IDENTITY OF OIL COLLECTING STATION (OCS): 5 · IDENTITY OF OIL COLLECTING STATION (OCS): 5 ... EMPLOYEES BIODATA ... To ensure disposal of formation water in the disposal wells not

Oil Collecting Station 5

Production Without Pollution

IDENTITY OF

OIL COLLECTING STATION (OCS): 5

• DGMS APPROVAL LETTER : AS/OIL/4/PERM-3(98)/943 Dated

Sitarampur the 26.06.1998

• LOCATION : Duliajan.

• MINE : Production Oil Mine.

• MINING LEASE : Hoogrijan & Nahorkatiya Extension

• DATE OF COMMISSIONING : 05.08.1961

KEY PERSONNEL OF THE MINE:

• AGENT OF THE MINE : SRI. B.DEKA

• MINES MANAGER : SRI. N.K.DAS

• MINES SAFETY OFFICER : SRI. P.K.GOSWAMI

• INSTALLATION MANAGER : SRI. N.MEDHI

• FIRE OFFICER : SRI. G GOEL



1.1 PROCESS IN BRIEF

There are 06 (six) nos of well connected to OCS-5 namely NHK#43, NHK#53, NHK#57,

NHK#114, NHK#203 & NHK#548 out of which three are gas lift wells and three are SRP

wells.

Fluid from the wells enters the LP manifold and passes through the steam jacket to the

Three Phase Separator (TPS). The set pressure of this vessel is 3.5 Ksc. Gas, oil and free

water (if any) is separated here. Then the wet crude is taken to the Emulsion Treater

(ET) (Set Pressure: 2.4 Ksc). In the Emulsion Treater, the wet crude is heated up to

600C and a chemical called ‘Oil Soluble Demulsifier is added to it continuously. In this

process oil and water are separated from each other. Oil from the Emulsion Treater is

then taken to the Stabilizer (Set pressure: 0.8 Ksc) and from the stabilizer it goes to the

crude oil storage tanks. The stored crude oil is despatched to Central Tank Farm from

time to time with the help of reciprocating pump. Water is collected in formation water

storage tanks. There after it is disposed in water disposal wells with the help of

centrifugal pumps.

Gas separated in TPS and ET goes to the 30 psi Low Pressure Master Separator (LPMS)

and then to Booster suction at GCS. The excess gas is flared in the flare pit. Gas

separated in the Stabilizer goes to the 10 psi Low Pressure Master Separator (LPMS)

from where it is flared in the flare pit.

One gas well (NHK#69) is connected to OCS-5. It enters the HP manifold through the

steam jacket and then to the 250 psi High Pressure Master Separator (HPMS) from

where the gas enters the distribution network and the liquid enters the LP manifold.



1.2 PROCESS FLOW OF OCS-5:

DISTRIBUTION NETWORK

STORAGE TANK

PROCESS FLOW

COMPRESSOR STATION

FLARE

FW

STORAGE TANK

TO DISPOSAL WELLS

TO CTF



1.3 WELL STATUS OF OCS-5:

Total No of Wells Connected : 46

No. of S/F wells on Production : NIL

No. of gas lift wells : 03

No. of Rod Pumping wells : 03

No. of Water disposal wells : 03

No. of Water injection wells : 07

No. of Shut in well : 29

No. of Gas wells : 01

1.4 INSTALLED CAPACITY:

Dry Crude Handling Capacity : 800 KLPD

Wet Crude Handling Capacity : 900 KLPD

Crude Oil Storage Capacity : (1600 + 160+40) KLS

Crude Oil Pumping Rate : 80 KLS/HR

Formation Water Storage : 360 KLS

Formation Water Disposal Rate : 250 KLPD

1.5 CHEMICALS USED:

1. Lube Oil:20W40: For CODP lubrication

2. OSD: For breaking of emulsion at Emulsion Treater

3. De-oiler: For breaking of emulsion

4. Gear oil:EP90: Used in well NHK#57 (SRP Well)

5. High Speed Diesel – For cleaning purpose



1.6 SAFETY EQUIPMENT & SAFETY MANAGEMENT SYSTEM

• Spring Loaded Safety Relief Valves (SRV) in all pressure vessels & CODP.

• Breather Valves in the crude oil storage tanks.

• DGMS Approved Portable Gas Explosimeter.

• DGMS Approved Safety Hand Lamp.

• Stand-by fire fighting crew at Central Fire Station, Duliajan round the clock (1

km away)

• Static and Portable Fire Fighting facility

• Periodic Mines Vocational Training, first Aid Training, Fire Fighting Mock Drills and Refresher Courses for operating personnel.

• Regular Tool Box Meeting & Pit Level Meeting

• Periodic hydraulic testing of pressure vessels.

• Periodic testing of SRV.

• Fire Contingency Plan.

• Electrical earthing in all pressure vessels, tanks, pumps.

1.7 IN-HOUSE FIRE FIGHTING EQUIPMENT

DRENCHING PUMP: 2 Nos (Electric Motor driven)

o Pump Discharge Capacity: 2 x 300 m3/ hr.

Bolted Water Tank (160 KLS) : 2 Nos

Water Source- WTP (Tipling, Duliajan) at a distance of 4KM

Foam Tank : 01 No.

Hydrant Point : 01 No.

Fire Monitor : 01 No.

Monitor Discharge Capacity : 102 m3/hr

Fire Extinguishers :

Type: Mechanical Foam : 05 Nos.

DCP : 09 Nos.

