best practices on energy conservation at iocl … · best practices on energy conservation at iocl...
TRANSCRIPT
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 Licensor Existing Unit Capacity, 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
Process Unit Licensor Existing Unit Capacity, MMTPA
Year of Commissioning
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-1 M/s. Sulzer Chemtec /IFP France
0.060 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
Process Unit Licensor Existing Unit Capacity, MMTPA
Year of Commissioning
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 TPD 30.06.2010 (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
Best practices
4) Online chemical cleaning of furnaces for sustenance of high T’puts T’put
Arch Temp
608 m3/h 672 m3/h 874 deg C
760 deg C
AU-5 FURNACE
Best practices 5) Fortnightly calculation of cheapest fuel and maximizing use of the same
Best practices 6) 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 GR1 AU1 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 practices 7) In house PSV leak monitoring system
VPAC II LEAK CALCULATION Rs. 323,510.21
UNIT Valve ID Description
Signal
Level
Up
Stream
Down
Stream
Pressur
e
Differen
ce
Inlet Size Leak
Rates Loss Loss Cost Per Ton
Total Loss
Per Valve Remark
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 4 7.5 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 6SDV5102 Reactor Depressurisation
SDV 5 6 5 220 2
0.0 $16,000.00 OK
FGH Depressurisation
valve For 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.911PC406.MV ON 11V4 5 5 5 19.88 2 0.0 $16,000.00 OK
MTBE GJA.911PC1303.MV ON 11V7 5 5 5 19.88 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 1.5 2.0 0.03 0.6 Rs. 79,800.00 Passing, isolated.
19
S.NO PARAMETER UOM F-3 Remarks
1 Excess O2 analyzer reading at Furnace arch
Vol % 4.5 Best achieved 3.9%
2 Stack temp Deg C 188 Best 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 flow Nm3/
h 20889
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 % 88.15 Against 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 practices 8) Daily Furnace survey
Major ENCON initiatives
S.N Name of Scheme Fuel Saving (SRFT/Yr)
Completion Schedule
1 Installation 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
3 Stoppage 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’16 5 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
7 Rectification 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
9 Stopping 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’17 11 Stoppage of TPS old CT pump (110 KW) 150 Mar’17
12 CCRU NHT stripper column pressure reduced by 1.0 kg/cm2-g for reducing reboiler load and MPS savings
500 Oct’16
13 CRU NHT stripper column pressure reduced by 2.0 kg/cm2-g for reducing reboiler load and MPS savings
750 Oct’16
Major ENCON initiatives
S.N Name of Scheme Fuel 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
17 Idling of UDEX unit and importing benzene from Panipat refinery. (Fuel = 32.5 MT/day, Power = 0.5 MW)
12651 Nov'16
18 Provision of bypass controller for NG firing in HGU-3 reformer in order to reduce flare loss in PSA-2
5913 Jan'17
19 FCC 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
Major ENCON initiatives
Future ENCON initiatives
Sr. No. Name of Scheme Completion
Schedule Fuel 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
5 Parallel 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
9 To 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
10 AU-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
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