Bharat Oman Refineries Limited (BORL)

Transcription

1 18 th National Award for Excellence in Energy Management 2017 Bharat Oman Refineries Limited (BORL) Bina, Madhya Pradesh Nilesh Zode, Nitin Tripathi, Ashish Rai

2 BORL Facilities at a Glance 1 Single Point Mooring (SPM) at Vadinar VLCCs BORL JV company of BPCL & Oman Oil Company (OOC) 4 6 MMTPA Refinery at Bina Crude Oil From Middle East Delhi 2 Crude Oil Terminal & Pumping System (COT) Vadinar Vadinar Kota Bina BPCL Marketing Terminal Numaligarh Refinery 5 Bina Despatch Terminal (BDT) 3 Vadinar- Bina 935 km Crude pipeline (VBPL) Mumbai Refinery BPCL Refineries Crude pipeline 6 Bina-Kota pipeline (BKPL) linking BPCL s existing piping network (265 km) Kochi Refinery Product pipelines Advantageously placed to meet product requirements in high demand zone

3 Refinery Configuration Complex configuration, proven technologies, mid-distillate refinery Commercial production started - Jun 2011 Refinery Process Process Capacities CRUDE CDU VDU RCO O VD LVGO HVGO GO MS-BLOCK HCU + DHT GAS LPG NAPHTHA SKO ATF HSD Euro-III HSD Euro-IV MS Euro-III MS Euro-IV Units Capacity (MMTPA) Capacity (BPSD) CDU/VDU FCHCU DHDT DCU Hydrogen Unit 0.07 Process Licensor ABB Lummus Technology DELAYED COKER VR LCGO HCGO & C Naphtha H 2 HYDROGEN SOUR GAS SULPHUR BLOCK SULFUR NHT CCR PENEX POWER PLANT PETCOKE SOUR WATER Sulphur Recovery Unit 2 x 180 TPD Nelson Complexity Index 9.1 An ISO 50001:2011 EnMS certified company

4 Captive Power Plant General Overview CFBC Boilers MADE BY: BHEL CAPACITY: 3 X 275 MT/hr VHP steam 110 Kg/cm 2 (Petcoke) CFBC Boilers 3 Nos To Refinery 3 X 33 MW STEAM TURBINE GENERATOR STGs From Grid (220kv) Utility Boiler Net 160 TPH Power Steam INSTALLED CAPACITY 99 MW 985 TPH IMPORT FROM GRID CAPABILITY 100 MW HP steam 40 Kg/cm 2 MP steam 18 Kg/cm 2 LP steam 5 Kg/cm 2 To Refinery

5 En-Con Projects in last 3 yrs Year No. of En- Con Projects Implemented Fuel Oil (MT/Yr) Savings Rs Lakhs/Yr Investment Payback Period Rs Lakhs Months No. of ZERO INVESTEMENT En-Con Projects Total Any small saving in energy significantly impacts OP-Ex 4

6 Energy Conservation Measures Implemented Sr. No. En-con Measures implemented Power Consumption reduction: I. CDU - Single fan operation in CDU Heater FD Fan Net Reduction kw 85 II. MSB - Single fan operation in HOH Heater FD Fan 30 III. HCU - Stopping of Sour water Pump 16-PA-CF-813 A/B 9 1 IV. DHT - Parallel pump operation converted to single pump in product stripper reflux pump (701 A/B) & Fractionator bottom pumps 705A/B 280 V. Refinery CT - Low weight coupling installation in one of the refinery cooling tower fan 0.3 VI. VII. Township 244 nos 18w CFL replaced with 9w LED bulb, 63 nos 36w Tube light replaced with 20w LED tube light BDT Solar Power Generation Started Total Power Reduction 641

