(Eastern Region) 2, Gariahat Road South, Dhakuria Kolkata - 700 068

OF
Conducted By
(EASTERN REGION)
2, Gariahat Road South, Dhakuria
Kolkata – 700 068
Ph: 033 – 2414 5092, 2414 5088, 2414 5094;
Telefax: 033 – 2414 5091
e-mail: pcraer@pcra.org
Website: http://www.pcra.org
December’2012
Report on Energy Audit of OIL installation at GCS-2, Moran, Assam, India
---------------------------------------------------------------------------------------------------------------
Energy Audit by PCRA, Eastern Region Page 2 of 27
ACKNOWLEDGEMENT
Petroleum Conservation Research Association, Eastern Region (PCRA, ER),

appreciates the interest, participation and collaboration by the management &
engineers of the Oil India Limited (OIL) in carrying out Energy Audit at “Gas
Compressor Station-2(GCS –2), Moran”.
Our special thanks to the Installation Manager and his team of Engineers,
Supervisors and technicians attached to GCS-2 at Moran, who extended their
proactive co-operation and courtesy to the energy audit team during the audit.
The Energy Audit Team:
Sl.
From OIL From PCRA
No.
1. Mr. J. Bhowmik, Chief Engg. Drilling / Asset, Moran Sri D. Dutta, CEM
2. Mr. Dilip Kalita ,Installation Manager, GCS-2 Sri A.K.Mallick, CEA
3 Mr. R. Mandal, Chief Engr(Tech. Audit)
4 Mr. Jishu Shyam, Sr. Engineer, (P-Gas)
5 Mr. Kishore Deka (Sr.Technical Auditor)
---------------------------------------------------------------------------------------------------------------
INDEX
Chapter
Title Page
No.
Executive Summary
1.0 5
Introduction
2.0 6
Existing Energy System
3.0 9
Study of Air Compressor
4.0 13
5.0 Study of Gas Compressor System 17
6.0 Study of Illumination 21
Annexure – I List of Energy Efficient Equip. Suppliers 24
---------------------------------------------------------------------------------------------------------------
1.0 EXECUTIVE SUMMARY
Table-1.1 Major Findings and Estimated Savings
Simple
Estimated
Recommendations (Short / Savings per Annum Payback
Investment
Medium Term) period
KWh Rs. Rs. Years

1. Maintain separate Air
Compressors with
separate air receivers at 46712 2.12 Lakhs Nominal Immediate
14kg/cm2 and 5 kg/cm2
pressure level
2. Arresting line Leak and
running 20 HP To be
82519 3.75 Lakhs
compressors in place of estimated
40 HP compressors.
3. Replace 36 watt FTL
10.5
with 28 watt energy 5339 0.24 Lakhs 0.21 Lakhs
Months
efficient T5 lamps
Total 134570 6.11 Lakhs 0.21 Lakhs
---------------------------------------------------------------------------------------------------------------
2.0 INTRODUCTION
2.1 IMPORTANCE OF ENERGY CONSERVATION & ITS BACKGROUND
Energy is one of the most coveted inputs in the development of any society. With the
accelerated growth of the economy the demand for energy is increasing exponentially. On the
supply side the stock of the conventional energy resources like fossil fuel are limited and
rapidly depleting. India gradually becoming dependent on external sources of energy thereby a
considerable part of the GDP is exhausted for procurement of energy.
One of the easier available options for survival is energy conservation through energy
efficiency improvement; thereby reduction of energy consumption and cost thereof through
strategic energy management concept and mechanism.
Energy conservation is a worldwide objective. The energy policy of the Government of India
also calls for conservation of energy. With the enactment of ‘Energy Conservation Act-2001’,
amongst others has emphasized upon the power of the appropriate Govt. to enforce efficient
use of energy and its conservation.
The management of OIL has adopted the energy system study and implements solutions
thereof with the objective to optimal utilization and output of available energy consuming
systems and to conserve energy.
In view of energy efficiency improvement and cost reduction program for long-term business
solution the management of OIL sought the services of PCRA for energy system study on Gas
Compressors, air compressors and Lighting systems at their plant (GCS-2)at Moran in Assam.
PCRA has studied the energy systems of the plants accordingly with the help of OIL
representatives. During the study, the energy audit team has mapped present status of
electrical power and energy systems at the plant premises, identified, major energy loss areas
etc. The study has identified potential scope for improvement and energy efficiency
improvement in major energy consuming systems. It also recommends cost effective and fast
pay back solutions for energy cost control.
2.2 COMPANY PROFILE
The story of Oil India Limited (OIL) traces and symbolizes the development and growth of the
Indian petroleum industry. From the discovery of crude oil in the far east of India at Digboi,
Assam in 1889 to its present status as a fully integrated upstream petroleum company, OIL has
come far, crossing many milestones.
---------------------------------------------------------------------------------------------------------------
On February 18, 1959, Oil India Private Limited was incorporated to expand and develop the
newly discovered oil fields of Naharkatiya and Moran in the Indian North East. In 1961, it
became a joint venture company between the Indian Government and Burmah Oil Company
Limited, UK.
In 1981, OIL became a wholly-owned Government of India enterprise. Today, OIL is a premier
Indian National Oil Company engaged in the business of exploration, development and
production of crude oil and natural gas, transportation of crude oil and production of LPG. OIL
also provides various E&P related services and holds 26% equity in Numaligarh Refinery
Limited.
The Authorized share capital of the Company is Rs. 2000 Crores. The Issued, Subscribed and
Paid share capital of the company is Rs. 601.14 Crores. At present, The Government of India,
the Promoter of the Company is holding 78.43% of the total Issued & Paid-up Capital of the
Company. The balance 21.57% of the Equity capital is held by others.
OIL has over 1 lakh sq km of PEL/ML areas for its exploration and production activities; most of
it is in the Indian North East, which accounts for its entire crude oil production and majority of
gas production. Rajasthan is the other producing area of OIL, contributing 10 per cent of its
total gas production.
Additionally, OIL’s exploration activities are spread over onshore areas of KG Basin, Mahanadi
Basin, Cauvery Basin, Andaman Basin and Gujarat-Kutch Basin etc. OIL also has participating
interest in NELP exploration blocks in Mahanadi Offshore, Mumbai Deepwater, Krishna
Godavari Deepwater, etc. as well as various overseas projects in Libya, Gabon, Iran, Yemen,
Nigeria, Sudan and Venezuela.
In a recent CRISIL-India Today survey, OIL was adjudged as one of the five best major PSUs and
one of three best energy sector PSUs in the country.
Table-2.1 GENERAL DETAILS OF THE COMPLEX
Name of the Complex Gas Compressor Station, OIL, Moran

