Report On Industrial Attachment at BGFCL

BANGLADESH UNIVERSITY OF ENGINEERING AND
TECHNOLOGY
Report on Industrial Attachment in BGFCL
Submitted by: Submitted on: 25th March, 2018
Nishat Tabassum
(1402001)
Jannatul Ferdous
(1402016)
Al Ibtida Sultana
(1402018)
Mysha Momtaz
(1402044)
Marfua
(1402056)
Acknowledgement
As part of the short industrial attachment, we, five students of Department of Chemical
Engineering of BUET, visited BGFCL from 13th of March to 25th of March. This report is an
integral part of the short industrial attachment. This paper owes its existence to the help, support
and inspiration of several people.
We are sincerely grateful to our teachers Dr. Ijaz Hossain, Head of the Department of Chemical
Engineering, Dr. Ruhul Amin, Associate Professor and Dr. Nahid Sanzida, Assistant Professor of
Department of Chemical Engineering for their constant help and support.
We are grateful to Mr. Md. Kamruzzaman, Managing Director, Engr. Md. Ali Moktazer- G.M.
(operations), Mr. Shah Alam- G.M. (administration), D.G.M. Engr. Uttam Kumar Sarkar, D.G.M.
Kartick Chandra Ghosh for granting us permission to visit BGFCL. Our sincere thanks to Engr.
Md. Mamun Azad (Project Engineer), Engr. Md. Shafiqul Islam (Manager, Condensate
Production), Engr. Abdullah Al Mamun, (Manager, Production), Sheikh Moktadir Hossain
(Manager, Geology), S.M Ashikur Rahman (Manager, Lab), D.M (Plant Maintenance) Engr. Kazi
Yasin Arafat for taking the time out of their busy schedules to share their invaluable experience
and knowledge.
This acknowledgement would be incomplete without expressing our gratitude to Engr. Md.
Rafiqul Islam (Manager-Operations), and especially Engr. Md. Mostafizur Rahman- D.M
(Production) who has been our training co-ordinator and has relentlessly supported and guided us
to complete the training as scheduled.
We also thank all the other staff of the Titas gas processing plant for their kind support.
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Summary
This report is a short summary of Titas gas field at a glance, encompassing the various aspects of
natural gas processing at the plant. This includes a short insight of the quality control procedures
adopted at Titas for the product and raw materials, detailed description of the fractionation plant,
ETP plant, LTS with glycol injection gas process plant, glycol dehydration process plant, an
overview of the reservoir of Titas field, activities of Titas lab, plant equipment and maintenance,
management system of BGFCL, various applications of different machineries and safety of the
plant. Being the largest gas field company in BGFCL, Titas is divided into two divisions- North
and South. Our visit included gas process plants in location- A and location- G from the south
division and location- J from the north division. Natural gas is mainly dehydrated using a variety
of systems mentioned previously; a large quantity of hydrocarbon condensate is additionally
recovered with the gas and is separated for fractionation. The fractionation plant is located only in
location-A where the condensate from location-A along with the condensate being collected from
the rest of four fields of BGFCL on a weekly basis, is processed. BGFCL produces gas and sells
it to the Gas Transmission Company Limited (GTCL) and TGTDCL, which is then distributed to
the end users by six distribution companies owned by Petrobangla. MS, HSD are produced as
secondary products by fractionation of condensate which are handed over to the marketing
company; Bangladesh Petroleum company (BPC).
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Table of Contents
Acknowledgement .......................................................................................................................... ii
Summary........................................................................................................................................ iii
Table of Contents........................................................................................................................... iv
List of tables.....................................................................................................................................v
List of figures................................................................................................................................. vi
1. Introduction ............................................................................................................................. 1
2. Project Definition .................................................................................................................... 1
2.1. Company Background...................................................................................................... 1
2.2. Raw Materials .................................................................................................................. 2
2.3. Product ............................................................................................................................. 3
2.4. Capacity and turndown..................................................................................................... 3
3. Process Description ................................................................................................................. 4
3.1.1. Glycol dehydration.................................................................................................... 3
3.1.2. LTS without glycol injection .................................................................................... 4
3.2. Regeneration of glycol ..................................................................................................... 5
3.3. Fractionation plant............................................................................................................ 6
3.4. Maintenance ..................................................................................................................... 6
3.4.1. Maintenance Instructions .......................................................................................... 7
3.4.2. Periodic Maintenance Jobs ....................................................................................... 7
3.5. Activities of Titas Lab...................................................................................................... 9
3.6. Utilities........................................................................................................................... 10
4. Process Flow Diagram ...............................................................................................................14
5. Effluent Treatment Plant ........................................................................................................18
6. Safety ......................................................................................................................................23
6.1. General plant safety.........................................................................................................23
6.2. ETP Safety.......................................................................................................................26
7. Conclusion ..............................................................................................................................27
Appendix........................................................................................................................................28
Appendix A ................................................................................................................................28
Appendix B ................................................................................................................................32
Appendix C.................................................................................................................................34
List of tables
Table 2.1: Raw material...................................................................................................................2

Table 2.2: Total monthly production of February, 2018 in titas field .............................................3
Table 3.1: Periodic maintenance jobs ..............................................................................................7
Table 3.2: Activities of Titas lab......................................................................................................9
Table 3.3: List of major utilities under use ....................................................................................10
List of figures
Figure 4.1 :PFD without glycol injection ......................................................................................14

