295

First Prize Refnery

VISAKH REFINERY - HINDUSTAN PETROLEUM CORPORATION LIMITED
Visakhapatnam (Andhra Pradesh)
Unit Profle
Hindustan Petroleum Corporation Limited (HPCL) was formed after Government of India took over the
ESSO group of companies in Bombay in 1974. Caltex operations in India including its Refnery at
Visakhapatnam was also taken over by Government of India and amalgamated with HPCL in 1978.
The Refnery at Visakhapatnam was commissioned in 1957 with a capacity of 0.675 million TPA. The old
crude unit was modernized and revamped to increase its capacity to 1.5 million TPA. In 1984-85,
Refnerys crude processing capacity was increased to 4.5 MMTPA by adding 3 MMTPA crude unit along
with matching secondary processing capacity. In the second phase of expansion additional 3 MMTPA
refning capacity was added, bringing the total refning capacity to 7.5 MMTPA. It is planned to upgrade
product quality to EURO II & III standards. Clean Fuel Project is already under implementation .
Along with increase in refning capacity, Visakh Refnery implemented various environmental projects to
minimize its impact on environment. For example, Sulfur recovery unit for the desulfurisation of fuel gas
were installed both to treat FG & off gases during Diesel hydrodesulfurisation to reduce SO2 emission. A
DHDS unit is installed for HSD desulfurisation, to meet the new reduced Sulphur specifcation of the HSD
and will help in reducing SO2 emission pollution. Refnery has got the ISO 14001 certifcation in May
2002 by implementing the Environmental Management System in the Refnery,
Visakh Refnery is manufacturing petroleum fuel products like LPG, Propylene, Naphtha, Motor Spirit
(MS), Superior Kerosene Oil (SKO), Aviation Turbine Fuel (ATF), High Speed Diesel (HSD), Light Diesel
Oil (LDO), Jute Batching Oil (JBO), Wash Oil (WO), Furnace Oil (FO), Low Sulfur Heavy Stock (LSHS)
and Bitumen.
High capacity utilization with optimum yield and effcient energy uses is the operating philosophy of
Visakh Refnery and to be Environment friendly is one of the main priorities.
SO2 emission at VR has dropped from 23-24 tons per day in early eighties to 9 to 11.5 tons/day after the
commissioning of sulfur recovery unit & management control.
Energy Consumption
The refnery consumes fuels viz. LSHS and Refnery gas in steam boilers and furnaces, Naphtha for
captive power generation. In addition to captive power generation, the Refnery imports electricity from
APSEB to meet their power requirements in case of emergency
Energy Conservation Commitment, Policy and Set up
Owing to the steep rise in oil prices from the 1970s onwards oil industry took a hard look at their energy
performance and stepped up their energy conservation efforts. Visakh Refnery while implementing
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energy conservation schemes was not guided only by economic compulsion but adopted energy
conservation as part of its operating philosophy. As a result, energy conservation projects which were
implemented were incorporating state of the art technologies. For example, while designing new units for
the refnery expansion which was commissioned in 1985, the latest energy conservation strategies were
adopted. Visakh Refnery was the FIRST IN INDIA to install glass tube Air Preheater in their furnaces
while replacing crude unit furnaces in the old unit. Gradually the design effciency of the fred equipment
at Visakh Refnery has increased from 80% in early eighties to 90% by the end of eighties. In the second
phase of expansion furnaces of 91% effciency are being incorporated.
All the Furnaces in Refnery are provided with Air Preheater for better effciency. Following are the
photographs of typical furnace with APH:
Hydrogen Unit Reformer: (provided with Air Pre heater and steam drum which recovers heat from fue
gases for air pre-heating and generation of High Pressure Steam.)
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(Crude Distillation Unit-II Vacuum Furnace with Air Pre-Heater)
Visakh Refnery has a Energy Conservation department headed by Sr. Manger-Technical. This Group is
directly responsible to monitor and ensure effcient energy utilization in the refnery in coordination with
Operations, Maintenance, Technical & Project departments.
Energy Conservation Achievements
Visakh Refnery has implemented various energy conservation projects during 2006-2007:
Reduction in % opening of Steam Pressure Reducing Stations.
Improved Specifc Fuel consumption in Captive Power plant. The specifc fuel consumption was
reduced from 0.39 during 2005-2006 to 0.37 during 2006-2007.
