bharat oman refineries limited...

18th National Award

for “Excellence in Energy Management – 2017”

Bharat Oman Refineries Limited

(BORL)Bina, Madhya Pradesh

Nilesh Zode, Nitin Tripathi, Ashish Rai

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 – 9.1

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

4

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

2016-17 15 5439 1565 603 5 7

2015-16 28 10052 2513 126 1 20

2014-15 20 7514 3870 480 1 7

Total 63 23005 7948 1208 2 34

Any small saving in energy significantly impacts OP-Ex

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.


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

Total Fuel Consumption Reduction 1.3


Equivalent Fuel Oil saving ~ 5439 MT/Yr ~ 1565 Rs Lakhs/yr

Sr. No.

En-con Plan FY 2016-2019 Est. SRF

(MT/day)

1Implementation of Flash steam & Condensate recovery System in SRU. Investment - 2.54 Rs Cr, Planned & Completed in 2016-17

3.9

2Implementation of Steam System Management in Refinery . Investment - 3.46 Rs Cr, Planned & Completed in 2016-17

4

3CDU heater efficiency enhancement by implementation of VDU hot well gases conditioning system. Investment - 10 Rs Cr, Plan 2017-18

1

4Installation of Power Recovery Turbine in Hydrocracker 1st stage reactor feed pump. Investment - 13 Rs Cr, Plan 2018-19

6

5Installation of step less control in Make Up Gas compressorInvestment - 19 Rs Cr, Plan 2018-19

2

6Installation of LP steam generator in Hydrocracker light diesel product stream. Investment - 0.78 Rs Cr, Plan 2018-19

5

7Installations of Crude Preflash drum in CDU to increase energy efficiency. Investment - 25 Rs Cr, Plan 2018-19

9

8Implementation of Flare Gas Recovery System.Investment - 10 Rs Cr, Plan 2018-19

4

Total Investment – 84 Rs Cr (0.5% of Turnover), Total Saving Potential – SRFT/day 35

Energy Conservation Plan: FY 2016-2019

Specific Energy Consumption (SEC)

91.4486.17 84.32

68.4765.0

60

70

80

90

100

2013-14 2014-15 2015-16 2016-17 Q-1 2017-18

MB

N

SEC of BORL

Refinery Specific Energy Consumption measured in MBTU/BBL/NRGF (MBN)

68.47

405060708090

100110120

1 2 3 4 5 7 8 9

10

11

12

13

14

15

16

17

18

19

20

21

22

MB

N

Indian Refineries

SEC of Indian Refineries

Source: PPAC, BEE, CII website

Specific Energy Consumption (SEC) -

Electrical & Thermal

Refinery Specific

Electrical Energy

Consumption is

expressed in

kWh/MT of

Crude

Processed80

85

90

95

100

105

110

2013-14 2014-15 2015-16 2016-17

108

101

9491

Specific Electrical Energy ConsumptionkWh/MT of Crude Processed

2000

2400

2800

3200

3600

4000

2013-14 2014-15 2015-16 2016-17

3601 3565

30462781

Specific Thermal Energy ConsumptionkJ/kg of Crude Processed

Refinery

Specific

Thermal Energy

Consumption is

expressed in

kJ/kg of Crude

Processed

Solomon Benchmarking : Energy Intensity Index™ (EII®)

11

EII 92 indicating substantial improvement in energy performance of BORL

Participating in Solomon Benchmarking

since 2014 every alternate calendar year

Implementation of Encon Measures Plan FY 2016-19 will bring EII to 88 Q1

Innovative Project 1:

SRU Flash Steam & Condensate Recovery

12

Objective: Reduce energy costs & environmental impact by upgrading

waste steam & water to useful steam & water

Trigger:

LP steam is required in process

Heat Loss - Low low pressure

flash steam from existing flash

vessel was getting condensed

in Fin Fan condenser.

Water Loss - Tracing & Jacketing

condensate was being drained

locally.

Power Consumption - Fin Fans

were running continuously.

