INDUSTRIAL EXPLORATION PROJECT

OIL & NATURAL GAS CORPORATION. LTD

TATIPAKA COMPLEX

BY.
SAI VAMSI BOKKA (21021A2706)
DILEEP KUMAR ACHANTA (21021A2756)
RAKSHAN TEJA KANDREGULA (21021A2737)
SAHAS BABU PEKETI (21021A2709)
MADHU PRASAD MANGALAGIRI (21021A2735)
B.TECH. (PETROLEUM ENGINEERING)
JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY,
KAKINADA
INTRODUCTION TO CRUDE OIL AND ITS PROCESSING

 The wheel, without doubt, was man‟s greatest invention. However, until the
late 18th century and early 19th century the motivation and use of the wheel
was limited either by muscle power, man or animal, or by energy naturally
occurring from water flow and wind. The invention of the steam engine
provided, for the first time, a motive power independent of muscle or the
natural elements.
 This ignited the industrial revolution of the 19th century, with its feverish
hunt for fossil fuels to generate the steam. It also initiated the development
of the mass production of steel and other commodities. Late in the 19th
century came the invention of the internal combustion engine with its
requirement for energy derived from crude oil. This, one can say, sparked
the second industrial revolution, with the establishment of the industrial
scene of today and its continuing development. The petroleum products from
the crude oil used initially for the energy required by the internal
combustion engine, have mushroomed to become the basis and source of
some of our chemical, and pharmaceutical products.
The composition and characteristics of crude oil

 Crude oil is a mixture of hundreds of hydrocarbon compounds ranging in size

from the smallest, methane, with only one carbon atom, to large compounds
containing 300 and more carbon atoms. A major portion of these compounds
are paraffin‟s or isomers of paraffin‟s. Most hydrocarbon compounds
present in crude oil have been isolated however, but under delicate
laboratory conditions. In refining processes, the products are identified by
groups of these hydrocarbons boiling between selective temperature ranges.
 Thus, for example naphtha product would be labeled as a 90◦C to 140◦C cut.
There are present also as impurities, small quantities of sculpture, nitrogen
and metals.
 They are similar in structure tithe hydrocarbon families themselves, but with
the addition of one or moresulphur atoms. The most common metal impurities
found in crude oils are nickel, vanadium, and sodium. These are not very
volatile and are found in the residuum or fuel oil products of the crude oil .
Different types of crude oil:
 There are four types of crude oil:
 Class A: Light, Volatile Oils: These oils are highly fluid and highly toxic to
humans and include jet fuel and gasoline.
 Class B: Non-Sticky Oils: These oils are waxy and less toxic to humans
and include diesel fuel and light crude oil.
 Class C: Heavy, Sticky Oils: These oils are brown or black and sticky or
tarry and include most crude oils. Their toxicity is low, but if spilled, their
impacts on waterfowl and wildlife can be severe.
 Class D: Non-Fluid Oils: These oils are non-toxic and include heavy
crude oils. They are difficult to clean up, and if spilled, their impacts on
waterfowl and wildlife can be severe.


MAJOR PRODUCTS PRODUCED IN TATIPAKA
REFINERY:
 Crude oil is divided into four major products along with two additional two products:
 Major products:

 CRUDE OIL @ 3300C
 SKO: Superior Kerosene oil
 HSD: High Speed Diesel
 LSHS: Low Sculpture Heavy Stock (reduced crude oil)

 New products in addition:

 HF HSD (b/w SKO & HSD)
 MTO (b/w NAPHTHA& SKO)
 HF HSD: High Flash High Speed Diesel
 MTO: Mineral Turpentine oil

HF HSD Production:
 Normal HSD produced up to 2005
 Huge demand foreseen for HFHSD due to increased activity in KG offshore
 Already normal HSD demand met for RJY and CAUVERY onshore rigs and
production installations
 Feasibility of HFHSD studied
 Operational obstacles removed modifications carried out (additional
product order installed)
 Operating parameters analyzed and modified, succeed in the production of
HFHSD.
OUTLINE OF TATIPAKA REFINERY

The Tatipaka complex comprises the following facilities

Gas collecting station
Low pressure gas processing and compressionplant
(GCP)
Mini refinery
Effluent Treatment Plant (ETP)
Air compression facility
Power Generation facility
GAS COLLECTING STATION
 Largest onshore installation in RJY asset w.r.t capacity of gas
handling
 After producing 10 billion SCM gas, Tatipaka-GCS has become
the first on shore installation to achieve this milestone innings.
 •Tatipaka gas collecting station is designed to handle 2.5
MMCMD of natural gas collected from different onshore wells.
 Natural gas will be brought to GCS through sub surface pipe
lines processing consists of mechanical separation of gas,
condensate & water.

