Listing of Installation (Gas Compressor Facilities)

PRODUCTION GAS DEPARTMENT NOTE NO.
16
GAS COMPRESSION
FACILITIES
IN OIL
A GLIMPSE ON HISTORY,
PERFORMANCE AND CURRENT
STATUS
S. K. SARMAH
CEPG (O & M)
PRODUCTION GAS DEPARTMENT
CONTENTS
1. Executive Summary Page 3
2. Preamble Page 5
3. Function of gas compression facilities Page 6
4. History of compressor facilities in oil Page 7
5. Performance vis-à-vis OIL’s experience with Page 9

current fleet of compressor packages
6. Spares : provision modality, availability and constraints Page 12
7. Technology induction in Gas Compressor operation Page 14
8. Write-off plan of compressor packages Page 17
9. Augmentation of compression infrastructure Page 19
10. Hiring of compression service Page 21
11. Conclusion and Acknowledgement Page 22
ANNEXURES
Annexure I : Holding of Gas Compressors as on 1st April, 2013
Annexure II : Written Off Gas Compressor packages
Annexure III : Proposed write off plan of Gas Compressors up to 2016-17.
Annexure IV : Total holding of Gas Compressors after Write Off.
Annexure V : Capacity availability of Gas Compressor Stations
2
EXECUTIVE SUMMARY
1.0 OIL introduced compression facilities way back in 1962. Over the years, OIL
acquired a large fleet of Gas Compressor packages from 9 (nine) different sources,
both indigenous and imported.
2.0 Presently OIL uses gas compressors for collecting low pressure gas (LPB) and
providing gas lift gas (GL) for gas lift oil wells. Earlier gas compressors were also
used for gas injection and gas storage purposes.
3.0 Since gas injection and gas storage requirement no longer exits, some of the Gas
Injection and Gas Storage compressors have now been utilized as Gas Lift
Compressors.
4.0 Present population of LPB and GL compressors are 62 and 57 Nos. respectively. Out
of these compressors, about 30 Nos. LPB and 33 Nos. GL compressors are on
operation daily.
5.0 In order to sustain availability of compressor packages over the years, replacement
plan of the compressor fleet is done at regular interval. Accordingly, altogether 82
packages have so far been written off and replaced suitably. Presently, another 14
compressors have been earmarked to write off by 2015-16 and another 8
compressors by 2016-17.
6.0 Write off strategy is based on performance of the compressor packages and not on
vintage of the compressor.
7.0 So far as performance level is concerned, the performance of Worthington make

packages have been found to be much superior, as evident from lower breakdown
frequency, lower consumption of spares and consistent output throughout the
entire life cycle since commissioning in 1986.
8.0 As there is a large mix of make and models of gas compressor packages operating in
different service duties, wide range of spares are to be managed which is a
challenging task. Main constraints for spare management are long lead time, delayed
delivery, high cost of OEM spares, obsolesce due to technology up-gradation /
design change etc. However, with constant monitoring and advanced planning,
availability of the right spares at the right time has been achieved.
9.0 To keep pace with the latest development of technological changes, consistent
efforts have been put in for induction of newer and latest technology in compressor
operations. Two major technologies which have recently been inducted are CPU-95
Ignition System and Electronic Control Panel for gas compressor packages.
10.0 Continuous efforts have been put in to re-use costly machine parts like engine /
compressor blocks etc by reconditioning / salvaging the same at indigenous
workshops as a cost saving measure.
3
11.0 SCADA input is extensively used for on time monitoring of compressor operations.
12.0 Outsourcing of compression service is one of the significant initiatives taken by the
department towards collection of low pressure gas. Presently, about 2,20,000 SCM
of gas is collected through compression services. It is planned to hire compression
services for 2 more locations for collection of low pressure gas.
13.0 In order to meet the gas compressor requirement due to variable gas production
from OCSs, continuous efforts has been put in for relocation of compressors from
one location to another.
14.0 Construction of smaller capacity Compressor Station with reduced facility was
introduced to manage compressor requirement till permanent Compressor Station is
constructed. Such station is presently in operation in Dikom, and another station is
being built up in Tengakhat area.
15.0 To manage manpower shortage for compressor operation, it is planned to close down
a few stations, like Kathalguri (old) and GCS 7, by re-siting of the compressors
without any operational drawback.
16.0 Presently, procurement process has been initiated for acquisition of 6 nos. of LPB
and 7 nos. of GL compressors against approved capital budget.
17.0 Further, activities for construction of full fledged Gas Compressor Station in
Makum, Dikom and Tengakhat area has already been started under Production
Project Department. Additionally, compressor stations at Baghjan and Barekuri are
also planned as a long term measure.
_____________________
4
PREAMBLE
The gas compression history in OIL operational area dates back to 1962, with procurement
and installation of two (2) nos. Cooper Bessemer make Gas Injection compressors in GCS 1
for reservoir pressure maintenance purpose. Subsequently there is continuous growth of
compression infrastructure and till date, a total of 201 nos. of Gas Compressor packages
of different duties and capacities have been procured and installed in various installations
(GCS) over the years. Out of this, presently 119 nos. compressor packages have been in
operation.
The note captures the history of gas compressor facilities; performance level of current
fleet of compressors; provision, modality, availability and constraints in spares
management; write off plan of compressor packages and augmentation need of compression
infrastructure in various installations for enhancement / sustenance of oil production and
flare reduction in the fields. The initiative taken by department for hiring of compression
service through BOO system towards reduction of flare has also been highlighted in the
note.
__________________
5
FUNCTION OF GAS COMPRESSON FACILITIES
After multistage separation of crude oil and gas at the oil collecting station(OCS),
associated natural gas of low pressure (L.P) and high pressure (H.P) are available at the
pressure range of 1.3-2.5 Kg/cm2 and 14-21 Kg/cm2 respectively. The gas streams are then
compressed to different higher pressure ranges with the help of Low Pressure Booster
Compressors (LPB) and Gas Lift Compressors (GL) so as to utilize in different schemes,
such as
a) Meeting Market commitment, internal consumption and LPG extraction.
b) Gas Lift requirement to artificially lift oil wells for crude oil production
The recycled gas from gas lift wells is available at low pressure (LP stream) which is again
compressed to 14-21 Kg/cm2.
Besides the above two purposes, the company also used to operate Gas Injection
Compressor (GI) for reservoir pressure maintenance and Gas Storage Compressors (GS) to
store LPG stripped lean surplus gas. But these two types of Gas Compressors has been
discontinued in the field for non requirement of gas injection duty on geological
consideration and steady and increased demand in the market by various consumers. Some
of the GI compressors and entire fleet of GS compressors have now been utilized as Gas
Lift Compressors in the fields.
Considering more thrust on meeting the increasing market commitment and reduction of
wastage through gas flaring as well as to avoid any loss of crude oil production from
artificial wells as well as for achieving higher crude oil target, availability of optimum gas
compressors with adequate standby provision in the fields has become necessary to avert
downtime and production loss.
Presently there are 18 Gas Compressor Stations (GCS) in operation wherein the
compressor packages have been installed depending on low pressure gas availability and
requirement of lift gas of a particular area under the Oil Collecting Stations (OCS).
Earlier, operation of 2 GCSs, namely GCS 3 and Moran GCS 1 have been discontinued for
non existence of specific requirement in the respective areas.
_________________________
6
HISTORY OF COMPRESSOR FACILITIES IN OIL
The development of compression facilities in our fields were initiated way back in 1962,
and time to time compressor packages have been added based on review for compressor
requirement vis-à-vis gas availability at the OCSs/ gas lift gas requirement. Over the
years, OIL acquired a large fleet of compressors from various sources- both indigenous
and imported. Majority of the compressors are gas engine driven while some are electric
motor driven.
The requirement of compressors (L.P. Booster and Gas Lift duties) has been increasing on
account of ageing of the old fields, ageing of the existing equipment, discovery of new
fields in out step /new locations, as a measure necessary for reduction of gas flaring,
increasing gas demand from the consumers and for gas lift function. The following table
indicates make and quantum of compressors procured by the department over the years.
Sl Make Qty Year of P.O Reference

