of

HSD / Well

(KL)

Savings of

HSD / year

(considering

3 nos of

wells / rig)

(Rs.)

Investment

(Rs.) Payback

1

Rationalize Present

DG operations to

ensure more than

50% load with

existing on line

generators

16.7 KL 25 Lakhs NIL Immediate

2

Replacing D399

engines with new

D-3512B series

engines with 50%

loading.

45.95 KL 68.93 Lakhs

200 x 2 lacs

=400 lacs

(Considering 2

nos. of DGs

for

replacement)

5 years, 10 Months

3

Replace 66 nos.

40W FTL with

energy efficient T-5

FTLs

0.417 0.62 Lakhs. 0.29 Lakhs. 6 Months


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3.0 Introduction:

The story of Oil India Limited (OIL) traces and symbolizes the development and growth of

the Indian petroleum industry. From the discovery of crude oil in the far east of India at

Digboi, Assam in 1889 to its present status as a fully integrated upstream petroleum

company, OIL has come far, crossing many milestones.

On February 18, 1959, Oil India Private Limited was incorporated to expand and develop the

newly discovered oil fields of Naharkatiya and Moran in the Indian North East. In 1961, it

became a joint venture company between the Indian Government and Burmah Oil

Company Limited, UK.

In 1981, OIL became a wholly-owned Government of India enterprise. Today, OIL is a

premier Indian National Oil Company engaged in the business of exploration, development

and production of crude oil and natural gas, transportation of crude oil and production of

LPG. OIL also provides various E&P related services and holds 26% equity in Numaligarh

Refinery Limited.

The Authorized share capital of the Company is Rs. 2000 Crores. The Issued, Subscribed and

Paid share capital of the company is Rs. 601.14 Crores. At present, The Government of

India, the Promoter of the Company is holding 78.43% of the total Issued & Paid-up Capital

of the Company. The balance 21.57% of the Equity capital is held by others.

OIL has over 1 lakh sq km of PEL/ML areas for its exploration and production activities; most

of it is in the Indian North East, which accounts for its entire crude oil production and

majority of gas production. Rajasthan is the other producing area of OIL, contributing 10 per

cent of its total gas production.

Additionally, OIL’s exploration activities are spread over onshore areas of KG Basin,

Mahanadi Basin, Cauvery Basin, Andaman Basin and Gujarat-Kutch Basin etc. OIL also has

participating interest in NELP exploration blocks in Mahanadi Offshore, Mumbai Deepwater,

Krishna Godavari Deepwater, etc. as well as various overseas projects in Libya, Gabon, Iran,

Yemen, Nigeria, Sudan and Venezuela.

In a recent CRISIL-India Today survey, OIL was adjudged as one of the five best major PSUs

and one of three best energy sector PSUs in the country.

Objective of Energy Audit

With the advent of energy crisis and exponential hikes in the costs of different forms of

energy, Energy Audit is manifesting its due importance in Industrial Establishments. Energy

Audit helps to understand more about the ways energy and fuels are used in any

Establishment and helps in identifying areas where waste may occur and scope for

improvement exists.


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Energy Audit is the key to a systematic approach for decision-making in the area of energy

management as it attempts to balance the total energy inputs with its use and serves to

identify all the energy streams in a facility/ Establishment.

It was with this objective that Petroleum Conservation Research Association (PCRA) was

entrusted by OIL, the Energy Audit of E-1400-S-3 Drilling Rig at Makum, Assam.

3.1 Well Description:

The rig was deployed at Makum area in Assam.

Location: HVB

Rig Type: Electrical (E-1400)

Well No. Makum-44

Target Depth: 2960 Meter

Type of well: Deviated

Date of Spud-in: 05.03.2012

Process flow chart for the Rig is shown in Fig. 3.1.1. Types of drilling are as follows:

� Vertical drilling

� Horizontal drilling

� Inclined drilling(deviation)

Horizontal and inclined drilling increases the perforation area. The decision whether to

drill vertical, horizontal or inclined, is dependent on the strata and oil availability.

Complete drilling program is pre–decided and it is given in GTO for the well.

3.2 Drilling Fluid (Mud):

Mud has several roles while drilling the well; these are lubricant and coolant for the drill

bit, remove rock chips & cuttings from well, to soften the rock/soil. Therefore chemical

composition and specific gravity of the mud vary according to the depth and

requirement.

Constituents of the mud include lignite, Caustic soda, caustic potash, Causticities lignite

(Generally used up to 1300 m), Chrome lignite, Resin lignite (Generally used at last

depth), Barites, Bentonite, CMC (carboxyl methyl cellulose), Drilling detergent, Linseed

oil, Spoil- ting fluid, Sulphonated asphalt etc.


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3.3 Important Equipments / Attachments

1. Draw Works: This system provides drilling energy to the drill bit and all mechanical energy

requirements at the rig (e.g. operations like drilling, running-in, pulling-out) except

flow of the mud, which is powered by the mud pump.

2. Compressors: Compressed air is utilized for cranking of diesel engines, various pneumatic

controls and other support applications.

3. Supercharger: Mud pump is attached to centrifugal pump, which is also called as super-

charger (2 no’s of 100 hp each).

4. Mud pump: Mud Pump is used for pumping the drilling fluid (mud) at high pressure as per

the requirement of drilling operation.

5. Agitators: Mud is prepared with the help of number of agitators. Agitators are used for

agitation and also to prevent solidification or cake formation.

3.4 About Drilling Rig: E 1400 S-3

Presently the rig is located at HVB Site.

1) Rig Capacity: 1400 hp

2) Date of commissioning: 02.08.1985

3) Last Well drilled: Hapjan-56

4) Mast Height: 142 feet

5) Derrick Floor height: 25 feet

6) Asset Manager: Mr.

7) Installation Manager: Mr. Rajib Baruah

8) Engine/ sets: 4 nos.

9) Make/ Engine Model: Caterpillar / D-399

10) Engine Output: 972 hp at 1000 rpm

11) Alternator Capacity: 1215 kVA

.


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Fig 3.1.1:Process Flow Chart of Drilling Rig


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Fig 3.1.2 : GENERAL ARRANGEMENT OF THE RIG EQUIPMENTS

Sr. Equipment / Machine Capacity

1. DG – 1 1215 KVA

2. DG – 2 1215 KVA

3. DG – 3 1215 KVA

4. DG – 4 1215 KVA


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Fig. 3.1.3: DRILLING RIG ASSEMBLY

4.0 Total Connected Load in the Rig:

Connected Electrical load in the Rig are described below:

Connected DC load

Sl.No. Loads HP No. KW

1 D.C.Motor 900 5 3357

2 D.C.Motor 1000 1 746

3 ECB 10.5

Total 4113.5

Connected AC Load

A.C.Load

1 Blower Motors 7.5 6 33.57

2 Water Booster 30 2 44.76

3 Mud Agitators 10 12 89.52

4 Liner Flasher 3 2 4.476

5 Caller 3 1 2.238

6 BOP 15 1 11.19

7 Degasser 3 1 2.238

8 Fuel Pump 5 2 7.46

9 Shale shaker 5 3 11.19

10 Pill Chamber 10 1 7.46

11 Water Agitators 10 4 29.84

12 After Cooler 0.29

13 Trip Tank Motor 15 1 11.19

14 Air Compressor 40 2 59.68

15 Super Charger 75 2 111.9

16 Mud Mix 100 2 149.2

17 Desander/Desilter 75 2 111.9

18 Multistage 75 2 111.9

19 DCPR A/C 20

20 ACPR A/C 20

21 Area Lighting Load 20

22 Rig Lighting Load 20

Total 880.002

Total connected load = 4113.5 KW + 880 KW = 4993.5 KW = 5.0 MW (Approx)

Total Captive Power = 1215 KVA x 0.70(P.F.) X4Nos. = 3.4 MW


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5.0 Study of fuel consumption per unit drill depth:

Specific fuel consumption i.e. fuel consumption per meter of drilled depth is a prime objective of

this study. Hence, the complete activity of the drilling-rig starting from spud in to production testing

has been taken into consideration at Location: HVB. The well was spudded on 04.03.2012 and

handed over to production on 12.05.2012 after attaining the target drill depth and subsequent

necessary associated activities. Date wise details of drilling activity with DG- run, fuel consumption

and draw works/mud pump operation as recorded in the log book have been incorporated below:

Date of Spud-in: 04.03.2012 , Location: HVB Date Shift Depth

of

Drill

(M)

Operations Engine Run Hours DG -

1

DG -

2

DG -

3

DG -

4

Diesel

Cons

(Ltrs.)

DW

A

DW

B

MP

1

MP

2

E1 E2 E3 E4

04.03.2012 M 9 Spud- In 8 600 0 0 0 1385 3 3 1 1

05.03.2012 M 150 Circulation 21 3 500 0 300 0 2000 0 0 8 8

E 0 1650 0 0 8 0 7 0

N 0 1400 0 0 8 8

06.03.2012 M 150 BOP Planning 24 3 0 1130 0 450 2055 4 0 4 3

E 150 0 500 0 0 0 0 0 0

N 150 0 400 0 0

07.03.2012 M 150 BOP Planning 24 0 640 0 0 3260 0 0 0 0

E 150 0 640 0 0 0 0 0 0

N 150 0 690 0 0 4 0 0 0

08.03.2012 M 307 Drilling 20 21 0 1300 2210 3 3 3 0

E 0 1000 1200 300 8 7 8 0

N 0 0 0 1100 2 0 0 0

09.03.2012 M 307 Drilling 20 21 0 0 500 550 0 3 0 0

E 1030 650 1 2 3 2

N 1475 1475 0 7 7 0

10.03.2012 M 532 Drilling 15 20 9 1150 1330 5080 0 8 1 0

E NA

N 685 460 0 1 7 0 0

11.03.2012 M 532 Pull Out 24 18 1440 450 0 5 0 2 0

E 1695 1580 8 8 8 0

N 1020 1020 6 6 0 2

12.03.2012 M 712 Drilling/Pull

Out

20 21 3 1280 1280 360 3210 8 6 0 3

E 2950 2890 8 8 0 7

N 1460 1460 6 6 0 2

13.03.2012 M 783 Pullout/Drilling 19 17 5 1050 1050 835 2254 7 3 3 0

E 2700 3030 8 7 0 7

N 2000 1750 6 6 0 0


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of

Drill

(M)


1

DG -

2

DG -

3

DG -

4

Diesel

Cons

(Ltrs.)

