HPCL MEA REPORT 6 June 2017 Submitted

Report On
MANDATORY ENERGY AUDIT
for
HPCL-MUMBAI REFINERY,
MUMBAI
Conducted by
Petroleum Conservation Research Association

(Under Ministry of Petroleum & Natural Gas)
Western Region, C-5 / Keshava Building
Gr Flr, Bandra-Kurla Complex, Bandra (E)
Ph No: (022) 2659 2181 / 26592587 Fax No: (022) 26590034
Email: pcrawr@pcra.org
APRIL 2017
MEA 2017 HPCL Refinery Mumbai Page 1

Contents
1. ACKNOWLEDGEMENT ............................................................................................................................... 3
2 . E X C E C U T I V E S U M M A R Y .............................................................................................................. 4
3 . I N T R O D U C T I O N AB OU T T H E P L A N T ................................................................ 7
3 . 1 G N E R A L P L A N T / E S T A B L I S H M E N T D E T A I L S A N D
D E S C R I P T I O N S ................................................................................................................................... 7
CHAPTER-II: P R O D U C T I O N P R O C E S S D E S C R I P T I O N ....................................... 13
CHAPTER-III ............................................................................................................................................................... 21
CHAPTER-IV ............................................................................................................................................................... 28
CHAPTER-V ................................................................................................................................................................ 31
CHAPTER-VI ............................................................................................................................................................... 35
1.1 CONSERVATION MEASURES ...................................................................................................................................
2. COGENERATION POWER PLANT GAS TURBINE AND HRSG ..............................................................................
2.1 BACKGROUND ................................................................................................................................................. 37
2.2 FUEL GAS ANALYSIS ......................................................................................................................................... 39
2.3 COMBUSTION GAS TURBINE PERFORMANCE OF GT 1, GT 3 AND GT 5 ....................................................................... 40
2.4 HRSG PERFORMANCE OF GT 1, GT 3 AND GT5 .................................................................................................... 41
2.4.1 CPH PERFORMANCE ..................................................................................................................................... 41
2.4.2 ECONOMISER CIRCUIT PERFORMANCE.............................................................................................................. 42
2.4.3 EVAPORATOR OF HRSG 1, HRSG 3 AND HRSG 5 ................................................................................................... 43
2.4.4 SUPERHEATER PERFORMANCE ............................................................................................................... 43
3. UTILITTY BOILERS ........................................................................................................................................ 45
3.1 BACKGROUND ................................................................................................................................................. 45
3.2 BOILER SG 12 PERFORMANCE............................................................................................................................ 46
3.3 BOILER SG-10 PERFORMANCE ........................................................................................................................... 50
3.3.1 FD FAN OF BOILER SG 10 PERFORMANCE.......................................................................................................... 51
4. ENCON MEASURES ..........................................................................................................................................
4.2 LOW EFFICIENCY OF HRSG 1, HRSG 3, AND HRSG 5 .......................................................................................... 135

4.3 DRY FLUE GAS LOSS IN BOILER SG-10 AND BOILER SG-12 .................................................................................... 135
4.4 REPLACEMENT OF VHP BFP PUMP OF BOILER SG12 WITH SMALL SIZE PUMP ........................................................... 136
4.5 USE OF PLATE HEAT EXCHNGER INSTEAD OF FIN FAN COOLERS FOR GENERATOR LUB OIL COOLER WATER ..................... 136
4.6 INSTALLATION OF VFD FOR FD FAN OF BOILER SG-10 ......................................................................................... 137
4.7 REPLACEMENT OF FD FAN SUCTION FILTERS OF SG-12 ........................................................................................ 139
4.8 VHP HEADER INTERCONNECTION FOR SG-10, SG-11 AND SG-12 BOILERS.............................................................. 140
4.9 THERMAL IMAGING .......................................................................................................................................... 53
CHAPTER-VII ............................................................................................................................................................ 120
CHAPTER-VIII ........................................................................................................................................................... 126
ANNEXURE-2: COST SAVINGS BY REPLACING GRID POWER BY ROOFTOP SOLAR PV SYSTEM (CAPEX MODEL) .... 135

ACKNOWLEDGEMENT
We express our sincere gratitude to M/s. Hindustan Petroleum Corporation Ltd,
(HPCL) Mumbai Refinery, Centre for High technology (CHT), Ministry of
Petroleum and Natural Gas (MoP&NG) , Government of India for giving us the
opportunity to be a part of PAT program and to present the findings of
Mandatory Energy Audit of M/s Hindustan Petrole um Corporation Limited,
Mumbai Refinery.
We are thankful to M/s. HPCL, Mumbai Refinery, for their positive suppo rt in
undertaking this intricate task of Mandatory Energy Audit under PAT scheme of
Encon Act. The field studies would not have been completed on time without the
help interactions and timely support of following officers . We are grateful for
their co-operation during field studies and provision of all essential data for the
study.
Team of HPCL, Mumbai Refinery:

 Shri A.B. Chattopadhyay - General Manager Technical
 Ms. Jolly Sony - Chief Manager (Technical)
 Mr .B. Nayak & Team - Chief Manager (Electrical)
 Ms. Anurekha Bauri - Deputy Manager (Technical)
 Mr. Ajay Singh - Dy Manager (Technical)
M/s. Petroleum Conservation Research Association

 Ajith Kumar K.R. - AEA (Reg no 239 ).
 Mr. Shashank Herlekar - Certified Energy Auditor and AEA
 Mr. Atul D Vyawahare - Certified Energy Auditor -WR
 Mr. Dilip Makwana - Certified Energy Auditor- WR
 Lokesh Chourasia - CPP expert
 7 more team members of PCRA

Last but not the least; we are thankful to a ll officers and employees of HPCL,
Mumbai Refinery, with whom we interacted during the field studies for their
wholehearted support in undertaking measurements and eagerness to assess the
system / equipment efficiencies and saving potential.
Shashank Herlekar
Regional coordinator & Addl. Director PCRA WR
D. Roy Choudhury
Chief Regional Coordinator and Director
PCRA WR

EXECUTIVE SUMMARY
Mumbai Refinery of M/s. HPCL, spread on an area of 321 Acres, is engaged in oil
processing. The installed (nameplate) capacity of the refinery is 7 .5 MMTPA.
This versatile refinery which is the first of India’s modern refineries, symbolizes
the country’s industrial strength and progre ss in the oil industry. Mumbai
Refinery has grown over the years as the main hub of petroleum products. The
refinery has reached to present level through several up -gradation and
restructuring processes.
Electricity and fossil fuels are the main resource s of energy. The refinery power
demand depends mainly on 7.18 MW X 4 nos. and 20.39 MW X 1 no. Gas Turbine
(GT) captive power plant and partly on grid. The refinery generates elect rical
power which is consumed for different purposes. It also purchases power from
the TATA Power grid at 110 KV and 22 KV and step down to 6.6 KV, 3.3 KV, 0.415
KV through transformers and is distributed for different purposes . The
dependency on own generation is because of higher power quality and
reliability.
A comprehensive energy conservation study of the plant was carried out by Team
PCRA to identify potential areas of energy conservation and recommend energy
savings measures along with cost benefit analysis.

Potential Saving Areas:
Sr. Energy Saving Measures Investment Energy Kcals Thermal Electricity Payback
No savings savings in
MWH
Rs Lac Lakh Rs Month
1 HRSG 1 Efficiency improvement 877.9 35117063716
4 Dry flue gas loss in Boiler SG12 improvement 75.7 3332499612
5 Dry flue gas loss in Boiler SG10 improvement 246.8 10858567611
6
Replacement / Installation of VHP BFP Pump 50.0 83.1 1039.47 7
of Boiler SG12 with small size pump
7 Use of Plate Heat Exchanger instead of Fin Fan
coolers for Generator Lube Oil Cooling for all 50.0 93.77 1172.16 6
Gas Turbines
8 FD Fan Suction choked Filter replcement 20.0 38.5 530 6
9 VFD for FD Fan of SG-10 & SG-11 66 42.4 825.792 7
10
Interconnection of VHP BFW Header of Boiler 100.0 209.7 2621.5 6
SG-10, SG-11, and SG-12
11 Thermal Insulation heat loss reduction in CPP 4978399156
124.5
HRSG
12 Reducing pressure drop in various dryers by
120.0 76.3 954.0 18.9
replacing the decissicant
13 Improving & maintaining performance of
12.0 15.5 193.6 9.3
chillers
14 Replacing various lamps with LED lamps 157.0 134.6 1681.9 14.0
15 Replacing four SBR blowers (lobe type) with
128.0 114.0 1425.6 13.5
high efficiency turbo blower (centrifugal)
16 Installing solar hot water system for canteen
hot water applications 3.75 1.8 - 25.4
17 Installing solar PV systems on Admin Building,

Old Admin Building, Electrical Building, Old
263.25 38.9 486.0 81.3
Admin Building and LR& LOUP Control Room
(total 405 KW)
Total 970 3606.97 11225.97 MT 10930
Conversion from 10930 MWH = 10930000/5164 = 2116.6 MTOE
Total Oil equivalent MTOE = Thermal kcals / 10000000 converted in MTOE + MWH convertred in MTOE
= 11225.97 MTOE + 2116.6 MTOE
Total MT of Oil Equivalent (MTOE) savings = 13342.57 MTOE

1. I N T R O D U C T I O N ABOUT T H E P L A N T
i. GENERALPLANT/ESTABLISHMENT
DETAILS AND DESCRIPTIONS
HPCL’s Mumbai Refinery was established in 1952. Through progressive

revamps/ capacity expansions, curre nt crude oil processing of HPCL-MR is 7.5
MMTPA. It currently has two trains of primary distillation units (CDU -I and
II), secondary processing facilities viz. FCCUs, DHDS, MS Block (NHT/ISOM,
NHT/CCR and Prime -G), LOBS production facilities and other associated
treating and utility facilities.
The refinery has recently implemented the DHT project which includes
processing facilities such as a new Diesel Hydrotreating Unit, SRU, ARU, SWS
and necessary utilities and offsites. With the installed facilities, the refinery
shall be ab le to produce Gasoline and Diesel, meeting Euro IV quality
specifications, besides other petroleum products like LPG, Naphtha,
Kerosene, ATF, Fuel oil and Sulphur.
1 Name of the Unit Hindustan Petroleum Corporation Ltd
2 The sector in which unit falls Petroleum Refinery (PSU)
3 (a) Complete address of Unit's location (including Hindustan Petroleum Corporation Ltd
Chief Executive's name and designation) with Mahul, Chembur East, Mumbai 400 074
mobile, telephone, fax numbers and e-mail.
(b) Year of establishment 1952
4 Registered office address with telephone, fax numbers and

e-mail M/s. Hindustan Petroleum Corporation Ltd
Mahul, Chembur East, Mumbai 400 074
5 Name, designation, address, mobile, telephone, fax Ms Jolly Sony

numbers and e-mail of energy manager Chief Manager – Technical Department
Add. 2nd floor, Admin Building, HPCL Refinery, B.D.
patil Marg, Mahul, Mumbai : 400074
Phone: 022 25076400
Mobile: 9869405405
Email ID: jollys@hpcl.in
6 Period of field data collection survey of Energy Audit February 27th, 2017 to April 4th, 2017

Installed Capacit y of each unit at HPCL Refinery :
Name of the Unit Installed Capacity
Fuel Refinery
CDU-PG 4000 TMTPA
CDU-BH (Expansion) 3500 TMTPA
VDU-PG (FR) 21200 BSD
VDU-BH 27170 BSD
Propane Unit 12.35 M3/hr
Hexane Manufacturing unit 71.7 M3/hr
Hexane Treating unit (NMP) 14.7 M3/hr
DHDS 2275 TMTPA
Diesel Hydro-Treating (DHT) 1760 TMTPA
Hydrogen Unit 14.5 TMTPA
DHDS-SRU 2X65 TPD
DHT-SRU 2X65 TPD
FCCU 1000 TMTPA
New FCCU (check case) 1456 TMTPA
New FCCU (Design case) 1276 TMTPA
ATF Treating Unit 11000 BSD
Lube Refinery
VDU-PG (LR) 21130 BSD
Solvent Extraction Unit-I 5358 BSD
Solvent Extraction Unit-II 5358 BSD
Solvent Extraction Unit-III 5358 BSD
Propane Dewaxing Unit 335 TMTPA LOBS
Propane De-Asphalting Unit 755 TMTPA
LOUP UNIT (GR-II LOBS) 227 TMTPA
MS block

NSU 1222 TMTPA
NHT/CCR 545 TMTPA
NHT/ISOM 250 TMTPA
Prime-G+ 475 TMTPA
SWSU 120 M3/hr
ARU 260 M3/hr
LTU 439 TMTPA

1.1 Energy Audit team:
The detail of the study team including Designation, Professional qualification

& experience are furnished as under.
Sr No Name Qualification Designation Experience

