04 WEEKS INTERNSHIP REPORT AUG-21

AT BOBI OIL COMPLEX

PREPARED BY TARIQ JAVED
UNIVERSITY : MUET,JAMSHORO

I/C OF PRODUCTION FM OF BOC

CONTENTS
1. INTRODUCTION
2. HSEQ
3. HAZARD AND SAFETY RELATED TO O&G INDUSTRY
4. PROCESSING
5. LABORATORY
6. ELECTRICAL
7. INSTRUMENT
8. MARKETING
9. VISIT OF WELL SITE
 DST
 PLUG BRIDGE
 CHRISTMAS TREE
 INTRODUCTION:

Oil industry is a lifeline for an economy. It is a world of oil exploration, oil

refining and oil marketing. Pakistan knew the importance of this industry
in order to boost up its economy. Therefore the government of Pakistan
established OGDCL in 1961. OGDCL is the leading firm providing a major
portion of total consumption, saving Pakistan from imports and
contributing to economy by paying different charges to the government
and therefore the then government established several oil fields and Bobi
oil complex is one of them.

The Bobi field is located at 25km in the south of district Sanghar of Sindh
province. This field is a part of second OGDCL project funded by Asian
bank amounting $52 million from which, about $20.1 million were
allocated for development of Bobi Oil Complex. The first well at Bobi was
drilled in 1988 as condensate producer. However, 8 wells were drilled by
the year 1991. Condensate functioning facilities along with gas recycling
system was installed and field was declared as oil complex in 2002. Bobi
oil field consist of two types of reservoirs i.e gas condensate (from short
string) and volatile (from long string) and the production was nearly
about 2800bpd. . Extended production testing was carried out on Bobi
wells in order to obtain reservoir parameters and estimation of
reserves. The following wells are producing two types of fluids i.e gas
condensate and volatile oil through dual string production from each
well.
The following chart show the wells which has been produced so far. Most
of the wells have been dried however, some of the wells are still being
produced such as Bobi-3 and Chak Din-5. The total production from these
two wells is 430 bpd of crude oil, 5.3 mmcf of gas and 16 metric of LPG is
being produced per day at BOC.

Sr.# Discovered Discovery Distance

fields name Year (km)
01 Bobi Oil Field. 1988 06
02 Dhamraki # 01 1990 20
03 Chak Din – 5 1995 57
04 Chak Din – 5 1996 52
(South)
05 Palli Oil Field 1995 25
06 Jakhrao # 01 1998 50
07 Bobi # 09(LS) 2003 01
08 Bobi # 09(SS) 2002 01
09 Mithrao 2005 48
 HEALTH, SAFETY, ENVIRONMENT AND
QUALITY(HSEQ)

OGDCL has developed and implemented the HSEQ management system

to enhance its HSEQ performance and eventually to reduce the impact of
its operations and activities on the nearby surrounding. The HSEQ
management system complies with the International standard ISO
14001:2004 and OHSAS 18001:1999 and its scope cover the production
field and plant functions.
In carrying out all its activities, OGDCL ensures the welfare of
communities it operates in the protection of ecosystems and safety of its
workforce.
OGDCL believes in good HSEQ performance that can contribute to
business success. OGDCL believes that responsibilities for Health, Safety,
Environment and Quality cannot be delegated, it is a shared responsibility
across the company.
OGDCL ensures the safety of not solely of its assets but also its
employees. To lookout the safety of Bobi Oil Complex(BOC) , there is also
a HSEQ section which is prepared and alert 24/7 to maintain the safety of
the field and incase of any emergency, the well trained team of HSEQ
section tackles the situations and carries out operations accordingly.
HSEQ Equipments:
 PPE’S or personal protective equipments include the Helmet and safety
shoe which are for our own safety. While working in Lab and before
touching any hot machinery or object the worker should wear the
gloves.
 FIRE SUIT is a heat resistive suit which saves a person from burning.
 SELF CONTACT BREATHING is a mask which protects the person, if a
person is having a difficulty in breathing. It contain cylinder having
oxygen inside. It has max pressure 200 psi which lasts for 40 mints
continuously.
 Water storage tanks:
There are two tanks both have capacity of 8500 barrels which are can be
used for protection of plant in case of any emergency. All pipes and
safety valves are in red color which means that these are used for safety
of plant and safety water comes from fire storage tanks.