Dry CO2 : 02 No

Fire Alarm : 02 Nos. (One Electrical & One Mechanical)

Sand Bin : 07 Nos

1.7 MEDICAL FACILITIES Stretcher

First Aid Box

Stand-by doctor at OIL Hospital, Duliajan, round the clock (01 KM away)

Ambulance available at OIL Hospital, Duliajan.

Emergency Vehicle available round the clock at OCS



1.8 REGISTERS AND RECORDS MAINTAINED

EMPLOYEES BIODATA (FORM B).

NOTICE OF COMMENCEMENT AND END OF WORK (FORM A).

EMPLOYEES LEAVE POSITION (FORM G).

EMPLOYEES ATTENDANCE RECORDS.

DGMS APPROVAL LETTER.

JUNIOR ENGINEERS REPORT BOOK.

ACCIDENT RECORDS.

MINES VOCATIONAL TRAINING RECORDS.

FIRST AID AND FIRE FIGHTING TRAINING RECORDS.

FIRE CONTINGENCY PLAN AND FIRE ORDER.

COLD / HOT WORK PERMITS.

RECORDS OF HYDRAULIC TESTING OF PRESSURE VESSELS.

SAFETY VALVES TEST RECORDS.

EARTH RESISTANCE TEST RECORDS.

RECORD OF NEAR MISSES.

RECORD OF GAS TESTING.

RECORD OF MOCK FIRE DRILL

1.9 REGULAR DUTIES OF SHIFT INCHARGE FOR SAFE OPERATION

PRACTICE

To conduct TOOL BOX MEETING regularly in each shift for safe operation / maintenance of the installation and record it.

To ensure use of PPE

To check drain system of all pressure vessels in each shift.

To check pressure of each pressure vessel from time to time and ensure smooth

functioning of the control system.

To check temperature of the Emulsion Treater.

To conduct Gas Testing once in every 15 days and keep record of the same. If

gas leakage is detected beyond 20 % LEL the same should be informed to Installation Manager for corrective action.

To ensure use of proper PPE by all personnel inside the installation.

To check work permits if any job has to be carried out by service personnel.

Check and run the Drenching pump regularly (atleast 5 minutes) and keep the

record. Carry out Mock Fire Drill on monthly basis.

To ensure disposal of formation water in the disposal wells not in the flare pit or

drain. Send one formation water sample to Chemical Laboratory every month.



1.10 WHAT TO DO IN CASE OF FIRE

SHOUT FIRE, FIRE. BLOW SIREN.

FIGHT FIRE WITH AVAILLABLE FIRE EXTINGUISHER

INFORM FIRE SERVICE TELEPHONE NO 7333 MENTIONING THE EXACT LOCATION

OF FIRE AND YOUR TELEPHONE NUMBER 6465 AND YOUR REGN. NO.

CLOSE ISOLATION VALVE V1 FOLLOWED BY ALL MANIFOLD VALVES.

INFORM TO INSTALLATION MANAGER AND MAKE CALL ACCORDING TO THE LIST

DISPLAYED IN THE NOTICE BOARD (FIRE CALL LIST).

HELP AND GUIDE THE FIRE TENDER PERSONNALS.

1.11 WHAT TO DO IN CASE OF ACCIDENT

IMMEDIATELY RUN TO THE ACCIDENT SITE

HELP THE INJURED PERSON AND USE STRETCHER TO TAKE HIM TO A SAFE

PLACE

RENDER FIRST AID SERVICE TO THE INJURED

INFORM INSTALLATION MANAGER ABOUT THE ACCIDENT.

IF THE INJURY IS SERIOUS, CALL AMBULENCE (6361)



1.12.0 IDENTIFICATION OF LNSTALLATION & PHYSICAL HAZARDS

1.12.1 GENERAL:

Identification of oilfield installation is considered as a good visual aid to safety.

Identification of physical hazards by safety colour and safety signs attracts attention

rapidly to hazardous situations and objects and thus helps in prevention of accidents and

health hazards. It is with this idea that the following recommendations are made.

1.12.2 IDENTIFICATION OF INSTALLATION ON LAND

a. Every oil or gas well should be identified by a name or number and an identification

panel should be put up at the well head indicating the name, number and nature or

product (oil or gas) and status of well (producing, discontinued or abandoned).

b. Every production installation should be identified by a name or number and an

identification panel should be prominently displayed at the installation.

c. At every production installation a standard colour coding of pipeline should be adopted

to prevent accidents due to faulty manipulation of valves etc. and to promote greater

safety. Lettering as a mode of identification is also recommended. Arrows should be

used to indicate direction of flow.

1.12.3 HAZARDS IN PRODUCTION INSTALLATIONS:

The various production units such as separators, storage tanks, indirect Heater,

Emulsion Treaters are the basic facilities used in production installation. Any leakage in

these units/flow lines inside production installation can result into oil spillage/gas

leakage. This can lead to fires and can cause pollution in surrounding area. The safety

hazards common to production installations are as follows:

1. Pressurized vessels and pipelines:

Separators are operated at different pressure ratings. The safety valves, pressure gauge,

liquid level control are the safety and control gears used in the separator. Any

malfunctioning of these equipment can result in bursting of separator.

2. Back flow of fluid from the separator to wellhead/tank to separator:

The back flow of fluid may cause serious operation problem and safety hazards to the

installation.

3. Hydrate formation:

Hydrate formation in production system and wellhead needs to be prevented by taking

suitable measure.

