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19th National Award
for “Excellence in Energy Management – 2018”
Bharat Oman Refineries Limited
(BORL)Bina, Madhya Pradesh
Ambarish Mahajan – Manager
Sandeepan Nayak – Assistant Manager
BPCL Marketing Terminal
Kochi Refinery
Mumbai Refinery
Numaligarh Refinery
BPCL Refineries
Bina
Kota
Crude Oil From Middle East
Vadinar
Single Point Mooring (SPM) at Vadinar – VLCCs
1
2
3
Crude Oil Terminal & Pumping System (COT) Vadinar
Vadinar- Bina 935 km Crude pipeline (VBPL)
Delhi
Crude pipeline
Product pipelines
Advantageously placed to meet product requirements in high demand zone
BORL Facilities at a Glance
6 MMTPA Refinery at Bina
4
5
6
Bina Despatch Terminal (BDT)
Bina-Kota pipeline (BKPL) linking BPCL’s existing piping network (265 km)
BORL – JV company
of BPCL & Oman Oil
Company (OOC)
Refinery Configuration
➔ Complex configuration, proven technologies, mid-distillate refinery
Process Capacities
An ISO 50001:2011 EnMS certified company
Refinery Process
Units Capacity
(MMTPA)
Capacity
(BPSD)
Process
Licensor
CDU/VDU 6.0 130434
FCHCU 1.95 40211
DHDT 1.63 36010
DCU 1.36 24607
Hydrogen Unit 0.07
NHT 1.00 27248
CCR 0.55 14063
PENEX 0.302 8385
Sulphur
Recovery Unit
2 x 180
TPD
ABB Lummus
Technology
ATF
RCO
O
VRH
2 SOUR GAS
HCGO &C Naphtha SULFUR
CRUDE
SOUR WATER
GAS LPG NAPHTHA SKO
HSD Euro-III HSD Euro-IV
MS-BLOCK
DELAYED
COKER
VDU
HCU + DHT
SULPHUR
BLOCK
LVGO
HVGO
HYDROGEN
MS Euro-IIIMS Euro-IV
POWERPLANT
LCGO
CDU
VD
GO
PETCOKE
Nelson Complexity Index – 10.3
➔ Commercial production started - Jun 2011
STEAM
TURBINE
GENERATOR
VHP steam
110 Kg/cm2
MP steam 18 Kg/cm2To
Refinery
Power Steam
INSTALLED CAPACITY 99 MW 985 TPH
IMPORT FROM GRID CAPABILITY 100 MW
From Grid (220kv)
3 X 33 MW
Captive Power Plant General Overview
To Refinery
CFBC Boilers – 3 Nos
CFBC Boilers
MADE BY: BHEL
CAPACITY: 3 X 275 MT/hr
(Petcoke)
HP steam 40 Kg/cm2
LP steam 5 Kg/cm2
STGs
Utility Boiler
Net 160 TPH
Specific Energy Consumption (SEC) -
Electrical & Thermal
Refinery Specific
Electrical Energy
Consumption for
year 2017-18 is
higher due to
higher secondary
unit throughput
Refinery
Specific
Thermal Energy
Consumption is
expressed in
kJ/kg of Crude
Processed
90
91
92
93
94
2015-16 2016-17 2017-18
93.6
91.291.5
Specific Electrical Energy ConsumptionkWh/MT of Crude Processed
2000
2400
2800
3200
2015-16 2016-17 2017-18
30462781 2778
Specific Thermal Energy ConsumptionkJ/kg of Crude Processed
National Benchmarking
Specific Energy Consumption (SEC)
Refinery Specific Energy Consumption measured in MBTU/BBL/NRGF (MBN)
84.32
68.47 66.9
50
60
70
80
90
2015-16 2016-17 2017-18
MB
TU
/BB
L/N
RG
F BORL SEC
66.9
40
90
140
MB
N
Indian PSU Refineries & BORL
Indian PSU Refineries & BORL SEC
Source: PPAC, BEE, CII website
Global BenchmarkingSolomon Benchmarking : Energy Intensity Index™ (EII®)
6
EII 95.3 indicating substantial improvement in energy performance of
BORL
Participating in Solomon Benchmarking
since 2014 every alternate calendar year
Implementation of Encon Measures Plan FY 2017-20 will bring EII to Q1
111.3
101.795.3
60
70
80
90
100
110
120
2014 2016 2017-18
Energy Intensity Index TM (EII ®) - GOC2 Group
Q4
Q3
Q2
Q1
7
En-Con Projects in last 3 yrs
Year
No. of En-
Con Projects
Implemented
Savings InvestmentPayback
PeriodNo. of ZERO
INVESTEMENT
En-Con
ProjectsFuel Oil
(MT/Yr)
Rs
Lakhs/YrRs Lakhs Months
2017-18 12 4059 1310 1016 9 5
2016-17 15 5439 1565 603 5 7
2015-16 28 10052 2513 126 1 20
Total 55 19550 5388 1745 4 32
Any small saving in energy significantly impacts OP-Ex
Sr. No.
