TRAINING REPORT

ON
OIL AND NATURAL GAS CORPORATION LIMITED
SURFACE TEAM
AHMEDABAD ASSET

SUBMITTED TO: SUBMITTED BY:

I.C TRAINNING DEPARTMENT AKHILESH KUMAR

OIL AND NATURAL GAS CORPORATION NIT ,JALANDHAR

AVANI BHAVAN, CHANDKHEDA AHMEDABAD PUNJAB-144011

 ACKNOWLEDMENT
Firstly, I would to like Mr. D.SHINA for his great efforts in
arranging our training at Ahmadabad asset surface team
at navagam and kalol.
We would like to express our sincere thanks to
installation manager of GGS KALOL, G.C.S, G.C.P,
GGS VII, Nawagam C.T.F, Desalter plant, artificial lift &
security dept ongc Ahmadabad.
We express our deepest thanks to Mr.Rajendra kumar
for providing us the moral support and encouragement
without which it would have been difficult to complete
this training.
PREFACE: Theory of any subject is important but without
its practical knowledge it becomes useless, particularly
for technical students.
A technical student cannot become a perfect
engineering or technologist without practical
understanding of their branch.
Hence training provides a golden opportunity for all
technical students to interact with the working
environment.
The principal necessity of in-plant training is to get
details about unit operation and unit process which are
carried out in industries and to know more about the
equipment used in these industries.
The in-plant training program is very advantageous for
the technical students who have a vivid idea about the
industries.
This training helps to understand the basic concept of
the industry.
During this period the students becomes aware of the
problem faced in the plant and are also aware of the
industrial atmosphere and also with the industrial
people.
 CONTENT
NO TOPIC PAGE NO
1 GAS COLLETION STATION (GCS)-KALOL 4
2 GAS COMPRESSION PLANT(GCP)-KALOL 8
3 GGS-VII 13
4 CENTRAL TANK FARM(CTF)-NAWAGAM 18
5 DESALTER PLANT-NAWAGAM 20
6 INSRUMENTS LAB-KALOL 25
 GAS COLLECTION STATION (GCS)-KALOL
INSTALLATION MANAGER: Mr.B.B.PATEL
ESTABLISHED IN: 1973
RECEIVING STATUS:
Total wells connected -32
Total working wells-13
Receiving pressure-4kg/cm2

OBJECTIVES:
 To collect natural gas from wells
 To collect associated gas from GGS
 To send gas to GCP
 To send compressed gas to GGS artificial lifting
 To send CG to IFFCO, RIL etc.

FUNCTION:
Its main function is gas collection and distribution.GCS receives
associated gas from GGS and natural gas directly from the
wells. They both are mixed in scrubber, treated and they are
transferred to GCP for further compression .now the
compressed gas again is again received back by GCS and then
the compressed gas is sent to various destinations.

GCS FACILITIES
1. MANIFOLDS
 Gas grid manifold (to provide high pressure
compressed gas through 4” & 6” pipeline to north and
south kalol gas system).
2. BEAN HOUSING
 To control the flow of gas from the reservoir
3. SCRUBBER
Purpose: it is a purifier that removes impurities from gas.
Scrubber systems are a diverse group of air pollution
control devices that can be used to remove particulates
and/or gases from industrial exhaust stream. Traditionally,
the term “scrubber” has referred to pollution control device
that use liquid to “scrub” unwanted pollutants from a gas
stream. Recently, the term is also used to describe
systems that inject a dry reagent or slurry into a diary
exhaust stream to “scrub out” acid gases. Scrubbers are
one of the primary device that control gaseous emissions,
especially acid gases.
4. SEPERATOR
 Function at 4kg/cm2
 In this only natural gas is separated to remove any
condensed liquids if present. The gas firstly goes to
separator than to scrubber.
5. STOREGE TANK
 3 storage tanks of 45m3 are present but they are not
under usage.
6. VALVES
 Shut down valve-used in case of leakage or in any
other emergency.
 Control valves- when pressure in the pipelines
increases beyond the limit then these valves get
open itself to prevent danger.
 Safety valve-its gives safety for whole plant or
particular tank or important part.
GAS COLLECTION STATION (GCS)-
KALOL
 GAS COMPRESSION PLANT (GCP) -
KALOL
INSTALLATION MANAGER: Mr. Rajesh Kumar
DATE OF COMMISON:
GCP-I: 26.02.1990
GCP-II: 15.03.1994

TOTAL CAPACITY: 5 lakh m3/day

TOTAL COMPRESSORS: 10
6 in old plant and 4 in new plant
Capacity (old) =3 lacks m3/day
Capacity (new) = 2 lacks m3/day