Figure 4.2: PFD of glycol dehydration unit ...................................................................................15
Figure 4.3: PFD of glycol regeneration unit ..................................................................................16
Figure 4.4: PFD of fractionation plant...........................................................................................17
Figure 5.1: Typical block diagram of an ETP................................................................................18
Figure 5.2: Process block diagram of Titas Gas fields ETP ..........................................................20
Figure 5.3: API separator of Titash Gas fields ETP ......................................................................20
Figure 5.4: Equalization tank Titash Gas fields ETP.....................................................................21
Figure 5.5: Aeration tank Titash Gas fields ETP ...........................................................................22
Figure 5.6: Filtration units Titash Gas fields ETP .........................................................................22
Figure 6.1(a)-(g): Safety signs .......................................................................................................26
Figure A1: Pneumatic actuator ......................................................................................................28
Figure A2: a) Pressure controller b) Controller mechanism..........................................................29
Figure A3: Level controller ...........................................................................................................29
Figure A4: Positioner.....................................................................................................................30
Figure A5: Safety relief valve........................................................................................................30
Figure A6: Check valve .................................................................................................................31
Figure B1: Christmas tree ..............................................................................................................33
1. Introduction
Bangladesh Gas field Company Limited (BGFCL) is the largest govt. owned autonomous
natural gas producing company in Bangladesh. The company was formed on September 12,
1975. It is a corporate body registered under company act, 1913 (Revised in 1994) and a
company of Bangladesh Oil , Gas and mineral corporation (Petrobangla) under the Ministry
of Power, Energy and Mineral resources BGFCL now operates 6 gas fields namely Titas,
Habiganj, Bakhrabad, Narshingdi, Meghna and Kamta Gas Field. At present (28 February
2018) 801 employees are working in this organization out of which 314 no are officers and
487 under staff category.
2. Project Definition
BGFCL is an independent gas processing plant that discovers and develops gas fields by
drilling development wells and undertake work over of existing wells as and when required.
The gas fields are operated and natural gas is produced after separating the condensate and
water, thus dry natural gas is supplied to the transmission and marketing companies. The
condensate is then processed to finished products MS and HSD for marketing.
2.1. Company Background

Titas gas field is located some hundred km away into the direction of northern east from
capital city of Bangladesh, Dhaka. It lies at the skirt the Brahmanbaria district town. This
field was discovered by Pakistan Shell Oil Company in 1962. The structure is an elongate
north south asymmetrical anti cline measuring about 19×10 km square with a vertical closure
of 500 m as per Petrobangla re-estimation, total recoverable gas reserve of Titas gas field is
7582 billion cubic feet. Commercial gas production from this field was commenced in 1968
and till February 28, 2018 total 4496.273 billion cubic feet or 59.3 % of reserve has been
recovered.
Out of total twenty-seven nos. gas wells drilled so far in this field, 9 are vertical wells and the
remaining 18 are directional wells. The wells are spread at 9 different locations stretched over
about 11 km distance. In February 2018, average 531.23 million cubic feet of gas is produced
daily from 26 wells of this field and processed through 10 nos. glycol dehydration type, 4
nos. Low Temperature Separation (LTS) type and 2 nos. LTS with glycol dehydration type
process plants and supplied to the transmission pipelines of Titas Gas Transmission and
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Distribution Co. Ltd. (TGTDCL) and Gas Transmission Company Ltd. (GTCL). In february
2018, on average, 470.28 bbls condensate is produced daily with gas as by-product. In
February 2018, average condensate/gas ratio of this field is 0.885 bbls per million cubic feet
and water/gas ratio is 0.801 bbl/million cubic feet (excluding well no. Titas 12, 13, 21 and
22). Titas well no. 3 was plugged and abandoned by snubbing operation on 25-2-2008 to
prevent gas seepage from nearby locality.
Condensate produced from Titas gas field (about 470.28 bbls/day), Narshingdi gas field about
(43.25 bbls /day) and Habiganj gas field about (10.69 bbls/day) of BGFCL and 16 bbls
condensate from rupganj gas field of BAPEX, 131 bbls Srekail and 98 bbls from Bangura are
fractionated into MS (petrol) and HSD (diesel) through two fractionation plants at this field
having plant capacity of 500 bbls each. The products are being sold to Padma Oil Company
Ltd.
2.2. Raw Materials
Table 2.1: Raw material

Component Composition
( Molar Fraction)
Carbon dioxide 0.0031
Nitrogen 0.0036
Methane 0.9620
Ethane 0.0179
Propane 0.0036
n-Butane 0.0005
i-Butane 0.0009
n-Pentane 0.0002
i-Pentane 0.0002
n-Hexane 0.0004
n-Heptane 0.0002
Water 0.0067
Molecular Weight 16.7
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2.3.Product
Table 2.2: Total monthly production of February, 2018 in titas field
Production Amount Unit

Gas 14874.427 MMSCFD
Condensate 13168 BBL (600F)
Water 42663 BBL
2.4. Capacity and turndown
Maximum overall capacity is 75 MMSCFD and turndown ratio is 1:5.
3. Process Description
Wet raw gas coming from well is directed to the process plant for removing the impurities
such as water, hydrocarbon dissolved in it before being sent to national grid for sale. Wet gas
from pipeline is fed to forced draft air cooler where temperature drops from 1300F to 900F or
to the water bath heater in order to compensate temperature reduction after coming to the
surface through the well. After cooling the wet raw gas is fed to knock out drum for
separating liquid fraction mainly water and condensate from gas with the help of level control
valve (LCV) and exported to skim pit and condensate flash drum via gas-condensate heat
exchanger respectively.
In Bangladesh gas field process plant four types of dehydration methods currently being
used:
 Glycol dehydration (Absorption method)

