INTRODUCTION

Central Processing Facilities (CPF) is an

On-shore installation of Ankleshwar
Asset, to process and handle centrally
all the Crude Oil and Natural Gas
produced in the Gandhar Oil Field.
CPF is located approximately 40 KMs
NW of Bharuch and about 16 KMs from
Amod, near village Chanchwel. Total
area of CPF is 720 acres (420 acres of
plant area +240 acres of Green belt all
around the periphery of the plant
boundary)
FACILITIES:
Unit
Crude stabilization
Unit (CSU)
Gas Dehydration
Unit (GDU)
Condensate
Fractionation Unit
(CFU)

Design capacities
4 trains x 0.7
MMTPA
1.5 MMSCMD
165 TPD (LPG) &
50 TPD (NAPTHA)

Off Gas
Compressors-I
(OGC-I)
Off Gas
Compressors-II
(OGC-II)
Gas Injection Unit
I (GIU-I)
Gas Injection Unit
II (GIU-II)

3 nos x 0.18
MMSCMD

Gas Lift Unit

(GLU)
Additional
Condensate
Recovery (ACRU)
Water Injection
Unit (WIU)
Injection Water
Filtration Plant
(IWFP)
Heater Treaters

3 nos x 0.38
MMSCMD each
4 LCMD

4 nos x 0.17
MMSCMD each
2 nos x 0.5 LSCMD
6 nos x 0.17
MMSCMD

4 nos x 6000 m3/d

18000 m3/d (N)
19500 m3/d (Max)
11 nos x 200
m3/hr
20.5 MW (GT)

Combined Cycle
Power Plant

(CCPP)
Combined Cycle
Power Plant
(CCPP)

20.5 MW (GT)28
MW (Combined
cycle
Without Auxiliary
firing) 31 MW
(Combined cycle
With Auxiliary
firing)
720 m3/d (Ph-I)
5000 m3/d(Ph-II)
5000 m3/d(Ph-III)
1.5 MMSCMD (Ph-I)
8.0 MMSCMD (PhII)
4 nos x 10000 m3
4 nos x 20000 m3
3 nos x 1572 m3
2 nos x 1000 m3

Effluent
Treatment Plant
(ETP)
Flare
Crude Oil Storage
Tanks
LPG Sphere
Naphtha storage
Tanks
Wax Storage
Crude Oil Pumping
system (COPS)
Instrument Air
System4

2 nos
3 nos x 400m3/hr
4 nos comp.( Total
2100 Nm3/hr)

Cooling water
system
Inert gas system
(N2)
Fuel Gas System)
Raw Water System

2 nos CTs (Total

7000m3/hr)
1 no Vaporizer (15
Nm3/hr)
2 nos FG KODs
11000 m3 storage
reservoir
9900 m3 storage
reservoir
8 nos main pump x
410 m3/hr
2 nos Jockey x 50
m3/hr each

Fire Water
System(FW)

Purge Air System

2 Compressors
(250 Nm3/hr
3 tankers at a
time
2 tankers at a
time

Product Handling
Gantry LPG
Product Handling
Gantry Naphtha

BRIEF DESCRIPTION OF UNITS

CRUDE STABILISATION UNIT(CSU)

CPF Gandhar has two identical
trains of CSU (NO. 11 & 12) in Ph-I and
Two no.s of identical trains in phase
II(no. 14 & 15).Each train consists of HP
Separator, MP separator and LP
separator along with associated
systems like heat exchangers & pumps.
Phase-I compressor Unit (OGC-I): 32
KM A/B/C
3 reciprocating compressors each with
a capacity 1.8 Lac m3/day is available
for raising the pressure from 4.5
kg/cm2 to 25 kg/cm2 in two stages
Phase-II compressor Unit (OGC-II):
16/17/18/19 K-101
LP gas at 0.1 kg/cm2 is compressed to
2.0 kg/cm2 in 1st stage of compressor
and then to 8kg/cm2 in 2nd stage and
then from 8 kg/cm2 to 40 kg/cm2 in 3rd
stage. It is having all the associated
systems like intercoolers, pumps, KODs
etc.

