Santhal Main-ICP DESCRITION OF FACILITIES A’ SANT! MAIN y IN-SITU COMBUSTION ISC): e HEAT is used to thin the oil and wells. ¢ Ina fire flood, the formation is ignited, and by continued injection of air, a fire front is advanced through the reservoir « Mobility of oil is increased by reduced viscosi combustion gases, # Water injection improves the thermal efficiency Permit it to flow more easily towards production ity caused by heat and solution of Principle: Thermal Recovery Method: Ignition within the Reservoir and supply of air from surface through Injection Well to sustain the burning of fire front Process: Heat generation increases temperature causing reduction in viscosity and improving the mobility. Process Initiator: Ignition Trailer Process Sustainer: Air Compressor Plant > DESCRIPTION OF PLANT: © The plant system essentially consists of L.P. compressors, H.P compressors, (700000M3/Day @ 123 Kg/Cm2) water injection system, cooling water system, different chemical dosing system, and necessary electrical and instrumentation system. Its all about pushing of air to pull out oil Input: Compressed Air, Output: Heavy Oil Ambient Air 123 Kgfem? 9Kg/em? (max)Santhal Main-Icp. > [RAW WATER SYSTE! oa primary cooling wate Two numbers of tanks (one in service and other standby for receiving effluent) of 2520 M* ¢ temp.rise. The t capacity, each are installed for holding treated effluent. Other than inlet for treated effluent ;,strumentation, cont tank also has provision for bore well water. Transmitter type level indicators are provided of both LP and HP ¢ for reading the levels in the tanks. the intermediate buf interconnecting head will be able to take discharge lines of all line. It is also serv demands in excess ding of the cor > AIR COMPRESSION SYSTEM: Air compressor plants are hearts of EOR project as they are required to supply air continuously. In Santhal Main we have 6 trains of compressor (one LP and one Hp Unloa combination is called a train) of 7.0 lakh NM3 /day each capacity. Air is required at the rate of 10000-35000 (peak rate) NM3/day per well at a pressure of 105 kg/Cm2, DMR INIEO! * DETAILS OF LP COMPRESSORS fare 100 to 1051 - MAKE: CENTAC, INGERSOLL RAND, USA At present 0 = INSTALLED 6 = TYPE:CENTRIFUGAL * SANTHAL) - RATED DISCHARGE FLOW: ° SANTHALI - SUCTION PRESSURE: 1.0: - DISCHARGE PRESSURE:10.624 KG/CM2 - DRIVER: SIEMENS/BHEL INDUCTION MOTOR 3950 KW ° SANTHAL] Air injection ¢ DETAILS OF H.P.COMPRESSORS _6 nos. * Main d = Distrib MAKE:DRESSER RAND, UK = Distrib INSTALLED - 6 TYPE: ICIPROCATING a * STAGES: 03 MEN CAPACITY: 29000 NM3 OF AIR / HOUR at 123 KG/CM2 RPM:333 Twenty four wel INLET PRESSURE: 10.19 KG/CM2 from HP surge y DISCHARGE PRESSURE 125.47 KG/CM2 to individuallwe DRIVER: SIEMENS/BHEL SYNCHRONOUS MOTOR : 3950 KW The main heade t ; ene i to individual w. A closed circuit water cooling system is provided for the cooling requirements. The LP aitmanifold is pro compressor after coolers and HP air compressor intercoolers and aftercoolers are of aitto individual w cooled and hence do not require any cooling water. The closed circuit (secondary coolingon the downstre water) cooling water system utilises potable water for make-up supplied by 2 inch line. This secondary cooling water system comprises of the following. © Distrib i - Potable water make-up tank for make-up requirement. - Secondary cooling water circulation pumps. cm f ~ Chemical dosing requirement to maintain the following level of chemicals. tistbut a ~ Two numbers of plate type heat exchanger containing titanium plates for heat ution ce transfer with primary cooling water system. Sts suppli There are 23 ySanthal Main-icp inary cooling water to plate exchangers ig ¢ temprise, The total requirement of a rplied at 35 deg cand retuned with 16 deg Ooling Water is around 1200 m3/hr.All ee AIR INJECTION SYSTEM: AAAS ION SYSTEM: Air is to be injected at the rate of 10000 to 35000 nm3/day per well at a Pressure of ‘ ? 100 to 105 kg/em2. SANTHAL MAIN has earmarked 70 wells for injection of air. Dinosict sy, : At present 09 nos. of wells Connected from Santhal Main for air and water injection. SANTHAL MAIN: 3 WELL. SANTHAL DC-II: 5 WELL SANTHAL DC-I: 1 WELL Air injection is done in locations namely: * Main distribution centre * Distribution centre - 1 = Distribution centre - 2 ¢ Main distribution centre ction system: ‘wenty four wells are located within the range of main distribution centre. Compressed air irom HP surge vessel is routed through an 8 inch header. From this header compressed air o individual wells (24 no’s) is supplied through injection air manifold of 3 inch line size. he main header is provided with local pressure and temperature gauges. Compressed airs o