CII AWARD - IOCL-Haldia Refinery Presentation 2020 - rev-1€¦ ·

YEAR OF DIGITALISATION

Accelerating Efficiency, Empowering Growth

HALDIA REFINERYHaldia,West Bengal

S. N Name Designation Contact details

01 Mr. E Panthya Chief Manager Lead Presenter [email protected]: 9996140617

02 Ms. Lalitha Rani Assistant Manager Member [email protected]: 9679833427

03 Mr. Amit Kalyan Chandra Assistant Manager Member [email protected]: 9432946618



1.Brief Introduction on

company/unit



HALDIA REFINERY OVERVIEW

SN Attribute Remarks

1 Foundation Stone laid

by Late Prof. Triguna Sen, Hon’ble Petroleum Minister on 6th Dec 1969.

2 Area 583 Acres

3 Commissioned in January 1975

4 Located at Haldia, Medinipur (E) District of West Bengal, 130 km from Kolkata.

5 Employees 1529

6 Crude capacity 8.0 MMTPA crude capacity(Capacity revamp for 8 MMTPA done in Jan’20)

7 Crude imported from

Saudi Arabia, Iran, Iraq, UAE, Nigeria, Angola, Malaysia, Kuwait, America and Indigenous crudes



HALDIA REFINERY OVERVIEW

SN Attribute Remarks

8 Crude BasketArab mix, iran mix, basrah, Kuwait, das, mars, Ural, Maya, Girasol, Clov, Bonny Lt, Labuan AkPO, Bonga, Kissanje, Miri, Agbami, Seria Lt, Murban-LS,WTI midland, Egina, Escravos, Mondo.

9No of process plants

34 Nos (CDU1/2,VDU1/2,DCU,OHCU,FPU,RFFCU,DHDS, MHC, CGOT, HGU-1/2, CRU,KHDS, MSQ-ISOM,PRIME-G, LHFU, CIDWU,FEU,PDA,VBU, SRU2/3/4/5, SWSs, ARUs ETPs1/2 etc..)

10 CPP capacity

4 STGs:48 MWh 4 Boilers : 525 TPH3 GTs:60 MWh 3 HRSGs : 360 TPHTotal Power :108 MWh Total Steam : 885 TPH

11Total storage tanks

198Nos

12Despatchfacilities

PPL, Rail, Road, Coastal (Barge, tanker), Bitumen bulk loading and drum filling

13 ProductsMS, HSD, Kero, ATF, MTO, JBO, Naphtha, Bitumen, Bitumen emulsion, 5 grades of LOBS



HALDIA REFINERY-Block Flow Diagram

->Stream sharing among the process plants for manufacturing final products like LPG, MS, HSD, Kero, ATF, Bitumen etc..

-> DHDT is under commissioning stage

-> H2SO4 plant erection started



2. Production Data

&

Energy Consumption Overview



PRODUCTION DATA OF LAST THREE YEARS FY 2017-2020

7655 7965

6463

1293 1432 1240

3827 4135

3221

1535 15811193

166 174 810

1000

2000

3000

4000

5000

6000

7000

8000

9000

2017-18 2018-19 2019-20Year

Crude T'put Light distillatesMiddle Distillates Heavy end distillatesLOBS

Light Distillate includes:Production of LPG, Naphtha, MS.

Middle Distillate includes:Production of ATF, MTO, SKO, HSD, JBO.

Heavy end Distillate includes:Production of FO, Bitumen, Coke & Sulphur.

LOBS: H70,H150 Gr-2/3,H500,150BN

Figs in TMT

• Crude processed in FY2019-20 was less due to revamp shutdown of crude processing unit for capacity enhancement to 8 MMTPA



THERMAL AND ELECTRICAL ENERGY CONSUMED IN FY 2019-20

20.8%

29.9%

5.2%

36.8%

0.1%7.2%

Thermal Energy Consumption FY 2019-20

Fuel Gas, Naphtha,

Puge Gas, Fuel Oil

HSD, Coke,

Purge Gas

Fuel Oil

HSD

COKE

Fuel Gas

Naphtha

Note: Figs in % of total thermal energy consumed in Million Kcal

Electrical Energy consumption: 485 Million kWh

Overall Energy Consumption(Thermal + Electrical): 574031 TOE.