Tatipaka GCS is a major installation in KG project with good

infrastructural facilities. The GCS collects and processes the gas that is
produced from different wells under Tatipaka complex. This is the largest
on- shore installation of K-G project where all associated also exist.
PRODUCTION SEPARATOR
 The well fluid is received in a 3-phase low pressure production separator, operates at a
pressure 6.0 kg/cm2. Three phase separations are achieved inside the separator due to change
in momentum of the well fluid and providing the required time for the liquid phase. The gas
stream from the top of separator is routed to the filter separators for the filtration and knocks
out of entrained liquid particles.
 The produced gas from the LP production separator is routed to the Ligase compressor at
Tatipaka site. The hydrocarbon liquid is separated in the production separator is routed to the
existing condensate storage via two phase liquid separators. The separated water after passing
through the basket filter is collected in the produced water collection tank.
 Test separator has been provided at the site for testing performance of the individual wells at
low pressures
 i.e. 6.0 kg/cm2. The gas separated from the test separator is metered and is connected to the
separated gas from the production separator prior to filter separators.
 The hydrocarbon liquid stream from test separator is routed to two phase liquid separator and
produced water stream to produced water collection vessel. Well fluid from the wells will flow
to the production separator 10-V-101A/Operating at about 110-120 kg/cm2 for separation of
gas and liquid. The hydrocarbon condensate is sent for condensate stabilization.
A TYPICAL DIAGRAM OF THE GAS
COLLECTING STATION(GCS)
Gas Compression Plant (GCP)
ONGC intends to process and compress LP gas at TATIPAKA
refinery. The wells located in this region were producing gas at
high pressure 55‐65 kg/cm2, but over the period of time due to
ageing of reservoirs, the well pressure is depleting and the
same cannot cater to the GAIL gas distribution network. So it
is required to process the LP gas and compress it for feeding to
the GAIL gas network.
  Process overview:

.
 Liquid free low pressure gas after the filter separator is routed to the gas compressor
suction KOD operating at a pressure 5 kg/cm2. Gas flow from the overhead of the
suction KOD is metered before entering the compressor skid. Liquid collected in the
suction KOD flow to the intermediate blow down (IBD) vessel. Intermediate blow down
vessel is designed to receive various hydrocarbon liquid streams from the suction KOD,
discharge KOD, compressor package, trunk line KOD and the fuel gas conditioning
system. The gas stream from the blow down vessel is routed to the flare. There are three
compressor units, each of 4LSCMD capacities. Gas form suction KOD is routed to the
1st stage suction separator where any small amount of liquid left over in the gas stream is
knocked off.
 Gas from the suction separator flows into the 1st stage at 5kg/cm2 and discharge pressure
is 22-26 kg/cm2. As the discharge temperature of 1ststage gases 140 C, it is cooled in air
cooled heat exchanger up

to 58 C before entering the2nd stage suction separator. Gas from overhead of the 2nd
stage suction separators routed to the second stage of the compressor where it is
compressed to 60-62kg/cm2 and with a discharge temperature of 138 C. An air cooled
after cooler, cools the gas at the outlet of the second stage to a temperature of 58
Compressed gas leaves the compressor skid and is routed to the discharge KOD.Liquid
from discharge KOD flows to the intermediate blow down vessel. The gasfrom the
discharge KOD goes to the GAIL terminal.
.  Process Description:
 Liquid free LP gas after the Filter separator is routed to the gas compressor suction
KOD V‐107 operating at a pressure 5 kg/cm2. LP gas from the other threesites that
is Ponnamanda, Adavipalem and Mori is also routed to the compressor suction KOD
V‐107 via the Trunk KOD V‐109. Gas flow from the overhead of the suction KOD
is metered by FI 1202 before entering the compressor skid. SuctionKOD pressure
controller PIC 1201 is a split range controller and controls thepressure by operating
PCV 1201A or PCV 1201B. PCV 1201A opens to control thepressure around the set
point of the controller PIC 1201. In case, the pressurerises, PCV 1201B opens in
proportion to relieve the excess pressure to the flareheader. Liquid collected in the
suction KOD flows out under level control LIC 1204 to the intermediate blow down
vessel V‐106.
 Intermediate Blow down Vessel:
 Intermediate blow down vessel is designed to receive various hydrocarbon liquid
streams from the suction KOD, discharge KOD, compressor package, trunk linked
and the fuel gas conditioning system. The gas stream from the blow down vessel is
routed to the flare under pressure control PIC 1204. The interface level controller
ILIC 1203 controls and regulates the flow of HC liquid to the Liquid separator while
the water phase collected in the blow down vessel flows out into the produced water
vessel under level control LIC 1202.
Compressor Package:
 There are three compressor units of 4 LSCMD capacities The
compressor package 10‐KA‐101A/B/C comprises of:
 First stage suction separator 10‐V‐1301
 First stage suction volume bottle 10‐V‐1302
 First stage discharge volume bottle 10‐V‐1303
 First stage intercooler 10‐E‐1301
 Second stage suction separator 10‐V‐1304
 Second stage suction volume bottle 10 ‐V‐1305
 Second stage discharge volume bottle 10‐V‐1306
 After cooler 10‐E‐1302
 After cooler separator 10‐V‐1307
Tatipaka Mini-Refinery
.