 Low temperature separation (LTS) without glycol injection
 Low temperature separation (LTS) with glycol injection
 Silica-gel plant (adsorption)
Due to reduction in well head pressure LTS with glycol injection is not currently in use.
Silica-gel dehydration method is used in Bakhrabad gas field process plant while other two
methods are used in Titas gas field process plant.
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3.1.1. Glycol dehydration
The principle of glycol dehydration is contacting a gas stream with a hygroscopic liquid
which has a higher affinity for the water vapour than does the gas. Wet gas entering gas
dehydration section flows through the glycol contactor. In the bottom section, gas and liquids
are separated by gravity and water and condensates exported under automatic level control to
condensate separation section. In addition gas passes through a demister in order to eliminate
any residual droplet. Gas flows upward through a chimney tray distributor with stainless steel
structured packing bed or bubble-cap trays.
The chimney tray located immediately below the contacting section enables the rich glycol to
be drawn off from the contactor and distributes the incoming gas evenly across the glycol
contacting internals. Inside the column the wet gas is counter-currently washed by the lean
glycol fed to the top of the column which is able to absorb water thus reducing its contents in
gas. The water-rich TEG is collected in the bottom of the chimney tray and it is exported to
the regeneration equipment.
Before leaving glycol contactor, dried natural gas flows through a mist eliminates pad
installed on the top of the vessel in order to minimize the glycol mechanical losses due to
liquid carry-over. In addition, the wet gas passes through the coalescence filter, which is
arranged to be at the bottom of the glycol dehydration tower or as an individual unit after the
three phase separator, where the condensate droplets coalesce and falls down under gravity,
separating out from the wet gas. Natural gas exiting the dehydration column flows then
through gas-glycol heat exchanger, either placed inside or outside the glycol dehydration
tower, where it is slightly heated in order to guarantee the optimal temperature approach to
the lean glycol coming from the plant regeneration section.
3.1.2. LTS without glycol injection
Low temperature separation (LTS) is an effective and efficient method to remove both water
and hydrocarbon from natural gas or associated petroleum gas. Low temperature separation is
also commonly used to enrich the methane content of fuel gas. The principle of low
temperature separation is based on the ‘Joule-Thomson effect’ (JT). In Joule Thomson effect,
the temperature change of a gas or liquid when it is forced through a valve or porous plug
while kept insulated so that no heat is exchanged with the environment by the process of
throttling. Temperature drop depends on the amount of pressure drop and increase in volume.
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This principle is used in LTS to achieve the removal of water from natural gas. When a high
pressure gas is expanded into a lower pressure and larger volume system then auto-
refrigeration takes place there, causing a decrease in temperature. LTS depends on Joule-
Thomson effect where it is used to handle production from high-pressure gas and the well
fluids are a mixture of gas and some liquids. The LTS unit includes porous plug, separator
and heat exchanger coils. Sufficient temperature is maintained inside the LTS unit such that
hydrate formation is prevented.
Dry gas coming from gas dehydration section is sent to sales gas scrubber to remove any
glycol/condensate carry–over from the glycol contactor. The filter is two stage type with
cartridges in the first stage and stainless steel vane in the second one. Liquids are exported
under level control from each stage to the condensate separation section.
Before leaving the plant, dry gas flow rate is controlled by means of flow control valve, FCV
and it is measured through orifice meter which is then sent to GTCL.
3.2. Regeneration of glycol
The water rich glycol coming from glycol contactor is routed to glycol regeneration section
by means of glycol pump, energy recovery type (Kimray pump). Rich glycol then passes
through glycol reflux condenser. The rich-glycol is then fed to glycol flash drum with the aim
to remove any liquid hydrocarbon, while flash gas is recovered as fuel gas for glycol reboiler
and inlet heater. Liquid hydrocarbons and water are collected in an internal bucket and routed
to wastewater section under level control. The rich glycol is sent to plate type heat exchanger
for preheating with lean glycol after passing through several filter media. The rich glycol is
fed to glycol still column provided with stainless steel random packing. The glycol falls down
from the still column to the glycol reboiler where it is heated up to 3750 F. by means of the
flame generated by the fuel gas combustion. The temperature is kept constant in order to
minimize the glycol degradation and choking which can occur at higher temperature value.
Fuel gas for glycol reboiler burner comes from glycol flash drum if available, or from utility
gas section.
From glycol reboiler, glycol exits for overflow and enters glycol/glycol exchanger on gravity
flow. There it is cooled for heat recovery and warms the rich glycol entering in glycol still
column. The lean glycol is collected into glycol accumulator whose aim is to provide the
necessary glycol inventory for refilling or compensating of glycol losses during normal
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operation and to collect the unit glycol inventory in order to allow the drain of the whole unit
for maintenance. The lean glycol is pumped by glycol pumps back to glycol contactor via gas
glycol exchanger.
Hydrocarbon condensates are coming from gas-separation section, gas-dehydration section,