Improved service factor of New CO boiler on CO mode, thereby reducing fuel consumption in the
boiler.
Reduction in steam leaks by installation of MST 21 steam traps on Cu tracing lines Total steam leak
was reduced from 7T/Hr during 2005-2006 to 4.6 T/Hr during 2006-2007.
Reduction in compressed air leaks. Subsequent to identifcation of compressed air leaks by survey,
arresting of leak was carried out.
Increasing PFD vapourisation in CDU-II from ~14 % to ~19% by reducing the operating pressure.
Increased vapourisation of crude in prefash drum has resulted in lower fuel fring in Atmospheric
Furnace to heat the crude.
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Visakh Refnery has been given a second prize in best improvement category of specifc energy
consumption by Centre of Higher Technology for the year 2006-2007.
Specifc Energy Consumption of Refnery for 2006-07 was 87.9 MBTU/BBL/NRGF which is lowest
ever achieved in the history of the Refnery.
Energy Conservation Plans and Targets
To improve the energy performance further and to conserve energy, the following work is undertaken :
A feasibility study to recover complete condensate from the Refnery and to improve the steam
distribution management is in progress. It is planned to implement the recommendations of the
feasibility study to recover the complete condensate in phases. Already a part of the facility in one
unit is commissioned and job is in progress for three other units.
Compressed air system audit carried out in the Refnery in order to identify the areas of energy
consumption in the Refnery. New order for carrying out a fresh round of surveys is already placed.
Environment and Safety
The companys commitment for Environment improvement and safety is of equal importance along with
energy conservation. Visakh Refnery has always been committed to improvement of environment and
has implemented various environmental improvement projects to minimize the effects of pollutants on
the environment. It has also taken a keen interest in tree plantation activity.
Commitment to safety is another prime aspect of Visakh Refnery. Regular safety audits, monitoring and
implementation of safe working practices are carried out in the Refnery. The Refnery is ISRS level 8
company.
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Second Prize Refnery
NUMALIGARH REFINERY LIMITED
Guwahati (Assam)
Unit Profle
Numaligarh Refnery has been set up in 1993 in the district of Golaghat, Assam in fulfllment of the
commitment made by the Govt. of India in the historic Assam Accord for providing the thrust towards
industrial and economic development of North-East.The company started commercial productions from
October 2000 and has been performing creditably ever since. With its track record of proftability and
steady growth, it has earned the status of a Mini Ratna PSU.
Numaligarh Refnery, a subsidiary of Bharat Petroleum Corporation Limited is designed to process 3.0
MMTPA of crude oil with the confguration of Crude Distillation Unit, Delayed Coker Unit, Hydrocraker
Unit, Hydrogen Generation Unit, Sulphur Recover Unit,Coke Calcination Unit & Marketing Terminal
(NRMT). In order to value addition for the currently available surplus Naphtha as well as to meet the
market demand of MS in North- Eastern, Eastern and Northern regions, Motor Spirit Plant has been
recently set up. The main products of Numaligarh Refnery are Euro-II/Euro-III.
High Speed Diesel , Euro II/III Motor Spirit ,Liquifed Petroleum Gas ,Aviation Turbine Fuel , Superior
Kerosene Oil ,Naphtha , Fuel Oil ,Raw petroleum Coke/Calcined Coke etc.
Numaligarh Refnery is one of the latest refneries of the country
adopting state of the art technologies. Due to adoption of latest
process technologies for secondary processing units as well as
upgradation of residues / heavy ends, refnery ensures optimum value
addition. The net distillate yield of the refnery is as high as 85% of
which 74% is middle distillates.
Various provisions were incorporated at the conceptual stage to make
refnery energy effcient such as use of pinch technology, installation of high effciency furnaces,
maximisation of air cooling, installation of co-generation plant, installation of power recovery turbine,
installation of condensate recovery system, installation of state of art instrumentation and digital control
syste, Caste Iron & Glass Air Preheater in all the major Fired heaters in the refnery.
A number of Encon schemes have been implemented during last three years as a part of continual efforts
towards energy conservation and loss control. Some of the major schemes implemented are:
- Scheme for providing special type of Telescopic Insulation for all the 150 numbers of Catalysts
Tubes at the reformer top to cover the bare hot tube length (5500C to 600 0C) ,which is expected to
save around 600 MT of fuel per year.The project was selected for 1st prize by PCRA for exemplary
work in energy conservation under medium category project.
