Summer Internship Report

An Overview on Onshore Gas Terminal and its Processing Units

At OGT, P.Mallavaram

A report submitted in partial fulfilment for the award of degree of

Bachelor of Technology in Petroleum Engineering

By

Vankayalapati Sai Navaneeth

(15021A2610)
Under the Guidance and Supervision of

Shri P.S.Prasad
Chief Executive-Production
Onshore Gas Terminal – P.Mallavaram

DEPARTMENT OF PETROLEUM ENGINEERING AND

PETROCHEMICAL ENGINEERING
UNIVERSITY COLLEGE OF ENGINEERING KAKINADA (A)
JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY KAKINADA

KAKINADA – 533003
2018
 DECLARATION

I, VANKAYALAPATI SAI NAVANEETH, hereby declare that this summer

internship report entitled “A brief description on Air separation & De-Mineralising plant”
is original and has not previously formed the basis for the award of any degree to similar
work.

Place: Kakinada

Date: 03-01-19 Signature

ii
CERTIFICATE

iii
 ACKNOWLEDGEMENT

I would like to thank Mr. R. S. Rama Rao (Chief Manager-HR) for considering
my candidature as summer intern. I am deeply indebted to Mr. P.S.Prasad (Chief
Executive-Production) whose help, stimulating suggestions and encouragement helped
me to complete my summer internship successfully. I am also thankful to the entire HR
team of ONGC, HPHT that facilitated my internship.

I take this opportunity to express my gratitude and sincere thanks to Mr. Sanjay
Singh, Officer-Process & Mr. Dharnesh Garapati, officer-process for providing
excellent facilities to complete the training on “OGT PLANT OPERATIONS”.

I acknowledge sincere thanks and deep-felt gratitude to Prof. K.V.Rao,

Programme director, Petroleum courses, Jawaharlal Nehru Technological University,
Kakinada for arranging the summer internship program.

I take this opportunity to express my sincere thanks to Dr. k.Meera Saheb, Head
of the Department, Department of petroleum Engineering and Petrochemical Engineering
for encouraging and motivating me to complete the internship and report successfully.

Also, I express my special thanks to our beloved Principal, Dr. P.Subba Rao his
enthusiastic support in our endeavours.

V.Sai Navaneeth

15021A2610

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 Contents

Serial Number Title Page

Declaration ii
Certificate iii
Acknowledgements iv
Abstract vii
List of Figures viii
List of Tables viii
1.0 Chapter-1: Overview of OGT plant 1
1.1 Natural Gas Scenario in India 1
1.2 Introduction of Deen Dayal field 2
1.3 Overview of OGT plant 2
2.0 Chapter-2: Gas Sweetening Unit (GSU) 4
2.1 Introduction 4
2.2 Process Description 5
2.3 Unit Description 5
2.4 Challenges in GSU 9
3.0 Chapter-3: Gas Dehydration Unit (GDU) 10
3.1 Introduction 10
3.2 Process Description 10
3.3 Problems in GDU 14
4.0 Chapter-4: Dew Point Depression Unit (DPDU) 16
4.1 Introduction 16
4.2 Process description 17
4.3 Product Specification 18
5.0 Chapter-5: Condensate Stabilization Unit (CSU) 19
5.1 Introduction 19
5.2 Process description 20
5.3 Product Specification 21
6.0 Chapter-6: Utilities 22
6.1 Raw Water Treatment Plant 22
6.2 Demineralized Water Plant 22

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6.3 Cooling water system 23
6.4 Compressed Air and Nitrogen Plant 23
6.5 Flare 24
6.6 Effluent treatment plant 24
7.0 Chapter-7: Compressed Air and Nitrogen plant 25
7.1 Introduction 25
7.2 Unit Description 25
7.3 Nitrogen Plant 26
8.0 Chapter-8: Demineralised Water System 28
8.1 Introduction 28
8.2 Production of DM water 28
8.3 Types of tanks 31

vi
 ABSTRACT

Natural gas produced from wells is often called “raw gas”. A raw gas stream is
mostly methane, which is often called “dry gas”. A raw gas stream with a large amount of
natural gas liquids, which include ethane, propane, normal butane, isobutane, and natural
gasoline, is called “wet gas.” Raw gas also has some impurities such as water, carbon
dioxide, and sulphur.

Natural gas processing removes impurities and separates natural gas liquids (or
NGLs) from dry gas. Processing is valuable because natural gas liquids, as separate
components, have their own applications and are worth more extracted from the raw gas
stream. Plus, long-haul natural gas pipelines have certain requirements as to the natural gas
that enters the pipeline systems, and generally the gas has to be sufficiently dry (that is, it
can’t exceed a certain NGL content). NGLs are usually separated by cooling the raw
natural gas until the NGLs condense into a liquid and separate from the dry gas (ethane).
NGLs are heavier hydrocarbons, so they condense to a liquid at higher temperatures than
ethane, and so they can be removed through cryogenic recovery.

Plus, the impurities in raw natural gas, such as water, sulphur, or carbon dioxide,
can damage pipelines, and processing is useful to remove these impurities from the raw
gas stream.

