UNIVERSITY OF DAR ES SALAAM

COLLEGE OF ENGINEERING AND TECHNOLOGY (CoET)

DEPARTMENT OF CHEMICAL AND MINING ENGINEERING

PRACTICAL TRAINING REPORT.

(PT1)

2019/2020.

NAME: JOHN, BONIPHACE ARIYO.

REG. NUMBER: 2019-04-02928.

DEGREE PROGRAM: BSc. In PETROLEUM ENGINEERING.

YEAR OF STUDY: FIRST YEAR

COMPANY NAME: TANZANIA PETROLEUM DEVELOPMENT CORPORATION

(TPDC), GAS COMPANY (TANZANIA) LIMITED (GASCO).

TRAINING SUPERVISOR: MATHIAS ALEXANDER.

ACADEMIC SUPERVISOR: R. MINJA.

PT PERIOD: SIX (6) WEEKS.

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ACKNOWLEDGEMENT

Firstly, I would like to give my sincerely thanks to Almighty God for being with me all the time.
I also take this opportunity to express a deep sense of gratitude to Madimba Gas Company
Limited (GASCO) for their cordial support, valuable information and guidance which enabled
me in completing my practical training for six weeks.

I also to express my profound gratitude and deep regards to the assistance and co-operation from
Eng. Sultan Pwaga and Eng. Leonce Mrosso (Plant Managers), Eng. Daud Ngole, Eng. Said
Soud and Eng. Mathias Alexander (Shift Supervisors), Eng. Noel Nassar, Eng. Dominician
Muyuki, Eng. Rhobi Matiku, Eng. Alex Masumba, Eng. Felix Nanguka and all Headquarter and
GASCO technical staff for their exemplary guidance, monitoring and constant encouragement
throughout the course of this practical training.

My sincere thanks will also go to the University of Dar es Salaam through the College of
Engineering and Technology (CoET), Department of Chemicals and Mining Engineering for
giving a reasonable support and assistance. Great thanks to Mr. R. Minja from Department of
CME for his visitation, supervision, advice and encouragement.

Higher Education Students Loans Board of Tanzania (HESLB) was also very helpful for their
financial assistance to make me accomplish the training practical.

I am obliged to all staff members starting from camp area to the plant area for their big support
and help they showed to me that led to my accomplishment of my practical training at their
company.

My sincere thanks to my family and my fellow students, Ako Emanuel, Prisca Kasiaka, Manase
Lukundo and Catherine Assenga from UDSM, Juma and Dickson Melickiad from UDOM,
Robson, from MUST and all intern students who were my teammates on the training for their
support during my practical training.

DEDICATION.

This report is dedicated to the college of engineering and technology (CoET)

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ABSTRACT
GASCO (Gas Company (Tanzania) Limited) is a gas company under TPDC (Tanzania
Petroleum Development Cooperation) which deals with processing and transportation as well as
distribution of natural gas. This report covers my experience of six weeks of practical training at
Madimba Natural Gas Processing Plant in Mtwara region.

This report is divided into four main parts, the first part is the weekly reports part includes
weekly summary of daily activities which were conducted at Madimba Natural Gas Processing
Plant with engineering drawings for each week, second part is the main report with explanation
and description of the gas processing at Madimba Natural Gas Processing Plant and safety
measures taken in the company , the third part consists of description of single major equipment
which is Condensate Flash drum and the last part is the conclusion and recommendation.

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. Table of Contents .
ACKNOWLEDGEMENT ........................................................................................................... i

DEDICATION…………………………………………………….………………………………………………….i

ABSTRACT .............................................................................................................................. ii

LIST OF ABBREVIATIONS ………………………………………….…………………………v

LIST OF FIGURES : ................................................................................................................ vi

CHAPTER 1: INTRODUCTION TO THE COMPANY TANZANIA PETROLEUM

DEVELOPMENT CORPORATION (TPDC) .............................................................................1

1.1 Historical background of TPDC and GASCO ....................................................................1

1.1.1 Vision .........................................................................................................................1

1.1.2 Mission .......................................................................................................................1

1.1.3 Objectives ...................................................................................................................2

1.1.4 Roles ..........................................................................................................................2

1.2 The Organization Structure of Madimba Gas Plant ................................................................3

CHAPTER 2: THE PROCESS DESCRIPTION ..........................................................................4

2.1 THE PROCESS OF MADIMBA NATURAL GAS PROCESSING PLANT .....................4

MAIN NATURAL GAS PROCESSING FACILITIES SYSTEM .................................5

2.1.1 Reception Facility .......................................................................................................5

