ABSTRACT

Industrial fires can be intense emitters of heat, smoke, and other combustion products.
This is particularly true if the fuel is a petroleum based substance, with a high heat of
combustion and sooting potential. The radiant energy flux can be sufficiently high to threaten
both the structural integrity of neighboring buildings, and the physical safety of fire fighters,
plant personnel, and potentially people beyond the boundaries of the facility. There are many
types of fire scenario, the one which is taken into account in this project is “pool fire”. Fire
spread between objects within a compartment is primarily due to the impingement of thermal
radiation from the fire source. In order to estimate if or when a remote object from the fire will
ignite, one must be able to quantify the radioactive heat flux being received by the target.
Here we are considering the tank farm at CTF and we have various techniques for the
hazard identification, risk assessment and calculated the consequences of the specific hazard.
Some general recommendations are also suggested. We recommend the management to follow
these recommendations for the safe working of the plant and to avoid any fire accidents.

1
ACKNOWLEDGEMENT
On the onset, we would like to convey our heartfelt gratitude to the management of
ONGC, especially to Mr. DMR SHEKAR, Asset Manager ONGC, ankaleshwer for giving us
an opportunity to do our academic final year project in their esteemed organization.
We also express our sincere thanks to our mentor Mr.UMA SANKAR chief chemist,
HSE for helping us in every aspect of the project. we would like to thank the entire crew of
asset HSE section for the assistance which we received in the completion of the project.
We express our sincere thanks to Mr. ASHOK KUMAR TRIPATHI, DGM(FS)-I/c fire
services and our mentor Mr. SAVAD ASHRAF Sr.FO-I/c CTF fire station.
We extend our sincere thanks to Mr. THOMAS VETTATH, PROFESSOR AND
HEAD, SAFETY AND FIRE ENGINEERING, TOC H, arakkunnam and our internal guide
professor Mrs. SREECHITHRA.M.
We would also like to extend our sincere thanks to all ONGC employees who helped in
one way or other to the successful completion of this project work.

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 CONTENT

CHAPTER # 1 page no.

INTRODUCTION 10
1.1 ONGC 11
1.2 HISTORY 11
1.3 ANKLESHWAR ASSET 12
1.4 ANKLESHWAR FIELD 13

CHAPTER # 2
CENTRAL TANK FARM(CTF) 14
2.1 PROCESS LAYOUT 14
2.2 GATHERING LINES 15
2.3 HEADERS AND MANIFOLDS 15
2.4 SEPERATORS 16
2.5 SCRUBBER 17
2.6 GAS COMPRESSING UNIT(GCU) 18
2.7 RECIPROCATING COMPRESSOR 18
2.8 HEATER TREATER 18
2.9 CRUDE OIL DESALTING 19
2.10 LPG PRODUCTION PLANT 19
2.11 UTILITY SYSTEM 21
2.12 WATER SYSTEM 22
2.13 HEALTH SAFETY MEASURES 22

CHAPTER # 3
GROUP GATHERING STATION (GGS IV,GANDHAR) 24
3.1 OUTLINE FOR GGS 24
3.2 PROCESS DESCRIPTION 24
3.3 UTILITIES 26

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3.4 SAFETY AND ENVIRONMENT MANAGEMENT 26

CHAPTER # 4
ONSHORE RIG(E1400-7) 26
4.1 RIG COMPONENTS 28
4.2 CIRCULATING SYSTEM 28
4.3 ROTATING SYSTEM 30
4.4 BLOW OUT PREVENTION SYSTEM 30

CHAPTER # 5
CENTRAL PROCESSING FACILITY (CPF) 32
5.1 CRUDE STABILISATION UNIT 33
5.2 GAS DEHYDRATION UNIT 34
5.3 CONDENSATE FRACTIONATE UNIT 35
5.4 OFF GAS COMPRESSOR 36
5.5 GAS INJECTION UNIT 36
5.6 ADDITIONAL CONDENSATE RECOVERY UNIT 37
5.7 GAS LIFT UNIT 37
5.8 WATER INJECTION UNIT 37
5.9 INJECTION WATER FERTILIZATION PLANT 37
5.10 EFFLUENT TREATMENT PLANT 38
5.11 C.O.P.S 38
5.12 UTILITIES 39
5.13 WASTE HEAT RECOVERY SYSTEM 42
5.14 LPG AND NAPHTHA STORAGE & HANDLING 42

CHAPTER # 6
FIRE SERVICES IN ONGC ANKALESHWAR 42
6.1 CFS GANDHAR FIRE STATION 42
6.2 MAJOR FIRE APPLIANCES 43
6.3 MAJOR FIRE EQUIPMENTS 43

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6.4 MULTIPURPOSE FIRE TENDER 44
6.5 FIRE PROTECTION SYSTEM 46
6.6 TYPES OF FIRE PROTECTION SYSTEM 46
6.6.1 FIRST AID FIRE FIGHTING EQUIPMENT 46
6.6.1.1 THE VARIOUS FIRE PROTECTION SYSTEM 46
6.7 FIXED FIRE PROTECTION SYSTEM 48
6.8 CONVEYING SYSTEMS 52
CHAPTER # 7
HAZARD IDENTIFICATION (HAZOP) 54
7.1.1 STUDY OBJECTIVES 54
7.2 SCOPE OF STUDY 54
7.3 PROCEDURE 55
CHAPTER # 8
RISK ASSESMENT (EVENT TREE ANALYSIS) 60
8.1 METHODOLGY 61
8.2 MATHEMATICAL CONCEPTS 62
CHAPTER #9
CONSEQUENCE MODELLING 64
9.1 RELEASE MODELLING 65
9.1.1 RELEASE MODELLING OF CRUDE FROM STORAGE TANK 65
9.2 SOLID FLAME MODEL 71
9.3 THERMAL RADIATION FLUX 72
9.4VIEW FACTOR 72
9.5SURFACE EMISSIVE POWER 73
9.6ATMOSPHERE TRANMISSIVITY 73
9.7HEIGHT OF THE LUMINOUS ZONE 74
9.8OISD FOR DYKE ENCLOSURE 78
9.9GENRAL RECOMMENDATIONS 80

CHAPTER # 10
CONCLUSION

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 LIST OF ABBREVIATIONS
GGS - GROUP GATHERING STATION
GCS - GAS COLLECTING STATION
CTF - CENTRAL TANK FARM
CPF - CENTRAL PROCESSING FACILITY
ANK - ANKALESHWAR
EVT - EVENT TREE ANALYSIS
HAZOP- HAZARD OPERABLITY STUDY
OISD - OIL INDIA SAFETY DIRECTORATE
HT - HEATER TREATER

GIU - GAS INJECTION UNIT

GLU - GAS LIFT UNIT

WTU - WATER INJECTION UNIT

HP - HIGH PRESSURE

MP - MEDIUM PRESSURE

LP - LOW PRESSURE

GCU - GAS COMPRESSION UNIT

HRR - HEAT RELEASE RATE

ASD - ACCEPTABLE SEPARATION DISTANCE

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 LIST OF FIGURES
FIG 2.1 PROCESS LAYOUT

FIG 2.2 OUTLINE OF SURFACE PROCESS

FIG 3.1 OUTLINE OF GGS

FIG 4.1 OUTLINE OF RIG

FIG 4.2 DRILL COMPONENTS

FIG 5.1 SCHEMATIC DIA OF CPF GANDHAR

FIG 6.1 FIRE APPLIANCES AT CTF GANDHAR

FIG 9.1 FLAME MODEL

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 LIST OF TABLES

TABLE 6.1 DISTANCE TO SITES

TABLE 6.2 ACTIVITIES OF FIRE SERVICE AT GANDHAR
TABLE 6.3 PERFOMANCE OF EXTINGUISHERS
TABLE 6,4 PERFOMANCE OF CO2 EXTINGUISHERS
TABLE 7.1 HAZOP STUDY 1
TABLE 7.2 HAZOP STUDY 2
TABLE 7.3 RECOMMENDATIONS
TABLE 8.1 EVENT TREE VALUES
TABLE 8.2 ETA CONCLUSION

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1.INTRODUCTION
1.1About ONGC

Oil and Natural Gas Corporation Limited (ONGC) is an

Indian multinational oil and gas company headquartered in Dehradun, India. It is a Public
Sector Undertaking (PSU) of the Government of India, under the administrative control of
the Ministry of Petroleum and Natural Gas. It is India's largest oil and gas exploration and
production company. It produces around 69% of India's crude oil(equivalent to around 30% of
the country's total demand) and around 62% of its natural gas.

On 31 March 2013, its market capitalization was INR 2.6 trillion (US$ 48.98 billion), making it
India's second largest publicly traded company. In a government survey for FY 2011-12, it was
ranked as the largest profit making PSU in India. ONGC has been ranked 357th in the Fortune
Global 500 list of the world's biggest corporations for the year 2012. It is ranked 22nd among
the Top 250 Global Energy Companies by Platts.

ONGC was founded on 14 August 1956 by Government of India, which currently holds a
69.23% equity stake. It is involved in exploring for and exploiting hydrocarbons in
26 sedimentary basins of India, and owns and operates over 11,000 kilometers of pipelines in
the country. Its international subsidiary ONGC Videsh currently has projects in 15 countries.
ONGC has discovered 6 of the 7 commercially-producing Indian Basins, in the last 50 years,
adding over 7.1 billion tonnes of In-place Oil & Gas volume of hydrocarbons in Indian basins.
Against a global decline of production from matured fields, ONGC has maintained production
from its brownfields like Mumbai High, with the help of aggressive investments in various IOR
(Improved Oil Recovery) and EOR (Enhanced Oil Recovery) schemes. ONGC has many
matured fields with a current recovery factor of 25-33%. Its Reserve Replacement Ratio for
between 2005 and 2013, has been more than one. During FY 2012-13, ONGC had to share the
highest ever under-recovery of INR 494.2 million (an increase of INR 49.6 billion over the
previous financial year) towards the under-recoveries of Oil Marketing Companies
(IOC, BPCL and HPCL).

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1.2 HISTORY

Foundation to 1961

Before the independence of India, the Assam Oil Company in the north-eastern and Attock Oil
company in north-western part of the undivided India were the only oil producing companies,
with minimal exploration input. The major part of Indian sedimentary basins was deemed to be
unfit for development of oil and gas resources.

After independence, the Central Government of India realized the importance of oil and gas for
rapid industrial development and its strategic role in defense. Consequently, while framing the
Industrial Policy Statement of 1948, the development of petroleum industry in the country was
considered to be of utmost necessity.

Until 1955, private oil companies mainly carried out exploration of hydrocarbon resources of
India. In Assam, the Assam Oil Company was producing oil at Digboi (discovered in 1889) and
Oil India Ltd. (a 50% joint venture between Government of India and Burmah Oil Company)
was engaged in developing two newly discovered large fields Naharkatiyaand Moraan in
Assam. In West Bengal, the Indo-Stanvac Petroleum project (a joint venture
between Government of India and Standard Vacuum Oil Company of USA) was engaged in
exploration work. The vast sedimentary tract in other parts of India and adjoining offshore
remained largely unexplored.

In 1955, Government of India decided to develop the oil and natural gas resources in the
various regions of the country as part of the Public Sector development. With this objective, an
Oil and Natural Gas Directorate was set up towards the end of 1955, as a subordinate office
under the then Ministry of Natural Resources and Scientific Research. The department was
constituted with a nucleus of geoscientists from the Geological Survey of India.

A delegation under the leadership of the Minister of Natural Resources visited several European
countries to study the status of oil industry in those countries and to facilitate the training of
Indian professionals for exploring potential oil and gas reserves. Experts from Romania,
the Soviet Union, the United States and West Germany subsequently visited India and helped
the government with their expertise. Soviet experts later drew up a detailed plan

10
for geological and geophysical surveys and drilling operations to be carried out in the 2nd Five
Year Plan (1956-61).

In April 1956, the Government of India adopted the Industrial Policy Resolution, which placed
Mineral Oil Industry among the schedule 'A' industries, the future development of which was to
be the sole and exclusive responsibility of the state.

Soon, after the formation of the Oil and Natural Gas Directorate, it became apparent that it
would not be possible for the Directorate with its limited financial and administrative powers as
subordinate office of the Government, to function efficiently. So in August, 1956, the
Directorate was raised to the status of a commission with enhanced powers, although it
continued to be under the government. In October 1959,the Commission was converted into a
statutory body by an act of the Indian Parliament,which enhanced powers of the commission
further. The main function of the Oil and Natural Gas Commission subject to the provisions of
the Act, were “to plan, promote, organize, and implement programs for the development of
Petroleum Resources and the production and sale of petroleum and petroleum products
produced by it, and to perform such other functions as the Central Government may, from time
to time, assign to it “. The act further outlined the activities and steps to be taken by ONGC in
fulfilling its mandate.