 FIRE EXTINGUISHER are of several types such as DCP,CO2, and AFFF

which are used to extinguish different types of fire as mentioned in the
chart below.
 HAZARDS AND SAFETY RELATED TO OIL
AND GAS INDUSTRY

Hazards in oil and gas industry can be classified into two broad
categories
1) Safety and Injured hazard
 Fire and Explosion occurs due to the presence of highly
combustible hydrocarbons or due to short circuit or some
problem in machines. One should make sure that there is
limited or very little supply of oxygen where such hydrocarbons
are found.
 Slips, Trips and Fall occurs due to the uneven surfaces and lack
of proper equipment. To avoid this proper protective
equipment should be used.
2) Health and Illness hazard
Workers in oil and gas industry are generally susceptible to the
following health and illness hazard.
 Chemical Hazard includes toxicity, corrosiveness, irritation and
sensitizing substances.
 Physical Hazard includes noise, vibration, radiation and
extreme temperature.
 Biological Hazard includes the viruses and infections.

There is always a Management system in any Oil and Gas industry

whose aim is to identify and assess safety and health hazards existing
at the workplace and to define the appropriate control.
 PROCESSING

Following are the various units which are part of processing.

 Gathering area.
 Separation unit.
 Compression unit.
 Refrigeration unit
 Storage area
 GATHERING AREA:-
In this area all the well lines are connected to a single line (header) that
line runs towards separation unit.

SEPERATION UNIT:-

This Unit has three separators which are as follow.

 Test separator
 HP separator
 LP separator

INTERNAL WORKING PROCEDURE:-

The mixed phase enters into the separator from the top where the
momentum of the incoming fluid is being broken up by the deflector
plate so that the condensate and water achieve their terminal velocity
and settle down due to density difference. The gas leaves from the top
after passing through the demister pad, which traps the maximum water
contents from the gas; water is drained out from the bottom of the
separator and is sent to the water flash vessel (V-111).while the
condensate is sent to the heat exchanger E112 A/B.
HP SEPARATOR (V -100)
Due to the excessive demand of the methane, gas from the HP separator V-100
is directly lined up with the re-injection compression system. The plant is
designed for low capacity gas stream is also lined up with the line of knockout
vessel V-105, through a tie in valve, however the gas from the test separator is
also lined up towards the V-105.Only the TEST separator and LP separator is
induced in the plant for processing. The condensate is being separated through
a weir inside separator by maintaining the level of water with level control
valve. Condensate is sent to the crude stabilization unit and produced water is
sent to the produced water vessel.
TEST SEPARATOR (200 –FA-002)
The condensate and water are treated same as that of the HP separator. the
gas stream is divided into the two ,one is lined up with the LP separator and
the second is directed toward the feed gas compressor K-103 after passing
through the feed gas compressor suction knock out drum V-105 at 670 psi and
80˚ F. Compressor K-103 discharge the compressed gas at 765 psi .This
compression cause increase in temperature of the gas up to 110 ˚F .The gas is
subjected to cool at feed gas compressor discharge cooler E-104B.The cooling
is carried out by the jacket water which is also cooled by induced draft. This
compression and cooling causes the heavier to knock out in the vessel V-
107.Condensate level of V-105 is maintained up to 15 %
LP SEPARATOR (200 FA-001)
Like HP and TEST separator, the produced water and condensate are treated
the same. The gas stream is directed towards the HP compressor K-102A/B
after passing through HP compressor suction knock out drum V-106 at 220 psi
and 100 ˚F. Compressor K-102A/B discharge the compressed gas at 765 psi and
110 ˚F. The compressed hot gas is cooled at HP compressor discharge cooler E-
103B/D. This cooling is also carried by jacket water cooler E-103 C/D. this
stream is also sent to V-107 to knock out the heavier components. Condensate
level of V-107 is maintained up to 15 %
 COMPRESSION UNIT:-

There are basically five compressors which are used for compressing the
gases upto 750psi, their names and functions are enlisted below.

