1

CII

11th National Awardfor

“Excellence in Energy Management – 2010”

Reliance Jamnagar ComplexBy

Y.K .Lodha

U.K .Lal

Roma Tripathi

September 1st -2nd , 2010

2

Contents

q Refinery Overview

q ENCON Efforts summary

q Specific Energy Consumption/Refinery Benchmarking

q Details of Innovative projects

q CDM Projects/GHG Emission statistics

q Energy Management System

q Employee’s Involvement in ENCON

q Project Implementation as CA/PA for ISO 9000/14000

q Utilization of Alternative energy source

q Awards & Accolades

q Summary

3

Reliance Jamnagar Overview

q Highly Complex refinery integrated with Petrochemical, Power, Port &

Terminals

q Built in record 36 months, High degree of secondary processing

q World’s largest FCCU, Coker, Platformer and PX units

q Technologies from world wide leaders like UOP, Dow, Foster Wheeler etc

4

RIL – Creating Refining hub of the world

Ø RIL owns 2 of the largest complex refineries (660+580 KBPSD)

Ø Reliance owns 25% of worlds most complex refining capacity

DTA

5

Process Overview

SWS

6

En-Con Projects in 2009 - 10

Sr.

No

En-Con Project

Investment

SavingsPaybac

k Period

Rs. LakhsRs.

Lakhs/Ann

Months

1Recover additional process heat into cold preheat train from LVGO pump around stream by commissioning HE S35

76 590 1.6

2HP steam consumption reduction in FCCU by modifying Condensate pot line 0.25 351 0.01

3VDU 2 ejector motive steam optimization, 4.7 TPH MP steam saved 0 245 0

4NS Column operating pressure reduction by 0.1 Kg/Cm2 in Aromatics, saving 4 TPH MP steam 0 209 0

5VDU 1 ejector motive steam optimization, 3 TPH MP steam saved.

0 157 0

6In Coker, 3 TPH MP Steam consumption. reduction in NS Reboiler 372-S07 by recovering more heat from LCGO PA stream

0 157 0

7

En-Con Projects in 2009 - 10 cont…

Sr. No

En-Con Project

Investment

SavingsPaybac

k Period

Rs. LakhsRs.

Lakhs/Ann

Months

7Increase in HMU-2 RFG compressor efficiency by Installation of new tube bundle with additional baffles in Inter-stage cooler, saving power of 314 KWH/HR

2 67 0.4

81 TPH HP steam saving by De heptanizer Column Pressure Reduction

0 58 0

9In Aromatics, avoid down gradation of Isomar gases & increase H2 production by 0.4 MTD

2.2 34 0.8

Total 80.45 1869 0.6

05/09 ENCON projects mainly focus on operational excellence withZERO Investment Cost

8

En-Con Efforts in last 3 yrs

1103618Total

2595.542007-083

1250.4552008-092

1190.0892009-101

MonthsRs.

Crores/AnnRs. Crores

Payback Period

SavingsInvestmentNo. of En-Con

Projects Implemented

YearSr. No

Encon Projects – From extensive monitoring & focused Studies

9

Specific Energy Consumption

Quest for achieving the Best

10

Shell Benchmarking Performance

Energy & Loss Performance Corrected Energy and Loss index

80

100

120

140

160

180

200

220

JAM 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41

Inde

x

CEL Index SBR

Reliance, Jamnagar

RefineryCEL 89.5 in 2005

CEL 86.9 in 2006

CEL 85.4 in 2007

CEL 84.6 in 2008

CEL 83.5 in 2009

11

Solomon Benchmarking Performance

Solomon Energy Intensity Index (EII)

* 2006 – Major Turnaround & Capacity addition

Jamnagar

12

Current Performance

Potential Performance

GAP

Time

4. Benchmarkingmaintains stimulus for

continuous improvement

1. Benchmarking identifiesopportunities for improvement

2. Application of"Best Practices"

3. Benchmarking helpsto measure success in

closing the gapPe

rfo

rma

nce

Road Map to achieve Best

Every gap is an opportunity to strive for excellence

Detail – Innovative Projects 2009-10

14

En-Con Projects in 2009 - 10

Sr. No

En-Con Project

Investment Savings

Payback

Period

Rs. LakhsRs.

