Best Practices on Energy Conservation at IOCL Gujarat refinery · LAB UOP 0.12 Aug'04 MSQU (CCRU)...

Prepared for :

Western Region Workshop on “Capacity Building of Officers from

Petroleum Refinery Sector on Efficient Use of Energy”

Best Practices on Energy Conservation at IOCL Gujarat refinery

Presented by

HARISH SVS

Process Manager

IOCL Gujarat Refinery

Introduction to IOCL Gujarat refinery

WORK IN PROGRESS

FIRST GENERAL MANAGER OF GUJARAT

REFINERY MAJ. GEN. SHARDANAND SINGH

PRESENTING MODEL OF GUJARAT REFINERY

TO H’BLE PRESIDENT DR. SARVEPALLI

RADHAKRISHNAN

PANDIT JAWAHARLAL NEHRU LAYING FOUNDATION

STONE OF GUJARAT REFINERY ON 10TH MAY 1963

• Foundation stone laid on 10th May 1963

• Commissioned in October 1965 with 2.0 MMTPA

• Current Refining capacity upgraded to 13.7 MMTPA in 1999

• MS/ HSD Quality Improvement & Residue Up-gradation Project

completed successfully and commissioned in 2010-11

Brief History – Gujarat Refinery

Process Unit LicensorExisting UnitCapacity, MMTPA

Year of Commissioning

AU-I M/s EIL 2.0 15.10.1965

AU-II M/s EIL 2.2 25.09.1966

AU-III M/s EIL 2.7 28.09.1967

AU-IV M/s EIL/Sulzer 3.8 Oct-78

AU-V M/s EIL 3 Sep-99

FPU-1 (VDU) M/s EIL 2.5 July-1982

FPU-II (VDU) EIL/KVAERNER 3 Jan-1993

VDU M/s EIL 1.2 Feb-79

VBU M/s EIL 1.6 Feb-79

BBU EIL/Porner 0.5 Feb-79

LAB UOP 0.12 Aug'04

MSQU (CCRU) UOP 0.6 Oct'06

Process Units

Process Units



SR-CRU M/s EIL 0.33 Oct-66

UDEX UOP 0.166 Dec-68

FGH OPEN ART 0.105 Sep-95

FCC UOP 1.5 Dec-82

MTBE CD TECH 0.21 Sep-99

BUTENE-1M/s. Sulzer Chemtec

/IFP France0.060 Sep-99

DHDS UOP 1.7 Jun-99

HGU-2 Haldor Topose 0.011 Apr-99

HCU CHEVRON 1.2 Dec-93

HGU-1 Linde 0.038 Jul-93

SRU-1 M/s EIL 1 x 18 TPD Dec-93

SRU-2 STORK 2 X 35 TPD Jun-99



ISOM UOP, USA 0.23 18.07.2010

Delayed Coker Unit(DCU)

Foster Wheeler,USA

3.7 Mar-2011

Diesel Hydrotreater(DHDT)

AXENS 2.2 09.06.2010

HGU-3 Haldor Topose 0.0725 28.05.2010

VGO Hydrotreater (VGO-HDT)

UOP, USA 2.1 25.11.2010

SRU-3 BVPI 2 X 300 TPD30.06.2010 (1st Chain) &29.07.2010 (2nd Chain)

FCC LPG MEROX UOP, USA 225 26.12.2010

ATF MEROX UOP, USA 200 Mar-2011

COKER LPG MEROX UOP, USA 150 Mar-2011

Process Units

TPS CGP-1 CGP-2

POWER GEN. SOURCE STG-1 STG-2 STG-3 GT-1 GT-2 GT-3 GT-4 GT-5 GT-6

RATING (MW) 12 12 12.5 30 30 30 30 30 30

STEAM GEN SOURCE BLR-1 BLR-2 BLR-3 BLR-4 HRSG-1 HRSG-2 HRSG-3 HRSG-4 HRSG-5 HRSG-6

MCR (MT/HR) 75 75 75 130 100 100 105 100 100 125

PRESSURE (KG/CM2) 40 (HP) 15 (MP) 40 (HP)

GEN. VOLTAGE (KV) 6.9 KV 11 KV 33 KV

Power (MW) Steam (MT/Hr)

