INTERNSHIP

REPORT
KANDHKOT GAS FIELD
CHEMMICAL
PREPARED ENGINEERING
BY: MUZZAMIL SHAHZAD STUDENT
MEHRAN UNIVERSITY OF ENGINEERING AND TECHNOLOGY
 Table of Contents

Contents
1. Preface.
2. Introduction to Kandhkot Gas Field Compression Station.
3. Utilities
Power Generation
Compressed Air Package
Inert gas Package
Raw Water System
4. Process Description
Slug Catcher, Inlet Gas Filters, Inlet and Exit Headers and Gas Compression.
Condensate Recovery.
Fuel Gas Conditioning.
Flare System.
Corrosion Injection.
 1)Preface

This report is written in order to summarize the activities that I have performed and learnt throughout my Internship. The
tenure of this internship was of 4 weeks. The Kandhkot Gas Field has two operational units and tenure was divided in to 2
weeks for each unit, namely the Kandhkot Field Gas Compression Station and Dehydration Unit. The first half of the
Internship covers all the understanding of the compression process of the Natural gas in the Kandhkot Field Gas
Compression Station (KFGCS). The second half covers all the operations being carried out in the Dehydration Unit (DHU).
 2)Introduction to Kandhkot Gas Field

Kandhkot Gas Field located about 400 km north-east of Karachi at an elevation of 70 meters AMSL is owned and
operated by Pakistan Petroleum Limited (PPL). The Field has three gas bearing domes namely Southeast Dome,
Northeast Dome and West Dome. Each dome consists of three gas reservoirs in Habib Rahi Limestone (HRL), Sui Upper
Limestone (SUL) and Sui Main Limestone (SML) formations, The West Dome is producing from SML reservoir, North East
Dome from SML and SUL reservoirs and the South East Dome is producing from all the three reservoirs. Due to
continuing production since 1987, the field is now entering the depletion phase and it will not be possible to deliver the gas
to the customer at the delivery pressure (about 700 psia) by 2007/2008. Hence, Gas Compression Facility was required
(by 2008) to cater for the continuing decline in field pressure. The design, engineering, procurement and construction was
awarded to China Petroleum Engineering and Construction (Group) Corporation (CPECC). The Front End Engineering
Design (FEED) undertaken by the local Clough Engineering and Intergraded Solutions.

The Kandhkot Gas Field came into operation on 2nd of December 2010. KFGCS was designed to deliver pressure at the
delivery point (to customers), which is downstream of the DHU, will be 4828KPag (700 psia). The Kandhkot Gas Field has
three turbo compressors (SIEMENS SGT400 Gas turbine driven, 13.4MW), and three gas generators (CUMMIN 1.75
MW). They are backed up by Emergency generator (CUMMIN Diesel Engine driven-565kW).KFGCS has 02 air
compressors for instrument and plant air at 700kPag. 02 Insert gas packages installed for nitrogen generation for process
gas compressor sealing and inert gas for nullifying hydrocarbon effects before handing over for maintenance jobs at
700kPag.Two centrifugal pumps (diesel engine driven) of capacity 454.2m3 /hr for feeding 11 hydrants with monitors and
04 fire reel hose stations on Fire water header at a pressure of 1200kPag.Two centrifugal jockey pumps (electric motor
driven) installed to maintain fire water header pressure on 950 to 1050kPag on auto mode. KFGCS also has 02 water
treatment packages with a capacity of 10m3 / day each to provide potable water.
 3)Utilities
Power Generation
Purpose: It provides electricity for the entire gas compression plant in order to operate the process equipment and other
utilities inside the plant.

Power Generation: For the purpose of Power Generation 3 CUMMINS gas generators are available 2 in operation, 1 on
standby and 1 Diesel Generator is used as backup in situations of maintenance of Generators or any other problematic
situations. Each Gas Generator has a Rated Power of 1.75 MW and the Diesel Generator has a power of 565kW. The
generators have accessories of Lube oil pump, lube oil tank, fans, cooling system involving plate and frame heat
exchangers and a monitor screen for operating the generator.

