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ENERGY AUDIT REPORT- MAKUM OIL COLLECTING STATION

ACKNOWLEDGEMENT

Petroleum Conservation Research Association, Eastern Region (PCRA, ER), appreciates the interest, participation and collaboration by the management & engineers of the Oil India Limited (OIL) in carrying out Energy Audit at “Oil Collecting Station-Makum ( Makum OCS) in Tinsukia Districtin in upper Assam. Our special thanks to the Installation Manager and his team of Engineers, Supervisors and technicians involved for Makum OCS, who have extended their co-operation and courtesy to the energy audit team during the audit.

Petroleum Conservation Research Association, Eastern Region (PCRA, ER) appreciates the interest,

participation and support by the Management, Staff-members, Medical Administrators and Engineers of

M/s Oil India Limited (OIL) during the tenure of the field exercises, vis-à-vis, the Energy Audit, conducted

at Makum Oil Collecting Station during the period 07.08.14 – 10.08.14. Period of Audit: 07.08.2014 to

10.08.2014

We want to put on record our thankfulness to the Administration of Technical Audit, OIL, Duliajan and

Field Engineers and Technical Staff Members, attached with Oil Collecting Station, Makum, which have

been extended during the observation of facilities and measurement of field data during the period.

Our sincere thanks and gratitude are also to be put on record for the Management and Auditors of M/s

Oil India Limited, Department of Technical Audit, for their initiative for the audit and the support and

cooperation, received during the data collection, liaison and availability of necessary documents

required for the field exercises.

Finally, special thanks are due to all members of the Audit team for their planning, field data collection,

and all sorts of related exercises.The Audit team comprising the following team member from OIL and

PCRA ER are as stated below:

The Energy Audit Team for Makum Oil Collecting Station :Station:

On behalf of M/s Oil India Limited On behalf of M/s Petroleum Conservation .

M/s Oil India Limited, A/c- Makum OCSM/s Petroleum Conservation Research Association, Kolkata


Research Ass.ociation

Er. Ranen Mandal, Chief Manager- tech. Audit

Er. Debabrata Tamuly, Installation Manager,

Makum OCS

Er. Kishore Deka, Sr. Tech. Auditor

Mr. Ranen Mandal, Chief Manager- Tech. Audit

Mr. Debabrata Tamuly, Inst. Manager, Makum OCS

Mr. Kishore Deka, Sr. Tech. Auditor

Mr. Pranab Dutta, Tech. Auditor

Er. Abhijit Chanda, Addl. Director, PCRA

Er. Dabasis Ransingh, Jt. Director, PCRA

Mr. Abhijit Chanda, Addl. Director, PCRA

Mr. Dabasis Ransingh, Jt. Director, PCRA

ErMr. Subrata Sanyal, Certified Energy Auditor

INDEX

Chapter Title Page

1.0 Executive Summaery 3

2.0 SummerySummary of Savings Potential 4

3.0 Introduction to the Report 6



4.0 Scope of Work 9

5.0 Methodology of the Audit 10

6.0 Present Energy Scenario 12

7.0 Study of Electrical Power Consumption 15

8.0 Study of Pumps 18

9.0 Study of Electric Motors 23

10.0 Study of Air Compressor 25

11.0 Study of Performance & Efficiency of Gas Engines 27

12.0 Study of Crude Oil/ Natural Gas Consumption 30

13.0 Study of Illumination 33

14.0 General Observations of the Audit 35

15.0 Notes & Conclusion

Annexur

e

A1 Line Diagram of Material Flow

A2 List of Energy Efficient Equipment Suppliers

EXECUTIVE SUMMARY

1.1.1 Major Recommendations and Savings potentials :

Short and Medium Terms :Terms:



Recommendations Savings per Annum Estimated Investment (Rs.)

Simple pay backpayback periodkKWHrh/Cum Rs.

Savings of Natural Gas by running 125 KVA Gen. Set through-out the day

3,50,400 m3 22,70,592.00 Nil Immediate

By By iimproving the efficiency and flow rate of COD Pumps #1,2& 3

1,36,129 m3 9,12,113.00 Nil Immediate

By By mmaintenance of valves (#5) & increasing speed (#6)

63,773 m3 4,13,249.00 Nil Immediate

By By iimproving efficiency and flow-rate of F.W. pumps

1,43,631 KWHrkWh

6,53,521.00 Nil Immediate

By By oover-hauling of Booster pumps, running hours be reduced

18,746 KWHrkWh

85,294.00 Nil Immediate

By changing consumption pattern of gas by installing compressor to convert 10 psi to 30 psi

21,90,000 m3 1,41,91,200.00 2,37,12,300.00 1 year 8 months

By replacing fluorescent Tube lamps by T-5 lamps

6,407.94 KWHrkWh

29,156.00 32,494.00 13 months

[1.1.2] Medium / Long Terms :Terms:

[1.1.3] No recommendation

Energy metering for measuring the different types of utility i.e. electrical, crude oil, natural gas,

water to be installed at the installation for effective utilization of energy.



SUMMARY OF SAVINGS POTENTIAL

Maximize the use of 125KVA Run only 125 KVA Generator Set through-out the day, in place of

250 KVA generatorgenerator in the night. It will improver the loading on the generator, improve

its electrical parameters.

and reduce the load of utility attached with 250 KVA generator.

Adjust the running speed of gas-engines, attached with Crude Oil Disposal Pumps by adjusting

the governors. It will increase the lives durability of the engines.

Over-hauling of Crude Oil Disposal Pumps is solicited need to improve the efficiency and flow-

rate. The total running hours of the pumps will thus be reduced substantially. At present, the

flow rate is around 67% of the rated flow. The actual flow-rate is desired to be improved to 80%

of the rated.

Replacement of suction and delivery valves of Crude Oil Disposal Pumps is solicited along with

increasing of engine #6 speed to 1500 RPM by adjusting the governor. The flow rates/ hour will

be increased, along with reduction of fuel consumption at engine for same rate of delivery.

Over-hauling of Formation Water Pumps is urgently required to increase the flow rate and water

leakage. Actual working hours for the pump to complete the task will be substantially reduced.

Over-hauling of Booster pumps is required to reduce the running hours and to increase the flow.

Present pattern of usage of natural gas at 30 PSI and 10 PSI needs to be revisited. The present

level of flaring should be reduced by utilizing them for internal purpose of feed to the grid with

the compression at 3rd . party level.

Crude oil leakage at Crude oil Despatch (COD) Pump should be investigated and

checkedarrested.

Illumination inside the compound and at operation sheds to be increased, either by replacing

faulty fittings or adding new fittings.



Existing 36 watts Fluorescent Tube Lamps are to be replaced by T-5f energy saving efficient

fittings.

Meter facility to be incorporated at strategic levels to have regular checks and thereby, to take

appropriate measures, as required.

Operation log-book is to be maintained at operation level, namely, generator set, gas engine,

etc.

S ummary of above Efficiency Measures

Items Actions Remarkssults

125 KVA Gen Set to in p l ace of 250 KVA Gen Set

Load can be taken drawn by 125 KVA Gen set

-Improve the loading of Gen set - Improve its electrical parameters - Reduced the load of on attached with 2 2 50 KVA Genset

COD – Pumps Overhauling of pumps & crude oil leakage to be arrested

- Improve the efficiency - - flow rate- Flow rate is around 67% whereas actionual

at flow rate is desired to be 80%Suction & deliver valves

Replacement of valves & increasing the speed of engine # 6 to 1500 RPM

Flow rate / hour will increased

F.W pumps + Booster pumps

Over-hauling - Actual working hours will reduced

30 PSI & 10 PSI Gas Present pattern of Natural Gas to revisit

- To utilized them for internal purpose ofand fueedel to the gas grid on boosting



Illumination By replacing the faulty fittings or Add new light fittings

- For improving the Illumination to desired lev a e l

36 Wat FTL Replaced with TS5 energy saving fittings

- Save energy

Meter facility

&

Operation L og-book

-Energy Meter to be fitted

- Operation Log-book to be maintained

- For regular checkmonitoring

- For taking appropriate action in future

- Monitoring operating data Log-book s s pecially for Gen Set, Gas Engine etc.