• Major sources of fuel are Fuel oil,

naphtha and fuel gas

• Catalyst coke burnt in regenerator

of RFCCU is used for catalyst/feed

heating to reaction temperature

505 Deg C



3.Energy Consumption in

last 3 years (FY 2017-20)



OVERALL ENERGY CONSUMPTION OF LAST THREE YEARS FY 2017-2020

YearSp energy consumption

Annual TOE

% improvement

Reason for variation

2017-18 80.7Lower secondary units utilization due to total refinery shut down for taking DYIP project (DCU,CGOT,MHC,SRU-5) hookups.

2018-19 76.4 -5.33Higher crude unit & secondary utilization with higher energy savings schemes about 18370 SRFT implementation.

2019-20 88.7 16.10Higher due to delay commissioning of DYIP units , capacity revamp of CDU-1/VDU-2/MSQ/HGU-2 and OHCU/CIDW M&I. Lower crude capacity utilization(86%)

80.776.4

88.7

49.0

59.0

69.0

79.0

89.0

99.0

2017-18 2018-19 2019-20

MB

N -

>

Year

Actual New MBN MBN(SEC)=Million BTU/1000 Barrels/NRGF

NRGF= Equivalent Crude intake for all refinery units in KL/Crude processed in KL



BLOCK WISE ENERGY CONSUMPTION OF LAST THREE YEARS FY 2017-2020

1340328

947228

1878928

1291257

431761407374

Million Kcal in FY 2017-18

Fuel Oil Block Lube Oil Block

DHDS block OHCU block

CPP Offsite

1320880

899072

2063476

1515030

428112448131


Fuel Oil Block Lube Oil Block

DHDS block OHCU block

CPP Offsite

964068

555946

1432317850665

417985

546210177150


Fuel Oil Block Lube Oil BlockDHDS block OHCU blockCPP OffsiteDYIP

SN Block/section Process Units

1 Fuel oil Block CDU-1/2,KHDS,CRU

2 Lube Oil block VDU-1,PDA,FEU,CIDWU,LHFU

3 DHDS Block DHDS,VDU-2,MSQ, ARUs, SRU2/3/4, RFCCU

4 OHCU Block HGU-2,OHCU

SN Block/section Process Units

5 DYIP DCU, CGOT, MHC, SRU-5, SWS, ARU

6 Captive Power plant(CPP)

Boilers, STGs, GTs, HRSGs

7 Offsite Storage, Feeding, Despat(TTL, PPL, TW, Jetty, Barge)



4. Energy bench marking

and Road map



SPECIFIC ENERGY CONSUMPTION (SEC/MBN) ROAD MAP

88.73

76.5372.89 70.90

49.0054.0059.0064.0069.0074.0079.0084.0089.0094.00

2019-20 2020-21 2021-22 2022-23

MB

TU/B

bl/N

GR

F

Year

MBNSN PAT cycle

Base line MBN

Target MBN

Actual achieved

1 PAT-2 78.95(FY2014-15)

73.61(FY2018-19)

76.087(FY2018-19)

2 PAT-6 76.087(FY2018-19)

70.87(FY2022-23)

Projected Year Wise SEC/MBN Reduction

SEC Reduction Target given by BEE(MOPNG)

SEC reduction in PAT-2 cycle was 3.2% w.r.t baseline.

Couldn’t achieve target as DYIP commissioning done in Sep’19 against planned in FY2018-19

Total annual TOE reduction planned to achieve PAT-6 SEC/MBN target is: 60442 TOE



MAJOR ENCON PROJECTS PLANNED IN FY 2020-21

S. N ENCON SchemeEnvisaged TOE/Yr

01 Recovery of Hydrogen(550kg/h) from Refinery Off-gases 6600

02 Waste Heat recovery from HRSG blow down 676

03Hot feed to KHDS unit at 70°C directly from B/L & Increasing the Pre-heat by 3-4°C thus reducing the Furnace Duty

