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The Mangala and Bhagyam oil fields

13th November 2012

The Bhagyam field began production in January with the help of technology from Bornemann, Germany. It is now producing 25,000 barrels of oil/day. OGT talks to Dietrich Muller, from German based manufacturers, Bornemann about the project.

The Mangala and Bhagyam oil fields
Mangala & Bhagyam fields are currently producing Oil at the rate of 150,000 BPD & 25,000 BPD respectively

In the Spring of 2012 Cairn India got the go-ahead to increase output by another 25,000 barrels of oil/day from its producing Mangala fields in the Rajasthan block. Cairn’s Mangala field in Rajasthan is producing at 125,000 barrels of oil/ day since August 2010. Now, the field can take the offtake to 150,000 barrels of oil/day. OGT: The Mangala field is developing into a hugely important field with three satellites – can you say a few words about its development?

DM: Cairn India is the Operator, on behalf of the Cairn Energy and ONGC joint venture, of Contract Area RJ-ON-90/1 in the State of Rajasthan, India. In January 2004, following the largest oil discovery by any company in India since 1985, Cairn added Mangala oil field in Rajasthan to its assets and this, along with other discoveries in Rajasthan forms the core of future developments in India. Till date more than 25 discoveries have been made in this block with Mangala, Bhagyam and Aishwarya being the major ones. Mangala & Bhagyam fields are currently producing Oil at the rate of 150,000 BPD & 25,000 BPD respectively, While Aishwarya field is under development & expected to be online in next few months. Bhagyam field is in rampup mode & expected to achieve a production of 40,000 BPD in next couple of months’ time.

OGT: All three satellites are linked back to the processing facilities in Mangala. Can you talk about that arrangement?

DM: The produced fluids (Oil, water, and gas) from Mangala, Bhagyam and Aishwarya fields are transferred through an underground pipeline network to Mangala Processing Terminal for further processing and separation of Oil from water & gas.

OGT: I understand that oil is then exported to the western coast by the "longest heated pipeline in the world".

DM: After processing at the Mangala Terminal the Oil is exported through a Skin Effect Heat Management System (SEHMS) heated 24” dia, 680 Km long pipeline to various refineries (Reliance Industries Limited  - RIL, Essar and Indian Oil Corporation Limited -IOCL) & to Bhogat terminal (under development).

OGT: I understand that there will be 4 MPP (3 working - one stand-by) to export the entire production from Baghyam to Mangala. Can you tell me about this set-up – why three and do they all perform that same function.

DM: The 4 MPP’s are of identical capacities & perform the same functions. The operating philosophy is to have 3 pumps working and 1 pump on standby mode.

OGT: What technologies are there in the MPP? And were any developed specially for this operation?

DM: MPP’s are sourced from Bornemann, Germany as package units, fully isolated and heat traced.

OGT: The oil from the field is very heavy crude oil - not flowing, when totally de-gassed and at ambient temperature – what challenges does that present? How are you overcoming this problem?

DM: The oil from the fields is sweet & of medium gravity (26-30 API) & has a high pour point (Oil from these fields solidifies at room temperature), In view of this the oil needs to be heated for flow assurance purpose.

At Mangala & Bhagyam fields flow assurance is provided by commingling hot water with crude oil at the wells itself before transporting it to Mangala Processing Terminal (MPT). Also in view of large distance between Bhagyam & MPT, The Oil pipeline from Bhagyam to MPT is insulated & heat traced.

OGT: I understand that you have multiphase flow splitter pumps right upstream of the MPP to assure equal flow and portions of liquid and gas to each single Multiphase Pump (MPP). Can you describe how these work and the benefits?

DM: The MPP has a symmetrical suction as well have been provided with speed control facility to ensure equal distribution of flow through them. Apart from this the header has special type of inserts to aid to it.

OGT: You say that the MPP come as entirely self-contained systems, fully isolated and heat traced. Why is that important?

DM: In view of higher pour point of Bhagyam crude oil, it is important to keep the pump heat traced to avoid solidification of oil or precipitation of wax from oil.

OGT: I understand that Bournemann have supplied pumps for this project. Can you give me information on these, why they were chosen and the advantages they offer?

DM: Bornemann pumps were chosen in view of suitability of their technology for our application & in view of satisfactory performance of Bornemann pumps at other CEIL sites.

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