INTRODUCTION TO THE REPORT



[3.1] M/s Oil India Limited is the oldest oil exploration activities in India, starting from the inception of

digging for crude oil in 1889. Before the independence of the country, all activities were a private

initiative, rechristened into a public-private initiated under the present nomenclature, since the

establishment of M/s Oil India Limited in 1959, in collaboration of M/s British Oil Co. Ltd. The

Government of India bought back entire stake of the private company in 1981, leading the Company

to be the largest government initiative in this endeavour in north-eastern part of the country.

[3.2] M/s Oil India Limited (OIL), at present, is engaged in exploration of crude oil and natural gas in

north-east India, along with new ventures in the states of Rajasthan, Odisha, Andhra Pradesh,

Andaman and Gujarat.

[3.3] At present, there are 189 oil wells under OIL, spread over north-eastern India, mainly catering to

the crude oil exploration. As the by-product of the initiative, natural gas with pressure range from 10

psi to over than 250 psi are also mixed with crude oil.

[3.4] Makum Oil Collecting Station (Makum OCS) is handling around 25% of total explorationproduction,

where the output of 47 oil wells are pumped intocollected and processed. The main service function

of this OCS is to separate crude oil from the natural gas and , water and sediment/sludge, which are

produced as by-products of the crude oil explorationproduction..

[3.5] Makum OCS is handling 3,280 KL/ day of crude oil (as on 31.07.14) along with huge quantity of

natural gas. The natural gas over 250 psi is directly fed to the central gas supply network grid to

Hapjan Gas Collecting Station (Hapjan GCS). A portion of gas retrieved during process at 30-40 psi

pressure level is directed to gas compression station, where the pressure is increased to 250 psi

level and fed to the central grid. Another portion of the remaining quantum is utilized in-house for

running of gas engines for power generation, gas engine driven COD pumps, heating source

generation at Emulsion- treatoer (ET) and Indirect Heater(IH) and the rest portion is just flared up.



There is no facility to utilize remaining portion of gas below 10 psi level and is totally being

flaredwasted.

The produced formation water disposed into the water disposal wells.

3.1[3.6] The Operational Capacity of Makum OCS is shown here :

SURFACE HANDLING CAPACITY OF MAKUM OCS

Well Fluid Processing Capacity : 3600 KL/day

Crude Oil Storage Capacity : 4930 KL

Formational Water Storage Capacity : 640 KL

Water Separation Capacity : 1800 KL/day

HP (250 PSI) Gas Processing Capacity : 0.82 Metric Million Std. Cum/day (MMSCUM)

LP (30 PSI) Gas Processing Capacity : 0.32 Million Std. Cum/day(MMSCUM)Metric Million

Cum/day

LP (10 PSI) Gas Processing Capacity : 0.15 Million Std. Cum/day(MMSCUM)Metric Million

Cum/day

3.2[3.7] The single line diagram for the process is shown here :

Natural Gas above 250 psi to Grid

Gas Grid

N.G. at 30 psi

Flare

From Wells N.G. 10 psi

Mixed Crude Oil


ID Heater G.U.-I G.U.-II E.T.

Booster Comp

Int. Cons.

E.E.T.

WaterStabilizer

Crude Tank

Pump

G.U.- Group Unit I/IIE.T. – Emulsion TreaterE.E.T. – Electrostatic Emulsion Treater

WDP

WDWell


3.3[3.8] The mixture of crude oil-water-natural gas (Well fluid) is tested periodically to determine the

production rate of liquid and gas of a particular well. Well fluid coming from different wells to OCS

are categorized as H.P. Dry, H.P. Wet and L.P. Wet based on well head pressure and water content in

well fluid. Similar category wells connected in one manifold. From manifold, well fluid goes to

Indirect Heater for improve flow-ability and enhance better phase separation in next stage

separation. Indirect Heater (Water Bath Type) maintains the temperature below 60o C.

3.4 From Indirect heater, HP (wet) fluid goes to GU-I(W) separator where gas and liquid separated.

Separates liquid then goes to GU-II(W) separator and gas goes to central gas grid(Distribution

Network) through HPMS(High Pressure Master Separator).The pressure maintain in GU-I(W),HPMS

& GU-II(W) around 20.0 Kg/cm2 ,19.5 Kg/cm2 and 5.5 Kg/cm2 respectively. GU-II(W) is a two phase

separator, separated liquid goes to Emulsion Treater and gas escape to Low Pressure Master

Separator(LPMS-30 psi). In LPMS, back pressure maintains around 30 psi. Major portion of LPMS(30

psi) gas goes to private owned booster compressor(BOO) for boosting 30 psi gas to 250 psi and then

the boosted gas(250 psi) gas fed to central gas grid. Other portion of 30 psi gas utilize for internal

consumption of OCS. Rest portion, if any flared up. Daily production of LP gas (30 psi) is around

1,30,000 to 1,50,000 SCUM, out of which, 72,000 SCUMPD is dispatched to private owned booster

compressor(BOO). Another 9,500 SCUM per day is used in-house for generation of electricity,

running of gas engines, burning as a fuel in IH, ETs & EETs and to maintain pneumatic pressure at

pneumatic control apparatus.

3.5 From GU-II(W), wet crude goes to Emulsion Treater. In Emulsion Treater(ET), wet crude (emulsified

crude) is treated by using Thermo-Chemical process for breaking emulsion and water is separated .

Separated Oil is goes to EET(Electrostatic Emulsion Treater) , gas goes to LPMS(30 psi) and water

goes to Formation water tank. Pressure maintain in ET and EET are 3.5 Kg/cm2 ,2.8 Kg/cm2

respectively. In ET, water content in crude reduced to 0.5%. For further reduction of water content ,

the treated crude goes from ET to EET ,where Electro-static process is used and water content

comes down to 0.1%. The separated oil, water and escape gas goes to Stabilizer, Formation water

tank and LPMS (10 psi) respectively. In stabilizer back pressure maintain around 1.0 Kg/cm2 . From



stabilizer, oil enters to Crude oil storage tank (height: 12mtr) and gas escape to LPMS (10 psi). Water

produced thus dispose into water disposal well.

3.6 The mixture of crude oil-water-natural gas is tested periodically to determine the percentage of

each component through Test Unit. One normal operation is resumed, the direct in-flow from the

wells are categorized as H.P. Dry, H.P. Wet and L.P. Dry and channelized through separate Indirect

Heater (I.D. Heaters) to maintain the temperature below 60oC. The heating at this stage ultimately

increases the flow of the liquid. The fuel used in indirect heating is Natural gas at pressure range of

30-40 psi.

Group Unit I separates liquid and gases and gas with pressure range above 250 psi is directly fed to the

gas grid through High Pressure Master Separator (HPMS). The Group Unit II is meant for low pressure,

where gas with pressure range between 30-40 psi is separated and a portion is dispatched to the

Booster Compressor Station, outside the OCS compound. Daily production of natural gas at 30-40 psi

level is around 1,30,000 to 1,50,000 cum, out of which, 72,000 cum per day is dispatched to 3 rd. party

booster station. Another 9,500 cum per day is used in-house for generation of electricity, running of gas

engines and to maintain pneumatic pressure at nipping apparatus.

In Emulsion Treater, oil (around 95%) and crude oil are separated by thermo-chemical process inside a

vessel, where as is charge for maintenance of flame inside and extra chemical is fed from outside.

Residual water (maximum 5%) is separated from crude oil (to maintain water content of 0.2% to be sent

to the refinery). Here electro-static process is used. The back pressure from the EET is 2.8 Kg/cm2, which

is further reduced to 1 Kg/cm2 at stabilizer. 1 Kg/cm2 back pressure pushes the oil upto a height of 12

Ft.

[3.9] The capacities of G.U. vessels are 910 KL/day, that of EET is 2,000 KL/day.

