TRAINING REPORT

ON
OIL & NATURAL GAS CORPORATION
GAS PROCESSING PLANT
HAZIRA, SURAT (GUJARAT)

BY

KUNAL SOPORI
CHEM 22/13
B.TECH (CHEMICAL ENGINEERING) 2013-17
NIT, SRINAGAR

UNDER THE GUIDENCE OF

Ms. D. SWAROOPA
OIL & NATURAL GAS CORPORATION
GAS PROCESSING PLANT
HAZIRA, SURAT (GUJARAT)

09/12/2015 - 08/01/2016
 PREFACE

As part of our curriculum, I had to undergo a industrial training that

includes the overall case study of the related areas of our branch of
engineering in industrial environment. So far as the field training is
concerned I have obtained practical knowledge regarding different
systems of Hazira Gas Processing Plant at ONGC, Hazira.

During this vocational training course I had hands on practical

experience of different processing techniques in the plant which
helped us immensely in enhancing our existing knowledge about gas
processing as well as familiarizing our self with the new technologies
in industry and its future challenges. Besides, it helped ME in
familiarizing with the industry environment.

This report has been prepared at HGPP of ONGC Ltd. This training
was very helpful in the actual implementation of knowledge of an
engineer in the field of the process industries. The subsequent pages
provide the details of our experience gathered in the training.

I would like to thank Mr. S.V.Acharya - Chief Engineer (CE) - In-

charge Training and Mr. N.R. Choudhury - Resident Engineer
(RE), who guided and motivated me throughout the whole training
program.
 AKNOWLEDGEMENTS

I wish to thank OIL AND NATURAL GAS CORPORATION

LIMITED Hazira Plant for allowing me to attend the vocational
training programme at their premises and for providing all the needful
facilities required for the completion of the entire program.

I would also like to express my sincere gratitude towards

Mr.S.V.Acharya - Chief Engineer - In-charge Training
Programme for providing me with an opportunity to undergo training
programme in ONGC Hazira Plant.

I would also like to thank my mentor Mr.A.K.Mallick - DGM

(Production) for his continuous guidance and for enlightening me
with his vital knowledge throughout the programme. Working under
his guidance has been an honor and a fruitful learning experience.

I extend my thanks to Mr. N.R. Choudhury - Resident Engineer for

his constant support and for arranging several plant visits during the
course of my training.

I am also thankful to Ms. D.Swaroopa for providing/sharing

valuable knowledge about Plant operations.

I express my deep gratitude to those who have helped and encouraged

me in various ways in carrying out this training program. I would like
to extend my sincere thanks and would like to acknowledge the
ONGC personnel for sharing their valuable knowledge.
 TABLE OF CONTENTS

TOPIC PAGE NO.

1. Introduction to ONGC 05
2. About Hazira Plant ONGC 10
3. Gas Receipt Terminal 13
4. Gas Sweetening Unit 22
5. Gas Dehydrating Unit 33
6. Dew point Depression Unit 40
7. Sulphur Recovery Unit 44
8. Condensate Fractionation Unit 52
9. LPG Recovery Unit 55
10. Kerosene Recovery Unit 65
11. Storage 69
12. Cogeneration Plant 70
13. Utilities and Offsites 73
14. Product Terminal 76
15. Raw Water Treatment 77
16. Waste Water Treatment 78
17. Bibliography 80
ONGC HAZIRA PLANT: Introduction
Type - PSU Maharatna Company
Founded in 1956
Headquarter - Dehradun, India
Corporate Office - New Delhi, India
Industry - Petroleum & Natural Gas
Oil and Natural Gas Corporation (ONGC) is Indias biggest public sector company. The
mission of this company is to stimulate, continue and accelerate exploratory efforts to
develop and maximise the contribution of hydrocarbons to the economy of the country.
The discovery of Bombay High was an important event in ONGCs success as a result
many oil fields were discovered in the western offshore. Out of them South Basin proved
to be phenomenal having reserves of approximately 200 billion cubic meters of sour gas.
To sweeten this sour gas (make it sulphur free) and make it suitable for industrial use
Hazira Project materialised.

Hence a gas terminal was constructed in 1985 to receive the sweet gas. Initially the gas
received at this terminal was fed to KRIBHCO. Thus, entire Hazira area saw the
beginning of gas based industrial era. With increased demand in gas and its availability in
the south Basin ONGC, Hazira improved its production capacity and infrastructure.

Hazira Gas Processing Complex (HGPC)

5
ONGC - ORGANISATIONAL CHART

6
ONGC FUNCTIONAL ORGANISATION :

7
PROCESS FLOW DIAGRAM :

The gas processing plant of ONGC at Hazira processes gas coming from the Vasai, south
Basin, Heera, Panna, Mukta and other fields of the Bombay offshore region, established
in 1985, it is the largest gas processing plant of its type in India with a production
capacity of about 45 Mm3 of gas/day and 8000m3 of condensate/day. Spread over 705
hectares, with a boundary covering 11km, it has about 770 employees working for it
presently and had an initial capital expenditure to the tune of Rs.1300 crores.

8
Initially it was set up in 1985 to receive sweet gas from Bombay high but with time it was
seen that there were concentrations of sour gas that with the incoming flow and it was
then completely turned up into a sour gas plant. The gas terminal was constructed in 1985
to receive sweet gas from Bombay High through 217 km 36 & 42 submarine pipes
from south basin to Umbrhat and then 14 km pipeline on land till the gas terminal. The
output of the plant sustains the HVJ pipeline, which is a gas pipeline of more than 3000
km in length and covers many states like Gujarat, M.P, Rajasthan, Haryana, U.P, and
Delhi. The plant also supports various fertiliser plants and power plants which depend on
the gas coming out of the Hazira plant.

The important process units within the plant (and visited) are:

UNITS NUMBERS TOTAL CAPACITY

Gas Terminal 2 Trunk Lines 50MMSCMD

Gas Sweetening Unit 9 Trains 47.3MMSCMD

Gas Dehydration Unit 8 Trains 45.0MMSCMD

Dew Point Depression Unit 9 Trains 46.2MMSCMD

Liquefied Petroleum Gas Plant 1 Train 5.3MMSCMD

Condensate Fractionating Unit 7 Trains 12,600 m3/day

Kerosene Recovery Unit 1 Train 1.45MMSCMD

Sulphur Recovery Unit 7 Trains 0.84MMSCMD

9
10
Main Utilities and Offsites :
UNITS NUMBERS TOTAL CAPACITY
Cogeneration Plant 3 gas turbines 57.6 MW
Raw Water Reservoir 4 reservoirs 8 lakh m3

Raw Water Treatment Plant 1 48000 m3/day

LPG Storage sphere 9 22500 m3

Naphta Storage Tanks 7+1(NGL) 112000 m3

Kerosene Storage Tanks 4 20000 m3

ATF Storage Tank 2 1000 m3

HSD Tank 3 1000 m3

Propane 1 311m3

Main products of HGPC are as following:

Sweet natural gas

Liquefied petroleum gas

Naphtha

Superior Kerosene Oil

Aviation Turbine Fuel

High Speed Diesel

Sulphur

Propane

11
The input lines are feed to the GTU, which separates the gas from any condensates. The
gas then goes to GSU, where it is sweetened i.e. freed from H2S .The condensate goes to
CFU. From GSU, the gas goes to GDU, where the moisture content from the gas is
removed. The H2S gas which is ripped in GSU is sent to SRU, where sulphur is
recovered in elemental form. After GDU, the gas goes to DPD unit and then to
consumers. The condensate from CFU goes to KRU plant and any LPG produced is sent
to CWU for recovery by removing H2S. The process is represented in the flow chart as
shown above.Consumers : Consumers: IOCL, BPCL, HPCL, RIL, KRIBHCO, NTPC
etc.

ARN is exported out of the country.

12
 GAS TERMINAL UNIT

The Hazira Onshore terminal begins at the point where South Basein Hazira Pipeline
ends at the distribution outlet points for the gas and the condensate streams. The terminal
has facilities for

Receiving the two-phase flow

Separating into Condensate and gas streams

Condensate stabilisation and gas distribution.

The two-phase flow is received in the slug catcher, where the gas and condensate streams
are separated. The gas is filtered, metered and sent to the GSU plants for further
processing. The separated condensate from the slug catcher is metered and sent to the
CFU plants for further treatment.The gas is supplied in the existing 36 pipeline and 42
pipeline.

The following main equipments are provided at this terminal:

1.Pig receiver

2.Pressure reducing valves

3.Slug Catcher

4.Filtering Unit

5.Metering Unit

6.Blow Down

13
The characteristics of the pipelines are as follows:

CHARACTERISTICS 36" 42"

Offshore Length 217km 222km
Onshore Length 14km 22km
Design Pressure 98kg/cm2 120kg/cm2
Capacity 25MMSCMD 25MMSCMD
Valve Station Umbrhat, Danti, Bhimpore, Umbrhat,Bhata,Abha
Magdala

The pig receiving trap is a facility to recover the pig when scraping the line and to
remove the foreign matter and residual solids entrained by the pig itself.

During the normal operation, the terminal inlet valve and pig receiving trap by pass valve
are kept open and the trap inlet, outlet valves the drain valves and the vent valves kept
closed. The trap is kept in depressurised condition.

When the pig is to be received:

The receiving trap is pressurised by opening the bypass valves of the inlet valve.
When the trap is pressurised to the operating pressure as indicated by the pressure
indicator and the outlet valves are opened and flow established through the trap.

