OFFER LETTER

iii
 ACKNOWLEDGEMENTS

An endeavour over a period can be successful only with constant advice and support of the
well-wishers, I take this opportunity to express my gratitude and everyone who has guided
me during this internship. Firstly, I would like to thank OCS SERVICES INDIA (PVT LTD)
for giving me the opportunity to learn and experience the applications of offshore oil and gas
industries through the means of this Internship. I would also like to thank my institution
Manipal Institute of Technology (MIT), Manipal for allowing me to take up this opportunity.
I would like to thank Mr. Chandra Sekhar Edara, General Manager-Operations &
Maintenance, Mr. Aravind Velamuri-Operations Engineer for taking out time from their busy
schedule and guiding me throughout my internship and providing me with valuable
knowledge and feedback.

I would also want to express my gratitude to all my lecturers for ensuring that I have a good
foundation in chemical engineering concepts, which I used significantly in my project work.

For their advice, supervision, and crucial contributions as and when it was needed during my
project. I am honoured to have had the opportunity to be taught by such accomplished
professors.

iv
 I. SYNOPSIS

OCS services India Private Limited company which is a leading Oil & Gas industry service
provider, with various offshore and onshore projects. OCS Services is a joint venture between
BW Offshore and Planet Energy. BW Offshore - the world's second largest Floating
Production System Provider is listed on the Oslo Stock Exchange. OCS has five regional
offices across the globe-Brazil, Nigeria, UAE, India and Singapore. Oil and gas production is
the general process of manufacturing oil and natural gas from wells and turning them into the
final petroleum products that consumers can use. Oil and gas production includes systematic
steps starting from the site exploration, to actual extraction, and even up to the distribution of
the products to businesses and the general public. The oil and gas industry are one of the
largest sectors in the world and a huge factor in the global economy. But just like any other
industry, it can also be very fragile and prone to volatility. OCS services is currently working
on MOPU (Mobile offshore production unit). This MOPU which is 140-145km west of
Mumbai, located at Mumbai High, Western Offshore.

The converted MOPU is equipped with facilities like oil, gas and water separation, gas
dehydration and compression, chemical injection, flare system, utilities and accommodation.
For initial years, well fluids from the Western offshore 16 platform will be transferred to
MOPU for processing. The produced oil and associated gas after compression from MOPU is
exported via WO-16 Well head platform.

Oil and gas are passed through several stages in the production unit. The mixed oil is
extracted from the WHP and is sent to the separation systems to separate out into more
products; Oil, water and gas.

v
 I. LIST OF TABLES

Table No Table Title Page No

2.3.1 Comparisons of the three separators 22
2.4.1 Pumps used in MOPU Comparison 28
2.7.1 TEG vs MEG 33
3.6.1 MOPU System1 Data (TEG process contactor) 45
3.6.2 MOPU System 2 Data (MEG process injection system) 45

vi
 II. LIST OF FIGURES

Figure No Figure Title Page No

1.3.1 Well head diagram 14
1.3.2 Well-Head Composition 15
2.1.1 Jack-up drill Rig 17
2.2.1. Gate valve 19
2.2.2. Globe valve 19
2.2.3 Check valve 20
2.2.4 Plug valve 20
2.2.5. Ball valve 20
2.2.6. Butterfly valve 21
2.3.1. Horizontal separator 23
2.3.2. Vertical separator 23
2.3.3. Spherical separator 23
2.3.4. Horizontal 2 phase separator 24
2.3.5. Horizontal 3 phase separator 25
2.4.1. A centrifugal pump 26
2.4.2. Positive displacement pumps 27
2.5.1 Types of compressors 28
2.5.2. Rotary compressor 29
2.5.3 Centrifugal compressor 29
2.5.4 Reciprocating compressor 30
2.5.5. Axial compressor 30
3.1.1. PFD of MOPU 34
3.3.1 Glycol dehydration process PFD 36
3.4.1. Process flow diagram of TEG re-generation unit 39
4.1.2. Inlet and Outlet conditions 44
4.1.3 Flash Tank separator 47

vii
 III. LIST OF ABBREVIATIONS

THE FOLLOWING ARE THE FULL MEANING OF THE ABBREVIATION USED IN

THE REPORT

MOPU -Mobile Offshore Production Unit

GOR- Gas to Oil Ratio

GDU-Gas Dehydration Unit

PFD-Process Flow Diagram

TEG-Tri-Ethylene Glycol

MEG- Mono-Ethylene Glycol

WHP-Well Head Platform

WO-16- Western Offshore 16

MMSCF -Millimetre Standard Cubic Feet

MMSCFD- Millimetre standard cubic feet per day

PSIG- Pound Square Inch Gauge

PSIA- Pound Square Inch Absolute

FTS- Flash Tank Separator

ix
TABLE OF CONTENTS

Page No
Synopsis vii
List of Figures viii
List of Tables ix
List of
xi
Abbreviations

Chapter 1 INTRODUCTION 11
1.1 About the Company 11
1.2 Overview of the Indian Oil & Gas Industry 12
1.3 Introduction to Oil & Gas processing 13
1.4 Project Objective 16
1.5 Project Methodology 16
1.6 Project Outcome 16

Chapter 2 LITERATURE REVIEW 17

2.1 Equipment’s list on MOPU 18
2.2 Valves, types and their application 19
2.3 Oil Separation systems. 22
2.4 Pumps, Centrifugal pumps in detail. 26
2.5 Compressors 38
2.6 Dehydration and methods of dehydration 31
2.7 TEG vs MEG 33

Chapter 3 METHODOLOGY 34
3.1 Process flow diagram of MOPU 34
3.2 Summary of the process flow diagram 35
3.2 Dehydration process flow diagram (Glycol Dehydration Process) 36
3.4 Dehydration process used in MOPU 38
3.5 Analysis of two dehydration assets (System-1 & System-2) 40
3.6 Analysis of two dehydration assets – Procedure and calculations 41

Chapter 4 RESULTS & DISCUSSION 43

4.1 Inlet & Outlet Condition of Equipment’s on MOPU 44
4.2 Analysis of two dehydration assets- Final results and comparison 45
Analysis of two dehydration assets- Optimization and
4.3 46
recommendations to the system

Chapter 5 WORK TO BE DONE 48

REFERENCES 49

x
 CHAPTER 1. INTRODUCTION

1.1 About the company:

OCS Services is a joint venture between BW Offshore and Planet Energy. BW Offshore - the
world's second largest Floating Production System Provider is listed on the Oslo Stock
Exchange. OCS is leading service provider to the Oil & Gas and Marine industry. With an
experience of over 3 decades, we are experts at delivering comprehensive business solutions,
robust procedures, glitch free Maintenance, Repairs and Overhauling services (MRO), Total
Corrosion Management (TCM) services and Total Integrated Crew Management services to
clients across the Oil & Gas and Marine sectors.

OCS is currently serving more than 40 leading E&P clients from offices in Dubai, India, and
Singapore. Since its establishment in 1984 as a technical manpower provider, services have
expanded across a range of client needs.

