A Sunrise Project for a Sunshine Future Core Group

A Sunrise Project for a Sunshine Future

Captive Power Plant
-Encon Measures
A Sunrise Project for a Sunshine Future Core Group A Sunrise Project for a Sunshine Future Core Group
CONTROL ROOM
CMY-
1/2
TOSHIBA
GIS (66KV)
UB-2
UB-1
GTG-2
C
M
Y
H
R
S
G
-
2

STG-2
STG-1
GTG-1
C
M
Y
H
R
S
G
-
1

GTG-3
DB
H
R
S
G
-
3

C
M
Y
DB
DB
D
E
A
R
E
A
T
O
R
-
2

D
E
A
R
E
A
T
O
R
-
1

BFPs
To Process
CPP CONFIGURATION AT PARADIP
BSDG
N
A
P
N
A
P
H
S
D
H
S
D
H
S
D
H
S
D
F
O
F
O
FRP CT
FO/HSD/
NAPHTHA
PUMP BOP
CMY-
3/4
UB-4
UB-3
SIEMENS
GIS (66KV)
A Sunrise Project for a Sunshine Future Core Group
CPP MAJOR EQUIPMENTS & EFFICIENCY
Sl.
No.
Description Qty. Capacity
Standalone
Design
eff.(%)
Cogeneration/
Combined
Cycle design
eff.(%)

Expected
CPP
efficiency(%)*
1
Gas Turbine
(GE Frame 9E)
3
103.98MW
@ 39

C
31
79.2
76.1
(2GT+2STG+2UB)




79.3
(2GT+1STG+2UB)




81.4
(3GT+1UB)

2
Heat Recovery Steam
Generator (HRSG)
(Single Pressure drum)
3 220 T/H 70
3 Utility Boiler (UB) 4 300 T/H 86
74
4
Steam Turbine
(2Stages extraction
cum condensing Type)
2 30 MW 86
*Expected Power load 186.5MW (Including CPP consumption),
Net export to process units HHP 416 TPH, HP 175 TPH ,MP 144 TPH & LP 0 TPH
A Sunrise Project for a Sunshine Future Core Group A Sunrise Project for a Sunshine Future Core Group
Salient Features of Frame 9E Gas Turbine
S. No. GT Frame
Size
MW Rating
(ISO)
Design Heat
Rate (kcal/ kWH)
Remarks
1 Frame 5e 26 3250 Efficiency of Frame-9e m/c will
be greater than Frame-5e m/c if
the load is above 64MW and
greater than Frame-6e m/c if
the load is greater than 95MW
2 Frame 6e 42 2850
3 Frame 9e 126 2545
GT rated for 103.98MW at 39C ambient
Ambient temperature of Paradip in the range of 28 32C for majority of
the time

Hence, GT output assured in the range of 110 115MW with the Generator
(GTG) capacity at 118.3MW .
A Sunrise Project for a Sunshine Future Core Group A Sunrise Project for a Sunshine Future Core Group
Salient Features of Utility Boilers & Flue Gas
Desulphurization System


Utility Boiler (UB):
Designed to operate on low cost High Sulphur Fuel Oil (HSFO) with 4.9%
Sulphur wt./wt.
Corner fired Burners for improved combustion efficiency (overall boiler
efficiency 86%)
Regenerative Air Pre-Heater for improved reliability & efficiency
2 ID & 2 FD Fans for each UB (All drives are Turbo & Motor Driven)
Flexibility in Fuel (Gas Oil, HSFO, Refinery Gas)
Electrostatic Precipitator (ESP) provided for ash absorption from Flue Gas
& meeting FGDS input requirement

Flue Gas Desulphurization System (FGDS):
Desulphurization of Utility Boiler (UB) Flue Gas to meet stringent
environment regulations for Paradip Refinery fixed at 1000kg/hr SO
2
.
Capacity of absorption of 12576 kg/hr SO
2
from Flue Gas (96% efficiency,
rated SO
2
flow 13100 kg/hr. in Flue Gas)

A Sunrise Project for a Sunshine Future Core Group
Major areas Identified (Short term)

Non essential loads on grid supply

Additional module of MUH in all three HRSGs for reduction in HRSG stack temperature from 170
deg C to 130 deg C

FG utilization for supplementary firing in HRSG

Utilization of SR Naphtha for firing in Gas Turbines

Minimizing Condenser loading during STG operation

Optimization of UBs and HRSGs BFP pumps operation through interconnection of headers

Stoppage of condensate transfer pump in CPP

Stoppage of 1 No. HSD (back up fuel) forwarding pump for GT

Rerouting of AA cooler DM water to Condensate storage tank



A Sunrise Project for a Sunshine Future Core Group
Major areas Identified (Long term)


