Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
SUBMITTED BY
Swetabh Sahay
Dhiraj Kumar
Shashwat Kaushik
Deepak Kumar Sahu
Aman Singh
The discovery of large oil fields both in offshore and onshore, technological up
gradation in its E&P activities, and the need for compliance to guidelines issued by
the regulatory authorities, viz. Director General of Mines Safety Directorate
(DGMS)- under the Ministry of Labour & the Oil Industry Safety Directorate (OISD)
under the Ministry of Petroleum & Natural Gas, forced the ONGC management to
expand and upgrade the Fire Services by inducting qualified Fire Engineers from
National Fire Service College, Nagpur, the only Govt College under the Ministry of
Home Affairs (MHA). Since then, the ONGC Fire Services has travelled a long way.
With 11 Main and 17 Sub - Fire Stations in onshore areas and 12 offshore Process
Complexes equipped with sophisticated, modern and state of art fire Fighting
Equipment, the ONGC Fire Services has grown into a professional industrial Fire
Service. The unsung heroes of the ONGC Fire Services have provided yeomen
service for building a safe environment at various levels so that the E & P
operations of the company are conducted without any hindrance.
Overview of Hazards in ONGC
Oil & Gas continues to be the major source of energy and dependency has grown
too high since majority of energy needs are met by this sector. This has
necessitated the adoption of new technologies in exploration, refining & storage of
the hydrocarbon in Oil & Gas Industry.
Thus a lot of technological improvements have taken place both in upstream &
downstream sectors of Oil & Gas to enhance oil recoveries in upstream and make
environment friendly products in downstream.
ONGC is committed to the idea that all the incidents (including fire) are preventable;
hence every fire incident can be classified by the place of work of its occurrence. In
ONGC, working areas can be classified as:-
1. Exploration
2. Drilling
3. Production
a) Well on land
b) Well Platform at Offshore
c) Well Head Installation (WHI) on land
d) Early Production System (EPS)
e) Group Gathering Station (GGS)
f) Production Platform – Unmanned
g) Production Platform – Manned
h) Gas Collecting Station (GCS) – Onshore
i) Gas Compressor Station
j) Central Tank Farm (CTF) area
k) LPG Plant
l) Process Plant
m) Processing Complex
n) Effluent Treatment Plant (ETP)
o) Central Processing Facility (CPF)
4. Transportation
5. General Services
i. Workshops
ii. Laboratories
iii. Electrical Substations
iv. Stock Yards
v. Central Stores
vi. Explosive Magazines
vii. Multistoried Office Buildings
viii. Residential Colonies, etc.
The major hazards associated with the oil industry are fire, explosion, sudden
pressure release and toxic release. Of these, fire is the most common, but explosion
is particularly significant in terms of fatality and losses. ONGC has been engaged in
oil and natural gas exploration and production since its inception. Since exploration,
production, refining and marketing of hydrocarbons are the multidisciplinary task
and are spread on land and sea, hence one has to be extremely cautious and safe
in each operation being performed. Therefore, ONGC encounters all types of
common fire hazards known in the industrial operations, besides some special types
of fire hazards specific to oil industry only. Some of the major hazards are listed
below:
Most of these hazards lead to major fires as fuel in liquid and gaseous form, air and
heat (as a result of various operations) are present abundantly which under
uncontrolled conditions or malfunctioning of operations may lead to fires or
sometimes explosion.
Fire Protection Philosophy
The Fire Protection Philosophy in oil and gas industry is based on Fire safety, Loss
Prevention and Control. It considers that in the hydrocarbon industry, the risk of fire
is omnipresent at all levels of operational activities like exploration, drilling,
production, processing and distribution, critical operations requirement and large
inventories stored at facilities. A fire in one part of these operational areas can
endanger other part/section of the area, if not controlled or extinguished as quickly
as possible to minimize the loss of life and property and prevent further spread of
fire.
Considering the above philosophy, the basic fire protection requirement depends on
various factors like area of operations, size of storage tanks, layout of facilities like
GGS, CTF, Oil & Gas Processing installation, pipeline installation, disposal system
of blow down, drainage from equipment handling petroleum product, pressure &
temperature conditions in the process, terrain, etc. Material of construction for
infrastructure facilities shall conform to various statutory regulations like National
Building Code (NBC), Oil Industry Safety Directorate (OISD), National Fire
Protection Association (NFPA), American Petroleum Institute (API), etc.