DW

A

DW

B

MP

1

MP

2

E1 E2 E3 E4


Out/Recirculation

24 17 3 1560 1500 3176 6 0 2 3

E 1680 1420 580 8 1 6 0

N 1475 1250 5 5 0 0

15.03.2012 M Drilling 3 20 20 17 0 0 0 0 4370 0 0 0 0

E 1028 2800 2800 2800 8 8 8 0

N 1178 2250 2250 2250 8 8 8 0


Out/Recirculation

10 24 23 3 850 1720 1720 870 3370 6 6 4 2

E 1960 2210 2210 8 8 5.5 0

N 1640 1560 6 6 0 0

17.03.2012 M 1452 Drilling 16 24 17 2 520 1960 500 900 8730 6 6 0 4

E 1960 1960 1960 8 8 0 6

N 2000 2080 2000 8 8 0 5

18.03.2012 M 1452 Drilling 8 16 11 17 1200 150 5 0 0 0

E 1513 1825 900 1825 7 4 0 4

N 1624 2400 2400 2400 8 8 0 8

19.03.2012 M 1652 Recirculation 9 15 24 12 2200 2200 2200 3545 8 8 0 8

E 1000 1000 1000 7 7 0 1

N 820 820 4 4 0 0

20.03.2012 M Pull out 16 8 24 21 1950 2250 1850 5179 8 8 6 0

E 3200 3200 3200 8 8 8 0

N 1800 1800 1800 8 8 4 0

21.03.2012 M 1753 Pull out(Logging) 6 8 7 24 600 1100 1300 2952 6 7 1 0

E 0 700 2 0 0 0

N 0 2300 1200 8 8 2 0

22.03.2012 M Casing/Recirculation 5 24 12 3 1250 1590 750 231`4 5 5 2 0

E 0 640 240 0 8 0 0 0

N 0 560 560 0 8 8 0 0

23.03.2012 M Casing 16 8 3 17 0 780 750 680 1760 7 7 0 0

E 900 200 0 1100 7 7 1 0

N 850 0 0 0 3 0 0 0


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of

Drill

(M)


1

DG -

2

DG -

3

DG -

4

Diesel

Cons

(Ltrs.)

DW

A

DW

B

MP

1

MP

2

E1 E2 E3 E4

24.03.2012 M Cementing 3 0 7 21 225 0 450 525 1540 3 3 0 0

E 0 175 625 0 0 0 2

N 0 480 0 0 0 0

25.03.2012 M Wetting cement 0 0 0 24 0 440 4 4 0 0

E 0 640 0 0 0 0

N 0 600 0 0 0 0

26.03.2012 M BOP Planning 0 15 3 6 0 100 310 2310 1 0 0 0

E 560 0 0 0 0

N 375 0 0 0 0 0 0

27.03.2012 M Riger Planning 0 8 16 0 600 1510 2 0 0 0

E 0 0 400 0 0 0 0 0

N 0 0 560 0 0 0 0 0

28.03.2012 M Recirculation/Drilling 0 15 19 0 0 0 560 0 2630 0 0 0 0

E 0 700 250 0 1 3 0 0

N 0 1850 1850 0 8 8 8 0

29.03.2012 M Cement/Cutting 20 24 4 0 850 1500 650 3530 8 8 8 0

E 2320 2320 8 8 3 2

N 2400 2400 8 8 8 0

30.03.2012 M 1812 Drilling 12 6 16 18 1988 1440 620 3910 7 7 3 1

E 350 1760 1390 7 7 0 1

N 750 1500 1500 8 8 0 2

31.03.2012 M 2271 Drilling 24 0 24 24 2030 2400 2400 14220 8 8 1 7

E 2000 2000 2000 8 8 8 0

N 2080 2080 2080 8 8 8 0

01.04.2012 M 2271 Pull out 6 18 24 24 1560 700 2640 2640 8 8 8 0

E 2000 2000 2000 8 8 8 0

N 2400 2400 2400 8 8 5 3

02.04.2012 M 2271 Recirculation 0 14 12 14 1180 1380 1260 6 6 0 4

E 0 0 240 0 0 0 0 0

N


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of

Drill

(M)


1

DG -

2

DG -

3

DG -

4

Diesel

Cons

(Ltrs.)

DW

A

DW

B

MP

1

MP

2

E1 E2 E3 E4

03.04.2012 M 2411 Circulation 1 24 17 23 0 1350 1140 1490 5160 7 7 5 1

E 0 2060 1200 1900 8 8 8 0

N 2400 3120 2400 8 8 8 0

04.04.2012 M 2411 Circulation 10 17 24 8 300 1420 1600 1200 5204 8 8 6 0

E 1600 1800 1800 8 8 4 0

N 720 4 4 0 0

05.04.2012 M 2411 Circulation 0 0 11 0 0 0 0 0 0 0 0 0

E 0 0 0 0 0 0 0 0

N 0 0 0 0 0 0 0 0

06.04.2012 M 2411 Running in/

Reaming

3 14 0 12 0 0 640 0 0 0 0 0

E 300 1050 0 750 5 5 0 0

N 1300 1300 6 6 4 0

07.04.2012 M Drilling 19 24 0 24 890 2350 2350 16266 8 8 1 5

E 2477 2540 2750 2750 8 8 0 8

N 2551 2750 2750 2750 8 8 0 8

08.04.2012 M 2686 Drilling/Pull out 18 14 16 24 2560 2800 2800 8 8 0 8

E 1050 2100 2450 2750 8 8 0 8

N 2560 2880 2880 8 8 0 8

09.04.2012 M 2690 Reaming/Drilling 13 14 24 10 1540 1600 1600 4086 8 6 4 0

E 1730 1940 1200 5 5 0 0

N 1240 2350 2360 0 8 8 4 0

10.04.2012 M 2716 Drilling 23 21 5 24 2350 2730 1330 1750 6727 8 8 8 0

E 2795 2800 3040 0 3200 8 8 8 0

N 2832 2400 2400 2400 8 8 8 0

11.04.2012 M 2888 Drilling/Pullout 23 21 7 17 2740 2820 0 2860 5986 8 8 8 0

E 2954 2800 3200 0 3200 8 8 8 0

DRILLING COMPLETED

N 1880 1960 1600 8 8 3 0


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of

Drill

(M)


1

DG -

2

DG -

3

DG -

4

Diesel

Cons

(Ltrs.)

DW

A

DW

B

MP

1

MP

2

E1 E2 E3 E4

12.04.2012 M Circulation 3 17 20 2 0 450 550 14087 1 1 0 0

E 250 400 150 1 1 0 0

N 80 1640 1600 600 7 7 0 2

13.04.2012 M Circulation 0 17 24 10 2000 2080 2200 8 8 0 6

E 1795 1795 600 8 8 0 0

N 600 0 0 0 0

14.04.2012 M Run in 0 11 24 0 600 0 0 0 0

E 180 490 2 2 0 0

N 900 900 2 2 0 0

15.04.2012 M Circulation 10 24 4 16 800 1800 1000 800 8 8 0 8

E 1550 1960 1960 7 7 2 1

N 1300 1050 3 3 0 0

16.04.2012 M Logging/Run

in /Pull out

17 24 13 0 525 825 5 3 0 0

E 1200 1200 750 8 8 5 0

N 1300 1400 1520 6 6 2 0

17.04.2012 M Casing Run

In

0 23 24 0 1000 1050 2184 5 5 0 0

E 1060 1060 6 6 0 0

N 2250 2250 8 8 0 0

18.04.2012 M Casing JOS 0 24 24 0 2400 2400 2101 8 8 0 0

E 1660 1660 8 0 7 0

N 1300 1300 8 8 0 0

19.04.2012 M Casing JOS 15 24 19 6 1500 350 1250 5705 6 6 4 0

E 2080 2480 2380 7 7 5 5

N 3200 3200 3200 8 8 8 8

20.04.2012 M Casing JOS 24 10 24 15 2000 2000 2080 3834 0 0 8 8

E 800 250 800 550 5 3 2 1

N 900 900 700 8 8 0 2

21.04.2012 M Casing

Pullout

3 0 24 21 900 2180 1280 4096 8 8 0 0

E 2400 2400 8 8 0 0

N 1140 1140 5 5 0 0

22.04.2012 M Casing

Pullout

0 7,5 24 1 1480 1480 8 8 0 0

E 1950 6 6 0 0

N 1300 1300 5 5 0 3


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of

Drill

(M)


1

DG -

2

DG -

3

DG -

4

Diesel

Cons

(Ltrs.)

