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UNIVERSITY COLLEGE OF ENGINEERING, KAKINADA (A),

JNTUK

Petroleum engineering | 2012-2016 |

Table of Contents

An overview..............................................1

Industrial visit-ONGC
ODALAREVU-GAS COLLECTING STATION

Gas processing.........................................2
Fluid processing........................................3
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UNIVERSITY COLLEGE OF ENGINEERING, KAKINADA (A), JNTUK

Old and New plant....................................3


summary..................................................4

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UNIVERSITY COLLEGE OF ENGINEERING, KAKINADA (A), JNTUK

AN OVERVIEW
ONGC, the largest oil E & P Company in India has various
working projects and Odalarevu plant is one of them. Though
India is able to produce only 40% of countrys demand,
ONGC still stood in its position inherently fighting for the
success of the nation among the world. Odalarevu plant is a
GCS(Gas Collecting Station) which gathers the oil from
onshore as well as offshore and with minor processing
techniques they send the oil and gas to the respective
industries.

The plant is mainly working for offshore wells which


accommodates 5 wells in which two wells namely D1-11 and
D1-10 are ready for production and old plant concentrates
mainly in collecting oil and gas from the onshore wells.
These wells have intelligent completions. The technology
utilized in both the plants are more or less of same kind with
some changes in the new plant like utilization of separate
tanks in three phase separator whereas in the old plant both
the separation tanks are assembled in only one tank and the
control of valves in the old plant is manual.

The key part in the industry is the Master Control System


which monitors the pressure and temperature and gives an
update of each and every issue going there in the offshore.
We can even control the valves and the extent upto which
they have to counteract can be decided and the control
action can be given there itself. This control system is
integrated with all other functionalities of the plant and thus
the required personnel for operating the plant are minimum

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UNIVERSITY COLLEGE OF ENGINEERING, KAKINADA (A), JNTUK
in number. Besides this system the other systems are the
ESD (Emergency Shut Down), which operates the valves
to shut down in case of an emergency and F&G (Fire &
Gas) system which operates in case of a fire or a gas leak in
the plant. In the safety system of the new plant there are
smoke detectors, spark detectors, leakage detectors
etc which on detecting even a minute amount shut down the
valves and the processing is stopped. The heart of the
control system is the Subsea Control Module which has a
manifold i.e., all the wells are connected to this system and
this is controlled by the use of Electro hydraulic
Distribution Unit which gives the signals to the module.
The EHDU sends the signals from the MCS through the
Umbilical Unit to the offshore wells. The umbilical has 4
pipes for HP, LP, Annular pressure and Methanol, that send
the signals down to the wells. The manifold has the
construction of sending and receiving the pigging material
that is often required for the maintenance of the pipes for
flow assurance as with time the pipes get clogged and
pigging helps in removing these and maintain the flow rate
of the well fluids. In the path of fluid, we come across with
many valves like master valve, wing valve, and annular
master valve and shut down valve (automatic). The other
important thing is that the injection of methanol into the
fluid and this valve called hydrate injection valve is present
in between the master valve and the wing valve and this is
important because it removes any moisture present in the
pipe that effects the flow of fluid in the pipe. The annular
pressure pipe in the umbilical is useful in removing any gas
that is present between the casings (which happens rarely)
by changing the pressure from the MCS.

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UNIVERSITY COLLEGE OF ENGINEERING, KAKINADA (A), JNTUK
GAS PROCESSING
The fluids that come from the offshore wells through the
riser pipes contains oil, water and gas are first made to
enter the slug catcher where the gas and the liquids are
mixed thoroughly so that slugging is minimized and then the
mixture is sent to the cohesive filter(coalescer) where the
initial separation of oil and liquid takes place. These are
operated at low pressures and for transporting of the gas to
GAIL (they are licensed to get the gas from ONGC), the gas is
compressed and again sent to filter if any further liquid that
contained is removed and the compressed gas is been sent
to GAIL. The plant is equipped with 5 compressors and 3
filters, 1 being standby in case of emergency situations and
cleaning purposes.

LIQUID PROCESSING
The liquid being separated from the oil in the filter moves to
the 3 phase separator where all the oil, gas and water tends
to separate and the gas being separated may be sent to pipe
connecting to GAIL. Then the remaining oil and water are
being sent to electrostatic separator which uses an
electrolyte and electrodes for the separation process and
any water present with the oil is completely removed in this
process. The oil so filtered is being sent to HPCL for further
processing and the waste water so formed is sent to
Effluent Treatment Plant and the processed water in ETP
is sent to nearby dead well for disposal.

OLD PLANT AND NEW PLANT


There are only a minute differences between the old plant
and the new plant as described below

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UNIVERSITY COLLEGE OF ENGINEERING, KAKINADA (A), JNTUK
1. There are no standby tanks in the old plant whereas in
the new plant each function has been given a standby
path.
2. We have to manually control the valves in case of old
plant whereas in new plant, it is completely automatic
and the Direct Control System and Master Control
System have the powers to automatically shut down
the valves in case of any emergency situation.
3. In the old plant, the fluid is been collected at high
pressures and therefore the gas so separated is directly
sent to GAIL with no compression whereas in the new
plant the fluid is been operated at low pressures, then
compressed to high pressures for sending.
4. A vertical separator and heater treater are the
notable equipment in case of old plant where the
vertical separator has the function of a two phase
separator and the heater treater is a 3 phase separator
with electrostatic separator inside it i.e.., all the liquid is
being processed in that single tank.
5. All the equipment are being functioned using
pneumatic air controllers in the new plant where in the
case of old plant, such control action is not seen.

SUMMARY

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