INTRODUCTION

 The refinery processes a normal quantity of 1500bpd of crude and condensate with a maximum processing
capacity of 2000bpd.
 On average crude oils are made of the following elements or compounds :

 These hydrocarbons are named as below depending on their structure. Methane(C1), Ethane (C2), Propane
(C3), Butane (C4) Naphtha(C5-C12), Kerosene(C12-C16), High Speed Diesel (C16-C32), Low Sculpture
Heavy Stock (C-32 &above). The raw material crude oil is refined into various types of products such as
Naphtha, SKO, HSD and LSHS. Crude oil characteristics vary from light (which
is straw coloured liquid) to heavy (tar black solid). Crude oil isalso called sweet (<0.1ppm sulphur) and sour
(>0.1ppm sulphur) crude oildepending upon the amount of sculpture it contains. At tatipaka crude oil is
received in tankers from the wells at Kesanapalli, Lingala, Nagayalanka, Raghavapuram, Nandigama,
Vadaparru, Kanukollu,Matsyapuri and many other wells in KG base.

.

PROCESS DESCRPITION
 STORAGE OF CRUDE OIL:
 Two tanks each of 500 m3 capacity are used for storage of crude which isreceived every day
from nearby fields constituting feed for refinery. One of these tanks receives crude oil from
tanker intermittently and condensate frocks on continuous basis. The other tank supplies feed
to the refinery throughcentrifugal pumps.
 CRUDE & CONDENSATE STORAGE:
 •Two tanks of 1500m3 capacity exist at the Gas Collecting Station.These tanks are used as
Crude/Condensate feed storage tanks for therefinery.
 •320m3 of Crude/Condensate is received every day from nearby fieldsinto these tanks
constituting feed for refinery. One of these tanksreceives Crude oil from tanker intermittently
and condensate from GCSon continuous basis. The other tank supplies feed to the
refinerythrough centrifugal pumps.
 •They are mixed in the desired ratio and fed to the preheater by pump.
 CRUDE CHARGING & PRE-HEATING
 A mixture of crude and condensate with a composition range of 30% to 70%is fed in a
distillation column by adding de-emulsifier, at a temperature of3300 C, after passing through
two stages of preheating exchangers, a de-saltervessel and furnace. In first stage of preheating
the crude feed is made to exchange heatwith Kerosene, Diesel &LSHS (cold LSHS) product
streams in respectiveheat exchangers
.

CRUDE FURNANCE
 At a temperature of 170-1900C, feed enters the gas-fired furnace where crudegets partially
vaporised gaining a temperature of 3300C.The CRUDE Furnace is also a HEAT TRANSFER
ZONE wherein CONVECTION HEAT TRANSFER further heats the pre-heated crude in the
CONVECTION ZONE firstly, followed by RADIATION HEATTRANSFER in the
RADIATION ZONE finally.
 The desalted crude from the desalter unit is further heated up to atemperature of 220oC by
successive heat exchangers where in kerosenecirculating reflux at 185oC, Diesel circulating
reflux at 254oC and RCO productat 333oC respectively is used as heating medium. The
heated crude is fed intothe furnace. By this operation, theCrude gets partially vaporized,
gaining atemperature of 340oC.
.

ATMOSPHERIC DISTILLATION COLOUMN:

 The atmospheric Crude column is the unit wherein, by HEAT TRANSFER and MASS
TRANSFER (DISTILLATION )operations, fractionates present in thecrude oil are extracted.
 The crude column operates at atmospheric pressure and fractionates crude feed into Naphtha,
Kerosene, Diesel & LSHS products. The column contains 49 trays (48 valve trays and 01 sieve
tray).
 The liquid component drops down (as L.S.H.S.) 6 trays onto tray #49.
 The vaporized component moves upwards to tray #1.
VALVE TRAYS (known as TRIPOD TRAYS):
 The upper extended surface of the tray is known as the WEIR. The lowerextension is the
DOWN COMER. The inter tray distances are approximately0.70m (except of the flashing zone
trays). The trays are so designed that thelevel of Weir of one tray lies higher than that of the
preceding tray‟s down
PROCESS DIAGRAM OF MINI REFINERY
Effluent Treatment Plant (ETP)
Effluent Water Characteristics:
 .

