First Prize Refinery

HINDUSTAN PETROLEUM CORPORATION LIMITED

MUMBAI REFINERY
Mumbai (Maharashtra)

Unit Profile

HPCL’s Mumbai refinery, one of the complex refineries in the country, is constructed
on an area of 321 acres. Mumbai Refinery has grown over the years as the main
hub of petroleum products. Around 31 products are manufactured at HPCL-MR
which are mainly, fuels 15 (propane, LPG 2 grades, HAN, LAN, ATF, HSD 3 grades,
LDO, SKO,MS, FO, LSHS) lubes 9 (Neutral oils, turbine oils, industrial oils,
transformer oil base stocks, bright stock) and specialties 10 (hexane, solvent,
asphalt, sulphur etc). It owns and operates the largest Lube Refinery in the India
producing Lube Base Oils of international standards, with a capacity of 450 TMT.

The current installed capacity of the refinery is 6.5 MMTPA.

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Energy Consumption

As a result of continuous efforts towards energy efficiency, lowest ever MBN is

achieved for Mumbai Refinery in 2013-14

EII MBN

125
122 91.1
117 100.0 81.4 82.6
120 75.4
115
108.3 106.3
110 50.0
105
100
95 0.0

F&L Btu/bbl of crude oil

7.9 474.1
8.0 7.6 480.0
7.5
460.0 449.9
7.5 440.5
6.9 440.0
7.0 417.3
420.0
6.5 400.0
6.0 380.0

Energy Conservation Measures Taken

1. Online Chemical Cleaning of Furnaces

2. LR, LOUP and DHDS CT fan FRP blade installation
3. Convection rows installation in FR APS furnace 11F1
4. Acoustic sensors for steam traps in LEU and PDU
5. Installation of free float steam trap at FR stabilizer
6. Steam Optimization in DHDS stripper
7. Reduction in Fuel Gas consumption in NSU
8. Reduction in Fuel Gas consumption in Prime G
9. Increase in CIT by 3.77 °C for 80% crude processing in FR
10. Optimization of Steam consumption in FR
11. Routing VDU Off gas to FR APS furnace
12. Improvement FRE APS furnace CIT by 2-4 °C

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13. Increasing APS BPA in lieu of O/H reflux in FRE
14. Reduction in VPS bottom steam consumption in FRE
15. Reduction in overhead Pressure of APS by 0.2 kg/cm2 in FRE
16. Improvement in efficiency of SG-10 by Super heater tubes removal
17. HRSG V Evaporator module replacement
18. Solar Power generation at Quality control lab
19. Fuel reduction in DHDS due to Catalyst change & optimization of reactor
temperature
20. Installation of Auto drain valves on white oil tanks
21. Reduction of MAB and AMAB amps
22. Optimization of steam consumption in NFCC
23. Optimization of COT in SEU Furnaces
24. PDA revamp
25. Thermo graphic Insulation Survey for steam headers and high temp process
lines

Energy Policy

ENCON Mission Statement:

"All communications with the employees and others with whom we do business are
of utmost importance in carrying out the Energy Conservation responsibilities for
Mumbai Refinery. Our Time, Skills, Abilities, Intelligence, Creativity, Hard work and
Services are focused with an emphasis on search of Energy Saving Potential and
immediate action for utilization of these Energy for upliftment of profitability of
Mumbai Refinery."

HPCL Mumbai Refinery is committed to continual improvement in energy

performance by using energy in an efficient, cost effective and environmentally
responsible manner through:

• Creation of awareness on energy conservation amongst all employees

• Setting of energy targets on an annual basis as part of MOU plan
• Monitoring and review of energy performance vis-à-vis target for each unit
• Adoption of best available technology & practices for energy conservation
• Procurement of energy-efficient equipment & services
• Increase in Renewable Energy to the extent possible

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Second Prize Refinery

INDIAN OIL CORPORATION LIMITED

Bongaigaon Refinery (Assam)

Unit Profile

Bongaigaon Refinery is the 8th Refinery of Indian Oil Corporation Limited. Situated
at Dhaligaon in Chirang district of Assam, it is 200 km west of Guwahati, the Capital
of Assam. The refinery is the result of amalgamation of erstwhile Bongaigaon
Refinery and Petrochemicals Limited (BRPL) with Indian Oil Corporation Limited on
25th March, 2009. Prior to it, BRPL was a subsidiary of Indian Oil since 29th March,
2001.

Processing capacity of the Unit is 2.35 MMTPA of crude oil. Presently, the refinery
processes Assam Crude and Low Sulfur imported Crude to produce a wide range of
petroleum products namely LPG, Naphtha, MS, SKO, HSD, LDO, LSHS, LVFO, RPC,
CPC, Needle Coke.