Once the natural gas is processed, the result is a stream of processed dry gas or
“residue gas” and a stream of natural gas liquids. The residue gas then either enters into
larger pipelines that can transport it over longer distances or into storage facilities. The
natural gas liquids move by pipelines or trucks to a fractionator so that the mixed NGL
stream can be separated into its individual components (such as ethane, propane, and
butane)

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 List of figures

Figure Caption Page

1.1 Gas Production in India 1
1.2 Pipeline from production to plant 2
1.3 Overview of OGT 3
2.1 Overview of GSU unit 4
2.2 Adsorption section in GSU unit 7
2.3 Regeneration section in GSU unit 8
2.4 Filter section 9
3.1 Overview of GDU unit 10
3.2 Adsorption section in GDU unit 12
3.3 Adsorption and Regeneration process 13
4.1 Overview of DPDU plant 16
5.1 Condensate Stabilization Unit 20
7.1 Pressure Swing Adsorption process 27

List of tables:

Table Title Page no

2.1 Feed specification of GSU plant 5

2.2 Production specification of GSU plant 9

3.1 Feed specification of TEG in GDU unit 11

3.2 Product specification of GDU unit 13

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 Chapter 1

Overview of OGT plant

1.1 Natural Gas Scenario in India

Historically, India has relied on coal to power its electricity sector, liquid sector as
feed stocks and oil for its transport sector. But for environment reasons we need to focus
on cleaner fuels.

The development of natural gas industry in the country started in 1960’s with
discovery of gas fields in Assam and Gujarat. After discovery of south basin field ONGC
in 1970’s, Natural gas assumed importance.

Initial Natural oil companies, later private companies using NELP. As per ministry
of petroleum, India has 1437 billion cubic meters (50.7x1012 cubic feet). As per EIA data,
India produced 996 billion cubic feet. In 2004, India consumed 1089x109Cu.ft.

During 2004, India imported 93x109Cu.ft. of Liquid Natural Gas (LNG) from Data.
The India’s Natural gas production is shown in below Figure 1.1.

Figure 1.1-Gas production in India

1
1.2 Introduction of Deen Dayal field:

Oil and Natural Gas Corporation is the operator of the Deen Dayal Field/Block,
situated offshore from the Yanam, Kakinada coast of Andhra Pradesh, India. The area of
block awarded is 1850km2. ONGC has discovered a significant reserve of gas in Deen
Dayal west area with KG-8 exploration well located 15km offshore in 60m of water. The
reservoir is characterized by high pressure and high temperature.

Initial Deen Dayal development is expected to consist of a well head platform

(WHP), process cum living quarter platform, multi stage pipeline to shore and On Shore
Gas Terminal (OGT). The pipe line route will be via Gowthami Godavari river estuary to
avoid encroaching on the Korangi sanctuary. Block diagram of PLQP, WHP & Pipeline is
shown in below Figure 1.2.

Figure 1.2-Pipeline from production to plant

1.3 Overview of OGT plant:

All production gas from the Deen Dayal field will be gathered at the DDW
production hub and exported to the onshore gas terminal at p.mallavaram, East Godavari,
Andhra Pradesh via a common pipe line(up to the pipeline capacity) after dehydration at
process platform.

2
 It has been decided to design the OGT for a throughout of 200 MMscf(2x100) to
provide operational flexibility for turndown scenario for adding two more trains in the
future.

For condensate stabilisation unit total two trains are planned with one train to be
installed now and one train in future. For sulphur unit only one train with two reactors shall
be installed now and provision shall be kept for two additional future trains. Overview of
OGT is shown in below Figure 1.3.

Figure 1.3-Overview of OGT

3
 Chapter 2

Gas Sweetening Unit

2.1 Introduction:

Sour gas from the slug catcher and Off-Gas from the Condensate
Stabilization Unit will be processed in the Gas sweetening unit. Capacity of GSU is 2*100
MMSCFD.

The main function of Gas Sweetening Unit or GSU is to remove Hydrogen

Sulphide (H2S) and Carbon Dioxide (CO2) from the gas to meet sales gas specification.
This is an absorption-regeneration type process based on MDEA (Methyl Di-ethanol
Amine) as the solvent. Acid gas and Flash gas from GSU will be sent to SRU and fuel gas
header respectively. The condensate generated will be routed to CSU. Overview of GSU
is shown in below Figure 2.1.

Figure 2.1- Overview of GSU unit

4
Feed Specifications:

Feed Specifications are shown in below Table 2.1.

Table 2.1- Feed specification of GSU plant

Feed Parameter UOM Specification

Sour Gas CO2 Mole % 10%

Sour Gas H2S Mole % 0.0098%

2.2 Process Description:

The selective removal amount of H2 is made by absorbing the gas with an aqueous
solution of MDEA. MDEA is a tertiary amine which does not react easily with CO2. The
selectivity is so prompted by using the difference in rate of reaction H2S and of CO2 with
the tertiary amine. To perform a selective desulfurization using a MDES solution, it is
necessary to provide in the absorber a gas-liquid contact time large enough to remove H2S
but short enough to retain CO2. H2S and CO2 absorption performance control is therefore
mainly controlled by the gas-liquid contact time in he absorber. The concentration of
MDEA solution is 45%.

