A

REPORT ON SUMMER INTERNSHIP

IN
OIL AND NATURAL GAS CORPORATION
SURAFCE TEAM
AHMEDABAD ASSET

SUBMMITTED BY: AKSHIT PATIDAR MENTOR: Sh. K.C. JOSHI

SIGNATURE

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 ACKNOWLEDGEMENT

Firstly, we would like to thank Mr. K.I. JOSHI Sir for his great efforts in arranging
our training at Ahmedabad asset under surface team.

We would like to express our sincere thanks to installation manager of GGS I,

GGS II, GGS III, C.T.F, G.C.P, E.T.P, Desalter NAVAGAM and O.N.G.C. Ahmedabad
Asset (Avani Bhavan) and all the other working staff for co-operating with us and
making us familiar with all the plants and various processes taking place in the
plant, without their support and helpful nature it would be impossible for us to
understand all the complicated things so easily.

We express our deepest thanks to Prof. A.K. Dwivedi (Head of chemical

Engineering Dept., Ujjain Engineering College, Ujjain) for providing us the moral
support and encouragement, without which it would have been difficult to
complete this training. And also, we would like to thank Prof. A.K. Sharma (Ujjain
Engineering College, Ujjain) sir for providing us letter of recommendation.

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 PREFACE

Theory of any subject is important but without its practical knowledge it

becomes useless, particularly for technical students. A technical student cannot
become a perfect engineer or technologist without practical understanding of
their branch, hence training provides a golden opportunity for all technical
students to interact with the working environment.
The principle necessity of in-plant training is to get details about unit operation
and unit process which are carried in chemical industries and to know more
about the equipment used in these industries.
The in-plant training program is very advantageous for the technical students
who have a vivid idea about the industries.
These training helps to understand the basic concept of the industry. During this
period the students become aware of the problems faced in the plant and are
also aware of the industrial atmosphere and also with the industrial people.

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 INDEX

TOPIC PAGE NO.

ABOUT O.N.G.C. 5

WELLS AND THEIR TYPES 6

GROUP GATHERING STATION I 13

GROUP GATHERING STATION II 24

WATER INJECTION PLANT 29

CENTRAL TANK FARM 31

GAS COMPRESSION PLANT 32

EFFLUENT TREATMENT PLANT 35

DESALTER 44

FIRE FIGHTING SYSTEM 48

LATEST TECHNOLOGY 49

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 ABOUT O.N.G.C.

Oil and Natural Gas Corporation Limited (ONGC) is an

Indian multinational oil and gas company earlier headquartered in
Dehradun, Uttarakhand, India. As a Corporation, it's registered office is now at
Deendayal Urja Bhavan, Vasant Kunj, New Delhi India. It is a Public-Sector
Undertaking (PSU) of the Government of India, under the administrative control
of the Ministry of Petroleum and Natural Gas. It is India's largest oil and gas
exploration and production company. It produces around 70% of India's crude
oil (equivalent to around 30% of the country's total demand) and around 62% of
its natural gas.
On 31 March 2013, its market capitalisation was INR 57.2 trillion (US $ billion),
making it India's first largest publicly traded company. In a government survey
for financial year 2016-17, it was ranked as the largest profit-making PSU in
India. It is ranked 11th among the Top 250 Global Energy Companies by Platts.
ONGC was founded on 14 August 1956 by Government of India, which currently
holds a 68.94% equity stake. It is involved in exploring for and exploiting
hydrocarbons in 26 sedimentary basins of India and owns and operates over
11,000 kilometres of pipelines in the country. Its international subsidiary ONGC
Videsh currently has projects in 17 countries. ONGC has discovered 6 of the 7
commercially producing Indian Basins, in the last 50 years, adding over 7.1
billion tonnes of In-place Oil & Gas volume of hydrocarbons in Indian basins.
Against a global decline of production from matured fields, ONGC has
maintained production from its brownfields like Mumbai High, with the help of
aggressive investments in various IOR (Improved Oil Recovery) and EOR
(Enhanced Oil Recovery) schemes. ONGC has many matured fields with a current
recovery factor of 25–33%. Its Reserve Replacement Ratio for between 2005 and
2013, has been more than one. During FY 2012–13, ONGC had to share the
highest ever under-recovery of INR 8993.78 billion (an increase of INR 567.89
million over the previous financial year) towards the under-recoveries of Oil
Marketing Companies (IOC, BPCL and HPCL). On 1 November 2017, the Union
Cabinet approved ONGC for acquiring majority 51.11 % stake in HPCL (Hindustan
Petroleum Corporation Limited). On Jan 30th 2018, Oil & Natural Gas
Corporation acquired the entire 51.11% stake of Government of India.

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 WELLS AND THEIR TYPES

An oil well is a hole dug into the Earth that serves the purpose of
bringing oil or other hydrocarbons - such as natural gas - to the surface.
Oil wells almost always produce some natural gas and frequently
bring water up with the other petroleum products.

PLANNING

Before a well is drilled, a geologic target is identified by a geologist or

geophysicist to meet the objectives of the well.

 For a production well, the target is picked to optimize production from the
well and manage reservoir drainage.
 For an exploration or appraisal well, the target is chosen to confirm the
existence of a viable hydrocarbon reservoir or to ascertain its extent.
 For an injection well, the target is selected to locate the point of injection in
a permeable zone, which may support disposing of water or gas and /or
pushing hydrocarbons into nearby production wells.
The target (the end point of the well) will be matched with a surface location
(the starting point of the well), and a trajectory between the two will be
designed.
When the well path is identified, a team of geoscientists and engineers will
develop a set of presumed properties of the subsurface that will be drilled
through to reach the target. These properties include pore-pressure, fracture
gradient, wellbore stability, porosity, permeability, lithology, faults, and clay
content. This set of assumptions is used by a well engineering team to perform
the casing design and completion design for the well, and then detailed
planning, where, for example, the drill bits are selected, a BHA is designed,
the drilling fluid is selected, and step-by-step procedures are written to provide
instruction for executing the well in a safe and cost-efficient manner.

