NATURAL GAS

1. Natural gas is worlds cleanest fossil fuel.

2. Primarily composed of methane, the

lightest of the hydrocarbon compounds..

3. Because of its high- energy value and its

low emission of carbon dioxide (CO2) and
nitrogen oxides (NOx) when burned, it
has become the fuel of choice for new
electric power plants and many new
industrial facilities.
 NATURAL GAS SOURCES
1.Natural gas is found in underground
rock formations known as reservoirs.

2.The reservoir rock is typically a porous

sand, sandstone, limestone or
dolomite.

3.The gas in the reservoir may be mixed

with oil, or the reservoir may contain
only natural gas and natural gas
liquids, commonly referred to as
condensate.
 NATURAL GAS--PRODUCTION
1.As production begins from a reservoir, gas,
oil or condensate and water are produced
simultaneously.

2.Production equipment located at the surface

separates each of the fluids.

3.The oil and condensate can be stored in

aboveground tanks or pumped into a
pipeline.

4.The water is collected for disposal, and the

gas can be compressed into a pipeline or re-
injected into the reservoir to maintain
reservoir pressure.
 NATURAL GAS--PROPERTIES

1. Natural gas is colorless.

2. While delivering the gas as a fuel for household,

Local gas utilities add mercaptan for safety
purposes-since it allows small leaks at low
pressures in the distribution systems to be easily
detected.

3. The specific gravity of natural gas is about 0.67.

4. The heating value of natural gas is approximately

8900 kcal/ per standard cubic meter. However, it
depends upon the actual composition of the gas.
 NATURAL GAS--PROPERTIES
Since natural
gas is primarily
methane it is a
high-energy,
clean-burning
fuel. This quality
is clearly
illustrated in the
graph to the
right comparing
emissions from
natural gas, fuel
oil and coal.
 HVJ PIPELINE
UTTAR PRADESH
HARYANA GAIL PATA
DADRI
DELHI BABRALA

SHAHJAHANPUR

RAJASTHAN JAGDISHPUR
AURAIYA
KOTA

ANTA
GUJARAT KALOL
KADI VIJAIPUR
KHERA MADHYA
BARODA
JHABUA PRADESH
VAGHODIA
HAZIRA

SOUTH BASSEIN MAHARASHTRA

MUMBAI
BOMBAY HIGH URAN
HEERA THAL
 NATURAL GAS PROCESSING
1. Crude oil and natural gas are of little use in their raw state;
their value lies in what is created from them: fuels,
lubricating oils, waxes, asphalt, petrochemicals and pipeline
quality natural gas.

2. On an energy equivalent basis, Natural gas liquids (C2+)

generally have a greater economic value as a raw material
for petrochemicals and motor gasoline compared to their
value as a component in natural gas.

3. Natural gas from the well, while principally methane,

contains quantities of other hydrocarbons - ethane,
propane, butane, pentane and also carbon dioxide and
water. These components are separated from the methane
at a gas fractionation plant.
 NATURAL GAS PROCESSING
Natural gas when produced at the wellhead, may contain
contaminants such as water, carbon dioxide, nitrogen and
hydrogen sulfide.. Commercial natural gas is principally methane
and, to a lesser extent, ethane. Natural gas processing plants
extract natural gas liquids from natural gas after fractionation
where the mixed hydrocarbon liquid are separated into the
purity NGL products of ethane, propane, normal butane,
isobutane and natural gasoline.
 USE OF NATURAL GAS
Industries use natural gas to provide energy for various
manufacturing processes. Natural gas is also being used
as a transportation fuel.
Compressed natural gas or CNG: Used in car and van
fleets.
Three important components are obtained from natural
gas: ethane, propane, and butane.
Ethane: Raw material in the petrochemical industry.
Ethane is processed to make ethylene that is used to
manufacture polyethylene.
Ethylene is used to manufacture following:
• ethylene glycol or anti-freeze for radiators.
Ethylene oxide. vinyl chloride, polyvinyl chloride or
PVC.
• Raw material to manufacture vinyl acetate for
paints and adhesives. Polystyrene manufactured
from ethylene is used to make resins for rubber.
• Ethanol is also produced from ethylene..
 USES OF NATURAL GAS
1. Propane and butane are used to manufacture the chemical
building blocks: propylene and butylene.

2. Propylene oxide produced from propylene is used to sterilize

medical and food products and to manufacture surfactants.
Propylene glycol, is used as industrial antifreeze and as
hydraulic and brake fluid.

3. Butylene is an important chemical used in manufacturing

products that improve the quality of gasoline.

4. Natural gas is a raw material to make ammonia for

agricultural fertilizer.

5. Carbon black, which is used to reinforce rubber and make

ink and batteries, comes from natural gas.

