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ONGC Training Report
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ONGC Training Report
TRAINING REPORT
SURFACE TEAM, AHMEDABAD ASSET
PREPARED BY:
KUMAR VIKRAMADITYA
BHUPENDRA PAL SINGH
GEETHA BAKKI
ANKITA BHELWA
1
ONGC
TRAINING REPORT 2
DEEPSHIKHA SINGH
ACKNOWLEDGEMENT
CERTIFICATE
N. Khanduri
CE (P)
ST DEPARTMENT
ONGC AHMEDABAD
AVANI BHAWAN
CHANDKHEDA CAMPUS
AHMEDABAD 380005
Table of Contents
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1. Introduction 5
2. GGS 6
3. CTF 19
4. DESALTER PLANT 21
5. GCS 23
6. ETP 29
7. WWTP 31
8. WIP 34
9. GCP 38
10.ARTIFICIAL LIFT 43
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Introduction
The Crude oil produced from the various oil fields are being transported through
pipelines to a Group Gathering Station (GGS). In GGS the oil is being separated from
impurities n water by the process of Three Stage Separator which contains De-
emulsifier injection in its first stage followed by Heating Process and the third stage
is Electrostatic separation. And the produced Gas is being transported through
pipelines to Gas Collecting Station (GCS).
The Processed Crude oil from many GGS is being transported to a Central Tank Farm
(CTF) where again the crude oil is subjected to separation process in a “Heater
Treater” which also works on the same principle of Three stage separation. Later on
the processed crude is being transported to the Desalter Plant for the further
reduction of the water content of the crude oil to 0.09%- 0.10%.
In Desalter Plant the received oil is again subjected to three stage separation
process after which final crude oil is recovered with 0.10% water cut which is being
transported through pipeline to the nearby refinery for production of finished
products.
The collected gas at GCS is at very low pressure of about 2-5 kgs pressure which is
being transferred to a Gas Compression Plant (GCP) to compress the gas to a
pressure of 40-45 kgs to use the gas for the injection process for enhance oil
recovery through GGS.
The waste water collected from all separation processes are being sent to
Effluent Treatment Plant (ETP) where the trace oil is being recovered from the waste
water. The treated water is being sent to a Water Injection Plant (WIP) which is
being pumped to various wells for enhance oil recovery process. The recovered
water from Desalter plant is being sent to Waste Water Treatment Plant (WWTP).
Self drive wells have their own pressure to produce. Sucker Rod Pumps works on the
principle of Hand Pumps to produce form the well. And in Artificial Lift Wells either
gas is injected or water is injected for the production of oil. The wells having a high
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flux are mainly subjected to artificial lift. The gas injection can be done as a
continuous process or can be done in a fixed interval process.
Kalol field group gathering station 7 is designed to handle produced from oil wells
located in this area. Following facilities are provided in this GGS.
- EMERGENCY GENERATOR
- BOOSTER COMPRESSOR
▪ It receives 46,000 m3/day of gas at 41 kg/m2 for gas injection in gas lift
wells.
▪ Crude oil water content is reduced 50% water .i.e water cut is 50%.
List of equipments:-
Vessel:-
PUMPS:-
BOOSTER COMPRESSOR:-
Process Description:-
Oil is received in GGS- 7(k) from the wells through 4” pipelines into the following
headers
1. Group header
2. Test header
3. Emulsion header
4. H.P header
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Well fluid from the wells to header, to bath heater, for preheating & then to
group separator .Oil water mixture after separation of gas in group separator goes to
heater -treater for emulsion treatment .Oil from HT goes to oil storage tank & from
tank it goes it is pumped to CTF (K) with the help of oil dispatch pumps. Gas from
the group separator goes to booster compressor for compression & goes to the gas
grid of Kalol area to GGS (K) which is measured by flow recorder.
Emulsion Header:-
Well fluid flows from the wells to header & goes to emulsion separator for
separating liquid & gas. Liquid goes to heater treater for emulsion separation oil
from HT goes to oil storage tank & gas from e/ sep goes to the gas grid of kalol area
of GGS which is measured by flow recorders.
HP header:-
Description of facilities:-
Feed Supply:-
Valves are also provided in manifold to divert well fluid coming from the 4” phi
pipelines to any of the headers.
This is a 8 “PHI & 4 “phi line system connecting the valve manifold to the
separator via bath heater. It is meant for collecting oil from wells & diverting the
same to the separators.
Separators:-
Pressure gauges are provided on the separators to monitor the operating pressure .