DW

A

DW

B

MP

1

MP

2

E1 E2 E3 E4

23.04.2012 M Pull out 0 24 24 13 975 1095 520 4420 7 7 2 2

E 2150 2150 2150 8 8 4 4

N 1500 1500 5 5 0 0

24.04.2012 M Pull out/Run

In/Circulation/Pull

out

6 24 1 15 620 75 3325 0 4 0 0

E 2160 2160 6 6 0 0

N 1600 2100 2100 8 8 2 2

25.04.2012 M Pull out 9 24 0 19 1250 1490 1250 3745 6 5 0 0

E 400 1840 1300 8 8 2 0

N 2400 2400 2400 8 8 1 0

26.04.2012 M Casing 8 8 10 24 1660 1810 2155 8 8 0 0

E 900 4 4 0 0

N 1200 1200 8 8 0 0

27.04.2012 M Waiting for

Cementing

0 3 18 24 1200 1200 2605 8 8 0 0

E 1280 1280 4 4 0 3

N 200 200 680 0 0 2 0

28.04.2012 M BOP Dismantling 8 15 0 9 400 2890 0 0 0 0

E 400 850 5 5 0 0

N 380 700 0 0 0 0

29.04.2012 M Pipe breaking 0 24 13 0 680 0 2 0 0

E 655 500 6 4 0 0

N 630 550 0 4 0 4

30.04.2012 M Pipe breaking 0 17 20 0 865 530 4115 6 3 0 0

E 650 830 4 0 0 0

N 325 650 3 3 0 0

01.05.2012 M Production Tube

Joining

0 0 24 0 600 0 0 0 0

E 760 2 0 0 0

N 600 0 0 0 0

02.05.2012 M Tubing Run In 0 0 24 0 600 0 0 0 0

E 600 0 0 0 0

N 600 0 0 0 0


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of

Drill

(M)

Operations Engine Run Hours DG - 1 DG - 2 DG - 3 DG - 4 Diesel

Cons

(Ltrs.)

DW

A

DW

B

MP

1

MP

2

E1 E2 E3 E4

03.05.2012 M Tubing Run

In

0 17 12 12 400 230 1835 4 4 0 0

E 1460 1460 6 6 0 0

N 950 950 5 0 1 0

04.05.2012 M Pull

out/Tubing

1 8 6 20 100 900 1030 1890 6 6 0 0

E 75 1155 4 3 2 0

N 720 400 5 5 0 0

05.05.2012 M Pull

out/Tubing

0 20 5 0 900 2410 2 0 0 0

E 1080 2 2 0 0

N 620 540 2 2 0 0

06.05.2012 M Run In 0 12 20 0 400 0 0 0 0

E 800 1200 4 4 0 0

N 755 435 3 3 0 0

07.05.2012 M Waiting for

Logging

0 21 0 8 540 620 1330 2 2 0 0

E 240 240 0 0 0 0

N 400 0 0 0 0

08.05.2012 M Logging 0 12 12 0 640 1105 0 0 0 0

E 320 0 0 0 0

N 525 0 0 0 0

09.05.2012 M Logging 0 0 8 5 150 150 250 875 0 0 0 0

E 200 0 0 0 0

N

10.05.2012 M Nitrogen

pumping

0 6 0 0 100 450 0 0 0 0

E

N

11.05.2012 M Nitrogen

pumping

0 0 5 0 200 456 0 0 0 0

E

N

12.05.2012 M Pipe Br. 0 2 8 0 1500 310 2 0 0 0

E 150 0 0 0 0

N

Total 2954 431 932 918 687 108713 182890 156960 143225 193538


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From the above study, it is found that starting from spud in to attain the target drill depth and

handing over to production the diesel consumption by Diesel Generators are 193538 Ltrs. = 193.548

KL.

Total running Hours = 431+932+918+687 =2968 Hrs.

Fuel Consumption per hour of Engine running = 193538/2968 = 65.21 L/Hr.

Total kWh generated by the DGs =591788 kWh

Total depth of drill hole = 2954 M

Fuel consumption per meter drill = 193538/2954 =65.52 Ltrs./Mtr.

Power generating cost: 9676900/ 591788 = Rs. 16.35/ kWh


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6.0 Study of DG Sets:

6.1 Details of DGs:

The rig is having four nos. identical DGs. The capacity of each DG is 1215 KVA and each connected to

a common bus to cater both AC and DC load. The DG operations are increased or decreased as per

the required demand. The details of each DG have been given below:

DG#1

Alternator Details

Make KATO Engg.

Sr. No. 17190-1

Yr. of Mfg. 2004

KVA 1215

Rated Voltage 600

Full load current 1169

P.F. 0.7

Engine Details

Make Caterpillar

Model 3512

Power 830 KW at 1000 RPM

Engine Type 4 Stroke, Turbocharged, V12 water cooled

No. of Cylinders 12

Sump Cap 318 L

Rated Speed 900-1800 RPM

Bore 6.7", Stroke 7.5"

DG#2

Alternator Details

Make BHEL

Sr. No. 4600126

Yr. of Mfg. 2004

KVA 1215

Rated Voltage 600


P.F. 0.7

Engine Details

Make Caterpillar

Model D399

Power 972 H.P.


No. of Cylinders 16

Rated Speed 1000 RPM

Bore 6.25", Stroke 8"


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DG#3

Alternator Details

Make KATO Engg.

Sr. No. 90169-8

Yr. of Mfg. 1984

KVA 1215

Rated Voltage 600


P.F. 0.7

Engine Details

Make Caterpillar

Model D399

Power 972 H.P.


No. of Cylinders 16



DG#4

Alternator Details

Make KATO Engg.

Sr. No. 90169-4

Yr. of Mfg. 1984

KVA 1215

Rated Voltage 600


P.F. 0.7

Engine Details

Make Caterpillar

Model D399

Power 972 H.P.


No. of Cylinders 16




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6.2 Single line diagram for electricity distribution:

6.3 Load on DGs:

The load on DGs have been calculated during the drilling operations. DG wise load have been sorted

from lowest to highest. The observations have been given as under:

DG#1:

Sl.No.

DG-1

Date Shift Depth of

Drill (M) Operations

Av.Load on

DG-1

Av.%Load

on DG-1 1 0 0 05.03.2012 E

2 0 0 05.03.2012 N

3 0 0 06.03.2012 M 150 BOP Planning

4 0 0 06.03.2012 E 150

5 0 0 06.03.2012 N 150

6 0 0 07.03.2012 M 150 BOP Planning

7 0 0 07.03.2012 E 150

8 0 0 07.03.2012 N 150

9 0 0 08.03.2012 M 307 Drilling

10 0 0 08.03.2012 E

11 0 0 08.03.2012 N

12 0 0 09.03.2012 M 307 Drilling

13 0 0 09.03.2012 E


29 | P a g e


Sl.No.

DG-1

Date Shift Depth of


Av.Load on

DG-1

Av.%Load

on DG-1 14 0 0 09.03.2012 N

15 0 0 10.03.2012 M 532 Drilling

16 0 0 10.03.2012 E

17 0 0 10.03.2012 N

18 0 0 11.03.2012 M 532 Pull Out

19 0 0 11.03.2012 E

20 0 0 11.03.2012 N

21 0 0 15.03.2012 M Drilling

22 0 0 15.03.2012 E 1028

23 0 0 15.03.2012 N 1178

24 0 0 16.03.2012 N

25 0 0 18.03.2012 M 1452 Drilling

26 0 0 18.03.2012 E 1513

27 0 0 19.03.2012 E

28 0 0 19.03.2012 N

29 0 0 20.03.2012 M Pull out

30 0 0 21.03.2012 E

31 0 0 21.03.2012 N

32 0 0 22.03.2012 E

33 0 0 22.03.2012 N

34 0 0 23.03.2012 M Casing

35 0 0 24.03.2012 E

36 0 0 24.03.2012 N

37 0 0 25.03.2012 M Wetting cement

38 0 0 25.03.2012 E

39 0 0 25.03.2012 N

40 0 0 26.03.2012 M BOP Planning

41 0 0 26.03.2012 E

42 0 0 26.03.2012 N

43 0 0 27.03.2012 M Riger Planning

44 0 0 27.03.2012 E

45 0 0 27.03.2012 N

46 0 0 28.03.2012 M Recirculation/Drilling

47 0 0 28.03.2012 E

48 0 0 28.03.2012 N

49 0 0 01.04.2012 E

50 0 0 01.04.2012 N

51 0 0 02.04.2012 M 2271 Recirculation


30 | P a g e


Sl.No.

DG-1

Date Shift Depth of


Av.Load on

DG-1

Av.%Load

on DG-1 52 0 0 02.04.2012 E

53 0 0 02.04.2012 N

54 0 0 03.04.2012 M 2411 Circulation

55 0 0 03.04.2012 E

56 0 0 03.04.2012 N

57 0 0 04.04.2012 N

58 0 0 05.04.2012 M 2411 Circulation

59 0 0 05.04.2012 E

60 0 0 05.04.2012 N

61 0 0 06.04.2012 M 2411 Running in/ Reaming

62 0 0 06.04.2012 N

63 0 0 09.04.2012 E

64 0 0 12.04.2013 M Circulation

65 0 0 13.04.2013 M Circulation

66 0 0 13.04.2013 E

67 0 0 13.04.2013 N

68 0 0 14.04.2013 M Run in

69 0 0 14.04.2013 E

70 0 0 14.04.2013 N

71 0 0 15.04.2013 N

72 0 0 17.04.2013 M Casing Run In

73 0 0 17.04.2013 E

74 0 0 17.04.2013 N

75 0 0 18.04.2013 M Casing JOS

76 0 0 18.04.2013 E

77 0 0 18.04.2013 N

78 0 0 19.04.2013 M Casing JOS

79 0 0 21.04.2013 E

80 0 0 21.04.2013 N

81 0 0 22.04.2013 M Casing Pullout

82 0 0 22.04.2013 E

83 0 0 22.04.2013 N

84 0 0 23.04.2013 M Pull out

85 0 0 23.04.2013 E

86 0 0 23.04.2013 N

87 0 0 24.04.2013 M Pull out/Run

In/Circulation/Pull out

88 0 0 24.04.2013 E


31 | P a g e


Sl.No.

