Zeeshan Hyder

INTERNSHIP REPORT
Zeehan Hyder Baloch | Dawood UET, Karachi
1
INTERNSHIP REPORT
KANDHKOT GAS FIELD
PAKISTAN PETROLEUM LIMITED.
PREPARED BY: Zeeshan Hyder
B.E Chemical (2ndYEAR)
FROM:Dawood, UET.
Duration: 22th June to 28nd July 2015.
Email: zeeshanhyderbaloch@gmail.com
Contact: 0300-3447458

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CONTENT
Kandhkot Gas Field Overview
Health Safety and Environment
Departments
Utility Area
Process Area
Process Description
DHP plant
CondensateRecovery System
Slug Catcher
Slug Vessel/low pressureVessel
Oil/Condensate SepratorTank
Oil/water Seprator
Glycol dehydration Unit
Gas Inlet Scrubber
Up/down Stream Filter
Absorption tower
Fins fan air cooler
Glycol Regenration

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OVERVIEW OF KANDHKOT GAS FIELD
Kandhkot Gas Field is the second largest gas reserve of Pakistan Petroleum
Limited after Sui Gas Field. Kandhkot is a small city of SINDH situated in District
Kashmore, 65km south west of “Guddu” Barrage having mining lease area
284.274 sq km. In 1959 field was discovered but it was commence in 1987.
Kandhkot gas field have three gas bearing Domes. South East Dome, North-east
Dome and West Dome. Each dome have different formation. South-East Dome
consist of SML (Sui Main Limestone), SUL (Sui Upper Limestone) and HRL
(Habib Rahi Limestone) formation.
North-East Dome consist of SML and SUL formation. West Dome consist only
SML formation. Total 32 wells in which well no 1 is abandoned. 31 wells give the
production. Total approximation of gas produced 197MMSCFD and condensate
recovery of 8000 lit/day.

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ACKNOWLEDGMENT
“In the name of Almighty ALLAH the most gracious and the most merciful”
I reported Pakistan Petroleum limited (PPL) on 22th June 2015 as an internee in
Chemical department and completed my internship on 17nd July 2015, where I
ascertain my technical knowledge.
Special thanks to the following people who had been very friendly, co-operative
with me throughout my internship period in PPL made it possible for me to learn
and gather information.
I am very thankful to:
KFGCS
Mr. Engr. Tashfeen Ahmed (senior engineer operation)
Mr. Abdul Hafeez Babar (shift Incharge C.R)
Mr. Nasir Farooqui (Shift Incharge)
Mr. Engr. Naseer Khan(shift incharge C.R)
Mr. Engr. Younis Jawed (Shift Incharge C.R)
Mr. Engr. Qamar Ul Islam (Shift incharge C.R)
Mr. Muhammad Tayyab (technician)
Mr. Faisal Manzoor (Technician)
Mr. Khalid (Technician)
DHP
Mr. Aarab Bhayo (DCE)
Mr. Pir Muhammad Shah (Senior Engineer)
Mr. Muzzamil (Shift Incharge)
Mr. RameezAhmad

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Health, Safety and Environment
I got the basic tips and information about the safety of the plant, personal safety, and safety of
fellow workers. Information about the importance of safety equipments like Helmet, Safety
shoes, Gloves, Well fitted suiting & other equipments, as goggles, ear plugs etc
They also give brief information about the following.
 Plant entry and checking system
 Emergency response, Fire alarm system.
In present, HSE is conducting three policies:
1-Health Safety and Environment Policy
2-Smoking Policy
3-Seat Belt Policy
HSE Policy:
HSE gives the topmost priority to the health and safety of its employees. This policy states that
every employee should wear the PPE’s (Personal Protection Equipment) before going to work in
plant. This will minimize the possibility of getting harmed.
Smoking Policy:
Smoking at all locations in plant is prohibited except the locations named as Smoking Areas.
SeatBelt Policy:
Every employee should wear the seat belt while driving, and vehicle speed must not be greater
than 20km/hr

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Kandhkot Gas Field
Dehydration plant KFGCS
Production and maintenance
Operation Maintenance
Control Room
Mechanical Electrical
Mechanical Workshop
Primary function of mechanical workshop is to give mechanical services to run the plant. This
workshop is responsible of maintaining mechanical equipments such as valves, flanges, shafts,
etc and rotary machines those cause problems such as pumps, compressors, turbines etc.
Electrical & Instrumentation/Control room
Whole plant is being monitored by engineers in control room. If any of the system is not working
properly then electrical and mechanical department would be permitted by them to investigate
and to sort out the problem