Depending on the nature and size of installation and risks involved, appropriate
fire
protection facilities out of following shall be provided
The fire protection facilities shall be designed considering that city fire water
supply is
not available close to the installation.
The fire protection facilities at drilling rig, workover rig and production installations
like
WHI, QPS and EPS shall be designed to initiate an immediate fire fighting
operation
so as to prevent escalation into a major emergency.
A single largest fire risk shall be considered for providing fire fighting facilities.
Fixed foam system or Semi-fixed foam system shall be provided for all tanks
(floating
roof or fixed roof) and storing Class A or Class B petroleum.
Water cum foam monitors/foam hose streams shall be considered for fighting
fires in
dyke area and spills.
In an ETP plant, all the areas susceptible to fire hazards shall be covered by
fixed fire
fighting system with water cum foam monitors and hydrants.
Fire water system shall be designed for a minimum pressure of 7 kg/cm2 at the
most
hydraulically remotest point of application.
Functions
To attend and respond all emergency situations calls (like- Gas leakage,
blow out situation ,Fire call ,disaster)
Keep a record of all the employees attendance.
Maintain records of Daily activities in situ of fire station
Maintain a log book and location tracking (GPS) of every fire tender and its
movement
Conduct Mock drill ,One day training programmers to ONGC as well as
people in the vicinity of installations.
Communiction
A. Line Communication:-
I. A telephone only with incoming calls facility for receiving fire calls in the
fire station/control room.
II. Another telephone for communication with outside agencies like local
civil/police/fire authorities, mutual support stations, etc.
III. Intercom / hotline connection for intra communication within the
Asset/Installation/Work Centre etc.
B. Wireless Communication:
I. All Main / Sub Fire Stations are equipped with VHF sets of required
capacity as Base Station to communicate among themselves as well as
with the fire appliances of the station.
II. All fire tenders/fire vehicles are fitted with VHF sets of sufficient capacity
as
Mobile Stations to be in constant contact with their respective fire
stations.
III. Each fire vehicles is are equipped with 4 walike – talkie sets of 5 watt
capacity for use by the crew on fire fighting duty away from the tender.
FIRE TENDERS
Specifications for fabricating a fire vehicle commonly used in petroleum industry are
given here
1. FOAM TENDER
The Foam Tender including all accessories should be designed and manufactured
as per relevant Indian Standards and Tariff Advisory Committee (TAC) ’s
requirements wherever applicable and should be as per sound engineering practice.
The specifications mentioned hereunder lays down the minimum requirements
regarding material, design, construction, workmanship and finish, accessories and
acceptance tests of foam tender. All the equipment and accessories should be fixed
on the appliance in a compact and neat manner and should be so placed that each
part is easily and readily accessible for use and maintenance. The centre of gravity
should be kept as low as possible.
1.1 CHASSIS
(i)Foam tender should be fabricated and built on suitable chassis of payload 10
tones or payload 16.8 tones or equivalent to match engine and pump
characteristics.
(ii) The Foam Tender should have power steering.
(iii) Drag hook or eye of adequate strength and design should be provided at
the front and rear of the chassis.
(iv) All wiring should be properly fixed in position and should be protected
against heat, oil and physical damage.Wherever possible wiring should pass
through PVC sleeves.
(v) All important electrical circuits should have separate fuses suitably indicated
and grouped in a common fuse box located in an easily accessible position.
Provision should be made for a minimum four (4) spare fuses in the fuse box.
(vi) Engine : The vehicle engine should be diesel driven preferably with
synchromesh 5 forward and 1 reverse speeds gearbox. Engine should be
equipped with a complete starting system of 24 V type. An alternator and
rectifier capable of delivering a minimum of 50 A at 24 V should be provided.
(vii) Batteries : Ordinary lead acid batteries. Master isolation switch should be
provided in dashboard panel.
(viii) Radio suppression of the electrical system, which is sufficient to ensure
positive operation of radio equipment without interference, should be provided.
