naphtha stabilizer to NSU may be examined as being practiced at other refineries. IOCL Digboi has already initiated action. Scheme is under study by M/s Mott Macdonald for feasibility 2 Delayed Coker furnace coil outlet temperature is 495C, whereas coke drum inlet temperature is 479 C. Insulation job to be implemented. PO Placed for job
3 Higher Steam Carbon ratio is maintained at 4.05 against a design value of 3.0 in HGU reformer due to hot spots in two no of reactor tubes. Action has been initiated to replace the catalyst for reduction of steam consumption. Implemented in Jun12 Savings achieved : 310 SRFT Current S/C ratio is 3.84 SN Schemes Action Plan 4 Preheat in CDU was found below the design value. Heat exchanger survey including temperature, pressure and flow may be carried out to ascertain the reasons for lower preheat. Digboi refinery has already carried out a pinch study through external agency which indicates scope for improving the pre-heat and implementation being planned. Proposal is under management approval.
5 Stripping Steam rates for LK, LGO were observed to be in the range of 18 kg/M3 of product to 20 kg/M3 of product; Vs. normal recommended of about 15 kg/M3 (maximum 18 kg/M3). Stripping Steams shall be optimized and maintained within the range. Stripping steam at LGO stripper has been stopped in Jul12. Stripping steam at LK stripper is maintained at 15-15.5 Kg/M3 of product. Savings achieved : 35 SRFT
SN Schemes Action Plan 6 Crude column bottom temperature was 327 C, whereas RCO temperature at Vacuum heater inlet was 320 C. Reason for temperature drop shall be analyzed as locations of TIs are nearby. Line is already insulated with Calcium Silicate. 7 Steam condensate is being used as wash water in the desalter, where as the desalter effluent water is cooled by cooling water. Normally in other refineries sour water from crude and vacuum overhead is used as wash water. Use of sour water in place of steam condensate and feasibility of preheating wash water with desalter effluent may be explored. This scheme is implemented. Currently sour water from CDU column is routed to desalter. SN Schemes Action Plan 8 Combustion air temperature is observed to be at 144 C which is on lower side (AVU). Modification job in control system for partial stack damper opening initiated. Currently stack damper of both CDU as well VDU are closed. 9 Ejector steam in VDU, for creating pressure 32 mmHg at column top, is around 8.5 MT/Hr which is very high. For BPCL Kochi the amount of steam required is 10 TPH for creating a pressure of 5 mm Hg for crude capacity of 5 MMTPA. Ejector system may be examined and option of vacuum pump may be explored. Feasibility study by Mar13 10 RVP of SRN to be checked periodically to ensure that no light ends are being carried over, and to avoid flaring from NSU. In practice SN Schemes Action Plan 11 DCU furnace is a natural draft furnace. Flue gas / stack temperature is about 224C and excess oxygen is around 7% as checked by portable analyzer. Possibility of heat recovery from flue gases to be explored. This proposal is not found feasible due to high payback. (With improved burner performance current stack temp lowers to 210 o C) 12 At DCU cooler inlet temperatures of LDO & CFO were found to be 140 & 190 C respectively. Possibility of heat recovery may be explored. Cold feed is going to stripper column in LRU. Possibility of preheating the stream with DCU hot stream (e.g. CFO, LDO) may be checked. As per Pinch study carried out at DCU, same was not found economically viable. 13 Debutanizer bottom naphtha RVP is to be checked for monitoring performance of debutanizer and to ensure that no light ends are being carried over which leads to flaring from NSU. In practice
SN Schemes Action Plan 14 At CRU Hydrogen to Hydrocarbon ratio is maintained as 5 against design of 4.5. This has to be optimized. Possibility for Implementation of step less controller for compressor loader may be explored. Presently, there is no control system to control Hydrogen to Hydrocarbon ratio. 15 Hydrogen rich CRU gas (90% purity) is presently supplying hydrogen to WHFU and NHDT. Surplus CRU off gas is used as fuel gas. Possibility of recovering hydrogen from CRU off gas and WHFU off gas may be ensured so that hydrogen generation requirement from HGU can be reduced thereby consumption of Natural Gas as HGU feed should come down. Moreover recovering hydrogen from the off gas stream will reduce the generation of fuel gas. Job is in progress Target completion : Jun13. SN Schemes Action Plan 16 Makeup Gas Compressor spill back is open 79 % at HDTU. Feasibility of employing step less control for controlling compressor load may be checked. Step less controller at HDTU is not economically feasible due to small capacity 17 At SRU SO2 analyzer in the first thermal reactor was not functioning which do not allow to control the flow of air in the reactor (to maintain burning rate at 1/3rd of H2S). Order placed for health check up of all analyzers at SRU. Target : Dec12. Action shall be initiated as per recommendation of health check up survey. 18 All the analyzers in the SRU stack are found to be not functional. As above ( Point no. 17) SN Schemes Action Plan 19 At WHFU temperature drop of 8 c between electric heater outlet and reactor inlet is observed. TIs to be checked. Insulation of transfer line checked and observed to be OK. Currently avg temp drop is noted to be 4 0 C. 20 MP steam is being used in De-aerator, feasibility of using LP steam to be explored. At DR SL steam is produced with PRDS. Hence savings opportunity is not considered significant. 21 Energy efficient nozzles to be used in plant air utility points. All plant air battery valves are kept closed except at the time of occasional requirement. 22 To improve specific fuel consumption further IOC may examine selling of additional power, at the same time maintains reliability. APDCL reply awaited for supply of transformer to increase power load. Further action shall be initiated after reply from APDCL. Target Dec13. Expected Savings: 401 SRFT SN Schemes Action Plan 23 The difference between cooling water supply and return temperature to refinery is 4 Deg C. Reason for the same (e.g. high water circulation rate) shall be examined. IOC has initiated necessary action. Depending upon ambient temp and humidity temp difference is observed to vary between 4-8 0 C 24 Oxygen analyzer for CDU, HDTU & SDU furnace was not working, to be made operational. O2 analyzer at CDU and HDTU are in working condition. SDU: Analyzer received at site. Job shall be completed by 20.12.2012.
25 Painting of Naphtha tanks, CPP stacks and offsite structures may be initiated. Job initiated. Target completion: Dec13 SN Schemes Action Plan 26 Condensate recovery exists for some of the units, to be implemented for other Units. Condenasate recovery system is implemented in all units except WHFU. At WHFU same shall be implemented by Dec12. 27 Feasibility of flare gas recovery may be studied to minimize flare loss after implementation of the Hydrogen Recovery Project. Shall be examined after implementation of H2 recovery project. 28 Mass flow meters in loading line of products at TTL shall be provided. Shall be implemented along with modernization of TTL Gantry.