Encon Measures CPP

8/12/2019 Encon Measures CPP

1/20

A Sunrise Project for a Sunshine FutureCore Group

A Sunrise Project for a Sunshine Future

Captive Power Plant-Encon Measures


2/20

A Sunrise Project for a Sunshine FutureCore Group A Sunrise Project for a Sunshine FutureCore Group

CONTROL ROOM

CMY-

1/2

TOSHIBA

GIS (66KV)

UB-2UB-1

GTG-2

C

M

Y

HRSG-2

STG-2

STG-1

GTG-1

C

M

Y

HRSG-1

GTG-3

DB

HRSG-3

C

M

Y

DB DBDEAREATOR-2

DEAREATOR-1

BFPs

To Process

CPP CONFIGURATION AT PARADIP

BSDG

N

A

P

N

A

P

H

S

D

H

S

D

H

S

D

H

S

D

F

O

F

O

FRP CT

FO/HSD/

NAPHTHA

PUMP BOP

CMY-

3/4

UB-4UB-3

SIEMENS

GIS (66KV)


3/20


CPP MAJOR EQUIPMENTS & EFFICIENCY

Sl.

No.

Description Qty. CapacityStandalone

Design

eff.(%)

Cogeneration/Combined

Cycle design

eff.(%)

ExpectedCPP

efficiency(%)*

1Gas Turbine

(GE Frame 9E)3

103.98MW@ 39C

31

79.2

76.1(2GT+2STG+2UB)

79.3(2GT+1STG+2UB)

81.4(3GT+1UB)

2Heat Recovery Steam

Generator (HRSG)(Single Pressure drum)

3 220 T/H 70

3 Utility Boiler (UB) 4 300 T/H 86

74

4Steam Turbine

(2Stages extractioncum condensing Type)

2 30 MW 86

*Expected Power load 186.5MW (Including CPP consumption),

Net export to process units HHP 416 TPH, HP 175 TPH ,MP 144 TPH & LP 0 TPH


4/20


Salient Features of Frame 9E Gas Turbine

S. No. GT Frame

Size

MW Rating

(ISO)

Design Heat

Rate (kcal/ kWH)

Remarks

1 Frame5e 26 3250 Efficiency of Frame-9e m/c will

be greater than Frame-5e m/c if

the load is above 64MW and

greater than Frame-6e m/c if

the load is greater than 95MW

2 Frame6e 42 2850

3 Frame9e 126 2545

GT rated for 103.98MW at 39C ambient

Ambient temperature of Paradip in the range of 28 32C for majority of

the time

Hence, GT output assured in the range of 110

115MW with the Generator

(GTG) capacity at 118.3MW .


5/20


Salient Features of Utility Boilers &Flue Gas

Desulphurization System

Utility Boiler (UB): Designed to operate on low cost High Sulphur Fuel Oil (HSFO) with 4.9%

Sulphur wt./wt.

Corner fired Burners for improved combustion efficiency (overall boiler

efficiency 86%)

Regenerative Air Pre-Heater for improved reliability & efficiency

2 ID & 2 FD Fans for each UB (All drives are Turbo & Motor Driven) Flexibility in Fuel (Gas Oil, HSFO, Refinery Gas)

Electrostatic Precipitator (ESP) provided for ash absorption from Flue Gas

& meeting FGDS input requirement

Flue Gas Desulphurization System (FGDS): Desulphurization of Utility Boiler (UB) Flue Gas to meet stringentenvironment regulations for Paradip Refinery fixed at 1000kg/hr SO2.