6. Paints use lamp black formed from natural gas for tinting.
 USES OF LPG
DOMESTIC USE: FOR HOUSEHOLD COOKING

INDUSTRIAL USE
•AIR HEATING
•BOILER FIRING
•ASPHALT MELTING
•CARBON BLACK APPLICATIONS
•DESALINATION OF SEA WATER
•RUBBER PRODUCTS CURING
•PAPER PRODUCTS DRYING
•PAINT DRYING
•PORTABLE FLOOD LIGHT ILLUMINATING
•INCINERATORS
 USES OF PROPANE
• AS A HIGH CALORIFIC VALUE FUEL IN DIFFERENT INDUSTRIES
• AS AN AUTOMOTIVE FUEL
• BLENDED WITH BUTANE FOR PRODUCTION OF LPG
• FEEDSTOCK FOR POLYPROPYLENE & PROPYLENE GLYCOL

USES OF PENTANE
• Pentane is used as solvents. as an additive in automotive and
aviation fuels.
• Raw material for the production of chlorinated pentanes and
pentanols.
• It is used in artificial ice manufacture, low--temperature
thermometers, solvent extraction processes, blowing agent
in plastic, etc.
 USES OF NAPHTHA

• Naphtha is sold to large consumers in Power (NTPC

etc.) & Fertilizer Sectors.
NATURAL GAS PROCESSING PLANTS IN GAIL

• GAIL (INDIA) LTD has LPG recovery plant at Vijaipur,

Vaghodia, Usar, Pata, Gandhar & Lakwa.
• LPG is recovered from Natural Gas by expansion,
chilling & fractionation after dehydration of natural
gas.
• LPG RECOVERY PLANT PATA is integrated with Gas
Processing Unit of UPPC Pata. C2+ liquid
hydrocarbon produced in GPU is sent to LPG plant for
production of C2/C3, Propane, LPG, Pentane &
Naphtha.
• The main processes involved in LPG plants are
• Feed gas drying/regeneration
• Feed gas expansion by using expander
• Feed gas chilling.
• Separation
• Fractionation for separation of products.
 TYPICAL NATURAL GAS COMPOSTION
AT GAIL PATA
Component Typical Analysis
(mole %)
Methane 79.50
Ethane 10.0
Propane 3.4
Butane 1.2
Pentane 0.25
Hexanes plus 0.1
Carbon Dioxide 5.5
Nitrogen 0.05
Specific Gravity 0.70
 BLOCK DIAGRAM OF
GAIL, PATA

CO2 TO ATMOSPHERE

NATURAL GAS
FROM HBJ PIPELINE GAS C2/C3 GAS
SWEETENING RECOVERY CRACKER
12.66 MMSCMD UNIT UNIT UNIT

LEAN NATURAL GAS BACK TO HBJ ETHYLENE

LLDPE
+HDPE
NAPHTHA + PENTANE LPG
RECOVERY ETHANE / PROPANE
UNIT 400,800 TPA

258,250 TPA LPG 71,085 TPA PROPANE

LLDPE:160,000TPA
HDPE:200,000TPA
LEGEND
MMSCMD : MILLION STANDARD CUBIC METRES PER DAY
TPA : TONNES PER ANNUM
FEED:
DEMETHANISER BOTTOM LIQUID FROM GPU
(12.66 MMSCMD OF NATURAL GAS
PROCESSING )

PRODUCTS:
LPG 2,58,250 TPA
C2/C3 4,00,080 TPA
PROPANE 71,085 TPA
NAPHTHA 26,742 TPA
PENTANE 19,755 TPA
 PROCESS FLOW DIAGRAM
12.66
MMSCMD GAS
SWEETENING UNIT
Rich Gas from
GAIL Vijaipur
(HVJ P/L) 11.35 MMSCMD
SWEET GAS

9.3
MMSCMD C2+
RECOVERY C2/C3
GAS CRACKER UNIT
Lean Gas back UNIT 400,800 TPA
to HVJ pipeline

LPG LPG 258,250 TPA

UNIT Propane 71,000 TPA
Pentane/ Naphtha 46497 TPA
TPA : Tonnes per Annum

MMSCMD : Million Standard Cum. Mtrs. Per Day

 GAS SWEETENING UNIT

CO2 : ~ around 1000 TPD

Feed Gas
From HVJ
12.66 MMSCMD Sweet Gas
(CO2: ~5 Mole %) (CO2 : < 50PPM)
Gas
Sweetening
Unit
 PROCESS FLOW DIAGRAM OF GAS SWEETENING UNIT

FILTER- Sweet gas to

COASLESCER WATER
WASH C2+
COLN.
Natural Recovery
gas
Unit

ABSORBERS
CO2
K.O.D
VV-001
Reflux
.
drum

Amine
Flash Drum tank
Lean/
Rich Amine
Exch. Filtration
Lean Package
Amine
Cooling
Cooler.
water
 GAS SWEETENING UNIT
Brief Process Description :
Receiving sour feed gas from HVJ pipeline after
filtration & pressure reduction.
Counter-current Absorption of CO2 from feed gas by
Dow Speciality amine CS plus in Absorbers at 50
Kg/cm2.
Flashing of Rich Amine from 50 Kg/cm2 to 5.5
Kg/cm2 to remove the dissolved hydrocarbons
Preheating of Rich Amine to 100 deg C utilizing the
heat of regenerated lean amine and subsequently,
desorption of CO2 in Regenerator column by heating
the amine to 120-123 deg C using LP Steam in
reboilers.
 GAS SWEETENING UNIT
Brief Process Description :
Heat Exchange between lean amine & rich amine and
Cooling of lean amine to 48-52 deg C using cooling
water.
Storage & recycling of lean amine to Absorbers.
Water-washing of sweet gas (containing less than 50
ppm of CO2) to remove entrained amine.
Side stream filtration of lean amine using cellulose
pre-coat filter and charcoal filters.
 GAS SWEETENING UNIT
Problems experienced:-

