Transcript Gas Handling & Processing – Shri M. M. Mandal

ENERGY EFFICIENCY IMPROVEMENT
IN
GAS HANDLING & PROCESSING
(5th JUNE 2008)
DELHI
M M MANDAL
1
GAIL (INDIA) LTD.
PRESNTATION OUTLINE
•
ENERGY SCENARIO – AN OVERVIEW
•
BARRIERS TO ENERGY CONSERVATION
•
BENEFITS OF CONSERVATION
•
GAIL’s APPROACH TO ENERGY EFFICIENCY
•
SUGGESTIONS
2
INDIAN ECONOMY: SNAPSHOTS
• INDIAN ECONOMY IS:
- 12TH LARGEST IN THE WORLD WITH A GDP OF US
$ 1.25 TRILLION (CHINA-3.25 TRILLION & USA13.79 TRILLION)
- 3RD LARGEST ECONOMY IN THE WORLD, IN
TERMS OF PURCHASING POWER.
(SOURCE: CIA WEBSITE)
• ACHIEVED A GDP GROWTH RATE OF 9.4% IN 2006-07
viz-a-viz CHINA-10.7 %, BRAZIL-3.7% & RUSSIA-6.7%.
• TARGET FOR NEXT 20 YEARS – 10 %.
3
ENERGY SCENARIO
(INDIA Vs OTHERS)
●
15% OF WORLD’S POPULATION- 3% OF GLOBAL
ENERGY USAGE.
●
PER
CAPITA
CONSUMPTION
(TOE/CAPITA):
INDIA
: 0.49
CHINA
: 1.32
BRAZIL
: 1.12
USA
: 7.89
WORLD AVERAGE : 1.77
OF
ENERGY
FLOURISHING
ECONOMY
–
HIGH
REQUIREMENT TO SUSTAIN GROWTH.
ENERGY
(Source: Key world Energy Statistic-2007 - IEA)
●
4
ENERGY SCENARIO: PRIMARY
ENERGY CONSUMPTION PATTERN
World
Energy Consumption
(MTOE)
10,878
India
5th
423
Largest Energy
Consumer
Energy Mix (%)
Coal
28.4%
56.2%
Oil
35.8%
28.4%
Natural gas
23.7%
8.5%
Nuclear
5.8%
0.9%
Hydro
6.3%
6.0%
Oil & Gas Imports
(MTOE) -2006
3,264
119
Total Primary Energy
2.3%
5.6%
Natural Gas
2.7%
9.4%
Growth in Energy (10 yrs)
Source : BP Statistical Review of World Energy June 2007
5
BARRIERS TO ENERGY
CONSERVATION EFFORTS
●
NEW PROJECTS GET PRIORITY
●
ANNUAL BENEFITS ON ENERGY CONSERVATION LOOKS
SMALL AND HENCE USUALLY GET LESS ATTENTION.
●
LACK OF FOCUS / ADEQUATE KNOWLEDGE TO IDENTIFY
POTENTIAL AREAS FOR ENERGY OPTIMIZATION.
●
IN-ADEQUATE R&D INVESTMENTS.
●
IN-ADEQUATE
TECHNOLOGY.
INDUSTRY
AWARENESS
OF
NEW
6
CONSERVATION
IN
GAS SECTOR
7
OVERALL DEMAND SUPPLY
BALANCE
MMSCMD
2007-08
2008-09
2009-10
2010-11
2011-12
Projected Domestic
Supply
80.54
119.98
189.97
197.09
202.3
LNG Supply
30.45
33.6
52.5
70
83.12
Total Supply
110.99
153.58
242.47
267.09
285.42
Total Demand
179.17
196.64
225.52
262.07
279.43
Demand Supply Gap
68.18
43.06
(-) 16.95
(-) 5.02
(-) 5.99
Source: Sub-Group of Natural Gas, MoP&NG
8
ENERGY CONSERVATION
GAIL’s APPROACH
●
IDENTIFICATION OF AREAS OF IMPROVEMENT AND THEIR
SOLUTION THROUGH
-
QUALITY CIRCLE AT SHOP FLOOR
STATISTICAL PROCESS CONTROL(SIX SIGMA)
5S
KAIZAN
RE-ENGINEERING & EVALUATION
●
IDENTIFICATION
EQUIPMENT.
●
TRAINING AND AWARENESS TO ALL EMPLOYEES THROUGH
SEMINARS / WORK SHOPS / QUIZES AT PERIODIC INTERVALS.
●
PERIODIC ENERGY AUDITS AT ALL WORK CENTERS.
●
IMPLEMENTATION OF EMPLOYEES SUGGESTION SCHEMES.
●
SYSTEM OF MoU INCLUDING ENERGY PARAMETERS BETWEEN
VARIOUS REGIONAL CENTRES & CORPORATE MANAGEMENT.
OF
ENERGY
EFFICIENT
TECHNOLOGY
/
9
ENERGY CONSERVATION MEASURES TAKEN
●
QUICK HIT PROJECTS
-
BENCH MARKING OF VARIOUS PROCESS UNITS WITH WORLD BEST.