En-con Plan FY 2017-2020Est. SRF
(MT/day)
1CDU heater efficiency enhancement by implementation of VDU hot well gases conditioning system.Investment - 4 Rs Cr, Planned & Completed in 2017-18
0.7
2Installation of step less control in Make Up Gas compressorInvestment - 3.5 Rs Cr, Planned & Completed in 2017-18
2.8
3Insulation improvement in Delayed Coker unit with improved type of insulation. Investment - 2 Rs Cr, Plan 2018-19
0.6
4Installation of Power Recovery Turbine in Hydrocracker 1st stage reactor feed pump. Investment - 13 Rs Cr, Plan 2018-19
3.6
5Installation of flash steam recovery system in DCUInvestment - 1.2 Rs Cr, Plan 2018-19
1.3
6Installation of LP steam generator in Hydrocracker light diesel product stream. Investment - 0.78 Rs Cr, Plan 2018-19
4.5
7Installations of Crude Preflash drum in CDU to increase energy efficiency. Investment - 25 Rs Cr, Plan 2018-19
8.1
Total Saving Potential – SRFT/day 21.6
Energy Conservation Plan: FY 2017-2020
Sr. No.
En-con Plan FY 2017-2020Est. SRF
(MT/day)
8Implementation of process gas waste heat recovery in HGU to pre-heat DM water . Investment - 4.5 Rs Cr, Plan 2018-19
9.7
9Installation of LRVP (Liquid Ring Vacuum Pump) in Vacuum Column Overhead Ejector System. Investment - 29 Rs Cr, Plan 2018-19
3.5
10Implementation of Flare Gas Recovery System.Investment - 10 Rs Cr, Plan 2018-19
4
11Installation of Rooftop Solar power system of 140 kW on Admin Building car parking area rooftop.Investment - 1 Rs Cr, Plan 2019-20
0.3
12Installation of Solar Water Heater (SWH) system of 3*500 LPD hot water on Refinery Canteen.Investment - 0.1 Rs Cr, Plan 2019-20
0.1
Total Investment – 94 Rs Cr (0.5% of Turnover), Total Saving Potential – SRFT/day 39.2
Energy Conservation Plan: FY 2017-2020
Sr. No.
En-con Measures implemented 2015-16*Net Reduction
kW
1
Power Consumption reduction:I. IFO & RFO inter connection in CDU/VDU is completed which
reduced power consumption by 24 kw by stopping one IFO pump
II. CCR single Net gas compressor- B operation after overhauling and modification, saved power 0.8 MW.
III. Installation and commissioning of Air cooler cum humidifier in Laboratory, saved power 8.66 KW by reducing no. of compressor running.
IV. DCU BCR sump pump ( 14-PA-136 A/B ) impeller modification to reduce pump running hour, saved power 19.2 kw
V. Installation and commissioning of 9 nos of flameproof local control station in Laboratory for the energy conservation in Fume Hood operation
24
813
8.6
19.2
6.4
Total Power Reduction 871.2
Energy Conservation Measures Implemented 2015-16
Sr. No.
En-con Measures implemented 2015-16 *Net Reduction
kW
1VI. Installed ETC based Solar Water heating system of 8x500 LPD
for providing preheated water to bathing purpose in township6.4
Total Power Reduction 877.6
2
Steam Consumption reduction:I. Installation of new control valve in secondary MP steam to
Hydrocarbon Flare tip to optimized MP steam flow.
Steamreduction MT
0.1
3
Insulation Improvement reduction:I. Heat Loss minimisation by providing removable pad type
insulation to process heat exchangers end covers in CDU/VDU.
FO MT/day
1.9
Total Fuel Consumption Reduction 1.9
Energy Conservation Measures Implemented 2015-16
Equivalent Fuel Oil saving ~ 10052 MT/Yr ~ 2513 Rs Lakhs/yr
* 20 nos Zero investment EnCon measures are not listed.
Sr. No.
