INTERNSHIP REPORT

2017
OIL AND GAS DEVELOPMENT PAKISTAN

LIMITED

VISITED TO;

HEAD OFFICE, DAKNI PLANT & CHANDA

Submitted To:

ZAFAR IQBAL

OGTI, ISLAMABAD

SubmittedBy:

ENGR: ISRAR AHMAD

Electronics engineering

Supervisor:

Engr.Inayat Ullah khan(D.C.E Instrument)

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ACKNOWLEDGEMENT
First of all I am really thankful toalmighty ALLAH who blessed me with a great opportunity
of internship in Oil and Gas Development Company Limited Pakistan. It was indeed a great
experience for me to have an internship program with OGDCL Pakistan. I am also very
thankful and present salute to many individuals who have helped me in shaping this report. I
would also like to thank everyone that has helped and made my stay comfortable.
During my One Year stay at Head Office, Dakni Gas Processing Plant and CHANDA Oil
Field, I had spent mostly time in Instrument Section in Process & Plants Department. I had
some days in HSEQ and in the other departments. I am very thankful to all the Plant’s staff
and special thanks to, Engr. Inayat Ullah Kahn (D.C.E Instrument) and Engr. Tabassum
(D.C.E Process) and other who teach and helped me.

PREFACE:
This report covered all activities that I performed during my internship at Head Office, Dakni
Gas Processing Plant and CHANDA Oil Field.. It briefly discusses the processes, electrical,
instrumentation & control system, maintenance department and HSEQ Department.

DEDICATION
I dedicate this work to the memory of my respected parents.Furthermore I dedicate this work
to the memory of my teachers and my best friends, from school to university and from
children’s play to armed struggle.Finally to all my patients and to all who’s made this
possible.
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Table of Contents
ACKNOWLEDGEMENT ............................................................................................................................. 1
INTRODUCTION: ...................................................................................................................................... 3
CHAPTER NO: 01 ..................................................................................................................................... 5
1 Health, Safety, environment HSE Induction:............................................................................ 5
1.1 HES importance ...................................................................................................... 5
1.2 PPE: ....................................................................................................................... 5
1.3 Firefightingsystem: .................................................................................................. 6
1.4 Detection systems:.................................................................................................. 8
CHAPTER NO: 02 ..................................................................................................................................... 9
2 Process description: ........................................................................................................................ 9
2.2 Glycol Regeneration Unit ...................................................................................... 12
2.3 Gas process and flow circuit: ................................................................................ 18
2.4 Emergency shutdown valves (ESD’s) and blows down valves (BDV’s): ................ 22
2.5 Flare system: ........................................................................................................ 22
CHAPTER NO: 03 ................................................................................................................................... 25
3 Electrical and Instrumentation: ................................................................................................. 25
3.1 Instrumentation: .................................................................................................... 25
3.2 Central Control System (CCS): ............................................................................. 30
3.3 Electrical: .............................................................................................................. 36
Chapter No: 04 ...................................................................................................................................... 45
4 Maintenance department: ......................................................................................................... 45
4.1 Mechanical tools: .................................................................................................. 45
4.2 Machine: ............................................................................................................... 46
4.3 Valve:.................................................................................................................... 46
4.4 Pumps: ................................................................................................................. 50
5 Main activities during my internship: ....................................................................................... 54
6 Conclusion: .................................................................................................................................. 55
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INTRODUCTION:
Dakhni gas processing plant is situated in Tehsil Jand; district Attock about 120 KMs
north-west of Islamabad. It has been named after the geographical territorial name of the land
where the existing facility stands. It is the first ever oil & gas processing facility set up by
OGDCL.

Dakhni oil and gas field was discovered in 1983 by OGDCL. Dakhni Oil Field has
drilled 11 wells out of them only six wells are producing wells. Three well fluid contains 7-8
% H2S (Hydrogen sulfide) and remaining three wells are sweet.

As well # 8 and Dakhni deep 1 & 2 are also producing which are sweet gas reservoirs
so new facility is being installed to bypass the gas coming from those wells into the new
system in which water removal will take place and gas will be sold directly from this unit.

Since H2S is highly toxic, lethal and corrosive gas, it was decided to install processing
treatment facilities for sweetening gas and crude. Apart from gas treatment section, the
facility also has LPG recovery, sulfur recovery unit, condensate stabilization, offsite and
utilities.

In December 1989 the plant was commissioned and production was started.

 Gas Sweetening Unit = 30 Mmscfd

 Gas Dehydration Unit = 30 + 50 Mmscfd
 LPG Recovery Unit = 10 M. Tons/Day
 Sulphur Recovery Unit = 78 M. Tons/Day
 Power Generation = 5.4 Mw
 NGL Stabilization = 900 Bbls/Day
Different utilities are also required at plant site such as

 Raw water
 Cooling water
 Demine water
 Electric power
 Hot oil
 Methyl diethanolamine (MDEA
 Tri-ethylene glycol (TEG)
 Steam

Chanda/Mela field is located in Shakardara area in District Kohat of the Khyber

Pukhtunkhwa province at a distance of about 70 Km from Kohat city. Chanda oil field, the
first ever discovery of hydrocarbons in Khyber was brought on to stream and it started
production from 17 July, 2004. Chanda LPG plant was installed in October 2006 producing
25-45 M.tons per day of LPG. The field has added a new dimension to petroleum exploration
in the Province. First well Chanda 1 was drilled in 1999 and second well was drilled in 2000.
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The facilities accomplish this processing objective with a three-stage inlet phase separation
process to separate the incoming raw gas into a gas, produced water, and hydrocarbon
condensate streams, a glycol dehydration process which uses a circulating flow of tri-
ethylene glycol to remove moisture from the gas and a hydrocarbon dew point control
(HCDP) where heavy hydrocarbons are removed by pressure reduction through a turbo
expander unit.
To assist in the production of marketable gas and hydrocarbon condensate, the Gas Plant
Facilities are also equipped with the following main auxiliary systems.

A condensate flash separation system which separate gas from hydrocarbon condensate
before it is stored. A produced water degassing system which separate gas from the produced
water before it is disposed of. An instrument air system, which supplies compressed dry air to
pneumatic control applications such as valves and controllers, Power generation system,
Hydrocarbon condensate storage and loading system, A flare system for safe disposal of gas
and condensate in emergency and A fuel gas system which distributes dry gas to,

 Burners for combustion purposes

 Gas generator for power generation
 Pressure vessels and piping for purging and blanket gas applications
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CHAPTER NO: 01

1 Health, Safety, environment HSE Induction:

HSE is to control or to eliminate recognized hazards in the work environment which could
adversely affect the safety, health and well-being of its personnel, clients, subcontractor and
as well as environment.
The words ‘hazard’ and ‘risk’ are used throughout this leaflet. Hazard means anything that
can cause harm (e.g. chemicals, electricity, working from ladders, etc.). Risk is the chance,
high or low, that someone will be harmed by the hazard.

1.1 HES importance

Accidents are likely to happen in any industry but in oil and gas sector even a smallest
careless act may cause injuries or even deaths of many people. Safety first is the slogan of
OGDCL HSE while doing any type of job in or outside plant area. Vigilant behavior is the
key to avoid any accident and HSE department is working at its best to create a vigilant
behavior in OGDCL workers. The basic purpose of HSE department is to create not only a
safe working environment but to induce safety awareness in workers and engineers.
Prevention is better than reaction is the policy of HSE department.

