Title : Resolving NHT separator LCV block valve issue online without impacting production while achieving energy savings through flaring mitigation
Abstract:
Objectives/Scope:
This paper presents an advanced online troubleshooting methodology to resolve a malfunction in the NHT Separator Level Control Valve (LCV) block valve at HPCL Mumbai Refinery. The primary objectives are to optimize flaring control, maintain pressure stability, and mitigate operational disruptions without necessitating a unit shutdown. By deploying a temporary bypass scheme and a structured valve replacement strategy, the approach ensures continuous production while achieving substantial cost savings and environmental benefits.
Methods,Procedures, Process:
The troubleshooting strategy involved a multi-stage approach to execute the valve replacement under live plant conditions. A detailed risk assessment and technical feasibility analysis were conducted to evaluate the operational impact and safety constraints. A strategic temporary piping configuration was designed to facilitate controlled fluid diversion and maintain system stability. The malfunctioning upstream block valve was replaced in a methodical stepwise manner during a low-feed window, ensuring minimal process disturbances. Post-replacement, separator pressure regulation mechanisms were fine-tuned to restore optimal performance. This methodology leveraged precision engineering and real-time process control adjustments to mitigate risks while maintaining refinery throughput.
Results, Observations, Conclusions:
The implementation of this troubleshooting methodology resulted in a significant reduction of hydrogen flaring by 500 kg/hr, translating into annual cost savings of approximately ₹95 crore. Enhanced separator pressure control minimized level fluctuations, improving overall process stability and operational reliability. By eliminating uncontrolled passing through the separator pressure control valve bypass block valve, energy losses were mitigated, and emissions were significantly reduced, aligning with environmental compliance requirements. The success of this intervention underscores the efficacy of proactive maintenance strategies in preventing unplanned shutdowns and optimizing refinery performance.
Novel/Additive Information:
This paper introduces a novel approach to online troubleshooting and component replacement in high-pressure refinery systems without interrupting operations. By integrating advanced engineering solutions with a structured execution methodology, this approach provides a benchmark for enhancing process reliability and sustainability in petroleum refining. The insights gained from this study contribute to the evolving best practices for operational excellence in refinery troubleshooting and flaring control.