All the separators are provided with pressure relief valve PSV -
101/102/103/104/105/106 to protect the vessel against over pressure . The valves
are set at a pressure of 6.6kg/cm2 & PSV – 106 set ata a pressure 16.5 kg/cm2.
a) Emulsion separator:
Emulsion separator(s): 2
Capacity: 6 m3
b) LP separator:
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Capacity: 6 m3
c) Test separator:
Nos.: 2
Capacity: 6 m3
Four crude despatch pumps p -01/02/03/04 are provided for transferring crude oil
from the oil storage tanks to kalol CTF through 8” pipeline. These are motor driven
reciprocating pumps having a rated discharge rate 38m3/hr,10m3/hr,35m3/hr & 42
m3/hr respectively. Each pump discharge line has a safety valave discharging to
suction line. Safety valve discharging is set at 24kg/cm2.
Make: BPCL
Type: Reciprocating
Capacity: 35(m3/hr)
Power(Kw/Hp): 75(100)
Speed(RPM): 1470
Efficiency: 64%
b) Dosing pump:-
LPH: 700
SPM: 100
Pressure: 5kg/cm2
SYSTEM DESCRIPTION:-
The utility system of GGS-7(K) consists of the following:
Two reservoirs having a capacity of 120m3& 350m3 are provided for storing of
fire water. There is one motor driven pump 7-P-06 of 170m3/hr capacity &
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170m3/hr & 6kg/cm2 discharge pressure . Fire water is supplied to the system
through a 4” ring to which discharge of all the above pumps are connected.
Make: Minimax
Nos.: 1
Type: Centrifugal
Apart from the above mentioned equipments the facility has sand buckets, a fire bell
and a hooter system.
Power Management:-
The power to the plant is supplied from 11kw grid of the state electricity
board . The overall normal power requirement envisaged has been power supply of
the order of 100kva.
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Emergency power:
Emergency power to the plant is maintained by 320 KVA diesel generator set.
In case of normal power failure , the DG set shall be manually started to provide
power supply to essential services.
Earlier, 160 KVA, DG set was available but with the installation of new DG set, almost
all equipment can be operated simultaneously.Two numbers of 12 volt battery for
starting the DG are set. A trickle & booster is provided to maintain the batteries fully
charged, even when the DG set is not running. As there is no uninterrupted power
supply system, there will be a total shut down of the plant .To provide lightning till
DG set is started in case of power failure during night , emergency light is available
at the shift I/C room as well as DG set room.
Storage System:-
Process:
Oil from heater treater is taken into overhead cylindrical type tanks, whereas oil
from separator is taken to testing tanks to facilitate measurements.
Nos. : 3
Capacity (M3): one tank of 400 M3 and the other two tanks with 90 M3
The tank of 400 M3 is used for Oil Storage and the other two tanks are used for Well
Testing.
Make: BPCL
Size: 3 ½ inch
Nos.: 4
Capacity (M3/Hr): 35
Seal Type-
Good demulsifier must not only be able to flocculate water particles but also
be able to disrupt films surrounding them & allow them to unite. Such
disruption removes the barriers or opens the doors. The strong natural desire
for water to seek its kind is reestablished. Since the particles are all closer
together because of flocculation, this door opening process results in a very
rapid growth of water drop size & water separation.
In most crude oils , solids such as iron sulphide, silt, clay, drilling mud,
parrafin etc. complicate the demulsification process. They tend to collect at
interphase & contribute significantly to emulsion stability. Often such solids
are primary stabilizing agents / materials & their removal is necessary to
achieve satisfactory treatment.
For removal from interphase, these solids can be dispersed in the
oil or they can be water wetted & removed with water. If, dispersed in oil,
emulsion may be treated, but the solids will still remain as a contaminant in
oil. Therefore it is desirable to remove the solids with water. Paraffins &
organic solids are exception to this as these can be recovered in refining
process.
Heater treater:-
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Emulsion oil from separator is first mixed with demulsifier & then taken into
heater treater . Emulsion oil first enters inlet degassing section. A fire tube is
fitted in the heater treater encompassing degassing section & heating section.
Due to the effect of heat , the free gas in emulsion oil is liberated & then
enters into heating chamber through the equalizer . The fluid enters into the
heating chamber through multiple orifice distributors.
Heating section:
The fire tubes which extend up to this section are in a submerged condition in
emulsion oil . The heating of emulsion oil decreases the viscosity of oil &
water reduces the resistance of droplet movement. The heat further reduces
the surface tension of individual droplets by which they coalesce to form
bigger droplets. The progressive action results in separation of oil & free
water to a greater extent & water settles down in the heating chamber. The
oil water interface in this section is controlled by an interface level controller
which operates the control valves for draining free water.
