PAT in PSU Refinery

Ajay Vijay Joshi

Projections for Energy Consumption
Fossil fuels remain main energy source
Global energy demand will increase by around 30% to 2035, an average growth of 1.3%/year,
driven by increasing prosperity in developing countries, partially offset by rapid gains in energy
efficiency.
 Projections for Energy Growth Rates

Source IEA Energy Outlook 2017

 Global Primary Energy Projections

Source IEA Energy Outlook 2017

What is at Stake?
 Energy Efficiency – Indian Scenario

Source IEA 2014

Energy Efficiency – Indian Approach
 Energy Efficiency – Targets

Long Term Targets – INDC Goals related to

reduction in Emission Intensity

Short Term Goals- Reduction in Energy

Intensity between 2016 & 2019 by 7%
PAT -Definition
PAT - Features
PAT -Coverage
PAT Cycle-1
 PAT Cycle-2
PAT 2 Coverage
Target Energy Saving Share

Discom
Railways 0.0% Aluminium
0.6% 4.7%

Refinery Chlor- Alkali

8.2% Cement 0.8%

mtoe
PAT II – 227mtoe 9.5% Fertilizer
TPES: 825 mtoe

TFEC: 556 mtoe

Industry: 390ind
3.6%
(58% of Industry)

Iron & Steel

17.8%
Thermal Power
Plant
53.0%
Paper & Pulp
Textile 1.2%
0.7%
TPES: Total Primary Energy Supply
TFEC: Total Final Energy Consumption Target : 8.869 TOE
Industry includes Thermal Power Plants and Railways
Baseline Year: 2014-15
mtoe: Million tonnes of Oil Equivalent
Data Source: IEA and BEE 13
Why Refinery Sector?
Refinery Sector Energy Indicators
Energy Efficiency Measurement Concept
PAT Scenarios upon Mandatory Energy Audit
PAT Targets in Cycle-1
PAT Results in Cycle-1
PAT Cycle-2
PAT Cycle-2 Targets for Savings
PAT Cycle-2 Refinery wise Targets
Basis of Targets
 Challenge Posed to PCRA

 Formal direction given to PCRA for taking up Mandatory

Energy Audit in 12 PSU Refineries on 24th October 2016

 Effectively only eight months available to Audit and submit

reports for 12 MEAs

All MEAs and reports including form-2 were submitted as per

schedule by 30th June 2017
 PCRA’s approach to MEA of PSU Refineries

To determine performance deviation in present equipment /

system w. r. t. design.
Find out losses in different systems w.r.t. predicted
performance.
Opportunity for improvement in system/process.
Operational & Maintenance practices improvement.
Equipment wise loading and capacity utilization.
 Systems Audited by PCRA
1. Captive Power Plant
 Gas Turbine(GT)
 Steam Turbine Generator(STG)
 Heat Recovery Steam Generator (HRSG)
 Boiler and Steam System
2. Heating Ventilation & Air Conditioning (HVAC) and Chillers
3. Pumping System
4. Blowers & Fans
5. Electric Motors
6. Lighting System
7. Cooling Towers
8. Transformers & Electrical System
 Average Saving Potential under Major Heads
General Recommendations-
Lighting, 6% Others, 2%
HRSG – Heat Recovery Steam Generator,
maximisation of waste heat
GT, 22%

HRSG, 24% GT – Gas Turbine, recommendation to operate

on design efficiency
Boiler, 20%
Steam Boiler – Minimisation of losses
Management,
11% Pump & Motor - Matching with loads for
Cooling obtaining best efficiency
Tower, 4%
Steam Management – Plug leakage of steam
Pump &
motor system, Lighting - Retrofit with LEDs
11%
Cooling Tower – Heat transfer optimisation
 Identified Energy Savings, MRPL
SR. DESCRIPTION ENERGY CONSERVATION MEASURES SAVINGS
NO. TOE
1 PRDS – Back Pressure Turbine Use of Back Pressure Turbine in place of PRDS in CPP-3

2 Boilers and its auxiliaries
3 Power plant (CPP)
4 Cooling Water System
FD fan replacement in CPP-1,2 boilers, BFW pressure
reduction, proper loading, regular maintenance, tube
replacement, dry ice blasting of HRSG
MUH and CTP pump optimization, CEP pump pressure
reduction
Pressure reduction in Cooling water system

5 Air Compressor Overhauling and improving performance of intercoolers

6 HVAC, VAM Replacement with screw compressors and VFD’s

7 Lighting System
Replacement of existing lighting fixture with LED light
8 Process Pumps VFD’s on pumping system
Total expenditure for the Refinery - ₹ 413 Million
Maximum Payback period – 2 Years
 Identified Energy Savings CPCL
SN. Description Energy Conservation Measures Savings
TOE
1 Boilers and Elimination of air leakages in air pre heaters and de-staging
auxiliaries / Steam of boiler feed water pump
generation
2 Steam Utilization Prevention of steam leakages

3 Power plant (CPP) / Replacement of steam ejector with liquid ring vacuum pumps
Electricity and arresting leakage in HP heater drain
generation
4 Cooling Water Replacement of old Cooling water pumps with energy
System efficient correct head pumps in cooling water system and DM
plant system
5 Air Compressor Overhauling and improving performance of intercoolers and
replacing heat activated desiccant driers with heat of
compression dryers
6 HVAC, VAM Overhauling of VCR systems
7 Lighting System
Replacement of existing lighting fixture with LED light
8 Process Pumps Avoiding throttling losses in process pumps
Total Expenditure for the Refinery - ₹ 487.2 Million
Payback period – 3 Years
Panoramic View of Refinery wise Savings Potential

100%

90%

80%

70%
60%
50%
40%
30% HPCL Vizag Refinery
IOCL panipat Refinery
20% IOCL Mathura Refinery
NRL ,Numaligarh Refinery
10% MRPL, Mangalore Refinery
IOCL, Haldia Refinery
0% IOCL, Gujrat Refinery
IOCL, Barauni Refinery
HPCL Mumbai
CPCL, Chennai
BRPL, Bongiagaon
BPCL ,Mahul Refinery Mumbai
 Identification of Energy Savings
Indian Oil - Bongaigaon Refinery 6671

Numaligarh Refinery 6424 Total 2,14,055 TOE

Hindustan Petroleum - Visakhapatnam Refinery 11860

Bharat Petroleum - Mumbai Refinery 28812

Indian Oil - Mathura Refinery 17500

Indian Oil - Barauni Refinery 26115.1

Hindustan Petroleum - Mumbai Refinery 11528.7

Mangalore Refinery 23427

Chennai Petrochemicals 21079.2

Indian Oil - Haldia Refinery 7562

Indian Oil - Panipat Refinery 18254

Indian Oil - Gujarat Refinery 34823

0 5000 10000 15000 20000 25000 30000 35000 40000

Refinery MBN Present Status
PAT Cycle-2 Projections
Thank You