No purchase
1 Cooper Bessemer (USA) 2 1962 a) 1459 of 20.07.1962 – 2 Nos.
2 Nouvo Pignone (Italy) 24 1967 a) SSF/1 of 19.11.1966 – 6 Nos.
b) SSF/7 of 22.06.1967 – 9 Nos.
c) SSF/8 of 22.06.1967 – 7 Nos.
d) SSF/12 of 27.01.1968 – 2 Nos.
3 CA Parson (USA) 4 1966 a) OIL/3654 of 09.02.66 – 4 Nos.
4 IR (Canadian) 33 1972 a) SSF/38 of 30.03.72 – 21 Nos.
to b) 140044/DJ of 17.09.73 – 5 Nos.
1974 c) 140320/DJ of 17.07.74 – 7 Nos.
5 KG Khosla (India) 5 1983 a) 130026/DJB of 20.07.83 – 5 nos.
6 CSIWorthington (USA) 19 1986 a) 145000/DJ of 03.06.85 – 19 Nos.
7 BPCL ( India) 43 1975 a) 136200/DJ of 24/3/75 - 8 Nos.
to b) 137120/DJ of 14/8/76 - 2 Nos.
2010 c) 137640/DJ of 3/2/77 - 2 Nos
d) 130174/DJ of 27/4/85 - 4 Nos.
e) 135014/DJ of 31/5/86 - 3 Nos.
f) 135015/DJ of 31/5/86 - 2 Nos.
g) 135400/DJ of 02/01/94 - 7 Nos.
h) 135806/FDP6 of 12/2/99 - 2 Nos.
i) 136346/FDP6 of 21/10/03- 3 Nos.
j) 7902498/DFD of 03.11.07 -10 Nos.
8 Ingersoll-Rand (India) 22 1977 a) 137485/SJ of 10/1/77 - 19 Nos
1994 b) 135415/DJ of 9/3/94 - 3 Nos.
9 Atlas Copco (India) 49 1989 a) 135076/DJof 16/04/88 - 15 Nos.
to b) 135128/DJ of 7/7/89 - 16 Nos
1992 c) 135236/DJ of 27/3/91 - 18 Nos.
TOTAL 201
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In the past for various reasons such as ageing, inefficiency, high operating runs with
increased maintenance efforts, machine beyond economic repairing etc. machines have
been written off from time to time as shown below.
Sl No Make Quantity Written Off

1 Cooper Bessemer (USA) 2
2 Nouvo Pignone(Italy) 24
3 CA Parson (USA) 4
4 IR (Canadian) 29
5 BPCL ( India) 14
6 IR (India) 4
7 KGK 5
TOTAL 82
After written of the above units, total holding of compressor packages at present is 119
nos. Out of this 62 nos. are LPB compressors and 57 nos. are Gas Lift Compressors. The
details of the presently available compressors are provided in the following table.
Sl No Make LP Booster Gas Lift Total

1 IR (Canadian) 3 1 4
2 CSI Worthington 14 5 19
4 BPCL 13 16 29
5 Ingersoll-rand (India) 11 7 18
6 Atlas Copco (India) 21 28 49
TOTAL 62 57 119
Station wise deployment of the above compressors along with relevant details such as
vintage, cumulative running hours, present condition are presented in enclosed Annexure
I.
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8
PERFORMANCE VIS-À-VIS OIL’S EXPERIENCE WITH CURRENT FLEET OF
COMPRESSOR PACKAGES
The current fleet of operating Gas Compressors in our field were installed at different
times starting from 1972 and almost 65 % of total available units are of vintage more than
25 years. A summary of the installed units during the last five decades along with average
vintage of packages is presented below.
Procurement Quantity Written off Quantity Currently Average Vintage of

Period Procured quantity in operation operating units
1960 - 1970 30 30 0 0
1970 - 1980 64 42 22 35 years
1980 - 1990 64 10 54 25 Years
1990 - 2000 30 0 30 15 Years
2000 - Present 13 0 13 5 years
Total 201 82 119
For the units having vintage more than 25 years (procured till 1985), current performance
level is expected to be lower than optimum because of aging associated with increased
wear and tear as well as material fatigue, uninterrupted operation, operational severity and
a host of other factors. However with increased maintenance efforts, it has been possible
to keep the units operational, but at reduced efficiency.
It is pertinent to mention here that, except K.G. Khosla make compressor packages, all
other compressor packages have found to be performed at satisfactory level in general
during the operating life cycle despite occasional failures. However, out of the entire lot,
performance level of Worthington make packages have found to be much superior, as
evident from lower breakdown frequency, lower consumption of spares and consistent
output throughout the entire life cycle since commissioning in 1986.
A brief write up on the individual performance level vis-à-vis problems encountered with
different makes of the compressor packages is presented below.
(i) Ingersoll-Rand (Canadian) Make Compressor
These units are of 1972-74 vintage, having Waukesha Engines as prime movers (Model
L7042, L5790, L5108 and L3711). These machines with sound inherent design and
packaging have been performing satisfactorily excepting machines with L3711 Engines.
Almost all of them have crossed their economical operational life and few are long shut
down beyond economical revival. Because of ageing and natural wear & tear, machines
presently do not perform trouble- free beyond operating speed of 600/700 RPM.
The gas engines, Waukesha models, L5108 and L3711 (Clinton series) have been
discontinued in the OEM’s production line. The L3711 Gas Engines have inherent problems
of cylinder head overheating following high rate of breakdown due to cracked cylinder
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heads/ manifolds. Many of these have crossed long operational run (most of them are
beyond 1 lakh hours) and have extreme worn-out condition. From economical standpoint,
revamping of these units is not feasible. Moreover spares availability of the model is
extremely difficult. Already all units having L3711 engines have been written off.
Although L5108 Waukesha Engines are discontinued in the production line, the engines do
not have much serious problem on design and operational consideration. However
availability of spares has now become a serious concern for operating the units.
(ii) BPCL make Compressors
Due to the poor packaging and certain internal design flaws of earlier lot, these machines
are very much affected by vibration and increased frequency of breakdown, particularly 5
MMSCFD or 130 MSCMD capacity LP Booster Compressors, at speed higher than 700 RPM.
In the packages supplied (1990 and beyond) by them, improvement in the packages has
been noticed to some extent in terms of delivery, erection schedule, packaging of units,
reliability of equipment, design, and after sale service. But these machines again have
acute problem in the indigenously make coolers. However, in the recently supplied units
(2010), imported coolers have been incorporated and out of 10 units supplied, 4 nos. Gas
Lift compressors and 1 no. LPB compressor has so far been commissioned. But several
issues cropped up during erection / commissioning of these packages, like material short
supply, statutory approval / certification of field instruments, commissioning schedule
etc., in which BPCL has failed in fulfilling the contractual obligations. Poor after sales
service of BPCL is also a matter of great concern. Further, post commissioning run of the
units is also discouraging as there are a number of breakdown of critical components of
the compressor packages, presumably due to lack of adequate quality control measures
during manufacturing and packaging stages.
Till date, 14 units of BPCL make have been written off.
(iii) KG Khosla make Compressor
Electric motor driven L P Boosters (2 nos.) and Gas Lifters (2 nos.) units of KG Khosla
make were installed in 1985. KGK Compressors have acute operational problems due to
inherent design / manufacturing flaws, and lack of workmanship in manufacturing and
packaging. It is obvious that efficient operation of gas compressor packages is result of
quality and soundness in the design of machinery, manufacture, packaging, erection and
after sales service. In respect of the supplied packages, M/S KGK has appeared to be
lacking in attaining the expected level in terms of delivery, erection schedule, packaging of
units, reliability of equipment, design, and after sale service. The operating performance
of these machines is very poor with low availability and the maintenance efforts required
for these machines are high.
Another gas engine (2 stroke Janbacher make, Austria) driven LP Booster unit installed at
GCS7 could not be operated and had to be discontinued for various problems including very
high degree of sound level.
All the above five units have been written off.

10
(iv) Worthington Gas Compressors
Out of all the lots procured so far, both imported and indigenous, these machines have
been operating very smoothly (since commissioned in 1986) for last 25 years without any
major problems and with minimum spares consumption. Only recently due to normal fatigue
and wear & tear, these have been showing ageing effect and much attention is now needed
to carry out major overhaul and replacement of many vital/major and minor components.
However it is opined that all these units are expected to cover another 5 years with
constant monitoring and scheduled servicing.
(v) Ingersoll-Rand ( India)
These units were procured and installed in two batches, the first batch of 19 nos. between
1980 to 1984, and the second batch of 3 nos. in 1994. The performance of 19 (13 Motor
driven, 6 Engine driven) units was not up to the mark as there had been frequent
breakdown, high rate of spares consumption and labour cost due to failures in the
compressor components. Although the design criteria of the compressors are similar to
that of IR (Canadian), but the machines are performing poorly presumably due to inferior
materials, finish of the components, inefficient packaging etc. It is pertinent to mention
that identical model of compressors, supplied by their foreign principal are devoid such
problems. However with constant in-house effort and with replacement of many
components, there has been improvement in their availability.
The last 3 units (with Waukesha L7042 engine) are functioning well without any major
trouble (except indigenous make cooler) till now.
Till date, 4 units of IR (I) make have been written off.
(vi) Atlas Copco (India) Compressors
These machines were procured and installed in three batches (15, 16 & 18 nos.) between
1988 and 1992.The performance of these machines so far satisfactorily below 700 RPM,
especially in L.P. Booster units. These are problematic beyond 700 RPM causing vibration
and exhaust overheat/overload. Spares consumption presently are on the rise due to
ageing of the machines. However it is expected that these will continue in operations (with
capacity deration) for next 5 - 7 years.
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11
SPARES : PROVISION MODALITY, AVAILABILITY AND CONSTRAINTS
As there is a large mix of make and models of gas compressor packages operating in
different service duties, very wide range of spares are involved in the Spares Management
System. However because of little interchangeability, inventory control of Gas
Compressors is very critical. Spares are required to provide for failures and preventive
maintenance (PM) due to
i) Normal wear & tear owing to ageing/operation

