INDUSTRIAL VISIT: ONGC-MEHSANA ASSET

Report submitted by:

SOUMYA JAISWAL (R870215134)

in partial fulfilment of the requirements

for the award of the degree of

BACHELOR OF TECHNOLOGY
in

APPLIED PETROLEUM ENGINEERING with

specialization in UPSTREAM

Under the guidance of

Dr PUSHPA SHARMA
Professor
Department of Petroleum Engineering and Earth Sciences

Dr Vamsi Krishna,
Mr. Amit Verma
Assistant Professors
Department of Petroleum Engineering and Earth Sciences
&

Mr. ANKIT
Lab In charge
Department of Petroleum Engineering and Earth Sciences

DEPARTMENT OF PETROLEUM ENGINEERING AND EARTH SCIENCES

SCHOOL OF ENGINEERING STUDIES

UNIVERSITY OF PETROLEUM AND ENERGY STUDIES
Bidholi Campus,Energy Acres.
Dehradun,248007.
May, 2018.
 ACKNOWLEDGEMENT

This report is my sincere attempt to condense the wealth of knowledge that I acquired during the course our 3
day-Industrial Visit to the assets of Mehsana, under ONGC, in February 2018.

I am thankful to Dr Pushpa Sharma, whose constant guidance and encouragement have helped me utilize this
exposure to the fullest.

I like to thank Dr VK Kudapa, Mr Amit Verma and Mr Ankit for their support and encouragement too.

I would also like to thank my classmates for sharing the information collected by them with me, such a pictures,
specifications, etc.

Soumya Jaiswal

B. Tech Applied Petroleum Engineering (Upstream)

UPES, Dehradun
Industrial Visit
The industrial visit was for a tenure of three days, each day covering a different aspect of the Oil and Gas
Industry operations. The sites were were all under ONGC, based at Mehsana, Guajarat, India.

The description of the three days at the Industry is as described below.

DAY: 21st February, 2018.

Visit to: a WORKOVER RIG, Mehsana Asset.

Rig Specifications: NK 324 workover rig, ONGC-Deep

Industries

 Rig: Vishal-100-2. It was a Chinese double stand

rig. It was capable of conducting hoisting
operations up to 100 tons. It was being operated
by RG-Petro.
 Rig Engine was of 540 HP and draw-works had a
capacity of 530 HP.
 The well was on AL- Gas Lift.
 Height of mast – 108 ft. and that of monkey board
was 22 ft.
 Blind Ram and BOP were of Chaffer.
 The completion fluid used was 1.09 gravity Brine.
 BOP control was three ways
o Accumulator Figure 1 NK 324 Workover Rig

o Remote operated
o Through driller console

The rig was being run by people from ONGC, Deep Industries. The on site coordinator, Mr Gunjan, briefed
us about the operations being carried out on the field. At the time of our visit, the workover job was
focussed on retrieving a hydraulic packer that had got stuck in the wellbore. A general overview of the
equipment was given: such as the drawworks, BOP, control van, etc.

As the operations were being carried out, pipe stands were being tripped out of the hole and stored.

General Overview of the Workover Rigs, Mehsana.

 They are owned by ONGC and workforce is also from ONGC. 5 such rigs operational
 Crew & maintenance by Vishal, APL. 8 such rigs are operational.
 Charted hire rigs: The rig is hired and the crew, maintenance and infrastructure are all
outsourced. 6 such rigs are operational.
 1 rig is in workshop, Romania-50-3.
DAY 1: 21st February, 2018
The second day comprised visits to two locations in the two respective halves of the day.

I. The first visit was to a CTF, ie, a Central Tank Farm under ONGC, situated at Sobhasana, Mehsana.
A Brief review on the history of the Station.
Sobhasana GGS (Group Gathering Station) cum CTF (Central Tank Farm) which got commissioned on 4th
October, 1975 is the third largest production installation in the Mehsana Asset which handles crude and
gas from the Sobhasana field. It is ISO 9001:2008, ISO 14001:2004 and OHSAS 18001:2007 certified.

The Mehsana field being a matured field now requires secondary and tertiary techniques for production.
Gas lift and Enhanced oil recovery are some of the techniques used in Mehsana. The wells under
Sobhasana GGS cum CTF are mainly on artificial lift i.e gas lift and Sucker rod pump.

