Pakistan Oilfield Limited

University of the Punjab, Lahore

BSc. (Eng.) Energy Engineering

COURSE TITLE:
Internship Report

DURATION TIME:

06 Weeks

SUBMITTED BY:

Muhammad Adnan

SUBMITTED TO:

Senior Electrical Engineer Mr. Muhammad Ali Akram

SUBMISSION DATE:

20th JULY 2023.

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Table of Contents
Section 01.............................................................................................................................................................4
Introduction to POL..............................................................................................................................................4
Introduction......................................................................................................................................................4
Section 02.............................................................................................................................................................5
HEALTH SAFETY & ENVIRONMENT Department (HSE)..........................................................................................5
Introduction......................................................................................................................................................5
Safety................................................................................................................................................................5
Small-scale fire.................................................................................................................................................7
Large Scale Fire.................................................................................................................................................7
Hydrogen Sulfide (H2S) Gas..............................................................................................................................8
Section 03...........................................................................................................................................................12
Pari Wali Production Facility (PPF)......................................................................................................................12
Introduction....................................................................................................................................................12
Inlet Separation.............................................................................................................................................12
Oil Stabilization..............................................................................................................................................12
Amine Sweetening.........................................................................................................................................12
Glycol Dehydration.........................................................................................................................................13
Auxiliary units.................................................................................................................................................13
Explanation.....................................................................................................................................................15
Amine Sweetening..........................................................................................................................................17
GAS SWEETENING...........................................................................................................................................18
Glycol Dehydration..........................................................................................................................................20
AUXILLARY UNITS............................................................................................................................................22
Section 04...........................................................................................................................................................24
Khaur Power House................................................................................................................................24
Generators:.....................................................................................................................................................24
Governor:........................................................................................................................................................25
Switch Gears...................................................................................................................................................26
Circuit Breakers:..............................................................................................................................................26
Transformer....................................................................................................................................................27

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 Parts of Transformer:......................................................................................................................................27
Transformer Winding......................................................................................................................................28
MOTORS..........................................................................................................................................................30
Variable Frequency Drive (VFD)......................................................................................................................32
Adjustable Speed Drive (ASD).........................................................................................................................34
Comparison of ASD and VFD...........................................................................................................................36
Pumping Section.............................................................................................................................................37
Section 05...........................................................................................................................................................38
Instrument Department......................................................................................................................................38
Programmable Logical Controller (PLC)...........................................................................................................38
PLC INPUTS AND OUTPUTS.............................................................................................................................38
SCADA.............................................................................................................................................................39
Comparison between PLC & SCADA................................................................................................................39

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Section 01
Introduction to POL
Introduction
Pakistan Oilfields Limited (POL) is a subsidiary of Attock Oil Company Ltd and was incorporated
on November 25, 1950, as an oil exploration and production company. The Attock Company has
discovered oil at:

 Khaur 1915
 Joyamair 1944
 Dhulian 1936
 Balkassar 1946
 Karsal 1960
 Meyal 1968

Under an agreement with the Government of Pakistan, POL took over AOC's oil and gas
exploration, production, gas processing, and transmission activities. Currently, the company is
quoted on all three stock exchanges in Pakistan. The company pioneered 3-d seismic acquisition
and its interpretation of state-of-the-art technology. POL has successfully drilled horizontal
wells in the Meyal, Turk Wal, and Pindori oilfields which are highly complex tectonic areas of
Pakistan. POL has exploration and production joint ventures with OGDCL, Orient Petroleum Inc.,
Tullow Pakistan (Development) Limited, MOL Pakistan Oil and Gas Company, B.V., and Pakistan
Petroleum Limited. POL has gas processing plants at Meyal, Pari Wali, and Pindori fields.

POL operates an extensive pipeline network for the transportation of crude oil from fields to
Attock Refinery Limited at Rawalpindi. In addition to exploration and production of
hydrocarbons, the company also produces and markets Liquefied Petroleum Gas (LPG), sulfur,
and solvent Oil. POL holds a marketing license for LPG and is selling bottled LPG under the
brand name of POLGAS POL continues to pursue an aggressive oil and gas exploration program
in Pakistan and acquires reserves as well as participates in low to medium-risk prospects in
joint ventures with reputed oil companies
To be Pakistan's leading oil and gas exploration and production company with the highest
proven hydrocarbon reserves and production, which provides optimum value to all
stakeholders.

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Section 02
HEALTH SAFETY &
ENVIRONMENT Department
(HSE)
Introduction
Health, safety, and environment are important factors for the survival of human life in this world
and these are closely interlinked with each other. Good health and safe working conditions are
of utmost importance in any engineering company to increase productivity and reduce time
losses. The safety of employees and workers is the top priority of any organization. The major
hazards are fire Anand hydrosulfide gas (H2S) release. All the hazards are mentioned below,

1. Fire 2. Snake bites

3. Electric shocks 4. Leakage in crude oil pipelines
5. Release of H2S gas

Safety
Safety means zero accidents. The department of HSE creates awareness about safety. They brief
people about possible hazards in the working areas and how to avoid them. The priority is
always given to human life and the mechanical equipment in the working vicinity.

In the petroleum industry there are two major types of hazards:

 Fire Hazard
 Gas Hazard (H2S)
Fire
Fire is an exothermic chemical reaction between fuel and oxygen at elevated temperatures to
produce water and carbon dioxide.

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Chemical Representation:

CAHB + O2 CH2O + DCO2

Fire triangle:
A fire triangle is a hypothetical triangle that represents 3
requirements for a fire to exist. As long as Heat, fuel, and
oxygen are available to the fire, the triangle is complete and
the fire will continue to burn. Therefore, the basic principle
of firefighting is to break ‘the fire triangle’. Depriving the
fire of fuel, oxygen or heat is the solution to control the fire.

Methods to control a fire:

1. Starving: Remove the supply of fuel to the fire

2. Cooling: Remove the heat by cooling, such as water sprinklers.

3. Smothering: Remove the oxygen from the fire such as by using foam.
Fire can be categorized according to the fuel type and medium to control it.