Lakhs/Ann

Months

1 Recover additional process heat into cold preheat train from LVGO pump around stream by commissioning HE S35 76 590 1.6

2 NS Column operating pressure reduction by 0.1 Kg/Cm2 in Aromatics, saving 4 TPH MP steam 0 209 0

3Increase in HMU-2 RFG compressor efficiency by Installation of new tube bundle with additional baffles in Inter-stage cooler, saving power of 314 KWH/HR

2 67 0.4

Total 78 866 2.0

Our Innovative Best practices -Replicated by associates

15

QGAà Aromatics OX à Cumene impurity

1800 TPA of Fuel saved only be reduction of QGA

16

12.23% reduction in GHG emission due to Major Fuel Substitution from Liquid

fuel à Gas fuel

Efforts for GHG Emission reduction at RIL, Jamnagar

17

Carbon Emission Reduction Projects at RIL, Jamnagar

Sr. No. Project Activity Description

Annual CER

(MT of CO2)

Remarks

1Rerouting of Sat Gas Con Stripper off gases directly to Primary absorber feed by passing HP receiver in CDU I/II

36690

Registered with UNFCCC & verified two times, 102935

CERs issued

2Reduction in steam consumption in stripper reboiler of ATU by replacing Shell & Tube HE with Plate & Frame HE.

96867 Validation over, Project approved at

Chicago Climate Exchange3

Reduction in steam demand for Naphtha splitter reboiler in Coker through innovative process integration.

23174

4 Main Flare Gas Recovery System 45000 Project approved at Chicago Climate

Exchange5 Coker Blow-down Vent Gas recovery system 45000

6 Solar water heater installation at RIL Township

7000 Project Design Document Prepared

Total 253731

18

En-Con Team

Reliance Jamnagar has dedicated Energy Group within Technical

Services and a dedicated Energy Manager heading the Group.

19

ENCON-PIO Management Process

- ENCON-PIO Identification

Benchmarking,

-In-house suggestion

scheme,

- Monitoring & exception reporting

-Brainstorming,

-Revisit old study reports

- Third party ENCON study

- RCA - PIP etc

Implementation through MOC

process

Firm up scope and basis for ENCON-PIO

study

Summarize the impact on E&L,reliability

etc.,

Inputs from Energy Cell/EPS

for economic evaluation

Monthly review for

ENCON-PIO progress

ENCON-PIO closure report

ENCON projects

performance monitoring

Sp. ConsNorms

revision

Infeasible ENCON

Schemes

Records

Business plan &

Monitoring

20

Monitoring and Reporting Practices

Parameter Monitoring/Reporting

Frequency

Fuel & LossDaily / Weekly / Monthly/Quarterly

Energy consumption (Norms Vs Actual)

DailyWeekly Review at Refinery Chief level

Energy Index Monthly / Yearly (Values displayed on internal Web site)

Furnace/ Boiler Performance Daily / Weekly

Flare Loss Daily / Weekly / Monthly

Improvement Opportunities Report Daily

“To manage we have to control and to control we have to measure”

2121

En-Con Efforts (Flare Reduction) - Employee Involvement

DTA - Main Flare Hydrocarbon Flaring (TPD)

0

5

10

15

20

25

30

35

40

45

4/1/

2009

5/1/

2009

6/1/

2009

7/1/

2009

8/1/

2009

9/1/

2009

10/1

/200

9

11/1

/200

9

12/1

/200

9

1/1/

2010

2/1/

2010

3/1/

2010

Date

Hyd

roca

rbon

Fla

ring

(TPD

)

Main Flare Flaring Norms 2009-10 (10 TPD) Avg.Flaring (31, 20, 11, 17.2, 13, 6.5 TPD)

DTA - LLP Flare Hydrocarbon Flaring (TPD)

0

4

8

12

16

204/

1/20

09

5/1/

2009

6/1/

2009

7/1/

2009

8/1/

2009

9/1/

2009

10/1

/200

9

11/1

/200

9

12/1

/200

9

1/1/

2010

2/1/

2010

Date

Hyd

roca

rbon

Fla

ring

(TPD

)

LLP Flare Flaring Norms 2009-10 ( 7 TPD) Avg. Flaring ( 10, 8.6, 6.7, 6.5 TPD)

• Main Flare reduction of 24.5 TPD has achieved

• By extensive monitoring & rectification of passing valves

• Benefit by the reduction of flaring is Rs. 10.4 Crore/Annum

• LLP Flare reduction of 3.5 TPD has achieved

• By extensive monitoring

• Benefit by the reduction of flaring is Rs. 1.48 Crore/Annum

* FG Price – 11645 Rs./ MT

22

1HP steam consumption reduction due to condensate line modification in FCCU 0.25 351 0.01

Sr. No

En-Con Project

Investment Savings

Payback

Period

Rs. LakhsRs.