2.1.2 Dehydration and Dehydrocarbon unit..........................................................................6

2.2.3 MEG Recovery System……………….……………………………….……………………………………..……..7

2.1.4 Condensate Stabilization Unit. ....................................................................................8

2.2 THE AUXILLIARY FACILITIES SYSTEM ....................................................................9

2.2.1 Flare and venting system.............................................................................................9

2.2.2 Air and Nitrogen system ........................................................................................... 11

2.2.3 Fire fighting system .................................................................................................. 11

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 2.2.4 Fresh Water supply and Raw Water Treatment ......................................................... 12

2.2.5 Waste Water Treatment unit ..................................................................................... 13

CHAPTER 3: MAJOR EQUIPMENT: CONDENSATE FLASH DRUM.................................. 15

3.1 Introduction. .................................................................................................................... 15

3.2Function of the equipment: ........................................................................................... 15

3.3Description of the equipment ........................................................................................ 18

3.4Reason for Maintanance ............................................................................................... 18

3.5 The sequence in faults Diagnosis………………………...……………………...…...…19

3.6 Sequence in shutdown and checkups of the equipment……………………………………………....19

3.7 Repairing of the replacement parts of the equipment…………..………………………………………19

3.8 Testing/Commissioning of the maintenance………….…………………………………………………….20

CHAPTER 4: CONCLUSION AND RECOMMENDATION ............................................... 21

4.1 CONCLUSION ........................................................................................................... 21

4.2 RECOMMENDATION ............................................................................................... 21

REFERENCES ......................................................................................................................... 22

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LIST OF ABBREVIATIONS

BOD- Biological Oxygen Demand

CCR- Central Control Room
COD- Chemical Oxygen Demand
DD- Dehydration Dehydrocarbon
HP- High Pressure
KO Drum- Knock Out Drum
LTS- Low Temperature Separator
LCV- Level Control Valve
MB- Madimba
MS-Msimbati
MEG- Mono Ethyl Glycol
MMSCF/D- million Standard Cubic Feet per Day
PH- Hydrogen Potential
PCV- Pressure Control Valve
RO- Reverse Osmosis
RVD- Reid Vapor Pressure
PSV- Pressure Safety Valve
TCF- Trillion Cubic Feet
TPDC- Tanzania Petroleum Development Corporation.

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LIST OF FIGURES

Figure 1: A picture of Madimba Natural Gas Processing Plant………………………….……....1

Figure 2: Organization structure of Madimba Gas Processing Plant…………………….……….3
Figure 3: Gas process flow diagram at Madimba Gas Processing Plant ………….………..…....5
Figure 4: Process Flow Diagram Of The Reception Unit……………………………..………….6
Figure 5: Process flow diagram for Dehydration and Dehydrocarbon unit……………………....7
Figure 6: Process flow diagram of MEG in the MEG Recovery system………………………....8
Figure 7: Process flow of Condensate stabilization unit……………………………..……………9
Figure 8: Process flow diagram of flare system………………………………………….……....10
Figure 9: A real picture of flare system………………………………...………………………..10
Figure 10: A real picture of air and Nitrogen system……..……………………………………..11
Figure 11: A real picture of firefighting system……………………………..………………….12
Figure 12: A real picture of tanks of Raw water treatment and the RO system rooms………….13
Figure 13: A picture of Waste Water Treatment unit………………………………………...….14
Figure 14: Picture showing HSE induction on rescue in case of emergence…………………….15
Figure 15: A figure showing flows in the condensate flash drum……………………………….17
Figure 16: A real picture of Condensate Flash Drum at Madimba ………………………….…18

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CHAPTER 1: INTRODUCTION OF THE COMPANY
Madimba Gas Processing Plant is under Tanzania Petroleum Development Corporation
(TPDC) a subsidiary company which is Gas Company (Tanzania) Limited (GASCO). The
plant is located at Madimba village Mtwara Rural 23.4km from Mtwara town.

Figure 1. A picture of Madimba Natural Gas Processing Plant.