Capacity of absorption of 12576 kg/hr SO2from Flue Gas (96% efficiency,

rated SO2flow 13100 kg/hr. in Flue Gas)


6/20


7/20A Sunrise Project for a Sunshine FutureCore Group

Major areas Identified (Long term)

Utilization of Natural gas instead of naphtha / HSD in GT/HRSG/UB

Installation of chiller at GT Inlet to Augment power output &Efficiency( if there is LP steam surplus in the refinery post HRSGs WPH addition)

Adoption of Coal Water Slurry Fuel(CWSF) technology of M/s. LemarLCC, USA to burn pet coke in existing UBs

OrInstallation of pet-coke based CFBC UB
http://localhost/var/www/apps/conversion/tmp/scratch_7/Payback_analysis_GT%20Inlet%20air%20chilling.pptx



Energy Conservation Initiatives in

Electrical Distribution SystemVariable Speed Drives being installed in process units & offsite (for

process control) provide substantial energy saving Total capacity of VSDs being installed in Refinery 76.7MW (225 drives ranging

from 1.1 KW to 110KW at 0.4kV level & from 315KW to 8.2MW at 6.6kV level)

Even 10% energy conservation would result in recurring savings equivalent to

7.7MW. Actual savings would be much higher.

Capacitor Banks being installed for Power Factor (p.f.) Improvement

Total capacity of Capacitor Banks in the entire refinery equal to 50.64MVAR

Designed for Power Factor improvement from 0.9 to 0.93

Synchronous Motors of 7.927MW & 15.2MW installed which aid in p.f.

improvement

Improvement in capacity utilization of generators & reduced losses in distribution

network

Power Recovery Turbine Generator (PRTG) of 19MW being installed in

Indmax Unit for power generation from Process Flue Gas




Electrical Distribution System

Lighting Transformers for the entire lighting system being installed inthe refinery

Total 82 nos. Lighting Transformers being installed in the Refinery

Improved power system reliability through isolation of lighting circuit faults

Reduced voltage results in improved life of luminaires maintaining the desired light

output

Solar LED Street Lights installed in Township

26 nos. of 14W Solar LED lights installed in place of 70W LPSV Lights

Recurrent energy saving of Rs. 2.9 Lacs/ annum, payback period 3 yrs.




Electrical Distribution System

Adoption of Compact Fluorescent Lamps (CFL) in place of Fluorescent

Tube Light (FTL) in Township Total 3393 nos. CFL being installed in place of FTL, energy saving & payback period

< 1 year

Adoption of CFL in place of FTL in all building lighting inside the Refinery on the

same lines

Illumination of entire refinery area through High Masts

Total 293 nos. of High Masts (each 8 x 1kW luminaires) installed for coverage of

entire area of about 2945 acres.

Localised area lighting & street lighting eliminated


11/20A Sunrise Project for a Sunshine FutureCore Group A Sunrise Project for a Sunshine FutureCore Group

11


12/20A Sunrise Project for a Sunshine FutureCore Group A Sunrise Project for a Sunshine FutureCore Group

Utilization of Grid Power to non-critical loads

for operating cost reductionPower supply arrangement to non-critical loads

The power supply to Administration Block, Township,

Mechanical Workshop, Electrical Workshop, CISF, Pipelines &

Marketing are fed from S/S#311N, S/S#311AN & S/S#312AN

The modification in power supply arrangement for utilizing grid

power is done with the existing resources and does not require

additional capital expenditure.

Grid Power is cheaper than incremental cost of generation in

Captive Power Plant

The cost differential works out to be approx. Rs. 3/- per unit

(kWH)

Hence, Total Cost Saving per annum for 15MW load

amounts to Rs.39.42 Crores



Flue Gas Desulphurization System (FGDS)

UBs

C

h

i

m

n

e

y

SO2

Absorption

Tower(=96%)(Unit 107)

HSFO

4.9% (wt./wt.)

SO2Stripper(Unit 109)

SRU

SO2

SO2

absorbed

Rich Amine

Lean

Amine

315

m3/hr

FG

180 deg c QuenchTower

(Unit 107)

Quench Water

Circulation

(Service/Fire)

FG

56 deg C FG SO2



FG HEADER OF CPP

Existing FG Header

Proposed FG Header

Utility Boilers

HRSG



Scheme Proposed Potential Savings Action Plan

FG header extension up to existingindividual FG skid of

Supplementary firing of HRSG

102 Crores /Yr FG header is not erected for

UBs. Header extension job will

be carried out by TS.

Present scheme

FG Header is existing for UBs.