1.2 ANKALESHWAR ASSET

The establishment of Ankleshwar oil field dates back to late fifties, and the production started
in 1961. The first oil well drilled was Vasundhara which was put on production by Hon. Mr.
Pandit Jawaharlal Nehru.

It is the largest onshore asset of ONGC. It makes second highest profit after Mumbai High.

Major Oil & Gas fields are:

1. Ankleshwar Field (found in 1960)

2. Gandhar Field (found in1984)
In addition 21 satellite Oil & Gas fields have been discovered around the main fields.

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Ankleshwar Asset is divided into 4 areas:

1. Area 1 (Ankleshwar, Motwan, Sisodra, Andada )

2. Area 2 (Kosamba, Kim, Olpad, Elao)
3. Area 3 (Gandhar, Dahej, Pakhajan)
4. Area 4 (Nada, Jambusar, Dabka, Sarbhan, Degam)

1.4 ANKALESHWAR FEILD

Ankleshwar fields have anticline structure. It is intersected by 7 faults. Northern part has
3-7° dip and southern part has 10-30° dip. Ankleshwar has nearly 340 wells and production
started in1962.Two important formations are Hazard and Ardol.

Hazard has S1 – S4 sand.

Ardol has S6 – S12 sand.

Presently, the age of this asset is more than 50 years and still continuously providing oil and
gas. At present, the production is declined to about 800 m3 per day. The field has eight no. of
GGS, one CTF, one GCS and one water injection plant.

Till now around 350 wells have been drilled.

A nearby structure was drilled in 1975 named after the village Motwasisodra. This structure
was put on production in 1979. 28 oil wells and 16 gas wells have been drilled in this area. Oil
wells are connected are to the oldest GGS but wells producing gas have been connected to a
separate GCS near Motwan village to produce about 8 lakhs m3/day. A new LPG plant was
commissioned in 1986 with a capacity of 140 tonnes per day.

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2.CENTRAL TANK FARM

2.1PROCESS LAYOUT

FIG 2.1 PROCESS LAYOUT

SURFACE PROCESSES: It is the process that takes the product from the wellhead manifolds and
delivers as stabilized marketable products, in the form of Crude oil and Gas. The surface

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processes starts from the well and through the gathering lines the crude oil, along with gas and
water is transported to the Group Gathering Station

FIG 2.2 OUTLINE OF SURFACE PROCESS

2.2 GATHERING LINES

Pipelines which brings the well flow into the manifolds are known as gathering lines. These
lines carry multiphase materials in form of boil water-oil and gas.

2.3 HEADERS & MANIFOLDS

In a gathering system a pipeline arrangement that connect the flow lines from several wellheads
into a single gathering line is a Header. A header has production and testing valves to control
the flow of each well, thus directing the produced fluids to production or testing vessels.

14
Individual GOR and well production rate of oil-gas-water can be assigned by opening and
closing selected valves in a header and using individual metering equipment or separator.

Oil and water is received at C.T.F after 2nd stage of oil and gas separator at GGS. This oil &
water comes to horizontal separators which are installed at height of 14.5 m. To avoid pumping
and are operated at 0.5 Kg/cm2 gauge pressure.

Associated gas in horizontal separator is fed to 1st stage compressor at compressor plant. From
separators the oil goes to a vertical 17.5 m vapor recovery column operated at 0.0 Kg/cm2 gauge
pressure to suck all the remaining vapors in the oil by vapor recovery unit.

This gas free oil along with formation water goes to the first wash tank where free water is
separated from oil in wash tank water level is maintained at 6.0 m height and oil overflow from
the overflow pipe at 9.25 m. This oil goes to DD plant intermediate tanks by gravity. Water
goes to ETP from the bottom of tank through a siphon system. After treatment at DD plant oil is
received in one of the seven number of 5000 M3 storage tank. Quality of oil is checked after
first wash tank every four hours. Oil stored in 5000 M3 tanks after the treatment from DD plant
is checked for its salinity and BS&W and if found within prescribed limit oil is pumped to CPF
Gandhar by centrifugal pump through 16’’ dia. Oil line and if it is not as prescribed limit, it is
sent back to the second wash tank again for the retreatment. This oil line is scrapped fortnightly
by a mechanical line scrapper consisting of a wire brush with two rubber cups at both the ends
to clean the line and hereby maintaining the line efficiency.

2.4 SEPARATORS

The main separators are gravity type. On the right you see the main components around the first
stage separator. As mentioned the production choke reduces will pressure to the HP manifold
and First stage separator to about 3-5 MPa (30-50 times atmospheric pressure). Inlet
temperature is often in the range of 100-150 degrees C.

The pressure is often reduced in several stages; here three stages are used, to allow controlled
separation of volatile components. The purpose is to achieve maximum liquid recovery and
stabilized oil and gas, and separate water. A large pressure reduction in a single separator will
cause flash vaporization leading to instabilities and safety hazards.

15
The retention period is typically 5 minutes, allowing the gas to bubble out, water to settle at the
bottom and oil to be taken out in the middle. In this platform the water cut is almost 40% which
quite high. In the first stage separator, the water content is typically reduced to less than 5%.
At the crude entrance there is a baffle slug catcher that will reduce the effect of slugs. However
some turbulence is desirable as this will release gas bubbles faster than a laminar flow.
At the end there are barriers up to a certain level to keep back the separated oil and water. The
main control loops are the oil level control loop controlling the oil flow out of the separator on
the right, and the gas pressure loop at the top.(FV0105 20 above) These loops are operated by
the Control System. An important function is also to prevent gas blow-by which happens when
low level causes gas to exit via the oil output causing high pressure downstream. There are
generally many more instruments and control devices mounted on the separator.
The liquid outlets from the separator will be equipped with vortex breakers to reduce
disturbance on the liquid table inside. This is basically a flange trap to break any vortex
formation and ensure that only separated liquid is tapped off and not mixed with oil or water
drawn in though these vortices. Similarly the gas outlets are equipped with demisters,
essentially filters that will remove liquid droplets in the gas.
Emergency Valves (EV) are sectioning valves that will separate the process components and
blow-down valves that will allow excess hydrocarbons to be burned off in the flare. These
valves are operated if critical operating conditions are detected or on manual command, by a
dedicated Emergency Shutdown System. This might involve partial shutdown and shutdown
sequences since the flare might not be able to handle a full blow-down of all process sections
simultaneously.
A 45.000 bpd design production with gas and 40% water cut this gives about 10 cubic meters
from the wellheads per minute. There also needs to be enough capacity to handle normal
slugging from wells and risers.

2.5 SCRUBBER

Various gas drying equipment is available, but the most common suction (compressor)
scrubber is based on dehydration by absorption in Tri Ethylene Glycol (TEG). The scrubber
consists of many levels of glycol layers. A large number of gas traps (enlarged detail) force the
gas to bubble through each glycol layer as it flows from the bottom up each division to the top.

16
Lean glycol is pumped in at the top, from the holding tank. It flows from level to level against
the gas flow as it spills over the edge of each trap. During this process it absorbs liquids from
the gas and comes out as rich glycol at the bottom. The holding tank also functions as a heat
exchanger for liquid from and to the re-boilers.
The glycol is recycled by removing the absorbed liquid. This is done in the re-boiler, which is
filled with rich glycol and heated to boil out the liquids at temperature of about 130-180 °C
(260-350°F) for a number of hours. Usually there is a distillation column on the gas vent to
further improve separation of glycol and other hydrocarbons. For higher capacity there are often
two re-boilers which alternatebetween heating rich glycol and draining recycled lean glycol.
On a standalone unit the heat is supplied from a burner that uses the recovered vaporized
hydrocarbons. In other designs the heating will use a combination of hot cooling media from
other parts of the process and electric heaters, and recycle the hydrocarbon liquids to the
separator.
2.6GAS COMPRESSION UNIT : (GCU)

The gas liberated from the produced liquids must be delivered to the export pipeline at
the specified pressure. This required pressure is achieved by used of gas compression unit .

2.7RECIPROCATING COMPRESSOR

Reciprocating Compressor that use a piston and cylinder design with 2-2 cylinders are
built up to about 30 MW power, around 500-1800 rpm (lower for higher power) with pressure
up to
5MPa (500 bars). Used for lower capacity gas compression and high reservoir pressure gas
injection. Compressors are driven by gas turbines or electrical motors.
2.8 HEATER-TREATER

Inlet degassing section: Oil mixing with demulsifying chemicals enter the heater Treater
through degassing section, above the fire tubes. Free gas is liberated from the flow stream and
is equalized across the entire degassing and heating areas of the Treater. The degassing section
is separated from the heating section by baffles. The fluid travels downward from the degassing
area and enters the heating section under the fire tubes through multiple orifice distributors.

17
Heating section: Oil enters this section from bottom of degassing section and passes through
heater at bottom and washing action takes place and free water and solids fall out the oil stream.
The oil and entrained water flow upward from the distributors around the fire tubes, where the
required temp is reached. The increase in temperature of the oil releases some additional gas.
The heat released gas then joins the free gas from the inlet section is discharged from the
Treater through a gas back pressure control valve.

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

Coalescing section (electrical chamber): Heat Treater uses a high voltage potential on the
electrodes for coalescing of the water droplets in the final phase of processing. The electrodes
are suspended o the insulated hanger from the upper portion of the vessel. The ground electrode
is furnished with solid steel hangers to ensure grounding with the steel of the Treater.

2.9 CRUDE OIL DESALTING

The water content of the crude oil can be brought to the acceptable limit of less than 1% by
electrostatic treatment, however, the salinity of oil might be still higher than the accepted limit
fixed by refinery.

2.10 LPG PRODUCTION PLANT

Natural Gas Liquids Processing

Raw natural gas contains valuable heavier hydrocarbons when extracted from the well head.
The heavier hydrocarbons which are associated with the raw natural gas are ethane, propane,
butane and natural gasoline (condensate from). These associated hydrocarbons are called
natural gas liquids. These NGL components must be recovered to control the dew point of
natural gas stream and also to earn revenue by selling out the separated components.

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LPG Recovery Processes

Natural gas mainly contains methane and smaller amounts of ethane, propane, butane and
heavier hydrocarbons along with varying amount of water vapors, carbon dioxide, sulfur
compounds and other non-hydrocarbons. Ethane, propane, butane and propane are known as
associated gases. The removal of these gases from raw natural gas is necessary to meet the
desired consumer specifications of natural gas and to extract valuable products such as LPG

Extraction Unit

The feed of extraction unit is the combination of associated gases and condensate. The product
streams are divided into three steps .One having the liquid stream rich in propane, butane, and
gasoline is sent to the fractionation tower for LPG production and other two streams to the
product gas unit for further processing.

Fractionation Unit

Liquid stream consisting of ethane, propane, butane and pentane is treated in the fractionators
trains to separate them and sold as LPG. Complete process flow sheet is shown in figure.
Fractionation tower consists of three columns: De-ethanizer, De-propanizer and Debutanizer.

De-Ethanizer Section

Raw gas containing associated gases is fed from the top of the De-ethanizer. De-ethanizer
operated at approximately 390lb/in2. We separated out ethane from this column. The overhead
product is ethane in the form of vapors, which is partially condensed in the condenser by using
propane at 20oF and collected in the reflux drum. Condensed product is recycled to the De-
ethanizer tower and non-condensed vapors (mainly ethane) are sent to the fuel gas system.
Temperature inside tower is maintained by supplying heat from re-boiler. The bottom product
from De-ethanizer enters into the next columns, de-propanizer.

De-propanizer Section

The pressure of De-ethanizer bottom product is reduced to 290 lb/in2 and then entered into the
de-propanizer. The overhead product of this column is propane rich and is condensed in the

19
condenser by using cooling water. The condensed product is collected in the reflux drum. Some
amount of this is refluxed back to the column. Heat is supplied through direct fired heater.

Debutanizer Section

De-propanizer bottom product is expanded to a pressure of 110 lb/in2 and fed to the top of the
tower. Propane is separated as top product and condensed further in condenser by using cooling
water. Bottom products are the heavier hydrocarbons. Fractionators of different types are
commonly used in gas plant.