Classification of Fire

Type Material (fuel) Medium to Control

A Class Solids e.g., wood, cloth, paper Water + Dry Chemical Powder
(DCP)

B Class Liquids e.g., crude oil, petrol, diesel, LPG DCP, Fluro protein (FP 70)

C Class Electric fire and Gas fire Carbon dioxide gas (CO2)

D Class Metal Fire e.g., Aluminum molding Lead powder

Small scale fire

Small-scale fires can be controlled using fire extinguishers. There
are three types of fire extinguishers,

1. Pressurized (CO2)

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 2. Internal Cartridge (DCP + CO2)
3. External Cartridge (DCP + CO2)

How to use a fire extinguisher: If the fire is in an open place, always stand in the
direction of the wind to be able to use the fire extinguisher closer to the fire and avoid the heat. A
technique called PASS is used to operate a fire extinguisher.

P = Pull the pin

A = Aim at the base of the fire
S = Squeeze the handle
S = Sweep from side to side

Characteristics of fire extinguishers:

Type Range Operating time
DCP 12 to 14 feet 16 seconds
CO2 9 feet 90 seconds

Large Scale Fire

Fire Network system: A fire network system is present at Khaur field that is active 24/7 to
control any fires in case of emergency. It includes pressurized underground water pipelines laid
across the field and a pumping station. Two engine-driven pumps and two motor-driven pumps
are used at the pumping station. All the pumps are centrifugal pumps. A motor-driven pump
maintains a pressure of around 100 psi in the pipeline and is kept on all the time.

Only one engine-driven pump and one motor-driven

pump are required for the operation of the fire
system. The others act as backups in case of failure.

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A control room is used to operate the engine-driven pumps. The engine-driven pumps are
cranked using two 12 V batteries in series. Below is a picture of the control room.
The motor-driven pumps can operate at 1400 rpm
while the engine-driven pumps can operate at
2100 rpm.

Fire Truck: A fire truck is operational in the

field. It has 2 pumps. One is driven by the truck’s
engine while the other has a separate engine and
can be used as backup.

Hydrogen Sulfide (H2S) Gas

H2S gas is a major hazard in oil and gas fields and it
can be fatal if safety measures are not taken.

Properties of H2S gas:

 Commonly known as “killer gas”.
 H2S is 1.189% heavier than air.
 Rotten egg-like smell
 As H2S is heavier than Air so it stays near the ground.
 Soluble in water.

Classification on the bases of concentration:

 Up to 10 ppm H2S: Working with 10 ppm H2S in the air for 8 hours headache and
unbalancing.

 Up to 20 ppm H2S: Working with 20 ppm H2S in the air is safe, if ‘gas masks with filters’
are used.

 Up to 100 ppm H2S: Working with 100 ppm H2S in the air damages the sensing power of
the worker. Therefore, as long as a worker can smell H 2S gas, it’s safe for him/her to work
in that environment and when the worker starts to lose his/her senses, he/she should
immediately move to the open air.

 Up to 200 ppm H2S: At 200 ppm concentration of H 2S gas, workers have to leave the
environment within 2 to 15 minutes.

 Up to 500 ppm H2S: At 500 ppm concentration of H 2S gas, workers have to leave the
environment in 3 minutes.

 Up to 700 ppm H2S: 500 ppm concentration of H2S gas is damaging for the workers. No
time to get out of the system.

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  1000 ppm H2S: Exposure to 1000 ppm H2S gas causes immediate brain hemorrhage.

The concentration of H2S gas at Khaur field, POL:

 8000 ppm H2S

Problems in handling H2S gas:

 Highly soluble in water.
 It damages the sensing power of humans, so it can only be handled with proper life-
support kits.

H2S Gas detection:

 H2S sensors are installed in different units
of the plant, which are controlled by PLC
and give an alarm when H2S concentration
increases 10ppm.
 Gas meters are used to detect the
concentration of all the gases present in the
working environment.
 At Khaur field, the HSE department has gas
meters but ‘DRAGER x-am-5600’ is mostly
used to detect the concentration of gases in
the environment.

H2S gas can be found in:

 Oil wells

 Sewerage

 Near crude oil

 Drainage systems

 Coal mines

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How to work in environments having high H2S concentrations in the air?
There are two main categories of safety apparatuses used according to the concentration of the H 2S
gas in the working environment. Gas masks with filters can be used by workers while working in
low H2S concentration environments such as 10ppm to 30ppm.

Life support apparatuses:

Two types of apparatuses are commonly used by workers in high-concentration H2S environments:

SCBA ELSA

SCBA
A self-contained breathing apparatus, or SCBA, sometimes referred to as a Compressed Air
Breathing Apparatus (CABA), air pack, or simply Breathing Apparatus (BA) is a device worn by
rescue workers, firefighters, and others to provide breathable air in an IDLH (Immediate Danger to
Life and Health) Atmosphere. When not used underwater, they are sometimes called industrial
breathing sets. The term "self-contained" means that the breathing set is not dependent on a
remote supply (e.g., through a long hose). If designed for use underwater, it is called SCBA (self-
contained underwater breathing apparatus).

A SCBA typically has three main components: a high-pressure tank, a pressure regulator, and an
inhalation connection, connected and mounted to a carrying frame.

SCBA
Self-Contained Air Breathing Apparatus
Sr Properties of SCBA
.
Capacity of cylinder 6 liters
1
Pressure 200 bars
2
3 Working time 30 minutes
4 Safe time 25 minutes
5 Evacuation time 5 minutes

Disposal of H2S gas:

At Khaur, H2S gas is burned at the plant site to be converted to sulfur dioxide gas.

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Leakage in pipelines:
The department of HSE also handles the leakage in gas and crude oil pipelines. Patrolling teams
inform HSE of any leakages and HSE takes necessary action to stop the leakage.

