TRAINING REPORT

JAIMIN RAMI Pandit Deendayal Petroleum University 10BPE110 Summer Training (6th 18th May,2013)

North Kadi Area (NK-4) 6th & 7th MAY,2013

Went their with Mr. Ashok Soni. The plant is of Group Gathering Station(GGS). It is called GGS because the crude coming from well containing oil,gas and water come here.

Description of plant:
Total nos. Of wells=68 Out of which 54 are flowing and 14 are sick wells. Of 54 flowing wells self flow are 12 and 40 are SRP wells.The remaining are PCP type wells. Plant produces around 410 M3 of Oil and around 700800 M3 of Effluent water. Plant has 4 storage tanks of 500 M3 of capacity.2 Effluent water storage tank of same capacity.And 2 testing storage tank. In case of fire, it has spare water tank of capacity of 600 M3 of storage. Also, in case of powercut it has generator of 400 kW of power generation capacity.

Process in Plant:
The main sections of plant are Header, Bath Heater, Separator and Heater Treater. A. Header: The crude of different wells comes to GGS through header.All the 4 inch pipeline from wells having crude meet to a main pipeline called Header which then

supplies crude to GGS. This decreases the cost of manufacturing pipelines and increases the rate of flow.Now the crude from header goes to Bath Heater . B. Bath Heater: Bath Heater works on principle of shell and tube heat exchanger.The crude goes in tubes and the shell is filled of hot water.This rise the temperature of crude to around 65 degree celcius.Due to this the volatile substances which are having low boiling points vapourizes as gas which is sent to flaring.So the oil then sent to separator with water and some gases. C. Separator: The separator has trays in the column.The crude falls from above of separator on the trays.The crude goes down and due to heat it also vapourizes at the bottom. The gas then moves upward from where it goes to flaring.In separator most of the gases are removed out.Then the emulsion containing mainly water and oil with little traces of gas moves to heater. The crude in NK area is lighter than other regions crude so the use of separator is there to remove gaseous constituents. D. Heater Treater: It has the temparature of 70-80 degree celcius.In this their are two chamber.First is mechanical and the second is electrical.Emulsion from separator moves first to mechanical chamber.Here the emulsion is settled for a time.Due to difference in density of both liquids oil comes above and floats on water.After certain level of height, oil above starts to pour down to the

electrical chamber. Here transformer is their at the upper part of chamber.Due to the electromagnetic effect the oil with water comes up and coalscening effect takes place. So the oil is removed from upper part and sent to the storage.The water from down pipeline sent to the Effluent treatment plant. SCADA: Supervisory Control And Data Acquisition is a type of control system used to control the pressure and temperature valves and many things in the plant.All this is controlled from a control room having SCADA in their.We can see the flow rate of liquids,gases and oil entering and leaving any system. The pressure and temperature of system can be seen on screen of computer.If any of the parameter increases or decreases we can control it from the screen.If pressure or temperature increases the alarm starts and the problem is highlighted due to SCADA system. Then the person switch off the alarm and control the problem. Eventhough having this control room a member of staff has to go to check the the quality of oil and water in every system.If it doesnt touch the quality he opens the valve to match it. The stored oil in this plant is sent to the Mehsana CTF plant with the help of a pump.

BALOL Area 10th May,2013

Went with sir to Balol-1 and Balol-2 stations.Both the stations are GGS stations.But this are smaller than the NK ones.

Balol-1:
Here the crude is coming from the Balol and Jotana area. Total of 35 wells are processed here. The plant has 5 Bath Heater and 4 Separator. The crude from Balol wells are entering to no. 1-2 of Bath Heater and crude coming fromJotana wells enters the 3 & 5 no. Of Bath Heater.4th no. of Bath Heater is for testing well. Same for the Separator.No. 1 of Separator is for Balol crude,no. 2 is for testing and no.3 & 4 is for crude coming from Jotana wells. Plant has 2 storage tanks with capacity of 1000M3 and 1 test storage tank of capacity 500M3. Plant has 2 chemical dozing tanks.

Description of Plant:
Same as NK GGS,buty as it is small plant it didnt have Heater Treater in it. The crude from wells goes to Header. From their it goes to Bath Heater. From their the processed emulsion goes to the separator in which the gas are separated.Then

the emulsion goes to storage from where it is pumped to the North Santhal CTF Plant.

Balol-2:
I meet here Installation Manager Mr.Omkar Srivastav and supritendent engineer Babulal Sharma. This region has 38 wells under it to be processed.Out of which most are SRP. Description pf plant is same as Balol-1 plant. The crude in Balol region is heavy crude.So it hgas high amount of asphaltenes in it,its viscosity is also too high.This type of crude are difficult to drawn out of well.They stick inside the well tubings and create scaling.So to overcome this difficulty EOR techniques are is used.Here mainly Fire Ignitor technique is used. In Fire Ignitor Technique method,a tubing is drawn down in the well upto the maximum stable crude level.At the end of tubing their is chemical which is to be ignited.For ignition air required is coming form Insitu Combution Plant and gas is coming from the removed out gases form GGS. Then the chemical is ignited in presence of air and gas due to which crude burns and its temperature increases.This process is depends on the pressure and temperature of well.This method goes for 5-6 days depenmds on the viscosity of crude in well.

 After that water injection is done in the well. This sudden injection converts it in steam due to the high temperature of crude.Due to the high pressure of steam it pushes the crude to the producer wells from where the crude is obtained. Then this crude from the wells is sent to GGS for processing. They uses Xylene,Demulsifier,Asphaltenes etc. Chemicals which can break the bond between oil and water and easy to processed.

Bechraji Area 14th May,2013

Here i went to one GGS plant and one ETP plant.

GGS Plant:
Here Kantilal Makwana explained me the whole plant. The description is same. The area has 75 wells under it . Out of which 10 are sick wells and 65 are working. Total emulsion coming is 1200M3.Of which oil production is 260 M3 and rest water went to ETP plant.

Effluent Treatment Plant(ETP):

Here the installation manager is Bhanuprasad Mehta. Here the water coming from GGS is processed for further recovery of some oil.The effluent contains the water with amount of oil , some paraffins,olefins etc. which on exposing to land creates land pollution ,air pollution ,makes land non-fertile and also harmdul to humans. So it is processed with different kind of chemicals and processed under certain conditions and then disposed to the wells. After that the leftover water is disposed by the rules of Central Pollution Control Board(CPCB). The plant has: 1 Tilte Plate Intercepor with capacity of 335 M3

 1 Equlization Tank with capacity of 500M3 1 Dissolved Air Floatation unit with capacity of 500M3 1 Filter Feed wih capacity of 225 M3 The plant produces 1800-1900 M3 of disposal water and the remained oil is sent back to then GGS plant.

Description of Plant:
The water from GGS comes in the storage tank of capacity of 2000M3 with flow rate of around 40 m3/hr. Then the liquid undergoes series of tanks processes.They are:

A.Tilte Plate Interceptor:

Then the water containing oil moves to tilte plate interceptor from above of tank.Her the water is allowed to fall down on the tilted plates so it breakes down the oil and water bond.Also some demulsifiers are also added to break the bonds.Then it send to the equalization tank.

B. Equilization Tank:
Here the water from tilte separator is stored for time. Due to the density difference oil comes on top of water.Then this oil is separated as the end is tilted.And by this way most of the oil is separated.

C. Dissolve Air Floatation Unit:

The water and oil mixture from tank comes to this unit. In this unit a high pressured air is blown in the

mixture.This creates foam of oil,asoil having low density then water floates on it. Then this foam is removed and stored in filter feed sump.

D.Filter Feed Sump:

The foam containing mainly oil is stored in this tank.When it reaches to certain level the pump starts and sent the liquid mixture to the dual media separator.The pump works automatically based on the level of liquid in the tank.

E. Dual Media Separator:

There are 3 of this. This separator contains three stages of separation.First stage of passing liquid from activated charcoal which mainly removes the colour of water and make it clean.In Second stage it passes from the sand which removes the little particles of dirt.And at last in third stage it passes from small gravels tomake it more clean. Then the water from this separator pumped to the storage tanks from where it is disposed into the wells as per the norms of CPCB.

Different types of chemicals added during process to separate oil and water are: I. Polyelectrolyte: used to remove the charges II. Alum: used to decreases the basisity of liquid

III. Sodium Sulphate: used to decreases basisity of liquid IV. V. VI. VII. Sodium Hypochloride: used to decreases the pH of liquid Corrosion inhibitors: used to decreases the corrosive nature of liquid HEDP: used to decreases basisity of liquid

Bectiriocides: It includes the mixture of formaldehyde and sodium sulphate.Used to kill bacterias ,algaes in liquid. When the water is dispatched, it has oil less than 10 ppm.It is disposed in the wells below 1000m. It has less than 100 ppm of Total Suspended Solids. It has pH level less than 7.5.