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Utility Area
This area comprises of
 Power Generation
It includes three gas generators (GENSET A, B and C) and one diesel generator use
for emergency. One of these GENSETS is isolated so that can be used for maintenance purpose.
 Reverse Osmosis (RO)
It includes sedimentation of water to reduce its TDS and to make it portable for
personal usage.
 Inert Gas System
Nitrogen is an inert gas so is being collected from air for two purposes. One is used
as sealing element for compressor’s shaft so that lube oil and raw gas cannot be react each other
and other is to purge gas from pipes to prevent wear. Inert gas compressors are used to compress
it.
 Fire Water system
In case of fire or any other emergency jockey and diesel pumps are planted, collect
water from storage tanks so that situation can be controlled with in no time.
 Air Compression Package
Air is being filtered to remove its moisture content and being compressed to
instrumentation vessel for instrument purposes such as pneumatic valves and plant vessel for
plant purposes such as gas turbine.
 Storage Tanks
Storage tanks are used to store water. Two storage tanks are located, one is fire water
tank and the other is portable water tank.
 Cooling Towers
Two cooling towers are linked with GENSETS to cool generators by using LT and
HT heat exchangers. Positive displacement diaphragm pumps are used to inject chemicals in
water so that scaling would not be occurred on heat exchanger plates.

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ProcessArea
This area comprises of
 Compressors
Three centrifugal compressors are used to increase pressure of gas up to 47bars. Out
of these one is used as standby. These are seven stage driven by Gas turbine respectively (TUCO
A, B &C) also called as Train.
 Scrubbers
These scrubbers are separators used for the separation of process liquid from gas. Three
scrubbers are linked with each train named as SUCTION, INTERSTAGE & DISCHARGE.
 Inlet Gas Filters
Working principle of inlet gas filter is to remove solid content from gas to prevent
erosion in impellers. Three gas filters are interconnected with scrubbers, out of these one is
isolated.
 Gas Turbines
A twin shaft gas turbine comprises of eleven stage compressor and four stage itself
turbine is used to drive centrifugal compressors. The compression ratio is 16.7:1 and 13Mega
Watts is its capacity and present utilization is up to approx 4Mega Watts. These gas turbines can
be called as generators. A shim pack coupling is used to couple these generators with centrifugal
compressors. Operating temperature can be controlled by ventilation ducts.
 Flare Knock Out Vessel
Gas from various equipments is vented to atmosphere through flare K.O vessel and
is burnt out through flare stack. This also helps in flaring the gas in case of any equipment
shutdown or if any safety gets operated.
 Fin/Fan Coolers
Coolers are used to control temperature of gas that is compressed by centrifugal
compressors.

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 Slug Catchers
Overall eight slug catchers are connected horizontally with KFGCS Plant. Working
principle is to separate gas from liquid with the help of gravity.
 Corrosion Inhibitors
Corrosion inhibitors are using PD pumps to inject chemicals in pipes so that inner
walls may not be corroded.
ProcessDescription
Separated gas from slug catcher will be filtered through gas filters for solid particulate removal.
Gas Filters are proposed to provide filtered gas for compression system.
After passing the filters the gas enters the compression system. Each compression train will
incorporate scrubbers to remove liquid and droplets in the incoming gas stream.
Phase-1 compression will be provided with two stage gas compression i.e. interstage and
discharge stage. Interstage and discharge gas cooling will be provided by fin/fan type air coolers.
Compressed gas from all running compression trains will be routed to inlet of existing
dehydration plant (DHP).
During phase-2 (2017-2031) when the inlet pressure to the gas plant drops to 50 psia, the system
utilizes an additional two compression stages per train to achieve the delivery pressure.

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DehydrationPlant:
This is most important part of this field. Here the gas from well is dehydrated, which means the
water and moisture content and all condensate is removed from gas and make it completely
dry. Then it is supplied to the consumers and KFGCS as turbine fuel and to operate generators.
DHP plant production started from 1987 and its capacity 360 MMscd. DHP plant consist of
Slug catcher system/condensate recovery system, Dehydration unit and Glycol Regenration
Unit.
Process:
Initially gas from well having a pressure of about 200 KPag is received in DHP plant then it is
sent to KFGCS where the pressure is increased to 600 KPag. The gas coming from the KFGCS is
first pass through a scrubber having 12 fingers where gas strikes and water is separated from it.
Gas in then treated with Tetra Ethyl Glycol in absorption tower, where gas is enter from bottom
of the tower and glycol from top. They both interact and water from gas is absorbed by glycol.
Glycol is then drained out from bottom and dry gas from top. The dry gas by passing through
filters is sent to the consumers.
All water separated from gas at any stage is then sent to the storage tanks. Where the
condensate is separated In condensate towers by means of density difference.
Condensate Recovery System
Slug Catchere:-
Kandhkot Gas Field have two main section line from wells to DHP for transportation
of (Gas+slug). (Gas+Slug) transfer to slug recovery system to seprate gas and recover
condensate from gas. Slug catchere consist of main header line and 12- 13" pipe line. 12-
13" pipe lines also called 12 fingers. Slug fingers attach at 45° with main header line.
(Gas+slug) enter in main header line and seprate on the top of lieader, sent to KFGCS for
increase of its pressure and slug slide to fmgers due to gravity difference. At the other end
of slug cature slug header line, in which slug collect and enter to next slug vessel or low
pressur vessel to seprate remain gas.