ii) Working /operating conditions
iii) Overload of machines
iv) Accidents/Breakdowns.
During the operational life of compressors, due to dynamic motion of components, wear
and tear occurs in various components warranting repairing or replacement during
overhauling (Top & Major overhauling) and other scheduled maintenance. Similarly
working/operating conditions also attribute to the cause of spares requirement. Spare
part requirements can be planned and the policy pertaining to stocking can be made based
on annual rate of consumption with some tolerances against uncertainty. The problem of
failures and spares requirement gets more complicated towards the end of life of a
particular machine.
The entire spares are categorized based upon (i) their consumption value (ii) their
criticality-whether vital, essential or desirable (iii) their availability-whether scarce,
difficult and easy and (iv) Usage Rate – frequency of use or slow/fast moving item etc. By
analyzing criticality level of each spares, stocking policy is required to be determined. The
items that are subject to dynamic loading/frictional force can have more wear & tear and
/or fatigue and usually have high usage rate and this require much attention in spares
management for PM (Preventive Maintenance) to reduce downtime due to any breakdown.
For catering spares of large fleet of gas compressor packages, provisioning of spares is
primarily done against store’s stock of Materials department, keeping in mind the
consumption value, consumption pattern of items and insurance item. Other procurements
are made through Direct Charge Indents for items of non- regular consumption. Besides,
some high value items, which have been replaced following failure due to wear & tear are
salvaged and kept for re-use. Many components of gas engines, compressors, aerial coolers
have been indigenously developed at low cost. However the reliability factors of the
salvaged and indigenous components are low and sometimes failures are unpredictable.
There are some other groups of materials that are non-standard in nature which are
developed / fabricated in-house.
While making provisions for spares of the large variety of makes and models, constraints
are usually faced, like long lead time, delayed delivery, high cost of OEM spares, obsolesce
due to technology up gradation / change in design etc. Because of the criticality of the
operations, most of the spares (frame components) of the Engines are made available from
the OEM. But problem(s) faced when the OEM either discontinue the component
supply/manufacture or change/ modify the design aspects of various components. This
12
situation happens and can be envisaged in the machines of old vintage. The following is
worth mentioning in this regard.
(i) The Waukesha L3711 model engines have been discontinued in the OEM’s
production line and availability of major spares from the OEM have not been
possible. Spares from other source(s) are also difficult and sometime not possible.
Even if they are available, operation of machines with critical components from
source(s) other than the OEM becomes unreliable. Nevertheless, as the units are
of very old vintage, all these have been phased out.
(ii) The Atlas Copco (I) machines procured between 1988 to 1991 have already
undergone technology changes, such as design in compressor frame components,
lube oil pump etc. It is apprehended that many such design modification and
obsolescence are likely in future.
(iii) In the Worthington gas compressors, some components of compressor that were
fitted with the original compressors are no longer available and the new version
(modified) of major components from the OEM cannot be readily used unless
modifications are carried out. Besides, the cost has also been increased
substantially.
(iv) With advancement of technology, more concern for safety aspects and efficient
control of operations, there have been remarkable changes in control philosophy
of compressor packages across the globe. The electronic type control panels in
place of earlier pneumatic type have now become most preferred option. Similar is
the case with ignition system of the engines. The latest version of shielded type
ignition system like Altronic or CPU 95 system in place of earlier Magtronic
system has got wide acceptability across the industry. To keep pace with the
latest development of technological changes, efforts are on to replace the old
systems with the new systems in phased manner.
(v) The older version of IR Compressors (pre eighties) has been fitted with channel
type valves, which are no longer available with OEM. However these valves are
being replaced with rugged and reliable metallic/nonmetallic plate or ring type
valves.
(vi) The Waukesha model L5108 G engines has been discontinued in the manufacturer’s
production line, along with vital component like engine crankshaft etc. Unless other
alternative source(s) are available for requisite spares, maintenance of the units
will be difficult. Otherwise these engines will have to be replaced with other
version of engines.
Thus, from the above few cases of non availability of components, especially critical
ones from the OEM or any other reputed/ reliable source(s), availability of machines as
desired cannot be maintained and down time cannot be avoided. Beside considerable
time is wasted for exploring new vendor(s), cost incurred in procurement of spares is
very high.
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13
TECHNOLOGY INDUCTION IN GAS COMPRESSOR OPERATIONS
OIL has so far acquired a large fleet of Gas Compressor Packages for boosting LP gas and
supplying Gas Lift gas for oil winning purposes. Majority of these Gas Compressor packages
are gas engine driven, while few are electric motor driven. Over the years there has been
significant development in gas compression technology across the world on consideration
of safety aspects and efficiency in control of operations. To keep pace with the latest
development of technological changes, consistent efforts have been put in for induction of
newer and latest technology in our operations. Two major technologies which have recently
been inducted in our gas compression service are as below.
1.0 CPU-95 Ignition System
The existing gas engines have either Magtronic or Altronic based Ignition system. These
systems typically have mechanical components for triggering the spark needed for
sustaining the ignition. Recent advances in ignition technology have led to the development
of the Microprocessor Based Ignition System. Such systems incorporate a dedicated
microprocessor which controls the release of the spark needed for the ignition to occur.
The Altronic CPU-95 ignition system is such a microprocessor-based ignition system
designed for application on natural gas fueled engines.
The basic features of the system can be summarized as below.
 A microprocessor-based, crankshaft referenced digital ignition system.

 The system features crankshaft-triggered timing accuracy and the capability to
vary timing electronically.
 The system is field-programmable and offers a variety of advanced control
methods.
 Comprehensive display capability
 Spark characteristic control
 Global and individual cylinder timing control
 Diagnostic capabilities and Serial communications
The Display Module of the system enables the following
 System status and mode

 Normal running information
 Diagnostic messages
 Timing status
 Engine over speed set point
The CPU-95 features several advantages over the traditional magneto / alternator
powered mechanically actuated ignition system.
a) Flexibility of use
b) Better Diagnostic capabilities, which help to fix any problem easily and thus
reduce down-time.
14
c) Better Timing Control and Fuel Efficiency which helps to boost engine
performance and achievement of better emission norms.
d) Troubleshooting at the Field and diagnose a problem through a series of Fault
Codes.
e) Easy Maintenance which eliminates complicated mechanical repair jobs requiring
skilled technicians.
f) Enhanced Spark-Plug life due to the feature which makes it possible to vary the
energy level of the Spark Plugs on the basis of requirement.
g) Multi-strike capability which helps to start difficult engines or hard start engines
in cold weather conditions or with low cranking RPM.
Benefits derived with CPU 95 system over Altronic III system is as presented below.
Parameter Altronic III CPU 95 Results
Ignition Self Alternator Microprocessor based Reduce maintenance

principle powered Mechanical digital ignition system cost and downtime
drive
Diagnostic No diagnostic Directly communicating Fix the problem
feature for real ignition Status easily
Timing & fuel Timing adjustment Real ignition timing exhaust emission are
efficiency limitation control reduced
Troubleshoot Takes more time Easy Reduce downtime
at field
Timing control Fixed Can be varied depending High Fuel efficiency
upon the process helps the engine to
condition run smoothly in
optimized condition
Multi strike Single strike Multi Strike facility Easy start in all
weather conditions
2.0 Electronic Control Panel :
The earlier gas compressor packages were supplied with pneumatic type Control Panels.
With advancement of control philosophy, presently electronic type control panels in place
of pneumatic type have now become most preferred option across the industry.
Accordingly, all new compressor packages have now been procured with the most
sophisticated and advanced Altronic Exacta Series XI Control Panels. Basis features and
advantages of this Panel may be summarized as below.
 The system is pre-programmed and need only be configured and tuned for the
application resulting in greater “usability” and flexibility.
 The Series XI Panels offers extensive data storage and trending capability. It can
store up to 1400 data records, taken at user-selectable intervals (process
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variables, faults, shutdowns, etc.). 40 records are taken at 1 second intervals and
stored prior to each shutdown
 The Series XI series Panels offers advanced monitoring and control capability,
including
 Pre-lube
 Auto or manual start
 Warm-up
 Compressor loading/valve control
 Safety shutdown, alarm annunciation and monitoring
 Fast or auto-cool down
 Auto-depressurization (unloading)
 Post-lube
 The Panel is equipped with Smart Analog and Digital I/O boards.
 An unlimited number of alarms and shutdowns can be added on each channel,