(ix) Braking distance should not be more than 9m at 32 km/hr. when fully
loaded. 4
1.2 PUMP
(i) The foam tender should be mounted with one centrifugal type, single / double
stage pump. 9
(ii) The pump should be capable of discharging minimum 4000 lpm at 8.5 Kg/cm2 .
The suction side of the pump should be connected to water tank independently.
(iii) The pump should be capable of discharging not less than 150% of the rated
capacity at a head not less than 65% of the rated head. The shut off head of the
pump should not exceed 120% of the rated head for the pumps.
(iv) Pump should be suitably mounted on the rear / midship on the chassis and
should be accessible and readily removable for repair and maintenance. The pump
should have its control panel installed suitably.
(v) The pump should be of rigid construction and should be made of gunmetal/ any
suitable light alloy, compatible with fire fighting water and foam compound with
stainless steel grade 304 shaft should be suitable for use with saline water.
(vi) The pump impeller shaft should be fitted with antifriction bearings. (vii) The pump
impeller neck rings and impeller rings should be renewable types and the gland
should be self-adjusting type. A drain plug should be provided at the bottom of the
casing.
(viii) Primer : The pump should be fitted with an automatic water ring /reciprocating
primer. It should be capable of lifting water atleast from a depth of 7.0 m at a rate of
not less than 30 cm per second.
(ix) The delivery outlet of the pump should be connected to the monitor and 4/6/8
numbers of screwed 63 mm female instantaneous couplings in accordance with
IS:903 – 1975. The monitor and other 63 mm female coupling outlets should be fitted
with lever operated ball valves.
(x) Suction lines should be provided with strainers which should be removable easily
2. FOAM NURSER
The Foam Nurser including all accessories should be designed and manufactured as
per relevant Indian Standards and TAC requirements wherever applicable and
should be as per sound engineering practice. The specifications given here are
guidelines for material, design, construction and accessories etc. for Foam Nurser.
All the equipment and accessories should be fixed on the appliance in a compact and
neat manner and should be so placed that each part is easily and readily accessible
for 17 use and maintenance. The centre of gravity should be kept as low as possible.
2.1 CHASSIS
The foam nurser should be fabricated on a suitable chassis of pay load capacity 10
tonnes or 16.8 tonnes or 19.0 tonnes. The spare wheel assembly (supplied along
with chassis) should be fitted at a suitable place on the appliance. Rest same as
foam tender
3 WATER BOUSER
3.1 CHASSIS
The water tank should be fabricated and built on a suitable chassis of pay load
capacity 10 tonnes or 16.8 tonnes.
3.2 PUMP
The Tender should be mounted with one centrifugal type, single / double stage pump.
The pump should be capable of discharging minimum 4000 lpm at 8.5 Kg/Cm2 . The
suction side of the pump should be connected to water tank independently. The pump
should be capable of discharging not less than 150% of the rated capacity at a head
not less than 65% of the rated head. The shut off head of the pump should not exceed
120% of the rated head for the pumps. The pump impeller shaft should be fitted with
antifriction bearings.
Primer : Pump should be fitted with an automatic water ring /reciprocating primer. It
should be capable of lifting water at-least through 7.0 m at a rate of not less than 30
cm per second. The delivery outlet of the pump should be connected to the monitor
and 4/6/8 numbers of screwed 63 mm female instantaneous couplings should be in
accordance with IS:903 – 1975. The monitor and other 63 mm female coupling outlets
should be fitted with lever operated ball valves. Suction lines should be provided with
strainers which should be removable easily.
Since the most commonly encountered fire in everyday life is class A fires,
water tenders from the bulk of fire vehicles in organized Fire Services.