BGR is committed towards maintaining excellence both in environmental

management and energy conservation. Some of its efforts include installation of
Solar Water Heating System (SWHS) and Solar Photovoltaic System (streetlights) in
guest houses, canteens, clubs and parks. The Unit is certified with ISO 14001:2004,
OHSAS 18001:2007 and ISO 50001:2011.

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Energy Consumption

Continuous efforts are being made by the unit towards energy efficiency through
implementation of energy conservation schemes, continuous monitoring and control
of operational activities. This is reflected in the reduction in Specific Energy
Consumption. Highest ever MBN reduction achieved in 2013-14.

Energy Conservation Commitment

BGR is committed towards achieving excellence in Energy Efficiency and all the
employees across the organization put in their continual efforts towards this goal.

The energy and loss performance is reviewed by the management monthly. The
monthly targets are compared with the actual achieved and deviation analysis is
done for identification of energy losses. Corrective actions are taken by all
concerned for bridging the gap.

The daily energy and loss performance is reviewed by all departments in the daily
GRM improvement meeting chaired by GM (Technical Services) and GM (Technical).
Actions to be taken for performance improvement are discussed thereafter and
implemented by the concerned department(s).

Apart from the conventional energy parameters, BGR has adopted the system of
calculating internationally accepted refinery performance indices (introduced by M/s
Solomon Associates during benchmarking) viz. Energy Efficiency Index (EII),
Volumetric Expansion Index (VEI), Operational Availability (OA) and Process
Capacity utilization (PCU) on a monthly basis. A gap analysis between the refinery
indices and that of the World best refineries’ is carried out.

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Implementation of ISO 50001:2001 “Energy Management System”

ISO 50001: 2011 is an Energy Management System (EnMS) whose purpose is to

enable organizations to establish the systems and processes necessary to improve
energy performance, including energy efficiency, use and consumption. As a part of
strategic initiatives for 2013-14, BGR implemented ISO 50001:2011 “Energy
Management System” to meet the objective of this International Standard.

The final Certification Audit of ISO 50001:2011 of IOCL Bongaigaon Refinery (BGR)
was conducted by M/s DNV in September 2013, following which BGR was certified
with the system in October 2013

With this, IOCL-BGR became the first refinery of the country to be certified for
Energy Management System ISO-50001: 2011.

Energy Policy

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 Certificate of Merit Refinery

ESSAR OIL LIMITED

Vadinar, Jamnagar (Gujarat)

Unit Profile

Essar Oil, Vadinar Refinery having an installed capacity of 10.5 MMTPA, is part of
Essar Oil Limited. Essar Oil Vadinar Refinery of 10.5 MMTPA capacity began
commercial operations in May 2008. With the refinery expansion project operational,
Essar Oil has become India’s second largest single location refinery having 20
MMTPA (405,000 bpd) crude processing capacity.

Energy Consumption

During the year 2013-14 refinery has implemented several projects which have
contributed significantly in reduction of energy consumption. This is reflected by the
fact that Refinery’s MBN (MBTU/BBL/NRGF – as per CHT method) has reduced from
60.35 to 54.9.

SPECIFIC ENERGY CONSUMPTION

110
MBN (MBTU/bbl/NRGF)

100
90
91.3
80
88.5
70
60
60.35
50 54.9
40
30
2010-11 2011-12 2012-13 2013-14
Year

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Energy Conservation Measures Taken

1. The Unit has been accredited under IS0 50001:2011 on 16th May’14.
2. Replacement of CDU/VDU Heater ID fans (10ID921 A/B) with higher capacity.
3. Replacement of Base refinery Process Cooling Tower Fans by Energy Efficient
Fans (6 nos.)
4. Provision of Ultrasonic flow-meters in place of Orifice flow-meters for Coker
heater pass flows and Charge pump discharges
5. Increase of Suspect Condensate temperature at ISOM Battery limit
6. Heat recovery from heavy naphtha with BFW in CDU-1
7. Up gradation of existing glass wool insulation of HP Steam header with Perlite
Insulation in East-west pipe rack
8. Provision of insulation for energy saving at suspect condensate system in DCU
9. Identification of Passing Steam Traps and Replacement
10. To stop all three unit's Auxiliary Cooling Water (ACW) booster pumps in Phase-
2A. Circulation of ACW continues in all the units by differential pressure across
PHE.
11. Condensate Pump P-101A Impeller trimming

Energy Policy

Essar Oil Limited is committed to adopt the best energy management practices in all
our activities and continually improve the overall energy performance through:

• Complying with all applicable legal and other requirements related to energy
use, consumption & efficiency.
• Enhancing awareness and involve all associates in improving energy
performance.
• Ensuring optimization in Energy consumption and minimize losses by process
improvements.
• Ensuring the availability of necessary information and resources for achieving
planned targets.
• Encouraging procurement of energy efficient products & services and adopting
best available technology in design to enhance energy performance.

We shall communicate this Policy to all employees and contractors in service.

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