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Page 7 of 51
 TYPE OF WELLS
SELF FLOW WELLS
A well in which the formation pressure is sufficient to produce oil at a
commercial rate without requiring a pump. Most reservoirs are initially at
pressures high enough to allow a well to flow naturally.

GAS LIFT WELLS

Gas lift is a method of artificial lift that uses an external source of high-pressure
gas for supplementing formation gas to lift the well fluids. The principle of gas
lift is that gas injected into the tubing reduces the density of the fluids in the
tubing, and the bubbles have a “scrubbing” action on the liquids. Both factors
act to lower the flowing bottom hole pressure (BHP) at the bottom of the tubing.
There are two basic types of gas lift in use today—continuous and intermittent
flow.
CONTINUOUS GAS LIFT WELLS
The vast majority of gas lift wells are produced by continuous flow, which is very
similar to natural flow. In continuous-flow gas lift, the formation gas is
supplemented with additional high-pressure gas from an outside source. Gas is
injected continuously into the production conduit at a maximum depth that
depends upon the injection-gas pressure and well depth. The injection gas mixes
with the produced well fluid and decreases the density and, subsequently, the
flowing pressure gradient of the mixture from the point of gas injection to the
surface. The decreased flowing pressure gradient reduces the flowing bottom
hole pressure below the static bottom hole pressure thereby creating a pressure
differential that allows the fluid to flow into the wellbore.
Continuous-flow gas lift is recommended for high-volume and high-static BHP
wells in which major pumping problems could occur with other artificial lift
methods. It is an excellent application for offshore formations that have a strong
water drive, or in waterflood reservoirs with good PIs and high gas/oil ratios
(GORs). When high-pressure gas is available without compression or when gas
cost is low, gas lift is especially attractive. Continuous-flow gas lift supplements
the produced gas with additional gas injection to lower the intake pressure to
the tubing, resulting in lower formation pressure as well.

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Continuous gas lift wells

Intermittent gas lift wells

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INTERMITTENT GAS LIFT WELLS
As the name implies, intermittent flow is the periodic displacement of liquid
from the tubing by the injection of high-pressure gas. The action is similar to
that observed when a bullet is fired from a gun. The liquid slug that has
accumulated in the tubing represents the bullet. When the trigger is pulled
(gas lift valve opens), high-pressure injection gas enters the chamber (tubing)
and rapidly expands. This action forces the liquid slug from the tubing in the
same way that expanding gas forces the bullet from the gun. The disadvantage
of intermittent-flow gas lift is the "on/off" need for high-pressure gas, which
presents a gas-handling problem at the surface and causes surging in the
flowing bottom hole pressure that cannot be tolerated in many wells
producing sand. Because of the intermittent production of the well,
intermittent-flow gas lift is not capable of producing at as high a rate as
continuous-flow gas lift. Intermittent flow should not be considered unless the
flowing bottom hole pressure is low, and the well is gas lifting from the bottom
valve.
The intermittent gas-lift method typically is used on wells that produce low
volumes of fluid. Wells in which intermittent lift is recommended normally
have the characteristics of high productivity index (PI) and low bottom hole
pressure (BHP) or low PI with high BHP. Intermittent gas lift can be used to
replace continuous gas lift on wells that have depleted to low rates or used
when gas wells have depleted to low rates and are hindered by liquid loading.

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SUCKER ROD PUMP (SRP)
Beam pumping, or the sucker-rod lift method, is the oldest and most widely used
type of artificial lift for most wells. A sucker-rod pumping system is made up of
several components, some of which operate aboveground and other parts of
which operate underground, down in the well. The surface-pumping unit, which
drives the underground pump, consists of a prime mover (usually an electric
motor) and, normally, a beam fixed to a pivotal post. The post is called a
Sampson post, and the beam is normally called a walking beam.
This system allows the beam to rock back and forth, moving the downhole
components up and down in the process. The entire surface system is run by
a prime mover, V-belt drives, and a gearbox with a crank mechanism on it. When
this type of system is used, it is usually called a beam-pump installation.
However, other types of surface-pumping units can be used, including
hydraulically actuated units (with and without some type of counterbalancing
system), or even tall-tower systems that use a chain or belt to allow long strokes
and slow pumping speeds. The more-generic name of sucker-rod lift, or sucker-
rod pumping, should be used to refer to all types of reciprocating rod-lift
methods.
Linked rods attached to an underground pump are connected to the surface
unit. The linked rods are normally called sucker rods and are usually long steel
rods, from 5/8 to more than 1 or 1 1/4 in. in diameter. The steel rods are
normally screwed together in 25- or 30-ft lengths; however, rods could be
welded into one piece that would become a continuous length from the surface
to the downhole pump. The steel sucker rods typically fit inside the tubing and
are stroked up and down by the surface-pumping unit. This activates the
downhole, positive-displacement pump at the bottom of the well. Each time the
rods and pumps are stroked, a volume of produced fluid is lifted through the
sucker-rod tubing annulus and discharged at the surface.

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SUCKER ROD PUMP (SRP)

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 GROUP GATHERING STATION (GGS I)

INSTALLATION MANAGER: Sh. A.J. PATEL

ESTABLISHED IN: 1967
LOCATION: AREA II NAVAGAM
WELL PRODUCTION STATUS:
TOTAL NUMBER OF WELLS: 71
SELF FLOW WELLS: 5
GAS LIFT WELLS: 24
ABANDONED WELLS: 16
SUCKER ROD PUMP(SRP): 23
DAILY LIQUID PRODUCTION: 230M3/DAY
AVERAGE WATER CUT: 65%

EQUIPMENTS

GROUP SEPARATOR/EMULSION SEPARATOR:

Function: It is a two-phase separator which separates gas from oil and water.
In this type of separator fluid is allowed to flow in spiral path from top of the
separator to the bottom from where gas evolves and gets separated from
liquid and flows out from the top of the separator.
WORKING PRESSURE: 6.0 Kg/cm2
HYDROTEST PRESSURE: 9.0 Kg/cm2
SAFETY VALVE PRESSURE: 6-7 Kg/cm2

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TEST SEPARATOR:
Function: It is used to measure the potential of oil well.
WORKING PRESSURE: 6.0Kg/cm2
In this type of separator fluid is allowed to flow in spiral path from top of the
separator to the bottom from where gas evolves and gets separated from
liquid and flows out from the top of the separator. It is same as group
separator though it is used for only testing purpose.