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Slug Vessel/LowpressureVessel:-
Slug enter from top the vessel and contact with reflecting plate than reduce its velocity and
due to high density slug settle donwn to bottom of veesel. Remain gas also contact with
reflecting plate, seprate due low pressure of vessel and low density to top of vessel. Slug
transfer to oil/water Seprator Tank to seprate oil from water and seprate gas sent to Air
conditioning vessel to remove H2S.
Oil/Water Seprator Tank:-
Oil/Water Seprator Tank Consist of three section top, cent, bottom in tank. Slug enter
from the top of the tank. Slug distribut in two section, water collect in bottom. condensate
flow over water in center due to low density than water. Condensate transport through two
pump to condensate storage tank. Condensate sale out to PRL (Pakistan Oil Refinery
Limited). Bottom water have little amount of condensate. Water sent to Oil/Water Seprator to
seprate oil from water.

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Oil/Water Seprator:-
Oil/Water Seprator consist of two portion, one of them large other small in size. oil/water
enter from the top of large portion , large amount of water settle down in bottom of
portion. Min amount of Oil flow over on water and sent to second portion of seprator,
further sepration occur on the basis of density. Oil seprate from the top of second portion.
Water also seprate from bottom of large portion. Water sent to the water pond and
Oil sent to condensate storage tank.
DehydrationUnit:-
Inlet Scrubber:-
Three Inlet Scrubber installed in DHP, one of them use for plant start up and others use for
process. Gas from KFGCS enter inlet scrubber for seprate exist minimum amount of water.
Gas enter inlet scrubber and contact with reflecting plate, than reduce water velocity.
Water setlle down in the bottom of scrubber due low velocity and high density than
gas. Water drain out of scrubber through valve. Gas also contact with reflecting plate
due low density, escap from top portion of scrubber and transfer to up/stream f1lter for
filtration of dust partical and little amount of water.
AbsorptionTower/Contact Tower:-
Four absorption tower installed in DHP. On of them called SDHU (Stand by Dehydration
Unit) and other called unit-2, unit-3, unit-4, respectivily but Unit-2 not operate due some
problem.
3

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SDHU vertical tower consist of two section, upper and lower section.In upper section gas
contact with TEG to seprate from water, lower section called scrubber in which water
seprate on the basis of density. Gas enter from the bottom of tower and after contact with
glycol seprate from top of the tower.
Lean glycol shower from the top of tower and drain out from the bottom of the tower for
regenration. Gas enter contact with reflection plate in lower section, water settle down int
bottom and gas pass through demister pad to remove dust than gas enter in upper section
through chimney tray.
4

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Dry gas pass though fins air cooler to reduce dry gas temprature. Fins air cooler consist of
two fins fan, tubes. Fan attach from the bottom of cooler, heat exchange with atmospher
air and sent to the sales metering skid.
Glycol Regenration:-
Rich glycol discharge from the bottom of upper section of absorption tower. We want to
recycle rich glycol. Glycol regenration operation that convert rich glycol into lean glycol for
reuse in absorption of natural gas.
Description:-
Rich glycol discharge from absorption tower after absorb water from natural gas. Lot of
amount of water prensent in glycol, glycol sent to reboiler for removal of water by
evaporization. Glycol also contain some content of natural gas.
Rich glycol transfer to flash seprator through PD pump. Rich glycol sent to flash seprator to
seprate gas from glycol.due to low pressure and high temprature of flash seprator, gas
seprate out from the top of horizental vessel and glycol settle down in the bottom.
Natural Gas used as for fuel for burner and flare. Natural gas have sulfer impurties like

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hydrogen sulphide, necessary to remove these impurties from gas before
burnig.Therefore natural gas sent to the air conditioning veesel to remove hydrogen sulphide
and natural gas used as fuel for burner and flare system. The remainig glycol from the
flash seprator tranfer to glycol filter and charco! filter for further purification of glycol.
After then rich glycol sent to plate and frame heat exchanger to gain heat from lean glycol
Lean glycol shower over rising water vapour to evaporate water from rich glycol in the still
column and rich glycol glycol convert into lean glycol, settle down in the reboiler for further
evaporation. Lean glycol store at specific level in rcboiler and after achieve this level drain out
from reboiler to surg tank to store. Lean glycol tranfer to absorber for recycle through PO
pump from surg tank.
Therefore natural gas sent to the air conditioning veesel to remove hydrogen sulphide and
natural gas used as fuel for burner and flare system. The remainig glycol from the flash
seprator tranfer to glycol filter and charco! filter for further purification of glycol. After then
rich glycol sent to plate and frame heat exchanger to gain heat from lean glycol.
Lean glycol shower over rising water vapour to evaporate water from rich glycol in the still
column and rich glycol glycol convert into lean glycol, settle down in the reboiler for further
evaporation. Lean glycol store at specific level in reboiler and after achieve this level drain out
from reboiler to surg tank to store. Lean glycol tranfer to absorber for recycle through PO
pump from surg tank.
THANK YOU

Zeeshan Hyder

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