TRAINING REPORT ON ORIENTATION IN

ENGINEERING SERVICES OF ONGC

SUBMITTED BY
MEGHNA SARKAR
SECOND YEAR MECHANICAL
ENGINEERING
CUMMINS COLLEGE OF ENGINEERING FOR
WOMEN, PUNE
MENTOR
SHRI SUDIP GUPTA
DGM(P), ENGG. SERVICES
ONGC, MUMBAI
DECEMBER 2013
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ACKNOWLEDGEMENT
I convey my deepest regards and sincere gratitude to my mentor Mr. Sudip
Gupta, DGM(P), Engineering Services, ONGC for his constant valuable
guidance, co-operation and encouragement that helped me to complete the training.
I sincerely thank Ms. Manisha
CE(M),

Srivastava, CE(M),

Mr. K.C.Deka, CE(C),

Ms. Bandana Gupta,

Mr. Avinash Kumar, Dy. SE(E), Ms.

Mousumi Das Roy, EE(I), Mr. R.V. Gawande, EE(M), Mr. Sanchit Rastogi,
Mr. Maruti Vishwakarma, AEE(E), Mr. Palash Naskar, AEE(P) for their
guidance and for always taking out time and going an extra step to share their
knowledge with me.
I also express my gratitude to Head RTI, ONGC, Bandra Kurla Complex
without which it would not have been possible for me to undergo this training.
Also, thanks are due to Offshore Engineering Services, ONGC for providing me
the platform for carrying out the internship.

I also thank all those who have directly or indirectly helped me during the tenure of
my training.

Meghna Sarkar
Second year Mechanical Engineering
MKSSSs Cummins College of Engg. for Women
Karvenagar Pune-400052
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CONTENTS
Sr.no

Subject

Page
no.

1.

Abstract

2.

Introduction to oil and gas industry and

classification

3.

Major elements of offshore plant

4.

Process of oil and gas production

5.

Designing of offshore platforms

10

6.

Processing of produced oil and gas

12

7.

Piping

13

8.

Pipelines

14

9.

Instrumentation

15

10.

Electrical

15

11.

Mechanical

16

12.

Structure

18

13.

Major elements of offshore production systems

19

14.

Summary

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3

ABSTRACT
Being a part of an esteemed organization as a winter internship trainee was an
opportunity wherein as a student I could get an industrial approach to the
theoretical concepts. It was a good learning experience in which I got an exposure
to most of the segments of petroleum discipline where I could find application of
the previously gained theoretical knowledge.
A systematic approach to the oil and gas industry and the entire process of
production of oil and gas in ONGC right from exploration to designing,
construction and transportation were elaborately explained.
Furthermore, I got to learn about the various areas of work of a mechanical
engineer in a petroleum industry.
My training was concentrated on the design and engineering for offshore platform/
plant which is taken care of by Engineering Services, 11 High, ONGC, Mumbai.
The study includes:
Creating the process flow diagrams (PFD)
Creating a piping and instrumentation diagram(P&ID)
Piping design and 3D modeling of platform
Design of structure (jackets, piles and deck),
Design of pressure vessels, various mechanical equipment
Design of piping systems for the entire plant.
Electrical single line diagrams.
Review of detailed engineering documents and drawing by various
departments like instrumentation, electrical, process, mechanical, structural,
piping and pipeline.
Revising the existing design and finally approval of the entire documents
and drawing of the project, followed by its actual construction.