Problem Effect of the problem

Frequent failure of the Frequent plant shutdown
regenerator reboiler tubes.
The shell side of the reboilers are
high temperature and two-phase
flow region. The earlier tube
bundles were made of CS which
were used for cooling DEA
solution which was corrosive in
nature
 GAS SWEETENING UNIT
Problems experienced:-
Problem Effect of the problem
Insufficient cooling from the High lean amine temperature
amine coolers. leading to poor absorption
Earlier, there were 03 nos
coolers as per original design (2
working in parallel + 1 standby).
Required cooling was not
obtained due to improper
distribution of amine in the
coolers
 GAS SWEETENING UNIT
Problems experienced:-
Problem Effect of the problem
Corrosion in earlier amine Reduction in thickness of
system. pipelines & elbows. High iron
DEA was being used earlier. content in recirculating amine
Being corrosive in nature, it had
caused depletion of the corrosion
allowances in the pipelines,
especially at the bends & elbows.
High foaming tendency Restriction of plant load due to
This was due to the presence of high pressure drop across the
impurities such as dust particles, absorbers on account of
oil-mists etc in the sour feed gas foaming
which was carried over to the Degradation of amine
absorbers and mixed up with the
circulating amine
 GAS SWEETENING UNIT
Problems experienced:-

Problem Effect of the problem

Severe corrosion of regenerator Inefficient mass transfer in the
top trays top trays of the column leading to
The top trays of the regenerator high LP steam consumption in
column were badly corroded due reboilers
to high concentration of acid
gases at the region which was
further aggravated due to
corrosive nature of DEA used
earlier
High pressure drop in absorbers Restriction of plant load
The valve trays inside the
absorbers put higher restriction
against the gas flow, causing
high pressure drop across the
absorbers
 GAS SWEETENING UNIT
Measures adopted to counter the problems:-

Measures Benefits
Provision for putting amine Effective reduction in lean amine
coolers in series as well as in temperature.
parallel.
This has ensured proper
distribution of amine in the amine
coolers leading to more effective
heat transfer. Also, one additional
amine cooler installed which
results into additional surface
area available for heat transfer.
 GAS SWEETENING UNIT
Measures adopted to counter the problems:-
Measures Benefits
Replacement of CS tube bundle Elimination of plant downtime on
of the reboilers with SS 316L account of tube leakage of the
tube bundle. reboilers
This has effectively countered
the corrosion & tube leakage
problem for the reboilers
resulting into no further tube
leakage.
 GAS SWEETENING UNIT
Measures adopted to counter the problems:-
Measures Benefits
Complete changeover of solvent Elimination of corrosion problem
to Dow Speciality Amine CS Lower regeneration temperature
plus.
This is basically a tertiary amine
which is less corrosive in nature.
This speciality amine also
contains activator such as
piprazine etc. which increases
the reactivity of the amine with
the acidic components present
in the sour feed gas
 GAS SWEETENING UNIT
Measures adopted to counter the problems:-
Measures Benefits
Installation of additional charcoal Reduced foaming tendency
filters having higher capacity for Reduced iron & HC content
more effective removal of iron &
HC.
Earlier, there was only one
charcoal filter of smaller size
through which the amine flow rate
th
was maintained as 1/100 part of
the re-circulating amine flow rate.
In order to enhance the capacity of
the charcoal filter, 02 nos new
filters were installed in parallel to
the old one and thus the total
capacity of the charcoal filters
th
have increased to 1/10 part of re-
circulating amine flow rate.
 GAS SWEETENING UNIT
Measures adopted to counter the problems:-
Measures Benefits
Installation of Filter-Coalescer at Effective separation of oil-mists/
the U/s of absorbers. HC droplets from the feed gas
This had been installed to leading to reduction in foaming
restrict the carryover of oil-
mists/heavier HC along with the
sour feed gas to the absorbers
which had led to foaming
Replacement of top 11 nos trays Reduced corrosion of trays
of the regenerator with SS 316L Effective mass transfer at the
valve trays. upper part of the column where
This had replaced the badly the concentration of acid gas is
corroded trays at the upper side very high.
of the column which were made
of SS 304.
 GAS SWEETENING UNIT
Measures adopted to counter the problems:-
Measures Benefits
Replacement of valve trays of Reduced pressure drop
the absorbers with high capacity Increased gas throughput
SS 316L Nye trays.
This had been done to
overcome the problem of high
pressure drop (around 0.5
Kg/cm2) across the valve trays
which was restricting the gas
flow. The Nye trays are having
fixed opening for gas flow
through the same leading of low
pressure drop (around 0.28
Kg/cm2) and thus higher gas
handling capacity.
 GAS SWEETENING UNIT
Additional Measures adopted to increase plant performances:-
Earlier status
Amine carried over along with the
sweet gas was drained out from
the d/s vessels of the water wash
column
The residual amine inside the
cellulose pre-coat filter was
drained during replacement of
cellulose pre-coat
For routine analysis, sample of
amine was taken thrice a day. The
amine for sample line purging was
being drained.
Present status
Carried over amine is reclaimed and
recycled back to amine system
through Amine filtration system
The residual amine is taken into the
amine system by rinsing the pre-
coat filter with condensate water
before discarding the old pre-coat
The sample line purging is being
done in closed system and the
amine is taken back into the system

Benefits:-
Saving of Rs 90 Lakhs per annum on account of saving of 32 MT of
amine per year.
Positive impact on environment due to reduction in amine loss
 GAS SWEETENING UNIT
Additional Measures adopted to increase plant performances:-

Earlier status Present status

The CO2 loading in rich amine was
earlier maintained as 0.38 mol of
CO2 per mol of amine. Average LP
steam consumption was 1.98 MT
per MT of CO2 removed.
The CO2 loading in rich amine
increased to 0.42 mol of CO2 per
mol of amine by reducing lean
amine flow rate to absorbers. As a
result, average LP steam
consumption is reduced to 1.85
MT per MT of CO2 removed.