[3.10] Production profile of Makum OCS as on 31.07.2014 stands as :

PRODUCTION PROFILE OF MAKUM OCS

Crude Oil Production : 2,710 KL/day

Formation Water Production : 787 KL/day

HP (250 PSI) Gas Production : 350,000 scum/day

LP (30 PSI) Gas Production : 130,000 scum/day



LP (10 PSI) Gas Production : 11,500 scum/day

SCOPE OF WORK4.1 Pumps :

4.1.1 Determine Hydraulic Pressure, Efficiency of Motor-Driven Pumps.

4.1.2 Evaluate the performance of the Engine Driven Pumps including the study of the pumping and

allied Systems to evaluate their operational efficiencies and feasibility of reduction of in the

energy consumption, wherever possible.

4.2 Electric Motors :

4.2.1 Study of Loading and Efficiency of Motors,

4.2.2 Performance parameters of motors, Economics of Replacement of Under-loaded and in-efficient

motors.

4.3 Air Compressors :

4.3.1 Determine FAD of air Compressor

4.3.2 Determine the compression ratio

4.3.3 Specific Power Consumption,

4.3.4 Isothermal efficiency of Air Compressor,

4.3.5 Evaluate the Utilization pattern of the compressed air, leakage in the system, feasibility for

pressure optimization.



4.4 Study the loading / % impedance of transformers

4.5 Study the performance & Efficiency of Gas Engine

4.6 Study of Natural Gas Consumption :

4.6.1 Study the consumption of natural gas by Indirect Heaters, Emulsion Treaters, Electro-static E.T.,

Gas Turbines for power generation and pumping system, etc.

4.6.2 Calculate specific Fuel Consumption of all the equipments running in the installation,

4.6.3 Determine total Gas consumption of the Installation,

4.6.4 Determine the Energy Index of the Installation.

4.7 Area Lighting/ Shed Lighting/ Control Room Lighting :

4.7.1 Determined Installed Load Efficiency & Installed Load Efficacy Ratio (ILER)

4.7.2 Study the Illumination system at the installation and suggest measures for improvement

wherever possible

METHODOLOGY OF AUDIT

5.1 In Makum Oil Collecting Station, direct out putoutput from the wells are fed to the manifold. The

conglomeration of the input is a mixture of crude oil, mudsludge / sediment, water and natural gas.

Through the indirect heater, the mixture is heated up to 60o deg C to maintain the flow and resist

the deposition of sludge / sedimentmud inside the pipes, which would reduce the flow pressure.

5.2[5.1] Prior to the field study at Makum OCS, a detail list of the scope of work had been provided by

OIL, which became the basis of the field measurement and the parameter testing. For proper

measurement and testing, understanding of the process is a must. So the method applied during the

study are a chronological of the given below :

5.2.1[5.1.1] Understanding of the process and identification of the Units.5.2.2[5.1.2] Study of the electrical power generation and measurement of electrical parameters at site,

during day time and evening time.5.2.3[5.1.3] Measurement of other electrical equipments at the site, namely, electric motors,

transformers, lighting loads and illumination level.



[5.1.4] Measurement of mechanical parameters of the crude oil pumps and , formation water/ and booster pumps, namely, head, flow, RPM, etc.

5.2.4[5.1.5] Measurement of mechanical and electrical parameters of Air Compressors.[5.1.6] Study and measurement of speed, flow, etc of the gas engines at crude oil pump and power

generator.5.2.5[5.1.7] Study of the material flow for natural gas and crude oil at various points to prepare a

material balance of the OCS.5.2.6[5.1.8] Certain deficiencies were observed and documents were lacking, who deter during the

performance measurements of the following :

[5.1.9] There is no flow meter for gas flow measurement and High speed dieselelectricity at any point of

the network.

[5.1.10] The operational log-book of the Gas-alternator station has never been maintained. So, the

performances evaluation of the power generator is previous period could not be

possibleassessed.; tEven, the power curve for 24 hours basis could not be prepared. During the

field study, electrical parameters during day and evening time were measured, high highlighted

the connected electrical load through-out the day (load was mostly constant and day-time load

for 12 hours was less than evening time load for 12 hours)

5.2.7[5.1.11] A number of gas engines, connected directly with COD pumps were age-old, no operational

or maintenance manual was available.

5.2.8[5.1.12] There are two air compressors, one runs at a time. There is single unit to be catered by the

air compressor, half-an-hour, twice a day (morning and evening).

[5.1.13] Measurement of flow up to the stabilizer level could not be verified as the fluid contains crude

oil, natural gas and waterwas not a fruitful venture, as due to high rate of sedimentation of mud

inside the pipes deters and the ultra-sonic flow-meter is not able to to sense properly flow.

5.2.9[5.1.14] Few equipments could not be tested due to operational constraint.

5.3[5.2] The following Equipments were deployed during the field study :

Three Phase power Analyzer,

Single Phase Power Analyzer,

Lux Meter

Ultra-sonic flow meter,

Non-contact type Infra-red Thermometer,



Non-contact type Tachometer

PRESENT ENERGY SCENARIO

6.1 At present, in Makum OCS, energy is utilized in three forms :

(i) Electrical Energy, generated in gas engine-alternator combined, to run electric motors of various

sizes, illumination and small electrical gadgets,



(ii) Mechanical Energy, generated in gas based engines to run ‘Crude Oil Delivery (COD)’ pumps;,

alternator, as well as directly by usinedg natural gas to pressurizemaintain a pneumatic controls

pressures for nipping of vessels..

(iii) Thermal EnergyThermal Energy, by using burning natural gas to develop a flame in side Indirect

Heaters and Emulsion Treaters.

[6.2] There is no electricalElectrical connection power is not drawn from the State electricity grid

network. The required electrical power required at various points equipments/insidemachines

inside the OCS is met by running gas engine driven -Aalternator set. There are two 250 KVA gas

genitor generator sets (of same rating, one runs at a time) and one 125 KVA gas-generator set.

During the day time, generally normally 125 KVA gas generator is used to cater the load but often

runs, but often, it was replaced by 250 KVA gen-set is utilized instead of 125 KVA gen-set. running.

After sun-set, when station lighting is switched onAt night, 250 KVA gen-set is utilized for the total

load. set is run. The gas supply to any of the gas-generator set is continuous through pipeline, when

natural gas with pressure 30-40 psi is directly fed to the engines. Natural gas required for the gas

engines for power generation is supplied from the 30/40 psi gas network available inside the

installation. Power is generated at 415 volt, 3 Ph, 50 Hz level, which is connected connected to the

power control centre to be fedfeed to the individual feeder. There is no metering system to

measure the gas flow at individual pointgas engines directly.

[6.3] At present, natural gas of pressure between 30-40 psi is utilized for in-house requirement. There is

no metering system to measure the gas flow at individual point directly.

[6.4] Details of energy consuming installations equipment/machineries are :

Sl Equipment Total capacity Energy Used Energy requirement

01 Indirect Heater (6 nos)

Separate for HP Dry & wet, LP wet

Natural gas is used to maintain the heat temperature of crude oil to 40o-50oC

2,700 cum/day

02 Group Unit I ( 2 nos) 1820 KL/day Practically nil N.A.

03 Group Unit II (2 nos) 1820 KL/day Practically nil N.A.



042

Emulsion Treater (3 nos)

2730 KL/day Natural gas is used continuously to maintain the flame in the thermo-chemical process

????