Address Moran, Assam
Contact Person Mr. Dilip Kalita-Installation Manager
Tel 9435004588
Type of Ownership Central PSU
Contract Demand Self-Generation by Moran Gas Turbine
2.3 ENERGY AUDIT STUDY:
a) SCOPE OF THE STUDY

• To study Electrical system and transformers
• To study Electrical Motors
• To study Gas Compressors.
---------------------------------------------------------------------------------------------------------------
• To study air compressor system.

• To study lighting system & illumination level at various work places & suggest for improvement.
b) METHODOLOGY
The study was concentrated on the above areas to find out energy conservation options. Discussion
was held with the concerned personnel regarding the system familiarization and the operation of the
specific equipment. Trial and field measurement by portable instrument were conducted in selective
areas. Related data also collected from estate department for further analysis. Cost benefit analysis
was carried out in some energy conservation options.
c) INSTRUMENTS USED
1. Three phase power analyzer

2. Single phase power analyzer
3. Non-contact thermometer
4. Lux meter
---------------------------------------------------------------------------------------------------------------
3.0 EXISTING ENERGY SYSTEM:
The source of Energy for GCS-2 is as follows:
1) Electrical energy for GCS -2 from Gas based Captive Power Plant at Moran.
2) Fuel gas for engine driven gas compressor - fuel gas taken from the main suction line
through LP header coming from OCS and MP header from OCS.
3.1 MAJOR EQUIPMENT LIST:
Low Pressure Gas Booster Compressors
a) LPB 1 Make: IR(I) Compressor / NGEF Motor

Capacity: 2802 Standard Cubic mtrs/hr
b) LPB 2 Make : IR(I) Compressor / NGEF Motor

c) LPB 3 Make : IR(I) Compressor / Waukesha L7042 (Engine)

d) LPB 4 Make : IR(I) Compressor / Waukesha L7042 (Engine)

Capacity: 5614 Standard Cubic mtrs /hr
e) LPB 5 Make : Worthington Compressor / Caterpillar (Engine)

f) LPB 6 Make : Atlas Copco Compressor / Waukesha engine L7042

g) LPB 7 Make: Atlas Copco Compressor / Waukesha engine L7042

Gas Lifter Compressors
a) GL 1 Make: Ingersoll Rand Compressor / NGEF Motor

b) GL 2 Make: Ingersoll Rand Compressor / NGEF Motor

c) GL 3 Make: Worthington Compressor / Caterpillar G 399 Engine

d) GL 4 Make: BPCL Compressor / Waukesha engine L 5108

Capacity: 3200 Standard Cubic mtrs / hr
e) GL 5 Make: Atlas Copco Compressor / Caterpillar G 399 Engine

---------------------------------------------------------------------------------------------------------------
f) GL 6 Make: Atlas Copco Compressor / Caterpillar G 399 Engine

g) GL 7 Make : Atlas Copco Compressor / Waukesha L 5108 Engine

3.2 ELECTRICAL MOTOR DETAILS:
SL. NO L.T. LOADS K.W.

1 AIR COMPRESSOR MOTOR NO -1 30
6 AUX. WATER PUMP-1 MOTOR 5
11 ETHYLENE GLYCOL PUMP MOTOR 10
12 LIGHTING LOAD 18.2
LOAD IN K.W. 188.2
SL. NO H.T. LOADS K.W.