TEST SEPARATOR/GROUP SEPARATOR

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HEATER TREATER:
Function: It is used to separate oil and water also known as de-emulsifier.
Working: Horizontal heater treaters are used in the oil/gas industry to help
facilitate oil/water separation by speeding up emulsions separation through
applying heat. Heater treaters can be thought of as low pressure, three phase
separators equipped with fire tubes. They separate gas from the incoming
emulsion and separate the emulsion into a water phase and an oil phase. Heater
treaters can also function as a free water knockout, a heat exchanger, a filter,
and as a water wash tank.
It has 3 chambers first is heating chamber where oil water emulsion is heated
till 80 degrees Celsius. Then the emulsion is allowed to settle down in second
chamber known as rest chamber. After this it is passed to next chamber which
is known as electrical chamber which electric discharge is provided to pop up
the bubbles and allow the further separation of oil and water. After this oil and
water are discharged from top and bottom respectively due to density
difference.

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BATH HEATER:
The primary applications for Water Bath Heaters include:
1) Heating Natural gas prior to pressure reduction manifolds to prevent
freezing of expansion valve.
2) Hydrate prevention.
3) Heating of process fluid upstream of separation units to enhance separation
efficiency.
4) Heating of crude oil to maintain temperature above the paraffin pour point.
The heater consists of three main components: the shell, the firetube, and the
process coil. These components are carefully designed for each standard size
as well as for our customized packages.

BATH HEATER

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MASS FLOW METER:
A mass flow meter, also known as an inertial flow meter is a device that
measures mass flow rate of a fluid traveling through a tube. The mass flow rate
is the mass of the fluid traveling past a fixed point per unit time.
The mass flow meter does not measure the volume per unit time (e.g., cubic
meters per second) passing through the device; it measures the mass per unit
time (e.g., kilograms per second) flowing through the device. Volumetric flow
rate is the mass flow rate divided by the fluid density. If the density is constant,
then the relationship is simple. If the fluid has varying density, then the
relationship is not simple. The density of the fluid may change with
temperature, pressure, or composition, for example. The fluid may also be a
combination of phases such as a fluid with entrained bubbles. Actual density can
be determined due to dependency of sound velocity on the controlled liquid
concentration.

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DISPATCH PUMPS:

1) CENTRIFUGAL PUMP:
Centrifugal pumps are used to transport fluids by the conversion of rotational
kinetic energy to the hydrodynamic energy of the fluid flow. The rotational
energy typically comes from an engine or electric motor. The fluid enters the
pump impeller along or near to the rotating axis and is accelerated by the
impeller, flowing radially outward into a diffuser or volute chamber (casing),
from where it exits.
Common uses include water, sewage, petroleum and petrochemical pumping;
a centrifugal fan is commonly used to implement a vacuum cleaner. The reverse
function of the centrifugal pump is a water turbine converting potential energy
of water pressure into mechanical rotational energy.
CAPACITY – 20-30 m3

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2) RECIPROCATING PUMP:
A reciprocating pump is a class of positive-displacement pumps which includes
the piston pump, plunger pump and diaphragm pump. When well maintained,
reciprocating pumps will last for years or even decades; however, left
untouched, they can undergo rigorous wear and tear.[1] It is often used where a
relatively small quantity of liquid is to be handled and where delivery pressure is
quite large. In reciprocating pumps, the chamber in which the liquid is trapped,
is a stationary cylinder that contains the piston or plunger.

CAPACITY – 20-30 m3

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3) GEAR PUMP:
A gear pump uses the meshing of gears to pump fluid by displacement. They
are one of the most common types of pumps for hydraulic fluid
power applications.
Gear pumps are also widely used in chemical installations to pump high
viscosity fluids. There are two main variations; external gear pumps which use
two external spur gears, and internal gear pumps which use an external and an
internal spur gears. Gear pumps are positive displacement (or fixed
displacement), meaning they pump a constant amount of fluid for each
revolution. Some gear pumps are designed to function as either a motor or a
pump.

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DOZING PUMP:
Dozing pump is used to doze demulsifier to break the substances in the Heater
treater. It is applied or mixed with water before the separator and main
purpose of it is to make water separation more efficient and easy in heater
treater.

STORAGE TANKS:
OIL STORAGE TANK: 500 m3 capacity
OVERHEAD/TEST TANK: 45m3 capacity 2 NO. S
EFFLUENT STORAGE TANK: 400m3 capacity

GAS SCRUBBER:
It has a thin sieve plate like structure and is used for the further separation of
gas and liquid. Gas Scrubber removes traces of liquid droplets from gas
streams to protect downstream equipment from damage and failure. It is used
before pipeline to gas compression plant (GCP) to make sure that only gas is
sent to the GCP.

PIG LAUNCHER:
While build-up in a pipeline can cause transmittal slows or even plugging of the
pipeline, cracks or flaws in the line can be disastrous. A form of flow assurance
for oil and gas pipelines and flowlines, pipeline pigging ensures the line is
running smoothly.
The maintenance tool, pipeline pigs are introduced into the line via a pig trap,
which includes a launcher and receiver. Without interrupting flow, the pig is
then forced through it by product flow, or it can be towed by another device or
cable. Usually cylindrical or spherical, pigs sweep the line by scraping the sides
of the pipeline and pushing debris ahead. As the travel along the pipeline,
there are a number functions the pig can perform, from clearing the line to
inspecting the interior.
It has cylindrical pig having white brush at front and also have a plate at front
which push liquid forward while moving in the line.
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KNOCKOUT DRUM
A vapor–liquid separator may also be referred to as a flash drum, break pot,
knock-out drum or knock-out pot, compressor suction drum or compressor inlet
drum. When used to remove suspended water droplets from streams of air, it is
often called a demister. For the common variety, gravity is utilized in a vertical
vessel to cause the liquid to settle to the bottom of the vessel, where it is
withdrawn.