4. Fire hazards:

Flammable matter like oil and gas are constantly present at the installation and unless



source of ignition like naked lights, fractional sparks, electric sparks, static electric

charges, lighting etc. are carefully controlled, fire could be a major hazard.

5. Accumulation of oil vapour:

Oil vapour, which is heavier than air tends to settle down above the open pit containing

oil and around storage tank, loading points etc. The accumulated oil vapour can easily be

ignited and may even explode.

6. Explosion hazard:

A part of unused gas is burnt in the flare pit. But in case of flare is extinguished, large

quantities of unburnt gas are discharged into the atmosphere which may lead to an

explosion.

7. Pollution due to effluents produced in the installation:

Surface pollution may occur in the surrounding area of the installation if the effluent

produced in the installation is not handled and disposed properly.

8. Corrosion:

Corrosion may also pose severe safety hazard with uncontrolled release of hydrocarbon

from any pressurized system / pipeline.

1.13.0 SAFE PRACTICES:

The following recommendations should provide guidance for safety in the light of hazard

mentioned above:

(i) Enclosure:

a) The protected area surrounding every production installation should be enclosed by

wall a barbed wire fencing not less than 2.5 meters in height with gates which can be

duly locked. Security guards should be posted at gate to restrict entry of unauthorized

persons. There should be a wicket gate in the opposite side of the entrance gate.

b) A Green-belt area of 30 mtrs should be kept all around inside the boundary wall.

ii) Safety distances:

a) Inter-unit safety distances to be maintained as per the OISD Std. 118

b) Smoking/ Naked light/ Open flame/ Spark is not permitted within 30 mtrs of any well

or Petroleum storage tanks.

c) Flare shall be sited not less than 90 mtrs from any part of petroleum storage tanks

well.

(iii) Hydraulic Testing:

(a) All manifolds, separators, connecting lines, valve flow lines etc. should be

hydraulically tested to 1.5 times of maximum working pressure and the records to be

kept in the installation.



(b) All pressure vessels, heater treater should be periodically hydraulically tested once in

3 years to 1.5 times of operating pressure for about 12 hours duration.

(c) Thickness test of all the pressure vessels and piping to be done at least once in every

three years.

(iv) Safety Relief Valves (SRV):

(a) Every separator should be provided with safety valve. The SRV set pressure should

be 10% above the maximum allowable working pressure.

(b) Safety valve should be installed directly on the separator and no valve should be

fitted between the vessel and the line connecting the safety valve.

(c) In case of 2 safety valves used in a vessel OISD STD - 106 to be followed.

(d) SRV is to be installed on the crude oil delivery line and in any other discharged line

of positive displacement pump.

(e) The discharged line of every safety valve should be connected to flare line for safe

disposal of gas release from it.

(f) Safety valves should be tested at least once in every six month.

v) Non Return Valve (NRV):

(a) At the manifold header, a non-return valve should be provided in each flow line

connected to well.

(b) The product lines should be provided with NRV to avoid back flowing from the

storage tank.

(c) NRV should be provided in the crude oil delivery line to avoid back-flowing.

(d) If two or more outlets (gas or oil), operated in different operating pressures are

connected to a common header/ line, NRV should be used in the low pressure outlets to

avoid back flowing.

(e) If two or more tanks are connected from the same header, NRV should be installed in

all the low height tanks to avoid back flowing.

vi) Electrical Earthing:

Double earthing connections to be provided in all header manifold, heater treater,

Indirect Heater, pressure vessels, pumps and tanks to dissipate static electricity.

vii) Thermal Insulation:

Thermal insulation should be provided in the indirect heater and heater treater and also

on the exhaust pipes of these units, prime mover of crude oil pump, generating set etc.

to a height of at least 3 meters from the ground level to avoid accidental burning.

viii) Adequate workinq space for safe operation:

All the processed areas should have space for safe working of operators. In case of

interference of pipelines, suitable walkways should be provided.



ix) Corrosion protection:

All the lines are to be laid at least 30 cm above the ground level to avoid corrosion and

should be fixed with supports with the help of pipe clamps and the underground pipes

should have proper protective coating.

x) Colour code:

All the processed pipelines should be painted with proper colour code and direction of

flow also to be painted on the body of the pipeline at regular interval for easy

identification.

xi) Approach road:

Approach road for fire tenders inside the installation should be in good condition and

there should not be any interference from any flow lines, overgrowth of grass etc.

xii) Steam trap:

Steam trap should be provided in the pipeline before entering the storage tank.

xiii) Pressure monitoring device:

Each flow line gas-oil separator, Heater treater vessels, pump delivery lines should be

provided with a pressure monitoring device (pr. Gauge / pressure recorder) for

monitoring pressure.

xiv) Flame arrestor:

All the fired vessels should be provided with Flame Arrestor.

xv) Effluent handling facilities:

The processed water in the installation should be led to an oil-water separator through a

closed piping system for further processing / treatment to avoid surface pollution and

the storm / rain water should be allowed to flow through the surface drainage system for

disposal in the natural stream.

xvi) Communication System:

The installation should have full-proof communication facilities.

1.14.0 HAZARDOUS AREAS:

The Classifications of Hazardous area should be as per the classified circular issued by

DGMS time to time. Following classifications are based on the the circular issued by

DGMS in the year 2001. (Circular No. I(G) 2011 - Genl. / 3604-3753 dated 12th Sept,

2001)

1.14.1 CLASSIFICATION OF ZONES:

The areas inside a production installation are classified in different zones.

a) In every Zone- 1 hazardous area, only intrinsically safe of flame proof electrical

apparatus and equipment should be used.

b) In every Zone-2 hazardous area only flame proof or increased safety or pressurized

electrical apparatus and equipment should be used.