When the pig signal is actuated the operator is alerted about the approach of the
pig. The operator should now reduce the gas flow through the main Line and
increase the flow through the receiver trap by throttling the trap bypass valve to
75% of the initial opening.

Immediately after the actuation of the pig signal the trap inlet and outlet valves are
closed and normal flow established through the bypass valve.

After isolating the pig barrel the drain valve is opened gradually to drain the
condensate into the condensate blow down drum. The pig trap pressure will start
falling. It is an indication that he trap is drained of liquid. The drain is then closed
and the vent valve is opened to elevated flare to pressurise the trap.
14
 The manhole cover should be opened carefully only after ascertaining that the trap
is completely depressurised. The trap contents are emptied out and the pig is then
retrieved.

It is necessary to clean the pig trap and inspect he gas kits before bottling up the
trap. The pig receiving trap should be restored to the same condition as before the
launching of the pig operation. Pig indicator switch to be reset in the field.

The residual solids and foreign matter collected as are result of the pig operation have a
tendency to catch fire when exposed to the atmosphere for a long time. This is perhaps
because of the heat generated due to the oxidation of nascent iron in the waste.

There are a number of precautions that need to be taken at the terminal, during the pig
operation.

Checking and pressure testing of pig receiving trap.

Testing and recalibration of the pig signal sensors and the safety valve mounted on
the receiving trap.

Keeping the Slug Catcher condensate level low to receive the pipeline hold up
liquid.

Maintaining the gas distribution to consumers at a reduced level because as the line
is filled with the condensates pushed by the pig, the plants downstream would
remain without gas until the pig arrives.

Taking care during condensate drain from trap to blow down drum at the time of
depressurisation. To avoid freeze up in the blow down system the electric heating
elements on the pipe should be energised.

Complete depressurization of receiving trap before the manhole is opened.

Proper disposal of foreign and residual matter collected in the trap during the pig
operation.

15
The frequency of pig operation depends upon a number of factors:

Gas/condensate flow rate

wax content in the condensate

Hydrogen Sulphide content in the gas.

16
Flow Diagram of the Gas Terminal

17
SLUG CATCHER
Length 498m
Diameter 48
Angle of separation 5% slope
Area of storage 11000 m3
Capacity 22000 m3

Downstream of the control valves is the slug catcher, which has existing 48 fingers and 6
new fingers. During normal operation phase-1 slug catcher (24- fingers) separates
condensate of 25 MMSCMD sour gas (approximately) from 42line. Phase-2 slug catcher
(24 fingers) separates gas and condensates from 36 line. There are three phases, two
works at a time and one remains standby. However, during pigging of the 42 line, all the
48 fingers will be lined up to receive the liquid hold up in the 231 km line. During this
time the 36 lines shall be lined up to the 6 new fingers to separate gas and condensate.

18
Slug catcher consists of :

Condensate storage section for storage of incoming gas

Separating section for separating the gas and liquid condensate

Primary riser close to the inlet side of the slug catcher, allows separated gas to come
out during normal flow
Secondary riser positioned approximately in the catcher, diverts small amount of gas
coming with liquid, also it acts as escape route for gas lift in this area during arrival of
condensate slug during pigging
Equalising riser positioned at the end of storage area, to prevent liquid agitation and
entrainment of product by current flow of gas and liquid towards primary header.

Gas and condensate from pig receiver is fed to slug catcher separation section where due
to slant line liquid accumulate at lower section and the gas is separated. Initially line is
steeper and has a slant ratio of 1: 5, then it becomes gradual and slant ration become
1:500. The separated gas goes to gas filtering unit through primary risers. Condensate,
which is removed from gas, is stored in slug catcher and for further separations of any
entrained gas. The separated gas from primary riser, secondary riser and equalising riser
combines together and goes to filtering unit. Slug catcher-3 has 6 fingers. Condensates,
which are collected, in each finger goes to condensate header and further goes to
condensate metering unit.

GAS FILTERING

The gas from slug catcher is sent for filtration in which any condensate entrained along
with the gas is separated. Sour gas from Phase-1 slug catcher is sent to existing filtration
unit and sweet gas from Phase-2/Phase-3 slug catcher is sent to new filtration unit. For
normal operation, two filters will be operated to cover the 256 MMSCMD of sour gas
and one is standby. New filtration unit has three filters. Each filter can treat a maximum
of 580,000 SCMH (13.92 MMSCMD) sweet gas to remove 99% of 10 solid particles.

19
For normal operation, two filters are operated to cover sour gas. Sweet gas which is
removed of solid particles goes to metering unit and then goes to DPD.

Each filter is equipped with liquid automatic discharge, which is controlled by the liquid
level inside filter itself. The condensate from sweet and sour gas is metered separately.
Gas filter separates gas from condensate particles with principle of centrifuge.

Gas filter has 200 diameter cyclones. Feed is injected tangentially into the upper part of
the cylindrical section and develops a strong swirling motion with the cyclone. Liquid
containing the fine particle fraction is discharged out through the under flow.

Gas filters equipped with differential pressure gauge to monitor any leakage. The liquid
coming out of the filters will be sent to a single collecting line, connected with both the
line conveying the condensate to blown down and with the feeding line of the
stabilisation plant. The condensate from sour gas is metered separately.

METERING UNIT

There are four sour gas metering units and one condensate metering unit. Sweet gas from
gas filtering unit goes to sweet gas metering unit to measure the flow rate with
compensation of pressure and temperature. Each metering unit consists of flow meter,
pressure gauge and temperature gauge. Condensate from Phase-2/Phase-3 slug catcher
feed to condensate metering unit and measure the condensate flow rate. After then, it
goes to condensate fractionating unit.

BLOW DOWN

Blow down is a process through which water sludge, foreign particle and unwanted
material is removed from pipeline. The gas travels a long distance from offshore to
Hazira plant through pipelines. During this line take turn and become slant due to gravity.
Heavier molecules and foreign solid particle get accumulate there. To remove them from
the pipeline a pig is send from offshore terminal. It travel through pipeline and scraps all
the accumulated sludge are received at the pig receiver. The Pig is taken out and the pig
receiver cleaned. This process is done once in a year.

20
 GAS SWEETENING UNIT

The main purpose of this gas treatment step is to remove the H2S from the sour gas with a
high severity, and at the same time, to limit CO2 co-absorption to the minimum required
and in any case, to not more than 32%.Two Gas Sweetening Trains of Phase-3A and one
train of Phase 4 can handle a total of 18.9 MMSCMD of sour gas. The remaining trains
of GSU can handle 28 MMSCMD with 5 trains operating and one train standby. This
makes a total capacity 46.3 MMSCMD with one train of capacity 5.6 MMSCMD as
standby. The plant has been designed such that the maximum capacity for each gas
sweetening train is 40% of the design capacity. In the sweetening process, gas is washed
with aqueous solutions of MDEA. The MDEA and TEG trains are connected with one

21
another by a pipe rack supplying products (raw gas, desulphurised and dried gas) and
required utilities.

GAS FEEDSTOCK SPECIFICATIONS:

The following mixed gas composition (mix of slug catcher gas and CFU off- gas) has
been considered for the design of GSU and GDU. (Based on design of phase-3A)

Pressure at Battery Limits : 96-54 kg/cm2 abs

Temperature at Battery Limits : 20-33C

Gas sweetening train will have a maximum operating pressure of 77 kg/cm2. A pressure
control valve and heating device upstream of the pressure valve will prevent hydrate
formation. H2S and CO2 content will vary depending on conditions.

PRODUCT SPECIFICATION:

The product from each Gas Sweetening train will meet the following specifications

Sweet and Dry Gas:

H2S content : 4 ppm volume maximum.

Pressure at Battery Limits : 74.9 51.9 kg/cm2 abs.
Temperature at Battery Limits : 40C.

Rich MDA Flash Gas:

H2S content : 4 ppm volume maximum.

Pressure at Battery Limits : 4.5 kg/cm2 abs.

Temperature at Battery Limits : 48-55C.

22
Acid Gas:

Hydrocarbon content will be minimised.

Pressure at Battery Limits : 1.9 kg/cm2

Temperature at Battery Limits : 50C

COMPONENTS DESIGN CASE (MOLE %) CHECK CASE (MOLE %)

N2 0.21 0.19

CO2 6.00 6.50

H2S 0.137 0.137

Cl 79.84 78.596

C2 7.48 7.41

C3 4.14 4.54

iC4 0.18 0.23

nC5 0.17 0.22

C6 0.22 0.15

C7 0.05 0.11

C8 0.01 0.05

C9 0.002 0.01

C10 0.001 -

23
Flow Diagram of the Gas Sweetening Unit

24
PROCESS DESCRIPTION:
In the sweetening process, gas is washed with aqueous solutions of MDEA and TEG
trains are connected with one another with a pipe rack supplying products (raw gas,
desulphurized and dried gas) and required utilities.

MDEA PROCESS PRINCIPLES:

The selective removal of H2S made by washing the sour gas with an aqueous solution of
Methyl-Di- Ethanol-Amine (MDEA).The process principles are similar to the well
known SNPA-DEA process. The only difference is the behavior of the ethanol amine
used. Methyl-Di-Ethanol-Amine (MDEA) is tertiary amine, which does not react easily
with CO2. The selectivity is so prompted by using the differences in the reaction rates
between both H2S and CO2 and tertiary amine. First the case a primary or secondary
amine (mono- ethanol amine or di ethanol amine) whose reactions with the acid
components H2S and CO2 are similar is investigated.