1.2 PPE:
PPE stands for Personal Protective Equipment. It includes fire proof coverall, helmet, shoes, glasses,
gloves, masks and ear plugs. Nobody is allowed to enter the plant without coverall, helmet and safety
shoes whereas other equipment may be used as per requirement.

Fig: 1.2 a
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1.3 Firefightingsystem:
1.3.1 Fire water system:
Fire water tank supplies fire water. Raw Water is stored in underground water pit. The raw water is
pumping to a large, fire water tank by an electric motor running, centrifugal pump. The fire water is
pressurized into a hydrant at pressure 80-120Psig. Three pumps are used to maintain the fire water
pressure.
 Jockey pump.
 Electric pump.
 Diesel pump.
Jockey pump:
The jockeypump runs continuously to keeps the system pressurized at 80-120 psig pressure. The
jockey pump is auto ON/OFF pump controlled by pressure switch. It also has manual ON/OFF option.

Electric pump:
An electric motor driven fire water pump is also installed in Plant Area which is not used nowadays
because of its large electrical energy consumption. It is centrifugal pump.
Diesel pump:
A third diesel engine driven pump comes online automatically in case of emergency when the jockey
pump could not maintain the required pressure. It is centrifugal pump.
The fire water is utilized by hydrants located at various locations in the plant. Hydrants are of two
types, fire hydrant and fire hydrant monitor. Fire hydrant contains a hose pipe with a nozzle connected
to the hydrant terminal whereas fire hydrant monitor is a type of hydrant in which the nozzle is
connected to the hydrant terminal and upon opening of the discharge valve it can be used as a gun.

Fig: 1.3.1 a
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1.3.2 Fire extinguishers:

Fire extinguishers are also used in Plant for fire protection. Fire extinguisher is a fire protection device
used to control small fire.A rule of PASS is used to operate the fire extinguisher safely.
P: Pull the pin
A: Aim the hose
S: Squeeze the handle
S: Sweep the extinguisher back and forth.

Fig: 1.3.2 a

1.3.3 Foam system:

Foam is also used in Plant Area for fire protection of storage tanks containing flammable or
combustible liquids i.e. condensate storage tanks and diesel storage tank.

Fig: 1.3.3 a
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1.4 Detection systems:

In plant there is a hydrocarbon processing facility and there is a great fire risk at the facility
so various detectors are employed to detect and active ate alarm in case of any leakage,
flame, smoke or intense heat. Plant area and loading area have flame detectors and gas
detectors located at various locations thatare PLC controlled. Following detectors are used
are employed in the facility:
 IR flame detectors
 Gas/hydrocarbon detectors
 Smoke detectors
 Heat detectors
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CHAPTER NO: 02

Process Description:
The process department extracts the raw gas from reservoir; process it into marketable natural
gas and hydrocarbon condensate. They control the entire process and different process
parameters.
The main process of Dakhni plant is categorized in two parts.
 Overview of Plant
 Separation
 Sweetening
 Dehydration
 Dew Point Reduction
 LPG Recovery
 NGL Stabilization
 Sulfur Recovery

OTHER FACILITIES
Dakhni plant has equipped with utilities and offsite. Utilities include.

 Power Generation
 Water Treatment
 Instrument Air and Plant Air Generation
 Cooling Tower
 Demine Plant

OVERVIEW OF PLANT

 Sour gas and oil from well head is received at separators area (100) through gas
gathering system.
 After separation oil and gas are sent to the respective units for treatment, while water
is sent to water disposal area.
 Sweet gas from separator (100-FA-05 & 6) is directed to TEG unit.
 Sour gas from separators (100-FA-01, 02) having H2S and CO2 is taken to gas
sweetening system (area 20), where it is treated with 12-13 % solution of DEA (Di-
ethanol amine). Then gas goes to TEG absorption process (area-20) for the removal of
water.
 Sweet gas from new separator installed after ATA-2010 is sent directly to SNGPL
through gas metering skid.
 Sweet gas is taken to dew point reduction unit (area-50), where it is chilled to low
temperature for the removal of heavy hydrocarbons from gas to have feed. While gas
is sent to SNGPL through gas metering skid.
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 LPG feed from DPR is sent to LPG recovery area, where LPG is recovered and sent
to storage from where it is pumped to LUB GAS.
NGL from separator are sent to the fractionation unit (area-60), here higher hydrocarbons
and H2S is removed from NGL and sent to storage.

Sulphur for explosives and medicines

H2S sulphur (77 M tons/day)

Recovery
Sale gas

(50 MMSCFD)

Sweet LPG
Gas Amine area
Glycol unit LPG unit
Wells gas (22
(Sweetening LPGMtotons/day)
SNGPL
1 area)
3
Separator
4 NGL Area Stabilized Condensate or
8 NGL Condensate
Crude oil to ARL
1 stabilization
1
To API (American Petroleum Institute)
water Water

Disposal area

DAKHNI PROCESSING PLANT BLOCK DIAGRAM

Fig: 2.2.2 a

Fig: 2.2.2 b
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TABLE (2.1) FEED GAS COMPOSITION

COMPONENTS MOL %

METHANE 82.9066

ETHANE 3.5587

PROPANE 1.3272

i-BUTANE 0.3236

n-BUTANE 0.3780

i-PENTANE 0.1517

n-PENTANE 0.1088

HEXANE + 0.1018

CO2 4.00

N2 0.3360

H2S 7.00

Specific gravity 0.6841

HEATING VALUE 1015.18 btu/ft3

Safety:
To operate the inlet separator in safe mode, it is equipped with a pressure safety valve (PSV).
If the pressure exceeds the Operating Pressure (2245 psig) limit the PSV open to release the
gas and reduces the pressure.
After the inlet separator the gas, condensate and produce water is process individually.

1.4.1 Gas process:

1.4.1.1 Gas/gas Exchanger:

The gas/gas exchanger is a horizontal heat exchanger. The raw gas coming from inlet
separator is very hot and it has to cool down to a certain temperature. This is done by heat
exchanger. In heat the two gas flow, raw gas coming from inlet separator and cool gas from
low temperature separator, they transfer their heats. The hot gas gets cool and cool gas gets
hot.
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1.4.1.2 Contactor Knockout Drum :

Incoming raw gas enters the K.O drum and strikes a diverter plate. This plate breaks the
incoming flow momentum. The abrupt change in the direction of flow allows the gas to
disengage from the liquids. The liquids fall to the bottom of the separator as a dispersion of
oil in water. To help separate the hydrocarbon condensate from the water, it is allowed to
settle for a certain period of time. This allows the fluids of different densities to separate. The
condensate and separated on the bases density separation. The settled at bottom of the vessel
and condensate floating over water. The water and condensate are drained through individual
level control valves.
The gas flow out from the top of the vessel and flow forward to Water Dew Point Control
Unit, Where the gas is farther processes.

1.4.1.3 Water Dew Point Control Unit:

The gas coming from K.O drum contains water vapors. To remove these vapors, a
dehydration process is used. Here at MGP plant Tri-Ethylene Glycolis used for this purpose.
The removal of water from gas is called dehydration of gas. The water is removed from gas
because in hydrocarbon dew point controller unit the gas is process at very low temperature
-2 to -4 degree F, the water can freeze and disturb the overall process.

