Documente Academic
Documente Profesional
Documente Cultură
M. Yalmaz Akhtar
(Manager Production)
Disclosure Page
I hereby state and verify by my signature that I have reviewed this internship report. I hereby
affirmed that the report contains the actual project or assignment that I (or the company I work
for) assigned to these interns.
We are greatly thankful to Sir Faisal Amjad throughout the internship duration and especially for
this internship report has positioned us as a knowledgeable, hardworking and flexible personality
so that we can perform better in the Practical field life. We are thankful to be for injecting such
knowledge in my mind and for the guidance, he has given to us. We are also thankful to our dear
parents who have assisted us financially, mentally and physically so that today we are proud to
call ourselves as educated and an important part of the society and will be looking forward to
make positive contributions to the society with the knowledge that we have acquired. Here I
must not forget to thank Sir Saqib and Sir Iqram who have helped us to learn the nature of work
being done in the organization and also helped us to scrutinize what we have learnt in our
classroom settings from a practical point of view.
We are also greatly thankful to HOD’s and Principle of our respective universities who kindly
provided us opportunity to check our abilities in a good organization like Mari Gas. It was valuable
experience and interesting work for us and it was really a delightful job. We are extremely
thankful to all the operators at Mari for sharing their knowledge with us during internship.
1
VISSION & MISSION STATEMENT
2
Table of Contents
................................................................................................................................................ 5
Corrosion: ...................................................................................................................................................... 14
External Section: ....................................................................................................................................... 15
Internal Corrosion: .................................................................................................................................... 20
Field Laboratory: ........................................................................................................................................... 25
Field Maintenance: ....................................................................................................................................... 25
................................................................................................................................ 26
Introduction: .................................................................................................................................................. 26
Central Manifold (CMF): .............................................................................................................................. 26
3
CMF-I: ....................................................................................................................................................... 27
CMF-II:...................................................................................................................................................... 28
Knock-Out Drum: ......................................................................................................................................... 29
Liquid Level Controller:................................................................................................................................ 29
Dump Valve System: ..................................................................................................................................... 30
Flow Recorder: .............................................................................................................................................. 30
Flow Recorder Calibration: ...................................................................................................................... 31
Orifice Plate: .................................................................................................................................................. 32
Gas Compressors:.......................................................................................................................................... 32
Function:.................................................................................................................................................... 32
Starting of Compressor: ............................................................................................................................ 33
Bottom Head Pressure (BHP) Survey: ........................................................................................................ 34
Safety Shutdown System: .............................................................................................................................. 35
Emergency Action Plan: ........................................................................................................................... 35
Drilling Rig: ................................................................................................................................................... 36
List of Items: ............................................................................................................................................. 37
Simple diagram of a drilling rig and its basic operation ............................................................................. 37
....................................................................................................................................... 38
Introduction: .................................................................................................................................................. 38
Mari Deep Central Processing Facility (MDCPF)...................................................................................... 39
Process Explanation: ................................................................................................................................ 39
T.E.G Recovery System ............................................................................................................................ 43
Process Diagram: ...................................................................................................................................... 45
SCADA SYSTEM: ..................................................................................................................................... 45
Mari Deep Wells: ........................................................................................................................................... 46
................................................................................................................................................... 48
4
Mari Petroleum Company Limited (MPCL) is one of Pakistan’s largest E&P Company operating
the country’s 2nd largest gas reservoir at Mari Field, District Ghotki, Sindh. Esso Eastern Inc. (EEI)
discovered this field in 1957 with the drilling of first well – Mari X-1.
Administration Department
The administration is the heart and soul of any company or organization. This is the
administration which complete controls the affairs of the organization. Mari Petroleum Company
Limited has administration department which comprises of Housing department, Land
Acquisition Department, Purchase Department and HSE Department.
The administration of MPCL is performing several important functions which includes providing
transport facility to the officers and employees, perform welfare works, land acquisition matters
and supervising the management club and employee club.
Housing Department:
The name of the department implies, this department deals with the housing accommodations.
The repair, maintenance work of any house or household equipment comes under the shade of
the housing department. The housing department analyzes and judges the nature and condition
of the work and if any material is required for the completion of the work, they will fill a Material
Issuance Voucher to the warehouse.
5
Land Acquisition Department:
The main job of this department is to acquire legal documentation of the land which is to be
consummated by the Mari Petroleum Company for drilling or any other activity. This is performed
according to policies of the Mari Petroleum Company.
Purchase Department:
Purchase Department is one of the important departments of Administration. This department
deals with the purchase of new equipment and materials. Daharki Branch Purchase department
deals with purchases of low cost items. For high cost items, they have to contact with Islamabad
Head office.