CONDENSATE FRACTIONATION UNIT

(CFU)
It consists of Condensate receiving
system, LEF column & LPG column.
Feed condensate is received in
Condensate surge drum (CSD) for water
separation through interface control.
Then the condensate is pumped to LEF
column after passing through coalescer
filter. Water and any foreign material in
the condensate is filtered & drained.
GAS DEHYDRATION UNIT (GDU)
The gas dehydration is designed to
handle 1.5MMSCMDof gas. Triethylene
glycol (TEG) is used as a dehydrating
agent, which is regenerated & reused.
The system comprises of two sections:
a) Gas dehydration system
b) Glycol regeneration
system.
GAS INJECTION UNIT (GIU):

As the oil & gas are produced and taken

out from the reservoir, pressure of the
reservoir depletes. In order to maintain
the reservoir pressure for continued
exploitation and to maximize the oil
recovery, high pressure gas is injected
back into the reservoir. Dehydrated and
CO2 free lean gas coming from IPCL at
37kg/cm2 is compressed to 310kg/cm2
in 3rd stage reciprocating compressor.
ADDITIONAL CONDENSATE RECOVERY
UNIT:
The gas leaving OGC-II still has
considerable quantities of LPG and
Naphtha fractions. In addition the field
HP gas which is used internally in CCPP
as a fuel is rich in nature and has
potential to generate condensate for
recovery of LPG and Naphtha.
Both thee streams (2 LCMD each)
collected and dried in dryer unit. This
dried gas is compressed in one GLC
compressor up to 120 kg/cm2.high
pressure gas is expanded through J-T
valve and -25 deg C temperature

achieved. Due to chilling effect

condensate recovered in separator and
then sent to CFU for further processing.
WATER INJECTION UNIT(WIU):
To maximize the oil recovery and
maintain the reservoir pressure, water
is also injected. Filtered and de
aerated water is injected at a pressure
of 180kg/cm2 with the help of 4 nos of
7 stage centrifugal pumps, Before
injecting water into reservoir raw
water is filtered in water filteration
unit to reduce the turbidity < 0.1 NTU
GAS LIFT UNIT (GLU):
For lifting of crude oil from low
pressure wells, compressed gas is used.
Three numbers of single stage
reciprocating compressors, each having
capacity of 0.38 MMSCMD, are used to
compress dehydrated gas at 37 kg/cm2
up to 122kg/cm2.Dehydrated gas is
either rich gas from GDU or lean gas
returned from GAIL. The compressed

gas is sent to GGSs through a header for

further distribution into the wells for
gas lift operations.
EFFLUENT TREATMENT PLANT (ETP):
ETP treats the effluent generated from
water drain from CSU,CFU and crude oil
storage tanks, cooling tower blow
down, floor washing, filters backwash
and rain water etc.
The treatment process is broadly
classified into three stages.
1. Primary treatment (bulk oil is removed)
2. Secondary treatment (biological
treatment)
3. Tertiary treatment (COD removal)
CRUDE OIL PUMPING STATION(COPS):
Stabilized crude oil received from CSU
is routed to intermediate crude oil
storage tanks to remove any residual
gas and some water. This liquid is then
transferred to main crude oil storage
tanks, by four numbers of transfer

pumps. Liquid is allowed to settle in

the main tanks for sufficient time and
free water is then drained to ETP.
Stabilized crude oil having water
content < 0.1 % is pumped to KT
refinery, IOCL, Baroda.
HEATER TREATERS:
Dead Oil, pumped from GGSs is routed
to CPF Crude Storage unit through
Heater Treater. Dead oil is processed in
Heater Treater unit to provide Gas
separation, free water removal and
coalescence of entrained water particle
to allow the oil to meet pipeline
specifications. After processing, oil is
sent to LP separators of CSU unit and
then pumped to storage tanks.
UTILITIES & OFFSITES (U & O)
Instrument Air System
All the units are equipped with
automatic control instrumentation. To
operate various field instrumentation,

10

dry instrument air is required @ 5-6

kg/cm2.To meet this requirement,4 nos
IA Compressors of Total capacity
2100Nm3/hr are installed.
Cooling Water System:
Cooling Water system comprises of
cooling towers & cooling water
circulation pumps (3 nos x 650 m3/hr
and 4 nos 2100 m3/hr) which circulates
cooling water in a closed network
through various heat Exchangers. The
cooling tower cools the water from 45
Deg C to 33 Deg C and works under
forced draught air circulation.
Inert Gas System:
Liquid Nitrogen is received from
Tankers and is stored in a double walled
pressure Bullet. Liquid Nitrogen is then
vaporized in a Vaporizer and is used in
the plant for Inert Gas blanketing in
the lub oil system of OGC-II, GIU & GLC
etc .and also during line inertisation for
hot works to remove any hydrocarbons.