The extent of classified hazardous area should be as follows -

i) Effluent pit and Open sump:

a) The free space above the level of flammable liquid within the effluent pit or sump

shall be zone-I.

b) The free space lying up to 3m in horizontal direction from the edge of the pit and

0.5m vertically above shall be Zone-2.

ii) Flowing well:

a) An area below ground level is Zone-1.

b) Area lying up to 3m horizontal direction from the edge of the cellars, trenches or

sump shall be Zone-2.

iii) Well servicing operation:

a) The area within a radius of 10 m in all direction from a well servicing shall be Zone-2.

iv) Gas vent:

a) The area within a radius of 1.5m from open end of the vent extending in all direction

shall be Zone-1.

b) Area lying within a radius beyond Zone up to 3m of the vent shall be Zone-2.

v) Gas oil separator/ fired vessel:

a) The area within a radius of 3m from any oil-gas separation vessel, and fired vessel

shall be Zone-2.

vi) Safety relief valve:

a) The area within a radius of not less than 3m from discharge of a relief valve extending

in all directions shall be Zone-2.

vii) Pig trap:

a) The area within radius of 1.5m of the pig launching/receiving trap extending in all

directions is Zone-1.

b) And the area lying beyond Zoned up to radius 3m in all direction of the trap is Zone-

2.

viii) Crude oil pump:

a) Area lying up to 3m in all direction from the pump is Zone-2.

ix) Storage tank:

a) The area inside the tank and within a radius of 1.5m from all opening including

breather valve, dip hatch, thief hatch is Zone-1.

b) And the area beyond Zone-1 up to 3m in all directions from the shell and roof is

Zone-2.

X) Dyke:

a) The sump in the dyke shall be Zone-1.



b) And an area extending vertically up to a height of the dyke and horizontally up to

physical boundary of the dyke shall be Zone-2.

1.15.0 PRECAUTIONS AGAINST FIRE:

i. Smoking is strictly prohibited inside the production installation. Prohibitory sign for this

precaution should be displayed on the panel board near the entry gate. Any person

entering the installation with any smoking apparatus like cigarettes, matches and lighter

must deposit the same at the gate.

i. The installation should have an emergency exit.

iii. Hand tools used should be of non-sparking type.

iv. The prime mover used for the crude oil service should be FLP type. If gas or diesel

engine is used the same should be separated with the pump with a sealed wall.

v) Ignition of indirect heater and heater treater should be done through remote ignition

device.

vi) Proper size of canopy should be provided on the exhaust of chimney.

vii) Flame failure fuel cut off device should be installed in the I. Heater, heater treaters

and all the fire vessels should be provided with flame arrestor.

viii) While loading and unloading oil in road tankers, its engine should be stopped and

battery isolated from the electric circuit. The engine should not be re-started and the

battery should not be connected to the electric until all tanks and valves have been

securely closed.

ix) At the loading arm, all oil pipelines, filling and delivery hoses, metallic-loading arm,

swivel joints, tank and chassis of tank vehicle should be electrically continuous and be

efficiently earthed.

x) Hot work permit should be issued to the concerned persons by shift in charge with

approval from IM, prior to commencement of any hot job inside the installations.

xi) Efficient earthing of all vessels and equipment should be done to take care of static

charges. Earthing connections should be checked every 6 month and measured values

should be recorded in a register. Earthing pits should be clearly marked for inspection.

xii) Spillage of flammable liquids should be minimized to mitigate risk of fire and should

be immediately cleared.

xiii) All fire fighting equipments should be maintained in good condition.

xiv) Electrical control room, switch gear room, computer room etc. should be maintained

in good condition. There should be rubber mats in electrical control room and switch

gear room and cables should properly led in trenches. Lighting fixtures should be

permanent and no hanging wires or naked bulbs permitted.



xv) Vessel entry permit is to be issued by Installation Manager prior to taking cleaning /

maintenance jobs in any vessel. Fire hydrants, water sprinkler system, foam lines of

storage tanks should be inspected regularly to ensure their smooth functioning.

xvi) Regular inspection of well head fittings is to be carried out for any leakage of

gas/oil. To prevent unauthorized entry to the wells, periodical inspection of fencing is to

be done.

xvii) Keep flammable material away from source of heat and store them in suitable cans

and at proper place.

xviii) All the wells should be clearly marked for easy identification

xix) Electrical equipment and fittings should be maintained properly.

xx) Easy access to fire extinguishers and learn how to operate them.

xxi) First aid items should be maintained properly.

xxii) Regularly removal of accumulated waste material like dry vegetation is to be

ensured.

xxiii) Routine maintenance of all machinery should be ensured.

xxiv) Close supervision of premises at all times is to be ensured.

xxv) There should be proper drainage system in process areas. Necessary sumps should

be available in all operating areas like pump house, storage tanks, separator platforms

etc. to collect and recover spilled oil.

xxvi) Water supplies should be adequate.

xxvii) Prohibitory caution signs should be displayed at all critical places.