However, in the hydrocarbon industry, B & C classes’ fires are major hazards
and so Foam Tenders are required. The drawback of the two types of fire
tenders above is that they cannot be effectively used in combating electric fires,
for which Dry Chemical Powder (DCP) is the more appropriate firefighting
medium. Initially, fire tenders in use were catering to each of the above
segment and so water tenders, foam tenders and DCP tenders were kept in the
fire stations. However, the concept of multipurpose fire tender incorporating all
the three extinguishing medias i.e. water, foam and DCP in the same vehicle
evolved over a period of time and the convenience of having a single fire
vehicle which can be effectively utilized in fighting all classes of fire gave the
ONGC Fire Services more capabilities in its fire
ONGC NORMS FOR FIRE FIGHTING EQUIPMENT AT FIRE STATIONS
SL DETAILS OF ITEM MAIN FIRE STATION SUB - FIRE STATION
GVW)
GVW)
Narsapur
Mist System.
capacity
capacity
facility.
trailer
cylinder
cylinder
cylinder
cylinders
probes)
9. Turbo/submersible pump 01 0
Circular Saw.
50 ton cap
Diamond chain
Couplings . .
standards
of varying size)
valve
and FB-20)
allied accessories
Sensitivity
batteries at a time.
2. Smoke generator 01 0
1 Transport jeep. 01 01
Overall Process Flow in ONGC AHEMDABAD
Important Definitions and abbreveations as per OISD 189
Central Tank Farm (CTF)-It is a facility where petroleum is received and stored
in bulk for further dispatch either by pipeline, rail or road. The aggregate storage
capacity of petroleum should be above 5000KL for class A and B petroleum
products.
Drilling Rig (DR)-It is a compact mobile unit comprising of derrick structure,
power generating unit for running the draw-works, mud preparation unit and other
associated equipment necessary for carrying out drilling operation in the earth’s
crust by mechanical means to reach down to the petroleum bearing zones below
the ground for exploration and development of oil and gas field.
Early Production Set-up (EPS)
It is a production installation similar to GGS/OCS in nature; however, smaller in
capacity. It is generally setup at a very early stage of development of any oilfield
area where the number of wells are limited and the aggregate petroleum storage
capacity is above 240KL but up to 1000 KL for class A and B petroleum products.
Effluent Treatment Plant (ETP)
A plant where effluent (produced water) is treated to bring down outlet
parameters to an acceptable level as per the applicable regulatory requirements.
Gas Collecting Station (GCS) and Gas Compressor Plant (GCP)
A plant/station where gas is received, liquids separated, gas is dehydrated (if
required) and gas is further compressed for onward transmission. However the
installations where gas processing also involves dew point depression, etc,
this standard is not applicable. Refer OISD-STD-116 on “Fire protection facilities
for petroleum refineries & oil/gas processing plants” and OISD-STD-226 on
“Standard on natural gas transmission pipelines” for applicable provisions.
Group Gathering Station (GGS)/Oil Collecting Station (OCS)
It is a production installation where petroleum production from number of wells is
collected for treating and separating oil, water and gas before dispatch. The
aggregate storage capacity of petroleum is above 1000 KL but up to 5000 KL for
class A and B petroleum product.
Workover Rig (WOR)
It is a compact mobile unit comprising of derrick structure, equipment
necessaryfor mud/ workover fluid preparation and power generation, etc. The
unit is mainly used for oil and/or gas well servicing to perform a variety of
remedial operations on oil and/or gas well based on the technical requirement
with the overall objective of restoring/increasing its production.
GGS-MOTERA
DATE OF COMMISION:
29.03.1992
VESSELS:
LOW PRESSURE SEPARATOR- (vol- 6 m3)
GROUP SEPARATOR- (vol-6 m3)
TEST SEPARATOR- (vol- 6m3)
VERTICAL SCRUBBER-(capacity-1.7 lacks m3/day)
HORIZONTAL SCRUBBER-(capacity- 50000 m3/day)
BATH HEATER- 1 NO.S
TANKS
OIL STORAGE TANKS- 3 NO.S (45 m3)
FUNCTION:
At group gathering system (GGS) fluid from various wells is collected in
header from various we l l s t h r o u g h p i p e l i n e n e t wo r k . T h e n t h e l o w
p r e s s u r e f l u i d ( 1 - 2 k g / c m 2) g o e s t o t h e l o w p r e s s u r e s e p a r a t o r , a n d
t h e n i n t h e o u t p u t we g e t s e p a r a t e d o i l a n d g a s . O i l g o e s d i r e c t l y t o
storage tanks and gas goes to common sucker separator. On the other hand
fluid of 4-5 kg/cm2 pressure goes to group separator. Then from the outlet of
this separator gas goes to common suction separator and oil goes directly to
storage tanks. Th e n i n c o m mo n s u c t i o n s e p a r a t o r a l l t h e g a s e s f r o m t h e
o u t l e t o f g r o u p s e p a r a t o r a n d l o w pressure separator is further separated,
thus if any amount of oil is still present in gas can be separated. So after
separation gas is directly sent to GAIL and oil goes to storage tank.