H2S reacts to give amine hydrosulfide:

H2S + R2NH , R2NH + (1)

CO2 can react directly with amine to form an amine carbonate:

CO2 + 2R2NH R2N , R2NH2 + (2)

But CO2 can also react with water or hydroxyl ions to form carbonic acid or bicarbonate
ions:

CO2 + H2O H2CO3 (3)

CO2 +H2O HCO3 (4)

These acids then react with the amine to form amine bicarbonate [HCO3 , RNH2+ ] and
amine carbonate [CO2, (R2NH2+)2]. As regards kinetics, three types of reactions can be
distinguished :

Reaction(1) whose rate is infinite,

Reaction(2) whose rate is moderate, depending on amine

25
 Reaction(3) and (4), known to be slow.

It is known that using MEA or DEA the absorption rate CO2 in the absorber may be
lower than the absorption rate of H2S; however CO2 removal is regarded as complete.
The case of tertiary amine is different. As a matter of fact, the molecular structure of the
tertiary amine prevents the direct reaction of CO2 with carbonate formation (reaction (2)).

Fig: High Pressure Absorption

Contact time depends on:

The gas flow rate

The liquid height above the active plant area

The number of plates in the absorber

26
The first two parameters cannot be acted upon. The third parameter (plate quantity)
allows adjusting contact time according to the feeding conditions and required
performance.

ABSORPTION SECTION:

Slug-catcher derived raw gas is first heated in steam heater. Then it is passed through the
pressure regulating control valve. Its temperature is maintained above 25C by
controlling the heater steam flow. This raw gas is then mixed with the condensate treating
unit derived raw gas, which is made up of light hydrocarbon fraction in the raw
condensate. This raw gas mixture passes through a knock out drum where liquid
carryover (water, hydrocarbon) are retained to be pumped to the condensate treating unit.
Upon leaving separator raw gas enters an amine absorption column where it comes into
contact counter currently with the aqueous solution of MDEA. The absorber column
includes 14 valve trays. The lean MDEA solution at 45C at the column upper part.
Different liquid feed possibility to the column allows selecting adequate number of the
trays to obtain the required results taking into account about feed gas quality and
operating conditions. The selected feed position could be to the trays 1, 3, 5, 7, or 9 and
the switching over from one to another is done manually.

The MDEA feed nozzles are arranged such that the liquid feed is fed to the down comers
of trays (1, 3, 5, 7 and 9) and not the trays themselves. The upper tray is dry and retains
the major part of carryovers. The total lean MDEA solution flows to the column under
flow control valve. At the top of absorber, treated gas contains less than 4 ppm volume of
H2S. Temperature ranges from 40C to 44C. The gas is cooled to 38C by passing
through a water cooler. Liquid phase resulting from cooling (condensed water + vesicular
amine carryover) is separated in the treated gas knock out drum and returned to rich
amine circuit at a lower pressure. Treated gas is piped to TEG drying unit.

AMINE REGENERATION SECTION:

The stream of the rich amine solution is recovered under level control valve from the
bottom of the absorber and piped to the rich amine flash drum . The sour flashed gas from
this drum contains about 200 ppm (vol.) H2S. In order to meet the fuel gas specifications
(less than 4 ppm vol. of H2S) this sour fuel-gas is brought into contact with a small lean
MDEA flow in a 6 valve tray absorption tower placed on the top of the rich amine flash
drum .The rich amine solution flows from the flash drum to the rich/lean amine
27
exchanger. The rich amine flash drum level control valve is located downstream of the
exchanger in order to minimise the solution degassing by the exchanger plates.

MDEA solution stripping is accomplished in the regenerator by the vapour generated

from the reboiler .The lean amine collected at the bottom of the regenerator is routed
through amine/amine exchanger and cooled to 45C in a lean amine cooler and sent to a
large lean amine storage tank. The hot acid- gas/steam mixture from the overhead of the
regenerator is cooled to 50C in condenser where water vapor condenses. This condensed
vapour is separated in the reflux drum and pumped back to the top section of the
regenerator. The trays are provided for washing the acid gas with reflux water in order to
minimise amine carryover. Acid gas is sent to an acid gas header through a pressure
control valve, which maintains a 2.0 kg/cm2 minimum pressure on top of the reflux drum
.From the storage tank , lean amine is pumped back to the absorbers by the main amine
charge pump .The discharged amine stream is split into two parts through flow rate
control valves: a main stream flows to the high pressure Absorber and a smaller one to
the fuel-gas absorber.

Storage section:

The total amine circulating stream is drawn-off toward a large storage tank. This tank has
several functions:

Its capacity allows the recovery of the total amount of amine in circulation when
the train is drained for maintenance operations.

In normal operations, it has a regulating effect on the disturbances caused by the

level control valve actions on the rich amine and the lean amine circuits It
simplifies the pure solvent make-up and control of the MDEA concentration in the
lean solution.

It effects an efficient decantation of the amine solution before filtration.

MDEA is very sensitive to oxygen whose contact produces acidic elements. In order to
avoid direct contact with air, the storage tank is equipped with a gas blanket. Inert gas is
normally used as blanketing gas. However the inert gas at

28
Hazira plant contains residual amounts of oxygen (0.5%) making it unsuitable for this
purpose. Even though the quality of the fuel gas available from the fuel gas header is
rather unattractive due to the presence of large amounts of CO2, which may cause
undesirable effects on the lean amine quality, this fuel gas was finally preferred.
SNEA(P) confirmed that the expected lean amine degradation due to the CO2 reaction
with MDEA was very small considering the mass- transfer conditions at the gas liquid
interface in the storage tank.

FILTRATION PACKAGE:
This filtration package is designed to treat approximately 10% of the total lean amine
flow. It consists of three filters:

A pre-coat filter

An activated charcoal bed

A cartridge filter

A side stream, approximately equal to 10% of the total lean amine flow is drawn off the
storage tank by the Lean Amine Filter Pump. It passes under flow control through the
Pre-Coat Filter . The pre-coat filter is designed to remove solid particles such as iron
sulphides, and iron carbonates from the lean amine.

Downstream of the pre-coat filter the stream splits. The main stream returns to the amine
storage tank. A side stream, approximately equal to 1 % of the total lean amine flow, is
taken off and passes under flow control to the Activated Charcoal Filter . In the activated
charcoal filter any further degradation products and hydrocarbons are removed. This
stream then passes through a Cartridge Filter where any entrained activated charcoal is
removed. It joins the outlet of the pre-coat filter and returns to the amine storage tank. All
amine solution collected in the Sump Drum (see the following section) is pumped to the
suction of the lean amine filter pumps .

SUMP DRUM:

The MDEA section is provided with a sump drum to collect the drips and drains from the
unit. All low point drains from columns,vessels, pumps etc. are piped into where the
MDEA is collected. If part or all of the MDEA unit are shutdown, then the amine
29
solution is first drained to the sump drum, pumped to the amine filter pumps and passes
through the filtration package before going to the storage tank.The sump drum is fitted
with a pump that starts automatically when a high level is reached and stops
automatically on low level. The sump tank is also blanketed with fuel gas to prevent
solution by degradation of the MDEA due to ingress of oxygen.

ANTIFOAM PACKAGE:

An antifoam package is provided for the injection of antifoam chemicals into the MDEA
circulation system, at the suction of the amine charge pump . This antifoam package is
common to all sweetening trains. Based on the LACQ Plant experience, the antifoam
chemical is mixed with stabilized hydrocarbon condensate in a storage drum. Sufficient
amounts of aromatic hydrocarbons are necessary in this condensates for a good
dispersion of the antifoam product.

Circulation pump ensures a sufficient liquid velocity in the distribution line to prevent
solid deposits. A normal injection flow rate, adjusted by manual valve and controlled by a
Rota meter and a rapid injection flow rate through a control valve operated from the
control room panel are provided in each sweetening train.

FLARE SYSTEM:
A common flare header, Flare KO Drum and flare blow down pumps are provided within
B/L for trains of both, sweetening & dehydration units. All the hydrocarbon
vapors/liquids collected from vents and pressure relief valves will go to the flare KO
Drum through the flare header. From there the gas goes to the flare stack through an off-
sites flare header. The liquid collected from Flare KO. Drum will be pumped through to
slop tank located in off-sites.

TURNDOWN RATIO:
Overall turn down ratio to 40% of the design capacity can be obtained without any
special additions to the standard features of the equipment. With this turn down ratio of
40%, design sweetening and drying performances will be maintained, with an increase in
the specific energy consumption.

30
 GAS DEHYDRATING UNIT (GDU)

The removal of water from sweet gas is made by contacting the gas with a tri- ethylene
glycol solution. Due to their hygroscopicity, glycols are widely used for this purpose. The
hygroscopicity is directly related to the solution concentration. So water vapor will be
absorbed by a glycol solution as long as the partial pressure of the water in the vapor
phase exceeds the vapor pressure of the solution. Furthermore, the molecular
compatibility of the couple solvent- solute plays an important role. So, greater the
molecular attraction between solvent and solute, lower the vapor pressure of the water. In
liquid state, water is highly associated through hydrogen bonds. Among all the glycols,
tri- ethylene glycol represents the optimum choice between hygroscopicity, price, losses
and regeneration ability: in this case, the required specification is 85 kg of water/million
Nm3 of gas.

DESIGN CAPACITY:
The design capacity for each gas dehydration train of 46,47& 48 is 6.3 MMSCMD of
sweet gas. Other GDU trains from 41 to 45 are having capacity of 5.697 MMSCMD
each. The plant has been designed such that the minimum capacity for gas dehydration
train is 40 % of the design capacity.