gas-filtration section are collected in condensate flash drum. Water and hydrocarbon
condensates are exported on level control respectively to waste water section and condensate
storage section.
3.3. Fractionation plant
Average 450 barrel condensate is produced as by product in titas gas process plant.
Generally, two types of condensate tank are available: one is for storage and another is for
production. The condensate is directed to distillation column from fractionation unit by multi
stage centrifugal pump as pressure drop through 2 inch heat exchanger is more. In distillation
column components are separated by the principle of boiling point difference. Top product is
MS (motor spirit) and bottom product is HSD (high speed diesel) which is finally pumped to
the separate storage tanks being ready for sale. The condensate is fed at 9th tray of distillation
column after preheating with the bottom product, HSD, in a heat exchanger. The distillation
column is maintained with total condenser and partial reboiler having 16 bubble cap trays.
During the startup, MS and HSD are brought back to feed tank via merged valve keeping the
respective valve closed that leads to corresponding MS and HSD storage. After startup is
over, the merged valve is kept closed and flow towards the respective storage is kept open.
3.4. Maintenance
Maintenance division of the factory ensures the availability of the machines, buildings and
services required by other sections of the factory for the performance of their functions at
optimum return on investment whether this investment be in material, machinery or
personnel. The objective of plant maintenance is to achieve minimum breakdown and to keep
the plant in good working condition at the lowest possible cost. Machines and other facilities
should be kept in such a condition which permits them to be used at their optimum (profit
making) capacity without any interruption or hindrance.
Some common maintenance strategies are:
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Breakdown maintenance is the oldest method for unexpected and sudden faults or
breakdown
Preventive maintenance is time-based and predetermined which is done periodically,
used on inspection
Predictive maintenance is for the future period to predict equipment failure using
predictive technologies i.e. vibration analysis, infrared thermographs, ultrasonic
detection.
Proactive maintenance is the monitoring and correction of root causes to equipment
failures as well as designed to extend the useful age of the equipment.
3.4.1. Maintenance Instructions
The work should be done by trained personnel who is prepared enough with
equipment and sufficient time
The work is planned carefully prior to the start of maintenance such that unexpected
delays and risks are reduced
The maintenance area should have an easy entrance and exit
Safety of surrounding equipment and people must be maintained by isolating the
working area using the isolating valve
Hot components of equipment should be given sufficient time to cool down
3.4.2. Periodic Maintenance Jobs
Table 3.1: Periodic maintenance jobs

Target Equipment Maintenance Action
Master and wing control valve check

Pressure and temperature gauge check
Manual valve greasing
Well Head
Well control panel check
Pressure and flow recorder check
WHP measurement by DWT
Reboiler temperature check
Glycol Reboiler Surge drum and reboiler level check
Glycol pump leak check
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Glycol pump lube oil check
Flame arrester check
Manual valve greasing
Pressure, temperature gauge, flow recorder,
Gas gathering line, gathering manifold,
pressure controller, temperature check
water bath, water bath heater, air
Regulator bleeding
cooler
Air cooler fan belt and motor check
Flame arrester check
Safety relief valve check
Pressure regulator bleeding and check
Pressure controller and positioner check
Temperature controller check
Separator and Tower Level controller valve check
Instrument/Fuel gas system check
Production recorder zero check
Sales and production compare
Gas-gas heat exchange check
Back Pressure Valve check
Scrubber Sales recorder check
Level, Pressure check of flash separator
Valve leak check
Tank area Overall Tank area check
Condensate, HSD and MS transfer pump check
Feed recorder, circulation recorder, reflux
recorder, HSD and MS production recorder
check
Fractionation plant Stabilizer pressure check
Overhead temperature check
Condenser motor and fan check
Stabilizer and accumulator level check
Sales meter Sales recorder calibration and check
Skim Pit Skim pit check
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Control panel check
Control Panel, Fire system and Flare
Fire system check
system
Flare system check
3.5. Activities of Titas Lab
Table 3.2: Activities of Titas lab

Analysis Parameters Tested
Compositional Analysis
Specific Gravity
Gas Analysis Liquid Carryover
Calorific Value
Dew Point Test
Reid Vapor Pressure
Copper Strip Corrosion
Flash Point
API Gravity
Aniline Point
Hydrocarbon Analysis
Diesel Index
Cetane Index
Distillation (IBP, 10% recovery, 50% recovery,
90% recovery, FBP, Residue, Evaporation loss)
Viscosity
Specific gravity
pH (acidity and alkalinity)
Water content (wt%)
Glycol Analysis
Hydrocarbon Content
Salinity test by titration
Total solid and condensate color
pH (acidity and alkalinity)
Water Analysis Ca2+ , Mg2+ & Iron by EDTA Titration method
Salinity test by titration
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3.6.Utilities
Table 3.3: List of major utilities under use
Serial Number Name of the Equipment Description
Type: Pressure Vessel

