The document discusses efficiency improvements for processing units at ONGC's Uran plant in India. It provides background on ONGC and describes the various units at the Uran plant. The objective is to study the processes, find recovery factors for key units like LPG and EPRU, observe efficiency changes, and suggest solutions. Graphs show recovery factors and production for units over time. Recommendations include periodic maintenance, improved software/training, and replacing gas turbines with electric motors. Cost-benefit analysis estimates annual profit of over 23 crore rupees from improved maintenance of heat exchangers.

1. EFFICIENCY IMPROVISATION OF THE PROCESSING
UNITS IN THE ONGC URAN PLANT
By Aditya Oak

2. 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

3. Location of Uran
BHN
Heera
URAN

4. 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)

5. 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.

6. 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

7. OFFSHORE
GSU
I & II
LPG
I &II
EPRU
S/C
II & III
OFFSHORE
LPG
LAN
C2C3
LEAN GAS
CSU
STABILIZED OIL TO REFINERY
MUMBAI REGION OFFICE
URAN ASSET
FINANCEHR MM
CORPORATE OFFICE - DELHI
CFU
I & II
LAN
COGEN & UTIL
CONSUMERS
MSEB
MIDC
POWER
WATER
POWER
STEAM
GAS
COND
OIL
HP BP IOC
IOTL
IPCL
GAIL
HP BP IOC
HL PROCESS MAP
OF URAN
PPCL
GPG
OPG

8. 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

9. 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.

10. Analysis(graph for 2 lpg production unit)
150
155
160
165
170
175
180
185
190
2004-05 2005-06 2006-07 2007-08 2008-09
LPG I
LPG II

11. Analysis lpg 1
145
150
155
160
165
170
175
2004-05 2005-06 2006-07 2007-08 2008-09
RF
RF
0
5
10
15
20
25
30
2004-05 2005-06 2006-07 2007-08 2008-09
NW
NW

12. Analysis lpg 1
286000
288000
290000
292000
294000
296000
298000
300000
302000
2004-05 2005-06 2006-07 2007-08 2008-09
prod
prod

13. Analysis lpg 2
165
170
175
180
185
190
L2RF
L2RF
0
5
10
15
20
25
30
NW
NW

14. Analysis lpg 2
270000
280000
290000
300000
310000
320000
330000
340000
350000
360000
370000
2003-04 2004-05 2005-06 2006-07 2007-08 2008-09
production
production

15. Analysis of EPRU unit
340
350
360
370
380
390
400
410
2004-05 2005-06 2006-07 2007-08 2008-09
EPRURF
EPRURF
0
2
4
6
8
10
12
2004-05 2005-06 2006-07 2007-08 2008-09
NW
NW

16. Analysis of EPRU
1020000
1040000
1060000
1080000
1100000
1120000
1140000
1160000
1180000
1200000
2004-05 2005-06 2006-07 2007-08 2008-09
production
production

17. Effect of climatic conditions on RF
• For lpg 1
150
152
154
156
158
160
162
164
166
168
summer rainy wnter
RF avg
RF avg

18. Effect of climatic conditions on RF
• For lpg 2
177
178
179
180
181
182
183
184
185
summer rainy winter
RF avg
RF avg

19. Effect of climatic conditions on RF
• For EPRU
376
377
378
379
380
381
382
383
384
385
summer rainy winter
RF avg
RF avg

20. 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.

21. 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.

22. 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.

23. 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.

24. 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

25. 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

26. 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

27. Biblography
• www.ongc.com
• Journal for petroleum technology
• ONGC performance report
• Chemical engineering world magazine
• Chemical weekly
• Maintenance engineering and management ; Author:sushil kumar
shrivastav

28. THANK YOU