Lakhs/Ann

Months

ENCON project -Employee Involvement

23

Naphtha Splitter -2 Reboiler HP steam reduction by condensate line modification in FCCU

24

Naphtha Splitter -2 Reboiler HP steam reduction by condensate line modification in FCCU

25

Benefits of the Project

q HP steam consumption has reduced by 6 TPH which is

equivalent to fuel of Rs. 3.51 Crores per annum

q Operation reliability has improved

q It will help in reducing the downstream piping erosion

Naphtha Splitter -2 Reboiler HP steam reduction by condensate line modification in FCCU

26

Sr. No En-Con Project

Investment Savings

Payback

Period

Rs. LakhsRs.

Lakhs/Ann

Months

1Heat recovery from New plate-frame type Rich /lean Amine Exchanger in ATU-4 by replacing shell & tube HE, saves 12 TPH LPS

97.65 548 3*

2Reduction in OX steam generator by providing bypass in convection section of OX reboiler heater and increasing MP steam generation by 5 TPH

10.61 297 1

3Effective utilization of LCGO P/A heat within Coker Complex using additional redundant LPS generator, generates 3 TPH LP steam

147 137 12

4Aromatics Reformate Splitter feed preheater condensate routing to MP condensate flash drum to avoid the loss of 2 TPH LP steam

2.39 91 1

5 In PP, Routing of Line D degassing column vent line to fuel gas header, saves 0.72 TPD FG 32.5 50 8

6 PRU Propylene Treater Regeneration Sequence modification to avoid Propylene loss at the beginning of regeneration 0.5 43 1

En-Con Projects planned in 2010-11

27

7 Replacement of Existing Fin Fan blades With high efficiency blades in LNUU, saving power of 100KWH/Hr 8.61 35 3

8 Replacement of Existing Fin Fan blades With high efficiency blades make in HMU-3, saves power of 60KWH/Hr 5.74 21 3

9In Aromatics, Divert condensate header to the MP Flash drum, where LP steam can be generated & condensate can be recycled

1 17 1

10In HMU-1, Installation of new tube bundle with additional baffles in Inter-stage cooler of RFG compressor, saves power of 14 KWH/Hr .

2 5 5

Total 308 1244 3

Sr. No

En-Con Project

Investment Savings

Payback

Period

Rs. LakhsRs.

Lakhs/Ann

Months

Project No-1,7,8 taken under ISO-9001 CA/PA Implementation

En-Con Projects planned in 2010-11 cont..

28

q Comprehensive and well thought out Waste Management Plan

q Segregated collection of non-hazardous saleable scrap like metal, wooden, plastic waste etc.

EMS ISO 14001 Corrective/preventive actions

Adopted 3R – Reduce, Reuse, Recycle

29

Solar Water Heaters in township :

q Domestic geysers were used in

township which consumes more

electricity.

q Total 1300 Solar Heaters are

installed in new township area out of

which 1000 no. ( 300 lit cap.) and

other 300 no. ( 500 lit cap.)Project Benefits:

q This has resulted in saving of 99 Lakhs electricity units, which in turn

reduced CO2 emissions by 7000 tonnes annually.

q High-efficiency, Up to 75% energy saving, Eco-friendly, no exhaust gas, no

waste water drain to harm environments.

Use of Renewable energy resource-Solar water heater

30

Use of Renewable energy resource-Solar blinking Lights

Total no. of Traffic Signal pole Installation = 46 (DTA=30+SEZ=16)Total Saving in power /annum = Rs. 1 lakh/annum

31

Waste Utilization--Anaerobic Digester

Anaerobic Digester

Project Benefits:

q Produce cooking gas from food

waste and supplied to canteens

in labour colony.

q Biogas generation is around

23-25 m3/day

q Reducing the volume of waste.

q Savings of 50TPA of Fire

woods

32

1998 - 2010

Waste Utilization—Greening the Refinery

q Develop a natural Barrier around the

complex that acts as a ‘Sink’ for

Ground Level Emissions.

q 2,200 acres total area covered by

Green belt

q Created South East Asia's largest

mango orchard. Over 200 species have

been planted

q Treated sewage and effluent in

best combination used for greenbelt

development.