1.16.0 DISPOSAL OF GAS THROUGH FLARE SYSTEM:

i. A flare line should be laid from the production installation to a flare stack /flare pit

located at distance of not less than 90 meters from the production installation.

i. The flare line should terminate with a vertical riser pipe of not less than 9 meters in

height or in a flare pit enclosed with proper wall.

iii. When the gas flow is intermittent, the flare line should be provided with a pilot burner

with remote control electrical ignition device to ensure that the pilot burner is

continuously lighted.

iv. At the flare stack, a water seal drum should be provided to prevent ingress of air into

the flare line to be ensured.

v. Leakage of gas if any in flare line and in the flare stack should be attended on priority

basis.

vi. There should not be any seepage of effluent from effluent evaporation pit located in

gas flared area.



vii. Effluent evaporation pit should be produced with suitable masonry boundary wall and

Asbestos, enclosed to prevent seepage and transmission of heat respectively.

viii. Passage-to flare should be kept accessible and free from dry vegetation.

1.17.0 BLOWING OF SRV IN A PRESSURE VESSEL:

1.17.1 SRV of a pressurized vessel in a production installation may blow for many

reasons. The major causes are:

a. Sudden thrust of incoming fluid which may be due to opening up of the well at the

wellhead in uncontrolled manner.

b. Due to uncontrolled entry of input gas in intermittent lifting system.

c. Due to sudden change in well behaviour.

d. Restriction at the outlet of the gas controller.

e. Drop of wedge of the gate valve at the outlet.

f. Closure of outlet valve due to operational mistake.

g. Inadequate size of orifice in gas outlet line.

1.17.2 MEASURES TO BE TAKEN TO OVERCOME THE PROBLEMS:

i. Sudden thrust of incoming fluid:

Wells during opening in the wellhead should be opened up in very slowly and steadily to

avoid sudden thrust in the production installation. It may be done in the following ways:

(1) Check the closure of all the valves in the X-mass tree and also the flow line valve.

(2) Install required size of bean in the bean housing and close the housing.

(3) Open-up the master valve of the well fully, thereafter arms valve and side valve of X

mass tree should be opened. Open the flowline valve slowly in controlled manner. The

well fluid will start flowing through the flow line.

(4) Open-up the flow line valve gradually and observe the pressure in the flow line. The

operation should be repeated till the valve attains full open position.

ii. Uncontrolled rate of gas production due to improper faulty gas lifting system:

In gas lifting system high pressure lifting gas from the casing is allowed to enter tubing

to lift the fluid from the well. Improper functioning / design of the gas lift system may

also lead to problem of handling excessive gas and may lead to blow of SRV of the

separators. To overcome this problem the following actions should be taken.

(1) Installation of proper size of G/L valves at the sub-surface.

(2) Ensure the injection of required/calculated quantify of lifting gas in to the casing at

suitable interval by adjusting the interval and duration of the time cycle controller (TCC).



(3) By optimizing the quantity of lifting gas i.e. the opening of TCC of the G/L wells in

the area should be set in such a way that two or more TCCs should not be opened

simultaneously.

This will avoid the excessive gas handling problem in the pressure vessels and thus

eliminate the problem of blowing of SRV apart from the optimization of lifting gas.

iii. Change in well behaviour:

There may be sudden change in behaviour of certain wells to convert into high gas

producer (high GOR). Producing such wells in the installation may be problematic and

may lead to blow of SRV. These wells should be identified and precautionary measures

such as reducing the size of flow-arm bean etc. are to be taken to avoid gas-handling

problem in the installation.

iv. Gas controller:

Restriction in the gas controller causes obstruction of outgoing gas and may leads to

blowing of SRV. To overcome this problem the seat of the control valve should be

cleaned from all the foreign materials. All the rusts, cutting chips, welding waste etc. left

inside the line at the installation stage should be flushed out before commissioning.

v. Malfunctioning of gate valves:

The SRV may also blow due to malfunctioning of gate valves. Hence, all the valves used

in the installation should be of good quality and conform to API standard.

vi. Operational Mistake:

One of the reasons for blowing of SRV is the mistake made by operational personnel.

The mistake may be minimized by adopting the following -

(1) All piping should be laid at least 30 cm above the ground level for easy identification.

(2) Piping should not be clumsy.

(3) Colour code including the direction of flow should be marked on the line for easy

identification.

(4) Raising stem gate valve should be used in the installation for easy identification of

the mode of operation of the valves from a distance.

vii. Improper size of orifice at gas outlet line:

Sometimes improper size of orifice in the gas outlet line may restrict the flow and leads

to blow of SRV in an installation. In such case the orifice should be replaced with proper

size of orifice plate.



1.17.3 PROCEDURE FOR ATTENDING A VESSEL DURING POPPING OF SAFETY

RELIEF VALVE (SRV):

1 Shift-in charge with his co-worker should rush to the site and identify the popped

vessel. It may be identified by the visual / audio control alarming system or by

observing the pressure gauge installed on the body of the vessel.

2. After identification the over pressurized vessel, the by pass valve of the gas controller

is to be opened and should be throttled in such a way that the pressure of the vessel

dropped down to normal pressure and the SRV stops popping.

3. At this time, the gas controller of the flare line may require to be by-passed to release

the excess gas in the system. While throttling the by-pass valve of the controller in the

flare line, in no case the upstream pressure should be bled off below the gas distribution

pressure. Otherwise, the gas from the distribution system will flow back to the flare.

4. Identify the problem and rectify the defects (as mentioned above).

5. Close all the by-pass and restore back to normal operation.

1.18.0 LIQUID CARRYOVER IN PRODUCTION INSTALLATION:

Liquid carryover is a most common problem encountered in production installation.

When liquid phase of the flow enter the gas stream the phenomena is called liquid

carryover.