1 Ajith Kumar K.R. B Tech Mechanical Addl Director 26 years industrial and
Engg PCRA and AEA auditing experience
2 Shashank BE Electrical Engg, Addl Director 25 years industrial and
Herlekar PCRA WR, auditing experience
M Tech elect.
Regional
Coordinator
WR and AEA
3 Atul D B Tech Chem Engg Addl Director 27 years industrial and
Vyawahare PCRA WR and auditing experience
Cert. EA
4 Mr. Dilip BE Chem. Engg SRO and cet. 8 years industrial and
Makwana EA auditing experience
5 Mr. Lokesh BE Mech Engg CPP expert 12 years industrial and
Chourasia auditing experience
6 7 engineers of Engg Field More than 5 years field
PCRA team engineers experience

List of Instruments utilized during the field survey:
1. Tri-vector Power meter with 3 clamp-on type CTs for measurement of unbalanced and balance load.
2. Tri-vector Power meters with 1 clamp-on type CT for measurement of balance load.
3. Flue Gas analyzer.
4. Vane type Anemometer.
5. Hot wire type Anemometer.
6. Digital temperature indicator for liquids.
7. Digital temperature indicator for surface.
8. Infra red digital temperature indicator for surface.
9. Thermal Imager for thermography of electrical panels, HVAC & Chilled Water System
10. Digital Hygrometer for temperature and humidity measurement.
11. Transit time Ultrasonic non-contact flow meter for measurement of liquid flow rates.
12. Lux Meter.
13. Digital pressure gauges
14. Ultrasonic leak detector
15. Ultrasonic distance meter

1.2 Component of production cost (raw materials, energy, chemicals,
manpower, overhead, others):
The monthly expenses sheet is shown in the following table.
Per unit
Description Rs cr UOM cost(Rs/T)
- Imported Crude 1147 405 TMT 28321
- Indigenous Crude 845 279 TMT 30287
other raw materials 3
Hydrogen 8 570.5 T 140228
BH/RLNG 7 2513.1 T 27854
Demmurage/wharfage 3
Manpower 31
chemicals and catalyst 8
M&R 13
Insurance & taxes 3
Equipment Hire Charges 0
Rent 0
Travelling and Conveyance 1
Printing and Stationery 0
Electricity 32 44326.18 7.22 Rs/KWH
Water 1
Security Expenses 2
Consultancy & Technical Services 0
Other purchased services 2
Sundry Exp. 1
Environment Protection / Upgradation 0
HQO overheads/inter-func.charges 3
Depreciation 34
Interest Exp. 6
Total 2151
1.3 Major energy use areas :
The major consumers of energy resources include

 Heaters , Utility Boilers, GTs
 Air compressor
 Nitrogen compressors
 Pumps – Cooling water & process
 Process blowers & compressors
 Cooling Towers

Chapter-II: P R O D U C T I O N P R O C E S S D E S C R I P T I O N
2.1 Brief description of manufacturing process :
The HPCL Mumbai Refinery has following four main processing complexes. The
Fuels Refinery produces fuels from the crude by distillation & by removing
impurities. It has two major complexes viz. Fuels Refinery, DHDS/DHT and GFEC.
DHDS/ DHT was commissioned in the year 2000/2011 respect ively for production
of various Bharat Grades diesel. GFEC was commissioned in 2010 for production
of Euro III/IV MS. The Lube Refinery manufactures lubricant base material,
which, after adding additives by Marketing is sold as finished lubricants for
automobiles.
FUELS REFINERY:
Fuels Refinery has following processing units.
a. Fuels Refinery Crude Distillation Unit (FR CDU ):
FR – CDU has design capacity to processes 3.5 MTPA imported Persian Gulf crude.
Crude oil is heated in crude preheat exchangers utilizing the available waste
heat. It is further heated in furnaces and then fractionated in the distillation
tower to get various products like LPG, Naphtha, Flash Blending Stock, Aviation
Turbine Fuel, Kerosene, MTO, Light Virgin Gas Oil, Heavy Virgin Gas Oil and
Reduced Crude Oil. From these products LPG, Naphtha, Kerosene & MTO are
finished products. Others are intermediate pr oducts going to further processing
units.
b. Fuels Refinery Vacuum Distillation Unit (FR VDU):
Reduced Crude Oil is the bottom product of CDU. It is further heated in VDU
furnace & then sent to distillation tower operating under vacuum condition.
Intermediate products are obtained from VDU. Lighter Vacuum Gas Oil goes to
diesel. The other intermedia te products viz. I SS (Side Stream), II SS & III SS go
to FCCU for converting into valuable products by cracking or to Lube Refinery

for manufacturing lubricant base oils. The bottom product Vacuum Tower
Bottoms either goes for making Asphalt or to Lube Re finery PDA unit for
producing Bright Stock.
c. Fuels Refinery Expansion Crude Distillation Unit (FRE CDU ):
FRE – CDU has design capacity to processes 3.0 MTPA Bombay High low Sulphur
crude. Crude oil is heated in crude preheat exchangers utilizing the avai lable
waste heat. It is further heated in furnaces and then fractionated in the
distillation tower to get various products like Naphtha, Flash Blending Stock,
Kerosene, Light Virgin Gas Oil, Jute Batching Oil and Reduced Crude Oil. From
these products Naph tha, Kerosene are finished products. Others are
intermediate products going for secondary processing units.
d. FRE Vacuum Distillation Unit (FRE VDU):
The bottom product of CDU, Reduced Crude Oil from FRE CDU goes to FRE VDU.
Reduced Crude Oil is further h eated in VDU furnace & then sent to distillation
tower. Intermediate products are obtained from VDU. Lighter Vacuum Gas Oil
goes to diesel. The other intermediate products of FRE VDU viz. I SS (side
stream), II SS & III SS go to FCCU for converting into va luable products by
cracking. The bottom product Vacuum Tower Bottoms goes to fuel oil.
e. Naphtha Stabilizers:
Un-stabilized Light Virgin Naphtha obtained from CDUs is stabilized by

separating LPG and Naphtha by distillation. This Virgin LPG is then treate d with
Di-ethanol Amine (DEA) to remove Hydrogen Sulfide.
f. Hexane Maximization Unit (HMU):
Stabilized and sweetened Light Virgin Naphtha obtained from FR CDU is distilled
in this unit to produce raw Hexane, this is subsequently processed in NMP
extraction unit to remove aromatics for producing Food Grade Hexane. This
Hexane is used for extracting oil from seeds in the food industry.

g. Fluidized Catalytic Cracking Units (FCCU) Old and New:
Low value Vacuum distillates from FR & FRE VDU and Wax from Lube Refi nery
PDU are catalytically cracked in the FCC Unit to produce valuable products. The
products of this unit are unstab ilized cracked Naphtha, Cracked Gas Oil and
Residue. The cracked unstabilized naphtha is further separated into cracked LPG
& cracked naphtha. The cracked gas oil goes to diesel & resid goes to fuel oil.
h. Cracked LPG Manufacturing Unit:
Un-stabilized Cracked Naphtha and Cracked Gases produced in FCCU unit are
processed in this unit to yield Cracked LPG and Light Cracked Naphtha (LCN).
Cracked LPG is treated in DEA unit to remove Hydrogen Sulphide, whereas, LCN
is treated in Merox unit to remove Mercaptans. This treated LCN then goes to
PrimeG and then to Gasoline or petrol.
i. DHDS COMPLEX
This is the secondary processing unit complex. The purpose of the complex is to
reduce Sulphur in the diesel to meet various Bharat Fuel specifications. It has
the following units.
a. Hydrogen Generation Unit (HGU):
This unit generates pure Hydrogen required for hydro-fining of diesel. A

conventional process of steam naphtha reforming is used for manufacturing
Hydrogen. Pressure Swing Adsorption technology is used to separate this
product hydrogen from other impurities like carbon monoxide, carbon dioxide &
methane. The plant is designed to manufacture 43.5 tons/day of hydrogen.
b. Diesel Unionfining Unit (DUU):

This unit treats raw Diesel for removal of sulfur with the help of hydrogen from
HGU. Proprietary catalyst is used for the desulphurization reaction at high
temperature & pressure. The finished product diesel meets various Bharat Fuel
specifications. Originally it was designed to process 1.65 MMTPA of raw diesel
feed. The plant was revamped in 2015 using Iso therming technology offered by
DuPont, USA which increased the capacity of the unit from 1.65 MMTPA to 2.27
MMTPA and the diesel quality was upgraded from Euro -III to Euro-IV/V.
c. Sulphur Recovery Unit (SRU):
The Hydrogen Sulfide gas generated as a side product in the DUU/DHT is

converted into elemental sulfur by Claus process. This helps in reducing the
environmental pollution.
d. Diesel Hydrotreater Unit (DHT)
The DHT unit is designed to process the feed which mainly comprises straight
run diesel streams from FR/FRE CDU’s and light cycle oil (LCGO) streams from
FCCU/New FCCU. DHT unit is designed to process hot feed (directly from units)
as well as cold feed (from offsite storage tanks). The plant capacity is 2.2 million
tones per year with 8000 hours operating per year. The principal processing
objective of unit is to produce ULSD with sulfur content of 8 wt ppm or less.
About 540 Tons per day of Kerosene range product (TBP 140 -165 °C) will be
fractionated as a side stream product from fractionator column with flash point
above 38 °C.
ii. GREEN FUEL AND EMISSION CONTROL PROJECT
In order to meet Euro -IV MS norms towards a greener environment, HPCL

Mumbai Refinery commissioned a project called “Green Fuel and Emission
Control Project” (GFEC) for up -gradation of Motor Spirit fuel. The major changes
in specif ications of Euro -IV MS are with respect to higher Octane number, lower
Sulfur, Olefin, Aromatics and Benzene content.
The following process units are under GFEC Project:

 Naphtha Hydro-treating/Continuous Catalytic Reforming unit.
 PRIME G+ unit (FCC Gasoli ne Treating unit)
 NHDT/ ISOM unit. (Naphtha Isomerization unit)
 Associated facilities like Utilities, Offsite and auxiliary units.
The brief details of each major unit are given below:
a. NSU:
The Naphtha Splitter Unit splits the whole range naphtha into light naphtha (C5 -
90C) and heavy naphtha (90 -130 C) by the method of distillation.
b. NHT/CCR:
The purpose of this unit is to generate Reformate stream from straight run Heavy
Naphtha with high O ctane number and low Sulphur content for blending in Euro
IV MS pool. The design capacity of the unit is 545 TMTPA. Heavy Naphtha from
Naphtha Splitter Unit is hydrotreated to remove catalyst poison (Sulfur,
Nitrogen etc.). This hydrotreated naphtha is se nt for reforming and resultant
product (Reformate) high in RON is blended with MS pool.
c. PRIME G+:
The purpose of this unit is to desulfurize FCCU gasoline stream while maintaining
high Octane level (RON). The design capacity of the unit is 475 TMTPA. FCC
Naphtha is subjected to selective hydrogen desulphurization first, then split into
Light and Heavy FCCU gasoline. Light FCC gasoline is recovered as a final product
from this section. Heavy gasoline is further subjected to deep desulphurization
while minimizing loss of RON during desulphurization.
d. NHDT/ISOM:
The purpose of this unit is to upgrade Octane number of Light Naphtha and
generate Isomerate stream with very low benzene, olefin, Sulphur and aromatic

content for blending in MS pool. The design capa city of the unit is 250 TMTPA.
Light Naphtha from Naphtha Splitter unit is hydrotreated to remove catalyst
poison (Sulphur, Nitrogen etc). Benzene saturation of hydrotreated Light
Naphtha is carried out first. Later Isomerization of straight chain molecule s
(paraffins) into branched chain is carried out to increase RON.
Euro-IV MS is a blend of various streams namely Reformate, FCCU gasoline and

Isomerate in an approximate weight ratio of 40:40:20. Mumbai Refinery has the
distinction of being the first amo ng all Public sector refineries in manufacturing
Euro-IV MS.
iii. LUBE REFINERY (LR):
The Lube Refining complex of the refinery situated on the south side of the Fuels
refinery comprise of the following processing units. The Lube Refinery is
designed to manufacture 335 TMT of Lube Oil Base Stocks per year. A brief
description of the Processing units in the Lubes refinery is given below:
a. LR Vacuum Distillation Unit (LR VDU):
The feed to the unit is Reduced Crude Oil received from FR CDU. This unit is
identical to FR VDU. Product streams from the unit are various raw distillates
like Vacuum Gas Oil, I SS, II SS, III SS & Vacuum Tower Bottoms (VTB). Vacuum
Gas Oil goes to diesel while all SS go to solvent extraction units for making
Lubricating Oil Base Stoc ks. VTB is used for making asphalt or it goes to Propane
Deasphalting Unit for making Bright Stock.
b. Solvent Extraction Units I, II & III (SEU -I, II & III):
The I SS, II SS & III SS intermediate products from FR VDU & LR VDU are the feed
streams for these units. Extraction is done with NMP to remove aromatics and
further hydrofined to improve their colour and colour stability. The products
are 150N, 500N, 1300N Raffinates and Extracts. The raffinates are further
processed in Propane De -waxing Unit to remove wax. Extracts are also valuable
products and can be sold as RPO and CBFS.

c. Propane De-waxing Unit (PDU):
Feed to this unit is various hydrofined raffinates of 150N, 500N, 1300N & Bright
Stock. Wax from streams is removed to improve the pour point & the products
of this unit are various 150N, 500N, 1300N & Bright Stock Lube Oil Base Stocks.
Propane is used as a solvent for removing wax.
d. Propane De-asphalting Unit (PDA):
Feed to this unit is FR & LR VTB. The valuable oil from VTB which cannot be
separated by distillation is recovered by extraction with propane. The De -
asphalted Oil distillate is sent to Solvent Extraction Unit & Propane De -waxing
Unit above to make finishe d product called as Bright Stock. This is the most
valuable product in Lube Oils & it is mixed with various grades of Lube Oil
Products. This unit also produces very good quality of asphalt.
e. Lube oil up-gradation project (LOUP):
In order to meet current and future international Lube base stock standards,
HPCL has implemented the Lube Oil Base Stock Up -gradation Project (LOUP) at
Mumbai refinery to operate in conjunction with the existing lube plant. The
design intent of LOUP is to process waxy raffinates from the existing NMP
extraction unit into high quality Group II and Group III Lube Base Oils. LOUP is
designed to produce 227 KT/year of Group II base stock based on processing
100% Arab Light feeds.