En-con Measures implemented 2016-17 Net Reduction
kW
1
Power Consumption reduction:I. CDU - Single fan operation in CDU Heater FD Fan
II. MSB - Single fan operation in HOH Heater FD Fan
III. HCU - Stopping of Sour water Pump 16-PA-CF-813 A/B
IV. DHT - Parallel pump operation converted to single pump in product stripper reflux pump (701 A/B) & Fractionator bottom pumps 705A/B
V. Refinery CT - Low weight coupling installation in one of the refinery cooling tower fan
VI. Township – 244 nos 18w CFL replaced with 9w LED bulb, 63 nos36w Tube light replaced with 20w LED tube light
VII. BDT – Solar Power Generation Started
85
30
9
280
0.3
0.1
237Total Power Reduction 641
Energy Conservation Measures Implemented 2016-17
Sr. No.
En-con Measures implemented 2016-17 Net Reduction
TPH
2
Steam Consumption reduction:I. ARU - Amine regeneration column LP steam reduction to 41 TPH
from 45 TPH by optimization
II. DCU - Velocity steam reduced by 25 kg/hr in all passes resulted in steam consumption reduction by 100 kg/hr
III. VDU - Ejector steam consumption reduction by 1 TPH
IV. SRU - Implementation of Flash steam and Condensate recovery System. 2.1 TPH flash steam & 2.2 TPH condensate is being recovered.
V. HCU - RGC Lube Oil Turbine leak off steam routed to LP steam header, saved 0.5 TPH steam
3.2
0.1
0.3
0.5
0.2
Sub Total 4.3
Energy Conservation Measures Implemented 2016-17
Sr. No.
En-con Measures implemented 2016-17 Net Reduction
TPH
2
Steam Consumption reduction:VI. All - CDU/VDU, MSB, HCU/DHT, HGU, DCU, CPP, SRU, Offsite &
Utilities steam system management by specialised agency, 10 TPH steam loss reduced.
1.8
Total Steam Consumption Reduction 6.1
3
Insulation Improvement reduction:I. VDU Column insulation improvement reduced 0.06 MMkcal/hr
heat loss.II. HGU-Reformer APH and combustion air duct insulation
improvement- 0.5 MMkcal/hr heat loss reduced
FO MT/day
0.14
1.2
Total Fuel Consumption Reduction 1.3
Energy Conservation Measures Implemented 2016-17
Equivalent Fuel Oil saving ~ 5439 MT/Yr ~ 1565 Rs Lakhs/yr
Sr. No.
En-con Measures implemented 2017-18Net Reduction
kW
1
Power Consumption reduction:I. ETP power reduction by blower operation optimization,
reduced sp. power by 6%.
II. Installation of Stepless controller in one of Make Up Gas compressor in HCU
III. Refinery - 108 Nos street light pole fixtures-HPSV-150W replaced, High Mast fixtures-24 nos HPSV-400W, 300 nos 36W Florescent tube lights repalced with LED lights.
IV. Single FD fan operation in HCU-DHT 501/701 heater.
V. HCU filter backwash one fin fan stopped
VI. Utility Boiler seal air fan on standby mode & blow down transfer pump on manual mode resulted into power saving.
VII. Low weight coupling installation in Refinery Cooling Tower fans.
23
500
25.4
117
19
39
17
Total Power Reduction 740.4
Energy Conservation Measures Implemented 2017-18
Sr. No.
En-con Measures implemented 2017-18 Net Reduction
TPH
2
Steam Consumption reduction:I. All - CDU/VDU, MSB, HCU/DHT, HGU, DCU, CPP, SRU, Offsite &
Utilities steam system management by specialised agency, 2 TPH steam loss reduced.
II. ARU - Amine regeneration column LP steam reduction to 39 TPH from 42 TPH by optimisation
2
3
Total Steam Consumption Reduction 5
3Fuel consumption reduction:I. CDU heater efficiency enhancement by implementation of VDU
hot well gases conditioning system.
FO MT/ day
0.65
4
Insulation Improvement reduction:I. DCU Coke drum insulation improvement reduced 0.13
MMkcal/hr heat loss.0.31
Total Fuel Consumption Reduction 0.96
Energy Conservation Measures Implemented 2017-18
Equivalent Fuel Oil saving ~ 4059 MT/Yr ~ 1310 Rs Lakhs/yr
Innovative Project 1:
DCU Coke drum B insulation improvement
17
Objective: Reduce energy loss & improve reliability by replacing
conventional insulation with panel type insulation
Trigger:
▪ Liquid yield improvement - Thermal cracking is an endothermic reaction,
hence retention of heat with proper insulation is favourable for reaction.