-
AWARENESS CAMPAIGN TO SAVE ENERGY THROUGH OPTIMAL
UTILIZATION / RUNNING OF STATIC AND ROTATING EQUIPMENTS.
-
MAINTAINING P.F. IN THE RANGE OF 0.95 TO 1.0 THROUGH
INSTALLATION OF ADDITIONAL P.F. IMPROVEMENT EQUIPMENTS
RESULTED IN ANNUAL SAVINGS OF RS. 20.6 LACS.
-
MODIFICATION IN LIGHTING SYSTEM RESULTED IN OVER 8 LACS KW
HRS OF ENERGY SAVING WITH COST SAVINGS OF RS 40 LACS.
-
REDUCTION IN NITROGEN CONSUMPTION IN PROCESSING PLANT
RESULTED IN COST SAVINGS OF RS 1.27 CRS PER ANNUM.
-
SAVINGS IN FUEL GAS CONSUMPTION THROUGH SWITCHING OVER
FROM FUEL GAS TO NITROGEN FOR FLARE END PURGING RESULTED IN
FUEL SAVINGS OF RS 14.72 CRS PER ANNUM.
10
ENERGY CONSERVATION
MEASURES TAKEN (Contd…)
●
VARIABLE FREQUENCY DRIVE(VFD) SYSTEM IMPLEMENTED
FOR SOME PUMPS e.g. JOCKEY PUMPS (LPG-GANDHAR),
REACTOR FEED PUMP (LLDPE UNIT).
●
REINFORCEMENT OF METTALIC EXPANSION BELLOWS OF
HRSG WITH FABRIC EXPANSION BELLOWS FOR ARRESTING
LEAKAGES RESULTING IN REDUCTION IN FUEL GAS
CONSUMPTION TO THE TUNE OF 4.8 CRS PER ANNUM.
●
REPLACEMENT OF THYRISTOR BASED UPS WITH ENERGY
EFFICIENT UPS SYSTEM RESULTING IN ANNUAL COST
SAVINGS OF RS 28 LACS.
●
STATE OF THE ART TECHNOLOGY FOR MONITORING &
CONTROL OF P/L OPERATION THROUGH SCADA.
●
RR 15 (JAGOTI), BECOMES THE FIRST “GREEN RR” WITH ALL
LOADS ON SOLAR POWER IN HVJ
11
ENERGY EFFICIENCY – MEASURES TAKEN
BENEFITS OF SCADA
• REAL TIME MONITORING AND CONTROL FROM A CENTRAL
LOCATION.
●
LEAK DETECTION.
●
PREDICTIVE LOOK AHEAD MODEL FOR OPERATION.
●
PREDICTIVE MAINT. REQUIREMENTS FOR COMPRS.
12
ENERGY EFFICIENCY –MEASURES
PLANNED
●
ENERGY SAVING IN HVJ COMPRESSOR STATIONS AT JHABUA &
KHERA
- MODIFICATION FOR SWAPPING OF APM + PMT RICH GAS & LNG
BETWEEN DVPL & HVJ SYSTEM RESULTING IN STOPPING OF
COMPRESSORS AT JHABUA & KHERA.
• ADVANCED PROCESS CONTROL SYSTEM(APC) IS UNDER
IMPLEMENTATION FOR UPSTREAM UNITS (GPU/LPG/GCU) AT
PATA PETROCHEMICAL PROJECT. EXPECTED REDUCTION IN SP.
ENERGY CONSUMPTION TO THE TUNE OF 3%.
●
ETHYLENE BOIL OFF GAS & SPHERE VAPOURS DIVERSION TO
HDPE UNIT - REDUCING RECYCLING IN GCU. EXPECTED
BENEFIT OF RS. 10 CRS PER ANNUM
●
32 SVs CONVERTED TO GRID POWER FROM TEG IN JLPL
RESULTING IN SAVING OF 232 MT OF LPG IN 2007-08
13
ENERGY EFFICIENCY –MEASURES
PLANNED (Contd….)
●
SOLAR POWER SYSTEM AT GANDHAR AT AN APPROX. COST OF
RS 9.3 LAKHS WHICH WOULD RESULT IN ANNUAL ENERGY
SAVING @ 45360 KWH AND ANNUAL COST SAVING OF RS 2.43
LAKHS.
• INSTALLATION
OF VARIABLE SPEED DRIVE IN DVPL
COMPRESSOR STATION, VIJAIPUR. EXPECTED SAVINGS OF RS
7.84 LAC / ANNUM.
●
WIND ENERGY PROJECTS IN THE STATE OF MAHARASHTRA,
RAJASTHAN & GUJARAT.
●
WASTE HEAT RECOVERY PROJECTS (GT’s EXHAUST) FOR
STEAM / POWER GENERATION AT VAGHODIA / HAZIRA /
JHABUA / KHERA COMPRESSOR STATIONS.