2.2 Process flow diagram and major unit operations :
The block diagram of HPCL -MR refining process is given below.
2.3 Major raw material Inputs, quantity and costs :
The major raw material inputs, quantity and costs are given in the section 1.3

Chapter-III
E n e r g y a n d U t i l i t y S y s t e m D e s c r i p t i o n
3.1 List of utilities / equipment:

 Air Compressors
 Nitrogen Compressors
 Cooling Tower & Cooling Water Pumps
 Air Conditioning System
3.2 Brief description of each utility:
3.2.1 Electricity:
The electricity is procured from M/s Tata Power as well as generated through
gas turbine based captive power plant.
The Gas turbine Generating unit mainly consists of Gas Turbine, Reduction Gear
box, Electric Generator, Starting Diesel Engine & Auxiliary Gear box.
Four Gas Turbine Units of Mumbai Refinery a re double shaft simple open cycle
machine and one is single shaft simple open cycle machine. The gas turbine is
composed of Gas Generator along with compressor and power turbine drives the
generator through reduction gear.
The details of self-generated electricity and imported electricity are shown in

following table.
FY 2 0 1 5 - 1 6 FY 2 0 1 4 - 1 5 FY 2 0 1 3 - 1 4
Generation Capacity of the plant (MWH) 421632 420480 420480
Gross Generation(MWH) 249685 150722 188433
Aux. Power Consumption (MU) Ni l Ni l Ni l
Energy Export to the Grid(MU) Ni l Ni l Ni l
Energy imported from the Grid (MWH) 453868 532510 457345
Energy Export to Township / other (MU) Ni l Ni l Ni l
Plant Load Factor Average** 0.592 0.358 0.448
The electricity is procured from Tata Power Ltd as well as through Open access, the details of the
consumption is as under.

Description Unit Apr-16 May-16 Jun-16 Jul-16 Aug-16 Sep-16
Consumer Name - HPCL Mumbai Refinery, Chembur (E), Mumbai.
Consumer No. - 9000 0000 1511
Category - HT I - Industry Sanctioned Demand- 42136 KVA
Contract Demand- 33500 kVA
Meters No. - 10102235, 2037405
Consumption KWH 5261920 3432000 1670720 819520 4473920 11689600

Reactive Power KVARH 1585120 984960 362880 20800 1360960 3474880
Maximum Demand KVA 28564 14753 25056 25056 25056 26153
Power Factor (PF) 0.957 0.961 0.977 1.000 0.957 0.959
PF Penalty/Incentives Rs -519770 -357771 -601028 -885714 -449736 -1052192
Demand Penalty Rs 0 0 0 0 0 0
Energy Charges Rs 44410605 28966080 14100877 6916749 37759885 98660224
Bill Amount Rs 57556109 39571700 21698078 13141092 49781968 116762582
Consumer Name - HPCL (100KV) Mumbai Refinery, Chembur (E), Mumbai.
Consumer No. - 9000 0002 1997
Category - HT I - Industry
Sanctioned Demand 90000KVA
Contract Demand 57500 KVA 37500 KVA 17500 KVA
Total Consumption KWH NA NA NA NA NA 30107382
Open Access Units KWH NA NA NA NA NA 25579461
Net Tata Power Units (Billed Units) KWH 19827961 19730582 22700317 21316592 7932184 4527922
Tata Units - existing CD KWH NA NA NA NA NA 3410468
Tata Units - above existing CD KWH NA NA NA NA NA 1117454
Lapsed Energy at Consumer Meter KWH NA NA NA NA NA 7120
Reactive Power KVARH 6174078
Power Factor (PF) 0.98
Penalty Demand Rs 0 0 0 0 0 580240
Energy Charges - up to existing CD Rs 0 0 0 0 0 28208663
Energy Charges - above existing CD Rs 0 0 0 0 0 13185957
Bill Amount Rs 210510691 210569783 238011744 17229966 114263633 106715472
D escription Unit Oct-16 Nov-16 Dec-16 Jan-17 Feb-17 Average

Consumer Name - HPCL Mumbai Refinery, Chembur (E), Mumbai.
Consumer No. - 9000 0000 1511
Category - HT I - Sanctioned Demand- 42136KVA
Industry
Contract Demand- 33500kVA
Meters No. - 10102235, 2037405
Consumption KWH 15601280 12330080 8599040 8765120 9105280 7431680.00

Maximum Demand KVA 23831 34263 25697 25697 25697 25438.45
Power Factor (PF) 0.963 0.947 0.977 0.966 0.980 0.968
PF Penalty/Incentives Rs -1296011 0 -2488843 -1688050 -2801157 -1103661
Bill Amount Rs 144108532 132578172 90255230 92671004 101443235 78142518
Consumer Name - HPCL (100KV) Mumbai Refinery, Chembur (E), Mumbai.
Consumer No. - 9000 0002 1997

Contract Demand 17500 KVA
Total Consumption KWH 37138608 38635068 36150840 37973454 35220900 35871042
Open Access Units KWH 27916470 28176808 29147248 28950566 26638080 27734772
Net Tata Power Units KWH 9222138 10458260 7003592 9022889 8582820 12756841
(Billed Units)
Tata Units - existing KWH 8098539 9660846 6750786 8793237 8582820 7549449
CD
Tata Units - above KWH 1123599 797414 252806 229652 0 586820
existing CD
Lapsed Energy at KWH 0 197432 7972 8022 0 36757
Consumer Meter
Power Factor (PF) 0.97 0.96 0.98 0.97 0.96 0.97
Energy Charges - up to Rs 51587693 61539589 43002507 56012920 54672563 26820358
existing CD
Energy Charges - Rs 7977553 5661639 1794923 1630529 0 2750055
above existing CD
Bill Amount Rs 191166460 210838906 184455367 216889419 191929586 172052821
Following is the graph for power consumption pattern in MW H vs month:
Power Consumption Pattern

68000
66000
64000
62000
MWH/Month
60000
58000
56000
54000
52000
50000
Apr-16 May-16 Jun-16 Jul-16 Aug-16 Sep-16 Oct-16 Nov-16 Dec-16 Jan-17 Feb-17 Mar-17

Graph for annual fuel consumtion in MT /month
Fuel Consumption Pattern
60000
50000
40000
Ton/Month
30000
20000
10000
0
Apr-16 May-16 Jun-16 Jul-16 Aug-16 Sep-16 Oct-16 Nov-16 Dec-16 Jan-17 Feb-17 Mar-17

3.2.2 Steam:
The source of steam generation in the plant are as under,
a. SG-10, SG-11 and SG-12 boilers installed at Utility complex block

b. HRSG units of Captive P ower Plant (GTG)
The details source of steam generation and their percentage share for financial
year 2016-17 is sho wn in following table:
Steam Consumption Steam generation

Month
(T/Month) (T/Month)
Mar 17* 260996 307314
Feb 17 257499 298844
Jan 17 274990 330932
Dec- 16 271600 320490
Nov -16 283723 313618
Oct-16 275067 319245
Sep-16 229933 276125
Aug-16 261321 315015
Jul-16 260355 316421
Jun-16 252859 300772
May-16 246191 289842
Apr-16 257419 299151
Note : * denotes projected figure for March 2017.
Heat Recovery Steam Generators are put at the exhaust side of GTG to recover
exhaust heat of GTG. By doing so, steam is generated for refinery use and co -
generation plant efficiency is optimized.
Each waste heat steam generator is a Horizontal Natural Circulation Bi Drum,

supplementary fired water tube boiler. It generates steam at 15 kg/cm2 at 256°
C. The HRSG steam generation can be boosted up by supplementary firing by
firing Natural Gas as and when required. Heat Recovery Steam Generators are
put at the exhaust side of GTG to recover exhaust heat of GTG.

3.2.3 Water:
Water is supplied from Municipal Corporation of Greater Mumbai, local

governing authority at a rate of 426M 3 /hr. Bearing cooling water, service
water, drinking, process and miscellaneous requirement is fulfilled by
155M 3 /hr. Demineralization plant is supplied with 341M 3 /hr water and
310M 3 /hour dematerialized water is supplied for steam generation purpose.
10M 3 /hr dematerialized water is used for analyzers, caustic dilution, and
LOUP. 160M3/hr water from condensate recovery is fed to steam generator.
10M3/hr boiler feed water is used by DHT/DHDS. The steam generator is
supplied with 450M 3 /hr water.
160M 3 /hr condensate is recovere d and 80M 3 /hr condensate is lost. 25M 3 /hr
steam is lost due to leakage and trapping system. 85M 3 /hr water after steam
generation and 15M 3 /hr water after sanitary usage is supplied to IETP where
20M 3 /hr rain water is added. 90M 3 /hr water from IETP is re used. 20M 3 /hr
water is reused as FGDS make up and remaining 70M 3 /hr water is supplied to
dematerialization plant. 30M 3 /hr water is used as fire water make up. Fresh
water consumption during the year 2016/17 is given below:
Month Fresh Water (M3)

Apr.2016 295089
May.2016 264928
Jun.2016 263368
Jul.2016 226138
Aug.2016 206516
Sep.2016 223638
Oct.2016 232158
Nov.2016 258578
Dec.2016 289538
Jan.2017 272169
Feb.2017 251188
Mar. 2017 262549

3.2.4 Compressed air:
The compressed air system comprised of centrifugal compressors supplying air

to entire plant.
The compressor houses are located in the various department including DHDS,
LR, Utility as well as or Nitrogen generator.
While major part the compressed air is consumed for instrumentation as well
as nitrogen generation, a small part is utilized for the plant air applications.
The compressed air lines are interconnected for emergency usage; but the
inter-connection may not be suitable for complete plant load.
3.2.5 Chilled water:
The chilled water is primarily used for space cooling including offices, control
and panel rooms. Centralized chillers are provided for administration building
as well as major panel rooms with air handling units are installed for the
individual locations.
A few of the areas are provided with Ductable split as well as split air
conditioners.
3.2.6 Cooling water:
Sea cooling water (SCW) at the design rate of 2500 M 3 /hr is supplied by GEFC
SCW CT Pump, 2400M 3 /hr by DHDS SCW CT Pump, 2500M 3 /hr by LR SCW CT
Pump, FR/FRE sea cooling tower and LOUP SCW CT Pump. Bearing Cooling
Water (fresh water) at the design rate of 600 M 3 /hr is supplied by GEFC BCW
CT Pump, 250M 3 /hr by DHDS BCW CT Pump, 600M 3 /hr by DHT BCW CT Pump
and 165M 3 /hr by LOUP BCW CT Pum p.

Chapter-IV
D e t a i l e d P r o c e s s F l o w D i a g r a m a n d E n e r g y a n d
M a t e r i a l B a l a n c e
4.1 Flow chart showing flow rate, temperature, pressures of all input -
output streams:
4.2 Water balance for entire industry :
Water is supplied from Municipal Corporation of Greater Mumbai, local

governing authority at a rate of 426M 3 /hr. Bearing cooling water, service
water, drinking, process and miscellaneous requirement is fulfilled by
155M 3 /hr. Demineralization plant is supplied with 341M 3 /hr water and
310M 3 /hour dematerialized water is supplied for steam generation purpose.
10M 3 /hr dematerialized water is used for analyzers, caustic dilution, and
LOUP. 160M3/hr water from condensate recovery is fed to steam generator.
10M 3 /hr boiler feed water is used by DHT/DHDS. The steam generator is
supplied with 450M 3 /hr water.