individual wells are supplied through injection air manifold of 3 inch line size. Each lanifold is provided with a flow transmitter with flow indicator and controller. Air flows 0 individual wells are controlled by means of control valves. Pressure gauges are provides ithe downstream of flow control valves to monitor the downstream pressure, * Distribution centre -. here are 23 wells located near distribution centre 1. This distribution centre is around 5 m from the main centre. An 8 inch line from the main injection centre is routed to this istribution centre. This serves as the header from which compressed air to individual cll is supplied through 3 inch injection air manifold.Santhal Main-icp Distribution centre -2: There are 23 wells located near distribution centre 2. This distribution centre is around 5 km from the main centre. An 8 inch line from the main injection centre is routed to this distribution centre. This serves as the header from which compressed air to individual ~ wells is supplied through 3 inch injection air manifold. I Fig.2-Schematic diagram of Air Injection Grid >» INSTRUMEN IR SYSTEM: Instrument air at 7.5 kg/cm2 is required for instruments, both at main centre and distribution centre 1&2.The instrument air dryer system of 150 nm3/ hr capacity is provided at the main centre to supply instrument air to instruments control valves and compressors. The system includes an air filtration package and air dryer. The air dryer is of adsorption type using activated alumina as desiccant. Water molecules in compressed air are removed by the means of adsorption. A 2 inch tapping from plant air header line from HP surge vessel is routed to instrument air system through a pressure control valve for reducing the pressure from 122 kg/cm? to 7.5 kg/om?.Also a 2 inch tapping intermediate buffer vessel is connected to the instrument air system through a pressure control valve. This provision is given so that plant air can be directly taken from LP compressor discharge at a low pressure itself. The outlet air line from the instrument air dryer serves as the header from which tapping’s are taken for individual instruments and the panel, Pressure indicator is provided on the header to indicate the instrument air header pressure. 5Santhal Main-ICP > COOLING WATER SYSTEM: ‘tal capacity of cooling tower is 1200 m3/hr. each cell is equipped with a motor driven duced draft fans of 20 kW rating, Design supply temperature is 32 deg ¢ whereas the hot ge fens ees cooling eae Supplies primary cooling water to plate heat exchanger usin T as secondary coolar echged LP aif compressor, the hbe oil coolers of hath LP HP a eppee es aoe facket cooling requirements in the reciprocating air compressors. This primary cooli ‘ater system iS a open circuit recirculating system having a total design reales apacity Of 1200 m3/hr. also there is a provision of sump drain, The basin is open ai type. Flow to cooling water basin is measured by flow transmitter with flow nda Flow is indicated in the local panel at CWTP building. Two cooling water recirculation pumps (One operating, one standby) of 1200m3/hr capacity each will be provided to ply cooling water to the consumers. The discharge line of the pumps is connected to mmon header of 18 inch size line. The header line is provided with the local mp.,pressure gauges and flow transmitter. | aoe | i Q = | a \ | Plate Heat oa Exchanger Fig.3-Schematic diagram of cooling water system v WATER INJECTION SYSTEM: © Water injection is required during wet phase when Dry phase is over (90-120 day after ignition) in 6 days water and one day Water pattern. We receive effluent water from NSETP which is polished here by adding chemicals and passing through a series of filters. MAKE: NATIONAL OILWELL, USA NUMBER OF PLUNGER: 05 IN EACH PUMP CAPACITY:38 M3/ Hr. max. DISC] E 2Santhal Main-icp - DRIVER (MAKET 'Y PE): TOSHIBA / INDUCTION MOTOR Water is required to be injected at a rate of 5.0 to 38 m3/day per well at a pressure of 50 to 115 kg/em2. The water injection system shall be designed to cater to the requirement of 960 m3 / day injection water, The source of injection water is cooling water system Injection water filtration package is provided to produce water of high quality for injection to wells. The filtration scheme consists of 3 nos of primary dual media filter followed by 6 nos activated carbon filter and 3 nos of Pressure sand filter. The filters are designed for a cycle time of 24 hours between three backwashes. e ; Oxygen removal, scale and corrosion inhibitor, biocide injection.are required to be carried out at the main centre before injecting the water in to the wells. Oxygen removal, scale and corrosion inhibitor, biocide