- For the frst time in the country, NRL adopted Stepless control system in HCU make up Gas
Compressor.
- Combination Coke Cutting tool in DCU has been implemented
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- Implementation of Advanced Process Control (APC) in CDU/VDU to optimize Product recovery and
improve product yield
- Improved and more reliable Steam Traps have been installed ,for which considerable amount of
steam losses have been reduced
- Auto drain Traps for moisure separation in air compressor have been installed
- Mass fow meter in the Flare Header has been installed
- Reduction of GTG frequency to 49.5 Hz from 50 Hz resulted in saving of around 666 MT of fuel per
year
- Energy master installed for even distribution of load in the air compressors that facilitates saving of
energy by maintaining bypass valve opening to zero.
- Replacement of one Motor driven HRSG BFW feed pump by steam drive to cater BFW requirement
of both HRSG & UB.
- Stopping of one Forced Draft Fan in CDU furnace and one Forced Draft Fan in HCU Furnace
contrary to the normal operation philosophy.The action resulted in saving of around 600 MWH of
power per year
- Optimisation of HSD pool blending components with unconverted oil of hydrocracker unit resulted
in the saving of around 300 MT of fuel per year
- Stopping of steam heating in the crude tanks resulted in saving of around 666 MT of fuel per year
- Use of slop oil in place of gas oil for quenching purpose in DCU unit resulted in the saving of around
300 MT of fuel per year
- Routing flter back wash of hydrocracker unit to VR feed tank instead of slop resulted in saving of
around 300 MT of fuel per year
- Regular monitoring for any passing valves and fugitive emission by Acoustic Leak Detector and
Gas Measuring Instrument (GMI) is carried out as part of loss control measures and timely remedial
actions are taken as required.
Energy Consumption
Numaligarh Refnery consumes various types of fuel viz. refnery fuel gas and low sulphur internal fuel oil
in furnaces/boilers. Naphtha is consumed in Captive Plant for power generation and in Hydrogen unit for
Hydrogen generation. Many numbers of energy conservation schemes has been implemented in
Numaligarh Refnery contributing a lot for reducing consumption of fuel.
DESCRIPTION UNIT 2004-2005 2005-2006 2006-2007
Annual Production MT 1834149 1918876 2226735
Specifc Energy Consumption MBN 76.4 75.4 70.4
Energy Cost as % of
Manufacturing Cost
Electricity - 3.36% 3.19% 3.02%
Liquid Fuel - 2.97% 3.16% 2.95%
Refnery Gas - 3.48% 3.79% 4.26%
Total 9.81% 10.14% 10.23%
F& L% 9.71 10.37 10.53
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The energy consumption in refnery is reported in terms of % Fuel & Loss on crude and MBTU/BBL/
NRGF (MBN), where the term MBTU refers to total heat value of fuel and loss in thousand BTU, BBL
refers to barrel of crude processed and NRGF is a derived factor that depends upon actual intake in both
primary and secondary processing units as per industry standard. The % fuel & loss, MBN and energy
cost as % manufacturing cost for last three years is as given below: The specifc energy consumption is
gradually improving over the last three years, graphical representation of which is given below.
Energy Conservation Commitment, Policy and Set up
Numaligarh Refnery has the highest concern and commitment for conservation of Energy and preservation
of Environment. Numaligarh Refnery is having commitment for compliance of all the statutory regulations
and acts pertaining to energy conservation and to attain sustained excellence in the feld of energy
management and energy effciency. The Energy Management Policy of the refnery has been approved
by the board of directors of the refnery which consists of adopting and nurturing Energy Effcient and
environment technologies and undertaking social responsibility to educate, share and promote energy
and environment aspects with others in the vicinity. A fully functional ,dedicated and separate Energy &
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Environment Cell manned by qualifed engineers headed by a Chief Manager and reporting to Head
(Production) is continuously working for continuous improvement ,monitoring of energy and environment
related activities.