In water dew point controller Tri-Ethylene Glycol is showered from thetop of the TEG tower
(Glycol ContactorC-14-01) at pressure higher the gas pressure and gas flows in at the bottom
of the tower. The TEG absorbs the water vapors from gas at high pressure and low
temperature to dry the gas for father process and becomes rich TEG. The rich TEG is
processed in TEG regeneration unit.

The gas flows forward to hydrocarbon dew point controller unit. Where, the heavers are
separated from dry gas for farther purification.

1.5 Glycol Regeneration Unit

Tri-ethylene glycol is the most commonly used glycol for dehydration units because of its
higher decomposition temperature allowing regeneration to a higher purity than di-ethylene
glycol. This higher purity of the re-concentrated glycol allows corresponding higher dew
point depressions of the gas stream.

Lean tri-ethylene glycol after passing through raw gas absorbs moisture as well as some
hydrocarbons from gas. TEG enters from top of glycol contactor tower and after absorbing
 13

moisture from gas leaves from bottom. The glycol which leaves from bottom is called rich
glycol.

1.5.1 Glycol Flash Drum :

Cold rich glycol from the tower, having a temperature of 95oF, comes to the reflex coil to get
preheated. This also controls the temperature of the top of the still column. The temperature
at the top of still column is maintained at 160oF. A temperature control valve is installed at
the outgoing cold rich glycol line. If the temperature of the still column drops down, the TCV
sends glycol back to the reflex coil. The glycol then moves to the TEG flash drum. The
glycol coming in has high pressure while to remove condensate we required low pressure, so
the pressure control valve is used to reduce down the pressure to 45Psig. The hydrocarbons
are separated here from glycol.

1.5.2 Glycol / Glycol Heat exchanger

It then passes through lean-rich glycol heat exchanger. It is a plate heat exchanger that uses
metal plates to transfer heat between two fluids. This has a major advantage over a
conventional heat exchanger in that the fluids are exposed to a much larger surface area
because the fluids spread out over the plates. It exchanges heat between the cool incoming
rich glycol and hot lean glycol leaving the stripping column. Rich glycol is heated from 95°F
to 210oF by exchanging heat with the lean glycol. Lean glycol loses its temperature from
390°F to 240°F.

1.5.3 Glycol Re-boiler

After exchanging heat from hot lean TEG, glycol enters into the still column of the re-boiler.
Still column is a vertical pack column in which glycol is showered from top. The steam from
re-boiler moving upward strips off moisture from downward coming glycol. This stem
containing moisture moves out into the atmosphere from the top of still column. Glycol falls
down into the re-boiler. The re-boiler is a shell tube re-boiler and the heating media is fuel
gas. Fuel gas burns into the shell from which rich glycol is heated up to 390oF.

At this temperature absorbed moisture in TEG,vaporize and goes outside into atmosphere
through still column. TEG after re-boiler goes to the stripping column. Here stripping gas is
bubbled upwards and it increases the water removal from glycol. Then the lean glycol flows
through the lean/rich glycol exchanger to the accumulator at a temperature of 180oF. Lean
glycol from accumulator is pumped in the TEG contact tower by two plunger type positive
displacement plunger pump.
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Glycol cycle:

Fig: 2.3 a

1.5.3.1 Hydrocarbon dew point Control Unit (HCDP):

The Hydrocarbon Dew Point Control (HCDP) unit consists of a Turbo Expander Suction
Knockout Drum, Turbo Expander/Re-Compressor and Low Temperature Separator. The gas
coming from dehydration unit enters into Turbo Expander Suction Knockout Drum, from
Turbo Expander Suction Knockout Drum to turbo expender for expansion and energy drop to
achieve hydrocarbon dew point and after turbo expender the gas flow into Low Temperature
Separator. Where, hydrocarbons are separated from gas.
Turbo Expander Suction Knockout Drum:

Dehydrated gas flows from the dehydration unit and enters the Turbo Expander Suction
Knockout Drum at a temperature 95°F and pressure of 1550 psig, where any entrained glycol
is removed from the dry gas stream via a stainless steel knitted wire mesh pad. Separated
 15

glycol is level controlled via LT and dumped by level control valve to the Glycol Flash
Drum. The gas stream then flows towards the Turbo Expander/Re-Compressor unit, which is
a turbine unit employing high pressure gas to turn a pressure let-down impeller connected,
via shaft drive, to a pressure generating compressor unit.
Turbo expender:

After the separation of TEG from gas in Turbo Expander Suction Knockout Drum, the gas
flows to turbo expender. In turbo expender the gas expends and the pressure down from
1550Psig to750Psig. The gas passes through turbine and expend across the turbine blades.
Due sudden expansion the temperature drops to -2 to -4°F“according to Joules-Thompson
affect sudden expansion cause cooling”. The gas also does work to runs the turbine and its
internal energy drop. The turbine shaft transfers the work to re-compressor. In this way the
heaver hydrocarbons dew point achieved and they get condense.

Fig: 2.3.3.1 a

Low temperature separator:

After the condensation of hydrocarbons the gas is forwarded to LTS for the separation of
hydrocarbons, at very low temperature. The condense hydrocarbons settled at the bottom of
vessel and drained out via level control valve from the vessel after a certain level controlled
by LT.
After the LTS the gas is pure and able to export the achieving desirable temperature and
recompression. The temperature of gas coming from LTS is very low and can’t export
directly to SNGPL, to achieve the desired temperature the gas is passes through heat
exchanger. As discussed above.
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Re-compressor:
After the heat exchanger the gas flow to re-compressor for re-compression to achieved
requiredsale gas pressure 1100Psig. After re-compression the gas is exported to client
(SNGPL) via metering skid.

1.5.3.2 Flash gas compressor:

Compressor is any instrument use for the purpose of compression.Compressor is use to deal
only gases.Compressor increases the pressure of the gas to the required value.Upstream and
downstream pressures depend on stages. FGC of plant is a three stage compressor.Upstream
pressure is approximately 20Psi, coming from flash separator, and downstream pressure is
nearly 1000Psi.
Compressor mainly consists of three parts.
 Scrubber
 Compressor
 Cooler
 Scrubber is used to remove the liquid component from natural gas. Because compressor is
only for compression and liquid cannot be compressed.
 Compressor used to increase the pressure of the gas.
 Cooler is use to decrease the temperature of the gas ,so that if any heavier are present with
the gas molecules achieve their condensation point and then will settle down in the
scrubber.

1.5.3.3 Metering skid:

To sale the gas some important parameters (flow rate, energy of gas, gas
compassion,temperature, pressure and moisture contents in gas etc.) are measured. To
measure these parameters different instruments are used. The following instruments are used
here at plant.
 Daniel Box
 Moisture analyzer
 Gas chromatograph

Daniel Box:
Daniel box is used to calculate the amount of flow gas passing through. Orifice meter is
present inside of the Daniel Box. Static pressure, differential pressure and flow of the gas are
 17

calculated with the help of Daniel Box. Bernoulli equation is used to control and calculate the
static pressure and flow rate of the fluid.

Moisture analyzer:
Moisture Analyzer is used calculate the moisture content flow with gas molecules.