With prime focus on QHSSE (Quality, Health, Safety, Security and Environment), the
business vertical encompasses various features which include Plant Integrity and
Maintenance, Operational Uptime, Inventory Management, Warehouse Management,
Turnaround Management, Major Equipment Overhauls, Engineering Support, Production
Chemical Management, Facility Management, Procurement support and Logistics
management .The above service spectrum is expanded leveraging existing capabilities,
credentials & learnings of well established companies like BW Offshore & Planet Energy as
our parents to include technology development and personnel competency development &
assessment framework. OCS offers integrated operation & maintenance solutions or specific
suite of bespoke solutions, based on customer requirement. Its experience to manage
operations across the world gives OCS Services an exceptional strategic advantage in terms
of understanding local requirements across geographies.

11
1.2 Overview of The Indian Oil & Gas Industry:

The oil and gas sector plays a vital role in influencing decision making for all the other
important sections of the economy as it is among the eight core industries in India.
The need for oil and gas is projected to grow more in the near future, thereby making the
sector quite conducive for investment. To fulfil the increasing demand, government of India
has adopted several policies. The government has allowed 100 per cent Foreign Direct
Investment (FDI) in many segments of the sector, including natural gas, petroleum products,
and refineries, among others.[1]

The oil and gas sector are among the eight core industries in India and plays a major role in
influencing the decision-making for all the other important sections of the economy.

India’s economic growth is closely related to its energy demand, therefore, the need for oil
and gas is projected to increase, thereby making the sector quite conducive for investment.
India retained its spot as the third-largest consumer of oil in the world as of 2021.

The Government has adopted several policies to fulfil the increasing demand. It has allowed
100% foreign direct investment (FDI) in many segments of the sector, including natural gas,
petroleum products and refineries, among others. The FDI limit for public sector refining
projects has been raised to 49% without any disinvestment or dilution of domestic equity in
existing PSUs. Today, it attracts both domestic and foreign investment, as attested by the
presence of companies such as Reliance Industries Ltd (RIL) and Cairn India. The industry is
expected to attract US$ 25 billion investment in exploration and production by 2022. India is
already a refining hub with 21 refineries, and expansion is planned for tapping foreign
investment in export-oriented infrastructure, including product pipelines and export
terminals.[2]

Challenges for the Indian oil and gas industry

Some of the problems faced by the Petroleum Industry in India are:
1. Shortage of petroleum crude
2. Dependence on foreign countries.
3. Price hike.
4. Shortage of oil refining capacity.
5. Exploration of new reserves.
6. Technical problems.
7. Pollution.
8. Lack of market-determined pricing system. [3]

12
1.3 Introduction to Oil and Gas Processing:

Oil has been used for lighting purposes for many thousand years. In areas where oil has been
found in shallow reservoirs in seeps of crude oil or gas may naturally develop and some oil
can be collected from seepage or tar ponds. Soon, oil had replaced most other fuels for
motorized transport. The automobile industry developed at the end of the 19th century, and
quickly adopted oil as fuel.

Gasoline engines were essential for designing successful aircraft. Ships driven by oil could
move up to twice as fast as their coal powered counterparts, a vital military advantage. Gas
was burned off or left in the ground. Chemicals derived from petroleum or natural gas are an
essential part of the chemical industry today. Petrochemistry is a fairly young industry.

Oil and natural gas are major industries in the energy market and play an influential role in
the global economy as the world's primary fuel sources. The processes and systems involved
in producing and distributing oil and gas are highly complex, capital-intensive, and require
state-of-the-art technology. Historically, natural gas has been linked to oil, mainly because of
the production process or upstream side of the business. Natural gas is a mixture of gases
which are rich in hydrocarbons. All these gases (methane, nitrogen, carbon dioxide etc are
naturally found in atmosphere. Natural gas reserves are deep inside the earth near other solid
& liquid hydrocarbons beds like coal and crude oil.

Constituents of crude oil. Hydrocarbons are generally divided into four groups:
(1) Paraffins
(2) Olefins
(3) Naphthene
(4) Aromatics

Among these groups, paraffins, olefins, and naphthene are sometimes called aliphatic
compounds, as different from aromatic compounds. [4]
Oil and gas wells produce a mixture of hydrocarbon gas, condensate or oil; water with
dissolved minerals, usually including a large amount of salt; other gases, including nitrogen,
carbon dioxide (CO2), and possibly hydrogen sulphide (H2S); and solids, including sand
from the reservoir, dirt, scale, and corrosion products from the tubing.

The purpose of oil and gas processing is to separate, remove, or transform these various
components to make the hydrocarbons ready for sale. The purpose of oil and gas processing
is to separate, remove, or transform these various components to make the hydrocarbons
ready for sale. [5]

A complete oil or gas production system consists of a reservoir, well, flowline, separators,
pumps, and transportation pipelines. The reservoir supplies wellbore with crude oil or gas.
The well provides a path for the production fluid to flow from bottom hole to surface and
offers a means to control the fluid production rate. The flowline leads the produced fluid to
separators. The separators remove gas and water from the crude oil. Pumps and compressors
are used to transport oil and gas through pipelines to sales points.

13
Hydrocarbon accumulations in geological traps can be classified as reservoir, field, and pool.
A ‘‘reservoir’’ is a porous and permeable underground formation containing an individual
bank of hydrocarbons confined by impermeable rock or water barriers and is characterized by
a single natural pressure system. A ‘‘field’’ is an area that consists of one or more reservoirs
all related to the same structural feature. A ‘‘pool’’ contains one or more reservoirs in
isolated structures.

[5,2]

Fig 1.3.1 Wellhead diagram.

Wells in the same reservoir can fall into categories of oil, condensate, and gas wells
depending on the producing gas–oil ratio (GOR).

14
WELL FLUID DATA:

1. Well Fluid Arrival Conditions:

The arrival pressure of the fluid is 9-10 bar(g). For process design the inlet separator
pressure is to be fixed at 8 bar(g). The arrival temperature of well fluid is 40-45 °C.

2. Well Fluid Compositions:

The well-head fluid composition data obtained is given as below:

SR NO. Component Composition (Mole %)

1 N2 0.74
2 CO2 2.6
3 H2S 0.11
4 C1 73.74
5 C2 4.88
6 C3 3.25
7 IC4 0.69
8 NC4 0.9
9 NC5 0.2
10 C6 0.21

Fig 1.1.1. WELL HEAD FLUID COMPOSITIONS

15
1.4 Project Objective:

1. The purpose of this project is to understand the principles of Oil & Gas processing
and how the offshore production unit operates.
2. Drawing of Process flow diagrams, Piping & Instrumentation diagrams (P&ID’s) of
the Processing unit.
3. Purpose of dehydration, methods of dehydration and its applications.
4. Clear understanding and applications of various types of valves, Compressors and
Pumps used in O&G processing.
5. Analysis and optimization of two given dehydration assets and comparing which is
better and adding recommendations to improve efficiency of the given asset.

1.5 Project Methodology:

This project was divided into 5 stages for mid-term.

Stage 1: The process flow diagram of the production unit.
Stage 2: The application of the Equipment’s.
Stage 3: The inlet and outlet parameters which controls the process flow.
Stage 4: Working and types of Valves, Pumps and compressors used.
Stage 5: Application of dehydration processes in the unit and the importance of glycol
dehydration along with comparison of TEG vs MEG.
Stage 6: Comparison of two assets of TEG and MEG packages and analysing which is more
efficient and optimising of the package.

Process design control and P&IDs are very essential components to learn in an Oil & Gas
industry. To attain the goals, we must adhere to a certain methodology and techniques to get
the desired results in the process flow diagram, various input and output parameters are
maintained to get the desired product from the production unit. PFDs are drawn to understand
the process pathway and get to understand where and when the conditions are entered so as to
get the required product.

1.6 Project Outcome:

• To read PFD and P&ID’s and their importance in design phase and operational phase
as well.
• To understand the functions of the equipment’s on MOPU and the role they play in
processing of oil and natural gas.
• To implement working principles of valves and their types being used.
• To analyse the various types of compressors and its importance.
• To draw the process flow diagram and the purpose of dehydration and the role it plays
in the final product delivery of the system and also understand the various methods of
dehydration.
• To analyse the data of the two given dehydration systems-1 & 2 and provide
optimization to the system

16
 CHAPTER 2. BACKGROUND THEORY

Introduction to project MOPU:

Company intends to develop the WO-16 cluster field located in the Mumbai High field ,140-
145 km west of Mumbai. As part of the WO-16 development, company intends to convert the
jack up drilling rig to a MOPU (Mobile Offshore Production Unit). It will be located adjacent
to the WO-16 well head platform (WHP) in 76 metre water depth, where it will receive and
process fluids from WO-16 well head. Following the processing of well fluids at MOPU, the
associated free gas will be compressed for export via the WO-16 WHP. Produced oil will also
be exported from the MOPU via WO-16 WHP. Produced oil will also be exported from the
MOPU via the WO-16 WHP.

Fig 2.1.1 Jack-up drill Rig

17
2.1 Equipment list on MOPU:

The MOPU consists of the following

1. Oil separation train:
• Inlet separator
• Three phase separators
2. Pumps:
• Oil booster pumps
• Oil export pumps
3. Gas compression train:
• Export gas compression train
• Export gas compressor (2nd stage)
• Export gas compressor (3rd stage)
4. Gas Dehydration Train:
• TEG contactor
• TEG regeneration package
5. Fuel Gas System:
• Startup Fuel Gas System
• Primary Fuel Gas Conditioning Skid
6. Flare system
7. Off-gas Compression
8. Chemical Injection System
9. Utilities: -
• Potable water distribution system
• DM water distribution system
• Nitrogen Supply and distribution
• Diesel distribution system
• Sea Water distribution system
• Service Air distribution system
• Instrument Air distribution system
• Hazardous and non-hazardous open drains
• Closed drains [5]

18
2.2 Valves, types and their application:

A valve is a device or natural object that regulates, directs or controls the flow of a fluid by
opening, closing, or partially obstructing various passageways.

Valves provide several functions, including:

• Starting or stopping flow based on the valve state
• Regulating flow and pressure within a piping system
• Controlling the direction of flow within a piping system
• Throttling flow rates within a piping system
• Improving safety through relieving pressure or vacuum in a piping system
Choosing a proper valve size is essential to both optimizing costs and ensuring safe,
accurate, and reliable operation. [6]
Here are some of the valves used in the Oil & Gas industry.

1.Gate Valves:
The gate valve may be the most commonly used in the industry. It uses a gate system to open
or close a pipeline entirely. This is an excellent choice if the flow rate needs to be controlled
and maintained. When the actuator completely opens the valve, the channel is unobstructed,
allowing even slurry fluids like crude oil to flow easier. While it is not an ideal candidate if
throttling is required in an application, there is not a noticeable pressure drop when this valve
is used.

Fig 2.1.1 A Gate valve

2.Globe Valves:
When pressure control is necessary, the globe valve is frequently chosen. It is also often used
for open and close operations. The valve plug sits vertically raised and lowered by the
actuator as needed. They tend to create a more significant pressure drop than other valve
types because of the S-shaped passageway within them. They are a good choice for flow
regulation and throttling functions.

Fig 2.2.2 Globe valve

19
3. Check Valves:
Gas refineries find check valves extremely helpful as the device opens under pressure and
does not allow backflow of fluid or material. Because of the restricted backflow, cross-
contamination of the product is prevented. That is, different materials can use the same
pipeline. There is no need for an actuator as required in other valve types. However, it does
need precise installation to ensure the response to fluid pressure occurs as required.

Fig 2.2.3 Check valve

4.Plug Valves:
The plug valve comprises a plug-shaped disc with a horizontal passageway bored through it.
When the linear valve is open, fluid will move through the hole. Turning the actuator 90
degrees from the open position blocks any flow through the pipeline. This valve is not
suggested for throttling functions but is ideal for unrefined oil products as found in biogas
production.

Fig 2.2.4 Plug valve

5. Ball Valves
Ball valves are rotary valves that give pipelines fast shut-offs where tight sealing is often
required. They are best suited for operation under fully open or fully closed positions as they
do not offer reasonable regulation control or throttle functions. This type of valve comes in
many different styles, which provides options within the industry. For example, a floating
ball valve works better in low-to-medium pressure pipelines, and trunnion ball valves can
handle high-pressure conditions. These are easy to repair, offer solid sealing, and provide
quick shut-offs.

Fig 2.2.5. Ball Valve

20
6. Butterfly Valves:
These valves are simple in their construction, are lightweight, and compact. They use a disc-
type element held by a rod to regulate flow. They can handle high-pressure pipelines and
allow easy flow of materials. When they are closed, they shut tightly. Often, these are used in
pipes with large diameters and where a gate valve is not applicable. [6,1]

Fig 2.2.6 Butterfly Valve

21
2.3 Oil Separation:

The fluids produced from oil wells are normally complex mixtures of hundreds of different
compounds. A typical oil well stream is a high-velocity, turbulent, constantly expanding
mixture of gases and hydrocarbon liquids, intimately mixed with water vapor, free water, and
sometimes solids. The well stream should be processed as soon as possible after bringing
them to the surface. Separators are used for the purpose.

Three types of separators are generally available from manufacturers:

1. Horizontal.
2. Vertical.
3. Spherical separators

Table 2.3.1. Comparisons of the three separators:

Horizontal Vertical Spherical

Easy to clean. Spherical separators are compact
Small diameter
vessels and provide good gas
separation.
Less occupied area. They are not widely used
Large gas-liquid interface &
perfect separation effect
Sensitive level controlling. They are difficult to fabricate
Skid-mountable design, easy
to install & transport
Large space for gas-liquid
Low cost
separation.
Large separator diameter.
Difficult to clean (the
separator is not suitable for
sand-containing conditions)
High cost.
High requirement for level
control
Inconvenient to transport
Large occupied area &
inconvenient high-level
erection.

[7]

22
Three types of separators:

Fig 2.3.1 Horizontal Separator

Fig 2.3.2. Vertical Separator

Fig 2.3.3 Spherical Separator

23
The oil separation system in MOPU consists of:
1. Two phase-separator (Horizontal).
2. Three phase-separator (Horizontal).

Two phase separators:

The fluids from wellhead platform enter the two-phase separator. All the fluids, including
water, oil and emulsion residue, are collected in the bottom. Associated gas from inlet
separator is sent to gas compression system.
In the MOPU, well fluids are routed via the production manifold into the inlet separator.
Associated gas from the inlet separator is sent to the gas compression system while liquid is
fed at the three-phase separator. Due to the presence of naphthenates and Asphaltenes with
the consequent possibility of strong emulsion formation, injection of de emulsifier is
provided at the inlet of separator.[8]

Fig2.3.4 Horizontal Two-Phase Separator

Depending on the specific application and the vapor-liquid mixture being separated, two-
phase vessels can be oriented vertically or horizontally. In their simplest form, they are an
empty tank that’s used to reduce the velocity of a fluid on entry, thus allowing the liquid to
fall to the bottom of the vessel and the vapor to rise to the top. Most separators include
internal devices that assist in the separation process, such as:

• An inlet diverter – An inlet diverter includes a downcomer that directs the inlet flow below
the liquid level in the tank. This has the effect of stabilizing the liquid level while preventing
splattering and foaming.