Fire Protection System for GGS
Design fire water flow rate for GGS shall be the largest of the following two:
Fire water flow rate for tank farm shall be aggregate of the following :-
Water flow rate for cooling single largest tank on fire and exposure
protection to other tanks as
Flow rate for water spray application for fixed or floating roof tanks shall
be aggregate of the following :-
3 lpm/m² of tank shell area for cooling a tank on fire.
lpm/m² of tank shell area for exposure protection for all other tanks
falling within a radius of (R +30) m from center of the tank on fire (R is
the radius of tank on fire).
1 lpm/m2 of tank shell area for exposure protection for all other tanks
falling outside a radius of (R+30) m from center of the tank on fire (R
is the radius of tank on fire) and located in the same dyke.
Water flow rate for applying foam solution on single largest tank on fire.
Fire water flow rate for supplementary water streams shall be based on using 4
single
hydrant outlets and 1 water monitor simultaneously. Capacity of each hydrant
outlet as 36 m3 / hr and of monitor as 144 m3/hr should be considered.
The fire water system at Group Gathering/Oil Collecting Station shall be designed to
meet the fire water flow requirement for fighting a single largest fire.
Assuming that other tank is also located at a distance less than 30 m from the tank
shell.
Therefore, in such case cooling required is at the rate of 3 lpm/m2 of tank shell area.
Cooling water required for tanks falling within (R+30) from centre of tank on fire
Cooling water rate : 3 lpm/m2 of tank area.
Cooling water required : 3.142 x 12 m x 9.7m x 3 lpm/m2.
= 1098 lpm. = 66 m³/hr.
Total cooling water required = 66 + 66 = 132 m3/hr.
Jet Length Not less than 6 mtrs. Not less than 6 mtrs.
Duration of Discharge 60 – 120 Seconds 60 – 120 Seconds
As per ONGC specification based on IS 15683
Parameters Requirement
the cap
Type
A problem that has plagued producers since the discovery of the first oil well is that of
paraffin deposition in well tubular. This is especially true for oils with a high asphaltine
base.The low ends of oil may build up on the tubular to the extent of completely
shutting off production. Usually production gets chocked with solid paraffin deposition
in upper portion.
An effective method of removing paraffin build-up is to melt the paraffin with hot oil/hot
water/chemicals circulation. Specially designed Hot Oil Units are used to heat the
oil/water to a temperature of 2000 to 5000 F and either bullhead it into the well or
circulate it through a work string.
If the paraffin depositing is solid it will often have to be “washed” out with a work string.
Common Procedure for Paraffin Removal from the Well Tubing using CTU :-
Common procedure to remove paraffin from the tubing involves rigging up of CTU in
standard manner and circulating hot oil using hot oil unit. A high temperature pack-off
rubber should be used in the pack-off. Procedure in brief is as described below.
1. The hot oil unit discharge line is connected to the rotating hub of the CTU reel. Hot
oil/hot water/chemicals should be circulated through the CT until the CT is hot prior
to going in the hole.
2. Circulation of the hot fluid should be maintained from surface to approximately 500
feet below the fresh water zones. Circulation should be maintained for at least two
hours after reaching the desired depth. This will ensure melting away all the paraffin
rather than simply washing a hole through it.
3. Returns should be monitored to be sure the oil is hot enough to melt the paraffin
before circulation is stopped.
4. Extreme caution should be used when working around hot oil. If the hot come in
contact with someone, then creates severe burn.
5. Hot water and chemicals can also be used for paraffin removal depending upon the
situation.
Packer – SRP
Units used for Job: Oil tanker and hot oil Pumper.
Job Details –
Oil was transferred from oil tanker to the hoc unit where it was heated at 850 C and then
pumped into the well in the annulus. Circulated oil and produced oil was observed in
return.