18/9/2013 HAFIZ HARUN JAMIL

INTERNSHIP
REPORT

DHAKNI GAS PROCESSING PLANT

Submitted to | Sir Umar Maqbool Submitted by

HARUN JAMIL (EE103033)

ACKNOWLEDGEMENT

I would like to thanks my university authority to provide us a great chance of exploring the outer world and letting us know where we stand at present in the market. It was certainly a great experience for me to know the practical meaning of our engineering degree in the market. It comes out to be a great success and I hope that I will bring light to the title of my university MAJU.

PREFACE

They say "Experience is the best Teacher. Training at OGDCL proved to be an important milestone in our practical lives. I have gained knowledge of oil and gas industry and experience of process environment. This experience gave us an exposure to various procedures employed in oil and gas processing plants. The oil and gas processing plant does not involve a single process. It is a combination of several processes, from the arrival of raw fluid from well head to processed gas and partially processed oil, which is sent to Attock Refinery Limited (ARL). In fact during this short duration of 4 weeks I went through an extensive learning process. This report gives an idea of working methodologies employed in Dakhni Gas Processing Plant with instrumentation perspectives. For me this training was very informative and full of knowledge. This report is based on the study of areas that I have visited, and I have tried to describe briefly the operation and working of the concerning areas, according to my knowledge.

ABSTRACT
The brief and the short summary of my internship is that I enjoyed every bit and every second of the opportunity provided to me to gain as much knowledge as I can. The staff at Dhakni oil field was very supporting in terms of sharing their knowledge with the internees. They shared their ideas and also assigned me a task of inspecting the pressure level in different areas of the field and how do we control the level in these lines. It was kind of a good experience for me and with this I also got to know a little bit about line tracing in the field. So in my opinion, this is a very good opportunity for the students and they should grab it with both hands, which will help them in their future jobs in different areas.

Contents
INTRODUCTION ........................................................................................................................................... 12 1.1 HISTORY: ........................................................................................................................................... 12 1.2 EXISTING PLANT CAPACITY ............................................................................................................... 12 1.3 Process Description ........................................................................................................................... 12 1.4 PALNT BLOCK DIAGRAM ................................................................................................................... 13 2. ELECTRONICLY CONTROL EQUIPMENT ................................................................................................... 15 2.1 DCS (Distributed Control System) ..................................................................................................... 15 2.1.1 USES OF DCS............................................................................................................................... 15 2.1.2 APPLICATION OF DCS ................................................................................................................. 15 2.2 QCS (QUALITY CONTROL SYSTEM) .................................................................................................... 16 2.3 ACTUATORS AT DHAKNI OIL FIELD .................................................................................................... 16 2.4 PLC (programmable logic control) .................................................................................................... 17 2.4.1 Introduction ............................................................................................................................... 17 SUMMARY ................................................................................................................................................... 18

1
INTRODUCTION

INTRODUCTION
1.1 HISTORY:
Dakhni Gas Processing plant is situated in Tehsil Jand District Attock about 120 km north-west of Islamabad. It has been named after the geographical /territorial name of the land where the existing facility stands. It was the first major oil & gas processing facility set-up by OGDCL in 1983 by OGDCL. So far, 11 wells have been drilled out of which, 05 wells are producing wells. Upon evaluation of raw fluid, it was found that it contains 8-10 % H2S gas. Since H2S gas is a highly toxic, lethal and has very corrosive effect and is an environmental hazard, it was decided to install oil & gas sweetening facility and also to Recover marketable products e.g. LPG, Elemental Sulfur, NGL. It is the largest sour gas processing plant in Pakistan. Pakistani firm M/S ENAR in collaboration with M/S LUMMUS CREST of U.K. Major fabrication, erection and designed the plant. M/S HMC did the installation. In December 1989 the plant was commissioned and production was started.

1.2 EXISTING PLANT CAPACITY

GAS SWEETENING UNIT LPG RECOVERY UNIT SULPHUR RECOVERY UNIT NGL STABILIZATION = = = = 35 MMSCFD 20 M.TONS/D 71 M.TONS/D 1400 BBLS/D

1.3 Process Description

Sour gas and oil from wellhead is received at separators through gas gathering lines. In the feed treating system, the feed gas is first cooled or preheated, depending on the inlet temp. in the Inlet Gas Cooler/Heater to 105oF.The feed gas then enters into the Inlet Gas Separator, a horizontal three phase gas separator where feed is allow to expand, as a result condensate (oil and water) separates from the raw gas stream (Sour Gas). After separation, gas and oil are sent to their respective treatment units, water is sent to waste water disposal area. The condensate, which gets separated at the separator, is brought to condensate treatment unit where decreasing pressure and increasing temperature up to about 4500F strip off all the volatile hydrocarbons along with H2S. The stabilized crude is then sent to storage

tanks. The crude is pumped to the Meyal Terminal facility from where after metering, it is sent to Attock Refinery Limited (ARL) through pipeline.