1. LP COMPRESSOR K-100:-
Gas from V-102 ,being hot ,is subjected to cool first in the LP compressor
suction cooler E-101B and then directed to the LP compressor K-100 ,by
passing it through the LP compressor suction Knock out drum V-103 at 8 psi
and 100 ˚F. Compressor K-100 discharge the gas at 75 psi and 160 ˚F .The gas is
then sent to the LP compressor discharge cooler E-101A,though,the gas from
vessel V-101 is also lined up with the LP compressor discharge line. the cooling
of the gas knocks out the heavier mainly LPG in the vessel V-104 which is also
called MP compressor suction drum at 70 psi and 80 ˚F .condensate level inV-
103 andV-104 is maintained at 20 %.

2. MP COMPRESSOR K-101:-
Medium pressure or MP compressor takes the suction from V-104 at 70 psi
and compresses it up to 225 psi. This compression increase the temperature
up to 160 ˚F .which is subjected to cool by MP compressor discharge cooler
and then sent to V-106 i.e. HP compressor suction drum.

3. HP COMPRESSOR A/B (K-102/103):-

The discharge of MP compressor is sent to HP compressor suction drum i.e. V-
106. This drum is also carrying the LP separator gas. As it has been discussed
that the HP compressor take the suction of this gas from V-106 at 220 psi and
100 ˚F and discharge at 780 psi at 200 ˚F and then cooled to maintain the
temperature up to 110˚F .This gas is now lined up with V-107.
4.FEED GAS COMPRESSOR K-104.
Gas coming from HP Separator, V-100 is compressed in feed Gas Compressor,
K-103. The outlet steam of both K-102 and K-103 are mixed before entering in
HP Compressor Discharge Cooler, E-104. The compressor discharges the gases
up to 700-750 psi.
5. RE-INJECTION COMPRESSOR:-
Sale gas exit from Gas-Gas exchanger E-105A/B at 75 F and the pressure is
controlled by the PCV-160 up to 700 psi, and the remain pressure is blow out
towards the gas flare header. The sale gas from E-105 is combined with the gas
from V -100 and it is then feed to the re-injection compressors RIC A/B. this is
three stage compressor operated by gas engine.(Waukesha Gas Engine,L57GL)
Though all the engines of the plant i.e. (Engine of RIC, AJAX, Package
compressor and CAT generator) is run by the plant gas feed from the fuel gas
drum V-300. RIC discharge the sale gas at 2500 psi and 60 ˚F .Gas flow rate and
pressure is maintained by using choke valve.

REFRIGERATION UNIT:-
It works on vapor Compression cycle. The propane is used as a refrigerant ,it
become the suction of the k700 screw type oil flooded compressor (wooden
Compressor) which is driven by Waukesha Gas engine (P48GL) ,The inlet
temperature of Refrigerant is 20C and pressure 35 psi where the propane is
compressed and discharged at pressure170 psi and temperature 60 C then it
enters in to V700 oil separator where the oil separated from propane because
the oil is used for lubrication of K700 screw type oil flooded compressor then it
enters in to condenser E71A./B at temperature 60C and pressure 190 psi
where the water showered ,(there are three blowers that are also installed in
condenser to cool down the water) on tubes of condenser in which propane is
present, .The outlet of the condenser E71A/B passes through Joule Thomson
valve at temperature 24C and pressure 190 psi then the temperature
decreased at -5C and pressure also, then it enters into the chiller ,extracts
heat from the gases, and gets changed into vapor .
STORAGE UNIT:-
After the extraction of condensate from feed condensate is passed to storage
area and from storage area it is loaded into browser after the proper
inspection of bowsers condition such as leakage or puncture of tire.These
bowsers then transfer condensate to other companies i.e Refinery for further
purification. LPG which is the mixture of propane & butane is also lined-up
towards bullet area(storage area of LPG) from bullet area it is loaded in
bowsers and given to other users.