including normal high and low alarms and shutdowns, plus :
 Differentials
 Calculated Shutdowns
 Time Delayed Shutdowns
 It records the date and time of each shutdown and stores this data for future
reference. In addition it takes a snapshot of all analog values at the time of
shutdown.
 Series XI Panels records data of all analog values for 39 intervals back in time prior
to the fault (usually 1 second apart).
 The Control Panel displays a combination of analog inputs, shutdowns, alarms,

recorded history, and events.
_______________________
16
WRITE-OFF PLAN OF COMPRESSOR PACKAGES
For the reasons as explained in previous pages, quite a large number of Gas Compressor
packages have been written off in past in phases. Further, few more packages are
presently lying shut down for a long period of time and are beyond revival from economic
point of view. Revival of these units will involve substantial cost and also, efficient and
trouble free operation is unlikely. It is pertinent to mention in this context that as more
and more thrust is given to meet gas supply commitment to the present & future
consumer’s requirement, enhanced oil production and flare reduction in the fields, it is
very essential to have only a healthy, reliable and efficient fleet of gas compressor units
for un-interrupted operational availability.
Apart from phasing out of 31 nos. compressor packages of Cooper Bessemer, Nouvo
Pignone, C A Parson and BPCL make in late 80s / early 90s, 12 nos. packages in 2003, 4 nos.
in 2004 and 35 nos. in 2012 have been written off from the list of holding. Thus a total of
82 compressor packages have so far been written off. The machines have been written off
for one or more of the following reasons:
i) Ageing and crossing of normal /economic operational life

ii) Unreliability in operation / acute operational problems due to inherent design flaws
iii) High frequency of breakdown/shutdown and high maintenance efforts
iv) Long shutdown machines beyond economic repairing / revival
v) Spares constraints
vi) Low efficiency with high degree maintenance costs/efforts.
Details of written off compressor units are shown in enclosed Annexure II
Under this evaluation based on health, spares availability, running hours covered life cycle,
poor operational condition, remote chance of revival and other factors as stated above, 23
units are now earmarked and proposed for written off during the next 4 years in phased
manner. The write off will be done in two phases.
i) Phase I - Presently seven (7) nos. electric motor driven Gas Compressors (4 Gas
Lifters & 3 L.P Boosters) are in operation in GCS-1, GCS-7 and GCS-8. Further one (1)
motor driven GL compressor in GCS 7 is presently shutdown for compressor problem.
Because of the prevailing constraints in electric power availability in the captive
Power Plant in Duliajan, restriction in operations of these units has become necessary
which affects operational requirement. Off late, the issue has gained much
importance due to steep rise in electrical load, especially in the summer, which
restricts operation of the units. Therefore these electric motor drive units have
been proposed for write off in 2015-16. Budget approval for procurement of
replacement units has already been obtained.
Further, 6 units (4 nos. IR (C) and 2 nos. BPCL), which were procured in 1976 / 1979,
are presently in operation in much reduced efficiency and increased breakdown rate
because of long vintage and operational run. These 6 units are also proposed for
write off during 2015-16.
17
However after written off the above 14 units, the units will be kept as standby as
far as possible so long as spares consumption is moderate and maintenance cost /
efforts are minimal.
ii) Phase II – Eight (8) units, which are of 1985 and earlier vintage, have already
crossed economical operating life and presently are in operating condition with much
reduced efficiency, high breakdown rate and increased maintenance efforts and
costs. These units have also been proposed to write off in 2016-17 in the second
phase.
Details of the units proposed for written off indicating make, type, vintage, phase out
plan, cumulative running hours are presented in Annexure-III.
5.4 Out of total 22 units proposed for written off, 13 units are Booster Compressors and
9 units are Lifter Compressors. Make and type of compressors of these are stated in the
Table below.
Sr No Make / Model Quantity Total

1 IR (C) – Wau L 5790 1 No. IR (C) – 4 Nos.
IR (C) – Wau L 7042 3 Nos.
2 IR (I) – Electric Motor 9 Nos. IR (I) – 14 Nos.
IR (I) – Wau 5108 3 Nos.
IR (I) – Wau 7042 2 Nos.
3 BPCL – Electric Motor 2 Nos. BPCL – 4 Nos.
BPCL – Wau L 7042 2 Nos.
5.5 Station wise holding of Gas Compressors after phasing out of 14 units in first phase
(2015-16) and 8 units in second phase (2016-17) together with installed boosting / lifting
capacities are presented in enclosed Annexure IV.
_________________________
18
AUGMENTATION OF COMPRESSOION INFRASTRUCTURE
In the present and future thrust for meeting gas supply commitment, reduction of gas
flare to a bare minimum level, and for augmentation of crude oil production from artificial
lift wells, adequate no. of compressors, both L.P Booster and Gas Lifter need to be
catered to avert operational interruption/downtime in the existing installations, and also
to create additional infrastructures in the new areas.
Existing Installations / Areas :
With phasing out a number of compressor packages in recent times and also considering
the proposed write off plan till 2016-17, the availability scenario of compression
infrastructure in existing areas is shown in Annexure V. It is worth mentioning here that
the actual operating capacity becomes much less than designed capacity for varied makes
of compressors because of various reasons like safe maximum operating speed,
temperature effect and effect due to lower suction pressure etc. Therefore these de-
rating factors have been considered while calculating total available capacity of the
operating compressors.
Considering the availability scenario of compression infrastructure in existing areas as

detailed in Annexure V, augmentation of gas compression facility is required to be made in
the following installations as bare minimum requirement by 2015-16.
CATEGORY INSTALLATION QUANTITY TOTAL

L.P.B COMPRESSORS GCS 1 1 10 Nos.
(2.5 MMSCFD capacity) GCS 5 1
GCS 8 3
GCS Kathalguri 1
GCS Ushapur 1
GCS Nagajan 1
GCS Moran 2
GAS LIFT COMPRESSORS GCS 1 1 7 Nos.
GCS 2 / 6 / 8 3
GCS Ushapur 1
GCS K’Guri / L’kasi 1
GCS J’Jan / N’Jan 1
While assessing the above requirement, the following considerations / assumptions have
been taken into account.
a) There shall be no change in gas profile for the next 3 / 4 years and as such,
current low pressure gas availability and gas lift gas consumption in a particular
area will remain same.
b) The proposed write off plan of the compressor packages as stated earlier.
19
c) Presently there are 19 nos. of Worthington make compressor packages which were
installed in 1986. Off late, due to normal fatigue and wear & tear, these packages
have been showing ageing effect and therefore breakdown frequency is on
increasing trend. To cope up with increased breakdown and long shutdown duration,
additional compressor packages have been proposed to be installed in critical areas
/ installations in order to curtail flare and maintenance of gas lift pressure.
New Installations / Areas :
With continued thrust on oil exploration and production activities, development of gas
compression facility is required to be taken up as and where required in order to pickup
and utilize the produced gas so as to avoid flare. Presently, creation of full fledged gas
compression facility in Makum, Dikom and Tengakhat area is planned and the project will
be executed by Production Project department. However, action has already been initiated
by the department to set up gas compression facility in Tengakhat area on temporary basis
by relocating one (1) no. LPB compressor from Kathalguri GCS and one (1) no. Gas Lift
compressor from Moran GCS. Similar temporary GCS is already in operation in Dikom.
Additionally, outsourcing of compression service under BOO concept has been planned in
two more locations. Further, compressor stations at Baghjan and Barekuri are also planned
as a long time measure.
_________________________
20
HIRING OF COMPRESSION SERVICE
With the development of gas compression infrastructures in various operational areas over
the time, it has been possible to pick up and utilize the produced gas with gradual
reduction of flare over the years. However there is still scope to arrest flare. The main
challenges for flare reduction are as below:
 Long lead time for construction of full fledged Gas Compressor Station as it takes
considerable time to develop and establish a field.
 Long lead time for material procurement specially the Gas Compressor packages and
also due to the fact that most of the high cost equipment for natural gas
processing has to be sourced from abroad.
 Locational disadvantage, difficult logistics, difficulty in land procurement, space
constrains, quantum of gas availability etc. are also some of the other constraints in
developing full fledged Gas Compressor Stations.
To mitigate the above challenges, the department has taken proactive decisive measures
to reduce flare with introduction of BOO (Build Own Operate) concept for outsourcing of
compression service in six locations where compression infrastructures / facilities are not
available. The contract was awarded to M/s Assam Air Products Limited on 23rd June 2010
for developing infrastructure and providing compression service in six locations namely
Bhogpara, Dikom, Makum, HJC (Chabua), Barekuri and Hatiali.
All the above six installations was put into operation in May 2011, initially with one (1)
compressor packages in each installation. Subsequently, compression capacity was
augmented in three installations, namely Makum in 2012, Dikom in 2013 and Hatiali in 2013
with addition of one (1) more compressor packages in each installation. Details of the
above installation are stated below.
Sr. No. Installation Unit Compression Capacity Date of Commissioning