6
PERSONAL PROTECTIVE EQUIPMENTS (PPE’s):
Personal Protective Equipment’s PPE’s are those safety equipment’s that must be with everyone
on the field.
Primary PPE’S:
Helmet
Safety Goggles
Cover-all/Uniform
Hand Cotton Gloves
Boots
Secondary PPE’S:
Dust mask
Ear plug
Welding gloves
Rubber gloves
Fire Triangle:
Fire triangle includes three components and to
extinguish it we need to eliminate at least one
of them.
Classification of Fire
Class A: Those fires which leave behind ash, generally the combustible material in this case is
solid. DCP, water, CO2 and foam can be used to extinguish such fires.
7
Class B: Fires in which a liquid serves as the fuel are classified as class B. Generally foam is sprayed
from one end of the pool of liquid which gradually spreads out curtailing the flame by forming a
layer and thus effectively depriving the flame of oxygen.
Class C: The fires due to gasses are classified in this category. Shutting down the gas supply is the
only viable option to contain such fires.
Class D: Fires involving chemicals fall under this class. Any kind of fire extinguisher can be used
for these fires.
Class E: Fires due to electricity fall in this category. Generally caused by short circuiting these
kinds of fires pose another threat i.e. Oxidizing Agent Fuel Ignition electrocution
Fire Extinguisher
Firstly we had to look for green or red pointer
(Pressure indicator). If it is green we go ahead with
it and if it is red, it’s of no use. Then we look for
date of last inspection and expiry date.
Now how to use it??
First pull the seal
Disengage the needle
Then press the handle pointing it at the
base of fire.
The direction of air must be taken into
account and fire extinguisher must not
be used against the direction of wind.
Muster Points:
In case of emergency, evocation point. People get together at time of fire.
8
There is a separate department in MPCL which supervises the services provided by the company
to its employees. There are generally four types of services which are overlooked by this
department.
Water Supply
Gas Supply
Power Supply
Maintenance of Auto mobiles
Water supply:
This department is responsible for providing water to the industry and its residential colony.
Water is pumped from a canal few kilometers away from the company to two storage tanks
having capacity of 150,000 gallons each. Water from these tanks is then pumped to an overhead
tank of a capacity of 50,000 gallons by three centrifugal pumps of 25 hp. From here water is
directly distributed to the consumers for bathing, washing and cleaning purposes. However for
water for drinking purpose is first purified and then provided at the water purification plant.
Gas Supply:
Gas supply to the industry and its residents is also the responsibility of the services department.
For this gas extracted from wells is directly distributed to the consumers after its pressure has
been regulated to the amount required by using gas regulators.
9
Vehicle Maintenance:
Mari Petroleum has a large fleet of vehicles and as they are used in a large field so problems
occur in them .The vehicle maintenance department is concerned with following duties
Service of Vehicle
Repair
Welding and Painting
Auto workshop
Air Conditioner Workshop
Machine Shop
Welding and Fabrication Shop
The machine shop is used to repair defective parts of the machines especially of vehicles by using
heavy machines which are central lathe machine, grinder and manually operated Drill machine.
Power Supply:
Introduction:
The generation of power and its distribution is also a responsibility of the services department.
For this purpose a power plant is built to meet the power demands of residential colony,
workshop and the admin department. This generated power is also supplied to well areas by
underground cabling. The Power generation plant of the MPCL Contains two Solar Gas Turbines
and one CENTRAX UK Gas turbine. Two solar gas turbines are of the DALE TECHNOLOGIES and
have the capacity of 0.6MW each which can be used together by synchronization system. These
two turbines are named GT1 and GT2 respectively. The third turbine is known as GT3 and has
largest capacity of power generation i.e. 3.8 MW. This GT is used when more power consumption
occurs for example in summers the electricity demand is at its peak.
To meet the current demand of 2.8MW approximately GT 3 is in operation but as the demand
declines especially in winter season, GT 1 and 2 are used. They are synchronized and load is
distributed. GT 1 and 2 were commissioned in 1989 while GT 3 was commissioned in 2011. GT 3
is controlled through SCADA and PLC. Gas to all gas turbines comes from well No. 23.Power house
also has a power backup system in form of a “Black Start Generator” which runs on diesel and
has a production capacity of 365 KV. The generator is kept at standby in case of any system failure
or tripping of turbine will provide the requisite energy for the start-up of the turbines.
10
Gas Turbine Overview:
Essentially, the turbine can be viewed as an energy conversion device that converts energy stored
in the fuel to useful mechanical energy in the form of rotational power. The term “gas” refers to
the ambient air that is taken into the engine and used as the working medium in the energy
conversion process.