LOW PRESSURE GAS BOOSTER NO -1 & 2 (MAIN
1 MOTOR) 670
2 GAS LIFTER NO -1 & 2 (MAIN MOTOR) 670
LOAD IN K.W. 1528.2
3.3 THE POWER SYSTEM:
The source of power supply for GCS-2 is from Moran (Gas Turbine) Power Generating Station
(generated at 11 kV) for 3.3 KV HT supply to the 4 nos. of Motor driven Gas Compressors (2 nos. Gas
Lifters & 2 nos. Low Pressure Boosters) and 2 nos. Transformers, out of which one is kept standby.
The 11 KV to 3.3 KV Transformers Details are as below:

---------------------------------------------------------------------------------------------------------------
Transformer No: 1
Make: Crompton and Parkinson

Capacity: 2000 KVA
Voltage Range: 11000/3300 V
Ampere Range: 104.9 / 349.9
Impedance: 5.66 %
Mfg: 1960
Transformer: 2 (Standby)
Make: Bharat Bijlee
Capacity: 2000 KVA
Ampere Range: 105 / 350
Impedance: 5.9 %
Mfg: 1993
Another one transformer is present to cater the need for the LT load of 433 Volt. The detail of the
transformer is as below:
Transformer-3:
Make: Not Available
Capacity: 500 KVA
Ampere Range: 26.2 / 666.7
Impedance: 4.68 %
Mfg: 2003
---------------------------------------------------------------------------------------------------------------
Fig. 1, shows percentage share of electrical power consumption by major equipment at the OIL’s-GCS-2
plant:
Observation :
It is observed that the major portion of the electrical power is consumed by the HT motors.
Monitoring of electrical power consumed by the plant is not practiced at present. Energy
monitoring and targeting is primarily a management technique that uses energy information as
the basis to eliminate wastage, reduce and control current level of energy usage and improve
the existing operating procedures.
---------------------------------------------------------------------------------------------------------------
4.0 STUDY OF AIR COMPRESSOR
4.1 AIR COMPRESSOR DETAILS
The compressed air system of GCS-2, Moran has five reciprocating type air compressors. Four nos. are
of 30 kW and the other one is of 15 kW capacities.
Table-4.1 Specification of Air Compressors
Air Comp. No. Air Comp. No. Air Comp. No. Air Comp. No. Air Comp. No.
1 2 3 4 5
MAKE Kirloskar Kirloskar Ingersoll Rand Ingersoll Rand Ingersoll Rand
MODEL 2HY2ST 2HY2ST 2HYST 15T2 15T2
CAPACITY
2.83 M3/HR 2.83 M3/HR 2.83 M3/HR 4.8 M3/HR 4.8 M3/HR
Motor
30 30 15 30 30
Rating, kW
Discharge
pressure in 14 14 14 14.8 14.8
kg/cm2
Air compressors are connected to common receivers. Air is supplied at 14 kg/ cm2 for cranking
operation of the gas engines of gas compressors during start-up. Air @ 6 kg/cm2 is required for the
pneumatic control of the gas engine valves & circuit.
Pneumatic air taken from the air receiver passes through a pressure reducing device and air dryer and
supplied to pneumatic systems @ 6 kg/cm2 at the gas compressor panel only as the pneumatic control
valves in the unit are controlled by the NG after reducing the pressure.
Air Pressure of around 12 kg/cm2 is only required at the time of start-up of the gas engines and once
the engines are started then maintaining 14 kg/cm2 header pressure is not required. Continuous air
pressure is only required for the pneumatic control valves & circuit of the gas engines and that too at 6
kg/cm2 pressure.
In present condition the air is maintained from 14 kg/cm2 at any point of time. The unloading of the air
compressor is set at 14kg/cm2 and the loading set is at 10 kg/cm2. But, in eight hours of our stay in the
air receiver area, it never got unloaded and it was told to us that the compressor always runs without
unloading. This means the line leak is almost 90%, approx 10% air is being used in the compressor
panel.
Hence in the above condition it is clear that although the air pressure requirement of 14 kg/cm2 is only
required during starting of the Gas engines but still the pressure is maintained at 14 kg/cm2 throughout
the day in order to start any engine when sudden requirement is there.
The performance of the Air Compressors (FAD Test) could not be carried out as the compressors could
not be isolated due to operational inconvenience.
It should be noted that more power is required to compress air at higher pressure compared to lower
pressure i.e, energy required to compress air from 6 to 14 kg/cm2 is much higher compared to
pressurizing air from 3 to 6 kg/cm2.
---------------------------------------------------------------------------------------------------------------
Power Consumption Data:

Air Compressor-4 (Load Power)
Power
Line Voltage Current Factor Power Total
V1, Volt 238.1 I1 Amp 39.02 Pf1 0.830 P1, kW 7.711 Pt, kW 23.04
V2, Volt 239.2 I2 Amp 38.88 Pf2 0.82 P2, kW 7.626 Qt, kVAr 15.88
V3, Volt 237.9 I3 Amp 39.47 Pf3 0.82 P3, kW 7.700 St, kVA 27.98
Freq., Hz 50.0 Avg Pf = 0.823
Air Compressor-4 (UnLoad Power)

Power
Freq., Hz 50.0 Avg Pf = 0.623
Air Compressor-5 (UnLoad Power)

Power
Freq., Hz 50.0 Avg Pf = 0.667
Air Compressor-5 (Load Power)

Power
Freq., Hz 50.0 Avg Pf = 0.797
Air Compressor-2 (Load Power)-40 HP

Power
Freq., Hz 50.0 Avg Pf = 0.640
---------------------------------------------------------------------------------------------------------------
Air Compressor-3 (Load Power)-20 HP

Power
Freq., Hz 50.0 Avg Pf = 0.757
RECOMMENDATIONS:
At GCS, compressed air is used for two purposes:
1. To start Gas compressor engines (pressure requirement 14 kg/cm2).

2. To drive pneumatic instruments (pressure requirement 6 kg/cm2).
Pressure requirement for both the works are different as mentioned above.
1. It is recommended to maintain different air receivers for 14 kg/cm2 and 6 kg/cm2 line pressure.
Also one of the compressors should be dedicated to 14 kg/cm2 and the other one for 6 kg/cm2
line so that total running time of both the air compressors would reduce in a day.
To have redundancy in operation of the air compressors, one bypass line can be connected
from both the air receivers with a valve in-between so that whenever one compressor is under
shutdown then the other compressor can be compensated.
With a rough estimate min. of 25% of energy can be saved with this kind of arrangement.
Power Running Energy Energy

25% Energy
Consumption, Hour per Consumption Consumption
Saving, kWh
Kw day per day, kWh per year, kWh
If AIR
COMP. 4 23.04 24 552.96 201830 50457.6
is run
If AIR
COMP. 5 21.33 24 511.92 186850.8 46712.7
is run
Investment for this recommendation = NIL (as existing pipeline and knock out drums can be
used)
Monetary value of energy saved per annum with Comp-4 @ Rs. 4.55 per kWh = 50457.6 x 4.55
= Rs. 2.29 Lacs
Monetary value of energy saved per annum with Comp-5 @ Rs. 4.55 per kWh = 46712.7 x 4.55
= Rs. 2.12 Lacs
Investment: Yet to be estimated for checking the very old embedded lines and carry out
segregation job.
---------------------------------------------------------------------------------------------------------------
Simple Payback period = To be estimated on the basis of the cost for line excavation and
replacement.
2. It is advised to arrange to carry out leak test at the air line flanges, instrument air reducing
points and copper tubing connectors. This will allow the use of 20 HP compressor to run and
cutoff.
Savings: Power savings in one year= (21.33 - 11.91)x 8760hrs = 82519.2 Kw = Rs. 375462
Investment: Nil and Payback is immediate.
---------------------------------------------------------------------------------------------------------------
5.0 STUDY OF GAS COMPRESSORS
5.1 FUEL CONSUMPTION BY INDIVIDUAL EQUIPMENT:
Gas Power Equivalent Natural

Compressor
Compressed Consumption Gas Consumption Remarks
No
(SCMD) (KwH) (SCUM/HR)
1 LPB 1 41500 256 114.61
2 LPB 2 41500 238 106.6
3 LPB 3 Stand By
4 LPB 4 Stand By
5 LPB 5 Stand By
6 LPB 6 83000 183.5
7 LPB 7 83000 183.5
8 GL 1 S/D
9 GL 2 50000 288 128.9
10 GL 3 50000 135.9
11 GL 4 Stand By
12 GL 5 Stand By
13 GL 6 Stand By
14 GL 7 50000 133.2
Note: The equivalent gas consumption for motor is based on the gas consumed to generate power
at Moran Gas based Power Plant.
---------------------------------------------------------------------------------------------------------------
5.2 ACTUAL FUEL CONSUMPTION OF GAS COMPRESSORS W.R.T. DESIGN
Natural Gas Design Gas

Gas Compressor
Consumption consumption at 60%
Number
(SCUM/HR) load
LPB 6 183.5 119.8