Energy Conservation Achievements
The major energy conservation projects implemented at Numaligarh Refnery are as given below:
1)Implementation of Stepless Control System in HCU make up Gas Compressor:
This is the frst of its kind in the country implemented in Numaligarh Refnery in HCU at Make up Gas
Compressor saving energy by eliminating excess fow of gas to the compressor .
Without the Stepless Control System, hydrogen is supplied
by the compressor in steps of 50% -75%-100% .At variable
plant load, gas compressed more than the plant requirement
was spilled back which is mere wastage of energy. This
energy lost at partial load is recovered by installation of
Stepless Control System which operates in a range between
0-100% and hence spillback fow becomes zero.
Hydraulically actuated unloader keep the suction valves
open during part of the compression cycle. Thus part of the
gas taken into the cylinder during suction cycle is pushed
back into the suction plenum. In this way, the gas volume
per working stroke can be controlled. This system saves
compression power at part load, since the energy consumption of a compressor is proportional to the
quantity of gas compressed per compression cycle.
Around 39 lakh kWh of energy is saved per annum by implementing this scheme.
2) Combination Coke Cutting Tool in DCU
As a measure towards continual improvement in operating systems as well as conservation of energy.
Combination Cutting tool has been introduced in coke cutting operation .Major benefts of the combination
nozzles are: reduced cutting time, increased safety, operator convenience, ability to readily revert to the initial
cutting mode in the event of cave-ins and convenience of maintenance.
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Hydraulically, combination nozzles are superior to any
nozzle used in decoking service. The combination coke
cutting tool is integration of features of boring and cutting
tools of conventional coke cutting operation.An especially
designed jet nozzles is its unique feature that enhances
more effective coke cutting by creating a sharper jet of
water. A tighter stream of water is maintained at the wall of
coke drums (larger diamter) by the jet nozzles.
Using same head the pilot bit mode of the coke cutting tool
can be switched to cutting mode that eliminates maintenance
activity related to tool change.In comparison to earlier two
tool coke cutting method ,the combination coke cutting method saves 1 to 1&1 /2 time ,thus running time
of the jet pump driven by an electric motor of 1.7 MW rating gets reduced.
Around 3.57 Lakh kWh energy per annum is being saved by implementing the project
3) Installation of telescopic insulation for the catalyst tubes at the reformer top to cover the bare
hot tube length
Numaligarh refnery is operating a 38000 TPA hydrogen plant licensed by Haldor Topsoe A/S. Unit was
commissioned in Feb2000 and plant is operating normal.Steam reformer is the side fred furnace having
150 nos. of catalyst flled tubes.
Signifcant heat loss was taking place from the bare portion of the reformer tubes extending outside the
reformer at the top having surface temperature in the range of 550
0
C.During normal operating condition
tube skin are maintained in the range of 950
0
C inside the reformer. High temperature operating condition
causes signifcant vertical movement due to the thermal expansion of reformer tubes.
Thermal expansion causes variation in the exposed length of the tube thus making it diffcult to provide the
conventional insulation over the exposed length as it exist only during operation in hot condition. Till date no
refnery in country could carry out the insulation on bare portion of reformer tube extending outside the
reformer due to the vertical movement which takes place from cold condition to hot condition caused by
thermal expansion because of its variable nature of length.
Technical Analysis
Telescopic Insulation- A Unique solution frst implemented by Numaligarh Refnery in Country.
The problem was studied and a suitable scheme for insulating the expanded portion of catalyst tubes was
developed. Various expert parties and supplier were searched through out the world for providing the
suitably designed insulation, for controlling the heat loss from the catalyst tubes. Nine numbers of vendors
responded to the problem however only one party i.e. M/s INSULCON B.V Holland could provide the
suitable design for insulating the bare portion of reformer tube. The scheme was also concurred by M/s.
Haldor Topsoe A/S, licensor of the unit.
M/s INSULCON B.V Holland was entrusted to provide the telescopic seals built up of two overlapping
stainless steel shells capable of compensating 310 mm of vertical movement in hot and cold condition.
Shells are flled with 19 mm layer of ceramic fber blanket of high insulation properties.
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The arrangement is shown below (Not to the scale):
Hot Position (with telescopic seal) Cold Position (with telescopic seal)
Impact of implementation
After installation of telescopic seal considerable amount saving in heat loss was achieved.
