| |
|
1 |
Reduction in power consumption
to the tune of 260 MWH per year by implementing
unique split seal in one of the cooling water
pumps. |
|
2 |
Reduction of power
consumption to the tune of 350 MWH per year by using
surplus plant air in sulphur recovery unit with
suitable modification. |
|
3 |
Replacement of one
of the un-loader valves of Hydrocracker off-gas
compressor with high performance un-loader resulted
in the saving of around 80 MWH per year. |
|
4 |
Stabilisation and
optimisation of Hydrocracker Power Recovery Turbine
(PRT) resulted in the saving of around 4800 MWH
per year. |
|
5 |
Optimum operation
of air fan coolers by adjusting blade angles. |
|
6 |
Optimum Cooling
Tower operation by close monitoring of cooling tower
fan operation. |
|
7 |
Maximization of
hot feed to DCU and HCU. |
|
8 |
Implementation of
recommendations of Energy Audit carried out by M/s
PDIL. |
|
9 |
Monitoring of passing
valves by Acoustic leak detector. |
|
10 |
Close monitoring/rectification
and replacement of passing steam trap valves resulted
saving of steam. |
|
11 |
Close monitoring
of flare system and maintaining more than 95% fuel
gas utilisation. |
|
12 |
Optimisation of
steam generation in process units resulted in fuel
saving by optimisation of Utility Boiler. |
|
13 |
Diversion of slop
oil to HSD pool resulted in reduction of slop oil
generation, which in turn reduced the re-processing
cost. |
|
14 |
Single GT operation
through out the year. |
|
|
1 |
Comprehensive energy
audit was carried out during the year and many of
the audit recommendations have been already implemented. |
|
2 |
Reduction of GTG
frequency to 49.5 Hz from 50 Hz resulted in saving
of around 666 MT of fuel per year. |
|
3 |
Stopping of one
Forced Draft Fan in CDU furnace and one Forced Draft
Fan in HCU Furnace contrary to the normal operation
philosophy. This action resulted in saving of around
600 MWH of power per year. |
|
4 |
An innovative measure
of diversion of flash drum vapours in CDU from flash
zone to kero zone was implemented during the year.
This action resulted in saving of around 500 MT
of fuel per year. |
|
5 |
Optimisation of
HSD pool blending components with unconverted oil
of hydrocracker unit resulted in the saving of around
300 MT of fuel per year. |
|
6 |
Implementation of
unique spilt seal in the three cooling water pumps
in cooling tower area resulted in saving of 500
MW of power per year. |
|
7 |
Stopping of steam
heating in the crude tanks resulted in saving of
around 666 MT of fuel per year. |
|
8 |
During annual turnaround
most of the exchangers were cleaned and many of
the major equipment were overhauled resulting in
the improvement of their efficiency. |
|
9 |
Use of slop oil
in place of gas oil for quenching purpose in DCU
unit resulted in the saving of around 300 MT of
fuel per year. |
|
10 |
Diversion of VDU
slop oil to gas oil pool resulted in saving of 300
MT of fuel per year. |
|
11 |
Routing filter back
wash of hydrocracker unit to VR feed tank instead
of slop resulted in saving of 300 MT of fuel per
year. |
|
12 |
Regular monitoring
of passing valves and fugitive emission by Acoustic
Leak Detector and Gas Measuring Instrument (GMI)
as a part of loss control measures. |
|
13 |
Close monitoring
of flare system and maintaining maximum fuel gas
utilization. |
|
14 |
Close monitoring
of water content in crude oil. |
|
15 |
Optimisation of
secondary processing. |
|
16 |
Maximum running
of all steam turbines resulted in saving of power. |
|
17 |
Optimum operation
of air fin fan coolers by adjusting blade angles. |
|
18 |
Optimum Cooling
Tower operation by close monitoring of cooling tower
fan operation. |
|
|
|
1 |
Implementation
of Advanced Process Control (APC) in CDU/VDU to
optimize Product recovery and improve Product yields |
|
2 |
Providing special
type of Telescopic Insulation for all the 150 numbers
of Catalyst Tubes at the reformer top to cover the
bare hot tube length (550 to 600 °C) which comes
out above the roof metal casing plate during running
due to thermal expansion of the Catalyst Tubes.