33

Awards & Accolades -Energy

u Shell Energy Benchmarking - CEL Pace Setter 2000 onwards

u Solomon Benchmarking – Ist quartile EII rating 2000 onwards

u ICMA award for excellence in energy management 2003 & 2005

u Federation of Guj Ind. Award in energy conservation 2004

u Energy Conservation Award – PCRA (MoP&NG) 2004 - 2006

u National Energy Conservation award-Ministry of Power 2004 - 06

u CHT Award for Excellent Boiler/Furnace performance 2006

u CHT Award for Excellence in control of steam leak 2005 /07 /09

u Infraline Award for contribution to Indian Energy Sector 2007

u CII award for Excellence in Energy Management 2003 to 09

u CHT award for Energy Performance of the Year 2009

u CII award for Innovative Encon Project 2009

34

% Break up of time spent by Senior Executive

35

Summary

q Reliance refinery leading in Energy performance both in

Shell & Solomon Indices

Ø Consistent reduction in SEC through Team work

q Major Focus on energy management

Ø Dedicated team of professionals

Ø Innovative best practices

Ø Linking QGA à ENCON & GHG reduction

Ø Scouting for alternative energy sources

q Robust end to end business processes- project Identification

to benefit closure

Thank You

37

En-Con Project - 1

1. Recover additional process heat into Crude Cold Preheat train

from Light Vaccum Gas Oil (LVGO) pump around

q The Crude Preheat train is divided into 3 sections which are Cold Preheat Train, Warm Preheat Train and Hot Preheat Train

q In cold preheat train, Crude from BL at 30 oC is preheated to 145 oC by hot Naphtha PA*, HK PA, Diesel PA, LK & VR product

streams

q In warm preheat train, Crude is preheated from 145 oC to 170 oC by hot HK PA , Diesel PA, HAGO PA, HVGO PA and VR product

q In hot preheat train, Crude is preheated from 170 oC to 242.7 oC by

hot HVGO PA, HAGO PA, Slope wax PA & VR streams.

q Crude finally enters Crude Heaters at ~ 242.7 o C for further preheating

38

1. Recover additional process heat into Crude Cold Preheat train from Light Vacuum Gas Oil pump around

Heat Exchanger Service

Cold Preheat Train-1

S01 A/B Naphtha Pumparound

S02 Heavy Kero Pumparound

S03 A/B MP steam preheater

S25 Vaccum Residue

Cold Preheat Train-2

S04 A/B Naphtha Pumparound

S05 A/B Light Kero Rundown

S08 A Diesel Pumparound

S35 A/B Light Vaccum Gas

Oil (LVGO) Pumparound

q Crude preheat trains optimization was carried out using the Pinch

Technology to exploit potential available of integrating CDU with

other units

q Modifications have been implemented in the Cold preheat

exchanger train of CDU-1 which involved Light VGO pump around

stream used for preheating Crude in exchanger S 35A/B

q Exchangers S35 A/B were available spare for exchangers

S01,S04,S05 A/B

En-Con Project -1 cont.

40

En-Con Project - 1 Benefit

qHeat Gain in Cold Preheat train

6 MMKcal/Hr heat gain added to cold preheat train

q Increase in Desalter Temperature

Desalter tempearature increased by 3.1 degC from 139.3 degC to

142.4 deg C which helped in good desalting operation

q Increase in Furnace Inlet temperature

Furnace inlet temperature increased by avg. 1.8 degC from 242.7 deg C

to 244.5 deg C.

q Stopping of Fin Fan cooler fan

5 nos of Fin Fan cooler fans has stopped to maintain the LVGO heat

duty.

q Economical Benefit

Due to commissioning of HE S-35 A/B for LVGO service, total 13.7

TPD fuels of Rs. 5.9 Crores per annum has been saved.

41

Increase in HMU-2 RFG compressor efficiency

42

q There is Net Potential Benefit of Rs. 7.2 Lac / day in terms of Saving of LPG and

Power.

q Safe and Smooth Start up and Shut down – Improved Reliability

Increase in HMU-2 RFG compressor efficiency

43

Furnace Monitoring Web Page

44

Furnace Monitoring Web Page

45

Weekly Fired Heaters Performance Monitoring Report

46

Shell Energy Index Web Page

47

Web based Daily Energy Consumption Monitoring

48

Weekly Energy Consumption Monitoring Report

49

For Entire COMPLEX

Measure OR Calculate

ACCOUNTABLE LOSS

INPUT – OUTPUT + ∆ INVENTORY=FUEL & LOSS

Measure FUEL(COMBUSTIBLE

PART)

Calculate FUEL & LOSS (BY BALANCE)

Fuel Gas + Fuel Oil + Natural

Gas

FCC Coke + Platformer

Coke + Waste Gas Of HMU

FLARE LOSSCHEMICAL LOSS

0.2-0.25 %0

TANK EVAPORATION

LOSS

0.02%

TOTAL LOSS = FUEL & LOSS - FUEL

UN A/C LOSS = TOTAL LOSS – A/C LOSS

Calculate TOTAL LOSS

(BY BALANCE)

