PROJECT EXPERIENCE (FEW)

this is a subtitle

Project Brief :

Indian Oil Corporation Limited planned to add Rail Loading Facility at existing LPG Terminal at Dumad, Gujarat, India. LPG is received thorough pipeline from Koyali Refinery and till then LPG was evacuated through Road Trucks and Cylinders. Rail Loading was planned to reduce transport cost by Road Trucks. The project was awarded on EPCM basis. The scope was to include facilities for commissioning and decommissioning of Rail Wagons for maintenance purposes. To Rail Spurs were proposed to have one rail spur for Loading and One Rail Spur for Decommissioning / Re-Commissioning.
Statistical Analysis :
It was proposed to visit the existing Rail Loading Facilities at two locations by other operating companies to understand the existing Operational Philosophy, mainly decommissioning / re-commissioning procedures. The complete operational details for six months was analysed with reference to the LPG Loading, Decommissioning and Re-commissioning. There were many deficiencies noted. First Facility : It was using water fill and drain method to evacuate residual LPG. Though LPG is fully recovered, during decommissioning lots of time is wasted for water filling and draining and the water could not be reused again due to contamination. The same difficulty was faced during re-commissioning too along with filling of Nitrogen as additional measure. Monitoring the operation was a tough task during water filling and draining. Second Facility : LPG was evacuated by repeated pressurising and depressurising with Nitrogen and Air and the entire evacuation was flared. This results in lots of time delay for one decommissioning operation. For Re-commissioning, the same operation was reversed with Nitorgen and then LPG. While there was a direct LPG flaring, indirect energy consumption was from Air / Nitrogen apart from more time for operation.
New Process .Operations Design :
Design of Rail Wagons was first analysed and found that the design is for full vacuum. A new concept of using a Vacuum Pump along with a small LPG Compressor to recover LPG fully from Rail Wagons and send back to LPG bullets. After evacuating LPG fully, one Nitrogen filling and evacuation and then filling with Air was proposed with one more set of Vacuum Pumps. The Rail Wagons would be released for Maintenance. While Re-commissioning, the same procedure shall be reversed with first evacuating Air and then Nitrogen. A perfect operation timeline for one Decommissioning and Re-Commissioning was simulated and compared with existing operations in other two facilities. It was approved by client that there is a full recovery of LPG, no usage of water, only 20% of Electrical Energy used and reduction in operational time by 60%. This also reduced the fixed cost of facility since only one Rail Spur was considered adequate due to reduction in time.

Project Brief :

IndianOil Petronas Pvt. Ltd owns and operates an Import Terminal at Haldia, West Bengal for Refrigerated Propane and Butane through Marine Tanker. It was proposed to have one more Import Terminal at Chennai with a larger capacity. Technology Consultants was awarded the EPCM Consultancy for the unloading pipeline system including a process simulation to size the Flash Gas Compressor and Boil Off Compressor. The scope of work included taking operational information from the existing terminal and design the new facilities to avoid flaring, optimise the unloading time.
Statistical Analysis :
A site visit was conducted along the pipeline and a detailed interaction with the operating team revealed operational difficulties pertaining to (1) pre-cooling prior to unloading, (2) Flaring of Propane upto 70% of unloading time. The physical inspection of pipeline revealed that the insulations in bad conditions and pipeline not properly stress analysed. The operating data for six months were analysed and found out that the duration of unloading operation was more than the estimated time.
New Process / Operation :
The step by step customised process simulation was carried out and optimal FG Compressor sizing was done. The Insulation was designed with Insulated supports and the stress analysis was carried out after simulation results for proper support position. The temperature profile of the pipeline during the unloading period was also simulated. Based on the all new considerations, a new operating procedure was defined by reversing the flow direction during the pre-cooling time. After commissioning and one year of operation, it was clear that (1) Unloading time was within the estimated time period, (2) There was no flaring during pre-cooling and unloading, (3) One Flash Gas Compressor was operated for 30% of unloading time during peak summer and (4) Pipeline was being operated at 140% than the design. Capital Cost Saving was considerable by reducing the FG Compressor from 3 to 2. Energy Saving was due to the reduced operation of FG Compressor and higher productivity and profitability due to higher throughput and no flaring.

Project Brief :

Indian Oil Corporation Limited is owning and operating a Lube Blending Plant and Barrel Filling facility (LBP) at Asoati. There are few Small Can filling Plants (SCFP) within 100 km radius from LBP to fill cans from 0.5 lit to 50 lit. The lube oil was transported by trucks to the SCFP from LBP. The existing SCFP were older. Indian Oil proposed to build a full SCFP at Asoati in the LBP premises and relocate all facilities in other locations to the new SCFP and add required handling facilities. Technology Consultants was awarded EPCM Contract.
Statistical Analysis :
Study of the existing operations and the data in the other locations revealed that the existing filling machines are obsolete and not productive. It was also revealed that the retrofitting of the existing machines would only worsen the operations. The hourly operation was studied and presented to Indian Oil and it was then decided to proceed with completely new efficient filling machines for higher throughput. Also the proposal of installing new Automatic Manifold for product changeover was studied with the existing such manifold and it was highlighted that one more Automatic Manifold would reduce the productivity.
New System Design :
The all new Pigging System with a unique design was implemented. This means one single feeder line for 5 filling lines having intermediate isolation valves could provide single pigging system in one line. Considerable reduction in capital and operating costs were proven. The new pigging system along with the Fully Automatic Filling lines with flexible day tanks could provide 130% throughput in terms of the quantity and also increased number of products than the original design. The energy consumption per throughput was 80% compared to original estimate. As a result, Indian Oil has shut down the operations in other two locations and centralised the operations more economically in the new SCFP.