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
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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
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.
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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
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