160M 3 /hr condensate is recovered and 80M 3 /hr condensate is lost. 25M 3 /hr
steam is lost due to leakage and trapping system. 85M 3 /hr water after steam
generation and 15M 3 /hr water after sanitary usage is supplied to IETP where
20M 3 /hr rain water (available during monsoon season) is added. 90M 3 /hr
water from IETP is reused. 20M 3 /hr water is reused as FGDS make up and
remaining 70M 3 /hr water is supplied to dematerialization plant. 30M 3 /hr
water is used as fire water make up.
The water balance for HPCL -MR is tabulated below.
Water Balance of Refinery (Block wise)

From To M 3 /hr
Supply from MCGM HPCL-MR 426
IETP ( 100 m3/hr) and Fire water Make up 30
Rain water (20
m3/hr) Recycle to DM plant + 70
FGDS make up 20
Steam Generator Losses 20
(SG) 450 m3/hr Steam to process 390
DA steam 40
DM Plant 341 m3/hr DHT/DHDS 10

+ condensate Steam generators 460
recovery 160 m3/hr Effluent 31
Analysers, caustic dilun 10
Main 155 m3/hr Service water 25

BCW 90
Drinking water 25
Miscellaneous 10
process 5

IETP recycle to FGDS Process 20
Make up 20 m3/hr
IETP recycle to DM Recycle water 70
plant 70 m3/hr
Main : drinking water Sanitary treatment to IETP 15
use 25 m3/hr losses 10
SG 450 m3/hr Blow down 20
Process steam 430
Steam to stripper, Process loss 40
reboilers, turbines, IETP 85
ejectors, heating, Steam trap loss 25
steam tracing, BFW Condesate recycle 160
for process Condensate loss 80
390 m3/hr

Chapter-V
P e r f o r m a n c e E v a l u a t i o n o f M a j o r U t i l i t i e s a n d
P r o c e s s E q u i p m e n t ’ s / S y s t e m s
5.1 List of equipment’s and process where performance testing was done:
The performance testing was done on the following systems wherever
possible and feasible.
 Boiler
 Turbines
 Cooling Tower
 Cooling Water Pumps
 Process Pumps
 Air Conditioning Units / AHUs
 HVAC Chillers
 Vapour Absorption Machines
 HVAC Cooling Towers performance
 HVAC Cooling Water Performance
 Air Compressors
 Air Dryers
 Fans & Blowers
 Motors
 Lighting
 Capacitor
 Transformers
 Electricity Bill
 Solar Heating System

5.2 Results of performance testing :
Sr Description Outcome Remarks

No
1 Boiler Low efficiency in SG-10 Improvement in heat
feed pump and SG-12 transfer for HRSG.
FD fan. Low Low Boiler efficiency
efficiency for HRSG improvement.
1,3,5.
2 Turbines GT-5 heat rate high. Improve maintanence
practices thereby reduce
heat rate
3 Cooling Tower Approach is higher for Cooling effect & L/G ratio
FR / FRE CTs as well as could not be assessed for
LOUP BCW CT. It is Sea Water Cooling
marginally higher for Towers. FR, FRE SCT fills,
DHDS CTs. drift eliminators were
partially choked.
4 Cooling Water Performance of GFEC The performance of SCW
Pumps BCW CT 504-PM-1001A pumps could not be
& DHDS BCW CT assessed due to limitation
92P02A is on lower side in flow measurement .
Flow not detected due to
MOC and lining.
5 Process Pumps Many of the pumps are Detail options avaialable
operating with are impeller trimming or
throttled Control Valve suitable size pump or
condition install VFD based control
to eliminate control valve
throttling where
applicabble.

6 Fans & Blowers Performance was The furnace FD fans are
observed to be provided with VFD based
marginally lower control to modulate speed
based on operating load.
IETP lobe blowers to be
replaced by high
efficiency tubo blowers.
7 Air Conditioning Performance was The servicing and

Units / AHUs observed to be on the maintainence p ractices
lower side for most of may be reviewed to
the machines increase performance.
Filters found partially
choked.
8 HVAC Chillers Performance was The servicing and
observed to be on the maintainence practices
lower side for all the may be reviewed to
machines increase performance.
9 HVAC Cooling Performance is No savings are projected
Towers satisfactory in this area.
performance
10 HVAC Cooling Performance is No savings are projected
Water Pumps satisfactory in this area.
Performance
11 Air Compressors Performance could not Drain valves were
be assessed since flow observed to be partly
could not be measured . open leading to air loss
12 Air Dryers Pressure drop in many The desiccant in dryers
of the dryers is on the may be replaced , cleaning
higher side of dryers.

13 Motors Most of the motors are No savings are projected
appropriately loaded , a in this area.
few are under loaded.
14 Lighting Lux Measurement LED Lamps installed in
done, lighting survey some areas, to be
conducted. installed in other places.
15 Transformers Many of the Transformer isolation may
transformers are lead to moisture gains due
loaded at lower levels. to coastal atmosphere
16 Electricity Bill Power factor was Capacitors are provided in
observed to be from Refinery, maintenecne is
0.95 to 1.00 done regularly.
17 Hot water for Natural gas is utilized Consider solar water
canteen to provide hot water in heater to meet the
the canteen. process requirements.
18 Solar energy Solar panels provided Consider roof top solar
application for QA lab building. energy system as
Roof top of admin renwable application.
budling, LOUP, Elect
office bulding etc.
identified

Chapter-VI
E n e r g y E f f i c i e n c y i n U t i l i t y a n d P r o c e s s S y s t e m
6.1 Specific energy consumption :

As per data given by HPCL Refinery, annual Specific Energy
Consumption is given as follows:
Month Crude Oil (TMT) KWH/Ton of Crude Oil
Apr-16 714.14 85.17

May-16 723.86 83.69
Jun-16 625.37 97.77
Jul-16 689.34 88.03
Aug-16 736.65 82.51
Sep-16 630.68 89.1
Oct-16 720.12 91.86
Nov-16 715.83 89.79
Dec-16 758.22 84.95
Chart
800
700
600
500
400
300
200
100
0
Apr 16 May 16 Jun 16 Jul 16 Aug 16 Sep 16 Oct 16 Nov 16 Dec 16
crude TMT KWH/MT

Table showing various parameters vis a vis annual crude consumption
for the past 3 years
Year Crude Fuel % MBN NR G F MBTU/BBL KWH/TON

input, on crude OF CRUDE OF CRUDE
TMT
2014-15 7496.97 6.5 94.62 5.0797 480.64 92.22
2015-16 8021.4 6.86 90.63 5.1933 470.66 87.73
2016- 6321.02 6.53 88.37 5.1577 455.81 87.9
17*
(Apr-Dec
16)
From above, it is clear that though crude input has increased in the
year 15-16 from the year 14 -15 by 7% , MBN has been reduced by 3.99
and KWH/ Ton of crude reduced by 4.49 due to various energy
conservation measures implimen ted at Refinery during the year.

6.2 Boiler Efficiency Assessment:
COGENERATION POWER PLANT GAS TURBINE

6.2.1 BACKGROUND
The Co-Generation Captive Power Plant of the Mumbai Refinery comprises Gas Turbines to
generate continuous power output of 49.11 MW excluding its own requirement of power for
running its auxiliaries. The Gas turbine Generating unit mainly consists of Gas Turbine, Reduction
Gear box, Electric Generator, Starting Diesel Engine & Auxiliary Gear box. Four Gas Turbine Units
of Mumbai Refinery are double shaft simple open cycle machine and one is single shaft simple
open cycle machine. The gas turbine is composed of Gas Generator along with compressor and
power turbine drives the generator through reduction gear. The Gas turbine uses Natural Gas or
Naphtha as a fuel.
Heat Recovery Steam Generators are put at the exhaust side of GTG to recover exhaust heat of
GTG. By doing so steam is generated for refinery use and co-generation plant efficiency is
optimized.
Each waste heat steam generator is a Horizontal Natural Circulation Bi Drum, supplementary
fired water tube boiler. It generates steam at 15 kg/cm2 at 256° C. The HRSG steam generation
can be boosted up by supplementary firing by firing Natural Gas as and when required.
Table 1: GT and HRSG Nameplate Details
PARAMETER GT 1,2, & 3 GT 4 GT 5

Mitsui, SB -60 BHEL Frame-III BHEL Frame- V
Make
firing fuel HSD, Natural Gas, HSD, Natural Gas, HSD, Natural Gas,
Naphtha Naphtha Naphtha
Base Load 7180 kW 7180 kW 20390 kW
Heat Rate 3707 kcal/kWh 4099.61 to 3943.57 3390 kcal/kWh

kcal/kWh
PARAMETER HRSG 1, 2, & 3 HRSG 4 HRSG 5

BHEL, MR-
Make BHEL, MR-12052 BHEL, MR-12999
11517/11516/11515
HRSG Type Water tube Waste Heat Water tube Waste Water tube Waste
Recovery Boiler Heat Recovery Boiler Heat Recovery Boiler

PARAMETER HRSG 1, 2, & 3 HRSG 4 HRSG 5
Rated Steam Output 23900 kG/hr 27000 kG/hr 59300 kG/hr
Quantity
HRSG Heat source GT exhaust Gas GT exhaust Gas GT exhaust Gas
HRSG Flue Gas Inlet 504.5 °C 543 °C 509 °C

Temperature
HRSG Flue Gas Exhaust 104 °C 115 °C 135 °C

Temperature
Feed Water temperature, 110.8°C , 23.9 TPH 110.8°C , 27 TPH 111°C , 59.3 TPH
flow
Steam Pressure, 14 kg/cm2, 256°C, 23.9 14 kg/cm2, 256°C, 27 14 kg/cm2, 256°C,

temperature, flow TPH TPH 59.3 TPH
As part of Energy Audit study the unit operating data collected during close to base load. During
the audit all the energy going in and going out was observed and measured during the test. The
Blow down was isolated, Desuperheating was in control mode, and Equipment changeover was
not performed for the data collection duration.
During the trials, the key parameters namely, unit load, main steam temperature, main steam
flow rate, gas flow rate, and other key parameter were monitored, and the fuel and flue gas
sample was collected as needed. The results are presented in the table. The key findings are as
follows:
Table 3: Overall Performance HRSG and GT
GT PERFORMANCE UOM GT 1 GT 3 GT 5
Open Cycle Gross Heat Rate
(LHV Basis) kcal/kwh
3760 3663 4269
Parameter Unit HRSG 1 HRSG 3 HRSG 5
GT Exhaust Flow Rate TPH 155 154 367
GT Exhaust Enthalpy Kcal/kg 127 126 129
GT Exhaust energy Kcal/hr 19627709 19288397 47444627
Total energy gain by Water and
Steam Kcal/hr 11269747 11395728 35619658
HRSG Efficiency % 56.37% 57.58% 75.24%

Cogeneration Efficiency
Cogeneration Efficiency % 66%
Observations:
 The HRSG efficiency was calculated from the calculation of the energy gain by the working
fluid water and energy supplied by the GT exhaust.
 The Cogeneration efficiency is 66%.
 The GT exhaust flow was calculated based on PTC 22 procedure.
 From the above data, it has been observed that the HRSG efficiency is calculated as
56.37% for HRSG 1 and 57.58% for HRSG 3, and 75.24% for HRSG 5.
 The Gas turbine Heat rate was calculated as 3760 kcal/kwh for GT 1 and 3663 kcal/kwh
for GT 3. The design heat rate was 3707 kcal/kwh. The GT 5 Heat rate was 4269 kcal/kwh.
6.2.2 FUEL GAS ANALYSIS
Fuel Gas quality features have a major influence on GT and HRSG performance. The Gas sample
was taken and analysed by the internal lab of Mumbai Refinery. The Naphtha and Natural gas
sample analysis is presented as follows:
Table 2: Fuel Analysis Report for Naphtha
Table 5 : Fuel Analysis Report for Natural Gas
Composition UoM Percentage
Methane Vol % 96.1%