LPB 7 183.5 119.8
GL 3 135.9 83.21
GL 7 133.2 102.9
5.3 GAS PRODUCTION AT OCS-Moran
MONTHWISE GAS PRODUCTION

HP Gas Production
LP Gas Production (KCM)
(KCM)
JUNE,12 2,767.05 2027
JULY,12 2,686.60 2382.5
AUGUST,12 3,207.09 2275.38
SEPTEMBER,12 2,010.07 2306.692
OCTOBER,12 2,607.78 2356.7
NOVEMBER,12 2,503.81 2265.2
---------------------------------------------------------------------------------------------------------------
5.4 REPLACEMENT OF MOTOR DRIVEN COMPRESSORS WITH GAS ENGINE DRIVEN TO CONSERVE
POWER
It was informed to us by OIL personnel that though presently there is surplus power
avaliable at Moran Power Station but in future due to commissioning of new motors
replacing Crude Driven Engines in the Crude oil pumping Station, the power may not be
available for running gas engines in the Gas compression station.
Therefore, following calculation is given to calculate the cost of replacement of

Compressor Motors with New Gas engines.
By matching the RPM of the Gas compressors and BHP of the present Electric Motors, it is
found that Waukesha Dresser F 3521GL is suitable for replacing motors of GL-1,GL-2,LPB-1
and LPB-2.
As per the data sheet the compressor is having Compression Ration of 10.5:1, RPM of 1000
and BHP of 615.
The fuel consumption at full load is 110.6 m3/hr. as the load curve the fuel consuption at
60% load as per design will be 98 m3/hr
Cost of purchasing the Gas Engine is $1,65000 = 1,65000 X 55= Rs. 90075000/-
The cost of running one Gas engine is 98 X 24X365 = 858480 X Rs.8.83 (Cost of NG) = Rs.
7580383.00
Present average equivalent power consumption of running one motor is 260.7 kwh
Cost of running of one motor is 260.7 X 24 X365 X Rs.4.55 = Rs. 10390980/-

---------------------------------------------------------------------------------------------------------------
Savings per year = Rs. 2810597
Payback= 90075000/2810597 = 32 years.
Therefore, it is economically not feasible to replace the motors with gas engines but in
case of non avaliability of power, gas engines can be procured.
---------------------------------------------------------------------------------------------------------------
6.0 ILLUMINATION SYSTEM
6.1 SUMMARY OF LUMINAIRES
No of Fittings available in the Plant:
GAS COMPRESSION UNIT-2 AREA WISE LIGHTING DETAILS

400 W
36W 400W 100W 160W HPSV/MH
SL. No LOCATION
T/LIGHT HPMV BULB MLL
1 SECURITY ROOM 8 6
2 ENGINE / GAS COMPRESSOR AREA 6 3 16 15
3 PUMP HOUSE 8
4 GENERATOR HOUSE
5 CHEMICAL HOUSE
6 MATERIAL HOUSE 6
7 CONTROL ROOM
8 EMERGENCY HOUSE 0 6
9 FIRE HOUSE 0 5
15
10 STREET/AREA LIGHT
11 INSTALLTION MANAGER ROOM 4
12 OFFICE ROOM 6
13 SUPERVISOR ROOM 3
14 PUMPING AREA
15 AIR COMPRESSOR HOUSE 12 6

15
TOTAL NUMBER OF TOTAL LIGHTS 53 3 34 20
6345
WATTAGE WITH CHOKE 2756 2538 3400 3200
TOTAL KW LOAD INCLUDING CHOKE 18.2
---------------------------------------------------------------------------------------------------------------
The average lux levels in different areas are shown below:
RECOMMENDED
LOCATION LUX LEVEL COMMENTS
LUX
SECURITY ROOM 22 50 NEEDS IMPROVEMENT
ROAD TO RIGHT SIDE OF GATE 7 10-20 NEEDS IMPROVEMENT
IN FRONT OF MAINT GODOWN 1 10-20 NEEDS IMPROVEMENT
GAS COMPRESSOR SHED 18 100-150 NEEDS IMPROVEMENT

CONDENSATE RECOVERY
0 50-70 NEEDS IMPROVEMENT
PLANT
ROAD AT THE UNIT 3 10-20 NEEDS IMPROVEMENT
ROAD OF AIR COMPRESSOR 1 10-20 NEEDS IMPROVEMENT
AIR COMPRESSOR HOUSE 11 100-150 NEEDS IMPROVEMENT
SWITCH ROOM IN FRONT OF
25 100-150 NEEDS IMPROVEMENT
COMPR SHED
6.2 RECOMMENDATIONS AND PAYBACK ANALYSIS:
1. Replace all the conventional 36 watt FTL tube light with energy efficient T5 (28 watt).
2. To replace all 160W MLL lights with 150 W MH lights in the shed, this will improve the lights in the
shed which is presently very poor with respect to OISD standard.
Table- 6.3 ANNUAL ENERGY SAVING OPTIONS
Present Expected
Total Daily Annual Annual
Present Proposed Annual Annual
No. of Working Working Savings
System System Consumption Consumption
Item Hours Day (kWh)
(kWh) (kWh)
FTL of 36
watt with T5 light of
53 12 365 12071 6732 5339
choke of 12 29 watt
watt
Investment for T5 lights = 53 Nos. x Rs. 400/- = Rs.21,200/-
Annual Monetary Savings = 5339 x 4.55 = Rs. 24292/- (Rate of Electricity = Rs.4.55/kWh)
Simple Payback Period = 21200 / 24292 = 10.5 Months
---------------------------------------------------------------------------------------------------------------
Energy conservation opportunity in lighting :
Installation of electronic ballast for fluorescent lamps

