BCPL Training Report
BCPL Training Report
On
PRODUCTION GAS DEPARTMENT
OIL India Limited
And
BCPL PLANT
Duliajan
Submitted in partial fulfillment of requirements for the award of
In
Mechanical engineering
Submitted By
JUNALI GOGOI
ET15BT0011L
CERTIFICATE
This is to certify that the internship on “PRODUCTION GAS DEPARTMENT AND
BCPL PLANT OIL INDIA LIMITED,DULIAJAN(ASSAM)” submitted to the MECHANICAL
ENGINEERING DEPARTMENT, THE ASSAM KAZIRANGA UNIVERSITY, in partial
fulfillment for the award of the BACHELOR OF TECHNOLOGY in MECHANICAL
ENGINEERING DEPARTMENT, is a record of bona fide work carried out by JUNALI GOGOI
(ETBT150011L),under my supervision and guidance.
All help received by them from various sources have been duly acknowledged.
No part of this report has been submitted elsewhere for award of any other degree.
Date:
………………………….. ………….…………………..
HOD, Dept. of ME
Examiner
Faculty Name
Designation
i
ABSTRACT
Industrial training is an important phase of a student life. A well planned, properly executed and
evaluated industrial training helps a lot in developing a professional attitude, It develop an
awareness of industrial approach to problem solving, based on a broad understanding of process and
mode of operation of organization. The aim and motivation of this industrial training is to receive
discipline, skills, teamwork and technical knowledge through a proper training environment, which
will help me, as a student in the field of information Technology, to develop a responsiveness of
self-disciplinary nature as problems in information and communication technology. During a period
of 15 days summer training at Production (Gas) Department of Oil India ltd. and BCPL plant,
Duliajan, at our disposal I was allotted with two section of department Viz. Compressor
Maintenance section and SCADA.
The Compressor Maintenance section is involved in the maintenance of the compressor packages in
the GCSs .During our week long training we saw the top overhauling of an Air compressor. I learnt
about the different parts of the gas engine and reciprocating compressor.
The SCADA section helped me to understand how the present SCADA system helps to monitor the
wide gas pipeline or distribution network and provide data about production, flow-rate and
temperature of the gas in the network.
The BCPL plant helped me to how GDU works where Feed Natural Gas is received from Oil India
Limited, where Naphtha received from M/s. NRL is unloaded, Lakwa GSU Cum C2+ Hydro Carbon
Recovery Unit where Feed Natural Gas supplied by M/s. ONGC is processed and The Main
Petrochemical Complex at Lepetkata, Dibrugarh where Polymers are being produced after
processing the feed stocks.
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LIST OF FIGURES
TITLE PAGE
Figure 1 Compressor maintenance section 3
Figure 2 Compressor package 5
Figure 3 Reciprocating Compressor: Multi throw, multi 6
stage, double acting, horizontally opposed
balanced.
Figure 4 PV Diagram of Reciprocating Gas Compressor 7
Figure 5 Four Stroke Spark Ignited (IC) Gas Engine 10
Figure 6 Cooling water flow diagram 11
Figure 7 Aerial cooler (60F 4S) 12
Figure 8 Flow diagram of Plant overview 13
Figure 9 Flow diagram of GDU 15
Figure 10 Gas turbine 16
Figure 11 Single Shaft Centrifugal Compressor 18
Figure 12 Glycol Dehydration Unit 19
Figure 13 Contactor tank 21
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INDEX
Page
I. Acknowledgement i
II. Abstract ii
1. Introduction 1
1.2 BCPL 2
3. BCPL Plant 4
4. Conclusion 22
5. Bibliography 23
iv
INTRODUCTION
Oil India Limited(OIL) is an E & P company is a premier National Oil Company engaged in the business
of Exploration, Production and Transportation of crude oil and natural gas. A Nirvana Company under The
Ministry of Petroleum and Natural Gas, Government of India, it is the second largest national oil and gas
company in India as measured by total proved plus probable oil and natural gas reserves and production.
Incorporated as a private company in 1959, OIL has been present in the Indian oil and gas exploration and
production industry for over five decades. The company presently produces around 3.90MMTPA(Metric
Million Ton Per Annum) of crude oil, around 7.93MMSCUMD(Metric Million ) of natural gas and more
than 45,010 tons of LPG annually.
• The company operates a crude oil pipeline in the North-East for transportation of crude oil produced for
both OIL and ONGCL in the region to feed Numaligarh, Guwahati, Bongaigaon and Barauni refineries
and a branch line to feed Digboi refinery.
• Moreover it has also extended its blocks overseas in Iran, Libya, Gabon, Nigeria, Sudan, Yemen, Egypt
and Timor Leste.
• A reservoir of hydrocarbons from where natural gas and oil are collected through a drilling in the earth is
called a well.
