The document discusses efficiency improvements at the Oil and Natural Gas Corporation's (ONGC) Uran plant in India. The Uran plant processes 50% of India's oil production through various units like gas stabilization, ethane/propane recovery, and LPG production. The study analyzes recovery factors for the LPG and EPRU units over time, finding a decline in the oldest LPG1 unit likely due to fouling heat exchangers. Recommendations include periodic maintenance, equipment replacements, and optimization of resources to increase production and profits. Replacing gas turbines with electric motors in LPG1 could save electricity costs and increase profits by over 23 crore rupees annually.
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
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. 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
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.
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:sushilkumarshrivastav