Ethane Vol % 3.06%
Propane Vol % .33%

Butane Vol % .05%
n-Butane Vol % .07%
i-Pentane Vol % .003%
n-Pentane Vol % .0004%
Specific Gravity Vol % .57631
NCV kCal/m3 8353.603
6.2.3 COMBUSTION GAS TURBINE PERFORMANCE OF GT 1, GT 3 AND GT 5
The Gas Turbine performance was calculated for the open cycle operation. The calculations are
as follows
Table 6: Gas Turbine Performance
Parameter UoM GT 1 GT 3 GT 5
Audit date 1/03/2017 1/03/2017 7/03/2017
CTG Power Output MW 7.18 7.28 15.75
CTG Exhaust Temperature °C 476.56 492.11 532.6456
CTG Exhaust Flow rate TPH 155 154 367
Inlet air Relative Humidity % 27.95 40.00 32
Ambient Temp at 35.61
°C
compressor inlet 30.85 36.58
Naphatha flow Rate m3/hr 1.42 9.14
Naphatha Temperature Degree C 30.00 30
NCV of fuel kj/kg 44350.4 44350.4 44350.4
Density gm/cc 0.694 0.694
Naphatha Mass Flow Rate kG/hr 985.5 6343.93
RLNG flow Rate nm3/hr 1832 2954.44
RLNG Temperature Degree C 30 30
NCV of RLNG kcal/M3 8353.6 8353.6
specific gravity 0.576 0.576 0.576
RLNG Mass Flow Rate kg/hr 1397 2253
Inlet fuel energy Naphatha Kcal/hr 10446088 0.0 67245670
Inlet fuel energy RLNG Kcal/hr 16531434.4 26660932
Fuel LHV Kcal/m3 45267 45267
Open Cycle Gross Heat Rate
kcal/kwh 4269
Without Correction Factor 3760 3663
The Gas Turbine 5 heat rate is very poor. It gives a very poor performance of gas turbine. The
GT 5 consuming more than design fuel energy. But at the same time they are giving less power
output. The improper combustion may be due to insufficient compressor discharge pressure,
problems in the GT blades or machine may need upration. With the preventive measures,
compressor water washing and overhauling will improve the performance of GT-5. HPCL
clarified that GT-5 overhauling is done after every 48000 hours of operation and it was carried
out 2 years ago. Compressor water washing is carried out during shut down as per OEM
recommendation.
 GAS TURBINE AIR COMPRESSOR PERFORMANCE of GT 1, GT 3, and GT 5

Table 7: Compressor Performance
GT 1 GT 3 GT 5
Parameter UoM
Compressor Compressor Compressor
Compressor inlet pressure (P1) mbar 1008.00 1008.00 1008.00
Compressor discharge Pressure
Bara
(P2) 8.50 8.19 7.181111
Compressor Inlet Temp (T1) °C 30.85 36.58 35.60544
Compressor discharge Temp
°C
(T2) 347.33 356.44 329.6381
Barometric Pressure mbar 1008.00 1008.00 1008.00
P2/P1 9.60 9.28 8.26
Ratio of specific heats 1.40 1.40 1.40
Numerator ((P2/P1)^((1.4-
1)/1.4) )-1) 0.91 0.89 0.83
Denominator (((T2-
T1)/(T1+273)) 1.04 1.03 0.95
Adiabatic Efficiency % 87.20% 86.13% 86.93%
The GT 3 Compressor has lower discharge pressure as compare to GT 3. Its adiabatic efficiency
is 1% less compare to GT 1.
6.2.4 HRSG PERFORMANCE OF GT 1, GT 3 AND GT5
 CPH PERFORMANCE
CPH performance is assessed as follows:
Table 8: CPH Performance
PARAMETER UOM HRSG 1 HRSG 3 HRSG 5
Water Circuit
DM Plant Outlet to Preheater
Pressure kg/cm2g 15.00 15.00 15
DM Plant Outlet to Preheater
Temperature °C 34.00 35.00 29.85
DM Plant Outlet To Preheater Flow
rate TPH 10.30 14.60 67
Preheater Outlet to deaerator
Temperature °C 110.00 110.00 85.25
Preheater Outlet to deaerator Flow TPH 10.30 14.60 67.00
flue Gas circuit
Flue Gas Temp at CPH Inlet °C 271.99 311.28
Flue Gas Temp at CPH outlet °C 233 223.41 142.59
Calculation

Inlet FW Enthalpy Kcal/kg 34 35 30
Outlet FW Enthalpy Kcal/kg 110 110 85
Total Energy Gain Kcal/hr 778704.1 1089225 3684891
Effectiveness % 31.9% 27.1%
Observations:
The exhaust flue gas temperature is higher than the design value of 110 °C. This will increase
the exhaust loss. The effectiveness of Condensate Pre Heater (CPH) is very low. This indicates
a poor heat transfer to the working fluid. In addition there is no flow meter, temperature
transmitter, and pressure transmitter in the line. Therefore, it is not possible for the control
room operator to monitor the temperature gain and performance of the CPH. It is
recommended to install all these transmitters. The energy saving recommendations are
given in Encon Savings.
 ECONOMISER CIRCUIT PERFORMANCE
Performance of Economiser Circuit of the HRSG 1, HRSG 3, and HRSG 5 is as follows:
Table 9: Economiser Circuit Performance
Water Circuit
FW to HRSG Feed Control Station Valve
position % 44.0% 81.0% 60
FW to HRSG 1 Feed Control Station Valve
DP kg/cm2g 26.76 44.43
FW to economiser inlet Pressure kg/cm2 34.24 16.57 21.28
FW to economiser Inlet temperature °C 109.02 92.59 121.31
FW to economiser Inlet Flow TPH 17.66 19.19 54.30
Eco outlet temp °C 197.99 184.97 193.44
flue Gas circuit
Flue Gas Temp at Economiser Inlet °C 316.37 296.44 220.68
Flue Gas Temp at Economiser outlet °C 271.99 311.28
Calculation
Inlet FW Enthalpy Kcal/kg 110 93 122
Outlet FW Enthalpy Kcal/kg 201.7 188 197
Total Energy Gain Kcal/hr 1622403 1817632 4056622
Effectiveness % 42.9% 45.3% 72.6%
Observations:

The effectiveness of Economiser Circuit for HRSG 1 and HRSG 3 is very low. This indicates a
poor heat transfer to the working fluid. The energy saving recommendation is given in Encon
Savings.
 EVAPORATOR OF HRSG 1, HRSG 3 AND HRSG 5
Table 10: Evaporator Performance
PARAMETERS UOM HRSG 1 HRSG 3 HRSG 5
water -Steam Circuit

Drum Level mm 60.30 60.23 70.08
Drum Pressure kg/cm2g 14.57 14.14 17.10
Drum Temperature °C 200.55 199.23 207.90
Flue gas Circuit
Flue Gas Temp at Evaporator Inlet °C 428 435.11 468.15
Flue Gas Temp at Evaporator
Outlet °C 316 296.44 220.67
Calculation
Total Enthalpy Gain Kcal/kg 466.4 468 459
Total Energy Gain Kcal/kg 8235483 8974982 24938456
Pinch Point °C 115.82 97.21 12.78
Observations:
The Pinch Point of HRSG 1 and HRSG 3 is very high. This indicates a poor heat transfer to the
working fluid. The energy saving recommendation is given in Encon Savings.
 SUPERHEATER PERFORMANCE
The Performance of Superheater Circuit of HRSG 1, HRSG 3, and HRSG 5 are as follows:
Table 11: Superheater Circuit Performance

Steam Circuit
Superheat outlet Pressure kg/cm2g 14.20 13.43 14.39
Superheat outlet Temp °C 263.97 263.90 266.37
Superheat outlet flow TPH 17.60 17.10 54.50
Flue Gas Circuit
Flue Gas Temperature at the
Superheater Inlet °C 476.56 471.89 484.40

Flue Gas Temp at Superheater
Outlet °C 427.67 435.11 468.15
Calculation
Outlet Steam Enthalpy Kcal/kg 706 707 708
Total Energy Gain Kcal/kg 684836.1 679460 2133127
Effectiveness % 23.0% 23.7% 21.1%
Observations:
3. The effectiveness of Superheater section of HRSG 1, HRSG 3, and HRSG 5 is very low. This
indicates a poor heat transfer to the working fluid. The energy saving recommendation
is given in Encon Savings.

Utilitites Boilers
6.2.1 BACKGROUND
The Utility boilers consists of 3 Boilers for steam generation. The generation is of 405
TPH of steam generation capacity.
The boiler can be operated with single fuel or dual fuel mode. The Boiler is operated with
Refinery fuel gas and Furnace Oil.
Table 3: Boiler Nameplate Details
PARAMETER BOILER SG- 10/11 BOILER SG -12
Make BHPV THERMAX
firing fuel HSD/ RFG/ FO HSD/ RFG/ FO
Capacity 140 TPH 125 TPH
Flue Gas Temperature 151 °C 135 °C
Efficiency 92% 94.5%
Design Steam Pressure/ 41 kG/cm2 / 360 °C 41 kG/cm2 / 360 °C

Temperature
As part of Energy audit study the unit operating data collected during operating load for
Boiler SG 10 and Boiler SG 12. Other Boiler was stopped due to ongoing maintenance
work. During the audit all the energy going in and going out was observed and measured.
The Blow down was isolated, Desuperheating was in control mode, and Equipment
changeover was not performed for the data collection duration.
During the trials, the key parameters namely, unit load, main steam temperature, main
steam flow rate, gas flow rate, and other key parameter were monitored, and the flue
gas sample was collected as needed. The results are presented in the table. The key
findings are as follows:
Table 4: Overall Performance Boiler SG-10 and Boiler SG-12
DESIGN BOILER SG-

PARAMETER UOM DESIGN BOILER SG-10
12
Boiler Efficiency % 92% 79.69% 94.50% 80.73%
Capacity TPH 140 100.2 125 67.70

Observations:
1. The Boiler efficiency was calculated from the heat loss method.
2. From the above data, it has been observed that the Boiler efficiency is calculated as 79.69 %
for Boiler SG-10 and 80.73% for Boiler SG-12.
3. The Boilers are operating below their design capacity. The Energy conservations are given in
the Encon Savings
FUEL ANALYSIS
Fuel quality parameters have a major influence on Boiler performance. The Fuel sample was
taken monthly and analysed by the internal lab. The fuel sample analysis is presented as follows:
Table 14: Fuel Analysis Report
Furnace Oil
Density 0.977 gm/cc
Net Calorific value 9760 kcal/kg
Refinery fuel gas
CH4 7.5%
C2H6 10%
C2H4 0%
C3H8 9.8%
C3H6 5.1%
IC4 3.2%
NC4 6%
C4H8 3.1%
IC5 0.1%
H2 52.8%
C3H6 5.1%
N2 2.5%
6.2.2 BOILER SG 12 PERFORMANCE
The Boiler SG-12 and its component performance were calculated for the operating load. The
calculations are as follows
Table 15: Boiler SG-12 Performance
Boiler SG-12
Parameter UoM
Data
FW Inlet Control Valve Position, FCV, 30% % 37.27
Drum coil heater inlet pressure kg/cm2g 59.11
Drum Coil Heater Inlet temp °C 113.76
Drum coil Heater Outlet Temp °C 114.96
Eco Inlet Temperature °C 114.96
Eco Inlet Flow TPH 63.85

Boiler SG-12
Parameter UoM
Data
Eco Outlet Temp °C 252.74
Drum Pressure kg/cm2g 39.91
Drum Level % 51.60
Secondary SH Inlet Temp °C 385.80
Secondary SH outlet temp °C 261.03
Desuperheating spray Flow TPH 7.10
Main Steam Outlet Pressure kg/cm2g 39.16
Main Steam Outlet Temperature °C 338.54
Main Steam Outlet Flow TPH 67.70
Fuel Flow
RFG Pressure kg/cm2g 0.27
RFG Flow TPH 1.2
FO Oil Pressure, control valve kg/cm2g 4.1
FO Oil Temperature °C 172.1
FO Oil Flow TPH 2.6

Weighted Average Property of fuel in Boiler Combustion
Weighted Average based
UoM RFG FO on % Fuel Flow rate
flow rate TPH 1.2 2.6
% of total Fuel Flow rate % 32% 68%
H2 % 61.21 11.56 27.3
C % 36.39 87.54 71.3
N2 % 2.5 0 0.8
S % 0 0.9 0.6
Ash % 0 0.1 0.1
moisture % 0 0.1 0.1
GCV kcal/kg 11100 10454 10659
Boiler Efficiency Calculation
Parameter UoM Data Note

Weighted GCV Kcal/Kg 10659 From weighted average of Fuel flow
CARBON % 71.32 From weighted average of Fuel Flow
HYDROGEN % 27.30 From weighted average of Fuel Flow
SULPHUR % 0.615 From weighted average of Fuel Flow
OXYGEN % 0.00 From weighted average of Fuel Flow
Nitrogen % 0.79 From weighted average of Fuel Flow
Calculation
((11.6*%C)+(34.8*(%H2-
Theoretical Air Required kg/kg 17.80
(%O2/8)))+(4.35*%S))/100
Excess Air Supplied % 19 O2 / (21 - O2)
Actual Air Supplied Ton/ton 21.24 (1 + EA) x Theoretical Air
Mass of Dry Flue Gas Tons/Ton 19.77
Specific heat of Gas Kcal/kg k 1 As Per PTC 4.0, Fig no.5-19-3
Boiler Efficiency ( loss method)
Operating Parameter Unit Calculation
Dry Flue Gas Loss % 5.40%

Boiler Efficiency Calculation
Parameter UoM Data Note

Heat Loss due to H2 in fuel % 13.36%
Heat loss due to moisture in
% 0.004%
fuel
% 0.16%
air
Heat Loss due to Radiation and
% 0.35%
Unaccounted
Total Losses % 19.27%
Boiler Efficiency % 80.73%
The Boiler efficiency is lower than the design value the primary reason is high flue gas loss and
higher value of Hydrogen in the fuel.
The fuel source of the boiler is Furnace Oil or Refinery Fuel Gas. The furnace Oil contains H2 about 11 % whereas,
the RFG contains more than 61% of H2 in fuel. The sources of hydrogen stream which may be entering in fuel gas
stream needs to be identified by Refinery and stop the same. The ratio of RFG to FO is currently 0.462. This needed
to be reduced to decrease the H2 losses in Fuel.
The Hydrogen in fuel should be within 10% to keep the losses “Heat loss due to H2 in fuel” within 5%.
 FD Fan of Boiler SG 12
Table 5: FD Fan
Parameter UoM Test Data Note
Suction Air pressure mmwc -0.3
FD Fan Damper Position % 87.6
Discharge Air Pressure, (SCAPH Inlet) mmwc 71.6
discharge Air temperature (Scaph
°C 36.1
Outlet
Discharge Air Flow rate TPH 80.4
FD Fan Amp amp 257.9
FD Fan Power Consumption kW 166.8
Fan Isentropic head Nm/kG 623.5
Density kg/m3 1.153
Flow rate m3/s 19.38
FD Fan Efficiency % 8.72%
FD Fan Hydraulic Power kW 15
FD Fan of Boiler SG-12 is working on extremely low efficiency. The FD Fan suction filter
was found choked/ damaged during the field visit. The Fan is consuming power but not
able to deliver the air to the boiler. The isentropic head of the FD Fan is very low.

