Training Report

of
Dew Point Depression Unit

Oil and Natural Gas Corporation

Ltd., Hazira, Surat

Training period: 10th December 2017 to 09th January 2019

Under the guidance of

Vinod Kumar
DYSE (P) CPF No. - 105013

Submitted by
Sutariya Mehulkumar Himmatbhai
U16CH044

Chemical Engineering Department;

Sardar Vallabhbhai National Institute of Technology, Surat;

India.
th
Date : 11 December, 2019
i
 Certificate

This is to certify that the Training report submitted by Candidate

Sutariya MehulKumar Himmatbhai (U16CH044) B. Tech. IV (7th
Semester) in the partial fulfillment of the requirement for the award of
degree B. Tech. in Chemical Engineering. We certify that the work is
comprehensive, complete and fit for evaluation.

Examiner 1 Name: Dr. M. Chakraborty Sign:

Examiner 2 Name: Dr. A. K. Jana Sign:

Examiner 3 Name: Dr. G. C. Jadeja Sign:

Dr. Mausumi
Mukhopadhyay
Head Of Department;
Chemical Engineering

ii
 Acknowledgement

Industrial Training - a vital part of engineering curriculum provides engineers a chance to

work with cutting edge technologies and gives them knowledge of the practical aspects of
their studies. We are immensely indebted to ONGC family for the invaluable help that
they have rendered at every step of this training to achieve this goal. The preparation of
this report would not have been possible without the valuable contribution of the ONGC
family comprising of several experienced engineers in their respective field of work.
It gives me great pleasure to have completed my training at Gas Processing Plant of
ONGC at Hazira and we are submitting the training report for the same.
We express our deep sense of gratitude to C.K. Sakumaran, Dy. General Manager
(Elect.) – I/C Training Centre for giving us the permission for visiting and orientation
of the plant. Our sincere thanks to Mr. Vinod Kumar, DySE (P) as a mentor during
the training program at ONGC Hazira and for continuously guiding us throughout the
various aspects, functioning and processes of the plant and their effective coordination
in terms of allotting us the appropriate schedule to undertake the training. We are very
much thankful to Mr. J.K.Ash CE (P)-RE CELL for helping us in various aspects
of our project work given in this training
A major contribution of this work would definitely be our parents who have constantly
supported us for our training in here and our friends who have always been there as a
pillar of strength.
Lastly we are also thankful to all the staff members of plant for their kind cooperation
and valuable guidance throughout the process of work.
Our cordially thanks to those who contributed a lot in giving us important data related
to the ONGC field and its functioning in a lucid and accurate manner which helped us
to gain the necessary points in a very short time of this Winter Internship.

Yours Sincerely,
MehulKumar Sutariya

iii
 Preface

In any organization success or failure of the company depend upon 4 M’s i.e. Materials,
Men, Machine and Method. Today is the age of competition and an organization cannot
survive without satisfaction of its customers. Quality of material is to be maintained in
order to stand in the competitive market.
To be a perfect engineer one must be familiar with individual experience in industrial
environment. He must be aware of basic industrial problems and their remedies.
While undergoing this type of industrial training at ONGC, Hazira, Surat (Gujarat) we
learned a lot of practical aspect. Our theoretical knowledge was exposed here practically.
In this report we have tried to summarize what we have learned in the ONGC plant.
For preparing this report we visited the plant, referred to the process and cleared related
doubts to the responsible personal & inferred to manuals and process reports.
This study has been primarily undertaken by us with a view to evaluate proper working
process in the organization. Born as the modest corporate house in 1956 as a commission
ONGC has grown today into a full fledges integrated upstream petroleum company with in
house service capabilities and infrastructure in the entire range of oil and gas exploration
and production activities achieving excellence over the years on the path of further growth.

iv
Contents

1 Overview Of Hazira Gas Processing Plant 1

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Process Overview of Hazira plant . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Process Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.4 Main Product of ONGC . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2 Dew Point Depression Unit 7

2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2 Process Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2.1 Chill Down Section . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2.2 Propane refrigeration section . . . . . . . . . . . . . . . . . . . . . . 9

3 Project work 11
3.1 Title of Project Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.1.1 Parameter Considered . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.1.2 Assumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.2 Flowsheet and Simulation Study . . . . . . . . . . . . . . . . . . . . . . . . 12
3.2.1 Sensitivity Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.3 Graphical Representation of Collected Data . . . . . . . . . . . . . . . . . 14
3.4 Drawback of study . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.5 Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4 Pumps and Valves 18

4.1 Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.1.1 Centrifugal Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.1.2 Reciprocating Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.2 Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.2.1 Gate Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.2.2 Ball Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.2.3 Butterfly Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.2.4 Globe Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

5 Line Sizing and MOC 22

5.1 Colour coding for piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.2 Line Sizing and MOC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

6 Instrumentation 23
6.1 Resistance Temperature Detector . . . . . . . . . . . . . . . . . . . . . . . 23
6.1.1 Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.2 Level Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.3 Flow Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

v
CONTENTS vi

6.4 Rotameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

7 Plant Safety 27
7.1 Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7.2 Possibilities of any Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7.3 Safety Equipments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7.3.1 Personal Protective Equipments . . . . . . . . . . . . . . . . . . . . 28
7.3.2 First Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
7.3.3 Eyewash and Safety Showers . . . . . . . . . . . . . . . . . . . . . . 32
7.3.4 Fire Fighter Devices . . . . . . . . . . . . . . . . . . . . . . . . . . 33

8 Utilities 35
8.1 Inert Gas Plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
8.2 Water Water Treatment Plant . . . . . . . . . . . . . . . . . . . . . . . . . 36

9 Environmental Issues 37
9.1 Health: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
9.2 Greenhouse gas: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
List of Tables

1.1 Main Processing Plants of ONGC Hazira Complex . . . . . . . . . . . . . . 3

1.2 Main Utilities and offsites of Hazira Plant . . . . . . . . . . . . . . . . . . 3

5.1 Colour code for piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

5.2 Line Sizing and MOC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

vii
List of Figures

1.1 Block Flow Diagram Of Gas Processing . . . . . . . . . . . . . . . . . . . . 2

1.2 Drone view of the Hazira Gas Processing Plant . . . . . . . . . . . . . . . 5
1.3 HBJ pipeline Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.1 Process Flow Diagram of Chill Down Section . . . . . . . . . . . . . . . . . 8