Bare tube surface temperature : 500
0
C (Before
putting insulation)
Surface temperature after insulation
(Outer insulation) : 260 deg C
(Inner insulation) : 320 deg C
Heat loss reduced : 0.38 MMKcal /hr
Saving of Fuel Naphtha : 288 TPA
Total Investment Incurred : 21 lakhs
Energy Conservation Plans and Targets
Installation of 12 MW Steam Turbo Generator (STG) for Captive Power Generation by recovery
and utilisation of the waste (thermal & pressure ) of HP steam .The project will be implemented by
January,2008.
Use of natural Gas in GTG and Hydrogen Unit by replacing Naphtha.
Utilisation of very low low pressure hot well gases from VDU to CDU furnace is under
implementation.
Replacement of conventional lighting fxtures by more energy effcient fttings.
Improvement of insulation effectiveness of steam lines and heaters.
Implementation of LDAR (Leak Detection and Repair Program).
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Environment and Safety
Numaligarh Refnery is situated near ecologically sensitive zone. The requirement of safety and
environment is incorporated during design and construction stage itself, for new facilities. All relevant
national and international standards like ISI, ASME, OISD, API, NFPA etc. are taken into consideration
at the design stage. Requirements of various statutory rules and regulations like Factories Act, Petroleum
Act and Rules, Boiler Rules, Environment and pollution Regulations etc. are complied with. NRL
Management accords top most priority to Health, Safety and Environment Issues.The Environment &
Safety performance is reviewed by the apex committee once in two months which is chaired by Director
Technical of the refnery. Besides unit level and area level safety committees meet every month to review
the safety performance of respective unit/area, the environment and safety issues are also reviewed in
functional co-ordination meeting chaired by the Managing Director every month.
Environment Management in Numaligarh Refnery is based on recommendations forwarded by National
Environmental Engineering Research Institute (NEERI), stipulations laid down by Ministry of Environment
& Forests & Pollution Control Board, Assam.
Following are the some of the Initiatives taken by NRL for environment protection since its inception:
Selection of process technology/equipments made on basis of special care for environment
protection.Hyydrocracker technology has been incorporated to produce low sulphur products
Sulphur Recovery unit has been incorporated inspite of low sulphur processing crude.
Sweet refnery gas/low sulphur naphtha is used as primary fuel resulting in low SO2 emission to the
atmosphere.
Low Nox burners installed in all the refnery furnaces to minimize pollution because of nitrogen
dioxide.
Stack heights have been kept at 60/77 mtrs to minimize pollution concentration at ground level.
Hazardous solid waste generated in the refnery is disposed off by Secured Landfll technology.
Schemes for 100% recycle of effuent discharge will be implemented very soon.
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Certifcate of Merit Refnery
GUWAHATI REFINEERY - INDIAN OIL CORPORATION LIMITED
Guwahati (Assam)
Unit Profle
Indian Oil Corporation Ltd. is one of the Nine gems among Indian Public Sector Units and only Indian
Company to have secured 135th place in the Hallowed rolls of the Fortune 500s corporations of the
world. Ever since its inception, India Oil, besides providing fuel to the countrys progress, has also
maintained pace with the most state-of-the-art developments worldwide. Indian Oil has seven operating
refneries at Guwahati, Barauni, Haldia, Mathura, Koyali, Digboi and Panipat. Yet another refnery is
being set up on the East Coast at Paradip.
The Guwahati Refnery in North East India - the frst Public Sector refnery of the country -- was commissioned
in 1962 with a capacity of 0.75 MMTPA which was subsequently increased to 1.0 MMTPA through
debottlenecking projects. The refnery processes only indigenous crude oil from the Assam oil felds. With
its main secondary unit, a coking unit, it produces middle distillates from heavy ends and supplies petroleum
products to North-Eastern India, and surplus products onward to Siliguri in West Bengal in 2003. Hydrotreater
Unit for improving the quality of diesel has been commissioned in 2002. In 2003, the refnery installed an
Indmax Unit, a novel technology developed by IOCLs R&D Centre for upgrading heavy ends into LPG,
Motor Spirit and Diesel oil.
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GRAPHICAL REVIEW OF ENERGY CONSERVATION EFFORTS
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Energy Conservation Commitment, Policy and Set up
310
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Energy Conservation Achievements
a) Pressurised cooling water system
b) Condensate Recovery System
Before:
Increase in refnery water consumption and
increased fouling rate due to low velocity at higher
elevation in process coolers.