Gas chromatograph:
Gas Chromatograph is used to find the sale gas composition. i.e. it shows the percentage of
Methane, Ethane, Propane, Butane etc. Gas chromatograph takes reading after every four
minute and displays it of flow computer.
These entire instruments sent the data to Flow computer.
 Static pressure of sale gas of MGP plant is about 1050Psi.
 Differential pressure across orifice is 60Inch Water Column.
 Flow rate of gas from OGDCL plant to SNGPL is approximately 42MMscfd.
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1.6 Gas process and flow circuit:

Fig: 2.4 a
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1.6.1 Condensate process:

After the inlet separator the condensate forwarded to flash separator to remove the gas and
water from it. For stabilization the condensate is sent to stabilizer tank. The condensate
coming from LTS is heat up in utility heater to achieve the required temperature. And at last
the condensate is stored in storage tank.

1.6.1.1 Utility heater:

Utility heater is used to increase the temperature of condensate coming from low temperature
separator. Utility heater increases the temperature from 4deg F to 130-145deg F.
In Plant Area burner is used to increase the temperature of condensate. Burner is operated by
plant gas. Purpose of heating is to preheat the cool condensate before entering to stabilization
unit. In stabilization unit lighters are removed from heavier by heating phenomena. Utility
heater works in series with re-boiler of stabilization unit in case of condensate coming from
low temperatures separator. The condensate is forwarded to flash separator.

1.6.1.2 Flash separator:

The condensate is separated from raw gas in inlet separator and forwarded to flash separator
for farther separation. In flash separator the gas and water is removing from condensate at
low pressure, this process is called flashing. After the separation the gas flows to flash gas
compressor FGC. Water transferred to water degasing boot. The condensate is forwarded to
stabilizing unit for stabilization purpose.

1.6.1.3 Stabilizing unit:

The condensate passes throughstabilizing unit to remove the lighter from condensate, at high
temperature due to boiling point difference. Stabilization is actually a distillation process to
stabilize the heavier hydrocarbon. Condensate stabilization unit is used to control one of the
most important factors of condensate called Reid Vapor Pressure (RVP).

RVP
The absolute vapor pressure of condensate at 100deg F is called Reid Vapor Pressure. Vapor
pressure relates the tendency of particles to escape from the liquidReid Vapor Pressure must
be less than 7Psi. Reid Vapor pressure is used to judge condensate whether it is feasible for
transportation or not. If the RVP is under 7Psi then liquid is feasible for transportation,
otherwise not.
The stabilizing unit consists of,

 Re-boiler
 20

 Heat exchanger
 Stabilizer

1.6.1.3.1 Re-boiler:

The re-boiler is used to heat up the condensate. Electric heaters are used for heating. On
heating the lighter achieved their boiling points and evaporate from condensate and flow out
from the top of stabilizer.

1.6.1.3.2 Heat exchanger:

In exchanger the incoming condensate is heating up and outgoing condensate is cooling

down. Only the heat is exchange so that the condensate takes less time in heating up, in re-
boiler

1.6.1.3.3 Stabilizer:
In Inside of the stabilizer Rushing rings are present. Rushing rings are for the purpose to
increase the retention time and to avoid the escaping of heavier component.

1.6.1.4 Condensate storage system:

There are two condensate storage tanks at plant area to store the condensate. Each tank has
capacity to store 3000 barrels condensate coming from different stabilizer; slop and vent
stack. The Incoming condensate enters the storage tank through a side nozzle provided on top
of tank.

The evaporation stabilized the condensate, reducing the RVP, the vapors are sent to vent
stack via flame arrestor.
Pressure vacuum relief valve (PVRV) is provided on top of the tanks to help to prevent the
tank from vacuum or overpressure, which may produce in the tank.
Along with the pressure/vacuum breaker an Emergency vent (EV) is also provided on top of
the tanks to prevent the tank from damage or any emergency status.
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1.6.1.5 Condensate Loading Pumps:

The condensate is loading into road tankers and browsers for transportation to its end users.
The stabilized condensate is taken to the condensate loading Arms by condensate loading
pumps from storage tanks. The loading capacity of each pump is 126 US gallons per minute.
One pump is on standby while the other is running during loading operation.

Condensate process and flow diagram:

Fig: 2.4.1 a

1.6.2 Produce water process:

Water is also mixed the raw gas coming from reservoir. The water is separated from gas and
condensate in different vessels. The water gathered from all vessels to water degasing boot In
water degasing boot the gas is removed from water. After the water degasing boot the water
discharged into slop vessel. The water settled in slop and the condensate separates on density
bas separation. The condensate is forwarding to storage tanks and water is disposed of into
evaporation ponds (EP’s). There are seven EP’s at plant area. The water is evaporated by
forced evaporation trough sprinkler.
 22

Produce water process and flow diagram:

Fig: 2.4.2 a

1.7 Emergency shutdown valves (ESD’s) and blows down valves (BDV’s):
To handle any emergency case ESD’s and BDV’s are installed at different places and vessels.
The main ESDV and main BDV is installed at main line coming from assembly. During the
level-1 all ESDV’s are closing and the BDV’s are opening to de-pressurized the plant the
BDV’s are opening to flare. During level-2 only the ESDV’s are closing.

1.8 Flare system:

Its purpose is to provide a safe means of disposing of waste gases/hydrocarbon condensate
and emergency releases by ignition and burning of these gases/hydrocarbon condensate.
These gases/hydrocarbon condensate is burnt; they could not disposed to air freely, because
they are harmful for life. The gas flare system gathers waste gases and liquids discharged by
safety/relief valves and blow-down valves.

1.8.1 Flare K.O drum:

Waste gases from all the operating facilities enter the Flare Knockout Drum through the flare
header. In the flare header the waste/emergency gases are coming from the following
operating facilities:
 Fuel gas purge supply
 23

 Inlet header PSV-10001 and BDV-11101

 Inlet separator skid

 Gas/Gas exchanger & contactor knockout drum skid

 Dehydration package skid

 Turbo expander & low temperature separator skid

 Sales gas metering skid

 Flash separator & water degassing boot skid

 Fuel gas scrubber skid

In the flare K.O drum the gas and hydrocarbon condensate are separated the gas is flowing through
the top of vessel and the liquid settled down in the vessel and drained out through a level control
valve after getting some certain level and pumped away by flare knockout drum pumps. Flare
knockout drum prevent liquid hydrocarbons from reaching the flare stack (Liquid hydrocarbons
emerge from the flare stack as burning droplets, which descend to earth and pose a fire hazard).

Flare system diagram:

Fig: 2.6 a
 24

Overall process and flow diagram:

Blue for water Fig: 2 a

Black for flare

Orange for gas

Brown for condensate

 25

CHAPTER NO: 03

2 Electrical and Instrumentation:

2.1 Instrumentation:
This department supervises different apparatus, equipment, instruments and devices which
are used for sensing, measuring, monitoring and transmitting purposes and keep these devices
related to process in good condition.Like temperature, flow, pressure, resistance etc. they also
do the maintenance job of these devices. Here at Plant instrumentation is the combination of
Temperature instrument, pressure instrument, level instrument, flow instrument HD’s, MA,
GC and FC.