2.2 Process flow diagram of Refrigeration cycle . . . . . . . . . . . . . . . . . . 10
2.3 Real view of DPD unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3.1 DWSIM Flowsheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3.2 Flowsheet’s part for data generation . . . . . . . . . . . . . . . . . . . . . . 13
3.3 Flow Rate vs Chilling Temperature (For Lite Component) . . . . . . . . . 14
3.4 Flow Rate vs Chilling Temperature (For Heavy Component) . . . . . . . . 14
3.5 Flow Rate vs Chilling Temperature (For Value add Component) . . . . . . 15
3.6 Mass Fraction vs Chilling Temperature (For Lite Component) . . . . . . . 15
3.7 Mass Fraction vs Chilling Temperature (For Heavy Component) . . . . . . 16

4.1 Schematic of Centrifugal Pump . . . . . . . . . . . . . . . . . . . . . . . . 18

4.2 Gate Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.3 Gate Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.4 Butterfly Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.5 Globe Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

6.1 Resistance Temperature Detector . . . . . . . . . . . . . . . . . . . . . . . 24

6.2 Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.3 Level Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.4 Flow Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.5 Rota Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

7.1 Personal Protective Equipments . . . . . . . . . . . . . . . . . . . . . . . . 30

7.2 First Aid Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
7.3 Eye wash and Safety Shower . . . . . . . . . . . . . . . . . . . . . . . . . . 33
7.4 Fire Fighter Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

viii
Chapter 1

Overview Of Hazira Gas Processing

Plant

1.1 Introduction
Oil and Natural Gas Corporation (ONGC) is India’s biggest public sector company. The
mission of this company is to stimulate, continue and accelerate exploratory efforts to
develop and maximize the contribution of hydrocarbons to the economy of the country.
The discovery of Bombay High was an important event in ONGC’s success as a result
many oil fields were discovered in the western offshore. Out of them South Basin proved
to be phenomenal having reserves of approximately 200 billion cubic meters of sour gas.
To sweeten this sour gas (make it Sulphur free) and make it suitable for industrial use
Hazira Project materialized.

Hence a gas terminal was constructed in 1985 to receive the sweet gas. Initially the
gas received at this terminal was fed to KRIBHCO. Thus, entire Hazira area saw the
beginning of gas based industrial era. With increased demand in gas and its availability
in the South Basin ONGC, Hazira improved its production capacity and infrastructure.

Hazira Plant set up in 1985 & the largest sour gas-processing complex in the country,
has presently been processing about 34-35 MMSCMD of Sour Gas and approx. 5000-6000
M3 / day of Sour Condensate to produce Sweet Gas & Value Added Products, viz. – LPG,
Naphtha, SKO, ATF, HSD & Propane. The feedstock in the form of Sour Gas and Sour
Gas Condensate is received from different fields, of B & S Asset of ONGC and PMT-JV
consortium, located in Mumbai offshore. Hazira plant receive sour gas from Bombay High
through 217 km 36” & 42” submarine pipes from south basin to Ubrahat and then 14
km pipeline on land till the gas terminal. Hazira Plant Complex sprawls over an area of
about 640 hectares with approx. 19 Km of peripheral boundary wall. Plant has a direct
strength of 820 employees.

The Plant is of strategic importance to the nation as the 3000 km HVJ Pipeline emanates
from Hazira Plant. It is the life line to scores of industries ranging from Fertilizer to
Power, Petrochemical, CNG, Domestic Supply, Ceramic and others in 6+ states of India.

1
CHAPTER 1. OVERVIEW OF HAZIRA GAS PROCESSING PLANT 2

1.2 Process Overview of Hazira plant

SRU Sulfur

Acid Gas

Sweet Gas to
GSU GDU DPD
HBJ pipeline

Sour Gas
36”
From Gas
offshore Terminal
42” Sweet Gas to
Sour Local Consumers
Condensate LPG

CFU CWU LPG

ARN
KRU Heavy Cut
SKO

Figure 1.1: Block Flow Diagram Of Gas Processing

The input lines are feed to the GTU, which separates the gas from any higher condensates.
The gas then goes to GSU, where it is sweetened i.e. freed from H2 S. From GSU, the gas
goes to GDU, where the moisture content from the gas is removed. The H2 S gas which is
ripped in GSU is sent to SRU, where Sulphur is recovered in elemental form. After GDU,
the gas goes to DPD where condensate till minimum temperature 5 o C are removed from
gas and then to HBJ pipeline. Condensate from DPD unit and the GTU are send to the
CFU. The condensate from CFU goes to KRU plant and any LPG produced is sent to
CWU for recovery by removing H2 S. The process is represented in Figure 1.1.
The various products of the plant, apart from gas for HVJ pipeline includes LPG, Kerosene,
HSD, ATF, Propane, Sulphur, Naphtha etc. The consumers of the plant include IOC,
BPCL, HPCL, RIL, KRIBHCO, NTPC etc. ARN is exported out of the country.
CHAPTER 1. OVERVIEW OF HAZIRA GAS PROCESSING PLANT 3

Table 1.1: Main Processing Plants of ONGC Hazira Complex

Units Numbers Total Capacity

Gas terminal 2 lines 50 MMSCMD
Gas sweetening Unit (GSU) 9 trains 52.5 MMSCMD
Gas dehydration Unit (GDU) 8 trains 47.4 MMSCMD
Dew point depression Unit (DPD) 9 trains 46.2 MMSCMD
Liquefied Petroleum Gas (LPG) plant 1 trains 5.3 MMSCMD
Condensate Fractionating Unit (CFU) 7 trains 12600 m3 /day
Kerosene recovery Unit (KRU) 1 trains 6600 m3 /day
Sulphur recovery Unit (SRU) 6 train 1.063 MMSCMD
Incinerator 1 168KN m3 /day

Table 1.2: Main Utilities and offsites of Hazira Plant

Units Numbers Capacity

Co-generation plant 3 gas turbines 57.6 MW
Raw water reservoir 4 reservoirs 8 lakh m3
Raw water treatment plant 1 48000 m3 /day
LPG Storage sphere 9 22500 m3
Naphtha storage tanks 8 99000 m3
NGL storage tank 2 33000 m3
Kerosene Storage tank 4 20000 m3
HSD/ATF storage tank 2 2000 m3
Heavy cut /HSD tank 3 6000 m3
Propane Storage Sphere 1 311 m3

1.3 Process Units

1) Gas Terminal:
It receives and separates sour gas and associated condensate from offshore.

