Workshop on Energy Management Efficiency Improvement in the Oil Gas Sector

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Slide 1

Workshop on Energy Management & Efficiency Improvement in the Oil & Gas Sector Case Study : Technology Application November 13, 2009 Hotel Claridges, Aurangzeb Road, New Delhi By: P.Sur, Executive Director (Operations), Indian Oil Corporation Ltd

Slide 2

Agenda for the Presentation Energy execution of IOCL Refineries Major Technologies connected for Energy Conservation Energy administration at Japan Discussion on some Case Studies: Flare Gas Recovery System Foggy Coolers in Gas Turbines Step less control System in Reciprocating Compressors

Slide 3

Agenda for the Presentation Energy execution of IOCL Refineries Major Technologies connected for Energy Conservation Energy administration at Japan Discussion on some Case Studies: Flare Gas Recovery System Foggy Coolers in Gas Turbines Step less control System in Reciprocating Compressors

Slide 4

Energy Performance pattern of IOCL Refineries w.r.t. Industry Figs in MBTU/BBL/NRGF MBN Industry IOCL

Slide 5

Agenda for the Presentation Energy execution of IOCL Refineries Major Technologies connected for Energy Conservation Energy administration at Japan Discussion on some Case Studies: Flare Gas Recovery System Foggy Coolers in Gas Turbines Step less control System in Reciprocating Compressors

Slide 6

Major Technologies Applied in IOCL for Energy Conservation Modernization of let go radiators. Arrangement of APH & OBSG to recuperate vitality from waste warmth of heater vent gasses. Warm exchanger prepare redo through Pinch think about. Establishment of Gas Turbines with co-era framework in power plants. Modernisation of Instrumentation and use of Advanced Process Control Strategies. Flare gas recuperation framework. Foggy cooler in Gas turbine. Step less control framework in Reciprocating compressors. Tank cultivate mechanization

Slide 7

Agenda for the Presentation Energy execution of IOCL Refineries Major Technologies connected for Energy Conservation Energy administration at Japan Discussion on some Case Studies: Flare Gas Recovery System Foggy Coolers in Gas Turbines Step less control System in Reciprocating Compressors

Slide 8

Energy Management at Japan The trigger In Japan Primary Energy utilization per GDP is the most reduced on the planet. In India it is 9.2 times that of Japan. Japan needs to decrease CO2 emanation by 14% to respect Kyoto Protocol. When contrasted with 1973 position, there is no adjustment in Energy utilization at Industrial Sector, 112% expansion in Transportation Sector and 147% expansion in Commercial/Residential Sector.

Slide 9

Energy Management at Japan The trigger Primary Energy Consumption per GDP in Japan versus others China Asia Korea EU

Slide 10

Energy Management at Japan Energy administration Practices at Japan Factories, which expend add up to vitality of 3000 KL or more for every year of unrefined proportionate is named as Type 1 assigned plant. Sort 1 processing plant needs to utilize qualified vitality director (required), no. of which relies on upon the yearly fuel utilization. If there should be an occurrence of refineries min. 4 nos. are to be utilized. Accommodation of intermittent reports on vitality utilize. Best Runner Program: Introduced in 1999 for Energy Conservation principles for local machines & vehicles. Pertinent for aggregate 21 items. Target has been set for development of vitality utilization productivity of these items by 16.4% to 66.1% contingent upon the item in 2010 with base year of 1995. In the vast majority of the cases target has been accomplished in 2005.

Slide 11

Energy Management at Japan Energy administration Practices at Japan Energy sparing naming framework acquainted with illuminate customers of vitality proficiency of home apparatuses (13 items). Presentation of Home Energy Management System (HEMS) and Building Energy Management System (BEMS) to control aerating and cooling and lighting. Point is to enhance vitality utilization productivity by in any event another 30% by 2030.

Slide 12

Energy Management at Japan Energy administration at Japanese Refineries There are add up to 34 refineries. Every one of them are private refinery. Add up to unrefined petroleum handling limit is around 225 MMTPA. No seat stamp for Energy Intensity Index is forced by Govt. Be that as it may, every refinery needs to enhance it by 1% in every year i.e. cum 5% in 5 years. M&I of units at 2-4 years interim relying upon the kind of plant. APC is broadly utilized for process control & mixing operation

Slide 13

Energy Management at Japan General rules issued for Japanese Refineries on taking after operational measures Distillation, Extraction & Absorption Fired Heaters Reactors/impetus regenerators Heat Exchanger, warming and cooling Steam and Electrical Power Rotating Machine and other gear Process Instrumentation and Management framework Material misfortune anticipation and others Details