1.1 Historical background of TPDC AND GASCO

Tanzania Petroleum Development Corporation (TPDC) is the National Oil Company of

Tanzania through which the Ministry of Energy implements its petroleum exploration and
development policies. TPDC has a manpower strength of about 400 and is organized into six
(6) directorates and four (4) Units, namely: Directorate of Exploration Development and
Production, Directorate of Oil and Gas Business, Directorate of Planning and Investment,
Directorate of Finance and Administration, Directorate of Legal Services, Directorate of
Internal Audit, ICT and Statistics Unit, Procurement Management Unit, Public Relations and
Communication Unit and Risk Management Unit. TPDC was established through the
Government NoticeNo.140 of 30th May 1969 under the Public Corporations Act No.17 of
1969. The Corporation began operations in 1973. TPDC is a wholly owned Government
parastatal, with all its shares held by the Treasurer Registrar.

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 1.1.1. Vision

To become a leading integrated National Oil and Gas Company competing nationally,
regionally and globally in an environmentally responsible manner to the benefit of all
stakeholders.

1.1.2. Mission

To participate and engage in the exploration, development, production and distribution of oil
and gas and related services; facilitate a fair-trading environment; safeguard the national
supply of petroleum products; at the same time developing quality and safety standards to
protect people, property and the environment.

1.1.3. Objectives

The objectives of the Corporation as laid down in the TPDC establishment order:

 To explore and produce petroleum

 To carry out standard activities of an oil company including, distribution and storage
facilities
 To hold exploration and production rights
 To contract, hold equity or participate in oil concessions, franchises and licenses
 To manage parastatals or other legal entities transferred to the corporation
 To develop an adequate industrial base for the oil industry

1.1.4. Roles of TPDC

The roles of TPDC as defined by the July 2006 announcement by the Government are:

 To promote and monitor the exploration for oil and gas

 To develop and produce oil and gas
 To conduct research and development of the oil and gas industry in the country
 To manage the exploration and production data
 To advise the Government on petroleum related issues
 To market and sell natural gas under PSA arrangement
 To undertake the management of strategic fuel reserves and
 To undertake trading in petroleum produc

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1.2. THE ORGANIZATION STRUCTURE OF MADIMBA GAS PROCESSING
PLANT.

Figure 2. A figure showing the organization structure of Madimba Gas Processing Plant.

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CHAPTER 2: THE PROCESSDESCRIPTION

2.1 THE PROCESS OF MADIMBA NATURAL GAS PROCESSING PLANT.

Natural gas is found in the underground reservoir which was allowed to accumulate to form
potential reserves. It is allowed to flow to the surface through production well. Natural gas
produced from these wells is normally a complex mixture of many different compounds. A
typical gas stream is a high velocity, turbulent, constantly expanding mixture of gases and
hydrocarbon liquids mixed with water vapor, free water and solid particles. The well streams
should be processed as soon as possible after bringing it to the surface.

Madimba Gas Processing Plant facility has gas processing capacity of 210MMSCF/day with
three trains each with a capacity of 70MMSCF/day, maximum condensate production
being44barrels/day. The gas is produced from five wells which are MB#1, MB#2, MB#3,
MB#4 and MS-1X. The gathering is at MB#3

The Natural Gas Processing Plant of Madimba consists of two systems which are: -

1. Main Natural Gas Processing facilities system.

2. Auxiliary facilities systems.

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MAIN NATURAL GAS PROCESSING FACILITIES SYSTEM.

Figure 3: Gas Process Flow diagram at Madimba Gas Processing Plant.

Main Natural Gas Processing facilities systemconsists of the following units: -

2.1.1 RECEPTION UNITY.

The natural gas from the gathering station is received in the reception unit of the plant. The
facilities in the unit consist of two High Pressure (HP) separators and one low pressure three
phase separator. Raw gas is firstly separated in HP separator to streams of gas and liquids
where gas goes to dehydration and dehydrocarbon unit while the liquid goes to the three-
phase separator. The three-phase separator separates the liquid into three streams of
condensate, waste water and flash gases. The condensate stream goes to condensate

5
stabilization unit, waste water goes to waste water treatment unit and flash gases goes to flare
system.

Figure 4: Process flow diagram of reception unit

The feed gas by passes the pig receiver which is utilized during pigging of the pipeline. PIG
stands for pipeline inspection gauge or pipeline intelligence gauge. The two high pressure
separators operate in substitution. They have a design pressure of 140 bar, operating at 94-
108bar, design temperature range -10⁰C – 60⁰C, they have handling capacity of 210mmscfd
design value, operating at 80-140mmscfd. HP separators are equipped with safety valves with
constant pressure of 140bars, in case of fire.