1.4 PALNT BLOCK DIAGRAM

2
ELECTRONICLY CONTROL EQUIPMENT

2. ELECTRONICLY CONTROL EQUIPMENT

Main electronically controlled equipments used at Dhakni gas processing plant are DCS QCS ACTUATORS PLC RELAYS

2.1 DCS (Distributed Control System)

A distributed control system (DCS) refers to a control system usually of a manufacturing s, process or any kind of process, in which the controller elements are not central in location (like the brain) but are distributed throughout the system with each component sub-system controlled by one or more controllers. DCS (Distributed Control System) is a computerized control system used to control the production line in the industry. The entire system of controllers is connected by networks for communication and monitoring.

2.1.1 USES OF DCS

DCS is a very broad term used in a variety of industries, to monitor and control distributed equipment. Electrical power grids and electrical generation plants Water management systems Oil refining plants Chemical plants

2.1.2 APPLICATION OF DCS

Distributed control systems (DCSs) are dedicated systems used to control manufacturing processes that are continuous or batch-oriented, such as oil refining, petrochemicals, central station power generation, fertilizers, pharmaceuticals, food and beverage manufacturing, cement production, steelmaking, and papermaking. DCSs are connected to sensors and actuators and use set point control to control the flow of material through the plant. The most common example is a set point control loop consisting of a pressure sensor, controller, and control valve. Pressure or flow measurements are transmitted to the controller, usually through the aid of a signal conditioning input/output (I/O) device. When the measured variable reaches a certain point, the controller instructs a valve or actuation device to open or

close until the fluidic flow process reaches the desired set point. Large oil refineries have many thousands of I/O points and employ very large DCSs. Processes are not limited to fluidic flow through pipes, however, and can also include things like paper machines and their associated quality controls (see quality control system QCS), variable speed drives and motor control centers, cement kilns, mining operations, ore processing facilities, and many others. DCSs may employ one or more workstations and can be configured at the workstation or by an off-line personal computer. Local communication is handled by a control network with transmission over twisted pair, coaxial, or fiber optic cable. A server and/or applications processor may be included in the system for extra computational, data collection, and reporting capability.

2.2 QCS (QUALITY CONTROL SYSTEM)

A quality control system (QCS) refers to a system used to measure and control the quality of moving sheet processes on-line as in the paper produced by a paper machine. Generally, a control system is concerned with measurement and control of one or multiple properties in time in a single dimension. A QCS, on the other hand, is designed to continuously measure and control the material properties of the moving sheet in two dimensions: in the machine direction (MD) and the cross-machine direction (CD). The ultimate goal is maintaining a good and homogenous quality and meeting users' economic goals. QCS is used in the following process Paper Machines

2.3 ACTUATORS AT DHAKNI OIL FIELD

There are various actuators at Dhakni oil field but we are only going to discuss the following
A pneumatic actuator converts energy formed by compressed air at high pressure into either linear or rotary motion. Pneumatic energy is desirable for main engine controls because it can quickly respond in starting and stopping as the power source does not need to be stored in reserve for operation. An electric actuator is powered by motor that converts electrical energy to mechanical torque. The electrical energy is used to actuate equipment such as multi-turn valves. It is one of the cleanest and most readily available forms of actuator because it does not involve oil.

2.4 PLC (programmable logic control)

2.4.1 Introduction
A Programmable Logic Controller is a digital computer used for automation of electromechanical processes, such as control of machinery on factory. PLCs are

used in many industries and machines. Unlike general-purpose computers, the PLC is designed for multiple inputs and output arrangements, extended temperature ranges, immunity to electrical noise, and resistance to vibration and impact. Programs to control machine operation are typically stored in battery-backed-up or non-volatile memory. A PLC is an example of a hard
real time system since output results must be produced in response to input conditions within a limited time,

SUMMARY
In this intern ship I have learned a lot of things which are related to our professional life

experience. For instance how to interact with the outside people, punctuality, how to handle sudden problems, how to manage yourself away from the home. These are very important things which as a professional you know. The field which I belong to is BS (Electronic Engineering) which is very demanding in the industry todays time. The place where I work is OGDCL (Oil & Gas Development Company) in which there is a separate department for electronic engineers with the name of INSTRUMENT. This department covers all the electronic equipments which are used in the industry. Few of them which are of great importance are DCS (Distributed Control System), QCS (Quality Control System), ACTUATORS, PLCs, RELAYs, MICRO-CONTROLERS etc. I understand the basic functionality of these equipments. It is very helpful for me to see the daily life applications of these electronically control equipments, which I have studied only in my bo oks.