REVERSE-OSMOSIS PLANT (R-O):2

DISCHARGE PRESSURE: 40 kg/cm3

PROCESS DESCPRIPTION:
In this plant, gas from GCS (gas collecting system) at
4kg/cm2 pressure comes through pipelines to GCP.
Firstly it goes to common inlet separator, where the
primary separation is done, usually the content of oil in
gas is negligible but if it’s there it gets separated. Now
the gas goes to 1st stage suction separator, there
further separation is done. Till now the pressure is
4kg/cm2, now this gas goes for first stage compression
goes into compressor. After compression the gas we
 get is of 12-14kg/cm2 and because of compression
temperature rises to 1250 C so to low down the
temperature to 40-45oC, compressed gas is sent to inter
gas cooler.
Now the cooled gas of 12-14 kg/cm2 pressure goes to
2ndstage suction separator where further separation
occurs. Then is goes to 2nd stage gas compressor there
compression is done and in the output we get gas of 40
kg/cm2 pressure but temperature has again gone up to
145o C because of compression so it again goes to
cooler which is also known as after cooler. Now as
cooling has occur so condensation will be done so
again whatever amount of oil will be there will be
drained out from discharge separator.
Then finally gas from the discharge separator at
40kg/cm2 pressure is sent back to GCS.

GCP FACILITIES
1. GAS COMPRESSION SYSTEM
 PURPOSE
 To compress gas at high pressure.
 It has two stage compression systems.
 First stage compressors takes gas from first
suction separator and other stage takes gas
from second suction separator as shown in the
flow diagram.
 RPM=990
 Capacity =2100m3/hr
 Model -14X8X52 RDH-2
 Make –Ingersoll sand
 Type – double acting reciprocating horizontal
  Number of stage-two
2. RAW WATER TREATMENT SYSTEM (R-O
PLANT)
 Purpose
 to remove a true deposit solids from water

3. AIR COMPRESSION SYSTEM:

 make –Ingersoll rand

 model -8X5E & 1-NL2
 discharging pressure -110 PSI
 capacity -200 CFM(each)
4. COOLING SYSTEM:
 purpose:
 There are two types of gas coolers inter gas
coolers and after gas coolers. It’s a type of heat
exchanger. Running water through it helps in
cooling of gas and they are sent finally to
discharge separator. Inter gas cooler takes the
gas of first compression and gas cooler takes
second stage compression.
 Process:
It’s a type of heat exchanger, it contains baffles and
one shell and two pass exchanger system. Cooled
treated water enters from one side and gas enters
from the other side. There occurs a counter current
flow. This results in exchange of heat between two
liquids and hence the fluid is cooled.
5. GAS DETECTION & MONITORING SYSTEM
  Used to detect the leakage of gas in the plant

6. FIRE FIGHTING SYSTEM

 6 fire fighting pump
 4 diesel pump and 2 motor driven pump
7. ELECTRICAL SYSTEM
 2 11kv sub station
 8 step down tranformer
 GGS-VII (KALOL)
INSTALLATION MANAGER: MR.AJAY. RATAN

DATE OF COMMISION: JULY-1976

WELL PRODUCTION STATUS:
Total wells connected-57
Total flowing wells-52
Total liquid production-380 m3day
WATER INJECTION WELLS-20
GAS INJECTION: 40000-50000 M3/DAY

VESSELS:
1.TEST SEPATOR-(working pressure – 6kg/cm2 and
hydraulic test pressure – 9 kg/cm2
2. EMULSION SEPARATOR – (working pressure-
6kg/cm2 and hydraulic test pressure- 9kg/cm2)
3. EMULSION SEPARATOR – (working pressure-
6kg/cm2 and hydraulic test pressure- 9kg/cm2)
4. EMULSION SEPARATOR –II: (working pressure-
6kg/cm2 and hydraulic test pressure- 9kg/cm2)
5. EMULSION SEPARATOR –III: (working pressure-
6kg/cm2 and hydraulic test pressure- 9kg/cm2)
6.HIGH PRESSSURE SEPARATOR – (working pressure-
15kg/cm2 and hydraulic test pressure- 24kg/cm2)
7. HEATER TREATER: – 2 in number, first one is of 800
tons/day capacity and second one is under construction.
TANKS
1. TANK-1: 90,000 Liters
2. TANK-2:90,000 Liters
3. TANK-3: 4, 00,000 Liters
4. TCS I&II: 32,000 Liters & kg/cm2 pressure
FUNCTION:
At GGS well fluid is connected in header from various
wells through pipeline Network. There gas is separated
from liquid in group separator and send to GCP through
GGS to return back compressed gas for gas lift wells.
Then water is separated from oil in heater treater. Oil is
stored in tanks and sends to CTF (central tank farm). The
effluent remained after separating from oil is send to ETP
(effluent treatment plant).