Installed Capacity 216.5 985

Peak Load 122 530

Power plant

Best practices

Best practices

1) Daily calculation of Fuel and loss, MBN and EII. Target vs Actual comparison

8.65

8.85

8.65

8.80

8.70

8.76

8.20

8.40

8.60

8.80

9.00

9.20

9.40

TARGET F&L for theday

ACTUAL F&L for theday

TARGET F&L for themonth

ACTUAL F&L for themonth

STGT F&L for 2017-18

ACTUAL F&L for2017-18

Best practices

1) Daily calculation of Fuel and loss, MBN and EII. Target vs Actual comparison

Best practices

2) Target setting for all units w.r.t Fuel, steam and power consumption

0.00

1.00

2.00

3.00

4.00

5.00

6.00

7.00

DA

Y 1

DA

Y 1

6

DA

Y 3

1

DA

Y 4

6

DA

Y 6

1

DA

Y 7

6

DA

Y 9

1

DA

Y 1

06

DA

Y 1

21

DA

Y 1

36

DA

Y 1

51

DA

Y 1

66

DA

Y 1

81

DA

Y 1

96

DA

Y 2

11

DA

Y 2

26

DA

Y 2

41

DA

Y 2

56

DA

Y 2

71

DA

Y 2

86

DA

Y 3

01

DA

Y 3

16

DA

Y 3

31

DA

Y 3

46

DA

Y 3

61

UNIT % SRFT

50.0

100.0

150.0

200.0

250.0

300.0

350.0

DA

Y 1

DA

Y 1

7

DA

Y 3

3

DA

Y 4

9

DA

Y 6

5

DA

Y 8

1

DA

Y 9

7

DA

Y 1

13

DA

Y 1

29

DA

Y 1

45

DA

Y 1

61

DA

Y 1

77

DA

Y 1

93

DA

Y 2

09

DA

Y 2

25

DA

Y 2

41

DA

Y 2

57

DA

Y 2

73

DA

Y 2

89

DA

Y 3

05

DA

Y 3

21

DA

Y 3

37

DA

Y 3

53

UNIT SPECIFIC STEAM

TARGET TARGET

Actual best performance achieved for 1 or 2 weeks on sustained basis in the last one year is considered as Target for the unit

Best practices

3) Identification of gaps in fuel and loss unit wise everyday w.r.t Target

Best practices

Best practices

4) Online chemical cleaning of furnaces for sustenance of high T’puts T’put

Arch Temp

608 m3/h 672 m3/h874 deg C

760 deg C

AU-5 FURNACE

Best practices5) Fortnightly calculation of cheapest fuel and maximizing use of the same

Best practices6) Flare loss monitoring using RTDBMS based excel templates (Real time)