Heater Treaters :
Specifications
Size 8’ x 20’
Volumetric Capacity 800
(tones/day)
Capacity Free Water 125 - 400
(M3 / day)
Fire Tube Size (inch) 24
Cross-sectional Area of 8
Coalescing Section
(Square-Meters)
Transformer Rated 5
Capacity (KVA)
Number of Fire Tubes 2
Transformer Input (V) 240
Transformer Output (KV) 23
FUNCTION:-
CTF only receives the oil
from GGS. Two types of oil
are received from GGS;
treated as well as
untreated oil. Treated oil
is directly dispatched to
desalter plant through
dispatch pumps, whereas
untreated oil is sent to
heater treater for the
removal of water effluent
from oil. Water cut of
around 5% is maintained at
CTF plant and the water
cut is further reduced to
0.25% with the removal of salts at the desalter plant. The main function of
CTF is to maintain water cut of fluid to 5% and is sent to desalter plant for
further treatment.
MANIFOLDS :-
Purpose:
• To receive oil from GGS in controlled manner
• Both treated and untreated oil is received from the manifold
STORAGE TANKS:-
Purpose:
• They are used to store the treated and untreated oil from GGS
• They help in taking measurements of oil collected and how much to be
dispatched.
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HEATER TREATER:-
Purpose:
• Demulsification of oil into oil and water by chemical thermal and electrical
means. The process has been explained in the GGS installation part.
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• It is used for storing water effluent. These effluents are removed from
heater treater and they are directed to effluent storage tank.
• In the effluent storage tank water effluent settles at the bottom and oil is
recovered at its top. These oil is recovery pumps help in pumping the
recovered oil to the dispatch pumps.
EFFLUENT PUMPS:-
• These pumps help in pumping the discharged effluent from effluent tank to
ETP (effluent treatment plant) for its further treatment.
DISPATCH PUMPS:-
• They are in the final stage of the whole process of CTF plant. Their main
function is to dispatch or pump the oil recovered to desalter plant where
removel of further salts take place and water cut till 0.25% is achieved which
is in accordance to the refineries norms and regulations.
Commonly centrifugal pumps are used. The figure shows a common centrifugal
pump with its working. The capacity of the pump will depend on the work that
the pump is used in.
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DESALTER PLANT
Introduction:-
The oil we get directly from the reservoir contains many unwanted
components which are required to be removed by the upstream industries
before it is sent to the refineries. The unwanted components include the
saline water, different emulsifications of oil and water, drilling fluids and
other formation chemicals. These are required to be removed before it is sent
to the refineries. Crude oil from different wells is first sent to GGS (Group
Gathering Station). Here the oil coming from different wells is collected at a
single station. From GGS the oil is received at the desalter plant. From there
it is sent to CTF (Central Tank Farm).
Plant has four numbers of Floating roof crude oil storage tanks, each of 30000
m3 capacities.We have in total four lines coming in to desalter plant. These
are for receipt, feed, product and dispatch. The desalter plant receives crude
oil with an average BSW 10-15%. The output of the plant is up to 0.2%.
The plant operates on PLC based operating system. The desalting process is a
combination of Chemical treating, washing, heating and electric coalescence.
Each train consists of a set of Heat exchangers, Feed Heater & Desalter
Vessel. Incoming crude is received in one of the storage tanks and fed to the
processing unit by Feed pump. Chemical dosing is done for demulsification.
Processed crude is stored in another tank and after draining of free water is
pumped to Nawagam CTF by set of Booster pumps for onward dispatch to
Koyali Refinery.
There are five basic components which forms the desalter plant. These are:
1) Feed pump
2) Heat exchanger
3) Economizer
4) Main heater
5) Desalter vessel
The main function of the desalter plant is to separate emulsified water and
oil. For this following steps are taken in order:
1) Chemical Dosing: To separate oil and water from each other different
chemicals are added to break the emulsifications. These chemicals are called
demulsifiers and the process is known as demulsification. Demulsifiers are
added before the feed pump which is actually a centrifugal pump. So
whatever amount of demulsifiers are added in the crude oil are well mixed.
3) Economizer: From heat exchangers oil is sent to economizers. Here the oil
is further heated up to 65oC.
5) Desalter Vessel: Final separation of oil and water takes place here. It
contains a system of electrostatic grid which is very effective in removing
water from oil. It has two outlets for draining water and the oil above the
water is easily recovered in the floating type receiving tank. The water which
is drained through outlets contains 100 ppm of oil. This small amount of oil is
further recovered when it is sent to WWTP (Waste Water Treatment Plant).