This air is first drawn into the engine where it is compressed, mixed with fuel and ignited. The
resulting hot gas expands at high velocity through a series of air foil-shaped blades transferring
energy created from combustion to turn an output shaft. The residual thermal energy in the hot
exhaust gas can be harnessed for a variety of industrial processes.
Drive assembly
Compressor
Combustion chamber
Turbine assembly
Exhaust duct
Reduction gears
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Mechanism:
Gas at 450 psi from the well is reduced to 150-160 psi and then fed to the combustion chamber
of turbines. It has a set of primary filters for filtration of air entering compressor. It has a 3 stage
turbine and an 8 stage compressor. It has an RPM of 22300 which is reduced with the help of
reduction gear to 6000 RPM and then to 1500 RPM. It has pneumatic start-up for auxiliaries. It
has a 4 pole 50 HZ alternator by New Age International U.K which produces an output voltage of
400V.it also has a control system by Dale Electronic which consists of 24 volt DC, relay control
panel (Wood Ward, governor electronic + mechanical) Load Sharing & Speed Controller,
Synchronizer SPMA-A Type of Wood Ward Governor Co Ltd USA. Offline maintenance is
scheduled after every 2000 hours. These GTs are overhauled after 40000 hours.
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Offline maintenance is scheduled after every 2000 hours.
These GTs are overhauled after 40000 hours.
Mechanical Section
The mechanical section deals with the following matters:
Mari Petroleum Company has a total of about 140 vehicles which include, Land Cruiser, Prado,
Toyota Hilux (Single and Double Cabin), Nissan, Cranes (Truck Mounted as Well Simple), Motor
Grader, Fire Brigade
Mechanical Workshops
They have 3 workshops:
Auto Workshop:
They provide maintenance to vehicles to keep them in a good running condition
Machine Workshop:
This workshop includes equipment, US Made Lethe Machine, Central Lethe Machine which can
work up to inch as well as compare to US Lethe machine, HexaCutter and Hydraulic Press.
13
Field maintenance department is headed by Nasarullah Khan at Mari Petroleum Company. This
department deals directly with control of corrosion by different methods, field laboratory and
maintenance of field from different problems.
Corrosion
Field Field
Laboratory Maintenance
Field
Maintenance
Corrosion:
Corrosion is basically the disintegration of a material into its constituent atoms due to chemical
reactions with its surroundings. In the most common use of the word, this means a loss of
electrons of metals reacting with water and oxygen. The corrosion is classified as Internal
Corrosion and External Corrosion.
14
External Section:
Cathodic Protection:
Definition:
Galvanic anode systems employ reactive metals as auxiliary anodes that are directly electrically
connected to the steel to be protected. Impressed-current systems employ inert anodes and use
an external source of DC power to impress a current from an external anode onto the cathode
surface.
15
Cathodic protection enables the cost effectiveness and safe operation of the grounded and
submerged metal structures. It is relatively simple, has proven efficiency and its effectiveness can
be monitored continuously. Cathodic protection is the key to protecting and extending the life of
metal equipment.
Application:
Cathodic protection is one of the few methods of corrosion control that can be effectively used
to control corrosion of existing buried or submerged metal surfaces. Cathodic protection systems
are most commonly used to protect:
Steel
Water or fuel pipelines
Storage tanks
Steel pier piles
Ships
Offshore oil platforms
Onshore oil well casings
Cathodic protection can be, in some cases, an effective method of preventing stress corrosion
cracking.
The negative side of cathodic protection is that excessive negative potentials can cause
accelerated corrosion of lead and aluminum structures because of the alkaline environments
16
created at the cathode. Hydrogen evolution at the cathode surface may, on high-strength steels,
result in hydrogen embrittlement of the steel, with subsequent loss of strength. This may lead to
catastrophic failures. It may also cause disbandment of coatings; the coating would then act as
an insulating shield to the cathodic-protection currents. It cannot be used to prevent atmospheric
corrosion on metals.
Thermoelectric generators (also called Seebeck generators) are devices that convert heat
(temperature differences) directly into electrical energy, using a phenomenon called the Seebeck
effect (a form of thermoelectric effect).
Uses:
17
Pipe to Soil Potential Survey (PSP)
Definition:
The voltage potential (emf) generated between a buried pipe and its surrounding soil, the result
of electrolytic action and a cause of electrolytic corrosion of the pipe.
C-Scan Survey
Definition:
C-Scan is the latest development of the series of non-contact pipeline survey systems for buried
transmission pipelines. C-Scan is in regular use by the world’s petroleum and gas industries
producers, pipeline constructors, operators and survey companies.