Utilization of Natural gas instead of naphtha / HSD in GT/HRSG/UB

Installation of chiller at GT Inlet to Augment power output &Efficiency
( if there is LP steam surplus in the refinery post HRSGs WPH addition)




Adoption of Coal Water Slurry Fuel(CWSF) technology of M/s. Lemar
LCC, USA to burn pet coke in existing UBs
Or
Installation of pet-coke based CFBC UB
A Sunrise Project for a Sunshine Future Core Group
Energy Conservation Initiatives in
Electrical Distribution System
Variable Speed Drives being installed in process units & offsite (for
process control) provide substantial energy saving
Total capacity of VSDs being installed in Refinery 76.7MW (225 drives ranging
from 1.1 KW to 110KW at 0.4kV level & from 315KW to 8.2MW at 6.6kV level)
Even 10% energy conservation would result in recurring savings equivalent to
7.7MW. Actual savings would be much higher.

Capacitor Banks being installed for Power Factor (p.f.) Improvement
Total capacity of Capacitor Banks in the entire refinery equal to 50.64MVAR
Designed for Power Factor improvement from 0.9 to 0.93
Synchronous Motors of 7.927MW & 15.2MW installed which aid in p.f.
improvement
Improvement in capacity utilization of generators & reduced losses in distribution
network

Power Recovery Turbine Generator (PRTG) of 19MW being installed in
Indmax Unit for power generation from Process Flue Gas

A Sunrise Project for a Sunshine Future Core Group
Energy Conservation Initiatives in
Electrical Distribution System
Lighting Transformers for the entire lighting system being installed in
the refinery
Total 82 nos. Lighting Transformers being installed in the Refinery
Improved power system reliability through isolation of lighting circuit faults
Reduced voltage results in improved life of luminaires maintaining the desired light
output

Solar LED Street Lights installed in Township
26 nos. of 14W Solar LED lights installed in place of 70W LPSV Lights
Recurrent energy saving of Rs. 2.9 Lacs/ annum, payback period 3 yrs.

A Sunrise Project for a Sunshine Future Core Group
Energy Conservation Initiatives in
Electrical Distribution System
Adoption of Compact Fluorescent Lamps (CFL) in place of Fluorescent
Tube Light (FTL) in Township
Total 3393 nos. CFL being installed in place of FTL, energy saving & payback period
< 1 year
Adoption of CFL in place of FTL in all building lighting inside the Refinery on the
same lines

Illumination of entire refinery area through High Masts
Total 293 nos. of High Masts (each 8 x 1kW luminaires) installed for coverage of
entire area of about 2945 acres.
Localised area lighting & street lighting eliminated
A Sunrise Project for a Sunshine Future Core Group A Sunrise Project for a Sunshine Future Core Group
11
A Sunrise Project for a Sunshine Future Core Group A Sunrise Project for a Sunshine Future Core Group
Utilization of Grid Power to non-critical loads
for operating cost reduction
Power supply arrangement to non-critical loads

The power supply to Administration Block, Township,
Mechanical Workshop, Electrical Workshop, CISF, Pipelines &
Marketing are fed from S/S#311N, S/S#311AN & S/S#312AN

The modification in power supply arrangement for utilizing grid
power is done with the existing resources and does not require
additional capital expenditure.

Grid Power is cheaper than incremental cost of generation in
Captive Power Plant

The cost differential works out to be approx. Rs. 3/- per unit
(kWH)
Hence, Total Cost Saving per annum for 15MW load
amounts to Rs.39.42 Crores

A Sunrise Project for a Sunshine Future Core Group
Flue Gas Desulphurization System (FGDS)
UBs
C
h
i
m
n
e
y
SO
2

Absorption
Tower
(=96%)
(Unit 107)

HSFO
4.9% (wt./wt.)
SO
2
Stripper
(Unit 109)
SRU
SO
2
SO
2

absorbed
Rich Amine
Lean
Amine
315
m3/hr
FG
180 deg c
Quench
Tower
(Unit 107)

Quench Water
Circulation
(Service/Fire)
FG
56 deg C FG SO
2

<150 ppm
(v)
LP
Steam
Limit for SO
2
emission for
Paradip Refinery is 1000 kg/hr.
A Sunrise Project for a Sunshine Future Core Group

FG HEADER OF CPP
Existing FG Header
Proposed FG Header
Utility Boilers
HRSG
A Sunrise Project for a Sunshine Future Core Group
Scheme Proposed Potential Savings Action Plan
FG header extension up to existing
individual FG skid of
Supplementary firing of HRSG
102 Crores /Yr

FG header is not erected for
UBs. Header extension job will
be carried out by TS.
Present scheme
FG Header is existing for UBs.