FUNCTION:-
Gas Collecting
Stations are installed
in oil/gas fields for
accumulation and
transportation of
raw natural gas
directly from
wellheads to gas
processing plants.
Gas extracted from
gas wells is sent to
nearby gathering
stations by reducing
the well pressure at
wellheads. Next
comes the "cleaning"
at gas processing
plants.
OVERALL PROCESS:-
Gas lines from different wells are connected to the Test Header. It is followed
by Low Pressure Header (LP), High Pressure Header (HP) and Group Header.
The Group Header in then connected to separators. The associated gas is
initially dubbed "wet gas" as it is saturated with water and liquid alkanes. The
gas is typically routed through scrubbers, compressors and coolers which will
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remove the bulk of the liquids. This "dry gas" may be exported, re-injected
into the reservoir, used for gas lift, flared or used as fuel for the installation's
power generators.
The gas from the separators is either sent to consumers at low pressures or
sends to GCP (Gas Compressing Plant) to compress the gas and increase the
pressure to deliver it to long distance consumers or eject in the well for gas
lift. The pressure in LP pipes is about 2-4 Kg/cm2 and the gas which comes
back from GCP is around 40Kg/cm2.
Gas Collection:
The gas from different wells are collected through the valve manifold. The
manifold is used to collect the gas in a controlled manner. The gas collected
from the wells is wet and contains liquid alkanes.
Gas Separation:
The measured gas is then passed through the separators which will remove the
bulk of liquids from the associated gas. There are different types of separators
used in the station to free the gas from liquid. The associated liquid collected
is sent to CTF.
A separator for petroleum production is a large drum designed to separate
production fluids into their constituent components of oil, gas and water.
May be either 2-phase or 3-phase.
- Two- phase separators remove the total liquid from the gas
- Three phase separators also remove free water from hydrocarbon
liquid.
It works on the principle that the three components have different densities,
which allows them to stratify when moving slowly with gas on top, water on
the bottom and oil in the middle. Any solids such as sand will also settle in the
bottom of the separator.
Gas can be removed from the top of the drum by virtue of being gas. Oil and
water are separated by a baffle at the end of the separator, which is set at a
height close to the oil-water contact, allowing oil to spill over onto the other
side, while trapping water on the near side. The two fluids can then be piped
out of the separator from their respective sides of the baffle. The produced
water is then either injected back into the oil reservoir, disposed of or
treated.
Parts:
- Diverter baffle
Centrifugal force or abrupt change in direction throws major portion of
entrained liquid from the gas stream
Mist extraction:
Provides retention time to let entrained gases evolve out of oil & rise to vapor
space
The bulk level (gas - liquid interface) and the oil water interfaced are
determined using instrumentation fixed to the vessel. Valves on the oil and
water outlets are controlled to ensure the interfaces are kept at their
optimum levels for separation to occur.
Tracerco provides a range of specialist services to assess separator
performance, which is supported by a range of nuclear gauges which are
mounted external to the process. The Separator will only achieve bulk
separation. The smaller droplets of water will not settle by gravity and will
remain in the oil stream. Normally the oil from the Separator is routed to a
Coalescer to further reduce the water content.
The gas collected from the separators are either exported to consumers or
sent to the GCP plant. Some gases are also sent to the flare.
• IFFCO
• GAIL
• GCP
The main function of this plant is to collect effluent water coming from GGS
and CTF and treat that water. It is expected that this plant must receive
water having 2000 ppm of oil content.
But sometimes this may not happen and hence oil must be removed and again
sent back to CTF from there. Finally the treated water is sent to water
injection plant for final treatment.
Waste water treatment plant also known as WWTP, has same function as that
of ETP.
WWTP receives the waste water from the Desalter plant and treat it. The oil
content in waste water is up to 100ppm which is then recovered through
treatment.
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OPERATIONS:
Manifold:
Its main function is to receive water effluent from installations like GGS, CTF
and lagoon in a controlled manner.
Storage Tank:
It helps in storing effluent water obtained. Here oil and water is separated oil
through a pump is sent to lagoon and it is collected there as sludge.
Mostly the storage tanks are open roof type. Open roof types are preferred
because the total cost of treatment is not compensated in the floating roof
type tanks.
There are 2-3 tanks for storage depending upon the discharge from
installation.
Agitator:
Its main function is to separate oil from water by addition of compounds like
alum, catalyst polymers and non polymers.
It consists of blades which agitates the water with the addition of above
chemicals. Therefore water molecules are separated from oil molecules.
Finally after this process the whole solution is transferred to clari flocculator.