Size(ND×L): 8''×10'-9'' [200×3300mm]
1. Pig Launcher Installation: Horizontal
Material: Carbon Steel
Manufacturer: U Scambiatori S.r.l - Italy
Size(ND×L): 8''×10'-9'' [200×3300mm]
2. Pig Receiver Installation: Horizontal
Size(ID×L): 4'- 11.1/16'' × 12'- 5.5/8''
[1500mm×3800mm]
3. Inlet Separator Installation: Horizontal
Manufacturer: Pietro Fiorentini S.p.a – Italy
Internals: PG05-IV-01 Stainless Steel Wire mesh
Size(ID×L): 3'×7.5/6'' × 31'- 9.7/8''
[1100×9700mm]
Installation: Vertical
4. Glycol Contactor Material: Carbon Steel
Internals: PG06-IC-01A Stainless Steel Diameter
PG06-IC-01B Stainless Steel Chimney Tray
PG06-IC-01C Stainless Steel Structured Packing
Type: Shell & Tube Heat Exchanger
Size(ND×L): 1'-2''×-8'0'' [355mm×2440mm]
5. Gas/ Glycol Exchanger Installation: Vertical
Size(ID×L): 2'-7.1/2''× 9' 6.3/16''
[800mm×2900mm]
Installation: Horizontal
6. Sales Gas Scrubber Material: Carbon Steel
Internals: PG07-IF-01A Cartridges
PG07-IF-01B Stainless Steel Vane Devices
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Size(ID×L): 3'- 3.3/8'' × 9' 10.1/8''
[1000×3000mm]
7. Condensate Flush Drum
Type: Energy Recovery
Capacity: 6.6 USGPM [1.5 m3/h]
8. Glycol Pumps Installation: Horizontal
Manufacturer: Kimray
Size(ID×L): 3'- 3.3/8'' × 9' 10.1/8''
[1000×3000mm]
9. Glycol Flash Drum
Size(ND×L): 8''×4' 5.1/8'' [200×1350mm]
10. Glycol Filter
Internals: SY01-IF-01A/B Cartridges
Size(ND×L): 16''×4' 9.1/16'' [400×1450mm]
11. Glycol Carbon Filter
Internals: SY01-IF-02 Carbon Cartridges
Size(ND×L): 8''×4' 5.1/8'' [200×1350mm]
12. Glycol Guard Filter
Internals: SY01-IF-03 Cartridges
Type: Plate Heat Exchanger
Size(L×W×H): 24''× 24''× 4'- 4'' [610mm× 610
mm× 1300mm]
13. Glycol/ Glycol Exchanger
Material: Stainless Steel
Manufacturer: GEA Ecoflex S.p.a – Germany
Size(ID×L): 4'×3.3/16'' × 19'- 8.1/4''
14. Glycol Reboiler Installation: Horizontal
15. Glycol Accumulator Size(ID×L): 5'×3'' × 21'- 3.7/8''
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Type: Controlled Volume Pump
Capacity: 14.7 USGPM [3.33 m3/h]
16. Glycol Drain Pump
Material: Ductile Iron
Installed Power: 1878 BTU/ h [0.55 KW]
Manufacturer: Axflow (Bran- Luebbe)
Size(ID×L): 5'- 10.7/8'' × 24'- 7.1/4''
[1800mm×7500mm]
17. Flare drum
Material: Low Temperature Carbon Steel
Size(L×W): 50' × 20' [15000mm×6000mm]
18. Burn Pit Installation: Horizontal
Material: Rcc/ Refractory
Size(ND×L): 20'' × 150' [500mm×45700mm]
Material: Low Temperature Carbon Steel
19. Flare
Manufacturer of Flare Tip: Flare Industries -
USA
Type: Atmospheric Tank
Size(ID×L): 15' × 32' [4572mm×9754mm]
20. Condensate Production Tank Installation: Vertical
Internals: TC01-IT-01 Nitrogen Ring
Type: Atmospheric Tank
Size(ID×L): 35' × 32' [10688mm×9754mm]
21. Condensate Storage Tank Installation: Vertical
Internals: TC01-IT-02 Nitrogen Ring
Type: Centrifugal Pump
Capacity: 200 BPH [31.75 m3/h]
22. Condensate Storage pumps
Manufacturer: Axflow – Italy (Blackmer)
Type: Submersible Pump
Capacity: 250.80 USGPM 57 m3/h]
23. Wastewater pumps
Manufacturer: Xylem Water Solutions - Italy
Type: Forced Draft
Size(L×W×H): 4'- 7''× 4' – 5.9/16'' × 91'- 4.5/8''
24. Cooling Towers
Material: Polyester Resin/ fibreglass
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Manufacturer: MITA - Italy
Type: Gas Driven

Installation: Indoor
25. Gas Generators
Required Continuous Power: 250 kVA
Manufacturer: Compagnia tecnica Motori
Capacity: 26.4 USGPM [6 m3/h]
26. Firewater Jockey Pump
Installed Power: 13660 BTU/ h [4 KW]
Manufacturer: SPP Pumps Ltd. - UK
Capacity: 132 USGPM [30 m3/h]
27. Water Circulating Pump
Material: Cast Iron
Manufacturer: GVR Pumps s.r.l. - Italy
Size(ND×L): 8''×4' 5.1/8'' [200×1350mm]
28. Utility Gas Filter
Internals: UG01-IF-01 Cartridges
Type: Shell & Tube Heat Exchanger
Size(ND×L): 12'×2'-3.9/16'' [300×700mm]
29. Glycol Reflux Condenser Installation: Vertical
Material: Stainless Steel
Type: Hollow Disk Pump
Capacity: 8.80 USGPM [2 m3/h]
30. Oil Pumps Material: Cast Iron
Manufacturer: Officine Meccaniche Gallaratesi -
Italy
Page | 13
PCV
PCV
TCV
Gas-Gas Heat Exchanger
Low-Temperature Separation
Tower (LTS)
to flare and burn
Gas-Condensate HX pit
Condensate flash separator
Inlet Knockout Separator
FCV LCV
to API separator
to condensate
Inlet Air Cooler to sales gas flow
from wellhead LCV storage tank
Condensate LCV recorder
to API
Gas Scrubber
separator Water LCV
LCV
Figure 5.1: PFD of LTS without glycol injection Page I 14
Lean glycol from
regeneration section
Rich glycol to
PG06-E-01 PG06-C-01 regeneration
section
F-100
to flare and
burn pit
LCV
PC01-V-01
PG05-V-01
PCV to API
A-01 separator
LCV LCV to condensate
storage tank
to API
separator
PG07-F-01 to sales gas flow
control section
LCV
LCV
A-01 PG05-V-01 PG01-F-01 PG06-E-01 F-100 PG06-C-01 PC01-V-01
Inlet air Inlet 3-Phase Sales Gas Gas-Glycol Coalescence Glycol Condensate Flash Drum
cooler separator Scrubber Exchanger Filter Contactor
Figure 5.2: PFD of glycol dehydration unit
Page I 15
Lean Stack gas M
Rich glycol from
glycol to absorption tower
absorption
section
To vapour
SY01-E-05 drum
SY01-P-01
SY01-E-02
SY01-C-01
SY01-V-02
Fuel Gas
SY01-V-04 SY01-V-01
SY01-F-01
SY01-E-03
LCV
to API separator
SY01-E-03 SY01-V-01 SY01-F-01 SY01-E-05
SY01-V-02 SY01-C-01 SY01-V-04
SY01-P-01 SY01-E-02
Glycol Reboiler Glycol Accumulator Glycol/Glycol Heat Exchanger Glycol Flash Drum Glycol filters Vapor cooler
Glycol Reflux Glycol Still Column
Glycol pumps
(energy recovery) Condenser
Figure 5.3: PFD of glycol regeneration unit Page I 16
To flare and
burn pit
EX-2
V-1
To HSD storage
EX-1
P-3a/b
From condensate
storage tank C-1
To MS Storage
tank
H-1
P-2a/b
EX-1 EX-2 C-1 P-3a/b V-1 P-2a/b H-1
Feed/HSD MS condenser Fractionation MS pumps Reflux vessel HSD pumps Direct fired heater
exchanger column
Figure 5.4: PFD of fractionation plant
Page I 17
5. Effluent Treatment Plant
Effluent treatment plant is a process to convert wastewater into an effluent that can be either
returned to the water cycle with minimal environmental issues or reused. Wastewater can be
termed as the water that is no longer needed or suitable for its most recent use. And effluent
is the liquid waste flowing out from factory farm, commercial establishment or household to
a water body or reservoir. Mainly, there are three types of effluent treatment plant based on
the method used for treating wastewater. Chemical method consists of treating the water with
chemical products, Biochemical method includes both biological and chemical treatment and
Biological treatment includes bacteria growth resulting large amount of sludge. A generalized
concept of Biological ETP can be shown by block diagram:
Figure 5.1: Typical block diagram of an ETP
From the above block diagram, the units used for the treatment and their sequence are the
indication of the overall process.
Screening unit
Screening unit screens out the coarse and fine solid particles from the wastewater. It works as
a filter.
Page | 18
Equalization unit
Equalization unit serves the purpose of uniform concentration and well mixing. Different
waste water from varies process is stored and makes a homogeneous mixture by mixing
different concentration of waste water.
pH control unit
Neutralization of waste water is performed by dosing chemicals as required to control the pH