2.11 UTILITY SYSTEM

Fire and Gas Systems

The Fire and Gas System is not generally related to any particular process. Instead it divides
into fire areas by geographical location. Each fire area should be designed tobe self-contained,
in that it should detect fire and gas by several types of sensors, and control fire protection and
fire fighting devices to contain and fight fire within the fire area. In case of fire, the area will be
partially shut off by closing ventilation fire dampers. A fire area protection datasheet typically
shows what detection exists for each fire area and what fire protection action should be taken in
case of an undesirable event.
Telemetry / SCADA
SCADA (Supervisory Control and Data Acquisition) is normally associated with telemetry and
wide area communications, for data gathering and control over large production sites, pipelines,
or corporate data from multiple facilities. With telemetry, the bandwidth is often quite low and
based on telephone or local radio systems the SCADA system is often optimized for efficient
use of the available bandwidth. Wide area communication operates with wideband services,
such as optical fibres and broadband internet.
Flare and Atmospheric Ventilation
The flare subsystem includes Flare, atmospheric ventilation and blow down. The purpose of the
Flare and Vent Systems is to provide safe discharge and disposal of gases and liquids
Instrument air

20
A large volume of compressed air is required for the control of pneumatic valves and actuators,
tools and purging of cabinets. It is produced by electrically driven screw compressors and
further treated to be free of particles, oil and water.
HVAC
The heat, ventilation and air conditioning system (HVAC) feeds conditioned air to the
equipment rooms, accommodations etc. Cooling and heating is achieved by way of water
cooled or water/steam heated heat exchangers. Heat may also be taken off gas turbine exhaust.
In tropic and sub-tropic areas, the cooling is achieved by compressor refrigeration units. Also,
in tropical areas gas turbine inlet air must be cooled to achieve sufficient efficiency and
performance. The HVAC system is usually delivered as one package, and may also include air
emissions cleaning.
2.12 WATER SYSTEMS
 Potable Water
 Seawater
 Ballast Water
 Chemicals and Additives
 Scale inhibitor
 Emulsion breaker
 Antifoam
 Drag Reducers
 Hypochlorite
 Biocides
 Corrosion Inhibitor
 Methanol (MEG)
 Polyelectrolyte
2.13 HEALTH SAFETY MEASURES

Health Safety Management system provides a safe structures path for accomplishment of goals,
development of personnel, improved communication and improvement of business process. It
also helps to maintain consistency in performance.

21
HSE management system is a cyclic management system maintaining Plan-Do-Check-Act
elements in complete equilibrium and ensures self- sustained perpetual performance system.
1. Plan : Design or revise business process components to improve result.
2. Do : Implement the plan and measures its performance.
3. Check : Assess the measurements and report the results to decision makers.
4. Act : Decide on changes needed to improve the process.
5. Precautions against fire:
 The protection area surrounding every gas compressor station should be provided with a
metal or barbed wire fencing not less than 1.8 meter in height with suitable gates which
can be duly locked.
 Entry of unauthorized persons into the compressor station should be checked.
 Inside the compressor station no smoking, open flame, welding or gas cutting should be
permitted
 Pipelines and vessels should be electrically continuous and effective earthed.
 The exhaust of gas engines should be insulated and provided with spark arrestors
 All electrical equipment in Zone-1 and Zone-2 hazardous area should be flame-proof
and increased safety or pressurized type of equipment respectively.
 Lube oil, grease and other flammable material should be stored in safety cans and stored
at the designated place. In case of spilling of gas oil should be immediately cleaned to
prevent danger of fire.
 The drive belts of prime movers should be of fire-resistant type and should have guards.
 Adequate portable fire extinguisher and firefighting arrangement should be provided.
 Every person employed at the gas compressor station should be conversant with the use
of firefighting equipment. Regular fire drills should be conducted for this purpose.

22
3 GGS-IV GANDHAR

3.1 OUTLINE FOR GROUP GATHERING STATION (GGS)

FIG 3.1 OUTLINE OF GGS

3.2 PROCESS DESCRIPTION

Well fluids from various wells connected to GGS-4 Gandhar are divided into three streams at
the well manifold i.e. HP (High pressure), MP (Medium pressure) and LP (Low pressure)
streams depending on their well head pressures.

HP well fluid: Well fluid from the HP header is routed to two horizontal HP separators
operating at 35 Kgs/cm2 pressure. Separated gas is metered and sent to CPF through the 12” HP
23
gas line. Separated liquid (termed as live oil) is routed to CPF through the 12” live oil line for
further separation at their end.

MP well fluid: Well fluid from the MP header is routed to the MP separators which operate at
12 Kgs/cm2 pressure. Separated liquid is routed to the downstream LP separator. Gas is sent to
CPF via the 8 “MP gas line for further compression.

LP well fluid: Well fluid from the LP header is routed to the LP separator which operates at 2.5
kgs/cm2. Separated gas is sent to Gas Compression Plant (GCP). Liquid from LP separator is
sent to storage tanks, 4 in No. each of 400 M3 capacities. Liquid from the storage tank is
pumped to CPF via 8” dead oil line.

Testing battery: Facility is available to test wells so that their liquid rate and gas production
rates can be monitored. The test battery consists of three separators i.e. HP test separator, MP
test separator and LP test separator and four 45 M3 testing tanks. A sample tank is provided
where samples of the well being tested are collected.

Water Injection facilities: Treated injection water from CPF is routed to various injectors via
the water injection header to maintain reservoir pressure. Present rate of water injection is
around 1600 M3/day at 125 kgs/cm2.

Lift gas facilities: Gas lift facility consists of Gas Dehydration Unit to meet specification of gas
compression unit and compressors to compress the gas at required gas lift pressure. The fee to
the unit is natural gas from the outlet of existing separator platform and from the dry gas from
M/s IPCL at a pressure of 36 Kg/cm2 and temperature of 35-40 ͦ C. The facility is designed for
a capacity of 0.48 MMSCMD each out of which 2 compressors of maximum capacity of 0.24
MMSCMD each out of which 2 compressors are operating and one is standby. Final discharge
pressure is 115 Kg/cm2. The discharge of the compressors is sent to the lift gas header from
where it is injected into wells.

Gas Compression Plant: Low pressure gas is received from GGS-IV, GGS-VII, GGS-VIII,
Dahej and Jolwa GGS at GCP. GCP consists of four units with a total capacity of 7.0 LSCMD.
Gas is compressed from 1.8 – 2 Kg/cm2 to 36 Kg/cm2 and sent to GAIL via CPF.

24
3.3 UTILITIES

Electrical Power and instrument gas are the utilities required to run the plant.

Electrical Power: The primary source of electrical power is from Gujarat Electricity Board
(GEB). It is stepped down from 11 KV to 440 V by a transformer inside the GGS premises. In
case of power failure in the GEB grid two standby diesel generators are provided of 200 KVA
and 160 KVA capacities. The 160 KVA generators is run when oil despatch has to be done and
the 200 KVA generator is run when the electrical load is only for air compressors for GCP,
lighting and communication.

Instrument Gas: The pneumatic medium for the various transmitters, controllers and control
valve is air. For this two Air compressor of 750 NM3/Hr. each are installed. The operational
strategy is one running and one standby.

3.4 SAFETY & ENVIRONMENT MANAGEMENT

Fire suppression system also exist with 2 nos. diesel driven fire water pumps and 1 no
electrical motor driven fire water pump(each has a Capacity of 410 M3/Hr) for firefighting
facilities including 2 nos of fire water storage tanks (capacity 3450 M3 each ). Jocky Pump
is running round the clock for keeping the Fire Water Header Pressure at 9 Kg/cm2.

Communication system exists. Mart phone, BSNL landline phone, one wireless set (VHF)
and pair of walkie talkies to create a reliable communication network..

An emergency vehicle (jeep) for 24 hrs is available at site, for operational work and emergency
conditions. An ambulance is available for 24 hrs at the site.

25
4 ONSHORE RIGS(E1400-7)

A drilling rig is a machine that creates holes in the earth sub-surface. Drilling rigs can be
massive structures housing equipment used to drill water wells, oil wells, or natural gas
extraction wells, or they can be small enough to be moved manually by one person and are
called augers.

The current depth of the well is about 1400 meter and its target is at a depth of 2300 meter.

FIG 4.1 OUTLINE OF A RIG

26
4.1RIG COMPONENTS

FIG 4.2 DRILL COMPONENTS

HOISTING SYSTEM

Whenever the drill stem is suspended by the traveling block and drill line, the entire load rests
on the derrick. The standard pyramid derrick is a structure with four supporting legs resting on
a square base. In comparison, a mast is much more slender and may be thought of as sitting on
one side of the rig floor or work space.
Traveling Block, Crown Block, Drill Line and Hook
The traveling block, crown block and drill line are used to connect the supporting derrick with
the load of drill pipe to be lowered into or withdrawn from the borehole. During drilling
operations, this load usually consists of the weight of the drill pipe, drill collars and drill bit.
The drill line passes from the draw works to the top of the derrick.
4.2 CIRCULATING SYSTEM
When drilling is in progress (Figure 3-7), the components of the hoisting system, mud pumps
and prime movers are used to circulate drilling fluid from the mud pits through the drill string
and out the bit. Cuttings are flushed from the bottom of the borehole up to the surface, thus
cleaning the bottom of the hole and providing the logging geologist with samples at the surface.
27
Mud Pumps
A drilling rig usually has two mud pumps, and these are the heart of a fluid-circulating system.
Their function is to circulate the drilling fluid under pressure from a surface pit, through the
drill stem, to the bit, return it up the annulus, and back to the pit. Mud pumps are either duplex,
double-acting reciprocating pumps or triplex, single-acting pumps.

Mud fluid

In geotechnical engineering, drilling fluid is used to aid the drilling of boreholes into the earth.
Often used while drilling oil and natural gas wells and on exploration drilling rigs, drilling
fluids are also used for much simpler boreholes. Liquid drilling fluid is often called drilling
mud. The three main categories of drilling fluids are water-based mud (which can be dispersed
and non-dispersed), non-aqueous mud, usually called oil-based mud, and gaseous drilling fluid,
in which a wide range of gases can be used.

The main functions of drilling fluids include providing hydrostatic pressure to

prevent formation fluids from entering into the well bore, keeping the drill bit cool and clean
during drilling, carrying out drill cuttings, and suspending the drill cuttings while drilling is
paused and when the drilling assembly is brought in and out of the hole. The drilling fluid used
for a particular job is selected to avoid formation damage and to limit corrosion.

Standpipe and Rotary Hose

In addition to the mud pumps, the surface portion of the fluid circulating system consists of
high pressure piping from the pumps to the standpipe. The standpipe is firmly clamped to the
derrick and topped with a gooseneck fitting. The standpipe anchors one end of the rotary hose
and keeps the hose clear of the rig floor when the drill stem is lowered during drilling. The
other end of the rotary hose is connected to a gooseneck on the swivel.
Drill string
The drill string is made up of the drill pipe, drill collars, and specialized subs through which the
drilling fluid and rotational power are transmitted from the surface to the bit.

28
Drill Bits
The drill bit is probably the most critical item of a rotary rig operation. It is the most refined of
the rotary-rig tools, available in many styles, and is more highly specialized for every condition
of drilling than any other tool on the rig.
4.3 ROTATING SYSTEM
This system has undergone the most change in recent years. Rigs now-days may be operating a
“conventional” lower rotating system or a “top drive” rotating system.
Top Drive Rotary System
It is so called because all drill stem rotation is accomplished by a drive motor located below or
attached to the swivel. With such a system the kelly and kelly bushing are not required, and the
master bushing and rotary table serve only as conduits for the drill string to be raised or lowered
into the borehole.
4.4 BLOWOUT PREVENTION (B.O.P.) SYSTEM
The hydrostatic pressure of the drilling fluid column will be greater than the formation fluid
pressures, preventing those formation fluids from entering the borehole. If the hydrostatic
pressure drops below the formation fluid pressure, formation fluids will enter the borehole. If
this flow is minimal, causing a slight decrease in the drilling fluid density (mud density), the
drilling fluid is said to be “gas cut”, “oil cut” or “saltwater cut”, depending on the fluid. When
noticeable amounts of formation fluids enter the bore hole, the event is known as a “kick”. An
uncontrolled flow of formation fluids is a “blowout”.
Annular Preventor
This consists of an annular rubber sealing element which, when pressure is applied, closes
around the drill pipe or kelly.
Pipe Rams
These have a rubber face molded to fit around a certain size of drill pipe. If more than one size
drill pipe is in use, there must be one set of pipe rams for each size of pipe.
Blind Rams
These are hydraulic rams which will close and completely close off the borehole. As such, they
are used only when there is no drill pipe in the borehole.

