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ACKNOWLEDGEMENT
I convey my deepest regards and sincere gratitude to my mentor Mr. Sudip
Gupta, DGM(P), Engineering Services, ONGC for his constant valuable
guidance, co-operation and encouragement that helped me to complete the training.
I sincerely thank Ms. Manisha
CE(M),
Srivastava, CE(M),
Mousumi Das Roy, EE(I), Mr. R.V. Gawande, EE(M), Mr. Sanchit Rastogi,
Mr. Maruti Vishwakarma, AEE(E), Mr. Palash Naskar, AEE(P) for their
guidance and for always taking out time and going an extra step to share their
knowledge with me.
I also express my gratitude to Head RTI, ONGC, Bandra Kurla Complex
without which it would not have been possible for me to undergo this training.
Also, thanks are due to Offshore Engineering Services, ONGC for providing me
the platform for carrying out the internship.
I also thank all those who have directly or indirectly helped me during the tenure of
my training.
Meghna Sarkar
Second year Mechanical Engineering
MKSSSs Cummins College of Engg. for Women
Karvenagar Pune-400052
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CONTENTS
Sr.no
Subject
Page
no.
1.
Abstract
2.
3.
4.
5.
10
6.
12
7.
Piping
13
8.
Pipelines
14
9.
Instrumentation
15
10.
Electrical
15
11.
Mechanical
16
12.
Structure
18
13.
19
14.
Summary
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3
ABSTRACT
Being a part of an esteemed organization as a winter internship trainee was an
opportunity wherein as a student I could get an industrial approach to the
theoretical concepts. It was a good learning experience in which I got an exposure
to most of the segments of petroleum discipline where I could find application of
the previously gained theoretical knowledge.
A systematic approach to the oil and gas industry and the entire process of
production of oil and gas in ONGC right from exploration to designing,
construction and transportation were elaborately explained.
Furthermore, I got to learn about the various areas of work of a mechanical
engineer in a petroleum industry.
My training was concentrated on the design and engineering for offshore platform/
plant which is taken care of by Engineering Services, 11 High, ONGC, Mumbai.
The study includes:
Creating the process flow diagrams (PFD)
Creating a piping and instrumentation diagram(P&ID)
Piping design and 3D modeling of platform
Design of structure (jackets, piles and deck),
Design of pressure vessels, various mechanical equipment
Design of piping systems for the entire plant.
Electrical single line diagrams.
Review of detailed engineering documents and drawing by various
departments like instrumentation, electrical, process, mechanical, structural,
piping and pipeline.
Revising the existing design and finally approval of the entire documents
and drawing of the project, followed by its actual construction.
I got the chance to work on a few software like Hysys and Pipesim and was
introduced to other software like Autocad, Caesor-II, PDMS, PDS, SACS,
PVLITE.
I also got familiarized with concepts and work of the different departments of
engineering services like electrical, mechanical, instrumentation, process, piping,
structure, was given by the respective engineers from each department.
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UPSTREAM
INDUSTRY
EXPLORATION AND
PRODUCTION
DOWNSTREAM
INDUSTRY
TRANSPORTATION
TO PROCESS PLANT
(reservoir to
ground)
(ground to plant)
REFINING
OFFSHORE
PLATFORM
ONSHORE
INSTALLATION
RETAILING
BULK
PROCESSING
(SEPARATION)
TRANSPORTED TO
PLANT FOR
FURTHER
PROCESSING
FABRICATION
DESIGNING
(Actual construction)
ONGC
(Upstream
industry)
OFFSHORE PLATFORM
ONSHORE
INSTALLATION
FABRICATION
DESIGNING
ENGINEERING
SERVICES
WORKS
DESIGN
PROCESS
INSTRUME
NTATION
PIPELINE
MECHANICAL
PIPING
STRUCTURE
ELECTRICAL
JACKUP RIG ON WELL PLATFORM FOR PROCESS PLATFORM COMPLEX WITH SEPARATION,
DRILLING/WELL SERVICING
GAS PROCESSING, WATER INJECTION FACILITIES
TYPES OF :
1.WELLS
2.PLATFORMS
Fixed
Compliant
Sea star
Floating production system
Tension leg platform
Sub sea system
SPAR
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10
11
12
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I.
Living Quarter
II.
PIPING
The piping discipline under ODS looks after the pipes on the process
platform. Plant layout and design of piping systems constitutes a major part of the
design and engineering effort. Basically the following are the main tasks carried
out by this discipline:
Piping and instrumentation diagrams (P&IDs)
Piping design and engineering principles
Terminology, symbols and abbreviations used in piping design
Piping materials
Piping specifications and piping codes
Components of piping systems - fittings, flanges and valves
Piping routing
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III.
PIPELINES
Pipelines are used for a number of purposes in the development of offshore
hydrocarbon resources These include e.g.: Export (transportation) pipelines
Pipeline bundles
Flow lines to transfer product from a platform to export lines
Water injection or chemical injection flow lines
Flow lines to transfer product between platforms, subsea manifolds and
satellite wells
The design of pipelines is usually performed in three stages, namely;
Conceptual engineering,
Preliminary engineering or pre-engineering,
Detailed engineering
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IV.