053

Electro-static Emul-sion Treater (1 no)

2000 KL/ day Electricity supply is required here to maintain the voltage potential for the electro-static process

Load is fluctuating, power drawn varies from 2.73- to 4.8 KW

06 Stabilizer (2 nos) 3600 KL/day Practically nil N.A.

057

Crude Oil Delivery Pump (6 nos)

1-3 : 40 KL/hr4 : 100 KL/hr5-6 : 60 KL/hr

Mechanical power to run the pump is met by gas engine

37.0 scum/hr

068

Formation Water Pump (4 nos) Note : 2 pumps run operate at a time

1000 cum/hr Pumps run operates by 3 Ph electric motors of capacity 30 KW each

Electric power drawn by each motor = 22 KW, total power = 44 KW

079

Booster Pump ( 5 nos), 1 pump continuously + 1 pump occasionally

75 cum/hr Pumps run by 3 Ph electric motors of capacity 15 KW

Electric power drawn by each motor 11.54 KWKW, av power drawn = 17.31 KW

108 Circulating Pump ( 3 nos), one runs at a time intermittently

23 cum/hr Pump run by 3 Ph electric motor of 7.5 KW (run hr- 5 hrs/day)

Electric power drawn = 4.5 KW

119 Cooling Tower ( 2nos), one with each Gas generator

50 cum/hr Pump power = 3.75 KWFan power = 3.75 KW,Run by electric power

Available with 250 KVA set only, runs for 15 hrs a day with electric power drawn = 4.88 KW

102

Air Compressor ( 2 nos) one stand-by

Receiver cap.=225 litre

Run by electric motor of 3.75 KW, runs 10 mins x 2 times/day

Power drawn = 2.25 KW

113

Illumination (for 3 high-masts)

24 KW Run by three phase power, distributed to single phase to individual fittings

Total capacity = 8 KW eachTotal power drawn = 17.59 KW

124

Illumination (other than high masts)

11.5 KW Single phase electrical power, rated capacity-

Actual power drawn = 9.81 KW



not known135

Misc Mechanic Utility, e.g. submp pump,

N.A. Three phase electrical power, capacity – 7.5 KW

Actual power drawn =4.5 KW at certain intervals

6.2[6.5] Details of Energy consumption per day :

Daily Electricity consumption = 59.1 KW x 12 hours + 86.5 KW x 12 hours = 1,747.2 KWHr.

Daily Natural Gas Consumption as fuel and for pneumatic purpose = 6,800 cum + 2,700 cum = 9,500

cum, @ 8,700 Kcal/Kg x 580 Kg/cum = 47,937 x 106 Kcal, which is equivalent to 5,57,40,698 KWHr.

A slight quantity of High Speed Diesel is required for running Drenching pump, but the consumption

level is not at par.

Daily Energy Consumption Curve :

Electricity Consumed Natural Gas Consumed0.00

10.0020.0030.00

40.0050.00

60.0070.0080.0090.00

100.00

Series1

Study of Transformer :Transformer:



DETAILS OF TRANSFORMER

Isolation Transformer, 200 KVA, Dry-type, 415 Volt/415 Volt, 278.24 Amp, AN, Dyn11, impedance -

4.73%, Sr. No. DT/1693/01, Yr. 2008

Note :Note: Since the transformer is not a power transformer, but an isolation transformer, no

detail study is required.

STUDY OF ELECTRICAL POWER CONSUMPTION

[7.1] As said earlier, the source of electrical power is through captive power generation by using gas-

generator. The Gas-Generator generates power at 415 volt, 3 Ph, 50 Hz level. There are five three

gas-Generators : 250 KVA x 2 nos + 125 KVA x 1 no + 125 KVA old generators x 2 nos.

7.1[7.2] The details of Gas-Generators are :

250 KVA ( 2 nos) Generators 125 KVA New Generator 125 KVA (2 nos) Old Generators

Gas Engine : Model – CJ250G5P, Sr. No. CJX-SGG-10020327, 313 BHP, 1500 RPM, Battery volt- 24 V, make- Jackson, 2010Alternator : A.C., 3 Ph, 50 Hz, 250 KVA, 1500 RPM, 348 RPM, 415 volt, 48 volt excitation, type-HC143401, Sr. No. N10B01905, make- Stamford

Engine : Model – CJ125G5P, Sr.

No. 25321873, 157 BHP, 1500

RPM, 24 volt battery, Make-

Jackson, Year- 2007

Alternator : A.C., 3 Ph, 50 Hz,

125 KVA, 1500 RPM, 174 Amp,

58 volt excitation, make-

Stamford

125 KVA, NGEF sets, currently

disconnected.

NOTE : 125 KVA new Generator generally runs during day time, often relieved to be taken over by

250 KVA generator. During evening time, either of the 250 KVA runs continuously.

7.2[7.3] There is no operational log-book maintained by the Generator Operators. So, the electrical and

mechanical parameters could not be checked.



7.3[7.4] The single line diagram for the power distribution is shown :

E.E.T. Lighting W/F. Pump Comp. Lightg Booster Utility Panel I Panel II Pump

[7.5] During the field study at OCS, the load was checked twice, i.e. at day time and at evening time. The

reason of checking waschecking :was: though the electrical load at the process was constant, the

load used to increase during evening time due to campus illumination. On the basis of the same, the

measurement, as given below was found :

Reading during day time Reading during evening time

Parameters Phase R Phase Y Phase B Phase R Phase Y Phase B

Voltage (v) 238.8 238.2 240.7 236.6 238.3 238.8

Current (A) 103.6 109.4 101.4 142.2 126.7 152.9

Power (KW) 18.3 18.4 22.4 28.2 26.4 31.9

Powr Factor 0.766 0.79 0.87 0.84 0.87 0.91

Observations :

During day time, if 125 KVA Gen. Set runs, loading becomes 59.1%

During day time, if 250 KVA Gen set runs, loading becomes 29.55%

During night time, when 250 KVA Gen set runs, loading becomes 43.25%

During night time, when 125 KVA Gen set runs, loading becomes 86.5%

Poor loading on Gen set causes P.F. below rated value. Lower P.F. demands higher

excitation currents and results in increased losses.

Unbalancing of load observed during evening time due to single phase lighting loads. It

causes over-heating of alternator.

7.4[7.6] Energy Saving Potential :


3 Ph, A.C. Generator

POWER DISTRIBUTION CENTRE


[7.6.1] Rationalize the loading on gen-set during day and night. If 125 KVA gen-set is capable to cater the

entire load of OCS at night also, 125 KVA gen-set to be utilized for effective loading of gen-set.

Run entire station load on 125 KVA Generator only, as it is capable of taking load of plant. Even

during the evening time, when the load becomes 86.5 KW, 125 KVA set is sufficient to take load

at 86%.

[7.6.2]

7.4.1 The rated consumption of Natural Gas for 250 KVA is 77 Scum/Hr, whereas that for 125 KVA is

37 cum/Hr. So, by running 125 KVA in place of 250 KVA, gas consumption can be reduced by 40

Scum/hr. Considering 24 hours run for 365 days a year, the yearly savings in gas = (77-37)

Scum/hr x 24 hrs/day x 365 days = 3,50,400 Scum @ Rs.6.48/cum, the yearly monetary savings is

Rs.22,70,592.00( Rupees Twenty two lacs Seventy thousand Five hundred Ninety two).

[7.6.3] Moreover, by replacing 250 KVA gen set, total electrical load of cooling tower, @7.5 KW can be

eliminated, which will ultimately reduce total load within safe margin of Alternator.

[7.7] Details of Electrical Connected Load with Rated Capacity, Maximum Load and Av. Load are :

Location Rated Load on continuous basis

Rated Load on intermittent basis

Av. loading Actual Load

[A.] A.Day-time Load

Isolation Transformer

160 KW Nil 25% 0.75 KW

Formation Water Pump

60 KW Nil 73% 44 KW

Booster Pump1 15 KW Nil 57.7% 8.66 KWCirculating Pump 7.5 KW Nil 60% 4.5 KWCooling Tower.2 7.5 KW Nil 65% 4.88 KWAir Compressor 3.75 KW Nil Nil 3.75 KW 20% 0.75 KWMisc. Mechanical Utility

7.5 KW Nil Nil 7.5 KW 20% 1.5 KW

Total connected Load during day time

65.04 KW

[B.] B.Evening Time Load



Day-time load Calculation as before

65.04 KW

Illumination3 15.35 KW Nil 97% 14.89 KWTotal load during Evening Time

79.93 KW

NOTES :

1. One Booster pump runs at a time, if COD Pump #5 or 6 runs. It won’t run, if COD Pumps # 1-4 run

2. The cooling tower runs when 250 KVA Gen. Set in operation. If 125 KVA Gen set replaces 250 KVA gen set, cooling tower with total load of 7.5 KW won’t run.

3. Total single phase lighting load is 46.05 KW

Electrical Connected Load Summary :

If 250 KVA Gen Set runs If 125 KVA Gen set runs

Connected Load in Day Time 65.04 KW 60.16 KW

Connected Load in Night Time 79.93 KW 75.05 KW

STUDY OF PUMPS

[8.1] There are pumps to handle two kinds of stuffs liquids : Crude Oil and Formation Water.