Snake bites:
Snakebite is a biological and occupational hazard and is 4 th most common hazard in the Khaur
field.
Reason: Snakes have been cited at the plant due to rising temperatures in the summer.
Role of HSE:

HSE workers are professionally trained to kill the snakes in plants by using sticks and special
snake-catching equipment. First AID for snake bite:

1. Clean the bite area 3. Cover with a bandage

2. Coat with antibiotic 4. Commute to the hospital

Things not to do after a snake bite:

1. Shock the bite site 3. Suck the venom out

2. Suspect you will die 4. Slice open the wound

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Section 03
Pari Wali Production Facility
(PPF)

Introduction
The Pari Wali Production Facility (PPF) processes raw, sour gas into marketable oil and gas. To
achieve these following processes are used:

 Inlet separation
 Oil Stabilization
 Amine Sweetening
 Glycol Dehydration

Inlet Separation
Raw sour gas is subjected to three stages of inlet separation. The separators divide the raw,
sour gas into its gas, oil, and water components. Separated gas from the first separator is
directed to the amine sweetening and glycol dehydration processes. Separated oil from the
second separator heads to the third separator and finally feeds the soil stabilization process.

Oil Stabilization
Separated sour gas and sour oil from the third stage of separate testers the stabilization unit. In
the oil stabilization process, a distillation tower (stabilizer) removes the light and medium
hydrocarbon vapors from the oil to reduce its volatility. If required, the bottom injection of
sweet gas assists in stripping the remaining acid gases from the oil from the stabilization
process is of sales quality and is cooled and stored on-site to await pipeline delivery to market.

Amine Sweetening
An amine solution is used to sweeten the sour gas fed from the first stage of inlet separation. In
the sweetening process, the amine solution becomes “rich” or laden with acid gases from the
sour gas in an absorber tower. The rich amine solution is then regenerated so that it can be
recirculated to sweeten further sour gas. Amine regeneration involves.

 Steam stripping in a regeneration tower to remove acid gases

 Flaring the removed gases

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 After regeneration, the amine is considered “lean” and is cooled before storage for recirculation
through the amine sweetening process. The process also includes filtration to remove
contaminants and particulate from the mine.

Glycol Dehydration
A glycol solution is used to remove moisture from the sweetened gas. In the glycol dehydration
process, the glycol solution scrubs water from the sweet gas. The glycol solution becomes “rich”
or laden with water in an absorber tower. The rich amine is then regenerated so that it can be
recirculated to dehydrate more sweetened gas. Glycol dehydration involves

 Flashing to remove hydrocarbons from glycol.

 Steam stripping in a regenerator tower and gas stripping (if required) in a
supplementary stripper to remove most of the water.
After regeneration, the glycol is considered lean and is cooled before storage for recirculation
through the glycol dehydration process. The process also includes filtration.

Auxiliary units
Auxiliary units are also installed to assist the Pari Wali Production Facilities which are as follows

 Flare gas system

 Instrument Air system
 Heating medium system
 M-unit compressor
 S and T unit compressors

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14
 Explanation
Following is a detailed description of the processes that are being done in the Pari Wali Production
Facilities.

Inlet Separation: Inlet separation is the first process in the Pari Wali Production Facilities
in which three separators divide the raw, sour gas into its gas, oil, and water components. PPF uses
three stages of inlet separation (multiple separations) at successively lower pressures that
contribute to a more recovery of hydrocarbon liquids otherwise there would be a large pressure
drop those results in the aggressive flashing of heavy hydrocarbons decreasing the liquid
hydrocarbon recovery

PROCESS FLOW SUMMARY: Raw, sour gas enters the High pressure (HP) separator/inlet slug
catcher from which sour water is dumped into the sour water tank. The separated high-pressure
gas goes to the amine sweetening unit while the crude flows to the medium-pressure separator.
From the medium-pressure separator, the gas goes to the M-unit for compression while the crude
flows to the Low pressure (LP) separator through a heat exchanger. The heated crude is then sent
to the stabilization unit for stabilization.

High-pressure separator (V-100)

The HP separator/inlet slug catcher is a horizontal three-phase separator operating at high
pressure that uses gravity, retention time, and coalescing elements to disengage water and
gases from the crude oil. The incoming raw, sour gas strikes a diverter plate at the entry
which absorbs the incoming flow’s momentum. Due to this abrupt change in the flow’s
momentum, the gas disengages from the liquids. The liquid passes through a coalescing
mesh and crudely separates into a distinct layer at the top of the water. The water and oil
are drained in the sour water tank and MP separator respectively through level control
valves LCV 100 and LCV 102 which are controlled by their respective controllers.
Medium pressure (MP) Separator (V-110)
MP separator is a horizontal 2-phase separator that uses gravity and retention time to
separate gas and crude and it operates at a lower pressure than an HP separator. There is a
diverter plate that absorbs the inflow momentum and disengages the gas from the liquid.
The liquid is drained by LCV 110 to an LP separator through a crude oil pre-heater E120.
The gas is passed to the S and T unit for compression through PCV 110 before which a mist
eliminator coalesces the mist from gas.
Low pressure (LP) Separator (V-130)
LP separator is a horizontal 3-phase separator that uses the same principles as the HP
separator to disengage gas from liquid. LP separator is working at a pressure lower than the
MP separator. The heated liquid is drained to the oil stabilization unit by LCV 131 while PCV
131 directs the gas to the M-unit for compression.

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Sour Water Flash Tank (V 140)
The sour water flash drum is a horizontal drum that removes sour gas and hydrocarbon
liquids from the water that is drained from the HP separator. The water enters the flash
drum from the top inlet nozzle. From the nozzle, a horizontal discharge pipe extends into
the separator which disengages the sour gas from the water. The water settles down after
passing through a coalescer.
Oil Stabilization
In the oil stabilization unit, the volatile hydrocarbon gases and acid gases are removed from the
crude oil. Removing these gases results in an oil that meets the sales specifications for low
volatility and low acid gas content.

This process is of prime importance as the removal of volatile hydrocarbons reduces the
evaporation losses from the oil when it is stored and handled at atmospheric pressure. Also, the
sweetened oil does not present the H2S toxicity hazard.