PRODUCT SPECIFICATION:
The product from the gas dehydration unit will meet the following specifications:

High Pressure Case:

H2S content 4 ppm vol. maximum

H2O content 85 kg/mm Nm3 maximum, (-7C dew pt.)

Pressure at battery limits 74 kg/cm2

Temperature at battery limits 40C

31
Low Pressure Case:
HS content 4 ppm vol. maximum

HO content 50 kg/mm Nm max. (-11C dew point)

Temperature at battery limits 40C

32
33
PROCESS DESCRIPTION

Sweetened gas is dried by washing with TEG. The MDEA Gas Sweetening Trains and
the TEG Gas Dehydration Trains are connected with one another by a pipe rack-
supplying products (raw gas, de-sulfurized and dried gas) and required utilities.

Treated gas leaving the gas-sweetening units enters the dehydration unit. It pressure
0
ranges from 74.9 kg/cm2 a to 51.9 kg/cm2 a, and its temperature is 38 C. The
dehydration is supposed to be run with same liquid flow while the pressure is varying. So
3 0
the gas is dried to 85 kg/million Nm (-7 C dew point) in the higher-pressure case and
3 0
to 50 kg/million Nm (-11 C dew point) in the lower pressure case.

ABSORPTION SECTION:
Sweet gas at the TEG unit battery limit enters to the Feed Gas KO. Drum where entrained
or condensed liquids are removed. To avoid or minimise condensation of liquids due to
ambient cooling, lines going from the gas sweetening trains to the gas dehydration trains
are insulated. Liquid collecting in the base of surge drum are sent to the rich amine flash
drum under level control by LCV.

The gas leaving the top of surge drum then flows to the absorption column where it is
contacted with the lean tri ethylene glycol solution (TEG) (99.7% wt). The column is
fitted with 9 bubble cap trays, 8 of which are absorption trays and a top dry tray (Tray
No. I).The purpose of this dry tray is to retain the major part of carry-over to reduce the
glycol losses. The feed gas enters the lower part of the column below the bottom tray
(Tray No. 9) and is scrubbed by the lean glycol as it passed up the column counter-
current to the glycol, which enters above Tray No. 2.

The scrubbed gas leaving from top of passed to the dried gas scrubber where entrained
glycol carry-over is removed. The gas leaving from top is passed through the glycol unit.
and hence to the hydrocarbon dew point depression units. Rich glycol collected in the
bottom of the Absorber is sent under level control to the Rich Glycol Degassing Drum.
Before entering degassing drum this stream is combined with the glycol from the
scrubber.

Due to the lower operating pressure (10kg/cm2) of the Degassing Drum absorbed
hydrocarbons are released from the glycol. The released light hydrocarbons are sent to
34
the fuel gas header. If insufficient gas is available from for use as stripping gas then this
will be made up directly from the sweet, dry gas stream from the gas scrubber.

The Degassing Drum is fitted with 2 skimming lines for the removal of any condensed
hydrocarbons, which accumulate on the surface of the glycol. These condensed
hydrocarbons must be drained manually to the flare header.

TEG FILTRATION PACKAGE:

Tri ethylene glycol will not exhibit a high degree of foaming if it is kept free of
surfactant-type materials. These materials may be introduced through compressor oil,
plug-cock lubricant, and corrosion inhibitors used in either the formation or in the gas
gathering system. So such products must be chosen carefully.

Special attention has been given in the design to foaming and fouling by use of:

TEG degassing and hydrocarbon condensate removal.

Cartridge filter on the full rich glycol stream with a standby unit.

Charcoal filter on 30% of the rich glycol stream.

Each of the cartridge filters is designed to take 100% of the glycol flow, with one filter in
service and the second on standby. The cartridge filter removes any solid particles from
the glycol stream. An activated carbon filter is located downstream of the cartridge filter
and is designed to take up to 33 percent of the glycol flow with the major stream
bypassing the charcoal filter under control of Flow valve.

REGENERATION SECTION:
Before entering the regenerator column to be regenerated the glycol is preheated in a
heating coil at the top of the regenerator. The flow of glycol to
the heating coil is controlled by a 3-way valve TV-1215 which controls the top
o o
temperature of column from 97.8 C to 98.4 C. Temperature controller TV- 1215 opens
to allow cold rich glycol to flow to the heating coil. As the glycol flows through the coil
it cools and partially condenses the hot vapours rising up the column there by reducing
the overheads temperature and providing and internal reflux for the column. The glycol,

35
which is not required to maintain column top temperature, flows through the by-pass port
of TV-1215 and rejoins the preheated glycol stream from the heating coil.

The rich glycol stream then flows to the rich/lean glycol plate type exchanger where it is
o o
heated from 52 C to 175 C by exchange with the regenerated lean glycol" before
entering the glycol regenerator column.

The regenerator column is an atmospheric column, which contains 4 bubble cap type
trays and the previously mentioned heating coil. The temperature in the regenerator
o
reboiler is controlled at 204 C by TV-1212, which controls the flow of H.P. steam.
Glycol from the reboiler overflows to the stripper, which is end- mounted on to the
reboiler. Then it is stripped by hot dry fuel gas to achieve a concentration of 99.7% wt.
The fuel gas is preheated in a second coil of the reboiler before it enters the stripper.

The hot, stripped glycol from the base of stripper flows by gravity through the rich/lean
o o
glycol plate type exchanger, where it is cooled from 204 C to 80 C by heat exchange
with the cold rich glycol feed to regenerator, before going to the surge drum. The gases
from the top of the stripper are piped to the reboiler and the surge drum to maintain a
slight positive pressure in these vessels.

0
The lean glycol collected in the surge drum at 80 C is pumped by the lean glycol
0
injection pumps to the trim cooler, where it is cooled to 45 C by exchange with cooling
water, it then returns to the absorber.

36
Flow Diagram of the Gas Dehydration Unit

37
 DEW POINT DEPRESSION UNIT (DPD)

The dew point depression unit is designed, as the name suggests lowering or depressing
the dew point of the gas. This objective is achieved by lowering the gas temperature well
below the minimum temperature which the gas may attain in the HVJ pipeline.

PROCESS DESCRIPTION:

Sweet and dehydrated gas is treated in this DPD unit to lower hydrocarbon dew point of
gas well below the minimum temperature which the gas may attain in the HVJ pipeline.
Expected minimum temperature that the gas may attain in HVJ pipeline is 11C. Dew
point depression unit is designed to chill the gas up to 5C and recover condensate
formed due to gas chilling. The process description for dew point depression unit is
described in two sections:

1.Chill down section

2.Propane refrigeration section

CHILL DOWN SECTION:

The feed gas is first cooled by outgoing (dew point depressed) product in the gas-gas
exchangers and it is then finally cooled to 5C in a gas chiller by the evaporating
refrigerant propane. The gas temperature at the outlet of chiller is controlled by the
bypass control valve.

Provision is kept to inject tri-ethylene glycol up stream o f the gas -gas exchangers and
when required to avoid freezing problems in chill down section which may crop up
during malfunctioning of dehydration unit. Normally TEG injection shall not be done.

The chilled gas is sent to the filter-separator to knock out hydrocarbon condensate, traces
of water and glycol (if any) formed. The separated gas from the filter-separator
exchanges its cold partially with the incoming feed gas in the gas-gas exchangers. The
gas is then sent for transportation in HBJ pipeline. Hydrocarbon condensate from filter-
separator is pumped by the condensate transfer pumps to LPG unit / Condensate
fractionating unit or Slug catcher condensate header on level control valve.

38
PROPANE REFRIGERATION SYSTEM:
Propane refrigeration system has been provided in the DPD unit to supply refrigeration
required in the gas chiller. Once the system is filled with liquid propane it operates in a
closed cycle and very little makeup of propane from external source is required. Single
stage refrigeration is provided.

Propane from accumulator at 45C flows over to propane sub- cooler where it is
sub cooled by cooling water to 40C.

Then it flows over to gas chiller through level.

Refrigerant propane after evaporation in the chiller flows over to

propane compressor via suction knock out drum .

Propane vapour is then compressed by reciprocating propane

compressor driven by electric motor.

The compressed propane vapor is condensed in the propane condenser and taken to
the accumulator for reuse in the propane recirculation cycle.

The temperature of the bypassed propane vapor is maintained at 0C by spraying liquid

propane in a quench nozzle via a temperature control valve. In each train, two refrigerant
propane compressors are provided. One compressor will be in operation and other will be
stand- by.

CHEMICAL SYSTEM:

Glycol (Methanol) system:

A common glycol (Methanol) tank with glycol injection pumps is provided within B/L
in phase-1. Glycol injection being an intermittent requirement, the same header is
extended for the two trains. Pure glycol (Methanol) will be received in tank from off-
sites. This glycol is used to prevent/melt hydrates which may form in the process unit
during process upset conditions.

39
EFFLUENT SUMMARY:
It comprises mainly of vessels / filterseparator drains, floor washings and storm water
effluents. As such, during normal operation there will be no release of continuous
effluents. While during shut down or mal-operation, intermittent release of oily water
from filter-separator can take place. Another source of leakage is occasional dripping of
lubricating oils around the rotating equipment such as propane compressor and
condensate transfer pumps.

During floor washing, waste-water is generated and it is likely to be contaminated with

oil. During rainy season, there could be chances of rain / storm water also getting
contaminated with oil.