8.1[8.2] There are six crude oil delivery pumps, run by gas engines, directly coupled. The details of the

pumps are :

Parameters COD #1 COD #2 COD # 3 COD # 4 COD # 5 COD #6

Delivery

Max Discharge Pr

Input BHP

Rated RPM

Make

40 KLPH

1585 PSI

205 BHP

370 RPM

Copper

40 KLPH

1865 PSI

205 BHP

370 RPM

Cooper

40 KLPH

1865 PSI

205 BHP

370 RPM

Cooper

100 KLPH

70 Kg/cm2

11.09 KW

227 RPM

BPCL

60 KLPH

1865 PSI

205 BHP

370 RPM

Cooper

60 KLPH

1047 PSI

250 BHP

400 RPM



Year

Gear Box Ratio

N.A.

6.2:1

N.A.

5.6 :1

N.A.

5.6:1

N.A.

5.6:1

N.A.

5.6:1

N.A.

5.6:1

8.2[8.3] The measured parameters of COD Pumps are :

Parameters COD #1 COD #2 COD # 3 COD # 4 COD # 5 COD #6

Flow (m3/hr

Discharge Pr (Kg/cm2)

Suction Pr.(Kg/cm2

Hydraulic Power (KW

Shaft power input (KW Pump Effici-ency (%)

Remarks

27.3

40.0

0.5

25.83

118.61

21.78%

Discharge is 68.25% of rated, eff is low

34.6

40.0

0.5

32.74

117.17

27.94%

Discharge is 86.5% of rated, eff is moderate

46.49

40.0

0.5

43.99

129.89

33.87%

Discharge is 116% (due to higher eng. speed

Under B/down

40.4

35.0

4.0

30.00

163.39

18.36%

Discharge is 67% of rated, eff too low

45.31

31.0

4.0

29.31

146.41

20%

Discharge is 75.5% of rated, spe-ed too low

8.3 Energy Saving Potential for COD Pumps :

[8.3.1] Out of five pumps under observation, pumps #1-3 are of equal rating. The flow in pump # 3 is

higher than others due to higher prime-mover speed. But the efficiency level for #3 is much

higher than other twos. Considering pump efficiency of 40% (av)- for the pumps of age group,

10-15 years, with same shaft power input, the hydraulic power output and the discharge

(considering common discharge line) for the pumps should increase by 18%, 12%, and 12%



respectively. This can be achieved by (i) regular maintenance of the pump, (ii) sequential

matching of lower capacity pumps with higher capacity pumps, vis-à-vis, common delivery line,

and (iii) replacing by impellor plunger of lower flow design. Thereby, the running hours of pumps

# 1,2 & 3 can be reduced by 18%, 12% and 12% respectively. (Note : Prime Mover #3 is at

present running at 1715 RPM against 1500 RPM rated and fresh consideration is based on its

running at 1500 RPM only)

8.3.1[8.3.2] Energy Savings per year for Pumps # 1, 2& 3 :

(i) For Pump #1 : 37 m3/hr (N.G. consumption at prime mover)x 24 hours/ day x 365 days x

18% = 58,341 m3/year @ Rs.6.48/m3 = Rs.3,78,050.00

(ii) For Pump #2 : 37 m3/hr x 24 hours/day x 365 days/year x 12% =38,894 m3/year @

Rs.6.48/m3 = Rs.2,52,033.00

(iii) For Pump #3 : Same as Pump #2 = Rs.2,52,033.00/Year

[8.3.3] Observations for Pumps #5 &6 :6: These are of same capacity (discharge @60 KL/Hour). But

their discharge rates depend upon running of Pump #4 (discharge @100 KL/hour). When Pump

#4 is not running, the discharge pressure is 31 Kg/cm2, with running of #4, it increases to 37

Kg/cm2. The prime mover speed of #6 is also low (1337 RPM), compared to rated. The efficiency

of both at present is very low (18.36% -20%), whereas the pumps are only 4-5 years old. As per

the information gathered daily pumping rate of crude oil varies between 150-200 KL/Hr. General

operation sequence of the pumps is – (i) run two of #1-3 along with #4, or (ii) run all of #1-3 with

either of #5 &6. The inner diameter of delivery pipeline (starting from #1side) is 10”Ø, throttled

to 4”Ø at the outlet of #4, increased to 6”Ø at the outlet of #5&6. The delivery of # 5& 6 is

always less, necessitating the service of Booster pump, which otherwise not required if #1-4 run.

But the running of #5 & 6 is not economical, given by the present rate of pump output and fuel

consumption at engine. The recommendations are :

(a) Take up total overhauling of #4 by replacing its suction and delivery valves,

(b) Take up overhauling of #5 by repairing/replacing its suction and delivery valves, thereby

increasing the flow rate from 40.4 m3/hr to 52 m3/hr, i.e. around 30%. The corresponding

savings potential (for same range of delivery with average 8 hours duty per day) is – 30% x

52 m3/hr x 8 hrs/day x 365 days/year = 45,552 m3/year, @ Rs.6.48/m3 = Rs.2,95,177.00)

(c) Adjust engine speed of #6 to its rated speed of 1500 RPM, whereby its delivery will be

increased to 52 m3/hr., leading to increase of flow rate by around 12% and subsequent



reduction of fuel consumption for present rate of crude oil discharge. (Savings : 12% x 52

m3/hr x 8 hours/day x 365 days/year = 18,221 m3/year, @ Rs.6.48/m3 = Rs.1,18,072.00)

(d) Avoid running #1-3 along with #5 &6, as the discharge pressure of #1-3 is 40 Kg/cm 2,

whereas that for 5&6 is below 35 Kg/cm2. COD Pumps #5 & 6 can be run with the previous

ones, if the discharge pressure is increased above 40 Kg/cm2 (which is possible by increasing

engine speed of #6 and by replacing suction/delivery valves of #5).

(e) Adjust the throttle valve (near #4) to allow more delivery from #5 &6, if #4 is run along with

either of #5 &6 is running.

8.4 Details of Formation Water (F.W.) Pumps : There are four F.W. pumps, out of which, one was found

in out of order situation. Two pumps run at a time. The details of F.W. pumps are given :

Formation Water Pump with Motor :

Pump : Multi (7)-stages pump, total head- 200 mtrs, Capacity -25 m3/Hr., Efficiency -58%, BKW-23.29

KW, RPM-2940, NPSH required – 1.6 mtr, Bare shaft- 166 Kg, make-Kirlosker Brothers

Electric Motor (Drive) : 3 Ph, 50 Hz, 30 KW, 2955 RPM, Efficiency -91%, make-KEC

8.5 Measured Parameters of F.W. Pumps :

Parameters F.W.Pump #1 F.W.Pump #2 F.W.Pump #3 F.W.Pump #4

Flow (m3/hr)


Suction Pr.(Kg/cm2)

Hydraulic Power (KW)

Shaft power input (KW), eff-91%

Pump Effici-ency (%)

% discharge of rated capacity

9.96

21.5

0.5

5.68

19.838

28.63%

39.84%

13.38

21.5

0.5

7.626

22.75

33.52%

53.52%

Efficiency low,

Under B/down 4.36

16.0

0.5

1.834

21.476

8.54%

17.44%

Eff. extremely low,



Remarks Efficiency low, impeller at every stage to be checked, gland leakage

impeller at every stage to be checked, leakage to be arrested

profuse gland leakage, impeller at every stage to be checked

8.6 General Observation of Formation Water Pump : As found during the testing, there were (i)

mechanical noise from the pump, (ii) excessive leakage from the gland, and (iii) discharge in # 1 & 4

is poor, and (iv) for almost same power input, hydraulic power output is varying widely and at low

level. The discharge is to be improved by checking and replacement (if necessary) of impeller at

every stage and arresting any loss of alignment.

[8.7] Savings potential :potential: The rated efficiency of the pumps is 58%, whereas the actual

efficiency is varying between 28.36%-33.52% (for pumps 1 & 2) and at lowest of 8.54% (for #4).