Three phase separator helps liquor separation by restricting incoming material flowing in
axial direction leading to liquor to collect at the bottom of the container. It is equipped with
weir plate to separate water and condensate oil and mist catcher to remove residual liquid
drops in flash gases. It is equipped with safety valve with setting value of 10barg, to be used
under over pressure conditions.

2.1.2 DEHYDRATION AND DEHYDROCARBON UNIT.

After the reception facilities the gas still contains finite amount of water vapor. Through the
dehydration and dehydrocarbon unit, the water and heavy hydrocarbons are removed from
the gas stream through lowering the temperature of the gas to meet the maximum
hydrocarbon and water dew points (-12⁰C and -30⁰C respectively). If the gas pressure is high

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i.e. 108 bar the J-T valve will be used to cool the gas to the required dew point, unless
otherwise both J-T valve and Propane refrigeration are used. To prevent hydrate formation
MEG (Mono Ethylene Glycol) is injected in the raw gas in second pre-cooler and before J-T
valve in order to trap the water which will be mixed with gas. The mixture of the gas and rich
MEG is separated in the Low temperature separator (LTS). The gas out of the LTS has a
temperature of around -30⁰C; it is first used to cool the incoming raw gas in the second and
first pre-coolers to export and metering, while the rich MEG out of LTS goes to MEG
recovery system for regeneration.

Figure 5: Process flow diagram of dehydration and dehydrocarbon unit

2.1.3. MEG RECOVERY SYSTEM.

The cold rich MEG out of LTS and second pre-cooler of the DD unit passes through the
lean/rich MEG heat exchanger, rising its temperature before heading to the re-boiler. The rich
pre-heated MEG then goes to three phase separator in which it is flashed to recover any
trapped hydrocarbons. The recovered gas out of three phase separator is sent to flare system,
condensate sent to condensate stabilization unit, while the MEG passes through the filters to
remove any solid particles then to the re-boiler. The three filters are pre-mechanical filter,
activated carbon filter and post-mechanical filter. It is boiled to temperature around 120⁰C
through MEG regeneration column and re-boiler which makes all the water in it to evaporate
and leave behind the lean MEG. The hot lean MEG from the re-boiler is then cooled by the

7
cold rich MEG in the lean/rich MEG heat exchanger before being pumped back to the
injection points by MEG injection pump in the DD unit.

Figure 6: Process flow diagram of MEG in the MEG Recovery system.

2.1.4. CONDENSATE STABILIZATION UNIT.

The raw condensate from the three phase separators of the reception, waste water treatment
facility and MEG regeneration units are both directed to condensate stabilization unit, where
it passes through the electric heaters where it is heated to about 60⁰C to 80⁰C. The condensate
is stabilized by flashing light components in the flash drum with design pressure of 10bar,
operating pressure of 0.4bar.Where the gas are sent to low pressure flare, water to water
treatment facilities and condensate passing through the cooling fin cooled to 50⁰C. The
stabilized condensate having RVP of less than 10psia at 37.8⁰C is pumped by stabilized
condensate export pump to condensate storage and loading unit.

The unit consists of two condensate tanks with the volume of 1000m3 each, inner floating
tank; composite silicate is used for wall insulation, and thickness is 100mm; vent hole with
flame arrester, and two condensate export pumps; one in work and the other standby. The
condensate storage tanks are equipped with liquid level gauge and transmitter, liquid level
can be observed locally and display in CCR.

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 Figure 7: Process flow diagram of condensate stabilization unit

2.2. AUXILIARY FACILITIES SYSTEMS.

2.2.1 Flare system.

This system is a set of auxiliary production facility that ensures safety in process. It gathers
and discharge flammable gas and liquid during start up, shut down and emergency incidents.
The gas is ignited safely after flowing through the knock out drum, molecular seal and flare
drum. It is divided into high pressure and low-pressure system

Liquid drops bigger than 300µm are separated from the stream in the knock out drum, this is
to prevent fire rain that is a falling droplets of burning liquid. The gas is allowed to the flare
tower from the bottom and burned by the torch head.

