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.
En-con Measures implemented 2016-17 Net Reduction
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
Energy Conservation Measures Implemented 2016-17
Sr. No.
En-con Measures implemented 2016-17 Net Reduction
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
Energy Conservation Measures Implemented 2016-17
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
SRU Flash Steam & Condensate Recovery
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
SRU Flash Steam & Condensate Recovery
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
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
Monitoring and Reporting Practices
Flare Monitoring:Energy Dashboard:
Unit EII
monitoring
Monitoring and Reporting Practices
Unit Specific Energy Consumption (MBN) monitoring graphic in DCS :
Monitoring and Reporting Practices
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