Proposed scheme
For HRSG Supplementary firing FG header is to be extended up to
existing FG skid of each HRSG.

Benefits
HRSG Naphtha firing will be reduced and steam flow will be maintained
by FG firing. At UBs, FG firing will be reduced with increase in HSFO
consumption. The cost differential of Naphtha &HSFO for 33 Mkcal
supp. Firing works out to be 102 Crs/yr.

A Sunrise Project for a Sunshine Future Core Group
DM water line
Condensate storage tank
Condensate transfer pump (3)
12 kg/sqcm
LCV
LCV
LCV
W/W heat exchanger
HRSG MUH
Deaerator 2
Condensate receiving line
W/W heat exchanger
MUH transfer pump (3)
Deaerator 1
Bypass line
Equipment to be bypassed
7 kg/sqcm
Condensate transfer pump bypass scheme
Potential Savings by stopping 2 Nos CTP(385 KW) works out to be 4.3 crs/yr
A Sunrise Project for a Sunshine Future Core Group
Scheme Proposed Potential Savings Action Plan
Additional module of MUH in all
three HRSGs
64.00
Crores/Yr
(for 2 HRSGs
Operation)
Offer sought from BHEL Trychi
in May2013.
Present scheme
Design Flue gas temperature from HRSG is 170 Deg C which is very high if we
burn SR Naphtha (Sulphur 250 to 400 ppm) instead of design fuel SR GO.
This temperature can be reduced up to 130 Deg C
Proposed scheme
This can be achieved by adding additional module of MUH in HRSG after existing
MUH Module.
Condensate after W/W exchanger can be routed to De-aerator through this
module
This scheme is discussed with M/s BHEL. Offer is sought in May2013.However
M/s BHEL, Trychi agreed to execute it after PGTR.
Benefits
Flue gas temperature can be reduced by 40 Deg C ( 170 to 130 Deg C)
Condensate Water temperature to De-aerator can be increased from 78 to 108
A Sunrise Project for a Sunshine Future Core Group
Scheme Proposed Potential Savings Action Plan
Utilization of untreated naphtha
for firing in Gas Turbines
30.00 Crores/Yr

Implemented.
Present scheme
Facilities available with hydro-treated naphtha and HSD utilization
Hydro-treated naphtha is obtained after hydro-treatment and
splitting
Proposed scheme
Facilities for utilizing untreated naphtha in gas turbines
Utilizing the untreated straight run naphtha (SO2 content -500 ppm
max)
Benefits
Savings on the treating cost for the naphtha
A Sunrise Project for a Sunshine Future Core Group
HRSG BFP
FLOW: 295 m3/h(Each pump)
P
UB BFP
FLOW: 585 m3/h(Each pump)
UBs
HRSGs
Scheme Proposed
Potential Savings Action Plan
UB and HRSG discharge headers
interconnection to optimize
operation. 2 UBs and 2 HRSGs
load will be met by running 2 UB
BFPs and HRSG BFP (2.1 MW)
would be stopped.
14 Crs /Yr

Scheme implemented
A Sunrise Project for a Sunshine Future Core Group

GT Power without chiller MW 114
Relative Humidity % 60 60 60 60 85 85 85
85
Temp U/S of Chiller DegC 33 33 33 33 33 33 33
33
Temp D/S of chiller DegC 25 22 20 18 25 22 20
18
Refrigeration capacity Tr 641 157 2826 3610 3073 4053 5338
6148
Electrical power reqd for
refrigeration
KW 100 245 441 563 479 632 833
959
Net GT Powerv (Less chiller
power)
MW 120 122 123.5 125 120 122 123
125
Incremental power due to chiller MW 6 8 9.5 11 6 8 9
11
Capital cost of chiller plant Rs Cr
2.9 7.1 12.7 16.2 13.8 18.2 24
27.7
PAYBACK ANALYSIS
Heat Rate Saving Kcal/Kwh
37.63(Heat rate@18DegC-2521.2)
Heat rate saving@90MW for
8000Hrs
KCal 27093600000
Naptha Fuel saaving/Year RsCR 12.54 (Calorific value-10800Kcal/Kg,Cost-Rs 50000/MT)
Payback Period Year
2.2
I/L heat reqd for Chiller of 6148Tr Kcal 18444000(1TR~3000KCal)
Heat Saved Kcal 3386700
% of I/L Heat saved % 18.36
GT Fr9E-I/L air cooling Payback Waste Heat-HRSG Stack