2.3 Unit description:

GSU consists of two major sections:

1. Absorption Section
2. Regeneration Section

Absorption Section:

As slug catcher derived sour gas can have wide range of operating temperatures,
provision for cooling by water cooler as well as preheating the sour gas by steam heater

5
has been made at the inlet of Absorption section. The cooling or preheating requirement of
the gas is to be decided based on arrival temperature w.r.t. absorption temperature
requirement. Absorption is an exothermic reaction. The feed gas after flow control is then
mixed with CSU off-gas and taken to Inlet gas knock out drum. The condensate so
separated in knock out drum is transferred to CSU. The separated gas from Inlet gas K.O.
Drum enters the amine absorption column where it comes in contact counter currently with
the aqueous solution of MDEA. The absorber is equipped with 21 valve trays for the
purpose of equilibrium operation. The lean amine has given a provision to enter through
1st or 3rd or 5th tray basing on the operating conditions. The treated gas then enters Water
wash column equipped with packed bed of pall rings. Here, the gas is counter currently
contacted with circulating water to remove any amine solution carryover. The treated gas
is then cooled by passing through a water cooler and piped to downstream unit of GDU.
Liquid phase resulting from cooling (condensed water + amine carry-overs) is separated in
the treated gas K.O. Drum and returned to rich amine circuit at low pressure along with
Rich amine from GDU. Absorption process is shown in Figure 2.2.

MDEA immediately reacts with H2S to yield Hydro Sulphide by proton transfer.
CO2 dissolves in water and forms bicarbonate ion. These acids then react with amine to
form amine bicarbonate and amine carbonate.

The overall time depends on the upon contact time. Contact time depends upon
1. The gas flow rate.
2. The liquid height above the plate area (Weir height).
3. Number of trays.
4. Only parameter that can be varied is the number of active trays.

The gas which is free from H2S AND CO2 is recovered from the top side of the
absorber, sent into the water wash column to remove the MDEA from sweet gas, if any
present. Next, the sweet gas is sent into the GDU unit.

6
 Figure 2.2-Absorption section in GSU Unit

Regeneration section:

The stream of the rich amine solution is recovered under level control valve from
the bottom of the absorber and piped to the rich amine flash drum. The sour flashed gas
from flash drum is brought into contact with a small lean MDEA flow in an absorption
tower placed on the top of the rich amine flash drum in order to meet the fuel gas
specifications. The rich amine solution flows from the flash drum to the rich/lean amine
exchanger. The rich amine flash drum level control valve is located downstream of
exchanger in order to minimize the solution degassing in the exchanger plates. MDEA
solution stripping is accomplished in the regenerator by the vapour generated from the
Reboiler. The lean amine collected at the bottom of the regenerator is pumped & routed
through rich/lean amine exchanger, which is a plate type exchanger to air cooler followed
by water cooler before sending it to lean amine storage tank. MDEA is very sensitive to
oxygen when they come in contact, produces heat stable salts, primarily the acetate,
formate and glycolate. In order to avoid direct contact with air, the storage tank is equipped

7
with a gas blanket. Nitrogen is being used as the blanketing gas. The hot acid gas mixture
from the overhead of the regenerator is cooled in an air cooler followed by a water
condenser where water vapour condenses. This condensed vapour is separated in the reflux
drum and pumped back to the top section of the regenerator as reflux liquid. Acid gas is
sent to Sulphur Recovery Unit (SRU) through an acid gas header. Regeneration process is
shown in following Figure 2.3.

Figure 2.3-Regeneration process in GSU Unit

Filtration section:

There exists a provision for removal of impurities like dust and rust which was
carried through the solution. There are 3 filters of which 2 are cartridge filters for the
removal of impurities like rust and dust and one charcoal filter for removing organic
impurities like oil and grease which may lead to foaming. Filter section is shown in
following Figure 2.4. Production specifications are shown in Table 2.2.

8
 Figure 2.4-Filter section
Table 2.2-Production specification of GSU unit

Product Parameter UOM Specification

Sweet gas CO2 Mole % <3%

Sweet gas H2S ppm <4

Hydrocarbon
Acid gas Mole % <1%(to be minimised)
content
Rich MDEA flash
H2S PpmV <4(to be minimised)
gas

2.4 Challenges in GSU:

Two major challenges representing a significant threat to an amine gas treating

plant are corrosion and instability of operation, resulting in unscheduled upsets and
outages. High corrosion rates, typical for a number of amine plants, as well of stainless
steel, usually attributed to chloride, create serious safety concerns. High corrosion leads to
high repair costs, potential environment implications, and lost production. The results of
survey conducted by the National Association of Corrosion engineers (NACE) indicate
that 60% of total 24amine plants surveyed experience stress corrosion cracking in the
amine absorbers.

9
 Chapter 3

Gas Dehydration Unit

3.1 Introduction:

All raw natural gas is fully saturated with water vapor when produced from an
underground reservoir. Because most of the water vapor has to be removed from natural
gas before it can be commercially marketed, all-natural gas is subjected to a dehydration
process. As shown in the below Figure 3.1, One of the most common methods for removing
the water from produced gas is glycol. This page discusses the types of glycols that may
be used, the process used to remove water with glycol, and the control of air emissions
from glycol dehydration units.