I got the chance to work on a few software like Hysys and Pipesim and was
introduced to other software like Autocad, Caesor-II, PDMS, PDS, SACS,
PVLITE.
I also got familiarized with concepts and work of the different departments of
engineering services like electrical, mechanical, instrumentation, process, piping,
structure, was given by the respective engineers from each department.
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INTRODUCTION TO OIL AND GAS INDUSTRY

OIL AND GAS
INDUSTRY

UPSTREAM
INDUSTRY

EXPLORATION AND
PRODUCTION

DOWNSTREAM
INDUSTRY

TRANSPORTATION
TO PROCESS PLANT

(reservoir to
ground)

(ground to plant)
REFINING

OFFSHORE
PLATFORM

ONSHORE
INSTALLATION

RETAILING

BULK
PROCESSING
(SEPARATION)

TRANSPORTED TO
PLANT FOR
FURTHER
PROCESSING
FABRICATION
DESIGNING

(Actual construction)

ONGC
(Upstream
industry)

OFFSHORE PLATFORM

ONSHORE
INSTALLATION

FABRICATION

DESIGNING

ENGINEERING
SERVICES

WORKS

DESIGN

PROCESS

INSTRUME
NTATION

PIPELINE

MECHANICAL

PIPING

STRUCTURE

ELECTRICAL

MAJOR ELEMENTS OF OFFSHORE PLANT

PLANT
WELLS
PLATFORMS:
i) WELL HEAD PLATFORMS (UN-MANNED PLATFORM)
ii) PROCESS PLATFORMS (MANNED PLATFORMS)
DRILL RIGS
PIPELINES:
i) SUB SEA TRUNK PIPELINES
ii) TRANSPORT IN FIELD PIPELINES
TANKERS (for evacuation of oil)

JACKUP RIG ON WELL PLATFORM FOR PROCESS PLATFORM COMPLEX WITH SEPARATION,
DRILLING/WELL SERVICING
GAS PROCESSING, WATER INJECTION FACILITIES

TYPES OF :
1.WELLS

Producers: Self flow, Gas lifted and ESP.

Injectors
Subsea wells
Directional wells
Horizontal wells
ERD Wells
Multilateral wells
Intelligent wells

2.PLATFORMS

Fixed
Compliant
Sea star
Floating production system
Tension leg platform
Sub sea system
SPAR

PROCESS OF OIL AND GAS PRODUCTION

Exploration of site of oil and gas reservoir.

Designing of platform to be built.
Approval of design.
Foundation of platform on sea bed.
Deck is mounted on the structural foundation.
Platform (well head and process) mounted with necessary equipments
transported to location on a barge.
Platform is fixed on strong structure.
Heli-deck mounted on top of process platform.
Drill rigs are taken to location.
Rigs lay their legs on sea bed and using cantilever method wells are dug on
the well head platforms at the appropriate location.
Cantilever is drawn in and the rig legs are withdrawn.
Well fluid from the well is produced using various methods.
Well fluid from various well head platforms are transported to process
platform which has living quarters, separators, compressor, various pipings,
etc mounted on it.
On the process platform, well fluid from other platforms are passed through
separator to separate out water, oil and gas.
The separated components are further processed in different ways:
i. Gas: It is compressed dehydrated using glycol and then either used to
run gas turbines for power generation on platform or sent to process
plant onshore or flared out if excess.
ii. Oil: Oil is put to another separator to further separate moisture and gas
content and then oil is pumped through pipelines to process plant
onshore.
iii. Water: It is conditioned and then discarded to sea taking into
consideration environmental impact. It is ensured that the disposed
water contains almost zero oil content and does not harm the
environment impacts.

DESIGNING OF OFFSHORE PLATFORM

Making a process flow diagram(PFD) for the Process

system

Analysis of the PFD doing simulations using software like

Hysys, etc. is done by process department.

Based on the PFD, create a piping &instrumentation

diagram (P&ID) using software like Autocad, Smartplant
giving details of various equipments.

Analysis of the system and doing various calculations

related to it.

Specific designing of structure including foundation,

jacket, deck, helideck, etc using software like SACS by a
group of structural engineers.

Designing of 3D model of the platform for better analysis

using softwares PDMS, PDS, etc by piping

10

10

11

12

Designing and analysis of pressure vessels and other

mechanical equipments mounted on platforms using software
like PVLITE by a group of mechanical engineers.