Madimba processing plant is equipped with High pressure flare and Low-pressure flare. High
pressure flare system is composed of H.PK.O Drum, K.O Drum Pump and HP flare. HP K.O
drum has design pressure of 7.8 bar, operating at 6 bar, design temperature of -30⁰C. Low
pressure flare and vent system is composed of LP.KO Drum and LP flare.

flash gas from both HP.K.O drum and LP.K.O drum, leaving the condensate and go to flare.
The condensate from the drums is carried by K.O Drum pump to condensate stabilization
unit.

9
 Figure 1: Process flow diagram of flare system

Figure 2: Real picture of the flare system

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2.2.2 Air and Nitrogen system
Plant air, instrument air and nitrogen are the producedin this unit. The air that is
manufactured in this unit is supplied in areas where there could be a deficiency in oxygen
when personnel are doing maintenance activities; also, there are instruments which needs
instrument air for their operation example Shutdown valves which are pneumatic valves.
Nitrogen is an inert air hence used in blanketing flammable liquids, purging and cleaning in
pipelines to create an inert environment.

Air is first compressed into buffer tanks, filtered by two mechanical filters then into air dryer
which dry the air by adsorption, then sent to storage while some is used to regenerate the
other dryer. The dry air splits to plant air, instrument air, and nitrogen generation skid.

Figure 10: Real picture of the Air and Nitrogen system

2.2.3 Firefighting system

The fire-fighting system is employed for protecting personnel and equipment when on fire or
explosion. Enough fire-fighting extinguishers are provided at appropriate places to eliminate
fire risks.

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The fire-fighting system includes firewater pumps, fire water storage tank, foam
extinguishing unit, proportioned, foam concentrate storage tank, diesel storage tank, fire
water system, fire hydrant, and portable fire extinguishers.

The fire water storage tank collects water from the raw water system and the fresh-water
maker system. The set point of the liquid level is 80%, and the fire water pump and jockey
pump can keep the pressure of the fire water spray system as 11.5bar.

The Balanced Pressure Pump Type Proportioning System is extremely applied in low-,
medium-, and high-expansion foam extinguishing system. It can mix water and foam
concentrate as steady proportion within wide flow and pressure range.

Figure 11: Real picture of the fire fighting system

2.2.4 Fresh Water supply and Raw Water Treatment

Gas plant has water source well system in order to supply water for fresh water maker skid
and firefighting system. This system includes three water source wells equipped with deep
well pump, three sets of cyclone de-sander and other water from well storage tank in camp.

Madimba gas processing plant includes two raw water tanks, two raw water pumps, one
desalinated water tank, two fresh water pumps, and two RO (Reverse Osmosis) treatment
devices. Fresh water is provided for process system and living area.

Water from water source well flow into raw water tanks, when tanks level reaches 60%-80%,
raw water pumps start and pump water to RO treatment device.

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There are two sets of RO devices, one in use and one standby. Each RO device is equipped
with four cartridge filters, 5 sets of chemicals injection devices, one filter, three groups of
osmotic membranes, and six pumps. Raw water inlet flowrate is 18.2m3/h, and fresh water
flowrate is 10m3/h.

Figure 12: Real picture of tanks of Raw Water Treatment and the Reverse Osmosis
systemrooms.

2.2.5 Waste Water Treatment unit

The waste water, oils and sewage wastes are treated before being disposed in the ocean after
making sure that they meet the chemical oxygen demand (COD) of less than 65 and
biological oxygen demand less than 35, and PH specifications

In the plant that mainly dealt with treatment of waste water from drainage systems, the waste
oily waters after acid-caustic mixture. The package has four units; oily water treatment unit,
deep treatment unit, discharge pump, and sludge dehydration equipment unit. After that the
waste water is treated by ozonation process then deposited in the ocean.

13
 Figure 13: A picture of Waste Water Treatment unit

2.3. SAFETY MEASURES

The natural gas processing plants involve high risk activities including processing of highly
flammable and exclusive material, accident consequences could be catastrophic in term of
number of casualties, environment pollution, lost of investment and reputation damage. This
is why safety measures are required to be conducted.

2.3.1. HSE (Health, Safety and Environment)

This is the management that is responsible for planning, implementing, monitoring and
optimizing operational processes in the areas o environmental management, health protection
and occupational safety. Safety measures taken at Madimba gas processing plant to ensure
safety of people are being handled by HSE (Health, Safety and Environment)

2.3.2. ROLES OF HSE

a. Protect the health and safety of workers.

b. Decrease accident risks, theft and damage.
14
 c. Decrease the risk of environmental damage.
d. Gain recommendations for future safety maintenance.