1.18.1 DETECTION OF LIQUID CARRYOVER:

Liquid carryover may be detected with

1. Black smoke in the flare pit due to burning of liquid phase of hydrocarbon.

2. Malfunctioning of gas controller which may lead to blowing of SRV in the separator.

3. Sudden drop in gas reading in the gas flow meter.

1.18.2 FACTORS CONTRIBUTING THE LIQUID CARRYOVER:

Liquid carryover may occur for the following reasons -

(i) More load on the separator than its capacity:

Gas-oil separators need some retention time for separation of gas from liquid phase. If

the quantity of incoming fluid is more than its design volume, the retention time will be

less and some amount of liquid will present in the outgoing gas and liquid carryover may

occur.



(ii) Restriction / malfunctioning of motor valve/valve in the liquid outlet line of

the separator:

Liquid carryover may occur if the liquid outlet line of the separator is chocked and also

due to malfunctioning of motor valve / faulty valve.

(iii) Malfunctioning of Liquid level controller:

The level of liquid in a separator is controlled through LLC. If LLC does not work properly

the liquid level will rise inside the separator and may go along with the gas stream

causing liquid carryover.

(iv)Closure of tank inlet valve/faulty check valve in the production line:

The oil separated in separators is finally collected in the crude oil storage tank. If the

inlet valve to the tank is closed or the flapper of the check valve got chocked, fluid may

enter to the gas stream and liquid carryover may occur.

1.18.3 ACTION TO BE TAKEN TO PREVENT LIQUID CARRYOVER:

(1) To ensure that the proper preheating of inlet fluid.

(2) Ensure that the servo control pressure is maintained at the recommended level (it

may be adjusted with the help of air/pressure regulator installed in the line) and there is

no leakage in the sensor line leads to the motor valve.

(3) Check the LLC and functioning of the liquid control valve (motor valve).

1.18.4 ACTION TO BE TAKEN AFTER THE LIQUID CARRYOVER:

(1) Open the by pass of the liquid control valve (motor valve) and allow to drop down

the liquid level in the separator. Shut the by-pass valve after the float of the LLC come

back to its normal position.

(2) Flush out the liquid from the gas outlet line and clean the gas controller properly.



1.19.0 SAFE OPERATING PROCEDURE

LINING UP OF WELL FOR TESTING

1. Check the latest information viz. SITP, FTHP, FAP Flow rate, GOR, water cut and the

flowline pressure at the manifold (upstream of manifold) etc. of the well to be tested.

2. Check for Pressure gauge in the flowline at the manifold of the well to be tested.

3. Ensure sufficient ullage at Test tank.

4. Lining up of High Pressure Well:

i) The inlet valve to Test tank is in open position.

ii) Ensure functioning of Oil Dump valve and the gas control valve of TU-II. The inlet

valve to TU-II is in open position.

iii) Ensure functioning of Oil Dump valve and the gas control valve of TU-I. The inlet

valve to TU-I is in open position.

iv) Ensure functioning of the gas flow meter and install proper orifice plate and meter

chart (A-meter).

v) The inlet valve to HPMS and LPMS are in open position

vi) Ensure the functioning of the Steam Jacket.

vii) Close the Group Valve of the well to be tested in the group manifold slowly and

monitor the flowline pressure at the manifold (Upstream of the Check Valve)

viii) Open the Test Valve of the above well in the test manifold slowly and observe the

flowline pressure as well as the TU header pressure. There may be a marginal increase

in the flowline pressure from the normal line pressure due to restriction at the test plug

valve, which is normally smaller in size to that of the Group valve. However, if the

flowline pressure begins to shoots up, open the Group valve and close the Test valve in

the manifold. Do not put the well on test unless and until the cause of increase of

flowline pressure is identified and rectified.

5. Lining up of Low Pressure Well:

1. The inlet valve of Test tank is in open position.

2. Ensure functioning of Oil Dump valve and the gas control valve of TU-II. The

inlet valve to TU-II is in open position.

3. Ensure TU-I is by-passed.

4. Ensure functioning of the gas flow meter and install proper orifice plate and

meter chart.

5. The inlet valve to LPMS is in open position.

6. Ensure the functioning of the Steam Jacket.

7. Close the Group Valve of the well to be tested in the group manifold slowly and

monitor the flow line pressure at the manifold (Upstream of the check valve).



8. Open the Test valve of the well to be tested in the test manifold slowly and

observe the flow line pressure as well as the TU header pressure. There may

be a marginal increase in the flow line pressure from the normal line pressure

due to restriction at the test plug valve, which is normally smaller in size to

that of the group valve. However, if the flowline pressure begins to shoot up,

open the group valve and close the test valve in the manifold. Do not put the

well on test unless and until the cause of increase of flowline pressure is

identified and rectified.

1.20.0 LIGHTING PROCEDURE OF EMULSION TREATER:

1. Ensure the closure of all the valves and check the fluid level in the Emulsion

Treater.

2. Crack open the fuel valve in pilot line and put the ‘low temperature shut down

switch’ to starting position. Gas will start leaking through the pilot burner.

3. Light the pilot burner by carefully placing a lighting stick near the burner (in case

of nonavailability of remote ignition system; do not stand directly behind the

lighting stick) and adjust the flame if required.

4. Once the pilot flame heated the thermostat of the ‘Low temperature shut down

switch’ the switch will automatically come to its running position.

5. Open the valves on the main fuel line to light the main burner and adjust the air

mixture if required.

6. Check the function of the temperature controller by increasing the temperature of

the fluid to the setting temperature. At this point the temperature controller

installed in the main fuel line will cut off the fuel to the main burner.