These Telescope Seals are capable of compensating
at least 225 mm of Catalyst Tube movement (during
thermal expansion), which is expected to save around
600 MT of fuel per year. |
|
3 |
Installation of
12 MW Steam Turbo Generator (STG) for utilising
surplus steam and recovering power from PRDS, for
which detailed engineering completed during the
year. The project is expected to recover around
14000 MWH of energy through PRDS as well as utilize
the total surplus steam of the refinery. |
|
4 |
Step less control
system in HCU make up Gas Compressors, which is
in the advanced stage of implementation. The implementation
of this scheme will result in a saving of around
600 MT of fuel per year. |
|
5 |
Scheme for using
VDU hot well waste gas in the CDU furnace has been
taken up |
|
6 |
Implementation
of DCS in CPP, which helps in optimization of fuel
consumption by allowing close monitoring of the
steam parameters, steam venting etc through the
DCS. |
|
7 |
Improved and more
reliable Steam Traps have been installed, for which
considerable amount of steam losses have been reduced. |
|
8 |
Auto drain Traps
for moisture separation in air compressor have been
installed leading to reduction in compressed air
losses. |
|
9 |
During the Oil
& Gas Conservation Fortnight in the month of
January’ 2005, a joint team of CHT conducted
Steam Leak survey. Remedial actions have been taken
for all the identified leaks. |
|
10 |
In addition to
these, regular monitoring for any passing valves
and fugitive emission by Acoustic Leak Detector
and Gas Measuring Instrument (GMI) is carried out
as part of loss control measures and timely remedial
actions are taken as required. |
|
| |
As a part of NRL’s
continual efforts towards energy conservation and
loss control, the following new Encon schemes have
been taken up for implementation during the year
2005 – 06: |
|
1 |
Scheme for providing
special type of Telescopic Insulation for all the
150 numbers of Catalyst Tubes at the reformer top
to cover the bare hot tube length (550 to 600 °C)
which comes out above the roof metal casing plate
during running due to thermal expansion of the Catalyst
Tubes was implemented. These Telescope Seals are
capable of compensating at least 225 mm of Catalyst
Tube movement (during thermal expansion). This project
was selected for 1st prize by PCRA for exemplary
work in energy conservation under medium category
project. |
|
2 |
Implementation
of 12 MW STG for utilizing surplus waste steam and
recovering power from PRDS for which PMC has been
lined up, tender has been floated and activities
regarding the registration of the project under
CDM have been initiated during the year. |
|
3 |
Combination Coke
Cutting Tool in DCU has been implemented during
the year. |
|
4 |
For the first time
in the country, NRL adopted Step less control system
in HCU make-up Gas Compressors for which majority
of the jobs were completed during the year. |
|
5 |
Modification of
one of the HRSG Boiler Feed Water pump to cater
to the need of BFW requirement of both HRSG as well
as Utility Boiler in CPP, for which detail engineering
has been completed and fabrication started at the
vendor’s workshop during the year. |
|
6 |
Single burner operation
of Utility Boiler has been implemented |
|
7 |
Ultrasonic mass
flow meter to measure flare gas flow has been installed. |
|
8 |
During the Oil &
Gas Conservation Fortnight in January 2006 a joint
team of CHT conducted furnace efficiency and insulation
effectiveness survey. |
| |
In addition to these,
regular monitoring for any passing valves and fugitive
emission by Acoustic Leak Detector and Gas Measuring
Instrument (GMI) is carried out as part of loss
control measures and timely remedial actions are
taken as required. Suggestion scheme amongst the
employee is also in place for identifying energy
conservation schemes. |
|
| |
As a part of NRL’s
continual efforts towards energy conservation, the
following Encon schemes have been taken up for implementation
during the year 2006-2007: |
|
1 |
A unique Step Less
Control system has been implemented in the Make-up
Gas Compressor of the Hydrocracker Unit during the
year 2006-07 which is expected to save around 600
MT of fuel per year. This has also improved the
energy efficiency of the machine as well as the
operational convenience. NRL bagged the prestigious
TERI award for best Energy Management with the above
mentioned Stepless control system as case study. |
|
2 |
Implementation of
12 MW STG for utilizing surplus waste steam and
recovering power from PRDS is under progress. The
project is expected to recover around 14000 MWH
of energy through PRDS as well as utilize total
surplus steam of the refinery. |
|
3 |
During Oil &
Gas Conservation Fortnight in the month of January
2007, a joint team of CHT conducted steam leak survey,
and remedial actions initiated for all the identified
leaks. |
|
4 |
Special type of
telescopic insulation has been provided in all the
150 nos of catalyst tubes at the reformer top to
cover the bare hot tube length (550 to 600 C) which
comes out above the roof metal casing plate during
running due to thermal expansion of the Catalyst
Tubes. These telescopic seals are capable of compensating
at least 225 mm of catalyst tube movement (during
thermal expansion) and is saving around 600 MT of
fuel per annum. This project has received PCRA exemplary
award for energy conservation. |
|
5 |
Dual-purpose turbine
has been implemented in CPP.
In addition to these, regular monitoring for any
passing valves and fugitive emission by Acoustic
Leak Detector and Gas Measuring Instrument (GMI)
is carried out as part of loss control measures
and timely remedial actions are taken as required. |