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FUNCTION
GGS or group gathering station is installation used for collecting fluid from
various wells. Fluid from various wells is collected through pipeline networks
into the headers. There are usually three types of headers namely group header,
test header, low header. This whole assembly of headers is called oil manifold.
Fluid first enters the test header to test potential of the well from where it is
coming. If the pressure of fluid from well is low (1-2 kg/cm2) then it is directed
towards low header from where it is stored in overhead tanks. On the other
hand, if the pressure of oil from well is high (4-5 kg/cm2) it is directed to group
header from where it is forwarded to group separator. In group separator liquid
and gas are separated and therefore it is also called two-phase separator. The
excess gas evolved in group separator sent to flare line via safety valve. The flare
line is of two types hot and cold flare line. The treated gas released in
environment is called hot flare line whereas the un-treated gas released in
environment is called cold flare line. Now the liquid from the separator is then
sent to heater treater, where oil and water are separated from each other by
electro-chemo-mechanical process. Oil and water are then collected from top
and bottom of heater treater respectively. Oil leaving from heater treater is then
sent to storage tank. Then the oil is sent to Central Tank Farm (CTF) with the
help of dispatch pump. Some well are far away from the group gathering station
so it is inconvenient to bring fluid to the station via pipelines so tankers are filled
and unloaded at the tanker unloading platform with the help of pumps.
The gas extracted from group separator is send to gas scrubber and knockout
drum where further separation of gas and liquid takes place to ensure that only
pure gas is sent to Gas Compression Plant (GCP) and excess gas produced is used
as fuel for heater treater and sold to the consumers. This gas is at low pressure
(3-3.5 kg/cm2) which is sent to GCP for increasing its pressure to around 40
kg/cm2. This high-pressurised gas from GCP is sent back to GGS and used for gas
lift wells. The high pressurised gas is sent to various gas lift wells via networks of
headers and pipelines known as gas manifold.

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Page 24 of 51
 GROUP GATHERING STATION II
INSTALLATION MANAGER: Sh. K.C. JOSHI
ESTABLISHED IN: 1967
LOCATION: AREA II NAVAGAM
WELL PRODUCTION STATUS
TOTAL NUMBER OF WELLS: 100
1) FLOWING WELLS: 42
SELF FLOW WELL: 3
SUCKER ROD PUMP WELL: 26
GAS LIFT WELL: 13
2) NON-FLOWING WELLS: 24
SELF FLOW WELL: 3
SUCKER ROD PUMP WELL: 18
GAS LIFT WELL: 3
3) WATER INJECTION WELLS: 22
WATER INJECTED WELLS: 16
NON-INJECTED WELLS: 6
4) ABANDONED WELLS: 12
DAILY LIQUID PRODUCTION: 150-180 M3/DAY
AVERAGE WATER CUT: 50-60%
DISPATCH PUMPS
GGS II have 4 reciprocating pumps for dispatching liquid of different capacities
1) Capacity: 250 LPM
Pressure: 60 kg/cm2
RPM: 300
Horsepower: 50 Input Power: 37KW

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2) Capacity: 355 LPM
Pressure: 42.7 kg/cm2
RPM: 1440
Horse Power: 40
3) Capacity: 177 LPM
Input Power: 35 KW
Voltage: 415V
Ampere: 65A
4) Capacity: 200 LPM
Pressure: 50 kg/cm2
RPM: 335
Horse Power: 40
Input Power: 30 KW
TANKS
OIL STORAGE TANKS: 4 NO. S
Number of tanks: 2 TANKS 2 TANKS
Capacity: 90 m3 200 m3
Height: 5.5m
Diameter: 5m
Safe filling height: 5.16m 5.7m

WATER TANK/EFFLUENT TANK

Capacity: 400 m3
Height: 10.5 m
Diameter: 7.5 m
Safe Filling Height: 10.16 m

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OVERHEAD TANK:
Capacity: 40 m3
Safe filling height: 220cm
TEST SEPARATOR/GROUP SEPARATOR:
Working pressure: 6 kg/cm2
Safety test pressure: 6.6 kg/cm2
Hydro test pressure: 9 kg/cm2
HEATER TREATER:
Hydro test pressure: 5.2 kg/cm2
Safety test pressure: 3.8 kg/cm2
PIPELINES:
Oil dispatch pipeline: 8’’
Gas pipeline to GCP: 4’’
Oil from well pipeline: 4’’

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Page 28 of 51
 WATER INJECTION PLANT
PROCESS DESCRIPTION
Water from ETP through pipelines comes to water injection plant in GGS II and
GGS III for further chemical treatment before it is sent to GGS for water
injection.
Water at 35 – 37 m3/hour of flow rate and at pressure of 4 kg/cm2 is pumped
into water injection plant through pipelines from effluent treatment plant
(ETP). Effluent enters the treated water tank (600 m3) where tube well water is
also added in fixed proportion. This tube well water (raw water) is passed to 3
micro filters of 100-microns, 30 microns and 3 microns one by one and then
finally it is sent to raw water hold tank. At the outlet of the tank 5 chemical are
added, sodium sulphite (40 PPM) which acts as oxygen scavenger, corrosion
inhibitor (20 PPM) is added to prevent corrosion and scale inhibitor (20 PPM) is
also added to decrease precipitate formation, biocide is added to prevent the
growth of bacteria and to kill them, sodium hypochlorite used to kill the
aerobic bacteria. Now this effluent is sent to treated water tank where water
from ETP is mixed with it by means of agitator. This effluent is then pumped
with the help of water injection pump to headers.
Now from headers the water is injected at high pressure and at low pressure
through 4” pipeline. Water is injected at high pressure to various water
injection wells used for artificial lifting which are connected to GGS II and GGS
III.

PUMPING SYSTEM
4 reciprocating pumps are available and out of which 2 are working and 2 are
standby.
Specification of pump are:
Capacity: 35 m3/hour
RPM: 314
Pumping pressure: 126 kg/cm2
Maximum working pressure: 140 kg/cm2

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CHEMICAL USED
Sodium sulphite: used as oxygen scavenger 40ppm
Scale inhibitor: to prevent scale formation 20ppm
Corrosion inhibitor: to prevent corrosion formation 20ppm
Sodium hypo chloride: to kill aerobic bacteria
BIOCIDE:
1) bactericide aldehyde
2) bactericide amine
3) NANA (Non-aldehyde non-amine)
These 3 biocides are dosed alternately so that bacteria don’t create an
immunity against any particular type of dosing of biocide.