1.20.1 SHUT DOWN PROCEDURE OF EMULSION TREATER:

Cut off fuel supply to the main burner and pilot burner by shutting down the main fuel

valve.



1.21.0 OPERATING PROCEDURE FOR RUNNING CRUDE OIL DESPATCH PUMP

(CODP):

1. To inform receiving section (Central Tank Farm-Ph No: 6460).

2. To ensure proper connection of the Electric Motor.

3. To ensure opening of suction, delivery and circulating valves of the pump.

4. To check the pump skid.

5. To open the suction valve of the tank.

6. To ensure proper functioning of the pressure gauge.

7. Check and fill lubricating oil (20W40) in the force feed lubricator.

8. Start the prime mover by putting the power supply on.

9. Close the circulating valve slowly with a closed observation on the pressure gauge

and also observe any gland leak or not. After shutting down the circulating valve

completely observe the pressure at least for 30 minutes.

1.21.1 SHUT DOWN PROCEDURE FOR CODP:

1. Stop the Electric Motor by cutting the power supply.

2. Open the circulating valve.

3. Close the suction valve.

1.22.0 OPERATING PROCEDURE OF FORMATION WATER DISPOSAL PUMP:

1. Open the suction valve/valves of the Tank and Pump.

2. Ensure opening of water line for cooling of bearing.

3. To start the pump and observe the pressure developed and ensure the current

drawn in acceptable limit (within 52 Amps).

4. Open the delivery valve of the pump gradually to discharge in the disposal

well/wells maintaining the delivery line pressure.



1.22.1 SHUT DOWN PROCEDURE OF STOPPING FWD PUMPS:

1. Shut the delivery valve of the pump.

2. Switch off the motor of the pump.

3. Shut the suction valve of the pump.

1.23.0 MANUAL TANK DIPPING PROCEDURE:

1. Working personnel should inform the shift in-charge at the time of going for dipping.

2. Climb-up to the top of the tank. Always use safety belt. Loosen the cover of the

dipping hole slightly and allow the gas to release completely.

3. After releasing the gas the cover should be removed and the dip gauge should be

inserted slowly into the tank through the hole till it touches the bottom of the tank. In

no case the dip weight should be dropped from a height.

4. Pull out the gauge and note the fluid level of the tank from the mark on the dip gauge.

5. Position the cover over the hole and tighten it properly.

6. Climb down from the tank.

7. Working personnel climbing up the tank should ensure that there is no cotton waste

and any other wiping/foreign material is thrown at the top of the tank.

8. No gauging and sampling of tanks should be undertaken during thunder and hail

storm.

9. Dip should not be taken during filling and evacuation of the tank.

1.24.0 PROCEDURE FOR LIGHTING OF FLARE

1. Close the flare control valve leading to the flare pit.

2. Crack open the flare controller by-pass valve.

3. Light the burner with the help of a lighting stick. Precaution to be taken while

lighting the flare:

i. Never go alone to light the flare

ii. Keep one fire extinguisher while going to light the flare.

4. Open the valve and allow the gas to enter flare pit and thus to burn the gas.

1.24.1 PROCEDURE FOR SHUT DOWN OF FLARE

1. Open the valves in the vent lines

2. Close the flare control valve leading to the flare and thus put off the fire.



1.25.0 SAFETY PRECAUTIONS DURING LOADING OF A ROAD TANKER

1. No tanker should be loaded if it is found to be leaking or otherwise in unsafe

condition.

2. No smoking or open flame should be permitted within 30 meters of the loading

point and within the protected area.

3. The tanker, filling hoses and the chassis of the tanker should be efficiently bonded

and connected to the earthing system by metal wire or tape. Earthing connection

should be kept intact until loading operation is completed and all valves and

discharge faucets have been securely closed.

4. In the loading areas adequate arrangement for ventilation should be made to

prevent accumulation of flammable vapor near ground level due to low ambient

temperature.

5. Before commencement of loading operation, the engine of the road tanker

(bowser) should be stopped and its battery isolated from the electric circuit. The

battery should not be reconnected until the tanks and valves have been securely

closed.

6. Every road tanker while it is being loaded should be attended by a competent

person authorized for the purpose. The competent person should particularly

ensure that there is no fire hazard during loading operation.

7. It is absolutely prohibited to leave a tanker unattended during loading.

8. The tanker should be checked for its fitness and safe condition before loading.

9. Tankers should not be loaded if the driver is found to be in toxic/under the

influence of alcohol.

10.Night loading should be avoided to the extent possible. If the loading is to be

carried out in the night hours, the loading area should have proper illumination

and the gas measurement should be carried out in every hour and should be

recorded in a bound book.

1.25.1 STARTING & SHUT DOWN PROCEDURE FOR BOWSER LOADING PUMP:

1. Open suction valve of tank T1/T2

2. Open valve VBowser1 (6”), VBowser2 (6”) & VBowser3 (4”)



3. Open valve V28.

4. Open suction & delivery valve of the Bowser Loading Pump.

5. Open valve VBowser4 (4”)

6. Ensure opening of valve VBowser5 (normally keep in open position)

7. Start the pump by putting the power supply on.

8. Ensure the presence of one person round the clock during loading operation near

the pump in such a position that he can see the loading point.

9. Ensure that, the person riding above the bowser take proper dip.

10.After the loading operation is over stop the pump.

11.Ensure that, all the chambers and valves of the bowser are properly sealed before

leaving the installation.