 Distillation: the segregation of low volatile components from a mixture of multiple

components through proper heating. With oil being a mixture of hydrocarbon
components, distillation involves the heating and partial vaporization of oil so that the
lighter hydrocarbons concentrate in vapors and heavier hydrocarbons concentrate in
liquid.
 Stripping: is the operation whereby the dissolved acid gases of a liquid steam are
removed with another gas stream. The sour oil fed to the stabilization unit is sweetened
by the injection of sweet fuel gas that strips the acid gases from the oil.

PROCESS FLOW SUMMARY In a distillation tower, known as a stabilizer the volatile hydrocarbons
are removed from the incoming oil stream. Oil stabilization is achieved through the input of heat at
the base of the tower. A reboiler partially vaporizes the oil drained from the base and then supplies
this hydrocarbon vapor to the tower. The rising vapors heat and drives off light hydrocarbons from
the oil.

 Stabilizer (V 600) The sour oil from the LP separator is fed to the stabilizer which is
a distillation tower equipped with 14 valve trays. The oil enters from the top tray and starts
flowing downwards. At the same time, the rising heated stream of heated hydrocarbon
vapors generated from the reboiler and the supplementary sweet fuel gas stream rises
upwards. At each tray, the rising gas blows open the tray’s valve and bubbles through the oil
flowing crosswise over the tray. Two operating problems may occur during the distillation
tower operation
1. Weeping: in which at low flow rates of gas the oil weeps down the tray through the
valves instead of their correct flow path.

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 2. Flooding: is a tower problem to obtain a net downflow of liquid through the tower. It
may be caused by an excessive gas flow rate up through the stabilizer or an excessive
liquid flow rate fed to the stabilizer.
Stabilizer Reboiler (H 610): It is like a shell tube heat exchanger and is commonly known as
the kettle-type reboiler. It has an internal tube bundle through which the thermal fluid heat
medium circulates. Given that the tube bundle is submerged in the cooler shell side of the
oil, heat is transferred to the oil to boil off some of the medium hydrocarbons. The shell is
enlarged so that a large vapor space is available to allow volatile hydrocarbons to disengage
from newly boiled oil. A level controller LC-610 monitors the oil level in the reboiler and
drains the oil to the stabilizer through LCV-610 while a temperature controller monitors the
temperature in the area of the tube bundle.

Amine Sweetening
Amine sweetening is a process based on a reversible chemical reaction between acid gases (H 2S
and CO2) and a family of weak organic bases known as alkanol amines.

In the chemical reaction that sweetens the sour gas, a neutralizing action takes place. Under high-
pressure and low-temperature conditions in the amine contactor, the aqueous solution of amine
absorbs and reacts with the acids to form water-soluble salts. (Rich amine loading).

The type of amine used at PPF is methyl Di ethanol amine (MDEA). Compared to other amines,

 MDEA has a high selectivity for H 2S in the presence of CO2. This allows a strong removal of
H2S while avoiding excessive CO2 removal which would otherwise cause a reduction in the
volume of gas.
 MDEA does not react with CO2 to form degradation products.
 MDEA permits a lower amine circulation rate and demands less pumping horsepower

PROCESS FLOW SUMMARY: The sour gas from the HP separator enters the absorption tower from
the bottom after passing through a double barrel filter and MDEA is showered from the top. The
amine unit thus constitutes the following processes

A. Gas Sweetening
B. Rich Amine Flow to Regeneration
C. Amine Regeneration
D. Lean Amine Flow and filter action

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 GAS SWEETENING
The sour gas is filtered through a double barrel filter and is fed to the amine contactor where it
enters from the bottom and lean amine is showered from the top.

 Inlet filter separator (F 200): It is a horizontal double barrel separator using an internal
filter core, gravity, and retention time to remove solid contaminants and hydrocarbon
liquids from the sour gas that arrives from the HP separator.
1. Amine Contactor (V 210): It is an absorber tower with 20 valve trays, where the sour gas
is sweetened by lean amine flowing from the top. During the amine/sour gas contact at
each tray, the amine absorbs the acid gases and becomes richer while the gas becomes
sweetened. Tray 1: Injecting lean amine at tray 1 results in all 20 of the trays working
efficiently to remove H2S and CO2. Feeding amine at this tray results in the highest
removal of H2S and CO2.
2. Tray 5: When lean amine injection at tray 1 results in satisfactory H2S removal but
excessive CO2 removal, consideration may be given to feeding the lean amine at tray 5. In
this way, all the trays above tray 5 become inactive in removing the acid gases.
3. Tray 9: When the lean amine injection at tray 5 results in satisfactory removal of H 2S but
excessive removal of CO2, the amine may be injected at tray 9. This results in the
inactivation of all the above trays and hence a lower removal of acid gases.

The rich amine is dumped into the flash tank using LCV-210 controlled by LC210.

Amine contractors may experience the problem of foaming-based carryovers. It occurs

when the contaminants rise and due to condensation produce stable foam. This stable foam
fills the area between trays resulting in excessive entrainment of amine liquids by the rising
gas and a loss of amine sweetening.

Sweet gas Scrubber (V 220): It is a vertical scrubber using an internal filter core to coalesce
and recover the entrained amine mist. The gas enters the scrubber and rises upwards
through the filter elements which coalesces the amine droplets. The amine droplets then
pool at the bottom while the gas is directed to the Glycol dehydration unit. The amine is
drained to the flash tank by actuator LCV-220.

RICH AMINE FLOW TO REGENERATION

After leaving the absorber, the amine goes to the flash tank in which there is a strong reduction in
pressure causing the absorbed hydrocarbon vapors to condense. The rich amine then flows
through the heat exchanger to absorb heat and goes to the amine regenerator.

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  Rich Amine Flash tank (V 230): It is a vertical, two-phase separator using gravity and
retention time to remove hydrocarbons from amine. The sudden reduction of pressure
in the flash tank causes the hydrocarbons to condense and settle at the bottom and are
skimmed off manually. The reduction of pressure also contributes to the achievement of
conditions necessary for the amine regenerator.
 Lean/Rich Amine Exchanger (E 240): It is a plate and frame heat exchanger, where the
rich amine warms up and the lean amine from the regenerator partially cools up.