1 Dikom Package 1 40000 SCMD 09.05.2011
Package 2 40000 SCMD 30.06.2013
2 Chabua Package 1 20000 SCMD 10.05.2011
3 Barukuri Package 1 20000 SCMD 15.05.2011
4 Bhogpara Package 1 20000 SCMD 15.05.2011
5 Hatiali Package 1 40000 SCMD 11.05.2011
Package 2 40000 SCMD 12.07.2013
6 Makum Package 1 40000 SCMD 12.05.2011
Package 2 40000 SCMD 13.11.2012
Since commissioning till 31st March, 2013, a total of 86.3 MMSCM of low pressure gas,
which was otherwise flared earlier, has been compressed in the above installations and fed
into distribution network, resulting in reduction of flare substantially.
21
CONCLUSION
The current fleet of operating Gas Compressors in our field were installed at different
times starting from 1972. Out of the entire fleet, the average vintage of 22 units is 35
years, 54 units is 25 years, 30 units is 15 years and 13 units is 5 years. As such almost 65
% of total available units are of vintage more than 25 years. In this context it is worth
mentioning that it is very essential to have only a healthy, reliable and efficient fleet of
gas compressor units for un-interrupted operational availability. Keeping this in mind, the
department has taken adequate steps for skill and competency development of the
engineers / employees by imparting requisite training, induction of new proven technologies
for operational efficiency, efficient spares management practices, cost reduction /
control measures etc. Action for write off of old vintage compressors and procurement of
replacement packages has also been initiated by the department. Further, the department
has taken decisive measures to reduce flare by introducing BOO (Build Own Operate)
concept for outsourcing of compression service in 6 locations where compression
infrastructures / facilities are not available.
ACKNOWLEDGEMENT :
Inputs provided by the departmental colleagues greatly helps in preparation of this note
and the under signer takes this opportunity to acknowledge the help and assistance
received from all concerned. Further, guidance and supports provided by GMP (Gas) i/c in
preparation of this note is also gratefully acknowledged.
Susanta Kumar Sarmah

CEPG (O&M)
Production Gas Department
*****************************
22
TOTAL HOLDING OF GAS COMPRESSORS AS ON 1ST APRIL, 2013 ANNEXURE I
Sr No GCS Duty Unit No. Unit Detail Rated Capacity Vintage Cum R/hrs (up Asset No. Remarks
to Mar'13)
Compressor Prime Mover MMSCMD
1 1 LPB LPB 4 IR (I) Motor 130 1983 134564 4000001365
2 LPB 5 WORTH Cat G399 65 1986 173355 4000001034
3 LPB 6 AC Wau-L7042 130 1989 159877 4000002010
4 GL/GI GL 5 BPCL Motor 76 1990 189744 4000008237
5 GI 4 Atlas Copco Wau-L5790 70 1991 85356 4000001013
6 GL 6 BPCL Cat 3516 76 2012 0 N/A Under commissioning
7 2 LPB LPB 5 AC Wau-L7042 130 1990 158093 4000001398
8 LPB 6 BPCL Wau 5790 65 2012 0 N/A Under commissioning
10 GL/GI GI 3 Atlas Copco Wau-L5790 70 1992 119444 4000001002
11 4 LPB LPB 3 AC Wau-L7042 130 1989 162432 4000001011
12 LPB 4 AC Wau-L7042 130 1992 169345 4000001094
13 LPB 5 BPCL Wau-L5790 130 1996 156363 4000000175
14 GL/GI GL 3 IR (C) Wau-L5790 76 1976 181891 4000004476
15 GL 6 Atlas Copco Wau-L5108 76 1992 149496 4000000091
18 5 LPB LPB 1 IR (C) Wau-L7042 130 1976 52944 N/A Inv. No. NK-5075
19 LPB 4 Worth Cat G399 65 1986 193297 4000001182
20 LPB 5 AC Wau-L7042 130 1990 136960 4000003461
21 6 LPB LPB 2 IRC Wau-L7042 130 1976 126161 4000001928
22 LPB 3 AC Wau-L7042 130 1989 128381 4000001897
23 LPB 4 AC Wau-L7042 130 1989 144357 4000001903
24 GL/GI GL 7 Atlas Copco Cat G399 76 1991 136522 N/A
27 7 LPB LPB 2 BPCL Wau-L7042 130 1979 127057 4000001996/97
28 LPB 3 IR(I) Motor 130 1984 77568 N/A S/D
29 LPB 4 IR(I) Motor 130 1985 98686 4000001364
30 GL/GI GL 2 IR(I) Motor 76 1983 134210 4000001057
31 GL 3 IR(I) Motor 76 1983 13604 4000001059
32 GL 4 IR(I) Wau-L5108 76 1985 N/A N/A S/D
to Mar'13)
33 8 LPB LPB 2 BPCL Wau-L7042 130 1979 154457 4000002053
34 LPB 3 IR(I) Motor 130 1984 101105 4000002047
35 GL GL 1 Worthington Cat G399 76 1986 200810 4000004473
36 GL 3 BPCL Motor 76 1991 97229 N/A
38 K'GURI LPB LPB 2 Worthington Cat G399 65 1986 127365 4000001217
39 LPB 3 Worthington Cat G399 65 1986 161108 N/A
40 LPB 7 Atlas Copco Wau-L7042 130 1992 119665 4000001207
41 GL/GS GL 1 IR (I) Wau-L5108 76 1986 73582 N/A S/D
42 GL 3 BPCL Wau-L5108 76 1989 130168 4000001906
43 GS 1 Atlas Copco Wau-L5790 70 1994 116408 4060007924
45 JRN LPB LPB 1 IR (C) Wau-L7042 130 1976 113652 4000001928
46 LPB 2 Worthington Cat G399 65 1986 165040 4000001133
49 LPB 5 Atlas Copco Wau-L7042 130 1991 124059 N/A
50 GL / GI GL 1 IR (I) Wau-L5108 76 1983 99141 4000001149
51 GL 2 Worthington Cat G399 76 1986 202267 4000003630
52 GL 3 Atlas Copco Cat G 399 76 1989 147599 4000001103
54 U'PUR LPB LPB 1 Worthington Cat G 399 65 1986 118273 4000001036
55 LPB 2 Worthington Cat G 399 65 1986 134657 4000001035
57 GL/GI GL 1 Worthington Cat G399 76 1986 201140 4000001039
58 GL 2 IR (I) Wau-L5108 76 1984 72306 4000001043
59 GL 3 Atlas Copco Cat G399 76 1989 141477 N/A
60 N'JAN LPB LPB 1 Worth Cat G399 65 1986 141826 4000001089
61 LPB 2 AC Wau-L7042 130 1989 111546 4000001069
62 GL GL 1 BPCL Wau-L5108 76 1989 103810 4000001472
63 GL 2 Atlas Copco Cat G399 76 1989 146559 4000001063
64 L'KASHI LPB LPB 1 Atlas Copco Wau-L7042 130 1992 95894 4000001155
to Mar'13)
68 GL GL 1 Atlas Copco Wau-L5108 76 1993 109201 4000003559
69 GL 2 Atlas Copco Wau-L5108 76 1994 121255 N/A
70 J'PUR LPB LPB 1 Atlas Copco Wau-L7042 130 1993 144684 4000001097
71 LPB 2 BPCL WauL5790 130 1996 22024 N/A NK-15781
75 S'MARI LPB LPB 1 IR(I) Wau-L7042 130 1996 129263 4000000055
76 LPB 2 IR(I) Wau-L7042 130 1996 110765 4000000057
79 GL/GS GL 1 BPCL Wau-L5108 76 1996 92956 4000000053
80 GL 2 BPCL Wau-L5108 76 1996 94007 4000000059
83 GS 5 Atlas Copco Wau-L5790 70 1994 N/A N/A
84 K'LONI LPB LPB 1 Atlas Copco Wau-L7042 130 1993 114188 4000003496
85 LPB 2 BPCL Wau-L7042 130 2000 68466 4000004730
87 LPB 4 BPCL Cat G3516G 65 2005 36436 N/A
90 GL 2 BPCL Wau-L5108 76 2000 88921 4000004733
92 GL 4 BPCL Cat 3516G 76 2005 44082 N/A
94 DIKOM LPB LPB 1 Worthington Cat G399 65 1986 170190 4000004730
to Mar'13)
97 MRN-2 LPB LPB 1 IR(I) Motor 65 1982 86504 4000003505
98 LPB 2 IR(I) Motor 65 1983 134710 4000003508
99 LPB 3 IR(I) Wau-L7042 130 1983 139759 4000003492
100 LPB 4 IR(I) Wau-L7042 130 1985 141604 4000003501
101 LPB 5 Worth Cat G399 65 1989 175021 4000001049
102 LPB 6 AC Wau-L7042 130 1991 167770 4000003502
103 LPB 7 AC Wau-L7042 130 1991 124264 4000003500
104 GL/GI GL 2 IR (I) Motor 76 1983 145332 4000003514
105 GL 3 Worthington Cat G399 76 1986 137291 4000001128
106 GL 4 BPCL Wau-L5108 76 1988 114136 N/A Inv. No. NK-15089
107 GL 5 Atlas Copco Cat G399 76 1989 109901 4000001168/69
108 GL 6 Atlas Copco Cat G399 76 1992 101626 4000003567 Inv. No. NK-14652
110 H'JAN LPB LPB 1 BPCL Wau-L7042 130 1996 70637 4000000053
111 LPB 2 IR(I) Wau-L7042 130 1996 82281 4000000052
115 GL GL 1 BPCL Wau-L5108 76 1996 78999 4000000101
116 GL 2 BPCL Wau-L5108 76 1996 90023 4000000102
118 GL 4 BPCL Cat 3516G 76 2005 33268 4060019333
TOTAL HOLDING IN 2012-13 LPB 62 Nos.
GL 57 Nos.
TOTAL 119 Nos.
PHASING OUT OF COMPRESSOR PACKAGES ANNEXURE - II
GCS Unit No. Unit Detail Vintage Phase out Write Off Reference
Compr. Prime Mover Year
1. Written off during 1989 to 1994