Benefits:-
The benefit is Rs 3 crores per annum on account of reduction in
LP steam consumption
 GAS SWEETENING UNIT
Additional Measures adopted to increase plant performances:-

Earlier status Present status

The cellulose pre-coat of the
cellulose pre-coat filter of
amine filtration system was
replaced every week in a
routine manner.
The same is now being
replaced once in a month
depending upon the actual
performance of the cellulose
pre-coat filter which is
reflected by the pressure drop
across the filter.

Benefits:-
Cellulose consumption is reduced by 800 Kg per year
Positive impact on environment due to reduction in cellulose
disposal from amine filtration system
 C2+ RECOVERY UNIT
Lean Gas : 9.4 MMSCMD

Sweet Gas
from GSU
11.35 MMSCMD C2+
(CO2:< 50 PPM)
RECOVERY Feed Stock for LPG
plant.
UNIT
PROCESS FLOW DIAGRAM OF C2+ RECOVERY UNIT
PROPYLENE

VV VV 002
EE 035 DRYER
015 A/B

KE 001 EE 007 EP 007

VV 001 COMP A/B
EP 006
LEAN GAS KE 002 EP 001
COMPRESSOR
COMPRESSOR
EE 019 SEP 3
EP 002
CC 001
SEP 1
EE 015 EP 005
A
EP 003 A
KE 001
CC 002 SEP 2 EXP
LEAN GAS
KE-002 EP 004
EXPANDER CC 001
C2/C3 COLUMN
IN LPG

PRODUCT
 C2+ RECOVERY UNIT
Brief Process Description :
Compression of sweet gas to 55 Kg/cm2 followed by
temperature reduction to 18 deg C using propylene
refrigeration.
Drying of sweet gas to the dew point of -100 deg C &
subsequent filtration of dried sweet gas.
Stage-wise chilling of sweet gas through a series of
plate-heat exchangers with intermediate separation of
liquid HC from gas.
Expansion of gas from 50 Kg/cm2 to 22 Kg/cm2
through turbo-expander resulting into temperature
reduction to -90 deg C.
Separation of methane from the liquid HC in
Demethaniser column.
 C2+ RECOVERY UNIT
Brief Process Description :

Expansion of Demethaniser column O/H vapor from

20 Kg/cm2 to 10 Kg/cm2 resulting into further
reduction in temperature to -117 deg C.
Heat exchange between sweet feed gas and lean gas
in plate heat exchangers.
Pre-compression of lean gas to 12 Kg/cm2 using
energy of gas expansion.
Further compression of lean gas to 50-55 Kg/cm2
using Gas turbine driven centrifugal compressors for
putting it back into the HVJ pipeline.
 C2+ RECOVERY UNIT
Problems experienced:-
Problem Effect of the problem
High pressure drop across EP- Restriction of plant load; Frequent
004. derimings (once in every month)
This was due to frequent hydrate to bring down the pressure drop
formation inside the core of EP-04
High pressure drop across feed Restriction of plant load
gas filters at the D/s of the Dryers. Frequent cleaning of filter
The filter elements for the earlier elements
dryers were of monel metal and
the pores of the same were
frequently blocked by the
carryover of molecular sieve dust
from the Dyers.
 C2+ RECOVERY UNIT
Problems experienced:-
Problem Effect of the problem
Poor reboiling in EP-005. Restriction of plant load and high
This was due to higher pressure methane content in Demethaniser
drop against the flow of liquid bottom product
from the 24 thtray of the
Demethaniser to EP-05 on
account of zig-zag routing of the
line.
Poor reboiling in EP-006. Restriction of plant load and high
This was mainly due to the methane content in Demethaniser
combined effect of presence of bottom product
heavier HC at the bottom of
Demethaniser and insufficient
surface area for EP-06
 C2+ RECOVERY UNIT
Problems experienced:-
Problem Effect of the problem
Malfunctioning of important trip Frequent plant tripping
switches.
In past, the important trip switches
had actuated on false reasons on
several instances causing plant trip
High pressure drop across EP-001. Restriction of plant load.
EP-01 was used to exchange heat Failure of EP-001
between lean gas at subzero
temperature and sweet gas
saturated with moisture. As a
result, the exchanger was
experiencing high pressure drop
across its sweet gas side on
account of hydrate/ice formation
 C2+ RECOVERY UNIT
Measures adopted to counter the problems:-
Measures Benefits
Introduction of Dryer purging Reduction in deriming frequency
system before putting in of EP-04 from once in a month to
adsorption cycle. once in a year.
By adopting this procedure, the
residual regeneration gas inside
the regenerated Dryer is flushed
out with fresh sweet gas in order
to remove all the oil-mists etc from
the Dryer bed which is carried over
by the regeneration gas and which
may cause hydrate formation at
the plate heat exchangers
especially in EP-04. The purged
gas is put into lean gas header
without any wastage.
 C2+ RECOVERY UNIT
Measures adopted to counter the problems:-
Measures Benefits
Depressurization and blowing of Reduction in pressure drop
EP-004 done in the backward across EP-04
direction i.e from the Reflux drum Reduction in deriming
to Demethaniser during deriming. frequency of EP-04 from once
This ensures blowing of the in a month to once in a year.
exchanger in backward direction
which effectively removes the
hydrates & its nucleus from the
core of EP-04
 C2+ RECOVERY UNIT
Measures adopted to counter the problems:-

