Recent Technological up-gradations at

LPG Plant

Horton Sphere

Mounded Bullet Pump House area

Mounded Bullet Area

Water Reservoir

Office area

LPG Recovery Plant

Cooling Towers

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Background

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LPG plant was commissioned way back in 1982; ageing plant Outdated technology- unavailability of spares Unix based Control system; MIS reporting was

not user friendly High maintenance cost; Plant availability was less due to high

downtime Complex operating conditions

Aim

Approach

To provide ease of operation through higher accuracy with precision, more flexibility and superior reliability for smoother operation with cutting edge technology

Existing set up was re-evaluated for parameters like safety, productivity, quality, cost effectiveness etc. Compliance with highest industry standards that are prevailing in contemporary industries was considered as bench mark.

Recent Major Technology Up-gradation at LPG Plant

Commissioning Status

3. 18/05/2010

Project Details

Up-gradation of old cylinder filling system with PLC based electronic cylinder filling system along with upstream & downstream ancillaries; aprox Rs 2.8 crores

Mounded Bullet Project; Rs. 35 crores

7. Expected Commissioning - July 2011

6. 04/02/2011

Front-end up-gradation of DCS system with state-of-the-art 800Xa system of M/s ABB, replacing the old UNIX based system; Rs 1.2 crores

5. 31/01/2011 Replacement of old 3nos. Of transformers with new ones; Rs. 1.2 crores

Terminal automation system in LPG FP 8. Ongoing

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1. 28/02/2010 C&I system up gradation for heater system with BMS; approx Rs. 2.0 crores

2. 23/02/2010

Up-gradation of PLC system of LPG recovery plant with latest Ethernet based processor system and SOFT SCREEN PROGRAMMABLE PANELVIEW HMI was commissioned for replacing the old relay based ESD panel and alarm annunciator in control room; Rs. 50 lakhs

4. 10/06/2010

Expander-Compressor C&I up-gradation Rs. 3.2 crores

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Key Steps/ Initiative 1. Initiatives taken for various technological advancement 2. Focus on Safety, Productivity, Quality, Cost effectiveness etc

Input Periodical Reviews Plant visits Pit Level meetings Tool Box meetings

Output Achievement of quantum improvement in the performance of plant

Performance measure

Improvement in Productivity

Reduction in no of breakdowns

Enhanced safe working environment

Ensure safe working condition System compliance evaluation during Friday weekly meeting ISO recommendations Internal/ Technical audit recommendations Compliance to quality standards IS-4576

Operational Fundamentals

Description of Project execution thro’ Turtle Diagram

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Before

After

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Before

After

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Before

After

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Before

After

Benefits- both tangible & intangible

S- Enhanced Safety Q- Improved Quality P- Increased Productivity C- Cost reduction D- Delivery of targets M- High Employee Moral

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₪ Increased production volume ₪ Reduction in no of breakdowns ₪ Ease of operation ₪ Windows based DCS system for easy MIS reporting and trend monitoring ₪ Improved spare management ₪ At par with best contemporary industry standards ₪ Mass flow meter based LPG metering system introduced for better precision and mass balancing ₪ System compliance as well as adherence to ISO/ audit recommendations ₪ Reliable safety system in place

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Some of the minor but significant up-gradations

₪ Flare metering system – First of its kind in “OIL” ₪ Digital weigh bridge with IMS facility ₪Telescopic Conveyor System ₪Auto evacuation system & other filling accessories ₪Online GC with APC ₪Electronic versa valves for SDV control

Initiatives/ activities on the move

₪ Up-gradation of old field instruments with SMART digital instruments. ₪ Commissioning of Digital level transmitters in place of the old pneumatic transmitters for accurate level control ₪Digital control valves are introduced for replacing the old control valves ₪ Replaced the old relay logic based control system which was working in series with the PLC control system in LPG recovery plant entirely with in-house expertise

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Empty Cylinder Shed

Filled Cylinder Shed

Condensate Filling Point

LPG Tanker Filling point

Tanker Evacuation Point