14
ENERGY EFFICIENCY –MEASURES
PLANNED (Contd….)
●
USE OF REACTOR EFFLUENT HEAT TO PRE-HEAT DEBUTANISER COLUMN FEED, EXPECTED BENEFIT OF RS. 7.84
LACS PER ANNUM.
●
DIVERSION OF 0.5 MMSCMD GAS IN BHARUCH REGION FOR
PROCESSING AT GPU-GANDHAR.
●
REPLACEMENT OF V-BELT WITH POLY V-BELT IN INST. AIR
COMPRESSOR IN LPG-USAR FOR ENERGY SAVING.
15
ENERGY EFFICIENCY IMPROVEMENTS
– SOME SUGGESTIONS
●
BENCHMARKING OF ENERGY CONSUMPTION
-
INTERNALLY THROUGH HISTORICAL / TREND ANALYSIS.
EXTERNALLY ACROSS SIMILAR INDUSTRIES.
IDENTIFICATION OF BEST PRACTICES (BASED ON
EXTERNAL
BENCHMARKING DATA).
●
PERIODIC ENERGY MONITORING AND TARGET SETTING.
●
MATCHING SYSTEM / EQUIPMENT SIZING OR RATING WITH
ACTUAL PROCESS REQUIREMENTS.
●
USE OF SP. ENERGY
PERFORMANCE.
●
JUDICIOUS LOADING
EVALUATION OF BIDS.
ON
PARAMETERS
ENERGY
FOR
ASSESSING
REQUIREMENTS
FOR
16
ENERGY EFFICIENCY IMPROVEMENTS
SOME SUGGESTIONS (Contd…)
●
LUCRATIVE DIRECT INCENTIVES TO INDIVIDUAL EMPLOYEES
THROUGH SUGGESTION SCHEMES INDUCES MANY FOR OUT OF
BOX THINKING.
●
SUBSTITUTING EXISTING FOSSILS FUEL WITH MORE EFFICIENT
& LESS COST / LESS POLLUTING FUELS.
●
CREATION BY STATE BODIES OF AN APPROPRIATE SET OF
INCENTIVES THROUGH PRICING & OTHER POLICY MEASURES
FOR PROMOTING ENERGY EFFICIENCY & CONSERVATION.
17
THANK YOU
18
GAIL’s ENERGY CONSUMPTION
(LIQUID HYDROCARBON)
S.
NO
UNIT
CAPACITY
(MMSCMD)
LHC PROD.
(000’ MT)
FUEL GAS CONSUMPTION (% OF
O/P ENERGY)
2005-06
2006-07
2007-08
BENCH
MARK
ACTUAL
2005-06
2006-07
2007-08
1
LPG VIJAIPUR
15.0
601.59
569.41
588.51
11
9.24
9.32
8.34
2
LPG GANDHAR
5.0
285.62
297.73
299.89
11
10.18
10.32
10.42
3
LPG USAR
5.0
45.21
47.20
50.65
11
24.93
25.34
21.3
4
LPG VAGHODIA
2.5
79.60
75.06
81.38
11
2.50
2.65
2.4
5
LPG PATA
12
288.85
323.0
293.45
11
9.35
8.93
7.46
6
LPG LAKWA
2.0
24.87
31.03
33.19
11
74.60
70.93
60.81
DUE TO INCONSISTENT SUPPLY OF FEED GAS FROM ONGC, FUEL CONSUMPTION IS HIGH
FOR LPG – LAKWA & USAR
19
GAIL’s ENERGY CONSUMPTION
(PETROCHEMICALS)
S.
NO
PRODUCT
PRODUCTION
CAPACITY
(KTA)
SP. ENERGY CONSUMPTION (KWH/MT)
GLOBAL
INTERNAL
TARGET
ACTUAL
2005-06
2006-07
2007-08
1
ETHYLENE
400
4850
5465
5365
5395
4892
2
LLDPE
210
980
1077
1117
1136
1171
3
HDPE
100
980
890
967
884
891
20
GAIL’s ENERGY CONSUMPTION
(PIPELINES)
A.
NATURAL GAS PIPELINES
AVG. FLOW RATE (MMSCMD)
2005 - 06
45.49
B.
S. NO
2006 - 07
47.86
2007 - 08
49.37
FUEL GAS CONSUMPTION (% OF GAS DELIVERED IN
ENERGY TERMS)
BENCHMARK
2.8
ACTUAL
2005-06
2006-07
2007-08
2.0
2.05
2.068
LPG PIPELINES
PIPELINE
AVG. FLOW
RATE
ENERGY CONSUMPTION (KJ/MT/KM)
INTERNAL
TARGET
ACTUAL
2005-06
2006-07
2007-08
1
JAMNAGAR-LONI LPG
P/L
168 MT/HR
34.2
34.34
33.16
30.23
2
VIZAG –
SECUNDERABAD LPG
P/L
100 MT/HR
67.48
79.63
69.21
63.06
21