Clari flocculator:
Oil separates at the top of its periphery and pumped through pump to lagoon
and collected as sludge there. Whereas water is sent to filter for its further
purification.
Filter:
Its purpose is to filter the water for the impurities and contaminants present
in it.
The filter consists of membrane made up of sand and gravel. Water is
circulated here and all the particles are filtered by them. Back wash water
arrangement is also made in order to clean the filter when its cleaning is
required. After this the water is sent to conditioning tank where pH level is
maintained by the addition of chemicals like SHMP. And finally the treated
water is sent to WIP (water injection plant) where it is mixed with treated
raw water and sent to GGS for water injection process.
The function of all water treating equipment is to cause the oil droplets that
exist in the water continuous phase to separate from the water phase so they
can then be removed. In gravity separation units, the difference in specific
gravity causes the oil to float to the surface of the water. The oil droplets are
subjected to continuous dispersion and coalescence during the trip up the
wellbore through the surface chokes, flow lines, control valves and the
process equipment. When energy is put into the system at a high rate the
drops are dispersed to smaller sizes. When the energy input rate is low, small
droplets collide and join together in the process of coalescence.
EQUIPMENTS:
1. Settling tanks:
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TRAINING REPORT 38
2. Plate coalescers:
3. Skimmers/coalescers:
Several designs that are marketed for improving oil-water separation rely on
installing plates within horizontal skimmers or free-water knockouts to
encourage coalescence and capture of the oil particles within the water
continuous phase.
4. Precipitators/
coalescing filters:
Water injection refers to the method in oil industry where water is injected
back into the reservoir, usually to increase pressure and thereby stimulate
production. Water injection wells can be found both on- and offshore, to
increase oil recovery from an existing reservoir.
Water is injected (1) to support pressure of the reservoir (also known as void
age replacement), and (2) to sweep or displace oil from the reservoir, and
push it towards a well.
Normally only 30% of the oil in a reservoir can be extracted, but water
injection increases that percentage (known as the recovery factor) and
maintains the production rate of a reservoir over a longer period of time.
Any and every source of bulk water can be, and has been, used for injection.
The following sources of water are used for recovery of oil:
Produced water is often used as an injection fluid. This reduces the potential
of causing formation damage due to incompatible fluids, although the risk of
scaling or corrosion in injection flow lines or tubing remains. Also, the
produced water, being contaminated with hydrocarbons and solids, must be
disposed of in some manner, and disposal to sea or river will require a certain
level of clean-up of the water stream first. However, the processing required
to render produced water fit for reinjection may be equally costly.
As the volumes of water being produced are never sufficient to replace all the
production volumes (oil and gas, in addition to water), additional "make-up"
water must be provided. Mixing waters from different sources exacerbates the
risk of scaling.
Aquifer water from water-bearing formations other than the oil reservoir, but
in the same structure, has the advantage of purity where available.
River water will always require filtering and biociding before injection.
Filters:
The filters must clean the water and remove any impurities, such as shells and
algae. Typical filtration is to 2 micrometers, but really depends on reservoir
requirements. The filters are so fine so as not to block the pores of the
reservoir. Sand filters are a common used filtration technology to remove solid
impurities from the water. The sand filter has different beds with various sizes
of sand granules.
The sea water traverses the first, finest, layer of sand down to the coarsest
and to clean the filter, the process is inverted. After the water is filtered it
continues on to fill the de-oxygenation tower. Sand filters are bulky, heavy,
have some spill over of sand particles and require chemicals to enhance water
quality. A more sophisticated approach is to use automatic self-cleaning back
flushable screen filters (suction scanning) because these do not have the
disadvantages sand filters have.
De-oxygenation:-
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Oxygen must be removed from the water because it promotes corrosion and
growth of certain bacteria. Bacterial growth in the reservoir can produce toxic
hydrogen sulfide, a source of serious production problems, and block the
pores in the rock.
A deoxygenation tower brings the injection water into contact with a dry gas
stream (gas is always readily available in the oilfield). The filtered water
drops into the de-oxygenation tower, splashing onto a series of trays, causing
dissolved oxygen to be lost to the gas stream.
An alternative method, also used as a backup to deoxygenation towers, is to
add an oxygen scavenging agent such as sodium bisulfate.
The high pressure, high flow water injection pumps are placed near to the de-
oxygenation tower and boosting pumps. They fill the bottom of the reservoir
with the filtered water to push the oil towards the wells like a piston. The
result of the injection is not quick, it needs time.
Water injection is used to prevent low pressure in the reservoir. The water
replaces the oil which has been taken, keeping the production rate and the
pressure the same over the long term.