GGS-VII

1. HEATER TREATER
 NAME- crude oil emulsion treater
 TYPE- vertical flow horizontal CE treater
 SIZE-8’X20’
 DUTY-continuous
 WORKING PRESSURE-50 psi
 WORKING TEMPERATURE – 90o maximum
 TEST PRESSURE- 75 psi(hydraulic)
 CURRENT- 25 amp
 VOLT-250 volt
 Reciprocating pump is used to transfer the fluid
from separator to heater treater
 POWER- 375 KW
 VOLT- 415v
  RPM-1410
 Demulsifier chemical mixed with the oil as
chemical injection
2. TRIPLEX RECIPROCATING PUMP
 Used for pumping oil from storage tank to
discharge line to NAWAGAM
 Maximum pressure- 64 kg/cm2
 Input-86kw
 Pump RPM-260
 Oil used for lubrication-80L
 Servo gear HP-140
 It is motor driven pump
 KW-110
 HP-150
 RPM-1480
3. BOOSTER COMPRESSOR
 Used to compress the which out from the
separator vent at pressure 1.5kg/cm2 to 4-5 kg/cm2
which is then send to GCS for further
compression.
 Make – Ingersoll rand
 Model – 8.5” X 7” single stage
 Capacity – 10000 m3/day
 Suction pressure-1.5kg/cm2
 Discharge pressure- 5kg/cm2

4. POWER SUPPLY
 Normal power is supplied from 11kv grid of the
electrical board
 The overall normal requirement envisaged has
been of the order of 100KVA
  Emergency power plant is maintained by 320KVA
diesel generator whose power factor is 0.8 and
power of engine is 396HP.
5. FIRE WATER SYSTEM
 2 reservoir of water having capacity 120m3 and
350 m3 respectively are available.
 2 pumps are also present one is motor driven and
one diesel engine driven .second one is used as
stand by.
 Specification of motor driven pump.
 Capacity-170m3/hr
 Discharge pressure-6kg/cm2
 Specification of engine driven pump
 Head-100m
 Discharge rate- 171 m3/hr
 Size-100X125 mm
 Speed- 1800 RPM
 Pump input- 64.9 KW
CENTRAL TANK FARM (CTF)-NAWAGAM

INSTALATION MANAGER –MR.B.K.SHIT

AREA OF INSTALLATION-100 acres
RECEIVING STATUS
 GGS-I,II,III-500m3/day
 Ramol, Nandej, Wasna fields-:800-900 m3/day
 CTF kalol- 8000 m3/day
 Mehsana fields -8000m3/day

STORAGE TANKS
8 tanks-2000 m3

Main objective
 As such in this installation no processing is
done, they just pump desired crude oil to
desalter plant which has come from various
CTF.
 Every hour water content is checked in the
sample of treated crude oil of desalter plant
after fulfilling the desired conditions of refineries
dispatching is done from desalter to refineries.
 They target to have water content of 0.5-1% in
oil before discharging.

PUMPING SYSTEM
 Make BPCL
 Type-quintuplex plunger pump
 Maximum discharge-120m3/hr
 Maximum operating pressure-40 kg/cm2
 Rate BHP-430 HP
 Motor
 HP-545
 KW-400
 RPM-1450
 Voltage-415
 Frequency-50 Hz
 Current-676 amp
 DESALTER PLANT NAWAGAM

INSTALLATION MANAGER: MR.B.KSHIT

DATE OF COMMISSION: .01.1995

PLANT CAPACITY: 6.7 MILLION METRIC TONS
PER YEAR

NUMBER OF TRAINS (UNIT)-4 TRAINS OF 2.2

MILLION METRIC TONS PER YEAR 92 TRAINS
ARE OPERATING AND 2 IS STAND BY)