Applications:
C-Scan accurately locates the buried pipeline and displays its position and depth - even
for pipelines under roads, concrete, sand, mud, growing crops, ice or water courses
C-Scan displays the average condition of the wrap or coating between any two locations
C-Scan pinpoints individual wrap or coating faults for excavation and repair
C-Scan stores and analyses all survey data and prints out comprehensive reports, plots
and maps utilizing the GPS interface (integrated in model 2010 – external unit required
with model 2000)
C-Scan using Dialog’s proprietary software, downloads all data to a computer for further
analysis and comparisons
Does not:
18
Pearson Survey
Definition:
The Pearson survey is a widely accepted method to precisely trace electrical contact points as
well as insulating coated pipeline joints. It may be performed on pipelines with coating in any
location.
This technique works by following the direction of audio frequency or impressed current in
coated pipelines and identifying the exit points. This survey is regarded as a practical way to
interpret and gauge findings in a quick and accurate manner.
Explanation:
The Pearson survey is a survey method that was developed by J.M. Pearson. It is capable of
providing professionals, such as engineers and other skilled personnel, the ability to perform the
following:
The soil resistivity value is subject to great variation, due to moisture, temperature and chemical
content. Typical values are:
19
Cathodic Protection Bed
A cathodic protection bed is an electrode array that is installed beneath the ground to give off a
path with low resistance to ground. It is a vital component of the grounding system. In terms of
cathodic protection, this ground bed refers to the anodes' arrangement in water or ground, which
provides a way for protective currents out of anodes into an electrolyte.
The application of a ground bed serves the purpose of covering cathodic protection. Different
ground beds have been successfully used to provide cathodic protection to surface equipment
as well as pipelines to prevent the occurrence of corrosion and any form of damage.
Explanation:
Almost all types of steel tanks, pipelines and equipment have anodes, typically magnesium. These
anodes are eventually reduced or become damaged by corrosion. As anodes undergo corrosion,
they produce small electricity currents that protect steel from the harmful effects of corrosion.
Due to this, magnesium anodes are also referred to as sacrificial anodes. This highly effective
type of protection is known as cathodic protection. The expected lifespan of anodes is up to three
decades. When its life ends, no more protection is expected for steel tanks, pipelines and other
structures.
The options are to replace the entire structure, which can be very expensive, or bury more
anodes close to these structures. Although the second option has a lower initial expense than
the first, it is pricier in the long run. The best and most cost effective option is to make use of a
ground bed current protection system to replace the magnesium. These anodes should be buried
deep in the ground a certain distance away from the structure it protects.
Internal Corrosion:
Corrosion Inhibitor:
Corrosion inhibitors provide critical protection to minimize the corrosive effects of liquids and
gas in gas pipelines.
Applications:
20
Injector Pumps:
One of the most practical preventive maintenance
methods for minimizing or controlling corrosion in
product pipelines, vessels, Casing etc. is to treat the
corrosive environment with chemical inhibitors. While
corrosion inhibition is a complex technology and is
under constant study and development, it is an
effective means of corrosion control. We use Injector
pump for easy, reliable access, inhibitors can be
injected with safety and simplicity while under full
operating pressure. In addition, a variety of injection
devices and systems can be used to provide the most
efficient delivery and dispersion for a given
application.
The probes may be used in all relevant environments, such as oil, water and gas.
Introduction:
The electrical resistance (ER) technique is an "on-line" method of monitoring the rate of corrosion
and the extent of total metal loss for any metallic equipment or structure. The ER technique
measures the effects of both the electrochemical and the mechanical components of corrosion
such as erosion or cavitation. It is the only on-line, instrumented technique applicable to virtually
all types of corrosive environments.
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Applications:
Corrosion coupon testing is an in-line monitoring technique; coupons are placed directly in the
process stream and extracted for measurement. This monitoring technique provides a direct
measurement of metal loss that allows you to calculate the general corrosion rate. The results
are not depend on environment.
Corrosion coupons are most frequently used to investigate general corrosion and determine the
corrosion rate based on weight loss of the coupon.
22
Water Sample Analysis:
Independent water analysis for the oil and gas industry offers organizations a detailed insight into
the makeup of the fluids they require to maintain the consistency of their operations.
Oil and gas production is heavily reliant on a range of waters - from produced water that must
be monitored to maintain the integrity of reservoirs, wells and hardware, to the vital potable
supplies on offshore platforms.
Water analysis is important to maintain the health of your water systems and typically forms part
of a comprehensive management strategy.
Such monitoring methods need to be implemented and maintained to ensure that you are
adhering to best practice and acknowledging any important alterations in microbial activity or
water quality.
Pigging Pipeline:
Pipeline pigs are devices that are placed inside the
pipe and traverse the pipeline.