150

04 Maximizing Feed Preheat Temperature in NHT (CRU) unit 550

05 Installation of fan less cooling tower in GT 250

06Excess air optimization of the Heater 16-F-01/F101,31-F-01/F-02 by installation TDLS analyzer

660

Total 8886



YEAR WISE ENERGY SAVING SCHEMES PLANNED IN 2021-22

S.N ENCON SchemeEnvisaged TOE/Yr

01 Routing of UCO to RFCC as hot feed 650

02Crude Preheat Temperature Improvement by Pinch Analysis and modifications in Preheat train in Crude Distillation Unit II (CDU II)

6000

03 Steam network reduction by 40TPH from present consumption of 470 TPH 23700

04 Flaring gas recovery from RFCCU Gascon section through modifications 2000

Total 32350



YEAR WISE ENERGY SAVING SCHEMES PLANNED IN 2022-23

SN SchemeEnvisaged TOE/Yr

01 Heat Recovery from SR & IO Product Rundowns in VDU I 650

02 Routing of hot VR from VDU-I (during HS mode) to DCU 1556

03 Low End Heat Recovery From Exhaust Gases of DHDS/CIDWU furnaces 400

04 Installation of LRVP in last stage of ejector in VDU-2 3000

05 Implementation of RLNG in boilers/Fired heaters/HGU-1/HGU-2 6000

06 About 10 TPH Condensate recovery from open loop steam traps 5500

07 Switch De-isohexaniser Reboiler in the ISOM Unit from MP Steam to LP Steam (KBC-PR) 700

08 Power Recovery Train (PRT) – in Regen flue gas (KBC best practices) 900

09 Use O2 rich outlet gas from N2 plant in regenerator to increase the efficiency (McK-PDR) 500

Total 19206



5. Energy projects

implemented in last 3

years (FY2017-20)



SUMMARY OF ENERGY SAVING PROJECTS IMPLEMENTED IN LAST THREE YEARS FY 2017-20

YearNo. of

ProposalsInvestments in Rs Million

Savings, Rs Million

2017-18 14 90.82 432.63

2018-19 07 51.15 187.39

2019-20 07 14.56 112.55

Major energy saving project implemented in last three years:

Installation of CDU-II MF & LGO Stripper column internals and LGO CR Exchanger : Investment made:5.7 Cr Annul saving 4500 TOE

CDU-2 Main Fractionator is operated at high pressure due to the limitation in internals which isleading to substantial slippage of LGO product in RCO (Recovery @ 366°C approx. 25-30vol %). Also,due to the limitation in the pump around duty of LGO CR, reflux ratio requirement is high tominimize Naphtha generation within the limit of overhead water dew point.(Details covered in Innovative projects slides):



ENCON PROJECTS IMPLEMENTED IN 2017 - 18

S.N Project description RemarksInvestment in

Rs MillionsSavings

Rs Millions

Payback period in Months

01

Improving the performance of WGC ofRFCCU turbines by upgradation of CCCto CCC+ for better and finer anti-surgecontrol

MP Steam saving 3 T/hr 0.50 35.33 0.17

02Tuning and upgradation of CCC to CCC+for better and finer anti-surge control(blow out valve-BOV) in MAB of RFCCU

MP Steam saving 5 T/hr 5.73 62.82 1.10

03

Reduction of WGC turbine load byabsorption of heavier components fromMF off gases by washing withHCN+debutanizer bottom

Power saving 47 KWh 0.50 1.95 3.07

04Installation of CDU-II MF & LGO StripperInternals and LGO CR Exchanger

Low pressure operation (FlashZone pressure reduced from 2.9 to2.6 kg/cm2) & Reduction in RCOyield (~3.0 wt% in both LS & HSmode)

56.51 105.99 6.40

05Cleaning of 8 No’s of Pre Heat Exchangers 11-E-10 A/B/C/D (Crude vs. RCO) & 11-E-05 A/B/C/D (Crude vs. Kerosene CR)

Improvement of ~10 °C is observed in CDU-1 Preheat post unit start-up.

