Bharat Oman Refineries Limited (BORL) · Crude Oil From Middle East Vadinar Single Point Mooring (SPM) at Vadinar –VLCCs 1 2 3 Crude Oil Terminal & Pumping System (COT) Vadinar

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


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


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


Sr. No.


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


Sr. No.


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




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



Sr. No.


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




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


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


• 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


Flare Monitoring:Energy Dashboard:

Unit EII

monitoring


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

Documents

Bharat Oman Refineries Limited (BORL) · Crude Oil From Middle East Vadinar Single Point Mooring (SPM) at Vadinar –VLCCs 1 2 3 Crude Oil Terminal & Pumping System (COT) Vadinar