Considering average efficiency of 50% for such pumps, running hours for electric motors can be

reduced (considering same volume of water to be pumped daily). By proper over-hauling of pumps,

the flow rate can be increased by 21% & 16% (in case of pump I & II respectively) and 40% (in case of

pump #4). The reduction of running hours for pump # 1 is 21%, #2 is 16% and that for Pump #4 is

40%. The corresponding savings in electricity : For Pump #1 - 19.838 KW x 21% x 24 hours/day x 365

days = 36,494 KWHr/year, @ Rs.4.55/KWHr = Rs.1,66,048.00

For Pump #2 : 22.75 KW x 16% x 24 hours/day x 365 days =31,886 KWHr/year, @ Rs.4.55/KWHr =

Rs.1,45,081.00

For Pump # 4 : 21.476 KW x 40% x 24 hours x 365 days = 75,251 KWHr/year, @ Rs.4.55/KWHr=

Rs.3,42,392.00

Total Yearly savings : 1,43,631 KWHr or Rs.6,53,521.00

8.7[8.8] Measured Parameters of Booster Pumps : There are three booster pumps, out of which, one is

out of order. One runs at a time. The Booster pump runs, if crude oil delivery pump # 5 and/or 6

runs.

Parameters Booster Pump #1 Booster Pump #2 Booster Pump #3

Flow (m3/hr)


Suction Pr.(Kg/cm2)

42.78

4.0

0.5

Under B/down 39.73

3.5



Hydraulic Power (KW)

Shaft power input (KW), eff-93%

Pump Effici-ency (%)

Remarks

4.06

10.66

38%

Rated efficiency level is 62%, present efficiency is to be improved with maintenance of suction, discharge lines and impeller

0.5

3.23

10.72

30.13%

Rated efficiency is 62%, present efficiency to be improved by thorough over-hauling

Savings Potential :Potential: By over-hauling of Booster pumps, 20% reduction in running hours of

the pumps can be achieved (note :note: The rated flow for the Booster pump is 52 m3/hr at 5

Kg/cm2. The estimation is based on the assumption of over-hauling of the pump and considering

performance improvement in COD Pumps #5 &6). The reduction in power drawn in one pump

(running) = 10.7 KW x 20% = 2.14 KW. Yearly savings = 2.14 KW x 24 hours x 365 days = 18,746

KWHr, @ Rs.4.55/KWHr = Rs.85,294.00

[8.9] Circulating Pump (Rotto Pump) : Used as sump/pit pump

Pump Details :Sr. No. NH111400, rated delivery- 23 m3/Hr, 6 bar, 7.5 KW, 720 RPM, make- Rotto

Motor Details : 7.5 KW, PF-0.78, 710 RPM, Efficiency -86%, 5.5 Amps.

The electrical and Mechanical parameters could not be checked as there was no water in the circuit.



STUDY OF ELECTRIC MOTORS9.1 Electric motors with rated capacity of 7.5 H.P .and above were taken up for testing, because,

efficiency of lower H.P. motors are generally less, as designed.

9.2 Testing of Electric Motors : All are 3 Ph, 50 Hz motors.

Parameter Phase R Phase Y Phase B RemarksFormation Water Pump #1Voltage (Volt) 236.1 232.7 234.6Current (Amp) 35.4 35.9 36.7Power (KW) 6.7 7.5 7.6Power Factor 0.84 0.862 0.865 Low P.F.

Formation Water Pump #2Voltage (Volt) 235.3 232.5 239.1Current (Amp) 44 41.1 43.5Power (KW) 8.3 7.8 8.9Power Factor 0.818 0.873 0.831 Low P.F.

Formation Water Pump #4Voltage (Volt) 235 231.8 238.5Current (Amp) 39 38.8 40Power (KW) 7.7 8.3 7.6Power Factor 0.852 0.887 0.856

Booster Pump #1Voltage (volt) 234.7 235.2 236.9Current (Amp) 18.1 18.7 19Power (KW) 3.82 3.85 3.8Power Factor 0.876 0.88 0.87

Booster Pumo #3Voltage (Volt) 235 232.9 239Current (Amp) 18.4 18.4 18.7Power (KW) 3.84 3.87 3.82Power Factor 0.876 0.869 0.88

NOTE : The low power factor and unbalance current in three phases cause over-heating of Motor.



Abstract of Measurement of Motor Performances :

Location Rated Load/ RPM/Efficiency

Measured Load

% loading Remarks

Formation Water Pump #1

30 KW, 2970 RPM, Eff.-91%

21.8 KW 79.85% Adequately loaded


30 KW, 2970 RPM, Eff.-91%

25 KW 91.57% Over-loaded, over-heating observed


30 KW, 2970 RPM, Eff.-91%


Booster Pump #1 15 KW, 2880 RPM, eff.-93%


Booster Pump #3 15 KW, 2880 RPM, eff.-93%


9.3 Motor performances :

9.3.1 A.C., 3 Ph motors’ efficiency improves with loading improves over 50% of loading. But the safe

region for motor operation is 60%-85%, as over 85% loading, motor tends to over-heat.

9.3.2 In Makum OCS, majority of big motors are related to pumps with RPM around 2880 and are

directly coupled. Hence, little mechanical loss is observed at the couple point.

9.3.3 All of the motors are started by Y-Δ starters, though excessive cable congestion could be

observed inside the starter panel and bus-bar area.

9.3.4 During day time, if 250 KVA Gen Set runs, power factor reduces due to low loading on the

generator, which improves with increasing load after sun-set. With increasing P.F., loading

pattern on the motor also improves.

9.3.5 Electrical load on F.W. #2 motor is to be checked further, to reduce the loading within safe 85%.



STUDY OF AIR COMPRESSOR

10.1 There are two air compressors of same rating, one runs at a time. The details of the air

compressor are given below :

Compressor : Model – 2475, Sr. no. 3012004, year- 2006, receiver capacity – 225 litre, maximum

working pressure- 12.3 Kg/cm2, make- Elgi.

Drive Motor : A.C., 3 Ph., 50 Hz, 5 H.P. (3.75 KW), 1430 RPM, efficiency -84%, make- Crompton

Greaves.

10.2 Calculation of Free Air Deliver(FAD) :

Final pressure after filling of Air Receiver (P2)– 4.5 Kg/cm2

Initial pressure after bleeding (P1) – 0 Kg/cm2

Atmospheric Pressure (P0) – 1.026 Kg/cm2

Storage Volume (V) – 225 Litre = 0.225 cum

Time taken (T) – 2 mins 19.74 secs = 2.329 min.

(P2-P1) x VActual Free Air Delivery = Q= P0 x T = [(4.5 -0) x 0.225] / 1.026 x 2.329 Nm3/min

= 0.424 Nm3/min10.3 Calculation of Compression Ratio :

Compression Ratio = Receiver Pressure / Inlet pressure

= 4.5 Kg/cm2/ 1.026 Kg/cm2 = 4.5/1.026 = 4.386

10.4 Calculation of Specific Power Consumption :

Specific Power Consumption = Actual Power Consumption by the compressor (KW) Actual Free Air Delivery (m3/Hr)

Actual Power consumption by the compressor = electrical load of motor x efficiency of motor = 2.325 KW x 0.84 = 1.953 KW

Actual Free Air Deliver = 0.424 cum/min = 25.44 cum/hr.

Specific Power Consumption = 1.953 KW 25.44 cum/Hr = 0.0768 KW/cum/Hr

10.5 Calculation of Isothermal Efficiency :



Calculation of Isothermal Power (KW) = P1 x Qf x ln r36.7

Where P1 = Inlet pressure = 1.026 Kg/cm2

Qf = Free Air Delivery (cum/Hr)r = compression Ratio 1.026 x 25.44 cum/hr x ln 4.386 38.58Isothermal Power = 36.7 = 36.7 = 1.05 KW

Isothermal Efficiency = (Isothermal power ) / (Compressor Input Power) = 1.05 KW / 1.953 KW = 53.76%

10.6 Air Compressor Performance :

Figures in Summary

Actual Free Air Delivery : 0.424 Nm3/min = 25.44 cum/hr

Compression Ratio : 4.386

Specific Power Consumption : 0.0786 KW/Cum/Hr

Isothermal Power : 1.05 KW

Isothermal Efficiency : 53.76%

10.7 Observation of Performances in Air Compressor :

[10.7.1] The compressor runs twice a day, morning and evening for the cleaning purposeIR filter plant

for internal consumption of water (with duration of running each time 45 mins to 1 hour).