2 GI NP YSC 206/2ap 1967 1989-90 A/Cs-54-593/89 dated 29.09.1989
GI NP YSC 206/2ap 1967 1989-90
GI NP YSC 206/2ap 1967 1989-90
LPB NP YSC 206/2ap 1967 1989-90
GL NP YSC 206/2ap 1967 1989-90
3 LPB NP YSC 206/2ap 1967 1989-90
4 GI NP YSC 206/2ap 1967 1989-90
LPB NP YSC 206/2ap 1967 1989-90
6 GI NP YSC 206/2ap 1966 1989-90
LPB NP YSC 206/2ap 1967 1989-90
LPB NP YSC 206/2ap 1967 1989-90
MRN 1 GI NP YSC 206/2ap 1966 1989-90
1 GI NP YSC 206/2ap 1966 N/A Write off approval reference not tracable
GR NP YSC 206/2ap 1966 N/A
GI C. Bessemer Wau-F 1905 1962 N/A
GI C. Bessemer Wau-F 1905 1962 N/A
2 GI NP YSC 206/2ap 1967 N/A
3 GL CA Parson Roles Royce 1966 N/A
4 GI NP YSC 206/2ap 1967 N/A
LPB NP YSC 206/2ap 1967 N/A
6 GI NP YSC 206/2ap 1966 N/A
1 GI NP YSC 206/2ap 1966 1994-95 A/Cs:51/12/11/94-95 dated 14.06.1994
2 GL NP YSC 206/2ap 1967 1994-95
GL NP YSC 206/2ap 1967 1994-95
4 GL NP YSC 206/2ap 1967 1994-95
5 GL CA Parson Roles Royce 1966 1994-95
6 GL NP YSC 206/2ap 1967 1994-95
GL NP YSC 206/2ap 1967 1994-95
7 GL BPCL Wau-L3711 1975 1994-95
2. Written Off during 2003 - 04

1 LPB1 IR (C) Wau-L3711 1974 2003-04 A/Cs/51/12/533/02-03 dated 20.05.2003
2 LPB1 IR (C) Wau-L3711 1974 2003-04
GI 1 IR (C) Wau-L3711 1974 2003-04
3 LPB 1 IR (C) Wau-L3711 1974 2003-04
GL 1 IR (C) Wau-L3711 1974 2003-04
GL 2 BPCL Wau-L3711 1979 2003-04
4 GL2 IR (C) Wau-L3711 1976 2003-04
6 LPB 1 IR (C) Wau-L3711 1976 2003-04
GL4 IR (C) Wau-L3711 1976 2003-04
GL5 IR (C) Wau-L3711 1976 2003-04
MRN 1 LPB3 IR (C) Wau-L3711 1976 2003-04
GL 1 IR (C) Wau-L3711 1976 2003-04
3. Written Off during 2004-05

1 LPB3 IR (C) Wau-L7042 1976 2004-05 A/Cs/51/12/026/04-05 dated 06.12.2004
3 LPB 2 BPCL Motor 1985 2004-05
5 LPB1 IR (C) Wau-L7042 1976 2004-05
K'GURI LPB 1 BPCL Wau-L7042 1979 2004-05
PHASING OUT OF COMPRESSOR PACKAGES ANNEXURE - II
GCS Unit No. Unit Detail Vintage Phase out Write Off Reference
Compr. Prime Mover Year
4. Written Off during 2012- 13

1 LPB2 IR (C) Wau-L3712 1974 2012-13 A/cs:51/12/025/2012-13 dated 10.10.2012
GL1 IR (C) Wau-L3711 1974 2012-13
GL2 IR (C) Wau-L3711 1976 2012-13
GL3 BPCL Wau-L3711 1979 2012-13
GL 4 IR(I) Motor 1977 2012-13
GI 1 BPCL Motor 1990 2012-13
GI 2 BPCL Motor 1990 2012-13
2 LPB2 IR (C) Wau-L3711 1976 2012-13
GL3 IR (C) Wau-L3711 1974 2012-13
GL4 IR (C) Wau-L3711 1974 2012-13
GL5 IR (C) Wau-L3521 1974 2012-13
3 LPB 3 KGK Motor 1983 2012-13
GL 3 IR( (I) Motor 1983 2012-13
4 LPB 1 BPCL Wau-L7042 1979 2012-13
LPB2 KGK Motor 1985 2012-13
GL2(N) IR (C) Wau-L3711 1973 2012-13
GL4 KGK Motor 1986 2012-13
5 LPB2 BPCL Wau-L3711 1979 2012-13
LPB 3 BPCL Motor 1976 2012-13
6 GL3 IR (C) Wau-L3711 1974 2012-13
GL 6 IR (C) Wau 5790 1976 2012-13
7 LPB1 KGK JANBACHER 1988 2012-13
GL5 KGK Motor 1988 2012-13
GI 1 BPCL Motor 1978 2012-13
GI 2 IR (I) Motor 1985 2012-13
8 LPB1 IR (C) Wau-L3711 1976 2012-13
GL 2 IR (C) Wau L3711 1975 2012-13
J'JAN GI 1 BPCL Wau L3521 1989 2012-13
U'PUR GI 1 BPCL Wau L3521 1989 2012-13
MRN - 1 LPB1 IR (C) Wau-L3711 1973 2012-13
LPB2 IR (C) Wau-L3711 1974 2012-13
GL3 IR (C) Wau-L3711 1974 2012-13
GI 1 IR (C) Wau-L 5790 1972 2012-13
MRN 2 GL 1 IR (I) Motor 1977 2012-13
GI 1 BPCL Motor 1977 2012-13