Gaseous effluents:

Gaseous effluents come mainly from vessels and safety valve discharges. During normal
operation there will not be any gaseous effluents, excepting small quantities from
occasional gas venting from some equipment.

40
Flow Diagram of the Dew Point Depression Unit

41
 SULPHUR RECOVERY UNIT (SRU)

The SRU is designed to treat 35,000 Nm/hr of acid gas from the gas sweetening unit.
Each train is capable of treating up to 7000 Nm/hr of acid gas with a hydrogen sulfide
concentration ranging between 0.3 and 5.2 mole percent i.e. 3000 to 52000 ppm of H S.
The sulphur production will range between 0.7 to 12.2 metric tons per day per train.
Under normal circumstances four trains will operate at full capacity while two remains on
standby/under maintenance.
The SRU of Hazira Plant consists of 6 Trains which came up in phases Tr. 61, 62, 63
(Phase I); Tr. 64, 65 (Phase II) and Tr. 66 (Phase III). In addition to these, there is one
Incinerator (Tr. 60), which came up with Phase I.

42
FEED SPECIFICATIONS:
The acid gas composition will vary with variation in sour gas throughout , arrival
pressure and temperature at Hazira. The acid gas has the following properties:

COMPOSITION DESIGN INLET ACTUAL INLET VENT GAS

HS 52000 PPM 6000-12000 PPM < 30 PPM
CO 85.3% 95-98% 35-40 %
HO 8.5% 3-8% 9-16%
Hydrocarbons 1.0% 1-1.5% 0.3-0.4%
N2 - - 39-41%
O2 - - 9-11%

PRODUCT SPECIFICATIONS:

Sulphur produced by the SRU is a consequence of melting an environmentally accepted

gaseous effluent.
The sulphur is expected to have the following characteristics :

Sulphur Purity 99.9 %

Moisture 0.1 %
Ash Less than 400 ppm
Organics Less than 500 ppm
As, Se, Te Commercial nil
Fe 250 ppm maximum
Form Solid, in flakes form
Packaging 25-30 kg bags

PROCESS DESIGN:

The LOCAT unit will reduce the HS with a liquid phase catalytic reagent, which absorbs
the HS and converts it to elemental sulphur and HO. Details of the theory and operation
of the LOCAT unit designed for this application are contained in the following sections.

43
THEORY OF OPERATIONS:

The LOCAT process brings about the following reactions to produce solid elemental
sulphur from hydrogen sulphide gas.

Absorption:

HS( g ) + HO( l ) H2S( l ) + HO( l (1)

First Ionization:
HS( l ) H + HS (2)

Second Ionization:
HS H + S-2 (3)

Oxidation by Metal Ions (Fe) :

S-2 + 2Fe Ss + 2Fe (4)

Overall Reaction:
HSg + 2Fe 2H + S + 2Fe (5)

The metal ions must then be deoxidized in the regeneration part of the process using O
from either ambient air (anaerobic process) or the process gas itself (aerobic process).

Absorption:
Og + 2HO( l ) Ol + 2HO( l ) (6)

Regeneration of Metal Ions:

O l + HO + 2Fe 2(OH) + 2Fe (7)

Overall reaction:
Og + HO + 2Fe 2(OH) + 2Fe (8)

44
Now, adding equations (5) & (8) together gives
HSg + Og + HO Ss + 2HOl (9)

OR
HSg + Og Ss + HOl (10)

In this overall reaction, the metal serves to transport electrons from the absorber side of
the reaction to the regeneration side, and it is necessary to supply at least two metal ions
per atom of sulphur produced. In this sense, the metal ions are a reagent. However, they
are not used up in the overall reaction and serve as a catalyst for the reaction of HS and
O. Because of this dual function, the metal ion concentrate, ARI-310 solution is
described as a catalytic reagent. The auto circulation LO-CAT unit addressed in this
manual utilizes the differential density between two aerated liquid phases at different
aeration rates to circulate ARI-310 solution from the oxidizer section to the absorber
section of the vessel. The solution absorbs HS and small amounts of CO and is
absorbed into the solution. This absorbed oxygen regenerates the catalyst. Equation (10)
indicates that there is no net production of H ions of OH ions and that the pH of the
solution is not changed by the basic reaction.

45
 Fig: Process Flow Diagram of Sulphur Recovery Unit

PROCESS DESCRIPTION:

Feed gas enters Unit 61 through flow control valve and in to the feed gas knock out drum,
which removes any condensate entering the unit. This condensate is removed on level
control / manually and sent off to the MDEA Sump Storage tank. Low level switch will
automatically close flow control valve to prevent the acid gas from entering MDEA
Sump Storage tank. The scrubbed acid gas continues to the oxidizer / absorber
Absorption of H2S is accomplished by contacting the sour gas with basic solution of
ARI-310 catalytic reagent in the center well of the liquid full Absorber / Oxidizer. The
process gas is introduced into each of the four (4) absorber sections through four (4) 8
process gas Spurger assemblies. Process gas leaves the absorber section of the vessel
through a perforated gas-liquid distributor plate at the top of the center well is mixed with

46
spent air from the oxidizer section of the vessel and is finally vented to the atmosphere
through the Cooling Tower. An H2S analyzer located in the discharge neck of will
activate an alarm when the H2S concentration reaches 15 ppm. Circulating Lo-cat
solution is introduced into the absorber section of the vessel by spilling over the center
well wall through the gas-liquid distributor plate.
The sulphur created by the reaction forms in the absorber section of the vessel. Since the
density of solid sulphur is approximately twice that of water, the formed sulphur will
settle down into the settler section of the vessel. A small amount of fine sulphur particles
will continuously circulate with the liquid catalyst solution but this will equilibrate at a
low enough concentration to not interfere with H2S removal. The reduced solution from
the absorber section of the vessel underflows the center well wall and enters the oxidizer
section.

47
As the reduced solution proceeds through the oxidizing section, it is regenerated by
contact with air. The injection of air also serves the purpose of providing the driving
force necessary to circulate the Lo-cat solution by lowering the bulk density of the
oxidizing section. The solution is completely regenerated by the time it reaches the top of
the oxidizer section. Regenerated solution spills over the top wall of the absorber center
wells and proceeds downward making counter current contact with upward flowing acid
gas bubbles, thus completing the oxidation / regeneration cycle. Sulphur particles
produced in the absorber section of drop out into the settling section. The sulphur
particles are about two times the density of water and rely on gravity and on the
centrifugal force resulting from the circulation of LOCAT solution to settle out into the
cone section . Sulphur will accumulate in the cone section to about a concentration of
approximately 10-wt%. A continuously operating scraper prevents bridging of sulphur
off the inside walls of the cone. An air blast Spurger ring directs air jets towards the wall
of the cone to prevent sulphur bridging in the lower section of the cone (below the
scraper).
Sulphur is withdrawn from the bottom cone of the settler section and pumped to the
sulphur melter section of the unit by one of the two mono type progressive cavity positive
displacement pumps .Liquid sulphur exiting the sulphur separator, flows to the sulphur
surge tank where it is stored the storage capacity of this tank is about 7 days.

CHEMICAL REQUIREMENTS:

Chemical make-up is normally required in order to maintain the Lo-cat solution at its
most desirable chemical composition. The Lo-cat process uses the following make-up
chemicals:
ARI - 310M Surfactant
ARI - 310C Biochem
KOH
The addition of these chemicals on a regular basis has been provided for in the process
design. However, chemical addition should be governed by the chemical composition of
the circulating Lo-cat solution.
KOH solution is added to the process to maintain the required pH for H2S absorption.

48
Flow Diagram of theSulphur Recovery Unit

49
 CONDENSATE FRACTIONATION UNIT (CFU)

Condensate fractionating unit is designed to remove HS and to recover LPG & NGL
from slug catcher condensate. The design capacity for the Gas Condensate Fractionation
Units is 51.5 tons/hr or 75 m3/hr of sour condensate. This feed comes from Slug-catcher.
There is also stream of sweet condensate from Dew point depression Units (DPD) which
can be processed in CFU along with the slug-catcher condensate. The plant has been
designed such that the minimum running capacity for each condensate fractionating unit
is 40 % of the designed capacity i.e. 30m/hr. each train is independently operated with
all trains continuously in service.

PROCESS DESCRIPTION:

The fractionation unit consists of:

Condensate receiving system
HS stripper
Condensate off gas compression
LPG column

Condensate Receiving System:

The condensate as it comes from the slug catcher is heated in a condensate preheater and
received in surge drum under level control through LCV. The preheater uses LP steam to
heat the condensate up to 33C to 36C to avoid any hydrate formation. Hydrate
formation is possible if there is high pressure drop across valves. The flash vapor from
the surge drum is taken to gas sweetening unit directly (bypassing compressor) when
condensate inlet pressure is at 80 kg/cm or more. Below 80 kg/cm, the pressure is
maintained 2 kg/cm, below the inlet pressure in the surge drum to allow differential for
incoming liquid and the vapor is routed through the compressor system. Any free water
droplets gets separated in the surge drum and are collected in boot. Water level is drained
through interface level control mechanism. The condensate in the surge drum is taken
into condensate transfer pumps (one operating & one standby). This pump is provided to
generated sufficient head and flow to avoid any condensate

50
flashing in the down steam filter coalesce. Two units of cartridge type filter-coalesce are
provided (one operating & one standby). The filtering elements of the filter are being
used for filtering out any scale/dust/debris/iron sulphides / black material which may
entail during pre-commissioning/commissioning, pigging operation of the trunk lines.
The Coalescer element is used for removal of free water. The free water collected in the
boot and is drained through interface level control mechanism. The condensate flows
further through flow control valve into the stripper column top tray. This is designed to
maintain a back pressure to ensure that no flashing occurs in the filter chamber. Dew
point depression units condensate can also be processed in FU besides LPG plant as
and when required so. At the top of stripper column lighter fractions come out. It is the
offset gas which further goes into knockout drum, where liquid is separated. From there it
goes to GSU. LPG component moves into reboiler from where it is refluxed in stripper
column for purification. Some part of this liquid after purification goes to LPG Line.
trippers temperature is maintained by P steam. LPG which comes out from reboiler
section further goes for caustic washing( since it has H2S). From bottom of the stripper
column Naphtha and NGL are produced. This NGL either goes to KRU or NGL line
depends on consumer demand.