AMINE REGENERATION
After being warmed in the heat exchanger the rich amine flows to the regenerator tower from near
the top through the rising stripping steam. The steam’s heat breaks down the water-soluble salts
and strips the acid gases.

 Amine Regenerator (V 300): It is a stripping tower operating at low pressure having 3

packed beds of metallic ranching rings each resting on a support tray. They are used for two
reasons. First, they can be replaced at a lower cost after being corroded.
 Amine Reboiler (H 310): It is a shell and tube heat exchanger in which heated sun oil enters
the tubes while lean amine is in the shell. The lean amine flows from below the reboiler
while the steam exits from the two top outlet streams. A level controller LC-310 drains the
lean amine to the amine accumulator by LCV-310.
 Reflux Condenser (E-370): It is a horizontal tube fin heat exchanger. The acid gas and steam
from the regenerator pass through the finned tubes which are condensed by a fan-
generated air stream passing over the outer surface of the tube. A proper reflux
temperature is important as too hot reflux may not condense the amine vapors rising in the
top packing. Also, a too-cool reflux makes a load on the reboiler.
 Reflux Accumulator (V 380): It is a vertical two-phase separator using gravity and retention
time for separation. The acid gases pass through a mist eliminator and are flared by PCV-
380. The LCV-380 dumps the reflux to the regenerator via centrifugal pumps.
 Reflux Pumps (P-385 A/B): It is a pair of centrifugal pumps in parallel. One is lead
(operational) while the other is lag (non-operational They are driven by a 2-horsepower
motor.

AMINE FLOW AND FILTRATION

The hot lean amine from the reboiler passes through the plate and frame heat exchanger
E-240 to the amine accumulator. From here the amine is sent to the fin fan cooler for further
cooling. After that, the amine is subjected to filtration and then its pressure is increased by PD
pumps so that it can be fed to the amine contactor.

 Lean Amine Accumulator (V 320): It is a horizontal drum that stores the lean amine after it
passes through the heat exchanger plate and frame heat exchanger E-240. It has a diverter

19
 plate at the inlet that disengages any gas in the amine. A BPCV-320 opens if, the pressure in
the accumulator increases and the acid gases are flared.
 Lean Amine Booster Pumps (P-325 A/B): A pair of centrifugal pumps driven by a single
motor of 7.5 horsepower. They draw lean amine from the accumulator and discharge it to
the amine cooler E-350.
 Lean Amine Cooler (E-350): It is a horizontal tube fin fan heat exchanger. This aerial cooler
is a forced draft type. A 9 feet diameter underside fan forces an upward draft of air. The lean
amine cooler must cool the amine so that it is 5-10 0F warmer than the sour gas.
 Amine Particle Filters (F-330 A/B): These filters filter the solid contaminant particles that
may trigger foaming or plugging in the equipment. They have a differential pressure gauge
that gives the pressure difference at the two sides of the filter.
 Carbon Filters (F-340): This filter has a charcoal filter that adsorbs any traces of
hydrocarbons left in the lean amine. It also has a differential pressure gauge.
 Lean Amine Charge Pumps (P-355 A/B) : This is a pair of positive displacement pumps
placed in parallel, driven by a 40-horsepower motor.

Specialty chemicals are added to lean amine in the amine accumulator V 320, such as antifoaming
agents to reduce foaming and corrosion inhibitors to reduce the corrosion abilities of acid gases
absorbed in the amine.

Glycol Dehydration
The glycol dehydration process removes the water vapors from the sweet gas so that the gas meets
the required sales specifications of low water content. Glycol dehydration is based on the physical
absorption of water vapors by a family of liquid desiccants known as glycols. The physical
absorption of water vapor in glycol occurs at low temperatures and high-pressure conditions.

The glycol dehydration at PPF uses Tri Ethylene Glycol (TEG) because

 It has high thermal stability. The temperature at which heat decomposition begins is 404 0F.
 It is regenerated efficiently to high glycol concentration because of the large boiling point
difference between TEG and water.
 It has low evaporation losses due to its high boiling point.
 TEG along with other glycols are extractants of carcinogenic aromatics BTEX compounds.
TEG has a high affinity for the BTEX compounds although they are removed during
regeneration.

As a glycol, TEG can be degraded by

 Oxygen contamination- as oxygen and glycol react to form corrosive acids.

20
  Overheating Glycols- above their decomposition temperature results in glycol breakdown
and the formation of corrosive acids.

PROCESS FLOW SUMMARY The sweet gas enters the glycol absorber where the glycol is introduced
from the top. The contact of sweet gas and glycol at each tray results in material transfer. The glycol
regeneration involves the stripping of water vapors from rich glycol to make it lean for
recirculation to dehydrate more gas.

Following are the steps in the glycol dehydration process.

A. Gas Dehydration B. Glycol regeneration

C. Lean Glycol Flow D. Rich Glycol filtration and flow to the regenerator

GAS DEHYDRATION
Gas dehydration takes place in an absorption tower where the sweet gas enters from the bottom
and glycol is showered from the top.

 Glycol Contactor (V-400): It is an absorption tower having 9 bubble cap trays. The sweet
gas enters from the bottom and rises upwards through the slots in the trays while the
lean glycol enters from the top and flows downwards crosswise over the trays.
 Sales gas Separator (v-410): It is a vertical separator that coalesces any glycol mist
carried from the dried gas. The incoming dried gas enters from the bottom and rises
through a mist collector. An LCV-410 dumps the liquids into the storage tank. In this way,
the sweet dried gas is sent to the main pipeline heading to the market pipeline.

RICH GLYCOL FILTRATION AND FLOW TO REGENERATOR

The rich glycol leaving the absorber enters a flash tank where a sudden pressure reduction causes
hydrocarbon vapors to condense and hence remove from the glycol. After flashing the rich glycol is
then filtered.

 Hydrocarbon Flash Tank (V 540): It is a horizontal two-phase separator using gravity and
retention time to separate hydrocarbon vapors. Due to a sudden pressure drop, a flashing of
hydrocarbon vapors occurs. The liquid glycol settles at the bottom of the tank and is drained
by LCV-540 while a BPV-540 maintains the pressure of the tank by flaring the hydrocarbon
vapors.
 Glycol Particulate Filters (F-550 A/B): These filters remove the solid contaminants from the
glycol that may otherwise increase the foaming tendency of glycol, increase the wear in the
glycol pumps or increase the possibility of equipment plugging.