10.7.1[10.7.2] The pressure release station is around 30 mtrs from the air receiver, air pipe line ID is

1”Ø. During the operation of the compressor, no air leakage could be found, either physically or

through the operation of the compressor.

10.7.2[10.7.3] The required pressure at the discharge location is merely 2.5 -3 Kg/cm2. The pressure

switch is fixed at 4.5 Kg/cm2 (cut-off) and 3 Kg/cm2 (start-in).

10.7.3[10.7.4] No alteration is suggested for the air compressor, which is running effectively .



STUDY OF GAS ENGINES

11.1.1 The gas engines are located at two points : (i) at Power House to run A.C. alternator to generate

electricity at 415 volt level, and (ii) at Crude Oil Delivery Pumping station to run the pumps.

[11.1.2] In power-house, there are three engines, suitable for run alternatelyone run at a time, 2 nos x

333 BHP engines and one 157 BHP engine. The 157 BHP engine is air cooled, whereas the bigger

333BHP engines are water-cooled, for which separate cooling tower is maintained.

11.1.2[11.1.3] All of the three gas generators are pretty new and are running on continuous basis.

During the field study, nothing abnormal could be found.

11.2 The details of the Prime-movers for Generator Sets are :

Engine # Model Make Rated BHP at 1500 RPM Rated Fuel Consumption (m3/hr)

250 KVA G-1150 Cummins 333 77.0

125 KVA G-855-G-BC Cummins 157 37.0

Note : The fuel consumption of 250 KVA Gen set at 45% is 37.98 m3/hr and that for 125 KVA at 60%

loading is 24.64 m3/hr.

Gas Gen. set Electrical Power Output (kw)

Fuel consumption (m3) per Hr.

Specific Fuel Consumption (m3/Kw/Hr)

Remarks

250 KVA 86.5 37.98 0.439 Load is too low, current S.F.C. is not indicative of performance, though at 45% loading, S.F.C. is satisfactory

125 KVA 59.1 24.64 0.417 Load is low, current S.F.C. is indicative of performance, which is satisfactory



Note : Both of the gas generating sets are new. The flow of gas consumed by the engines was not

measured and the present calculations are based on rated consumption figures, which should be

figure at present. It is highly advisable to put adequate load and calculate the specific fuel

consumption at 75-80% of the rated load.

11.3 The ratings of the natural gas fuelled engines (prime mover) for Crude Oil Delivery Pumps are

given :

Engine # Model Make Rated BHP at 1500 RPM Rated Fuel Consumption (m3/hr)

1 G-855 Cummins 157 37.0

2 G-855 Cummins 157 37.0

3 G-855 Cummins 157 37.0

4 GV-1710 NA 480 103.0

5 GTA-855 Cummins 227 52.0

6 GTA-855 Cummins 227 52.0

11.4 The speeds of the Gas Engines along with the COD Pump speeds as measured :

COD Pump/ Engine #

Engine speed measured

Rated Speed of Engine

Pump Speed measured

Rated Pump Speed

# 1 1,566 RPM 1500 RPM 246.5 RPM 242 RPM

# 2 1,547 RPM 1500 RPM 253.3 RPM 268 RPM

# 3 1,715 RPM 1500 RPM 275.6 RPM 268 RPM

# 4 B/down 1500 RPM Not running 227 RPM

# 5 1,492 RPM 1500 RPM 254.6 RPM 268 RPM

# 6 1337 RPM 1500 RPM 242.7 RPM 268 RPM

Observations : The speed of engine no. 3 is much higher than rated, whereas that for engine # 6 is

much lower. Governor settings of the engines are to be adjusted as close as 1500 RPM.

11.5 During the testing of the Natural Gas fuelled engines, the shaft mechanical power output and

the corresponding fuel consumption (ideal) have been found as :

Engine # Mechanical Power Output (kw)

Fuel consumption (m3) per Hr.

Specific Fuel Consumption (m3/Kw/Hr)

Recommended sp. Fuel consum-ption (m3/Kw/Hr)

1 122.27 38.628 0.315 0.23

2 161.92 38.16 0.2356 0.23



3 179.50 42.30 0.2356 0.23

4 Not running NA NA NA

5 225.79 51.72 0.2290 0.22

6 202.33 46.35 0.2290 0.22

Note : As per the manufacturer’s guideline, the S.F.C. should be around 12.2 MJ/KW/Hr (G-855) and

12 MJ/KW/Hr (GTA-855) at 100% loading and 14.0 MJ/KW/Hr (G-855) and 12.8 MJ/KW/Hr (GTA-

855) at 75% loading.

11.6 General Observations during Audit for the Engines (attached with COD pumps) :

11.6.1 Individual flow meter should be incorporated at the feeding of each engine.

11.6.2 Mechanical noise could be observed at engine nos. #2 & 3, as well as in #5.

11.6.3 There is starting problem in engine #6.

11.6.4 The speed for engines #3 & 6 are either higher or lower than rated. Adjust the governor setting

for engines # 3 & 6, so as to match the speed as close as its rated speed.



STUDY OF CRUDE OIL & NATURAL GAS CONSUMPTION

12.1 The Flow-line of the Natural Gas inside the Station is :

Natural Gas above 250 psi to Grid

Gas Grid

N.G. at 30 psi

Flare

From Wells N.G. 10 psi

Mixed Crude Oil

Flare

12.2 Study of Crude Oil Consumption : (Figures are per day basis)

Location/Stage Liquid Received (KL) Liquid Output (KL)

ManifoldID Heater

G.U.I

G.U.II

E.T.

E.E.T.

Stabilizer

Oil Water3,497 Mixed with oil3,497 Mixed with oil,

3,427 Mixed with oil,

3,376 Mixed with oil

3,342 Mixed with oil

2,960 45 (1.5% est.)

Oil Water

3,427 Mixed with oil, 2% water loss

3,376 Mixed with oil, 1.5% water loss

3,342 Mixed with oil, 1% water loss

2,960 733 (water loss occur, not quantified)

2,9,15 30 (rest lost in EET, not quantified, residual level 0.2%


ID Heater G.U.-I G.U.-II E.T.

Booster Comp

Int. Cons.

E.E.T.

G.U.- Group Unit I/IIE.T. – Emulsion TreaterE.E.T. – Electrostatic Emulsion Treater


Tank & COD Pump

Dispatch to Refinery

2,915 Nil

2,880 (+ loss in tank)

Nil

2,612

2,915 Nil

2,640 (+loss in pump & fittings)

Nil

Note : The material balance is prepared on the basis of flow measurement, input from the

Installation Manager & information from the Hand-book.

12.3 Study of Natural Gas Generation/Consumption : (Figures are in m3/day)

Stages Generation of Natural Gas

Consumption /Flare Remarks

Manifold (inflow to the Station)

491,500 N.A. Actual amount is very hard to ascertain, as the flow was mix with crude oil and continuously changing

Group Unit I 3,50,000 350,000 At 250 PSI and higher level, directly fed to grid through HPMS

Group Unit II 110,000 Internal Consumption as Fuel – 6,800Internal Consumption for instrument- 2,700Flaring Up = (110,000-72,000-6,800-2,700)= 28,500

At 30 PSI, 72,000 of which is sent to 3rd. party for boosting.

Emulsion Treater

20,000 Flaring Up = 20,000 Generation at 30 PSI

Electro-static E.T.

4,000 Flaring Up = 4,000 Generation at 10 PSI

Stabilizer 7,500 Flaring Up = 7,500 Generation at 10 PSI

Distribution of Natural Gas generated



m3/day

Fed to Grid at 250 PSIBoosting through 3rd. PartyInternal consumption at 30 PSIFlaring up at 30 PSIFlaring up at 10 PSI

So, daily quantum of flare up at 30 PSI level is 20,000 cum/day and at 10 PSI level is 11,500 cum/day.