1.60 50.87 0.38





Rs MillionsSavings

Rs Millions


06

Cleaning of 7 No’s of Pre Heat Exchangers 16-E-13 A/B/C/D (Crude vs. LGO CR), 16-E-114 A&C (Crude vs. RCO) & 16-E-11B (Crude vs. LGO)

Improvement of ~10 °C is observed in CDU-2 Preheat post unit start-up.

1.40 60.06 0.28

07Convection Zone & APH Cleaning of 16-F-01 & 16-F-101 furnaces

16-F-01 Stack temperature reduced by 65 °C (from ~250 °C to ~175 °C)

0.20 18.84 0.13

08Pre heat Exchangers 31E-6AC/7/122AB cleaned

Improvement of ~10 °C is observed in VDU-1 Preheat post unit start-up.

0.24 24.73 0.12

09 Replacement of leaky APH of 31-F-02Stack temperatures reduced by 25°C from 240 to 215°C

22.94 3.76 73.30

10Fouled HEx 37E-01A/B/E/F cleaned in VBU

CIT improved by 20°C from 273 to 293°C

0.80 14.30 0.67





Rs MillionsSavings

Rs MillionsPayback period

in Months

1132F01 furnace convection and radiation zone external cleaning

Reduction in stack temp by 60°C from 455 to 390°C

0.20 7.76 0.31

12Savings of Energy by routing of atomizing air cooler hot DM water directly to De-aerator in GT-2

savings in LP steam - 1.71 T/h, stopping pump - 3.7 KW, cooling water - 130 m3/h

0.10 23.44 0.05

13GT – 1 Atomizing Air cooler hot DM line up to De-aerator 0.10 18.07 0.07

14

HRSG Boiler Feed line up was done from only one De-aerator by opening BFW discharge interconnection between both De-aerators

stopping pump - 220 KV NIL 4.71 -

Total 90.82 432.63

• All the planned schemes could be executed and implemented due to total refinery shutdown





Rs MillionsSavings

Rs Millions


1H2 Recovery from OHCU HP Rich Amine (H2 recovery potential is 75.47 Kg/h equivalent to 0.6 MMTPA)

Equivalent Energy savings against H2 recovered 49.70 7.62 78.23

2Stoppage of Stripping steam to LGO & HGO stripper in CDU I

Stripping Steam to LGO: actual savings 580 kg/hr vs. envisaged 760 kg/hr

NIL 12.10 -

3Stoppage of Stripping steam to LGO & HGO strippers in CDU II

Stripping Steam to HGO: actual savings 300 kg/hr vs. envisaged 685 kg/hr

NIL 6.30 -

41% Improvement in Boiler-4 Efficiency by Insulation Repair

Insulation repaired during M&I 0.50 46.64 0.13

5Survey of PSV/CV connected to flare for identification of passing valves

Passing valves Identified and rectified: 47 no's with total passing flow 42.16 T/day 0.36 105.41 0.04





Rs MillionsSavings

Rs Millions


6 ARC for Compressed Air leak Total air leaks Identified and rectified: 700 no's with flow 1485.7 Nm3/hr 0.39 8.45 0.55

7 ARC for Nitrogen leakTotal air leaks Identified and rectified: 28 no's with flow 67.44 Nm3/hr, 0.20 0.87 2.77

Total 51.15 187.39




S.N Project descriptionInvestment

in Rs MillionsSavings

Rs Millions


1 Replacement of 30 nos of LT motors with energy efficient motors 2.30 2.83 9.76

2Excess air optimization of the Heater 11-F- 01 by replacement of O2 Analyzer with TDLS O2 analyzer

1.46 40.81 0.43

3Excess air optimization of the Heater 82-F- 01 by replacement of O2 Analyzer with TDLS O2 analyzer

1.46 2.76 6.35

4Excess air optimization of the Heaters 91- F-01 and 91-F-02 by replacement of O2 analyzer with TDLS O2 analyzer

2.92 14.06 2.49

5 Recovery of steam/condensate loss in refinery complex,20TPH 0.50 19.30 0.31

6 Tube inserts for 2 no’s of HE of CDU-II. 5.92 19.69 3.61

Total 15.16 112.55



6.INNOVATIVE PROJECTS

IMPLEMENTED IN LAST

THREE YEARS FY 2017-2020



INNOVATIVE PROJECT- 01

Name of the Project: Reduction of CDU-II MF column pressure by installation of high efficiency trays in MF & LGO Stripper during Dec’17 TRSD to recover more LGO.