 Glycol Carbon Filters (F-560): It removes the dissolved hydrocarbons from the rich glycol. It
has a porous charcoal element that adsorbs the hydrocarbons.

21
LEAN GLYCOL FLOW

The lean glycol from the storage tank is drained through a bank of the tube-fin heat exchangers for
additional cooling after which the glycol is pressurized by PD pumps and sent to the glycol
contactor.

 Air Glycol Cooler (E-535): It is a set of 6 horizontal tube fin heat exchangers and helps to
reduce the operating temperature of pumps.
 PD pumps (P-420 A/B): They draw the lean glycol from the air glycol cooler and increase
the glycol pressure in preparation for the high-pressure conditions of the glycol contactor.
 Glycol Cooler (E 430): It is a horizontal tube fin heat exchanger with an underside fan.
Specifically, a 4 ft. diameter fan forces an upward draft of air through the heat exchanger.
The E-430 cools the lean amine so that it is 10-15 0F warmer than the sweetened gas. This
temperature difference is important as overcooled glycol results in the condensation of
hydrocarbons causing foaming while excessively warm glycol causes the dehydrating
performance to decrease.

AUXILLARY UNITS
 FLARE SYSTEM: It gathers waste gases through safety valves. It provides the safe
disposal of
 Gases when depressurizing the facilities in case of emergency.
 Gases when depressurizing individual vessels.
 Concentrated acid gases are produced during amine regeneration.

 INSTRUMENT AIR SYSTEM:

It is the system in which the air is compressed and then dried to form pneumatic signals. These
signals are utilized to control the system at the local loop level. The set point of the controller is
given manually while these signals are used to control the opening and closing of valves.
 HEAT MEDIUM SYSTEM: This is a shell and tube type furnace in which the heating
medium in the coil of the tube is heated via means of a fire that is ignited from the sweet
fuel gas and 10% excess of air. The heating medium used in PPF is Exotherm 46, which is
also called sun oil.
 M UNIT: M-unit is commonly known as an LP compressor because it compresses the gas
from LP to MP.

22
  S & T UNIT: S/T units are commonly known as MP compressor as it compresses gas from
MP to HP. In the first stage, gas is compressed from a pressure of about 230 psi to 410 psi,
and from 410 psi to 800 psi in the second stage.

PPF Plant Diagram

RECOMMENDATIONS:
 DCS system should be installed instead of manual controlling of valves.
 All the damaged and non-operational valves should be replaced immediately for safety
concerns.
 Lightening Arrestors should be installed to prevent any damage by lightning.
 The use of anti-foaming agents should be minimum as their higher dose can trigger further
foaming.
 The temperatures of reboilers can be optimized to reduce the consumption of sweet gas
using HYSYS software.

23
Section 04
Khaur Power House
A power plant or powerhouse is an
industrial facility for the generation of
electric power. The powerhouse of
Khaur has a capacity of generating
3.29MW of electric power but the peak
load is almost in between 1.5 to 2MW.

Generators:
An electrical generator can be defined
as an electrical machine that converts mechanical energy into electrical energy. An
electrical generator typically consists of two parts: a stator and d rotor. There are various
types of electrical generators such as direct current generators and, alternating current
generators.

Main Components of Generator:

 Engine
 Alternator
 Fuel System
 Voltage Regulator
 Cooling and Exhaust system
 Lubrication System
 Battery Charger
 Control Panel
 Main Assembly/Frame
Securities of Engine

1. Low Frequency
2. Over Speed
3. High Frequency
24
 4. Generator Short Circuit
5. High Water Temperature

Generators specification:

Company Unit Tag Rated Power Model No. of

(kW) Number Cylinders

Waukesha 1 505 L590G 12

Waukesha 2 635 L7042G 12

Caterpillar 3 550 G399 16

Caterpillar 4 550 G399 16

Waukesha 5 525 L7042G 12

Waukesha 6 525 L7042G 12

Exciter:

Excitation systems can be defined as the system that provides field current to the rotor
winding of a generator. Well-designed excitation systems provide reliability of operation,
stability, and fast transient response.

The four common excitation methods include:

 Shunt or Self Excited

 Excitation Boost System (EBS)
 Permanent Magnet Generator (PMG)
 Auxiliary Winding (AUX)

Governor:
The governor is a device that varies the amount of fuel delivered to the engine to maintain
a constant speed. Without a governor, the engine would slow down and probably stall
when a significant load was added.

25
Switch Gears:
Switch gears are used in the Power Houses. That
describes the wide variety of switching devices that
all fulfill a common need: Controlling, Protecting,
and Isolating Power Systems. In po,l switchgear is
used for monitoring generators' Transmission lines
and the switch gears make sure that the lines going
towards specific POL areas don’t cause any hazards in case of failure. The KPH control
room mostly uses the air-type switch gear circuit breaker in the different lines.

Circuit Breakers:
Safety switches: Electrical devices that automatically interrupt the flow of electricity in a
circuit when a fault or excessive current is detected, protecting against electrical hazards.

Line Area Circuit Breaker

SS Bungalows, Hospital, Attock ACB

Pump, School

Labor Labor colony, Offices ACB

WPS Water pump station in Ikhlas ACB

KCDF 750V Pumps to send crude to ACB

Rawalpindi
(pumping)

KCDF 500V Decanting pumps ACB

(Decanting)

26
BUSBAR

Busbars are used in electric power distribution,

inside switchgear, panel boards, and busway
enclosures for local high-current power
distribution.

In pol 2 bus bars are used which are coupled.

This has been done to reduce the load on one bus
bar.

Transformer
A transformer is an electrical device that works on the principles of electromagnetic
induction, and transfers electrical energy from one electric circuit to another, without
changing the frequency. The energy transfer usually takes place with a change in voltage
and current. Transformers either increase or decrease AC voltage

There are many different types of transformers in use today. This resource will take a
closer look at Power Transformers, Auto Transformers, Distribution Transformers,
Instrument Transformers, Isolation Transformers, Potential Transformers, and Current
Transformers.