Operations may conduct pigging on a regular basis to clean solids, scale, wax buildup (paraffin),
and other debris from the pipe wall to keep the pipeline flow efficiency high. In addition to
general cleaning, natural-gas pipelines use pigs to manage liquid accumulation and keep the pipe
free of liquids. Water and natural-gas liquids can condense out of the gas stream as it cools and
contacts the pipe wall and pocket in low places, which affects flow efficiency and can lead to
enhanced corrosion.
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Inspection
Pigs are being used more frequently as inspection tools. Gauging or sizing pigs are typically run
following the completion of new construction or line repair to determine if there are any internal
obstructions, bends, or buckles in the pipe. Pigs can also be equipped with cameras to allow
viewing of the pipe internals. Electronic intelligent, or smart, “pigs” that use magnetic and
ultrasonic systems have been developed and refined that locate and measure internal and
external corrosion pitting, dents, buckles, and any other anomalies in the pipe wall.
Pig launchers and receivers
24
Field Laboratory:
Field Laboratory is used for testing well products including gas, condensate and water for
property analysis including calorific value, API gravity, viscosity, measuring toxic substances like
SOx and NOx content, H2S presence and moisture content. These measurements not only helps
in gas and condensate pricing but also in determination of initial measures required to be taken
to provide standard quality crude to refinery such as dehydration by density difference in storage
tanks. The Laboratory contain following instruments:
Field Maintenance:
The responsibilities of this department include:
25
Introduction:
The Mari Gas field is the largest field in Pakistan in terms of production at 645 MMSCF. It is
spanned over an area of roughly 969 km2. The total reserves of the field is approximately 1.2 TCF
with a reservoir recovery of 65%. The shallow production portion of the company handles the
production from wells that have a depth of up to 1000m.
Thus the shallow department handles three of the four reservoirs in the Mari field. It has a total
of 101 wells under its umbrella.
The average energy content of the gas from these reservoirs is 730 BTU/SCF and they have nearly
the same composition. This gas has a higher energy content than the gas from the Guru B
reservoir being processed by MDCPF. It also has a much lower CO 2 concentration as compared
to Guru B.
The gas from each of these reservoirs is mixed at appropriate levels at the central manifolds to
give one uniform specifications of properties and then is sent to the customers. As per
requirement of the customers, the gas is passed through Knock out Drums at the well side and
then again at the manifolds to remove moisture content before being sold.
26
CMF-I:
Central Manifold (CMF-I) at well # 6 is tied with two lines of different sizes. The gas from 63 wells
is collected at Central Manifold.
At Central Manifold there are three inlet headers, two outlet headers and five knock out drums
(KOD). There are 4 customers on CMF-I:
27
CMF-II:
This consists of two headers each receiving gas from the shallow wells. The construction is similar
to the central manifold – 1, consisting of Knock out Drums and a network of pipes sending gas to
customers like Engro and Fauji Fertilizer.
Both the manifolds are connected with each other so if that there is a problem in one of the
manifolds gas continuous to flow to the customers regardless. There is also a water disposal
arrangement at the manifold where the water from the Knockout drums is disposed of.
28
Knock-Out Drum:
Knock out drum is also termed as Vertical
Separator. This is used to separate the water from
the gas coming out of the reservoir.
Internal fittings of KOD:
Wire Mesh
Baffle Plate
Float
External fittings of KOD:
Mechanism:
29
The dump valve is air to close type. When air supply is cut off then dump valve operates. When
the 30 psi air supply is ON then diaphragm push the stem to close position.
Main Parts:
01. Input Pressure Gauge 02. Nozzle
03. Output Pressure Gauge 04. Relay Assembly
05. Bourdon Tube 06. Proportional band
07. Flapper 08. Zero Adjustment
Main Parts:
1. Diaphragm Plate
2. Spring
3. Seat
4. Cage
5. Stem
6. Ring
Flow Recorder:
The Flow Recorder is device which is installed on every well site and also on the manifolds, Central
Manifold-I (CMF-I) and Central Manifold-II (CMF-II) at Shallow section and Mari Deep Central
Processing Facility (MDCPF). It is a device used to measure and record temperature, pressure
(static) and differential pressure between the upstream and downstream pressure of the gas
flowing through the main pipe. It contain a cycle of 24 hours or 7 days.
30
Main Parts:
Procedure:
31
Orifice Plate:
Gas flow rates are usually measured by means of an orifice
plate. An orifice plate is inserted into the gas carrying line,
and then the pressure drop across the plate is crossed. This
differential pressure will determine the flow rate. The orifice
plates are of different diameters.