The lube oil pump circulates the lube oil inside the generators cylinder piston assembly and splashes it to other important
parts of the generator such as connecting rod, crank shaft and throughout the casing of the generator. The purpose of the
lube oil is to provide necessary lubrication between the moving parts and act as a Heat Transfer agent.

Note: The presence of heaters inside the generators sump increases the temperature of the lube oil up to 40C before the
generators have started.

The Generator during its operation increases the temperature of the lube oil up to 80C which is normalized for the
operation by Heat Exchange System. A small plate and frame heat exchanger LT Low Temperature is used for the
normalizing the temperature of the combustion chamber and the larger one HT and High Temperature for the cylinder
piston assembly installed. The cooling water is obtained by cooling towers 2 in operation 1 on standby. The water from
heater exchangers is recirculated back to the cooling towers and this cycle of power generation along with the cooling
system continues.

Compressed Air System

Purpose: Compress Air System is used to provide compressed air for operating Pneumatic Equipment and Plant air is
used for cleaning jobs etc.

Equipment and Process Description: Air from the atmosphere followed by an air filter allows the air to enter into the
Screw Compressor. It has two lobes in which the air along with oil enters into the compressor. The compression of the air
increases its temperature.

Note: The purpose of the oil is to lubricate the lobes, heat transfer and also the oil absorbs the solid particles coming
along with the air.

As the air is being compressed its temperature and pressure is rising continuously to around 80C or even more, the
increased temperature is cooled down by an Air cooler.

Note: Cooler removes the moisture from the compressed air.

The compressed air is now mixed with oil (due to the oil present in the compressor). The Air/Oil mix is separated in a Two-
phase separator.
Working Principles Involved: The separator has a receiver or separator tank with specially designed internals, a two-
stage, coalescing-type separator element and provision for return of the separated fluid back to the compressor. The
Air/Oil mix flows on to the walls of the separator oil being heavier flows onto the circumference of the separator vessel and
falls on the receiver sump (bottom). The air stream now a fine mist flows through a separator element which is a
concentric cylindrical sections of closely packed fibres, each held in steel mesh. It is flanged mounted at the receiver
outlet cover.

Oil is drawn back into the compressor inlet through the filter screen and orifice fitting installed in the separator scavenge
line which has a scavenge tube. The purpose of the scavenge tube is to consistently draw oil accumulated at the bottom
of the separator by making use of differential pressure.

The air free from oil, enters into the Dryers one in operation and other in regeneration.

Working Principle Involved: The dryers involved are packed bed of different adsorbents having the ability to absorb the
water vapours from the compressed air by a Mass transfer process called as Adsorption. The adsorption is carried out
by a bed of Carbon molecular sieves (CMS) which have minute pores that absorbs the moisture from the air allowing it to
be dried. The dried air up to 99.5% is stored as Instrumentation air and Plant air in storage vessels.

Inert Gas Package

Purpose: To provide Nitrogen gas for compressors secondary seal, Buffer gas and maintenance purging on the
compressor facility.

Equipment and Process Description:

1) Air compressor (AC-101/201)

2) Dryer (D-101/201)

3) Pressure Swing Adsorber (PSA 101/201)

4) Booster Compressor (BC-101/201)

2 x 100% Nitrogen generator units each of capacity of 427m3/h with 99.5 purity. It operates in the same manner as the
Compress Air Package. The pressure of the Nitrogen receiver is let down to the user pressure using two parallel PCV-
5201 and 5211 and Nitrogen for utility consumption is used at the full Nitrogen receiver pressure until the receiver falls to
900kPag in each PCV-5201 will close to conserve Nitrogen for purposes. The inert gas system is to supply 99.5% pure
Nitrogen for the compressor seal buffer gas and separator.

