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Western Region Workshop on “Capacity Building of Officers from Petroleum Refinery Sector on Efficient Use of Energy”

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Date/Time
Date(s) - 07/07/2017
9:00 am - 6:00 pm

Location
Indian Oil Corporation Limited

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7th July 2017, Vadodara Gujarat : The Western Regional Workshop for facilitating “Capacity building of officers from Petroleum Refinery Sector on Efficient use of Energy” was organized on 7th July, 2017 by Bureau of Energy Efficiency in partnership with the Knowledge Exchange Platform (KEP) initiative. KEP is a joint initiative of Bureau of Energy Efficiency (BEE) and Institute for Industrial Productivity (IIP) for promoting energy efficiency through best practice transfer in industries covered under the Perform Achieve and Trade (PAT) scheme.

The workshop was hosted by Indian Oil Corporation Limited, Gujarat Refinery at Spandan Hall, IOCL Gujarat Refinery township, Vadodara. This workshop was an important event in the Petroleum Refinery sector as it marked the beginning of first best practice sharing and collaborative effort by the industries in the sector for implementing PAT scheme. The workshop becomes even more important as the Petroleum Refinery sector has recently been included under the  2nd cycle of PAT and such events will go a long way in bringing the 18 Designated Consumers (DCs) under the sector on a common platform to jointly work towards the common mandate of enhancing energy efficiency.

The agenda of the workshop was carefully designed to promote sharing of best practices and energy efficient technologies among the industry professionals, certified energy auditors and energy managers, technology suppliers and experts that can help the industries in achieving the targets set under PAT Cycle 2. The workshop was attended by more than 90 participants, which included representatives of refinery plants (HPCL, BPCL, ESSAR Oil, Reliance, IOCL), Petroleum Conservation Research Association (PCRA), Centre of High Technology (CHT), Federation of Indian Chambers of Commerce & Industry (FICCI), Confederation of Indian Industry (CII), Engineers India Limited (EIL), energy auditors and energy managers, technology providers and senior industry professionals amongst many others.

The workshop was inaugurated by Mr. Sudhir Kumar, Executive Director, Indianoil Corporation Limited, Gujarat Refinery. In his inaugural address, he highlighted the importance of minimizing waste and mentioned that energy efficiency can be easily achieved by simply following the 3 R’s of waste minimization viz. Reduce, Reuse and Recycle.  He mentioned that industries should assess the waste minimization opportunities by assessing the economic viability, technical feasibility, environmental aspects and then select solutions to implement them.  He hoped that the industries will try to explore additional channels for promoting energy efficiency through optimum utilization of resources.

Welcome address was delivered by Mr. Milind Deore, Energy Economist, Bureau of Energy Efficiency. In his address, Mr. Deore emphasized the need of monitoring energy consumption in-order to meet the national goals. He hoped that this forum will provide an ideal opportunity for knowledge sharing and networking among the wide range of participants.  Vote of thanks was delivered by Mr. Subhajit Sarkar, General Manager, Indianoil Corporation Limited, Gujarat Refinery. He conveyed his thanks to the dignitaries, speakers and delegates for their presence and participation in the workshop.

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Dignitaries at the Inaugural Session

The inaugural event was followed by best practice presentation by the host refinery and four technical sessions. Sharing and discussing the innovative best practices, the presentation by Indian Oil Corporation Limited highlighted the energy savings achieved by installing additional row of tubes in convection section of CRU NHT furnaces for enhancing the heat recovery and reduction in stack temperature, reducing the operating pressure of the CGP-2 deaerator from 1.4 to 0.8 kg/cm2-g, installing ISOM to FCC HPS header and  rectification of problems being faced in HCU dump valve which resulted in annual fuel savings of 800 Standard Refinery Fuel Tonnes (SRFT), 2060 SRFT, 1224 SRFT and 1400 SRFT respectively.

The first technical session had presentations from Bureau of Energy Efficiency on Perform Achieve & Trade Scheme. The discussion in the session focused on Perform Achieve and Trade scheme and strategies to be adopted to meet the energy efficiency targets. Mr. Milind Deore, Energy Economist, Bureau of Energy Efficiency, presented the overview of Perform Achieve and Trade scheme which covered details on PAT scheme, success stories achieved under PAT 1 Cycle, methodology for second PAT cycle, target for refinery sector and projected impacts of PAT Cycle 2, information on the current status as well as the mandatory requirements to be fulfilled by DCs and key aspects of ESCerts trading scheme. Mr. Sarabjot Saini, Sector Expert, Bureau of Energy Efficiency, explained the normalization factors identified for the  refinery sector and obligations to be fulfilled by DCs as per PAT Rule.

Mr. K K Chakarvarti, Expert Consultant, Bureau of Energy Efficiency, apprised the audience that as PAT moves in to the subsequent cycles of implementation, the targets for energy efficiency for the existing and new sectors are expected to become more challenging, with the need to build the capacity of the industry and enhancing the knowledge of the industry on new technologies. KEP as a platform is assisting PAT sectors by disseminating information on all these aspects by organizing sector & cross- sectoral workshops, sector learning group meetings, policy roundtables, sector specific best practice case studies and energy efficiency exchange visits. He mentioned that KEP is committed to supporting industry in all their effort towards meeting the national energy efficiency goals. His presentation also envisaged success stories of National Energy Conservation Award (NECA) winners from the refinery sector. He mentioned that huge opportunities exist within the plant while maintaining or enhancing the productivity of the plant. Some of the areas where the plant can identify the energy efficiency improvement are utilities, fired heaters, process optimization and steam from waste heat.

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Panelists of the first technical session while receiving mementos

The second technical session focused on energy efficiency technologies available for Refinery sector. The session was Chaired by Mr. Milind Deore, Energy Economist, Bureau of Energy Efficiency. This session was planned in a manner that it brought together the technology providers and industry representatives with a view to promote interactions between the two stakeholder groups that can help in facilitating adoption of cleaner technologies. The session had presentations on technologies available for various operating areas viz. Frigitech technology for air conditioning and refrigeration which improves heat transfer and reduces internal friction by Greenwave Products Pvt. Ltd, solutions to improve upon energy efficiency in compressed air system by Atlas Copco (India) Limited, energy efficient cooling towers by Armec Cooling Towers, applications of Computational Fluid Dynamics for oil & gas refineries by Mechwell Industries Limited and energy conservation opportunities in steam & condensate network by Forbes Marshall.

Panelists of the second technical session while delivering their presentations

The third technical session was focused on sharing of experience of the Certified Energy Auditors and experts on energy efficiency in electrical and thermal utilities, was chaired by Mr. K K Chakarvarti, Expert Consultant, Bureau of Energy Efficiency. The presentation by Devki Energy Consultancy Pvt. Ltd. explained the challenges & energy efficiency opportunities in electrical utilities viz. cooling water pumps, compressed air systems, process pumps and process compressors. The presentation by International Copper Association India explained the opportunities in electrical motors. He informed the participants that as per the Gazette notification issued on 19th January, 2017, it specifies that minimum energy performance standards for 3phase induction motors in India shall be IE2 class from 1st October, 2017. This means the industry will have to buy fresh stocks of efficient ones (IE2/IE3) to meet their new motors requirement. The presentation by SyGuru Innovators Private Limited explained the strategies that can be adopted for enhancing energy efficiency in compressed air system viz. optimum pressure rating of compressor should be adopted, the cold condensate should be used to pre-cool air streams as it reduces the consumption of chilled water use and ensuring low DP across filters.

The presentation by STEAG Energy Services (India) Pvt. Limited explained the energy saving opportunities in captive/co- generation plant viz. by optimizing water balancing, reducing malfunction of steam traps, improvements in condenser vacuum, minimizing boiler losses, using waste heat for generating power for refrigeration and air conditioning units by using Vapor Absorption (VAM) etc. The presentation by Energetic Consulting Limited explained the energy saving opportunities in thermal utilities. The energy optimization in thermal utilities can be achieved by integrating process and electricity generation, upgrading low temperature energy for different applications and process interventions for substituting cooling demand by secondary energy generation.

Mr. K K Chakarvarti presenting memento to the panelists of third technical session

The fourth technical session focused on sharing the best practices implemented by industry and cross- sectoral best practices that can be adopted by refinery sector, was chaired by Mr. I.H. Shivaraya, Director, Centre for High Technology. The presentation by Hindustan Petroleum Corporation Limited (HPCL), Mumbai highlighted the energy savings achieved by routing the rich amine flash drum gases of ARU to Prime G+ furnace and power recovery through back pressure steam turbine which resulted in annual fuel savings of 864 SRFT and 1096 SRFT respectively. The presentation by Confederation of Indian Industry highlighted the applications of the cross-sectoral technologies that can be adopted by refinery sector viz. Multistage Drag Valves, Computational Fluid Dynamics, Micro-turbines, Gas Expanders, Intermediate Controllers for compressed air and Turbo Blowers. The presentation by Engineers India Limited explained the energy efficiency improvement areas that industries should focus on viz. process optimization & integration, hydrogen & fuel management, optimum utilities utilization and equipment oriented approach.

Mr. I.H. Shivaraya presenting memento to the panelists of fourth technical session

On behalf of Bureau of Energy Efficiency and Knowledge Exchange Platform, Mr. Milind Deore thanked the top management of Indian Oil Corporation Limited and the entire team of IOCL for extending their earnest support in organizing this workshop and pulling through an event of this scale. He also expressed his appreciation to the speakers and delegates who participated in the workshop and thanked them for their comments and suggestions and assured that each will be given consideration so that future workshops will be even more of a success.

The workshop had participation from over 90 eminent industry leaders of refinery sector, industry associations, energy auditors & managers and technology suppliers

Participants at the Western Region Workshop on “Capacity Building of Officers from Petroleum Refinery Sector on Efficient Use of Energy”

INAUGURAL SESSION (9.30 AM- 10.00 AM)
Lighting of Lamp
Welcome Address

Mr. Milind Deore, Energy Economist, Bureau of Energy Efficiency
Inaugural AddressMr. Sudhir Kumar, Executive Director, Indianoil Corporation Limited, Gujarat Refinery
Vote of ThanksMr. Subhajit Sarkar, General Manager, Indianoil Corporation Limited, Gujarat Refinery
TEA BREAK (10.00AM -10.20 AM)
SESSION (10.20 AM – 10.40 AM): BEST PRACTICES IMPLEMENTED BY THE HOST REFINERY
Best Practices implemented by IOCL, Gujarat, Refinery• Mr. SVS Harish, Process Manager, Indianoil Corporation Limited, Gujarat Refinery
TECHNICAL SESSION I (10.40 AM – 11.20 AM): OVERVIEW ON PERFORM, ACHIEVE & TRADE(PAT) SCHEME
Overview of PAT Scheme and implementation framework for Petroleum Refinery Sector

Normalisation & Obligations of DCs as per PAT Rules
Mr. Milind Deore, Energy Economist, Bureau of Energy Efficiency

Mr. Sarabjot Singh, Sector Expert, Bureau of Energy Efficiency
PAT- An Opportunity to reduce energy intensity and associated costMr. K. K. Chakarvarti, Expert Consultant, Bureau of Energy Efficiency
TECHNICAL SESSION II (11.20 AM – 12.45 PM): TECHNOLOGY SOLUTIONS TO ENHANCE THE ENERGY EFFICIENCY INDEX IN ELECTRICAL & THERMAL UTILITIES BY TECHNOLOGY SUPPLIERS
ChairmanMr. Milind Deore, Energy Economist, Bureau of Energy Efficiency
Electrical Utilities
Energy Savings in HVAC systemMr. P K Gajjar, GM Sales, Greenwave Products Pvt. Ltd.
Energy Efficiency in Compressed Air SystemMr. Ujval Pandya, Area Sales Manager, Atlas Copco Compressor Technique
How Green / Cool & Energy Efficient is your cooling system
Mr. Shailesh Harani, Managing Director, Armec Cooling Towers
Part BMr. Shailesh Harani, Managing Director, Armec Cooling Towers
Thermal Utilities
Applications of CFD for Oil & Gas RefineriesMr. Akshay Shah, Sr. Engineer Marketing, Mechwell Industries Limited
Energy Conservation Opportunities in Steam & Condensate Network of Refineries Mr. Vishwas Patil, Manager - Energy Services, Forbes Marshall
LUNCH BREAK (12.45 PM – 1.45 PM)
TECHNICAL SESSION III (1.45 PM – 3.00 PM): ENERGY EFFICIENCY IN ELECTRICAL & THERMAL UTILITIES
ChairmanMr. K. K. Chakarvarti, Expert Consultant, Bureau of Energy Efficiency
Electrical Utilities
Improvement opportunities in Electrical Utilities Mr. R. Paraman, Director, Devki Energy Consultancy Pvt. Ltd.
Energy conservation through High Efficiency MotorsMr. Lokesh Sharma, Associate, International Copper Association India
Improvement opportunities in Electrical Utilities Mr. Som Derashri, Managing Director, Syguru Innovators Pvt Ltd
Thermal Utilities
Energy Savings in Captive power/Co-generation power plant Mr. KG Sudhan Ramkumar, Steag Energy Services India Pvt. Ltd.
Improvement opportunities in Thermal UtilitiesMr. Rakesh Desai, Executive Director, Energetic Consulting Pvt Ltd.
TEA BREAK (3.00 PM – 3.30 PM)
TECHNICAL SESSION IV (3.30 PM – 4.45 PM) : BEST PRACTICE & CROSS SECTORAL CASE STUDIES
ChairmanMr. I.H. Shivaraya, Director, Centre for High Technology
Case Study from Petroleum Refinery Units: Best practices adopted by the unit by selected Refinery
Best Practices adopted in the area of energy efficiency Mr. Mohit Naidu, Sr. Manager, HPCL Mumbai
Mr. Anand Wagh, Sr. Manager, HPCL Mumbai
Cross Sectoral case studies: Best Practices related to energy efficient technologies adopted in other sectors
Cross Sectoral Best Practices that can be adopted by Refinery SectorMr. Dinesh Ghai, Senior Counsellor, Confederation of Indian Industry
Energy Reduction Measures for Petroleum Refineries- EIL ExperienceMr. S C Gupta, DGM (R&D), Engineers India Limited
CONCLUDING SESSION (4.45 PM – 5.15 PM)
Open House Discussion
Concluding Remarks by

Mr. I.H. Shivaraya, Director, Centre for High Technology

Mr. Milind Deore, Energy Economist, Bureau of Energy Efficiency

Mr. K K Chakarvarti, Expert Consultant, Bureau of Energy Efficiency

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