Gas Compressors:
Compressor is a device which is used to
increase the Pressure of the gas in the flow
line. Those wells which have less producing
pressure, for that we use the compressor to
increase the pressure by decreasing its
volume.
Reciprocating Compressor
Rotary Compressor
Function:
The compressors are installed after the flow
recorder system. The gas is entered into
suction cylinder. This cylinder delivers the required amount of gas to the compression chamber
through two suction valves where the piston is moving in forward and backward stokes; the gas
is compressed in the forward direction of the piston and discharged through puppet discharge
valve.
32
Due to increase in pressure the temperature of the gas is also increased. Therefore the gas is
flown through the heat exchanger where the gas is cooled by the moving fan. After the cooling
process gas goes into the pipeline at the pressure of 640psi. This gas stream is again divided into
stream.
Main Parts:
Starting of Compressor:
The compressor is started by three requirements of Power Chamber
1. Ignition
2. Fuel
3. Oxygen
Starting of flywheel: When starting valve is opened for starting of flywheel, a turbo starter
(requires 150 psi pressure) for starting the flywheel. A pinion gets engaged into the flywheel that
runs the flywheel.
Spark Generation: During running of flywheel, 2 magnets placed around it produce electric
current in which through electronic box transfers to ignition coil which inurn is connected to spark
plug to produce spark during forward or the power stroke.
Fuel: The fuel is supplied through the fuel injector pump. Governor is used to control the fuel in
the power chamber.
Air: The air is sucked from the atmosphere through air filter which is used to remove the dirt
particles from air.
33
Bottom Head Pressure (BHP) Survey:
The Bottom Hole Pressure Survey is performed in order to measure the bottom hole flowing
pressure while the well is flowing and then bottom hole Static Pressure is monitored when the
well is shut in.
There are two types of test which are performed on a single well
1. Pressure Draw down Test, for the first 6 hours, when the well is flowing at constant
production rate
2. Pressure Built up Test, for the next 40 hours, when the well is shut in and let the pressure
stabilized.
Important Equipment:
34
Safety Shutdown System:
Most of the wells at Shallow side are equipped with Safety Shutdown System. The main purpose
of the installing safety shutdown system at the well sites is to shut down the well safely when
any type of pipeline burst, fire occurs in the vicinity of the well site.
Main Parts:
35
Drilling Rig:
A drilling rig is a machine that creates
holes in the earth sub-surface. Drilling
rigs can be massive structures housing
equipment used to drill water wells, oil
wells, or natural gas extraction wells, or
they can be small enough to be moved
manually by one person and are called
augers. Drilling rigs can sample sub-
surface mineral deposits, test rock, soil
and groundwater physical properties,
and also can be used to install sub-surface
fabrications, such as underground
utilities, instrumentation, tunnels or
wells. Drilling rigs can be mobile
equipment mounted on trucks, tracks or
trailers, or more permanent land or
marine-based structures (such as oil
platforms, commonly called 'offshore oil
rigs' even if they don't contain a drilling
rig). The term "rig" therefore generally
refers to the complex of equipment that
is used to penetrate the surface of the
Earth's crust.
36
List of Items:
Simple diagram of a drilling rig and its basic operation
1. Mud tank
2. Shale shakers
3. Suction line (mud pump)
4. Mud pump
5. Motor or power source
6. Vibrating hose
7. Draw-works
8. Standpipe
9. Kelly hose
10. Goose-neck
11. Traveling block
12. Drill line
13. Crown block
14. Derrick
15. Racking Board (Sometimes referred to as
the Monkey Board
16. Stand (of drill pipe)
17. Setback (floor)
18. Swivel (On newer rigs this may be
replaced by a top drive)
19. Kelly drive
20. Rotary table
21. Drill floor
22. Bell nipple
23. Blowout preventer (BOP) Annular type
24. Blowout preventer (BOP) Pipe ram &
blind ram
25. Drill string
26. Drill bit
27. Casing head or Wellhead
28. Flow line
37
Introduction:
Mari deep consists of 9 deep wells with the formation of Guru B. These wells are called deep
wells because of their depth with is larger as compared to shallow, the depth of these wells are
almost 3000 meters. The well head pressure is also greater approximately 2800 psi because of
the over burden stresses in the wells.
The amount of carbon dioxide and water content is very large. The international standards
suggest that it should be less than 7lb/MMSCF. So dehydration plant is also installed on the
central processing facility of these deep wells. There are basically two costumers of Mari deep
i.e. FPDCL and SNGPL. The condensate recovered from these 9 wells is also greater as compared
to the shallow wells so condensate is also stored from here.
