A Report

On

“Industrial visit”

Submitted by

Muntasir Mahmud
(Roll No. – R820216075)

B. Tech Applied Petroleum Engineering with Specialization in Gas – III Year

Department of Chemical Engineering

University of Petroleum and Energy Studies

P.O. Bidholi Via-Prem Nagar
Dehradun-248007
 Industrial Visit Report

1. Details of industry

Sr. No. Name and address of Date Plant/facility visited

industry

1. ONGC Rajahmundry Asset 04-02- Tatipaka Oil Refinery,

Godavari Bhavan, 2019 Nagaram Village, Razole Taluka,
Base Complex, East Godavari District,
Rajahmundry-533 106, East Andhra Pradesh
Godavari District (A.P.)

2. ONGC Rajahmundry Asset 05-02- Kesanapalli Gas Collecting Station

Godavari Bhavan, 2019 (GCS)
Base Complex, Razole Taluka,
Rajahmundry-533 106, East East Godavari District,
Godavari District (A.P.) Andhra Pradesh

2. Description of plant/facility visited:

i. Tatipaka Oil Refinery: Active since 2001

Refining Capacity: 1,300 barrels of crude oil per day

0.66 million metric tonne per annum (MMTPA)

Products:
Naphtha – 100 tonnes per day
High Speed Diesel (HSD) – 60 tonnes per day; high fire point used in offshore,
Superior Kerosene Oil (SKO) – 70 tonnes per day; high smoke point,
Reduced Crude Oil (RCO) – 30 tonnes per day,
Mineral Turpentine Oil (MTO) used as paint thinner,
Low Sulphur Heavy Stock (LSHS) used as feedstock in different industries.

Facilities:
GCS – Gas Collecting Station: Group gathering station has well manifold with metering
devices for measuring the quantity of fluid and monitoring condition of well. They also
 houses separator to separate oil, gas and water and storage tank for oil, water and gas
sometimes gas and water injection facilities, supply chain facilities is also house in the
premises. It is also a part of supply chain management from well to refinery.

GCP – Gas Compression Plant: It includes many compressors, pipe line and valves.
The main function is to compress the gas to the desired pressure.

GDU – Gas Dehydration Unit: It is a liquid desiccant system for the removal of water
from natural gas and natural gas liquids. It is the most common and economical means of
water removal from these streams. Glycols typically seen in industry include triethylene
glycol (TEG), diethylene glycol (DEG), ethylene glycol and tetra ethylene glycol

ETP – Effluent Treatment Plant: It is a type of waste treatment plant which is

particularly designed to purify industrial waste water for its reuse and its aim is to release
safe water to environment from the harmful effect caused by the effluent.

Crude Furnace: It is used to heat the petroleum feedstock for fractionation, thermal
cracking and high temperature processing. They are usually fired by oil and gas.

Demineralization (DM) water treatment plant: Demineralization is the process of

removing mineral salts from Water by using the ion exchange process. Demineralized
Water is completely or almost free of dissolved minerals as a result of one of the
following processes: Distillation or Deionization. Water used in industries should be ion
free and DM plant provides the same with the help of varying process.

 Other facilities are desalter, heat exchangers, distillation unit, storage tanks etc.

Quality Control Lab: The role of quality control lab is to test the petroleum products
such as petroleum, fuels and other refined products. It monitors the quality of refined
products, gas composition etc.

Assembly Point: A safe place closer to the exit gate, in case of an emergency, workers
should reach this place.

Typical flow diagram of the refining processes in Tatipaka refinery:

Crude oil Heat exchanger Desalter Furnace Distillation unit Product

 A sample of product composition obtained in Tatipaka refinery:

Components Percentage in mol%

Methane(CH4) 94.05%
Ethane(C2H6) 1.88%
Propane(C3H8) 1.77%
i-Butane(i-C4H10) 0.39%
n-Butane(n-C4H10) 0.36%
i-Pentane(i-C5H12) 0.10%
n-Pentane(n-C5H12) 0.088%
Hexane(C6H14) 0.13%
Carbon Dioxide(CO2) 1.66%
Nitrogen(N2) 0.07%
Helium(He) 0.01%

Temperature: 150C
Pressure: 14.69 psia
Apparent molecular weight of product: 17.52 g/mol
Specific gravity of product: 0.606

ii. Kesanapalli Production Facility:

There are a total of 42 wells in three different districts, East Godavari, West Godavari and
Krishna district in Andhra Pradesh. Out of which only 12 wells are now in flowing state.
Among the remaining wells some wells are non-flowing wells, injection wells and effluent
disposal (ED) wells.

This is ONGC dispensing station where crude oil is extracted and filled into tankers and
transported by road to the nearest refinery. It is the largest oil producing installation of ONGC
Rajahmundry. The low pressure wells in this GCS has pressure of around 250-300 psia whereas
the high pressure wells have pressure around 3000 psia. The crude oil produced from the low
pressure wells before being sent to dehydrating plant are sent to compressor for equalizing the
pressure to that of high pressure well. During equalizing of pressure compressors of capacity of
40SCMD are used. After equalizing of pressure, H2S (Hydrogen disulphide) scavenger is added
to reduce the amount of H2S to 5ppm .The gas is then sent to dehydrating unit where using
glycol the water content is reduced to minimum. The gas dehydrating plant consists of tada
system which is used for measuring pressure and temperature. In GDU section, pour point
depressor is present for reducing the viscosity. There are separators also preset for separating the
glycol so that it can be reused. The reboiler temperature is kept less than 200 0C in order to
maintain the quality of glycol. Usually, the reboiler temperature is kept to 192 0C.Gas injection is
used for secondary recovery.

Facilities:
 Drilling rig and other drilling equipment
 Surface production facilities, Christmas tree, flow line
 High, medium and low pressure header and test header
 Flare stack to burn out the excess gas

Significant of different color pipeline

Color of pipe Fluid transported

Yellow Gas
Brown Oil
Red Water

3. Learning output:

 The industrial visit was very helpful to me. That was my first visit to a refinery complex
as I had visited to a production field before. It was very amazing to experience by my
own presence how the refining plant and production plant work in actual, which we had
been studying in books only from a long time.

 We learned the current technologies which are being used in the industry, the flow
process in which the production, processing and refining of crude was taking place.

 We got to know about the safety rules in the oil and gas industry, about the Personal
Protective Equipment (PPE), wind socks, assembly point and other safety programs.

Date: 20/02/2019 (Signature)

Place: Dehradun Muntasir Mahmud