injection. Main injection water pumps of 38 m3/hr capacity (each) are provided to inject the treated water into the wells.These pumps are connected to a 6 inch header from the filtration package, a 4 inch suction line and deliver high pressure water through 3 inch line pressure control valves are provided to bypass the discharge fluid to suction line in case there is no take-off of water or any abnormal situation. These pressure control valves are actuated by individual pressure transmitter along with pressure indicator and controller. Two more > branches of 6 inch line size is taped from the main header line, These branch lines serve as header in distribution centre 18:2 for water injection purpose. The main header line after we a branching is reduced to 4 inch line. Injection water to individual well is supplied through } 99 x 24 nos injection water manifold of 4 inch line size. Each manifold is provided with flow transmitter along with flow indicator and controller. Water flows to individual wells are controlled by flow control valves. Pressure gauges are provided at the downstream of control valves to indicate the exit pressure, Capacity: 40 M3/Hr Pr: 123 KgiCm2 Injection Header Main Injection |” Pumpone Op frumentation system ieee > Ins ‘Ysten, ig, “d 44h Fea Yer tory y - Con able Air in 1 5,9 plenad andl ipa fen ystem, Seon ae Data Arrieg le ang F 220 KV Sub-Station > Step down from 220 Ky to ¢ n 6 Ky 4 Power Transformers 29 / 34 SMva tion Input to Compressors; 616 9:9; Surg Power factor: 0.997 ng by, Ore THE WORLD Is w -DIS WATCHING Us. > ay RR > on NSU: tep doing In-situ Comme, ercialization ip We are m’ which is unique in the world wy, 100 Kg/e at the depth € t ‘m) Of 1000 Mts. and pressure of around20.0%5 TOVREA OLS ADH sostosssidusoy, aug { ony dung u = Hun womens f fe a | AVUYPVId MOA S83008.1INTRODUCTION Oil & Natural Gas Corporation Ltd sector enterprises in the country wi the energy demand in particular - industrial and economic growth in general. Born as a modest Corporate house in 1956 as commission, ONGC has grown today integrated upstream Ppetrole; into a full-fledged um company with In-house service capabilities and infrastructure in the entire tange of oil and gas exploration and production activities. {t is One of the top nine Public sector enterprises (Navaratnas) of India and has achieved excellence over the years and is on the Path of further growth. as heavy crude oil fields in Lanwa, Balol & the heavy oil recover © one of the leading public ibstantial Contribution to Santhal area. For technology is being y IN-SITU combustion used at field since March 1990. The first well CP# 10 was ignited on 16/03/1990, at Balol pilot IN-SITU Combustion ¢ ignited on 04/c SITU Combust Production Was taken to hemes at this field from these under take Under commercialis In-Situ projec of crude oil. On seeing the named SANTHAL MAIN IN- been implemer FIELDS. The SANTHAL. MAIN tc ation scheme Balol Phase-| & Santhal Phase- is has been “MEC TO enhance thi of these, a m: SITU Com ted to exploit the h avy iplen © recovery suc @\Or project 'SUSTION PLANT has crude oil of SANTHAL OIL seen Commissioned on CP h 23.06.2001. a part of the reservoir oil, For ae of ignition process. One is th air is simply injected ina central inverted five Spot patterns where the wells are drilled in a geometric fashion having an equal distance of 220 meters. Such thermal Tecovery is only suitable where the API gravity is less than 15, degree it inside the reservoir by burning ration of heat we apply two types PONTANEOUS IGNITION, where the ly located well. This is called theand viscosity is very high. As we in i : ected air ‘i Process starts which is by nature an Steno ee heating effect changes the oil flow Characteristics, Its = ae sweep efficiency |S Increased and it tries to Move t Bae eel _ production wells. aise a In ARTIFICIAL IGNITION, the ignition a along with a burner and thermocouple the perforation face. Th ccessories are lowered Wire into the sand fac rough wire line some rile ) the sand face by ch: the air / gas ratio through the ignition trailer. The Syn Saas compound catches fire in pres is the lowest part of the Dae eaaTar es ralec a eo injection through compressor plant is coi heat away from the ignition well and close to the production well Initially rate of injection is minimum, this rate increases at regular Intervals and injection rate approaches the peak rate in about 3- 4 months. This phase of only air injection is called DRY PHASE of IN-SITU. After this by the help of Work Over Rig burner and ignition accessories are retrieved and well is made teady of Injection of air and water on cyclic way through tubing only. This process of injection of air