• A mist eliminator – A mist eliminator removes liquid droplets entrained with the gas. [8,1]
Three phase separators:

24
Liquid from inlet separator enters the three phases production separator at 3.5 Bar(g) and
sized in order to guarantee 5 minutes as residence for both crude oil and water. In the liquid
collection section of the vessel, the oil and emulsion separate, forming a layer (or “pad”)
above the free water. A weir maintains the oil level, while an interface liquid level controller
maintains the water level. The oil spills over the top of the weir, and then a level controller,
which operates the oil dump valve, controls its level. An interface level controller also senses
the height of the oil-water interface. This controller signals another dump valve to release as
much water from the vessel as is needed to maintain the oil-water interface at the pre-
determined height. Meanwhile, gas rises to the top of the separator. It flows horizontally and
exits through a mist extractor to a high-pressure control valve, which maintains constant
vessel pressure. [9]

Fig 2.3.5 A Horizontal Three Phase Separator

Three phase separators are commonly used in the oil and gas industry for the separation of
oil, water and hydrocarbon gases from raw product streams. All crude oils contain dissolved
gases that will come out of solution once oil is brought to the surface. The amount of gas in
the oil is referred to as the gas/oil ratio (or GOR).

horizontal separators have three main sections:

• A primary separation section – The primary separation section is situated at the inlet to the
vessel and is designed to separate the fluids from any entrained gas.

• Secondary separation – The secondary separation section is designed to facilitate the

separation of the liquid constituents into light and heavy phases according to their specific
gravity. Typically, oil comprises the light phase and water the heavy phase.

• Coalescing section – The coalescing section includes a vapor coalescer or mist extractor to
remove liquid droplets from the gas. A wire mesh eliminator is often used for this purpose.
[9,1]

25
2.4 Application of Pumps:

A pump is a device that moves fluids, or sometimes slurries, by mechanical action, typically
converted from electrical energy into hydraulic energy.

There are two main types of pumps:

1. Centrifugal Pump
2. Positive displacement pump.

1. A centrifugal pump
It is a mechanical device designed to move a fluid by means of the transfer of rotational
energy from one or more driven rotors, called impellers. Fluid enters the rapidly rotating
impeller along its axis and is cast out by centrifugal force along its circumference through
the impeller’s vane tips.

Application: Centrifugal pump designs offer simple and low-cost solutions to most low
pressure, high-capacity pumping applications involving low viscosity fluids such as water,
solvents, chemicals and light oils. Typical applications involve water supply and circulation,
irrigation, and the transfer of chemicals in petrochemical plants.
Design and working of pump:
The impeller is the key component of a centrifugal pump. It consists of a series of curved
vanes. These are normally sandwiched between two discs (an enclosed impeller).
Fluid enters the impeller at its axis and exits along the circumference between the vanes. The
impeller, on the opposite side to the eye, is connected through a drive shaft to a motor and
rotated at high speed. The rotational motion of the impeller accelerates the fluid out through
the impeller vanes into the pump casing. [9]

Fig 2.4.1. A centrifugal pump.

26
 2. Positive displacement pumps:
Positive displacement pumps add energy to a fluid by applying force to the liquid with a
mechanical device such as a piston or plunger. A positive displacement pump decreases the
volume containing the liquid until the resulting liquid pressure equals the pressure in the
discharge system.

Application of Positive displacement pump: Positive displacement pumps are preferred for
applications involving highly viscous fluids such as thick oils and slurries, especially at high
pressures, for complex feeds such as emulsions, foodstuffs or biological fluids, and when
accurate dosing is required.

Working and design: A positive displacement pump works by using a screw, a blade, a vane,
a lobe, a gear or diaphragm. It creates a chamber or cavity between the pumping elements and
the cavity in which the fluid is temporarily stored is moved by the reciprocating or rotary
motion along the pipe to its destination.[10]

Fig 2.4.2 Positive Displacement Pumps

27
Pumps utilised on MOPU:

Table 2.4.1 Pumps and their function in the MOPU.

OIL BOOSTER PUMP OIL EXPORT PUMP

Oil stream from the three-phase separator is
pumped first by Booster pumps which are in
configuration with rated capacity of 150
m3/hr each at 6.5 Bar(g).
This centrifugal type pump is used to
increase the pressure of the processed oil to
the extent of the required pressure of 54
Bar(g).
This oil is ultimately exported to WO-16 well
head platform

[10]

2.5 Introduction to Compressors:

A compressor is a device used to compress air or other gases to pressures higher than
atmosphere pressure. It compresses the air taken from the atmosphere and increases its
pressure.
Air compressors work by forcing atmospheric air under pressure to create potential energy
that can be stored in a tank for later use. Just like an open balloon, the pressure builds up
when the compressed air is deliberately released, converting the potential energy into usable
kinetic energy. From there, this energy transfer can be harnessed to power various pneumatic
tools. Compressors are driven by gas turbines or electrical motors.

Fig 2.5.1 Types of compressors

28
Types of compressors and their applications:
1.Rotary Air compressors:
They fall into two main categories based on how they operate: positive displacement and
dynamic. Positive displacement options, like rotary screw compressors, provide a constant
flow regardless of outlet pressure. In a rotary screw machine, this happens by a pair of screws
rotating in opposite directions to compress air in a sealed chamber

Fig 2.5.2. Rotary Air Compressor

2.Centrifugal compressors:
Centrifugal compressors are dynamic. That means they draw air in from the outside rather
than using a closed reserve of air. In a centrifugal machine, that happens thanks to a rotor
called an impeller spinning inside a cylinder to force air inside.
Some centrifugal machines use multiple stages to increase pressure, delivering more power.
Multi-stage compressors can deliver remarkable horsepower, making them ideal for powering
heavier equipment.

Fig 2.5.3 Centrifugal air compressor

29
3. Reciprocating-
Another positive displacement option is the reciprocating, or piston, compressor. As the
name implies, these use pistons to compress and displace air within their chamber. These are
among the most powerful compressors for home use, making them a popular choice. While
rotary screw compressors can produce more power overall, reciprocating options can
generate a lot with low energy consumption. They’re also more compact than rotary screw
machines, making them better for shorter, more flexible jobs. This low energy consumption
and portability make piston compressors an appropriate choice for powering hand tools.

Fig 2.5.4 Reciprocating Air Compressor

4.Axial –
Axial compressors are another type of dynamic machine. Instead of using an impeller, these
use rows of fan blades within a shaft. As air passes through each row, its velocity gradually
increases, leading to higher pressure. These compressors are typically smaller and lighter than
their centrifugal counterparts and operate at higher speeds. This lets them provide constant
flow rates at high volumes, but often with less pressure than alternatives. [11]

Fig 2.5.5 Axial Air Flow Compressor

30
2.6 Dehydration and methods of dehydration:

The main reason for removing water vapor from natural gas is that water vapor becomes
liquid water under low-temperature and/or high-pressure conditions. Specifically, water
content can affect long distance transmission of natural gas because of the following reasons:

1. Liquid water and natural gas can form hydrates that may plug the pipeline and other
equipment.
2. Natural gas containing CO2 and/or H2S is corrosive when liquid water is present.
3. Liquid water in a natural gas pipeline potentially causes slugging flow conditions resulting
in lower flow efficiency of the pipeline.
4. Water content decreases the heating value of natural gas being transported.