0

10

20

30

40

50

60

70

80

7:0

0

7:5

5

8:5

0

9:4

5

10

:40

11

:35

12

:30

13

:25

14

:20

15

:15

16

:10

17

:05

18

:00

18

:55

19

:50

20

:45

21

:40

22

:35

23

:30

0:2

5

1:2

0

2:1

5

3:1

0

4:0

5

5:0

0

5:5

5

6:5

0

FLARING FROM GR1AU1 K8 AU-1 K1

AU - 5 TOP GR FG to Flare

AU1 K9 V1 feed surge drum for K8

0

1000

2000

3000

4000

5000

6000

7000

7:0

0

7:5

5

8:5

0

9:4

5

10

:40

11

:35

12

:30

13

:25

14

:20

15

:15

16

:10

17

:05

18

:00

18

:55

19

:50

20

:45

21

:40

22

:35

23

:30

0:2

5

1:2

0

2:1

5

3:1

0

4:0

5

5:0

0

5:5

5

6:5

0

KG

/hr

GR to new flare GHC to new flare

FGRS, KG/hr GHC to old flare

0

5

10

15

20

25

30

35

7:0

0 7

:50

8:4

0 9

:30

10

:20

11

:10

12

:00

12

:50

13

:40

14

:30

15

:20

16

:10

17

:00

17

:50

18

:40

19

:30

20

:20

21

:10

22

:00

22

:50

23

:40

0:3

0 1

:20

2:1

0 3

:00

3:5

0 4

:40

5:3

0 6

:20

MW

MOLECULAR WEIGHT

GR MW GHC MW

0.0

10.0

20.0

30.0

40.0

50.0

60.0

70.0

80.0

90.0

100.0

7:0

0

7:5

5

8:5

0

9:4

5

10

:40

11

:35

12

:30

13

:25

14

:20

15

:15

16

:10

17

:05

18

:00

18

:55

19

:50

20

:45

21

:40

22

:35

23

:30

0:2

5

1:2

0

2:1

5

3:1

0

4:0

5

5:0

0

5:5

5

6:5

0

% O

P

FLARING FROM MTBE

MTBE: 11V7 MTBE 11V4 MTBE 11V5 MTBE 11V6 O/L TO FLARE

Best practices7) In house PSV leak monitoring system

VPAC II LEAK CALCULATION Rs. 323,510.21

UNIT Valve IDDescription

Signal

Level

Up

Stream

Down

Stream

Pressur

e

Differen

ce

Inlet Size Leak

RatesLoss Loss Cost Per Ton

Total Loss

Per ValveRemark

dB dB dB PSI ins NB ft^3/hr Kg/hr tons/yr Rs Rs/yr

AU3 GJA.3PC3503.OP K-2 TOP PC 6 11 16 11.36 2 0.0 $16,000.00 OK

AU3 GJa.3PC3901.OP VR drum pC 7 6 11 18.46 2 0.0 $16,000.00 OK

FGH gja.06pc1402.op C3 top 5 5 5 42.6 4 0.0 $16,000.00 OK

FGH GJA.06PC1201.op HEX OVHD 21 21 21 21.3 47.5 0.99 8.7 Rs. 28,000.00 Rs. 243,710.21 Passing, isolated.

FGH GJA.06PC1102.OP DEP TOPS 5 5 5 21.3 6 0.0 $16,000.00 OK

FGH GJA.06PC1301.op HEX SURGE DRUM 5 5 5 15.62 2 0.0 $16,000.00 OK

FGH GJA.06PC1101.op FEED SURGE DRUM 5 5 5 7.1 2 0.0 $16,000.00 OK

FGH 6SDV5102Reactor Depressurisation

SDV5 6 5 220 2

0.0 $16,000.00 OK

FGHDepressurisation

valveFor high Reactor pressure 5 5 5 220 6 0.0 $16,000.00 OK

MTBE GJA.911PC503.MV ON 11V5 5 5 5 9.94 2 0.0 $16,000.00 OK



MTBE GJA.911PC1002.MV 11V6 O/L TO FLARE 3 3 3 85.2 2 0.0 $16,000.00 OK

UDEX GJA.4PC2201.OP BEN COL OVHD 5 5 5 4.26 2 0.0 $16,000.00 OK

UDEX GJA.4PC1301.OP STRIPPER OVERHEAD 5 5 5 8.52 3 0.0 $16,000.00 OK

UDEX GJA.4PC3101.OP V12-HOT OIL SURGE DRUM 5 5 5 14.2 1.5 0.0 $16,000.00 OK

UDEX GJA.4PC1101.OP EXTR COL TOP 15 5 20 106.5 1.52.0 0.03 0.6 Rs. 79,800.00 Passing, isolated.

19

S.NO PARAMETER UOM F-3 Remarks

1Excess O2 analyzer reading at Furnace arch

Vol % 4.5Best achieved 3.9%

2 Stack temp Deg C 188Best achieved 168.5 against design 170

3 Draft Mmwc -4.78

Furnace overdraft,air register and ID fan suction damper need to be optimized

4 Stack damper opening % 5

Stack damper opening in normal running condition to be 0%

5 Combustion air flowNm3/

h20889

6 Combustion air temp inlet to APH Deg C 39.68

7 Flue gas inlet temp to APH Deg C 379.42

8 Flue gas outlet temp ex APH Deg C 174.9

9 Combustion air temp ex APH Deg C 248.9

10 Furnace efficiency % 88.15Against design efficiency of 90%

1) Air ingress observed in peepholes near burner No. 1,3,4,5,6.2) Insulation damage near burners.3) Burner No. 02 and 05 are not in line.