The activities performed in Sobhasana GGS cum CTF can be summed up in following points:

 To receive emulsions and gas from wells.

 To receive emulsion and Low pressure (LP) gas from Sobhasan GGS-I.
 To receive LP gas from Sobhasan GGS-II.
 To receive/feed LP gas in Gas grid.
 To receive emulsion from well site tanks through road tankers.
 Process of emulsion and to store treated oil in storage tanks and dispatch to Mehsana CTF.
 Compression of LP gas (1.5 kg/cm2) to HP gas (50 kg/cm2) for gas lift (GLV) wells of Sobhasan
Area.
 Separated effluent is sent to Sobhasan ETP for further treatment and disposal.
 LP gas supply to GAIL.
 RO water plant is used for GCP cooling system, Steaming units, Drilling rigs and for drinking
purposes.
 Testing of effluent sample, water cut and salinity of emulsion in Chemistry Laboratory.

The batch was divided into two groups. Each group was taken for a theoretical class where in the on site
worker gave us a brief review about the surface production facilities. Subsequently, the group was taken
to the field, for e review of the equipments: which included the High and Low Pressure pipelines coming
from various locations, the separators, etc.

PLANT LAYOUT
Description of the Equipments present
 Flow Lines.
Oil Lines:
The wells are connected to the GGS with 4’’ and 8’’ lines.
Gas Injection Lines:
The compressed gas from the Gas compressor plant is send to the wells for gas lift with 2’’ lines.

 Production manifold/Headers
Production from wells, which comes from flow line is taken into different headers, according to
their pressure. A suitable valve arrangement is used to direct the flow to one of the separators.
The header pipe connected to the production separator is called production header, and to test
separator for routine testing of individual wells is called test header. Check valves are installed
between well and manifold to check the backflow through the manifold from high to low pressure
well.

Figure 2 Main header

  Separators and Process Equipments:
The produced well fluid is generally a mixture of oil, salt water and natural gas. Separation of gas and
liquid is therefore the first processing step. The separated liquid is further subjected to dehydration and
desalting to remove water and salt. The Sobhasan CTF dehydrates the liquid and sends it to Mehsana
CTF, which pumps it to Nawagaon desaltor plant where salt is removed. The pure oil (<.25% water cut)
from Nawagaon is metered and despatched to the refinery. The water removed from oil, known as
effluent water, is treated to meet the environmental system disposal requirements and is then disposed
off. The gas separated from oil is used for Gas compressor plant and given to other customers like GAIL,
Sabar dairy.

 Separator:
The separator is used to remove gas from the well fluid, as the field is of low to medium
GOR vertical two-phase separators are used. Attached is the image of a Vertical Separator.

Figure 3 Vertical Separator

 Scrubber:
The gas from the separator or free gas well is taken to scrubber, where any entrained oil is removed
through vortex separation.

There are 6 separators and 6 scrubbers in Sobhasan plant which are connected to different headers

 Bath Heaters:
Water Bath Heaters are indirect fired type; these devices are traditionally used to heat natural gas and
oil. In fired tube type heaters, the coils are immersed in a bath of water. The water is heated by a fire
tube that is in the bath below the coils. The fire tube provides a heat flux that heats the water bath. The
water bath in turn exchanges heat by convection and conduction to the process fluid.
 There are two bath heaters in plant to increase the temperature of emulsion to around 60oC.

Figure 4 Bath Heater

 Heater Treaters:
It is a horizontal vessel employing a method of heating, chemical action, electrical coalescence, water
washing of oil and settling for emulsification of oil. Movement of fluid through treater is controlled by a
system of differential pressure combined with static heat.
Heater Treater vessel is divided into four section:

I. Inlet Degassing section:

Oil mixed with demulsifying chemical enters the heater treaters through degassing section,
above the fire tubes. Free gas is liberated from the flow stream and is equalised across the
entire degassing and heating areas of the treaters. The degassing section is separated from the
heating section by baffles. The fluid travels downward from the degassing area and enters the
heating section under the fire tubes through multiple orifice distributes.