LABORATORY

For maintaining the quality of LPG and CONDENSATE a QEC (quality

enhancement cell) was opened at BOC which delivers the best
product to their customers and therefore after every 3 hours
sample of LPG and Condensate is being checked at laboratory with
the aid of several tests.
Following machines are used for different tests.
1 -Centrifuge machine: this machine is used for to check the
suspended particles in condensate.
2 Hydro-meter: This is used to determine the observed specific
gravity.
3 -Spectrophoto meter: it is used to check the suspended particles
in water e.g ( Ca, Mg, Ar, Fe).
4 -Basic sediment and water (BS&W) is a both a technical
specification of certain impurities in crude oil and the method for
measuring it. ... The residual content of these unwanted impurities
is measured as BS&W.
5 -PH meter: it is used to check the power of hydrogen in water.
6 -BOD-incubator: ( biological oxygen demand ) it is used to check
the level of bacteria in water, that level defines that either water is
useful or harmful for our lands.
7 -Turbid meter: it is used to check the impurity of water.
8- Salt analyzer: it is used to check that how much salt is present in
our condensate.
WATER ANALYSIS TEST:-
1) PH In this test we determine the power of Hydrogen generally known
as PH. If the PH is <7 then the water is acidic. If the PH is >7 then the
water is basic. In case of exact 7 the water is neutral.
2 TDS In general, the total dissolved solids concentration is the sum of the
cations (positively charged) and anions (negatively charged) ions in the
water. Therefore, the total dissolved solids test is used as an indicator
test to determine the general quality of the water.

CONDENSARE ANALYSIS TEST:-

1)Salt Analysis Test(PTB) This test is done with the help of titration by
adding Xylene and mixture of alcohol. After some calculation we
determine the amount of salt with the help of Chart
2) RVP is used to characterize the volatility of gasolines and condensate.
The absolute pressure at 100 °F (37.8 °C) in the container is the RVP for
the mixture. Since a portion of the liquid has been vaporized to fill the
vapor space, the liquid has lost some of the lighter components.
3)Basic sediment and water (BS&W) is a both a technical specification of
certain impurities in crude oil and the method for measuring it. The
residual content of these unwanted impurities is measured as BS&W .
4) API Gravity it is basically a formula which decides the worth of crude
oil. API=141.5/(sp . gravity )−131.5 .

LPG ANALYSIS TEST:-

1)Specific Gravity is the relative density of LPG and water which is about
0.495 at 25 °C and it is measured with the help of hydrometer.
2 Residue(weathering & centrifuge) the sample of LPG is collected in the
weathering tube while in centrifuging the sample is being rotated at the
assigned RPM and in the end the impurities are settle down at the bottom
 ELECTRICAL

Anywhere in the world the electricity has become the necessity of

life. Likewise, most of the machineries in BOC are operated on
electricity and to provide the electricity various generators are used.
POWER GENERATION:-
Currently two generators of caterpillar having capacity of 480kW are
being used at BOC which means that the current generation at BOC is
960 kW, the transmission of this power is through underground
cables/wires.

Quantity Name Type Capacity

02 Caterpillar Gas operated 480 KW
02 Cummins Gas operated 380 KW
01 Siemens Diesel 280 kw
operated

LOAD DESCRIPTION:-
Installed Load 1450kW
Peak Load 500kW
Summer Load 400kW
Current Load 350kW
Winter Load 250kW
Beside generators the following chart gives details about the
machineries which are being used at BOC.
 INSTRUEMENTS

In order to take the continuous measurements of temperature, flow,

pressure, level and other physical quantities BOC uses different
electronic as well as pneumatic meters (Gauges).
Following are the main systems are being used for measurement at BOC.
1- SCADA Telemetry System.

2 -PLC System.

3 -Simple gauges.

4 -calibrating instruments.