 BOILER SG-10 PERFORMANCE
Boiler SG-10 is 140 ton boiler. During the audit 2 burners are fired with FO and 1 is with
Refinery Fuel Gas. Due to process limited requirement it was not possible to run the boiler
at design load. Therefore, the trial data is collected at 100.2 TPH steam flow. The test data
analysis and observations is given below. The Boiler SG-10 and its component performance
were calculated for the operating load. The calculations are as follows
Table 17:Boiler SG-10 Performance
Test
Parameter UoM Design data
Parameter
Eco Inlet Pressure KSC 42.39
Eco Inlet Temperature °C 131.16
ECo Inlet Flow TPH 99.71
Eco Outlet Temp °C 188.86
Drum Pressure kg/cm2g 40.73
Drum Level % 51.34
Steam temp before Ds oC 260.74
Desuperheating water Pressure,
kg/cm2g 67.84
before BFW Heater
Desuperheating water
°C 108.48
Temperature
Desuperheating spray Flow kg/hr 5031.90
Main Steam Outlet Pressure kg/cm2g 38.5
Main Steam Outlet
°C 359.8
Temperature
Main Steam Outlet Flow TPH 100.2
Fuel Parameter
FO Oil Pressure kG/cm2g 13.1
FO Oil Temperature °C 169.2
FO Oil Flow kG/hr 4334.5
RFG Temperature °C 47.1
RFG Flow kG/hr 1442.0
Furnace Pressure mmwc 81.8
O2 % eco outlet % 2.1
Furnace Temp at Boiler bank
°C 386.9
outlet/eco inlet
temp at Eco outlet °C 185.7
Calculation

Table 17:Boiler SG-10 Performance
Test
Parameter UoM Design data
Parameter
Fuel Composition
CARBON % 74.75
HYDROGEN % 23.97
SULPHUR % 0.675
OXYGEN % 0.00
Nitrogen % 0.63
Weighted GCV kCal/kG 10616
((11.6*%C)+(34.8*(%H2-
Theoretical Air Require kg/kg 17.04
(%O2/8)))+(4.35*%S))/100
Excess Air Supplied % 11% O2 / (21 - O2)
Actual Air Supplied Ton/ton 18.94 (1 + EA) x Theoretical Air
Mass of Dry Flue Gas Tons/Ton 17.76
As Per PTC 4.0, Fig no.5-19-
Specific heat of Gas Kcal/kg k 1
3
Boiler Efficiency ( loss method)
Operating Parameter UoM Calculation
% 0.005%
fuel
Dry Flue Gas Loss % 6.23%
Heat Loss due to H2 in fuel % 13.29%
Heat loss due to moisture in air % 0.19%
Heat Loss due to Radiation and
% 0.60%
Unaccounted
Total Losses % 20.31%
Boiler Efficiency % 79.69%
The Boiler efficiency is lower than the design efficiency. The primary reason for lower efficiency
is high flue gas loss. The Flue gas temperature at stack is 185.7 Degree C. which is much higher
than the expected value.
 FD FAN OF BOILER SG 10 PERFORMANCE
Performance of FD Fan of the station is as follows:

Table 8: FD Fan 1 Circuit Performance
PARAMETER UOM DESIGN DATA AT TEST DATA

Suction Air pressure mmwc -5.0
Suction Air Temperature °C 42 35.0
FD Fan IGV Position % 26.4
Discharge Air Pressure, (SCAPH Inlet) mmwc 802 201.5
discharge Air temperature (Scaph
°C 41.6
Outlet)
Discharge Air Flow rate kg/hr 102958.4
FD Fan Power consumption kW 400 135.8
Isentropic Head Nm/kG 1822.9
Calculation
Density kg/m3 1.099 1.133
Flow rate m3/s 43.1 25.25
FD Fan Efficiency % 36.72%
FD Fan Hydraulic Power kW 49.9
Observations:
The Fan Efficiency is very low to 36.22%.The fan is operating below it isentropic head at this
efficiency level. The energy conservation opportunity is given in encon savings.

 Thermal Imaging
The detailed insulation survey and calculation is given below
Heat transfer coefficient of Air, w/m/k h 0.0271

Stephen Boltzmann constant ,W/m2K4 σ 5.67E-08
Ambient temperature Degree K 328
convective Radiation
surface Surface Temp in
Location S.No Details Image No. heat loss, heat loss,
temp, °C area, m2 Degree °k
watt watt
1 Soot Blower MOV-1017 3232 260 0.13 533 0.70 492.58
Superheater outlet hdr vent line 0.07
2 3233, 3234 209
no insulation and valve leakage 482 0.30 169.93
Superheater header bad 3.00
3 3235 93
insulation 366 3.09 1083.52
4 Drum Manholes no insulation 3237, 3241 234 3.14 507 15.24 9707.97
5 Startup vent line passing 3236 90 0.11 363 0.10 35.80
6 Drum level transmitter pipe 3238 234 0.17 507 0.81 515.02
Drum level instrumentation line 0.14
7 3239 234
no insulation 507 0.69 436.86
steam atomizing line no 1.05
SG- 12 8 3240 234
insulation 507 5.08 3235.99
Boiler
9 Economiser manhole 3242 90 0.79 363 0.74 257.79
Deaerator Steam line header 0.13
10 3243, 3244 360
valve no insulation 633 1.04 1061.48
11 MP Steam to Deaerator 3245 234 0.11 507 0.53 337.08
BFP Suction line valve no 3246, 1.00
12 103
insulation in 15 valves 3247, 3248 376 1.30 477.01
PRDS (MP PRDS) Control Valve 0.17
13 3249 78
leakage 351 0.10 34.06
14 CBD Tank 3250 108 4.00 381 5.75 2154.01
15 Economiser Outlet Duct 3252 60 4.00 333 0.54 163.76
16 Mud Drum Bad Insulation 3253 100 1.57 373 1.92 693.15
17 VHP Header (Ground Floor) 3254 166 1.00 439 3.01 1449.65
18 BFW Control Valve 3255 122 0.20 395 0.36 142.16
3256 &
19 VHP Header 2 (First Floor) 3257 111 1.00 384 1.52 576.58
HP Steam Line to SG-10-5001
20 Blower 3258 169 1.00 442 3.09 1507.81
SG-10 21 VHP Steam from SG-12 3259 234 1.00 507 4.85 3090.14
Boiler 22 SG-10 Steam Drum 5V 3261 206 0.11 479 0.45 254.01
23 Steam Drum Hole 3262 225 1.57 498 7.24 4447.12
Towards Steam Drum 3 (Line
24 Uninsulated) 3263 239 0.79 512 3.92 2544.79
3264 &
25 Back Side of Steam Drum 3265 241 0.11 514 0.55 360.12
26 Steam Drum Hole 3266 231 1.57 504 7.49 4715.93
Drum Pressure Gauge Line no
HRSG 3
27 insulation after valve, 1/2" 3267 160 0.11 433 0.31 145.83

Drum Manhole no insulation, .5
28 m 3268 155 1.57 428 4.26 1957.81
29 Furnace at Boiler drum level 3269 70 2.00 343 0.81 257.07
HRSG bad insulation below
30 drum level 3270 140 5.00 413 11.52 4966.77
31 GT Exhaust to HRSG duct 3271 172 5.00 445 15.85 7835.82
32 GT Exhaust Below 3272, 3273 340 5.00 613 38.62 36749.54
33 MS Line valve no insulation 3274 230 1.00 503 4.74 2973.30
34 Mud drum manhole insulation 3275 150 1.57 423 4.04 1820.58
35 CBD Drain to tranch 3276 95 368 0.00 0.00
Spray line CV line + valve no
36 insulation 3277 101 2.00 374 2.49 906.18
37 diverted stack after damper 3279, 3280 140 4.00 413 9.21 3973.42
GT Exhaust damper no
38 insulation 3281, 3283 153 4.50 426 11.95 5449.81
39 Furnace LHS bad parting 3284 183 2.00 456 6.94 3590.59
Drum floor NRV, Silence valve
HRSG 5 40 no insulation 3285, 3286 210 0.79 483 3.30 1908.17
deaerator FST vent valve
41 passing 3288, 3289 206 0.11 479 0.45 254.01
42 Furnace LHS below drum 3290 235 4.00 508 19.51 12479.15
43 IBD draining passing 3291 83 4.00 356 3.04 1017.81
44 SH safety valve 3298 150 0.20 423 0.51 227.57
45 Drum manhole 3299 190 1.57 463 5.75 3062.00
Drum standpipe no aluminium
46 cladding 3300 120 0.17 393 0.31 121.52
47 Drum to SH line 3301 192 1.05 465 3.89 2088.79
48 CPH outlet isolating valve 3302 95 0.09 368 0.09 33.47
49 Furnace top insulation 3303 85 6.00 358 4.88 1650.55
3304,
50 Furnace after damper 3305, 3313 124 1.00 397 1.87 752.20
51 GT Main damper 3306 400 3.00 673 28.05 32926.32
HRSG 1
52 Bypass Stack 3307, 3311 87 360 0.00 0.00
SH spray bypass line no
53 insulation 3308 103 2.09 376 2.72 999.05
54 Mud drum manhole insulation 3309 160 0.79 433 2.23 1049.97
GT Main duct before damper
55 had passing 3310 240 513 0.00 0.00
56 Furnace LHS 3312 72 2.00 345 0.92 294.00
57 Drain line in front of GT Filter 3314 183 1.31 456 4.54 2350.04
58 Drain header 3315 91 3.00 364 2.93 1017.35
59 CBD 3316 88 5.00 361 4.47 1533.52
Heat Loss in the CPP Area of Refinery, kJ/s 270.59 174336.57
Total Heat Loss in the CPP Area of Refinery, kJ/s 174.61
Total Heat Loss in the CPP Area of Refinery, kCal Yearly 4978399156

6.3 Cooling Towers
The sea cooling water is handled by GEFC, FR, FRE, DHDS, LR and LOUP cooling
towers. The bearing cooling water (fresh water) is cooled by GEFC, DHDS, DHT
and LOUP BCW cooling towers.
The performance of cooling towers in terms of % TDS, Range, Approach

and Effectiveness is evaluated as follows.
% Rated TDS= Circulating water TDS/Permissible TDS

Range of cooling tower= Cooling tower inlet water temp – outlet cooling
water temperature
Approach of cooling tower = Cooling water outlet temperature – wet
bulb temperature
Effectiveness of cooling tower= 100 x Range/ (Range + Approach)
The actual air flow rate is calculated based on air velocity measurement
but could not be compared with de sign air flow rate due to non-
availability of design specification data .
Actual air flow rate (kg/hr)= Fan effective area (M 2 ) x Air velocity
(M/Sec) x 3600 x Air density (kg/M 3 ) x Temperature correction factor
The performance of cooling towers is shown below.