Measures Benefits
Introduction of hold-on grating at Even distribution of gas across
the bottom and distributor plate at the Dryer bed leading to improved
the top for the dryer bed. performance of the Dryer
This ensures even distribution of
feed gas across the entire Dryer
bed reducing the possibility of
channeling of gas. This also
ensures retention of Dryer bed
above the moisture basket at the
bottom of the Dryer.
 C2+ RECOVERY UNIT
Measures adopted to counter the problems:-
Measures Benefits
Changeover of molecular sieve Reduced pressure drop across
from IPCL make to UOP make. filter
The dust formation from the UOP Increased plant throughput
make molecular sieve is quite less
than the earlier IPCL make.
Installation of new feed gas filter of
higher capacity in parallel with the
old filters.
The new filter is having non-monel
type filter elements and is of
higher capacity
 C2+ RECOVERY UNIT
Measures adopted to counter the problems:-
Measures Benefits
The inlet and outlet lines of EP-005 Improved reboiling in EP-05 &
(Demethaniser side reboiler) were EP-06
rerouted with minimum bends &
turns. Improved efficiency of
This results in less pressure drop in Demethaniser column
the line from Demethaniser column to
EP-05 due to straightening of the line
th
The height of the chimney tray (24 )
of Demethaniser was increased in
order to increase hydraulic head
acting on EP-005.
Installation of additional core for EP-
06 (Demethaniser Bottom reboiler) in
order to enhance the surface area for
heat transfer.
 C2+ RECOVERY UNIT
Measures adopted to counter the problems:-
Measures Benefits
Installation of EE-035 (Propylene Cooling of sweet gas before Dryer
Refrigeration exchanger) after failure as a permanent substitute for EP-
of EP-01. 01
This acts as the permanent
replacement of EP-01 which cools
the sweet gas to 18 deg C at the U/s
of Dryer.
Installation of EE-007 (Plate heat Heat exchange between feed gas
exchanger) after failure of EP-01. after Dryer and Lean gas in
absence of EP-01
 C2+ RECOVERY UNIT
Measures adopted to counter the problems:-
Measures Benefits
Installation of new moisture More effective removal of free
separator (VV-002B) in parallel to moisture at the U/s of the Dryers
the existing one (VV-002A).
This ensures reduction of gas
velocity through the moisture
separators leading to effective
removal of free moisture
Installation of Prestripper Column. Reduction of liquid load on
The heavier HC condensed in Demethaniser column
Separator-III is diverted to this
column. The bottom product from
the column is directly sent to the
C2/C3 column bypassing
Demethaniser.
 C2+ RECOVERY UNIT
Measures adopted to counter the problems:-
Measures Benefits
Installation of Filter-separator in More effective separation of
the feed gas line at Gas receiving foreign particles from sour feed
terminal. gas at the gas receiving point
This ensures removal of all foreign
particles from the feed gas at the
Gas terminal itself which is the
entry point for the feed gas for
GAIL, Pata
Introduction of 2 out of 3 voter Elimination of frequent plant trip
logic for all the trip switches. on account of malfunctioning of
This ensures that plant will not trip trip switches
on account of malfunctioning/false Enhanced operational reliability
actuation of any trip switch. It will
trip only if any genuine reason
exists for tripping of the plant
 C2+ RECOVERY UNIT
Additional Measures adopted to increase plant performances:-

Earlier status Present status

The LG compressors were
tripped every time on
actuation of plant trip.
The trip logic is modified so that on
actuation plant trip, the LG
compressors will keep on running at
minimum governing speed with
antisurge valves in full open
condition.
As a result, the plant load is restored
3-4 hrs earlier due to saving of the
start up time for the LGCs

Benefits:-
Saving of Rs. 60 lakhs for saving of each tripping of LGC
Minimization of thermal stress on Gas Turbines on account of
frequent tripping
 C2+ RECOVERY UNIT
Additional Measures adopted to increase plant performances:-
Earlier status
The ventilation fans of Gas
Turbines were drawing high
current (140-145 amps against
F.L.C of 148 amps) with the inlet
damper of the fans opened by 15-
20% only leading to insufficient air
flow inside the GT enclosure.
The fans used to trip very
frequently on overload
Present status
The pulleys of the fan and the
motor were interchanged so that
the r.p.m of the fans were
reduced
As a result, the current drawn by
the fans reduced to 80-90 amps
only.
The inlet damper of the fans are
now being opened fully resulting
into sufficient air flow inside the
Gas Turbine enclosure

Benefits:-
Saving of Rs 20 lakhs per annum on account of reduced
energy consumption by the fans.
 C2+ RECOVERY UNIT
Additional Measures adopted to increase plant performances:-

Earlier status Present status

Flare & Blowdown Nitrogen is being used at
headers of GPU were present for this purpose
kept under positive in place of fuel gas.
pressure using fuel gas
as end purge.

Benefits:-
Saving of Rs 28 Lakhs per annum on account of
saving of fuel gas.
 C2+ RECOVERY UNIT
Additional Measures adopted to increase plant performances:-

Earlier status Present status

The feed gas Dryers are
designed for 12 hrs adsorption
cycle.
As a result, there were 02 nos
of regenerations every day.
The adsorption cycle time for
the Dryers are increased to 24
hrs depending on the actual
performance of the Dryers.
As a result, there is only 01 no
regeneration every day leading
to the saving of Fuel gas
required for 01 no regeneration
(5200 SCM per day).

