A

REPORT ON TRAINING
IN
OIL AND NATURAL GAS CORPORATION LIMITED
SURFACE TEAM
AHMEDABAD ASSET

“ARTIFICIAL LIFT METHODS USED IN CRUDE OIL EXTRACTION”

B.Tech. Petroleum Engineering (2014 – 2018)

Rajasthan Technical University, Kota

Submitted by:

Pradyumna Singh Rathore Prabhat Shekhar Ashish Gupta

Hasan Sherwani Alok Ranjan Manish Sharma

Bhanwar Lal Shubham Singh

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 CERTIFICATE

This is to certify that Prabhat Shekhar, Alok Ranjan, Bhanwar Lal, Pradyumna Singh
Rathore, Manish Sharma, Ashish Gupta, Hasan Sherwani and Shubham Singh of
Rajasthan Technical University Kota has successfully completed his internship on
“ARTIFICIAL LIFT METHODS USED IN CRUDE OIL EXTRACTION” under my
supervision at ST ONGC Ahmedabad Asset from 15th May, 2017 to 15th July,
2017 as part of the summer internship program in their pre final year B.Tech. course
in Petroleum Engineering ,6th semester.

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 UNDERTAKING

Prabhat Shekhar, Alok Ranjan, Bhawar Lal, Pradyumna Singh Rathore, Manish Sharma, Ashish
Gupta, Hasan Sherwani and Shubham Singh, third year students of B. Tech. Petroleum
Engineering of Rajasthan Technical University, Kota have done our Summer Internship at
Surface Team ONGC, Ahmedabad Asset from 16th May, 2017 to 30th July, 2017 on the topic
“ARTIFICIAL LIFT METHODS USED IN CRUDE OIL EXTRACTION” I undertake the
following that I will not disclose any confidential information (proprietary information)
received from the ONGC to any other person, company, organization, and firm; as I know that
confidential information cannot be sold, exchanged, published or disclosed to anybody by any way
including photocopies or reproduced materials etc. without prior written consent of ONGC. That
I will keep confidentiality to the highest extent to avoid the disclosure or use of the information
received during internship. That I will not publish/use data provided by ONGC anywhere in India
or outside India. That if I am proved to be guilty for the disclosure of the confidential or proprietary
information, ONGC has the sole discretion the right for the reimbursement of damages borne due
to the disclosure.

Date:

Place: Ahmedabad

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 ACKNOWLEDMENT

Apart from the efforts of own, the success of any project depends largely on the encouragement
and guidelines of seniors and colleagues. I take this opportunity to express my gratitude to
the people who have been instrumental in the effective completion of this project. I would
like to convey my gratitude to the entire Ahmedabad Asset and especially to the sub surface
team, Ahmedabad Asset, for all the guidance, knowledge and support that I received during
my Vocational Training.

Firstly, I would like to thank Mr. P.K. Mishra, ED, Ahmedabad Asset and Mr. V.K. Mehta for
providing best facilities for technical sessions and their great efforts in arranging my training
at ONGC Ahmedabad asset under sub-surface team. I take this opportunity to acknowledge
tire relentless and generous support of Mr. P.L. Sonkar, CE (P), ST for his guidance as my
mentor, guiding me through his valuable insights and suggestions during the internship. I am
deeply indebted to Mr. Kamad Shukla for his constant support to me during the training.

Pradyumna Singh Rathore

Prabhat Shekhar
Manish Sharma
Alok Ranjan
Bhanwar Lal
Hasan Sherwani
Shubham Singh
Ashish Gupta

Rajasthan Technical University, Kota

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 PREFACE

Theory of any subject is important but without its practical knowledge it becomes useless,
particularly for technical students. A technical student cannot become a perfect engineer or
technologist without practical understanding of their branch, hence training provides a golden
opportunity for all technical students to interact with the working environment.
The principal necessity of in-plant training is to get details about unit operation and unit process
which are carried out in chemical industries and to know more about the equipment used in these
industries.
The in-plant training program is very advantageous for the technical students who have a vivid
idea about the industries.
This training helps to understand the basic concept of the industry. During this period, the students
becomes aware of the problems faced in the plant and are also aware of the industrial atmosphere
and with the industrial people.

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 CONTENT

TOPIC PAGE NO.

1. BRIEF HISTORY ABOUT ONGC 7

2. PLANTS VISITED 10

3. GROUP GATHERING STATION (GGS) - MOTERA 11

4. GAS COLLECTION STATION (GCS) - KALOL 16

5. GAS COMPRESSION PLANT (GCP) - KALOL 21

6. CENTRAL FARM TANK (CTF) - KALOL 25

7. GROUP GATHERING STATION (GGS) VII - KALOL 30

8. CENTRAL WATER INJECTION PLANT (CWIP) 36

9. CENTAL TANK FARM (CTF) - NAWAGAM 39

10. DESALTER PLANT: NAWAGAM 41

11. SUPERVISORY CONTROL AND DATA AQUISITION (SCADA) 45

12. ASSET CHEMISTRY LAB - AHMEDABAD 50

13. ARTIFICIAL LIFT METHODS USED IN CRUDE OIL

55
EXTRACTION (PROJECT REPORT)

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 BRIEF HISTORY

Oil and Natural Gas Corporation Limited (ONGC) is an Indian multinational oil and gas company
headquartered in Dehradun, Uttarakhand, India. It is a Public-Sector Undertaking (PSU) of the
Government of India, under the administrative control of the Ministry of Petroleum and Natural
Gas. It is India's largest oil and gas exploration and production company. It produces around 77%
of India's crude oil (equivalent to around 30% of the country's total demand) and around 62% of
its natural gas.

On 31 March 2013, its market capitalization was INR 2.6 trillion (US$48.98 billion), making it
India's second largest publicly traded company. In a government survey for fiscal year 2011–12,
it was ranked as the largest profit-making PSU in India. ONGC has been ranked 449th in the
Fortune Global 500 list of the world's biggest corporations for the year 2015.It is ranked 17th
among the Top 250 Global Energy Companies by Platts.

ONGC was founded on 14 August 1956 by Government of India, which currently holds a 68.94%
equity stake. It is involved in exploring for and exploiting hydrocarbons in 26 sedimentary basins
of India, and owns and operates over 11,000 kilometers of pipelines in the country. Its international
subsidiary ONGC Videsh currently has projects in 17 countries. ONGC has discovered 6 of the 7
commercially producing Indian Basins, in the last 50 years, adding over 7.1 billion tons of In-place
Oil & Gas volume of hydrocarbons in Indian basins. Against a global decline of production from
matured fields, ONGC has maintained production from its brownfields like Mumbai High, with
the help of aggressive investments in various IOR (Improved Oil Recovery) and EOR (Enhanced
Oil Recovery) schemes. ONGC has many matured fields with a current recovery factor of 25–
33%. Its Reserve Replacement Ratio for between 2005 and 2013, has been more than one. [3]
During FY 2012–13, ONGC had to share the highest ever under-recovery of INR 494.2 billion (an
increase of INR 49.6 million over the previous financial year) towards the under-recoveries of Oil
Marketing Companies (IOC, BPCL and HPCL).

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-8-
ASSETS/PLANTS:

1.Mumbai High Asset, Mumbai

2.Neelam & Heera Asset, Mumbai
3.Bassein & Satellite Asset, Mumbai
4.Uran Plant, Uran
5.Hazira Plant, Hazira
6.Ahmedabad Asset, Ahmedabad
7.Ankleshwar Asset, Mehsana
8.Mehsana Asset, Mehsana
9.Rajamundry Asset, Rajamundry
10. Karaikal Asset, Karaikal
11. Assam Asset, Nazira
12. Tripura Asset, Agartala
BASINS:

1. Western Offshore Basin, Mumbai

2.Western Onshore Basin Vadodara
3.KG Basin, Rajamundry
4.Cauvery Basin, Chennai
5.Assam & Assam-Arakan Basin , Jorhat
6.CBM- BPM Basin , Kolkata
7.Frontier Basin , Dehradun

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 PLANTS VISITED

We visited the following plants of the Ahmedabad Asset while working on the project:

• Kalol CTF

• Kalol GCP

• Kalol GGS

• WIP-I, II

• Nawagam CTF

• Nawagam GCP

• Nawagam Desalter

• Motera GGS

• Artificial Lift

• Asset. Chemistry Lab

• SCADA Lab

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 GGS-MOTERA

DATE OF COMMISION: 29.03.1992

WELL PRODUCTION STATUS:

TOTAL WELLS CONNECTED-33

TOTAL FLOWING WELLS-28

TOTAL LIQUID PRODUCTION-40 m3/day

WATER INJECTION WELLS- nil

GAS INJECTED-20000 m3/day

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
wells through pipeline network. Then the low-pressure fluid (1- 2 kg/cm2) goes to the low-pressure
separator, and then in the output we get separated oil and gas. Oil goes directly to 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.

Then in common suction separator all the gases from the outlet of group separator and low 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.