51
Flow Diagram of the Condensate Fractionation Unit

52
 LIQUEFIED PETROLEUM GAS ( LPG UNIT)

Oil and Natural Gas Corporation Ltd. Of India has set up a gas processing plant at Hazira
in Gujarat. The Plant is designed to process 20 MMNm3/day of gas and associated
condensate (in Phase-I & II). The gas and associated condensate are received at the Plant
from the Offshore platforms in Bombay High/ South Bassein Oil/Gas fields through a
sub-sea pipeline. After commissioning of Phase-III & IIIA, total design capacity has
increased to 38.5 MMNm3/day of gas (one GSU train standby concept) & associated
condensate. LPG recovery plant is designed to process 5 MMNm3/day of sweet gas. The
balance gas (33.5MMNm3/day) after routing it through gas dehydration dew point
depression units will be supplied to various fertilizer plants along the 1500 km long
pipeline route from Hazira to Jagdishpur (HBJ pipeline) in U.P. The condensate collected
in the dew point depression units is also processed in LPG recovery plant.

FEEDSTOCK

Gas:
5.12 MMNm3/day free gas from South Bassein field after sweetening.
OR
5.12 MMNm3/day associated gas from Bombay High Offshore field.

Liquid:
Average amount of condensate generated in 3 Dew point depression units (upto 40
m3/hr) (presently 7 to 8 trains equivalent to 2300 m3/day) OR
Pipeline condensate corresponding to 5.12 MMNm3/day of associated gas from Bombay
High (presently sweet condensate is not being received).

PRODUCT SPECIFICATIONS

LPG: The plant is designed to extract LPG from the feed gas and condensate.
Specifications of LPG will be 50:50 by wt.(approx.) of C3:C4 and will conform to IS-
4576 for marketing system. Vapor pressure of LPG is 16.87 kg/cm2 (max) at 45C.
ARN: By product Aromatic Rich Naphtha is a mixture of pentane and heavier
hydrocarbons as present in feed streams.
Vapor pressure= 0.9 kg/cm2 (max) at 40C.
53
Lean Gas: Composition of Lean Gas from LPG recovery facility will depend on the feed
gas composition and is expected to vary with time.

54
PROCESS DESCRIPTION

Feed gas from gas sweetening unit available at the LPG plant B/L at a pressure range of
75-52 kg/cm2 (around 60 Kg/cm2 presently) and a temperature of around 38C (32-34C
presently) flows to a K.O. Drum where any liquid present in the gas is knocked off. Bulk
of the water is removed from the gas by cooling it up to 25 C (presently 22-24C). After
this, the gas flows through a molecular sieve dryer where the moisture is reduced to up to
1ppm level. This dried gas is cooled to -30C in a Cold Box and the condensed liquid is
separated out in Separator-I. Vapors from separator are expanded almost isotropic ally in
an expander as a result of which the temperature further falls down to -54 C (presently
around
-50C).Liquid condensed on cooling is separated out in Separator-II. The refrigeration of
the vapor stream from Separator-II is recovered to cool down the feed gas stream.
Further, this lean gas is compressed by expander compressor to about 37 kg/cm2 (from 30
kg/cm2) and finally to 48.5 kg/cm2 (presently 46.5 kg/cm2) by the lean gas compressor
and supplied to consumers as high-pressure lean gas.
Condensate from Dew Point Depression unit available at plant B/L at 73-50 kg/cm2 (60
kg/cm2 at present) pressure is flashed into surge drum after heating to 25C (28-30C
presently) to avoid hydrate formation. Condensate is passed through a Coalescer where
most of the free water present in the condensate is separated out. Hydrocarbon liquid
from Coalescer flows to liquid dryers where the moisture content is brought down to 5
ppm.
Liquid from Separator-I & II along with condensate from liquid dryer outlet is routed to
Light Ends Fractionator (LEF) column. The light hydrocarbons (a part of propane and
lighters) are removed from the top of the column. These light hydrocarbons are expanded
in LEF 0/H expander and the refrigeration recovered by cooling the feed gas stream in a
cold box. LEF O/H gases from the cold box is compressed to supply to KRIBHCO as
Low-pressure lean gas and also used for internal fuel gas consumption. Excess gas is
compressed by residue gas compressor to high-pressure lean gas header.

55
Liquid from the bottom of LEF column is routed to LPG recover column. Liquefied
Petroleum Gas (LPG) is withdrawn from this column as overhead product and sent to
storage. The bottom product, ARN is also sent to storage. Propane is used as refrigerant
for LEF overhead condenser and is generated by fractionating a small part of LPG
product in the Propane column.

Gas Dryers

Gas from feed gas K.O. drum is sent to gas dryers, on flow control. This flow controller
controls the feed gas flow rate to the LPG plant. The gas dryers are designed to reduce
the moisture content of the incoming saturated gas to less than 1 ppm. This is considering
the requirement of C2-C3 Recovery unit, which may come up in future. One dryer is used
for drying while the other is under regeneration. PIC-402 is provided at dryer outlet to
flare the off-spec gas.
The driers are 3 m O.D. and 12.45 m height carbon steel vessels. They are filled with
molecular sieves of 3 mm 4 A type as desiccant. The molecular sieve is supported by a
bottom layer of ceramic balls. The top of molecular sieve bed is also covered with a layer
of ceramic balls. The drier bed is provided with two sampling connections each
connected to an online analyzer (which are isolated because probes cannot sustain high
temperatures during regeneration). Sampling connection is also provided at the common
outlet line of dryers for moisture analysis. The bottom of the dryer is provided with a
removable type bottom collector fitted with SS wire mesh screen to retain escaping
molecular sieves from going to downstream equipment. The total charge of molecular
sieves per dryer is about 37.0 tons (presently about 33.5 tons). The inlet and outlet valves
of the dryers are all motor operated. Dryer inlet valves and dryer outlet valves leading to
regeneration gas cooler are provided with a bypass valve and a restriction orifice for slow
pressurization and depressurization of dryers.

56
Feed Gas Chillers

Dry and filtered feed gas is chilled to -30 C in a brazed aluminum plate fin exchanger, E
housed in a cold box.
Other cold streams, which pass through the cold box and provide the cooling, are:

Liquid from separators .

Expander outlet vapor.
LEF overhead vapors after expansion in LEF overhead expander.

57
FEED GAS EXPANDER-COMPRESSOR :

Gas from separator-I outlet is isotropic ally expanded in the expander section of
Expander-Compressor EK-101A/B, and the liquid condensed on cooling is separated in
Separator- II. The refrigeration thus produced is recovered in Feed Gas Chiller, E-101
and Feed gas cooler, E-122 and the warm gases are compressed in the compressor section
of Expander Compressor. To prevent the mixing of cold process gas into lube oil and
consequent freezing of lube oil and, also to prevent the lube oil from leaking into the
expander casing, a stream of warm and dry seal gas is provided. During start up, the seal
gas would come from dryer outlet through a seal gas heater, E-125. Under normal
operation, seal gas will be supplied from the HP lean gas header.
Gases on expansion from 57 (presently 53-54) kg/cm2 to a pressure of 32.6 (presently 29-
30) kg/cm2 cool down to about 55C (presently 50C). Cold gases flow to Feed Gas
Separator-II, V-103. Separator-II is 3.4m O.D. and about 5.2m height vertical vessel of
alloy steel construction fitted with SS-304 wire mesh demister at the top. Condensed
liquid is separated from the vapor stream and is sent to LEF column after exchanging the
cold in E-101. Feed to LEF column is under flow control (FIC-602) cascaded to
Separator-II level controller, LIC-602. Gases at -54 C (presently -50C) from feed gas
Separator-II pass through feed gas Chiller where the cold is recovered by feed gas
flowing to separator-I. The gas leaving feed gas Chiller at 7 C is passed through the feed
gas cooler, E-122 to exchange cold with incoming feed gas. Warm gases leaving E-122 at
30.8 C are compressed to 37.7 kg/cm2 in the compressor section of the Expander
compressor. Low pressure at compressor suction is indicated by PAL-605/606. The
temperature of the compressed gas rises to around 55C. In case of very high temperature
at compressor discharge as sensed by TSHH-603A and 604B, the respective expander
compressors are tripped. Hot gases from compressor discharge at 55C are cooled to 40C
in after cooler.