The main function of WIP is to treat the water and maintain oil level of 10
ppm. Amount of oil is checked in the chemistry lab of installation, so regular
checking is done so that10 ppm is maintained. The water sample is also
checked for its salinity, alkalinity, ph (around 7.00) and hence record is
maintained of each day of inspection. After this final treated water is sent to
GGS through water injection manifold and from there this water is used for
water injection programs in different wells. Water is pumped to GGS at 52kg/
cm2.
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Purpose:
It’s a place where treated raw water and water form ETP is mixed up, and
they are measured here.
Purpose:
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It is used for the treatment of raw water for removing its hardness. After this
it is mixed with water obtained from ETP. Normally it is done because the
water available from ETP is not available in sufficient amount for water
injection purpose; therefore some mixing of treated raw water is done.
Process:
Here the raw water is made to enter in the chemical tanks. The chemical
such as SHMP and oxygen scavenger is mixed with it which removes hardness
to a great extent and after this it is pumped to treated water tank in which it
is mixed with water obtained from ETP.
BALANCING TANK:-
Purpose:
TREATED TANK:-
Purpose:
It’s a place where treated raw water and water from ETP is mixed up, and
they are measured here. Finally the water is pumped through water injection
manifolds to GGS for carrying out further activities.
About
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The Gas Compression plant, ONGC is located in Kalol, Ahmedabad. Its function
is to compress the gas. It has a capacity of 150000 m3/day. It has a total of 10
gas compressors (6 in old plant and 4 in new plant) and a water treatment
plant with 2 reverse osmosis plant and chemical treatment plant.
The main function of GCP is to compress the Gas it receives from Gas
Collecting Station (GCS) and then send it back to GCS and other receivers like
Reliance, IFFCO etc. It receives gas from GCS at about 3 kg/cm2 and
compresses it in two stages to about 40 kg/cm2 . In the first stage it
compresses the gas to 12 kg/cm2 and in the second stage it compresses it to 40
kg/cm2 .This gas is then received by GGS through GCS and here it is used for
gas injection in gas lift wells. It uses demineralized and pure water to cool
this gas in gas coolers.
Plant Description
INLET SEPERATOR
The general process of this is to separate liquid hydrocarbons from the gas.
This section tank contains baffles for this process at reduced temperature and
pressure of separator.
GAS COMPRESSORS
Gas Compressors are used to compress the gas to a high pressure of about 40
kg/cm2 to increase the flowing pressure. The compression is done in two
steps. In the first step the gas is compressed to 12 kg/cm2 and in the second
step it is compressed to 40 kg/cm2 .
DISCHARGE SEPERATOR
The function of Discharge Seperator is to finally separate the gas from the
condensates. It has the same process as that of Inlet Seperator.
CONDENSATE DRUM
This is the storage drum for the condensates which receives the liquid
hydrocarbons
from the inlet, suction and discharge separator. The gas is set to cold flare
while the liquid hydrocarbons, left at the bottom of the drum, is sent to the
Central Tank Farm for further treatment through a condensate transfer pump.
GAS COOLERS
It is a type of heat exchanger. It contains baffles and one shell and two tube
pass exchanger system. It is used to cool the gas. It is done at two points
(receiving gas from first stage compression and second stage compression)-
inter gas cooler and after gas cooler. In this heat exchanger, water enters from
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one side and the gas from other side. Here, counter current flow takes place.
And hence the gas is cooled.
The raw water which comes from submersible pump is stored in this tank. It is
then passed to R.O. plant for its processing.
Its function is to remove the TDS (Total Dissolved Solids) from the raw water.
Some of the chemicals like Sodium Hydrosulphite, Sulphuric acid and Sodium
Hypochlorite are also used for this purpose. The water is passed through the
membranes. The TDS does not pass through the membrane and is stored in a
separate vessel. The treated water is further passed to the degasser tank.
DEGASSER TANK
In the Degasser tank, Carbon Dioxide and Sulphuric Acid removal takes place.
Gasses removed are blown by blower so that it remains at the top while the
water is passed to the cation and anion exchange towers.
The basic function of this tower is to remove the hardness content in the
water and different salts, sulphates etc. Here exchange of ions take place
between electrolytes. After that process, water is sent to the cooling tower.
COOLING TOWER
It is used to cool water. From here, water is passed to the gas coolers. The
cold water is required to cool the hot gas in the heat exchanger
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TRAINING REPORT 49
• Hammoud type:
The disadvantage of this tank is that it only supports a fixed volume of oil. It won’t
adjust with the volume of oil in it.
tank shell
▪ Such tank designs have small vapor space under the seal between side of roof
& shoe.