Insulation damage

Open peep holes

Best practices8) Daily Furnace survey

Major ENCON initiatives

S.N Name of SchemeFuel Saving (SRFT/Yr)

Completion Schedule

1Installation of additional row of tubes in convection section of CRU NHT furnaces (21F1/21F2) for increased heat recovery and reduction in stack temp & other small modifications

800 Sep’16

2 Reduction of CGP-2 Deaerator operating pressure from 1.4 to 0.8 kg/cm2-g 2060 Sep’16

3Stoppage of motor driven air blower in SRU and operating single BPT HP-LP based air blower for energy savings

1400 Sep’16

4 ISOM to FCC HPS header isolation (1 km) 1224 Aug’165 Isolating additional MPS header in TPS (1 km) 265 Aug’16

6 Isolating 16 inch MPS header from TPS to CRU (header length 0.5 km) 441 Aug’16

7Rectification of HCU dump valve passing problem in Sep’16 s/d for reduction of flare loss

1400 Sep’16

8 Installation of 1 MW solar panel 1300 Oct’16

9Stopping of two LPG pipeline transfer pumps at LPG mounded bullets area and transferring the material directly

576 Jan’17

10 Stoppage of MUH pump in HRSG 6 (110 KW) 150 Feb’1711 Stoppage of TPS old CT pump (110 KW) 150 Mar’17

12CCRU NHT stripper column pressure reduced by 1.0 kg/cm2-g for reducing reboiler load and MPS savings

500 Oct’16

13CRU NHT stripper column pressure reduced by 2.0 kg/cm2-g for reducing reboiler load and MPS savings

750 Oct’16


S.N Name of SchemeFuel Saving (SRFT/Yr)

Completion Schedule

14 Rectification of CCRU debutanizer reboiler desuperheater for savings MPS loss 250 Nov’16

15 Hot feeding of HVGO to VGO HDT by 102 m3/h 465 Oct’16

16 Stoppage of reformate splitter in MSQU resulting in 5.5 Gcal/hr steam savings 4400 Nov'16

17Idling of UDEX unit and importing benzene from Panipat refinery. (Fuel = 32.5 MT/day, Power = 0.5 MW)

12651 Nov'16

18Provision of bypass controller for NG firing in HGU-3 reformer in order to reduce flare loss in PSA-2

5913 Jan'17

19FCC furnace preheat improvement by increasing hot feed to FCCU. Increment by 4 deg C at inlet of furnace

440 Nov'16

20 Processing of sour gas in SRU 1833 Sep’15

21 Routing of DHDT back wash to product E-III HSD 1388 Jul’15

22 LAB pre-fractionator preheat improvement 1010 Aug’15

23 Hot feed to coker 1080 Apr’15

24 Implementation of Dead band in 35 locations 2500 Oct’14


Future ENCON initiatives

Sr. No. Name of SchemeCompletion

ScheduleFuel Saving (SRFT/Yr)

1 Routing of NSU overhead PIC outlet from Flare header to FG header. May’17

(Completed)1200

2 Idling old TPS deareator with stoppage of 2*300 KW BFW pumps . May'17

(Completed)3030

3 Hot feeding of DCU from FPU-II & VDU Jul’17 680

4 VDU pre heat improvement by 7 Deg C (S/D) Jul'17 1700

5Parallel operation of two Naphtha splitter columns (K8 & K9) and hot feeding to MSQU.

Jul'17 2500

6 AU-1 preheat improvement Oct’19 4800

7 DCU WGC steam drive replacement with motor (HP to total condensate) Mar’19 4689

8 Provision of MUH in HRSG 5 for heat recovery from stack to DM water Apr'19 7800

9To install additional HC coils in Vacuum furnace for improvement in duty and hence increase in Tput by replacing one no of superheating and BFW coil.

Jul'17 800

10AU-IV preheat improvement and sustenance by reconfiguration of exchanger network and shifting of one set of preheat exchanger from AU-V

Jul'17 1920

11 Installation of Auto decantation valves in 37 nos of tanks Mar'18 2000

TOTAL 31119

THANK YOU

Best Practices on Energy Conservation at IOCL Gujarat refinery · LAB UOP 0.12 Aug'04 MSQU (CCRU)...

Documents

Transcript of Best Practices on Energy Conservation at IOCL Gujarat refinery · LAB UOP 0.12 Aug'04 MSQU (CCRU)...