11

Fuel Gas System:

Natural Gas is also used as fuel gas for
heating hot oil in Hot oil heater, firing
in the boilers, flare header purging,
pilot gas for pilot burners in flare,
power generation in Gas Turbines, firing
burners in Heater Treaters.2 nos FG
KODs are installed at CFU & GMS
respectively to meet the requirement.
Raw Water System:
Service water is used for cooling of
bearings of the rotating equipments,
floor washing, equipment & line
cleaning etc. System comprises of RW
storage reservoirs
(1100m3) and 2 nos S W pumps of 60
m3/hr each.
Fire Water System:
To fight any fire in plant, fire water is
used. A fire water ring is laid all around
the units with Fire Hydrants & Monitors
to use it for fire fighting. System
comprises of FW Reservoir (9900m3)
and 2 nos. Jockey pumps & 8 Main

12

Pumps .Jockey pumps are run

continuously to keep the fire water ring
in pressurized condition @ 10
kg/cm2.Main pumps are kept on auto
to take care of any pressure drop
during emergencies.
Flare System:
In order to dispose off unused natural
gas from the units & to keep
environment clean, Flare system is
installed which disposes excess gas
after complete combustion in the
atmosphere at a height of 60 mtrs.
System comprises flare-I and flare-II
with KOD to knock out any liquid
carried over, water seal to maintain 300
mm WC back pressure in the flare
header.
Power Generation:
CPF is having a combined cycle power
plant (CCPP) to generate 31 MW
Electrical Power to meet all the
electrical power required for
operation. Any surplus power is

13

exported to GEB under power wheeling

agreement. One DG set (630KVA,
876Amp) is also available in order to
meet Emergency Power requirement in
case of CCPP & GEB shut down.
LPG & Naptha Storage & Handling:
LPG & Naphtha are products of CPF in
addition of Crude Oil & Natural Gas.
LPG is stored in Horton sphere @ 8
kg/cm2.LPG is then dispatched to IOCL
bottling plants by road Tankers. Loading
of the tankers is carried out at LPG
loading Gantries (2 nos Loading gantry
+one dual purpose gantry for loading as
well as unloading sick tankers).Naphtha
is stored in 2 nos tanks. It is also
dispatched by road tankers to
consumers. A separate tank loading
gantry is available for this.

SAFETY SYSTEMS:
Following safety systems have been
provided at CPF:

14

1.
2.
3.
4.

Centralized Fire Alarm System

Gas Detection System
Fire Fighting System
Effective Communication
System

Centralized Fire Alarm System:

Total 118 nos Break Glass Units (BGU)
are installed all over the plant. In case
of any fire, a fire alarm is raised by
breaking the glass of BGU.
Fire alarm is received at Control Panel
located at CCR and a repeater panel at
Fire station. Appropriate action is
subsequently taken by CCR & fire
Station.

GAS DETECTION SYSTEM:

In gas detection system, the amount of
gas present in specified in terms of %
LEL. Relationship between % LEL &
Volume differs from Gas to gas (NFPA 5th
Ed.325)

15

Methane
Ethane
Propane
Butane
Pentane

100%LEL-5% by vol. in air

100%LEL-3% by vol. in air
100%LEL-2.2% by vol. n air
100%LEL-1.6% by vol. in air
100%LEL-1.5% by vol. in air

Low alarm settings

High alarm settings

20% LEL
40% LEL

Sensor Location:
If the gas is lighter than air (CH4, H2),
the sensor is located above the
probable leak source. If the gas is
heavier than Air (e.g.Butane, Propane,
Hexane, H2s) then the sensor is located
below the probable leak source. The
most critical locations are of lowpressure sites, as the leakage at low
pressure can not be easily detected
physically.