DG-1

Date Shift Depth of


Av.Load on

DG-1

Av.%Load

on DG-1 89 0 0 26.04.2013 M Casing

90 0 0 26.04.2013 E

91 0 0 26.04.2013 N

92 0 0 27.04.2013 M Waiting for Cement

93 0 0 27.04.2013 E

94 0 0 27.04.2013 N

95 0 0 28.04.2013 M BOP Dismantling

96 0 0 29.04.2013 M Pipe pro

97 0 0 29.04.2013 E

98 0 0 29.04.2013 N

99 0 0 30.04.2013 M Pipe pro

100 0 0 30.04.2013 E

101 0 0 30.04.2013 N

102 0 0 01.05.2013 M Production Tube Joining

103 0 0 01.05.2013 E

104 0 0 01.05.2013 N

105 0 0 02.05.2013 M Tubing Run In

106 0 0 02.05.2013 E

107 0 0 02.05.2013 N

108 0 0 03.05.2013 M Tubing Run In

109 0 0 03.05.2013 E

110 0 0 03.05.2013 N

111 0 0 04.05.2013 E

112 0 0 04.05.2013 N

113 0 0 05.05.2013 M Pull out/Tubing

114 0 0 05.05.2013 E

115 0 0 05.05.2013 N

116 0 0 06.05.2013 M Run In

117 0 0 06.05.2013 E

118 0 0 06.05.2013 N

119 0 0 07.05.2013 M Waiting for pumpout

120 0 0 07.05.2013 E

121 0 0 07.05.2013 N

122 0 0 08.05.2013 M Logging

123 0 0 08.05.2013 E

124 0 0 08.05.2013 N

125 0 0 09.05.2013 M Logging

126 0 0 09.05.2013 E


32 | P a g e


Sl.No.

DG-1

Date Shift Depth of


Av.Load on

DG-1

Av.%Load

on DG-1 127 0 0 09.05.2013 N

128 0 0 10.05.2013 M Nitrogen

129 0 0 10.05.2013 E

130 0 0 10.05.2013 N

131 0 0 11.05.2013 M Nitrogen

132 0 0 11.05.2013 E

133 0 0 11.05.2013 N

134 0 0 12.05.2014 M Pipe Br.

135 0 0 12.05.2014 E

136 0 0 12.05.2014 N

137 50 6 04.05.2013 M Pull out/Tubing

138 75 9 04.03.2012 M 9 Spud-in

139 75 9 24.03.2012 M Cementing

140 80 9 12.04.2013 N

141 80 9 28.04.2013 E

142 95 11 28.04.2013 N

143 100 12 05.03.2012 M 150 Circulation

144 100 12 20.04.2013 E

145 106 12 23.03.2012 N

146 113 13 20.04.2013 N

147 120 14 04.04.2012 M 2411 Circulation

148 129 15 23.03.2012 E

149 131 15 16.04.2013 M Logging/Run in /Pull out

150 133 16 25.04.2013 E

151 150 18 06.04.2012 E

152 150 18 16.04.2013 E

153 167 20 12.04.2013 E

154 170 20 29.03.2012 M Cement/Cutting

155 183 21 12.03.2012 N

156 184 22 14.03.2012 N

157 193 23 09.04.2012 M 2690 Reaming/Drilling

158 195 23 14.03.2012 M 829 Drilling/Pull

Out/Recirculation

159 200 24 21.03.2012 M 1753 Pull out(Logging)

160 200 24 04.04.2012 E

161 200 24 15.04.2013 M Circulation

162 208 24 25.04.2013 M Pull out

163 210 25 14.03.2012 E

164 217 25 16.04.2013 N


33 | P a g e


Sl.No.

DG-1

Date Shift Depth of


Av.Load on

DG-1

Av.%Load

on DG-1 165 225 26 20.03.2012 N

166 232 27 12.03.2012 M 712 Drilling/Pull Out

167 238 28 15.04.2013 E

168 245 29 17.03.2012 E

169 248 29 09.04.2012 N

170 249 29 30.03.2012 M 1812 Drilling

171 250 29 13.03.2012 N

172 250 29 22.03.2012 M Casing/Recirculation

173 250 29 30.03.2012 N

174 250 29 31.03.2012 E

175 250 29 20.04.2013 M Casing JOS

176 254 30 31.03.2012 M 2271 Drilling

177 260 31 17.03.2012 M 1452 Drilling

178 260 31 31.03.2012 N

179 260 31 01.04.2012 M 2271 Pull out

180 267 31 24.04.2013 N

181 269 32 11.04.2012 N

182 275 32 19.03.2012 M 1652 Recirculation

183 283 33 16.03.2012 M 1281 Drilling/Pull

Out/Recirculation

184 286 34 17.03.2012 N

185 290 34 29.03.2012 E

186 297 35 07.04.2012 M Drilling

187 297 35 19.04.2013 E

188 300 35 18.03.2012 N 1624

189 300 35 29.03.2012 N

190 300 35 10.04.2012 N 2832

191 300 35 21.04.2013 M Casing Pullout

192 310 36 25.04.2013 N

193 318 37 07.04.2012 E 2477

194 320 38 08.04.2012 M 2686 Drilling/Pull out

195 320 38 08.04.2012 N

196 336 39 10.04.2012 M 2716 Drilling

197 338 40 13.03.2012 E

198 343 40 11.04.2012 M 2888 Drilling/Pullout

199 344 40 07.04.2012 N 2551

200 350 41 13.03.2012 M 783 Pullout/Drilling

201 350 41 30.03.2012 E

202 350 41 08.04.2012 E


34 | P a g e


Sl.No.

DG-1

Date Shift Depth of


Av.Load on

DG-1

Av.%Load

on DG-1 203 350 41 10.04.2012 E 2795

204 350 41 11.04.2012 E 2954

205 356 42 16.03.2012 E

206 368 43 12.03.2012 E

207 400 47 20.03.2012 E

208 400 47 19.04.2013 N

209 DRILLING

COMPLETED

11.04.2012

Observation: From the above exercise it is observed that the load on DG has varied from 6% to 47%

during its 72 shifts(24days) operations. Hence, the entire DG operations has been carried out at part

load, which is energy wasting. Normally, load about 75% on DG is considered optimised and rational.

However in case of drilling rig, where the operators have to often play a safe side, let us consider

that load between 40% to 60% is realistic.

In the above study, it is clear that the DG was operated above 40% only for 12 shifts i.e. for 4 days.

For the remaining 20 days, load on DG was below 40% and many a days at part load condition.

DG#2:

Sl. No.

DG-2

Date Shift Depth of

Drill (M) Operations Av. Load

on DG-2

Av. Load

on DG-2 1 0 0 04.03.2012 M 9 spud in

2 0 0 05.03.2012 M 150 Circulation

3 0 0 08.03.2012 N

4 0 0 09.03.2012 M 307 Drilling

5 0 0 09.03.2012 E

6 0 0 09.03.2012 N

7 0 0 10.03.2012 M 532 Drilling

8 0 0 10.03.2012 E


10 0 0 12.03.2012 E

11 0 0 12.03.2012 N

12 0 0 14.03.2012 M 829 Drilling/Pull

Out/Recirculation

13 0 0 14.03.2012 E

14 0 0 14.03.2012 N

15 0 0 15.03.2012 M Drilling

16 0 0 18.03.2012 N 1624

17 0 0 19.03.2012 M 1652 Recirculation

18 0 0 20.03.2012 E


35 | P a g e


Sl. No.

DG-2

Date Shift Depth of


on DG-2

Av. Load

on DG-2 19 0 0 20.03.2012 N


21 0 0 21.03.2012 E

22 0 0 23.03.2012 N

23 0 0 24.03.2012 M Cementing

24 0 0 24.03.2012 E

25 0 0 24.03.2012 N


27 0 0 25.03.2012 E

28 0 0 25.03.2012 N

29 0 0 26.03.2012 M BOP Planning

30 0 0 27.03.2012 E

31 0 0 27.03.2012 N


33 0 0 30.03.2012 E

34 0 0 30.03.2012 N

35 0 0 31.03.2012 M 2271 Drilling

36 0 0 31.03.2012 E

37 0 0 31.03.2012 N

38 0 0 02.04.2012 E

39 0 0 02.04.2012 N

40 0 0 04.04.2012 N

41 0 0 05.04.2012 M 2411 Circulation

42 0 0 05.04.2012 E

43 0 0 05.04.2012 N


45 0 0 08.04.2012 N


47 0 0 13.04.2013 N

48 0 0 14.04.2013 M Run in

49 0 0 20.04.2013 N


51 0 0 21.04.2013 E

52 0 0 21.04.2013 N


54 0 0 22.04.2013 E

55 0 0 26.04.2013 E

56 0 0 26.04.2013 N


36 | P a g e


Sl. No.