Parts of Transformer:
I. Core: Magnetic component made of laminated steel sheets that efficiently transfers
energy between primary and secondary windings.
II. Windings: Conductive wires wrapped around the core, carrying electrical current
and inducing voltage across the transformer.
III. Insulation: Material used to separate and insulate the windings, preventing electrical
leakage and ensuring safe operation.
IV. Tap changer: Mechanism allowing adjustment of the transformer's output voltage
to accommodate varying load conditions.
V. Cooling system: Method or equipment employed to dissipate heat generated during
transformer operation, ensuring optimal performance and longevity.

27
 VI. Bushings: Insulated devices used to connect the transformer to external circuits,
providing electrical isolation and support.
VII. Conservative Tank: Reservoir that allows for expansion and contraction of the
transformer's insulating oil as temperature changes, maintaining oil levels and
preventing air contact.
VIII. Breather: A device that filters and dehumidifies air entering the conservator,
preserving the integrity of the insulating oil.
IX. Buchholz relay: Protective device installed in oil-filled transformers, detecting and
responding to internal faults, such as oil leakage or gas accumulation. Always in
between the main tank and the conservative tank. Main purpose safety.
X. Protective relays: Devices that detect abnormal operating conditions and initiate
actions to isolate the transformer from faults, ensuring equipment and system
protection.
XI. Expansion valve: if our relay becomes faulty, we use an expansion valve or vent

Losses of Transformer:
 Iron or core loss
 Hysteresis loss
 Copper or ohmic loss
 Eddy current loss
 Stray loss
 Dielectric loss
 Magneto striction loss

Transformer Winding

Transformer winding is a coil of wire

that is wrapped around the core of a
transformer. The windings are where
the electrical energy is transferred from
one circuit to another. The number of
turns in the windings determines the
voltage output of the transformer.

28
Power House Single Line Diagram

29
 MOTORS
A motor is a machine that converts electrical energy to mechanical energy. Almost
98% of motors are 3 phases that are used in Khaur. These motors are in different
ratings like the highest of 250 Horse Power motors and the low being Est 2.5HP
motors. In industry mostly Induction motors are used. Induction motors are also
called asynchronous motors.

Classification of Motors:

Induction motor
Induction motors consist of 2 parts

 Rotor
 Stator

30
Types of Induction Motors

The types of induction motors can be classified depending on whether they are single-
phase or three-phase induction motors. Single Phase Induction Motor

single-phase induction motors include:

1. Split Phase Induction Motor

2. Capacitor Start Induction Motor

3. Capacitor Start and Capacitor Run Induction

Motor

4. Shaded Pole Induction Motor

Three-Phase Induction Motors:

The types of three-phase induction motors include:

1. Squirrel Cage Induction Motor

2. Slip Ring Induction Motor

Synchronous Speed:
The rotational speed of the rotating magnetic field is called
synchronous speed.

f = frequency of the supply

P = number of poles

31
 Variable Frequency Drive (VFD)

A variable frequency drive (VFD) is a type of motor controller that drives an electric
motor by varying the frequency and voltage of its power supply. This allows the motor to
run at different speeds, which can be useful for a variety of applications.

Parts of a VFD

A VFD typically consists of the following parts:

 Rectifier: The rectifier converts the incoming AC power into DC power.

 Inverter: The inverter converts the DC power back into AC power but at a different
frequency and voltage.
 Control system: The control system regulates the frequency and voltage output of
the inverter.
 Cooling system: The cooling system removes heat from the VFD.

Working principle of a VFD

The working principle of a VFD is based on the fact that the speed of an AC motor is
proportional to the frequency of its power supply. By varying the frequency of the power
supply, the VFD can control the speed of the motor.

The VFD first converts the incoming AC power into DC power using a rectifier. The
DC power is then stored in a capacitor or inductor. The inverter then converts the DC
power back into AC power but at a different frequency and voltage. The control system
regulates the frequency and voltage output of the inverter.

The working method of a VFD

The working method of a VFD can be divided into two phases:

 Acceleration phase: In the acceleration phase, the VFD gradually increases the
frequency of the power supply to the motor. This causes the motor to gradually
increase in speed.
32
  Constant speed phase: Once the motor reaches the desired speed, the VFD
maintains the frequency of the power supply at a constant level. This keeps the
motor running at a constant speed.

Advantages of VFDs

VFDs offer several advantages over traditional motor control methods, including:

 Energy savings: VFDs can save energy by allowing the motor to run at the speed
that is needed for the application.
 Improved efficiency: VFDs can improve the efficiency of motors by reducing
losses due to friction and heat.
 Smoother operation: VFDs can provide smoother operation of motors by reducing
torque pulsations.
 Extended motor life: VFDs can extend the life of motors by reducing the stress on
the motor.

Shortcomings of VFDs

VFDs also have some shortcomings, including:

 Cost: VFDs are typically more expensive than traditional motor control methods.
 Complexity: VFDs are more complex than traditional motor control methods, and
they require more maintenance.
 Noise: VFDs can generate noise, which can be a problem in some applications.

33
 Adjustable Speed Drive (ASD)

An ASD, or adjustable speed drive, is a type of motor controller that drives an electric
motor by varying the frequency and voltage of its power supply. This allows the motor to
run at different speeds, which can be useful for a variety of applications.

Parts of an ASD

An ASD typically consists of the following parts:

 Rectifier: The rectifier converts the incoming AC power into DC power.

 Inverter: The inverter converts the DC power back into AC power but at a different
frequency and voltage.
 Control system: The control system regulates the frequency and voltage output of
the inverter.
 Cooling system: The cooling system removes heat from the ASD.

Working principle of an ASD

The working principle of an ASD is based on the fact that the speed of an AC motor is
proportional to the frequency of its power supply. By varying the frequency of the power
supply, the ASD can control the speed of the motor.