2) Gas Sweetening Unit:

H2 S gas is removed from sour gas by selective absorption of Methyl Di-Ethanol
Amine.

3) Gas Dehydration Unit:

Moisture is removed from the gas by absorption in Tri-Ethylene Glycol.

4) Dew Point Depression:

Liquid Hydrocarbon is removed by chilling to make it suitable for transportation
through 3000 km long HBJ pipe line without any formation of hydrates.

5) Sulphur Recovery Unit:

H2 S obtained from Gas Sweetening Unit is converted into elemental Sulphur and
dried into bricks.

6) Condensate Fractionation Unit:

Fractional Condensation of Sour condensate Obtained from Gas Terminal Unit to
produce LPG and LNG.
CHAPTER 1. OVERVIEW OF HAZIRA GAS PROCESSING PLANT 4

7) LPG Recovery Unit:

Production of LPG and NGL

8) Kerosene Recovery Unit:

Fractionation of NGL to produce Naphtha, ATF and HSD.

9) Cogeneration Plant:
It produces electric power to drive the plant via gas turbines.

1.4 Main Product of ONGC

Main products of HGPC are as following:

• Sweet natural gas

• Liquefied petroleum gas

• Naphtha

• Superior Kerosene Oil

• Aviation Turbine Fuel

• High Speed Diesel

• Sulphur

Various products of ONGC are transported by

• Railways

• Roadways

• Pipeline

• Shipping

Customer of ONGC:

• GAIL

• KRIBHCO

• ESSAR

• IOCL

• HPCL

• BPCL

• RIL
CHAPTER 1. OVERVIEW OF HAZIRA GAS PROCESSING PLANT 5

Figure 1.2: Drone view of the Hazira Gas Processing Plant

CHAPTER 1. OVERVIEW OF HAZIRA GAS PROCESSING PLANT 6

Figure 1.3: HBJ pipeline Network

Chapter 2

Dew Point Depression Unit

2.1 Introduction
As discuss earlier, Moisture contain in the gas are removed in the GDU and H2 S are
removed in SRU. The resulting sweet & dehydrated gas contains significant quantities of
heavier hydrocarbons, these hydrocarbons need to be recovered prior to transportation of
gas to HBJ pipeline to avoid condensation which may occur due to seasonal temperature
variations.
As name suggest, DPD unit lowering or depressing the dew point of the gas and remove the
remove the possible condensate form gas at selected temperature. As per MOU between
ONGC and GAIL; Maximum chilling temperature are 5 o C. But to obtain more value
added product from condensate, chilling temperature is set to -5 o C.

2.2 Process Description

Sweet and dehydrated gas is treated in this DPD unit to lower hydrocarbon dew point of
gas well below the minimum temperature which the gas may attain in the HVJ pipeline.
Expected minimum temperature that the gas may attain in HVJ pipeline is 11o C. Dew
point depression unit is designed to chill the gas up to 5o C and recover condensate formed
due to gas chilling. The process description for dew point depression unit is described in
two sections:
• Chill down section
• Propane refrigeration section

2.2.1 Chill Down Section

The feed gas is first cooled by outgoing (dew point depressed) product gas in the gas-gas
exchangers (E-501 A/B/C/D) and it is then finally cooled to 5 o C in a gas chiller
(E-502) by the evaporating refrigerant propane. The gas temperature at the outlet
of chiller is controlled by a chiller bypass control valve (TV-1101). The chilled gas is
sent to the filter-separator ( X-501) to knock out hydrocarbon condensate, traces of
water and glycol (if any) formed. The separated gas from the filter-separator (X-501)
exchanges its cold partially with the incoming feed gas in the gas-gas Exchangers (E-501
A/B/C/D). The gas is then sent for transportation in HBJ pipeline. Hydrocarbon
condensate from filter-separator is pumped by the condensate transfer pumps (P-501
A/B) to LPG unit/Condensate fractionation unit or Slug catcher condensate header on
level control valve (LV-1102).

7
 CHAPTER 2. DEW POINT DEPRESSION UNIT

Figure 2.1: Process Flow Diagram of Chill Down Section

8
CHAPTER 2. DEW POINT DEPRESSION UNIT 9

2.2.2 Propane refrigeration section

Propane refrigeration system has been provided in the DPD unit to supply refrigeration
required in the gas chiller (E-502). Propane refrigeration is a part of the DPD unit.
Once the system is filled with liquid propane it operates in a closed cycle and very little
make-up of propane from external source is required. A single stage refrigeration is
provided. Propane from accumulator (V-502) at 45 o C flows over to propane sub-cooler
(E-504) where it is sub-cooled by cooling water to 40 0 C. Then it flows over to gas chiller
(E-502) through level control (LV-1101). Refrigerant propane after evaporation in the
chiller, flows over to propane compressor via suction KO drum (V-501). Propane vapor
is then compressed by reciprocating propane compressor (K-501 A/B) driven by electric
motor. The compressed propane vapor is condensed in the propane condenser (E-503)
and taken to the accumulator (V-502) for reuse in the propane re-circulation cycle.

Suction pressure of the propane compressor is controlled by compressor discharge to

suction bypass control valve (PV-1102). The temperature of bypassed propane vapor
is maintained at 0 0 C by spraying liquid propane in a quench nozzle (X-502) via a
temperature control valve (TV-1102).

In each train, two refrigerant propane compressors are provided. One compressor will
be in operation and another will be stand-by.

Propane from accumulator (V-502) at 45 0 C is sub-cooled to 40 0 C by cooling water

in the propane sub-cooler (E-504) and then sent to the shell side of the chiller (E-502)
through level control valve LV-1101. The level control valve will maintain constant level
of liquid propane in the chiller.