Benefits:-
Saving of Rs 3.08 crores per annum on account of
reduction in fuel gas consumption.
Some other important modifications in GPU
Modification Benefit
Satellite dosing for the cooling Reduced pressure drop and
water system for amine coolers therefore, reduced frequency of
dismantling & cleaning of amine
coolers.

Conversion of relay based trip Easy identification of reason of

system to the PLC based system tripping and quick remedial actions
for LG Compressors and RG
Compressor

Installation of LEL detectors in the Improved safety in that location

Gas Terminal area
Some other important modifications in GPU
Modification Benefit
Installation of 3” line for supplying Sustained running of Gas Turbines
fuel gas to Gas Turbines directly in case of GPU trip
from the lean gas header in case
of GPU trip

Replacement of old feed gas To cater for the requirement of a

filters at Dryer D/s with new one standby filter to the existing new filter
having higher capacity at higher plant load (14 MMSCMD)

Installation of temperature control Better controlling of condensate flow

valve in the condensate line to the Desuperheater ensuring exact
leading to Desuperheater saturation of LP steam to reboilers
 Some future modifications in GPU
Modification
Implementation of automatic
blowdown control system for Heat
Recovery & Steam Generation
systems
Conversion of amine pump trip
logics from relay based to PLC
based system
Changeover of MOC of amine
lines, valves, control valves, MOVs
from CS to SS316L with increase in
pipeline diameter
Intended benefit
Reduction in energy and water
consumption due to reduction in
continuous blow down (CBD) from
steam drums
Easy and instant identification of
reason of tripping, resulting into
early resumption of plant
Reduced corrosion & erosion and
enhanced amine flow rate at higher
plant load (14 MMSCMD)
 LPG UNIT

C2+ Feed from

Demethaniser PRODUCTS
column – C2/C3
LPG – PROPANE
– LPG
– PENTANE
– NAPHTHA

Brief Process Description:

• Fractionation in four distillation columns.
• Propylene Refrigeration for C2C3 Column and various heat-
exchangers for GPU.
 PROCESS FLOW DIAGRAM OF LPG UNIT

Steam C3R Propylene

Turbine Compr Refrigeration

C2/C3 Propane LPG

Pentane

C2+ feed from

Demethaniser
Propane LPG NGL
C2/C3 Column Column Column
Column

Naphtha
 PROPYLENE REFRIGERATION SYSTEM

VHP STEAM
B/L

STEAM
TURBINE
09-KA-003
DRIVE T 40 T –7.0 T –28.0 T –41
P 16.9 T 13
P 4.8 P 2.3 P 1.4
P 8.7
09-VV-017

MP STEAM

09-VV-021

09-VV-020

09-VV-018
09-VV-019
LP STEAM T 68.4
C.W. P 17.3

SURFACE CONDENSER

COND.
PUMP TO C2/C3 CONDENSER

B/L FROM C2/C3 CONDENSER

B/L
MAKE UP REFRIGERANT 08-EE-019 08-EE-015
FROM EE-035

TO EE-035
 LPG UNIT
Brief Process Description :
The bottom product of Demethaniser column
containing C2+ hydrocarbons is fed into C2/C3
column
C2/C3 column separates C2/C3 (a mixture of 85% C2
& 15% C3) as the top product. The necessary chilling
is provided in the O/H condenser through propylene
refrigeration
The bottom product of C2/C3 column is fed into
Propane column which separates pure C3 as top
product.
The bottom product of Propane column is fed into
LPG column which separates LPG as top product.
 LPG UNIT
Brief Process Description :

The bottom product of LPG column is fed into NGL

column which separates pure C5 as top product and
Naphtha as bottom product.
All the products are sent to their respective storages.
Propylene refrigeration is provided by the Propylene
Compressor which is a steam turbine driven four-
stage centrifugal compressor consisting of a
propylene accumulator, four suction KOD’s, a
propylene condenser and other accessories. It
provides refrigeration at four different levels viz.
–7°C(for LPG unit), -28°C, –41°C and 18oC (for C2+
recovery unit).
 LPG UNIT
Problems experienced:-
Problem
Frequent tube leakage of C2/C3
column reboiler which uses
saturated LP steam as heating
medium.
This may be due to the carryover
of free moisture along with the LP
steam on account of ineffective
de-superheating
Frequent tube leakage in
Propylene condensers.
Effect of the problem
Intermixing of hydrocarbon and
condensate water
Increase of pressure in the
steam/condensate side of the
reboiler leading to restriction in
steam flow
Loss of propylene
Enhancement of microbiological
growth in cooling water system
 LPG UNIT
Problems experienced:-
Problem Effect of the problem
st
Less vapor load in 1 stage on Imbalance of vapor load among
account of no vapor available from the stages leading to higher steam
EE-015. consumption
Since, EE-015 was isolated from
the propylene side, no propylene
vapor was available from it for the
1 ststage of propylene compressor.
st
Therefore, the 1 stage runs with
antisurge valve in open condition.
 LPG UNIT
Measures adopted to counter the problems:-
Measures Benefits
Two stage controlling of BF water Better controlling over the LP
flow to Desuperheater. steam temperature ensuring
This helps in gradual reduction of exact saturation of LP steam.
BF water pressure instead of No free water is carried over
single stage pressure reduction with the LP steam which may
from 130 kg/cm2 to 4 Kg/cm2 cause tube leakage in the
reboiler upon impingement
Satellite dosing at the cooling Reduction in frequency of tube
water inlet for the individual leakage of propylene condenser
propylene condensers.
This localized dosing may be
helpful in reducing corrosion in the
cooling water side of the
condensers
 LPG UNIT
Measures adopted to counter the problems:-