Switching off lighting whenever not needed
Installation of automatic lighting controls
Installation of lighting voltage controllers
Regular maintenance and cleaning of lamps
Use of localized lighting close to working areas where appropriate
List of References :
1) BEE guide book on Energy Efficiency on Electrical Utilities

2) Handbook on energy conservation -by PCRA
---------------------------------------------------------------------------------------------------------------
Annexure-I
Energy Efficient Equipment Suppliers
Product/ Equipment Contact Details

AC Drives Rockers Control System,
SCO 819, 2nd Floor, NAC, Manimajra, Chandigarh 160101
Ph: 0172 – 2730900, 5071627
AC Drives Allen Bradley India Ltd
C-11, Industrial Area, Site-IV, Sahibabad, Ghaziabad 201 010
AC Drives Asea Brown Boveri Ltd.
Guru Nanak Foundation Building, 15-16, Qutab Institutional Area,
Saheed Jeet Singh Sansanwal Marg, New Delhi - 110 067
AC Drives Crompton Greaves Ltd.
Machine 3 Division, A-6/2, MIDC Area, Ahmednagar 414 111.
Automation, Panel Meters Conzerv System
44P Electronic City Phase –II, East Hosur Road, Bangalore –
560100
Ph: 080-51189700 www.conzerv.com
Automation, Panel Meters Selec controls Pvt Ltd
E – 121, Ansa Industrial Estate, Saki Vihar Road, Mumbai 400072
Ph: 022-28471882, 28476443 www.selecindia.com
Building Automation, sensors, Electro Art
twilight switches Plot No K-11, MIDC Area, Ambad, Nashik –422010,
Ph: 0253-5603954, 2380918 www.electronicswitchesindia.com
Burners WESMAN ENGINEERING (P) LTD.
503-504 Eros Apartments, 56 Nehru Place, New Delhi 110019
Tel: +91 (11) 26431723 Fax: +91 (11) 26434577
Burners, Furnace Recuperators, ENCON
Hot air generators, Heating & 12/3, Mathura Road, Faridabad-121003
Pumping unit, Laddle preheating Phone: 0129 -25275454 Fax: 0129 –25279070
www.encon.co.in
Capacitors Asian Electronics Ltd.
Plot 68, MIDC, Satpur, Nasik, Nashik - 422 007
Capacitors Shreem Capacitors Pvt. Ltd.
7/39, Vikram Vihar, Lajpat Nagar-IV, New Delhi - 110 024
Capacitors and APFC Panels Matrix Controls & Engineers Pvt Ltd
Rajeev Batra 9811624440, Rajeev@matrixcapacior.com
E- 725 DSIDC, Industrial Complex, Narela, GT Road, Delhi – 110040
Ph: 01127786945 / 46 / 47
www.matrixcapacitor.com
Capacitors and APFC Panels Standard Capacitors
B-70/43, DSIDC Complex, Lawrence road Industrial Area, Delhi –
110035
Ph: 011 –27181490, 27151027
---------------------------------------------------------------------------------------------------------------

www.standardcapacitors.com
Capacitors and APFC Panels Saif Electronics
174, Hira Building, 1st Floor, Carnac Road,
Opposite Police Commissioner office , Mumbai – 400002
Ph : 022 – 22064626 , 22086613
www.saifel.com
Compressed Air Piping Legris India Pvt Ltd.