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 The gas which was present in above withdrawn oil is low pressure gas, but some high pressure gas
also comes out of reservoir. So that gas is sent to gas scrubber where whatever amount of gas is
present in gas is separated and the gas what we get after separation is not suitable for consumers
so it is sent back to reservoir for artificial lifting.

GGS FACILITIES

1. PIPELINES

➢ For oil- 4inches in diameter

➢ Highly resistant against corrosive action of fluid
➢ For gas- 2inches in diameter

2. SCRUBBERS
➢ Horizontal scrubber
• Function- extract oil from gas
• Pressure- 40 Kg/cm2

➢ Vertical scrubber
• Function- same as above
• Pressure- 70 Kg/cm2

3. SEPARATOR:

➢ To flash the well fluid to separate into liquids and gas at a controlled pressure.

➢ Flow lines from various wells open into the pipelines of GGS.

Various provisions for various supplies to 3 types of separator:

• TEST SEPARATOR

Fluid enters tangentially and due to the sudden pressure drop to the set level, the fluid gets
separated into separated into liquid and gases. Baffles are fitted inside the separator to help in
better separation. It is used for testing the fluid obtained from a source. It can withstand pressure
of 9 kg/cm2.

• GROUP SEPARATOR

It is also a two-phase vertical cylindrical vessel just the same as the previous one but here fluid
from all the well comes whose pressure is up to 4-5 kg/cm2. Separated gas is sent to flare lines.

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• LOW PRESSURE SEPARATOR

When the fluids coming out of the wells have pressure of about 1-2 kg/cm2 then fluid goes to this
separator. All these separators have same capacity.

4. VALVES

➢ Gate valves: used to minimize the pressure drop in the open position and stop the flow rather than
controlling it

➢ Check valves: it is one-way valve which normally allow fluid to flow through it in only one
direction. This prevents the back flow of fluid into wells.

5. STORAGE SYSTEM

Purpose:

➢ To store oil before transporting

➢ To measure oil produced

Process:

➢ Oil from bath heater and separator is taken into overhead cylindrical tanks for measurement.

6. OIL DISPATCH SYSTEM

Purpose:

➢ To dispatch oil from GGS to CTF.

Process:

➢ Oil stored in the storage tanks is sent to CTF by road tanker as there is no pumping system available
in the installation.

7. BATH HEATER

➢ Used to reduce the viscosity of oil coming from reservoir by heating that oil in bath heater.

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8. FIRE FIGHTING SYSTEM

➢ Large water tank- (capacity- 350 m3)

➢ Small water tank- (capacity- 100m3)

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- 15 -
 KALOL GCS (GAS COLLECTION STATION)

ESTABLISHED IN: 1973

RECEIVING STATUS:

Total Wells Connected-32

Total Working Wells- 13

Receiving pressure-4kg/cm2

OBJECTIVES:

➢ To collect natural gas from wells

➢ To collect associated gas from GGS

➢ To send gas to GCP.

➢ To send compressed gas (CG) to GGS for artificial lifting

➢ To send CG to IFFCO, RIL, etc.

FUNCTIONS:

Its main function is gas collection and distribution. GCS receives associated gas from GGS and
natural gas directly from the wells. They both are mixed in scrubber, treated and they are
transferred to GCP for further compression. Now the compressed gas is again received back by
GCS and then the compressed gas is sent to various destinations.

GCS FACILITIES

1. MANIFOLDS

➢ Gas grid manifold (to provide high pressure compressed gas through 4’’ & 6’’ pipeline to north
and south Kalol gas system)

2. BEAN HOUSING

➢ to control the flow of gas from the reservoir

3. SCRUBBER

Purpose

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➢ It is a purifier that removes impurities from gas. Scrubber systems are a diverse group of air
pollution control devices that can be used to remove particulates and/or gases from industrial
exhaust streams. Traditionally, the term “scrubber” has referred to pollution control devices that
use liquid to “scrub” unwanted pollutants from a gas stream. Recently, the term is also used to
describe systems that inject a dry reagent or slurry into a dirty exhaust stream to “scrub out” acid
gases. Scrubbers are one of the primary devices that control gaseous emissions, especially acid
gases.

Process

➢ It involves the addition of an alkaline material (usually hydrated lime and soda ash) into the gas
stream to react with the acid gases. The acid gases react with the alkaline sorbents to form solid
salts which are removed in the particulate control devices. These systems can achieve acid gas
(SO2 and HCl) removal efficiencies.

4. SEPARATOR

➢ Functions at 4kg/cm2

➢ In this only natural gas is separated to remove any condensed liquids if present. The gas firstly
goes to separator then to scrubber.

5. STORAGE TANK

➢ 3 storage tanks of 45m3 are present but they are not under usage.

6. VALVES

➢ Shut down valve-used in case of leakage or in any other emergency

➢ Control valves- when pressure in the pipelines increases beyond the limit then these valves get
open itself to prevent danger.

7. FLARE

➢ Used for burning off unwanted gas or flammable gas released by pressure relief valves
during unplanned over-pressuring of plant equipment.

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 GAS ANALYSIS

COMPOUND MOL%

Methane(CH4) 87.150

Nitrogen(N2) 0.160

Carbon di oxide (CO2) 1.36

Ethane(C2H6) 5.22

Propane(C3H8) 2.5

Water (H2O) 0

Hydrogen bi sulfate(H2S) 0

Carbon monoxide(CO) 0

Oxygen(O2) 0

I-butane 1.35

N-butane 0.82

I-pentane 0.36

N-pentane 0.39

Hexane 0.68

Heptane 0

Octane 0

Nonane 0

Decane plus 0

Helium(He) 0

Argon 0

- 18 -
 SUPPLY FROM GCS

GAS SUPPLIED TO QUANTITY

IIFCO (Associated. Gas) 30000m3/day

SAHAND-II (Natural Gas) 50000m3/day

Bharat Vijay Mill(Sintex) (Associated Gas) 15000-20000m3/day

RIL (Compressed Gas) 1 lacks m3/day

Compressed gas to Grid 4.30 lacks m3/day

Gurukul (Kalol) 300 m3/day

Central Farm Tank (CTF) 1700m3/day

(Associated Gas)

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GCS (GAS COLLECTION STATION)

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 GAS COMPRESSION PLANT (GCP)-KALOL

DATE OF COMMISION:

GCP-I: 26.02.1990

GCP-II: 15.03.1994

TOTAL CAPACITY: 5 lacks m3/day

TOTAL COMPRESSORS: 10

6 in old plant and 4 in new plant

Capacity (old) =3 lacks m3 /day

Capacity (new) = 2 lacks m3 /day

REVERSE-OSMOSIS PLANT (R-O): two

DISCHARGE PRESSURE: 40 kg/cm 2

PROCESS DESCRIPTION:

In this plant, gas from GCS (gas collecting system) at 4kg/cm2 pressure comes through pipelines
to GCP. Firstly, it goes to common inlet separator, where the primary separation is done, usually
the content of oil in gas is negligible but if it’s there it gets separated. Now the gas goes to 1st stage
suction separator, there further separation is done. Till now the pressure is 4kg/cm2, now this gas
goes for first stage compression goes into compressor. After compression, the gas we get is of 12-
14 kg/cm2 and because of compression temperature rises to 1250 C so to low down the temperature
to 40-450C, compressed gas is sent to inter gas cooler.

Now the cooled gas of 12-14 kg/cm2 pressure goes to 2nd stage suction separator where further
separation occurs. Then it goes to 2nd stage gas compressor there compression is done and in the
output we get gas of 40 kg/cm2 pressure but temperature has again gone up to 1450 C because of
compression so it again goes to cooler which is also known as after cooler . Now as cooling has
occurred so condensation will be done so again whatever amount of oil will be there will be drained
out from discharge separator.

Then finally gas from the discharge separator at 40 kg/cm2 pressure is sent back to GCS.

GCP FACILITIES

1. GAS COMPRESSION SYSTEM

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➢ PURPOSE

• to compress gas at high pressure

➢ PROCESS

• It has two stage gas compression systems. First stage compressors takes gas from first suction
separator and other stage takes gas from second suction separator as shown in the flow diagram.

• RPM= 990

• Capacity-2100m3/hr.

• Model- 14 X 8 X 5 2 RDH-2

• Make-Ingersoll sand

• Type- double-acting reciprocating horizontal

• Number of stages- Two

2. RAW WATER TREATMENT SYSTEM (R-O Plant)

➢ Purpose:

• to remove true deposit solids from water

➢ Process

• Firstly, the raw water from the storage tank flows into pipelines and come into desired location.
To this raw water we add sodium hypo chloride which destroys the bacteria present in water. Then
the water is treated with sodium bi sulfate to reduce the chlorine content which would have
increased because of sodium hypo chloride addition. Then this treated water with sodium hexa
meta phosphate so that scaling can be minimized which will occur in tubing having membranes.
Then this water goes to multi grade filter where various types of gravel, sand are filtered. Then the
filtered water is treated with 98% H2SO4 so that pH of water is maintained. Then again, this water
goes to cartridge filter, so that if any filtration is left can be completed. Now this filtered water is
pumped into tubing system having membranes with the help of high pressure pump. Then there
high- quality demineralized water is produced which is then sent to storage tanks.