DG-2

Date Shift Depth of


on DG-2

Av. Load

on DG-2 57 0 0 27.04.2013 M Waiting for Cement

58 0 0 27.04.2013 E



61 0 0 01.05.2013 E

62 0 0 01.05.2013 N

63 0 0 02.05.2013 M Tubing Run In

64 0 0 02.05.2013 E

65 0 0 02.05.2013 N

66 0 0 04.05.2013 M Pull out/Tubing

67 0 0 04.05.2013 E

68 0 0 06.05.2013 M Run In

69 0 0 09.05.2013 N

70 0 0 10.05.2013 E

71 0 0 10.05.2013 N

72 0 0 11.05.2013 M Nitrogen

73 0 0 11.05.2013 E

74 0 0 11.05.2013 N

75 0 0 12.05.2014 E

76 0 0 12.05.2014 N

77 50 6 06.03.2012 N 150

78 50 6 07.05.2013 N

79 50 6 09.05.2013 M Logging

80 50 6 09.05.2013 E

81 50 6 10.05.2013 M Nitrogen pumping

82 63 7 06.03.2012 E 150

83 67 8 12.04.2013 E

84 70 8 22.03.2012 N

85 75 9 26.03.2012 N


87 75 9 08.05.2013 N

88 78 9 24.04.2013 M Pull out/Run


89 79 9 29.04.2013 N

90 80 9 07.03.2012 M 150 BOP Planning

91 80 9 07.03.2012 E 150

92 80 9 22.03.2012 E

93 80 9 26.03.2012 E

94 80 9 07.05.2013 E


37 | P a g e


Sl. No.

DG-2

Date Shift Depth of


on DG-2

Av. Load

on DG-2 95 80 9 08.05.2013 M Logging

96 80 9 08.05.2013 E

97 82 10 29.04.2013 E

98 85 10 29.04.2013 M Pipe pro

99 86 10 10.03.2012 N

100 86 10 07.03.2012 N 150

101 88 10 28.03.2012 E

102 88 10 28.04.2013 N

103 90 11 14.04.2013 E

104 90 11 04.05.2013 N

105 94 11 06.05.2013 N

106 98 11 23.03.2012 M Casing

107 100 12 27.04.2013 N

108 100 12 03.05.2013 M Tubing Run In

109 103 12 19.03.2012 N



112 108 13 30.04.2013 M Pipe pro

113 108 13 30.04.2013 N

114 113 13 14.04.2013 N

115 113 13 05.05.2013 M Pull out/Tubing

116 119 14 03.05.2013 N

117 121 14 28.04.2013 E

118 122 14 23.04.2013 M Pull out

119 124 15 05.05.2013 N

120 128 15 11.03.2012 N

121 130 15 30.04.2013 E

122 133 16 17.04.2013 E

123 135 16 05.05.2013 E

124 141 17 06.03.2012 M 150 BOP Planning

125 143 17 19.03.2012 E

126 143 17 17.04.2013 M Casing Run In

127 150 18 18.03.2012 M 1452 Drilling

128 150 18 12.04.2013 M Circulation

129 150 18 16.04.2013 E

130 163 19 08.03.2012 M 307 Drilling

131 163 19 06.04.2012 N

132 163 19 15.04.2013 N


38 | P a g e


Sl. No.

DG-2

Date Shift Depth of


on DG-2

Av. Load

on DG-2 133 163 19 18.04.2013 N

134 163 19 22.04.2013 N

135 167 20 08.03.2012 E

136 169 20 03.04.2012 M 2411 Circulation

137 175 21 05.03.2012 N

138 175 21 06.04.2012 E

139 178 21 04.04.2012 M 2411 Circulation

140 179 21 02.04.2012 M 2271 Recirculation

141 180 21 11.03.2012 M 532 Pull Out

142 183 21 03.05.2013 E

143 186 22 25.04.2013 M Pull out

144 188 22 29.03.2012 M Cement/Cutting

145 188 22 19.04.2013 M Casing JOS

146 188 22 23.04.2013 N


148 200 24 23.03.2012 E

149 200 24 06.05.2013 E

150 205 24 16.03.2012 N

151 205 24 12.04.2013 N

152 206 24 05.03.2012 E

153 208 24 18.04.2013 E

154 212 25 11.03.2012 E

155 215 25 16.03.2012 M 1281 Drilling/Pull

Out/Recirculation

156 224 26 13.04.2013 E

157 225 26 04.04.2012 E

158 225 26 15.04.2013 M Circulation

159 228 27 18.03.2012 E 1513

160 230 27 25.04.2013 E

161 231 27 28.03.2012 N

162 233 27 16.04.2013 N

163 237 28 26.04.2013 M Casing

164 240 28 30.03.2012 M 1812 Drilling

165 245 29 17.03.2012 M 1452 Drilling

166 245 29 17.03.2012 E

167 245 29 11.04.2012 N

168 245 29 15.04.2013 E

169 250 29 01.04.2012 E

170 250 29 13.04.2013 M Circulation


39 | P a g e


Sl. No.

DG-2

Date Shift Depth of


on DG-2

Av. Load

on DG-2 171 250 29 20.04.2013 M Casing JOS

172 250 29 20.04.2013 E

173 258 30 03.04.2012 E

174 260 31 17.03.2012 N

175 263 31 24.04.2013 N

176 269 32 23.04.2013 E

177 270 32 24.04.2013 E

178 276 32 16.03.2012 E

179 279 33 20.03.2012 M Pull out

180 281 33 15.03.2012 N 1178

181 281 33 17.04.2013 N

182 288 34 21.03.2012 N

183 290 34 29.03.2012 E

184 294 35 07.04.2012 M Drilling

185 294 35 09.04.2012 N

186 300 35 29.03.2012 N

187 300 35 01.04.2012 N

188 300 35 03.04.2012 N

189 300 35 10.04.2012 N 2832

190 300 35 18.04.2013 M Casing JOS

191 300 35 25.04.2013 N

192 300 35 12.05.2014 M Pipe Br.

193 310 36 19.04.2013 E

194 341 40 10.04.2012 M 2716 Drilling

195 344 40 07.04.2012 E 2477

196 344 40 07.04.2012 N 2551

197 346 41 09.04.2012 E


199 350 41 13.03.2012 N

200 350 41 15.03.2012 E 1028

201 350 41 01.04.2012 M 2271 Pull out


203 350 41 08.04.2012 E


205 379 45 13.03.2012 E

206 380 45 10.04.2012 E 2795

207 400 47 11.04.2012 E 2954

208 400 47 19.04.2013 N


40 | P a g e


Sl. No.

DG-2

Date Shift Depth of


on DG-2

Av. Load

on DG-2 209 11.04.2012


during its 128 shifts(42 days) operations. Hence, the entire DG operations has been carried out at

part load, which is energy wasting. Normally, load about 75% on DG is considered optimised and

rational. However, in case of drilling rig, where the operators have to often play a safe side, let us

consider that load between 40% to 60% is realistic.



DG#3:

Sl.No.

DG-3

Date Shift Depth of

Drill (M) Operations Av.Load on

DG-3

Av.%Load

on DG-3

1 0 0 04.03.2012 M 9 Spud-in

2 0 0 05.03.2012 E

3 0 0 05.03.2012 N

4 0 0 06.03.2012 M 150 BOP Planning

5 0 0 06.03.2012 E 150

6 0 0 06.03.2012 N 150

7 0 0 07.03.2012 M 150 BOP Planning

8 0 0 07.03.2012 E 150

9 0 0 07.03.2012 N 150

10 0 0 08.03.2012 M 307 Drilling

11 0 0 08.03.2012 N

12 0 0 10.03.2012 E

13 0 0 11.03.2012 E

14 0 0 11.03.2012 N

15 0 0 13.03.2012 E

16 0 0 13.03.2012 N

17 0 0 15.03.2012 M Drilling

18 0 0 18.03.2012 M 1452 Drilling

19 0 0 21.03.2012 E

20 0 0 21.03.2012 N


22 0 0 23.03.2012 E

23 0 0 23.03.2012 N

24 0 0 24.03.2012 N



41 | P a g e


Sl.No.

DG-3

Date Shift Depth of


DG-3

Av.%Load

on DG-3

26 0 0 25.03.2012 E

27 0 0 25.03.2012 N

28 0 0 26.03.2012 E

29 0 0 26.03.2012 N


31 0 0 29.03.2012 E

32 0 0 29.03.2012 N

33 0 0 30.03.2012 M 1812 Drilling

34 0 0 02.04.2012 N

35 0 0 05.04.2012 M 2411 Circulation

36 0 0 05.04.2012 E

37 0 0 05.04.2012 N

38 0 0 06.04.2012 E

39 0 0 06.04.2012 N

40 0 0 07.04.2012 M Drilling

41 0 0 07.04.2012 E 2477

42 0 0 07.04.2012 N 2551


44 0 0 10.04.2012 E 2795

45 0 0 10.04.2012 N 2832


47 0 0 11.04.2012 E 2954

48 0 0 15.04.2013 E

49 0 0 15.04.2013 N


51 0 0 22.04.2013 E

52 0 0 24.04.2013 E

53 0 0 24.04.2013 N

54 0 0 25.04.2013 M Pull out

55 0 0 25.04.2013 E

56 0 0 25.04.2013 N

57 0 0 26.04.2013 M Casing

58 0 0 26.04.2013 E


60 0 0 28.04.2013 E

61 0 0 28.04.2013 N

62 0 0 29.04.2013 M Pipe pro

63 0 0 03.05.2013 E


42 | P a g e


Sl.No.

DG-3

Date Shift Depth of


DG-3

Av.%Load

on DG-3

64 0 0 03.05.2013 N

65 0 0 04.05.2013 N


67 0 0 05.05.2013 E


69 0 0 07.05.2013 E

70 0 0 07.05.2013 N

71 0 0 08.05.2013 M Logging

72 0 0 08.05.2013 E

73 0 0 08.05.2013 N

74 0 0 09.05.2013 E

75 0 0 09.05.2013 N

76 0 0 10.05.2013 M Nitrogen

77 0 0 10.05.2013 E

78 0 0 10.05.2013 N

79 0 0 11.05.2013 E

80 0 0 11.05.2013 N

81 0 0 12.05.2014 M Pipe Br.