▪ No vapor discharge when pumping into tank, since the volume under seal
remains constant
▪ Danger of fire is also reduced since the oil surface is mostly covered
Advantages:
Disadvantages:
Types:
• Buoy Roof
• Double Deck
Out of the above given types double and pontoon type roof tanks are very efficient
in their work.
• Uses two separate decks with an insulating air space between them
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TRAINING REPORT 53
• Series of compartmented
annular rings of pontoons
around periphery & a single
deck center
• When center deck cools, center deck assumes its original contact position
ARTIFICIAL LIFT
Artificial lift refers to the use of artificial means to increase the flow of liquids, such
as crude oil or water, from a production well. Generally this is achieved by the use of
a mechanical device inside the well (pump or velocity string) or by decreasing the
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TRAINING REPORT 54
weight of the hydrostatic column by injecting gas into the liquid some distance down
the well. Artificial lift is needed in wells when there is insufficient pressure in the
reservoir to lift the produced fluids to the surface, but often used in naturally
flowing wells (which do not technically need it) to increase the flow rate above what
would flow naturally. The produced fluid can be oil and/or water, typically with
some amount of gas included.
Any liquid-producing reservoir will have a 'reservoir pressure': some level of energy
or potential that will force fluid (liquid and/or gas) to areas of lower energy or
potential. You can think of this much like the water pressure in your municipal water
system. As soon as the pressure inside a production well is decreased below the
reservoir pressure, the reservoir will act to fill the well back up, just like opening a
valve on your water system. Depending on the depth of the reservoir (deeper results
in higher pressure requirement) and density of the fluid (heavier mixture results in
higher requirement), the reservoir may or may not have enough potential to push
the fluid to the surface. Most oil production reservoirs have sufficient potential to
produce oil and gas - which are light - naturally in the early phases of production.
Eventually, as water - which is heavier than oil and much heavier than gas -
encroaches into production and reservoir pressure decreases as the reservoir
depletes, all wells will stop flowing naturally. At some point, most well operators
will implement an artificial lift plan to continue and/or to increase production. Most
water-producing wells, by contrast, will need artificial lift from the very beginning
of production because they do not benefit from the lighter density of oil and gas.
Hydraulic pumping systems transmit energy to the bottom of the well by means of
pressurized power fluid that flows down in the wellbore tubular to a subsurface
pump. There are two types of hydraulic subsurface pump:
a) A reciprocating piston pump, where one side is powered by the injected fluid
while the other side pumps the produced fluids to surface, and
b) A jet pump, where the injected fluid passes through a nozzle creating a venturi
effect pushing the produced fluids to surface.
These systems are very versatile and have been used in shallow depths (1000 ft) to
deeper wells (18,000 ft), low rate wells with production in the tens of barrels per
day to wells producing in excess of 10,000 barrels per day (1,600 m³/d). Certain
substances can be mixed in with the injected fluid to help deal or control with
corrosion, paraffin and emulsion problems. Hydraulic pumping systems are also
suitable for deviated wells where conventional pumps such as the rod pump are not
feasible.
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TRAINING REPORT 55
These systems have also some disadvantages. They are sensitive to solids and are the
least efficient lift method. While typically the cost of deploying these systems has
been very high, new coiled tubing umbilical technologies are in some cases greatly
reducing the cost.
Most oil reservoirs are of the volumetric type where the driving mechanism is the
expansion of solution gas when reservoir pressure declines because of fluid
production. Oil reservoirs will eventually not be able to produce fluids at economical
rates unless natural driving mechanisms (e.g., aquifer and/or gas cap) or pressure
maintenance mechanisms (e.g., water flooding or gas injection) are present to
maintain reservoir energy. The only way to obtain a high production rate of a well is
to increase production pressure drawdown by reducing the bottom-hole pressure
with artificial lift methods. Approximately 50% of wells worldwide need artificial lift
systems. The commonly used artificial lift methods include the following:
❖ Plunger lift
ESP:
c) The electrical motor, which transforms the electrical power into kinetic energy to
turn the pump, and
d) An electric power cable that connects the motor to the surface control panel. ESP
is a very versatile artificial lift method and can be found in operating environments
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TRAINING REPORT 56
all over the world. They can handle a very wide range of flow rates (from 200 to
90,000 barrels per day) and lift requirements (from virtually zero to 10,000 ft (3,000
m) of lift). They can be modified to handle contaminants commonly found in oil,
aggressive corrosive fluids such as H2S and CO2, and exceptionally high downhole
temperatures. Increasing water cut has been shown to have no significant
detrimental effect on the ESP performance. It is possible to locate them in vertical,
deviated, or horizontal wells, but it is recommended to deploy them in a straight
section of casing for optimum run life performance.