The water content of natural gas is indirectly indicated by the ‘‘dew point’’ defined as the
temperature at which the natural gas is saturated with water vapor at a given pressure. At the
dew point, natural gas is in equilibrium with liquid water; any decrease in temperature or
increase in pressure will cause the water vapor to begin condensing. The difference between
the dew point temperature of a water-saturated gas stream and the same stream after it has
been dehydrated is called ‘‘dew-point depression.’’ It is essential to accurately estimate the
saturated water vapor content of natural gas in the design and operation of dehydration
equipment.

Methods of dehydration:

Dehydration techniques used in the petroleum industry

fall into four categories in principle:
(a) Direct cooling.
(b) Compression followed by cooling.
(c) Absorption.
(d) Adsorption.

a) Direct cooling:
The ability of natural gas to contain water vapor decreases as the temperature is lowered at
constant pressure. During the cooling process, the excess water in the vapor state becomes
liquid and is removed from the system. Natural gas containing less water vapor at low
temperature is output from the cooling unit. The gas dehydrated by cooling is still at its water
dew point unless the temperature is raised again or the pressure is decreased. Cooling for the
purpose of gas dehydration is sometimes economical if the gas temperature is unusually high.
It is often a good practice that cooling is used in conjunction with other dehydration
processes.

b) Dehydration by Adsorption
‘‘Adsorption’’ is defined as the ability of a substance to hold gases or liquids on its surface.
In adsorption dehydration, the water vapor from the gas is concentrated and held at the
surface of the solid desiccant by forces caused by residual vagrancy. Solid desiccants have
very large surface areas per unit weight to take advantage of these surface forces. The most
common solid adsorbents used today are silica, alumina, and certain silicates known as
molecular sieves. Dehydration plants can remove practically all water from natural gas using
solid desiccants. Because of their great drying ability, solid desiccants are employed where

31
higher efficiencies are required. The incoming wet gas should be cleaned preferably by a
filter separator to remove solid and liquid contaminants in the gas. The filtered gas flows
downward during dehydration through one adsorber containing a desiccant bed. The down-
flow arrangement reduces disturbance of the bed caused by the high gas velocity during the
adsorption. While one adsorber is dehydrating, the other adsorber is being regenerated by a
hot stream of inlet gas from the regeneration gas heater. A direct-fired heater, hot oil, steam,
or an indirect heater can supply the necessary regeneration heat. The regeneration gas usually
flows upward through the bed to ensure thorough regeneration of the bottom of the bed,
which is the last area contacted by the gas being dehydrated. The hot regenerated bed is
cooled by shutting off or bypassing the heater. The cooling gas then flows downward through
the bed so that any water adsorbed from the cooling gas will be at the top of the bed and will
not be desorbed into the gas during the dehydration step. The still-hot regeneration gas and
the cooling gas flow through the regeneration gas cooler to condense the desorbed water.

C) Dehydration by Absorption
Water vapor is removed from the gas by intimate contact with a hygroscopic liquid desiccant
in absorption dehydration. The contacting is usually achieved in packed or trayed towers.
Glycols have been widely used as effective liquid desiccants. Dehydration by absorption with
glycol is usually economically more attractive than dehydration by solid desiccant when both
processes are capable of meeting the required dew point. Glycols used for dehydrating natural
gas are ethylene glycol (EG), diethylene glycol (DEG), tri-ethylene glycol (TEG), and tetra
ethylene glycol (T4EG). Normally a single type of pure glycol is used in a dehydrator, but
sometimes a glycol blend is economically attractive. TEG has gained nearly universal
acceptance as the most cost effective of the glycols because of its superior dew-point
depression, operating cost, and operation reliability. TEG has been successfully used to
dehydrate sweet and sour natural gases over wide ranges of operating conditions.

Glycol dehydrators also present several operating problems including the following:
. Suspended matter, such as dirt, scale, and iron oxide, may contaminate glycol solutions.
. Overheating of solution may produce both low and high boiling decomposition products.
. The resultant sludge may collect on heating surfaces, causing some loss in efficiency, or in
severe cases, complete flow stoppage.
. When both oxygen and hydrogen sulphide are present, corrosion may become a problem
because of the formation of acid material in glycol solution.
. Liquids (e.g., water, light hydrocarbons, or lubrication oils) in inlet gas may require
installation of an efficient separator ahead of the absorber. Highly mineralized water entering
the system with inlet gas may, over long periods, crystallize and fill the reboiler with solid
salts.
. Foaming of solution may occur with a resultant carry over of liquid. The addition of a small
quantity of antifoam compound usually remedies this problem.[12]

32
2.7 TEG VS MEG:

There are two different dehydration processes in the gas plant.

o Mono- Ethylene Glycol (MEG) is used to remove water from the wet gas,
o Tri-Ethylene Glycol (TEG), which is used in all production fields.

Advantages of dehydration by means of liquid sorbents:

-Relatively small capital expenditure and operating costs.
-Small pressure differentials in the dehydration system.
-Ability to dehydrate gases.
-Continuous processes. [13]

Disadvantages of dehydration by means of liquid sorbents:

-Smaller depression of the dew point (compared to solid sorbents).
-Foaming of glycols when the gas contains lighter hydrocarbons. [13,1]

Table 2.7.1 Comparison table for TEG vs MEG

Property MEG TEG

Formula HO(C2H4O) H HO(C2H4O)3H
Flash point 115°C 165°C
Boiling point 197°C 287°C

33
 CHAPTER 3. METHODOLOGY

3.1 Process Flow Diagram for MOPU:

Fig 3.1.1 Process Flow Diagram of MOPU

34
3.2 PROCESS DESCRIPTION:

1. Fluids from wellhead platform enter the 2-phase inlet separator operating at a pressure of 8
bar and 40-50°C.
2. The gas from inlet separator is sent to the gas compression system while liquid is fed to the
three-phase separator
3. The liquid from inlet separator enters the THREE PHASE production separator operating
at 4.5barg and sized in order to guarantee 5 minutes residence time for both crude oil and
water.
4. Oil from the three-phase separator is pumped first by booster pumps & enters the suction
of export oil pumps. Oil from discharge of export pumps is routed to Well Head Platform for
onward routing to trunk line.
5. Gas from the inlet separator is directed to the export gas compressor trains. The export gas
compressor trains comprise a three-stage compressor, with suction and discharge scrubbers
and inter stage cooling.
6. Gas from the second stage intercooler is directed to the TEG contactor for removal of
moisture. Tri ethylene glycol is used for moisture removal. Rich glycol is re-generated in the
TEG generation package.
7. There are two outlets from the TEG contractor, the first one which sends the gas to third
stage compression and then to export (Export gas pressure: 118.4 – 120 bar), and the second
one sends to fuel gas conditioning system.
8. Main fuel gas during normal operation is taken from downstream of TEG contractor and is
routed to fuel gas conditioning system which consists of following. High pressure fuel gas
will be available at approximately 25 Bar(g), high pressure uses of MOPU are:
a. Export gas compressor turbine
b. Export gas compressor seal gas
c. Main power generated turbines