29
Shear Ram
These rams have specially designed cutting structures, which when closed on drill pipe, will cut
through the drill pipe and completely close off the borehole.
Choke Line
After the B.O.P is closed, high-pressure fluid can be released at carefully controlled rates by use
of a hydraulically controlled valve. The choke line will carry the high pressure fluids away from
the drilling rig.
Kill Line
Heavy drilling fluid can be introduced through a check-valve in order to control high formation
pressures. It fills the borehole from the top, instead of using the drill pipe to fill the borehole
from the bottom. It is also used to fill the annulus when pipe is being tripped out.
Shale Shaker
Fluid returning from the borehole immediately passes over the shale shaker, which contains
sloping, vibrating screens. The mesh size is small enough to allow the mud to fall through,
returning it to large mud tanks (pits).
Settling Pit (Sand Trap)
The first pit to receive the drilling fluid after it leaves the shale shaker is the sand trap. The
bottom of this pit is usually sloped so that particles that passed through the shaker screens will
segregate out, by gravity, and settle towards clean-out valves. These valves are opened
periodically so that the solids can be dumped.
Desander, Desilter and Centrifuge
The desander and desilter separate solids in a hydroclone, in which the fluid rotates and the
solid content is caused to separate by centrifugal force.
Mud-Gas Separators
Various types of mud-gas separators are used. Most, however, consist of a vertical vessel
arranged to vent free gas from the upper end and discharge relatively gas-free mud from the
bottom. To operate a mud-gas separator, the borehole must be shut-in and mud circulated
through the choke manifold. Well flow is diverted from the flow line or choke manifold to the
mud gas separator. The separator releases the gas which is then carried by the vent line at the
top to a remote flare.

30
5 CPF GANDHAR

Central Processing Facility(CPF) is an On-shore installation of AnkleshwarAsset,WOBU to

process and handle centrally all the Crude oil and Natural gas produced in the Gandhar Oil
field.

CPF is located approximately 35 kms NW of Bharuch and about 16 kms from Amod,near
village Chanchwel. Total area of CPF is 720 acres(420 acres of plant area+ 240 acres of Green
beltall around the periphery of the plant boundary).

Integrated Schematic Of CPF Gandhar

FIG 5.1 SCHEMATIC DIAGRAM OF CPF GANDHAR

Major Facilities on Site

 Crude Stabilization Unit(CSU)

 Gas Dehydration Unit(GDU)

31
  Condensate Fractionation Unit(CFU)
 Off Gas Compressor –I(OGC-I)
 Off Gas Compressor –II(OGC-II)
 Gas Injection Unit(GIU)
 Gas Lift Unit(GLU)
 Water Injection Unit(WIU)
 Injection Water Fertilization Plant(IWFP)
 Combined Cycle Power Plant(CCPP)
 Effluent Treatment Plant(ETP)
 Flare
 Product storage Tank
i. Crude Oil Tank
ii. LPG
iii. Naphtha
 Crude Oil Pumping System
 Utilities
i. Instrument Air System
i. Cooling Water System
ii. Inert Gas System
iii. Fuel Gas System
iv. Raw Water System
v. Fire Water System
vi. Product Loading Gantry
vii. Purge Air System

5.1 Crude Stabilization Unit

CPF Gandhar has two identical trains of CSU(No.11 & 12) in Phase-I and two nos. of
identical trains in Phase-II (No.14&15). Each train consists of H.P Separator, M.P
Separator,L.PSeparator along with associated system like heat exchangers and pumps.

32
In addition to above, Phase-II of CSU is having gas fired LP pre-heater between M. P&L.P
separator of each train. In the crude stabilization process, well fluid is passed through series of
separators to reduce the pressure in stages by liberating the gas. The gas thus liberated is
removed under pressure control valve&sent to user. Water associated with well is also
separated, drained off and sent to Effluent Treatment Plant for further processing before its final
disposal.

The well fluid which comes from GGS is first sent to HP separatorat CPF which is operated at
25kg/cm2. Thereafter, Crude Oil goes to MP separator through alevel control valve which
operates 9kg/cm2and then to LP separator at 0.2kg/cm2.Oil passes through L.P Preheater before
it enters LP separator. The gas liberated in HP separator is directly sent to consumers while gas
from MP and LP separators is compressed in Off Gas Compressor Phase-I and Phase-II(OGC-
II). The stabilized oil along with water coming out of LP separator is sent to storage tanks with
the help of pumps. The heating of well fluid in LP preheater increase the heavier
componentsviz propane&butane in the low pressure gas which otherwise will get vented off
from storage tanks and helps in de-emulsification.

The excess gas is liberated from separators through pressure control valve, which is not
consumed by consumers and is vented in flare header after passing through unit flareKOD. Any
liquid carryover is knocked off in Knock Out Drum (KOD) and with the help of KOD pumps.
Separated liquid is sent to storage tanks. All the separators are protected from over
pressurization through individual pressure control valve and pressure safety valve.

5.2 Gas Dehydration Unit (GDU)

The Gas Dehydration Unit is designed to handle 1.5 MMSCMD of gas. Triethylene glycol(TEG) is
used as dehydration agent, which is regenerated & reused. The system comprises of two sections

 Gas dehydration system

 Glycol regeneration system.

Dehydration:

The gas coming from Gandhar field at 40 kg/cm2 is passed through coalescer separator to eliminate any
hydrocarbon condensate and free water and then is routed to Glycol contactor where it comes in contact

33
with lean TEG coming down from top of the contactor. The dehydrated gas leaves from the top and
passes through Glycol scrubber where entrained Glycol is removed. The gas is then supplied to
consumers. This gas is having maximum of 80 kg/ MMSCM of water vapors in it.

Regeneration:

The rich Glycol from the bottomofGlycol contactor and Glycol scrubber is taken out under level control
and passed through reflux condenser and then to tube side oflean/rich Glycolexchanger where it picks up
heat. Rich glycol is then fed to glycol flash drum, where dissolved condensate and water etc. is
separated due to reduction in pressure. It is then passed through activated charcoal filter to remove color
and oil from the glycol. The temperature of rich TEG is further increased by passing it through lean/rich
TEGexchanger. Finally, rich TEG is fed to glycol still, which is mounted on hot oil heated reboiler.
Glycol stripper is between reboiler and storage tank. Stripping gas is passed through stripper column to
take away any moisture still left in down coming glycol. The lean glycol, which is free from water, is
stored in storage tank which is fed to Glycol contractor with the help of booster&circulation pump after
reducing its temperature in lean/rich exchanger& TEG cooler.

5.3 Condensate Fractionation Unit (CFU)

CFU consists of mainly condensate receiving system, filtration, light end fractionation column and LPG
column. Feed condensate is received in condensate surge drum (CSD) which is normally operated at 30
kg/cm2.Weir plate and boot is provided to drain separated water through an interface level control valve
in CSD. Two condensate feed pumps(1+1 standby) are provided to feed the condensate to LEF column
after passing through coalesce filter. Water and any foreign material in the condensate is filtered and
drained off through interface level control valve. LEF column is designed to strip off methane, ethane,
CO2and part of propane. It is operated at a pressure of 30 kg/cm2 and has 35 bubble cap type valve trays.
Thermosyphon type hot oil reboiler is used to heat the condensate. The top and bottom temperature of
the column are maintained at 55 °Cand 100 °C respectively. The vapors from top of the column are
condensed in a condenser. The reflux thus generated is collected in LEF Reflux Drum from where it is
refluxed back to column to maintain it’s temperature.

The bottom product of LEF column is taken to LPG column under level control. LPG column is for
separating higher ends from LPG. Column is operated at 10.0 kg/cm2 and has 55 single pass bubble cap
type valve trays. Top and bottom temperature of LPG column are normally maintained at 57 °C and 131
°C respectively. The vapor from the top is condensed in LPG condenser, which is flooded type. The
liquid LPG is collected in reflux drum and a part of this is refluxed back in to the column through a

34
pump. Remaining LPG is sent to storage sphere under level control. The bottom product is stored as
Naphtha after passing through coolers.

5.4 Off Gas Compressor

The low pressure gas released in CSU is rich in propane, butane and higher fractions. In order to recover
these fractions and for transporting it to consumers, this gas is compressed in off gas compressors.

Phase-I compressor Unit (OGC-I): 32- KM A/B/C:

Three reciprocating compressors are available for raising the pressure in two stages. The MP Gas from
field is taken at suction of the compressors after passing through MP scrubber to scrub off any liquid
entrained with the gas. The excess gas from CSU MP Separator can also be diverted to OGC-I for
compression. The compressed gas, after compression, is passed through after coolers and knocks out
drum, before it is supplied to consumers.

Phase-II compressor Unit (OGC-II): 16/17/18/19 K-101:

The LP gas in 1st stage of compressor and passed through intercooler. Water and higher fraction i.e.
pentane & above get condensed. Which are knocked off in 1st stage discharge KOD, Gas is taken into
2nd stage of compressor, while condensate is routed to LP condensate drum from where it is pumped to
CFU by reciprocating pumps. In 2nd stage, gas is compressed from and again cooled in inter cooler
where propane, butane and higher fraction gets condensed. This condensate is knocked out in KOD from
where it is sent to CFU by centrifugal pumps.

The gas from 2nd stage KOD is mixed with the gas coming from MP separator i.e. MP gas from CSU
and passed through Suction KOD to separate any liquid carryoverfrom separator. This gas is fed to 3rd
stage compressor suction and compressed and again cooled in inter cooler where propane & butane and
small amount of ethane also, is knocked off, which is sent to CFU through level control valve.

5.5 Gas Injection Unit (GIU)

As the oil & gas are produced and taken out from the reservoir, pressure of the reservoir depletes. In
order to maintain the pressure of the reservoir for continued exploitation and to maximize the oil
recovery, high pressure gas is injected back into the reservoir. Dehydrated and CO2 free lean gas coming
from IPCL at 37 kg/cm2 is compressed to 310 kg/cm2 in a three stage reciprocating compressor. The
discharge pressure of the gas after 1st stage is compressed to 120 kg/cm2 before the gas is sent to
intercooler for cooling. During the 2nd stage the gas is compressed from 120 kg/cm2 to 180 kg/cm2 and

35
in the final stage the gas is compressed to 310 kg/cm2. The gas is cooled in the aftercooler and then sent
to Group Gathering Station for injection into gas injection wells. To control the capacity of the
compressor, a manual selector switch is provided in LCP to run the compressor either at 50% or 100%
load. Suction and discharge KOD is provided with automatic drain valve to remove any liquid
carryover.

5.6 Additional Condensate Recovery Unit

The gas leaving OGC-II still has considerable quantities of LPG and Naphtha fractions. In addition the
field HP gas which is used internally in CCPP as a fuel is rich in nature and has potential to generate
condensate for recovery of LPG and Naphtha.

The dried gas is compressed in one GLC compressor and then the high pressure gas is expanded through
J-T valve and condensate recovered is sent to CFU for further processing.

5.7 Gas Lift Unit (GLU)

For lifting of crude oil from low pressure wells, compressed dehydrated gas is used by deploying three
numbers of single stage reciprocating compressors. Gas is either rich gas from GDU or Lean Gas
returned from GAIL. The compressed gas is sent to GGSs through a header for further distribution into
the wells for lift operations.

5.8 Water Injection Unit (WIU)

To maximize the oil recovery and to maintain the reservoir pressure filtered and de-aerated water is
injected with the help of multi-stage centrifugal pumps and booster pumps. Four chemical treatment
systems are used to prevent corrosion of pipelines and Bacteriological treatment.

5.9 Injection Water Filtration Plant (IWFP)

Raw water from Zanore is filtered and de-aerated prior to using it for Injection in reservoir. Five nos. of
pressure dual media filters(Anthracite, Fine Garnet and Coarse Garnet) are used for filtration to reduce
the turbidity <0.1 NTU.

Two chemical treatment systems are used:

 Cationic Flocculent and FeCl3

 Chlorine

36
Cationic flocculent and FeCl3 are filter aids

The filters are regularly back washed by raw water and backwash water is sent to ETP. The filtered
water is then de-aerated in De-oxy Tower and thereafter is fed to WIU. Vacuum pumps are used to
remove dissolved oxygen from raw water at De-oxy tower.

5.10 Effluent Treatment Plant (ETP)

ETP treats the effluent generated from water drain from CSU, CFU and Crude oil Storage Tanks,
Cooling Tower blow down, floor washing, filters backwash and rain water etc.