Brief Description: CDU-2 Main Fractionator was operated at high pressure @ 1.9- 2.1 kg/cm2 due to the limitationin MF internals which is leading to substantial slippage of LGO product in RCO (Recovery @ 366°C approx. 25vol %).

Benefits of Low pressure operation of CDU-II MF column:

Better RCO recovery

Increase in Middle distillate (SKO+LGO)

Lower Pressure drop

Reduced flaring




Modifications carried out:

• Replacement of CDU-II MF & LGO stripper internals, supplied by M/s Sulzer)•Total 16 no. of trays, 3 packings, 2 distributors, Feed inlet device & 3 nozzle change in MF •Replacement of existing trays (05 nos.) with New Sulzer high performance trays •Two new LGO CR vs Crude exchangers (in PHT-III i.e. post PF PHT) to recover 3.7 MMKcal/h of heat from increased LGO CR flow




Benefits Achieved:

RCO recovery improved from 25-30 vol% to 12-16 vol%

Increase in Middle distillate (SKO+LGO) yield by 12 wt% (47 wt% against base level of 35 wt%)

Top pressure reduced from 2.1 to 1.5 kg/cm2

Annual Savings: 1060 Rs Lacs;

Investment made: 565.06 Rs Lacs




Name of the Project: Tube Inserts installation in CDU-II exchangers for preheat sustenance in Aug’2019

Problem: Frequent fouling of pre-heat exchangers resulting in loss of T’put and waste heat recovery

• Normally, heat exchangers in CDU-II are cleaned during every M&I shutdown and based on the survey donequarterly

• However, sustenance of performance and pre-heat availability from the cleaned exchanger is very short becauseof fast fouling

• Tube inserts installed in Pre-heat exchangers114A&C which are just before fired heaters

• Shell side fluid :Crude• Tube side fluid: RCO




Benefits of Installation of Turbotal:

• The on line rotation of the Turbotal due to fluid flow through tubes

• Mechanical effect against fouling

• Avoids the deposition of a thick fouling layer inside tube wall

• Reduced pressure drop

• The rotation of Turbotal increases the turbulence in the tube side flow

• Increased heat transfer coefficient on the tube side.

• Optimal use of the heat exchangers and reduces the outlet Delta T between Start of Run and End of Run.

HTC increased by 17-20% and sustained at higher than clean case.

Annual Savings: 240.34 Rs Lacs

Investment made: 59.22 Rs Lacs




Scheme: Utilization of GT1/2 Compressed air discharge cooler waste heat for DM water heating

Before ImplementationAfter Implementation

Investment made: Nil Implemented in 2017

Benefits:• Circulating Pump and

cooler removed• Reduced CW

requirement• Reduced CT load

Annual Savings: 29 Rs Lacs

dismantled



7.UTILISATION OF RENEWABLE ENERGY SOURCES



RENEWABLE ENERGY SOURCES – SOLAR ENERGY

Replacement of Electrical Energy with Renewable Energy

InstalledCapacity

(MW)

Annual EnergyGenerated in

2017-18(Million kW)


2018-19(Million kW)


2019-20(Million kW)

Solar (PV) - Onsite Gen 1.96 0.11 0.14 0.45

Sl No ZONES Location Installed Capacity (Kwp)

1 LOB 3A 20.5

2 LOBSS # 3 + 3

Ext61

3 offsite 4 414 offsite 6A 20.5

5 DHDS SS - 9 & 15 71

6 LOB 13 20.5

7 Offsite 14 20.58 DYIP 21 273

9 DYIP 22 50

10 DYIP 23 152

11 DYIP 24 9112 IMA TOWNSHIP 31

13 HOSPITAL TOWNSHIP 61

14KendriyaVidyalaya

TOWNSHIP 87

Total 1000

Sl No ZONES LocationInstalled Capacity

(Kwp)15 DHDS Reservoir-2 9016 OFFSITE CISF Barrack 5017 OFFSITE S/S-19 5018 FOB S/S-20 5019 FOB S/S-16 3020 LOB S/S-17 3021 OHCU S/S-18 200