The ASD first converts the incoming AC power into DC power using a rectifier. The DC
power is then stored in a capacitor or inductor. The inverter then converts the DC power
back into AC power but at a different frequency and voltage. The control system regulates
the frequency and voltage output of the inverter.

The working method of an ASD

The working method of an ASD can be divided into two phases:

 Acceleration phase: In the acceleration phase, the ASD gradually increases the
frequency of the power supply to the motor. This causes the motor to gradually
increase in speed.

34
  Constant speed phase: Once the motor reaches the desired speed, the ASD
maintains the frequency of the power supply at a constant level. This keeps the
motor running at a constant speed.

Advantages of ASDs

ASDs offer many advantages over traditional motor control methods, including:

 Energy savings: ASDs can save energy by allowing the motor to run at the speed
that is needed for the application.
 Improved efficiency: ASDs can improve the efficiency of motors by reducing
losses due to friction and heat.
 Smoother operation: ASDs can provide smoother operation of motors by reducing
torque pulsations.
 Extended motor life: ASDs can extend the life of motors by reducing the stress on
the motor.

Shortcomings of ASDs

ASDs also have some shortcomings, including:

 Cost: ASDs are typically more expensive than traditional motor control methods.
 Complexity: ASDs are more complex than traditional motor control methods, and
they require more maintenance.
Noise: ASDs can generate noise, which can be a problem in some applications.

35
 Comparison of ASD and VFD
Features VFD ASD
Full name Variable Frequency Drive Adjustable Speed Drive
Type of motor Controls the speed of an AC Controls the speed of an AC
controller
motor by varying the frequency motor by varying the
and voltage of its power supply frequency and voltage of its
power supply
Applications Used in a wide variety of Used in applications where
applications, including machine precise speed control is
tools, fans, and pumps required, such as in machine
tools, fans, and pumps
Advantages Energy savings, improved Energy savings, improved
efficiency, smoother operation, efficiency, smoother
extended motor life operation, extended motor
life
Disadvantage Cost, complexity, noise Cost, complexity, noise
s
Similarities Both VFDs and ASDs are types Both VFDs and ASDs offer
of motor controllers that use some advantages over
variable frequency and voltage to traditional motor control
control the speed of an AC methods, including energy
motor. savings, improved
efficiency, smoother
operation, and extended
motor life.
Differences VFDs are typically more VFDs are typically more
versatile than ASDs, and they expensive than ASDs.
can be used in a wider range of ASDs are typically more
applications. ASDs are typically complex than VFDs, and
more precise than VFDs, and they require more
they are better suited for maintenance.
applications where precise speed
control is required.

36
 Pumping Section
There are 26 pumps in total at this facility. Out of these, 8 are used for decanting of
which 6 are for sweet and 2 for sour crude. 9 pumps are booster pumps that act to
give pressure to crude for metering purposes and also give some head to main pumps
which reduce their load. After booster pumps, there are metering pumps to determine
the number of barrels being pumped or to show how much amount is being sent to
ARL. Then there are 9 main pumps out of which 4 are PD pumps (multistage plunger
pumps) and 5 are multistage centrifugal pumps. These are used to pump crude to ARL.

The main pumps at the crude oil pumping station are plunger pumps and centrifugal
pumps. These pumps are VFD controlled and can be operated from the control room.
Plunger pumps are used to increase the pressure in the line, while centrifugal pumps are
used to increase the flow rate. All the pumps can be controlled from the control room,
but only the main pumps are VFD controlled.

The crude oil that is pumped from the tank travels through Smith meters, which record the
flow of the crude oil and generate a report. This metering allows the company to
determine the number of barrels of crude oil that are pumped to Rawalpindi each day.

The company pumps its crude oil, as well as crude oil that it receives from the PPF plant
and other fields. Approximately 25,000 barrels of crude oil are decanted and pumped
each day. No more than three main pumps can be operated at a single time. If more pumps
need to be operated, special permission is needed from the powerhouse. This is because
the powerhouse needs to start another engine to distribute the load equally within the safe
limit. All of this information can be observed on the controller's computer software.

37
Section 05
Instrument Department

Programmable Logical Controller (PLC)

PLC is a digital computer designed for multiple inputs and output arrangements,
extended temperature ranges, immunity to electrical noise, and resistance to vibration and
impact Speed and accuracy of the operation can be greatly enhanced using plc.

PLC INPUTS AND OUTPUTS

o process can be automated using a PLC.
o Proximity Sensors Motor
o Limit Switches Actuators
o Pressure Switches Pumps
PLC APPLICATIONS

Robots manufacturing and control Car park control Train control station system Food
processing Materials handling Machine tools Conveyer system etc.

PLC ADVANTAGES

o Reliability.
o Flexibility in programming and reprogramming.
o High speed of operation.

PLC DISADVANTAGES

o Limited design
o Fixed Circuit Operations.

38
 SCADA
SCADA stands for Supervisory Control And Data Acquisition. As the name indicates,
it is not a full control system but rather focuses on the supervisory level. Purely software
package that is positioned on top of hardware to which it is interfaced, in general via
Programmable Logic Controllers (PLCs), or other commercial hardware modules. I/O
channels of several 100 thousand I/O's.

SCADA APPLICATIONS

Electrical power grids and electrical generation plants

Manufacturing
Oil and Gas Industry

Comparison between PLC & SCADA

Feature PLC SCADA
Purpose To control To monitor and control remote systems
electromechanical
systems
Applications Industrial automation, Power plants, water treatment plants,
manufacturing, robotics transportation systems
Size Typically, small and Typically, large and complex
portable
Cost Relatively inexpensive More expensive than PLCs
Programming Typically programmed Typically programmed in a high-level
in ladder logic language
Connectivity Typically connected to a Typically connected to a wide area
local network network

39
Material Indentation
There are a total of 9 steps. Which should follow for material indent.

I. Indent or purchase requiting

II. Market inquiry
III. Sealed bid
IV. Technical evaluation (unpriced)
V. Purchase order
VI. Material receives (infield)
VII. Material inspects
VIII. Material issue
IX. Material installs

In all the steps Engineer's work is indent, technical evaluation, and Material inspection.

40