OIL & NATURAL GAS CORPORATION LIMITED

OPERATION OF RWTP, ETP, AIR & N2 PLANT WITH

ASSOCIATED PROBLEMS & SOLUTIONS

Onshore Gas Terminal, HP-HT Asset

A SUMMER INTERNSHIP REPORT

SUBMITTED BY:

1) D.VANDANA
2) M.SAI DEEPTHI
3) Ch. NIVEDITHA
4) P.SOWMYA

1
 Acknowledgement

The internship opportunity I had with Oil & Natural Gas Corporation Limited (ONGC) was a
great chance for learning and professional development. My internship provided me with an
insight into the industry and laid down a path that would help me in seamless transition from
a student to a professional.

First of all, I would like to express my deepest gratitude and special thanks to Mr. S.Satyapal,
GGM-Asset Manager (HPHT Asset) who in spite of being extremely busy with his duties
allowed me to carry out my internship at their esteemed organization.

I express my deepest thanks to Mr. A.J Meshram, GM-Surface Manager & Mr. S.Subash,
DGM(P), for giving necessary advices, guidance and study material throughout.

I express my deepest thanks to Mr. Dharnesh Garapati, Officer-Process for giving necessary
advices, guidance, and providing me with such a great learning environment.

It is my radiant sentiment to place on record my best regards, deepest sense of gratitude to

the support of the entire administration department and staff members of ONGC, the
internship wouldn’t have been possible without your support.

I would like to thank Prof. R. Shyam Sunder Principal, University College of Technology,
Osmania University for providing me with this opportunity of industrial exposure.

I perceive this opportunity as a big milestone in my career development. I will strive to use
gained skills and knowledge in the best possible way, and I will continue to work on their
improvement, in order to attain desired career objectives. I hope for continuous cooperation
with all of you in the future.

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 CONTENTS

S.NO PARTICULARS PAGE NO.

1 RAW WATER TREATMENT PLANT 4-10

2 EFFLUENT TREATMENT PLANT 11-17

3 AIR&N2 PLANT 18-25

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RAW WATER TREATMENT PLANT

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 INTRODUCTION

For industrial companies using a raw water source for its facility, some type of raw water
treatment system is usually necessary to ensure an efficient process and quality product.
A raw treatment system might be made up of the technologies necessary to remove
suspended and colloidal particles, iron and bacteria.

Efficient and well-designed raw water system should be able to handle:

 Seasonal variations in turbidity and flow
 Variations in water chemistry needs and required chemical volume adjustments
 Changes in water quality requirements

Raw Water System:

Raw Water shall be made available at the OGT battery limit from Tallarevu Lock (Bank canal)
and Dawaleswaram Barrage. Raw water is pumped to OGT through pipeline.

At OGT, raw water reservoirs along with filtration and pumping facilities are envisaged under
the scope of GSPC OGT Project. One Raw Water reservoir having two compartments (Total
holding capacity shall be 72000 m3equivalents to 6 days requirement) are provided to ensure
uninterrupted supply of raw water. The raw water from the reservoirs shall be pumped, treated
and filtered in a Raw Water Treatment Plant (RWTP). The treated Raw Water would be stored
in a single reservoir (holding capacity shall be 12000m3 equivalent to 1 day requirement) from
where it will be pumped to various consumers in the OGT to meet its process and other
requirements.

The Raw Water System will comprise of:

 Raw Water Reservoirs, filtration and pumping.
 Raw water Treatment Plant.
 Treated Raw Water Pumping System.
Treated Raw Water is required to meet the requirements as listed below:
 Service Water
 Cooling Water make-up.
 DM plant feed.
 Fire water make-up
 Drinking Water.

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Treatment process:
 Aeration tank
 Parshall flume
 Flash mixer
 Reactor clarifier
 Rapid sand filters
 Filtered water reservoir
 Clarifier sludge pump
 Sludge thickener
 Thickened sludge pump
 Effluent collection sump
 Belt filter press

Characteristics of Treated water:

 pH=7.5
 Turbidity<1 NTU
 Total dissolved solids=1870mg/l
 Total suspended solids<1mg/l

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 PROCESS DESCRIPTION

Two pumps each of capacity 250m3 from the ponds enter to the aeration tank.

AERATION TANK:
Water enters to aeration tank through a suitable diameter pipe. Recycle water from sludge
can also be routed.
Pre-chlorination and lime dosing are done to remove bacteria and to maintain pH levels
respectively. Air blowers are provided at the bottom in order to remove iron traces and any
dissolved gases.
Cl2 + H2O → H+ + Cl- +HOCl
HOCl↔ H++ OCl-

PARSHALL FLUME:
Water from aeration next move through a channel of standard design. Here we have an
instrument of ultrasonic type for recording cumulative flow.
At the downstream we add alum and fuller earth to remove turbidity and oil& grease
respectively.
Al2 (SO4)3.18H2O+3Ca (HCO3)2→2Al (OH) 3+3CaSO4+H2O+6CO2

FLASH MIXER:
It is equipped with an agitator for mixing chemicals.

CLARIFIER:
Coagulated water enters to clarifier through pipes. Poly electrolyte is dosed for flocculation,
flocculated water flow into clarifier zone, where solid settle at floor.
Clarifier is provided with a turbine to mix the chemical. Sludge gets settle down and by
mechanical scrapper sludge is driven to central part.

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RAPID GRAVITY DUAL MEDIA FILTER:
Clarified water from clarifier will flow to RGDMF through filter inlet channel. The media in this
filter is activated charcoal followed by sand.
Residual suspended particles will be removed here.
Dirty backwash from filter will flow to ETP by gravity.

FILTERED WATER RESERVOIR:

Capacity=12000m3
It has two equal compartments with isolation gates.

BACK WASH WATER OVERHEAD TANK:

Water required for filter backwash is stored here.

EFFLUENT COLLECTION SUMP:

The dirty backwash generated from backwash of filter collected here.

CLARIFIER SLUDGE SUMP:

Sludge from reactor clarifier collected here.

SLUDGE THICKENER:
Designed with a sludge flow of 422m3/d
The scrapping mechanism moves slowly and pushes the thickened sludge into the centre.
Sludge will be drawn intermittently through sludge outlet pipes from concentrated sludge
hopper to thickened sludge sump under hydrostatic head.
Thickener feed pump also have discharge point to ETP in case of absence of dewatering
system.

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THICKENED SLUDGE SUMP:
It receives thickened sludge from thickener. It contains two compartments of recycle pumps
for recirculation of thickened sludge to clarifier sludge in the absence of dewatering system.

BELT FILTER PRESS:

Next the thickened sludge comes for dewatering system by filter press feed pump. Two
number of BFP shall be provided of handling 250kg/hr with DWPE dosing arrangement. The
filtrate is routed to effluent collection sump by gravity.
Dewatered sludge cake shall be channelled through a chute into tractor troller.

REGENERATION OF RWTP:

 AIR SCORING TIME: 3 min

 AIR+WATER: 2 min
 WATER: 3 min

GENERAL PROBLEMS ASSOCIATED IN RWTP&SOLUTIONS:

 Chlorine neutralisation tank is provided to avoid accidents by chlorine gas leakage.

 Seasonal variations in turbidity can be overcome by increasing or decreasing chemical
dosing.

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Raw water↓ parshall flume poly dosing↓

AERAION TANK FLASH MIXER REACTOR CLARIFIER RGF STORAGE TANK

Lime ↑ alum↑
Pre chlorination fuller earth
,

sludge

CLARIFIER
SLUDGE TANK

DWPE↓
SLUDGE THICKENED BELT PRESS
THICKENER SLUDGE SUMP FILTER

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EFFLUENT TREATMENT PLANT

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 INTRODUCTION

Effluent treatment plant covers the mechanisms and processes used to treat such waters that
have been contaminated in some way by industrial activities prior to its release into the
environment or its re use.
This effluent contains several pollutants an oil which can be removed with the help of an
effluent treatment plant.

We need to treat effluent to:

 Prevent ground water pollution
 Reuse the treated effluent
 Solve social problems caused by the accumulation of waste water
 industrial recycle
 Agriculture use
 To protect public health

ETP is further divided into 5 sections:

1. Slope Oil removal section
2. Polishing section
3. and sludge handling section
4. Chemical dosing section
5. Sewage water treatment section

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 PROCESS DESCRIPTION
1. OIL REMOVAL SECTION :
It consists of the following units-

 receiving sump
 equalization tank
 TPI separators
 Flash mixing tank
 Flocculation tank
 Dissolved air flotation system

1(a) OWS stream:

OWS receiving sump:

Combined OWS effluent is collected in OWS receiving sump through a 400 diameter
underground pipe.

Equalization tank:

It is used to receive effluent from OWS receiving sump, regular floor wash and all
drains from various process units.it is provided with enough retention time to equalize
the effluent properly.

OWS TPI oil separator:

It is covered with removable MS chequered plates with venting arrangement. Channel

is provided with bays, each bay is designed for handling suitable flow of OWS effluent.
Isolation gates are provided either of the bays, for maintain. The free oil raising to the
surface is skimmed through float type oil skimmer and routed to wet oil skimmer. The
sludge formed due to settling of suspended solids at the bottom of the TPI is removed
by gravity to oil& chemical sludge sump.

Flash mixing tank:

It is provided with bottom entry and top exit arrangement. 10% of alum solution is
dosed to serve as coagulant.

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 Flocculation tank:

It is provided with flocculator through mixing of dope with OWS effluent. The effluent
from flocculation tank enters to dissolved air floatation through pipe.

DAF tank:

If consists of a moving surface skimmer. The flocculated effluent enters the inlet
chamber within the floatation tank operated on dissolved air floatation type where
the de-emulsified oil and light suspended solids raise to the top of floatation tank due
to action of micro fine air bubbles getting released from the depressurized recycle
effluent. A part of the treated waste water is recycled back to a packed type saturation
vessel.
DAF air compressors are provided to supply air at required rate and pressure. The
recycled effluent gets saturated with air in the vessel and the air water mix under
pressure in the floatation tank. The de-emulsified oil and solid precipitates get
attached to micro fine air bubbles and raise to the top surface of floatation tank.

1(b) CRW stream

CRW receiving sump:

Contaminated air water comes to ETP through a underground pipeline with 800 mm
diameter.

TPI oil separator:

The free oil raising to the surface is skimmed through float type oil skimmer and routed
to wet slop oil sump. The sludge formed at the bottom at the TPI is removed by gravity
to oil and chemical sludge sump.

2. Polishing section:

2(a) OWS DMF feed tank:

Effluent from OWS DAF& Ex SRU flash mixing tank are collected in this tank consisting
of two compartments from which the effluent is pumped to DMF filters

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 2(b) CRW DMF feed tank:

CRW effluent from CRW TPI is collected in this tank from which the effluent is pumped
to DMF filters.

Dual media filters for OWS & CRW chain:

Vertical pressure DMF have been envisaged to ensure the desired suspended solids
removal from the treated waste water. Two different sets of DMF will be used for both
the streams separately.

Guard pond& treated effluent collection tank:

It is used to receive treated effluent from DMF. It will have three compartments
with individual inlet and outlet channel. From guard pond the treated water over flows
to treated effluent collection sump, from there treated effluent will be pumped to
reuse/discharge.

3. Slope and sludge handling section:

Oil skimmed from equalization TPI separator and various oil handling units shall be
routed to a wet slope oil sump then to wet slop oil tank.
Oily and chemical sludge generated in various oil handling units and
chemical treatment units shall be collected in oily and chemical sludge sump and then
pumped to oil and chemical sludge thickener. Thickened sludge shall be dewatered in
centrifuge.

4. Chemical dosing section:

 10% of alum solution dosing in OWS flash mixer

 0.1% de oiling poly electrolyte(dope) solution dosing in flocculation tank
 10% H2SO4 solution dosing in ORWS DMF feed tank
 10% H2SO4 and 10% caustic solution dosing in the guard pond

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5. Sewage treatment section:

Raw sewage collection sump:

It is provided to receive raw sewage water.

Bar screen chamber:

Sewage is subjected to screening to remove floating and over-sized materials in

manual bar screen.

Grit chamber:

The flow is sent to grit chamber from screen chambers to remove inorganic matter.
Sewage flows continuously but the inorganic matter settle down.

Aeration tank:

Designed based on extended aeration process principle.

Flow=70m3/d

Secondary clarifier:

Mixed liquor enters secondary clarifier where aerated sludge settle down. The sludge
is settling in hopper and collecting at central pit. Excess sludge is sent to packaged STP
bio-sludge storage tank and pumped to oily and chemical sludge sump.
Bio-sludge storage tank:
The water is pumped to dewatering bag and 20% sludge cake is disposed.

Treated sewage sump:

Treated sewage from secondary clarifier is received in treated sewage sump, further
sent to green belt area by a portable pump.

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QUANTITY OF OIL AND FLOORWASH

PARAMETER CONCENTRATION
Oil 600
TSS 200
BOD 200
COD 350
PH 6-9

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AIR & N2 PLANT

18
 INTRODUCTION

This system designed to supply compressed air to the various users at the required conditions,
quality& quantity.

 Instrument air to operate the various instruments in the facility and also for the
purging of some control panels.
 Plant air for cleaning, blowing, operating pneumatic tools.
 N2 is used for blanketing and purging.

Plant air requirement of the OGT complex shall be met through the plant air header. The
quality of instrument air required is different so separate header shall be provided for
distributing instrument air.

Compressed air specifications

s.no Parameter Plant air Instrument air

1 Dew point at atm pressure Water free -400c
2 Oil content, ppm Nil nil

 Plant air will not be available during power failure or L.P air compressor strip.
 Instrument air will be available only for 30 min during power failure or L.P air
compressor trip for safe shut down.

Compressed air system shall consist of

 L.P air compressor
 L.P sir receiver
 instrument air drier
 H.P air compressor
 H.P air receiver.

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 PROCESS DESCRIPTION
LP air compressor:
There are two centrifugal compressors of capacity 3750Nm3/hr each. The stand by
compressor shall be used along with working compressor to meet the peak air requirement.

Compressor specifications:
Type: integrally geared centrifugal
Drive: electric motor
Capacity: 3750Nm3/hr
Number: 2
Discharge pressure: 7.7kg/cm2 at compressor package
Air inlet temperature: 380C
Relative humidity: 74%
Air received from blowers will enter into LP compressor, it pressurize the air in three stages.
After every stage there is a cooler to decrease the temperature of pressurized air.
1st stage: 0.9-1.0 kg/cm2
2nd stage: 3.1-3.5 kg/cm2
3rd stage: 7.5 kg/cm2

LP air receiver:
Compressed air from the LP air compressor will be sent to a common LP air receiver to remove
any water being condensed.

Specifications for LP air receiver:

Type: vertical
Height: 8.4 m
Diameter: 3.4 m
Capacity: 87.5m3
Operating pressure: 7.7 kg/cm2

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Instrument air dryer:
There are two dryers each of net capacity 2500Nm3/h are provided. The dryer will be spilt
flow, closed circuit, heat reactivated type (dual bed adsorption type) with activated alumina
as desiccant.

Dryer sequence logic of operation:

Cycle time: 8+8 hours
Adsorption: 8 hours
Regeneration: 8 hours
Heating: 5.8 hours
Cooling: 2.2 hours
Dryer inlet flow is 2500Nm3/h, regeneration flow at the heat inlet required is 1486 Nm3/h.
since it is split flow type dryer, the inlet flow of dryer is spited into two streams. One stream
of regeneration flow will go to heater and other stream of balanced flow will pass directly
through the flow control valve and get mixed and ultimately 2500Nm3/h of air flow is passing
through desiccant vessel. The electric heater will be on during 1 minute-5.8 hours to increase
the temperature of regeneration air.
During 5.8-8 hours regeneration cooling will take place.
At 8 hours instant tower change will take place.

PRE-FILTER→HEATER→REGENERATION→COOLER→MOISTURE
SEPERATOR→ADSORPTION→AFTER FILTER→OUT

HP instrument air system:

A provision for the safe shutdown during a power failure shall be provided. This facility will
provide instrument air for minimum of 30 minutes in case of air compressors failure.

HP air compressor:
Type: reciprocating
Drive: electric motor

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Capacity: 250Nm3/hr
Discharge pressure: 31.5 kg/cm2
Instrument air from the dryer will directly enter the HP air compressor which pressurise the
air in two stages. After every stage a volume bottle and a cooler is provided to stabilize the
flow and decrease the temperature of pressurized air.
1st stage: 6.5-14 kg/cm2
2nd stage: 14-30 kg/cm2

HP air receiver:
The vessel will be sized with 25% designed margin based on depressurization from 30.6-
6.5kg/cm2 in 30 minutes. This reservoir will store instrument air from HP compressor.

Specifications for HP air receiver:

Type: vertical
Height: 11.8 m
Diameter: 4.7 m
Operating pressure: 30.6 kg/cm2
Number: 1

NITROGEN SKID

This unit broadly classifies to produce consistently 2*300 Nm3/hr nitrogen gas with 0.5%
oxygen at up to 6kg/cm2g pressure.

 Air receiver:
The incoming air from compressor may be having some pressure pulsation, to reduce
that an air receiver is installed before the air is feed into the PSA system.

 Pre-filter:
A high efficiency dust removal filtration module of PSA make has been provided. It has
5 micron poly propylene candles which removes fine dust particles from air and
improves performance.

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 Pressure swing adsorption unit(PSA):

If consist of carbon molecular sieves(CMS). Two vessels are filled with special grade
activated alumina to adsorb the moisture if present in coming air& CMS to adsorb
oxygen and CO2 present in air, inter connected by automatic change over valves. This
PS unit is being operated at 60+60 seconds cycle. Each tower remains in adsorption
cycle for 60 seconds and at the same time other tower remains under regeneration.
PSA nitrogen gas plants are based on well proven technology using carbon molecular
sieves. Separation of nitrogen from air is based on selective absorption of oxygen
particles in carbon molecular sieves at high pressure. CMS, the adsorbent has infinite
number of small cores. Oxygen molecule having small diameters than nitrogen
diameter enters into this pores.

 Silencer:

This is installed at the outlet of PSA tower exhaust line. After equalization of towers,
adsorption tower gets depressurized to atmospheric pressure through silencer.

 Nitrogen surge vessel:

This vessel gives product nitrogen at constant pressure with constant average gas
purity.

 Oxygen analyser:

For continuous monitoring of oxygen content in final nitrogen gas online percentage
oxygen analyser is installed in the centralized panel.

 Back pressure controller:

The back pressure controller always maintain minimum 6kg/cm2 pressure at surge
vessel.

 Three way vent valve:

This is an electro pneumatically operated three way valve. When there is no
instrument air signal, its one port is always open to atmosphere.

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 After filter:
May be some dust carried in nitrogen gas due to powdering of CMS in TSA towers. So high
efficiency dust removal filtration modules are provided.

 Pressure transmitter:
It has been installed at outlet of after filter to monitor the outlet pressure of nitrogen
gas.

GENERAL PROBLEMS ASSOCIATED IN AIR&N2 PLANT&SOLUTIONS:

 Surging may damage the LP air compressor to avoid this we have to increase the air
flow to the compressor.

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 PLANT SAFETY

Safety is of utmost important in the OGT. There are provisions of many safety equipments
and procedures in the plant. Some of them are:

a) Permit to Work (PTW) system to carry out any hot, cold, electric or confined space
entry work.
b) Pressure safety valves and safety interlocks.
c) Fire, smoke and HC detectors.
d) Personal Protective Equipment (PPE): It includes helmet, safety goggles, face mask,
safety shoes, cover-all and gloves.
e) Sprinkler systems and water hoses connected to fire water reservoirs with a capacity
of 18000 m3 and provision of use of treated raw water with capacity of 65000 m3.
f) Fire extinguishers and fire trucks.
g) Manual call points.
h) Total ban of mobile phones and any other spark producing device in the processing
area.
i) Instalment of spark arrestor at the exhaust of all the vehicles in OGT.
j) Battery limit isolation valves.
k) Lightning protection system.
l) Rim seal protection and deluge valve system is provided in the storage tank for
condensates.
m) Safety and hazard signs installed at every necessary location.
n) Material Safety Datasheet referred for handling Hazardous Chemicals.

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