3. AIR COMPRESSION SYSTEM:

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➢ Make- Ingersoll Rand

➢ Model- 8 X 5 E&1-NL2

➢ Discharge Pressure- 110 PSI

➢ Capacity- 200 CFM(each)

4. COOLING SYSTEM:

➢ Purpose:

• There are two types of gas coolers inter gas coolers and after gas coolers. It’s a type of heat
exchanger. Running water through it helps in cooling of gas and they are sent finally to discharge
separator. Inter gas cooler takes the gas of first stage compression and gas cooler takes second
stage compression.

➢ Process:

• It’s a type of heat exchanger, it contains baffles and one shell and two tubes pass exchanger system.
Cooled treated water enters from one side and gas enters from the other side. There occurs a
counter current flow. This results in exchange of heat between two liquids and hence the fluid is
cooled.

5. GAS DETECTION &MONITORING SYSTEM

➢ Used to detect the leakage of gas in the plant

6. FIRE FIGHTING SYSTEM

➢ 6 firefighting pumps

➢ 4 diesel pumps and 2 motor driven pump

7. ELECTRICAL SYSTEM

➢ Two 11 KV sub-station

➢ 8 step-down transformers

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- 24 -
 CENTRAL FARM TANK (CTF)-KALOL

COMMISSIONED IN: August 1971

OBJECTIVES:

➢ Collection of oil from Kalol, Sanand, Jhalore, South Kadi,Viraj, Paliyad, Limbodra

➢ Treatment of crude oil

➢ Chemical analysis

➢ Pumping oil to desalter Nawagam plant

➢ Pumping effluent to ETP (effluent treatment plant)

RECEIVING SYSTEM

➢ Crude oil received at CTF Kalol through.

➢ 8’’ diameter line from Sanand and Jhalore field at 1000m3/day.

➢ 12’’ and 8’’ lines from Kalol field at 170m3/day.

➢ 12’’ lines from south Kadi and Viraj field at 43m3/day.

COLLECTION

➢ 6000 m3/day

FUNCTIONS

Crude oil is received from various GGS. The oil which is having higher water cut is sent to heater
treater while oil having low water is directly dispatched to desalter.

TESTS PERFORMED

➢ Test for specific gravity-

• A hydrometer is an instrument used to measure the specific gravity (or relative density) of liquids;
that is, the ratio of the density of the liquid to the density of water.
• A hydrometer is usually made of glass and consists of a cylindrical stem and a bulb weighted with
mercury or lead shot to make it float upright. The liquid to be tested is poured into a tall jar, and
the hydrometer is gently lowered into the liquid until it floats freely. The point at which the surface
of the liquid touches the stem of the hydrometer is noted. Hydrometers usually contain a paper
scale inside the stem, so that the specific gravity can be read directly.

➢ Test for water content (DEAN STARK METHOD)

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 This method is used for determining water-in-oil. The method involves the direct co-distillation of
the oil sample. As the oil is heated, any water present vaporizes. The water vapors are then
condensed and collected in a graduated collection tube, such that the volume of water produced by
distillation can be measured as a function of the total volume of oil used.

CTF FACILITIES

1. DISPATCH SYSTEM

➢ Dispatch is done through 12’’diameter line, 51Km long pipeline to desalter Nawagam through to
pumps at 130 m3/hr. rate.

➢ 6 effluent dispatch pump each of 50 m3/hr. capacity.

➢ Oil dispatch pump

• (A-700) BPCL 3 in number each of 120 m3/hr. capacity.

• (C-558) BPCL 4 in number each of 135 m3/hr.

2. MASS FLOW METER

➢ Coriolis meter

3. STORAGE TANKS

➢ 10 tanks of capacity 2000 m3 out of which 2 are used for effluent storage and rest for storage of
oil.

➢ 8 tanks of capacity 10000 m3 for storage of oil.

4. SCRAPPER SYSTEM

➢ There are two scrappers receiving platforms from 12’’ pipeline for S.Kadi and 8’’ pipeline for
Sanand-Jhalore field also there is one scrapper launching platforms for 12’’ pipeline desalter plant
NGM.

5. HEATER TREATER

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➢ In all 6-heater treater are there in this plant.

➢ 4 of which are of capacity 300m3/day.

➢ 2 jumbo heater treaters are also there, one of which is of capacity 800m3/day and second one is of
1000m3/day

➢ One jumbo heater treater is under construction.

➢ 5 heater treater feed pumps are available which are centrifugal and there capacity is 45 m3/hr.

➢ It has three chambers namely

• Heating chamber

• Middle chamber

• Electrical Chamber

HEATING CHAMBER: The fire tube which extends up to this section is in submerged condition
in emulsion oil. The heating of oil emulsion decreases the viscosity of oil and water and reduces
the resistance of water movement. The heat further reduces the surface tension of individual
droplets by which when they collide form bigger droplets. This progressive action results in
separation of oil and free water.

MIDDLE CHAMBER: The fluids from heating enter this chamber through fixed water. It doesn’t
allow gas to pass into electrical chamber. The gas which enters heating chamber leaves from top
through mist extractor. The oil in this chamber is controlled by oil level controller.

ELECTRICAL CHAMBER: In this section, constant level of water is maintained so that oil is
washed and free water droplets of water are eliminated before fluid proceeds towards electrode
plates (electric grid). These plates connected to high voltage supply of 10000 to 25000 volts. When
fluid passes through these electrodes the droplets polarize and attracts each other. This attraction
causes the droplets to combine; they become large enough to settle into oil and water layers by the
action of gravity

6. FIRE FIGHTING SYSTEM

➢ 4 Motor driven pump of 410 m3/hr. capacity work at 10kg/cm2 pressure.

➢ 2 diesel engine driven pump of 410 m3/hr. capacity work at 10 kg/cm2 pressure.

➢ Jockey pumps are 2 in number which are motor driven and their capacity is 80 m3/hr.

➢ Various potable fire extinguisher are present such as dry carbon, carbon dioxide.

- 27 -
HEATER TREATER

- 28 -
CTF (Central Tank Farm)

- 29 -
 GGS – VII KALOL

DATE OF COMMISION: July- 1976

WELL PRODUCTION STATUS:

TOTAL WELLS CONNECTED-57

TOTAL FLOWING WELLS-52

TOTAL LIQUID PRODUCTION-380 m3/day

WATER INJECTION WELLS- 20

GAS INJECTED-40000-50000 m3/day

VESSELS:

TEST SEPARATOR- (working pressure-6 kg/cm2 and hydraulic test pressure- 9 kg/cm2)

EMULSION SEPARATOR-(working pressure-6 kg/cm2 and hydraulic test pressure- 9 kg/cm2)

EMULSION SEPARATOR-(working pressure-6 kg/cm2 and hydraulic test pressure- 9 kg/cm2)

EMULSION SEPARATOR-II: (working pressure-6 kg/cm2 and hydraulic test pressure- 9 kg/cm2)

EMULSION SEPARATOR-III: (working pressure-6 kg/cm2 and hydraulic test pressure- 9

kg/cm2)

HIGH PRESSURE SEPARATOR-(working pressure is 15 kg/cm2 and hydraulic test pressure-24

kg/cm2)

HEATER TREATER: 2 in number, first one is of 800 tons/day capacity and second one is under
construction

BATH HEATER- 1 NO. S

TANKS

Tank- I: 90000 Liters

Tank-II: 90000 Liters

Tank-III: 400000 Liters

TCS I &II: 32000 Liters and 3 Kg/cm2 pressure.

- 30 -
 FUNCTION:

At GGS well fluid is connected in header from various wells through pipeline network. There gas
is separated from liquid in group separator and send to GCP through GGS to return compressed
gas for gas lift wells. Then water is separated from oil in heater treater. Oil is stored in tanks and
sends to CTF (central tank farm). The effluent remained after separating from oil is send to ETP
(effluent treatment plant).

GGS- VII

1. HEATER TREATER

➢ NAME- crude oil emulsion treater

➢ TYPE- vertical flow horizontal CE treater

➢ SIZE- 8’ X 20’

➢ CAPACITY- 800 tons/day

➢ DUTY- Continuous

➢ WORKING PRESSURE- 50 PSI

➢ WORKING TEMPERATURE- 900 C maximum

➢ TEST PRESSURE- 75 PSI (hydraulic)

➢ CURRENT- 25 Amp

➢ VOLT-250 volt

➢ Reciprocating pump is used to transfer the fluid from separator to heater treater

• Power- 375 KW

• Volt- 415 V

• RPM- 1410

2. DEMULSIFIER

➢ CHEMICAL DESCRIPTION: mixture of ethoxylated, propoxylated surfactants and organic

aromatic solvent as inert diluents.

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➢ PHYSICAL & CHEMICAL PROPERTIES

• Ionic Nature- non-toxic

• Viscosity at 300C- less than 100 poise

• pH of 5% solution- 5.5 to 8.0

• Solubility in H20- dispersible

• Solubility in xylene & toluene- soluble

• Flammability- inflammable

➢ LABELLING, STORAGE & HANDLING

• Storage conditions- store in cool, well- ventilated area

• Disposal- incinerate in a furnace as per local state or national legislation

➢ EMERGENCY MEASURES

• Spillages- adsorb onto sand, earth or similar adsorbent material. Wash the spillage area.