The treatment process is broadly classified into three stages.

 Primary Treatment (Bulk Oil removal)

 Secondary treatment (biological Treatment)
 Tertiary Treatment (TSS & COD removal)

Primary treatment is done to remove bulk free oil and emulsified oil from the effluent. This is done up to
the DAF unit. After DAF unit, Secondary Treatment starts to bring down the BOD within the specified
limits. Tertiary Treatment is carried out to remove remaining COD & suspended solids in pressure sand
filters & activated charcoal filters. The treated effluent is stored in final disposal sump and is then
disposed through 14” dia line into the River Dhadhar creek after ensuring its conformance to GPCB
norms/standards.

5.11 Crude Oil Pumping Station (COPS)

Stabilized crude oil received from CSU is routed to intermediate crude oil storage tanks(IC, IE, IA, IB) to
remove any residual gas and some water. This liquid is then transferred to main crude oil storage tanks,
by four numbers of transfer pumps. Liquid is allowed to settle in the main tanks for sufficient time and
free water is then drained to ETP. Stabilized crude oil having water content <1.0% is pumped to KT
refinery, IOCL Baroda.

Heater Treaters

Dead Oil, pumped from GGSs is routed to CPF Crude Storage unit through Heater Treater. Dead oil is
processed in Heater Treater unit to provide Gas separation, free water removal and coalescence of
entrained water particle to allow the oil to meet pipeline specifications. After processing, oil is sent to
LP separators of CSU unit and then pumped to storage tanks.

37
5.12 UTILITIES & OFFSITES (U & O)

i. Instrument Air System:

All the units are equipped with automatic control instrumentation. To open various field
instrumentation, dry instrument air is required @5-6kg/cm2. To meet this requirement 4 nos. IA
compressors of total capacity 2100m3/hr are installed.

ii. Cooling Water System:

Cooling Water system comprises of cooling towers &cooling water circulation pumps(3 nos. x 650m3/hr
and 4 nos. x 2100m3/hr) which circulates cooling water in closed network through various heat
exchangers. The cooling tower cools the water from 45 °Cto 33 °C and works under forced draught air
condition.

iii. Inert Gas System:

Liquid Nitrogen is received from Tankers and is stored in a double walled pressure Bullet. Liquid
Nitrogen is then vaporized in a Vaporizer and is used in the plant for Inert Gas blanketing in the lube oil
system of OGC-II, GIU & GLC etc. and also to purge the line to remove any hydrocarbons for hot
works.

iv. Fuel Gas System:

Natural Gas is also used as fuel gas for heating hot oil in Hot oil heater, firing in the boilers, flare header
purging, pilot gas for pilot burners in flare, power generation in Gas Turbines, firing burners in heater
treaters, 2 nos. FG KODs are installed at CFU & GMS respectively to meet the requirement.

v. Raw Water System:

Service water is used for cooling of bearings of the rotating equipment, floor washing, equipment & line
cleaning etc. System comprises of RW storage reservoirs(1100 m3) and 2 numbers of SW pumps of 60
m3/hr each.

vi. Fire Water System:

To fight any fire in plant, fire water is used. A fire water ring is laid all around the units with Fire
Hydrants & Monitors to use it for fighting fire. System comprises of FW Reservoir(9900 m3) and 2 nos.
Jockey pumps & 8 Main Pumps. Jockey pumps are run continuously to keep the fire water ring in
pressurized conditions @ 10 kg/cm2. Main pumps are kept on auto to take care of any pressure drop
during emergencies.

38
 vii. Flare System:

In order to dispose-off the unused natural gas from the units & to keep environment clean, Flare system
is installed which disposes excess gas after complete combustion in the atmosphere at a height of 60
meters.

System comprises of KOD to knock out any liquid carried over, water seal to maintain WC back
pressure in the flare header, high flare stack, pilot burners, main burners and molecular seals, steam
injection system is also provided in flare-II to achieve smoke less flaring during normal operation.

To light up flame from ground, a flame front generator (FFG) is located at ground. Flame propagates in
a pipeline up to the pilot burners & main burners at the top of the stack.

viii. Power Generation:

CPF is having a combined cycle power plant (CCPP) to generate 31 MW Electrical Power to meet all
the electrical power required for operation.Any surplus power is sold to GEB under power wheeling
agreement. One DG set (630 KVA,876 Amp) is also available in order to meet emergency power
requirement in case of CCPP and GEB shutdown.

Combined Cycle Power Plant Layout

39
Waste Heat Recovery System

Exhaust from the GT is taken to Heat Recovery Steam Generator, HRSG via diverter damper. The water
used in HRSG is De-Mineralized (DM) Water – free from Silica.

Steam is fed to the steam turbine (ST) which rotates the generator’s shaft and power is produced. It is a
single drum, condensing type, 29- stage steam turbine. The condensing is done under vacuum.

The condensed steam in condenser, is pumped to Feed storage tank by Condensate Extraction pumps
and from there to HRSG through boiler feed pump. Thus the closed water cycle is completed.

There is a DM water plant for making DM water from the Narmada water, received from Zanore. The
DM water is used in closed cycle.

For cooling requirement of condenser, GT and for supplying cooling water to CPF, there is a Cooling
Tower and a pump hose.

LPG & Naphtha Storage & Handling

LPG & Naphtha are products of CPF in addition of Crude Oil & Natural Gas. LPG is stored in Horton
sphere at 8kg/cm2. LPG is then dispatched to IOCL bottling plants by road Tankers. Loading of the
tankers is carried out at LPG loading Gantries (2 nos. Loading gantry +one dual purpose gantry for
loading as well as unloading sick tankers).Naphtha is stored in 2 nos. of tanks. It is also dispatched by
road tankers to consumers. A separate tank loading gantry is available for this.

40
6 FIRE SERVICES IN ONGC ANKALESHWAR
The fire service is one of the most important emergency service of Oil and Natural Gas
Corporation Ltd. A premier PSU of India in the exploration and production (EEP) of
hydrocarbons business. The fire service as the name suggests, provide fire prevention &
protection services to ONGC, Ankleshwar Asset.

Ankleshwar fire service have four fire station in the field and one centralized work shop control
room at ankleshwar.

S.NO. NAME COVERAGE AREA

1 Central Fire Station South & West Gandhar field
2 CTF fire Station Ankleshwar field
3 North Gandhar fire Station North Gandhar field
4 Jolwa Sub Fire Station Gandhar Field
5 CPF fire Station CPF Gandhar
6 Work Shop Control Room To co-ordinate the entire field, & providing fire
protection to offices/workshops/colony/gas station
of ONGC & local authorities.

TABLE 6.1 FIRE STATIONS

6.1 CFS GANDHAR FIRE STATION

Central fire station (CFS) GANDHAR was established on January 06 in year 2004. It is
a main fire station manned by ONGC fire personnel. It is 65 km away from base office
Ankleshwar. It comes under Area 2 of ankaleshwar asset. CFS Gandhar fire protection
coverage area’s are south & west Gandhar field existing strength of CFS Gandhar is 32 , works
in four duty patterns.

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 6.2 MAJOR FIRE APPLIANCES

NAME NO.

I. Multipurpose fire tender 4

II. Ultra high pressure jeep 1
III. Trailor fire pump 1
IV. Portable pump 1

6.3 MAJOR FIRE EQUIPMENTS

NAME NO.

I. Fire enter suit 5

II. Gas Detector 3
III. Ejector pump 1
IV. Turbo pump 1
V. Fire proximity suit 2
VI. Breathing Apparatus Set 17
VII. Trolly Mounted water monitor 2
VIII. Trolly Mounted water cum foam monitor 1
IX. Trailer - Water cum foam 3
X. Trolly Foam monitor 3
XI. Hand operated siren 1
XII. Electric Barrel Pump 1
XIII. Portable Inflatable Emergency Lighting system 1

42
 FIG 6.1Fire Appliances Deployed at Central Fire Station Gandhar

FIG 6.1 FIRE APPLIANCES AT CTF GANDHAR

6.4 MULTIPUROPSE FIRE TENDER

Vechile No:GJ16X8328.

It Consists of storage facilities for water, foam concentrate , DCP powder ,pumping provision
& fire fithing equipments.The following are some of details :

Water tank:5000 ltr capacities tank connected to pump suction. 4 filling connection of 63mm
instanteous male couplings.

Foam tank:800 ltr capacities tank connected to foam proportioner.The tank is filled with AFFF
concentrate.

DCP powder:500 kg Capacities cyclinder container.the container is filled with Dry Chemical
Powder.

Pump:This is the main fire pump of centrifugal type.2250 lpm @7kg/cm2 capacity.it take
power through vehicle engine by the help of power take off.it unit fitted with 2no. Of female
coupling instantaneous type at the delivery side and the pump suction is connected to water
tank & fitted with 4 inch male suction coupling.

Other fire fithing equipments are Branches,Ladder, Hose pipe,foam container,BA Set etc.

43
DISTANCE OF INSTALLATIONS OF GANDHAR FIELD FROM CFS GANDHAR

SL. No. INSTALLATION DISTANCE

(Km)
1 GGS I 7
2 GGS II 4
3 GGS III 2
4 GGS IV 14
5 GGS V 9
6 GGS VI 12
7 GGS VII 9
8 GGS VIII 14
9 GGS Dahej 37
10 GGS Jolwa 30
11 EPS – 253 20
12 CPF Gandhar 12
TABLE 6,1 DISTANCE TO SITES

ACTIVITIES OF CFS GANDHAR FIRE SERVICE

DAILY WEEKLY MONTHLY QUATERLY

Drill(squad,pump, Fire fighting Mock fire drill Hyrant & Monitor
Ladder,hydrant) Training Maintance
DPR & updating Fire appliance Monthly report Extinguisher
Records Routine Check up maintance
Fire appliance Weekly Reports Fire water pump test
Routine check up
Fire call Maintance of store Training BA set
Stand by duties Installation visit
TABLE 6.2 ACTIVITIES OF CFS GANDHAR

44
6.5FIRE PROTECTION SYSTEM

The fire protection system has been determined by identification of fire hazards.

Objective of fire protection system:

 Provide appropriate and adequate fire protection system.

 Minimize the risk and consequences of an accidental event.
 Minimize the potential for hazardous occurrences.
 Provide sufficient safety devices and minimize uncontrolled release of flammable &
toxic liquids or gases and fire.

6.6 TYPE OF FIRE PROTECTION SYSTEM

 First Aid fire fighting Equipment

 Fixed Fire Protection system

6.6.1 FIRST AID FIRE FIGHTING EQUIPMENT

The Portable firefighting equipment is designed to control or Extinguish fire at the

incipient stage. i.e. is called first aid fighting Equipment. It considering the nature of fire
hazards and critically for the providing the portable firefighting equipment.

6.6.1.1 THE VARIOUS TYPE OF PORTABLE FIRE PROTECTION

SYSTEM

 Foam Type fire Extinguisher.

 Dry Chemical Powder fire Extinguisher.
 Carbon Di Oxide gas Type fire Extinguisher.
 Water Type extinguisher
FOAM TYPE FIRE EXTINGUISHER

45
 Foam portable fire extinguisher made up of mild steel it’s shape look like a cylinder. It
contains 8440 gm water, 560 gm foam & 60 gm co2 gas cartridge. Foam are used for
special application on flammable liquid fire. i.e. we can say that it is used on class B
fire. Foam blankets the burning surface and smothers the fire foam also gives cooling
effect.

DRY CHEMICAL POWDER FIRE EXTINGUSHER

The dry chemical powder type fire extinguisher provide in complex are of 5,10,50,75 kg
capacities.

Dry chemical powder fire extinguisher made up of mild steel. It shape look like a cylinder. It
contains dry chemical powder & gas cartridge. It used in all class of fire i.e. why we can say
that it is a multipurpose fire extinguisher. Dry chemical powder based agent that extinguisher.
By separating the for parts of the fire tetrahedron. It prevent the chemical reaction b/w heat,
fuel, oxygen & halts the production of fire sustaining “free-radicals “thus extinguishing of fire.

CO2 GAS TYPE FIRE EXTINGUISHER

Carbon di oxide portable extinguisher contains CO2 which is compressed in cylinder at high
pressure. They are small, hand operated with all permanent fittings normally not exceeding a
gross weight of 23 kg. Portable extinguisher are manufactured in 2,3,4.5 kg capacity.