2.3.3. SAFETY MEASURES TAKEN BY HSE AT MADIMBA GAS PROCESSING

PLANT.

So, all of the above are ensured by conducting the following safety measure at the gas
processing plant:

 Performing safety induction before anyone gets into any part of the plant.

Figure 14. A picture showing HSE induction on rescue in case of emergency

 Identifying of various hazards in different parts of the plant to keep reminding

workers and even the visitors which include:
i. Explosive gas
ii. Nitrogen gas
iii. Confined space
iv. Electricity
v. Noise
vi. Chemical exposure
vii. Condensate.
viii. Sunlight.
 Presence of flaring and venting system.
 Ensuring that all workers are provided with personal protective equipment to reduce
the chance of risk and also in case of new work, they must have a work permit before
it is performed.
 Presence of firefighting system to fight fire in case it happens.

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CHAPTER 3. MAJOR EQUIPMENT: CONDENSATE FLASH DRUM

3.1. Introduction

In natural gas processing plant raw gas is processed to remove the unwanted components
associated with the gas from production wells, components include waste water, heavier
hydrocarbons, sulphur and others. At Madimba Natural Gas Processing Plant heavier
hydrocarbons are also products obtained from raw gas, it is obtained from three phase
separator of reception unit and of all three dehydration and de-hydrocarbon units, the
condensate obtained from separation does not meet the required specification and thus needs
to be stabilized to meet the required specifications. Stabilization of condensate is done in the
equipment known as condensate stabilization unit where condensate flash drum is among of
the components of the unit.

3.2. Function of the equipment.

Condensate flash drum is mainly used to separates stabilized condensate from waste water
and flash gases which vaporize from the heated waste condensate.

3.3. Description of the equipment.

The condensate flash drum is the horizontal three phase separator included in the condensate
stabilization units. Its designing pressure is 10bar and operation pressure is 0.4bar. The inlet
of the drum is the unstabilized condensate from gas processing units including three phase
separator of the reception unit, from waste water treatment units, pre-coolers of the DD unit
and from three phase separator of MEG recovery system. Before inlet waste condensate is
heated to around 60-80°C to attain the vaporization of lower Hydrocarbons including C1-C4
and the temperature in the heaters is controlled by Temperature Control Valve in order not to
vaporize the required stable condensate which are C5 and higher Hydrocarbons. The
separation principle in the condensate flash drum is by Gravity.

16
Hot waste condensate

Figure 15. A figure showing flows in the condensate flash drum

The drum consists of the following parts:

 Inlet. The heated unstabilized condensate enters the stabilizer drum through inlet. It
consist of inlet diverter that directs the liquid inlets below the mixtures in the bottom
of vessel and after some retention time flash gas evolves to the upper part, free waste
water to the bottom and the stabilized condensate to the middle part. Inlet diverter
ensures that little gas is carried with the liquid.
 Interface Level Controller and weir. A level controller maintains the level of free
water and weir maintains the condensate level, they all ensure that no carryover of
one phase to the other phase streams.
 Outlets. There are three outlets from the condensate stabilization drum which are flash
gas outlet at the top, water outlet at the bottom and the stabilized condensate outlet at
the other side bottom of the stabilizer drum.

Stabilized condensate obtained from the drum is still hot and during pumping of the
condensate should be cooled by electric fans to beforebeing stored to storage tanks. The flash
gas goes to flare system and water goes to waste water treatment unit.

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Figure 16. A real picture of a Condensate Flash Drum

3.4. Reason for maintenance

Stabilized condensate specifications that are acceptable is the Reid Vapor Pressure (RVP)
below 66.7kPa or 10psi at 37.8°C and the relative density below 8.5. Laboratory analysis of
condensate sample drawn from the storage tanks show that the water contents in the
condensate is high and hence the density become more than the expected causing the
condensate to be not suitable one hence the drum must be maintained to ensure the
production of stable condensate. The problems include corrosion, Pressure build up in the
drum and water carryover to the condensate streams.

3.5. The sequence in faults diagnosis.

Faults in the condensate stabilization drum are primarily determined by studying up and
observation of the following: -

 The pressure build up in the drum indicates that the pressure safety valve set point is
higher than the required.

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  Color inspection of the condensate. When the colour of the condensate changes to
blackish indicates that drum is dirty and therefore needs to be cleaned.
 High water contents in the condensate storage tank indicates that water level
controller has defaults in detecting the level of water in the drum hence cause water
carryover by the condensate.