Innovative Project 1: Implementation


13

Project :

1. New Power Pressure Pump is installed to transfer Jacketing condensate

2. New Flash Vessel installed to generate flash steam from collected cond.

3. Thermo-compressor is installed to Upgrade LLP to LP steam

4. Pump & Hydrocarbon analyser is provided in condensate transfer header

1

2

3

4

1

2

3

4

Innovative Project 1: Benefits


14

LP steam being recovered – 2.1 TPH, Savings – 3.8 Rs Cr/yr

Condensate being recovered – 2.3 TPH, Savings - 0.11 Rs Cr/yr

Fin Fan Power consumption reduced – 18.5 kW, Savings - 0.08 Rs Cr/yr

Heat lost to atmosphere – 1.6 MMkcal/hr ~ 0.16 SRFT/hr

Invest – 2.54 Rs Cr , Payback – 7 Months

CO2 Emission reduction – 6826 t CO2/yr

Heat & water previously lost is being effectively recovered , reducing utility

bills,water treatment cost

• This project is being replicated in Delayed Coker Unit

• It has brought design change in new upcoming projects

Innovative Project 2: Capacity Enhancement in Net Gas

Compressor in CCR Platformer unit for energy saving

15

Objective: Net Gas Compressors in CCR Platformer unit were overhauled,

modified which helped in achieving operation of unit with single compressor

saving about 800 kW.

Trigger : Two compressors were running above 125% throughput

Project :

Flow pattern study in the compressor cylinder performed

Thermal imaging indicated warmer cylinder heads indicating passing

through clearance pocket valves

Cylinder head modified to increase capacity

Metal Seated Clearance Pocket identified as culprit

SQUEEZING COMPRESSION

Innovative Project 2: Capacity Enhancement in Net Gas

Compressor in CCR Platformer unit for energy saving

16

Benefits :

Discharge capacity increased ~ 22%, Single compressor operation at

Plant throughput of 148%

Power consumption reduction - 800 kW, 3.6 Rs Crs/yr

Investment - 0.27 Rs Cr, Pay Back ~ 1 Month

CO2 Emission reduction – 5405 t CO2/yr

Reduction of oil consumption – 0.26 Rs Cr/Yr

SQUEEZING COMPRESSION

ORIGINAL COMPRESSION

ACHIEVED

CLEARANCE

POCKET

BLINDED Rated Capacity achieved, Switched to Single Compressor above 125%

Modified Cylinder Head without clearance pocket

In house implementation

of project

Innovative Project 3:Operation of SINGLE Forced Draft (FD) fan in Fired heaters

17

Objective: Reduce energy costs by stopping one FD fan in fired heaters

Trigger: Vacuum Distillation Unit fired heater is equipped with two Forced

Draft (FD) fans each, designed for in tandem operation each at 50 % load to

increase reliability. Continuous running of both FD fan could not provide

opportunity for preventive maintenance.

To increase reliability and reduce specific energy consumption

Project :

Study of Design basis VDU heater

Feasibility study carried out – adequacy check of each FD fan

HAZOP carried out for the implementation

Trip logic modification - Auto cut in logic added

Enhanced the reliability of trip logic by providing 2 extra speed sensor

Trial run of the modified scheme and Simulation Studies

Implementation and execution of the plan

Innovative Project 3:Operation of SINGLE Forced Draft (FD) fan in Fired heaters

18

Benefits:

Stopped one FD fan in VDU Heater saved Power – 30 kW, Rs 15

Lakhs/yr

Zero Investment Project

Enhanced reliability of the equipment as PM can be done in running

condition.

Replication:

The successful implementation of project in VDU boosted confidence &

hence replicated in other fired heaters as well.