Total 500

Installation location & capacity of solar panels:



8. WASTE UTILIZATION AND MANAGEMENT



WASTE MANAGEMENT

S.N Type of waste GeneratedQuantity ofwaste generated(MT/year)

Disposal method

2017-18

01 Spent RFCCU catalyst 1173

To secured landfill through PCB authorized TSDF(treatment storage and disposal facility) agency

02 Spent adsorbent 7.96

03Oil soaked waste mineral wool

210

04 Residual oily sludge 3350

2018-19

01 Spent RFCCU catalyst 1219To secured landfill through PCB authorized TSDF agency

02 Spent adsorbent 51.71

03Oil soaked waste mineral wool

221Incineration through TSDF agency


05 Residual oily sludge 4995For co-processing in CPCB authorized cement plant (Ambuja Cement)

06 Spent resin 22 To secured landfill through TSDF agency

07 Spent RO membrane 21 To secured landfill through TSDF agency



WASTE MANAGEMENT

S.N Type of waste GeneratedQuantity of waste generated (MT/year)

Disposal method

2019-20

01 Spent RFCCU catalyst 839To secured landfill through PCB authorized TSDF agency

02 Spent adsorbent 356

03 Oil soaked waste mineral wool 788Incineration through TSDF agency


05 Residual oily sludge 5923For co-processing in CPCB authorized cement plant (AmbujaCement)

06 Spent resin 9 To secured landfill through TSDF agency

07 Spent hydro processing catalysts 312 Through MSTC to authorized recyclers for metal recovery

Other Initiatives taken for waste utilization & management:1.Food Waste: Use of food waste based bio-gas generator with 500Kg capacity commissioned in Dec'19 for use in industrial canteen.2.Waste Paper: Annually about 1500kg waste paper donation to Vivekananda mission for manufacturing recyclable paper products like files, envelopes etc.3.Spent RO membranes: Utilization of spent RO membranes for barricading local water bodies and improving aesthetics.4. Bio-gas generator(100 kg capacity) : installed for use by Vivekananda school. Manure generated is used for horticulture purpose.



9. GHG INVENTORISATION



GHG (Absolute Emission trend)

2110364

22508082227456

2268021

2056554 2071648 20700892054633

2079000

1934698

1700000

1800000

1900000

2000000

2100000

2200000

2300000

2010-11 2011-12 2012-13 2013-14 2014-15 2015-16 2016-17 2017-18 2018-19 2019-20

GHG emissions MT of CO2 eq / Year



GHG EMISSION PER TON OF PRODUCT

YEARTotal product,TMT

Total (kgCO2 / Ton of Final Product)

Remarks

2016-17 6793 304.74

2017-18 6820 301.25

2018-19 7321 283.94

2019-20 5734 337.39CO2 emissions higher on account of lower capacity utilization of the refinery

Target (short term/long term) for CO2 emission reduction and action plan:

S.N SchemeCO2 emission reduction

Target Year for completion

01 Replacement of fuel oil with LNG 18900 2022

02 Recovery of Hydrogen from Refinery Off-gases 17325 2020

03 Hot feed to KHDS unit 472.5 2020

04 Fan less cooling tower installation in GT 787.5 2020

05 Crude Preheat Temperature improvement BY 9 DEG C in CDU-2 18900 2021

Total 56385



Continuous Ambient Air quality monitoring

Station inside Refinery to monitor SO2, NOx,

PM10, PM2.5, Ammonia, Benzene, Ozone and

CO. This data being shared online to CPCB

and SPCB server and at Refinery Gate

Unit Limit Refinery Township

PM10 µg/m3 60 42-55 30-44

PM2.5 µg/m3 40 25-35 16-22

SO2 µg/m3 50 8-15 5-8

NOx µg/m3 40 15-25 21-33

CO µg/m3 2 0.5-0.8 0.4-0.7

EMISSIONS DISCLOSURE TO PUBLIC



Stack emission parameters (SO2, NOx, CO and PM) are monitored online and SMS alert generated in case of any deviation.