12.4 Energy Saving through Natural Gas Consumption :

Daily waste of natural gas as flare at 30 PSI = 48,500.00 cum/day

Internal consumption = 9,500.00 cum/day

Available natural gas at 30 PSI (if internal consumption were not there) = 58,500 cum/day

Suggestion for Energy Savings :

To develop any 3rd. Party to handle 50,000 cum/day natural gas at 30 PSI to convert into 250

PSI (vol.6000 cum/day) and to feed into the grid.

To convert available 10 PSI natural gas into 30 PSI natural gas for internal consumption

through installation of in-house booster compressor. Currently, 11500 cum at 10 PSI is

available, which is to be converted into 3,833 cum at 30 PSI level. The balance requirement

of gas at 30 PSI is to be available from the balance (8,500 cum/day) of gas left behind.

The volume of 50,000 cum/day at 30 PSI is equivalent to 6000 cum/day at 250 PSI level. The

selling price per year = 6,000 cum/day x 365 day x Rs.6.48/cum = Rs.1,41,91,200.00



STUDY OF ILLUMINATION

13.1 The illumination has been provided in open space, office (4 rooms) and machinery sheds (4

sheds). In rooms/ sheds, conventional tube light fittings of 36 watts have been provided with

standard electro-magnetic chokes.

13.2 The installed Illumination fittings at various points are

Location Fittings

No Lamp Wattage Fan No. WattageTotal Watt

Power Hous Old 8 FTL 36 0 0 288Power Hs New 5 FTL 36 0 0 180Water Pump Hs 3 FTL 36 1 60 168Drenching Pmp 3 FTL 36 0 0 108CISF Main Gate 1 FTL 36 0 0 36ET Shed 6 MVL 160 0 0 2880EET Shed 6 MVL 250 0 0 1500Flow Valve set 2 MVL 160 0 0 320Che. Pump Hs 4 MVL 160 0 0 640Filter Shed Hs 2 MVL 160 0 0 320High Mast I 24 HPSV 400 0 0 9600High Mast II 24 HPSV 400 0 0 9600High Mast III 24 HPSV 400 0 0 9600Office Room 5 FTL 36 2 60 300



Staff Room 5 FTL 36 2 60 300Computer Rm 5 FTL 36 2 60 300Supervisor Rm 5 FTL 36 2 60 300Dining Hall 7 FTL 36 3 60 432Godown 4 FTL 36 0 0 144Puja Room 1 FTL 36 0 0 36Civil Office 1 IL 100 2 60 220CISF Camp 17 FTL 36 11 60 1452FWD Pump Hs 8 FTL 36 0 0 288COD Pump Hs 12 MVL 160 0 0 1920Booster Pump Hs 3 MVL 160 0 0 480Booster Pump Hs 2 MVL 160 0 0 320Deoiler Pump Hs 2 MVL 160 0 0 320Sump Pump Hs 2 MVL 160 0 0 320PIG Receiver 2 MVL 160 0 0 320Yard Light 10 HPSV 400 0 0 4000

Abbreviated Form : FTL : Fluorescent Tube Lamp ; IL : Incandescent Lamp ; MVL : Mercury Vapour

Lamp ; HPSV : High Pressure Sodium Vapour

13.3 In the open compound, three high masts are located with individual rated capacity of 9.6 KW

each through a number of high pressure sodium vapour lamps (12 fittings x 2 HPSV lamps/fittings x

400 watt /lamp).

13.4 Based on the lux-level measured, the observations are :

Area/Location Maximum Lux Average Lux Recommended RemarksOpen Yard 3 2 50 The lux level at every corner Walk-way 7 4 50 poor. Immediate attention is Walk-way in front of high mast

21 15.4 50 this regard is solicited. All conventional tube-light fit-

Generator Shed 23 11.5 100 tings are to be replaced by Heater Shed 26 16 50 T-5 fittings with electronicWalk-way in front of Heater/Testing

24 19.6 50 Ballast. Around 1/3 of halogen lights at high masts

Area around G.U. 18 14.8 50 non-functional, which are to Along Boundary wall

8 4.29 50 Be replaced immediately. Extra lights are to be providd

COD Pump Area 20 11 100 Along the boundary wall for security reason.

Booster Pump House

3 2 100



Water Disposal Pump House

18 15.66 100

Walk-way in front of pump house

33 26.2 50

Office Verandah 72 56.5 100Office Room 172 80.16 200Workers’ room 90 59.5 200

13.5 Energy Savings :

13.5.1 Total conventional tube-lights of (36 + 12) watts are to be replaced by T-5 fittings (of 29

watts). There are total 77 nos of such fittings. Annual savings = (48 -29) watts x 77 nos x 12

hours/day x 365 days/year= 6407.94 KWHr, @ Rs.4.55/KWHr = Rs.29,156.00

13.5.2 Investment : 77 fittings x Rs.422.00 (cost of T5) = Rs.32,494.00. Simple pay-back period = 13

months.

13.5.3 40 watts Light Emmitting Diode (LED) fixtures can also be tested in place of 160 watt

mercury vapour lamp, but no specific recommendation is meted out in this sphere (the

concerned manufacturers should be consulted)

GENERAL OBSERVATIONS OF THE AUDIT

14.1 Makum Oil Collecting Station is a very compact and continuous type of operation, receiving

crude oil mix from 47 well exploration stations.

14.2 There is no metering facility at any consumption level, namely, electricity, natural gas, etc. Entire

range of natural gas at very low pressure (10 PSI) is being wasted and a part of 30 PSI is used for in-

house consumption, flaring up the remaining portion. As natural gas is abundant, the consumption

at any level is not meterized.

14.3 The electricity is generated at 415 volt level, but the loading on generator is not sufficient to

maintain electrical parameters of the generator. Optimum loading on the generator ultimately

increases the life of the generator.

14.4 The cooling tower with 7.5 KW load is connected with 250 KVA generator only. The effectiveness

of the cooling tower is not up to the mark due to low load on the generator.

14.5 Generator log-book should be maintained properly. At present, no such log-book is available.



14.6 Through over-hauling is water pumps are required, as high leakage from the gland has been

observed in all Formational Water Pumps.

14.7 Meter should be installed at every important junction to gauge the natural gas flow.

14.8 Starter panels for the pumps should be well dressed, so that measurement through outside

meters can be possible.

14.9 Over-load relays for the pumps should be periodically checked, as at certain points, Over-load

relay settings are not appropriate.

14.10 The gas engines for pumps are running at higher or lower speed than rated. Governor setting

should be done immediately.

14.11 Illumination level at every point should be improved, either by replacing faulty fittings, or adding

new fittings.

[14.12]

ANNEXURE : A2

ENERGY SAVINGS EQUIPMENT SUPPLIERS

1.0 LED LIGHTINGS : Synergy Solar (Pvt.) Ltd.,

SCO 133, Sector-28D, Chandigarh, Ph.-0172-6451133, www.synergysolars.com

2.0 OUTDOOR LIGHTINGS : Crompton Greaves Ltd.,

Lighting Business Group, 405, Concorde,R.C. Dutt Road, Vadodara- 390 007

Philips India Ltd.,Technopolis Knowledge Park,


http://www.synergysolars.com/


Nelco Complex, Mahakali Caves Road,Chakala, Andheri (East), Mumbai- 400 093Ph.-022-56912000

3.0 AUTOMATION & PANEL METERS : Selec controls Pvt Ltd

E – 121, Ansa Industrial Estate, Saki Vihar Road, Mumbai 400072Ph: 022-28471882, 28476443, www.selecindia.com

4.0 COMPRESSED AIR PIPINGS : Legris India Pvt Ltd.

Legris House, 99 Pace city –1, sector 37, Gurgaon- 122001 Ph : 9958297093 , 9811054826 www.transair.legris.com

5.0 LOW PRESSURE NATURAL GAS BOOSTER COMPRESSOR : G-Tech Pressure Booster

Ph.- 800-451-8294, 716-831-9695e-Mail : [email protected]


http://www.transair.legris.com/

http://www.selecindia.com/

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