RECEIVING STATUS
 CRUIDE OIL FROM
 MEHSANA
 AHMEDABAD ASSEST

DESALTED CRUDE OIL

CHARACTERSTICS
Salt content: 10-15 ptb

PROCESS DESCRIPTION
Crude oil is received from the existing tank
through a 30” suction header.4 no’s feed pumps are installed
for pumping feed to desalter to three trains whereas the fourth
pump is common stand by for all the three trains. Demulsifier
chemical is mixed with the feed crude oil in the suction line in
the feed pump. Crude oil from the feed pump is further mixed
with wash water at a rate of approximately 0.5% of the crude
before the crude is sent through heat
Exchanger .in this heat exchanger the feed is heated to about
630C any exchanging heat with the outgoing treated crude oil
from the desalter. Treated crude passes through the tube side
of the heat exchanger.
Crude from the exchanger will pass through the feed heater
where in the temperature is raised to 100o before entering the
desalter vessel. In the desalter vessel feed crude is fed at lower
portion of vessel where in it travels and separates through
electrostatic grid. The electrostatic grid acids the breaking of
emulsion and settlement of water at the bottom. The after
losing water/salts will be let out through the crude outlet line
from the top of vessel. Desalter has bottom outlet connections
at intervals for removal of water and sediments settled at
bottom of desalter. Pert of the produced water is circulated
back into desalter vessel through desaludging pump to
maintain the water phase in the desalter in a fluidized
conditions so that the sediments settle down at the bottom of
the vessel and form the thick mud.
The desalter vessel is providing with sampling valves various
elevations to collect and analysis the sample at various
elevations on the desalter vessel. So by analyzing these
samples discharging is done.

1. storage system
 Crude oil
 No of tanks-4
 Type-floating roof
 Capacity-30,000 m3
 Water
  Raw water tank:2
 Type: cone roof
 Capacity:700 m3 each
2. power supply system
 Distribution voltage:415 volts
 Normal power:240 Volts, AC
 Shutdown:110volts,DC
 Fire alarm system:240 Volts ,AC
3. Fire Fighting system
 2 jockey pump:
 Working pressur:8kg/cm2
 Feed rate : 10 m3/hr
 2 diesel engine driven pump
 Feed rate:410 m3/hr
 1 electrical driven pump
 Feed rate:410 m3/hr
 2 storing pond are there of capacity 3200 m3
each
4. pumping system:

Rotating Quantity Type Capacity(m3/hr) Head(m)

pump
Desalted 4 Centrifugal 330 146
feed pump
Service 2 Centrifugal 40 50
water pump
Process 2 Centrifugal 40 135
water pump
Desaludging 2 Centrifugal 50 25
pump
Drinking 2 Centrifugal 5 25
water pump
Injection 4 Centrifugal 700 lpm 29.7
pump
5. compressors
 Air compressor
 Quantity:2
 Capacity:350 Nm3/hr
 Discharge pressure: 9 kg/cm2
6. Burners
 No of burners: four reactor
 Type of burner: forced draft
 Type of fuel: natural gas
 Heat liberation(max)(mm BTU/hr):8
7. Miscellaneous
 Instrumental air dryer:
 Quantity:2
 Capacity:150 m3/hr
 Demulsifier mixed:
 Quatity:2
DESALTER PLANT DIAGRAM
 INSTRUMENT LAB – KALOL
We show the various types of instruments in the kalol
instrument lab. We could take the most effective information
and we learn effectively in the kalol instrument lab. As listed
instrument which learn in kalol instrument lab.
1. Pneumatic controller
2. Temperature transmitter
3. Differential pressure transmitter
4. Pressure transmitter
5. Flow measurement
6. Gas measurement
7. Level measurement
8. Air filter and regulate

1. PNEUMATIC CONTROLLER
 DEFINATION:
A Pneumatic Controller is a mechanical device designed to measure temperature or pressure and
transmit a corrective air signal to the final control element.

 Indicate the pressure and temperature

 Working on the proportional (P), integration (I),
derivative(D) controller.
 Range for:
 Temperature : -100o F to 600 oF
 Pressure : up to 30 psi
2. TEMPERATURE TRASMITTER
 DEFINATION: A temperature transmitter is an electrical
instrument that interfaces a temperature sensor (e.g. thermocouple,
RTD, or thermistor) to a measurement or control device . Typically,
 temperature transmitters isolate, amplify, filter noise, linearize, and
convert the input signal from the sensor then send (transmit) a
standardized output signal to the control device. Common electrical
output signals used in manufacturing plants are 4-20mA or 0-10V DC
ranges. For example, 4mA could represent 0°C and 20mA means
100°C.

 RTD:
 Resistanc temperature detector
 Temperature sensor
 RTD is widely used in industry.
 Used with thernowell
 2wire, 3wire, 4wire RTD used

3. DIFFERNTIAL PRESSURE TRASMITTER

 not measured with reference to a specific reference
pressure
 p1 will be increase and p2 will be decrease
 The differential pressure measurement is not concerned
whether the lower of the two pressures is at a vacuum,
atmospheric or some other pressure. It is only interested in
the difference between the two.
 All DPT does not measure with the between two pressure
 Used between flow meter to know flow

THANK YOU