2.1.1.1 Temperature Devices:

2.1.1.1.1 Temperature Indicator and Transmitter (TIT):

The TIT’s consists of temperature sensor, indicator (LCD display) and transmitter. The
sensor senses the temperature of the system and it is connected with an LCD display which
indicates the temperature in℉. The transmitter produces a signal and transmits the signal
trough a wire to the central control room (CCR). The transmitter analog out is 4-20mA. The
signal strength depends upon the temperature value.

2.1.1.1.2 Temperature Transmitter (TT):

The TT only detects the temperature and transmits the signal to central control room (CCR).
The transmitter analog out is 4-20mA.

2.1.1.1.3 Temperature Detector and Indicator:

The TDI detects and indicates the temperature. The TDI’s used here at MGP are RTD based.
RTD detects the temperature of the system. The RTD is connected with anLCD display
which indicate the temperature in℉.
 26

2.1.1.2 Pressure Devices:

2.1.1.2.1 Pressure Indicator and Transmitter (PIT):

The PIT consists of an indicatorLCD display and transmitter. The PIT measures the pressure
of the system and transmits a signal. The PIT indicates the pressure on LCD display in Psi.
The transmitter produces signal and transmits the signal to CCR. The transmitter analog out
is 4-20mA.

2.1.1.2.2 Pressure Transmitter (PT):

The PT only senses the pressure and produces the signal. The transmitter transmits the
signalto CCR. The transmitter analog out is 4-20mA.

2.1.1.2.3 Pressure Deferential Indicator and Transmitter (PDIT):

The PDIT measure the deferential pressure of two different systems a low pressure and high
pressure. It measures the pressure and indicates it on LCD display. The transmitter produces a
signal with corresponding pressure and transmits the signal to CCR. The transmitter analog
out is 4-20mA.

2.1.1.2.4 Pressure switch:

The pressure switch is a pressure control switch. It is auto operated switch, when the pressure
exceeds the high set point the switch will open to reduce the pressure.When the pressure
comes down from the low set point the switch will to retain the pressure.

2.1.1.3 LevelDevices:

2.1.1.3.1 Level Indicator & Transmitter (LIT):

The LIT consists of level sensor level meter & indictor (LCD display) and transmitter. The
level sensor senses the level of fluid, the meter measure the level and the indicator (LCD
display)indicates the level in water column inches. The transmitter produces a signal with
corresponding level and transmits the signal to CCR. The transmitter analog out is 4-20mA.

2.1.1.3.2 Level Transmitter (LT):

The LT consists of level sensor and transmitter. Level sensor senses the level and the
transmitter produces a signal with corresponding level transmits the signal to CCR. The
transmitter analog out is 4-20mA.
 27

2.1.1.4 Flow Devices:

2.1.1.4.1 Flow Indicator & Transmitter (FIT):

The FIT consists of flow sensor flow meter & indictor (LCD display) and transmitter. The
sensor senses the flow of fluid, the meter measure the flow and the indicator indicates the
flow in water column square feet. The transmitter produces a signal with corresponding flow
and transmits the signal to CCR. The transmitter analog out is 4-20mA.

2.1.1.4.2 Flow Transmitter (FT):

The FT consists of flow sensor and transmitter. Flow sensor senses the flow and the
transmitter produces a signal with corresponding flow transmits the signal to CCR. The
transmitter analog out is 4-20mA.

2.1.1.4.3 Flow Quantity Indicator (FQI):

The FQI measure the quantity of liquid flowing in pipe and indicates it on LCD display.

2.1.1.5 Pneumatic instruments:

To control the process automatically pneumatic instruments, which operated by pneumatic
air, are used. The pneumatic air is used to control different valve keep the pressuring. The
pneumatic or instrument air provided to pneumatic instruments from instrument air
compression unit, installed near fir water tank.

The instrument air compression unit consists of following parts,

 Air sucker.
 Compressor.
 Filters.
 Plant air storage tank.
 Instrument air storage tank

The air is sucked by air sucker from atmosphere. The compressor compresses the air. As the
air was taken from atmosphere, it should contain moisture, to remove the moisture from air, it
passes through different filters. The filter absorbs the moisture and air becomes moisture free.
The plant storage tank provides air for different utility purposes. The instrument air is stored
in instrument air storage tank. The air is distributed from storage all over the plant to provide
pneumatic source for pneumatic instruments.
 28

Fig: 3.1.1.5 a

2.1.1.6 Moisture Analyzer (MA):

According to the SNGPL and OGDCL agreement the moisture content should be less
7lb/MMscfd in sale gas. The moisture analyzer is used to trace the moisture concentration in
process gas stream. The MA used at Plant area is Analyzer MA-3050-OLVmade by Ametek
Company. It is compatible with He, AR, Ne, Xe, Kr,𝑜2 ,𝑁2 , 𝐻2 , NO, CO 𝑐𝑜2 , light gases,
hydrocarbons, natural gas, air and specialty gases.The heart of the MA is a quartz crystal
microbalance (QCM) sensor that is sensitive to moisture. The QCM moisture sensor is quartz
crystal oscillator in which the quartz crystal has been coated with hygroscopic coating. The
coating absorbs moisture from a sample gas. As the crystal exposed to a gas stream
containing water vapor, the coating absorbs moisture from gas, changing the mass of the
crystal. Change in the mass is detected as change in the natural frequency of crystal
oscillator. The calibration data is stored in an EPROM within the QCM sensor. It transfers
the daily report to flow computer.

2.1.1.7 Controller communication:

All the analyzer functions are controlled by a microprocessor housed within the analyzer. The
communication is achieved by the following connections.

 One Analog input signal 4-20mA.

 One Analog output signal is 4-20mA.

The analyzer has no locale user programing functions. It is connected serially with an
external PC for configuration. The analyzer is calibrated after each month. It calibrated to
measure the moisture contents from 1-2500ppmv.
 29

Fig: 3.1.1.6 a

2.1.1.8 Gas Chromatograph:

The slipstream withdrawn from the sales gas leaving the pressure control valve PCV-15041,
flows past the sensor probe of the Daniel 570 Gas Chromatograph/BTU Analyzer GC-15-01.
The gas chromatograph verifies the sales gas chemical composition and also measures the
BTU value. Here at MGP two Daniel 570 Gas Chromatographs/BTU Analyzers A&B, are
used. It generates daily report and transfers it to flow computer installed in CCR.

2.1.1.9 Flow Computer:

The flow computer is used to measure the flow of sale gas. It is installed in CCR. It is
connected with gas Chromatographs and Moisture Analyzerinstalled at sale gas metering
skid. It measures volume, gross heating value, daily flow rate and energy in BTU. The data is
stored in a computer which generates the daily report.

2.1.1.10 Barton Chart recorder:

Barton chart is three pin, recorder which records differential pressure, static pressure and
temperature of sale gas on a circular chart. These parameters are used to calculate the flow of
sale gas, to SNGPL. The pins are of different colors, red pin measures differential pressure,
blue pin measure static pressure and green pin measures temperature.
 30

Fig: 3.1.1.10 a

2.1.1.10.1 Design specification:

Differential pressure 0-100’’WC

Static pressure 0-2000psi
Temperature 0-150℉

2.1.1.11 Joint metering calibration:

It is monthly calibration of meters transmitters and devise which measure the flow of sale gas
to client (SNGPL). It is done jointly by OGDCL and SNGPL. The following equipment’s are
calibrated.