1- SCADA Telemetry System:

In order to measure the differential pressure, temperature, static

pressure, flow rate, moist, energy flow rate, volume of gas, energy in gas
Scada telemetry system is installed at BOC. This system is formed by
making metering station at 0 point which is 38 km away from BOC and
receiver at BOC and transmitter at 0 point. The communication is carried
out by using a free band (ISM BAND 5.1 GHz).
Differential Pressure is measured by using senior orifice assembly,
Moist of Gas is measured by using Moisture analyzer. Temperature and
Static pressure is measured by other Gauges. Continuous values of (DP,
SP, T, ENERGY RATE, VOLUME) of gas is measured by gauges and
measured data is sent to flow computer, Flow computer store the data
and also send the data to transmitter and transmitter sent the data to
receiver by using TCP/IP on ISM band (5.1 GHz), data is received by
receiver at BOC and data is sent to computer at control room data is
displayed on computer by using Wonder ware software.

Data received by computer is :

Differential pressure = 24.111
Temperature = 78.280
SP (Static Pressure) = 707.162
Flow rate = 15.212.
BTU = 1168.836 Btu/hr.
CO2 = 3.491.
Moist = 1.674 lbs.
Energy flow rate = 17872.121 MMBTU/hr
Today’s energy = 1365.636
Today’s volume = 14.7542
Yesterday Energy = 14.7542 MMBTU
Yesterday Volume = 17193.455
Charge Voltage = 14.135
Battery Voltage = 15.3207
Supply to SCADA telemetry system is given by Solar panel.
2 PLC System:
On following devices PLC (Programmable logic Controller) are used
1 Refrigeration package
2 Hot oil Furnace.
3 RIC, AJAX Compressors = Control panel.
4 Master Control panel = control room
5 Rose mount Pressure transmitter = (Air signal to electronic signals)
6 Controllers = (pressure, level, temperature and Flow controls )
7 Control Valves = (TCV, FCV, PCV, LCV )

8 Convertors = converts air signal to electronic signal (P to I). electronic

signal to pneumatic signal (I to P).

3 Simple Gauges:
1 For temperature:
Measurement we have used
Thermo couple, RTD (Resistance temperature detector), Bimetallic
Thermometer, Mercury Thermometer.
2 For pressure :

For measuring the pressure we use Mono Meters, Bourdon tube,

Diaphragm gauge (for low pressure), Bellow gauges (for very low
pressure changes).

3 For flow:
For measuring the flow we have used velocity flow meter, PD flow
meter, differential pressure flow meter, variable flow meter.

4 For level:
Level controller: It is used to control the level of liquid in any vessel.
For level measurement we have used glass level gauges.
 4 -Calibrating Tools & Devices:
These devices are used to calibrate automation instrument of level, flow,
temperature and pressure loops with integrity test of said loops with
controllers set point. Such as (psv, mechanical valve, controllers and
other devices ).

Test Bench & calibrators.

 PSV Test bench (UNI Grand TS15 make Germany): To calibrate the
pressure safety valve as per desired pressure with universal safety
standard
 pneumatic calibrator (Wika) make USA: to calibrate the pressure
device such as pressure switch, pressure transmitter, pressure control
valve

MARKETING

Not only in Oil and Gas Industry but in any industry of the world if you
don’t do proper marketing to your products, you cannot sell your
products to mass level or up-to the mark. Hence marketing plays a role
of backbone for any industry. Thus, to deliver its product accurately and
timely a marketing section is working in BOC which makes sure to satisfy
their clients. 4.00 mcf of gas is given to SSGC. 430 bpd is produced and
16 metric ton of LPG is produced which is given to different companies
such as POL, Parco, Foundation and so on.
 VISITING THE WELL SITE

I visited the well Mithari#1 which Is located near to Chundko,Sukkur Sindh. The
well was first produced in 2014 but due to more production of sand the well
was abandoned temporarily and then later in 2021 the well was re-produced.
During my stay at well the following thing came under my observation.