Description Units GFEC CT
Cell 1 Cell 2 Cell 3 Cell 4 Cell 5
Design Parameters
Make PAHARPUR
0
Approach Temperature C 4 4 4 4 4
3
Air Flow rate M /hr NA NA NA NA NA
0
Water Temperature -Sump C 32.0 32.0 32.0 32.0 32.0
0
Water Temperature -Inlet C 45.0 45.0 45.0 45.0 45.0
o
Range C 13.0 13.0 13.0 13.0 13.0
Water Flow M3/hr 3000 3000 3000 3000 3000
Cooling Effect TR 12897 12897 12897 12897 12897
Permissible TDS ppm 51600 51600 51600 51600 51600
Motor Rating kW 110 110 110 110 110
Actual Parameters
Circulating Water TDS PPM 41373.5 41373.5 41373.5 41373.5 41373.5
% Rated 80% 80% 80% 80% 80%
Make Up Water TDS PPM NA NA NA NA NA
COC NA NA NA NA NA
Ambient
0
Dry Bulb Temperature C 32.3 33.7 33.8 33.9 33.7
0
Wet Bulb Temperature C 25.7 25.7 25.7 25.7 25.7
Fan Out
Fan status On/Off On On On On On
0
0
Air Velocity M/Sec 6.25 6.99 6.67 7.84 8.38
Area M² 54.52 54.52 54.52 54.52 54.52
Air Flow rate kg/hr 1415369 1582497 1509269 1774346 1895863
0
0
3
Water Flow M /hr Not Possible due to internal coating and pipe MOC
Cooling Effect TR
Power Consumption kW 55.0 56.0 55.0 57.0 59.0
% Rated 50% 51% 50% 52% 54%
Specific Power kW/TR Not Possible due to internal coating and pipe MOC
Water to air (L/G) ratio
o
Actual Range C 2.5 2.1 1.8 2.4 2.3
% Rated 19% 16% 14% 18% 18%
o
Actual Approach C 4.0 4.4 4.7 4.1 4.2
% Rated 100% 110% 118% 103% 105%
Effectiveness % 38% 32% 28% 37% 35%
Remark: low range, high water
Cirl. rate

Description Units FR CT FRE CT
Design Parameters
Make PAHARPUR
0
Air Flow rate M3/hr NA NA NA NA NA
0
0
o
Range C 17.0 17.0 17.0 17.0 17.0
3
Water Flow M /hr 2500 2500 2500 2500 2500
Motor Rating kW 110 110 110 110 110
Actual Parameters
Circulating Water TDS PPM 30680 30680 30680 30680 30680
% Rated 59% 59% 59% 59% 59%
Make Up Water TDS PPM NA NA NA NA NA
COC NA NA NA NA NA
Ambient
0
0
Fan Out
Fan status On/Off On On On On On
0
0
Area M² 54.52 54.52 54.52 54.52 54.52
0
0
Water Flow M3/hr Not Possible due to internal coating and pipe MOC
Cooling Effect TR
Power Consumption kW 79.7 83.9 72.9 73.9 72.4
% Rated 72% 76% 66% 67% 66%
o
Actual Range C 4.2 3.9 3.8 3.9 3.7
% Rated 25% 23% 22% 23% 22%
o
% Rated 278% 290% 288% 303% 263%
Effectiveness % 27% 25% 25% 24% 26%

Remark: Clean drift eliminator , Higher Approach
Fills (clogging onserved)
Description Units DHDS CT LR CT

Cell 1 Cell 2 Cell 2 Cell 3
Design Parameters
Make PAHARPUR PAHARPUR
0
Approach Temperature C 4 4 4 4
3
Air Flow rate M /hr NA NA NA NA
0
Water Temperature -Sump C 32.0 32.0 32.0 32.0
0
Water Temperature -Inlet C 49.0 49.0 49.0 49.0
o
Range C 17.0 17.0 17.0 17.0
3
Water Flow M /hr 600 600 2500 2500
Cooling Effect TR 3373 3373 14054 14054
Permissible TDS ppm 51600 51600 51600 51600
Motor Rating kW 110 110 110 110
Actual Parameters
Circulating Water TDS PPM NA NA NA NA
% Rated NA NA NA NA
Make Up Water TDS PPM NA NA NA NA
COC NA NA NA NA
Ambient
0
Dry Bulb Temperature C 31.0 32.0 31.0 30.5
0
Wet Bulb Temperature C 21.0 21.5 21.5 21.5
Fan Out
Fan status On/Off On On On On
0
0
Air Velocity M/Sec 5.25 6.21 8.19 8.21
Area M² 54.52 54.52 54.52 54.52
Air Flow rate kg/hr 1170290 1382161 1818623 1840520
0
Water Temperature -Inlet C 37.1 37.2 37.9 35.1
0
Water Temperature -Sump C 28.2 28.2 30.2 30.2
Water Flow M3/hr Not Possible due to internal coating and pipe MOC
Cooling Effect TR
Power Consumption kW 66.1 68.4 61.0 NP
% Rated 60% 62% 55%
o
Actual Range C 8.9 9.0 7.7 4.9
% Rated 53% 53% 45% 29%

o
Actual Approach C 7.2 6.7 8.7 8.7
% Rated 180% 166% 217% 217%
Effectiveness % 55% 58% 47% 36%
Remark Marginally Higher Inlet line damaged. Higher Approach
Approach
Description Units LOUP CT GFEC BCW CT

Design Parameters
Make PAHARPUR PAHARPUR
0
Air Flow rate M3/hr NA NA NA NA NA
0
0
o
Range C 17.0 17.0 7.0 7.0 7.0
3
Water Flow M /hr 1250 1250 600 600 600
Motor Rating kW 110 110 22 22 22
Actual Parameters
Circulating Water TDS PPM NA NA 123 123 123
% Rated NA NA 26% 26% 26%
Make Up Water TDS PPM NA NA 59.33 59.33 59.33
COC NA NA 2.07 2.07 2.07
Ambient
0
0
Fan Out
Fan status On/Off On Off On On On
0
0
Area M² 54.52 9.23 9.23 9.23
0
0
Water Flow M3/hr Not Possible due to internal 572.3 572.3 572.3
coating and pipe MOC
Cooling Effect TR 568 662 568
Power Consumption kW 66.8 16.3 12.0 14.6
% Rated 61% 74% 55% 66%
Specific Power kW/TR Not Possible due to internal 0.03 0.02 0.03
Water to air (L/G) ratio coating and pipe MOC 1.34 1.65 1.46
o
Actual Range C 1.9 0.4 3.0 3.5 3.0

% Rated 11% 2% 43% 50% 43%
o
% Rated 55% 93% 63% 50% 63%
Effectiveness % 46% 10% 55% 64% 55%
Remark
Lower COC as lower TDS is maintained
in the blow down. Makeup water can be
saved by increasing COC to design level.
Description Units DHDS BCW DHT BCW CT LOUP BCW CT

Design Parameters
Make PAHARPUR PAHARPUR PAHARPUR
0
3
Air Flow rate M /hr NA NA NA NA NA
0
0
o
Range C 7.0 10.0 10.0 10.0 10.0
Water Flow M3/hr 250 600 600 550 550
Actual Parameters
Circulating Water TDS PPM 171 343 343 148.5 148.5
% Rated 36% 71% 71% 31% 31%
Make Up Water TDS PPM 59.33 59.33 59.33 59.33 59.33
COC 2.88 5.78 5.78 2.50 2.50
Ambient
0
0
Fan Out
Fan status On/Off On On On On Off
0
0
Area M² 8.06 12.28 12.28 7.65
0
0

Water Flow M3/hr 97.8 743 743 91.0 91.0
Power Consumption kW 6.1 22.4 22.0 4.2
% Rated 41% 102% 100% 38%
Specific Power kW/TR 0.08 0.02 0.02 0.03 0.00
Water to air (L/G) ratio 0.43 1.58 1.59 0.34
o
Actual Range C 2.4 4.8 5.0 4.7 0.6
% Rated 34% 48% 50% 47% 6%
o
% Rated 143% 130% 138% 203% 305%
Effectiveness % 30% 48% 48% 37% 5%
Remarks
Higher Aapproach
Lower COC as lower TDS is maintained in the blow down. Makeup

water can be saved by increasing COC to design level. HPCL MR
informed that water drainages at units have been eliminated and
COC’s are being mainained at design value of 4.

Cooling water Pump s
The sea cooling water is circulated in the plant by GEFC, DHDS, LR and LOUP
SCW pumps. The bearing cooling water is circulated in the plant by GEFC,
DHDS, DHT and LOUP BCW pumps.
The performance of SCW pumps is not evaluated as the flow measurements
were not possible. The performance of BCW pumps is evaluated as follows.
Efficiency of pump= Specific gravity x Flow (M 3 /hr) x Differential pressure (m) /
(Motor power (kW) x Motor efficiency (%) x 367)
Particular Unit BCW CT

LR SCW CT LOUP SCW GFEC BCW CT
CT
99-PM- 99-PM- 99-PM- 504-PM- 504-PM- 504-PM-
1264-A 1264-B 1264-G 1001A 1001C 1001D
Design Data
Make KBL KBL KBL KBL KBL KBL
Type 16UPH3 16UPH3 16UPH3 SCT 200/48 SCT SCT
200/48 200/48
Type Of Fluid Sea Water Sea Water Sea Water Raw Water Raw Raw
Water Water
Curve Y/N Y Y Y Y Y Y
Flow rate M3/hr 2500 2500 2500 600 600 600
Head M 61.7 61.7 58 64.3 64.3 64.3
Pump Efficiency % 91.5% 91.5% 86% 84.5% 84.5% 84.5%
Motor Efficiency % 90% 90% 90% 95.3% 95.3% 95.3%
Motor Rating kW 645 645 575 160 160 160
Actual Data
Type of liquid Sea Water Sea Water Sea Water Raw Water Raw Raw
Water Water
Flow m3/hr Not Not Not 416 606 695
Feasible Feasible Feasible
Temperature O C 30.2 30.2 28 26.3 26.3 26.3
Scoop Position % N.A. N.A. N.A. 100 100 100
(Opening)
Specific gravity gm/cm 1.03 1.03 1.03 1.00 1.00 1.00
3
Suction pressure kg/cm2 0.3 0.3 0.3 0.3 0.3 0.3

m 2.92 2.92 2.92 3.00 3.00 3.00
Discharge pressure kg/cm2 NA NA 6 6.2 6.5 6.8
m 58.31 62.00 65.00 68.00
Differential Pressure m 55.39 59.00 62.00 65.00
Motor actual power kW 365 365.5 556 101 130 144
Pump Efficiency % N.P. N.P. N.P. 69% 83% 89.70%
Remarks if any Low
Efficiency
The performance of SCW and BCW pumps is shown below.

Particular Unit
DHDS BCW CT LOUP BCW CT DHT BCW CT
92P02A 99P001A 99P001B 714-P- 714-P-1003C

1003A
Design Data
Make KSB KBL KBL WPIL WPIL
Type MEGA SCT 80/24 SCT 80/24 8 LN 18C 8 LN 18C
Type Of Fluid Water Water Water Water Water
Curve Y/N Y Y Y Y Y
Flow rate M3/hr 250 165 165 600 600
Head M 60 60 60 63.81 63.81
Pump Efficiency % 78% 80% 80% 85% 85%
Motor Efficiency % 90% 90% 90% 90% 90%
Actual Data
Type of liquid Water D.M. Water Water Water Water
3
Flow m /hr 97.8 182 740 745
O
Temperature C 27.2 33.4 33.4 27.4 27.4
Scoop Position (Opening) % 100 100 100 N.A. N.A.
Specific gravity gm/cm3 1.00 1.00 1.00 1.00 1.00
Suction pressure kg/cm2 0.23 0.18 0.18 0.25 0.25
m 2.30 1.80 1.80 2.50 2.50
Discharge pressure kg/cm2 6.8 N.P. N.P. 5.8 6
m 68.00 58.00 60.00
Differential Pressure m 65.70 55.50 57.50
Motor actual power kW 52.3 33.3 36.5 146.8 148
Pump Efficiency % 37% N.P. N.P. 85% 88%
Remarks if any Low Efficiency

6.4 Process Pumps:
The data was collected from DCS for the following pumps and other
equipments.
Tag Medium Density Flow Pressure CV Power