Figure 3.1- Overview of GDU process unit

3.2 Process description:

The removal of water from sweet gas is made by contacting the gas with Tri Ethylene

Glycol solution. In this unit, treated gas leaving the gas sweetening unit enters the

10
dehydration unit. It consists of two sections:

1. Absorption Section.
2. Regeneration Section.

Feed specification:

Feed specification of Tri Ethylene Glycol (TEG) is shown in below Table 3.1

Table 3.1-Feed specification of TEG in GDU unit

Product Parameter UOM Specification

Sweet gas Moisture Ppm

Lean TEG Concentration V% 99.7%

Absorption section:
Sweet gas enters the dehydration unit into the inlet gas K.O drum where entrained
or condensed liquids are removed. The liquids are sent back to the rich amine flash drum.
Then gas passes through the absorption column where it is contacted with lean Tri Ethylene
glycol solution (99.7%Wt). The glycol is highly hygroscopic, and most of the water vapor
in the gas is adsorbed by the glycol. This column is provided with packed bed where gas
flows upward through bed of the glycol contactor for counter current contact with Tri
Ethylene Glycol. Adsorption process is shown in flowing Figure 3.2.
Water is removed by a process called adsorption. Adsorption is the process of
removing impurities from a gas stream by means of a solid material called adsorbent (TEG)
that has special attraction for impurities (water). Tri Ethylene Glycol adsorbs water from
the gas until the equilibrium partial pressure of TEG & water in gas us reached. The result
achieved is 1 to 2% of moisture by wt. in the outlet.
Dehydrated gas exits from the top of Glycol contactor is scrubbed for any glycol
carryover in the Glycol filter separator and then goes to the downstream units and, then
sent to downstream hydrocarbon dew point depression units. Rich glycol is drawn-off
under level control off the bottom from the absorber and routed to the regeneration section.

11
 Figure 3.2-Adsorption process in GDU unit

Regeneration process:

Rich glycol received from dehydration section enters degassing drum where the
absorbed light hydrocarbons are released and sent under pressure control to the fuel gas
network is equipped with heavy hydrocarbon skimming lines. The degassed glycol leaving
enters the Glycol Filtration package consisting of Cartridge filters followed by Charcoal
filter. Another Cartridge filter provided at downstream of charcoal filters. Before entering
the still column to be regenerated, glycol is preheated in two steps.

First, in a heating coil atop the regeneration column, providing the desired overhead
reflux which is controlled by the 3 ways overhead temperature control valve and second in
the Glycol/Glycol Plate Heat Exchanger which is a plate type by the regenerated glycol.
The glycol regeneration column fitted with 5 trays is top mounted on the Reboiler. The
bath temperature is controlled by the action on the steam flow rate to the Reboiler.
Adsorption and Regeneration process is shown in below Figure 3.3.
Lean Tri Ethylene Glycol leaving Reboiler is afterwards stripped by dry fuel gas in
the packed stripping column to reach the final concentration of 99.7 % Wt. Then, it returns

12
to the glycol surge drum, after being cooled to 116.3 0C in the glycol/glycol exchangers.
From the surge drum, it is pumped by the reciprocating pumps to the Lean Glycol cooler
for cooling the lean glycol to 36.4 0C and further sent back to the absorber.

Figure 3.3-Adsorption and Regeneration process

Product specification:
Product specification of sweet after GDU process is shown in below Table 3.2

Table 3.2-Product specification of GDU unit

Product Parameter UOM Specification

Dehydrated gas Moisture Ppm 147

Rich TEG Concentration V% 94%

13
3.3 Problems in Gas dehydration unit:

Absorber and Insufficient Dehydration:

Reasons:

 High water content in lean Glycol (i.e.) Poor Regeneration.\

 Over or Under Circulation
 Over circulation → insufficient cooling → warm solvent → affinity to absorb
water is reduced → Contact time is reduced
 Under Circulation → amount of solvent is not sufficient for removing water.
 Causes (why does over or under circulation takes place?)
 Due to pump problems (wear, leakage…)
 Due to surge tank level problems
 Temperature of inlet gas increases (i.e.) water prefer vapor phase.
 Reduction in Pressure inside the Absorber.

Foaming:

Reasons

 Increase in gas velocity(Mechanical Reason) Due to plate plug ( no sufficient

free area)
 Presence of impurities (Chemical Reason)
 Solid impurities- Corrosion Inhibitor- Well Chemicals (chemicals added to
reduce well resistance)

Solution
To install filter (Activated Carbon filter) to remove any foaming materials.

Hydrocarbon Losses:

14
 Reasons
 Due to the physical properties of the solvent

Solution
 Can be overcome using a condenser after the absorber (this cause water pollution
because there is no complete separation).

Stripper:
 Thermal degradation of solvent is the only problem.
 This can be overcome by controlling the temperature inside the stripper not to
exceed 400°F depending on the type of solvent.

Reboiler:
 Heat Transfer Problems due to fouling
 Degradation (maximum temperature at the bottom due to bad temperature Profile)
 If solids (NaCl from water in the well) is greater than 1%; send to the reclaimer.

Surge Tank:

It is a level control problem

♦ The effect of level fluctuation on process performance:
♦ High level→ High flowrate → over circulation
♦ Low level → Low flowrate→ under circulation

Heat Exchanger:
 Fouling
 Corrosion

15
 Chapter 4
Dew Point Depression Unit (DPDU)

4.1 Introduction:

Sweetened & Dehydrated Gas from the GDU (Gas Dehydration unit) will be
processed in the DPDU. The main function of DPDU is to meet the hydrocarbon dew point
specification of sale gas. This process is based on removal of heavy hydrocarbons by
lowering temperature/pressure of the gas. The net gas separated in his unit is taken as the
sale gas product and will be sent to the sale gas product header. A part of net gas is sent to
Stripping Gas header. The separated Condensate will be routed to HC condensate header
and then to CSU (Condensate Stabilisation Unit). Overview of DPDU is shown in below
Figure 4.1.