Slide 14

Agenda for the Presentation Energy execution of IOCL Refineries Major Technologies connected for Energy Conservation Energy administration at Japan Discussion on some Case Studies: Flare Gas Recovery System Foggy Coolers in Gas Turbines Step less control System in Reciprocating Compressors

Slide 15

Technology application in Energy Conservation-Flare Gas Recovery System Flare Gas Recovery System Implemented in : Mathura, Guwahati , Haldia , BGR Under usage in: Barauni, Gujarat , Panipat Savings Achieved SRFT/Yr Reduction in Flare misfortune (Kg/hr) Mathura: 4500 510 Guwahati 1460 165 Haldia 3240 370 BGR 4800 550

Slide 16

Technology application in Energy Conservation-Flare Gas Recovery System Advantages Can deal with gasses With extensive variety of mol. wt. Sweet or destructive With intermittent fluid slugs Recovered gas is reused to Fuel gas System Can deal with variance in Gas Header Pressure in Coker based Refineries.

Slide 17

Technology application in Energy Conservation-Flare Gas Recovery System Components The Liquid ring compressor Mechanical seal flushing framework Separator vessel Heat exchanger (shell & tube) By-pass line for 100% course

Slide 18

Technology application in Energy Conservation-Flare Gas Recovery System Description The fluid Ring compressor takes suction from Downstream of Flare KOD Compressed gas goes to Fuel Gas System through a separator vessel where the fluid is isolated out. The spill back controller worked on compressor suction weight. DM water is utilized as fluid ring liquid.

Slide 19

Technology application in Energy Conservation-Flare Gas Recovery System Flow Diagram To FG framework Flare Hdr PT Separator Flare KOD Liquid ring Compressor DM water To Flare

Slide 20

Agenda for the Presentation Energy execution of IOCL Refineries Major Technologies connected for Energy Conservation Energy administration at Japan Discussion on some Case Studies: Flare Gas Recovery System Foggy Coolers in Gas Turbines Step less control System in Reciprocating Compressors

Slide 21

Technology application in Energy Conservation-Foggy Cooler in Gas Turbine Foggy coolers in Gas Turbines Implemented in: Mathura Under Implementation in : Gujarat Benefit acquired: Mathura – 1000 SRFT/yr Estimated befit : Gujarat – 7400 SRFT/yr

Slide 22

Technology application in Energy Conservation-Foggy Cooler in Gas Turbine Schematic stream Diagram

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Technology application in Energy Conservation-Foggy Cooler in Gas Turbine Mathura Refinery is first refinery in IOCL to actualize the idea of introducing foggy cooler in GT channel for better power era. To expand the effectiveness, it is being introduced at the GT's delta air conduit. Best misting gadget which decrease the ignition air temperature by producing to a great degree fine (<18 small scale meter) water mist at the air pipe of the GTG. Cooling the gulf air expands its thickness, enhancing compressor mass stream and along these lines permitting the turbine to work at a higher limit.

Slide 24

Technology application in Energy Conservation-Foggy Cooler in Gas Turbine Working Principle The foggy cooler chips away at the rule of evaporative cooling. Water fog dissipates, taking inert warmth of air accordingly decreases the temp which rely on upon distinction between dry & wet knob temp.

Slide 25

Agenda for the Presentation Energy execution of IOCL Refineries Major Technologies connected for Energy Conservation Energy administration at Japan Discussion on some Case Studies: Flare Gas Recovery System Foggy Coolers in Gas Turbines Step less control System in Reciprocating Compressors

Slide 26

Technology application in Energy Conservation-Step Less Control in Reciprocating Compressor Implemented in: Guwahati, Barauni, Mathura, Haldia Under Implementation in: Guwahati, Gujarat, Panipat, BGR Savings Achieved SRFT/Yr Guwahati (HDT MUG) 515 Barauni (CRU & DHDT MUG) 2600 Mathura (OHCU MUG) 1000 Haldia (DHDS RGC) 4500

Slide 27

Technology application in Energy Conservation-Step Less Control in Reciprocating Compressor Process necessities To take care of process hydrogen demand, the heap in the running compressor (s) ought to be kept up to meet the only prerequisite of hydrogen as a perfect case. Responding compressors work with altered stride burdens and along these lines release a settled amount of H2 at any heap because of accessibility of only four stacking choices. Accordingly there is dependably a conditions where measure of hydrogen packed at accessible load mix is in abundance of what is required by process. The overabundance H2 along these lines compacted, which is not required by the procedure, is spilled back to the compressor's suction, in this manner squandering significant measure of vitality.

Slide 28

Technology application in Energy Conservation-Step Less Control in Reciprocating Compressor Working standard Allows compressor to have step less stacking from 0-100%. Works in the standard of switch stream direction. PLC based electronic framework controls the using pressurized water worked actuators, introduced over the suc

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