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Certificate of Merit

Petrochemicals

OIL AND NATURAL GAS CORPORATION


LIMITED
Hazira Plant, Surat (Gujarat)

Unit Profile
Hazira Plant, set up in 1985 & the largest sour gas-processing complex in the
country, has presently been processing about 34-35 MMSCMD of Sour Gas and
approx 5000-6000 M3/ day of Sour Condensate to produce Sweet Gas & Value
Added Products, viz. LPG, Naphtha, SKO, ATF, HSD & Propane. The feedstock in
the form of Sour Gas and Sour Gas Condensate is received from different fields, of
B&S Asset of ONGC and PMT-JV consortium, located in Mumbai offshore. Hazira
Plant Complex sprawls over an area of about 640 hectares with approx. 19 Kms of
peripheral boundary wall. Plant has a direct strength of 820 employees.
The Plant is of strategic importance to the nation as the 3000 Km HVJ Pipeline
emanates from Hazira Plant. It is the life line to scores of industries ranging from
Fertilizer to Power, Petrochemical, CNG, Domestic Supply, Ceramic and others in 6
states of India.

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The state-of-the-art process facilities developed at Hazira Plant and its role in
overall national economy makes it a jewel in the crown of ONGC. The plant has
kept pace with the latest developments in the world to upgrade the technology and
safe working practices. An integrated QHSE Management System has been in place
incorporating the international accreditations of ISO-9001:2008, ISO-14001:2004
& OHSAS-18001:2007. Health, Safety and Environment is the foremost concern
with elaborate provisions using latest concept and gadgets for safety, effluent
treatment plants and 30% of total land is maintained under flora & fauna (Green
Belt).
Hazira Plant also produces power at its Cogeneration Power Plant through three
gas turbine generators, totaling about 60MW capacity. Electric power to all the
facilities of the Plant as well as to the township is supplied by the Cogeneration unit
and the surplus power is wheeled and exported to C2-C3 Plant Dahej & Mehsana
Asset of ONGC and GEB, respectively.
Hazira plant is self-contained with all utilities & offsite facilities such as water system,
air system, inert gas system, effluent treatment plants, product storage and dispatch
facilities, fire and safety system etc. for safe and smooth operation of the plant.

Energy Consumption
Energy Consumption details

2013-14

2014-15

Total consumption of electricity


(purchased + own generated
electricity consumption
within the plant)
(Lacs kWh/ year)

2660.34

2529.90

22878.95642

21757.10844

2013-14

2014-15

Total Electricity Consumption


in MTOE (Metric tonne of
oil equivalent)
Fuel Consumption for process heating
STEAM
Quantity used for process heating
(tonnes/ year)

LP

MP

HP

LP

MP

HP

1144589.2

1197417.25

613051.41

1339801

373100

651323

662000

667000

669000

662000

667000

669000

757718.05

798677.31

410131.39

886948.26

248857.70

435735.09

Weighted Av. Gross Calorific value


(GCV) (kCal/ Ton)
Total heat value of steam used
(Million kCal/year)

Total heat value of steam used


(Million kCal/year)

1966526.75

1571541.047

Absolute Savings and its percentage over previous year energy consumption
Elect. Saving
(Lac kWh)
in 2014-15

Thermal
(Fuel)
Saving
(Million kCal)
in 2014-15

Elect.
Consumption
(lac kWh) in
2013-14

Thermal
(Fuel)
Consumption
(Million kCal)
in 2013-14

% Elect.
Saving
(savings achieved/
electricity
consumption of
previous year)

% Thermal
(Fuel) Saving
(savings achieved/
thermal energy
consumption
of previous
year)

(i)

(ii)

(iii)

(iv)

(i) / (iii) x 100

(ii)/ (iv) x 100

130.45

394985.703

2660.34377

1966526.75

4.903501625

20.08544776

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Energy Conservation
Waste Heat Recovery:
Exhaust from the Gas Turbines is utilised in 3 Heat Recovery Steam
Generators(HRSG). By utilizing heat value of the fuel to the maximum extent (in
HRSG), Hazira Plant saves on precious resource (natural gas) as well as reduces
pollution & ensures emission on lower temperature.

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Savings:
Year

Steam from HRSG


waste Heat (MT)

Saving in
Rs. (Lacs)

2013-14

1052767.16

5661.36

2014-15

1257747.01

6763.66

Turbo Expander:
It works on Iso-entropic process. The work produced during expansion is conserved
and utilized for compression of the lean gas, thus makes it highly energy efficient.
Year

Energy Saving (KWH)

Saving in Rs. (Lacs)

16409910

311.79

2013-14

2014-15
11624584
Other
Energy Conservation Measures
Year

Project description

2013-14

220.87

Annual
saving
(Lac units)

Total
savings
(Rs. Lacs)

Investment
incurred on
the project
Rs. (Lacs)

Revamping of central AC plant at


Admn. Building including
replacement of 25 years old
reciprocating chiller unit & single
screen Air Handling Units (AHU)
with latest technology of Screw
Chillers & VFD
(Variable Frequency Drive)
controlled Double Screen AHUs.

3.61008

25.992576

99

2013-14

12 No. compressor house Lighting


made on auto mode (Timer mode)
with in-house efforts. Total 240
Nos. 250W HPMV lights were
made glowing in night time only.

2.73312

19.678464

0.18

2013-14

Installed 3000 Lts. per day capacity


Solar Water Heating system (6 nos.
x 500 LPD) at ONGC Guest House.

0.26280

1.89216

5.5

2014-15

Replaced 27 nos. of AHUs with


energy saver double skin AHUs
where-in air flow is controlled by VFD.

6.8766

49.51152

140

2014-15

Installed movement detectors in


Sub-stations Lighting System as
energy saving measure.

3.03648

21.862656

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Energy Policy

Energy Policy Main Points


Energy Conservation

Create Awareness all round by audiovisual means.


Emphasis on effective use of energy in any form.
Incorporate energy efficient design of systems in plants and
equipments (including transport equipments)
Use heat recovery systems and utilize the same for steam
generation, process heat requirement, air-conditioning etc.
Strict observation of methods of good housekeeping, best
up-keep of devices/equipments
All schemes & systems to have energy budgeting with clarity
of its use & efficiency
Conduct Energy Audit every year of all installations with
connected load above 500KW

Assist in Development of alternate sources of energy

Encourage use of Solar, Wind, Wave/Tidal, Hydel (run-of-theriver) & Hydrogen Energies for installations, townships &
automotive applications wherever feasible and get the Carbon
credit by reducing the carbon emission. Also avail the energy
subsidies.
Encourage development of Bio-Gas centers for residential
townships.

Promote Conservation of Oil

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Use of CNG as replacement of diesel, Kerosene etc.


Use of Natural gas as direct fuel.
Generate Energy by own power plant for internal use of plants
wherever gas is available instead of buying electricity from
the supply companies.
In case of marginal fields, where the gas is available a small
gas generating set/ gas turbine can be installed and power
generated and sold to power trading corporation, electricity
boards through a contract.