PROPOSED PHASE OUT PLAN OF LP BOOSTER AND GL DUTY COMPRESSOR ANNEXURE - III
GCS Unit No. Unit Detail Rated Vintage Present Phase out Cum R/hrs (upto Remarks
Capacity Status plan (Yr.) Mar'13)
Compr. Prime Mover
MSCMD
1 LPB 4 IR (I) Motor 130 1983 Operating 2015-16 134564 Proposed for electric power constraint in Power House
GL 5 BPCL Motor 76 1990 Operating 2015-16 189744 Proposed for electric power constraint in Power House
4 GL 3 IR (C) Wau-L5790 76 1976 Operating 2015-16 181891 Long vintage. Operates with low efficiency.
5 LPB1 IR (C) Wau-L7042 130 1976 Operating 2015-16 52944 Long vintage. Operates with low efficiency.
6 LPB 2 IR (C) Wau-L7042 130 1976 Operating 2015-16 126161 Long vintage. Operates with low efficiency.
7 LPB2 BPCL Wau L7042 130 1979 Operating 2015-16 127057 Long vintage. Operates with low efficiency.
LPB 3 IR (I) Motor 130 1984 S/d 2015-16 77568 Proposed for electric power constraint in Power House
LPB 4 IR (I) Motor 130 1985 Operating 2015-16 98686 Proposed for electric power constraint in Power House
GL 2 IR (I) Motor 76 1983 Operating 2015-16 134210 Proposed for electric power constraint in Power House
GL 3 IR (I) Motor 76 1983 Operating 2015-16 13604 Proposed for electric power constraint in Power House
GL 4 IR(I) Wau-L5108 76 1985 S/d 2016-17 N/A Long vintage. Presently shut down for engine problem.
8 LPB2 BPCL Wau L7042 130 1979 Operating 2015-16 154457 Long vintage. Operates with low efficiency.
LPB 3 IR (I) Motor 130 1984 Operating 2015-16 101105 Proposed for electric power constraint in Power House
GL 3 BPCL Motor 76 1991 Operating 2015-16 97229 Proposed for electric power constraint in Power House
J'JAN LPB 1 IR (C) Wau L7042 130 1976 Operating 2015-16 113652 Long vintage. Operates with low efficiency.
GL 1 IR (I) Wau-L5108 76 1983 Operating 2016-17 99141 Operates with low efficiency & high breakdown
U'PUR GL 2 IR (I) Wau-L5108 76 1984 Operating 2016-17 72306 Operates with low efficiency & high breakdown
MRN - 2 LPB 1 IR(I) Motor 65 1982 Operating 2016-17 86504 Operates with low efficiency & high breakdown
LPB 2 IR(I) Motor 65 1983 Operating 2016-17 134710 Operates with low efficiency & high breakdown
LPB 3 IR(I) Wau-L7042 130 1983 Operating 2016-17 139759 Operates with low efficiency & high breakdown
LPB 4 IR(I) Wau-L7042 130 1985 Operating 2016-17 141604 Operates with low efficiency & high breakdown
GL 2 IR (I) Motor 76 1983 Operating 2016-17 145332 Operates with low efficiency & high breakdown
TOTAL UNITS TO WRITE OFF - 23 Nos. 1st Phase (2015-16) - 14 Nos.
2nd Phase (2016-17) - 8 Nos.
TOTAL HOLDING OF GAS COMPRESSORS AFTER PROPOSED WRITE OFF ANNEXURE IV
Sr No GCS Duty Unit No. Unit Detail Rated Capacity Vintage Cum R/hrs (up to Asset No. Remarks
Mar'13)
1 1 LPB LPB 5 WORTH Cat G399 65 1986 173355 4000001034
2 LPB 6 AC Wau-L7042 130 1989 159877 4000002010
5 2 LPB LPB 5 AC Wau-L7042 130 1990 158093 4000001398
9 4 LPB LPB 3 AC Wau-L7042 130 1989 162432 4000001011
10 LPB 4 AC Wau-L7042 130 1992 169345 4000001094
11 LPB 5 BPCL Wau-L5790 130 1996 156363 4000000175
12 GL/GI GL 6 Atlas Copco Wau-L5108 76 1992 149496 4000000091
15 5 LPB LPB 4 Worth Cat G399 65 1986 193297 4000001182
16 LPB 5 AC Wau-L7042 130 1990 136960 4000003461
17 6 LPB LPB 3 AC Wau-L7042 130 1989 128381 4000001897
18 LPB 4 AC Wau-L7042 130 1989 144357 4000001903
19 GL/GI GL 7 Atlas Copco Cat G399 76 1991 136522 N/A
22 8 GL GL 1 Worthington Cat G399 76 1986 200810 4000004473
24 K'GURI LPB LPB 2 Worthington Cat G399 65 1986 127365 4000001217
25 LPB 3 Worthington Cat G399 65 1986 161108 N/A
27 GL/GS GL 1 IR (I) Wau-L5108 76 1986 73582 N/A S/D
28 GL 3 BPCL Wau-L5108 76 1989 130168 4000001906
31 JRN LPB LPB 2 Worthington Cat G399 65 1986 165040 4000001133
Mar'13)
35 GL / GI GL 2 Worthington Cat G399 76 1986 202267 4000003630
38 U'PUR LPB LPB 1 Worthington Cat G 399 65 1986 118273 4000001036
39 LPB 2 Worthington Cat G 399 65 1986 134657 4000001035
43 N'JAN LPB LPB 1 Worth Cat G399 65 1986 141826 4000001089
44 LPB 2 AC Wau-L7042 130 1989 111546 4000001069
45 GL GL 1 BPCL Wau-L5108 76 1989 103810 4000001472
47 L'KASHI LPB LPB 1 Atlas Copco Wau-L7042 130 1992 95894 4000001155
52 GL 2 Atlas Copco Wau-L5108 76 1994 121255 N/A
53 J'PUR LPB LPB 1 Atlas Copco Wau-L7042 130 1993 144684 4000001097
54 LPB 2 BPCL WauL5790 130 1996 22024 N/A
58 S'MARI LPB LPB 1 IR(I) Wau-L7042 130 1996 129263 4000000055
59 LPB 2 IR(I) Wau-L7042 130 1996 110765 4000000057
62 GL/GS GL 1 BPCL Wau-L5108 76 1996 92956 4000000053
63 GL 2 BPCL Wau-L5108 76 1996 94007 4000000059
66 GS 5 Atlas Copco Wau-L5790 70 1994 N/A N/A
67 K'LONI LPB LPB 1 Atlas Copco Wau-L7042 130 1993 114188 4000003496
68 LPB 2 BPCL Wau-L7042 130 2000 68466 4000004730
Mar'13)
70 LPB 4 BPCL Cat G3516G 65 2005 36436 N/A
73 GL 2 BPCL Wau-L5108 76 2000 88921 4000004733
75 GL 4 BPCL Cat 3516G 76 2005 44082 N/A
77 DIKOM LPB LPB 1 Worthington Cat G399 65 1986 170190 4000004730
80 MRN-2 LPB LPB 5 Worth Cat G399 65 1989 175021 4000001049
81 LPB 6 AC Wau-L7042 130 1991 167770 4000003502
82 LPB 7 AC Wau-L7042 130 1991 124264 4000003500
84 GL 4 BPCL Wau-L5108 76 1988 114136 N/A Inv. No. NK-15089
85 GL 5 Atlas Copco Cat G399 76 1989 109901 4000001168/69
86 GL 6 Atlas Copco Cat G399 76 1992 101626 4000003567 Inv. No. NK-14652
88 H'JAN LPB LPB 1 BPCL Wau-L7042 130 1996 70637 4000000053
89 LPB 2 IR(I) Wau-L7042 130 1996 82281 4000000052
93 GL GL 1 BPCL Wau-L5108 76 1996 78999 4000000101
94 GL 2 BPCL Wau-L5108 76 1996 90023 4000000102
96 GL 4 BPCL Cat 3516G 76 2005 33268 4060019333
TOTAL HOLDING IN 2016-17 LPB 49 Nos.
GL 48 Nos.
TOTAL 97 Nos.
YEAR WISE CAPACITY AVAILABILITY OF GAS COMPRESSOR STATIONS ANNEXURE V
GCS Duty Unit Unit Detail Rated Derating factor Available Phaseout Year wise available capacity at GCS Remarks
No. Capacity capacity Plan
Compressor Prime Mover MMSCMD Speed Suc. Press. Temp. 2013-14 2014-15 2015-16 2016-17
1 LPB LPB 4 IR (I) Motor 130 1 0.8 0.95 99 2015-16 217 217 217 118
LPB 5 WORTH Cat G399 65 0.8 0.8 0.95 40
LPB 6 AC Wau-L7042 130 0.8 0.8 0.95 79
GL/GI GL 5 BPCL Motor 76 1 0.8 0.90 55 2015-16 139 139 139 84
GI 4 Atlas Copco Wau-L5790 70 0.8 0.8 0.90 40
GL 6 BPCL Cat 3516 76 0.8 0.8 0.90 44 Under commissioning
2 LPB LPB 5 AC Wau-L7042 130 0.8 0.8 0.95 79 158 158 158 158
LPB 6 BPCL Wau 5790 65 0.8 0.8 0.95 40 Under commissioning
GL/GI GI 3 Atlas Copco Wau-L5790 70 0.8 0.8 0.90 40 40 40 40 40
4 LPB LPB 3 AC Wau-L7042 130 0.8 0.8 0.95 79 237 237 237 237
LPB 4 AC Wau-L7042 130 0.8 0.8 0.95 79
LPB 5 BPCL Wau-L5790 130 0.8 0.8 0.95 79
GL/GI GL 3 IR (C) Wau-L5790 76 0.8 0.8 0.90 44 2015-16 168 168 168 124
GL 6 Atlas Copco Wau-L5108 76 0.8 0.8 0.90 44
5 LPB LPB 1 IR (C) Wau-L7042 130 0.8 0.8 0.95 79 2015-16 119 119 119 40
LPB 4 Worth Cat G399 65 0.8 0.8 0.95 40
LPB 5 AC Wau-L7042 130 0.8 0.8 0.95 79
6 LPB LPB 2 IRC Wau-L7042 130 0.8 0.8 0.95 79 2015-16 237 237 237 158
LPB 3 AC Wau-L7042 130 0.8 0.8 0.95 79
LPB 4 AC Wau-L7042 130 0.8 0.8 0.95 79
GL/GI GL 7 Atlas Copco Cat G399 76 0.8 0.8 0.90 44 124 124 124 124
7 LPB LPB 2 BPCL Wau-L7042 130 0.8 0.8 0.95 79 2015-16 277 277 277 0
LPB 3 IR(I) Motor 130 1 0.8 0.95 99 2015-16
LPB 4 IR(I) Motor 130 1 0.8 0.95 99 2015-16
GL/GI GL 2 IR(I) Motor 76 1 0.8 0.90 55 2015-16 209 209 209 44
GL 3 IR(I) Motor 76 1 0.8 0.90 55 2015-16
GL 4 IR(I) Wau-L5108 76 0.8 0.8 0.90 44 2016-17
GL 7 IR(I) Motor 76 1 0.8 0.90 55 2015-16
8 LPB LPB 2 BPCL Wau-L7042 130 0.8 0.8 0.95 79 2015-16 178 178 178 0
LPB 3 IR(I) Motor 130 1 0.8 0.95 99 2015-16
GL GL 1 Worthington Cat G399 76 0.8 0.8 0.90 44 143 143 143 88
GL 3 BPCL Motor 76 1 0.8 0.90 55 2015-16
GL 4 BPCL Cat 3521 76 0.8 0.8 0.90 44
K'GURI LPB LPB 2 Worthington Cat G399 65 0.8 0.8 0.95 40 159 159 159 159
LPB 3 Worthington Cat G399 65 0.8 0.8 0.95 40
LPB 7 Atlas Copco Wau-L7042 130 0.8 0.8 0.95 79
GL/GS GL 1 IR (I) Wau-L5108 76 0.8 0.8 0.90 44 168 168 168 168
GL 3 BPCL Wau-L5108 76 0.8 0.8 0.90 44
GS 1 Atlas Copco Wau-L5790 70 0.8 0.8 0.90 40
JRN LPB LPB 1 IR (C) Wau-L7042 130 0.8 0.8 0.95 79 2015-16 278 278 278 199
GL / GI GL 1 IR (I) Wau-L5108 76 0.8 0.8 0.90 44 2016-17 176 176 176 176
GL 2 Worthington Cat G399 76 0.8 0.8 0.90 44
GL 3 Atlas Copco Cat G 399 76 0.8 0.8 0.90 44
GL 4 Atlas Copco Cat G 399 76 0.8 0.8 0.90 44
U'PUR LPB LPB 1 Worthington Cat G 399 65 0.8 0.8 0.95 40 159 159 159 159
LPB 2 Worthington Cat G 399 65 0.8 0.8 0.95 40
GL/GI GL 1 Worthington Cat G399 76 0.8 0.8 0.90 44 132 132 132 132
GL 2 IR (I) Wau-L5108 76 0.8 0.8 0.90 44 2016-17
GL 3 Atlas Copco Cat G399 76 0.8 0.8 0.90 44
N'JAN LPB LPB 1 Worth Cat G399 65 0.8 0.8 0.95 40 119 119 119 119
LPB 2 AC Wau-L7042 130 0.8 0.8 0.95 79
GL GL 1 BPCL Wau-L5108 76 0.8 0.8 0.90 44 88 88 88 88
L'KASHI LPB LPB 1 Atlas Copco Wau-L7042 130 0.8 0.8 0.95 79 238 238 238 238
GL GL 1 Atlas Copco Wau-L5108 76 0.8 0.8 0.90 44 88 88 88 88
J'PUR LPB LPB 1 Atlas Copco Wau-L7042 130 0.8 0.8 0.95 79 158 158 158 158
LPB 2 BPCL WauL5790 130 0.8 0.8 0.95 79
GL 3 BPCL Cat 3516 76 0.8 0.8 0.90 44
S'MARI LPB LPB 1 IR(I) Wau-L7042 130 0.8 0.8 0.95 79 316 316 316 316
LPB 2 IR(I) Wau-L7042 130 0.8 0.8 0.95 79
GL/GS GL 1 BPCL Wau-L5108 76 0.8 0.8 0.90 44 212 212 212 212
GL 2 BPCL Wau-L5108 76 0.8 0.8 0.90 44
K'LONI LPB LPB 1 Atlas Copco Wau-L7042 130 0.8 0.8 0.95 79 317 317 317 317
LPB 2 BPCL Wau-L7042 130 0.8 0.8 0.95 79
LPB 4 BPCL Cat G3516G 65 0.8 0.8 0.95 40
LPB 5 BPCL Wau 5790 65 0.8 0.8 0.95 40
Under commissioning
GL 2 BPCL Wau-L5108 76 0.8 0.8 0.90 44
GL 4 BPCL Cat 3516G 76 0.8 0.8 0.90 44
GL 5 BPCL Cat 3516 76 0.8 0.8 0.90 44
DIKOM LPB LPB 1 Worthington Cat G399 65 0.8 0.8 0.95 40 80 80 80 80
GL GL 1 Worthington Cat G399 76 0.8 0.8 0.90 44 44 44 44 44
MRN-2 LPB LPB 1 IR(I) Motor 65 1 0.8 0.95 49 2016-17 454 454 454 454
LPB 2 IR(I) Motor 65 1 0.8 0.95 49 2016-17
LPB 3 IR(I) Wau-L7042 130 0.8 0.8 0.95 79 2016-17
LPB 4 IR(I) Wau-L7042 130 0.8 0.8 0.95 79 2016-17
LPB 5 Worth Cat G399 65 0.8 0.8 0.95 40
LPB 6 AC Wau-L7042 130 0.8 0.8 0.95 79
LPB 7 AC Wau-L7042 130 0.8 0.8 0.95 79
GL/GI GL 2 IR (I) Motor 76 1 0.8 0.90 55 2016-17 275 275 275 275
GL 3 Worthington Cat G399 76 0.8 0.8 0.90 44
GL 4 BPCL Wau-L5108 76 0.8 0.8 0.90 44
H'JAN LPB LPB 1 BPCL Wau-L7042 130 0.8 0.8 0.95 79 317 317 317 317
LPB 2 IR(I) Wau-L7042 130 0.8 0.8 0.95 79
GL GL 1 BPCL Wau-L5108 76 0.8 0.8 0.90 44 220 220 220 220
GL 2 BPCL Wau-L5108 76 0.8 0.8 0.90 44
GL 4 BPCL Cat 3516G 76 0.8 0.8 0.90 44