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 CENTRAL TANK FARM (CTF)

Central tank farm consists of 12 tanks in which the crude oil from different
group gathering stations is collected and stored. Out of these 12 tanks 9 tanks
are of 2000 m3, 1 tank is of 200 m3, 1 tank is of 400 m3 and 1 tank is of 75m3.
Different pipe lines from different plants of ONGC come and meet at CTF.
A 12-inch pipe line from Kalol, a 14-inch line from Mehsana, a 12-inch line from
Navagam and an 8-inch line from RNW (Ramol Nandej and Wasna) combines at
CTF and an 30ss-inch line carry this crude oil to the desalter plant. Before loading
this crude oil to the desalter plant all these 4 pipe lines are connected to mass
flow meters.
There are 3 private companies who supply their crude oil to the CTF. These are:
1) GSPC (3 tanks)
2)JTI (2 tanks)
3)Selan (2 tanks)
If the water cut of the crude oil from these private industries is more than 5%
then the crude oil is rejected.

WORKING:
CTF plant has 12 storage tanks in which the crude oil is stored. This crude oil is
pumped to the Desalter plant with the help of BPCL Pump. It is a reciprocating
pump and delivers the crude oil at 20-30 m3 per hour. There is a regulator for
pump which is known as VFD (Variable frequency drive). Its function is to alter
the speed of the pump. CTF plant also consists of scrapping unit. Scrapping unit
consists of a scrapper which acts as a filter to oil from the impurities.
Central tank farm also has a pig launcher to clear the wax from the pipe lines.

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 GAS COMPRESSION PLANT (GCP)
INSTALLATION MANAGER: Mr. B.K. SHIT

AREA OF INSTALLATION: 100 Acres

RECEIVING STATUS:
GGS I, II AND III: 500 m3/Day

MEHSANA FIELDS: 8000 m3/Day

RNW FIELDS: 800-900 m3/Day

CTF KALOL: 8000 m3/Day

STORAGE TANKS:

8 TANKS OF 2000 m3

PUMPING SYSTEM:

MAKE: BPCL

TYPE: QUINTUPLEX PLUNGER PUMP

MAXIMUM DISCHARGE: 120 m3/Hour

MAXIMUM OPERATING PRESSURE: 40 kg/cm2

RATE BHP: 430 Horse Power

MOTOR

1) HP – 545

2) KW – 400

3) RPM – 1450

4) VOLTAGE – 415V

5) FREQUENCY – 50Hz 6) Current – 676 Amp

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INTRODUCTION:
Gas compression plant is attached to all the GGS plants. The gas sent to the
GCP plant from all the Group gathering stations are at low pressure and this
pressure is not sufficient to lift the oil from the wells. To pressurize the gas, it is
sent to the gas compression plant.

WORKING:
The gas from the group gathering stations enters the low-pressure header of the
gas compression plant and goes to the condensate. The Condensate is a
separator which helps in removing the moisture or any liquid from the gas
before entering the compressor. Gas coming out of the condensate enters
compressor. The compressor has 2 suction stages:
1) Stage 1 suction
2) Stage 2 suction
First the gas enters Stage 1 suction and get compressed from 3 kg/cm2 to
13 kg/cm2. Then this heated gas enters Inter cooler and comes out of After
cooler. Here the gas cooling occurs. Then the gas enters Stage 2 suction and gets
compressed from 13 kg/cm2 to 40 kg/cm2. Again, the gas is hot and needs to be
cooled so again it enters the inter cooler and comes out of the after cooler. This
compressed gas is then sent to the High-pressure header from where the gas is
sent to the Group gathering Stations from where it is sent to the gas injection
wells.
The gas is cooled in the coolers with the help of water which is supplied from
the cooling tower. The gases are flown inside a pipe and is surrounded with
water. Between these 2 phases heat transfer occurs and cools the gas. This
heated water is then sent to the cooling tower to again reduce the temperature
of the water and this is a continuous process.

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 COMPRESSOR
An air compressor is a device that converts power (using an electric motor,
diesel or gasoline engine, etc.) into potential energy stored in pressurized air
(i.e., compressed air). By one of several methods, an air compressor forces more
and more air into a storage tank, increasing the pressure. When tank pressure
reaches its engineered upper limit the air compressor shuts off. The compressed
air, then, is held in the tank until called into use.[1] The energy contained in the
compressed air can be used for a variety of applications, utilizing the kinetic
energy of the air as it is released and the tank depressurizes. When tank pressure
reaches its lower limit, the air compressor turns on again and re-pressurizes the
tank.
An air compressor must be differentiated from an air pump which merely pumps
air from one context (often the surrounding environment) into another (such as
an inflatable mattress, an aquarium, etc.). Air pumps do not contain an air tank
for storing pressurized air and are generally much slower, quieter, and less
expensive to own and operate than an air compressor.

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 EFFLUENT TREATMENT PLANT (ETP)
PROCESS DESCRIPTION
SURGE TANK
A surge tank (or surge drum) is a standpipe or storage reservoir at the
downstream end of a closed aqueduct, feeder, dam, barrage pipe to
absorb sudden rises of pressure, as well as to quickly provide extra water during
a brief drop in pressure.
In mining technology, ore pulp pumps use a relatively small surge tank to
maintain a steady loading on the pump.
For hydroelectric power uses, a surge tank is an additional storage space or
reservoir fitted between the main storage reservoir and the power house (as
close to the power house as possible). Surge tanks are usually provided in high
or medium-head plants when there is a considerable distance between the
water source and the power unit, necessitating a long penstock. The main
functions of the surge tank are: 1. When the load decreases, the water moves
backwards and gets stored in it. 2. When the load increases, additional supply
of water will be provided by surge tank.
In short, the surge tank Used as Storage tank for the ETP and Provide Starting
feed for the Plant.
FLASH MIXER

The water treatment process truly begins with a very brief turn in a flash mixing
chamber.