FIRE FIGHTING SYSTEM:

16

Fire fighting system can be broadly

classified into two categories:
1. Stationary Fire Water System
2. Mobile Fire Fighting Ring
Stationary Fire Water System:
To fight any fire in the plant, firewater
is used. A fire water Header ring is laid
all around the units with Double
headed Fire Hydrants & Monitors at
strategic locations to use it for fire
fighting. The ring is always kept
pressurized at 10 kg/cm2 with the help
of Jockey pumps with AUTO START &
STOP. In case of fire and more
withdrawal of water, pressure of the
ring drops below 10 kg/cm2 and Main
FW pumps start automatically. For easy
identification, FW lines are painted in
red color.
Water spray system has been provided
for LPG spheres and crude oil Storage
Tanks.
LPG sphere Security System:

17

In the event of fire in LPG storage area,

all the inlets & outlets of the spheres
are isolated and the sphere is kept cool
by spraying firewater on it.
On each sphere periphery,12 nos
thermal fusible plugs have been
provided and are located at an
elevation of about 1.5 to 2.0 mtrs from
the bottom Tl of the sphere. 3 nos
thermal fuses have been provided at
the top of the sphere and 01 no at the
bottom. Instrument air is supplied to
the thermal fuses. In the event of a fire
taking place, the thermal fuses will
blow as these are designed to melt at
85 Deg C. Instrument air will release to
atmosphere as a result of thermal fuse
blowing. This will actuate the pressure
switch (90-PSL-3301 & 3302) and will
initiate the following action
I. All ROVs on LPG lines will
CLOSE and LPG unloading
pumps will STOP.
II. All the FW sprinklers and
Deluge valves will OPEN
through ROVs.

18

Crude Oil / Naphtha Storage Tanks:

Each crude oil storage tank is equipped
with FW sprinklers and Foam Pourer
Lines. FW sprinkler ring has spray
nozzles and are used to cool the Tank
surface in case of fire. Foam is an
effective medium to put-off fire and is
poured through Foam Pourers and Foam
lines with the help of Fire Tenders.
Stationary Fire Fighting System:
Fire Water Reservoir
9900 M3
Jockey Pumps (50 M3/Hr)
02
Main Elect Pumps (410 M3/Hr) 03
Main Diesel Pumps (410 M3/Hr) 05
Fire Monitors (Foam,Water)
57
Fire Hydrants (Double Headed) 272
Water Sprinklers/Deluge System
Foam Chambers
CO2 Spray Nozzle system
Mobile Fire Fighting System:

19

CPF has Fire section equipped with Fire

Tenders, Fire Extinguishers and other
ancillary equipments to fight fire.
Following mobile equipments are
available
Fire Water Tender
Foam tenders
DCP Tender (2000 kg)
Portable pump set
Trailer pump
Long range monitors
(Water cum foam)
Portable Extinguishers:
DCP Extinguisher
CO2 Extinguisher

20

Mech. Foam Extinguisher

Foam Nurser
Long range Water cum Foam
Monitor
Ancillary Fire Fighting
Equipments/Consumables (available in
sufficient quantity)
AFFF Foam compound
Protein Foam compound
DCP (Monex)
Fire Fighting Hose
Asbestos fire suit
Breathing Apparatus Set
Aluminum Fire Restrainer Suit
MFG (Mech. Foam Generator)
Safety Torch
Portable battery charger
Water Gel
EFFECTIVE COMMUNICATION SYSTEM:
CPF has effective communication
means to communicate with each other
and with outside personal in case of
any emergency, fire etc.