The extinguisher consist of a high pressure seamless cylinder fitted with a high
pressure discharge hose with plastic horn. A plastic insulated handle grip is provided on
discharge hose near the horn to prevent the cold burn. The cylinder valve incorporates a safety
release dis. It is filled inside the cylinder at a pressure of 52kg/cm2.

WATER TYPE EXTINGUISHER

The water contained in the main shell/cylinder of extinguisher and CO2 gas is held under high
850 PSI pressure in a sealed cartridge. When the extinguisher is operated, by pressing the
plunger, the cartridge seal is broken allowing the CO2 gas to escape to the main shell/cylinder
and pressurize the water inside the shell, results in pushing out water through discharge nozzle.

46
 S.NO. TYPE OF CAPACITY DURATION OF THROW
EXTINGUISHER DISCHARGE
1 Water Type 9 Ltr 90-120 Sec 6 Mtr
2 Mech. Foam Type 9 Ltr 30-90 sec 6Mtr
3 DCP Type 1-2 kg 10-15 Sec 3-4.5 Mtr
4 DCP Type 5 kg 15-20 Sec 3.5-5.5 Mtr
5 DCP Type 10 kg 23-30 Sec 5-7.5 Mtr

6 DCP Type 25 kg 25-30 Sec 6-8 Mtr

7 DCP Type 50 kg 40-50 sec 8-10 Mtr
8 DCP Type 75 kg 50-60 Sec 10-12 Mtr
TABLE 6.3PERFORMANCE CHARATERISTICS OF FIRE EXTINGUISHER

S.NO. EXTINGUISHER CAPACITY DURATION OF

DISCHARGE
MIN MAX
1 Co2 Type 2 kg 8 18
2 Co2 Type 3 kg 10 20
3 Co2 Type 4.5 kg 10 24
4 Co2 Type 6.5-6.8 kg 10 30
5 Co2 Type 9 kg 12 36
6 Co2 Type 25 Kg 20 60
TABLE 6.4 PERFOMANCE OF CO2 EXTINGUISHER

6.7 FIXED FIRE PROTECTION SYSTEM

The various fixed fire protection system and facilities are:

 Fire water pump

 Fire water storage

47
  Fire hydrant and monitors
 Water spray system
 Water sprinkler system
 Foam pourer system

Fire water pump

It is used exclusively for fire fighting purpose.Fire water pump used are of following type.

(1) Electric motor driven centrifugal pump.

(2) Diesel motor driven centrifugal pump.
The pumps may be horizontal centrifugal type or vertical turbine submersible
pumps.

Distribution network

 The fire water network shall be laid in closed loops as far as possible to ensure
multidirectional flow in the system.

 Isolation valves shall be provided in the network to enable isolation of any section of the
network without affecting the flow in the rest.

Jockey pumps

 The fire water network shall be kept pressurised at minimum 7.0 kg/cm2 g by jockey
pumps.

 2 Jockey pumps (1 working plus 1 standby) shall be provided.

 The capacity of the pump shall be sufficient to maintain system pressure in the event of
leakages from valves etc.

FIRE WATER STORAGE

Water for the hydrant service shall be stored in any easily accessible surface or underground
lined reservoir or above ground tanks of steel, concrete or masonry, the storage should be
located as far away as possible from hazardous areas to avoid any damage in case of

48
fire/explosion. The effective capacity of the reservoir above the level of suction point shall be
minimum 4 hours aggregate working capacity of main pump where rate of make up water
supply is 50% or more this storage capacity may be reduced to 3 hours aggregate working
capacity of main pumps. Storage reservoir shall be in two equal inter connected compartments
facilities cleaning and repairs.

Large natural reservoirs having water capacity exceeding 10 times the aggregate water
requirements of fire pump may be left unlined.

HYDRANTS

I. Hydrants shall be located keeping in view the fire hazards at different sections of the
premises to be protected & to give most effective service . atleast one hydrant post shall
be provided for every 30 m of external wall measurement or perimeter of unit battery
limit in case of high hazard area.
II. The hydrant shall be located at a minimum distance of 15 m from the periphery of
storage tank or hazardous equipment under protection for process plant location of
hydrant shall be decided based on coverage of all area.
III. Double headed hydrant with two separate landing valve on “4” stand post shall be used.
All hydrant outlets shall be situated at a workable height of about 1.2 mtr above ground
level.

MONITOR

I. Monitor shall be located at strategic location for protection of cluster of columns,

heaters, grass fire etc. And where it may not be possible to approach the higher levels. A
minimum of 2 monitors shall be provided for the protection of heaters shall be installed
so that the heater can be isolated from the remainder of the plant in an emergency.
II. Monitors shall be located to direct water on the object as well as to provide water shield
to firemen approaching a fire. The monitors should not be installed less than 15 m from
hazardous equipment.

FIXED WATER SPRAY SYSTEM

49
 It is a fixed pipe system connected to a reliable source of water supply & equipped with
water spray nozzles. For specific water discharge and distribution over the surface of area to be
protected. The piping system is connected to the hydrant system water supply through an
automatically or manually actuated valve which initates the flow of water.

Fixed water spray system should be provided in high hazard area where
immediate application of water is required.

FIXED WATER SPRINKLER SYSTEM

I. Fixed water sprinkler system is a fixed pipe tailor made system to which sprinklers with
fusible bulbs are attached. Each Sprinkler /riser system includes a controlling valve and
a device for actuating an alarm for the operation of the system. The system is usually
activated by heating from a fire and discharge water over the fire area automatically.
II. Sprinkler system are used for the fire extinguishment when the hazards located inside
building for example:
a) Car parking in basement
b) Building /sheds storing combustible & flammable material.

FOAM MAKER (POURER) SYSTEM

Foam has been ultimate choice in controlling and extinguishing flammable / combustible liquid
fires over the past many decades. Foam is applied on to the burning liquid surface with a view
to form a blanket for flammable vapour suppression, cooling the upper layer of burning liquid,
prevent the mixing of air and flammable vapours and most importantly to prevent the transfer
of heat from the flame to the free burning liquid surface.
The vertical atmosphere storage tanks are the most popular means for storing large
amount of amount of flammable/ combustible liquids and when involved in fire presents typical
problem to the fire fighters if attempts are made to control and extinguish fires through hand-
held lines. Fixed or mobile foam monitors have certain operating limitations to discharge foam
onto the burning liquid surface in a tank.

50
 Foam chamber, a fixed discharge outlet installed on the tank shell at weak seam line to
facilitate application of foam down to the liquid surface connected to piping that terminates at a
safe distance from the tank, is the primary and the most effective means for atmosphere storage
tank protection.

6.8CONVEYING SYSTEMS

The system consists of an adequate water supply, supply of foam concentrate, suitable
proportioning equipment, a proper piping system, foam makers and discharge devices designed
to adequately distribute the foam over the hazard.

Conventional systems are of the open outlet type in which foam discharges from all foam
outlets at the same time, covering the entire hazard within the confines of the system.

There are three types of systems:-

(i) Fixed Foam System

Fixed foam conveying system comprises of fixed piping for water supply at adequate

pressure, foam concentrate tank, eductor, suitable proportioning equipment for drawing foam
concentrate and making foam solution, fixed piping system for onward conveying to foam
makers for making foam, vapor seal box and foam pourer.

FIG 6.2 FIXED FOAM SYSTEM

51
 (ii) Semi-Fixed Foam System

Semi-fixed foam system gets supply of foam solution through the mobile foam tender. A fixed
piping system connected to foam makers cum vapor seal box in case of cone roof tanks and
foam maker and foam pourers in the case of floating roof tanks conveys foam to the surface of
tank.

FIG 6.3 SEMI FIXED FOAM SYSTEM

(iii) Mobile System

Mobile system includes foam producing unit mounted on wheels which may be self propelled
or towed by a vehicle. These units supply foam through monitors/foam towers to the burning
surface.

(iv) Sub - surface foam injection

This system is for protection of fixed roof storage tanks. It comprises of high back pressure
foam generator connected through product lines or separate lines near the bottom of the tank.

(v) Under the Seal Foam application

This is a system for floating roof tank where the foam travels through a flexible pipe inside the
tank upto the center of the tank roof and exits at the seal rim of the floating roof precisely where
the fire is located thus rapidly flooding the seal rim area and quickly extinguishing the fire.

52
System components:-

(1) Foam maker

(2) Pipes & fittings

System description:- Foam maker is installed at top of tank wall with system pipe extended up
to roadside at safe distance from tank. System line has to be charged with foam solution with
help of foam tender / foam nurser. Orifice plate is provided at inlet of foam maker to control
flow rate. Foam solution get aerated at foam maker and after sufficient expansion gets in to
tank. System can be used to extinguish burning liquid in tank.

53
7 HAZARD IDENTIFICATION-(HAZOP)

7.1 STUDY OBJECTIVES

 To identify the potential Hazardous situations and operability problems associated with
the normal operation of the plant.
 To analyze chemical and process hazards, i.e. to examine the possible pathways of
occurrence of an unintentional event that may lead to any accident
 To evaluate the protection measures that are already incorporated in terms of their
effectiveness, adequacy, response time and resource mobilization
 To provide Management a basis for safety management program
 Finally, to suggest recommendations for safe operation of Installation.

7.2 SCOPE OF STUDY

 To carry out Hazard & Operability Study (HAZOP) of the GGS Dabka Installation and
to identify potential hazards incorporating the following aspects:
i. Verification and study of provided piping and instrumentation diagrams
(P&I)
ii. Study of measuring instruments, alarms, controls, safety, fire prevention
&firefighting systems provided & what if analysis.
iii. Simulation of HAZOP process cycle for possible deviations to identify
potential hazards for the operations.
iv. Identification and listing of remedial measures.
 To examine the safety measures incorporated in the installation to suggest additional
suitable safety measures

HAZOP is a technique commonly used by chemical process facilities to identify hazards and
difficulties that prevent efficient operation. There are two versions of the technique, one that
deals with "deviations" and the other with "disturbances". "Deviations are caused by
malfunction or mal-operation of a specific production system.”Disturbances "include problems
caused by influences outside the specified system including other activities and the
environment. The first version of HAZOP to be developed and the most widely known was
aimed at deviations and is called a "Guide Word" HAZOP. Each element of the process is
54
evaluated separately. The purpose of the element is specified and associating this purpose of the
element with distinctive words or phrases called “Guide Words” generates notational
deviations. These guidewords are "no" or "not", "more", "less", "as well as", "part of",
"reverse", and "other than" which, broadly speaking, cover all possible types of deviation.
The second version of HAZOP studies is called a "creative checklist" HAZOP. This version has
been developed as a complement to the guideword HAZOP to cover "disturbances". It is of
particular value in two situations. These are to enable HAZOP study to the carried out early in
the design process, even before the detailed design necessary for a "guideword" HAZOP is
available: and to cover hazards which may be caused by interactions between units which could
be perfectly safe if built in isolation, but may be capable of adverse interactions. This second
method uses a checklist of known major hazards and nuisances. The checklist would contain
words such as "fire," "explosion", "toxicity", "corrosion", "dust", and "small". The checklist is
initially applied to materials likely to be present; raw materials, intermediates, finished
products, byproducts and effluents. This establishes qualitatively whether hazards and
nuisances exist and also provides a quantitative database of the numerical intensities of
different hazards. Thus "fire" would result in not only a note that material is flammable but
numerical measurements such as a "flash point" and "flammable limits". The second method
continues with the association of the same checklist with each item of equipment. The materials
present in such equipment together with the inventories are known as the "materials hazards".
7.3 PROCEDURE
The main elements under consideration while preparing HAZOP worksheet during study are:
 Deciding parameter according to operations / process
 Deviation from ongoing operations
 Possible causes for deviation
 Consequences
 Hazards
 Operating Difficulties
 Existing safeguards at Installation
 Required safety measures / Corrective action if any.

Here the hazop study is taken around the tank farm and two process is taken

55
1. From Heater Treater to the tank
2. From the tank to dispatch
Transfer of Oil from HT to Storage Tank
Sno. Facilities HT To Storage Tank HAZOP Sheet no 1

Node Transfer Of Liquid From Heater Drawing/Diagram

treater to Storage Tank No.
Parameter Guide Possible Possible Safeguard Action/Corrective
Words Causes Consequences Measures / measures
(Deviation) Existing Facilities Required

1.1 Flow
1.1.1 No No crude No crude oil LC is Adherence to
oil in the will reach to provided at the
HT. storage tank. the HT. SOP and
Outlet PSV is maintenance
valve of the provided practices
HT may be on required
closed. HT.
Line BV is
leakage. provided at
Inlet valve storage
of the tank.
storage tank SCADA
may be monitoring
closed. system is
provided.
SOP

1.1.2 Less Less crude No flow of As 

oil in the crude oil above
HT. Operability
Outlet Problem
valve of the
HT may be
partially
closed.
Inlet valve
of the
storage tank
may be
partially
closed.
Heavy
leakage at
pipeline.