Lanwa Area 15th May,2013

Here I went to 1 GGS plant and ETP plant.

GGS Plant:
Installation manager of this plant is Mr.RajSingh. Mr.P A Patel gave me the whole description on plant.All processes are same expect the plant didnt have Heater Treater system. 47 no. of well came under this plant for processing.From these wells 11 are closed, 7 are self-flow and 29 are SRP wells. The plant has 4 storage tanks.2 in use and 2 in standby which are used when any of 2 in filled or at the time of one tank repairing work.In this 2 tanks has capacity of 500 M3and 2 has capacity of 400 M3. The plant has 2 test storage tanks with same capacity of 200 M3. The oil production of plant is180-190 M3. The process of this plant is same as other GGS plants . But due to the high proportion of H2S gas in this region EOR recovery plant is also established in this plant. In this recovery plant ,the crude containing more H2S goes to Header then to the Separator,which works same as in GGS.Then the crude moves to Knock Off Drum where it is heated to remove H2S .Then the crude moves to the the storage tanks.

Effluent Treatment Plant (ETP):

Om Prakash Chaturvedi is the installation manager of the plant. Mr. Zakir Hussain shows me the whole plant. Process of plant is same as other ETP plants. But here at one step the water from TPI is send to the settler where the sludge form water and oil is separated. The liquid from their send to the Slurry Drying Beds where the slurry is dried out to form waste ant the water from that is again recycled inthe process. The waste sludge is packed at the time period of 1 year and send to the Naroda based CPCB plant where it is processed to form fertiliers. The water entering the plant has dark colour and oil around 150 ppm,which is reduced to the less than 10 ppm and the colour of water is also removed.

North Santhal 16th May,2013

Here the installation manager is H D Udikwal. The plant is same as all the GGS plant. Plant has 55 flowing wells.Out of which 12 are self flow and 43 are SRP. Net oil production of plant is 575 M3.With total production of of5500-6000M3. It has main 3 Header of 8 inch pipeline. It has 12 Heater Treater. Of which 6 has capacity of 350 M3/day and 6 has capacity of 600 M3/day. Plant has 8 storage tanks. Of which 6 are of production storage and 2 for skimwash. Out of that 6 tanks 4 are of capacity of 1300M3 and 2 of 2000M3.And both skimwash tank has capacity of 650 M3. It has 1 Fuel Gas Scrubber. Around 2300 M3 of oil from Balol and 1200-1300 M3 oil from Lanwa comes to this plant. The oil produced here is sent to the Mehsana Central Tank Farm CTF Plant. It has total storage capacity of 9200 M3.

Enhanced Oil Recovery(EOR) Plant ,Santhal Main, 17th May,2013

Here Mr. B K Parmar is the insatallation manager. Mr. V C Dubey is CE of Electrical department. Mr. Manish Saxena shows me the whole Plant. The plant is called ICP (Insitu Combustion Plant) as it supplies air for fire ignitor method of EOR. It supply air to nearly 70 wells.

Description of Plant:
In this plant the pressure of air is increased by using compressors. First the air is supplied to the Low Pressure Compressor.This converts the pressure of air to the 10kg/cm2.Then it is send to High Pressure Compressor (HPC). As the air is compressed its temperature also increases. So to cool down that temperature 2 cooled water and 1 gas cooling is their. Then the air with 10 kg/cm2 of pressure enters HPC at 55 degreee celcius. HPC has 3 chambers. Air enters in first and gets compressed to 26 kg/cm2. Then the air in secnd chamber is compressed to the 54kg/cm2 and after cooling send to third chamber where its pressure increasesto 105kg/cm2. The air is

then cooled and send to the header and then to the wells. The flow of air should be continous. This is the working of plant .Plant has 6 sets of LPC and HPC. Pressure of air injected in wells is depends on the reservoir. The air is injected in the well for 6 days and 1 day water is injected, which converts the fire in steam. Now the steam having pressure 1300 times more than water it pushes the oil in the well. Due to this the oil comes out of the nearby steup wells which then called Producer wells. How much of gas is to be injected is calculated by IRS section and depends on the flow rate and pressure of formation. Gas for ignition in well is got from he GGS plant plants in pipeline for temporary period until the fire ignitor method is completed.

 Thank You to ONGC who gave me chance to train in organization. Also Thank You to whole staff of ONGC who support me well during training and explains me the plant functions.