Home Energy Audit at Nationalized Oil Company, Hazira, Gujarat
Energy Audit at Nationalized Oil Company, Hazira, GujaratPrint
The Nationalised Oil company at, Hazira, Gujarat is involved in the processing of Gas. Hazira Gas Processing complex is receiving Sour Gas and associate Condensate from South Bassein by 231 km. 36” dia. And 42” dia. Sub sea gas pipe line and is received ate Gas Terminal in a Slug catcher where primary separation of Gas and condensate are separated. The total capacity of above two Gas Trunk line is 50 MMSCMD. The gas is than fed to Gas sweetening unit (GSU). The condensate is fed to Condensate fractionation unit (CFU). The gas/condensate contains rich H2S proportion.
Electrical, Thermal and Water are the main sources of energy. A comprehensive energy conservation study of the plant was carried out by PCRA to identify potential areas of energy conservation and recommend energy savings measures along with cost benefit analysis. PCRA’s audit finding highlights potential savings of Rs. 1.97 lacs in electrical audit and Rs.95.92 lacs in thermal audit from 4 proposals. The proposed energy savings in water audit as under:
Savings in reservoirs: Yearly evaporation loss in reservoir=385553 m3 Yearly saving by limiting the storage to two reservoirs (from present 4 Nos. of Reservoirs)=385553m3X(50/100) =192777m3
Energy savings in service water pumps: In this case the pump capacity is 150 m3/hr, but it normally pumps 75 to 110 m3/hr. In 2001-2002 the average flow was 103 m3/hr. As such the energy saving by trimming of impeller by 10% is recommended.
PCRA covering the following areas:
Electrical Audit: Motor loading survey Sub-station survey Single line diagrams Transformer loading survey Illumination survey A.C. Plant study Compressed Air system
Thermal Audit: Boiler Efficiency test Heat loss due to poor/damaged insulation Steam trap survey
Water Audit: Process flow of water Analysis of water consumption pattern Cooling tower
Salient Features of Company
Process & Process Flow Diagrams
Specific Energy consumption
Appendices section & equipment manufacturers list
Proposed Energy Savings:
In LT Motors by converting to star connection : 57,134 kWh/Annum Monetary savings @ Rs. 1.00 per kWh : 57,134/-
By way of rectifying the air leakages : 16.22 KW/hr : 1,40,160 kWh/annum Approximately : 1,40,160/- per annum (these figures are applicable if the leaks are left unattended)
Identified energy savings: savings to the tune of 2817219 Nm3 of gas equivalent to Rs. 42.25 lacs can be achieved (considering gas cost of Rs. 1.5/Nm3).
I. Saving in heat losses after repair of poor/damaged insulation in the steam headers:
Equivalent steam savings = 12.07 kg/hr
II. Steam saving due to leakage in flangers = 1.5 Tonnes/hr.
III. The summary of steam savings after replacement of steam traps, repair/replacement of leaking bypass valves, headers and glands are as under:
a) Through steam traps = 1.190 tonnes/hr.
b) Through bypass valves and headers = 1.850 tonnes/hr.
c) Through valve glands = 0.1 tonnes/hr.
Total =3.140 tonne/hr.
Total steam leakages (I+II+III) =4.7 Tonnes/hr.
Cost of steam @ Rs. 130/tonne =612.68/hr.
(The above savings calculation assumes continuous steam leak throughout the year)
For further information, please write to:
Director (I/C), PCRA, Sanrakshan Bhawan, 10, Bhikaji Cama Place, New Delhi-110066 Tel : +91-11-26198856 Fax: +91-11-26109668 Web site:www.pcra.org