56
 
1.1.3 More High Leakage at GV LAH should be
discharge flanges/joints. provided in hooked up
from Chances of the through
Separator. pressure line. annunciator to
Malfunction rise into the LCV audible hooter/
LC/PG. pipeline. provided lamps
 Overfilling of on 
storagetanks. the HT.
Crude oil Vents/BV
spillage may are
occur. provided
on the
storage
tank for
release of
entrained
gases.
Dyke wall
provided
around
storage
tanks.
TABLE 7.1 HAZOP STUDY
For Oil dispatch through oil dispatch pump
FacilitiesStorage tank outlet to oil dispatch HAZOP Sheet No. 2
Pump
NODE Transfer of oil through Oil Dispatch Drawing/Diagram
SN Pumps No
Parameter Guide Possible Possible Safeguard Action/Corre
Words Causes Consequences Measures / ctive
(Deviation) Existing Facilities measures
Required

2.1 Flow
2.1.1 No 4. No Oil in 4. Pump will 1. Overload Pump
the storage run idle protection is tripped on
tank. and may provided to tank low
5. No overheat. pump level to be
sufficient 5. Process motor. provided
pressure gets stopped 2. Strict
inside the 6. Operability Supervision
storage tank Problem. &
6. Pipeline Pipeline
valve (Gate maintenance

57
 valve) closed is
7. Leakage in in place.
pipeline.

2.1.2 Less 1. Low level of 1. Operability 1. Level As above

oil in problem. indicator
storage tank. 2. Production provided
2. Pipeline loss 2. Pressure
valve (Gate gauge
valve) partially provided.
closed. 3. PSV
3. Leakage provided at
through discharge of
pipeline pump.
3. Overload
protection is
provided to
pump
motor.
4. Regular
maintenance
practices
followed

2.1.3 More 1. More 1. Operability 1. Pressure

pressure in problem gauge is
storage tank. 2. Pressure provided.
rise in the 2. Breather
pipeline. valve
provided
on tank.
3. Overload
protection is
provided to
pump
motor.

2.2 Pressure

58
 2.2.1 Low 1. Suction / 1. low Bypass line 1.
Discharge of production with valve Adherence
pump may be operability is to SOP
low problem provided to
2. Leakage in discharge &
pipeline suction
3. Less section
quantity of
product in tank
4. pump
malfunctioning
5. air lock
condition

2.2.2 High No Issue

2.3 Temperature High / low No Issue

TABLE 7.2 HAZOP STUDY 2

SPECIFIC RECOMMENDATIONS
SN Recommendations Reference from
Sheet

Table 1 Worksheet 1- For Transfer of

Oil from HT to Storage Tank

1 LAH should be hooked up 1.1.3

through annunciator to audible
hooter/ lamps

Table 2 worksheet - 2 for Oil dispatch

through oil dispatch pump

2 Pump tripped on tank low level 2.1.1

to be provided

3 Adherence to SOP 2.2.1

TABLE 7.3 RECOMMENDATIONS

59
8 RISK ASSESMENT (EVENT TREE ANALYSIS)

Event tree analysis (ETA) is a forward, bottom up, logical modeling technique for both
success and failure that explores responses through a single initiating event and lays a path for
assessing probabilities of the outcomes and overall system analysis. This analysis technique is
used to analyze the effects of functioning or failed systems given that an event has
occurred. ETA is a powerful tool that will identify all consequences of a system that have a
probability of occurring after an initiating event that can be applied to a wide range of systems
including: nuclear power plants, spacecraft, and chemical plants. This Technique may be
applied to a system early in the design process to identify potential issues that may arise rather
than correcting the issues after they occur. With this forward logic process use of ETA as a tool
in risk assessment can help to prevent negative outcomes from occurring by providing a risk
assessor with the probability of occurrence. ETA uses a type of modeling technique
called event tree, which branches events from one single event using Boolean logic.
Performing a probabilistic risk assessment starts with a set of initiating events that change
the state or configuration of the system. An initiating event is an event that starts a reaction,
such as the way a spark (initiating event) can start a fire that could lead to other events
(intermediate events) such as a tree burning down, and then finally an outcome, The loss end
state is highly dependent upon the system, for example if you were measuring a quality process
in a factory a loss or end state would be that the product has to be reworked or thrown in the
trash. Some common loss end states:

 Loss of Life or Injury/ Illness to personnel

 Damage to or loss of equipment or property (including software)
 Unexpected or collateral damage as a result of tests
 Failure of mission
 Loss of system availability
 Damage to the environment

60
8.1 METHODOLOGY

The overall goal of event tree analysis is to determine the probability of possible negative
outcomes that can cause harm and result from the chosen initiating event. It is necessary to use
detailed information about a system to understand intermediate events, accident scenarios, and
initiating events to construct the event tree diagram. The event tree begins with the initiating
event where consequences of this event follow in a binary (success/failure) manner. Each event
creates a path in which a series of successes or failures will occur where the overall probability
of occurrence for that path can be calculated.

Steps to perform an event tree analysis:

1. Define the system: Define what needs to be involved or where to draw the boundaries.
2. Identify the accident scenarios: Perform a system assessment to find hazards or
accident scenarios within the system design.
3. Identify the initiating events: Use a hazard analysis to define initiating events.
4. Identify intermediate events: Identify countermeasures associated with the specific
scenario.
5. Build the event tree diagram
6. Obtain event failure probabilities: If the failure probability cannot be obtained
use fault tree analysis to calculate it.
7. Identify the outcome risk: Calculate the overall probability of the event paths and
determine the risk.
8. Evaluate the outcome risk: Evaluate the risk of each path and determine its
acceptability.
9. Recommend corrective action: If the outcome risk of a path is not acceptable develop
design changes that change the risk.
10. Document the ETA: Document the entire process on the event tree diagrams and
update for new information as needed.

61
8.2 MATHEMATICAL CONCEPTS

1 = (probability of success) + (probability of failure)

The probability of success can be derived from the probability of failure.

Overall path probability = (probability of event 1) X (probability of event 2) X (probability of

event n....)

EVENT TREE DIAGRAM

Here the event tree diagram is constructed for the storage of crude oil

FIG 8.1 EVENT TREE DIAGRAM

1: Probability of immediate ignition taken from Bevi (2009) for highly flammable substances
(Tf < 21 ºC).
2: Default probability of delayed ignition (flammable vapor).
3: Probability of explosion in the event of flammable dispersion (Bevi, 2009), only if a
minimum amount (usually 500 - 1000 kg) is between flammability limits in the cloud. If this
criterion it is not fulfilled, use P3 = 0
4: The criterion of 100% for the probability of delayed ignition is probably too conservative, as
not always the release of these substances gives rise to a fire.

62
The following values are therefore proposed:
Probability If LFL exceeds Process Process releases Storage
the releases** in releases***
establishment classified areas
without
boundary*
any direct
ignition sources

P2 1 0.7 0.1 0.07

P2 0 0.3 0.9 0.93

TABLE 8.2 ETA CONCLUSION

63
9 CONSEQUENCE MODELLING
Consequence modelling refers to the calculation or estimation of numerical values (or
graphical representations of these) that describe the credible physical outcomes of loss of
containment scenarios involving flammable, explosive and toxic materials with respect to their
potential impact on people, assets, or safety functions. This datasheet presents (Section 2.0)
recommended approaches to consequence modelling for accidental releases of hazardous
materials, with the potential to cause harm to people, damage to assets and impairment of safety
functions, from offshore and onshore installations.
Consideration of environmental impacts is excluded, although the recommended
approaches to release modelling (in particular for liquids) may be applied to estimate potential
quantities of hydrocarbon spilt. This datasheet is not intended to be a textbook of consequence
modelling theory but rather to indicate the consequence phenomena that need to be considered
and to provide guidance on modelling that is fit for purpose

64
9.1 RELEASE MODELLING

Release modelling – also called discharge or source term modelling – is mainly used to
determine the rate at which a fluid is released to the environment in a loss of containment
incident, together with the associated physical properties (e.g. temperature, momentum). A
simple approach is to calculate the initial rate and to assume that this is constant over time. This
is often used for studies of onshore facilities, especially where the offsite risk is the motivation
for the study.
A more sophisticated approach is to model the time dependence of the release rate. This is often
used for studies of offshore facilities, where the time dependence has a significant impact on the
likelihood, in particular, of the initial event escalating. The modelling required is more complex
but avoids certain issues that arise when initial rate modelling is used:
• Initial rate modelling can lead to over-prediction of the flammable/explosive mass in
a vapour cloud
• Initial rate modelling can lead to over-prediction of the size of a jet fire over time but
under-predict its duration or the time for which it exceeds a critical length (e.g. to
other equipment)
• Initial rate modelling can lead to over-prediction of the impact of toxic gas or smoke
effects
In general, time dependence should be explicitly modelled in offshore studies, where the
impacts over relatively short distances (tens of metres) and over time periods up to the required
endurance times of the TR (Temporary Refuge) and other safety functions, which may be of the
order of 1 hour, are of concern. Time dependence is less often modelled in onshore studies,
where the impacts over relatively long distances (hundreds of metres to a few kilometres) and
over time periods up to that required for effective emergency action to commence. An
exception to this is the modelling of cross-country pipeline ruptures, for which time dependence
may be important.

9.1.1 RELEASE MODELLING OF CRUDE FROM STORAGE TANK

A storage tank is shown in Figure 4-5. A hole develops at a height hL below the fluid level. The
flow of liquid through this hole is represented by the mechanical energy balance (Equation 4-1)

65
and the incompressible assumption, as shown in Equation 4-2.

The gauge pressure on the tank is P,, and the external gauge pressure is atmospheric, or
The shaft work W, is zero, and the velocity of the fluid in the tank is zero. A dimensionless
discharge coefficient C,, is defined as

The resulting equation for the instantaneous velocity of fluid exiting the leak is

66
As the tank empties, the liquid height decreases and the velocity and mass flow rate decrease.
Assume that the gauge pressure P, on the surface of the liquid is constant. This would occur
if the vessel was padded with an inert gas to prevent explosion or was vented to the atmosphere.
For a tank of constant cross-sectional area A,, the total mass of liquid in the tank above
the leak is

where Q, is given by Equation 4-12. By substituting Equations 4-12 and 4-13 into Equation
4-14 and by assuming constant tank cross-section and liquid density, we can obtain a
differential equation representing the change in the fluid height:

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The first term on the right-hand side of Equation 4-19 is the initial mass discharge rate at
hL = hL.
The time t, for the vessel to empty to the level of the leak is found by solving Equation
4-18 for t after setting h, = 0:

EXAMPLE
A cylindrical tank 20 ft high and 8 ft in diameter is used to store benzene. The tank is padded
with nitrogen to a constant regulated pressure of 1 atm gauge to prevent explosion. The liquid
level within the tank is presently at 17 ft. A 1-in puncture occurs in the tank 5 ft off the ground
because of the careless driving of a forklift truck. Estimate (a) the gallons of benzene spilled,
(b) the time required for the benzene to leak out, and (c) the maximum mass flow rate of
benzene through the leak. The specific gravity of benzene at these conditions is 0.8794.

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SOLUTION
The density of benzene is

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This appears to be more than adequate time to stop the leak or to invoke an emergency
procedure to reduce the impact of the leak. However, the maximum discharge occurs when the
hole is first opened.
The maximum discharge occurs at t = 0 at a liquid level of 17.0 ft. Equation 4-19 is used to
compute the mass flow rate:

9.2 SOLID FLAME MODEL

Industrial fires can be intense emitters of heat, smoke, and other combustion products.
This is particularly true if the fuel is a petroleum based substance, with a high heat of

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combustion and sooting potential. The radiant energy flux can be sufficiently high to threaten
both the structural integrity of neighboring buildings, and the physical safety of fire fighters,
plant personnel, and potentially people beyond the boundaries of the facility. Depending on the
fuel and the size of the fire, up to 20 % of the fuel mass is converted to smoke particulate in the
combustion process. This smoke shields much of the luminous flame region from the viewer,
and it is this luminous flame region that is the source of most of the thermal radiation. This
shielding effect is most pronounced for fires that are tens or hundreds of meters in diameter
because of the decreased efficiency of combustion.