The dew point depression unit has been designed to ensure condensate free
transportation of product gas meant for sale, which may get exposed to different
temperatures during transportation.

Figure 4.1-DPDU process diagram

Unit Capacity:
DPDU capacity is as per the GDU outlet corresponding to 100 MMSCFD of slug
catcher gas to GSU inlet per train.

16
Feed stock and characteristics:
The feed to DPDU is sweetened / dehydrated gas from GDU (Gas Dehydrating
Unit) with gas composition as:
 H2S content: 4 ppmv(max)
 CO2 content: <3% by volume in sales gas
 Moisture content: 112Kg/MMSCM

4.2 Process description:

Sweetened & Dehydrated Gas from the GDU (Gas Dehydration unit) is processed
in this Unit. This process is based on removal of heavy hydrocarbons by lowering
temperature / pressure of the gas. The net gas separated in this unit is divided into two
streams; one stream is taken as the sale gas product and is sent to the sale gas product
header. A part of net gas is sent to stripping gas header. The separated Condensate is routed
to HC condensate header and then to CSU (Condensate Stabilisation Unit).

The dew point depression unit is designed to remove the heavier hydrocarbons
associated with the gas coming from GDU to ensure condensate free transportation of
product gas meant for sale, which may get exposed to different temperatures during
transportation.

Sweet and dehydrated gas is treated in this unit to lower its hydrocarbon dew point well
below the minimum temperature which the gas may attain in the pipeline. As per gas (ex-
DPDU) quality specification, the gas shall not exceed a HC dew point in excess of - 3 °C
below 100 bars. To meet this requirement Dew point depression unit is designed to chill
the gas up to -9°C and to recover the condensate formed due to gas cooling which is sent
to CSU for processing.

Sweet and dehydrated gas from GDU is received through a flow controller. The gas
is thereafter cooled to a level of 33.50C to 350C in dehydrated gas / depressed gas exchanger
by the chilled depressed gas from the condensate separator. The gas is then routed to the
expander-compressor system via inlet knock out drum which removes any condensate
associated with the incoming gas. The condensate collected in the Inlet Knockout Drum is

17
routed to HC condensate header through level control. By the expander, the downstream
pressure of the gas is lowered so that corresponding temperature of HC dew point is
achieved. The expanded stream containing heavier hydrocarbons in liquid phase and
lighter hydrocarbons in gaseous phase then flows into the condensate separator where the
phase separation takes place. The separated condensate is sent to the HC condensate header
on level control through and then to trains of CSU. The depressed gas from condensate
separator is distributed into two streams. One stream called the Sale gas product is sent to
a compressor running by the expander. From the compressor discharge the gas stream is
then sent to the sale gas product compressor for further raising the pressure to meet the
battery limit conditions. Since the temperature of the sale gas product rises in the
compression process, it is cooled in the sale gas product cooler to meet the sale gas product
specification. Finally, it is filtered through the gas filters and routed to sale gas product
header. The other stream of separated gas from condensate separator is sent to Stripping
gas header after preheating in fuel gas heater through hot sale gas product. As very low
turndown is envisaged for CSU, the separated gas in DPDU is taken as make-up gas to
CSU to operate the off gas compressor during very low turndown scenario.

The condensates from the inlet knock out drum and the condensate separator are
jointly sent to the HC condensate header and then to the trains of CSU for further
processing.

4.3 Product specifications:

The product from DPDU is Sale Gas. The Dew Point Depressed Gas shall not
exceed a hydrocarbon Dew Point in excess of minus three degrees Celsius (30C) below 100
Bar (One Hundred Bar).

18
 Chapter 5

Condensate Stabilization Unit

5.1 Introduction:

The process of increasing the quantity of intermediate (C3 to C5) and heavy (C6+)
components in gas condensate is called condensate stabilization. The main purpose of this
process is to reduce the vapor pressure of the condensate liquids to prevent the production
of vapor phase upon flashing the liquid to atmospheric storage tanks. On the other hand,
the scope of this process is to separate very light hydrocarbon gases, methane and ethane
in particular, from the heavier hydrocarbon components (C3+). Stabilized liquid has a
vapor pressure specification, as the product will be injected into a pipeline or transport
pressure vessel, which has definite pressure limitations. It is usually 10 psia in summer and
12 psia in winter case. It should be noted that acidic contents (i.e., H2S, CO2, mercaptans
etc), glycol, free water, and possible salts must be also removed to have a gas condensate
suitable for end-use applications. Overview of Condensate Stabilization Unit is shown in
below Figure 5.1.

There are two methods for stabilizing gas condensates: flash vaporization and
fractionation (distillation). Fractionation is more efficient and provides better control over
vapor pressure for tanker shipment. Non-refluxed distillation column is simpler but less
efficient than refluxed one. Since it doesn’t require any external cooling source, it is
particularly applicable to remote locations. Benoy and Kale investigated gas condensate
stabilization through three stage flashing, non-refluxed, refluxed distillation with and
without hydrocarbon recovery from the flashed gas by compression. They found that heat
duty in multistage flashing is much higher than distillation while liquid recovery was less.
Nevertheless, liquid recovery was independent of the technique applied when intermediate
hydrocarbons were recovered from the flashed gas. The gas from the Condensate
Stabilization Unit is sent to the condensate storage tank and stored in the inert
atmosphere.The gas is fired when it is comes in contact with air. So, N2 is used to create
inert atmosphere.