35
3.3 Dehydration Process Flow Diagram (Glycol dehydration):

Fig 3.3.1 Glycol Dehydration Process PFD (Process Flow Diagram

36
Glycol dehydration process description:
The dehydration process can be described as follows:
1. The feeding-in gas stream first enters the unit through an inlet gas scrubber to remove
liquid accumulations. A two-phase inlet scrubber is normally required.
2. The wet gas is then introduced to the bottom of the glycol-gas contactor and allowed to
flow upward through the trays, while glycol flows downward through the column. The gas
contacts the glycol on each tray and the glycol absorbs the water vapor from the gas steam.
3. The gas then flows down through a vertical glycol cooler, usually fabricated in the form of
a concentric pipe heat exchanger, where the outlet dry gas aids in cooling the hot regenerated
glycol before it enters the contactor. The dry gas then leaves the unit from the bottom of the
glycol cooler.
4. The dry glycol enters the top of the glycol-gas contactor from the glycol cooler and is
injected onto the top tray. The glycol flows across each tray and down through a downcomer
pipe onto the next tray. The bottom tray downcomer is fitted with a seal pot to hold a liquid
seal on the trays.
5. The wet glycol, which has now absorbed the water vapor from the gas stream, leaves the
bottom
of the glycol-gas contactor column, passes through a high-pressure glycol filter, which
removes any foreign solid particles that may have been picked up from the gas stream, and
enters the power side of the glycol pump.
6. In the glycol pump, the wet high-pressure glycol from the contactor column pumps the dry
regenerated glycol into the column. The wet glycol stream flows from the glycol pump to the
flash separator, which allows for the release of the entrained solution gas.
7. The gas separated in the flash separator leaves the top of the flash separator vessel and can
be used to supplement the fuel gas required for the reboiler. Any excess vent gas is
discharged through a backpressure valve. The flash separator is equipped with a liquid level
control and diaphragm motor valve that discharges the wet glycol stream through a heat
exchange coil in the surge tank to preheat the wet glycol stream.
8. The wet glycol stream leaves the heat exchange coil in the surge tank and enters the
stripping still mounted on top of the reboiler at the feed point in the still. The
stripping still is packed with a ceramic INTALOX saddle-type packing, and the glycol flows
downward through the column and enters the reboiler. The wet glycol passing downward
through the still is contacted by hot rising glycol and water vapor passing upward through the
column. The water vapor released in the reboiler and stripped from the glycol in the stripping
still pass upward through the still column through an atmospheric reflux condenser that
provides a partial reflux for the column. The water vapor then leaves the top of the stripping
still column and is released to the atmosphere.
9. The glycol flows through the reboiler in essentially a horizontal path from the stripping
still column to the opposite end. In the reboiler, the glycol is heated to approximately 350–
4008F to remove enough water vapor to re-concentrate it to 99.5% or higher. In field
dehydration units, the reboiler is generally equipped with a direct-fired firebox, using a
portion of the natural gas stream for fuel.
10. The re-concentrated glycol leaves the reboiler through an overflow pipe and passes into
the shell side of the heat exchanger/surge tank. In the surge tank, the hot re-concentrated
glycol is cooled by exchanging heat with the wet glycol stream passing through the coil.
The surge tank also acts as a liquid accumulator for feed for the glycol pump. The re-
concentrated glycol flows from the surge tank through a strainer and into the glycol pump.
From the pump, it passes into the shell side of the glycol cooler mounted on the glycol gas
contactor. It then flows upward through the glycol cooler where it is further cooled and enters
the column on the top tray.

37
3.4 TEG Regeneration process in MOPU:
1. Wet natural gas first flows through an inlet scrubber, integral to contactor, to remove all
liquid and solid impurities.
2.Then the gas flows into and upward through the absorber or contactor where it is contacted
counter-currently and dried by the glycol.
3. The lean or re-concentrated glycol enters the top of the contactor where it flows
downward through structured packing and absorbs water from the rising natural gas.
4. The rich or wet glycol flows through the reflux condenser and then into Cold lean/rich
glycol heat exchanger where it is preheated by the hot lean glycol, then flows into a flash tank
in order to separate any suspended hydrocarbons. And then flows through Hot lean/rich
glycol heat exchanger where it is further preheated by the hot lean glycol.
5. After the Hot lean/rich glycol heat exchanger, the rich glycol enters the still column and
flows down the packed bed section into the reboiler.
6 Vapours generated in the reboiler strips water from the liquid glycol as it rises up the
packed bed.
7.The water vapor and the dissolved natural gas are vented from the top of the stripper. The
hot reconcentrated glycol flows out of the reboiler into the stripping or Stahl column where it
is further re-concentrated by the use of the stripping gas. Then the glycol flows into the
glycol-glycol exchangers where it is cooled by the heat exchange with rich glycol.
8.Finally, the lean glycol is pumped back into the top of the contactor after being cooled
in a lean glycol air cooler. The efficiency and the operational cost are improved by the
additional equipment such as using glycol (sock) and charcoal filters where the glycol is
filtered.

Equipment’s in the Glycol Regeneration Unit on MOPU:

The proposed Gas Dehydration/Regeneration Package consists of the following:
a) Glycol Contactor with Integral Scrubber
b) Glycol Regeneration System
i. Glycol Fine Filters
ii. Activated Carbon Filter
iii. Still Column Reflux Condenser
iv. Lean TEG Cooler
v. Cold Glycol/Glycol Exchanger
vi. Glycol Circulation Pumps
vii. Glycol Filling Pump
viii. pH / Corrosion Inhibitor Pump
ix. Antifoam Pump
x. pH / Corrosion Inhibitor Tank
xi. Antifoam Tank
xii. Hot Glycol/Glycol Exchanger
xiii. Glycol Flash Drum
xiv. Glycol Reboiler
xv. Glycol Still Column
xvi. Glycol Stripping Column
xvii. Glycol Surge Drum
xviii. Glycol Reboiler Heater

38
PFD of Glycol Regeneration Unit on MOPU:

Fig 3.4.1 Process flow diagram of TEG re-generation unit.

39
3.5 Analysis of two dehydration assets – procedure and calculations

Two Assets are given in the dehydration section of MOPU:

1. SYSTEM-1 uses TEG process for gas dehydration.
2. SYSTEM-2 uses MEG process for gas dehydration.

System-2 operates by a method of chemical injection process-MEG injection method.

The lean glycol (MEG) is injected into the wet gas through four points in plant
system (there is no contactor –absorption tower). The injection of glycol will
prevent the freezing of the water in the gas when a refrigerant is used to cool the
gas to below 0 °F for glycol recovery. The rich glycol is collected, separated
from gas condensate in a two-section separator and then sent to a glycol
regeneration system similar to the systems used in other field plants.

The glycol dehydration process is affected by the following four major variables:
1. Temperature
2. Pressure
3. Glycol flow-rate
4. Glycol concentration
Aim:
To analyse the performance of SYSTEM-1(TEG process) and SYSTEM-2(MEG process) by
calculating the rate of water removed and the glycol flow rate.