38
Customers of Mari Deep
FPDCL 65 MMSCF
SNGPL 44 MMSCF
The maximum operating capacity of MDCPF is 125 MMSCF but it is operated at 109 MMSCF per
day. The facility was developed in 2009. This plant was developed because of the composition of
the gas from deep wells. The gas from these wells has high content of carbon dioxide and water
which may combine to form carbonic acid. That may cause corrosion in pipes. Hence removal of
water from the gas is highly important.
Process Explanation:
Gathering Station
The gas from different wells is combined into three headers H-1, H-2, H-3 and one line L1.
Each header and line has a NRV (Non Return Valve) and control valve.
Header H-1 receiving gas from MD (Mari Deep) 1 and 9, and line L-1 receiving gas from
MD 6 combine to form one header.
39
Header H-2 with gas coming from MD 2, 14 &15 and header H-3 with gas from MD 3, 4 &
12 combine to form second header of the lines entering the separators.
Separator
The gas from the gathering station enters into the two horizontal separators. It is equipment
which works on the principle of momentum breakage, gravity settling and coalescing to
separate the condensate and the water.
Condensate is lighter than water so it is separated by the help of the wire plate on the bases of
gravity settling. Two separators were used designed by DESCON engineering limited. Following
diagram illustrates some of the common components of a three face separator.
There are two types of water free and associated water, free water is separated in the separators
while associated water is removed in the contacting Colum by the help of TEG absorption process.
Specifications
Condensate production/day 100bbl
Water Separation/day 250bbl
Treating capacity/ separator 65MMSCF
Design Pressure 1400 psi
Design Temperature 140 F
Operating Pressure 700 psi
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Vortex Breaker
Vortex breaker prevents the swirling action of high flow rate fluids. This is located at the outlet
of water and condensate zones.
Inlet Deflector
The deflector plate breaks the momentum of the incoming gas stream. This sudden change in
kinetic energy results in condensation of lighter hydrocarbons in the gas stream.
Weir Plates
Weir plate divides the vessel into two zones containing water and condensate respectively.
Due to the fact that condensate has a lower specific gravity than that of water, it forms a layer at
the top of water upon condensation and therefore the condensate level gradually rises and at
some point starts pouring to the other side of the plate.
Demister Pad
To prevent entrainment of particles greater than 10 um demister pads are installed which
capture the condensate and moisture as smaller particles here coalescing take place which is
formation of bigger liquid droplets from the smaller liquid droplets.
Degasser:
The water received from the separators is sent to the degasser. The degasser removes any
trapped gas in water from the separator.
The flashing of water removes the gases from the water and water is sent the evaporation pit.
The gas recovered from the degasser is burnt in the flare.
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Contacting Tower:
In contactor tower the wet gas is entered to the tower from its
bottom and Lean TEG from the top of the tower to have counter
current flow of two fluids. Wet gas first passes through scrubbing
section and traces of condensate in the wet gas are removed in
this section. Then in contacting section the TEG level is
maintained on each bubble cap tray so that the wet gas coming
from the bottom comes in contact with Lean TEG removing water
from the wet gas.
Inlet Scrubber
Half Demister pad
Chimney tray
Bubble cap tray
Demister pad
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T.E.G Recovery System
The T.E.G which had been used in the contacting tower is recovered in the T.E.G recovery cycle.
Rich T.E.G has two components one is water and other T.E.G, boiling point of water is low as
compared to T.E.G so they can be separated from each other on the bases of boiling point.
The basic principle of the recovery system is by heating TEG in re-boiler to a temperature above
100C. The water associated with TEG will evaporate leaving behind lean solution.
Important Components
Reflux coil
The rich T.E.G is pre-heated at first by passing it through the reflux coil. The reflux coil is
mounted at the top of the still column. This coil is made of stainless steel.
Flash tank
Then T.E.G is introduced into the flash tank where sudden expansion results in flashing. As a
result of this sudden pressure drop, the condensate entrained in T.E.G flashes into vapors which
can be easily separated on the basis of differences in specific gravity of T.E.G water solution and
condensate. Two layers are formed with lighter condensate (on top of T.E.G) being separated by
skimming via overflow pipe.
Filters
There are two kinds of filters.
Particulate filters
Carbon filter
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Heat Exchanger (U-Tube)
U-Tube double pipe heat exchanger (with rich T.E.G from filters being fed to the shell side/outer
pipe and lean T.E.G from surge tank fed to tube/inner pipe side) is used for pre-heating the rich
T.E.G before it is introduced in the still column. This exchanger reduces the heating load on the
re-boiler.
Distillation Column
Rich T.E.G is introduced at the top of still column. Still column is packed with ranching rings. Here
the steam from re-boiler heats the rich T.E.G. Packing is to avoid erosion of the still column due
to high pressure rich T.E.G and to increase the contact time of rich T.E.G from the top and steam
from the bottom of still column.