Propane vaporizes at 0 0 C temperature and 4.8 Kg.cm2 a pressure in the chiller. Vaporized
propane from chiller goes to the suction of propane compressors (K-501 A/B) via suction
KO drum (V- 501) where traces of liquid propane in the vapour are removed. Propane
compressors are of single stage reciprocating type and compress propane to 16 Kg/cm2
a pressure. Compressed propane is then condensed at 45 0 C in the propane condenser
(E-503) by circulating cooling water. Condensed propane goes to the accumulator (V-502).
The pressure in the chiller is not allowed to go below a present value (4.8 Kg/cm2 a
corresponding to 0 0 C evaporation temperature) by the suction pressure control of propane
compressors. Propane vapours from discharge will be bypassed to the suction via pressure
control valve PV-1102. Hot compressor bypass propane gas is cooled by spraying liquid
propane in the mixing nozzle (X-502). The temperature of the propane at compressor
suction is maintained at 0 0 C by controlling the amount of liquid propane sprayed through
the control valve TV-1102.
CHAPTER 2. DEW POINT DEPRESSION UNIT 10

Figure 2.2: Process flow diagram of Refrigeration cycle

Figure 2.3: Real view of DPD unit

Chapter 3

Project work

In DPD unit, as per MOU with GAIL condensate till +5 0 C must be removed before
sending in to the HBJ pipeline. If we decrese the temperature more and more condensate
can be recovered. This condensate contain some valuable fraction like ARN, ATF and
Gas Oil. But if we continuously increase the temperature after one point we gives more
energy and get very little value add end product, so one must have to find the optimum
temperature at which there there is enough profits.

3.1 Title of Project Work

“Variation in the compound’s mass flow and the mass fraction with decrease in the chilling
temperature and most suitable chilling temperature for remove condensate from the sweet
gas in dew point depression unit before send it into the HVJ pipe line”

3.1.1 Parameter Considered

• Less condensations of C1 otherwise we distract from over main goal of sending the
gas to the HVJ pipeline.

• Maximum propane recovery; Because till Propane we consider it as Condensate.

• The total cost of refrigeration are less than the profit of value add product recover
(Here total lean gas; LPG (Liquefied Petroleum Gas), ARN (Aromatic reach naphtha))
for cost efficient chilling temperature calculation.

3.1.2 Assumption
• There is no any H2 S and H2 O in feed. Since it’s concentration is very less no need
to add in feed.

• Here the LPG contain 50 wt % C3:C4 so all other C3 are goes to the lean gas and
no any butane in the ARN.

• All condensed CO2 , Methane and Ethane with propane that does not used in the
LPG production are in lean gas.

• Total mass flow of C5-C9 are consider as ARN.

11
CHAPTER 3. PROJECT WORK 12

Whole calculation are done in the open source chemical process simulator DWSIM, which
gives a nearly same result as given by other commercial simulator and also supported by
the GNU and the FOSSEE group of IIT-Bombay. Here we use Peng-Robinson-Stryjek-Vera’s
2nd modification as thermodynamic bases. PRSV2 provide the best VLE data prediction
and here we have to work on condensate so proper VLE is require for the calculation.
And PRSV2 is made for the lower temperature region so it gives most satisfactory data
than other EOS (equation of state), but here is chance of introducing error due to the
saturated hydrocarbon.

3.2 Flowsheet and Simulation Study

Figure 3.1: DWSIM Flowsheet

First feed gas passes through the Gas-Gas heat exchanger where its temperature is
decrease to the 12 0 C. Then it further cool for remove the condensate, for that purpose
in plant, it pass through the chiller where by the refrigeration effect of propane it further
cool to our desire temperature; but here we directly use simple cooler for that purpose.
After the chilling stream has both phase, this mixed stream enter in the flash drum where
the condensate and the gas are separated from each other. Condensate are send to the
LPG unit. And the gas are passing through the Gas-Gas heat exchanger and then go
towards the HVJ pipe line.

Design of the simulation are as per the manual provide by the ONGC. Hence no energy
is provided or removed by the flash drum or no any pressure drop or temperature loss;
the energy require by the Flash drum (energy stream ‘energy required by flash’) is always
zero. Out late temperature of the Feed gas (Material stream ‘to chiller’) from the gas-gas
heat exchanger is set to the 12 o C

By using the ‘Sensitivity analysis’ option of the ‘Optimization’ menu, we collect the
data for the mass fraction and the mass flow (Kg/hr) of different compound and also
CHAPTER 3. PROJECT WORK 13

the volumetric flow (bbl/hr) of the ARN as per our assumption at different temperature
(Here total 91 point are collect; -40 0 C to 5 0 C with increment of 0.5 0 C)

3.2.1 Sensitivity Analysis

For this purpose we only consider the small part of this whole simulation.

Figure 3.2: Flowsheet’s part for data generation

This Decrease the calculation time of simulation; so the total time of the optimization
tool, Sensitivity Analysis are decrease.

In the Sensitivity analysis we select independent variable as chilled gas’s Temperature

(outlet temperature of cooler) which is vary from -40 0 C to 5 0 C and total data point
is set to the 91 which make increment of 0.5 0 C. The ‘Mass fraction of the compound
in liquid phase’, ‘Mass flow of compound in liquid phase’, ‘Total mass and Volumetric
flow of liquid phase’ are select as dependent variable. After the data generation or end of
the Sensitivity Analysis we copy the dependent variable’s data into the excel and further
calculation and graph plotting are done as per our assumption.
CHAPTER 3. PROJECT WORK 14

3.3 Graphical Representation of Collected Data

Figure 3.3: Flow Rate vs Chilling Temperature (For Lite Component)

Figure 3.4: Flow Rate vs Chilling Temperature (For Heavy Component)

CHAPTER 3. PROJECT WORK 15

Figure 3.5: Flow Rate vs Chilling Temperature (For Value add Component)

Figure 3.6: Mass Fraction vs Chilling Temperature (For Lite Component)

CHAPTER 3. PROJECT WORK 16

Figure 3.7: Mass Fraction vs Chilling Temperature (For Heavy Component)

From figure 3.6; it is clear that after -20 0 C there is comparatively more Ethane and
methane in the condensate; hence the recovery of the other component will increase, but
more methane and ethane are there in condensate.
From figure 3.5; we can tell that at -20 0 C, most of all possible N-Nonane, N-octane, and
NHeptane are condensed and nearly 95% of N-Hexane and 80% of N-Pentane are also
recovered.