➢ FIRST AID

• Skin contact- wash with water followed by soap & water

• Eye contact- irrigate with clean water or an eye wash solution, obtain medical attention as
precaution.

• Inhalation- The affected person should be moved to fresh air & made to rest.

• Ingestion- Give water or milk to drink.

3. TRIPLEX RECIPROCATING PUMP

➢ Used for pumping oil from storage tank to discharge line to NAWAGAM

➢ Maximum pressure- 64 Kg/cm2

- 32 -
➢ Input- 86 KW

➢ Pump RPM-260

➢ Oil used for lubrication- 80L

➢ Servo gear HP- 140

➢ It is motor driven pump

• KW- 110

• HP-150

• RPM-1480

4. BOOSTER COMPRESSOR

➢ Used to compress the gas which comes out from the separator vent at pressure 1.5 kg/cm2 to 4 – 5
kg/cm2 which is then send to GCS for further compression.

➢ Make- Ingersoll rand

➢ Model- 8.5” X 7” single stage

➢ Capacity- 10000m3/day

➢ Suction pressure- 1.5 kg/cm2

➢ Discharge pressure- 5 kg/cm2

5. POWER SUPPLY

➢ Normal power is supplied from 11KV grid of the electric board

➢ The overall normal requirement envisaged has been of the order of 100KVA

➢ Emergency power plant is maintained by 320KVA diesel generator whose power factor is 0.8 and
power of engine is 396 HP.

6. FIRE WATER SYSTEM

➢ 2 reservoir of water having capacity 120 m3 and 350 m3 respectively are available.

- 33 -
➢ 2 pumps are also present one is motor driven and second one diesel engine driven. Second one is
used as stand by.

➢ Specifications of motor driven pump:

• Capacity- 170 m3/hr.

• Discharge pressure- 6 Kg/cm2

➢ Specifications of engine driven pump

• Head- 100 m

• Discharge rate- 171 m3/hr.

• Size- 100X 125 mm

• Speed- 1800 RPM

• Pump input- 64.9 KW.

- 34 -
- 35 -
 CENTRAL WATER INJECTION PLANT (CWIP)

DATE OF COMMISION-04.04.1990

UNIT PRODUCTION- 1680 m3/day

POWER CONSUMPTION- 20000 KW/month

DISCHARGE RATE- 35 m3/hr.

CHEMICALS USED
Sodium sulfide- 40 ppm
Scale inhibitor- 20 ppm
Corrosion inhibitor- 20ppm

PROCESS DESCRIPTION-
Water from ETP through pipelines comes to CWIP for further chemical treatment before it is sent
to GGS for water injection.
Water at 35-37 m3/hr. of flow rate and at pressure of 4 kg/cm2 is pumped into CWIP through
pipelines from ETP. Effluent enters the treated water tank (600 m3) where tube well water is also
added in fixed proportion. This tube well water (raw water) is passed to three micro filters of 25
microns,10 microns and 3 microns one by one and then finally it is sent to raw water hold tank. At
the outlet of the tank three chemicals are added, sodium sulphite (40 ppm) which acts as oxygen
scavenger, corrosion inhibitor (20 ppm) is added to prevent corrosion and scale inhibitor (20 ppm)
is also added to decrease precipitation formation. Now this effluent is sent to treated water tank
where water from ETP is mixed with it by mean of agitator. This effluent is then pumped with the
help of water injection pump to headers.
Now from headers the water is injected at high pressure and at low pressure through four-inch pipe
line. Water is injected at high pressure of 60-62 kg/cm2 to 13 wells used for artificial lifting which
are connected to GGS VII.
Low pressure water is injected at 40-42 kg/cm2 connected to 28 wells used for artificial lifting.
Here 4 wells are connected to GGS I, 4 wells to GGS XI, 10 wells to GGS II and 10 wells are
connected to GGS VII. So, total wells connected to CWIP is 52 wells.

- 36 -
 CWIP FACILITIES

1. PUMPING SYSTEM
➢ 4 reciprocating pumps are available and out of which 2 are working and 2 are stand by.
➢ Specifications of pump are:
• Capacity-35 m3/hr.
• RPM-314
• Maximum working pressure- 170 kg/cm2
• BKW- 190.78

➢ MOTOR
• RPM-1455
• HP/KW-322/240
• Efficiency-95.5%
• Volt-415

2. STORAGE SYSTEM
➢ Balancing tank- 200 m3
➢ Storage tank -600 m3
➢ Treated water tank- 600 m3

- 37 -
CWIP (CENTRAL WATER INJECTION PLANT)

- 38 -
 CENTAL TANK FARM (CTF) – NAWAGAM

AREA OF INSTALLATION- 100 Acres

RECEIVING STATUS

➢ GGS- I, II, III – 500 m3/day

➢ Ramol, Nandej, Wasna fields- 800-900 m3/day

➢ CTF Kalol- 8000 m3/day

➢ Mehsana fields- 8000 m3/day

STORAGE TANKS

8 tanks- 2000 m3

MAIN OBJECTIVE

➢ As such in this installation no processing is done, they just pump desired crude oil to desalter
plant which has come from various CTF.

➢ Every hour water content is checked in the samples of treated crude oil of desalter plant after
fulfilling the desired conditions of refineries dispatching is done from desalter to refineries.

➢ They target to have water content of 0.5-1 % in oil before discharging.

PUMPING SYSTEM

➢ Make- BPCL

➢ Type- Quintuplex plunger pump

➢ Maximum discharge- 120 m3/hr.

➢
Maximum operating pressure- 40 kg/cm2

➢ Rate BHP- 430 HP

➢ MOTOR

• HP- 545

• KW-400

- 39 -
• RPM-1450

• Voltage-415

• Frequency- 50 Hz

• Current- 676 Amp

- 40 -
 DESALTER PLANT: NAWAGAM

DATE OF COMMISION: 01.01.1995

PLANT CAPACITY: 6.7 million metric tons per year

NUMBER OF TRAINS (UNIT) - 3 trains of 2.23 million metric tons per year
(2 trains are operating and 1 is stand by)

RECEIVING STATUS
➢ Crude oil from
• Mehsana
• Ahmedabad Asset

FEED STOCK CHARACTERSTICS

Chloride in oil feed water: 4500 ppm
Chlorides as Cl salt- 81 ptb
Specific gravity of oil-0.8948
Total Sulphur, % wt.- 0.007
Wax content, %wt-6.8
Total acidity, mg KOH/gm- 4.65

DESALTED CRUDE OIL CHARACTERSTICS

Salt content-10-15 ptb

PROCESS DESCRIPTION
Crude oil is received from the existing tank farm to new tanks through a 30” suction header. 4 Nos.
feed pumps are installed for pumping feed to desalter to three trains whereas the fourth pump is
common stand by for all the three trains. Demulsifier chemical is mixed with the feed crude oil in
the suction line in the feed pump. Crude oil from the feed pump is further mixed with wash water
at a rate of approximately 0.5 % of the crude before the crude is sent through heat exchanger. In
this heat exchanger, the feed is heated to about 630C by exchanging heat with the outgoing treated
crude oil from the desalter. Treated crude passes through the tube side of the heat exchangers.
The crude from the exchangers will pass through the feed heater where in the temperature is raised
to 1000C before entering the desalter vessel. In the desalter vessel feed crude is fed at lower portion
of vessel where in it travels and separates through electrostatic grid. The electrostatic grid aids the
breaking of emulsion and settlement of water at the bottom. The crude after losing water/salts will
be let out through the crude outlet line from the top of vessel. Desalter has bottom outlet
connections at intervals for removal of water and sediments settled at bottom of desalter. Part of
the produced water is circulated back into desalter vessel through desludging pump (rated at 50

- 41 -
 m3/hr. and 25 m head) to maintain the water phase in the desalter in a fluidized condition so that
the sediments settle down at the bottom of the vessel and form the thick mud.
The desalter vessel is provided with sampling valves at various elevations to collect and analyze
the samples at various elevations on the desalter vessel. So, by analyzing these samples discharging
is done.

NAWAGAM PLANT FACILITIES

1. Storage system
➢ Crude oil
• No. of tanks: 4
• Type: floating roof
• Capacity: 30,000 m3
➢ Water
• Raw water tank:2
• Type: cone roof
• Capacity: 700 m3 each

2. POWER SUPPLY SYSTEM

➢ Distribution voltage:415 volts
➢ Normal power: 240 volts, AC
➢ Shut down: 110 volts, DC
➢ Fire alarm system: 240 volts AC

3. FIRE FIGHTING SYSTEM

➢ 2 JOCKEY pumps:
• Working pressure: 8 kg/ cm2
• Feed rate: 10 m3/hr.

➢ 2 diesel engine driven pump

• Feed rate: 410 m3/hr.
➢ 1 electrical driven pump
• Feed rate: 410 m3/hr.
➢ 2 water storing pond are there of capacity 3200 m3 each
4. PUMPING SYSTEM

Rotating pump Quantity Type Capacity Head

(m3/hr.) (m)

Desalter feed pump 4 Centrifugal 330 146

- 42 -
 Service water pump 2 Centrifugal 40 50

Process water pump 2 Centrifugal 40 135

Desludging pump 2 Centrifugal 50 25

Drinking water 2 Centrifugal 5 25

pump

Injection pumps 4 Centrifugal 700 lpm 29.7

(reciprocating)

5. COMPRESSORS
➢ Air compressor
• Quantity: 2
• Capacity:350 Nm3/hr.
• Discharge pressure: 9kg/cm2

6. BURNERS

➢ No. of burners: four reactors

➢ Type of burner: forced draft
➢ Type of fuel: natural gas
➢ Heat liberation(max) (mm BTU/hr.): 8

7. MISCILLANEOUS

➢ Instrumental Air Dryer:

• Quantity: 2
• Capacity: 150 m3/hr.
➢ Demulisifier mixer
• Quantity: 2

- 43 -
- 44 -
 SUPERVISORY CONTROL AND DATA AQUISITION (SCADA)

Supervisory control and data acquisition (SCADA) is a control system architecture that uses
computers, networked data communications and graphical user interfaces for high-level process
supervisory management, but uses other peripheral devices such as programmable logic
controllers and discrete PID controllers to interface to the process plant or machinery. The
operator interfaces which enable monitoring and the issuing of process commands, such as
controller set point changes, are handled through the SCADA supervisory computer system.
However, the real-time control logic or controller calculations are performed by networked
modules which connect to the field sensors and actuators.
The SCADA concept was developed as a universal means of remote access to a variety of local
control modules, which could be from different manufacturers allowing access through standard
automation protocols. In practice, large SCADA systems have grown to become very similar to
distributed control systems in function, but using multiple means of interfacing with the plant.
They can control large-scale processes that can include multiple sites, and work over large
distances. It is one of the most commonly-used types of industrial control systems, however there
are concerns about SCADA systems being vulnerable to cyberwarfare/cyberterrorism attacks.

SCADA implies a highly configurable set of industrial software applications that can be used to
support management of almost any form of process production. SCADA is widely applied in the
upstream, midstream, and downstream oil and gas sectors. In the upstream sector, its role often is
stereotyped as being largely in support of remote data transmission. There are reasons to believe
this will change. One reason to believe so is the wide and varied use of SCADA in other
industrial sectors. In addition, owners and operators are recognizing how IT-based automation
can productively address even the unique challenges of the upstream oil and gas sector.

SCADA system components

A SCADA system usually consists of the following main elements:

• Supervisory computers

• Remote terminal units

• Programmable logic controllers

• Communication infrastructure

• Human-machine interface

- 45 -
- 46 -
The SCADA concept in control operations

The key attribute of a SCADA system is its ability to perform a supervisory operation over a
variety of other proprietary devices.
The accompanying diagram is a general model which shows functional manufacturing levels
using computerized control.
Referring to the diagram,
• Level 0 contains the field devices such as flow and temperature sensors, and final control
elements, such as control valves.
• Level 1 contains the industrialized input/output (I/O) modules, and their associated
distributed electronic processors.
• Level 2 contains the supervisory computers, which collate information from processor
nodes on the system, and provide the operator control screens.
• Level 3 is the production control level, which does not directly control the process, but is
concerned with monitoring production and targets.
• Level 4 is the production scheduling level.

Level 1 contains the programmable logic controllers (PLCs) or remote terminal units (RTUs).
Level 2 contains the SCADA software and computing platform. The SCADA software exists
only at this supervisory level as control actions are performed automatically by RTUs or PLCs.
SCADA control functions are usually restricted to basic overriding or supervisory level
intervention. For example, a PLC may control the flow of cooling water through part of an
industrial process to a set point level, but the SCADA system software will allow operators to
change the set points for the flow. The SCADA also enables alarm conditions, such as loss of
flow or high temperature, to be displayed and recorded. A feedback control loop is directly
controlled by the RTU or PLC, but the SCADA software monitors the overall performance of the
loop.
Levels 3 and 4 are not strictly process control in the traditional sense, but are where production
control and scheduling takes place.
Data acquisition begins at the RTU or PLC level and includes instrumentation readings and
equipment status reports that are communicated to level 2 SCADA as required. Data is then
compiled and formatted in such a way that a control room operator using the HMI (Human
Machine Interface) can make supervisory decisions to adjust or override normal RTU (PLC)
controls. Data may also be fed to a historian, often built on a commodity database management
system, to allow trending and other analytical auditing.
SCADA systems typically use a tag database, which contains data elements
called tags or points, which relate to specific instrumentation or actuators within the process
system according to such as the Piping and instrumentation diagram. Data is accumulated against
these unique process control equipment tag references.

- 47 -
Modern SCADA Systems

Modern SCADA systems allow real-time data from the plant floor to be accessed from anywhere
in the world. This access to real-time information allows governments, businesses, and
individuals to make data-driven decisions about how to improve their processes. Without
SCADA software, it would be extremely difficult if not impossible to gather sufficient data for
consistently well-informed decisions.

Also, most modern SCADA designer applications have rapid application development (RAD)
capabilities that allow users to design applications relatively easily, even if they don't have
extensive knowledge of software development.

The introduction of modern IT standards and practices such as SQL and web-based applications
into SCADA software has greatly improved the efficiency, security, productivity, and reliability
of SCADA systems.

SCADA software that utilizes the power of SQL databases provides huge advantages over
antiquated SCADA software. One big advantage of using SQL databases with a SCADA system
is that it makes it easier to integrate into existing MES and ERP systems, allowing data to flow
seamlessly through an entire organization.

Historical data from a SCADA system can also be logged in a SQL database, which allows for
easier data analysis through data trending.

- 48 -
- 49 -
 ASSET CHEMISTY LAB

1. Oil Analysis Lab

Petroleum (from Greek: petra: "rock" + oleum: "oil". is a naturally occurring, yellow-to-black
liquid found in geological formations beneath the Earth's surface, which is commonly refined into
various types of fuels. Components of petroleum are separated using a technique called
fractional distillation.
It consists of hydrocarbons of various molecular weights and other organic compounds. The
name petroleum covers both naturally occurring unprocessed crude oil and petroleum products
that are made up of refined crude oil. A fossil fuel, petroleum is formed when large quantities of
dead organisms, usually zooplankton and algae, are buried underneath sedimentary rock and
subjected to both intense heat and pressure.
The hydrocarbons in crude oil are mostly alkanes, cycloalkanes and various aromatic
hydrocarbons, while the other organic compounds contain nitrogen, oxygen and sulfur, and trace
amounts of metals such as iron, nickel, copper and vanadium. Many oil reservoirs contain live
bacteria. The exact molecular composition of crude oil varies widely from formation to formation
but the proportion of chemical elements varies over fairly narrow limits as follows

• Carbon 83 to 85%
• Hydrogen 10 to 14%
• Nitrogen 0.1 to 2%
• Oxygen 0.05 to 1.5%
• Sulfur 0.05 to 6.0%
• Metals < 0.1%

Four different types of hydrocarbon molecules appear in crude oil. The relative percentage of
each varies from oil to oil, determining the properties of each oil.

Hydrocarbon Average Range

Alkanes 30% 15%-60%
Naphthene 49% 30%-60%
Aromatics 15% 3-30%
Asphaltic 6% remainder

- 50 -
Crude Oil Properties:

The key oil properties that are generally needed for understanding a reservoir and its
producibility are:
• Bubble point pressure
• Solution gas oil ratio (GOR)
• Formation volume factor
• Viscosity
• Interfacial tension
• Density
• Isothermal compressibility

ONGC Ahmedabad Asset Producing Area

Area Field
I Kalol, Motera,Wadu,Paliyad
II Nawagam,Wasana,Ramol,Ahmedabad,Sadar,Nandej,Walod,Mahilaj
III Sanand, Jhalora,South Kadi,Wadsar,South Viraj
IV Limbodarra,Gamij,Halisa

- 51 -
 2.Demulsifier Lab

• Emulsion: An emulsion is a colloidal dispersion of one liquid (disperse phase) in another(

continuous phase).Type of emulsion:
• water in oil
• oil in water
• multiple emulsion

Stability:
• Emulsion are inherently unstable.
• Classified based on their kinetic stability
• loose-few minutes
• medium-tens of minutes
• tight-hours, days
• Presence of emulsifying agents
• Films act as physical barrier to coalescence
Factor affecting stability
• Heavy polar material in the crude oil
• Fine solids including organics(asphaltenes, waxes) and inorganic(clay,scales,corrosion
products)
• Temperature
• pH of the brine
• droplets size and distribution
• brine composition

- 52 -
Oil demulsification

Demulsification is the breaking of a crude oil emulsion into oil and water phases. From a
process point of view, the oil producer is interested in three aspects of demulsification:

• Rate or the speed at which this separation takes place

• Amount of water left in the crude oil after separation
• Quality of separated water for disposal

Flocculation
The first step in demulsification is the flocculation of water droplets. During flocculation, the
droplets clump together, forming aggregates or "floccs." The droplets are close to each other, even
touching at certain points, but do not lose their identity (i.e., they may not coalesce). Coalescence
at this stage only takes place if the emulsifier film surrounding the water droplets is very weak.
The rate of flocculation depends on the following factors

• Water content in the emulsion. The rate of flocculation is higher when the water cut is
higher.
• Temperature of the emulsion is high. Temperature increases the thermal energy of the
droplets and increases their collision probability, thus leading to flocculation.
• Viscosity of the oil is low, which reduces the settling time and increases the flocculation
rate.
• Density difference between oil and water is high, which increases the sedimentation rate.
• An electrostatic field is applied. This increases the movement of droplets toward the
electrodes, where they aggregate

Coalescence

Coalescence is the second step in demulsification. During coalescence, water droplets fuse or
coalesce together to form a larger drop. This is an irreversible process that leads to a decrease in
the number of water droplets and eventually to complete demulsification. Coalescence is enhanced
by the following factors.

• High rate of flocculation increases the collision frequency between droplets.

• The absence of mechanically strong films that stabilize emulsions.
• High interfacial tension. The system tries to reduce its interfacial free energy by
coalescing.
• High water cut increases the frequency of collisions between droplets.
• Low interfacial viscosity enhances film drainage and drop coalescence.
• Chemical demulsifiers convert solid films to mobile soap films that are weak and can be
ruptured easily, which promotes coalescence.
• High temperatures reduce the oil and interfacial viscosities and increase the droplet
collision frequency.

- 53 -
3.Water Lab

Water is classified in three categories

• Technical water
• Portable water
• Injection water

Requirement for water

• ETP
• Drinking
• WIP
• Drilling Mud Making

The various equipment

• Oven
• Met ohm Meter
• Turbidity Meter
• pH meter
• Weight Meter

The various test

• pH
• Turbidity
• Total Suspended Solid
• Dissolved Oxygen
• Filterability
• Total Hardness
• Oil & Grease
• Residual Chloride
• Iron
• SRB
• GAB

- 54 -
ARTIFICIAL LIFT METHODS USED IN
CRUDE OIL EXTRACTION

- 55 -
 FIELD PRODUCTION PHASES

The production of crude oil in oil reservoirs can include up to three distinct phases:

• Primary

• Secondary and

• Tertiary recovery.
Primary oil recovery refers to the process of extracting oil either via the natural rise of
hydrocarbons to the surface of the earth or via pump jacks and other artificial lift devices. Since
this technique only targets the oil, which is either susceptible to its release or accessible to the
pump jack, this is very limited in its extraction potential. In fact, only around 5% - 15% of the
well’s potential are recovered from the primary method.
Secondary Oil Recovery involves the injection of gas or water, which will displace the oil, force
it to move from its resting place and bring it to the surface. This is typically successful in targeting
an additional 30% of the oil’s reserves, though the figure could be more or less depending on the
oil and of the rock surrounding it.
Tertiary recovery: A technique used to extract the remaining oil from previously drilled and now
less desirable reservoirs where primary and secondary extraction methods are no longer cost
effective. There are three main types of EOR, including chemical flooding, gas injection and
thermal recovery.

ARTIFICIAL LIFT
Artificial lift is a method used to lower the producing bottom hole pressure (BHP) on the formation
to obtain a higher production rate from the well Artificial lift refers to the mechanical lifting of
wellbore fluids to the surface. Mechanical lifting of wellbore fluids is required when reservoir
pressure is insufficient to drive reservoir fluids to the surface. Artificial lift equipment also can be
used to increase production from flowing wells by reducing the producing bottom hole pressure.
The main goal of artificial lift is to maximize the ultimate recovery from any hydrocarbon
reservoir. Hydrocarbons will normally flow to the surface under natural flow when the discovery
well is completed in a virgin reservoir. The fluid production resulting from reservoir development
will normally lead to a reduction in the reservoir pressure, increase in the fraction of water being
produced together with a corresponding decrease in the produced gas fraction. All these factors
reduce, or may even stop, the flow of fluids from the well. The remedy is to include within the
well completion some form of artificial lift. Artificial lift adds energy to the well fluid which, when
added to the available energy provided “for free” by the reservoir itself, allows the well to flow at
a (hopefully economic) production rate.
Artificial lift is required when a well will no longer flow or when the production rate is too low to
be economic.

- 56 -
TYPE OF ARTIFICIAL LIFT

The most popular forms of artificial lift are:

• Sucker-rod (beam) pumping

• Electrical submersible pumping (ESP)

• Gas lift and intermittent gas lift

• Reciprocating and jet hydraulic pumping systems

• Progressive cavity pumps (PCP)

- 57 -
SELECTION OF ARTIFICIAL LIFT

To realize the maximum potential from developing any oil or gas field, the most economical
artificial lift method must be selected There are many factors that influence which is the preferred
form of artificial lift.
Some of the factors to be considered are:

• Operator experience

• What methods are available for installations in certain areas of the world

• What is working in adjoining or similar fields

• Determining what methods will lift at the desired rates and from the required depths

• Evaluating lists of advantages and disadvantages

• “Expert” systems to both eliminate and select systems

• Evaluation of initial costs, operating costs, production capabilities, etc. with the use of
economics as a tool of selection, usually on a present-value basis

These methods consider:

• Geographic location

• Capital cost

• Operating cost

• Production flexibility

• Reliability

• Mean time between failures

Artificial lift method selection should be a part of the overall well design. Once the method is
selected, the wellbore size required to obtain the desired production rate must be considered. Many
times, a casing program has been designed to minimize well-completion costs, but it is later found
that the desired production could not be obtained because of the size limitation on the artificial lift
equipment. This can lead to an ultimate loss of total reserves. Even if target production rates can
be achieved, smaller casing sizes can lead to higher long-term well-servicing problems. If oil prices
are low, it is tempting to select a small casing size to help with current economics.

- 58 -
 Advantage

Disadvantage

- 59 -
 SUCKER ROD PUMPS

History:

Sucker rod or beam pump was the first type of artificial lift to be introduced to the oil field. It is
also the most widely used in terms of the number of installations worldwide. In 1993, some 85%
of the USA population of artificially lifted wells was produced by rod pumps and more than 70%
of these produced less than 10 barrels of oil per day. The low cost, mechanical simplicity and the
ease with which efficient operation can be achieved makes rod pumps suitable for such low volume
operations.

Considerations

• Maximum*Operating Depth 100 -11,000’ TVD16,000’ TVDO

• Operating Volume: 5 -1500 BPD5000 BPD

• Operating Temperature:100° -350° F550° F

• Wellbore 0 -20° Landed 0 -90° Landed Deviation

• Pump-Pump -<15°/100’Build Angle

• Corrosion Handling: Good to Excellent w/ Upgraded Materials

- 60 -
 • Gas Handling: Fair to Good

• Solids Handling: Fair to Good Fluid

• Gravity >8° API

• Servicing: Work over or Pulling Rig

• Prime Mover: Type Gas or Electric

• Offshore Application Limited System

• Efficiency: 45%-60%

Selecting the sucker-rod pumping method

Sucker-rod pumping systems should be considered for new, lower volume stripper wells, because
they have proved to be cost effective over time. Operating personnel usually are familiar with these
mechanically simple systems and can operate them efficiently. Inexperienced personnel also can
operate rod pumps more effectively than other types of artificial lift. Most of these systems have a
high salvage value.

Because of its long history of successfully lifting well fluids, the sucker-rod lift method is normally
considered the first choice for most onshore, and even some offshore, installations all over the
world. This method is limited by:

• Size of the casing, tubing, and downhole pump

• Strength and size of the various rods

• Speed with which they can be reciprocated

Undesirable effects result when the producing equipment’s capacity is not properly balanced with
reservoir fluid inflow. These effects include the following:

• Loss or deferment of production.

• Excessive producing costs.

• Premature equipment failure.

• Ineffective use of energy.

• Increased operating expenses.

- 61 -
Advantage and Disadvantage:

- 62 -
ELECTICAL SUBMERSIBLE PUMP

- 63 -
History
In 1911, 18-year-old Armais Arutunoff organized the Russian Electrical Dynamo of Arutunoff Co.
in Ekaterinoslav, Russia, and invented the first electric motor that would operate in water.
In 1916, he redesigned a centrifugal pump to be coupled to his motor for dewatering mines and
ships. In 1926, at the American Petroleum Institute (API) conference in Los Angeles, two parties
joined together to start the ESP industry. Just before this conference, in 1962, Goulds Pump Oil
Field Submergible Division approached Franklin Electric to find a better motor for their oilfield-
pump product. By 1967, they had designed a new product and had formed a joint venture company,
Oil Dynamics Inc. (ODI). In 1997, ODI was sold to Baker Hughes Inc., and its product line was
merged into Centrilift’s.
The story behind the third company becomes a little more convoluted. In 1965, Hydrodynamics
was formed as a part of Peerless Pump to develop an oilfield submersible product. After limited
financial success, it was sold to FMC Corp. and renamed Oiline. In 1976, it was sold again, this
time to Kobe, and became Kobe Oiline. Kobe was sold to Trico in 1983, but the Kobe Oiline
product was spun off to Baker International, and it became Bakerlift Systems. Trico had also just
purchased the Standard Pump water-well line from REDA. A side branch to this tree starts with
the emergence of Western Technologies in 1978. It was sold to Dresser Industries and renamed
WesTech in 1982. Then, in 1985, it was sold to Bakerlift Systems. When Baker International and
Hughes merged in 1987, the US operation of Bakerlift was divested and sold to Trico, but Baker
Hughes retained the international segment of the Bakerlift business. Trico’s product line was made
up of equipment from Kobe Oiline, Standard Pump, WesTech, and Bakerlift Systems. It was
renamed Trico Sub Services. On another side branch, ESP Inc. was formed in 1983. Wood Group
purchased it in 1990. Then, in 1992, Trico Sub Services was purchased by Wood Group and was
merged into ESP Inc.

Introduction

The electrical submersible pump, typically called an ESP, is an efficient and reliable artificial-lift
method for lifting moderate to high volumes of fluids from wellbores. The ESP’s main components
include
• Multistage centrifugal pump
• Three-phase induction motor
• Seal-chamber section
• Power cable
• Surface controls

Normally, the production fluids are crude oil and brine, but they may be called on to handle:
• Liquid petroleum products
• Disposal or injection fluids
• Fluids containing free gas
• Some solids or contaminates
• CO2 and H2S gases or treatment chemicals

- 64 -
 Advantages

ESPs provide a number of

advantages.
• Adaptable to highly deviated
wells; up to horizontal, but must
be set in straight section.
• Adaptable to required
subsurface wellheads 6 ft. apart
for maximum surface-location
density.
• Permit use of minimum space
for subsurface controls and
associated production facilities.
• Quiet, safe, and sanitary for
acceptable operations in an
offshore and environmentally
conscious area.
• Generally considered a high-
volume pump.
• Provides for increased
volumes and water cuts brought
on by pressure maintenance and secondary recovery operations.
• Permits placing wells on production even while drilling and working over wells in
immediate vicinity.
• Applicable in a range of harsh environments.

Disadvantages

ESPs have some disadvantages that must be considered.

• Will tolerate only minimal percentages of solids (sand) production, although special
pumps with hardened surfaces and bearings exist to minimize wear and increase run life.
• Costly pulling operations and lost production occur when correcting downhole failures,
especially in an offshore environment.
• Below approximately 400 B/D, power efficiency drops sharply; ESPs are not particularly
adaptable to rates below 150 B/D.
• Need relatively large (greater than 4½-in. outside diameter) casing size for the moderate-
to high-production-rate equipment.

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 GAS LIFT METHOD

Continuous Flow Gas Lift

Installation

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Introduction

Gas lift is a method of artificial lift that uses an external source of high-pressure gas for
supplementing formation gas to lift the well fluids. The principle of gas lift is that gas injected into
the tubing reduces the density of the fluids in the tubing, and the bubbles have a “scrubbing” action
on the liquids. Both factors act to lower the flowing bottom hole pressure (BHP) at the bottom of
the tubing. There are two basic types of gas lift in use today
• continuous and
• intermittent flow.

Continuous-flow gas lift: The principle underlying the continuous flow gas lift method is that
energy resulting from expansion of gas from a high pressure to a lower pressure is utilized in
promoting the flow of well fluids in a vertical tube or annular configurations. Utilization of this
gas energy is accomplished by the continuous injection of a controlled stream of gas into a rising
stream of well fluids in such a manner that useful work is performed in lifting the well fluids.

Intermittent-flow gas lift operates on the principle of intermittent gas injection. This means that
gas lift injection occurs for a certain length of time and then stops. After a period a period of time
has elapsed, injection again takes place and the cycle is repeated.

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The basic components are:

• Gas Lift Valves

• Mandrels
• Latches
• Kick over Tools
• Surface Controls
• Coiled-Tubing
• Gas Lift Equipment
• Pack-Off Equipment

Advantage

• High Degree of Flexibility and Design Rates

• Wireline Retrievable
• Handles Sandy Conditions Well
• Allows For Full Bore Tubing Drift
• Surface Wellhead Equipment Requires Minimal Space
• Multi-Well Production From Single Compressor
• Multiple or Slim hole Completion

Disadvantage
• Needs High-Pressure Gas
Well or Compressor
• One Well Leases May Be
Uneconomical
• Fluid Viscosity
• Bottom hole Pressure
• High Back-PressureGas

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HYDRAULIC PUMPS

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Hydraulic pumping is a proven artificial lift method that has been used since the early 1930s. It
offers several different systems for handling a variety of well conditions. Successful applications
have included setting depths ranging from 500 to 19,000 ft and production rates varying from less
than 100 to 20,000 B/D. Surface packages are available using multiplex pumps ranging from 15
to 625 hp. The systems are flexible because the downhole-pumping rate can be regulated over a
wide range with fluid controls on the surface. Chemicals to control corrosion, paraffin, and
emulsions can be injected downhole with the power fluid, while fresh water can also be injected
to dissolve salt deposits. When pumping heavy crudes, the power fluid can serve as an effective
diluent to reduce the viscosity of the produced fluids. The power fluid also can be heated for
handling heavy or low-pour-point crudes. Hydraulic pumping systems are suitable for wells with
deviated or crooked holes that can cause problems for other types of artificial lift. The surface
facilities can have a low profile and may be clustered into a central battery to service numerous
wells. This can be advantageous in urban sites, offshore locations, areas requiring watering
systems (sprinkle systems), and environmentally sensitive areas.

Basic operation

Hydraulic pumping systems transmit power downhole by means of pressurized power fluid that
flows in wellbore tubulars. Hydraulic transmission of power downhole can be accomplished with
reasonably good efficiency using a reciprocating piston pump. With 30°API oil at 2,500 psi in 2
7/8-in. tubing, 100 surface hydraulic horsepower can be transmitted to a depth of 8,000 ft with a
flow rate of 2,350 B/D and a frictional pressure drop of less than 200 psi. Even higher efficiencies
can be achieved with water as the hydraulic medium because of its lower viscosity.

The downhole pump acts a transformer to convert the energy into pressure in the produced fluids.
A common form of a hydraulic downhole pump consists of a set of coupled reciprocating pistons,
one driven by the power fluid and the other pumping the well fluids. Another form of a hydraulic
downhole pump that has become more popular is the jet pump, which converts the pressurized
power fluid to a high-velocity jet that mixes directly with the well fluids.In the turbulent mixing,
momentum and energy from the power fluid are added to the produced fluids.The operating
pressures in hydraulic pumping systems usually range from 2,000 to 4,000 psi. The most common
pump used to generate this pressure on the surface is a multiplex positive displacement pump
driven by an electric motor or multi cylinder gas or diesel engine.

There are two primary kinds of hydraulic pumps:

• Jet pumps

• Reciprocating positive-displacement pump

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Applications

Hydraulic systems are normally is used in areas where other types of artificial lift have failed or,
because of well conditions, have been eliminated because of their shortcomings. Hydraulic
pumping systems have been labeled expensive, but they may have application where other
artificial lift methods may not be feasible.

• Using hydraulic free pumps in remote areas where the rig costs are unusually high or the
availability of workover rigs is limited
• Crooked or deviated wells
• Use of hydraulic systems in relatively deep, hot, high-volume wells (Note: Hydraulic
pumps can go through tubing with as much as a 24° buildup per 100 ft.)
• The use of jet pumps in sandy corrosive wells
• The use of reciprocating pumps in deep wells with low bottomhole producing pressure
• Wells with rapidly changing producing volumes
• The use of jet pumping systems in wells producing with gas/liquid ratios less than 750:1
but producing under a packer where free gas must be pumped
• Using hydraulic free pumps in wells with high-paraffin contents
• Using hydraulic open power fluid systems in low-API-gravity wells.

Advantages
• It is especially attractive on offshore platforms, remote locations, and populated and
agricultural areas.
• By changing the power-fluid rate to the pumps, production can be varied from 10 to 100%
of pump capacity. The optimum speed range is 20 to 85% of rated speed. Operating life
will be significantly reduced if the pump is operated above the maximum-rated speed.
• Deviated wells typically present few problems to hydraulic free pumps. Jet pumps can even
be used in through flowline installations.
• Jet pumps, with hardened nozzle throats, can produce sand and other solids.
• The power fluid can be heated, or it can have diluents added to further aid lifting the oil to
the surface.
• Corrosion inhibitors can be injected into the power fluid for corrosion control.

Disadvantages
• Removing solids from the power fluid is very important for positive-displacement pumps..
Jet pumps, on the other hand, are very tolerant of poor power-fluid quality.
• Positive-displacement pumps, on average, have a shorter time between repairs than jet,
sucker rod, and ESPs. Mostly,. Jet pumps, on the other hand, have a very long pump life
between repairs without solids or if not subjected to cavitation. Jet pumps typically have
lower efficiency and higher energy costs.

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• Positive-displacement pumps can pump from a low BHP (< 100 psi) in the absence of gas
interference and other problems. Jet pumps cannot pump from such low intake pressures,
especially when less than the cavitation pressure. Jet pumps require approximately 1,000
psi BHP when set at 10,000 ft and approximately 500 psi when set at 5,000 ft.
• Positive-displacement pumps generally require more maintenance than jet pumps and other
types of artificial lift because pump speed must be monitored daily and not allowed to
become excessive. Power-fluid-cleaning systems require frequent checking to keep them
operating at their optimum effectiveness. Also, well testing is more difficult.

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PROGRESSING CAVITY PUMP

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Introduction

Progressing cavity pumping (PCP) systems derive their name from the unique, positive
displacement pump that evolved from the helical gear pump concept first developed by Rene
Moineau in the late 1920s.Although these pumps are now most commonly referred to as
progressing cavity (PC) pumps, they also are called screw pumps or Moineau pumps. They are
increasingly used for artificial lift, and have been adapted to a range of challenging lift situations
(e.g., heavy oil, high sand production, gassy wells, directional or horizontal wells).

History:

Progressive cavity (PC) pumps initially were used extensively as fluid transfer pumps in a wide
range of industrial and manufacturing applications, with some attempts made to use them for
the surface transfer of oilfield fluids. However, it was not until after the development of synthetic
elastomers and adhesives in the late 1940s that PC pumps could be applied effectively in
applications involving petroleum-based fluids. Except for several limited field trials, it was not
until the late 1970s that a concerted effort was made to use PC pumps as a method of artificial
lift for the petroleum industry.

Principle

The rotor is rotated inside an elastomeric pump body or stator, which has been molded in the
form of a double helix with a pitch of the same diameter and exactly twice the length of the pitch
given to the rotor. when assembled, the center line of the rotor and the stator are slightly offset,
creating a series if fluid filled cavities along the length of the pump. the interference fit between
the rotor and stator creates two chains of spiral (fluid filled) cavities

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Advantage

• High overall system energy efficiency, typically in the 55 to 75% range.

• Ability to produce high concentrations of sand or other produced solids.
• Ability to tolerate high percentages of free gas.
• No valves or reciprocating parts to clog, gas lock, or wear.
• Good resistance to abrasion.
• Low internal shear rates (limits fluid emulsification through agitation).
• Relatively low power costs and continuous power demand (prime mover capacity fully
utilized).
• Relatively simple installation and operation.
• Generally low maintenance.
• Low profile surface equipment.
• Low surface noise levels.

Disadvantage

• Limited production rates (maximum of 800 m3/d [5,040 B/D] in large-diameter pumps,
much lower in small-diameter pumps).
• Limited lift capacity (maximum of 3000 m [9,840 ft]). Note that the lift capacity of larger
displacement PC pumps is typically much lower.
• Limited temperature capability (routine use to 100°C [212°F], potential use to 180°C
[350°F] with special elastomers).
• Sensitivity to fluid environment (stator elastomer may swell or deteriorate on exposure
to certain fluids, including well treatment fluids).
• Subject to low volumetric efficiency in wells producing substantial quantities of gas.
• Sucker rod strings may be susceptible to fatigue failures.
• Pump stator may sustain permanent damage if pumped dry for even short periods.
• Rod-string and tubing wear can be problematic in directional and horizontal wells.
• Most systems require the tubing to be pulled to replace the pump.
• Vibration problems may occur in high-speed applications (mitigation may require the use
of tubing anchors and stabilization of the rod string).
• Paraffin control can be an issue in waxy crude applications (rotation as opposed to
reciprocation of the rod string precludes use of scrapers for effective wax removal).
• Lack of experience with system design, installation, and operation, especially in some
areas.

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 ASSET CHEMISTY LAB

2. Oil Analysis Lab

Petroleum (from Greek: petra: "rock" + oleum: "oil". is a naturally occurring, yellow-to-black
liquid found in geological formations beneath the Earth's surface, which is commonly refined into
various types of fuels. Components of petroleum are separated using a technique called
fractional distillation.
It consists of hydrocarbons of various molecular weights and other organic compounds. The
name petroleum covers both naturally occurring unprocessed crude oil and petroleum products
that are made up of refined crude oil. A fossil fuel, petroleum is formed when large quantities of
dead organisms, usually zooplankton and algae, are buried underneath sedimentary rock and
subjected to both intense heat and pressure.
The hydrocarbons in crude oil are mostly alkanes, cycloalkanes and various aromatic
hydrocarbons, while the other organic compounds contain nitrogen, oxygen and sulfur, and trace
amounts of metals such as iron, nickel, copper and vanadium. Many oil reservoirs contain live
bacteria. The exact molecular composition of crude oil varies widely from formation to formation
but the proportion of chemical elements varies over fairly narrow limits as follows

• Carbon 83 to 85%
• Hydrogen 10 to 14%
• Nitrogen 0.1 to 2%
• Oxygen 0.05 to 1.5%
• Sulfur 0.05 to 6.0%
• Metals < 0.1%

Four different types of hydrocarbon molecules appear in crude oil. The relative percentage of
each varies from oil to oil, determining the properties of each oil.

Hydrocarbon Average Range

Alkanes 30% 15%-60%
Naphthene 49% 30%-60%
Aromatics 15% 3-30%
Asphaltic 6% remainder

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Crude Oil Properties:

The key oil properties that are generally needed for understanding a reservoir and its
producibility are:
• Bubble point pressure
• Solution gas oil ratio (GOR)
• Formation volume factor
• Viscosity
• Interfacial tension
• Density
• Isothermal compressibility

ONGC Ahmedabad Asset Producing Area

Area Field
I Kalol, Motera,Wadu,Paliyad
II Nawagam,Wasana,Ramol,Ahmedabad,Sadar,Nandej,Walod,Mahilaj
III Sanand, Jhalora,South Kadi,Wadsar,South Viraj
IV Limbodarra,Gamij,Halisa

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 2.Demulsifier Lab

• Emulsion: An emulsion is a colloidal dispersion of one liquid (disperse phase) in another(

continuous phase).Type of emulsion:
• water in oil
• oil in water
• multiple emulsion

Stability:
• Emulsion are inherently unstable.
• Classified based on their kinetic stability
• loose-few minutes
• medium-tens of minutes
• tight-hours, days
• Presence of emulsifying agents
• Films act as physical barrier to coalescence
Factor affecting stability
• Heavy polar material in the crude oil
• Fine solids including organics(asphaltenes, waxes) and inorganic(clay,scales,corrosion
products)
• Temperature
• pH of the brine
• droplets size and distribution
• brine composition

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Oil demulsification

Demulsification is the breaking of a crude oil emulsion into oil and water phases. From a
process point of view, the oil producer is interested in three aspects of demulsification:

• Rate or the speed at which this separation takes place

• Amount of water left in the crude oil after separation
• Quality of separated water for disposal

Flocculation
The first step in demulsification is the flocculation of water droplets. During flocculation, the
droplets clump together, forming aggregates or "floccs." The droplets are close to each other, even
touching at certain points, but do not lose their identity (i.e., they may not coalesce). Coalescence
at this stage only takes place if the emulsifier film surrounding the water droplets is very weak.
The rate of flocculation depends on the following factors

• Water content in the emulsion. The rate of flocculation is higher when the water cut is
higher.
• Temperature of the emulsion is high. Temperature increases the thermal energy of the
droplets and increases their collision probability, thus leading to flocculation.
• Viscosity of the oil is low, which reduces the settling time and increases the flocculation
rate.
• Density difference between oil and water is high, which increases the sedimentation rate.
• An electrostatic field is applied. This increases the movement of droplets toward the
electrodes, where they aggregate

Coalescence

Coalescence is the second step in demulsification. During coalescence, water droplets fuse or
coalesce together to form a larger drop. This is an irreversible process that leads to a decrease in
the number of water droplets and eventually to complete demulsification. Coalescence is enhanced
by the following factors.

• High rate of flocculation increases the collision frequency between droplets.

• The absence of mechanically strong films that stabilize emulsions.
• High interfacial tension. The system tries to reduce its interfacial free energy by
coalescing.
• High water cut increases the frequency of collisions between droplets.
• Low interfacial viscosity enhances film drainage and drop coalescence.
• Chemical demulsifiers convert solid films to mobile soap films that are weak and can be
ruptured easily, which promotes coalescence.
• High temperatures reduce the oil and interfacial viscosities and increase the droplet
collision frequency.

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3.Water Lab

Water is classified in three categories

• Technical water
• Portable water
• Injection water

Requirement for water

• ETP
• Drinking
• WIP
• Drilling Mud Making

The various equipment

• Oven
• Met ohm Meter
• Turbidity Meter
• pH meter
• Weight Meter

The various test

• pH
• Turbidity
• Total Suspended Solid
• Dissolved Oxygen
• Filterability
• Total Hardness
• Oil & Grease
• Residual Chloride
• Iron
• SRB
• GAB

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