The ONGC Uran Propane Refrigeration Compressor Project is a critical system modernization initiative implemented at the ONGC Uran Gas Processing Plant, Maharashtra. The project focuses on upgrading and strengthening propane refrigeration compressor systems that are essential for LPG recovery, hydrocarbon separation, and gas stabilization.
Propane refrigeration is a core process requirement at the Uran facility, enabling low-temperature operations required for efficient separation of propane, butane, and other valuable hydrocarbon components from natural gas streams. As part of this project, aging compressor equipment was replaced with high-capacity, energy-efficient, and reliability-focused compressor trains to ensure stable cooling performance under varying process loads.
This initiative supports ONGC’s strategy of enhancing plant reliability, improving process efficiency, and ensuring long-term asset sustainability, while strengthening Uran’s role as a key midstream gas processing hub within India’s energy infrastructure.
The scope of work for the ONGC Uran Propane Refrigeration Compressor Project covers engineering, installation, commissioning, system integration, and performance stabilization of upgraded propane refrigeration systems at the Uran Gas Processing Plant.
Key scope elements include detailed engineering review, equipment selection, layout optimization, piping and instrumentation integration, electrical and control system upgrades, and alignment with existing gas processing units. Engineering activities were carried out in compliance with ONGC design standards, safety norms, and operational requirements.
The mechanical scope included installation of new refrigeration compressors, drivers, auxiliary systems, lubrication oil systems, interconnecting piping, heat exchangers, and associated rotating equipment. Precision alignment, balancing, inspection, and quality checks were performed to ensure long-term mechanical reliability.
The project scope also covered automation and control system integration, including DCS interfacing, alarm configuration, protection logic implementation, interlock verification, and performance monitoring tools. These systems enable real-time control, fault detection, and operational optimization of the refrigeration process.
Pre-commissioning and commissioning activities formed a major part of the scope and included system flushing, pressure testing, functional testing, safety checks, trial runs, load testing, and performance validation. These activities ensured safe startup and seamless integration with the existing refrigeration and gas processing infrastructure.
Overall, the scope of work delivered a safe, efficient, and reliable propane refrigeration system capable of supporting current and future processing demands at the ONGC Uran Gas Processing Plant.
| Category | Description |
|---|---|
| Overall Purpose | Operations and maintenance activities ensure continuous, safe, and efficient performance of the propane refrigeration system, which is critical for LPG recovery, gas separation, and overall plant stability at the Uran Gas Processing Plant. |
| 24×7 Operations | Trained operators manage round-the-clock monitoring of refrigeration compressors, suction and discharge pressures, temperature profiles, and system loads to ensure stable low-temperature operation and uninterrupted gas processing. |
| Units Managed in Operations |
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| Process Monitoring & Control Systems | Advanced DCS and monitoring systems track temperature, pressure, vibration, and performance parameters. Automated alarms and interlocks enable early detection of abnormalities and rapid corrective action. |
| Maintenance Activities | Mechanical maintenance of compressors, bearings, seals, lubrication systems, valves, and piping. Electrical and instrumentation teams manage motors, sensors, control panels, and protective devices. |
| Preventive & Predictive Maintenance | Condition monitoring tools such as vibration analysis, oil analysis, and thermography are used to predict failures, schedule maintenance proactively, minimize downtime, and extend equipment life. |
| Shutdown & Overhaul Activities | Planned shutdowns involve inspection of compressor internals, seal replacement, alignment checks, system testing, and reliability audits to ensure long-term operational readiness. |
| Safety & Compliance | Strict adherence to permit-to-work (PTW) systems, cryogenic safety practices, emergency drills, HAZOP reviews, and ONGC safety standards ensures zero-harm operations in a high-risk, low-temperature processing environment. |
| Outcome & Performance | The integrated O&M framework delivers higher LPG recovery, improved energy efficiency, reduced operational disruptions, enhanced equipment reliability, and long-term asset performance for ONGC. |