From the figure 3.4; we can tell that after the -15 0 C production of the lean gas are become
dominant. At that point most off all ARN are recover. So less C1-C2 condensation point
of view, till -15 0 C chilling temperature is suitable.

Now For the Cost efficient chilling temperature; difference between total profit obtain by
the all value add product recover from the ARN, LPG and lean gas and the operating cost
of propane vapor-compression cycle must be maximum. Hence the SKO are used inside
the plant and the Now For the Cost efficient chilling temperature; difference between total
profit obtain by the all value add product recover from the ARN, LPG and lean gas and
the operating cost of propane vapor-compression cycle must be maximum. Hence the
SKO are used inside the plant and the.

Total profit is summation of all product’s profit, which are directly find from multiply
profit with product’s total flowrate. LPG and Lean Gas’s profit are directly calculated.
Here we find the ARN’s volumetric flow in barrel/hr (bbl/hr) also because this liquid
product are sell into the barrel. And the cost of refrigeration are calculated or directly
used standard value given by the DWSIM capital cost estimator plugin.

N et prof it of condensate = P rof ite of all value add product − Cost of ref rigration
CHAPTER 3. PROJECT WORK 17

Then the graph of Net profit vs Chilling temperature are plotted and the maximum profit
value are consider as cost efficient chilling temperature.

3.4 Drawback of study

• Here we does not consider any kind of aromatic and cyclic component or isomer of
any compound; which will create the influence in the production of the ARN.

• Here the feed to the chiller(refer figure 3.1) is always consider as 12 0 C but it is pre
cooled by the vapor of flash drum so as we decrease the chilling temperature; this
temperature is also going to decrease which lead to less energy requirement in chiller.
Which will create the influence in cost effective chilling temperature calculation if
further calculations are done.

3.5 Conclusion
From the above study we can tell that by using the sophisticated tool for thermodynamics
calculation we can solve the time consuming calculation in a fraction of second which is
not possible by manual calculation. Chemical Process Simulation Tool is a blessing for
chemical industry as prediction of result of any physical change in any unit operation is
possible without performing any experiment. Therefore, open source tool is a boon for
students and other users.
Chapter 4

Pumps and Valves

4.1 Pumps
4.1.1 Centrifugal Pump
In Centrifugal Pump, the mechanical energy of the liquid is increased by centrifugal
action. The liquid enters through a suction connection concentric with impeller, and
the rotating impeller sweeps the liquid out toward the ends of the impeller blades at
high pressure. Impeller carries radial vanes integrally casted in it. Advantages of using
Centrifugal pumps are much smaller size than any other pump, gives steady delivery, can
handle readily liquids containing high proportions of suspended solids.

(a) Close Impeller (b) Open Impeller

Figure 4.1: Schematic of Centrifugal Pump

4.1.2 Reciprocating Pump

Reciprocating Pump is a type of Positive Displacement pump. This type includes Piston
Pump, Plunger Pump, and Diaphragm pump. The given pump is single acting single
cylinder pump with air vessel. It can be used for less discharge at higher heads. Reciprocating
pumps are used in pumping water in hilly areas. Reciprocating pumps has lower efficiency
compared to centrifugal pumps. During the suction stroke the piston moves left thus
creating vacuum in the Cylinder. This vacuum causes the suction valve to open and
water enters the Cylinder. During the delivery stroke the piston moves towards right.
This increasing pressure in the cylinder causes the suction valve to close and delivery to
open and water is forced in the delivery pipe.

18
CHAPTER 4. PUMPS AND VALVES 19

4.2 Valve
A valve is a device for isolating or regulating the flowrate of gases, liquids and slurries
through pipework and launder systems

4.2.1 Gate Valve

In Service, Gate valves are either Fully Opened or Fully Closed. When fully opened,
the fluid or gas flows through the valve in a straight line with a very little resistance.
Generally, Gate Valves are designed to serve as isolation valves. Gate Valve is not used in
regulation or throttling control of flow because accurate control is not possible. High flow
velocity in partially opened valves may cause erosion of the discs and seating surfaces. In
Gate Valve, the pressure loss is minimum.

Figure 4.2: Gate Valve

4.2.2 Ball Valve

A Ball valve features a quarter-turn rotational motion. Ball valve has a spherical plug as
a closure member. If the valve is started out, the gaps in the ball stay in line with the
body inlet enabling the material to pass. Ball valves are mainly used in shut off operation.
They are not used in a partially open position for a long time under conditions of a high
pressure drop across a valve. They are mainly used for Air, Fumes and Fluids. The only
advantages of these type of valves are Lack of throttling qualities.
CHAPTER 4. PUMPS AND VALVES 20

Figure 4.3: Gate Valve

4.2.3 Butterfly Valve

The Butterfly valve is a quarter turn valve. The Butterfly is a metal disc mounted on
a rod. When the butterfly is oriented in the same direction as the pipe (presenting the
least cross sectional area to the moving fluid), this will result in full flow. As the butterfly
is oriented away from the direction of the pipe, the flow rate will be restricted by the
increased area of obstruction to the fluid and finally cut off completely when the butterfly
is oriented at 90 degrees to the pipe direction. The valves were used at the main supply
of the utilities. Head loss in this valve is slightly higher than Gate valves, because their
flow sections are totally free from obstacles.

Figure 4.4: Butterfly Valve

4.2.4 Globe Valve

Globe Valves regulate by the position of a movable disk in relation with a stationary ring
seat. Globe Valves are used for regulating flow in a pipeline. Shut off is accomplished by
CHAPTER 4. PUMPS AND VALVES 21

moving the disc against the flow stream rather than across it as in the case with a gate
valve. The flow pattern through a globe valve involves changes in direction, resulting in
greater resistance to flow, causing high pressure drop. The globe valve is an excellent
valve to use for on-off service, but is highly suited for frequent cycling and control of
fluids anywhere in amount or volume between the open and closed positions. The globe
valve must be installed in the proper relation to the media flow as indicated by the flow
direction arrow marked on the valve body. This valve is considered uni-directional and
must be installed with the pressure side or inlet under the seat. This valve is used in
handling steam.