Process Description:
 Oil Water Sumps (OWS):
 The Raw effluent feed from the underground sewer is collected in the OWS sump.The sump
possesses 2 auto level switches, which indicate the effluent level, &there are 4 transfer pumps,
which works based on the level of the sump. The effluents are then transferred to the wash tank.
 Wash Tank:
 The effluent transferred from the OWS sump through the pump is collected in thewash tank of 200
cubic meter capacity. The inlet of wash tank line will beconnected to an on-line dosing system. The
dosing of de-oiler chemical is done on-line to achieve de-emulsifying of oil from the effluent. The
sludge separated istransferred to the existing chemical sludge sump through sludge transfer pump.
 Balancing Tank:
 The effluent is transferred from wash tank to balancing tank of 200 cubic metercapacity. In a
balancing tank a separate slop oil overflow line is provided to collectthe slop oil in the slop oil
sump. The sludge is transferred to chemical sludge sumpthrough sludge transfer pump.
 Tilted Plate Interceptor:
 The outlet of the balancing tank i.e oily water is connected to two TPI feed pumpsto transfer the
effluent to tilted plate interceptor. These pumps transfer theequalized raw effluent for further
treatment.
 Flash Mixer:
 The outlet of the TPI treated effluent then passes through flash mixer. The flowfrom the TPI to the
flash mixer is under gravity over flow. The TPI createdeffluent is then subjected to coagulation of
solids with the help of alkali and alumdosing.
GAS DEHYDRATION UNIT(GDU)
Process Description:
 The process is described by the equipment used in the glycol plant.
 Inlet cooler
 An inlet cooler may be used because dehydration is more efficient at lowtemperatures. Another benefit of inlet
cooling is that some water (andhydrocarbons) in the gas will condense, and be removed in the inlet scrubber,
instead of in the contactor.
 Inlet scrubber
 The inlet scrubber removes free liquid and liquid droplets in the gas, both waterand hydrocarbons. Removing
liquid water in the scrubber decreases the amountof water that has to be removed in the contractor. This decreases
the size of thecontactor and the glycol needed in it, to reach the required conditions for theoutlet gas.
 Contactor
 The contactor is the absorption column where the gas is dried by the glycol. Thelean glycol enters at the top of the
contactor while the rich glycol is collected atthe bottom of the contactor and sent to regeneration. The wet gas
enters thecontactor at the bottom, while the dry gas leaves at the top. The required waterdew-point of the dry gas
dictates the lean glycol temperature and purity. This isillustrated in Figure 3-2. The glycol temperature into the
contactor must be 3 to11 °C (5 to 20 °F) higher than the gas entering the contactor to minimizehydrocarbon
condensation into the glycol.
 Flash separator
 It is a good idea to install a separator after the flash valve. Because of thedecreased pressure hydrocarbons
absorbed in the glycol will be released.Without a separator the gas in the glycol will be released together
with water inthe regenerator. In the regenerator the water vapour is usually just vented to theatmosphere,
thus increasing the plants emission of hydrocarbons
.

Glycol storage tank

 This is an optional instalment that ensures a constant glycol flow to thecontactor column.
Because there will be a loss of glycol in the dehydrationsystem, a storage tank can act a buffer
to prevent insufficient glycol flow and beused to measure the glycol contents in the system.
 Glycol circulation pump
 Because of the pressure difference between the regenerator and the contactor,the glycol
pressure needs to be increased. This is done with the glycolregeneration pump. The glycol is
cooled below 80 °C before pumping to protectthe pump

Heat exchangers
The numbers of heat exchangers vary with the design of the process plant.
Because of the large temperature difference between the contactor andregenerator column, rich
glycol needs to be heated while lean glycol must becooled. With proper design of heat
exchangers between the rich and lean glycolmost of the energy can be conserved .
CHEMISTRY LAB
 Hydrometer - (for measuring density)
 A hydrometer is an instrument used for measuring the relativedensity of liquids based on
the concept of buoyancy. They aretypically calibrated and graduated with one or more
scales such as specificgravity.A hydrometer usually consists of a sealed hollow glass tube
with a wider bottomportion for buoyancy, a ballast such as lead or mercury for stability,
and a narrow stem with graduations for measuring. The liquid to test is poured into a
tallcontainer, often a graduated cylinder, and the hydrometer is gently lowered intothe
liquid until it floats freely.
Abel flash point apparatus- (to determine flash point)
 Flash point is lowest temperature of the test portion, corrected to a barometric pressure of 101,3
kPa, at which application of an ignition source causes the vapourof the test portion to ignite
and the flame to propagate across the surface of theliquid under the specified conditions of
test.Flash point values are not a constant physical-chemical property of materials tested.
They are a function of theapparatus design, the condition of the apparatus used, and
theoperational procedure carried out.Flash point can therefore be defined only interms of
a standardtest method. Abel closed-cup tester measures the flash point the lowest
temperature at which the vapors of a sample ignite upon the applicationof an ignition
source
.