 Moisture analyzer.
 Barton chart.
 PDIT, TIT and PIT which transmit signal to flow computer.

2.2 Central Control System (CCS):

A CCS is a process control system that uses a network to interconnect sensors, controllers,
operator terminals and actuators.
 31

2.2.1 Basic Components of a Control System:

2.2.1.1 Sensor &Transducer:

A device which senses any physical quantity/parameter andTransducer converts it into an
electrical signal e.g. Level Sensors (LITs), Pressure Switches, Temperature Sensors (TITs)
etc.

2.2.1.2 Controller:
A controller manipulates the inputs to a system to obtain the desired effect on the output of
that system e.g. PLCs, Pneumatic controllers, embedded controllers etc.

2.2.1.3 Actuator:
A device that converts controller output to physical action, to have desired controlled
behavior of the system e.g. LCVs, Motors, ESDVs, etc.

2.2.2 Control System Basic Parameters:

• Input/Set point
• Controller
• Output
• Feedback

• Open Loop Control System

Fig 3.2.2 a
 32

• Closed Loop Control System

Fig 3.2.2 b

2.2.3 Some Important Terminologies:

2.2.3.1 Programmable logical controller (PLC):

A control device that uses a programmable microprocessor and is typically programmed in
IEC 61131 programming languages.

Fig: 3.2.3.1 a

2.2.3.1.1 PLC Components:

• Power Supply
• Input Cards( Digital & Analogue)
• CPU
• Memory (RAM)
• Output Cards( Digital & Analogue)
 33

Fig 3.2.3.1.1 a

2.2.3.1.2 PLC I/O’s:

PLCs are often categorized by the number of I/O ports they provide.

Digital I/O’s:
These are the Inputs/Outputs which can be described in two states .i.e. ON/OFF,
OPEN/CLOSE etc.
Input from pressure and level switches are digital inputs while controller output to Solenoid
valve, ESDVs, BDVs are digital Outputs. Digital I/So signals are 0-24v.
Analogue I/O’s:
Inputs/Outputs, that requires multiple state arguments to be described. Input from LITS, TITs
and FITs are analogue Inputs while controller outputs for LCVs, PCVs are analogue
outputs.Analogue I/O’s are 4-20mA

2.2.4 Human Machine Interface:

User can visualize all plant parameters, settings and controls on machine as well as he can
change different control inputs and settings keeping process parameters insight.

2.2.4.1 Operator Work Station OWS:

OWS provides an interface between plant process and plant operator.There are two machines
(HMI) named OWS and OWS1 at our plant.
Software installed on these machines is,
• RSView Run Time
• RSLinx
 34

OWS Snapshot:

Fig 2.1.2.4.1 a

2.2.4.2 Control Net:

Communication protocol used for the high speed transmissions of time critical data between
controller and I/O devices.

Fig 2.1.2.4.2 a
 35

2.2.4.3 EWS (Engineering Work Station):

In this Station different CCS software are installed which are used for control system backup,
modification and visualization of Logic and HMI.
Software installed on EWS:
• RSLogix 5000
• RSLogix500

2.2.4.4 Webserver/Historian Server:

Web Server is used for the logging of trend data, data of different process tags and after some
manipulation with this historical data miscellaneous reports are generated.
Following Reports are generated by this server
• Daily Report
• Hourly Averages Report
• SNGPL Metering Report
• GC Averages Metering Report
• Monthly Report

2.2.5 Remote Terminal Unit(RTU):

An RTU is a device installed at a remote location that collects data, codes the data into a
format that is transmittable and transmits the data back to a central station, or master (CCR).
An RTU also collects information from the master (CCR) device and implements processes
that are directed by the master (CCR). Here, at our plant, Well Head area’s instrumentation is
being monitored and controlled through RTU.

2.2.6 ESD (Emergency Shutdown System):

Every process plant is designed to operate in certain bands of physical parameters i.e.
pressure, temperature, flow etc. During control system, designing these limits are taken into
account and an ESD system is planned out to avoid any disaster and to operate the plant in
safe mode. ESD system is incorporated in CCS to ensure the safety of personnel, safeguard
the environment, protection of plant and its associated facilities. ESD system may have more
than one level e.g. Level 1, Level 2 etc. At our plant all ESD I/O’s actuation is made
redundant.
 36

Central control system diagram:

Fig 2.1.2 a

2.3 Electrical:
The electrical department deals with power generation, distribution, repairing, replacement
and maintenance of electric equipment’s. There is a control room for all electric equipment
named as “motor control center (MCC)”. The control of different motors, equipment and
generators are installed in MCC. The power is distributed from MCC.

2.3.1 Power generation system at MGP:

The Power generation & distribution system at Plant consist of three generators, UPS system
and solar system.

2.3.1.1 Generators:
There are three generators at Plant area.
 Gas generator (GG).
 Main diesel generator (MDG).
 37

 Emergency diesel generator (EDG).

Normally the GG is in running condition and supply the power to all plant and to the utility
area. When the load exceeded the power limit (70%) of GG, then the EDG is synchronized
GG to share the load.

2.3.1.1.1 Generators Synchronization:

To synchronize the EDG with GG, ON the EDG as follows,
 Switch ON the hand switch.
 Press release button.
 Press manual on load button.
After this process the synchronization relay synchronized the frequency, voltage and phase
of both the generators. After the synchronization the relay connect the EDG trough air circuit
breaker with bus bar automatically. And the shared equally.

Fig: 4.2.1.1.1 a
 38

2.3.1.1.2 Generator specification sheet:

Parameters Generators Gas generator Main diesel Emergency diesel

GG generator MDG generator EDG

Rated power 600KVA (480W) 635KVA (508W) 365KVA(292W)

Power factor 0.8 0.8 0.8
Rated voltage 400V 400V 400V
Frequency 50Hz 50Hz 50Hz
Connection Y Y Y
No# pols 4 4 4
Fuel Gas Diesel Diesel
Cycle 4-strok 4-strok 4-strok
Cooling system External water Self-contained Self-contained
cooling system radiator system radiator system
Operation Continues Standby Emergency
RPM 1500 1500 1500
No 8 12 6
# cylinders
Phase 3-phase 3-phase 3-phase

Table 3.2.1.1.1.2

2.3.1.1.3 Generator maintenance:

The generators are checked after 2000 running hours for following operations.
 Lube oil condition.
 Changing lube oil.
 Lubrication.
 Cooling system.
 Ignition timing.
 Air, fuel and oil filters.
 Loose connections.
 39

 Battery charging,
 External inspection for leaks and loose components.

2.3.1.2 Uninterrupted power supply (UPS):

At MGP UPS’s also used for power generation. The following UPS are installed at .

2.3.1.2.1 APC smart-UPS RT 5000

For communication and networking system,
Efficiency at full load 92.00%,

2.3.1.2.2 RT-4B-24V/50A rectifier:

Load,
 Terberg panels for generators.
 PLC for the turbo expender.
 Flow computer.

2.3.1.2.3 Two 10KVA, 400V, APC silicon UPS:

For instrument and control system

Efficiency 94.8%

Load,

 PLC based combine control system (PLC, ESD).