1.26.0 SAFE OPERATING PROCEDURE FOR RECHARGING OPERATION:

1. Open the suction valve of the tank to be recharged

2. Open valve VRecharge1 & VRecharge2 for recharging from Tank 1, 2, 3 &4 and VRecharge3

for recharging from the skimming tank.

3. Open valve V28

4. Open suction and delivery valve of the recharging pump (Roto Pump)

5. Open valve VRecharge4.

6. Open the group header valve (Valve of well NHK#177).

7. Start the pump by putting the power supply on.

8. Recharging operation is to be carried out by closely observe the separation in the

Emulsion Treater. If the separation is not good stop the pump, wait for some time,

allow separation to be ok and then again start the process. If required increase

the OSD dosing rate during recharging operation.

9. Check the dip of the recharged tank from time to time.

10.After the recharging operation is over stop the pump and shut all the valves.

11.Clean the area near the pump if any oil spillage is there.



1.27.0 SAFE OPERATING PROCEDURE FOR SKIMMING OPERATION:

(A) FOR SKIMMING FROM FW TANK NO.1:

1. Shut valve and allow the water level to rise in the tank.

2. Ensure opening of inlet and outlet valve of the skimming tank.

3. Ensure that, a person should present near the skimming tank round the clock

during the operation and observe filling of crude oil in the skimming tank from the

FW tank. He should check from time to time the oil level in FW tank and skimming

tank. When the oil level in the skimming tank rises then arrange to send the oil to

tank no. 4 with the help of recharging pump. For this:

i. Open valve VRecharge3, V28, inlet and outlet valve of the recharging pump and Valve

V36 & V17.

ii. Start the pump by putting the power supply on and send the oil from the

skimming tank into tank no.4.

(B) FOR SKIMMING FROM FW TANK NO.2:

1. Shut valve and open valve

2. The rest of the process is same as above.

1.28.0 SAFE PRACTICES FOR OPENING OF BEAN HOUSING:

1. Isolate the bean housing (B/H) by shutting in arm valves and side valves

respectively.

2. Measure the pressure in the bean housing at the test cock on the housing.

3. Release the pressure in the bean housing through the test cock.

4. If the pressure is not found to be released, (probably the side valve or arm valve

may be leaking) shut the Master valve/flowing valve. Note: Release of pressure of

the bean housing should be closely observed and proper judgement should be

applied to ensure complete release of pressure.

5. Slightly unscrew the bean cap by hammering with a non-sparking hammer. Then

release the pressure inside bean housing by hammering the top of the bean cap.

Observe the tightness of the bean cap. If the bean cap is loose then there is no

pressure and if the bean cap is tight then there is still some pressure. Repeated

attempt should be made to release the pressure.

6. Remove the bean cap once there is no pressure.

7. Remove the bean with the help of a bean wrench.



8. In case the bean housing is filled with sand/wax, then clean by standing in a safe

position. During cleaning operation of bean housing, nobody should stand in front

of the exposed bean housing in the same line.

9. Use safety goggles and hand gloves.

10.Incase, the pressure from the line cannot be released and there is heavy

sand/wax deposition inside the bean housing then report the matter to superior

and suspend operation till arrival of competent authority.

1.29.0 GENERAL SAFETY GUIDELINES

Report all unsafe practices or conditions to your supervisor immediately.

Report all injuries, no matter how minor, to your supervisor immediately.

Wear personal protective equipment (safety glasses, hard hats, gloves, etc.) as required for each job.

Wear appropriate clothing for the job.

Never keep or eat food in any area where hazardous materials are used or

stored.

Wash your hands after handling hazardous materials especially before eating, drinking or smoking.

Follow all warning signs and tags; they are for the protection of you and your fellow workers.

Never remove locks, warning, danger, or lockout tags on any apparatus, valves or switches unless you placed them and the hazard no longer exists. Consult your supervisor if someone else’s lock or tag prevents work.

Be sure that operators can always see you when working around heavy equipment, cranes, or trucks.

Be alert to conditions and work processes in surrounding areas so that you can foresee and avoid dangers. Be aware of the presence of other employees and equipment.

Do not enter barricaded or “roped off areas” without appropriate authorization. They are considered danger zones.

Do not throw or drop materials from one area or level to another unless under special controlled conditions and permitted by your supervisor.

1.30.0 HOUSEKEEPING

Follow these procedures for cleaning up spilled materials or liquids:

If you know what the substance is, and you know that it is not hazardous, clean it up immediately.

If the substance is known to be hazardous, ask your supervisor for specialized instructions for clean up.

If you do not know what the substance is, try to identify it and contact the

Safety Officer. Maintain a safe distance, and do not clean it up.



Collect rags, packing materials, sawdust and other combustible materials daily and place in appropriate containers.

Collect objects with sharp edges (scrap sheet metal, scrap glass, bottles, metal cans) and place in containers that will safely hold the material.

Return all tools and equipment to the appropriate storage area (toolbox, storeroom).

Keep all work surfaces dry and clean to prevent slips and falls.

Keep walkways, aisles, roadways and other travel routes clear.

Protect floor openings by providing adequate barriers and covers.

1.31.0 MATERIAL HANDLING

Some Basic Principles Apply To All Material Moving Situations:

a. Use mechanical means of moving materials when possible.

b. Maintain all mechanical devices must be regularly.

c. Store or stack equipment and materials so as not to create falling or tripping hazards.

Documents

IDENTITY OF OIL COLLECTING STATION (OCS): 5 · IDENTITY OF OIL COLLECTING STATION (OCS): 5 ... EMPLOYEES BIODATA ... To ensure disposal of formation water in the disposal wells not