FIG 9.1 FLAME MODEL

In this solid flame model the fire is idealized as a solid vertical cylinder emitting thermal
radiation from its sides. This model is relatively simple, but it does require estimates of the
diameter and height of the cylinder, plus an estimate of the emissive power. by this modeling
the thermal radiation flux and the atmospheric transmissivity are calculated by doing this the
acceptable safe distance for object and people can be estimated.

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THE SOLID FLAME MODEL (SHOKRI AND BEYLER)

9.3 THERMAL RADIATION FLUX

where, Ep = average surface emissivity power of the flame (kW/)

F = view factor between the flame and the target
τ = atmospheric transmissivity

where F is a geometric view factor that defines the fraction of energy radiated by the fire that is
intercepted by the receiving object; τ is the atmospheric transmissivity to thermal radiation,
mainly a function of humidity and distance between the radiation source and the receiver;
Also, to be on the conservative side, the transmissivity is taken as one. What remains to be
computed are the view factor F and the emissive power of the flame Ef.

9.4 VIEW FACTOR

The view factor depends on the three factors
 Height of the luminous zone (H)
 Breadth of the flame (in front of the object) W
 Distance between the fire and the target (S)
By calculating the value of H/W and S/W we can get the value of view factor for any target at a
distance.

9.5 SURFACE EMISSIVE POWER

The SEP is the amount of thermal radiation emitted by the fire at its outer surface
and is a function of the mixing dynamics and chemical kinetics of the flame. It is largely
driven by the difference in soot production rates and soot oxidation rates occurring in the
fire. As the pool fire diameter increases, the soot production rate increases, causing the

72
flame to become optically thick. As the flame becomes optically thick, the SEP increases
and heat radiates over greater distances from the pool. However, as the pool diameter
increases further, the soot production rate begins to exceed the soot oxidation rate. This
results in the flame becoming saturated and the soot (predominantly smoke particulates)
escapes past the flame envelope and effectively reduces the SEP by obscuring the flame
surface. As the SEP decreases, the distance over which heat radiates from the pool also
decreases. As a result, there is a specific pool diameter which will generate a maximum
possible SEP for a fire either over water or on land. Increases in pool size beyond this
diameter will result in a lower SEP. In addition, as the soot is buoyant, the SEP is not
homogeneous over the entire flame surface. Periodic smoke shedding due to wind will
also provide moments of higher mean SEPs for smoke obscured flames.

Emax = 140 kW/m2 (equivalent blackbody emissive power), Esoot = 20 kW/m2

D=Dyke diameter

9.6 ATMOSPHERIC TRANSMISSIVITY

Thermal radiation transmitted through the atmosphere will determine the thermal radiation that
may be absorbed by an object. Transmissivity is the amount of thermal radiation that is
transmitted through (and not absorbed by) the atmosphere. Transmissivity is a function of the
presence of products in the atmosphere that absorb thermal radiation from the fire. It is largely
driven by the amount of carbon dioxide and water vapor in the atmosphere. The amount of
carbon dioxide in the air is dependent on the ambient temperature and the amount of water
vapor in the air is dependent on both the relative humidity and ambient temperature. An
increase in the amount of carbon dioxide and water vapor in the air decreases the transmissivity
and subsequently decreases thermal radiation distances the expression for Atmospheric
Transmissivity

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Where, r = relative humidity of the atmosphere (%)
x = distance from flame surface to exposed target (m)

9.7 HEIGHT OF LUMINOUS ZONE

The flame length is the length of the flame as measured from the base of the fire. The flame
length will vary for the turbulent diffusion flames present in large scale pool fires and therefore
an average flame length is often reported for experimental data. Sometimes a maximum flame
length or a flame length that occurs at a certain frequency (e.g., 95%) may be the only value
reported for experimental data. The flame length is a function of the mixing dynamics and
chemical kinetics of the fuel and oxidant. For solid flame models, the flame length is typically
calculated using empirical correlations based on the mass burning rate and diameter of the pool
fire. For solid flame models, the flame height represents the height of the simplified geometry,
and is accounted for in the view factor for calculating the distance to a specified thermal
radiation level. Higher flame lengths will result in farther thermal radiation distances

HRR for the crude per unit area = 1900 KW/m2 = q(f)”

Where, D = Diameter of dyke

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 G =acceleration due to gravity
m(f)”=mass burning rate

Practical example For Solid Flame Model:

A 12m high gasoline tank containing 2000 of gasoline in it, situated in a rectangular dyke of 30m
25m. Diameter of the tank is 23m. An canteen is situated 230m away from the dyke area. Building is
parallel to the dyke wall of 30m length. Calculate the heat transfer in case of fire and comment on
separation distance.

Solution
Thermal radiation flux =

………………………….eqn1

Surface emissive power

…….eqn2

Emax = 140 kW/m2 (equivalent blackbody emissive power), Esoot = 20 kW/m2

D=Dyke diameter

D = √4𝐴/𝜋

A=area of the dyke

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A=length*breadth

A=30*25=750 m2

D=28 m2

E=140*.03473+20(1-.03473)

=24.1622 kw/ m2

View factor

By calculating the value of H/W and S/W we can get the value of view factor for any target at a
distance

H= Height of the luminous zone

W= Breadth of the flame (in front of the object)

S= Distance between the fire and the target

H/W=0.26, S/W=0.9 , so view factor(F) =0.064

Height of luminous zone :

………..eqn 4

Heat Release Rate for the crude oil per unit area = 1900kgW/m2 = q(f)”

H=6.4*0.003*1900

=36.48 m

Flame height

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 ………..eqn 5

Where, D = Diameter of dyke

m(f)”=mass burning rate

g= acceleration due to gravity

flame height = 4.2*28*.02722656

=3.2018m

Atmospheric Transmissivity:

…………………….eqn 6

Where, r = relative humidity of the atmosphere (%)

x = distance from flame surface to exposed target (m)

r=0.743

x=230

τ = 0.79*21.46*0.28

=4.748m

From equation 1,

Thermal radiation flux = q(R)’’ = EP F τ

=24.1622*0.064*4.748

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=7.342 kW/m2

Here the thermal radition flux of 7.342 kW/m2 is obatained..the acceptable separation distance
from the fire area is not followed as per standard ..the The HRR Per Unit Area, q(f)” for crud
eis 1900 kW/m2. fire diameter of 28 m yields an ASD of less than 15 430m for buildings and
430mfor people. These distances should be applied from the edge of the dike closest to the
potential target, not from the center of the dike.

9.8 O.I.S.D FOR DYKE ENCLOSURES

a) Petroleum storage tanks shall be located in dyked enclosures. Each dyke shall have roads all
around for access for normal operation and maintenance as well as for emergency handling.
Aggregate capacity (Combined safe capacity) of tanks located in one dyked enclosure shall not
exceed following values:
1. 60,000 cum. for a group of fixed roof tanks.
2. 120,000 cum. for a group of floating roof tanks
Fixed cum floating roof tanks shall be treated as fixed roof tanks. However in case these tanks
are provided with windows opening on the shell and these windows will not get blocked in any
case, then these should be considered as floating roof tanks.
If a group of tanks contains both fixed and floating roof tanks, then it shall be treated as a group
of fixed roof tanks for the purpose of above limits.
b) Dyked enclosure shall be able to contain the complete contents of the largest tank in the dyke
in case of any emergency. A free board of 200 mm above the calculated liquid level or 10% of
calculated dyke capacity whichever is higher shall be provided for fixing the height and
capacity of the dyke.
Enclosure capacity shall be calculated after deducting the following volumes:
1. Volume of the tanks other than largest tank up to enclosure height without free board.
2. Volume of all tank pads.
3. Volume of fire break walls.
4. Volume of pipes/supports/steps etc.
The height of tank enclosure dyke (including free board) shall be at least 1.0 m and shall not be
more than 2.0 m above average inside grade level. The dyke wall made up of earth, concrete or

78
solid masonry shall be designed to withstand the hydrostatic load and shall be impervious.
Earthen dyke wall shall have not less than 0.6 meter wide flat section on top for stability of the
dyke wall. Dyke enclosure area (inside area of the dyke) shall be also impervious to prevent the
ground water pollution.
c) The dyke and the enclosures will be inspected for cracks, visible damage etc. every six
months (pre and post monsoons) and after every major repair in the tanks / dykes etc. so as to
keep it impervious.
Piping thru’ dyke wall if any shall be properly sealed to make dyke impervious. The dyke area
shall have proper slope outward of tank pad towards the inner periphery of the dyke enclosure
to prevent reverse flow.
d) Earth-pits shall be provided outside of Dyke area and strips buried under the earth except at
termination points from a shortest possible distance. The earthing lay out diagram of each
facility shall be displayed near each facility for reference.
e) For excluded petroleum, the capacity of the dyked enclosure should be based on spill
containment and not for containment on tank rupture. The minimum height of dyke wall in case
of excluded petroleum shall be 600 mm.
f) Pump stations and piping manifold should be located outside dyke areas by the side of roads.
g) Horizontal above ground tanks mounted on pedestals shall meet separation distances and
shall have dyked enclosure.
h) In case of Under Ground Tanks :
1. Kerb wall of minimum 30 cm height shall be provided in the UG tank Farm Area to
contain accidental overflow.
2. A minimum of 3 M clear distance around the tank shall be maintained (from structures /
boundary
3. wall etc).
4. Vents shall be located / terminated at a distance of 15 mtrs from hazards.
5. Pressure / Vacuum vents for class A product and free vents for other class of products
shall be provided. Vent shall be at minimum 4 M height from the grade level.
6. The open end of free vent pipe shall be covered with two layers of non- corrodible metal
wire gauze having not less than 11 meshes per liner centimetre and shall be further
protected from rain by hood or by suitably bending it downward.

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 7. The petroleum shall enter a tank through closed piping system / coupled electrically
continuous and sound hose.
8. Under Ground tanks for Ethanol service shall be provided with Silica Gel Traps in the
Vents to prevent moisture ingress.
9. The manholes should be 30 cm above the grade level.
i) Corrosion control measures shall be undertaken

9.9 GENERAL RECOMMENDATIONS

1. No smoking within plant premises.
2. Usage of mobile phone prohibited in operational area. Only flameproof walkie-talkie sets to
be used
3. Personnel should be aware of Fire fighting facilities available and their immediate use
4. Personnel should be acquainted with various alarm signals and subsequent actions to be
taken.
5. In case of fire alarm, all personnel must go to Assembly point and instructions of Shift in
charge are to be obeyed.
6. Proper Personnel Protective Equipment (PPE) to be used
7. Proper check of Safety belts, safety shoes, helmets to be done before usage.
8. All electrical systems should be flameproof.
9. Double earthing to be made available on all electrical equipment as well as Separators and
Storage tanks
10. All vents must be connected to flare. In case of open venting, flames arrestor to be
provided.
11. First aid box must be available at the installation.
12. In case of injury to personnel, first aid to be delivered by First aid trained personnel.
13. In case of intrusion into eye, eye wash is to be used. Water must be continuously available
at eye wash shower.
14. Only brass hammers to be used.
15. Any work other than operational requirement should be done by taking specific work
permits for :
a. Hot jobs and Vessel entry – Hot work permit

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b. All other jobs – Cold work permit
16. Grass cutting is to be undertaken on regular basis and dry grass must be evacuated
immediately.
17. During maintenance of equipment, oil/ condensate must be collected in trays and not
allowed to spill or spread.
18. While loading and unloading oil in road tankers, its engine should be stopped and battery
isolated from the electric circuit. The engine should not be re-started and the battery should not
be connected to the electric until all tanks and valves have been securely closed.
19. Prohibitory caution signs should be displayed at all critical places.

The HAZOP report, FAULT TREE ANALYSIS, CONSEQUENCE MODELLING and

recommendations are made on the basis of available information & physical visit at site or
information provided by the Installation personnel. However the Installation Manager / Safety
Officer can take additional safety measures if required as per their convenience.

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CONCLUSION
After completion of 31 days of industrial training in ankaleshwar asset, we get the various
process involved in the industry and the various safety equipment that is present to prevent the
outbreak of any type of accident. The FIRE service division in ankleshwar asset is vigilant and
gives out weekly classes to all employees of ONGC. They also attend any fire civil fire calls.
They provide fire awareness classes to the students of Kendra vidyalaya. The HSE division of
ONGC is active in keeping the environment clean and safe. They had done many projects in
improving the living condition of the people in the ONGC colony by planting trees etc.
Together the FIRE and HSE have adopted many active and passive measures to keep the
industry accident free.

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