After screening out debris and testing raw water, chemicals that encourage
coagulation are added to the water stream. The mixture is agitated quickly and
thoroughly in a process called flash mixing. The chemicals introduced into the
water stream will attract any very fine particles, such as silt, that will not readily
settle or filter out and make them clump together. These larger, heavier
formations are called floc, which are much easier to remove from the water.

FLOCCULATION

The water treatment process truly begins with a very brief turn in a flash mixing
chamber.

After screening out debris and testing raw water, chemicals that encourage
coagulation are added to the water stream. The mixture is agitated quickly and
Page 35 of 51
thoroughly in a process called flash mixing. The chemicals introduced into the
water stream will attract any very fine particles, such as silt, that will not readily
settle or filter out and make them clump together. These larger, heavier
formations are called floc, which are much easier to remove from the water.

DONE IN A FLASH

The duration of the flash mix chamber is carefully controlled, and typically lasts
from 10-90 seconds. If the duration of the flash mix is not long enough, the
chemicals will not be properly distributed throughout the water. Too long, and
the newly formed floc will be damaged by impeller shear. When determining the
length of time that water needs to spend in the flash mix chamber, duration is
calculated using the size of the tank and the volume of flow.

MIXER CONFIGURATION

The directional flow of the mixing chamber will determine the appropriate
mixing flow to disperse chemicals throughout the water stream quickly.

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In order to rapidly blend the chemicals uniformly, a mixer needs to create a flow
pattern at a right angle to the flow through stream. This will increase distribution
and reduce residence time in the flash mix basin. The mixer will commonly be
centre mounted with a vertical shaft to accomplish this effect.

CORRUGATED PLATE INTERCEPTOR

CPI (Corrugated plate interceptor) or TPI (Tilted plate interceptor) separators are
predominantly used in separation of free oil from effluent water or suspended
solids for oily water treatment in an OWS (oily Water System).

The basic principle of difference in gravity between the phases (liquid – liquid or
solid – liquid) is employed in an OWS in separation of the two phases. This
phenomenon is defined as “Gravity Separation”.

It is therefore apparent that the phase with high density will settle and with
lower density float to the surface of fluid. In an OWS, the effectiveness of this
technique is subjected to various factors such as difference in the density,
viscosity, factors of the medium, temperature, turbulence, and also the nature
of impurity etc.

In some cases, chemical coagulation and flocculation is needed for removal of

the impurity by making them heavier or lighter.

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INDUCED GAS FLOTATION

Induced gas flotation (IGF) is a water treatment process that

clarifies wastewaters (or other waters) by the removal of suspended matter
such as oil or solids. The removal is achieved by injecting gas bubbles into the
water or wastewater in a flotation tank or basin. The small bubbles adhere to
the suspended matter causing the suspended matter to float to the surface of
the water where it may then be removed by a skimming device.
Induced gas flotation is very widely used in treating the industrial
wastewater effluents from oil refineries, petrochemical and chemical
plants, natural gas processing plants and similar industrial facilities. A very
similar process known as dissolved air flotation is also used for waste water
treatment. Froth flotation is commonly used in the processing of mineral ores.
IGF units in the oil industry do not use air as the flotation medium due to the
explosion risk. These IGF units use natural gas or nitrogen to create the bubbles.

PROCESS DESCRIPTION

The feed water to the IGF float tank is often (but not always) dosed with a
coagulant (such as ferric chloride or aluminum sulfate) to flocculate the
suspended matter.
The bubbles may be generated by an impeller, educators or a sparger. The
bubbles adhere to the suspended matter, causing the suspended matter to float
to the surface and form a froth layer which is then removed by a skimmer. The
froth-free water exits the float tank as the clarified effluent from the IGF unit.
Some IGF unit designs utilize parallel plate packing material to provide more
separation surface and therefore to enhance the separation efficiency of the
unit.
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NUTSHELL FILTRATION SYSTEM

Nutshell filters are the industry standard for process water filtration and
polishing. The filters incorporate a deep bed of walnut shell media, specifically
modelled and designed for high-efficiency oil & solids removal. Accelerated
offers the next generation of automated; self-cleaning granular media filters
with a unique design that outperforms any other technology. Accelerated
guarantees complete fluidization of the nutshell bed and contaminants during
backwash. No other technology can guarantee this level of media regeneration.
We utilize a proprietary design, incorporating a mixer and wedge wire screen
assembly that allows for increased flow rates and efficiencies versus traditional
pump design nutshell filter systems. The filter design has been selected as the
best available technology in most produced water filtration applications, and
has been utilized to remove oil and grease, as well as suspend solids from a
variety of oilfield, chemical plant, and refinery water streams.

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COOLING TOWER
A cooling tower is a heat rejection device that rejects waste heat to
the atmosphere through the cooling of a water stream to a lower temperature.
Cooling towers may either use the evaporation of water to remove process heat
and cool the working fluid to near the wet-bulb air temperature or, in the case
of closed circuit dry cooling towers, rely solely on air to cool the working fluid to
near the dry-bulb air temperature.

ULTRAFILTERATION
Ultrafiltration (UF) is a variety of membrane filtration in which forces
like pressure or concentration gradients lead to a separation through
a semipermeable membrane. Suspended solids and solutes of high molecular
weight are retained in the so-called retentate, while water and low molecular
weight solutes pass through the membrane in the permeate (filtrate).
This separation process is used in industry and research for purifying and
concentrating macromolecular (103 - 106 Da) solutions,
especially protein solutions. Ultrafiltration is not fundamentally different
from microfiltration. Both of these separate based on size exclusion or particle

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capture. It is fundamentally different from membrane gas separation, which
separate based on different amounts of absorption and different rates
of diffusion. Ultrafiltration membranes are defined by the molecular weight cut-
off (MWCO) of the membrane used. Ultrafiltration is applied in cross-flow or
dead-end mode.