II. Heating Section:

Heating section consists of two fire tubes bent at 180o. The constant level in this chamber is
maintained by weir height. Oil enters this section from bottom of degassing section and passes
through heater at bottom and washing action takes place, free water and solids fall out of the
oil stream. The water level in this is controlled by a weighted, displacement type interface
float.

III. Differential oil control chamber:

The heated fluid transfers from the heating section over the fixed weir into a differential oil
control chamber which contains a liquid level control float. The fluid travels downwards to
near the bottom of the chamber where opening to the coalescing section distributors is
located.

The Sobhasan plant has 10 heater treaters, which works at a pressure of 1.8kg/cm2 and temperature of
around 80oC.

 Storage Tanks:
The produced and treated oil and gas are required to be stored, for dispatch and improving the quality of
oil by increasing the settling time. The storage tanks may be of open roof, closed fixed roof and closed
floating roof type.
The tanks used in Sobhasan plant are of closed fixed roof type. The plant has a facility of 8 tanks with 6
storage tanks of 400m3 each and 2 testing tanks of 50m3 each.
  Dispatch pumps:
Dispatch to Mehsana CTF is done through 2 No. 45m3 pumps. 2 No. Pumps are used for recirculation of
tanker oil received at CTF to heater treaters.

GAS COMPRESSOR PLANT

The gas compressor plant is related to the gas lift wells, it supplies compressed gas for artificial
gas lift wells. It compresses natural gas available from the gas grid at 1.2kg/cm2 to 51kg/cm2 with
the help of 3 stage compressor driven by 12 cylinder gas engine.

There are 6 compressors (3 in GCP I and 3 in GCP II) at sobhasan CTF, which are maintained and
operated by Dresser-Rand India Pvt. Ltd. The capacity of total plant is around 470,000 m3/day.

Intercooling is done between stages by means of air cooled radiator. Air cooling reduces the
temperature range of plant.

 Gas Engine:
The 3 stage gas compressors are driven by field gas fired 12 cylinder Waukesha gas engines. Water with
nalcool, an additive is used as a coolant, so as to increase its heat capacity. Water is then cooled in a
radiator by air.

 Air compressor:
One air compressor with one stand by is used to feed compressed air to engine and measuring devices.
The compressor works at 14 kg/cm2 as discharge.

II. Visit to: Group Gathering Station, Shobhasana field, ONGC, Mehasana.

Description of Gas Gathering System

Gas gathering lines/systems 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. The impurities and various non-methane hydrocarbons & fluids are separated to
extract, what is known as "pipeline quality", dry natural gas. A gas processing plant also recovers
valuable natural gas liquids such as condensate, natural gasoline and liquefied petroleum gas, as
well as other substances like sulfur. Once the processing is over, marketable components are
transported via pipelines to areas of high consumer demand.

Facilities present at GGS

Heater Treater- A vessel that uses heat to break oil-water emulsions so the oil can be accepted by the
pipeline or transport. There are vertical and horizontal treaters. The main difference between them is
the residence time, which is shorter in the vertical configuration compared with the horizontal one.
Scrubber- A device to remove dirt, water, foreign matter, or undesired liquids that are part of the gas
flowstream. Air can be used to absorb water; also an oil bath might be useful to remove dust, dirt or
other liquids. A scrubber is used to protect downstream rotating equipment or to recover valuable
liquids from gas.

Separator- An oil/gas separator is a pressure vessel used for separating a well stream into gaseous and
liquid components. They are installed either in an onshore processing station or on an offshore
platform. Based on the vessel configurations, the oil/gas separators can be divided into horizontal,
vertical, or spherical separators. In teams of fluids to be separated, the oil/gas separators can be
grouped into gas/liquid two-phase separator or oil/gas/water three-phase separator.

The place also had several storage tanks camouflaged in a way that they cannot be detected by satellites
and appear as trees on the data.

Day 3: 23rd February, 2018

On the third day, we made a visit to a drilling site, under ONGC.

The specifications are as follows:

 The field under visit had M-750-2 on operation. It was commissioned in 1991 and could drill
up to 2000 m depth.
 ONGC Drilling Rig (Depth 1028 m)
 First 100 m were drilled fast and cased to prevent ponds/subsurface water getting affected.
 Mast was a folding mast.
 The capacity of hook load was 3,00,000 lb.
 The visit comprised of a brief glimpse at the GTO too.