19
 Figure 5.1- Condensate Stabilization Unit

5.2 Process description:

HP Separator section:

The unit consists of a HP separator which receives the hydrocarbon condensate

(HC) from the slug catcher and from GSU. The pressure in the separator is maintained by
pressure control of HP flash gas. The flow control valve maintaining the level in the HP
separator releases the condensate to MP separator which mixes with the incoming HC
condensate from DPDU and suction knock out drum.

MP Separator section:

The lowering of the pressure and the corresponding drop in the temperature
demands the heating of the stream. The required heating of the stream is done by a LP
steam Heater. The heated condensate then flows to the MP separator where the pressure is
maintained by a pressure control on MP flash gas line. The MP flash gas is routed to the
discharge of the first stage of the off-gas compressor. The condensate from the MP
separator flows to the suction KOD through the flow control valve.

20
Suction cod and Compression section:

An arrangement has been kept for the delivery of the fuel gas from DPDU in the
LP flash gas header in case of very low turndown requirement. The compressor is a four-
stage compressor which compresses LP flash gas generated in the suction KOD after which
the MP flash gas is mixed with the LP flash gas and the mixture is compressed to GSU
required pressure in the remaining three stages. In the discharge of the 4th stage HP flash
gas is mixed with the compressed mixture of LP and MP flash gas and this mixed stream
is sent to GSU for further processing.

Inter stage coolers and knock out drums have been provided in each stage for the
removal of the condensate and keeping in consideration the power economics. Suction
knock out drum receives the condensate from the first inter stage knock out drum which in
addition to being fed by the condensate in gas in the first discharge of the compressor also
receives a load of condensate from 2nd inter stage knock out drum. Similarly, the 2nd inter
stage knock out drum receives condensate from the discharge knock out drum. In this way
the condensate finally is received by suction knock out drum which is pumped through the
flow control valve by stabilised condensate pumps and delivered to the HC condensate
stream flowing to HP/LP HC condensate exchanger. In order to ensure safe operation of
the compressor the four stages have been provided with the anti- surge controllers.

The stabilized condensate from the suction KOD is pumped to storage tanks via
HP/LP HC condensate exchanger and stabilized condensate cooler in succession.

5.3 Product specifications:

The target specifications of stabilized condensate are given below

 BS&W: 0.5% Vol.(max)

 Salt: 8 PTB on the basis of ST oil (max)
 RVP: 10psia (Designed for 9psia)

21
 Chapter 6

Utilities

6.1 Raw Water Treatment Plant

Raw water treatment system will help the facility avoid cost downtime, expensive
maintenance fees, and not being able to sell its products in the market, among other
problematic issues.

An efficient water system should be able to handle:

 Seasonal variations in turbidity and flow

 Variations in water chemistry needs and required chemical volumes
adjustments
 Changes in water quality requirements

In this plant, they have two raw water ponds named pond1 and pond 2 of 31000
and 33800 cubic meters respectively. The intake of water is from new reservoirs 1 and 2
which they take from Tallarevu and Dhavaleswaram and they are if 1,84,000 and 2,72,000
cubic meters respectively.

6.2 Demineralized Water Plant

Demineralization process is the modern industrial water softening process.
Demineralized water also known as Deionised Water, Water that has had its mineral ions
removed. Mineral ions such as cations of sodium, calcium, iron, copper, etc and anions
such as chloride, sulphate, nitrate, etc are common ions present in water. Deionization is
physical process which uses specially-manufactured ion exchange resins which provides
ion exchange site for replacement of the mineral salts in water with water forming H+ and
OH- ions.

In OGT plant, Demineralised water is used for boilers feed, for the production of
steam, and process plants.

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6.3 Cooling water system
Cooling Tower are dedicated for water cooling in circulating water supply systems
supplied from process equipment. They can also be used for cooling compressors and other
process equipment.

Cooling water is used as a cooling medium in various heat exchanger located in

OGT. Three (2+1) cells each of 2800m3/hr capacity are provided to meet a total
requirement of 5047m3/hr. Cooling tower is specified to cool water from 430C to -330C.
HC and H2S detectors are provided at the cooling tower top. The basin of each cells has
provision to isolate for maintenance.

6.4 Compressed Air and Nitrogen Plant

Compressed air is required in the complex for the following main requirements:

 As instrument Air, to operate the various instruments in the facility and also
for the purging of some control panels.
 As Dry Air feed (Instrument air quality), for Nitrogen plant.
 As Plant Air, for cleaning, blowing and operating pneumatic tools.
 As Plant Air, for intermittent feed to some units (eg: aeration air for ETP),
scouring air for side stream filters of cooling water systems, etc.

Compressed air required for all of the above uses is generated at a centralised
location in the plant and distributed to the various users through headers. Two qualities of
compressed air are produced and distributed

 Plant air comprising compressed air cooled to ambient temperature. This

air, though not containing any entrained water droplets, is saturated with
water vapour at the supply conditions.
 Instrument air comprises compressed air cooled to ambient temperature and
dried to remove water vapour to meet stringent atmospheric dew point
requirements.

