PROCESS DESCRIPTION Document No.

6558-02-41-PD-01
Rev. No. 0
Page 1 of 6

PROCESS DESCRIPTION
FOR
REVAMP OF GGS-I AT RUDRASAGAR
ONGCL, ASSAM ASSET

0 06.04.2005 ISSUED FOR PROCESS PACKAGE

Rev no Date Purpose Prepared by Reviewed by Approved by

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 PROCESS DESCRIPTION Document No.
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MANIFOLDS
Well fluids from wells are received at the GGS in separate headers depending upon the
pressure available of the well fluid. Three headers namely MP, LP & Test are provided
for the purpose. These headers are connected to the respective production separators
i.e. MP header is connected to MP Separator, LP header is connected to the LP
Separator and Test header is connected to the Test Separator respectively. The Test
Separator is designed to handle both MP as well as LP well fluids.

In order to take care of any contingency, a spare header has also been provided which
is in turn connected to the MP, LP & Test headers respectively. All the headers are
designed for the same size and pressure to have flexibility in operation.

One Gas lift header coming from GCP B/L to GGS-I are also provided to meet the gas
lift requirement of GGS-I field.

Test Separator
One test separator has been provided for testing wells.

Test separator operates at either 7.0 – 3.5 Kg/cm2 g depending on wells being tested.
Test Separator normally operates at 7.0 Kg/ cm2g for testing of MP Wells where as it
operates at 3.5 for testing of LP Wells. Well fluid is heated in the water bath heater to
approximately 60 C before routing to test separator. Facilities for dosing of PPD and
Demulsifier have been provided. Separation gas is routed to either MP separator KOD or
LP separator KOD depending on the type of well being tested. Separated liquid is routed
to LP separator under level control when MP Wells are tested. When LP Wells are
tested, separated liquid is routed to intermediate transfer vessel. Alternatively, separated
liquid may be routed to existing Crude oil storage tanks (SR-1a & SR-1b), dedicated for
the purpose. Flow measurement has been provided for separated gas from the test
separator. Water cut meter has been provided on liquid outlet to measure the flows of
liquid and its water content.

During LP Well testing, LP liquid from the test separator shall be routed to intermediate
transfer vessel (01-VV-107) from where it will be transferred to the LP Separator through
Sampling liquid transfer pumps (01-PA-102 A/B). A sampling vessel (01-VV-106) has
also been provided for drawing representative samples during testing. The fluid from the

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sampling vessel is transferred to Intermediate transfer vessel (01-VV-107) by gravity
transfer.

Production Separators
Two production separators viz. MP Separator/ LP Separator have been provided for
processing MP and LP well fluids.

The MP well fluid, before being routed to MP Separator (01-VV-101 A/B) is heated upto
60 Deg C, first in MP well fluid/ Produced water exchanger (01-EE-101 A/B) and then in
the Water bath heater (01-FF-101 A/B). MP Well fluid/ Produced Water Exchanger have
been provided to recover waste heat from Produced water coming from Heater Treater.

MP separator (01-VV-101 A/B) operates at 6.5 kg/cm2g. Gas separated from the MP
Separator is routed to the MP KOD (01-VV-104 A/B). Liquid separated is routed to LP
Separator under level control. Gas from MP KOD is routed to MP gas header going to
Gas Compression Plant (GCP) at Rudrasagar under pressure control. Liquid from MP
separator KOD is also routed LP separator along with MP liquid outlet from MP
Separator under level control. Normally no liquid is envisaged in the KOD. Flow
measurement facilities have been provided to measure the gas & liquid from MP
separator.

The LP well fluid, before being routed to LP Separator (01-VV-102 A/B) is heated up to
60 Deg C, first in LP well fluid/ Crude Oil exchanger (01-EE-102 A/B/C/D) and then in
the Water bath heater (01-FF-101 A/B). LP Well fluid/ Crude Oil Exchanger have been
provided to recover waste heat from Crude Oil coming from Heater Treater.

LP separator (01-VV-102 A/B) operates at 3 kg/cm2g. Gas separated from the LP

Separator is routed to the LP KOD (01-VV-105 A/B). The liquid separated from the LP
Separator is routed to Heater treater (01-FF-102 A/B/C) under level control. The gas
from the LP KOD (01-VV-105 A/B) is routed to LP gas compressor located at GCP.
Liquid from the LP KOD (01-VV-105 A/B) is routed LP liquid header under level control
from which is further fed to the Heater Treater (01-FF-102 A/B/C). Normally no liquid is
envisaged in the KOD. Flow measurement has been provided to measure the flows of
liquid and gas from LP Separator.

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Water Bath Heater

LP & MP well fluid is heated in Water Bath Heater (01-FF-101 A/B) up to 60-65 Deg C.
Fuel gas is used as the fuel in the bath heater. Service water (after softening) will be
used as a make - up water to the water bath heater. Within the water bath heater a small
water bath heater circulation pump (01-PA-104 A/B) is envisaged for circulation of the
hot water within the water bath heater. Demulsifier and PPD chemicals are dosed to the
heated fluids before going to respective Separators.

Heater Treater
LP liquid from LP Separator (01-VV-102 A/B) is sent to heater treater for removal of
mud/ sand and water from crude oil to desired level. Strong electric field is applied in
heater treater to break the oil water emulsion and achieve desired phase separation.
Fuel gas is used as the fuel in the heater treater. Demulsifier and PPD chemicals are
also dosed to the liquid before entering in to the heater treater. Crude oil from heater
treater is cooled in LP well fluid/ Crude Oil exchanger (01-EE-102 A/B/C/D) and
subsequently routed to the existing as well as new Crude oil storage tanks (SR-1a, 1b &
SR-3a, 3b, 3c & 01-TT-101A/B). The produced water from the heater treater is cooled in
MP well fluid/ produced water exchanger (01-EE-101 A/B) before routing to the existing
as well as new Effluent tanks (SR-2a, 2b, 2c & 01-TT-102). Produced water is
subsequently routed to the existing effluent treatment plant through Effluent transfer
pumps (01-PA-109 A/B) for further treatment.