After:
Decrease in refnery water consumption and
improvement in cooling rate.
Results:
Energy saved per annum: 1700 SRFT /annum
Cost saving per annum: Rs 278 Lakhs /annum
Investment:
Cost : Rs 200 Lakhs
Pay back period : 7 months
Before:
Condensate from reboilers, tracing lines, etc was
drained to open channel.
After:
About 8T/hr of condensate is recovered and is
being used in generation of steam and in desalter
as wash water
Results:
Energy saved per annum : 400 SRFT /
annum
Cost saving per annum : Rs 66 Lakhs /annum
Investment:
Cost : Rs 226 Lakhs
Pay back period : 3.4 Years
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c) Calcium Silicate Insulation in Process lines in DCU
d) Installation of FRP blades
Before:
Loss of heat due to old glass wool insulation
between exit of furnace & inlet of coke chamber.
After:
Net reduction of ~5
o
C in temperature drop after
application of calcium silicate insulation
Results:
Energy saved per annum : 180 SRFT /annum
Cost saving per annum : Rs 29 Lakhs /annum
Investment:
Cost : Rs 42 Lakhs
Pay back period : 1.5 Years
Before:
The fans have been ftted with solid GRP blades
accounting for higher power consumption.
After:
Installation of FRP blades resulted in net 25%
power reduction.
Results:
Energy saved per annum : 100 SRFT /annum
Cost saving per annum : Rs 16 Lakhs /annum
Investment:
Cost : Rs 7.8 Lakhs
Pay back period : 5 Months
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f) Installation of Closed Draining Vessel at OM&S for HSD
Before:
Corrosion in two cast iron modules of APH which
lead to poor heat transfer.
After:
The modules were replaced which resulted in
increased heat transfer there reducing heat loss in
fue gas.
Results:
Energy saved per annum : 218 SRFT /annum
Cost saving per annum : Rs 36 Lakhs /annum
Investment:
Cost : Rs 54 Lakhs
Pay back period : 1.5 Years
Before:
The oily water sewage from HSD tanks were
drained to OWS line and then treated in ETP.
After:
Installation of closed draining reduced load to ETP
there by reducing slop generation in the refnery.
Results:
Energy saved per annum : 50 SRFT /annum
Cost saving per annum : Rs 8 Lakhs /annum
Investment:
Cost : Rs 15 Lakhs
Pay back period : 1.9 Years
e) Replacement of corroded APH in CDU
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Energy Conservation Plans and Targets
Energy Conservation Plans and
Targets for 2007-08
Anticipated Savings Approximate
Investment
(Rs. Lakhs)
Energy Value
(SRFT/ YR)
Rs. Lakhs
1 Flare Gas Recovery 1881 318 123
2 Replacement of old fuel gas & fare
control valves to Zero leak Class-VI
type control valves.
168 28 70
3 Modifcation in the Refnery Fuel
gas Network.
200 34 10
4 INDMAX Unit Heat Integration 500 84 75
7 FRP Blades for CT/Air cooler Fans
(29 Nos)
183 30 33
9 Steam leak reduction by replacing
defective traps
150 25 30
10 Replacement of DEA with MDEA 25 4 3
11 Calcium Silicate Insulation in
balance high temperature process
lines of Refnery
175 29 22
12 Installation of Plug Valves in HSD
tanks at OM&S
45 7 35
13 Step less Control in MUG
compressor of HDT
649 106 141
Total 3976 651 542
Environment and Safety
The Refnerys concern for Environmental Protection is demonstrated by full compliance of MINAS
(Minimal National Standard) specifcations with respect to quality and quantity of its treated effuents. A
modern Effuent Treatment Plant (ETP), full fedged Pollution Control Laboratory and the strategy for
maximising reuse of treated effuent in the refnery ensure adherence to such exacting standards. The
balanced treated effuent is fnally discharged into river Brahmaputra. The emissions from the Refnery as
well as ambient air quality in the Refnery fully comply with the notifed standards.
Safety
Safety is accorded the highest priority at all times. Refnery has a well-equipped Modern fre station with
elaborate fre protection facilities covering the entire Refnery. Gas Detection System and automatic
water sprinkler are also provided in critical areas like LPG facilities.