Proposed scheme

For HRSG Supplementary firing FG header is to be extended up to

existing FG skid of each HRSG.

Benefits

HRSG Naphtha firing will be reduced and steam flow will be maintained

by FG firing. At UBs, FG firing will be reduced with increase in HSFO

consumption. The cost differential of Naphtha &HSFO for 33 Mkcal

supp. Firing works out to be 102 Crs/yr.



DM water line

Condensate storage tank

Condensate transfer pump (3)

12 kg/sqcm

LCV

LCV

LCV

W/W heat exchanger

HRSG MUH

Deaerator 2

Condensate receiving line

W/W heat exchanger

MUH transfer pump (3)

Deaerator 1

Bypass line

Equipment to be bypassed

7 kg/sqcm

Condensate transfer pump bypass scheme

Potential Savings by stopping 2 Nos CTP(385 KW) works out to be 4.3 crs/yr


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Additional module of MUH in allthree HRSGs

64.00Crores/Yr

(for 2 HRSGs

Operation)

Offer sought from BHELTrychiin May2013.

Present scheme

Design Flue gas temperature from HRSG is 170 Deg C which is very high if we

burn SR Naphtha (Sulphur 250 to 400 ppm) instead of design fuel SR GO.

This temperature can be reduced up to 130 Deg C

Proposed scheme

This can be achieved by adding additional module of MUH in HRSG after existing

MUH Module.

Condensate after W/W exchanger can be routed to De-aerator through this

module This scheme is discussed with M/s BHEL. Offer is sought in May2013.However

M/s BHEL, Trychi agreed to execute it after PGTR.

Benefits

Flue gas temperature can be reduced by 40 Deg C ( 170 to 130 Deg C)

Condensate Water temperature to De-aerator can be increased from 78 to 108


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Utilization of untreated naphthafor firing in Gas Turbines

30.00 Crores/Yr Implemented.

Present scheme

Facilities available with hydro-treated naphtha and HSD utilization

Hydro-treated naphtha is obtained after hydro-treatment andsplitting

Proposed scheme

Facilities for utilizing untreated naphtha in gas turbines

Utilizing the untreated straight run naphtha (SO2 content -500 ppm

max)

Benefits

Savings on the treating cost for the naphtha


19/20


HRSG BFP

FLOW: 295 m3/h(Each pump)

P

UB BFP

FLOW: 585 m3/h(Each pump)

UBs HRSGs


UB and HRSG discharge headers

interconnection to optimizeoperation. 2 UBs and 2 HRSGs

load will be met by running 2 UB

BFPs and HRSG BFP (2.1 MW)

would be stopped.

14 Crs /Yr Scheme implemented


20/20


GT Power without chiller MW 114

Relative Humidity % 60 60 60 60 85 85 85 85

Temp U/S of Chiller DegC 33 33 33 33 33 33 33 33

Temp D/S of chiller DegC 25 22 20 18 25 22 20 18

Refrigeration capacity Tr 641 157 2826 3610 3073 4053 5338 6148

Electrical power reqd for

refrigeration

KW 100 245 441 563 479 632 833 959

Net GT Powerv (Less chiller

power)

MW 120 122 123.5 125 120 122 123 125

Incremental power due to chiller MW 6 8 9.5 11 6 8 9 11

Capital cost of chiller plant Rs Cr 2.9 7.1 12.7 16.2 13.8 18.2 24 27.7

PAYBACK ANALYSIS

Heat Rate Saving Kcal/Kwh 37.63(Heat [email protected])

Heat rate saving@90MW for8000Hrs

KCal 27093600000

Naptha Fuel saaving/Year RsCR 12.54 (Calorific value-10800Kcal/Kg,Cost-Rs 50000/MT)

Payback Period Year 2.2

I/L heat reqd for Chiller of 6148Tr Kcal 18444000(1TR~3000KCal)

Heat Saved Kcal 3386700

% of I/L Heat saved % 18.36

GT Fr9E-I/L air cooling PaybackWaste Heat-HRSG Stack

Documents

Encon Measures CPP