HVJ
HVJ
HVJ
Petroleum Pipeline
Auraiya 2+0
319
320
ENERGY CONSUMPTION
Year Gas Capacity Energy Consumption NG transmission Utilisation Transmission (MMSCM) in % Electrical Thermal MKcal Cost in Lakh KWH Rs. (Lakhs) 12081.87 11793.4 16387 99.10 96.734 103.4 448.78 447.45 421.12 3045017.58 2906029.92 2761241.72 367781.92 364296.15 473383.00 Energy
GRAPHICAL PRESENTATION
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CONSERVATION OF ENERGY IN HVJ - PIPE LINE SYSTEM: Conservation of energy is a consistent endeavor in every department at GAIL, with this spirit in mind, during the period year 2004-2005 following schemes have been implemented at GAIL, for conservation of energy which have resulted in considerable amount of saving for the company: The major projects which will have indelible effect on the energy consumption of this plant are given below:1. MODIFICATION IN DAMPERS OF THE GTC ENCLOSURE BLOWERS: The GTC'S are having two numbers of Enclosure blowers with dampers. Normally both blowers were running for cooling the enclosure. The matter was deliberated & concluded that it is due to improper alignment of the damper system with enclosure. The suitable dampers were developed indigenously for this imported machine. The new damper has been developed in house & installed in the turbine. This is
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one of the developmental projects of indigenization of import substitute of the spares. For cooling purpose the additional water spray was being done. With this improved damper design & modified sealing system the turbines are running with single blower without water curtain. TOTAL SAVING OF POWER PER ANNUM = 2.64 LAKH KWH / GTC. AMOUNT SAVING PER ANNUM =RS.36.35LAKH AMOUNT OF INVESTMENT =RS. 2.0 LAKH 2. OPTIMIZATION OF RUNNING OF HVAC COMPRESSORS:The HVAC compressors & its auxiliaries were running through-out the year with full load irrespective of variation in surrounding temperature. The running of HVAC compressors are optimized with respect to the variation in the surrounding temperature. TOTAL SAVING OF POWER PER ANNUM = 4.8 LAKH KWH AMOUNT SAVING PER ANNUM = RS 23.66 LAKH AMOUNT OF INVESTMENT = NIL 3. OPTIMIZATION OF GAS CONDITIONING HEATER OF GAS TURBINES: The Gas Conditioning heaters are required to run for conditioning the fuel gas. As per the data sheet of the compressor the fuel gas conditioning temperature should be within the 8 0C to 40 0C. The temperature setting of the heater was set at 40 0C the set point has been modified to 35 0C. Details of savings are given below TOTAL SAVING OF POWER PER ANNUM = 1.2LAKH KWH AMOUNT SAVING PER ANNUM = RS.5.92LAKH AMOUNT OF INVESTMENT = NIL 4. INSTALLATION OF NEW UPS At Vijaipur compressor station the old UPS was Thyristor based having low efficiency. Now the it has been replaced with the new IGBT based UPS having more efficiency than the old UPS. Details are given below:TOTAL SAVING OF POWER PER ANNUM=1.46LAKH KWH AMOUNT SAVING PER ANNUM = RS.7.20LAKH AMOUNT OF INVESTMENT = RS.24.4LAKH
NEW UPS
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5. OPTIMIZATION OF IA PLANT: There are two numbers of IA compressors for catering the instrument/plant air requirement in the HVJ compressor station at Vijaipur. After the completion of the DVPL compressor station at Vijaipur it was calculated that the DVPL IA compressor can supply Instrumentation/Plant air requirements to both the DVPL & HVJ compressor station. After this hook-up work was done between the DVPL & HVJ Instrument air compressors. By doing this modification HVJ Instrument air plant was completely stopped. The savings achieved are given belowTOTAL SAVING OF POWER PER/ANNUM = 6.57LAKH KWH AMMOUNT SAVING PER ANNUM = RS.36.35LAKH AMOUNT OF INVESMENT = NIL
IA COMPRESSOR STOPPED