DRILL STEM TESTING(DST)

Drill stem testing is a procedure for testing a well formation with the drill string
in the hole, the test was conducted by CNLC . It determines the fluid content of
a reservoir and its ability to produce. This test can be performed in both open
and cased-hole environment. When drilling operation has been completed, it is
important to determine whether to move on the next phase for production.
Formation test ascertain if there are enough hydrocarbons to produce from
the well, as it provides the important information to design the well
completion and production facilities. Drill stem testing is one of the various
methods for formation testing. In drill stem test the drill bit is removed from
the drill string and a drill stem testing tool assembly is attached. It is then
lowered all the way to the formation and activated, measuring the flow of oil
or gas. The amounts of hydrocarbons that flow into the drill string during the
test and recorded pressure are used to judge the production potential of the
formation.

We perform DST to check:

 Reservoir/Pore/Formation Pressure
 Permeability
 Productive Capacity
 Depletion or Drawdown
 Effect of Removal of Reservoir Fluids
 Well bore damage
Procedure To Perform DST
 The Drill Stem Testing Assembly is assembled and attached to the drill
string.
 The drill string along with the Drill Stem Testing Assembly is then
lowered into the bore hole.
 After reaching the desired depth the packers and the pores are
activated.
 After this flow in and shut in periods are started.
 After the last shut in period the pressure is equalize and the packers are
released to trip out the drill string and tool.
 After reaching the surface the recorded data is analyzed with the help of
guages and conclusions are made.

Conclusion
A drill stem test (DST) is a procedure for isolating the target zone and testing
the pressure, permeability and productive capacity of a reservoir. This test is
an important way of establishing whether a well has found a commercial
hydrocarbon reservoir.

DST TOOL COMPONENT:-

 RETRIEVABLE BRIDGE PLUG

It is a down-hole tool, composed primarily of slips, a plug mandrel and

a rubber sealing element, that is run and set in the casing to isolate a
lower zone with the help of packer while an upper section is being
tested or cemented, the operation was conducted by the ETS(Eastern
Testing Service). In addition, a type of plug is used to seal off a well
temporarily while the wellhead is removed. It may be run and set on
wire-line using a baker. It may also be run on tubing or endless tubing
using a Hydraulic Setting Tool.
It is double acting slips securely anchor the bridge plug against the
pressure differentials from above or below. The three element pack
off design ensures reliable sealing at high pressures and temperatures.
This unique equalizing valve design allows any pressure differential to
be equalized before the retrieving head is latched on the plug. This
feature is especially advantageous when retrieving it on endless
tubing.

Procedure To Perform the operation:-

 The plug is connected to the wire-line and run to the required setting
depth where it has to be set.
 The retrieving tool is lowered onto the Bridge Plug while circulating the
sand.
 The retrieving head will open the valve which allows any differential
pressure to equalize.
 The continuously downward movement retrieving head onto the Bridge
Plug.
 Eventually the upward motion releases the Plug.
 The retrieving head is disconnected from the bridge plug if crucial with
about 10-12 turns of right hand rotation while holding a slight amount of
tension.

Conclusion:-
Bridge plug is a useful device through which we can control the pressure easily.
It also acts as a mechanical barrier. With the Bridge Plug we can replace the
failed valves to make sure the process is carried out properly
 CHRISTMAS TREE

At the end the a Christmas tree is installed, containing valve manifold

that controls flow in the tubing, they must be strongly constructed to
contain full of reservoir pressure, a Christmas tree function is to control
the pressure. The main valve that controls the pressure are choke,
master, crown, the wing, and the safety wing valve.
HOW CHRISTMAS TREE IS OPERATED:-
 We usually start with the dual master valve which are used to shut
in the valve.
 The top valve is used to shut in the pressure,
 While the bottom valve acts as a backup which is used in case of
the top valve stop working.
 The crown valve is used when the lubricator is attached, it is used
when well service tool operations are being conducted such as
through tubing perforation.
 The wing valve is normally used for the routine opening and
closing of the well, the choke is an orifice that controls the well
flow rate.
 Finally the safety valve automatically shuts in the well in case of
alarming situations such as extreme low and high pressure is
recorded.