Figure 4.5: Globe Valve

Chapter 5

Line Sizing and MOC

5.1 Colour coding for piping

Table 5.1: Colour code for piping

Pipe Color
Fire Quenching Fluid Red
Gas Yellow
Two Phase Flow Dark Yellow
Water Green
Air Blue
Highly Flammable Liquid Brown
Liquid Gray
Condensate Sky blue

5.2 Line Sizing and MOC

Table 5.2: Line Sizing and MOC

Name Size (Inches) Material Of Construction

Fuel Gas 3” Mild Steel
Flare 3”/4” Mild Steel
Hot Water Utility 2” Mild Steel
Cold Water Utility 2” Mild Steel
Transportation Pipes (Gases) 10” Mild Steel
Transportation Pipes (Solvent) 3” Mild Steel
Drain 1” Mild Steel

22
Chapter 6

Instrumentation

6.1 Resistance Temperature Detector

RTD is a temperature sensor which measures temperature using the principle that the
resistance of a metal changes with temperature. In practice, an electrical current is
transmitted through a piece of metal located in proximity to the area where temperature
is to be measured. The resistance value of the RTD element is then measured by an
instrument. This resistance value is then correlated to temperature based upon the known
resistance characteristics of the RTD element.

RTDs work on a basic correlation between metals and temperature. As the temperature
of a metal increases, the metal’s resistance to the flow of electricity increases. Similarly,
as the temperature of the RTD resistance element increases, the electrical resistance,
measured in ohms (Ω), increases. RTD elements are commonly specified according to their
resistance in ohms at zero degrees Celsius (0o C). The most common RTD specification is
100 Ω, which means that at 0o C the RTD element should demonstrate 100 Ω of resistance.

Platinum is the most commonly used metal for RTD elements. Other metals used as
the resistor elements in an RTD include nickel, copper.

23
CHAPTER 6. INSTRUMENTATION 24

Figure 6.1: Resistance Temperature Detector

6.1.1 Pressure Gauge

Pressure gauge is instrument for measuring the condition of a fluid that is specified by
the force that the fluid would exert, on a unit area. Pressure gauges are useful tools that
are imperative to many industrial applications. They are reliable and easy to use.
Mechanical pressure gauges utilise an inner tube that is connected to a gear and shaft
assembly that work together to move a pointer. When the pressure within the tube
surges, the tube uncoils slightly. As the tube uncoils, the motion triggers the gear and
shaft system that moves the pointer on the gauge. The amount of uncoiling movement
that occurs is relative to the pressure within the tube. This movement then informs the
pointer, giving you a pressure reading.

Figure 6.2: Pressure Gauge

CHAPTER 6. INSTRUMENTATION 25

6.2 Level Indicator

Level indicators are devices used in the measurement of level of fluids. These devices are
used to determine the level of liquid in tanks, drums. Pressure vessels. Level devices
operate under three main different principles:
1. The position (height) of the liquid surface

2. The pressure head

3. The weight of the material

Figure 6.3: Level Indicator

6.3 Flow Meter

Flow meter is an instrument for measuring properties such as velocity or Pressure.

A flow meter works by measuring the amount of a liquid, gas, or steam flowing through
or around the flow meter sensors. Flow meter sensors work in different ways, but with the
same end goal: Provide the most accurate and repeatable flow measurements for a specific
application, whether for process control, general research activities, or semiconductor
processing. The flow (Q) is equal to the cross-sectional area of the pipe (A) in a volumetric
flow meter, and the velocity of the flowing fluid (v): Q = A * v. The mass flow can be
expressed in a mass flow meter as follows: ṁ = Q * ρ (where Q is the volumetric flow
rate and ρ is the fluid density).

6.4 Rotameter
A rotameter is a device that measures the volumetric flow rate of fluid in a closed tube.
It belongs to a class of meters called variable area meters, which measure flow rate by
allowing the cross-sectional area the fluid travels through to vary, causing a measurable
CHAPTER 6. INSTRUMENTATION 26

Figure 6.4: Flow Meter

effect.

The buoyant force exerted on an immersed object is equal to the weight of liquid displaced
by the object. Under this principle, the rotameter works with float-tapered tube system.
Fluid enters from the bottom of the tapered tube, then some of the fluid strikes directly
into the float bottom and others pass aside the float. Now the float experience two forces
in opposite direction, drag force upward and gravitational force downward.

Fluid flow moves the float upward against gravity. At some point, the flowing area reaches
a point where the pressure-induced force on the floating body exactly matches the weight
of the float. The float will find equilibrium when the area around float generates enough
drag equal to weight – buoyancy.

Figure 6.5: Rota Meter

Chapter 7

Plant Safety

In the operation of any plant, safety of personnel and equipment is a very important
consideration. Even through plants have in-built safety devices to take care of emergencies,
proper operating procedures and use of safety equipment are a must for the safe running
of the plant and preventing injury to personnel.

General safety regulations as applicable to hydrocarbon processing plants must be followed.

Hydrocarbon detectors are provided at various locations in the unit. Hydrocarbon vapors
make normal breathing difficult leading to asphyxiation and some adverse physiological
effects.

7.1 Precautions
The following precautions should be taken :

• Personnel should not come in contact with moving parts of equipments, hot surfaces
etc.

• Care to be taken to avoid sparks and naked fire. Smoking to be allowed only in a
restricted area.

• Avoid hydrocarbons coming in contact with air as mixing can form an explosion
hazard.

• All repair work to be carried out only after getting clearance from the appropriate
authority.

• All ends of platforms, staircases etc. to be secured and no obstruction should be

there in walkways.

• Special care to be taken when drawing samples from streams at high pressure /
temperature.

• All safety apparatus and first aid equipment should be easily available and operating
personnel must be properly trained in using them.

• Adequate safety shower and eye wash points to be provided.