Fired HeaterSavings CO2 Emission Reduction

Power (kW) Rs Lakhs/Yr t CO2/Yr

VDU Heater 30 15 196

CDU Heater 93 49 618

HOH Heater 42 22 279

HCU Heater 117 61 777

Total 282 147 1869

19

0.567 (3090 TMT) 0.539

(3343 TMT) 0.506(3240 TMT)

0.392(2492 TMT)

0.300

0.350

0.400

0.450

0.500

0.550

0.600

2013-14 2014-15 2015-16 2016-17

t C

O2

e/

t o

f cru

de t

hru

pu

t

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

~ 30% reduction in Specific CO2 emission in 4 years

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

Encon Project Management Team is a

cross functional team

Energy Management Team

Energy Conservation Project Management

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 :


Refinery Energy Balance Monitoring : Daily

02-Aug-17 Energy Demand, M Btu/day Energy Supply

Unit NameMBN

(MBTU/BBL/NRGF)

EII(D*100/E)

Target Energy

(E)

Actual Energy

(D=A+B+C)

Fuel(A)

Power(B)

Steam(C)

Gap (Target-Actual)

SourceM Btu/

day

Unit 1 51 72 11719 8387 8288 1192 -1093 3332 Produced Fuel 50939

Unit 2 109 152 4492 6813 3863 280 2670 -2321 Purchased Power 9294

Unit 3 100 139 6051 8429 3706 424 4299 -2378 Coal 739

Unit 4 62 87 2583 2249 1753 422 75 334 Petcoke 12698

Unit 5 72 99 5764 5732 3992 866 873 32 Power for non-refinery operation

-510Unit 6

84

64 2491 1596 784 622 191 895

Unit 7 115 890 1024 0 67 957 -134

Unit 8 60 1318 795 639 155 0 524

Unit 9 20 439 89 0 89 0 350

Unit 10 48 82 13792 11304 6355 4715 234 2488

Unit 11 54 75 3342 2501 683 2021 -203 841

Unit 12 54 58 18261 10555 15444 558 -5447 7706

Unit 13 22 30 794 240 0 240 0 554

Unit 14 169 235 53 125 0 125 0 -72

Unit 1531

111 2899 3207 982 1290 936 -309

Unit 16 192 264 507 0 82 425 -243

Unit 17 223 289 3305 9560 106 5389 4065 -6255 Total Energy Supply 73159

REFINERY 65.4 93.2 78459 73113 46595 18537 7981 5345 Total Energy Demand 73113

Energy Balance % 99.94

26

ISO 50001:2011 Energy Management System (EnMS)

Certification

Renewable Energy Sources: Initiatives at BORL

4 MW Solar Power Plant at

BORL generating 20000 units

per day

Solar Wind hybrid power supply

system for Campus video surveillance,

Wi-Fi and LED based street light.

10 kW Solar PV Panel in SV stations of VBPL pipeline.

Renewable Energy Sources: Initiatives at BORL

Installed 8x500 & 2x1000 LPD

ETC based Solar Water heating

system for providing preheated

water to bathing purpose, saves

90000 units/yr,

LED street lights on newly developed road as well as LED lights, 5 star

rated energy efficient ceiling fans in common area of new buildings,

Guest rooms. Replacement of CFL with LED bulbs.

Installed Solar Power based

electric fencing to refinery as well

as township boundary wall of 22

kms for security purpose.

Invest – 2 Rs Cr

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 &

50,000 sampling in township 2 Lakhs samplings in nearby villages

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 636963 SRFT of Fuel in 4 years

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,

• 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 9001:2008, ISO 14001:2004, OHSAS 18001:2007

• 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, Low level heat

recovery

• Maximization of Hot Feed (85-94%), Condensate Recovery (80-85%)

• High efficiency fired heaters/boilers, Use of Glass APH, API 560

• Low emissions - environment friendly CFBC boilers, adoption of Clean

Technology, 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

• 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 for

lower energy consumption and safety & environment friendliness.

BORLFuelling Nation…

Bringing Cheers

An ISO 9001, 14001,18001 & 50001 company

Thank You

‘Lowest Steam Leak’ award in OGCF 2015 from CHT MoP&NG at 20th Refinery Technology Meet

Bhamashah Award - MP Frost & Sullivan Award for

Environment & Op Excellence

Leadership Project

NHRDN CSR Competition-2016

award

bharat oman refineries limited...

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