7 Energy Conservation Measures Implemented Sr. No. En-con Measures implemented Steam Consumption reduction: I. ARU - Amine regeneration column LP steam reduction to 41 TPH from 45 TPH by optimization Net Reduction TPH 3.2 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 0.3 IV. SRU - Implementation of Flash steam and Condensate recovery System. 2.1 TPH flash steam & 2.2 TPH condensate is being recovered. 0.5 V. HCU - RGC Lube Oil Turbine leak off steam routed to LP steam header, saved 0.5 TPH steam 0.2 Sub Total 4.3

8 Energy Conservation Measures Implemented Sr. No. 2 En-con Measures implemented 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. Net Reduction TPH Total Steam Consumption Reduction 6.1 Insulation Improvement reduction: FO MT/day 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 Total Fuel Consumption Reduction 1.3 Equivalent Fuel Oil saving ~ 5439 MT/Yr ~ 1565 Rs Lakhs/yr

9 Energy Conservation Plan: FY Sr. No En-con Plan FY Implementation of Flash steam & Condensate recovery System in SRU. Investment Rs Cr, Planned & Completed in Implementation of Steam System Management in Refinery. Investment Rs Cr, Planned & Completed in CDU heater efficiency enhancement by implementation of VDU hot well gases conditioning system. Investment - 10 Rs Cr, Plan Installation of Power Recovery Turbine in Hydrocracker 1st stage reactor feed pump. Investment - 13 Rs Cr, Plan Installation of step less control in Make Up Gas compressor Investment - 19 Rs Cr, Plan Installation of LP steam generator in Hydrocracker light diesel product stream. Investment Rs Cr, Plan Installations of Crude Preflash drum in CDU to increase energy efficiency. Investment - 25 Rs Cr, Plan Implementation of Flare Gas Recovery System. Investment - 10 Rs Cr, Plan Est. SRF (MT/day) Total Investment 84 Rs Cr (0.5% of Turnover), Total Saving Potential SRFT/day

10 MBN MBN Specific Energy Consumption (SEC) Refinery Specific Energy Consumption measured in MBTU/BBL/NRGF (MBN) SEC of BORL Q SEC of Indian Refineries Indian Refineries Source: PPAC, BEE, CII website

11 Specific Energy Consumption (SEC) - Electrical & Thermal Refinery Specific Electrical Energy Consumption is expressed in kwh/mt of Crude Processed Specific Electrical Energy Consumption kwh/mt of Crude Processed Specific Thermal Energy Consumption kj/kg of Crude Processed Refinery Specific Thermal Energy Consumption is expressed in kj/kg of Crude Processed

12 Solomon Benchmarking : Energy Intensity Index (EII ) Participating in Solomon Benchmarking since 2014 every alternate calendar year EII 92 indicating substantial improvement in energy performance of BORL Implementation of Encon Measures Plan FY will bring EII to 88 Q1 11

13 Innovative Project 1: SRU Flash Steam & Condensate Recovery 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. 12

14 Innovative Project 1: Implementation SRU Flash Steam & Condensate Recovery Project : 1. 1 New Power Pressure Pump is installed to transfer Jacketing condensate 2. 2 New Flash Vessel installed to generate flash steam from collected cond Thermo-compressor is installed to Upgrade LLP to LP steam 4. Pump & Hydrocarbon analyser is provided in condensate transfer header

15 Innovative Project 1: Benefits SRU Flash Steam & Condensate Recovery LP steam being recovered 2.1 TPH, Savings 3.8 Rs Cr/yr Condensate being recovered 2.3 TPH, Savings Rs Cr/yr Fin Fan Power consumption reduced 18.5 kw, Savings 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 14

16 Innovative Project 2: Capacity Enhancement in Net Gas Compressor in CCR Platformer unit for energy saving 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 SQUEEZING COMPRESSION Metal Seated Clearance Pocket identified as culprit 15