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6.5 Flare

The flare system is provided for safe disposal of combustible, toxic gases that are
relieved from process plants and off-site during startup, shutdown and normal operation or
in case of an emergency such as:

 Cooling Water failure

 General power failure
 External fire
 Any other operational failure such as Blocked Outlet, Reflux Failure, Local
power failure, Tube rupture, system depressurisation.

Fire system consists of two sub systems:

a) Hydrocarbon flare system for hydrocarbon gases:

Hydrogen flare releases from GSU, GDU, DPDU and CSU units
shall be included in the HC flare system. Hydrocarbon flare releases shall
be at two levels HP and LP, both will merge at main flare KOD.
b) Acid flare system for acid gases:
Flare releases from SRU and GSU are included in the acid flare
system. The acid flare reliefs from SRU and GSU are taken together to acid
flare KOD. The acid gases from acid flare KOD are discharged to flame
zone of HC flare stack through a riser for burning and disposal. This flare
stream is provided with auxiliary fuel to combust acid gases containing
CO2.

6.6 Effluent treatment plant:

Effluent treatment plant treats effluent water coming from various other process
units in Onshore Gas Terminal.

Different types of effluent are listed below:

1. Oily Water System 3. Sewage Treatment Plant

2. Contaminated Rain Water System 4. Ex-SRU Effluent Treatment Plant

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 Chapter 7

Compressed Air and Nitrogen plant

7.1 Introduction:

Compressed air is required in the complex for the following requirements:

 As instrument Air, to operate the various instruments in the facility and also
for the pursing of some control panels.
 As Dry Air feed (Instrument air quality), for Nitrogen plant.
 As Plant Air for cleaning, blowing and operating pneumatic tools.
 As Plant Air for intermittent feed to some units (eg: aeration air for ETP),
scouring air for side stream filters of cooling water systems, etc.

Compressed air required for all of the above uses is generated at a centralised
location in the plant and distributed to the various users through headers. Two qualities of
compressed air are produced and distributed:

 Plant air comprising compressed air cooled to ambient temperature. This

air, though not containing any entrained water droplets, is saturated with
water vapour at the supply conditions.
 Instrument air comprises compressed air cooled to ambient temperature and
dried to remove water vapour to meet stringent atmospheric dew point
requirements.

This system will be designed to supply compressed air to the various users at the
required conditions, quality and quantity.

7.2 Unit description:

The unit consists of the following:

1. LP Air Compressor
2. LP Air Receiver
3. HP Compressor

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 4. HP Receiver
5. Air Dryers (2 nos.)
6. Nitrogen Plant

LP Air Compressor:

The air after filtration is passed through a three-stage centrifugal (L.P) compressor.
The capacity of the compressor is about 3750Nm3. There are two L.P compressor. After
each and every stage it is passed through a cooler in order to reduce the temperature that is
increased due to compression.

HP Compressor and Receiver:

The HP compressor is a 2-stage reciprocating compressor. In the first stage the

pressure is increased to 12kg/cm2 and in the second stage the pressure is increased to
31kg/cm2.It is stored in HP storage tank. A provision for the safe shutdown during a power
failure shall be provided. This facility will provide instrument air for minimum 30 minutes
in case of air compressor/ power failure. The HP instrument air system consists of an HP
air receiver sized for holding minimum 30 minutes supply of instrument air corresponding
to instrument air demand of 4045 Nm3/hr.

Air Dryers:

The dryers are split flow, closed circuit, heat reactivated type (dual bed adsorption
type) with activated alumina as desiccant. Split flow no purge loss type air dryers are
designed for complete removal of vapour moisture from the compressed air so that its
moisture content will be corresponding to a dew point of -400C at atmospheric pressure.

7.3 Nitrogen Plant:

A nitrogen plant based on PSA (Pressure Swing Adsorption), as shown in Figure

7.1, is provided to cater to the nitrogen requirement of the OGT. Gaseous nitrogen
generated in the PSA plant is distributed to the various users through a common
distribution system. Liquid nitrogen storage is provided to meet emergency nitrogen
requirement which cannot be met from nitrogen plant during normal period.

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 Figure 7.1-Pressure Swing Adsorption
PSA- Air from dryers are sent to N2 separation, the air is passed through pre-filters
and then to adsorption column in which Carbon Molecular Sieves, CMS is used to trap
oxygen. Two chambers are present, one chamber will be adsorption phase and other will
be in regeneration phase. The time interval for a single absorption or regeneration is 1min
in which 57sec will be for regeneration and other 3sec will be for equalization. During
regeneration the oxygen trapped in CMS is vented into atmosphere because of pressure
difference.

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 Chapter 8

Demineralised Water System

8.1 Introduction:

Demineralised water is nothing but the water which is free from ionns. Ions present
in water are CaHCO3, MgSO4, H2SiO3, H2CO3 etc: - These Ions cause scaling to the boilers
where steam is used. So, Demineralised water is produced and used for production of
steam. Demineralised water is free from turbidity. PH is likely equal to 7.

In OGT plant, Demineralised water is used for boilers feed, for the production of
steam, and process plants.