Designing of the pipelines for transport of well fluid, oil or

gases at various steps, material and specification of pipes
designed using software by a pipeline dept.

Electrical department looks after all the electrical equipment

and electricity supply on the platform. Distribution system by
creating sigle line diagrams of all the electrical equipments
considering the loads for various uses.

Instrumentation department is responsible for

the
mechanisms of control,monitoring and corrective actions on
the platform.So they contribute to the creation of the P&ID.

Selection of materials for fabrication and method of testing

used is taken care by quality control depratment.

Reviewing and revising the entire design by group of all

engineers and finally approving the project followed by actual
construction

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I.

PROCESSING OF PRODUCED OIL AND GAS

Any process platform is the gathering and distribution point for all the pipelines i.e.
well fluid lines, lift gas lines and oil export line for tanker loading. All the
processing facilities i.e. separation, produced water treatment, gas compression and
dehydration, gas sweetening is installed on this platform. In addition there are
testing facilities for testing of production coming from individual platforms.
Therefore, using many softwares like ASPEN HYSYS, SMARTPLANT etc. the
process discipline under ODS drafts out the basic plans for any offshore process
platform. The various diagrams like PFDs (Process Flow Diagram) and P&IDs
(Piping and instrumentation diagram) are being designed by the people of this
discipline. After the process design is completed the feasibility study for the
designed process is carried out for future bidding and finalisation for the design.
The key operations that will be conducted at the offshore platform include:
Produced Hydrocarbon Separation
Gas Processing
Oil and Gas Export
Well Testing
Produced Water Treatment and Injection
Utilities to support these processes
3Phase well fluid is received from Wells/Well Platforms and processed at
Large Process Platforms generally consisting of the following four Major
Processing Modules
Separation (Oil, Gas and Produced water) & Oil dispatch
Gas Compression & dehydration
Produced Water Conditioning
Sea water processing & injection system
These process complexes will also have the following:

Fire detection & Suppression system

Power Generation
Well services/drilling Modules
Water Maker/Utilities/Sewage Treatment
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 Living Quarter

Schematic Diagram of an Offshore Process Complex

II.

PIPING
The piping discipline under ODS looks after the pipes on the process
platform. Plant layout and design of piping systems constitutes a major part of the
design and engineering effort. Basically the following are the main tasks carried
out by this discipline:
Piping and instrumentation diagrams (P&IDs)
Piping design and engineering principles
Terminology, symbols and abbreviations used in piping design
Piping materials
Piping specifications and piping codes
Components of piping systems - fittings, flanges and valves
Piping routing
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 Piping stress analysis and support design

The main base for all calculations is Hoop Stress for all the stress
calculations and wall thickness. Wall thickness selection is one of the most
important and fundamental tasks in design of offshore pipelines. While this task
involves many technical aspects related to different design scenarios, primary
design loads relevant to the containment of internal pressure.
This discipline uses various software and standard codes for the design
purposes. Among the standard codes, ONGC follows the ASME B31 code for
pressure piping of a number of individually published sections. The codes used are
B31.3 (Process Piping), B31.8 (Gas transportation and distribution piping system)
and B31.4 (Pipeline transportation systems for liquid hydrocarbons and other
liquids).

III.

PIPELINES
Pipelines are used for a number of purposes in the development of offshore
hydrocarbon resources These include e.g.: Export (transportation) pipelines
Pipeline bundles
Flow lines to transfer product from a platform to export lines
Water injection or chemical injection flow lines
Flow lines to transfer product between platforms, subsea manifolds and
satellite wells
The design of pipelines is usually performed in three stages, namely;
Conceptual engineering,
Preliminary engineering or pre-engineering,
Detailed engineering

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IV.

