field and DCS panel) (Yokogawa Centum) in an oil and gas processing plant on a rotational basis. The units are operated through a (DCS) distributed control system from the control room. They are described briefly as under. I was responsible for the operation and maintenance. Of crude oil and sour gas purification and stabilizing unit my job involves.
Control room operation includes monitoring the operation on (DCS panel) control process parameters preparing daily operation and production reports.Plant patrolling which includes sampling, taking local readings, Checking field equipment’s like pumps, exchangers, columns, air fin cooler, blowers, heaters, Change over to stand - by equipment as per Schedule or during maintenance Jobs and emergencies. Maintenance job includes process pumps strainer cleaning and attending to small flange leaks and making hose connection for draining & purging. Assist in preparing of pig receiver station and pigging operation. Working during startup and shutdown as per schedule. Assist in unloading of chemical in to tanks for injection stage and adjust flow rate of chemical consumption rates as per production.
Gauging crude oil storage tanks, carrying out pre shipping & shipping samples. Monitors and coordinates the operation of acid gases (H2S & CO2) Removal units. Carrying out initial firefighting or other emergency action in work area and ensuring all times safety rules and regulation.
CRUDE PURIFICATION AND STABILIZING UNIT.
Mixing Demulsifier (inlet Skid) : To break emulsion
Heating (Heater) : To reduce viscosity
Separation (Inlet Separator) : To separate oil, gas & water
Settling (Dewatering tank) : To settle water
Desalting (De-salter) : To separate Salt
Stripping (Stripper) : To eliminate H2S
STORAGE : Finally oil is stored in large capacity tank & exported by the Shipment.
GAS SWEETENING UNIT (Monoethanol-amine-MEA) CAPACITY 3.5 MMSCFD.
Separated gas from the plant has considerable amount of acid gas (H2S & CO2) contained in it. This gas sent to the gas-sweetening unit for purification. This unit uses MEA solution as an absorbent to absorb the acid gas, while it is circulating through the system in a continuous absorption and regeneration recycle. Heat require for regeneration is provided by the re-boiler which is a gas fired, induced draught, direct heating type, purified gas is use for power generation, crude oil heaters & direct fired reboilers.
DEHYDRATION UNIT (Tri - ethylene glycol - TEG) = 50 mmscfd.
The natural gas after sweetening is made moisture free before injecting in the reservoir. The process utilizes tri - ethylene glycol (TEG) as a absorbing media. Which after regeneration is recycling the unit comprises of an absorber, regenerator, flash drum; a gas fired natural direct fire type of heater, re-boiler glycol circulation pumps, and gas/glycol coolers.
GAS SWEETENING UNIT (Di - glycol amine) = 60 mmscfd.
This unit is designed to remove selectively acid gases (H2S & CO2) contained in the hydrocarbon gas. The process utilizes chemical absorption by an amine solution (DGA) as a solvent to remove acid gases. The entire unit comprises of an absorber in which the reaction chemical absorption is carried out to remove acid gases, the regenerator in which the DGA solution (rich DGA) containing reaction products is feeds the heating system which uses two gas fired/natural draught direct fire type of heaters to heat up a heat medium oil (DOWTHERM -G) which in turn heats up the DGA solution in the reboilers as a result of which the acid is separated from the solution by the reaction (Thermal decomposition) separated acid gases is burnt in the flare stack. The unit also consists of amine & water circulation pumps, amine side cooler pumps amine storage tank, inlet gas scrubber, reflux drum, heat exchangers.
GAS INJECTION COMPRESSOR
The plant consists of three reciprocating electric motor driven five Stages gas injection compressors. The plant system is controlled by suction pressure controller of the compressors. The plant system is controlled by suction pressure controller of the compressor (165 to 170 Psig.) The injection compressors are used for injecting the dry sweet gas to the reservoir at high pressure (5000 psig). About 35mmscfd of sweet gas per day is being compressed and injected by these compressors we are involved in the starting and stopping and operation data collection and routine patrolling and checking all utilities as well as trouble shooting in case of any shut down.
Maintenance Activities
Thorough knowledge of preventive maintenance of different equipment’s as per PM list maintain record them all. Stroke checking and service of LCV, PCV and FCV and different type valves. Isolation and de isolation of vessels. Testing well through Three phase separator, Gas Calculation, Wing valve, Master valve, SSV, SSSV operation through wellhead control panel, Oil calculation, Gas Oil ratio, Acid pumping through coil tubing(Diesel and Hcl), Nitrogen lifting, Checking PH, Well activation, Well stimulation, Oil and Gas Sampling, gas gravity checking through Ranerax meter, BSW, ESD panel operation, Surface Pump operation, and good knowledge about wellhead operation Water Treatment unit operation, very good knowledge about testing separator like level setting, pressure setting, Recorder calibration through Dead Weight tester and pressure gauge calibration etc
- Company industry:
- Oil & Gas
- Job role:
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Engineering