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efficiency improvisation of LPG1, LPG2 and EPRU unit in uran

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ongc project ppt

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

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