INSTRUMENTATION
Instrumentation discipline comes into play after the process platform has
been designed by the process design section with the help of a P&ID. This
discipline helps in controlling and automating all the process parameters involved
in the offshore as well as in the onshore process platforms.
The various controlling instruments looked after by this discipline may be
either pneumatic or electronic. It deals with the measurement of pressure,
temperature, flow-rates with the help pressure transducers, temperature sensors
(RTD, Thermocouples etc.) and flow meters respectively. Instrumentation
discipline also takes care of the Shut Down Panel which shuts down all the
processes in case of an emergency.
SCADA(supervisory control and data acquisition) is used for well monitoring,
control and production optimization.

V.

ELECTRICAL
Every power plant needs one or the other way electrical power for its proper
functioning. For an offshore platform it requires huge electrical power to run all
15

the mechanical devices employed, living quarters electrical consumption and also
some power to run various instruments.
Electrical power requirements are classified according to the loads into categories
as:
Radio operation
Instrumentation requirements
Fire and gas detection systems
Navigation
For any general platform of ONGC, it requires about 20-25 MW or more
power to run the system. To produce such large amount of power is challenging.
For this ONGC has its own power production unit where power is generated by a
portion of the natural gas produced. There are huge Gas Turbine Units (GTU) for
power production. Also the circuit breaker station is installed on the platform itself.
For some other purposes which may require small power say few KWs, power is
generated by the renewable sources of energy like solar energy, wind energy etc.

VI.

MECHANICAL
Mechanical devices such as Turbines, Compressors, Pumps, Heat Exchangers
etc. are the basics for a plant to operate and such devices are included under the
Mechanical discipline for both running and maintenance of the same. A small
introduction about the main mechanical units operating in a offshore process
platform is given below
1. Gas Turbines
Gas Turbines are used for the power production by rotation of the turbine shaft
by steam generated due to heat generated by burning a portion of natural gas
produced. An efficient gas turbine used in a power plant produces about 10-15
MW of power under optimized conditions. Special care is taken for the inlet gas
entering into the turbine as wet gas may corrode the blades of the turbine and also
reduces the efficiency furthermore due to corrosion it may cost economic loss to
the plant.
2. Gas Compressors
Gas compressor is a mechanical device that increases the pressure of a gas
by reducing its volume. Compressors are similar to pumps: both increase the
pressure on a fluid and both can transport the fluid through a pipe. As gases
are compressible, the compressor also reduces the volume of a gas. Liquids
16

are relatively incompressible, while some can be compressed, the main

action of a pump is to pressurize and transport liquids. Normally a three
stage compression system is applied in a gas based power plant. Mostly
Centrifugal compressors are used in gas processing plant.

3. Heat Exchangers
Heat Exchangers exchanges heat between two fluids, In ONGC heat
exchanger used is the tube and shell type. Mainly these units are used during crude
oil components separation in which a portion of the crude oil is heated and passed
through tubes and other portion is passed through shell in this way exchange of
heat takes place reducing the viscosity of the fluid which is necessary to avoid
vortex formation and maintain almost laminar flow within the pipes which helps in
avoiding condensate formation. Also since compressors require the temperature of
the entering gas to be low for its efficient working temperature exchangers of
various forms are used to cool the gas.
4. Knock Out Drums (KOD)
Knock out drums is used for the separation of gas and oil from the saline
water. Mainly the principle involved is the gravity separation (baffle plates are
present inside them) in which the components are separated depending on their
density.

17

5. Pumps
Pumps are basically used for transporting incompressible fluids like crude oil
by creating large pressure difference for its transportation along pipelines.
Presently in ONGC centrifugal type pumps are used for general purpose.

VII.

STRUCTURE
Structure discipline designs the supporting structure of the platform and the
topside considering the stress analysis criteria. They use many softwares like
SACS, MicroStation etc. for the design purposes.
i. Supporting Structures
The supporting structure on which the platform rests is divided into:
1. Jackets
2. FPSO (Floating production storage and offloading)
3. Jack up rigs
4. Semi Submersible Platform
5. Gravity based structures
6. Spar
Topside
Topside is a structure resting on a supporting structure having all the basic
facilities for the process, unmanned platforms. They are divided into:
1. Cellar Deck
2. Sub-Cellar Deck
3. Heli Deck
4. Living quarters Deck
ii.