Listing of Installation (Gas Compressor Facilities)

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What are gas compression facilities used for in OIL?

What are gas compression facilities used for in OIL?

What is the history of compressor facilities in OIL?

What is the history of compressor facilities in OIL?

PRODUCTION GAS DEPARTMENT NOTE NO.

1. Executive Summary Page 3

3. Function of gas compression facilities Page 6

4. History of compressor facilities in oil Page 7

5. Performance vis-à-vis OIL’s experience with Page 9

6. Spares : provision modality, availability and constraints Page 12

7. Technology induction in Gas Compressor operation Page 14

8. Write-off plan of compressor packages Page 17

9. Augmentation of compression infrastructure Page 19

10. Hiring of compression service Page 21

11. Conclusion and Acknowledgement Page 22

Annexure I : Holding of Gas Compressors as on 1st April, 2013

Annexure II : Written Off Gas Compressor packages

Annexure III : Proposed write off plan of Gas Compressors up to 2016-17.

Annexure IV : Total holding of Gas Compressors after Write Off.

Annexure V : Capacity availability of Gas Compressor Stations

7.0 So far as performance level is concerned, the performance of Worthington make

a) Meeting Market commitment, internal consumption and LPG extraction.

Sl Make Qty Year of P.O Reference

Sl No Make Quantity Written Off

Sl No Make LP Booster Gas Lift Total

Procurement Quantity Written off Quantity Currently Average Vintage of

(i) Ingersoll-Rand (Canadian) Make Compressor

(ii) BPCL make Compressors

Till date, 14 units of BPCL make have been written off.

(iii) KG Khosla make Compressor

All the above five units have been written off.

(v) Ingersoll-Rand ( India)

Till date, 4 units of IR (I) make have been written off.

(vi) Atlas Copco (India) Compressors

i) Normal wear & tear owing to ageing/operation

1.0 CPU-95 Ignition System

The basic features of the system can be summarized as below.

 A microprocessor-based, crankshaft referenced digital ignition system.

The Display Module of the system enables the following

 System status and mode

Parameter Altronic III CPU 95 Results

Ignition Self Alternator Microprocessor based Reduce maintenance

2.0 Electronic Control Panel :

 An unlimited number of alarms and shutdowns can be added on each channel,

 The Control Panel displays a combination of analog inputs, shutdowns, alarms,

i) Ageing and crossing of normal /economic operational life

Details of written off compressor units are shown in enclosed Annexure II

Sr No Make / Model Quantity Total

Existing Installations / Areas :

Considering the availability scenario of compression infrastructure in existing areas as

CATEGORY INSTALLATION QUANTITY TOTAL

New Installations / Areas :

Sr. No. Installation Unit Compression Capacity Date of Commissioning

Susanta Kumar Sarmah

1. Written off during 1989 to 1994

2. Written Off during 2003 - 04

3. Written Off during 2004-05

4. Written Off during 2012- 13