 Moisture analyzer (MA).
 Gas chromate graph A & B.

2.3.1.2.4 30KVA APC smart UPS:

 Efficiency 96.6%
 Typical backup time 9.5 minutes at full load.
 Present time 15 minutes.

Load;

 Glycol pump A.
 Lube oil pump A of turbo expender.
 Lube oil cooler of turbo expender.
 40

2.3.2 Power distribution:

The power is distributed to the plant and utility area from MCC.

2.3.2.1 Motor control center:

The MCC contained all the control penal of distributed load. All the equipment’s are
controlled from MCC. The penal contained connection and ON, OFF switches and their PLC
controlled inputs and outputs.The MCCis further divided into two parts,

 Essential load.
 Non-essential load.

Essential load:
Essential load comprises of all the camp area, water systems, UPS and networking systems,
water wells motors, Main lighting distribution board, diesel loading pumps and condensate
heater.

Non-essential load:

Non-Essential Loads are the main plant loads that includes glycol pumps, turbo expander
lube oil pumps, cooling fan motor and condensate loading pumps etc.

Fig: 2.13.1.3.1
 41

2.3.2.1.1 Main circuit breakers:

The main circuit breakers are air circuit breakers, with solenoid operating mechanism and
manual operation. Each breaker has the following metering and monitoring devises.

 Ammeter with selector switch.

 Voltmeter with selector switch.
 Power meter (KW & KWh).
 Three indicators
Green for ON
Red for OFF

Yellow for trip

2.3.2.1.2 Protection system:

Different breakers are used to protect the system from any damage or any other fault due to
occurrence of the following causes,

 Under voltage/over voltage

 Thermal overload.
 Short circuit.
 Earth fault.

The breakers tsripped the system if one of these causes occurred.

2.3.3 Power consumption:

The power is consummated to run different motors, in operating different equipment’s and in
lighting system.
 42

Power distribution diagram:

Fig: 3.3.3 a
 43

2.3.3.1 Motors:
To operate different rotary equipment’s the motors are used. Mostly motors are three- phase
induction motors.

2.3.3.1.1 Motors specification sheet:

Name rating(kW) voltage (V) current(A) P.f rpm

Jockey pump motor 18.5 400 33.7 0.85 2945

electric fire water pump motor 100 380 133 0.91 2950
4 380 7.73 0.8 2900
raw water pump motors

portable water pump motors 7.5 380 14.3 0.8 2900

10 400 14.7 0.8 1500
inlet cooler fan motors

7.5 230/460 19.1/9.6 0.8 1180

lube oil cooler fan motor

125 400 167.4 0.8 1180

flash gas compressor main motor

flash gas compressor lube oil 1 200/400 3.66/1.83 0.8 935

pump motor

10 190/380 28.79/14.39 0.895 1455

flash gas compressor cooler fan
motor

7.5 400 9.89 0.91 2920

turbo expander motor

15/6 230/460 37.2/18.6 F 1175

glycol circulation motors

11 400 24 0.74 960

generator ventilation fan motor

2.2 380 4.61 0.8 2820

diesel transfer pump motors

2.2 380 4.61 0.8 2820

condensate loading pump motors
 44

2.3.3.2 Different testes:

MEGGER test:

To check the winding insulation of motors and generators, the MEGGER tester is used. The
MEGGER contained a high power battery. To test insulation one terminal of MEGGER is
connected to ground and the other one is connected to winding. If the resistance increases in
some mega ohm range the insulation will be OK otherwise it will be damage.

Continuity test:
To check the continuity of winding of motor or generator, the continuity test is used. In this
test the winding’s resistance between phase and neutral, is measured. The continuous winding
has limited resistance. If the winding is broken it will show open circuit. For three phase
winding the resistance between any two phase will be same, if it isn’t same the winding will
not continuous.
 45

Chapter No: 04

3 Maintenance department:
After processing we worked with maintenance department. Maintenance department holds
the responsibility of maintaining the working of machinery at the plant. It is a major
department in any industry and requires best engineering skills. We were first assigned to
enlist and study all the tools and machines in the mechanical workshop. Following are some
major tools and machines available in workshop:

3.1 Mechanical tools:

The following tools are available in workshop.

Adjustable wrench: It is used to tighten up (or loosen up) different types of nuts and bolts
(other than round headed). The wrench is adjustable, i.e. its opening can be varied according
to the size of nut or bolt head to be tightened or loosened.

Pipe wrench:it is used for tightening or loosening of pipes. This type of wrench can grip the
pipes firmly so no slippage occurs. This can also serve the purpose of adjustable wrench. It
comes in different sizes depending upon the use.

Spanner:Used to screw or unscrew nut and bolts. One end of the spanner is usually open ring
and other closed ring. Spanners come in different sizes depending upon the diameter of the
nut or bolt to be screwed or unscrewed.

Threaded: it is used to make threads in pipes. Different dies can be installed in it for making
the desired depth and Threads per Inch (TPI) in a pipe.

Saw:Two types of saws were there in mechanical workshop, i.e. hacksaw, and handsaw.
Hacksaw is used to cut sheet metals, pipes, or high tensions cables, whereas handsaw is used
for light duty purposes like cutting woods.

Pipe cutter:As clear from its name, pipe cutter is used to cut pipes. It grips the pipe firmly,
and cuts it very accurately. It is manually operated.

Grease guns:Two types of grease guns were present in the workshop. One was used for
feeding grease with high pressure, and the other was used for greasing the equipment at low
pressures.
 46

Fittings:

Elbow:Elbows are fittings used to connect two pipes on different angles. Elbows with
different angles were present in the workshop, for example, 90° elbow, 45°, etc.

Reducer:it is used to connect two pipes of different diameters. Normally, the upstream pipe is
of larger diameter than that of downstream pipe that is connected to the reducer. In this way,
it reduces the cross-section of the pipe for the flow of the fluids, thus know as a reducer.
Different types of reducers were placed in the workshop, for example, concentric reducers,
eccentric reducers, male-to-female reducers, female to female reducers, etc.

Flange:Flange is a type of fitting used to connect two pipes. A pair of flanges is necessary to
connect the two pipes. The pair of flanges is bolted together. Different types of flanges are
available in the industries, made to serve their respective purposes. These may include, flat
faced flanges, raised face flanges, threaded flanges, welded heads flanges, lapped flanges, etc.
Flanges are categorized according to their face shape, their installation mechanism, their
walls thickness (schedule), their materials, etc.

3.2 Machine:
The following different machines are available in workshop.

 Hand Cutter
 Bench Grinder
 Welding Plant
 Hand Grinder
 Lathe Machine
 Drilling machine
 Horizontal Milling machine
 Karcher/Steam Gun

3.3 Valve:
Valve is low controlling device, which control flow of fluid.

Types of Valves Installed at the Plant:

The following Different types of valves are used here at MGP plant.
 47

3.3.1 Gate Valve:

A gate Valve, or sluice valve, as it is sometimes known is a valve that opens by lifting a
round or rectangular gate/wedge out of the path of the fluid.

The distinct feature of a gate valve is the sealing surfaces between the gate and seats are
planar. The gate faces can form a wedge shape or they can be parallel. Gate valves are
sometimes used for regulating flow.