• Civil engineering
• Chemical engineering
• LPG
• Geological
• Electrical engineering
• Instrumentation
• IT
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• Fire and Safety
• Transport
• Field communication
• Field engineering
• Drilling
BCPL comprises of four work stations i.e. GDU Duliajan where Feed Natural Gas is received from M/s.
Oil India Limited, Railway Siding where Naphtha received from M/s. NRL is unloaded, Lakwa GSU
Cum C2+ Hydro Carbon Recovery Unit where Feed Natural Gas supplied by M/s. ONGC is processed
and The Main Petrochemical Complex at Lepetkata, Dibrugarh where Polymers are being produced after
processing BCPL(Brahmaputra Cracker and Polymer Limited) Duliajan plant,is well established for gas
dehydration and compressing facilities carried 6MMSCMD of natural gas from OIL,Duliajan to Lepetkata
plant, where C2 plus liquids is recorved and the lean gas is sent back to OIL,Duliajan for future
distribution to gas customers. Twin pipelines is laid between Duliajan & Lepetkata, BCPL is at advance
stage of acquiring land at Duliajan.
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OIL INDIA LIMITED
• Preventive and breakdown maintenance of 120 gas compressor package of different make duty
installed at different gas compressor stations.
• Preventive and breakdown maintenance of 42 air compressor package including mobile air
compressor installed at 15 different gas compressor stations .
• Top and major overhauling of gas compressor packages and air compressor units.
• Implementation of approved budgets including rising PRs for procurement of various non-stock
items.
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TYPES OF MAINTENANCE
The section performs three types of maintenance activities:
Predictive maintenance: This includes maintenance activity based on physical anomalies detected during
operation such as higher level of noise, higher temperature of exhaust etc.
b) Overhauling-
Major overhauling: This includes engine block removal, engine crank shaft removal, cylinder head
removal, piston removal, connecting rod bearing cganges and piston linear removal.
Top overhauling: This includes cylinder head removal, piston removal, connecting rod bearing
change and piston linear removal.
4
Fig 2:- COMPRESSOR PACKAGE
1. Compressor: Increases pressure of a natural gas stream by reducing volume (compression) for specific purpose.
2. Prime Mover: Power provider for the compressor. It is a Gas Engine or Electric Motor.
3 Ariel cooler: used for dissipation of heat produced in Compression and internal combustion of Gas Engines.
4. Coupling: used to transfer power from the prime mover to the compressor.
5. Control panel: required for the operational safety of the machine and equipment.
5
Reciprocating gas Compressors
Main objectives of Compressors:
To Compress mainly two streams of natural gas received from OCS / Distribution network:-
1. LPG Booster: Compress 30 Psig gas (LPMS) up to 250 Psig, fed into the distribution network for LPG
extraction and further consumption.
Compression Ratio (CR) = Discharge absolute pressure divided by intake absolute pressure. Hence, CR =
(264.7 / 44.7) = 5.92.
2. Gas Lifter: Compress 250 Psig gas (HPMS / Distribution network) up to 1500 Psig for artificial lifting of
crude oils from connected depleted oil wells. Hence, CR = (1514.7 / 264.7) = 5.72.
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Working Principle (Reciprocating Gas Compressor)
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Reciprocating Compressor: (Advantages Vs Disadvantages)
Merits:
1. Greater flexibility in capacity and pressure range
2. Higher compressor efficiency & lower power cost
3. Capability of delivering higher pressure
4. Capability of handling smaller volumes
5. Less sensitive to changes in gas composition & density.
Demerits:
Reciprocating compressor cannot handle liquid and solid particle entrained in the gas. Liquid and solid particles
tend to destroy cylinder lubrication and cause excessive wear. Liquids are non compressible and there presence
could cause major damage to the compressor cylinder or frame components.
B. Cylinder Components:
§ Cylinder with Liner
§ Cylinder heads
§ Pistonwithrings
Suction & delivery valves
§ Valvecovers
Rod (gland / stuffing box) packing
§ Distance piece (optional)
§ Clearance pocket (optional)
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Gas Engines
A gas engine is an internal combustion engine which runs on a gas fuel, such as coal gas, producer gas, biogas,
landfill gas or natural gas. Generally the term gas engine refers to a heavy-duty industrial engine capable of
running continuously at full load for periods approaching a high fraction of 8,760 hours per year.
A gas engine differs from a petrol engine in the way the fuel and air are mixed. A petrol engine uses a carburetor
or fuel injection but a gas engine often uses a venture system to introduce gas into the air flow. Early gas engines
used a three-valve system, with separate inlet valves for air and gas.
The weak point of a gas engine compared to a diesel engine is the exhaust valves, since the gas engine exhaust
gases are much hotter for a given output, and this limits the power output. Gas engines that run on natural gas
typically have a thermal efficiency between 35-45%.