• Adequate fire fighting devices to be provided.

27
CHAPTER 7. PLANT SAFETY 28

7.2 Possibilities of any Hazard

As outlined in the preceding paragraph the safety hazard mainly accrues in this unit due
to hydrocarbon leakage.

7.3 Safety Equipments

7.3.1 Personal Protective Equipments
PPE and It’s Requirements
• PPE as mandated by risk assessment and site requirement.

• Always wear core PPE such as Overall, Safety Shoes, Helmet, Gloves, Safety Goggles
and Ear Plug/Muff at work place.

• Ensure use of kits and liveries as per the requirement of MSDS.

• Wear appropriate kits and liveries while carrying out electrical and other specialised
jobs.

• Ensure that PPE is suitable for the task, is in good condition and serviced as
required.

• Ensure that visitors, contractual workers are also in appropriate PPE at workplace.

Eye Protection
Hazards:
Chemical or metal splash, dust, projectiles, gas and vapour, radiation

Options:
Safety spectacles, goggles, face screens, faceshields, visors

Head and Neck Protection

Hazards:
Impact from falling or flying objects, risk of head bumping, hair getting tangled in
machinery, chemical drips or splash, climate or temperature

Options:
Industrial safety helmets, bump caps, hairnets and firefighters’ helmets

Ears Protection
Hazards:
Noise – a combination of sound level and duration of exposure, very high-level
sounds are a hazard even with short duration

Options:
Earplugs, earmuffs, semi-insert/canal caps
CHAPTER 7. PLANT SAFETY 29

Hands and arm Protection

Hazards:
Abrasion, temperature extremes, cuts and punctures, impact, chemicals, electric
shock, radiation, vibration, biological agents and prolonged immersion in water

Options:
Gloves, gloves with a cuff, gauntlets and sleeving that covers part or all of the arm

Feet and legs Protection

Hazards:
Wet, hot and cold conditions, electrostatic build-up, slipping, cuts and punctures,
falling objects, heavy loads, metal and chemical splash, vehicles

Options:
Safety boots and shoes with protective toecaps and penetration-resistant, mid-sole
wellington boots and specific footwear, eg foundry boots and chainsaw boots

Lunge Protection
Hazards:
Oxygen-deficient atmospheres, dusts, gases and vapours

Options – respiratory protective equipment (RPE):

Some respirators rely on filtering contaminants from workplace air. These include
simple filtering facepieces and respirators and power-assisted respirators
Make sure it fits properly, eg for tight-fitting respirators (filtering facepieces, half
and full masks)
There are also types of breathing apparatus which give an independent supply of
breathable air, eg fresh-air hose, compressed airline and self-contained breathing
apparatus

Whole body Protection

Hazards:
Heat, chemical or metal splash, spray from pressure leaks or spray guns, contaminated
dust, impact or penetration, excessive wear or entanglement of own clothing

Options:
Conventional or disposable overalls, boiler suits, aprons, chemical suits
CHAPTER 7. PLANT SAFETY 30

(a) Industrial Safety Goggles (b) Industrial Safety Helmet (c) Earplug

(d) Industrial Safety Gloves (e) Industrial Safety boots (f) Industrial Safety Suit

(g) Chemical Safety mask (h) Breathing Apparatus

Figure 7.1: Personal Protective Equipments

7.3.2 First Aid

Always Have
Five first-aid essentials for every job site.

1 Adhesive Bandages:
The most-used item when it comes worksite injuries. Every first-aid kit should have
more adhesive bandages than anything else.

2 Antibiotic Application:
A top-used item, applicable to everything from paper cuts to burn treatment.

3 Antiseptic:
A must for anyone treating an injury. This helps reduce the risk of infection.

4 Burn Treatment:
New “burn packs” have supplies to treat large and small burns. If you work in a
place where burns are possible, consider a full kit devoted to burns.

5 Medical Exam Gloves:

The best guard against infection and bacteria. They should be worn by anyone
treating any skin injury.
CHAPTER 7. PLANT SAFETY 31

Speciality
Because manufacturing job sites have higher rates of injury, first-aid kits must be modified.
These three items help treat serious injury.

1 Splint:
For setting broken bones before the professionals arrive.

2 Tourniquet:
To slow or stop bleeding from a laceration, a danger when working with heavy
machinery.

3 2- and 4-Inch Roller Bandages:

For dressing deeper or larger skin injuries.

Uses
• Burn:
Pour cold water on the burn portion. Do not apply any ointment.

• Shock:
Remove the person from the place of clinger. If respiration is stopped give C.P.R.

• Injury:
Stop the blood flow. Clean the cut with sterilized cloth. Wash the wound with
water apply bandage.

• Suffocation:
Remove the person from the place of danger. Inspect and clean his respiratory tract
if necessary. If respiration is stopped give C.P.R.

• Eye injury:
If there is a foreign bodies in the eye try to remove it. If the eye infected with
chemical, wash it with water for 15 minutes. Do not apply ointment or oil. If the
eye is burnt use sterilized bandage after washing with water.

• Poisoning:
Remove the person from the place of danger. Make the person to lie down, remove
the infected cloths and wash the infected skin with water.

• Fracture:
The splints on the upper and lower part of the fractured body part, Take the person
to the hospital on a hard frame. In case of neck fracture summon the doctor on the
place of incidence.
CHAPTER 7. PLANT SAFETY 32

Figure 7.2: First Aid Box

7.3.3 Eyewash and Safety Showers

Safety shower specs
For safety showers, the shower head must be capable of flowing 20 gallons per minute
(gpm) at 30 psi and producing a 20-inch diameter spray pattern at 60 inches above the
surface where the user stands. The center of the sprayhead pattern should be at least 16
inches from any wall, door, or obstruction. It is recommended that the shower head be
mounted between 82 and 96 inches off the floor, with the valve no higher than 69 inches.

Eyewash specs
Eyewash stations target just the eyes and therefore have a lower flow requirement. Recommends
a flow of 0.4 gpm also at 30 psi. The nozzles should be at least six inches from any
obstruction and mounted between 33 and 45 inches above the floor. An eyewash gauge
should be used to verify and test the flow pattern.