Legris House, 99 Pace city –1, sector 37, Gurgaon- 122001
Ph : 9958297093 , 9811054826
www.transair.legris.com
DG Synchronization, Automation SGS Industrial Controls & Solutions Pvt Ltd
and Capacitors Floor-II, Madanpur Khadar, Sarita Vihar, New Delhi.
Ph 011 – 29942516, 41402992
Eco-ventilators Nu Plast pipes & profiles
SCF – 124, sector 17 Market, Faridabad – 121002
Ph : 0129 – 6546217 , 4070023
Electrical measurement Riken Instrumentation Ltd
Instruments 369, Industrial Area, Phase –II, Panchkula, Haryana
Ph : 0172 – 2591651, 2592028 ,
www.rikeninstrumenatation.com
Energy Management & Control Manaco Energy Solutions (P) Ltd.
Systems A-6, Shanti Apts.,21 & 22, 1st Cross St, TTK Road, Alwarpet,
Chennai-18 , 044-42316164,
www.mesco.co.in
Energy Saving Products Gautam Enterprises
205, Vinay Indl. Est., Chicholi Bunder Link Road, Malad (West),
Mumbai - 64, India
Tel: (91-22) 2875 04 22, Fax: (91-22) 2873 6985
www.gautament.com
Energy Saving products Techmark Engineers & Consultants.
K-1/28 Ground Floor, Chittaranjan Park New Delhi-110019
Telephone: 91-011-26238349
Fax : 91-011-51603925
Flue Gas Analyzers / Oxygen Nevco Engineers Pvt. Ltd.,
Analyzer 90A (2nd Floor), Amritpuri B, Main Road, East of Kailash,
Opp. Iskcon Temple, New Delhi – 110 065
Telephone No 26226328, 26213009; Fax: 26285202
www.nevco.co.in
Flue Gas Analyzers / Oxygen ACE Instruments & Controls
Analyzer 1, Biradari, Above Kashi Dairy, M.G. Road,
Ghatkopar (W), Bombay – 400 086
Tel.: 5125153, 5122762
Flue Gas Analyzers / Oxygen Testo India Pvt Ltd
---------------------------------------------------------------------------------------------------------------

Analyzer Pune 020 – 25665085,
www.testo.com
FRP Blades and cooling tower Eneertech Engineers
accessories SCO 144 – 145, Sector 34A, Chandigarh
Ph : 0172 – 5018077, 9876022225
HVAC related instruments Waaree , 36 Damji shamji Industrial Complex
Thermocouples, pipe fittings, Off Mahakali caves road, Andheri East Mumbai 400093
pressure gauges 022 –66963030 26874778
www.waaree.com
Infrared Temperature Meters (600 Toshniwal Industries Pvt. Ltd.
°C to 1800 °C) Industrial Area, Mahukupura, AJMER - 305 002,
Ph 91145 269 5171, 91145 269 5205
ajmer@tipl.com www.tipl.com
Infrared Temperature Meters (upto KUSAM MECO, G-17 , Bharat Industrial Area ,
1500 °C) T.J. Road, Sewree Mumbai 400015,
Ph : 022 – 24156638, 24124540
www.kusam-meco.co.in
Insulations Lloyd Insulation (India) Ltd.
P.B. No. 4321, Kalkaji Industrial Area,
Punj Sons Premises, New Delhi – 110 019
Ph: 26430746-7 Fax: 26478601/26467259
Insulations Himal Supply (India) Ltd
168 , Rajagarden, New Delhi – 110015
Ph : 011-25438602 , 25448602
www.himalsupply.com
LED lighting Synergy Solar (P) ltd
SCO 133, sector 28D, Chandigarh
Ph 0172-6451133
www.synergysolars.com
Lighting Systems Philips India Ltd
Regional office-North, 9th floor Ashoka Estate, 24,
Barakhamba Road New Delhi – 110 001
Telephone No.: 3353280, 3317442, Fax No.: 3314332
Lighting Systems Crompton Greaves Ltd.
Lighting Business Group, 405, Concorde, RC Dutt Road,
Baroda – 390 007
Lighting Systems OSRAM India Ltd. Signature Towers,
11th Floor, Tower B, South City-I, Gurgaon 122001, Haryana
Tel: 0124- 6526175, 6526178, 6526185
Fax: 0124- 6526184
Lighting Systems Asian Electronics
Surya Place, First Floor, K-185/1, Sarai Julena,
New Friends Colony, New Delhi – 110 025
---------------------------------------------------------------------------------------------------------------

Lighting Systems Asian Electronics
Surya Place, First Floor, K-185/1, Sarai Julena,
New Friends Colony, New Delhi – 110 025
Lighting Systems Philips India Limited , Technopolis Knowledge Park,
Nelco Complex, Mahakali Caves Road, Chakala,
Andheri (East), Mumbai 400 093.
Tel : 022 56912000
Lighting Systems Surya Roshni Ltd.
Padma Tower-I, Rajendra Palace, New Delhi 110 006.
Lighting Systems Wipro Limited
Sco 196-197, Sector 34-A, Chandigarh - 160 022
Lighting Systems OSRAM India Ltd. Signature Towers,
11th Floor, Tower B, South City-I, Gurgaon 122001, Haryana
Tel: 0124- 6526175, 6526178, 6526185
Fax: 0124- 6526184
Lighting Voltage Control Systems Jindal Electric & Machinery Corporation
C-57, Focal Point, Ludhiana – 141010
Ph : 2670250 , 2676890 ,
www.jindalelectric.com
Lighting Voltage Control Systems ES Electronics (India) Pvt. Ltd.