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Working Principle:
Four Strokes:
1. Suction
2. Compression
3. Combustion (Power)
4. Exhaust
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Aerial Cooler
This radiator has four Sections:-
1. Engine Jacket water Section: To dissipate heat from engine coolant, so that Engine cannot overheat.
2. Auxiliary Jacket Water Section: To dissipate heat from jacket water cooling circuit of Compressor and
Lube oil Coolers.
3. Inter Cooler:- To cool down the compressed gas, so that it can compress to next higher pressure with
less horse power.
4. After Cooler: To cool down the Final compression gas, so that it can be safely sully to customers.
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Fig 7: Aerial cooler (60F 4S)
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Plant overview
BCPL(Brahmaputra Cracker and Polymer Limited) Duliajan plant,is well established for gas
dehydration and compressing facilities carried 6MMSCMD of natural gas from OIL,Duliajan to
Lepetkata plant, where C2 plus liquids is recorved and the lean gas is sent back to OIL,Duliajan for
future distribution to gas customers. Twin pipelines is laid between Duliajan & Lepetkata, BCPL is
at advance stage of acquiring land at Duliajan.
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DESPATCH TERMINAL & GAS DEHYDRATION UNIT
The rich gas feed from Central Gas Gathering station and Off take point is filtered in Cartridge filter provided
at OIL B/L to remove the dust particles, metered using ultrasonic type flow meter and is fed into the
compressor at Duliajan. The gas composition for calculating the energy flow is obtained from dual stream Gas
Chromatograph (GC) installed to measure composition of rich/ lean gas at battery limit. The flow computer
indicates pressure, temperature, energy flow, the corrected volumetric flow rate as well as the gas composition
of the rich/ lean gas at OIL battery limit.
The rich gas is fed into the 1st stage compression suction K.O drum to remove any free condensate/ water and
is provided with demister to reduce liquid droplet size to less than 10 μ in separated vapor stream. Vapor
product is fed into 1st stage compressor. The rich gas is compressed and cooled in the 1st stage after cooler
provided to a temperature of 55 °C.
Cooled gas from 1st stage after cooler is fed into the 2nd stage suction K.O drum, from where the vapor stream
is compressed in the 2nd stage compressor to 75 kg/cm2_g pressure. The product is again cooled in 2nd stage
after cooler to a temperature of 55 °C. Gas from the 2nd stage after cooler is fed into the 2nd stage discharge
K.O drum. The rich gas from 2nd stage discharge K.O drum is the feed to the Gas dehydrating unit (GDU).
PROCESS SUMMARY
The removal of water from compressed gas is made by contacting the gas with triethylene 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 water vapor pressure of the solution. The removal of water from
Compressed Gas is made by contacting the gas with Tri-ethylene Glycol solution. The Compressed gas is at a
pressure of 74.0 Kg/cm2g & temperature of 55 °C and This gas is dried to 5lb/MMSCF at the battery limit
condition.
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Fig 9 :- Flow diagram of GDU
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Main plant equipments
(a) Gas turbine
02 no’s Make GE model PGT 25 DLE
Capacity-25 MW
(b) Centrifugal compressor
2 Stage (MCL,BCL)
Make – BHEL
Capacity each – 3MMSCMD
Suction- 7-7.5 kg
Discharge- 70-75 kg
(a) Gas turbine
The gas turbine is the engine at the heart of the power plant that produces electric current.
A gas turbine is a combustion engine that can convert natural gas or other liquid fuels to mechanical energy. This
energy then drives a generator that produces electrical energy. It is electrical energy that moves along power lines to
homes and businesses.
To generate electricity, the gas turbine heats a mixture of air and fuel at very high temperatures, causing the turbine
blades to spin. The spinning turbine drives a generator that converts the energy into electricity.
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The gas turbine can be used in combination with a steam turbine—in a combined-cycle power plant—to create power
extremely efficiently.
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(a) Centrifugal compressor
Compressor at BCPL , Duliajan plant is a BHEL centrifugal compressor maker. It has two stage BCL .1st
stage compressor suction 7.29 kg/cm2 . It compressed and discharged 26.59 kg/cm2 and 2nd stage
compressor suction 24.89kg/cm2. It compressed and discharge 67.82 kg/cm2
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Gas dehydration unit and Regeneration Unit
Lean, water-free glycol (purity >99%) is fed to the top of an absorber (also known as a "glycol contactor") where it is
contacted with the wet natural gas stream. The glycol removes water from the natural gas by physical absorption and
is carried out the bottom of the column. Upon exiting the absorber the glycol stream is often referred to as "rich
glycol". The dry natural gas leaves the top of the absorption column and is fed either to a pipeline system or to a gas
plant. Glycol absorbers can be either tray columns or packed columns.