Requirements for both

Both safety showers and eyewash stations must be able to provide the recommended flow
for at least 15 minutes. This usually translates into having the equipment plumbed in
with hard connections to the water supply. For example, a quick calculation for the safety
shower at 20 gpm yields 300 gallons needed. Self-contained or personal wash devices are
allowed, but they are considered supplemental units that can provide immediate flushing
while transiting to the permanent fixture.

If the local climate presents potential for freezing conditions, the equipment must be
designed to avoid freezing or protected against that situation. Activation valves must
open within one second and remain open until intentionally closed or turned off. It
goes without saying that these safety devices should be constructed of corrosion-resistant
materials.

We know we have the 10-second rule etched into your brain, as that is the most critical
element when it comes to safety showers and eyewashes. This means that travel to the
CHAPTER 7. PLANT SAFETY 33

unit should be under 10 seconds for all hazardous areas that need this equipment. This
equals about 55 feet. In addition, the drench shower or eyewash must be on the same
level as the hazard and have a clear path for travel. We recommend painting or marking
the floor area underneath the shower to help keep it clear. It is also recommended that
equipment be installed in a brightly lit area and marked with a highly visible safety sign.

Figure 7.3: Eye wash and Safety Shower

7.3.4 Fire Fighter Devices

Portable First Aid Fire Fighting equipment:
Fire extinguishers of dry chemical powder type and carbon di-oxide type of various
capacities have been installed at various locations for fighting fires at its incipient stage.
Dedicated maintenance crews keep the fire extinguishers in good working order.

Fixed Installations:
Critical Process Units have been provided with medium velocity water spray systems and
deluge systems for Horton spheres and hot pumps. These systems are augmented by Fire
water monitors and hydrants all around the Units. Floating and fixed roof hydrocarbon
storage tanks have been provided with cooling system in addition to fixed foam system.
Central hose stations, hose boxes and hose reels have been located as support systems.

Mobile Appliances:
Foam Tenders with one Foam Nurser as back-up and Dry Chemical Powder Tenders
make up the mobile appliances. The foam tenders have rear mounted pumps driven via
the Power Take-off in addition to foam tank and water tank.
CHAPTER 7. PLANT SAFETY 34

Figure 7.4: Fire Fighter Devices

Chapter 8

Utilities

Utilities are the services which are essential for the operation of the plant, though these
may not contribute directly towards the revenue generated. The major utility systems
the plant has include:
• Air system
• Inert gas system
• Water system
• Raw water treatment plant
• Fire water pump house
• Cooling water system
• DM water system
• Emergency Preparedness
• Cogeneration and steam systems
• Effluent treatment and disposal plant
• Fuel gas network

8.1 Inert Gas Plant

Air is used in many places within the plant. Inert gas systems are used for purging to
ensure hydrocarbon/air free state during shutdown and start-up activities. Inert gas is
prepared from the atmosphere at the inert gas plant through the PSA (pressure swing
adsorption), in which the air is passed through carbon molecular sieves, which have the
granules of a special compound which adsorbs N2 at the surface, and relieves O2 , when
under pressure. The container is then depressurized so that the entrapped nitrogen escapes
which is then delivered to appropriate location. Nitrogen is used for regular processes in
KRU (as sealing medium in certain pumps).

Two towers work in conjugation, one working under adsorption mode and the other in
regeneration mode. The requirement of nitrogen is approximately 400m3 /hr.
Instrument air is utilized in automatic plants, for use by instruments, so it has to be free
from any kind of moisture. Plant air, which may have some moisture is used in SRU
plant.

35
CHAPTER 8. UTILITIES 36

8.2 Water Water Treatment Plant

Another important utility system is the water system. Water is utilized in almost all
the units. Tapti River, the source being about 30-40 km from the Plant, through a weir
designed to ensure continuous supply of water. The water is then kept into reservoirs at
the plant, in which it is allowed to settle, and then is pumped out to various locations.
The total consumption of water at the plant is about 20,000 kl/day.

The water is used as service water for plant usage, and as make up water in cooling
towers (to counter evaporation losses etc.) Drinking water is also supplied after adequate
treatment, not only to the plant but also to nearby villages for social obligation and to
nearby ONGC residential colony.

Cooling water and service water lines are spread throughout the plant as sea green
pipelines. Red lines are for firefighting systems. Raw water systems have an operating
capacity of about 2000 m3 /hr. (5 pumps x 750 m3 /hr. 2 standby).
Chapter 9

Environmental Issues

One of the most important part of gas processing involve removal of sulphur and carbon
dioxide. Off-shore gas contain significant amount of sulphur and carbon dioxide, because
of the rotten smell provided by its sulphur content, is commonly called ‘sour gas’. After
absorption with MDEA the acid gas from top of sweetening unit is sent to Sulphur
Recovering Unit (SRU) to recover elemental sulphur. Elemental sulphur is a bright yellow
powder like material, and can often be seen in large piles near Sulphur Recovering Unit.
Sulphur can be extremely harmful, even lethal, to breath.

Sulphur can have the effects on workers’ health who are working there for prolonged
period of time:

• Suffocation

• Dermatological Effect

• Stomach & gastrointestinal disorder

• Damage to lever and kidney function

• Disturbance of blood circulation

• Effect on eyes and eyesight

• Damage to immune system, etc.

CO2 also have adverse effect on human being as well as environment as follows :

9.1 Health:
CO2 is essential for the survival of animals. Oxygen is carried to body tissue during
breathing and carbon dioxide is released. The gas protects the pH level of blood. Too
much CO2 , however can kill animals. If carbon dioxide is confined, it can decrease the
amount of oxygen reaching the body. Any increase or decrease to the amount of carbon
dioxide reaching the body can lead to kidney failure or coma.

9.2 Greenhouse gas:

CO2 is a naturally occurring greenhouse gas. These gases help keep the earth warm
by absorbing the sun’s energy and by redirecting energy back to the earth’s surface.

37
CHAPTER 9. ENVIRONMENTAL ISSUES 38

An increase in amount of CO2 creates an overabundance of greenhouse gases that trap

additional heat. This trapped heat leads to melting ice caps and rising ocean levels.