58
DRYERS REGENERATION

Regeneration of liquid and gas dryers (heating as well as cooling) is done by passing
hot/cold hydrocarbon gas through the dryers. LEF overhead vapor stream is expanded in
expander compressor and the refrigeration produced is recovered . This gas is
compressed by the expander compressor and used for regeneration of dryers after heating
the gas in a furnace. Hot gas at 265C passes through the dryer bed under regeneration.
The pressure of the gas to regeneration gas heater is maintained by PIC-803, which by
passes the excess pressure of the compressed LEF overhead gases to regeneration gas
moisture separator. The regeneration gas is cooled by regeneration gas cooler, and the
moisture condensed is separated in the regeneration gas moisture separator. This gas is
then supplied to KRIBHCO as low pressure gas after providing for internal consumption
of fuel gas. Provision exists to recompress this low pressure gas by residue gas
compressor, and put it to high pressure lean gas header in case for some reason low
pressure lean gas is not being taken by the consumers.

LEF COLUMN
Liquid from dryer and from feed gas separator-I and II are sent to Light Ends
Fractionators . The column removes methane, ethane, a part of propane and most of
carbon dioxide as overhead product.
LEF column is a 36.9 m tall column with 50 valve type trays. Carbon steel is used as
material of construction for the column and trays, and stainless steel for the valves. The
column is of varying diameter. It is 3.4 m O.D. at the stripping section and 2 M O.D. at
the rectification section. In the stripping section trays with 2-pass are used whereas in the
rectification section, trays with 1-pass are used.
Column overhead vapors are condensed in LEF condenser to about
-19.2C (presently, -23C to 24C). LEF condenser is a partial condenser with the
hydrocarbon vapors on the tube side being cooled by propane refrigerant on the shell
side. The temperature of propane on the shell side is about -25C.
The reboiler heat is provided by a kettle type reboiler. Heating media is modified to LP
steam (from MP) at kg/cm2 from cogeneration. At present either MP or LP steam can be
used as per the availability. Hydrocarbon on the shell side is heated by steam on the tube
side.

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LPG COLUMN
Liquid from LEF reboiler is fed to LPG column at about 105.5 C (113-115 C presently)
for separation of LPG and aromatic rich naphtha (ARN). LPG is withdrawn as column
top product and ARN withdrawn as column bottom product, are sent to storage. LPG
column is 2 m O.D. and about 37.4 m height, two-pass column with 54 valve trays.
Carbon steel is used as the material of construction for the shell and trays and Stainless
steel for the valves. The column operates at a top pressure of 11.3 kg/cm2 (presently 11.7
kg/cm2) and a temperature of 57.3C. Feed to the column can be sent to 14th, 18th or
22nd trays, depending upon the composition of the LEF bottom liquid. Presently 14th
tray is in use. Vapors from the column top are condensed in LPG column condenser and
the condensed liquid is collected in LPG column reflux drum.
Aromatic Rich Naphtha is withdrawn from the bottom of the column on level control and
sent to storage via Aromatic rich naphtha cooler that cools the column bottom stream to
45C.

PROPANE COLUMN

A part of LPG product from upstream of is sent to Propane Column on flow control for
fractionation to produce pure propane for use as refrigerant. LPG to propane column is
fed on the 25th tray. Propane column is 1.2 m O.D. and about 25.5 m tall column with 35
one-pass valve trays. The material of construction for shell and trays is carbon steel.
The column operates at a top temperature of 48.3C (42C at present). Vapors from the
column top are condensed in a water-cooled condenser (Propane Column condenser)and
the condensed liquid is collected in the reflux drum. The column top pressure is
maintained at 16.3 kg/cm2 (14.5 kg/cm2 presently) by a split range pressure controller
(PIC-1101) which either operates control valve on cooling water line to the overhead
condenser or operates PV on line to flare from the reflux drum. PV(Pressure valve) is
provided with a minimum stop position to ensure flow of minimum amount of water to
the overhead condenser.

60
The column is protected against over pressurization by a safety valve PSV. PSV has been
installed later on, for sending the lighters to
Fuel Gas Knock Out Drum, which was earlier, flared to maintain Column pressure during
the Propane Column in operation. Propane is withdrawn as a side stream from the 6th
tray and is sent on flow control (FIC) either to storage or directly to the refrigeration
system by Propane product Transfer pumps. The minimum flow requirement of the pump
is met by flow controller (FIC) which operates FV to send the pump discharge as reflux
to the column in case the product withdrawal rate is less than the minimum flow required
for the pump.
Propane product transfer pumps operate at a suction pressure of 17.4 kg/cm2 and a
discharge pressure of 19.6 kg/cm2. The pumps are designed for a normal flow of 2.75
m3/hr and can develop a differential head of 48.4 meters.
The reboil heat is supplied by propane column reboiler. The reboiler is of thermo-
pasiphon type. Carbon steel is used as the material of construction for shell and tubes.
Heat is supplied by low pressure steam regulated by flow controller( FIC)which is
cascaded with temp. controller; TIC which controls the column temperature at the 33rd
tray. The column at the 33rd tray is maintained at 66.8C. The column operates at a
bottom temperature of 79.25C and a pressure of 16.6 kg/cm2 as design or 69.0C at 13.5
kg/cm2 presently. Temperature indicators are provided for the 3rd, 27th and 33rd trays .
The column is provided with high and low level alarms. Condensate from the reboiler is
collected in propane Column Condensate Pot from where it is routed to condensate
header Propane Column bottom product is sent to LPG storage on level control after
cooling it to 45C in Propane Column Bottom Cooler. In case of high temperature at the
outlet, the column bottom flow is stopped by closure of the valves. Lighter fractions can
be diverted to fuel gas KOD through the modified line having the pressure control PV.

61
Flow Diagram of the Liquified Petroleum Gas Unit

62
 KEROSENE RECOVERY UNIT (KRU)
Three main products are produced in this unit Naphtha , kerosene and HSD. Based on
the mode of operations chosen for the unit, it can also produce ATF. Both kerosene and
ATF cannot be produced at the same time. The two modes differ in the maintenance of
physical parameters like temperature and density at appropriate time and unit within the
operation.

PROCESS DESCRIPTION

Two modes of operation are envisaged for the kerosene recovery from NGL produced in
the condensate fractionation units from CFU.
When the FBP of the NGL feed is greater than 290C, then the two columns are
planned to be operated in series mode to produce kerosene as per specifications.
When the FBP of the feed NGL is less than 290C parallel mode of operation is
planned under which the second column shall be used for the same service as the
first column.

The kerosene recovery unit is designed to fractionate 189.39 MT/hr, of NGL out of which
163.00 MT/hr is the feed NGL from 6 CFU trains and 11.67 MT/hr of the reprocessing
NGL produced during annual shut down of KRU. Reprocessing is for a period of 5.33
months (160 days) in a year (corresponding to 8.25 days NGL production). With process
optimization and de-bottlenecking the present processing capacity is 1.45 MMTPA.

The KRU consists of the following sections:

NGL feed receiving
Naphtha column feed preheat
Naphtha fractionation
Kerosene column feed preheat
Kerosene fractionation
NGL processing

63
Flow Diagram of the Kerosene Recovery Unit

64
Flow Diagram of the Kerosene Recovery Unit

65
CAUSTIC WASH UNIT
The LPG from CFU contains upto 20 ppm H2S which has to be removed to less than the
permissible limit of 4 ppm in CWU before it is sent for storage in Horton spheres. The
LPG is passed through the absorber (containing caustic solution ) and sand filter to wash
and remove H2S. Make -up caustic lye is added for maintaining the quality of solution.

PROCESS DESCRIPTION

The sour LPG passes through a caustic wash drum or the absorber (V-219), containing
(6.9 wt%) caustic solution . LPG enters drum near its bottom and a distributor is provided
for uniform mixing. LPG flows voluntarily through the absorber bed from the bottom to
the top due to the difference in their specific gravities. After the wash LPG passes
through a sand filter (X-218) to remove any caustic carryover.

When the caustic solution concentration goes down to about 5-wt% approximately 2m3
of fresh solution is added after draining the similar amount of spent or old solution. This
operation is carried out in running condition. The spent caustic is flashed in caustic flash
drum to remove any light hydrocarbon vapors dissolved in it. The hydrocarbon vapors are
routed to the flare header. The sand filter can be washed using service water.

ABSORPTION MECHANISM

H2S (g) + H2O H2S (aq)

H2S (aq) + NaOH NaHS + H2O

NaHS + NaOH Na2S + H2O

66
 STORAGE
Liquid and gaseous products must be stored during intervals between production,
transportation, refining , blending and marketing. The objective of storage at each of
these stages is firstly to supply a sufficient balance of each stock to ensure continuity of
operation and secondly to ensure that the product is conserved and maintained at an
acceptable level of quality. Various storage equipments are:

Horton Spheres : These are spherical tanks used for storage of gases that are under
pressure. It is used to store LPG and Propane.
Floating Roof Tanks : These type of tank are used to store liquids that are volatile in
nature e.g. petroleum products.
Fixed Roof Tanks : These are used for storage of non volatile liquids. The products are
sent to the various storage tanks and spheres.