METER UNCERTAINITY

HANDLING LOSS

Fuel & Loss (Flow Chart as per IP Method)

Calculate UNACCOUNTABLE

LOSS (BY BALANCE)

0.15%

FUGITIVE LOSS

0.03%

ZERO VALUE PRODUCT

(HMU Loss)

0.25-0.30%Excess Loss from

Tanks, Less Booking of Hold Up of facility

during commissioning

Measure INPUT, OUTPUT &

INVENTORY

50

Daily Fuel & Loss Monitoring Report

51

Daily Flare Monitoring Report

52

Web based Daily Improvement Opportunity report

53

MPS saving in NS by pressure reduction

54

MPS saving in NS by pressure reduction

55

En-Con Projects in 2008 - 09

Sr. No En-Con Project

Investment Savings Payback Period

Rs. Lakhs Rs. Lakhs/Ann

Months

1 Re-routing of Propylene Treater regeneration gases to improve Hydrocarbon Recovery in Flare Gas Recovery System 37 105 4

2Improving waste heat recovery by providing Medium Pressure Boiler Feed Water Heater in VGO Hydrotreater Unit. 9 150 1

3Routing of Platformer Separator gases to Sat./Unsat gas headers during slowdown 65 120 7

4Power saving through the stopping of Toluene column overhead one pump by changing the trim of net overhead control valve

1 77 0

5Main flare reduction of 12 TPD by acoustic meter survey of all PSVs & C/Vs & Nitrogen tracer technique. 0 1041 0

6LLP Flare reduction of 15 TPD by acoustic meter survey of all PSVs & C/Vs 0 983 0

7Steam Leak reduction of 26 TPD by steam leak survey and leak rectification. Also 92 TPD by replacing steam traps in CPP 3 238 0

Total 116 2714 1

En-Con Projects in the Year 2007 - 08

En-Con Projects implemented in the Year 2007-08

Sr. No

Project Implemented

Investment SavingsPayback Period

Rs. LakhsRs.

Lakhs/AnnumMonths

1Heat recovery from New Plate-Frame type Rich /lean Amine Heat Exchanger in 2 trains of ATU by replacing Shell & Tube HE

192 1100 2

2

Increase in crude preheat temperature by 20°C in Crude Distiller-1 by Heat recovery from hot VGOHT product stream (Pinch Technology)

441 1290 4

3Hydrotreaters stripper HP steam replacement by MP steam

4.53 94 1

Total 637.53 2484 3

En-Con Projects at RIL, Jamnagar

1. Reduction in steam consumption in stripper reboilers Of Amine Treating units (ATU).

– ATUs function is to remove H2S & CO2 from FG or LPG & to regenerate the rich amine to lean amine in stripper

– In original design Lean amine from stripper bottom routed through a Shell & Tube HE to heat rich amine feed to stripper

– Approach temp. in Shell & Tube HE was 48 oC– Replacement of S & T HE with Plate & Frame HE carried out to

increase the heat recovery from hot lean amine into the rich amine feed to stripper.

– Approach temp. in New Plate & Frame HE is 27 oC.– Steam consumption in stripper reboiler reduced due to increase

in heat recovery, reduction in GHG emission

1. LPS consumption in stripper reboilers Of Amine Treating units (ATU).

Stripper reboiler in Amine Treating Unit

Acid Gas to Knock-Out Drum

Rich Amine from Rich Flash Drum

Rich / Lean Amine Heat Exchanger(Shell & Tube type)

Rich Amine to Amine Stripper

Lean Amine from Amine Stripper

Lean Amine to Lean Amine cooler

Rich / Lean Amine Heat Exchanger (Plate & Frame type)

AmineStripper

1310C

83 0C

131 0C

104 0C

59 0C

59 0C

86 0C

107 0C

Lean Amine Pump

LP Steam from CPP

Amine stripper Reboilers (2 Nos)

with new Plate & Frame Heat Exchanger

Amine Stripper

En-Con Projects at RIL, Jamnagar

Photograph: Plate & Frame Heat Exchanger in ATU

q Fully In house developed scheme jointly by CTS/ R&T/Process

simulation

q Project has been implemented in four Units.

q Investment : Rs. 339 Lacs in four trains

q Reduction of 12 MT/Hr of LP steam per train costing Rs. 2198 Lacs

per annum in four trains

1. LPS consumption in stripper reboilers Of Amine Treating units (ATU).

QMS ISO 9000 Corrective/preventive actions

QMS ISO 9000 Corrective/preventive actions