Procedure:
1. The data of the two assets was collected in a data sheet from the company.
2. The pressure, gas flow rate, Gas inlet temperatures, rich and lean glycol concentration
and the glycol densities used were put up in an excel sheet data.
3. Calculations were performed on both the assets to find the glycol flow rate and the
rate of water removed from the system.
4. The Calculations are divided into two parts PART A (SYSTEM-1 -TEG process) and
PART B (SYSTEM-2- MEG process) respectively.
5. The amount of water required to be removed is defined from the initial water content
of the natural gas, and allowed water content of gas in use.
6. For SYSTEM-1, which uses TEG process, the initial water content of the natural gas
is determined; by using saturation curves for gas pressure of 143 PSIG & temp.100°F.
Pressure and temperature at 14.7 psia and 60°F is used to find the initial water content
from curve. [14]
7. For System-2, estimated and actual water balance is calculated from the table, lean
glycol flowrate and maximum and minimum water removed is found and eventually
the rich glycol flowrate is calculated.
8. The data is then put up in a results table and compared.

40
Calculations and tables:
The Calculations are divided into two parts – Part A for System-1 (TEG Process package)
and Part B FOR System-2 (MEG Process package).

PART A:
Table 3.5.1 gives the data of SYSTEM-1 of the TEG process for gas dehydration.

Table 3.5.1. Data for System-1 (TEG process)

PARAMETER (For SYSTEM-1-

TEG package) Quantity
GAS FLOW RATE 120 MMSCFD
GAS INLET TEMPERATURE 100 F
CONTACTOR GAS PRESSURE 143 PSIG
Lean glycol concentration 0.996
Rich glycol concentration 0.97
water content allowed in dry gas 7lbs / MMSCF
Glycol (TEG) density 9.35 lb /gallon

Step 1:
The amount of water removed by dehydration process is:
Lean glycol concentration -rich glycol concentration
(99.6 - 97.0) = 2.6 lb
Step2:
Lb of water removed Lb Glycol required for removal
2.6 Lb 100
1.0 n
n = 38.46 Lb of glycol 38.46/ 9.35 = 4.113 gallons
The minimum circulation rate of glycol to remove 1 Lb of water is 4.113 gallons.
Step 3:
The operational glycol rate should be more than minimum with 20%. So,
1+0.2=0.2
The operational glycol flow = 4.113 * 1.2
= 4.936 gal. glycol /Lb water removed.
Step 4:
The amount of water required to be removed is defined from the initial water content of the
natural gas, and allowed water content of gas in use.
The initial water content of the natural gas is determined; by using saturation curves for gas
pressure of 143psig & temp.100°F, [11].
The initial water content = 305 MMSCF (at 14.7 psia-60oF)
The water required to be removed = 305 -7 = 298 lb/MMSCF
Step 5:
The minimum glycol flow required/day =
Gas flow rate* water to be removed *weight of glycol required for removal(lb)
= 120 * 298 * 4.113
=147080.9 gallon/day

41
Calculations (Continued)
Step 5:
The minimum glycol flow required/day =
Gas flow rate* water to be removed *weight of glycol required for removal(lb)
= 120 * 298 * 4.113
=147080.9 gallon/day
Step 6:
Finally, the operational glycol flow per minute is calculated keeping in mind the 20% more
than minimum rate
Operational glycol flow per minute = 147080.9 *1.2 / (24*60)
(Operational glycol circulation rate) =122.6 gal/min
Step 7: The results is entered in the table.

PART B
Table 3.5.2 gives the data of System -2 of the MEG process for gas dehydration.

Table 3.5.2. Data for System-1 (MEG process)

PARAMETERS (For
SYSTEM-2- MEG package) Quantity
Gas flow rate 40 MMSCFD
Gas inlet temp (80 -120) F
Lean glycol concentration 0.82
Rich glycol concentration 0.67
gas water content required 5 lbs / MMSCF
(120 - 400) lb /
gas water content MMSCF
Glycol density (MEG) 9.16 lb/gal

Step 1:
Assume inlet glycol concentration, Ws (lean glycol) = 82 %, Wf = 67%
Step 2:
Calculate estimated water balance (EsWb) by
= 100(Lean glycol-rich glycol concentration)/ (rich glycol concentration)
= 100 (Ws-Wf) / Wf
= 100(82 - 67) / 67
= 22.388 %
Step 3:
Actual water balance = Max gas water content – gas water content required
=400-5 =395 lb/MMSCF
Step 4:
For gas flow rate of 40 MMSCFD, actual water balance is calculated
Actual water balance =40 * 395 / (24 * 60) = 10.97 lb/min.
Step 5:
Glycol flow rate = (100* Actual water balance / (Estimated water balance) *2
= (100*10.97 /22.388) * 2 = 97.9989
= 98 lb/mi

42
Calculations (Continued)

Step 6:
Calculate lean glycol flow rate and fin the minimum and maximum glycol flow rate.
• inlet glycol density = 9.16 lb/gal
• Water density = 8.328 lb/gal
Lean glycol flow rate = water balance/inlet glycol density (MEG)
=98 / 9.16 = 10.7 gal/min
Max. water Removed for 400lb/MMSCF = 10.97/8.328 = 1.3 gal/min
Min. water Removed for 120lb/MMSCF = 10.97*120/ (400*8.328) = 0.395
= 0.4 gal/min
Rich glycol flow rate: maximum. = 10.7 + 1.3 = 12.0 gal/min
Minimum. = 10.7+0.4 = 11.1 gal/min
Step 7: The results are entered in a table

43
 CHAPTER 4. RESULTS & DISCUSSION

4.1 Inlet & Outlet Condition of Equipment’s on MOPU

The below table summarizes the inlet and outlet temperatures and pressures which available
from the operation and control philosophy of the MOPU.

This table gives clear information of inlet temperatures and pressures of major equipment
present on MOPU.

1. The inlet separator operating pressure is maintained between 9-10 bar(g).

2. The inlet pressure and outlet pressure of gas at 1st stage export compressor is 7.7
bar(g) and 22.7 bar(g).
3. The inlet pressure and outlet pressure of gas at 2nd stage export compressor is 19.9
bar(g) and 48.2 bar(g).
4. The final stage of export gas compressor’s inlet and outlet pressures are also
following 47.1 bar(g). and approximately 120 bars(g).
5. The design capacities of the oil booster and oil export pumps is set at 150 m3/hr.
6. Final outlet pressure of the oil export pump is 54 bar(g).

Sr.No Equipment Inlet Pressure Inlet Temperature Outlet Pressure Outlet Temperature
1 Inlet Seperator 9- 10 barg 40-45°C
2 Oil booster pump 3.5 bar(g) 10.7 bar(g)
3 Oil export pump 9.5 bar (g) 54 bar (g)
4 1 st Stage export compressor 7.7 barg 40°C 22.7 barg 114°C
5 1st Stage compressor discharge cooler 114°C 50°C
6 2nd Stage export compressor 19.9 barg 50°C 48.2 barg 125°C
7 2nd Compressor discharge cooler 125°C 50°C
8 3rd Stage export compressor 47.1 barg 52°C 118.4 barg 140°C
9 3rd Stage discharge compression cooler 140°C 50°C
Fig 4.1.1. Inlet and outlet temperature & pressure for the major equipment’s on MOPU.