8.2 Production of DM water:

The DM Plant consists of Two Streams (1W + 1S) each of 78 m3 /hr and to produce
1560 m3 (Net) output between regeneration with 20 hours of working. The Mixed Bed is
designed to produce 4680 m3 (Net) output between regeneration. The Degassed Water
Storage tank is common for both the streams. Each stream consists of two phases. First
phase consists of ACF & SAC. Second phase consists of Degasser, WBA & SBA.
Treatment scheme for producing DM water consists of following:
1. Activated Carbon Filter (ACF)
2. Strong Acid Cation Exchanger (SAC)
3. Degasser (DEG)
4. Weak Base Anion Exchanger (WBA)
5. Strong Base Anion Exchanger (SBA)
6. Mixed Bed (MB)
Activated Carbon Filter (ACF):
The water comes to DM plant from RWTP (Raw Water Treatment Plant). In DM
plant, water first goes to ACF. ACF consists of Activated carbon. In ACF, all organic
particles are removed.
Here, Differential Pressure parameter is measured. It should be less than
0.25Kg/cm2. The feed comes from up and discharge comes from down of the tank.

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Strong Acid Cation Exchanger (SAC):
From ACF, the water is sent to SAC. In this, cation is exchanged with hydrogen
ions using cationic resin. As a result, basicity and Na+ ion concentration is increased.
SAC resins derive their functionality from sulfonic acid groups (HSO3¯). When
used in demineralization, SAC resins remove nearly all raw water cations, replacing them
with hydrogen ions, as shown below:

The exchange reaction is reversible. When its capacity is exhausted, the resin can
be regenerated with an excess of mineral acid.

The pH and Na+ of this discharged is monitored.

Degasser (DEG):

From SAC, the water is sent to Degasser. Here CO2 is removed. Degasser consists
of poly rings at different angles.

The water from SAC falls from top of degasser into poly rings and turn into small
droplets. The air is sent from down of the degasser using degasser blowers. As the gas
moves up, it takes away the CO2 from the water. Degasser Blowers is provided of adequate
capacity for Degasification.

Degassed Water Pumps are provided to pump the degassed water through Weak
Base Anion exchanger, Strong Base Anion exchanger, and Mixed Bed exchanger to the
DM Water Storage Tank.

Weak Base Anion Exchanger:

Weak base resin functionality originates in primary (R-NH2), secondary (R-NHR'),

or tertiary (R-NR'2) amine groups. WBA resins readily re-move sulfuric, nitric, and
hydrochloric acids, as represented by the following reaction.

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Strong Base Anion Exchanger (SBA):

From WBA, the water is sent to SAC. Some anions are removed in WBA and some
are removed in SAC based on basicity of ions. Reaction is same for both WBA and SBA.
As a result, most of the ions are removed.

SBA resins remove all commonly encountered anions as shown below:

As with the cation resins, these reactions are reversible, allowing for the
regeneration of the resin with a strong alkali, such as caustic soda, to return the resin to the
hydroxide form.

Mixed Bed:

Lastly, the water is sent to Mixed Bed. If any ions are present, they are removed in
Mixed Beds. Later, the water is sent to DM water storage tanks. These contains both
Anions and Cations. These are used to remove any remaining of ions present in the water
coming from Strong Base Anion Exchanger.

Storage capacity of different tanks are:

 DM water storage – 780m3

 Degasser water storage – 227m3
 Neutralizing pits – 360m3
 Filter back wash – 80m3
 Acid bulk storage – 50m3
 Alkali bulk storage – 34.5m3

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8.3 Types of tanks:

Morpholine Dosage Tank:

Morpholine is present after the Mixed Bed. Morpholine is used to increase the pH of the
DM water if pH of DM water is less than 6.5.

Degasser tank:

Degasser tank is used to store degassed water and sent the degassed water to WBA
through pumps.

DM Storage tank:
The DM water from Mixed Bed, through Morpholine tank, is sent to
the DM storage tank. It is stored in the inert atmosphere in the DM storage tank.
Regeneration of DM plant:
 ACF regeneration is done when differential pressure exceeds 0.5kg/cm2.
 ACF regeneration is done by giving air scouring.
 SAC regeneration is done by treating it 4% HCl.
 SBA regeneration is done by treating it with 4% NaOH.
 WBA regeneration is done by treating with solution obtained from SBA.
 WBA regeneration is done by treating it with solution obtained from SBA.
 For SBA filter back wash degasser water is used.
 Silica analysis is used after mixed bed.
Operational bed pressures:
 ACF – 5Kg/cm2
 SAC – 4Kg/cm2
 WBA – 6Kg/cm2
 SBA- 5.2Kg/cm2

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 BIBLIOGRAPHY

1. Smith, R.S. 1975. Improve Economics of Acid-Gas Treatment. Oil & Gas J
73(March): 78-79.
2. Tennyson, R.N. and Schaaf, R.P. 1977. Guidelines Can Help Choose Proper
Process for Gas-Treating Plants. Oil & Gas J 75 (2): 78.
3. King, J.C. et al. 1986. Rigorous Screening Selects Sour-Gas Plant Process. Oil &
Gas J 84 (36): 101-110.
4. Butwell, K.F., Kubek, D.J., and Sigmund, P.W. 1982. Alkanolamine Treating.
Hydrocarbon Processing (March): 108.
5. Fitzgerald, K.J. and Richardson, J.A. 1966. New Correlations Enhance Value of
Monoethanolamine Process. Oil & Gas J 64 (43): 110-118.

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