of waste water in pH control unit.
Aeration unit
In the aeration unit, continuous aeration is supplied so that entire harmful chemicals are
damaged here by breaking their bonds. This is done by bacteria. To ensure the proper
function work and growth of bacteria, certain conditions must be maintained.
Sedimentation unit
Treated water is overflown in the sedimentation unit from oxidation tank to sediment the
sludge produced in aeration unit. Sludge settles down and relatively clear water settles above
the sludge. Sedimentation occurs due to gravitational influence.
Sludge thickening unit
Thickening is a procedure used to increase the solids content of sludge by removing a portion
of the liquid fraction. To illustrate, if waste activated sludge, which is typically pumped from
secondary tanks with solids, can be thickened. Thickening is generally accomplished by
physical means including co-settling, gravity settling, flotation, centrifugation, gravity belt,
and rotary drum.
Page | 19
In Titash Gas field, some of the locations use ETP to treat the wastewater produced from the
processing of Natural Gas. The process block diagram and process description of the
Biological treatment method can be described in brief for further convenience.
Figure 5.2: Process block diagram of Titas Gas fields ETP

From the above process block diagram, the whole process can be classified into few steps.
First step is to pump effluent to the process. API Separator collects waste water form API
discharge tank when the water level is 90% in tank & collects up to 30% level. This separator
has two pumps for transferring wastewater to oil removal tank.
Figure 5.3: API separator of Titash Gas fields ETP
Page | 20
There are five tanks for oil separation and oil collection. After fourth tank, effluent goes to
equalization tank via screening process and separated oil goes to oil holding tank.
Equalization tank takes wastewater for flocculation by collecting and storing the waste,
allowing it to mix and become a regular quality before it is pumped to the treatment units at a
constant rate. Effluent equalizes for fourteen hours in this unit and it has two air distribution
lines.
Figure 5.4: Equalization tank Titash Gas fields ETP

After equalization, wastewater goes to flash flocculation chemical mixer tank. Ferrous
sulphate solution and Lime solution are dosed in the raw wastewater for the purpose of
removing color, BOD And COD Content of the wastewater to some extent. Polyelectrolyte
solution is added as a coagulant aid for removing suspended impurities.
Larger particles of incoming water from flocculator settle in primary settling tank. Effluent
holds on this tank for approximately 2-4 hours. Near about 65% of the suspended solids will
settle at the bottom of this settling tank. Settled sludge is carried away by a sludge pump and
the clarified water overflows through a channel to the aeration tank.
Aeration unit is used here for Chemical Oxygen Demand, Biological Oxygen demand and
Dissolved Oxygen control. Air is injected by air blower and fine bubble membrane diffusers.
Effluent is held in this tank for 16-20 hours. This tank also has two air distribution lines.
After aeration tank, water goes to the secondary settling tank where larger particles settle
down. The residence time for the water is 2-4 hours and around 35% of the suspended solids
will settled at the bottom of the sludge hopper.
Page | 21
Figure 5.5: Aeration tank Titash Gas fields ETP
Settled sludge is carried away by a sludge pump and the clarified water overflows through a
channel to the clean water tank. Cleaned water is stored in the clean water tank after sludge
settling. Air is added to this tank for maintain DO. Water from this storage tank goes through
Multi-media filter, activated carbon filter and iron removing filter for further clarification.
Figure 5.6: Filtration units Titash Gas fields ETP
From Primary and Secondary settling tank and aeration tank, suspended solids are collected
at the bottom sludge hopper to sludge holding tank. Approximately 30% sludge is returned to
the aeration tank by sludge pump. Remaining sludge goes to sludge drying bed for
dewatering and separated water is transferred to API by drain line. Lime solution is made by
mixing 12.5 kg lime powder for 250 kg water. Ferrous Sulfate solution is made by mixing 4.5
kg with 150 kg water. Polymer solution is made by adding 2 kg powder with 400 kg water
and finally 15 liter HCl is mixed with 100 kg of water.
Page | 22
6. Safety
6.1.General plant safety
The oil and gas refinery plant must follow some safety rules which must be ensured by chief
operator in order to safeguard personnel life and protect equipment from damage. Metal
vessels shall be grounded during the sampling operations to prevent dangerous electrostatic
accumulation. Throughout the plant no vent should be allowed to exhaust in environment as
prolonged inhalation of vapours or breathing of mist might have hazardous effect.
During handling the chemicals the following general recommendations will apply:
Strictly following manufacturers’ instruction and warning notes.