17 Innovative Project 2: Capacity Enhancement in Net Gas Compressor in CCR Platformer unit for energy saving Benefits : Discharge capacity increased ~ 22%, Single compressor operation at Plant throughput of 148% Power consumption reduction kw, 3.6 Rs Crs/yr Investment Rs Cr, Pay Back ~ 1 Month CO2 Emission reduction 5405 t CO2/yr Reduction of oil consumption 0.26 Rs Cr/Yr Modified Cylinder Head without clearance pocket In house implementation of project ORIGINAL COMPRESSION ACHIEVED SQUEEZING COMPRESSION CLEARANCE POCKET BLINDED Rated Capacity achieved, Switched to Single Compressor above 125% 16

18 Innovative Project 3: Operation of SINGLE Forced Draft (FD) fan in Fired heaters 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 17

19 Innovative Project 3: Operation of SINGLE Forced Draft (FD) fan in Fired heaters 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 Heater Savings Power (kw) Rs Lakhs/Yr t CO2/Yr VDU Heater CDU Heater HOH Heater HCU Heater Total CO2 Emission Reduction 18

20 t CO2e/ t of crude thruput GHG emission inventory trend t CO2 emission is calculated based on ISO methodology (3090 TMT) (3343 TMT) (3240 TMT) (2492 TMT) ~ 30% reduction in Specific CO2 emission in 4 years Effective Energy Management system, implementation of En-con measures & green initiatives helped BORL in reducing GHG emission. 19

21 Energy Management Team 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 atapex level Encon Project Management Team is a cross functional team

22 Energy Conservation Project Management Prioritisation OFI Hopper Quick Wins Short Term Long term / Project Basis - Payback Immediate / ZERO Invest. 0 6 Months / Small Invest Months / Large Investment

23 Monitoring and Reporting Practices Sr. No. Energy Performance Indicators 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 Monitoring Frequency 10 Hydrocarbon Loss Accounting Daily/ Monthly To manage we have to control and to control we have to measure

24 Monitoring and Reporting Practices Energy Dashboard: Flare Monitoring: Unit EII monitoring

25 Monitoring and Reporting Practices Unit Specific Energy Consumption (MBN) monitoring graphic in DCS :

26 Monitoring and Reporting Practices Refinery Energy Balance Monitoring : Daily 02-Aug-17 Energy Demand, M Btu/day Energy Supply Unit Name MBN (MBTU/BB L/NRGF) EII (D*100/E) Target Energy (E) Actual Energy (D=A+B+C) Fuel (A) Power (B) Steam (C) Gap (Target- Actual) Source M Btu/ day Unit Produced Fuel Unit Purchased Power 9294 Unit Coal 739 Unit Petcoke Unit Power for nonrefinery operation Unit Unit Unit Unit Unit Unit Unit Unit Unit Unit Unit Unit Total Energy Supply REFINERY Total Energy Demand Energy Balance % 99.94

27 ISO 50001:2011 Energy Management System (EnMS) Certification 26

28 Renewable Energy Sources: Initiatives at BORL 4 MW Solar Power Plant at BORL generating 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.

29 Renewable Energy Sources: Initiatives at BORL Installed 8x500 & 2x1000 LPD ETC based Solar Water heating system for providing preheated water to bathing purpose, saves units/yr, Installed Solar Power based electric fencing to refinery as well as township boundary wall of 22 kms for security purpose. Invest 2 Rs Cr 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.

30 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

31 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. Utilisation of waste gas as fuel saved SRFT of Fuel in 4 years Petcoke called as crude bottom product is being used as fuel in Circulating Fluidised Bed Combustion (CFBC) technology based Boilers.

32 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

33 Best Practices Implemented on Energy Front in Green Supply Chain: Manufacturing & Storage : Use of energy efficient design - max m 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.

34 Thank You BORL Fuelling Nation Bringing Cheers Lowest Steam Leak award in OGCF 2015 from CHT MoP&NG at 20 th Refinery Technology Meet Bhamashah Award - MP NHRDN CSR Competition-2016 award An ISO 9001, 14001,18001 & company Frost & Sullivan Award for Environment & Op Excellence Leadership Project