STACK ANALYSER CONNECTIVITY TO CPCB SERVER



10. GREEN SUPPLY CHAIN MANAGEMENT



GREEN SUPPLY CHAIN MANAGEMENT

S.N Projects ImplementedAnnual

capacity, MMTPA

Year of commissioni

ng

Investment Made

(Rs In Million)Benefits Achieved Remarks

01LPG Pipeline Transfer facility ex Haldia Refinery to Paradip - Haldia-Durgapur

0.67 Sep’2019 28.3

Reduction in CO2 emissions by 12.5 Thousand metric tonnesannually

LPG is being dispatched to Budge Budge BP, Kalyani BP, Durgapur BP directly from Haldia Refinery in pipeline mode via PHBPL LPG pumping station.

02Haldia-Barauni petroleum products pipeline

3.40

Expectedcommissionin

g by FY 2022-23

128.0

Reduction in CO2 emissions by 99 Thousand metric tonnesannually

Presently under execution stage

Company has green purchase policy. Our recent purchase PO details mentioned below.

SN PO number Value/qyt/item Remarks

1 26444826 dated 08.06.2020 Rs. 307,000.00Motor with Efficiency Class - IE3 as per IS 12615(2011)& IS 15999 (Part 2/Sec 1) has been purchased



11. Team work, Employee Involvement & Monitoring



ENCON Monitoring System at Haldia Refinery

Monitoring Tools

PRO-II

HRTI

HeXmodel

Online steam leak reporting

system

Dashboard

Energy Audits

S.N Monitoring Activity

01Daily/Monthly ActivityUnit Specific Energy Consumption

02 Energy Intensive Equipment's – Heater, compressor performance

03 Steam let down, flare, Pressure recovery Turbine

04 Fuel & Loss

06 Specific Energy Consumption (MBN)

07 Energy Intensity Index (EII)

2. Daily/Monthly – Monitoring1. Monitoring Tools available



ANNUAL PROGRAMS ON CREATING AWARENESS ON ENERGY CONSERVATION

Annual budget for Energy conservation awareness: ~ 7 to 10 Rs Lacs

Celebrated every year: 16th Jan to 15th Feb

Street Plays in Local Community for spreading the message of Energy Conservation at various places viz Schools / Township Parks/MARKETS/colonies etc

Quiz Competition for School Students/ Employees /House wives

Walk Rally by school children, IOCL employees and CISF dependents

Energy Audit by CHT nominated persons

Training program by external faculty

Drawing competition for school students.



PROJECTS IMPLEMENTED THROUGH KAIZENS – SUPERVISOR LEVEL



PROJECTS IMPLEMENTED THROUGH KAIZENS – WORKER LEVEL



12. IMPLEMENTATION OF ISO 50001



IMPLEMENTATION OF ISO 50001

Energy policy exists Internal audit completed Pre-audit phase completed. Certification audit– expected completion by

Sep’2020

Total turnover of the refinery in FY 2019-20 (Rs. Million) 233198Amount invested in EnCon Projects FY 2019-20 (Rs. Million) 14.56Investment % 0.0062%

Total expenditure on energy projects since last 3 years (Rs Million) 156.52

EnCon Project budget allocation %



13. OTHER INNOVATIVE TECHNOLOGIES IMPLEMENTED



Scheme: Installation of fan less Cooling Tower for GT• Installation Cost : 1.05 Rs Cr• Flow:500m3/h• CT fan power:130KW• Construction almost completed, Commissioning expected in a month time

1.Installation of fan less Cooling Tower for GT

Advantages of Fanless Cooling Towers:• No frills • No fan required• The louvers are used as the side wall of the cooling tower to restrict the

water spillage.• The hot water sprayed in the top of the cooling tower with spray nozzles.• No huge amounts of noise• Minimum drift losses• Less maintenance cost• Pressure difference is created by water spray through nozzles, allowing

cool air ingress into the tower, hot air exit from the tower.