and water into wells in cyclic pattern of six-day air and one day water in a week is called WET PHASE. Water injection is helpful to carry the heat away from the well. Moreover the steam generated in the heat zone also helps to push the oil towards the production well. ntinued to propagate the AIR INJECTION SYSTEM: For fulfilling the requirement of In-Situ process, high-pressure compressed air and water are required. Air is required at the rate _ of 21000-91000 (peak rate) NM‘/day, per well at a pressure of 99- 1150kg/cm’g. Based on initial feasibility report the total Injection system capacity required is 3.5 MM NCMD (peak requeney To cater to the compressed air requirement at SANTHAL Mi i ICP, 6 compressor trains (5 operating & 1 standby), each o'capacity 29600 NM°/Hr compression Capacities at a discharge pressure of 122 kg/cm’g has been installed. Each compressor train consists of one centrifugal Low Pressure (LP) compressor followed by a reciprocating High Pressure (HP) compressor. The LP compressors are high volume three stage centrifugal compressors. In this compressors air pressure is increased to 9.5 kg/cm2 from atmospheric pressure. This air is fed to three stage HP compressors where pressure is increased to 123 kg/cm2. This high pressure air is distributed to the individual wells through well manifold. The exact rate of air is governed by IRS. This plant is divided into three distribution centers. Altogether 70 wells have been planned for ignition in the span of 17 years. Santhal main is attached with 36 wells . There are two Distribution centers at a distance of almost two km on each side of the plant where 16 well are attached in each centre. From the well manifold only a single line is connected through which both air and water are injected. WATER INJECTION SYSTEM: The water is required to be injected at the rate of minimum to maximum of 5576 mi/day (peak requirement) at a pressure up to 115 kg/cm’g For fulfilling the requirement 7 water injection pump (6 operating and one standby) have been installed. In this plant partially treated effluent comes from the North Santhal ETP. Before going to the individual well the water is polished by adding chemicals like anti corrosion, flocculant's, inhibitors, emulsifier and then passing through a series of filter like pressure sand filter, Dual Media filter and Activated Carbon filters. A 4 cell cooling tower runs to cool the secondary water .Part of this cooling tower water is polished to use as injection water.| | [anna 93) waAYISANHA | ___wremdo ‘F 4 | “manana aay aN NEREND 3003 08 [asa | Shivis zogei FS ‘ave tog an NoUDarN ay [ana nowoarn [ | possaume> ea Nolvonaat70-W O/SIA/ASHO/NS/LS/NHW. vox auord astou [puuosiod UL Wonerodo ayeg-: ompaooig sooutiua Buppiom -sdumd say, 10-dW uonmuoumnsuy | — axp uo asiou Surjooo pue uonsafur A/SWE/ASHO/INS/LS/NH. Sp1ooex 2p Aq stout xis Kang Jo perdu TWA ‘stossordu0 | pO Ni Aeams sion ~ uejq | ampooord way OAs OsION, ou aonpoy a1 dH woyosion | 7g s10,¢9,pur Spadsy [eruomuoraug | -on 20UD19;0y aoueunt0y.19q syo8aey, aanralqo, aVIyTUsIg, padsy C [ WOHd/a/ASHOMAS/LSINEI ‘ON ‘D0@ ASH vloTPOzD WSINVHOGIW \ 0 ae pass JOWINOD GNV saayZVE Ssao0ua NV 1a ASNOdSa AONIOWAWATaIEM/, ToyeaviTe oInssasd aanssoad yBry Jo asvojer yry Jo aseayor Bunse) ospsy enp uosiad 0} sornfut onp suosiod 0) | 2:pored/ssueuaturEyy, | jeorskyd prone OL 09 | _soxmfur peorskyd sjossoa aunssaid |“ PAT spaezey | “ON wonepuaUmUr039y afao | 4sRe usra | Joadoag pasnea | 38. WOHd/daa/ASHO/INS/LS/NHW "ON “O00 aSHO IWSINVHOGW ylorroz0 +? ALVA ANSSI JOULNOD GNV SGYVZVH SSIQOUd Z0 *ON ANSSI NV Id dSNOdSaa AONAONAWAMedical / Emergency Evacuation: For smooth completion of the evacuation process, the responsibilities are divided into the following key personnel. 1 Installation Manager a) Will determine in consultation with the first-aider! Doctor that the situation is serious enough to warrant a Medical Evacuation especially during night hours. b) Will ensure that adequate first aid is provided to the patient and will designate responsibilities to key persons. ¢) Will communicate with the Base Manager and the ambulance in charge to identify self, patient, location of incident, nature of iliness/ injury to ensure preparedness for initiating evacuation d) Shall assist the ambulance crew end clector as required once the ambulance arrives to evacuate the pati nt, 2 First Aider / Will provide the tor mation ¢ condition of the patient and the nature of the injuries to the ambulance attendant and to the approved medical centre. First aid trained personnel must be deployed at all work centers finstaliations and in each shift. After first-aid the victim must be taken to ¢ relevant information about the ac: 1. Full Name. designation, age Contact details 2. Details of the ace! Person. , addres s of the patient(s) and family ident or symptoms 3. First aid/ treatment administered on the installation, 4. Patients blood group. 