21

Internal:
PA system
Control room with plant units: 64
locations
Fire stations with plant units: 20
locations
Sub station to plant units: 17 locations
CCPP C Room to plant units: 13
locations
EPABX Phones
: 110 locations
Wind Socks
(To know the wind direction)

:04

Siren: 01
External:
-EPABX
-Telemetry
-MART
-P&T
-Wireless VHF
-FAX
ENVIRONMENT MANAGEMENT SYSTEM:

22

To keep our environment clean and free

from Air, Water, Noise pollution,
industrial wastes like formation water,
flue gases, and unusual low pressure
natural gas are disposed off in the
environment after proper treatment
and within the permissible limits. CPF
Gandhar is following practicing
Environment Management System (EMS)
based on ISO-14001.since 19.09.2001.
Following measures are taken at CPF
for Environment Management:
Effluent treatment Plant
Flare System
Green Belt
Ambient Air Quality & Stack
Emissions monitoring
EFFLUENT TREATMENT PLANT:
Effluent Water is generated from many
sources at CPF like Formation water
drained from Crude oil Storage tanks,
cooling tower blow down, floor
washing, filter backwash, rain water
etc. After proper treatment at ETP and

23

meeting GPCB requirements, it is

disposed off in the River Dhadhar. CPF
has treatment capacity of:
ETP-I

720 m3/day (Normal)

1440 m3/day (monsoon)
ETP-II 5000 m3/day
ETP-III 5000 m3/day
FLARE SYSTEM:
Flammable, Toxic or corrosive vapors
discharged by pressure relief system in
the plant and any unused natural gas
are disposed off in the atmosphere
after complete combustion at a height
of 60 mtr. from grade level. CPF has
Flare capacities of:
Flare-I 70 Tons/hr
Flare-II 280 Tons/hr
Flare header collects vapors from
different process units and lead to the
tip of Flare Stack, where it is disposed
off after combustion. For smokeless
flare and minimum air pollution, LP
steam is injected near the Flare tip.

24

GREEN BELT:
Green plants & trees reduce the level
of air pollution in the atmosphere and
hence Air pollution. they are therefore
generously grown to act as antipollution measures. CPF has a 200 mtr
wide Green belt all around the
peripheral boundary of plant consisting
of Green plants & trees.
Total area of green belt is 240 acres
(Total plant area: 480 acres)
AMBIENT AIR QUALITY & STACK
EMISSIONS MONITORING:
Ambient air is regularly monitored by a
Mobile Van for Suspended particulate
matter (SPM), sulphur oxides (Sox),
nitrogen oxides (NOx), and
Hydrocarbons (HCs), flare gas emissions
from process stacks are also monitored
through on-line monitoring equipments.

25

CHEMICAL & PRODUCT HANDLING &

HAZARDS:
Type of chemicals handled (unit wise)
at CPF are indicated as under:
Unit

Chemicals/Products

CFU

Hot oil, Mercaptan / LPG,

Naphtha

GDU

TEG/Natural Gas

CSU

Demulsifier/Natural Gas,
Crude Oil

CW System

SHMP, HEDP, H2SO4,

Chlorine

WIU

HEDP, Sodium sulphite, Biocide

IWFP

Cationic Flocculant, FeCl3,

Chlorine

ETP

H2SO4, NaOH, FeCl3, DOPE,

DWPE Urea, DAP

26

A GPA (Gas Processors Association) test

for LPG for the determination of heavy
components in a sample by evaporation
of the sample specified.
USEFUL DEFINITIONS
Flash Point: The lowest temperature of
a Flammable liquid at which the liquid
gives of Sufficient Vapor to give a
momentary flash
When ignited.
Weathering: The evaporisation of
liquid caused by exposing it to the
condition of atmospheric temperature
and pressure. The Temperature of
heavy
components
after
partial
evaporisation of liquid by use of heat is
called weathering.
Weathering Test: A GPA (Gas Processors
Association) test for LPG for the
determination of heavy components in

27

a Sample by evaporation of the sample

specified.
Vapour Pressure: The pressure exerted
by a liquid at equilibrium when
confined in a specified tank or test
apparatus.
RVP:Reid Vapour Pressure is a Vapor
pressure for liquid products as
determined by ASTM test procedure D323. The RVP is reported as pounds per
square inch at 100 OF (The RVP is
always less than the true Vapor
pressure at 100 OF )
Specific Gravity: The ratio of the mass
of a given volume of a substance to
that of an equal
volume
of
another substance used as standard.
Unless otherwise stated, air is used as
the standard for gases and water is
used for liquids, and the volume
measured at 60 OF and atmospheric
pressure.
Vapor Cloud: Whenever liquefied gas is
released from its containment, some
portion of the liquid
starts
to