Raw Water System

Purpose: Raw Water System provides water in case of fire, water for Plant usage and portable water. The system
includes:

1) Fire Water System

2) Service Water

3) Portable Water
Fire Water System: For this purpose two submersible Centrifugal pumps are used to bore water from the bore holes 2
x100% (P-5501 A/B), one operating and the other on standby. The water from the bore holes enter into the bore water
filters (V-5502 A/B) filters the liquid by separating 100% of the 20 micron particles. The water pumped is stored in a fire
water storage (T-5503) of capacity 2800m3 and is capable enough for 6 hour firefighting with 454.2m3/h volume of water
per hour. In addition there are two jockey pumps (p-5504 A/B) to keep the fire water lines pressurized when the Fire water
pumps are not in service and to supply makeup water for line pressure to minor leakages their capacity is 4.5m3/h and
discharge pressure of 1000kPag.

Service and Portable Water System: Supplied from fire water tank and the usage is for workshop, Utilities area, Fuel
gas skid, Compressor area, Cooling Tower area, Condensate recovery, Inlet filters and different locations within the
vicinity. The pumps are 15m3/h and Pressure discharge of 500kPag. Portable water system gets its water from the (Z-
5600A/B) mostly in use for chemical injection, administration building, safety showers etc. The Pumps have a capacity of
1.1m3/h with a discharge pressure of 932kPag.
 4)Process Description
Slug Catcher, Inlet Gas Filters, Inlet and Exit Headers and Compression Process
Purpose: To enhance the composition of the fuel gas by removing moisture, particulate solids or any other undue liquid.

Equipment and Process Description:

Slug Catcher (V-4000), Inlet gas filters (V-1000A/B/C) and Phase 1 Suction Scrubber (V-1000A/B/C), Phase 1 Inter stage
suction scrubber (V-1001A/B/C) and Phase 1 discharge scrubber (V-1002A/B/C).

The gas from the well is directed to the Slug Catcher where the condensate settles down under the action of gravity the
gas is now moves towards the gas inlet filters (V-3000A/B/C), this is a Gas cartridge filter fitted with cartridges for here the
gas is filtered for any of the particulate solids that may enter along with the gas and are removed, the condensate settles
down and the gas moves to the inlet headers from where it goes into the 1st stage suction scrubber (V-1000A) here the
gas the is further removed for any of the mist that may have entered along with the gas through after being passed
through the meshed pads present inside the scrubbers. The gas from this scrubbers goes into the compressor for the 1st
stage compression and after being compressed it goes it comes into the cooler in order to get cooled as the compression
causes increase in temperature. The cooled gas from the coolers (X-1001A/B/C) and (X-2001A/B/C) enters into the inter
stage suction scrubber (V-1001A/B/C) in order to remove any sort of moisture that may have been formed due to the
cooling of the gas. The gas from (V-1001A/B/C) goes into the compressor for 2nd stage compression. The compressed
gas again goes into the coolers (X-1002A/B/C) (X-2002A/B/C) and finally into the 1st phase discharge scrubber for further
removal of moisture/mist from the process gas before discharging it back to the Dehydration Plant for supply.

Note: The compressor is a turbine operated multistage compression system having 4 impellers for 1st stage of
compression and 3 impellers for 2nd stage compression respectively. Turbines are of 13.7 MW each to run the
compressors for the compression purpose.

Condensate Recovery System

Purpose: The purpose of the condensate recovery to recover any sort of combustibles that may have entered into the
gas.

Equipment and Process Description:

1) Condensate from slug catcher flash vessel (V-5701).

2) Rest of the Facility to (V-5703).

Both the vessels have meshed pads for entrained liquids removal and the liquid lines of both the vessels contain vortex
breakers. Deflecting plates are also provided in each vessel as inlet device. The slug catcher flash vessel (V-5701)
operates at 414kPag. The condensate flash vessel (V-5702) acts as Knock out drum for the condensate flashed by
various sources through separate Level control valves (LVCs). 2 Condensate pumps (P-5703A/B) for pumping the
condensate to the condensate separation tank the discharge 99kPag vapors are sent to the flare system through manual
block valve.
Fuel gas Conditioning
Purpose: The purpose for the installation of fuel gas conditioning system is to ensure mist free fuel gas to the gas turbine
at required Pressure and Temperature of 2480-3450kPag and 60C.The fuel gas system is designed for a flow rate of
23.7MMscfd.