Although latest developments are aimed to enhance the ESP capabilities to handle
gas and sand, they still need more technological development to avoid gas locked
and internal erosion. Until recently, ESP's have come with an often prohibitive price
tag due to the cost of deployment which can be in excess of $20,000.
GAS LIFT:
An artificial-lift method in which gas is injected into the production tubing to reduce
the hydrostatic pressure of the fluid column. The resulting reduction in bottomhole
pressure allows the reservoir liquids to enter the wellbore at a higher flow rate. The
injection gas is typically conveyed down the tubing-casing annulus and enters the
production train through a series of gas-lift valves. The gas-lift valve position,
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TRAINING REPORT 57
operating pressures and gas injection rate are determined by specific well
conditions.
As the name denotes, gas is injected in the tubing to reduce the weight of the
hydrostatic column, thus reducing the back pressure and allowing the reservoir
pressure to push the mixture of produce fluids and gas up to the surface. The gas lift
can be deployed in a wide range of well conditions (up to 30,000 bpd and down to
15,000 ft). They handle abrasive elements and sand very well, and the cost of work
over is minimum. The gas lifted wells are equipped with side pocket mandrel and gas
lift injection valves. This arrangement allows a deeper gas injection in the tubing.
The gas lift system has some disadvantages. There has to be a source of gas, some
flow assurance problems such as hydrates can be triggered by the gas lift.
FIELD SPECIFICATIONS:
❖ Well visited = Motera well (M#7, 8, 9, 28, 30) – ONGC, Ahmedabad Asset
PCP:
Progressing Cavity Pumps, PCP, are also widely applied in the oil industry. The PCP
consists of a stator and a rotor. The rotor is rotated using either a top side motor or
a bottomhole motor. The rotation created sequential cavities and the produced
fluids are pushed to surface. The PCP is a flexible system with a wide range of
applications in terms of rate (up to 5,000 bpd and 6,000 ft). They offer outstanding
resistance to abrasives and solids but they are restricted to setting depths and
temperatures. Some components of the produced fluids like aromatics can also
deteriorate the stator’s elastomer.
ROD PUMPS:
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TRAINING REPORT 59
Rod Pumps are long slender cylinders with both fixed and moveable elements inside.
The pump is designed to be inserted inside the tubing of a well and its main purpose
is to gather fluids from beneath it and lift them to the surface. The most important
components are: the barrel, valves (travelling and fixed) and the piston. It also has
another 18 to 30 components which are called "fittings".
Every part of the pump is important for its correct operation. The most commonly
used parts are described below:
▪ Barrel: The barrel is a long cylinder, which can be from 10 to 36 feet long,
with a diameter of 1.25 inches (32 mm) to 3.75 inches (95 mm). After
experience with several materials for its construction, the API (American
Petroleum Institute) standardized the use of two materials or compositions for
this part: carbon steel and brass, both with an inside coating of chrome. The
advantage of brass against the harder carbon steel is its 100% resistance to
corrosion.
▪ Valves: The valves have two components - the seat and the ball - which create
a complete seal when closed. The most commonly used seats are made of
carbon nitride and the ball is often made of silicon nitride. In the past, balls
of iron, ceramic and titanium were used. Titanium balls are still being used
but only where crude oil is extremely dense and/or the quantity of fluid to be
lifted is large. The most common configuration of a rod pump requires two
valves, called the travelling valve and the fixed (or static or standing) valve.
▪ Piston rod: This is a rod that connects the piston with the outside of the
pump. Its main purpose is to transfer the up/down reciprocating energy
produced by the "Nodding Donkey" (pumping unit) installed above ground.
▪ Fittings: The rest of the parts of the pump are called fittings and are,
basically, small pieces designed to keep everything hold together in the right
place. Most of these parts are designed to let the fluids pass uninterrupted.
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▪ Filter: The job of the filter, as guessed, is to stop big parts of rock, rubber or
any other garbage that might be loose in the well from being sucked into the
pump. There are several types of filters, with the most common being an iron
cylinder with enough holes in it to permit the entrance of the amount of fluid
the pump needs.
(SRP) The rod pump is the most common artificial-lift system used in land-based
operations. The relatively simple downhole components and the ease of servicing
surface power facilities render the rod pump a reliable artificial-lift system for a
wide range of applications.
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FIELD SPECIFICATIONS:
Field visited: Motera well (M#7, 8, 9, 28, 30) – ONGC, Ahmedabad Asset
SRP Specifications:
▪ Make : Russian