Crude Oil storage tanks

Five nos. of existing crude oil storage tanks (SR-1a, 1b & SR-3a, 3b, 3c) and two nos of
new crude oil/ condensate storage tanks (01-TT-101A/B) are available for storing the
Crude oil. The capacity of existing tanks SR-1a, 1b is 65 m3, SR-3a, 3b, 3c is 400m3 and
01-TT-101 A/B is 500 m3. The crude oil from the tanks is pumped to CTF using Crude
Oil/ Condensate transfer pumps (01-PA-101 A/B). The loading / unloading pumps (01-
PA-108 A/B) are provided to load / unload crude oil/ LP Emulsion respectively.

Treated effluent storage tank and injection facility

Treated effluent shall be received from effluent treatment plant through 4” NB, 7KM
(approx.) long pipeline. Treated effluent received from ETP is stored in a new dedicated
Treated effluent tank (01-TT-102), with the provision for routing to all the three existing
effluent tanks (SR-2a, 2b, 2c). The treated effluent from existing as well as new effluent
tanks is injected to GGS-I well head through Treated water injection pumps (01-PA-110

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A/B). individual injector fingers will have flow measurement facility to measure the flow
rate of treated effluent.

Gas lift facility

Lift gas header of 8” NB size and 7 KM (approx.) long pipeline is coming from GCP B/L
to GGS-I. Lift gas system is provided with Gas lift KOD (01-VV-114). Condensate from
Gas lift KOD is routed to MP Separator. Gas from gas lift KOD is then injected to GGS-I
wells through injector fingers. Also 8” NB dedicated header is provided from GGS-I Gas
lift KOD outlet to GGS-IV. Flow measurement facility is provided on individual injector
fingers and to the header for flow measurement. Ethylene glycol is injected to the gas
coming out from he Gas lift KOD to prevent hydrate formation in the well during winter
season.

Process Utilities, Flare, Blow down & Chemical Dosing Facilities

Plant Air/ Instrument Air
Two reciprocating air compressors (01-KA-101 A/B) are provided to meet the Plant Air/
Instrument Air requirement. Plant Air requirement is envisaged for hose stations only.
Compressed Air from the compressors is routed to the Instrument Air Dryer, where it is
dried in a dual bed Heatless Air Dryer (01-LJ-101). Instrument Air from the dryer is
routed to the Instrument Air Receiver (01-VV-111 A/B). Instrument air from Instrument
Air receiver is routed to instrument air header for distribution. Instrument Air Receiver
has been provided to provide Instrument Air hold up for safe shut down of the plant in
case of Instrument Air failure.

Service water
Raw water available from ground will be used as service water. One no. Service water
tank (01-TT-103) of 50 m3 has been provided for storing service water. Service water
pumps (01-PA-113 A/B) are provided to supply service water to different consumers.
Service water will be used for hose stations and as make up water to water softener.
Water softener is provided to meet the soft water requirement of GGS-I. Soft water will
be used for drinking water, make up water to Water bath heater, Heater treater etc.

Inert Gas
Inert gas requirement for start up/ shut down and purging shall be met from Nitrogen
cylinders. Nitrogen manifold shall be provided for 5 nos. of Nitrogen cylinders.

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Fuel Gas
Fuel gas requirement for GGS-I will be met from LP gas header. Fuel gas requirement of
Heater treater will first be met with the fuel gas generated from Heater treater itself.
Balance fuel gas requirement will be met from fuel gas header. Fuel gas header will be
electrically traced and insulated to prevent liquid condensation.

Flare System
New flare system (Ground Flare) including Flare KOD (01-VV-113) and water seal drum
(01-VV-116) is provided for GGS-I. Hydrocarbon discharges from safety valves and
control valves are received in the flare system and routed to ground flare through Flare
KOD and Water seal drum. Flare KOD Pumps (01-PA-112 A/B) are provide to pumped
out the liquid from Flare KOD. Liquid from Flare KOD is normally routed to Heater
Treater.

Blow down
An underground closed blowdown system with blow down vessel (01-VV-112) is
provided to collect all hydrocarbon liquid drains. CBD pumps (01-PA-111 A/S) are
provided to pump out CBD liquid. Liquid from Flare CBD is normally routed to Heater
Treater or to the existing crude oil storage tanks.

Chemical Dosing System

Demulsifier
Demulsifier dosing vessel (01-VV-109) and dosing pumps are provided to inject
Demulsifier into the well fluid and liquid at the inlet of Heater Treater. Dedicated
demulsifier dosing pump is provided for MP well fluid, LP well fluid & Test fluid and at
Heater treater inlet. For these purpose three nos of Demulsifier injection pumps (01-PA-
105 A/B/C) are provided.
PPD
PPD dosing vessel (01-VV-110) and dosing pumps are provided to inject PPD into the
well fluid and liquid at the inlet of Heater Treater. Dedicated PPD dosing pump is
provided for MP well fluid, LP well fluid & Test fluid and at Heater treater inlet. For these
purpose three nos of Demulsifier injection pumps (01-PA-106 A/B/C) are provided.
Glycol
Glycol dosing vessel (01-VV-115) and Glycol dosing pumps (01-PA-107 A/B) are
provided to inject glycol into the Gas lift header to prevent hydrate formation.

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