wearing goggles and gloves when handling these chemicals
contact with the mucoses and eyes must be avoided
In case of spill, washing eyes soft water for at least 15 minutes, flushing hands and
skin with abundant water, to wash clothing before reusing.
Wearing boots cotton dresses are more preferred
In gas treating plant the highest temperature recorded is around 3750 F in glycol regeneration
section while minimum temperature depends on the ambient temperature which may achieve
400 F. Equipment and piping have been provided with thermal insulation where necessary.
For any unexpected situation like fire on well, explosion in any part of the equipment,
generally following decision can be taken
Isolate the hole gas processing plant from the source

Control valve in side path ways are shut off
Sub control surface safety valve (SCSSV) is shut off
Emergency shutdown valve (ESDV) becomes active
The warning alarm is kept ringing
Fire unit become active to extinguish the fire
Let the concerned person be informed about the situation
Some safety signs are hanged in different corner of the plant for safety maintenance. The last
accident was occurred in this plant on 20th May of 2017. No smoking zone enabled. They are
illustrated below:
Page | 23
(a)
(b) (c)
Page | 24
(d) (e)
(f)
Page | 25
(g)
Figure 6.1(a)-(g): Safety signs
6.2. ETP Safety
During the operation, some safety issues are kept in mind:
1. Using safety equipment in the time of ETP operation.
2. Keeping the total area of ETP clean.
3. Cleaning oil separation unit minimum one time a day.
4. Cleaning the plant minimum one time in a month.
5. Always keeping the chemical mixing tank clean.
6. After completing chemical using, running the chemical transfer pump by clean water.
7. Handling all the chemicals carefully.
8. After dewatering the sludge keeping this keck in a bag & transfer it at another site of plant.
9. Using stand by system for all machine or equipment.
10. Keeping Continue back-wash 45 minutes after 20 hours’ running ETP.
Page | 26
7. Conclusion
From the process of obtaining natural gas from the reservoir upto the sales point to TGTDCL
and GTCL, this was an informational report covering the overall process of Titas Field
natural gas processing system. As such this report is a shortcut to understanding the whole
process at a glance and therefore, does not cover all the units in detail and is beyond the limit
of this report. However, the report does include auxiliary information on daily production and
sales report of Titas field and monthly report of productive wells of all fields under BGFCL
which is capable of giving an insight to the real picture in gas production system of BGFCL,
also including sales under Titas Field.
Page | 27
Appendix
Appendix A
Automatic Control Valves
Automatic control valves are used to control flow, pressure or temperature of fluid. Normally
Globe, Ball or Butterfly type valve is used as control valve. Automatic control valve consists
of a valve body, actuator, controller and position.
Depending on use, valves are named as:
Pressure Control Valve

Flow Control Valve
Level Control Valve
Temperature Control Valve
Control valve body type:
For Pressure Control Valve: Globe

For Flow Control Valve: Globe, Ball or Butterfly
For Level Control Valve :Globe
For Temperature Control Valve: Globe (Three way)
Pneumatic Actuator
A pneumatic actuator converts pneumatic energy (typically compressed air but NG used in
BGFCL) into mechanical motion.
Figure A1: Pneumatic actuator
Page | 28
Pressure Controller
A device for the mechanical movement of another device (such as a valve stem) whose action
is controlled by variation in pneumatic pressure connected to the controller
(a) (b)
Figure A2: a) Pressure controller b) Controller mechanism

Level Controller
Link arrangement in the level controller converts the linear movement of the submerged float
into rotation such that a constant level of liquid is maintained in units or vessels.
Figure A3: Level controller
Page | 29
Positioner
Positioners receive a pneumatic control signal from a controller and translate that into the
appropriate pneumatic output signal to the control valve actuator.
Figure A4: Positioner