After leaving the absorber, the rich glycol is fed to a flash vessel where hydrocarbon vapours are removed and any
liquid hydrocarbons are skimmed from the glycol. This step is necessary as the absorber is typically operated at high
pressure and the pressure must be reduced before the regeneration step. Due to the composition of the rich glycol, a
vapor phase having a high hydrocarbon content will form when the pressure is lowered.
After leaving the flash vessel, the rich glycol is heated in a cross-exchanger and fed to the stripper (also known as a
regenerator). The glycol stripper consists of a column, an overhead condenser, and a reboiler. The glycol is thermally
regenerated to remove excess water and regain the high glycol purity.
The hot, lean glycol is cooled by cross-exchange with rich glycol entering the stripper. It is then fed to a lean pump
where its pressure is elevated to that of the glycol absorber. The lean solvent is cooled again with a trim cooler before
being fed back into the absorber. This trim cooler can either be a cross-exchanger with the dry gas leaving the
absorber or an air-cooled exchanger.
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Main Equipments of GDU:-
• Reboiler
• Heat Exchanger
• Strainer
• Pump
• Filter
• Surge drum
• Contactor tank
Reboiler:-
The Rich glycol is pourd in the reboiler and it heated up to 1800 c .During the process the moisture escapes
from the top and the lean glycol setting down in the sqrugedrum.
Pump:-
Two types of pumps are used in BCPL
1. Centrifugal pump
2. Reciprocating pump
Filter:- It is very important to maintain the glycol in as clean a condition as possible. For this reason, filters are
always incorporated in a glycol circulating system. These filters are usually particulate filters and carbon filters.
The particulate filters are intended to remove solids down to a 5-μm diameter. Solids can occur from
corrosion in the glycol system. Carbon filters are designed to remove dissolved impurities, such as
compressor oil or condensate from the glycol solution. Particulate filters are usually installed on the rich
glycol side and are in operation all the time. Carbon filters may be bypassed most of the time, if there is no
dissolved hydrocarbon in the glycol. Impurities in the glycol solution might promote foaming in the contactor
or still.
Surge drum:- Because the glycol that is being circulated might not always flow evenly at the same rate
throughout the system, a vessel, the surge drum, is required that can handle any surges in the circulation rate.
The reboiler always contains a liquid level above the fire tube. Glycol levels in the absorber or flash tank are
essentially constant but might fluctuate slightly. Thus, there is a need for a vessel that can absorb slight
temporary differences in circulation flow between the various vessels, as well as the thermal expansion of the
glycol upon startup.
The surge drum is usually located below the reboiler or at least at a level below the glycol in the reboiler. The
glycol level in the surge drum is important because in some instances there is a heat exchange coil in the
surge drum, as explained earlier. The level of glycol in the surge drum should be about at the two-thirds full
level. The liquid level in the surge drum is an item that is usually checked by the operators. If the level is
lower than normal, this might be the first indication of trouble, such as:
Heat Exchanger:- Because glycol must be relatively cool when entering the absorber and is heated to near
its boiling temperature for regeneration, the liquid is continuously subjected to heating and cooling. To
minimize the use of energy in the regeneration of the glycol at high temperature, several heat-exchange
opportunities are built into most glycol circulating systems. Heat exchange usually occurs in certain
locations:
In some cases, an additional heat exchanger is necessary to exchange heat with air, to cool the lean glycol
ahead of the contactor. It is necessary to limit the temperature of the lean glycol to only a few degrees above
the temperature of the gas to increase the absorption of the water by glycol. Too high a glycol temperature
reduces the transfer of water from the gas to the glycol, and the water dew point may not be met. This is
frequently the problem in summer operations, in which the gas is dehydrated after compression. On hot days,
the glycol, as well as the gas, might be above normal temperatures. Usually, by exchanging heat with the
dried gas through a double pipe exchanger or through a coil in the top of the contactor in small units, the
temperature of the glycol is adjusted to a few degrees above the temperature of the gas leaving the contactor.
Strainer:- A strainer should always be installed upstream of the suction of the glycol pump. The glycol strainer
ensures that no solid particles enter into the glycol pump. The main problem with solids entering the pump is that
they might lodge in the suction or discharge valves and prevent the pump from pumping at maximum efficiency.
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CONCLUSION
The Summer Training Programmer in Oil India Ltd and BCPL Plant, Duliajan has been beneficial in
making me familiar with the various operation involved in the production of petroleum hydrocarbons,
besides giving an opportunity to comprehend the basics of production operations and installations.
The programmer has been an immense help in understanding of the importance of conservation of fuel
and the environment as a whole. The opportunity, as the programmer presented, has allowed me to
witness the technology and human skill required in the field work of the company.
This training has allowed me to experience the amount of hard work of the people that goes into the
company which has led this company towards its growth and success. It has helped me to gain a lot of
practical knowledge in the professional area.
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