82 0 0 12.05.2014 N

83 38 4 12.04.2013 E

84 50 6 27.03.2012 E

85 50 6 06.05.2013 M Run In

86 50 6 09.05.2013 M Logging

87 50 6 12.05.2014 E

88 58 7 03.05.2013 M Tubing Run In

89 60 7 02.04.2012 E

90 61 7 14.04.2013 E

91 67 8 26.03.2012 M BOP Planning

92 69 8 22.03.2012 E

93 69 8 12.04.2013 M Circulation

94 70 8 22.03.2012 N

95 70 8 27.03.2012 N


97 75 9 13.04.2013 N

98 75 9 14.04.2013 M Run in

99 75 9 24.04.2013 M Pull out/Run




43 | P a g e


Sl.No.

DG-3

Date Shift Depth of


DG-3

Av.%Load

on DG-3

101 75 9 01.05.2013 N

102 75 9 02.05.2013 M Tubing Run In

103 75 9 02.05.2013 E

104 75 9 02.05.2013 N

105 75 9 04.05.2013 E

106 79 9 29.04.2013 N


108 81 10 30.04.2013 N

109 83 10 28.03.2012 E

110 83 10 29.04.2013 E

111 88 10 24.03.2012 E

112 88 10 19.04.2013 M Casing JOS

113 90 11 24.03.2012 M Cementing

114 90 11 04.04.2012 N

115 92 11 10.03.2012 N

116 95 11 01.05.2013 E

117 100 12 05.03.2012 M 150 Circulation

118 100 12 20.04.2013 E

119 100 12 27.04.2013 N

120 100 12 11.05.2013 M Nitrogen

121 103 12 19.03.2012 N

122 104 12 30.04.2013 E

123 108 13 05.05.2013 N

124 109 13 06.05.2013 N

125 113 13 14.04.2013 N

126 113 13 20.04.2013 N

127 125 15 09.03.2012 M 307 Drilling

128 129 15 09.03.2012 E

129 131 15 17.04.2013 M Casing Run In

130 133 16 17.04.2013 E

131 133 16 30.04.2013 M Pipe pro

132 137 16 23.04.2013 M Pull out

133 143 17 21.04.2013 N

134 143 17 19.03.2012 E

135 144 17 10.03.2012 M 532 Drilling

136 150 18 16.04.2013 E

137 150 18 26.04.2013 N

138 150 18 27.04.2013 M Waiting for Cement


44 | P a g e


Sl.No.

DG-3

Date Shift Depth of


DG-3

Av.%Load

on DG-3

139 150 18 04.05.2013 M Pull out/Tubing

140 150 18 06.05.2013 E

141 160 19 08.03.2012 E

142 160 19 27.04.2013 E

143 163 19 18.04.2013 N

144 163 19 22.04.2013 N


146 173 20 02.04.2012 M 2271 Recirculation

147 183 21 12.03.2012 N


149 184 22 09.03.2012 N

150 185 22 22.04.2013 M Casing Pullout

151 188 22 30.03.2012 N

152 188 22 23.04.2013 N

153 190 22 16.04.2013 N

154 200 24 11.03.2012 M 532 Pull Out

155 200 24 04.04.2012 M 2411 Circulation


157 208 24 18.04.2013 E

158 215 25 16.03.2012 M 1281 Drilling/Pull Out/Recirculation

159 217 25 29.03.2012 M Cement/Cutting

160 220 26 30.03.2012 E

161 223 26 16.03.2012 N

162 224 26 13.04.2013 E

163 225 26 20.03.2012 N

164 225 26 04.04.2012 E

165 229 27 11.04.2012 N

166 229 27 12.04.2013 N

167 231 27 28.03.2012 N


169 243 29 09.04.2012 E

170 245 29 17.03.2012 E

171 250 29 14.03.2012 M 829 Drilling/Pull Out/Recirculation

172 250 29 14.03.2012 N

173 250 29 17.03.2012 M 1452 Drilling

174 250 29 23.03.2012 M Casing

175 250 29 31.03.2012 E


45 | P a g e


Sl.No.

DG-3

Date Shift Depth of


DG-3

Av.%Load

on DG-3

176 250 29 01.04.2012 E

177 250 29 15.04.2013 M Circulation

178 253 30 03.04.2012 M 2411 Circulation

179 260 31 31.03.2012 N

180 260 31 13.04.2013 M Circulation

181 260 31 20.04.2013 M Casing JOS

182 269 32 23.04.2013 E

183 273 32 21.04.2013 M Casing Pullout

184 275 32 19.03.2012 M 1652 Recirculation

185 276 32 16.03.2012 E

186 281 33 15.03.2012 N 1178

187 281 33 20.03.2012 M Pull out

188 281 33 17.04.2013 N

189 284 33 14.03.2012 E

190 286 34 17.03.2012 N

191 295 35 09.04.2012 N

192 300 35 18.03.2012 E 1513

193 300 35 18.03.2012 N 1624

194 300 35 31.03.2012 M 2271 Drilling

195 300 35 01.04.2012 N

196 300 35 03.04.2012 E

197 300 35 18.04.2013 M Casing JOS

198 300 35 21.04.2013 E

199 330 39 01.04.2012 M 2271 Pull out

200 333 39 10.04.2012 M 2716 Drilling

201 340 40 19.04.2013 E

202 350 41 15.03.2012 E 1028

203 350 41 08.04.2012 E

204 360 42 08.04.2012 N

205 361 42 12.03.2012 E

206 390 46 03.04.2012 N

207 400 47 20.03.2012 E

208 400 47 19.04.2013 N

209 11.04.2012





46 | P a g e






DG#4:

Sl.No.

DG-4

Date Shift Depth of


DG-4

Av.%Load

on DG-4 1 0 0 04.03.2012 M 9 Spud-in

2 0 0 05.03.2012 M 150 Circulation

3 0 0 05.03.2012 E

4 0 0 05.03.2012 N

5 0 0 06.03.2012 E 150

6 0 0 06.03.2012 N 150

7 0 0 07.03.2012 M 150 BOP Planning

8 0 0 07.03.2012 E 150

9 0 0 07.03.2012 N 150

10 0 0 08.03.2012 M 307 Drilling

11 0 0 10.03.2012 E

12 0 0 10.03.2012 N

13 0 0 11.03.2012 M 532 Pull Out

14 0 0 12.03.2012 E

15 0 0 12.03.2012 N


17 0 0 13.03.2012 E

18 0 0 13.03.2012 N

19 0 0 14.03.2012 M 829 Drilling/Pull

Out/Recirculation

20 0 0 14.03.2012 N

21 0 0 15.03.2012 M Drilling

22 0 0 16.03.2012 E

23 0 0 16.03.2012 N

24 0 0 17.03.2012 E

25 0 0 17.03.2012 N

26 0 0 19.03.2012 N

27 0 0 22.03.2012 E

28 0 0 22.03.2012 N

29 0 0 23.03.2012 N

30 0 0 26.03.2012 E

31 0 0 26.03.2012 N



47 | P a g e


Sl.No.

DG-4

Date Shift Depth of


DG-4

Av.%Load

on DG-4 33 0 0 27.03.2012 E

34 0 0 27.03.2012 N


36 0 0 28.03.2012 E

37 0 0 28.03.2012 N

38 0 0 29.03.2012 M Cement/Cutting

39 0 0 29.03.2012 E

40 0 0 29.03.2012 N

41 0 0 02.04.2012 E

42 0 0 02.04.2012 N

43 0 0 04.04.2012 E

44 0 0 04.04.2012 N

45 0 0 05.04.2012 M 2411 Circulation

46 0 0 05.04.2012 E

47 0 0 05.04.2012 N


49 0 0 09.04.2012 N

50 0 0 11.04.2012 N

51 0 0 12.04.2013 M Circulation

52 0 0 12.04.2013 E

53 0 0 13.04.2013 N

54 0 0 14.04.2013 M Run in

55 0 0 14.04.2013 E

56 0 0 14.04.2013 N


58 0 0 16.04.2013 E

59 0 0 16.04.2013 N

60 0 0 17.04.2013 M Casing Run In

61 0 0 17.04.2013 E

62 0 0 17.04.2013 N

63 0 0 18.04.2013 M Casing JOS

64 0 0 18.04.2013 E

65 0 0 18.04.2013 N

66 0 0 19.04.2013 E

67 0 0 19.04.2013 N

68 0 0 20.04.2013 M Casing JOS

69 0 0 22.04.2013 N

70 0 0 23.04.2013 N


48 | P a g e


Sl.No.

DG-4

Date Shift Depth of


DG-4

Av.%Load

on DG-4 71 0 0 24.04.2013 M Pull out/Run


72 0 0 28.04.2013 E

73 0 0 28.04.2013 N

74 0 0 29.04.2013 M Pipe pro

75 0 0 29.04.2013 E

76 0 0 29.04.2013 N

77 0 0 30.04.2013 M Pipe pro

78 0 0 30.04.2013 E

79 0 0 30.04.2013 N


81 0 0 01.05.2013 E

82 0 0 01.05.2013 N

83 0 0 02.05.2013 M Tubing Run In

84 0 0 02.05.2013 E

85 0 0 02.05.2013 N

86 0 0 03.05.2013 M Tubing Run In


88 0 0 05.05.2013 E

89 0 0 05.05.2013 N

90 0 0 06.05.2013 M Run In

91 0 0 06.05.2013 E

92 0 0 06.05.2013 N

93 0 0 07.05.2013 N

94 0 0 08.05.2013 M Logging

95 0 0 08.05.2013 E

96 0 0 08.05.2013 N

97 0 0 09.05.2013 E

98 0 0 09.05.2013 N

99 0 0 10.05.2013 M Nitrogen

100 0 0 10.05.2013 E

101 0 0 10.05.2013 N

102 0 0 11.05.2013 M Nitrogen

103 0 0 11.05.2013 E

104 0 0 11.05.2013 N

105 0 0 12.05.2014 M Pipe Br.