Safety Relief Valve
A safety valve is a valve mechanism which automatically releases excess pressure from
pressure vessel before it exceeds the set pressure. The pressure is relieved by allowing the
pressurized fluid to flow from an auxiliary passage out of the system. The relief valve is
designed or set to open at a predetermined set pressure to protect pressure vessels and other
equipment from being subjected to pressures that exceed their design limits.
Figure A5: Safety relief valve
Page | 30
Check Valve
Check valves are designed to prevent the reversal of flow in the piping system. Valves are
straight through flow which works automatically. They are opened by the force of velocity
pressure and closed by the force of gravity and back pressure. The valves are single direction
flow and restrains flow in opposite direction. These valves are active by the flowing material
in the pipeline. The pressure of the fluid passing through the system opens the valve, while
any reversal of flow will close the valve.
Figure A6: Check valve
Page | 31
Appendix B
Drilling
Oil and natural gas were formed from the remaining of prehistoric plants and animals, that’s
why they are called fossil fuels. Hundreds of millions of years ago, prehistoric plant and
animal remains settled into the seas along with sand, slit and rocks. These underground traps
of oil and gas are called reservoirs. The natural gas is a mixture of lower and higher
hydrocarbons. Inside reservoir, this gas remains liquid at higher temperature and pressure.
When this liquid is brought onto the earth surface, temperature and pressure reduces and this
liquid divides into gas, condensate (liquid hydrocarbons) and water. The probability of the
existence of hydrocarbons is detected by 2D, 3D and 4D seismic survey. All these
explorations and drilling activities are imposed on BAPEX, a native company of Petrobangla.
The internal structure of underground rock mainly consists of shale and sandstone. Shale is
impermeable layer with high porosity while sandstone is permeable layer with low porosity.
The reservoir characteristics of our country are rock sandstone while the source of all gas
fields here is Borail shale. The Titas gas field reservoir type is Bhubon sandstone and the
fluid flow mechanism is gas driven.
The most common method of cude oil extraction is drilling. Geologists will first identify a
section of land they believe has oil flowing beneath it. This is not an overly complicated
process. A standard method has been developed to provide maximum efficiency. The first
step of the process involves drilling into the ground in the exact location where the oil is
located. Once a steady flow has been identified at a particular depth beneath the ground, a rig
is placed and a perforating gun with a bit is lowered into the well. The perforating gun has
explosive charges within it that allows for oil to flow through holes in the casing. Once the
casing is properly perforated a tube is run into the hole allowing the oil and gas to flow up the
well. To seal the tubing, a device called a packer is run along the outside of the tube, The last
step involves the placement of a structure called a Christmas tree which allows oil workers to
control the flow of oil from the well. It consists of production wing, maintenance wing, wing
actuator, master actuator, swab valve and a choke valve. Production wing supplies the
uplifting gas from source. Maintenance wing is used in case of maintenance activities. Wing
and master actuator is operated to close the valves when there is disastrous situation or
possibility of back flow. Swab valve is used in case of partial work over. Choke valve is used
to maintain the gas flow rate. A sub surface safety control valve (SCSSV) is situated at 320-
Page | 32
350 feet under the ground which is always kept open but closed in case of fire explosion or
any necessity to close the source in case of damage repairing work.
Figure B1: Christmas tree

Usually 2D seismic survey is done when source and receiver lines are at the same point. If
source and receiver are at two different directions, 3D seismic survey is performed. 4D
survey is necessary when there is structural change with time and upgrading 3D survey
demands. When hydraulic head is greater than reservoir pressure, overbalance is done. When
it is less than reservoir pressure, underbalance is necessary which is done with mud and
water. Cementation is done to fill up the spaces around the inserted gun. Pipe stuck may
occur due to fluid-pipe interaction which can be solved by riming. Well loss is also another
problem. If the out coming mud is not equal to the inserted mud, well loss occurs. The usual
well success ratio of BGFCL is 1:3.We can never ignore the geological history while drilling
a well.
Page | 33

Report On Industrial Attachment at BGFCL

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BANGLADESH UNIVERSITY OF ENGINEERING AND

Report on Industrial Attachment in BGFCL

Submitted by: Submitted on: 25th March, 2018

Table 2.1: Raw material...................................................................................................................2

Figure 4.1 :PFD without glycol injection ......................................................................................14

2.1. Company Background

2.2. Raw Materials

Table 2.1: Raw material

Table 2.2: Total monthly production of February, 2018 in titas field

Production Amount Unit

2.4. Capacity and turndown

Maximum overall capacity is 75 MMSCFD and turndown ratio is 1:5.

 Glycol dehydration (Absorption method)

3.1.2. LTS without glycol injection

3.2. Regeneration of glycol

Hydrocarbon condensates are coming from gas-separation section, gas-dehydration section,

3.3. Fractionation plant

Some common maintenance strategies are:

3.4.2. Periodic Maintenance Jobs

Table 3.1: Periodic maintenance jobs

Master and wing control valve check

3.5. Activities of Titas Lab

Table 3.2: Activities of Titas lab

Serial Number Name of the Equipment Description

Type: Pressure Vessel

Type: Gas Driven

Figure 5.1: Typical block diagram of an ETP

Neutralization of waste water is performed by dosing chemicals as required to control the pH

Sludge thickening unit

Figure 5.2: Process block diagram of Titas Gas fields ETP

Figure 5.3: API separator of Titash Gas fields ETP

Figure 5.4: Equalization tank Titash Gas fields ETP

Figure 5.6: Filtration units Titash Gas fields ETP

Strictly following manufacturers’ instruction and warning notes.

Isolate the hole gas processing plant from the source

Figure 6.1(a)-(g): Safety signs

6.2. ETP Safety

During the operation, some safety issues are kept in mind:

1. Using safety equipment in the time of ETP operation.

2. Keeping the total area of ETP clean.

3. Cleaning oil separation unit minimum one time a day.

4. Cleaning the plant minimum one time in a month.

5. Always keeping the chemical mixing tank clean.

7. Handling all the chemicals carefully.

9. Using stand by system for all machine or equipment.

10. Keeping Continue back-wash 45 minutes after 20 hours’ running ETP.

Depending on use, valves are named as:

Pressure Control Valve

Control valve body type:

For Pressure Control Valve: Globe

Figure A1: Pneumatic actuator

Figure A2: a) Pressure controller b) Controller mechanism

Figure A3: Level controller

Figure A4: Positioner

Figure A5: Safety relief valve

Figure A6: Check valve

Figure B1: Christmas tree

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