28

vaporize. The remaining is heated up

by the surroundings and causes the
liquid to boil. The Vapor generated by
this process then mixes with the air and
gets carried down wind. This is called a
'Vapor cloud'.
Vapor cloud explosion:
If the Vapor clouds after being formed
is very dense and large and falls within
the flammability limits, the cloud
explodes on ignition from a source of
sufficient energy. This is a Vapor cloud
explosion.
BLEVE:
Liquid expanding Vapor cloud explosion
is the name given to the catastrophic
failure of a pressurized storage tank
containing a liquefied gas. BLEVE can
occur when a pressurized tank is
exposed to a fire or when the tank has
been weakened by mechanical damage.
In case of exposure to fire, the internal
pressure increases and that weakens
the tank until the tank no longer
contains the pressure. The tank

29

then rupture violently with parts of the

tank being propelled great distances,
creates large fireball causing thermal
radiation and causes over pressure
similar to an explosion.
Auto Ignition Temperature: It is the
temperature at which the hydrocarbons
vapor catches fire on mixing with
oxygen from the atmosphere, even
without the help of a flame or spark.
As mol. wt. of hydrocarbons
increases,
the
Auto-ignition
temperature decreases i.e., the risk of
auto-ignition increases as the MW of
HCs increases.
Product
Hydrogen
Ethane
Ethylene
Propane
Butane
Pentane
Hexane

Auto-ignition temp
O
C
589
516
450
466
430
309
247

30

Gasoline
Kerosene
Lub. Oil

256
254
417

Lower Explosive Limits (LEL): LEL is

the
minimum
proportion
of
hydrocarbons in the hydrocarbon-air
mixture such that an explosion or fire
could occur in the presence of a source
of ignition such as spark or an open
flame. It is given as % vol/Vol. air
High Explosive Limits (HEL):
HEL is
the
maximum
proportion
of
hydrocarbons in the hydrocarbon-air
mixture such that an explosion or fire
could occur in the presence of a source
of ignition such as spark or an open
flame. It is given as % vol/Vol. air
The HC mixture is explosive
between LEL & HEL. Below its LEL value
& above its HEL value, it is not
explosive. An explosion occurs when
HC-air mixture is enclosed in a vessel
and a fire takes place when the above
conditions exist in the open.

31

Product
Hydrogen
Methane

LEL
%vol/vol
4.1
5.3

HEL
%vol/vol
74.2
14

Ethane
Propane
Butane
Pentane
Hexane
Naphtha
Keros

3.2
2.37
1.6
1.45
1.2
1.1
1.16

12.5
9.5
8.5
7.5
6.9
6
6

DO'S & DON'TS

DO'S
* Always BE VIGILANT in your unit.
* Wear proper uniform & kits
.

32

* Wear ONLY COTTON clothes.

*Remove clothes contaminated with
acids,
Alkali, caustics, alcohols, hydrocarbons
etc
Immediately and take shower.
* Use only BRASS hammer and other
nonSparking tools in hazardous area.
* Use SAFETY BELT while working at
Elevated height.
* Use handrails while climbing the
stairs.
* Keep your unit clean and remove any
oil
Spillage/
combustible
material immediately
And practice good House Keeping.
* Report any abnormality / sound to
control Room promptly.
*Use proper safety equipments

33

While working.
* Check all the electrical wires in the
unit are properly insulated.
*Check Security system of LPG spheres,
Crude oil storage tanks at
regular intervals.
*Check

the availability of Fire

extinguishers in your unit.

*Know the location of Fire Alarm BGU

points in your unit.
*Listen carefully for all announcements
from Control Room.
*Take / Hand-over charge of the unit
from/to outgoing/incoming shift
personnel.
DON'TS
* Never SMOKE in the plant area.

34

* Do not use defective tools.

* Do not drop tools and materials from
height.
* Do not TEMPER any Instrument,
Electrical
Apparatus.
* Never undertake any maintenance /
repair Jobs without work
permit.

Do

not operate any valve /

equipmentWithout knowing its
function.

35

CPF
QHSE Certified Plant
(ISO9001, OHSAS18001,
ISO14001)
36

37