Plot No.82, KIADB Industrial Area,
Bommasandra – Jigani Link Road, Jigani Hobli,
Anekal Taluk, Bangalore District – 562 106
Telefax: +91 - 8110 – 414547 / 414548,
414549 / 414550
E-mail ID: eleindia@energysaversindia.com
Website: www.energysaversindia.com
Soft starters Amtech Electronics (India) Ltd
E-6, GIDC Electronics Zone, Ghandinagar – 382028 , Gujarat
Ph : 079 –23289101-3,
www.amtechelectronics.com
Thermocouples and Heaters Beeco Electronics
450 –A, Industrial Area, Phase-II, Chandigarh 160002,
Ph : 0172 – 5083350, 5073750 ,
www.beecoelectronics.com
Thermocouples and temperature Radix Microsystem , 1005, Hemkunt House, 6, Rajendra Place
gauges & sensors New Delhi,
Ph : 011-25786350, 09312600075 ,
www.radix.co.in
Note: - The suppliers mentioned above are not the only ones or the best in the market. The plant may
contact other suppliers for competitive rates/ specifications.
---------------------------------------------------------------------------------------------------------------

(Eastern Region) 2, Gariahat Road South, Dhakuria Kolkata - 700 068

Hochgeladen von

Dokumentinformationen

Originaltitel

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

(Eastern Region) 2, Gariahat Road South, Dhakuria Kolkata - 700 068

Hochgeladen von

Copyright:

Verfügbare Formate

OF

Petroleum Conservation Research Association, Eastern Region (PCRA, ER),

The Energy Audit Team:

5.0 Study of Gas Compressor System 17

6.0 Study of Illumination 21

Annexure – I List of Energy Efficient Equip. Suppliers 24

1.0 EXECUTIVE SUMMARY

Table-1.1 Major Findings and Estimated Savings

KWh Rs. Rs. Years

2.1 IMPORTANCE OF ENERGY CONSERVATION & ITS BACKGROUND

2.2 COMPANY PROFILE

Table-2.1 GENERAL DETAILS OF THE COMPLEX

Name of the Complex Gas Compressor Station, OIL, Moran

2.3 ENERGY AUDIT STUDY:

a) SCOPE OF THE STUDY

• To study air compressor system.

1. Three phase power analyzer

3.0 EXISTING ENERGY SYSTEM:

The source of Energy for GCS-2 is as follows:

3.1 MAJOR EQUIPMENT LIST:

Low Pressure Gas Booster Compressors

a) LPB 1 Make: IR(I) Compressor / NGEF Motor

b) LPB 2 Make : IR(I) Compressor / NGEF Motor

c) LPB 3 Make : IR(I) Compressor / Waukesha L7042 (Engine)

d) LPB 4 Make : IR(I) Compressor / Waukesha L7042 (Engine)

e) LPB 5 Make : Worthington Compressor / Caterpillar (Engine)

f) LPB 6 Make : Atlas Copco Compressor / Waukesha engine L7042

g) LPB 7 Make: Atlas Copco Compressor / Waukesha engine L7042

Gas Lifter Compressors

a) GL 1 Make: Ingersoll Rand Compressor / NGEF Motor

b) GL 2 Make: Ingersoll Rand Compressor / NGEF Motor

c) GL 3 Make: Worthington Compressor / Caterpillar G 399 Engine

d) GL 4 Make: BPCL Compressor / Waukesha engine L 5108

e) GL 5 Make: Atlas Copco Compressor / Caterpillar G 399 Engine

f) GL 6 Make: Atlas Copco Compressor / Caterpillar G 399 Engine

g) GL 7 Make : Atlas Copco Compressor / Waukesha L 5108 Engine

3.2 ELECTRICAL MOTOR DETAILS:

SL. NO L.T. LOADS K.W.

SL. NO H.T. LOADS K.W.

LOAD IN K.W. 1528.2

3.3 THE POWER SYSTEM:

The 11 KV to 3.3 KV Transformers Details are as below:

Make: Crompton and Parkinson

4.0 STUDY OF AIR COMPRESSOR

4.1 AIR COMPRESSOR DETAILS

Table-4.1 Specification of Air Compressors

Power Consumption Data:

Air Compressor-4 (UnLoad Power)

Air Compressor-5 (UnLoad Power)

Air Compressor-5 (Load Power)

Air Compressor-2 (Load Power)-40 HP

Air Compressor-3 (Load Power)-20 HP

At GCS, compressed air is used for two purposes:

1. To start Gas compressor engines (pressure requirement 14 kg/cm2).

Power Running Energy Energy

Investment: Nil and Payback is immediate.

5.0 STUDY OF GAS COMPRESSORS

5.1 FUEL CONSUMPTION BY INDIVIDUAL EQUIPMENT:

Gas Power Equivalent Natural

5.2 ACTUAL FUEL CONSUMPTION OF GAS COMPRESSORS W.R.T. DESIGN

Natural Gas Design Gas

LPB 6 183.5 119.8

5.3 GAS PRODUCTION AT OCS-Moran