EXECUTIVE SUMMARY Recommendations and Savings potentials : Short and Medium Recommendations Savings per Annum Estimated Investment (Rs.) Simple period Savings of Gas by running 125 KVA Gen. Set the day Nil Immediate mproving efficiency and flow rate of COD Pumps #1,2& 3 Nil Immediate aintenance of valves (#5)& increasing (#6) Nil Immediate mproving efficiency and flow-rate of F.W. Nil Immediate ver-hauling of Booster pumps, running hours be reduced Nil Immediate By changing consumption pattern of gas by installing 2,37,12,300.00 1 year 8 months out
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 to 2,700 cum/day 0 Emulsion Treater (3 nos) 2730 KL/day Natural gas is used continuously to maintain the flame in the thermo-chemical process 0 Electro-static Treater (1 no) 2000 KL/ day Electricity supply is required to maintain the voltage potential for the electro-static process Load is fluctuating, power drawn varies from 2.734.8 KW 0 Crude Oil Delivery Pump (6 nos) 1-3 : 40 KL/hr : 100 KL/hr 5-6 : 60 KL/hr Mechanical power to run the pump is met by gas engine 0 Formation Water Pump (4 nos) Note : 2 pumps at a time 100 cum/hr by 3 Ph electric motors of capacity 30 KW each Electric drawn by each motor = 22 KW, total power = 44 KW 0 Booster Pump ( 5 nos), 1 pump continuously + 1 pump occasionally 75 cum/hr run by 3 Ph electric motors of capacity 15 KW Electric power drawn by each motor 11.54 Circulating Pump ( 3 nos), one runs intermittently 23 cum/hr Pump run by 3 Ph electric of 7.5 KW (run hr- 5 hrs/day) Electric power drawn = 4.5 KW Cooling Tower ( 2nos), one with each Gas generator 50 cum/hr Pump power = 3.75 KW Fan = 3.75 KW, Run by electric Available with 250 KVA set only, runs for 15 hrs a day with electric drawn = 4.88 KW
1 Air Compressor ( 2 nos) one stand-by Receiver cap.=225 Run by electric of 3.75 KW, runs 10 mins x 2 times/day Power drawn = 2.25 KW 1 Illumination (for 3 high-masts) 24 KW Run by three phase power, distributed to single phase to individual fittings Total capacity = 8 KW each 1 Illumination (other than high masts) 11.5 KW Single phase electrical power, rated capacity- not known Actual power drawn = 9.81 KW 1 Misc Mechanic Utility, e.g. su pump, N.A. Three phase electrical power, capacity – 7.5 KW Actual drawn =4.5 KW at certain intervals 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. 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. of DETAILS OF TRANSFORMER Isolation Transformer, 200 KVA, Dry-type, 415 Volt/415 Volt, 278.24 Amp, AN, Dyn11, impedance Sr. No. DT/1693/01, Yr. 2008 -
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. Details of Formation Water (F.W.) Pumps : There are four F.W. pumps, 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%, 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 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) Discharge Pr (Kg/cm2) Suction Pr. (Kg/cm2) Hydraulic Power (KW) Shaft power input (KW), Pump (%) % discharge of rated capacity Remarks 9.96 21.5 0.5 5.68 19.838 28.63% 39.84% Efficiency low, impeller at every stage to be checked, gland leakage 13.38 21.5 0.5 7.626 22.75 33.52% 53.52% Efficiency low, impeller at stage to be checked, leakage to be arrested Under B/down 4.36 16.0 0.5 1.834 21.476 8.54% 17.44% Eff. extremely low, profuse leakage, impeller at every stage to be checked 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
Area/Location Maximum Lux Average Lux Recommended Remarks Open Yard 3 2 50 The lux 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 electronic Walk-way in front of Heater/Testing 24 19.6 50 Ballast. Around 1/3 of halogen lights at high 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 3 2 100 Disposal Pump House 18 15.66 100 Walk-way in front of pump house 33 26.2 50 Office Verandah 72 56.5 100 Office Room 172 80.16 200 Workers’ room 90 59.5 200 Energy Savings : 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 Investment : 77 fittings x Rs.422.00 (cost of T5) = Rs.32,494.00. Simple pay-back period = 13 months. 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 Oil Collecting Station is a very compact and continuous type of operation, receiving crude oil mix from 47 well exploration stations.