Fig: 4.3.1 a

3.3.2 Globe Valve:

A Globe Valve is a type of valve used for regulating flow in a pipeline, consisting of a
movable disk-type element and a stationary ring seat in a generally spherical body.
Globe Valves are named for their spherical body shape with the two halves of the body being
separated by an internal baffle. This has an opening that forms a seat onto which a movable
plug can be screwed in to close (or shut) the valve. The plug is also called a disc or disk.

Fig: 4.3.2 a
 48

3.3.3 Ball Valve:

A ball valve (like the butterfly valve and plug valve are one of the families of valves called
quarter turn valves) is a valve that opens by turning a handle attached to a ball inside the
valve.The ball has a hole, or port, through the middle so that when the port is in line with
both ends of the valve, flow will occur. When the valve is closed, the hole is perpendicular to
the ends of the valve, and flow is blocked. The handle or lever will be in line with the port
position letting you "see" the valve's position.

Fig: 4.3.3 a

3.3.4 Needle Valve:

A needle valve is a type of valve having a small orifice and a threaded, needle-like plunger. It
allows precise regulation of flow, although it is generally used for, and is capable of, only
relatively small flow rates.

A needle valve has a relatively small orifice with a long, tapered, conical seat. A needle-
shaped plunger, on the end of a screw, exactly fits this seat. As the screw is turned and the
plunger retracted, flow between the seat and the plunger is possible; however, until the
plunger is completely retracted the fluid flow is significantly impeded.

Fig: 4.3.4 a
 49

3.3.5 Check Valve:

A check valve, non-return valve or one-way valve is a mechanical device, which normally
allows fluid (liquid or gas) to flow through it in only one direction.

Check valves are two-port valves, meaning they have two openings in the body, one for fluid
to enter and the other for fluid to leave. There are various types of check valves used in a
wide variety of applications.

Fig: 4.3.5 a

3.3.6 Foot valve:

Foot valves are a type of check valve and are placed at the pump's wet well. Unlike other
valves, a foot valve is created with a larger flow area than the actual pipe size to make sure
that there is less head loss. Foot valves are used to maintain hydraulic pressure to keep the
water flow in accordance with the given settings or configurations.

Fig: 4.3.6 a
 50

3.4 Pumps:
Pump is used to transfer liquid from one place to another place by pressure.

Types of pumps:

The following types of pumps are used here at MGP plant.

 Centrifugal pumps
 Positive displacement pumps

3.4.1 Centrifugal Pumps:

A centrifugal pump is a roto-dynamic pump that uses a rotating impeller to increase the
pressure and flow rate of a fluid. Centrifugal pumps are the most common type of pump used
to move liquids through a piping system. The fluid enters the pump impeller along or near to
the rotating axis and is accelerated by the impeller, flowing radially outward or axially into a
diffuser or volute chamber, from where it exits into the downstream piping system.
Centrifugal pumps are typically used for large discharge through smaller heads.

Fig: 4.4.1 a

3.4.1.1 Impeller:
It is the most important part of a centrifugal pump. It is mounted on the shaft and rotates with
it. It comprises of eye, vanes, and/or shrouds.
 51

Types of impellers:

Open impeller—vanes are directly attached to the hub and there are no shrouds to support the
vanes. It is good for pumping stringy materials such as paper stock.

Semi-open impeller—vanes are attached to the hub and shroud is on one side of the impeller.
It is good for pumping viscous fluids.

Closed impeller—vanes are attached to the hub and shrouds on either sides of the impeller.
Pump efficiency is maintained by the use of closed clearance wear rings. It is good for only
reasonably clear liquids.

Fig: 4.4.1.1 a

Types of centrifugal pumps:

3.4.1.2 Single Stage (Over Hung) Centrifugal Pump:

A pump with single impeller is called single stage centrifugal pump. Impeller is installed at
one end of the shaft while other end of the shaft is supported by bearings. Since impeller is
installed at one end of the shaft that is why this type of pump is called overhung pump. This
pump has one stuffing box.

3.4.1.3 Multistage Centrifugal Pump (Ends Supported):

A pump with two or more impellers installed on a shaft in series is called multistage
centrifugal pump. It has two stuffing boxes and is used for higher discharge head. In this
pump, impellers are located at the center of the shaft while shaft and impeller assembly
(called rotor) is supported at the shaft ends
 52

3.4.2 Positive Displacement Pump:

Positive displacement pumps are distinguished by the way they operate: liquid is taken from
one end and positively discharged at the other end for every revolution. In all positive
displacement type pumps, a fixed quantity of liquid is pumped after each revolution. So if the
delivery pipe is blocked, the pressure rises to a very high value, which can damage the pump.
Positive displacement pumps are widely used for pumping fluids other than water, mostly
viscous fluids.

Types of PD pumps:

Positive displacement pumps are further classified based upon the mode of displacement:

3.4.2.1 Reciprocating Pump:

If the displacement is by reciprocation of a piston plunger, Reciprocating pumps are used
only for pumping viscous liquids and oil wells.There are many types of reciprocating pumps.

Reciprocating pumps have two sections, the liquid section (hydraulic) and the power section.
The liquid section does the pumping and the power section provides driving force to operate
the liquid section. Reciprocating pumps may be plunger type or piston type.

Fig: 4.4.2.1 a

3.4.2.2 Rotary Pump:

If the displacement is by rotary action of a gear, cam or vanes in a chamber of diaphragm in
a fixed casing. Rotary pumps are further classified such as internal gear, external gear, lobe
and slide vane etc. These pumps are used for special services with particular conditions
existing in industrial sites.
 53

Fig: 4.4.2.2 a

3.4.2.3 Diaphragm Pump:

This pump is a positive displacement pump that uses a combination of the reciprocating
action of a rubber, thermoplastic or Teflon diaphragm and suitable non-return check valves to
pump a fluid. Sometimes this type of pump is also called a membrane pump.

Fig: 4.4.2.3 a

3.4.2.4 Piston & Plunger Pumps:

Piston pumps and plunger pumps are reciprocating pumps that use a plunger or piston to
move media through a cylindrical chamber. The plunger or piston is actuated by electric
motor. Piston pumps and plunger pumps are also called well service pumps, high pressure
pumps, or high viscosity pumps. Glycol pumps are triplex plunger pumps i.e. three-staged.
 54

Fig: 4.4.2.4 a

4 Main activities during my internship:

During my internship, I tried my best to involve myself in each and every activity of the
plant. The main activities that I performed or that were performed during my presence are:
 PM of generators, which is done after every 2000 hours by CATTERPILLER team.
 Joint metering calibration (JMC) which is done once in a month. Luckily it happened two
times during my internship..
 PM of Libra Panel.
 Replacement of AVR (Automatic Voltage Regulator) of EDG.
 Installation of lights for under construction FC watch tower near EP-6 and EP-7.
 Overhauling of different types of motors.
 Installation of night vision cameras.
 Installation of barriers.
 Presentation on motor types and read nameplate.
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Conclusion:
The internship program with OGDCL was an excellent experience. It has given me
a huge opportunity to apply my theory in practical field. This internship program has helped
me learn how to deal with the practical challenges. Also, it has immensely enhanced my
belief in team work.
In short, this stay at Dakhni and CHANDA will surely help me a lot in my practical career
and I will consider myself lucky to get an opportunity to serve such a reputed company in
future as well.

THE END