106 0 0 12.05.2014 E

107 0 0 12.05.2014 N

108 48 6 26.03.2012 M BOP Planning


49 | P a g e


Sl.No.

DG-4

Date Shift Depth of


DG-4

Av.%Load

on DG-4 109 50 6 28.04.2013 M BOP Dismantling

110 50 6 09.05.2013 M Logging

111 55 6 25.03.2012 M Wetting cement

112 60 7 24.03.2012 N

113 75 9 25.03.2012 N

114 78 9 24.03.2012 E

115 79 9 20.04.2013 E

116 80 9 25.03.2012 E

117 80 9 07.05.2013 E

118 85 10 27.04.2013 N

119 88 10 21.03.2012 E

120 88 10 24.03.2012 M Cementing

121 100 12 20.04.2013 N

122 100 12 04.05.2013 N



125 113 13 26.04.2013 E

126 119 14 03.05.2013 N

127 128 15 11.03.2012 N

128 129 15 04.05.2013 M Pull out/Tubing

129 130 15 09.03.2012 E

130 136 16 23.03.2012 M Casing

131 138 16 08.03.2012 N

132 138 16 09.03.2012 M 307 Drilling

133 138 16 23.03.2012 E

134 143 17 21.04.2013 N

135 143 17 19.03.2012 E

136 144 17 04.05.2013 E

137 150 18 06.03.2012 M 150 BOP Planning

138 150 18 08.03.2012 E

139 150 18 21.03.2012 N

140 150 18 26.04.2013 N

141 150 18 27.04.2013 M Waiting for Cementing

142 160 19 27.04.2013 E


144 163 19 06.04.2012 N

145 163 19 25.04.2013 E

146 166 20 10.03.2012 M 532 Drilling


50 | P a g e


Sl.No.

DG-4

Date Shift Depth of


DG-4

Av.%Load

on DG-4 147 173 20 23.04.2013 M Pull out

148 174 20 16.03.2012 M 1281 Drilling/Pull

Out/Recirculation

149 183 21 03.05.2013 E

150 184 22 09.03.2012 N

151 185 22 22.04.2013 M Casing Pullout

152 186 22 03.04.2012 M 2411 Circulation

153 188 22 30.03.2012 N

154 188 22 06.04.2012 E

155 191 22 02.04.2012 M 2271 Recirculation

156 193 23 14.03.2012 E

157 198 23 11.03.2012 E

158 199 23 30.03.2012 E


160 200 24 15.04.2013 M Circulation

161 208 24 25.04.2013 M Pull out

162 225 26 20.03.2012 N

163 226 27 26.04.2013 M Casing

164 228 27 18.03.2012 E 1513

165 244 29 22.04.2013 E

166 245 29 15.04.2013 E


168 250 29 31.03.2012 E

169 250 29 01.04.2012 E

170 256 30 21.04.2013 M Casing Pullout

171 260 31 31.03.2012 N

172 263 31 24.04.2013 N

173 267 31 04.04.2012 M 2411 Circulation

174 269 32 23.04.2013 E

175 270 32 24.04.2013 E

176 271 32 03.04.2012 E

177 275 32 19.03.2012 M 1652 Recirculation

178 275 32 13.04.2013 M Circulation

179 281 33 15.03.2012 N 1178

180 294 35 07.04.2012 M Drilling

181 300 35 18.03.2012 M 1452 Drilling

182 300 35 18.03.2012 N 1624

183 300 35 31.03.2012 M 2271 Drilling

184 300 35 01.04.2012 N


51 | P a g e


Sl.No.

DG-4

Date Shift Depth of


DG-4

Av.%Load

on DG-4 185 300 35 03.04.2012 N

186 300 35 10.04.2012 N 2832

187 300 35 12.04.2013 N

188 300 35 13.04.2013 E

189 300 35 21.04.2013 E

190 300 35 25.04.2013 N

191 308 36 20.03.2012 M Pull out

192 310 36 30.03.2012 M 1812 Drilling

193 313 37 19.04.2013 M Casing JOS

194 330 39 01.04.2012 M 2271 Pull out

195 344 40 07.04.2012 E 2477

196 344 40 07.04.2012 N 2551

197 344 40 08.04.2012 E

198 350 41 15.03.2012 E 1028


200 350 41 10.04.2012 M 2716 Drilling

201 350 41 15.04.2013 N


203 360 42 08.04.2012 N

204 400 47 20.03.2012 E

205 400 47 09.04.2012 E

206 400 47 10.04.2012 E 2795

207 400 47 11.04.2012 E 2954

208 450 53 17.03.2012 M 1452 Drilling

209 11.04.2012








6.4 Average specific fuel consumption by DGs:

As exercised earlier(ch.-3) the enrgy generated by DGs during the drilling operation = 591788 kWh

Diesel consumption for above generation = 193538 Ltrs.

Average specific fuel consumption by DGs = 193538 x1000x0.85/591788 = 278 gm /kWh


52 | P a g e


(Specific gravidy of diesel = 0.85)

Designed specific fuel consumption of D-399 Caterpillar Engine:

% Load Sp Fuel Con. (gm/kWh)

25 297

50 254

75 242

100 247

Comments: The derived average specific fuel consumption in relation to the present operating condition is 278

gm/kWh. The reason behind this higher specific fuel consumption is part load operation of the DGs

during the drilling operation. Most of the days the load on all the DGs varied between 4% to 40%.

Recommendation-1: Rationalize DG operations to ensure the load on DGs above 50% with existing

on line generators.

Estimated savings:

Established specific fuel consumption at existing operating practice = 278 gm/kWh

Specific fuel consumption at 50% load on DGs = 254 gm/kWh

Savings = 278 – 254 = 24 gm/kWh

kWh generated by all the DGs for drilling one well = 591788 kWh

Savings for drilling of one well = 24 x 591788 gm =24 x 591788/0.85 cc =16709308 cc

= 16.7 KL (considering, density of diesel = 0.85)

Market price of 1 KL diesel = Rs.50,000/-

Savings for drilling one well = Rs.50,000 x 16.7 = Rs.8,35,000/-

Considering 3 nos. drilling wells are carried out by a rig in a year

Annual savings = Rs.8,35,000 x 3 = Rs.25,05,000/-

Recommendation-2: The existing D399 engines may be replaced by energy efficient engines like D-3512B.

This is likely to result in saving of Rs. 2297529/- for one drilling well of 2960Mtrs completed in

70 days.


53 | P a g e


The fuel efficiency Vs load curve for D-3513B is as below:

Savings with new gen-set D-3512B and at 50% loading from the graph is

= (278-212) X 591788 x 50000/ (1000 x 850) = Rs. 2297529/-

Cost of one D-3512B engine = $ 396000 (USD) = 200 lacs (approx)

Therefore, by replacing 2 Nos. D399 engine with D3512B engines-

Pay back period will be = (200 x 2)/68.93 = 5.8 years= 5 years & 10 Months

Note: It was learnt that OIL is already in the process of replacing CAT-D399 engines with D-3512B

engines. It is suggested that the process may be expedited to achieve the desired savings as early as

possible.

Recommendation-3:

Install a gen-set of lower capacity (KVA as required) to cater auxiliary AC load. This will help

in reducing the running hours of bigger DG Sets on low load condition and result in

substantial savings apart from increasing the life of the rig engines.

Since, many a times, it is a usual practice to operate necessary AC connected load

during the drilling operations. It is very difficult to rationalize the load with existing higher

size (1215 KVA) DGs when the load requirement is very low. Hence, it is justified to install a

smaller size DG to cater the AC-load as and when required. It is advisable to use the lower

capacity gen-set during production testing / waiting for allied services etc. when only

auxiliary and lighting load is required. [(Note: Such practice is prevalent at the Rig of M/s.

JAY BEE Energy (P) Ltd. The model of the Rig is DZ 315/9-S and nominal drill depth of which

is 3000 – 5000M).They installed a 400 KVA DG of VOLVO PENTA make. ]

Investment:

Estimate cost of 400 KVA DG = Rs. 50,00,000/-


54 | P a g e


6.5 General Maintenance Recommendations for DG Engines

Trouble shooting and Remedy for DG Sets is presented below:

Checkpoint

Cause of Trouble Remedy

Starter Defective Pinion Gear(teeth stripped)

Engine Piston, crank bearing seizure, or other damage Repair or repair the related

parts

Injection Nozzle Injection nozzle starting pressure too low.

Improper spray condition

Adjust or replace the

injection nozzle

Injection pump

Defective fuel injection nozzle resulting in fuel

drippage after the fuel injection

Replace the delivery valve

Defective injection pump control rack

operation

Repair or replace the

injection pump control rack

Injection pump plunger worn or stuck Replace the injection pump

plunger assembly

Injection pump

Injection pump drive shaft seizure or other

damage.

Replace the injection pump

drive shaft.

Injection pump governor spring seizure. Replace the injection pump

governor spring.

Engine stop

mechanism

Defective engine stop mechanism. Control

wire improperly adjusted(In-line-pump)

Replace the engine stop

mechanism, adjust the

control wire.

Defective fuel cut-off solenoid valve(VE pump) Replace the fuel cut-off

solenoid valve

Fuel piping Clogged or damaged fuel lines. Loose fuel line

connections

Repair or replace the fuel

filter overflow valve.

