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 Indias Oil & gas production

Every LPG cylinder consumed in India comes from ONGC

one tenth Indias refining capacity is handled by ONGC

Location of Uran

BHN

URAN

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
MSEB
POWER

COGEN & UTIL POWER

STEAM

PPCL
CONSUMERS

MIDC

WATER

GPG

LPG

HP BP IOC

GSU OFFSHORE GAS S/C II & III

LPG

LAN LAN C2C3

I & II

I &II

IOTL

COND

CFU I & II EPRU LEAN GAS STABILIZED OIL TO REFINERY

IPCL

OPG OFFSHORE OIL CSU

GAIL

HP BP IOC

HR

FINANCE

MM

MUMBAI REGION OFFICE CORPORATE OFFICE - DELHI

HL PROCESS MAP OF URAN

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)

190

185

180

175

170

LPG I LPG II

165

160

155

150

2004-05

2005-06

2006-07

2007-08

2008-09

Analysis lpg 1

RF
175 30

NW

170

25

165

20

160

RF

15

NW

155

10

150

145 2004-05 2005-06 2006-07 2007-08 2008-09

0 2004-05 2005-06 2006-07 2007-08 2008-09

Analysis lpg 1
prod
302000 300000 298000 296000 294000 292000 290000 288000 286000

prod

2004-05

2005-06

2006-07

2007-08

2008-09

Analysis lpg 2

L2RF
190 30

NW

185

25

20 180 15 175 L2RF 10 170 5 NW

165

Analysis lpg 2
production
370000 360000 350000 340000 330000 320000 310000 300000 290000 280000 270000

production

2003-04

2004-05

2005-06

2006-07

2007-08

2008-09

Analysis of EPRU unit

EPRURF
410 12

NW

400

10

390 8 380

EPRURF
370

NW

4 360

2
350 0 2004-05 2005-06 2006-07 2007-08 2008-09 2004-05 2005-06 2006-07 2007-08 2008-09

340

Analysis of EPRU
production
1200000 1180000 1160000 1140000 1120000 1100000 1080000 1060000 1040000 1020000

production

2004-05

2005-06

2006-07

2007-08

2008-09

Effect of climatic conditions on RF For lpg 1

RF avg
168 166 164 162 160 158 156 154 152 150 summer rainy wnter

RF avg

Effect of climatic conditions on RF For lpg 2

RF avg
185

184
183 182 181 180 179 178 177 summer rainy winter RF avg

Effect of climatic conditions on RF For EPRU

RF avg
385 384 383 382 381 380 379 378 377 376 summer rainy winter RF avg

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 softwares 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 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 LPG=23, 31,

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:sushil kumar shrivastav

THANK YOU