Disch Suc Position
3 2
Kg/L m /hr kg/cm kg/cm2 % Open KW
FR Plant
11P5B Higher Kerosene 0.85 184 15 4 46% 65.3
11P6A Diesel 0.83 93 17 4 45%, 35% 37.4
11P7A Light Vacuum gas oil 0.82 226 10 3 60% 53.5
11P12A RCO 0.9 20 32 1 70% 110.5
12P4A heavy diesel 0.95 107 3 1 40% 7.6
12P9A Asphalt 0.92 117 10 1 60% , 70 % 38.7
FRE Plant
31P1C Crude Oil 1 570 45 2.5 50 357.0
31P1E 1 406.0
31P15A Light virgin naphtha 0.82 120 20 10 60 60.0
31P6A SKO 0.82 90 12.5 1.2 40 50.5
32P6A VGO 0.82 115 8 25 65.3
32P7A VBPA 0.82 85 10 53 69.4
32P9B VTB 0.82 35 17 35 81.4
DIU Plant
71-PM-12 A Lean Amine 0.85 53.9 50 14.14 40% , Spill Back 146.0
71-PM-21A Diesel 0.85 305.9 10 4.5 54% 154.0
NFC CCU Plant
114-P-3054A Stripper feed 0.68 190 28 14 40% 122.3
114-P-3058A LPG product R/D pump 0.55 52 14 10.5 32% 67.0
114-P-3062A Heavy Cycle Oil 1 225 23 1.5 30% 172.0
114-P-3071A Light Cycle Oil (Diesel) 0.95 180 12 1.1 40% 72.0
114-P-3074A Cat feed Blend 0.93 125 1.5 1 30% 145.0
114-P-3076A Stabilized Naphtha 0.72 40 18 0.55 30% 105.0
114-P-3051A Naphtha 0.62 40 22 4 40% 54.0
OFCC Plant
14P1 cat feed 1 72 9 1.5 50% 17.0
14P25C Naphtha unstable 0.6 75 12 1.5 55% 26.6
LOUP Plant
MP-307 C 0.5 117 43 13 52% 214.0
MP-312 A 0.5 110 18 1.5 Controlled by 67.2
Bypass flow
MP-101A 0.93 138 20 1 open 100% 193.0
MP-4201 A 0.95 30 12 0.3 63% 10.6

MP-4204A 0.9 22 55 2.9 45 % Recycle, 88.0
Forward Prod. No
CV
MP-4103B 1 60 14 0.5 Recycle 5%, 72.6
Forward 55%
MP-4120A 0.6 600 50 37 48% 414.0
MP-4121A 0.5 60 48 16 Recycle 34%, 133.0
Forward 29%
MP-3201A 0.95 40 16 1 50% 18.9
MP-3204A 0.9 30 68 2.8 50%(+,- 20%) 145.0
GFEC Plant
101-PM-1001A Naphtha 0.62 717.7 12 2.9 50% (multiple C V) 306.6
101-PM-1002A Naphtha 0.64 203.12 7.1 2 34% 66.0
101-PM-1003A Naphtha 0.64 85.937 11.5 2 61% 53.0
102-PM-1001B Naphtha 0.75 126.66 40 3 42% 170.5
102-PM-2004A DM Water 1 220 50 43 41% 77.0
103-PM-2001A Naphtha 0.68 90 28 2.5 41% 297.6
103-PM-2004A Naphtha 0.68 96.7 40.9 16 56% 157.1
103-PM-1001B Naphtha 0.67 47 35 3.6 62% 85.6
103-PM-2003B Naphtha 0.67 155 25 16 46% 95.4
103-PM-2006A Naphtha 0.65 180 7.8 1.2 66% 87.0
105-PM-1003B Naphtha 0.7 53 24 4.35 50% 119.0
The overall (pumps and motor together) operating efficiency of the pumps
were computed (under throttled conditions) by computing hydraulic and actual
power, the details are as under.
Tag Medium Densit Flow Hea Powe Efficienc CV Position

y d r y
Kg/L M3/hr MLC KW % % Open
FR Plant
11P5B Higher Kerosene 0.85 184 129. 65.3 84.5% 46%
4
11P6A Diesel 0.83 93 156. 37.4 88.1% 45%, 35%
6
11P7A Light Vacuum gas oil 0.82 226 85.4 53.5 80.6% 60%
11P12A RCO 0.9 20 344. 110.5 15.3% 70%
4
12P4A heavy diesel 0.95 107 21.1 7.6 76.8% 40%
12P9A Asphalt 0.92 117 97.8 38.7 74.0% 60% , 70 %
FRE Plant
31P1C Crude Oil 1 570 425. 357.0 86.5% 50
31P1E 1 0 406.0
31P15A Light virgin naphtha 0.82 120 122. 60.0 54.5% 60
0

31P6A SKO 0.82 90 137. 50.5 54.9% 40
8
32P6A VGO 0.82 115 97.6 65.3 38.4% 25
32P7A VBPA 0.82 85 122. 69.4 33.4% 53
0
32P9B VTB 0.82 35 207. 81.4 19.9% 35
3
DIU Plant
71-PM-12 A Lean Amine 0.85 53.9 421. 146.0 36.1% 40% , Spill Back
9
71-PM-21A Diesel 0.85 305.9 64.7 154.0 29.8% 54%
NFC CCU Plant
114-P-3054A Stripper feed 0.68 190 205. 122.3 59.3% 40%
9
114-P-3058A LPG product R/D 0.55 52 63.6 67.0 7.4% 32%
pump
114-P-3062A Heavy Cycle Oil 1 225 215. 172.0 76.6% 30%
0
114-P-3071A Light Cycle Oil 0.95 180 114. 72.0 74.3% 40%
(Diesel) 7
114-P-3074A Cat feed Blend 0.93 125 5.4 145.0 1.2% 30%
114-P-3076A Stabilized Naphtha 0.72 40 242. 105.0 18.1% 30%
4
114-P-3051A Naphtha 0.62 40 290. 54.0 36.3% 40%
3
OFCC Plant
14P1 cat feed 1 72 75.0 17.0 86.4% 50%
14P25C Naphtha unstable 0.6 75 175. 26.6 80.6% 55%
0
LOUP Plant
MP-307 C 0.5 117 600. 214.0 44.7% 52%
0
MP-312 A 0.5 110 330. 67.2 73.6% Controlled by
0 Bypass flow
MP-101A 0.93 138 204. 193.0 37.0% open 100%
3
MP-4201 A 0.95 30 123. 10.6 89.8% 63%
2
MP-4204A 0.9 22 578. 88.0 35.5% 45 % Recycle,
9 Forward Prod.
No CV
MP-4103B 1 60 135. 72.6 30.4% Recycle 5%,
0 Forward 55%
MP-4120A 0.6 600 216. 414.0 51.3% 48%
7
MP-4121A 0.5 60 640. 133.0 39.3% Recycle 34%,
0 Forward 29%
MP-3201A 0.95 40 157. 18.9 86.4% 50%
9
MP-3204A 0.9 30 724. 145.0 36.8% 50%(+,- 20%)
4
GFEC Plant

101-PM- Naphtha 0.62 717.7 146. 306.6 58.0% 50% (multiple C
1001A 8 V)
101-PM- Naphtha 0.64 203.125 79.7 66.0 42.8% 34%
1002A
101-PM- Naphtha 0.64 85.9375 148. 53.0 42.0% 61%
1003A 4
102-PM- Naphtha 0.75 126.666666 493. 170.5 74.9% 42%
1001B 7 3
102-PM- DM Water 1 220 70.0 77.0 54.5% 41%
2004A
103-PM- Naphtha 0.68 90 375. 297.6 21.0% 41%
2001A 0
103-PM- Naphtha 0.68 96.7 366. 157.1 41.8% 56%
2004A 2
103-PM- Naphtha 0.67 47 468. 85.6 47.0% 62%
1001B 7
103-PM- Naphtha 0.67 155 134. 95.4 39.8% 46%
2003B 3
103-PM- Naphtha 0.65 180 101. 87.0 37.2% 66%
2006A 5
105-PM- Naphtha 0.7 53 280. 119.0 23.8% 50%
1003B 7

Pumps operating at Low Effiiciency:
The following pumps were observed to be operating at low efficiency.
Tag Medium Density Flow Head Power Efficiency CV Position

3
Kg/L M /hr MLC KW % % Open
FR Plant
11P12A RCO 0.9 20 344.4 110.5 15.3% 70%
FRE Plant
32P6A VGO 0.82 115 97.6 65.3 38.4% 25
32P7A VBPA 0.82 85 122.0 69.4 33.4% 53
32P9B VTB 0.82 35 207.3 81.4 19.9% 35
DIU Plant
71-PM-12 A Lean Amine 0.85 53.9 421.9 146.0 36.1% 40% , Spill Back
71-PM-21A Diesel 0.85 305.9 64.7 154.0 29.8% 54%
NFC CCU Plant
114-P-3058A LPG product R/D pump 0.55 52 63.6 67.0 7.4% 32%
114-P-3074A Cat feed Blend 0.93 125 5.4 145.0 1.2% 30%
114-P-3076A Stabilized Naphtha 0.72 40 242.4 105.0 18.1% 30%
114-P-3051A Naphtha 0.62 40 290.3 54.0 36.3% 40%
OFCC Plant
LOUP Plant
MP-307 C 0.5 117 600.0 214.0 44.7% 52%
MP-101A 0.93 138 204.3 193.0 37.0% open 100%
MP-4204A 0.9 22 578.9 88.0 35.5% 45 % Recycle,
Forward Prod.
No CV
MP-4103B 1 60 135.0 72.6 30.4% Recycle 5%,
Forward 55%
MP-4121A 0.5 60 640.0 133.0 39.3% Recycle 34%,
Forward 29%
MP-3204A 0.9 30 724.4 145.0 36.8% 50%(+,- 20%)
GFEC Plant
101-PM-1002A Naphtha 0.64 203.125 79.7 66.0 42.8% 34%
101-PM-1003A Naphtha 0.64 85.9375 148.4 53.0 42.0% 61%
103-PM-2001A Naphtha 0.68 90 375.0 297.6 21.0% 41%
103-PM-2004A Naphtha 0.68 96.7 366.2 157.1 41.8% 56%
103-PM-1001B Naphtha 0.67 47 468.7 85.6 47.0% 62%
103-PM-2003B Naphtha 0.67 155 134.3 95.4 39.8% 46%
103-PM-2006A Naphtha 0.65 180 101.5 87.0 37.2% 66%
105-PM-1003B Naphtha 0.7 53 280.7 119.0 23.8% 50%

The remedial measures include installing a VFD based control, resizing the
pump impeller or replacing the pump with a smaller capacity pump, depending
on the process condtions.
It is suggested to analyze control valve position as well as the flow and

pressure data for past six months while deciding the remedial measures.
HPCL opined that for various identified pumps, motors, specific limitation is
occurring due to low unit through put during survey, revamp study is in progress
in a few units, etc. HPCL informed that VFD can be implimented for motors of
31 P1C and E (FRE), 32P7A , review shall be done by them for FR - 12 P9 A/B,
GFDS - 101-PM-1001A, 101-PM-1002A, 101-PM-1003A, 102-PM-1001B, 102-PM-
2001B, 102-PM-2004A, 103-PM-2001A, 103-PM-2004A, 103-PM-1001B, 103-PM-
2003A, 103-PM-2006A, 103-PM-2009A, 107-PM-1003A, 109-PM-1001A. For
these identified motors, the unit is undergoing revamp and post revamp flow
requirements will change. It was informed that for pump 105 -PM-1003 A /B ,
both pumps were operating during survey, however in normal condition only one
pump operates with 90% valve opening. For 107 -PM-1003 A and 107-PM-1001A
plant is operating at lower thruput since revam ping activities. For LR block MP -
305C, 307 C and MP 312 A PDU current feed rate is low , however in future it
may increase to design level. Trimming of impeller option shall be considered
for short duration savings. For MP -4121A , PDA unit is designed to run both BS
and Cat fee dmode. During Cat feed mode , recycle comes down. Hence VFD
option is not required. In LR unit , other identified pumps are running as per
process requirement, demand of various grades, throughput etc.

6.5 Fans & Blowers performance assessment:
The performance was ascertained by measuring flow rate, differential pressure

as well as power, the details are as under.
Description Units HGU DHT NSU

73-FAN 73-FAN 700-FANM- 101 FDF -
01(A) 01(B) 1001-A 1001
VFD HZ DOL 24.9
RPM 950 447.3
Actual Parameters
Temperature 0C 32.0 32.0 32.0 32.0
Air Velocity m/s 4.6 3.6 1.2 6.7
Cross-sectional M2 1.4 1.4 7.0 1.4
Area
Flow rate M3/sec 6.503 5.089 8.400 9.472
Discharge mm 90 93 122 155
Pressure WG
Suction Pressure mm -25 -25 -25 -25
WG
Differential Head mm
WG 115 118 147 180
Power - Motor kW 16 20.7 34.00 65
Input % NA NA 21% NA
Rated
Efficiency % 45.82% 28.44% 35.61% 25.72%
Description Units FR FRE APS FRE VPS

14FD 1X 31-FAN 1A 32FAN 1B 32 F 1002
VFD HZ
RPM 980 884.8 884.8 884.8
Actual Parameters
Temperature 0 C 32.0 32.0 32.0 32.0
Air Velocity m/s NA NA NA
Cross-sectional Area M2 NA NA NA
Flow rate M3/sec NA NA NA
Discharge Pressure mm WG 30 270 156
Suction Pressure mm WG -25 -25 -25

Differential Head mm WG 55 295 181
Power - