Energy Conservation Opportunities in Steam & Condensate Network. Forbes Marshall Pvt Ltd 1

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1 Energy Conservation Opportunities in Steam & Condensate Network Forbes Marshall Pvt Ltd 1

2 ENERGY CONSERVATION at Indian Refineries

3 Various utilities & their cost in refineries UTILITY BILL FOR REFINERY Power, 26 Raw Water, 3 DM-Water, 2 Steam, 55 Cooling Water, 9 Compressed Air, 5 Forbes Marshall Pvt Ltd

4 Priority Triangle Matching todays scenario MONITORING THE UTILITIES OPTIMISING PROCESS CONDENSATE EVACUATION AND RECOVERY SYSTEM STOP WASTAGE Metering for steam & condensate for each individual sub-unit/plant Managing the compressive system data base of entire Plants with help of Forbes Marshall Ever Sense Package Focus in process application in terms of steam consumption Optimized the flash & condensate recovery from the process application Objective to reduce the gap between existing and possible condensate recovery Correct the level pot system for process condensate evacuation Most important - Correct trapping for steam distribution network, steam tracing network and process heating applications Rectify the incorrect selection of the traps, application wise, pressure temperature wise

5 THE STEAM SYSTEM LOSSES Distribution Losses Steam leaks you? How much are they costing 25 mm valve stem 8 barg 3.5 kg/h Rs per annum 2 mm hole, steam at 7 barg 9 kg/h Rs per annum

6 Areas of Improvement Steam Trap System Management Condensate Recovery System Re- Engineering & Improvement Condensate Recovery System Design Boiler Blow down Heat Recovery Hot Insulation Study & Rectification

7 Forbes Marshall role in Steam & Condensate Management FM Methodology Savings of 75TPH (85Cr s) Steam Trap Management Steam Trap Audit Product Supply Steam Trap system turnkey projects (implementation & Sustenance) Bench marking/performan ce Guarantee/Savings (Savings of 300TPH (50Cr s) Condensate Condensate recovery Management recovery Management Steam Trap/Condensat e network Audit Product Supply Condensate system turnkey projects (implementation & Sustenance) Bench marking/perform ance Guarantee/Savin gs

8 Boiler blowdown heat recovery Deaerator Head Condensate Steam Boiler Blowdown valve Flash vessel Trap Hot well Heat exchanger Feed pump Cold make-up To drain

9 Case Studies Forbes Marshall Pvt Ltd 9

10 STSM Completed Refineries Steam Traps Steam Savings Achieved (Kg/hr) Initial Trap working Status Final Trap working Status HPCL Mumbai - DHDS+LRE % 98% 1 year Contract Period IOCL BGR 1st Contract % 99% 18 months IOCL BGR 2nd Contract % 99% 21 months IOCL Panipat Offsite Areas % 81% 1 year BPCL Mumbai 1st Contract CDU+FPU+BBU % 97% 1 year BPCL Mumbai 2nd Contract DHDS Block+CDU3+FCCU % 97% 1 year BPCL Kochi 1 st Contract % 99% 1 year IOCL Digboi 1st Contract months NRL 1 st Contract months HPCL Vizag 1 st Contract months IOCL, Guwahati % 99% 2 year IOCL Gujarat % 95% 2 year CPCL, Chennai % 96% 1 year

11 STSM Completed Refineries Steam Traps Progress Steam Savings Achieved (Kg/hr) Initial Trap working Status Final Trap working Status Contract Period IOCL Digboi 2nd Contract 3300 Sustenance % 99% 2 Year (Up to Nov-15) NRL 2nd Contract 4058 Sustenance % 97% 1 year (Up to March-15) HPCL Vizag 2nd Contract 4000 Sustenance % 96% 2.5 year (Up to Nov-15) BPCL-Kochi 2nd Contract 1500 Sustenance % 97% 1.5 year (Up to Sep-15) IOCL - BGR 3rd Contract 5700 Sustenance % 97% 1 year (Up to March-15)

12 Audit Complete comprehensive audit of Steam Trap applications, creating a database, Quantification of Steam Loss, Analysis of Failed Traps, Identification of Areas of Improvement and Detailed BOQ with complete rectification Plan. Rectification Improving Steam Traps performance above 95 %, & Corresponding Reduction in Steam Loss through traps, valves, flanges & pinholes. Correcting Application wise Selection, eliminating Group Trapping & Installation of Traps on NO TRAP locations. Detailed Report with Root Cause Analysis. Sustenance Sustaining achieved Steam Trap Performance above 95% & maintaining the Steam Leaks to minimal level through day to day monitoring. Designing schedule for routine maintenance based on priorities & implementing system improvement suggestions. Creating awareness and sharing knowledge through regular training programs.

13 Steam Trap Performance Rate % Steam Trap Performance Chart - IOCL (GR) Feb-13 Mar-13 Apr-13 May-13 Jun-13 Jul-13 Aug-13 Sep-13 Oct-13 Nov-13 Dec-13 Jan-14 Feb-14 Mar-14 Apr-14 Achieved Performace Rate % Achieved Reduction In Steam Loss Projected Performance Projected Reduction in Steam Loss% Forbes Marshall Pvt Ltd

14 Performance Rate % Steam Loss (Kg/hr) IOCL Digboi Refinery Updated Performance Chart Jul-16 Sep-16 Nov-16 Jan-17 Mar-17 May-17 Jul-17 Sep-17 Nov-17 Jan-18 Mar-18 May-18 Jul Achieved Per Rate % Projected Per Rate % Achieved Reduction in Steam Loss Projected reduction in Steam Loss

15 BORL STSM Proprietary content 15

16 Steam Trap Performance Rate % Steam Loss (kg/hr) BPCL MR STSM Steam Trap Performance Chart - BPCL MUMBAI REFINERY Jan-17 Feb-17 Mar-17 Apr-17 May-17 Jun-17 Jul-17 Aug-17 Sep-17 Oct-17 Nov-17 Dec-17 Jan Achieved Performace Rate % Projected Performance Rate % Achieved Reduction In Steam Loss Projected Reduction in Steam Loss% Proprietary content 16

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18 Condensate Recovery Projects Completed Refineries IOCL, Bongaigaon IOCL, Guwahati IOCL Haldia IOCL Panipat ESSAR OIL HPCL Vizag BPCL KR BPCL MR BORL Condensate Savings Potential 8000 Kg/hr 2500 Kg/hr kg/hr kg/hr kg/hr 5000 kg/hr 5000 kg/hr 6000 kg/hr 5000 kg/hr

19 BPCL MR-CPP condensate recovery Forbes Marshall Pvt Ltd

20 Phase wise CRS implementation in IOCL BGR Forbes Marshall Pvt Ltd

21 BPCL MR-Bitumen tank condensate recovery Condensate savings: 3.4 tph Flash steam recovery: 0.3 tph Monetary 1.04 cr s/annum Forbes Marshall Pvt Ltd

22 BPCL MR-Bitumen tank condensate recovery Forbes Marshall Pvt Ltd

23 BORL SRU CRS Steam savings of Rs 3.6cr/annum!!! Condensate savings of Rs 36 lacs/annum Forbes Marshall Pvt Ltd

24 BORL DCU CRS Efficient Condensate & Flash Steam Recovery Recommendations

25 IOCL PANIPAT Blow down heat recovery Sr. no. Equipment Pressure (Kg/cm2) CBD Quantity (TPH) Flash Vessel Flash Vessel Pressure (kg/cm 2 g) Flash Steam (TPH) 1 CBD From five Boiler Drum 125 Max. 15 Min V MAX. 4.7 MIN.3.8 Forbes Marshall Pvt Ltd 25

26 Insulation Study

27 Resulted in reduction in condensation loss by 80%

28 THANK YOU

29 Proprietary content 29