Fuel savings: 250 TOE/Yr



Use of Industrial Drone for monitoring Flare and furnace stacks for thermalimaging heat loss and insulation damage survey in FY2018-19

2.Use of drone for monitoring furnace and flare stacks for thermal imaging

remote visual inspection using unmanned drone

The drone utilized was equipped with high resolution visual as well asthermal imaging camera

Provides high quality image, video and thermograph of theinaccessible location of the tall structures.

For assessing the health condition of the flare tips, stacks andrefractory lining

Will help us plan for repair or replacement in more efficient manner.



Conventional O2 analyzers collect localized sample and Measure localized O2 readings

TDLS analyzers:

TDLS O2 analyzer measures cross sectional avg O2 %

Better accuracy of O2 reading and there by Furnace control Non contacting measurement Better control of excess air

TDLS analyzers installed in: CDU-1/CDU-2,VDU-1,VDU-2,OHCU furnaces in FY2019-20

3.Use of TDLS analyzers for furnace stack O2 measurement



14. LONG TERM VISION ON EE



LONG TERM VISION ON EE

Long Term Vision on Specific Energy Consumption(MBN): 55

Apart from Schemes mentioned earlier, the following are under discussion for reducing MBN further

S. N ENCON SchemeEnvisaged TOE/Yr

01 Boilers modification for efficiency improvement 10000

02Installation of hot separator in OHCU to produce M.P. Steam from Reactor Effluent & also reduction in reactor effluent air cooler duty

9300

03 Replacement of Full condensing Turbine of MAB to motor 12000

04 Replacement of Full condensing Turbine of WGC to motor 4400

05 Combined AVU instead of present 2 CDUs and 2 VDUs 55000

06 electrica heat tracing instead of steam tracing 4500

Total 95200



15. AWARDS & ACCOLADES



SN Name of award received Remarks

1 Won the Director (HR) Trophy for “Best CSR Unit” among 31 establishments across IndianOil at IndianOil CSR Conclave held at Digboi. FY 2019-20

2 Won “Best Swatch Establishment Award” for Refinery Division for outstanding contribution to Swatch Bharat Mission during Swatchhata Pakhwada. FY 2019-20

3 “TOLIC award” for 2018-19 in the field of best implementation of official language under aegis of Ministry of Home Affairs, Govt. of Indian. FY 2019-20

4 Haldia Refinery has won the prestigious “Suraksha Puraskar” (Bronze trophy & certificate) in Group –A under the manufacturing Sector from National Safety Council of India for the year 2016 on Thursday, the 20th April, 2017

5 Haldia Refinery has been conferred Best Performance Award in “Carbon Di-Oxide Emission” under Refineries without Natural Gas category. FY 2017-28

6 Haldia Refinery has been awarded OISD Award (2016-17) under “Refineries and other processing plant” category.

AWARDS & ACCOLADES



SN Name of award received Remarks

7 Received Golden Peacock Occupational Health & Safety Award-2016 by Institute of Directors

8 Received the prestigious National Safety Award – 2014 by DGFASLI, Government of India.

9 Received International Safety Award - 2016 achieved from British Safety Council with ‘Merit’.

10 Received CII Excellence Award in Safety with four Star rating, by CII Eastern Region.

11 Received 17th National Award for Excellence in Energy Management 2016 from CII on 24th Aug 2016 at Hyderabad

12 Haldia Refinery was recognized for best performance in Carbon dioxide Emission Awards (2014-15) under category of Refineries without natural gas on 7th Sep 2016 during 20th RTM at Gandhinagar.

13 Accreditation Certificate was issued by National Accreditation Board for Testing and Calibration Laboratories (NABL) on 18.10.2016 in the wake of the onsite assessment of Quality Control Laboratory,

14 First prize in the Oil & Gas Conservation Award for Furnace/ Boiler Insulation Effectiveness 2013-14

15 Conferred with Energy Conservation award 2012

16 Conferred with the Greentech Environment Excellence Award 2011 for environment management

AWARDS & ACCOLADES

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