▪ Reliability – Cyclic expansion and contraction was resulting in damaged
insulation.
▪ Radiation loss reduction – Coke drum surface temperature was higher.
Project Detail:
Slotted cleats were welded with insulation rings, which allows the free
movement (due to provision of slot) of insulation ring along with panels
with respect to coke drum during the cyclic changes and increases the
durability of insulation.
Innovative Project 1: Benefits
DCU Coke drum B insulation improvement
18
▪ Drum surface temperature improved.
▪ 20 kg/hr FG saving in fired heater , Savings – 0.34 Rs Cr/yr
▪ Liquid yield improvement.
▪ Invest – 1.22 Rs Cr , Payback – 3.7 Years
▪ CO2 Emission reduction – 448 t CO2/yr
• This project is being replicated in DCU Coke drum A
Innovative Project 2: VDU hot well gases conditioning
system to enhance CDU heater efficiency
19
Objective: CDU heater efficiency enhancement by implementation of VDU
hot well gases conditioning system
Trigger : CDU heater APH outlet temperature was maintained above 167 oC to avoid the sulphur dew point corrosion.
Project :
▪ Amine treatment of 10% H2S rich hot well gases to 10 ppm H2S.
▪ Low pressure drop structured packing amine column was installed as
VDU off gas pressure was lower in the range of 0.1 Kg/cm2
▪ CDU heater APH O/L temperature was reduced from 167 oC to 156 oC
with higher air pre-heat resulted in higher heater efficiency.
Innovative Project 2: VDU hot well gases conditioning
system to enhance CDU heater efficiency
20
Benefits :
▪ CDU heater efficiency improved by 0.5%, 0.65 MTOE/day saving
▪ Stack SOx emission reduction.
▪ Investment - 4 Rs Cr
▪ Savings – 70 Lakhs/yr
▪ CO2 Emission reduction – 685 t CO2/yr
Innovative Project 3: Stepless control logic
implementation in HCU MUG compressor
21
Objective: Make-up gas (MUG) compressor spillback optimization for
energy consumption
Trigger : MUG Compressor was provided with three step control loading
( 50%, 80%, 100%) , In between loading requirement was met with spillback
opening with higher energy consumption.
Project :
▪ Stepless capacity control logic was implemented by completely loading
and/ or loading some of the valve on same cylinder to match the exact
requirement of process with the compressed gas with no spill back and
hence no loss of energy.
22
Benefits :
▪ Power consumption reduction - 500 kW, 2.8 Rs Crs/yr
▪ Investment - 3.44 Rs Cr, Pay Back ~ 15 Month
▪ CO2 Emission reduction – 3320 t CO2/yr
• This project is being replicated in Net gas compressor
of Motor sprit block
Innovative Project 3: Stepless control logic
implementation in HCU MUG compressor
▪ 4 MW Solar Power Plant at
BORL generating 20000
units per day
▪ 10 kW Solar PV Panel in SV
stations of VBPL pipeline
▪ Installed Solar Power based
electric fencing to refinery as
well as township boundary
wall of 22 kms for security
purpose. Invest – 2 Rs Cr
▪ Installed Solar Water heating
system
▪ Solar Wind hybrid power
supply system for Campus
video surveillance, Wi-Fi and
LED based street light.
Utilization of Renewable Energy Sources:
Initiatives at BORL
Utilization of waste as fuel:
Waste gas generated in Vacuum
Distillation Unit is used as fuel in
Fired heater of Crude Distillation
Unit.
Waste gas called as Purge Gas
generated in Hydrogen
Generation Unit is used as fuel in
HGU Reformer.
Petcoke called as crude bottom product is being used as fuel in
Circulating Fluidised Bed Combustion (CFBC) technology based Boilers.
Utilisation of waste gas as fuel saved 187537 SRFT of Fuel in 3 years
25
Effective Energy Management system, implementation of En-con
measures & green initiatives helped BORL in reducing GHG emission.
t CO2 emission is calculated based on ISO 14064 -1 methodology.
GHG emission inventory trend
~ 27% reduction in Specific CO2 emission in 3 years
0.51(3240 TMT)
0.39(2492 TMT)
0.37(2484 TMT)
0.00
0.10
0.20
0.30
0.40
0.50
0.60
2015-16 2016-17 2017-18
tCO
2/ M
T o
f C
rud
e t
hro
ug
hp
ut
Best Practices Implemented on Energy Front in
Green Supply Chain:
▪ Management commitment to continual improvement in energy
performance is demonstrated by;
• bringing energy efficiency in the design stage,
• purchasing energy efficient equipment, based on life cycle cost.