INSTRUMENTATION
Instrumentation discipline comes into play after the process platform has
been designed by the process design section with the help of a P&ID. This
discipline helps in controlling and automating all the process parameters involved
in the offshore as well as in the onshore process platforms.
The various controlling instruments looked after by this discipline may be
either pneumatic or electronic. It deals with the measurement of pressure,
temperature, flow-rates with the help pressure transducers, temperature sensors
(RTD, Thermocouples etc.) and flow meters respectively. Instrumentation
discipline also takes care of the Shut Down Panel which shuts down all the
processes in case of an emergency.
SCADA(supervisory control and data acquisition) is used for well monitoring,
control and production optimization.
V.
ELECTRICAL
Every power plant needs one or the other way electrical power for its proper
functioning. For an offshore platform it requires huge electrical power to run all
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the mechanical devices employed, living quarters electrical consumption and also
some power to run various instruments.
Electrical power requirements are classified according to the loads into categories
as:
Radio operation
Instrumentation requirements
Fire and gas detection systems
Navigation
For any general platform of ONGC, it requires about 20-25 MW or more
power to run the system. To produce such large amount of power is challenging.
For this ONGC has its own power production unit where power is generated by a
portion of the natural gas produced. There are huge Gas Turbine Units (GTU) for
power production. Also the circuit breaker station is installed on the platform itself.
For some other purposes which may require small power say few KWs, power is
generated by the renewable sources of energy like solar energy, wind energy etc.
VI.
MECHANICAL
Mechanical devices such as Turbines, Compressors, Pumps, Heat Exchangers
etc. are the basics for a plant to operate and such devices are included under the
Mechanical discipline for both running and maintenance of the same. A small
introduction about the main mechanical units operating in a offshore process
platform is given below
1. Gas Turbines
Gas Turbines are used for the power production by rotation of the turbine shaft
by steam generated due to heat generated by burning a portion of natural gas
produced. An efficient gas turbine used in a power plant produces about 10-15
MW of power under optimized conditions. Special care is taken for the inlet gas
entering into the turbine as wet gas may corrode the blades of the turbine and also
reduces the efficiency furthermore due to corrosion it may cost economic loss to
the plant.
2. Gas Compressors
Gas compressor is a mechanical device that increases the pressure of a gas
by reducing its volume. Compressors are similar to pumps: both increase the
pressure on a fluid and both can transport the fluid through a pipe. As gases
are compressible, the compressor also reduces the volume of a gas. Liquids
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3. Heat Exchangers
Heat Exchangers exchanges heat between two fluids, In ONGC heat
exchanger used is the tube and shell type. Mainly these units are used during crude
oil components separation in which a portion of the crude oil is heated and passed
through tubes and other portion is passed through shell in this way exchange of
heat takes place reducing the viscosity of the fluid which is necessary to avoid
vortex formation and maintain almost laminar flow within the pipes which helps in
avoiding condensate formation. Also since compressors require the temperature of
the entering gas to be low for its efficient working temperature exchangers of
various forms are used to cool the gas.
4. Knock Out Drums (KOD)
Knock out drums is used for the separation of gas and oil from the saline
water. Mainly the principle involved is the gravity separation (baffle plates are
present inside them) in which the components are separated depending on their
density.
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5. Pumps
Pumps are basically used for transporting incompressible fluids like crude oil
by creating large pressure difference for its transportation along pipelines.
Presently in ONGC centrifugal type pumps are used for general purpose.
VII.
STRUCTURE
Structure discipline designs the supporting structure of the platform and the
topside considering the stress analysis criteria. They use many softwares like
SACS, MicroStation etc. for the design purposes.
i. Supporting Structures
The supporting structure on which the platform rests is divided into:
1. Jackets
2. FPSO (Floating production storage and offloading)
3. Jack up rigs
4. Semi Submersible Platform
5. Gravity based structures
6. Spar
Topside
Topside is a structure resting on a supporting structure having all the basic
facilities for the process, unmanned platforms. They are divided into:
1. Cellar Deck
2. Sub-Cellar Deck
3. Heli Deck
4. Living quarters Deck
ii.
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19
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Gas Dehydration:
Compressed Gas is dehydrated in a Glycol contactor with Tri Ethylene
Glycol(TEG) as an absorbent for moisture from compressed gas.
Glycol contactor is bubble cap tray column with many bubble cap trays. TEG
flows counter current with compressed gas from the top of the column.
TEG coming in contact with compressed gas in the bubble cap trays selectively
absorbs the moisture from the gas and dehydrates it.
The dehydrated gas is sent to feed gas lift wells in priority basis and remaining to
export gas line.
The TEG rich in moisture is sent for reconcentration, converted to Lean glycol
and recycled back to contactor for dehydration.
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SUMMARY
The topics covered under the training are:
Introduction to oil and gas industry.
Basics about ONGCs oil and gas production systems.
Types of wells and platforms.
Mechanism of oil lifting and processing.
Designing and analysis of an oil platform.
Simulation of fluid flowlines.
Specifications regarding all the equipments of an oil
platform.
Calculation, review and analysis of facilities in platforms.
Study about construction of the platform.
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