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TREATED WATER TANK
Finally treated water is dispatched to ONGC –ggs.
BELT FILTER
The belt filter (sometimes called a belt press filter, or belt filter press) is an
industrial machine, used for solid/liquid separation processes, particularly
the dewatering of sludge in the chemical industry, mining and water
treatment. The process of filtration is primarily obtained by passing a pair
of filtering cloths and belts through a system of rollers. The system takes
a sludge or slurry as a feed, and separates it into a filtrate and a solid cake.
WATER TREATMENT CHEMICAL (ETP): PAC
Poly Aluminium Chloride used as a substitute of the Alum and Ferrous
Sulphate.
CHEMICAL FORMULA: (Aln(OH)mCl3n-m) X
Cas: 1327-41-9
PAC is an inorganic chemical having polymeric structure soluble in water. For
the water treatment our team developed RI-9 more useful. Its specification
Mentioned below. The PAC- based water pollution treatment RI-9 is a highly
efficient uncomplicated system that is also easy to control. Its size is compact,
making it convenient to move and install. Moreover, it is inexpensive to build,
set up and maintain.

WATER TREATMENT CHEMICAL (ETP): DOPE

The Polyelectrolyte Flocculant is idyllically utilized in divergent domains for
applications such as water clarification, effluent treatment, product thickening.
We process this flocculant under higher prudency with precise pH value to make
it suitable for different industrial applications. These products are water soluble
polymers that take the ionic charge all along the polymer chain. The products
which we cater under Polyelectrolyte Flocculant are Non-ionic Polyelectrolyte,
Secondary Flocculation with polyelectrolyte, Dewatering Polyelectrolyte, De-
oiling Polyelectrolyte.
WATER TREATMENT CHEMICAL (ETP): BACTRICIDE
A bactericide or bacteriocidic, sometimes abbreviated Bcidal, is a substance
that kills bacteria. Bactericides are disinfectants, antiseptics, or antibiotics.

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WATER TREATMENT CHEMICAL (ETP): SODIUM SULPHITE
Sodium sulphite is a soluble sodium salt of sulphurous (sulphite) with
the chemical formula Na2SO3. It is a product of sulphur dioxide scrubbing, a part
of the flue-gas desulfurization process.
UNITS OF CHEMICAL
All chemicals are dosed in unit of PPM.

PROCESS FLOW DIAGRAM

wash
Tank
CPI
Surge Flash Floccu
Tank Mixer lator IGF FEED
SUMP
Wash CPI
Tank

IGF-A
NSF FEED
NSF

NSF

Cooling
NSF

SUMP Tower
IGF-B

UF Feed UF TWT
UF Sump
Sump
UF
TWT

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 DESALTER

INSTALLATION MANAGER: Mr. B.K. Shit

DATE OF COMMISSION: 01.01.1995

PLANT CAPACITY: 6.7 million metric tonnes per year

NUMBER OF TRAINS(UNIT): 3 trains of 2.23 million metric tonnes per year (2

trains are operating and one is standby).

RECIEVEING STATUS:
1)crude oil from –
Mehsana and Ahmedabad asset

FEED STOCK CHARACTERSTICS

Chloride in oil feed water – 4500 ppm
Chlorides as Cl salt – 81 ptb
Specific gravity of oil – 0.8948
Total sulphur, % weight – 0.007
Wax content, % weight – 6.8
Total acidity, mg KOH/gram – 4.65

DESALTED CRUDE OIL CHARACTERSTICS

Salt content – 10-15 ptb

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PROCESS DESCRIPTION
Crude oil is received from the existing tank farm to new tanks through a 30’’
suction header, 4 Nos. feed pumps are installed for pumping feed to desalter
to three trains whereas the fourth pump is common standby for all the 3
trains. Demulsifier chemical is mixed with the feed crude oil in the suction line
in the feed pump. Crude oil from the feed pump is further mixed with wash
water at the rate of approximately 0.5% of the crude before the crude is sent
through heat exchanger. In this heat exchanger the feed is heated to about 63
degrees Celsius by exchanging heat with the outgoing treated crude oil from
the desalter. Treated crude passes through the tube side of the heat
exchangers.
The crude from the exchangers will pass through the feed heater where in the
temperature is raised to 100 degrees Celsius before entering the desalter
vessel. In the desalter vessel, feed crude is fed at lower portion of the vessel
wherein it travels and separates through electrostatic grid. The electrostatic
grid aids the breaking of emulsion and settlement of water at the bottom. The
crude after losing water /salts will be let out through the crude outlet line from
the top of vessel. Desalter has bottom outlet connections at intervals for
removal of water and sediments settled at bottom of desalter. Part of the
produced water is circulated back into desalter vessel through the desludging
pump (rated at 50 m3/hour and 25 m head) to maintain the water phase in the
desalter in a fluidised condition so that the sediments settle down at the
bottom of the vessel and from the thick mud.
The desalter vessel is provided with sampling valves at various elevations to
collect and analyse the samples at various elevations on the desalter vessel. So
by analysing these samples discharging is done.

Page 45 of 51
Page 46 of 51
 FIRE FIGHTING SYSTEM
2 jockey pumps
Working pressure – 8 kg/cm2
Feed rate – 10 m3/hour
2 diesel engine driven pump
Feed rate – 410 m3/hour
One electrical driven pump
Feed rate – 410 m3/hour
2 water storing pond are there of capacity – 3200 m3
Line pressure is maintained at 10 kg/cm2. When the pressure in the line is
reduced jockey, pump starts automatically to bring it back to same pressure.
FIRE NETWORK
Fire hydrant: Its aim is fixed at one particular place to fight with fire for the
equipment it is designed.
Fire monitor: A deluge gun, fire monitor, master stream or deck gun is an
aimable controllable high-capacity water jet used for manual firefighting or
automatic fire protection systems. Deluge guns are often designed to
accommodate foam which has been injected in the upstream piping.