Fuel filter Fuel filter overflow valve does not close Repair or replace the fuel

filter overflow valve.

Clogged fuel filter element Replace filter

Fuel system

Air in the fuel system Bleed the air from the fuel

system

Clogged inline filter(located in the fuel inlet

banjo bolt on the fuel lift pump.(Inline

Injection Pump Models)

Remove banjo bolt and clean

debris from screen filter.


55 | P a g e


Checkpoint Trouble Cause Remedy

Low idling system Low idling improperly adjusted. Adjust the low idling.

Low idling speed

control device

Defective low idling speed control

device.

Repair or replace the low idling

speed control device.

Throttle control

system

Throttle control system improperly

adjusted.

Adjust the throttle control

system.

Fuel System

Fuel system leakage or blockage. Repair or replace the fuel

system

Air in the fuel system. Bleed the air from the fuel

system.

Water particles in the fuel system. Change the fuel.

Clogged inline filter (located in the fuel

inlet banjo bolt) on the fuel lift pump.

(Inline Injection Pump Models)



Fuel filter Clogged fuel filter element. Replace filter.

Injection pump

Defective governor lever operation. Repair or replace the governor

lever.

Regulator valve improperly adjusted

(VE pump only)

Adjust or replace the regulator

valve.

Broken plunger spring. Replace the plunger spring.

Worn plunger. Replace the plunger assembly.

Worn camshaft (in-line pump only) Replace the camshaft.

Worn roller tappet (in-line pump only). Replace the roller tappet.

Worn cam disc (VE pump only) Replace the cam disc.

Valve clearance Valve clearance improperly adjusted. Adjust the valve clearance.

Compression

pressure

Blown out cylinder head gasket, Worn

cylinder liner, Piston ring sticking or

broken, Improper seating between the

valve and the valve seat.

Replace the related parts.

Unstable Low Idling


56 | P a g e



Air cleaner Clogged air cleaner element Clean or replace the element

Fuel Water particles in the fuel Replace fuel

Fuel filter Clogged fuel filter element Replace filter

Fuel Feed Pump

Clogged inline filter (located in the fuel

inlet banjo bolt) on the fuel lift pump.

(Inline Injection Pump Models)



Defective fuel feed pump Repair or replace the fuel feed

pump.

Injection nozzle

Injection nozzle sticking Replace the injection nozzle.

Injection nozzle injection starting

pressure to low, Improper spray

condition.

Adjust or replace the injection

Fuel injection

pipes

Fuel injection pipes damaged or

obstructed.

Replace the fuel injection pipes.

Injection pump

Defective delivery valve Replace the delivery valve

Defective timer Repair or replace the timer.

Improper control lever operation Adjust or replace the control

lever.

Defective injection timing. Adjust the injection timing.

Repair or replace the injection

pump timer.

Weak governor spring. Replace governor spring.

Worn plunger. Replace plunger assy.

Worn camshaft (In-line pump only) Replace the camshaft.

Worn roller tappet Replace the roller tappet.

Turbocharger

Exhaust gas leakage from the exhaust

system, Air leakage from the intake

system.

Repair or replace the related

parts.

Defective turbocharger assembly Replace the turbocharger

Compression

Pressure






Valve clearance Valve clearance improperly adjusted. Adjust the valve clearance.

Valve spring Valve spring weak or broken. Replace the valve spring.

Exhaust system Exhaust pipe clogged. Clean the exhaust system.

Full load

adjusting screw

seal

Open and improperly set adjusting

screw seal

Adjust and reseal the adjusting

screw.

Insufficient Power


57 | P a g e



Fuel System Fuel leakage Repair or replace the fuel

system related parts.

Air Cleaner Clogged air cleaner element Clean or replace the air filter

element.

Low idling speed Poorly adjusted low idle speed Adjust the low idle speed.

Injection nozzle Injection nozzle injection starting

pressure to low, Improper sprays

condition.


nozzle.

Fuel injection

timing

Fuel injection timing improperly adjusted Adjust the fuel injection timing.

Injection pump Defective delivery valve resulting fuel

drippage after fuel injection

Replace the delivery valve.

Turbocharger

Air leakage from the turbocharger intake

side.

Repair the turbocharger intake

side.

Defective turbocharger assembly Replace the turbocharger

assembly.

Valve Clearance Valve clearance improperly adjusted. Adjust the valve clearance.

Compression

pressure






Valve spring Valve spring weak or broken Replace the valve spring.


Engine Oil Engine Oil unsuitable, Too

much engine oil

Replace the engine oil, correct the

engine oil volume.

Oil seal & gasket Oil leakage from the oil seal

and or gasket

Replace the oil seal and or gasket.

Air breather Clogged air breather. Clean the air breather.

Inlet and exhaust valve

stem seals

Defective valve seals, Worn

valve stems and valve

guides.

Replace the valve seals, the valves,

and the valve guides.

Piston rings Piston rings worn, broken or

improperly installed.

Replace the piston rings or properly

install.

Cylinders liners Cylinder liners scored or

worn

Replace the cylinder liners.

Excessive Fuel Consumption

Excessive Oil Consumption


58 | P a g e



Cooling water Insufficient cooling water Replenish the cooling water

Radiator Defective radiator cap or

clogged radiator core

Replace the radiator cap or clean

the radiator core.

Water Pump Defective water pump Repair or replace the water

pump

Cylinder head and cylinder

body sealing cap

Defective sealing cap resulting

in water leakage.

Replace the sealing cap.

Thermostat Defective Thermostat Replace the thermostat

Cooling System Cooling system clogged by

foreign material.

Clean the foreign material from

the cooling system.

Fuel injection timing Fuel injection timing

improperly adjusted.

Adjust the fuel injection timing.


Fuel Water particles in the fuel Replace fuel

Fuel injection timing Delayed fuel injection timing Adjust the fuel injection timing.

Compression pressure Blown out cylinder head gasket,

Worn out cylinder liner, Piston

ring sticking or broken,

Improper seating between the



Turbocharger Defective Turbocharger Replace the turbo

Inlet and exhaust valve

stem seals

Defective valve stem seals,

Worn valve stems and valve

guides.

Replace the valve stem seals, the

valves and the valve guides.

Piston Rings Piston rings worn, broken or

improperly installed.

Replace the piston rings or

properly install.

Cylinder liners Cylinder liners scored or worn Replace the cylinder liners.

Overheating

White exhaust Smoke


59 | P a g e



Air Cleaner Clogged air cleaner element Clean or replace the air cleaner

element

Injection nozzle Injection nozzle injection

starting pressure to low

Improper spray condition.


nozzle.

Fuel injection timing Fuel injection timing

improperly adjusted.

Adjust the fuel injection timing.

Injection Pump

Defective delivery valve

resulting in fuel drippage after

fuel injection.

Replace the delivery valve

Excessive injection volume Adjust the injection volume.

Dark Exhaust Smoke


60 | P a g e


7.0 Illumination Study:

Total lighting load in the Rig Unit are incorporated below:

List of lamp fitting

Sl. No. Room Lamp Type Wattage Nos. Total

Wattage

1 Security Incandescent 100 10 1000

2 Engine House MLL 160 5 800

CFL 23 2 46

3 Pump House MLL 160 4 640

4 Generator House - - - -

5 Chemical House MLL 160 3 480

6 Material House/Store - - - -

7 Control Room FTL 36 21 756

8 Emergency House FTL 36 2 72

9 Fire House MLL 160 1 160

10 Street Area Light SON 400 14 5600

11 Installation Manager Room FTL 36 3 108

12 Office Room FTL 36 19 684

13 Supervisor/Operator Room FTL 36 23 828

14 Pumping Area MLL 160 1 160

15 Other Areas HPMV 250 7 1750

MLL 160 16 2560

CFL 23 23 529

FTL 36 2 72

Total 16245

From the above table, it is observed that the total lighting load = 16.245 KW

It is further observed that according to the classified areas , the lamps are almost rationalized

except few areas with FTL.

The Rig unit is using 66 nos. 40 W FTL. At present context, it is not energy efficient. Use of

29W T-5 FTL in place of 40W FTL will produce same illumination effect at lower energy

input.

Hence, we recommend replacement all the 40W FTLs with energy efficient T-5 lamps

without declining the lux level.


61 | P a g e


Calculation of energy savings by replacing FTLs with T-5 FTLs:

Energy consumption by each 40W FTL = 40 W

Energy consumption by the attached conventional ballast = 12W

Total energy consumption per tube light = 52 W

Energy consumption by each T-5 FTL including ballast = 29W

Savings by replacing one lamp = 52 – 29 = 23 W

No. of lamps recommended to be replaced = 66

Daily glowing hour of a lamp = 12Hrs.

Average working days to complete a drilling operation in a site = 70 days

Glowing hours in 70 days = 70*12 = 840 Hrs.

Energy savings to complete a drilling operation in a site = 23 x 66 x 840 /1000 = 1275 kWh

Specific fuel consumption to generate 1 kWh energy = 278 gm of diesel

Savings to complete a drilling operation = 278/0.85 x1275 =417000 cc = 417 Ltr.

Price of 1 ltr. Diesel = Rs.50/-

Total savings = 417 x 50 = Rs.20,850/-

Considering 3 nos. drilling operation is carried out by a rig in a year

Annual savings = Rs.20,850 x 3 = Rs.62,550/-

Calculation of Investment and Payback:

Cost of one no T-5 lamp with retrofit = Rs.450/-

Cost of 66 nos T-5 lamp = Rs. 29,700/-

Simple pay back period = 0.47 Years. ≈6 Months

energy audit report-rig-e-1400 s-3 rig - oilweb · 2013-05-29 · energy audit of rig e-1400 s-3,...

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