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THE MAJOR ELEMENTS OF OFFSHORE PRODUCTION

SYSTEM
Separator
Oil ,Gas and Water is separated from the Wellfluid
Well Fluid from various Wells/ Well Platforms / Subsea Manifold reaches the
process complex via subsea pipelines and risers and is further processedin more
than one train.
Each Train will normally consist of a Production Manifold , Wellfluid heater,
Inlet Separator, Crude oil Manifold, Crude oil heater, Surge Tanks andMOL
Pumps.
Well Fluid is received in the Production Manifold . Demulsifier Chemical is
dozed in Production manifold to promote breaking up of WaterOil emulsion
Then it is heated in well fluid heater with Hot oil Flowing in Shell Side and well
fluid in tube side. This heating enables better separation of oil and water in Inlet
Separator.
The Well Fluid from Well fluid heater reaches Inlet Separator.

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Inlet Separator (first stage separation):

It is a vessel in which 3 phase separation of well fluid into Oil, Gas and Water
occurs.
Separation is by gravity mainly assisted by chemical and heat. Residence time in
the vessel is an important criteria for better separation.
Separated Gas is routed to Gas compression and dehydration Module.
Compressed gas is sent to the Lift gas network for lifting the producers and excess
gas is exported via pipelines to shore.
Separated oil flows to the oil manifold.
Separated water flows to Produced water conditioning unit.
From oil manifold crude oil flows to crude oil heater in which crude oil is heated
with hot oil. This enhances the separation of oil & water in Surge Tanks (second
stage separation).
Demulsifier chemical dozed in oil manifold further promotes the breaking of
waterOil emulsion.

Surge tank (Second stage separation):
It is maintained at a lower pressure to stabilize crude i.e. to remove maximum of
associated gas from the crude oil.
Oil from surge tanks can be either pumped directly with MOL pumps or can be
diverted to third stage separators (Surge tank3).
Separated crude oil is pumped with CTP / MOL pumps to export trunk lines.
Separated Gas is diverted to Gas compression module after boosting the pressure
LP booster compressor.
Separated Water is diverted to Produced water conditioning Unit.

Gas Compression
Gas from Separators ,Surge Tanks and export gases if any from other process
platforms are compressed to about 90100 kg/cm2 pressure as per the field gas lift
requirement.
Normally Gas turbine driven Centrifugal compressors (PGCsProcess Gas
Compressors) are used.
Gases compressed in PGCs is dehydrated to prevent formation of GAS
HYDRATES. Gas hydrates are formed at low temperatures when moisture is
present in Hydrocarbon gases. These gas hydrates are ice like substance which
prevent the smooth flow or block the flow of gases in gas flow lines.

20


Gas Dehydration:
Compressed Gas is dehydrated in a Glycol contactor with Tri Ethylene
Glycol(TEG) as an absorbent for moisture from compressed gas.
Glycol contactor is bubble cap tray column with many bubble cap trays. TEG
flows counter current with compressed gas from the top of the column.
TEG coming in contact with compressed gas in the bubble cap trays selectively
absorbs the moisture from the gas and dehydrates it.
The dehydrated gas is sent to feed gas lift wells in priority basis and remaining to
export gas line.
The TEG rich in moisture is sent for reconcentration, converted to Lean glycol
and recycled back to contactor for dehydration.

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SUMMARY
The topics covered under the training are:
Introduction to oil and gas industry.
Basics about ONGCs oil and gas production systems.
Types of wells and platforms.
Mechanism of oil lifting and processing.
Designing and analysis of an oil platform.
Simulation of fluid flowlines.
Specifications regarding all the equipments of an oil
platform.
Calculation, review and analysis of facilities in platforms.
Study about construction of the platform.

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