Measures Benefits
Propylene vapor load sharing Even distribution of vapor load
between 1 ,st2 nd& 3 rdstages of among all the stages
propylene compressor. Reduction in r.p.m of
Under this modification, the compressor resulting into
propylene vapor available from saving of steam
EE-035 is partially diverted to 1 st
stage of the propylene compressor
along with the 2 nd& 3 rdstages. As
a result, 1 ststage gets the required
vapor load.
 LPG UNIT
24” RP-09-2218-B4A-IC TO KA 003 1ST
STAGE SUCTION
09 HV 2201
24”-RP-09-2228-B4A-IC B/L I/V

09 VV 018
K OD-1 ¾” I/V

08 EE 015
TO 4TH STAGE SUCTION RP FROM 09PA13
ANTISURGE
FLOW LINE
08 PCV 3103 8”-RP-08-B1A-1C
I/V
NEW
09 VV 021 I/V
8”-RP-08-B1A-1C LINE
K OD-4
08 FCV 3602
6”B/P I/V
ANTISURGE 08 EE 035
FLOW LINE 08PCV3601 RP FROM 09VV017
10”-RP-08-3610-B1A-1C
FROM08EE-019
09 VV 019
K OD-2
LEGEND
EXISTING LINE
ANTISURGE
FLOW LINE
NEW LINE

09 VV 020
K OD-3
 LPG UNIT
Additional Measures adopted to increase plant performances:-

Earlier status Present status

The pump was being used to
transfer liquid propylene to
EE-019.
The pump (18.5 KW) is
stopped and liquid propylene
is being transferred by utilizing
the pressure differential.
As a result, 148 MWH of
energy is saved annually.

Benefit
Saving of Rs 5.10 Lakhs per annum.
 LPG UNIT
Additional Measures adopted to increase plant performances:-
Earlier status Present status
The pump was being used to The pump (22 KW) is stopped
transfer Naphtha to storage. and Naphtha is being
transferred by utilizing the
pressure differential.
As a result, 73 MWH of energy
is saved annually (considering
10hrs per day of pump
operation).

Benefit
Saving of Rs 2.52 Lakhs per annum.
 LPG UNIT
Additional Measures adopted to increase plant performances:-

Earlier status Present status

The average efficiency of the
cooling water pumps of CT-3 was
around 84%
The impellers & casings of the
pumps are coated with flake glass
filled synthetic coating leading to
reduction in frictional energy loss
As a result, the average efficiency
of the pumps is enhanced by 7%

Benefit
Saving of Rs 24.5 Lakhs per annum on account of
efficiency enhancement of the pumps.
STORAGE FACILITIES FOR PRODUCTS
Storages Type of Storage No Capacity

LPG Mounded Bullets 7 2800 M 3

each
Propane Mounded Bullets 2 2800 M 3
each
C2/C3 Spheres 8 1500 M 3
each
Pentane Pipeline bullet 1 3825 M3

NAPHTHA Atmospheric Tanks 2 850 M 3each

 LPG MOUNDED STORAGE
PSV TO FLARE
CAPACITY: 2800 M3
DIAMETER: 6 M
LENGTH: 96 M

MOUNDED BULLET
MERCAPTON DOSING

TO LOADING GANTRY
LPG
LOADING
PUMP
VAPOR BALANCE LINE

LPG RECIRCULATION LINE LPG FROM UNIT

LPG MOUNDED STORAGES :
LPG MOUNDED STORAGES
 PENTANE STORAGE PSV

PENTANE FROM UNIT ROV2403

VAPOR
ROV2402 BALANCE
LINE
6””--P-432419--B1A 8””--P 43-2418--B1A

FLARE
KOD
24 FINGERS OF 36” EACH
CAPACITY:
NOMINAL-4500 M3
LIQUID STG--3825 M3

FROM
12””--
P 43-2401--B1A
MOUNDED
STORAGE LT 2401 ROV2401
TO FLARE LT 2402

12””--
P-43-2406--B1A
PENTANE TO
TO MOUNDED GANTRY
STORAGE
PENTANE ROAD LOADING PUMPS
 NAPHTHA STORAGE
ATM VENT AT
PSV 1502 A/B SAFE HEIGHT
PSV 1501 A/B

LT 1501 PSV 1501 C

LT 1502 PSV 1502 C

LI 1503
LI 1504

Naphtha Naphtha
STORAGE STORAGE
TT-003 A TT-003 B

NAPHTHA CAPACITY=765 M3 EACH

FROM HEIGHT: 13.5 M
UNIT DIAMETER: 9.0 M

NAPHTHA
LOADING
PUMPS A/B NAPHTHA TO
LOADING GANTRY
PROPANE MOUNDED STORAGE (2 NOS.)
PSV TO FLARE
ROV
MAXIMUM STORAGE CAPACITY- 1200MT