Discussion – In order for the plant to operate economically & safely, such that a certain outlet
condition is desired for export oil & gas and fuel gas users on MOPU, temperatures and
pressures are maintained and controlled according to the plant specification.

44
4.2 Analysis of two dehydration assets- Final results and comparison

From the calculations, the results of the two assets are inserted in their tables,
Table 4.2.1 for System-1(TEG Process Contactor) and table 4.2.2 System-2 (MEG process
injection system).

Table 4.2.1 Results for System-1 (TEG process contactor)

Glycol flow rate Required,

Gas flow rate, MMSCFD gal/min
120 122.6
115 117.5
110 112.4

Table Results for System-2 (MEG process contactor)

Concentration
Type of glycol (pump discharge)/ % Flow rate/gpm
Lean glycol 82% 10.7
Maximum flow rate:
12.0
Minimum flow rate:
Rich glycol 67% 11.1

Conclusions:

• The glycol flow rate is directly proportional to the rate of gas flow rate. On decreasing
the gas flow rate, the glycol flow rate decreases.
• As from the data obtained from the results table, Glycol flow rate in System-1(TEG
process) is higher than System-2(MEG process). A higher glycol flow rate is
advantageous for the dehydration system as the rate of water removed from the
system is high, which signifies that the dehydration of process gas is more efficient in
System-1, as compared to System-2.

Here are some reasons why:

Tri-ethylene glycol (TEG) is the most commonly used glycol for dehydration of natural gas
because of its relative advantages relative to MEG:
- TEG is more easily regenerated to a higher degree of purity.
- Vapor losses are lower.
- Operating costs are lower.

45
4.3 Analysis of two dehydration assets- Optimization and recommendations to the
system

The economic efficiency of the absorption plants depends heavily on the sorbent losses. To
reduce this, it is necessary in the first place strictly to:
• maintain the designed temperature regime of the desorption,
• separate water vapor from the gas carefully, and
• use special additives in order to prevent foaming in the gas/absorbent contact area, if
possible.

Glycol dehydrators are the most common equipment to remove water from gas. Most use tri-
ethylene glycol (TEG)Glycol. dehydrators create:
• emissions Methane, Volatile Organic Compounds (VOCs),
• Hazardous Air Pollutants (HAPs) from reboiler vent Methane and pneumatic controller’s
source.

Most operating and technical problems occur when the circulating glycol solution gets dirty.
In order to get a
long, trouble-free life with the glycol system, it is necessary to recognize the following
problems and know
how to prevent them:
• Glycol loss.
• Foaming.
• Thermal Decomposition of glycol.
• Dew point control.
• Glycol PH control.
• Salt contamination.
• Glycol oxidation.
• Sludge formation.

Recommendations for optimization of the system:

Methane that flashes from rich glycol in an energy-exchange pump can be captured using a
Flash Tank Separator (FTS). When the glycol reaches the flash tank, its temperature has been
raised through the coil in the reboiler still, and the pressure in the flash tank is at a much
lower level, generally between 15 to 50 PSIG, than the pressure in the contactor. In light of
these changed conditions of pressure and temperature between the absorber and flash tank,
most of the dissolved gases evolve from the glycol in the flash tank. [15]

46
 Fig 4.3.1 Flash tank separator.

Flash Tank Separator (FTS), has the following merits:

• recovers about 90% of methane emissions.
• reduces VOC (Volatile organic compounds) by 10 to 90%.
• Cheap installation costs.
• Negligible Operational & Maintenance costs.

47
 CHAPTER 5. WORK TO BE DONE

The next phase of this project will be going to be divided into four major stages &
conclusion:
Stage 1 Flare system, importance and purpose of flaring.
Stage 2 Fuel Gas System, Off Gas Compression System
Stage 3 Importance of utility systems in an oil and gas processing plant.
Stage 4 Utility systems present on MOPU –Nitrogen Generation Package, Instrument Air
System, Chemical injection system, Potable water distribution system, DM water Distribution
System
Stage 6 Overall Heat and Mass balance of following systems:
1. TEG Contactor
2. Oil Export system
3. Separation system
Conclusion

48
 CHAPTER 6. REFERENCES

[1] Overview of the Indian Oil & Gas industry- https://ongcindia.com/web/eng/about-

ongc/ongc-at-a-glance/oil-and-gas industry#: ~:text=The%20oil%20and%20gas%20sector,
sector%20quite%20conducive%20for%20investment.
[2] Overview of the Indian Oil & Gas Industry-https://www.ibef.org/industry/oil-gas-india
[3] Challenges for the Indian oil and gas industry-
https://www.economicsdiscussion.net/india/industries-india/8-major-problems-of-petroleum-
industry-in-india/19183
[4] Introduction to Oil & Gas processing - https://guides.loc.gov/oil-and-gas-
industry#:~:text=Oil%20and%20natural%20gas%20are,of%2Dthe%2Dart%20technology.
[5] Introduction to Oil and gas processing-
https://petrowiki.spe.org/Oil_and_gas_processing#:~:text=The%20purpose%20of%20oil%20
and,Sold
[5,1] Introduction to Oil &gas processing- -Page 16 Petroleum production engineering by
BOYUN G ISBN: 0750682701 BY Publisher: Elsevier Science & Technology Books.
[5,2] Components list in MOPU- Operation Control philosophy (Industry controlled booklet)
[6] valves basic functions- https://www.unifiedalloys.com/blog/valves-101
[6,1] Valves and their applications- https://norgascontrols.com/blog/valves/7-types-of-gas-
valves-used-in-the-oil-gas-industry/
[7] Introduction to separation systems- research paper-
https://www.scribd.com/document/457026211/ADVANTAGES-OF-EACH-TYPE-OF-
SEPARATOR-pdf#
[8] Two phase separators- https://www.tech-fab.com/service/2-phase-
separators#:~:text=The%20basic%20design%20of%20a,collected%20in%20the%20bottom%
20valve.
[8,1] Two phase separator description-https://www.honiron.com/introduction-two-phase-
separators/
[9] Three Phase separator -https://kimray.com/training/3-phase-separators-
overview#:~:text=In%20a%20horizontal%20three%2Dphase,the%20gas%2Doil%20separati
on%20process.
[9,1]-three phases’ separators-https://www.honiron.com/basic-operation-three-phase-
separators/
[10] Positive Displacement pumps-https://www.flexachem.com/pumps/positive-
displacement-pump/
[11] Introduction to compressors and types
https://www.forconstructionpros.com/rental/power/article/21821509/do-you-know-the-7-
types-of-air-compressors-and-their-applications
[12] Dehydration and methods of dehydration-Page 125, Page 126, Page 127 Petroleum
production engineering by BOYUN G ISBN: 0750682701 BY Publisher: Elsevier Science &
Technology Books.
[13] Dehydration. 1998. In Engineering Data Book, 11th edition, Secs. 19-21. Tulsa,
Oklahoma: Gas Processors Suppliers Association/Gas Processors Association.
[13,1] Dr Alexandre L. & et al; 2016; Hydrate Management: Managing Uncertainty and Risk
through Enhanced Measurement; South East Asia Flow Measurement, 16-17 March.
[14] Mcketta, J.J. and A.H. Wehe. (1958) Use This Chart for Water Content of
Natural Gases. Petroleum Refiner 153–154.
[15] Flash tank separator- GDU (Gas Dehydration Unit) manual.

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