3.6. Sequence in shutdown and checkups of the equipment.

To prevent problems into the system of condensate stabilization resulted from the defaults in
the flash drum; it has to be cleaned at least after 6 months using caustic soda and portable
water
The activity takes place while the condensate stabilization unit is isolated from the operation,
and the activity continued with the use of standard operating procedures (SOP’s ) review
followed by Job safety analysis and permit to work being filled and it’s important to make
sure that all liquids in the flash drum has been drained to waste water treatment unit.

3.7. Repairing/ordering of replacement parts.

Repairing of the condensate fash drum is done through the following steps:-
i. Equipment isolation from the operation.
ii. Depressurization of the flash drum.
iii. Drainage of the liquids from the drum
iv. Cleaning and maintenance of the drum
v. Restoring of the system into operation mode for testing

i. Equipment isolation from the operation.

The isolation of the condensate flush drum is done by putting down of the electric heater that
heats waste condensate before entering the flash drum and then closing of the inlet valve to
ensure safety of the working environment.
ii. Depressurization of the flash drum.
Since the working pressure of the flash drum is 0.4bag, the depressurization of the drum is
done to prevent any possible cause of the fire outbreak in the drum
iii. Drainage of the liquids from the drum
The liquids inside the condensate flash drum are drained to the liquids outlet streams which
include pumping of the remaining condensate to the condensate storage tanks and draining of

19
waste oily water to the waste water treatment unit. The drum must be empty to ensure safety
when repairing and checking the drum.
iv. Cleaning and maintenance of the drum.
Cleaning of the condensate flash drum is done using caustic soda which is used in pipes
cleaning and the removal of buildup of condensates, caustic soda (NaOH) converts clotting
oils on the walls of the drum into soap which is then dissolve in water when water is
introduced into the flush drum for cleanness.
The other maintenance includes checking of the level controllers of the water and
condensates in the drum to ensure accuracy in separation and calibration of the pressure
safety valve (PSV) set point to maintain operation pressure of the drum which is 0.4bar even
when there is a pressure buildup in the drum for the safety of the drum.
v. Restoring of the system into operation mode ready for testing.
After maintenance is done, the system is restored to the normal operation mode by re-
installation of the unstalled parts of the drum and closing of all the outlets.

3.8. Testing/commissioning of the maintenance.

Testing of the equipment is done as follows:-
 Fill the drum with fresh water.
 Checks for leakage.
 Drain all fresh water from the system after leakage test and close outlets.

 Restore the removed insulation materials.

 Conduct housekeeping.
 Turn on the electric heater then monitor temperature of the waste condensate from
the electric heater to obtain the temperature of about 60°C -80°C which is the required
for condensate stabilization.
 Open the inlet.
 Run the unit for at least 2 days while examining the parameters of the stabilized
condensate which are RVP and the density.
 Write the report of the whole operation and hand it to the office.

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CHAPTER 4: CONCLUSION AND RECOMMENDATION.

4.1. CONCLUSION.
This final report is the result of the practical training at Madimba gas processing plant, the
gas sector up to now contributes to above 50% of the electricity production in Tanzania. It is
important to train the experts and increasing the capitals to the sector to ensure a great
contribution of the gas sector to the development of the country’s economy.

4.2. RECOMMENDATION.

In order to ensure efficiency stabilization of the condensate obtained from the gas process in
the plant, the condensate stabilization unit should be improved to obtain the condensate that
meets the requirement of the market since it is the one of the source for the income.

Ensuring regular checkup of the condensate stabilization unitequipments and troubleshooting

problems where necessary. This will help in maintaining efficient stabilization of the
condenate. Also there should be regular local and remote checkup of operating conditions
(temperature and pressure, levels) and flow rates as in all separators werethe waste
condensate is obtained from the gas process units to ensure that the stabilization is met easily.

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REFERENCES
Kidnay, A. J., & Parrish, W. R. (2006). Fundamentals of Natual Gas Processing. London:
Taylor and Francis .

Mkombwa, K. (2013). Madimba And Songosongo Natural Gas Plants. TPDC.

TPDC. (2014). About Us: TPDC. Retrieved November 2020, from tpdc website:
www.tpdc.tz.go.tz

TPDC. (2014). operation manual of the Madimba and Songosongo Gas Processing Plant.
Dar es salaam: Tanzania Petroleum Development Corporation.

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