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efficiency improvisation of LPG1, LPG2 and EPRU unit in uran

efficiency improvisation of LPG1, LPG2 and EPRU unit in uran

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    ongc project ppt ongc project ppt Presentation Transcript

    • EFFICIENCY IMPROVISATION OF THE PROCESSING
      UNITS IN THE ONGC URAN PLANT
      By Aditya Oak
    • Introduction to ONGC(oil & natural gas corporation ltd)
      Formed in 14th august 1956
      Most valuable company of India
      Market value 85000 crores
      contributes over 84% of India’s Oil & gas production
      Every LPG cylinder consumed in India comes from ONGC
      one tenth India’s refining capacity is handled by ONGC
    • Location of Uran
      BHN
      210 km
      30”
      26”
      URAN
      24”
      85 km
      26”
      Heera
    • About Uran plant
      One of the most important installations of ONGC
      Handles 50% of the Indian oil production
      5.5 km area & more than 1000 employee work there.
      The Uran plant has several units. They are listed as follows:-
      1.CFU (Condensate Fractionation Unit)
      2.GSU (Gas Stabilization Unit)
      3.EPRU (Ethane, Propane Recovery Unit)
      4.LPG unit
      5.CSU (Crude Stabilization Unit)
      6.Co-generation plant (Co-Gen)
      7.FGRU (Flare Gas Recovery Unit)
    • Function of Uran plant
      Stabilization of the crude and transportation of it to the refinery.
      Processing the natural gas for producing LPG, Naphtha, C2-C3.
      The primary objective is to maximize the production of LPG.
    • Objective of study
      To study all processes going on in Uran ONGC plant. 
      To find out recovery factor for following processing units in Uran plant:
      1.LPG I
      2.LPG II
      3.EPRU
       To observe changes in efficiency of each unit using recovery factor and find out possible reasons to these changes.
      To suggest solutions to problems faced and solutions for process improvisation in order to increase the total production of LPG as well as to increase the life of the equipments of the unit and analyze the cost benefits
    • URAN ASSET
      POWER
      POWER STEAM
      PPCL
      COGEN & UTIL
      MSEB
      CONSUMERS
      GPG
      WATER
      MIDC
      LPG
      HP BP IOC
      GSU
      I & II
      LPG
      I &II
      LAN
      GAS
      IOTL
      OFFSHORE
      S/C
      II & III
      LAN
      C2C3
      IPCL
      COND
      CFU
      I & II
      EPRU
      LEAN GAS
      GAIL
      OPG
      OIL
      STABILIZED OIL TO REFINERY
      OFFSHORE
      CSU
      HP BP IOC
      FINANCE
      HR
      MM
      MUMBAI REGION OFFICE
      HL PROCESS MAP OF URAN
      CORPORATE OFFICE - DELHI
    • Recovery factor
      Concept widely used in chemical industry
      Used for calculating the efficiency of the unit
      Output/input
      Gives the amount of valuable product extracted from the given unit input of raw material
    • Sample calculation
      For a given day
      input for lpg 1 unit = 5.4184 MMSCMD
      lpg produced = 863 cubic M
      recovery factor = 863/5.4184 M3/MMSCMD
      = 159.377 M3/MMSCMD
      similarly RF of each day for each year is calculated and mean of it gives the average RF of the unit per year.
    • Analysis(graph for 2 lpg production unit)
    • Analysis lpg 1
    • Analysis lpg 1
    • Analysis lpg 2
    • Analysis lpg 2
    • Analysis of EPRU unit
    • Analysis of EPRU
    • Effect of climatic conditions on RF
      For lpg 1
    • Effect of climatic conditions on RF
      For lpg 2
    • Effect of climatic conditions on RF
      For EPRU
    • Conclusions
      LPG 1 being the oldest unit is showing some drop in the efficiency.  
      Heat exchanger tends to get fouling frequently due to constant usage and heavy duty. Hence it shows drop in efficiency over the period of time.
      The gas turbine used in LPG 1 unit for compression purpose shows a serious drop in the efficiency in summers while the electrical motors in LPG unit is showing a very constant performance.
    • Conclusions
      The new modification in the equipment of EPRU unit has reduced the RF of the unit for (c2-c3) but it has helped in increasing the production of LPG. The objective of the plant has been achieved due to this modification.
      Summer season affects the overall productivity of the Uran plant.
      The plant requires periodic maintenance of the cooling units in Uran plant.
      The resources like human, software, electricity, water are not been used properly and effectively.
    • Recommendations
      Periodic shut down of LPG 1 plant for maintenance of heat exchangers at least once a year. 
      shut down should be taken just before summer to give maximum effect of maintenance.
      Heat exchangers of LPG1, LPG 2 and EPRU should be thoroughly inspected on regular basis. This should be done at least 2 times a year. Employees should be trained for resource management.
    • Recommendations
      Employees working on plant should have proper training and full time access to production and design related software’s such as HYSYS.
      Production of key products should be flexible so that the production volume can be controlled depending upon the demand of the products.
      Replace the gas turbine used in the LPG 1 unit with electrical motors.
    • Cost benefits
      LPG subsidized selling price - Rs. 15763.59 per metric ton
      Density: 0.55 tons per cubic meter
      Average production per day: 1000 cubic meter per day
      Electricity
      Cost of 1 KWH: Rs. 3.25
      Consumption of electricity by LPG gas turbines: 2.65 MWH
      Unprocessed gas
      Selling price: Rs. 3.2 per cubic meter
      Maintenance cost of 6 heat exchangers: Rs. 10, 00,000
    • Cost benefits
      Formula for calculating profit from LPG 1 plant due to annual maintenance
      Net profit (after maintenance) = {Profit gained by improved recovery Factor}+ {unprocessed gas sales} + {electricity savings} - {production loss due to shut down} – {Maintenance cost of heat exchangers}
      Profit gained by improved recovery Factor for LPG=23, 31, 16,592.4 Rs
      Profit gained by improved recovery Factor for
      Naphtha =6, 85, 18,296 Rs
      Unprocessed gas sales for 5 days = 41, 60,000 Rs
    • Cost benefits
      Electricity saved in 5 days = 10, 33,500 Rs
      Production loss of LPG per day = 86, 69,974.5 Rs
      Production loss of Naphtha per day = 4943600 Rs
      Net profit (after maintenance) per year is 30, 16, 34,888.4+41,60,000 +10,33,500-6,80,67,872.5-10,00,000 = Rs. 23,77,60,515.9
    • Biblography
      www.ongc.com
       
      Journal for petroleum technology
       
      ONGC performance report
       
      Chemical engineering world magazine
       
      Chemical weekly
      Maintenance engineering and management ; Author:sushilkumarshrivastav
    • Thank you