• Certification of EnMS ISO 50001:2011 within shortest time
• Steering committee formation for well structured reviews
• Promotion of participative energy conservation culture by launching
platform like RISE & Managing Director Award
• Certification of ISO 9001:2015, ISO 14001:2015, ISO 45001:2018
• Dedicated energy department – BEE certified Energy Manager, EnMS
auditor nos – 03 Lead / 34 Internal
▪ Transport of Raw Material:
• Use of Drag Reducing Agent (DRA) & VFD to reduce energy
consumption in pipeline & throughput maximization
Best Practices Implemented on Energy Front in
Green Supply Chain:▪ Manufacturing & Storage :
• Use of energy efficient design - maxm heat integration
• Maximization of Hot Feed (85-94%), Condensate Recovery (80-85%)
• High efficiency fired heaters/boilers, Use of Glass APH, API 560
• Low emissions - Double seal in tanks & pumps, LDAR
• Use of renewable resources – Solar power plant, Solar water heater
• Use of APC for energy optimization, third party energy audit
• Hydrocarbon loss accounting as per IP method
• Participation in Global Benchmarking
• Fly ash brick is being utilized in all construction work.
• Extensive monitoring of high energy intensive equipment
• Ultrasonic flare flow meter in all units, VFDs in Fin Fans & ID/FD
▪ Product Transportation: Maximized product evacuation though pipeline
Greening at BORL:
Water Conservation:
Rain Water Harvesting pond with ground
recharge facility within the refinery
premises with solar lighting installation &
RWH pits in township are developed.
Recharge to groundwater ~ 26 TKL
Sink for GHG Emission:
▪ 33% area covered under greenbelt
▪ 3 Lakhs samplings in refinery &
55,000 sampling in township▪ 2 Lakhs samplings in nearby villages
▪ Dedicated Energy Department headed
by Energy Manager who is BEE certified
Energy Auditor
▪ Each area has Energy Coordinator
▪ Two tier mechanism of review: Energy
performance & energy improvement
schemes are monitored in
• Monthly review at unit level
• Quarterly review at Apex level
chaired by MD, BORL.
▪ Encon Project Management Team is a
cross functional team
Energy Management Team
Monitoring of Energy Conservation Project
PrioritisationOFI
HopperQuick Wins
Short Term
Long term / Project
Basis - PaybackImmediate /
ZERO Invest.
0 – 6 Months /
Small Invest.6-24 Months /
Large Investment
Monitoring and Reporting Practices
“To manage we have to control and to control we have to measure”
Sr.
No.Energy Performance Indicators
Monitoring
Frequency
1 Fuel & Loss Daily
2 Flare Loss Daily
3 Fired Heater Performance & CPP Performance Daily
4 Hot & Cold Feed Optimization Daily
5 Unit wise Specific Fuel, Power, Steam Consumption Daily
6 Equipment wise Steam Generation Daily
7 Refinery Steam Balance Daily
8 Refinery Specific Energy Consumption (MBN) Daily
9 Refinery Energy Intensity Index (EII) Daily
10 Hydrocarbon Loss Accounting Daily/ Monthly
Monitoring and Reporting Practices
Flare Monitoring:Energy Dashboard:
Unit EII
monitoring
Monitoring and Reporting Practices
Unit Specific Energy Consumption (MBN) monitoring graphic in DCS :
Monitoring and Reporting
Refinery Energy Balance Monitoring : Daily
Daily Unit Energy Balance indicates where the energy improvement opportunities
are today.
35
ISO 50001:2011 Energy Management System (EnMS)
Certification
Awards and Recognition
Hon’ble President of India
Shri Ram Nath Kovind
conferring the ‘National
Energy Conservation
Award 2017’, Managing
Director, BORL Shri S S
Sunderajan receiving the
award at a ceremony
conducted in Vigyan
Bhavan, New Delhi on 14th
Dec 2017
‘Lowest Steam Leak’ award in OGCF 2015 from CHT MoP&NG at 20th Refinery Technology Meet
BORLFuelling Nation…
Bringing Cheers
An ISO 9001, 14001, 45001 & 50001 company
Thank You
Bhamashah Award - MP Frost & Sullivan Award for
Environment & Op Excellence
Leadership Project
NHRDN CSR Competition-2016
award
CII 18th National Award 2017
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