ROV

MOUNDED BULLET

TO LOADING GANTRY
PROPANE
LOADING
PUMP
VAPOR BALANCE LINE

PROPANE RECIRCULATION LINE PROPANE FROM UNIT

 LPG LOADING GANTRY
FLAME ARRESTOR

MOV 1701 MOV 1702

TT 1701

FV 1701
HS 1709
HS 1701

BATCH
CONTROLLER

WEIGH BRIDGE
 Critical Equipments in Gas Sweetening Unit

1) HP ABSORBERS (2 IN 2) REGENERATOR
PARALLEL)
Operating pressure (top) : 1.9
• Operating pressure (top) : 51.4 kg/cm2a
kg/cm2a Operating pressure (bot) : 2.2
• Operating pressure (bottom) : 51.7 kg/cm2a
kg/cm2a Operating temp (top) : 97oC
• Operating temp (top) : 45oC Operating temp (bot) : 123oC
• Operating temp (bottom) : 71oC No. of trays : 22
• No. of trays : 30 Type of tray : 21 valve + 1
• Type of tray : High chimney
capacity Nye trays No. of reboilers : 4 kettle type
• Gas flow handled :7 Steam flow to reboiler : 84 MT/hr
MMSCMD
• Amine flow handled : 400 m3/hr
 Critical Equipments in Gas Sweetening Unit

3) AMINE TANK
• Operating temp : 45oC
• Nominal Capacity : 770 m3

SPENT AMINE & FRESH AMINE TANK EACH

OF 400 m3 CAPACITY

4) AMINE CHARGE PUMPS (2 running + 1 standby)

• Suction pressure : Atmospheric

• Discharge pressure : 62 kg/cm2a
• Driver : HT motor
• Type : Multistage centrifugal
• No. of stages :5
• Power rating : 1.1 MW
• Head : 590 m
 Critical Equipments OF C2+ Recovery Unit
1) KE 001 (FEED GAS EXPANDER COMPRESSOR) MAKE: MAFI TRENCH, USA
• Comp suction pressure : 50 kg/cm2a
• Comp discharge pressure : 55 kg/cm2a
• Exp. suction pressure : 52 kg/cm2a
• Exp. discharge pressure : 22 kg/cm2a
• Comp. Suction/discharge temp : 40oC/ 50oC
• Exp. Suction/discharge temp : -67oC/--97oC
• Operating speed : 13800 rpm
• Power : 3.6 MW

2) DEMETHANISER
• Operating pressure (top) : 21.9 kg/cm2a
• Operating pressure (bottom) : 22.2 kg/cm2a
• Operating temp (top) : -97oC
• Operating temp (bottom) : 5--12oC
• No. of trays : 35
• Type of tray : 34 valve + 1 chimney
• No. of reboilers : 2 (bottom + side)
 Critical Equipments OF C2+ Recovery Unit
3) KE 002 (DEMETH O/H EXPANDER COMPRESSOR)
MAKE: MAFI TRENCH, USA
• Comp suction pressure : 10.8 kg/cm2a
• Comp discharge pressure : 12 kg/cm2a
• Exp. suction pressure : 21.7 kg/cm2a
• Exp. discharge pressure : 12 kg/cm2a
• Comp. Suction/discharge temp : 10oC/ 28oC
• Exp. Suction/discharge temp : -101oC/-117oC
• Operating speed : 8500 rpm
• Power : 2.7 MW

4) DEMETHANISER PRESTRIPPER
• Operating pressure (top) : 22.1 kg/cm2a
• Operating pressure (bottom) : 22.4 kg/cm2a
• Operating temp (top) : -38oC
• Operating temp (bottom) : 54oC
• No. of trays : 17
• Type of tray : 16 valve tray+ 1 chimney tray
• No. of reboilers : 1 (Thermo--syphon)
• Steam flow : 2.8 MT/hr
Critical Equipments OF C2+ Recovery Unit
5) LEAN GAS COMPRESSOR (2 IN PARALLEL)
MAKE: BHEL, HYDERABAD
DRIVER: GAS TURBINE (GE, FRAME V)
CONTROLS: MARK V SPEEDTRONIC
• No. of stages :2
• Type : Centrifugal
• 1st stage suction pressure : 10.8 kg/cm2
• 1st stage discharge pressure : 24 kg/cm2
• 2nd stage suction pressure : 23.8 kg/cm2
• 2nd stage discharge pressure : 54 kg/cm2
• Operating speed : 9896 rpm
• Power : 13.8 MW
• Fuel gas cal value : 8190 kcal/Sm3
Critical Equipments OF C2+ Recovery Unit
6) RESIDUE GAS COMPRESSOR
MAKE: BHEL, HYDERABAD
DRIVER: STEAM TURBINE (BHEL)
CONTROLS: WOODWARD GOVERNOR
• No. of stages
• Type
• Suction pressure
• Discharge pressure
• Operating speed
• Power
• Inlet steam pressure/temp :
• Outlet steam P/T
• Steam flow
: 1
: Centrifugal
: 23.2 kg/cm2a
: 54 kg/cm2a
: 13177 rpm
: 2.75 MW
41 kg/cm2a/365oC
: 4.5 kg/cm2a/140oC
: 30 MT/hr
 Critical Equipments OF LPG Unit
1) PROPYLENE REFRIGERANT COMPRESSOR
MAKE: BHEL, HYDERABAD
DRIVER: STEAM TURBINE
CONTROLS: WOODWARD GOVERNOR, CCC ANTISURGE CONTROL

No. of stages : 4
• Type : Centrifugal
• 1st stage suction pressure : 1.28 kg/cm2a
• 2ND stage suction. pressure : 2.3 kg/cm2a
• 3rd stage suction Pressure : 4.8 kg/cm2a
• 4th stage suction. Pressure : 6.7 kg/cm2a
• 4th stage discharge pressure : 17.3 kg/cm2a
• Operating speed : 6216 rpm
• Power : 8.77 MW
• VHP steam flow : 57 MT/hr
THANK YOU