6. PIGGING OF PIPELINE:"Pigs" were originally developed and utilized to remove the debris or material build-up which obstructed or restricted flow through a pipeline. Pipeline "pigging" is the propelling of a scrapper cleaning tool (the pig) through a pipeline to scrap / collect and push the dirt / pipeline deposits out. Pigging is utilized to flush out debris, scrape and clean the interior pipe walls. Pigging is also used to "batch" various products through the same piping system. The on line instrumented pigging (intelligent) on the HVJ line has been started for assessing the integrity of pipeline & accordingly take remedial measures. HVJ pipeline is a high pressure line, as six compressor stations are there to boost pressure at intermediate distances. Due to operation of compressors, a small amount of compressor lube / seal oil ingress into the pipeline which along with pipeline dirt deposit on pipeline internal walls and affect pipeline efficiency. It has been seen that cleaning of pipelines by pigging improves gas transport efficiency resulting in reduction in pressure drop which in turn contributes in lesser compression work at downstream compressor stations. On conservative basis, improvement in compression ratio by 1% results in fuel
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saving of 5% (considering a base thermal efficiency of 20% in gas compression) and pigging in gas lines contribute atleast 0.2% improvement in pipeline hydraulics. On these lines, pigging could be considered to reduce fuel costs by 1% amounting to about Rs 1.0 Crore per annum against the cost of pigging of entire section of about Rs 25 Lakhs(annualised).
PRELIMINARY ACTIVITIES
PIG LAUNCHING
7. OPTIMIZATION OF COMPRESSION:
PIG RECEIVING
HVJ pipeline is a trunk-line for transporting natural gas from Hazira to various consumer locations along its route right up to Delhi/Haryana at different consumer pressure and flow requirements. In order to maintain delivery pressure and quantity commitments, intermediate compressor stations (at Six locations) are operated in such a way to meet the customer requirements at the best possible pipeline hydraulics. Maintaining optimal hydraulics of the pipeline involve operating right number & capacity of compressor trains at each of the compressor stations. This activity is one of the main functions of the Master Control Centre at Vijaipur which manages the entire pipeline network. GAIL has initiated certain measures including. Close monitoring of pressure profiles
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The above measures directly translates into great savings in fuel. This is evident from the trend of cumulative run-hours of compressor trains across all the compressor stations. Year 2002-03 2003-04 2004-05 Cumulative Runhours (All stations) 168893.3 157191.4 155010.3 Reduction from base year 11701.9 13883 Amount Saving in Lakh Base Year 842.536 999.57
Average running cost of compressor is Rs.7200/hour. From the above and base fuel costs, a saving of Rs. 18.42 Crores has been achieved in two years 2003-04 & 2004-05 on the base year 2002-03. Solar Gas Turbine Compressor RR Allison Gas turbine compressor PROJECTS IMPLEMENTED DURING 2003-04.
1) Photocell control for lighting. 2) Electronic chokes in place of conventional chokes. 3) Switching off lights, fans, ACs, by individuals whenever offices are not occupied. 4) We have implemented the 5s' system (short, set in order, shine, standardize & sustain) for good & clean environment. Kaizens system has been implemented for improvement.
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Energy Conservation Measures (Planned) 1) Vapour Absorption Refrigeration at Vijaipur 2) Installation of MEEFOG System at Hazira. 3) Enclosure vent fan / Damper work at other stations 4) RR Power switching to State Grid at more locations 5) UPS Upgradation 6) Cleaning Pigging Operation 7) Conversion of Analog Fuel Management system to Digital system
Approx. investment
11.48Lakh KWH
54.53
70
2005-2006/2006-2007
28382 M Kcal
110.0
250
2005-2006/2006-2007
13.2LAKH KWH
181.7
10
2005-2006/2006-2007
16 30 25
27612.41mkcal
100.45
100
2007-2008/2007-2008