Re-boiler
Re-boiler is the heart of T.E.G regeneration unit and is a fired tube boiler. Here water is
evaporated from the rich TEG and steam is produced which rises up to the still column for
preheating of rich TEG. Here the steam is produced by using the heat from burner attached to
the boiler. Pure TEG which is called lean TEG is sent down to the surge tank.
Surge tank
Lean T.E.G from re-boiler then flows into Surge tank. Surge tank is just a storage vessel with
provision of T.E.G introduction to make up for the losses incurred during evaporation to
entrainment of T.E.G in still column where water is removed from it.
Pump
Positive displacement (reciprocating piston) pump then pumps the lean T.E.G to the top of the
contacting tower via shell and tube heat exchanger. There are three pumps installed in parallel.
At 20% speed each pump is capable of producing 600+ psi pressure.
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Process Diagram:
SCADA SYSTEM:
S CADA (supervisory control and data acquisition) is a system operating with coded signals over
communication channels so as to provide control of remote equipment (using typically one
communication channel per remote station).
The control system may be combined with a data acquisition system by adding the use of coded
signals over communication channels to acquire information about the status of the remote
equipment for display or for recording functions.
It is a type of industrial control system (ICS). Industrial control systems are computer-based
systems that monitor and control industrial processes that exist in the physical world. SCADA
systems historically distinguish themselves from other ICS systems by being large-scale processes
that can include multiple sites, and large distances.
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Mari Deep Wells:
D eep wells have depths ranging from 3000m to 4000m and generally they tap “GURU-B”
reservoir. The gas comes from the reservoir at 2700psi to 3000psi.
Well’s outer-most casing is called formation casing proceeded by casing 1, 2 and so on. The
number of casings increases with depth.
The surface facility for most of the deep wells are almost same, following is the P&ID of MD-6.
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Some Important Equipment
Sub Surface Safety valve It is an underground valve to shut the well from depth of 100 m in
case of explosion so that the well is safe despite of destruction of
Christmas tree.
Master Valve This is the main valve which is used to cut the supply of gas from
the well in case of emergency and it can be used during batch
injection of anti-corrosion chemical.
Surface Safety Valve This is also called emergency shutdown valve (ESDV). It cuts the
supply of gas from the well and is remotely operated by SCADA
system. This is secondary safety valve.
Wing Valve These are the valves from which we have the flow of gas,
condensate and water from the well.
In case we need more than one flow lines we can make the kill wing
valve, a flow wing valve by getting the flow of gas.
Choke This is used for manual flow control of gas, condensate etc. choke
is in full open condition until the SCADA system works. When the
SCADA system malfunctions we can regulate the flow of gas by
using choke.
Swap Valve This is the valve at the top of the Christmas tree. Which has the
pressure gauge installed in the weld-o-let in normal conditions and
this can be used during BHP survey or in a situation where the well
intervention is required.
Flow control Valve This valve is used to regulate the production of gas from a
particular well to get the requisite gas composition and this is
operated from the de-hydration plant via SCADA system.
Instrument Gas Pressure Instrument air or gas is used for the pneumatic operated components of
surface production facility.
At each well reservoir gas is used in place of compressed air by using first
a regulator which reduces the pressure of gas to 500psi. After that gas is
filtered and passed through a knockout drum removing liquid content
from the gas. Then again a regulator is used to reduce the pressure of
instrument gas further to 120-140psi. This gas is then distributed to all
pneumatically operated components at the well facility.
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The past month of our internship had been very instructive for us. MPCL has offered us
opportunities to learn and develop ourselves in many areas. We gained a lot of experience. A lot
of tasks and activities that we have worked on during our internship are familiar with what we
are studying at our universities. We worked in many areas where we did different work. This gave
us a chance to find out which areas we want work in after my education.
The experience which we gained is very valuable. We learned a lot about Dehydration plant.
Before our internship started our ideas did not match the experience we have gained during our
internship. There is a big difference in the school projects and the tasks and activities during the
actual wok. In school we learn how to describe the work in projects, where in work we learn how
to implement them in reality. This internship was definitely an introduction to actual work field
for us. We have learned to work in an organization and apply my knowledge in practice.
We also learned a lot from the different interns that we had been working with during our
internship. Each intern had a different educational background and that made it interesting for
us. By working with them we got to learn from them and become aware educational background.
Our supervisor Faisal Amjad was also very helpful, we learned a lot from him during internship.
He has a lot of technical knowledge in production department. He was very helpful and always
willing to give us advice and feedback which we appreciate. We have tried to learn as much as
possible from him.
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