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 LATEST TECHONOLOGY
The application of corrosion and biocorrosion inhibitors in industry
Substances considered as potential corrosion inhibitors, should be characterized
by the following physical and chemical properties:
• durability,
• inability to precipitate in the form of residue,
• inability to form emulsion.
Corrosion inhibitor, potentially applied in the oil industry, should possess
sufficient solubility in hydrocarbons.
The selection of an appropriate corrosion inhibitor intended for specific
industrial applications is an extremely complex issue [19]. The effectiveness of a
specific agent, among other things, depends on:
• the type of material which interacts with the inhibitor,
• the aggressiveness of the environment (e.g. pH of the environment, the
presence of redox substances),
• the place where the inhibitor is applied (refinery, gas and oil pipelines, drilling
equipment, etc.). This is absolutely vital as in each environment there are
various compounds which induce corrosion and microorganisms which induce
biocorrosion. There is nothing like one universal set of corrosion inhibitors that
can be applied both in the borehole and technical installation,
• the type of transferred or stored fuel.
Furthermore, the factors which determine the selection of a specific application
is the toxicity of the proposed agent, harmlessness towards the environment
and profitability of the chosen option.
As already stated, there are a few anti-corrosion methods, including:
• rational selection of appropriate material (metal, alloy) intended for specific
application. That selection should take into account the type of medium the
metal will be in contact with (natural gas, fuel, petroleum), the type of
equipment or installation where it will be used (transmission installations,
storage tanks, drilling equipment) and other factors.

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• reduction of aggressiveness of the environment; this method involves
introducing a neutralizer, for example ammonia, caustic soda, sodium carbonate
or low molecular weight amines.
In the oil industry, during the processing of sulphurous oil, the facilities for
fractional distillation are particularly prone
to corrosion. Distilled oil is highly aggressive because of the presence of:
• hydrogen sulphide (dissolved or as a product of pyrolysis of sulphur
compounds),
• hydrogen chloride (originating from magnesium and calcium chlorides from
deposit waters),
• carbon dioxide dissolved in oil,
• oxygen dissolved in oil,
• naphthenic acids,
• oilfields water (which occurs together with oil and creates electrolyte).
Fractional distillation plants are built mainly of carbon steel. However, in the
most corrosion vulnerable condensation- cooling systems of atmospheric
towers, copper alloys are used. They are more corrosion resistant than carbon
steel.
In most cases, the equipment used in drilling is exposed to corrosion induced by
the presence of oxygen, carbon dioxide and hydrogen sulphide. Out of all these
compounds, it is the carbon dioxide that is the most common factor to induce
corrosion, while hydrogen sulphide is the most hazardous compound which
poses threat not only to human life but also to the environment.
As mentioned before, corrosion and biocorrosion are extremely important as
they directly reflect specific economic loss [3, 7, 9]. Research work is being
conducted on new potential corrosion inhibitors and modification of the existing
ones, in order to effectively eliminate from the endangered system, the factors
responsible for corrosion. The application of chemical agents with desired
properties is absolutely necessary as they allow to avoid further damage in
refinery plants or tanks.

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Based on the chemical nature, corrosion inhibitors may be placed into one of
the following groups:
• amines and ammonium salts,
• imidazoline,
• quaternary ammonium salts,
• heterocyclic compounds which possess a nitrogen atom.
In common applications, the oil and gas industry prefer to use hydrophobic
corrosion inhibitors. Taking into account their physical and chemical properties
they are more effective as they ensure that an additional permanent protective
layer is created on the surface of the metal.
The corrosion inhibitors used currently are multicomponent mixtures. The
concentration of the active component is between 30÷40%, the remaining
fraction is the hydrophobic solvent (e.g. petroleum).
Sometimes corrosion inhibitors should demonstrate hydrophilic properties. In
this case, surface active agents or active polar compounds (e.g. quaternary
ammonium salts) are added to the mixture. Below, some chemical compounds,
commonly applied in oil and gas industry, are presented. Their inhibition
capabilities were also discussed.
Benzalkonium chloride (alkyldimethylbenzylammonium chloride) is a
quaternary amine which acts as a surface-active agent. Additionally, it is used as
a corrosion inhibitor, cationic surfactant and phase separation factor in the
chemical industry.
where: R – CnH2n+1
n = 8, 10, 12, 14, 16, 18
benzalkonium chloride
An example of a commonly used corrosion inhibitor is rhodamine (2-thioxo-4-
thiazolidinone) and its derivatives (3’ – and 5’ –) [34]. They are used as corrosion
inhibitors of iron to protect petroleum refinery plants.
Rhodamine
Another group of modern compounds that may be used as corrosion inhibitors
are complexes with zinc (Zn) or cerium (Ce). The com- plex of 2-propyl-3-ethyl-

Page 50 of 51
8-oxychinolin with ZnCl2 was successfully used as a corrosion inhibitor on steel
surfaces in an environment rich in O2. This compound is obtained in
condensation reaction between of ZnCl2, o-aminophenol and aldehyde in
benzene presence.
2-propyl-3-ethyl-8-oxychinolin – ZnCl2
Generally, corrosion inhibitors in the oil industry are added to fracturing fluids.
Apart from active substances, corrosion inhibitors also contain alcohols used as
components preventing the precipitation of iron and carbonates (table 2).
These data were included in a compilation of the year 2011. Despite certain
toxicity, the chemical agents prevent the action of compounds, which are even
more hazardous to humans and the environment such as hydrogen sulphide,
reduce the contamination by microorganisms and prevent uncontrolled
proliferation of bacteria. Moreover, these sub- stances eliminate the risk of gas
eruption, oil leakage, and most importantly, they enable safe and effective
extraction of hydrocarbons.
Type of substance Percentage by weight Water90.60 Solid phase (usually
sand)8.960 Acids 0.110 Substances which facilitate crushing 0.110 Biocides
0.001 Substances which prevent depositing of clayey minerals 0.050 Corrosion
inhibitors 0.001 Substances which increase viscosity 0.010 Substances which
reduce friction 0.050 Gelling agents 0.080 Agents which prevent the
precipitation of iron 0.004 Agents which prevent the precipitation of
carbonates0.040 Surfactants and pH regulators 0.090
Final conclusions
Corrosion as a natural problem of material deterioration will be exist. Similarly,
as biogenic processes, corrosion can only be limited as much as possible so as
not to bring great material loss or hinder extraction. The scale of this
phenomenon is immense and it concerns practically each sector of the oil and
gas industry. The rational solution which can reduce the occurrence of corrosion
is the application of agents which act as potential corrosion inhibitors. Over the
last few decades, the chemical industry has been working on new substances
which may inhibit this process, while the composition of commonly used
inhibitors is modified and improved.

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