Products Capacity Storage

LPG 225000 m3 Horton Spheres(9 nos.)
ARN 132000 m3 Floating Roof Tanks(4 nos.)
SKO 20000 m3 Floating Roof Tanks (5 nos.)
ATF 1000 m3 Fixed Roof Tanks (2 nos.)
Floating Roof Tank (1 no.)
Propane 311 m3 Horton Sphere

67
 COGEN, OFFSITE AND UTILITIES

COGENERATION

The electricity requirements of the Hazira plant are met through an in-house electricity
generation system without depending upon an external source. The Co- generation plant
is used for this purpose. Apart from generation of electricity the plant also undertakes the
generation and distribution of HP and LP steam throughout the plant wherever required.
The main feed for the generation of electricity is the LP gas generated within the plant. A
gas turbine system has been put in place to utilize this gas, with a daily usage of 0.7- 0.8
MMT. Initially, the gas is compressed and then it is sent to a combustion chamber, after
which it is used in gas turbine through which electricity is generated. The exhaust gases
coming from the gas turbine are used for heating up water in a boiler. Whenever heating
is not required, a special flap is there, which is opened so that the exhaust is released into
the atmosphere. Special arrangements are made to ensure continuous flow of water. The
steam generated is utilized in the main generator.
The DM plant takes raw water, which is then dematerialized to generate steam. Exhaust
gas is used in two stages - HP and LP, with HP steam generating and then LP steam.
Then it goes to economizer and from there it goes to exhaust line and is exhausted into
the atmosphere.
The whole system has 3 plants of 20 MW capacities, of which two are running at present.
Of the power generated, 30 MW is utilized by the Hazira plant. Rest 10MW is given to
other customers.
No steam turbine is there, so whatever the steam is generated; it is supplied to the Hazira
plant for further use.
A Combined cycle efficiency of about 55% is achieved by this process. The whole of co-
generation unit is controlled and monitored through the control room where special
panels are installed ( mfg. industrial and power system) which shows real time operations
going on and thus serves ease of use and operation.

Components of electricity generation system :

Gas turbine
Compressor
Combustion chamber
Turbine
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 Gas turbine load compartment
Gas turbine inlet plenum
Gas turbine inlet duct
Gas turbine exhaust duct
GT generator
Generator excitation compartment
Starting motor
Inlet filter house
Fuel gas module
Generator pedestral
Generator step up transformer
Transformer
Lube boil module
Liquid fuel module
Atomizing air module
Bypass stack
Heat recovery steam generator
HP steam drum
IP steam drum
LP steam drum
Water feed pump
Heat recovery steam generator stack
Sea water lift pump
Cooling water pump
Steam turbine
IP/LP compressor
HP compressor
Condenser
Steam turbine generator
Discharge Channel
Condensate hot well pump
Condensate water tank
Water treatment system

69
 Raw water tank
DM water tank

OFFSITE

Apart from the major process units described above, Hazira plant also has offsite
facilities spread over a wide area where the various products obtained from the
processing facilities are stored temporarily.
Storage of LPG is done in LPG spheres, which are large spherical storage tanks, divided
into two phases, consisting of six and three spheres in first and second phase,
respectively. The design capacity of the tanks is 2500 m3, with a safe filling capacity of
2100 m3. Presently, however these tanks are being used for 1200 m3 of storage. A
pressure of about 8.5 kg/cm2 is maintained.
The LPG from here is transferred to tankers, which are shipped to different locations
either through road or rail. Ethyl mercaptane, which is used for the detection of leakages,
is mixed with LPG here only, so that any leakage further down line can be identified
easily.

70
For propane storage, presently only one tank is there, with capacity half that of LPG
tanks.

Eight Naphtha tanks are available; each having a capacity of 16,500 m3. Naphtha from
here is transported to ships for export to other countries through nearby ports.

Fig: Naphtha tanks

UTILITIES

Utilities are the services which are essential for the operation of the plant, though these
may not contribute directly towards the revenue generated. The major utility systems the
plant has include:

Air system
Inert gas system
Water system
o Raw water treatment plant
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 o Fire water pump house
o Cooling water system
o DM water system

Emergency Preparedness
Cogeneration and steam systems
Effluent treatment and disposal plant
Fuel gas network

I/G PLANT

Air is used in many places within the plant. Inert gas systems are used for purging to
ensure hydrocarbon/air free state during shutdown and start-up activities. Inert gas is
prepared from the atmosphere at the inert gas plant through the PSA (Pressure Swing
Adsorption), in which the air is passed through carbon molecular sieves, which have the
granules of a special compound which adsorbs N2 at the surface, and relieves O2, when
under pressure. The container is then depressurized so that the entrapped nitrogen escapes
which is then delivered to appropriate location. Nitrogen is used for regular processes in
KRU (as sealing medium in certain pumps)
Two towers work in conjugation, one working under adsorption mode and the other in
regeneration mode. The requirement of nitrogen is approximately 400m3/hr.
Instrument air is utilized in automatic plants, for use by instruments, so it has to be free
from any kind of moisture. Plant air, which may have some moisture is used in SRU
plant.

72
 PRODUCT TERMINAL

At the product terminal all the products which are produced within the plant are loaded
off to different consumers either through rail, road, pipelines or sea routes.

Product Production Mode of Transport

Consumers
Rail Road Pipeline Ships
LPG 3500 kl/day YES YES YES NO IOC, BPCL
Reliance, UAE,
NAPTHA 5500 kl/day YES NO YES YES Singapore
SKO 600 kl/day NO YES YES NO IOCL
ATF 600 kl/day NO YES NO NO
HSD 60 kl/day NO YES NO NO ONGC
PROPANE NO YES NO NO IOCL, ONGC

At present, the production rates of the various products are as

follows:
Product Production
LPG 3500 kl/day
ARN 4000 kl/day
SKO 350 kl/day
ATF 350 kl/day
HSD 60 kl/day

73
 RAW WATER TREATMENT PLANT

Another important utility system is the water system. Water is utilized in almost all the
units. The water requirement for the Hazira plant is met by Tapti river, the source being
about 30-40 km from the Plant, through a weir designed to ensure continuous supply of
water. The water is then kept into reservoirs at the plant, in which it is allowed to settle,
and then is pumped out to various locations. The total consumption of water at the plant
is about 20,000 kl/day.
The water is used as service water for plant usage, and as make up water in cooling
towers (to counter evaporation losses etc.)
Drinking water is also supplied after adequate treatment, not only to the plant but also to
nearby villages for social obligation and to nearby ONGC residential colony.
Cooling water and service water lines are spread throughout the plant as sea green
pipelines. Red lines are for firefighting systems.
Raw water systems have an operating capacity of about 2000 m3/hr.
(5 pumps x 750 m3/hr, 2 standby).

74
WASTE WATER TREATMENT PLANT
Introduction :
The process Waste Water Treatment Plant is designed to treat waste water from LPG
recovery, Gas Sweetening, Gas Dehydration, Condensate Fractionation, Dew Point
Depression and Boiler units of the Hazira Gas Processing Complex. The major
contaminants in the above waste water streams are BOD, Hydrocarbons, Sulphides,
Phenols, suspended solids etc. The treated effluent is made to conform to the surface
discharge standards (MINAS/GPCB).

Operational Philosophy : The treatment scheme is shown in the flow diagram annexured
at Annexure - D. The following major process operations are carrie out in the treatment
plant:

1. Equalisation of waste streams

2. Separation of free oil
3. Chemical treatment for removal of emulsified oils & suspended oils
4. Biological treatment for removal of BOD, COD and phenols by bio-degradation
5. Tertiary treatment for removal of suspended solids and COD
6. Final polishing in Guard Pond.

Process Description : The total waste water is collected in the receiving sump. The
effluent is directly pumped through dry and wet weather pumps to the equalisation tanks.
A constant flow is taken to the cross flow interceptor for removal of free oil to the
maximum extent. The oil is removed off from the surface by a deoiler pipe and is
collected in the slop oil sump from where it is pumped to the slop oil tank via. slop oil
pumps. The oil free effluent from the crossflow interceptor is fed to the chemical
treatment section comprising of flash mixer CFI\ TPF Micro flotators with recirculation
pumps. This is provided to remove emulsified oil and suspended solids. Alum is dosed as
coagulant in the flash mixer. The floating material from the surface of TPF is skimmed
and collected in the chemical sludge pumps to the chemical thickener. The effluent from
the dissolved air flotation unit (CFI/ TPF) after chemical treatment flows to the biological
75
section constituting of an Aeration tank, Clarifier and Biological sludge pumps and
pumps. The biological process is the activated sludge process. The oxygen is supplied by
two mechanically fixed type surface aerators.
The required nutrients are dosed into the aeration tank. The final clarifier is provided to
separate out the biological sludge from the liquid flowing out from the aeration tank. The
clear effluent from the clarifier flows to the filter feed sump. The underflow sludge from
the clarifier is collected in the biological sludge sump and partly recirculated back to the
aeration tank via a splitter box. The excess sludge over dirt is to be recirculated being
taken to the sludge thickener.
The clear over flow from the sludge thickener flows back to the inlet/receiving sum and
thickened sludge drawn from the bottom of the sludge thickener taken to a thickened
sludge sump to be pump to the centrifuge by the thickness sludge pumps. Poly-electrolyte
is also used in the centrifuge for better sludge formation .The contrite from the centrifuge
is diverted back to the receiving sump. The sludge in the form the sludge cake is
discharged from the centrifuge to a trolley for disposal at the sludge lagoon .The effluent
from the filter feed sump is pumped by the filter feed pumps to the pressure sand filters
followed by the active carbon filters. The treated effluent flows to the back wash sump
and over flow from the back was sump goes to the guard pond. The back wash sump and
pumps are provided for back washing the pressure sand and active carbon filters. The
guard pond acts as a polishing unit and the treated process waste water is stored before
discharge through a weir for measurement of out flow. PH and dissolved oxygen of the
out flowing effluent is also monitored.

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 BIBLIOGRAPHY

All the data and information used in the report are taken with reference to:

ONGC Corporate Website portal.

Orientation Training Manual by K.D.Malviya Training Centre, ONGC Hazira

77