5. Known allergies (asthma, medications ete...)Special Medical Considerations (hypertension, diabetes etc..) (Note: The above information can also be provided by giving a copy of PME report available at installation) Based on the nature of the injurylillness, the first-aider/Doctor shall ensure that necessary medical equipment and facility is made available ‘on the ambulance during transit from the installation to the Approved Medica! Centre. He should also ensure that the patient is safely transferred and secured in the ambulance, c) Based on the candition of the patient and strength of the ambulance crew, the First Aider/Doctor will recommend to the installation Manager whether a first aid qualified attendant to travel with the patient. 3 Base Manager / Location Manager a) Will receive information from the Installation Manager and will notify the Ambulance incharge, Approved Medical Centre, family of the patient and his superiors. ) Will auithorize the Ambulance In charge to dispatch an ambulance to the installation in question and will inform the Installation Manager about the ETA of the ambulance at the Installation. ¢) He shall co ordinate with all concerned parties to ensure that the patient is transported to the Approved Medical Center (AMC) with minimum delay. d) Will Liaise with the nearby Police Station to notify them of the accident as por local law. 7 with the Base Poctor! First Aider to ensure that the Gentre is prepared to revive and ‘reat the patient.f) Will designate the Base Doctor to be present at the AMC to ensure that the patient's treatment is expedited and will inform the Installation Manager as and when the patient has been admitteditreated at the AMC. 4. Shiftin charge a) Will ensure that the patient reaches the AMC and will be responsible for relaying information. b) Will keep Installation In charge and Base Manager informed about arrival and departure times of the ambulance. ¢) Will Liaise with the nearby installation to arrange for altemative transport to ensure speedier evacuation of the patient. Base First Aider/Doctor 2) Liaise with the AMC to ensure preperodness to receive and treat the patient. b) Take copy of PME report (for quick Med. History) of the patient available at the dispensary record c) Accompany patient to the AMC and administer treatment, if necessary, during transit. 4) Will inform Base Manager and Installation manager as and when the patient has bean admittedltreated at the AMC. E. Disaster Alarting Process The ERP and the Onsite DMP should indicate the emergency alerting procedures in case of a specified emergency. For this purpose, two levels of alerting procedures should be indicated and detailed, - First AlertThe 4* alert should be one when certain initial procedures are to be followed by the person who first receives information referring to a serious incident. For example, in @ toxic gas leak situation the person may take an isolation action, pass information to the Emergency Control. Room. {ECR) and may also physically raise an alarm by shouting. 41. Second Alert inthe 2” Alert system, certain procedures are to be adopted after an jnitial assessment of the situation at site which requires additional responses in terms of authority and resources. Such procedures, for example, could be passing information to higher authorities, requisitioning and deploying additional help that is necessary to prevent further escalation of the event. it may involve evacuating people to safer places, shifting of essential materials from nearby area, jsolation of power supply etc. Include the following Annexure in Roles and responsibility:it . he 1° alert should be one when certain initial procedures are to be lowed by the person who first receives information referring to a serious incident. For example, in a c gas leak situation the person may take an isolation action, pass information to the Emergency Control Room (ECR) and may also physically raise an alarm by shouting. 11. Second Ale! t in the an Alert system, certain p are to be adopted after an initial assessment of ti at site which requires additional responses in terms of authority and resources. Such procedures, for example, could be passing information to higher authorities, 10! requisitioning and deploying additiona: help that is necessary to prevent further escalation of the event. it may inv evacuating people ial materials from nearby area, to safer places, shifting of isolation of power supply etc. lowing Annexure itt Roles and responsibility: