INTRODUCTION:

Description of the Installation:

Group Gathering Station SANAND(GGS-II), located at SANAND field is designed to handle crude oil
and gas produced from the wells located in the area. It was commissioned on 27.01.1973. It has the
approval of the Director General of Mines safety vide permission no UR/ONGUJ/Ahm/Perm/5247
dated and PML for this installation is SANAND with grant order no. PML-2007-4598-E dated
10.06.2008 with validity up to 9th May 2021.It has GPCB consent Order No. GPCB ID-AWH-34335
valid till 13-05-2014

Following facilities are provided in this SANAND GGS-II

i. Separation of oil and gas.

ii. Testing of oil and gas wells.

iii. Treatment of Oil emulsion.

iv. Transportation of oil & associated gas through pipeline.

v. Effluent disposal through tanker and pipeline.

vi. Emergency Generator.

vii. Tube well for Fire water and Drinking water.

viii. Fixed Fire Fighting System.

DESIGN BASIS:

Plant Capacity

Based on pure oil processing Design: 75 m3 /day

Feed –Stock source

Well Fluid from 19 wells scattered around SANAND GGS-II

Oil/Gas/Effluent Production

Crude oil Production: 75 m3 /day

Effluent: 120 m3 /day

Gas: 5,000 m3 /day

Production Specifications

a) Treated crude oil water is presently below 5% by volume.

Overview of Wells connected to SANAND GGS-II

Total wells connected – 34

Oil Wells:-17

No. of oil flowing wells: - 11

(As on date 28.11.2013)

No. of Non flowing wells: - 06

No. of polymer injection wells:-05

No. of ED wells:-07

No. of Sick injection wells:-05

Flowing oil wells:-

Under self-flow-NIL

With SRP- 13
 With electric submersible pump- 02

Under gas lift- NIL

Flowing gas wells-02

Non-flowing well:-

Under/Waiting for work over-04

Closed due to high water cut- NIL

Closed reservoir control- NIL

Other reason- NIL

Recompletion- NIL

Crude Oil Properties of group oil sample of SANAND GGS-II:

1) Density of oil @ 150 C(Not for emulsion) : 0.9158

2) Density of water @ 150 C (F/w in equilibrium with oil ) : NA
3) Viscosity (Cps)
@ 500 C: 164

@ 400 C: 318

@ 40 C: 6719

4) Free water in wells fluid at GGS (%)- NIL

FACILITIES IN SANAND GGS-II:

Details of Manifolds and Headers

Well Fluid Manifold

Well fluids (Oil, gas & water) received from the wells through 4” pipelines.

Headers:

The Headers in the oil well manifold have the following descriptions:

Sr no. Type of Header Operating Pressure Size Capacity

(Kg/ cm2 g) Ф

1 Group header 4.5 -5.5 6” 20

2 Test header 4.5 -5.5 4” 20

3 Low pressure 0 4” 20

FEED SUPPLY

SANAND GGS-II wells are spread to an area of appx. 10 Sq. km. pipelines of 4” dia. Size are provided
from each of 14 oil wells connecting them to the oil headers. High Pressure/Isolation valves and
check are provided on each pipeline from the wells. Valves are also provided in the manifold to
divert the well fluid coming from the 4” dia. Pipelines to the headers.

GAS-LIQUID SEPARATION FACILITY.

Group / Test Separators

Six separators V-01, V-02, V-03, V-04, V-05 & V-06 each having a designed capacity to handle
180 m3/day of well fluid are provided. Out of the six separators V-01, V-02, V-03, V-04 is
connected to Group production with all instrumentation and V-05 and V-06 is meant for
testing of wells, flowing wells for activation or depressurization during flow line leakage at
low pressure. Dosing of demulsifier is given at separator inlet.
From Group Emulsion Separators oil emulsion is diverted through 8 nos. of Heater Treaters
for further treatment. Emulsion from test separators is taken directly to storage tanks which
is recycled to heater treaters through 9-MGR pumps. The gas from high pressure
emulsion/test separators received in gas scrubber and diverted to low pressure suction line
of GCP Sanand through PCV.

Feed enters the group separators from the valve manifold through 8” dia. Line. The
operating pressure in the separators is about 5.0 - 6.0 Kg/cm2. The separator has two phase
separation, capable of separating oil and gas. The vessels are designed for a pressure rating
of 9.0 Kg/cm2 at a design temperature of 70C. The separated oil flows out from the
separator to oil storage tanks via heater treater.

Pressure gauges are provided on the separators to monitor the operating pressure. All the
separators are provided with pressure relief valve PSV-101/102/103/104/105/106 to
protect the vessel against over pressure. The valves are set at a pressure of 6.6 Kg/cm2.

EMULSION OIL TREATMENT FACILITY

To break the oil-water emulsion, Heater Treaters based on thermo-chemo-electro-mechanical

process for emulsion breaking are employed. Anti-scaling chemical is dosed at the inlet of heater
treator.

STORAGE UNIT FOR CRUDE OIL AND EFFLUENT.

After processing in the heater treaters, the well fluids are converted to crude oil and effluent water
(containing emulsified oil). These are stored separately. At times, to recover oil from effluent, de-
oiler addition is done in the effluent wash tank.

CRUDE OIL PUMPING SYSTEM

Two crude dispatch pumps P-01/02 are provided for transferring crude oil from the oil storage tanks
to Nawagam CTF through 12” dia. Pipeline. These are motor driven reciprocating pumps having a
discharge rate of 10 m3/hr. to 35 m3/hr.

Each pump discharge line has a safety valve discharging to suction line. Safety valve is set at 30
kg/cm2.
EFFLUENT DISPOSAL FACILITY

Two effluent transfer pumps P-01/02 are provided for transferring effluent from tank to ETP. These
are motor driven pumps having discharge rate of 25 m3/hr. to 35 m3/hr.

UTILITIES AVAILABLE IN THE INSTALLATION

The normal plant power to the plant is supplied at 11kv Power Supply from Gujarat Electricity
Board. The overall normal power requirement envisaged has been of the order of 630KVA. Besides
this there is also an emergency power supply by 125KVA diesel generator set. In case of the normal
failure, the DG set shall be manually started to provide power supply to essential service.

Prime source of Power: Gujarat State Electricity Board.

Stand by source power: D.G.SET

Make: Cummins

Models: NTC-495-G

WATER SUPPLY:-

Source => Ground Water

Lift => Submersible Pump

Storage => Open Tank

FIRE FIGHTING SYSTEM

Diesel engine driven fire water pumps, connected to tanks through hoses are provided in the
installation for fire fighting purpose.

Fire water storage tanks

Type U/G

Nos. 02

Capacity (m3) 1100(each)

Fire Water Pumps:

Make Kirloskar MWM

Nos. 1 2
Type. Centrifugal (Motor Operated) Centrifugal(Diesel Operated)
Total Head(m) 88 88
Discharge rate (m3/hr) 273 273

The Fire fighting equipments available in the installation are as under:-

Type Capacity Nos.

DCP Fire Ext. 5/10 / 15 kg 21

DCP Trolley 150 kg

CO2 Fire Ext. 4.5/6.8 / 9 kg 5

Buckets ------ ---

Hooter ------ 1

Fire Bell ------- 1

AFFF 9 ltrs 5
OPERATIONAL PHILOSOPHY

Different wells producing oil, gas and water using different mechanisms for production are
connected to the Group Gathering Station by flow lines. The different mechanisms used to produce
oil are based on the well potential and the production pattern desired. In the usual case, the well
flows on its own pressure and is termed as a self- flow well. In case the reservoir pressure declines,
artificial lift methods are used to lift the well fluids to the surface for processing of the produced well
fluid i.e. its composition and its pressure.

Medium-Pressure (Group) Emulsion Oil Header or Group Header( 6” Size): This header is main
header of the installation maintained at around 4.5 – 5.5 Kg/cm2.g Pressure presently. Wells
flowing to this header mainly comes from the wells that are diverted to this header.

Medium-Pressure Emulsion Oil Header or Test Header (4” size): This header is maintained at around
4.5 -5.5 Kg/cm2.g pressure. Wells flowing to this header mainly comes from the wells. This header is
mainly used for well testing & analysis through test separator.

Low Pressure Header: Low –pressure (LP) oil headers are routed to the LP separator where two-
phase separation takes place and gas & liquid gets separated. LP separators are maintained at
around 0-2.0 Kg/cm2.g pressure, by a pressure safety valve (PSV) and a pressure control valve (PCV)
in the gas outlet line of LP Separator. LP gas from the LP Separators is first used for internal
consumption as Fuel Gas.

In case of any upset/shut-down in the system or any high-pressure condition, a pressure safety valve
(PSV) and a pressure control valve (PCV) exists in the gas outlet line of each separator to divert the
gas to flare system. Moreover, all the separators is protected by pressure safety valves (PSV) to
prevent over pressure. The separated liquid from the separators along-with the condensate liquid is
sent to heater-treater followed by storage-tanks.

The treated oil from the Heater Treaters is first stored in the Crude Oil Storage Tanks before
pumping it to Nawagam CTF through 12” oil feeder Pipeline at a pressure of around 10-15 Kg/cm2 in
summer but line pressure increase mainly due to waxy nature of crude. Effluent Generated at the
installation is transferred to ETP jhalora through 4” pipeline with help of effluent dispatch pumps.

Storage tanks are cylindrical and horizontal tanks having Gate and Vent valves.
Four crude oil dispatch pumps P-01/02 are provided for transferring crude oil from the oil storage
tanks to Nawagam CTF through 8” dia. Pipeline. These are motor driven reciprocating pumps having
a discharge rate of 10m3/hr. to 35 m3/hr. Oil dispatch is normally carried out round o’clock

Associated gas which is separated from the well fluids sent to GCP Sanand through 14” AG line for
compression and further utilisation for gas lift purpose. High pressure gas received for GCP Sanand
through HP grid line is directly fed to gas lift manifold at GGS for injection in individual gas lift wells
of the installation.

As safety measure, gas vented out from the system is sent to a cold Ground flare system which ios
placed external to the gas complex premises.

Fire fighting facilities include fire water pond, fire water pumps and firewater network in addition to
the portable fire Extinguishers placed at various points.
PROCESS DESCRIPTION:

GROUP GATHERING STATION

Oil is received in the SANAND GGS-II from the wells through 4” pipelines into the following headers:

a) Group Header

b) Test Header

c) Low Pressure Header

Group Oil and Gas

Well fluid from the Headers goes to the header, to Group Separators. Oil after separating
from Group Separator goes to Heater Treater (HT) for emulsions separation. Oil from HT
goes to oil storage tank and from where it is pumped to CTF (NAWAGAM) with the help of
oil dispatch pumps. Free gas from separators and gas wells is used for internal consumption
and make up in compressors.

Test Oil and Gas

One test header with sectioning valves is provided to facilitate testing of individual wells.
One well can be tested at a time. The well to be tested is diverted to test separator, where
oil and gas separation takes place. Gas is sent to the gas grid and Oil flows to HT to oil
storage tank.

Low Pressure Header

Wells flows in this separator for activation or depressurization during flow line leakage at
low pressure. Emulsion from tank is then sent to HT for treatment.

Associated Gas

Associated gas from separators is sent to gas grid of the Sanand area.

MANIFOLD

Purpose:

A manifold is constructed to serve the following objectives

To group the wells based on their pressure similarly.

To isolate any individual well for testing purpose or to receive fluids during killing /activation
of wells.

To divert wells to the required header through operation of valves.

SEPARATOR

Purpose:

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

Process:

The fluid enters the separator tangentially and by virtue of sudden pressure drop, to the set
level, the fluid gets separated into liquid and gas. Baffles are fitted inside the separator to
help in better separation of fluid .The fluid is given certain residence time to allow better
separation and also for settling of the liquid into oil and water.

HEATER TREATER

Purpose:

Separation of emulsion oil into oil and water as per output designed characteristics through
chemical, thermal and electrical means.

Process:

Heater treater is a pressure vessel consisting of the following four sections:

a) Inlet degassing section

b) Heating section
c) Differential oil control system
d) Coalescing section
 a) Inlet degassing section :
Emulsion oil from separator is first mixed with demulsifier and then taken into Heater
Treater. Emulsion oil first enters Inlet Degassing Section. A fire tube is fitted in the heater
treater encompassing degassing section and heating section. Due to the effect of heat, the
free gas in emulsion oil is liberated and then enters into the heating chamber through the
equalizer. The fluids enter into the heating chamber through multiple orifice distributors.

b) Heating Section :
The fire tubes which extend up to this section are in a submerged condition in emulsion oil.
The heating of emulsion oil decreases the viscosity of oil and water and reduced the
resistance of droplet 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 oil and free water to a greater extent and water settles down in the heating
chamber. The oil water interface in this section is controlled by an interface level controller
which operates the control valve for draining free water.

c) Differential oil control chamber :

The fluids from the heating chamber enter into this chamber through fixed water. It does
not allow the gas to pass into electrical chamber which is hazardous. The gas which enters
heating chamber through equalizer leaves the heater treater from the top of this chamber
through a mist extractor contained in a centrifugal scrubber. From scrubber the gas releases
into a gas line through a back pressure control valve, which maintains the pressure of the
valve. The oil level in the chamber is controlled by the oil level controller which operates
through a float.

d) Coalescing section or electrical section :

Oil enters this chamber through a distribution tube. Constant level of water is maintained in
this section so that oil is washed and free water droplets are eliminated before the fluids
proceed towards electrode plates. These plates are connected with high voltage supply of
10,000-25,000 volts. When fluids pass between these electrode plates, the droplets are
polarized and attract each other. This attraction causes the droplets combine they become
larger enough to settle into oil and water layers by the action of gravity. The interface level
controller which senses oil water interface level and actuates the control valve for draining
free water.

STORAGE SYSTEM

Purpose:

To measure the produced oil.

To store oil before pumping to central tank farm.

Process:

Oil from Heater Treater is taken into over ground vertical type tanks, whereas oil from test
separator is taken to testing tanks (overhead) to facilitate measurement.

OIL DISPATCH SYSTEM

Purpose & Process:

Five crude oil dispatch pumps P-01/02 are provided for transferring crude oil from the oil storage
tanks to CTF NAWAGAM through 12” dia. Pipeline. These are motor driven reciprocating pumps
having a discharge rate of 10 m3/hr. to 30 m3/hr.
MEASUREMENT SYSTEM

Purpose:

To measure daily production of oil and gas (by SCADA).

Process:

Daily production of oil is measured by taking dip measurement in storage tanks on hourly
basis or by SCADA system. Gas production is measure hourly by Custody Transfer gas meters
which records quantity as well as pressure.

UTILITIES

Purpose:

To support the functioning of the installations, following utilities/facilities are provided:

 Power (Transformer, generator, lightings etc.)

 Water (Tube well, pump etc.)

 Office block with communication facility (such as telephone, Internet, Mobile and
wireless set).

 Fire Fighting System.