Process Equipment and Descriptions:

1) PCV-5102 and 5103 set at 3350 and 3450kPag.

2) Fuel gas KO drum (V-5101): The purpose of Fuel gas KO drum is to remove the water vapours from the Fuel gas.

3) Fuel Gas Filters (V-5103 A/B-394kW) each: Gas filters ensure that no traces of particulate solids are left in the fuel gas
before letting it enter into either Turbine or the Generator.

Sources of Fuel Gas: There are three sources of Fuel gas each having a shutdown Valve in order to shutoff supply from
other two sources while gas is in use from any one of the sources.

Downstream of DHU for normal operation (shut down valve YZV-5101A)

Compressor suction header for start-up purposes (shut down valve YZV-5100)

Sales gas pipeline (buy back) for start-up purposes (shut down valve YZV-5101B)

The fuel gas either from Dehydration Unit or from sales gas enters into the fuel gas KO drum which removes all the
water/condensate from the tank. At this point a stream from the KO drum enters into the heaters E-5102/B-394kW each
where the Gas is heated up to its dew point in order to make it saturated finally this gas is filtered through Gas filters (V-
5103A/B) and enters into the individual gas turbines TUCO-A/B/C and are from the heater the Gas is also fed to the
GENSETS area to provide fuel to the Generators.

Flare System
Purpose: Flare Systems are installed so that any leakages or excess gas inside the pipe streams of excessively
pressurized gas that could be difficult to handle are routed through highly pressure protection devices and is collected in a
400mm flare header.

Equipment and Process Description:

1) Flare knock out drum (V-5301)

2) Flare tip package

3) Flare stack

4) Flare ignition system

The pressure of any sort of liquid in the flare knock out drum will cause its pumps (P-5302 A/B) under vessel liquids level
control to the condensate flash vessel to the condensate flash vessel (V-5702).The flare drum pumps are centrifugal type
having discharge pressure of 500kPag. The Flare tip package is installed to dispose of hydrocarbon gas from the gas
compression facility and its purpose is to provide liquid free gas for burning. Flare stack is designed at such a high height
where the people outside the plant boundary are not exposed to any of the radiations. The burning of the flame is
accomplished through a reliable electronic ignition system.

Corrosion Inhibiting System

Purpose: Corrosion may be occurred by water, oxygen, hydrogen sulphide or through Carbon dioxide in a gas processing
facility. Problems may occur as dry corrosion due to the exposure of hot gas to the metals which is a common case or
could be wet corrosion by the electrochemical reaction of the metal in the presence of an electrolyte mostly water.

Equipment and description:

1) Form an invisible layer of inhibitor few molecules thick on the metal to be protected.

2) Forms a visible bulky layer of precipitates which protects the metal from further attack.

A Corrosion inhibiting package has the following equipment. Pumps, Tanks, Pressure Gauges, Pressure Transmitters,
Level Gauges, Piping valves, Electric Parts and Control panels. In order to Inhibit corrosion a Chemical Mix is prepared
and process goes as follow:

Three Tanks for the preparation of corrosion inhibiting are involved:

1) Chemical storage tank ( 1m3 volume ) is used to store pure corrosion inhibitor.

2) Calibration tank ( 0.0504m3 volume) is used to calibrate the corrosion inhibitor for making the solution.

3) Corrosion inhibitor solution tank (5.04m3 volume) is used to mix corrosion inhibitor and water.

A portable barrel pump driven by an electric motor is used to decant the corrosion inhibitor from the chemical drum into
the chemical storage tank 1m3 volume. The corrosion inhibitor is now filled in calibration tank (0.0504m3 volume) which is
1% of the chemical storage solution tank (5.04m3 volume) because we require a final concentration of 1% v/v of water-
corrosion inhibitor mix. Therefore the calibration tank is sized 1% of the corrosion inhibiting solution tank.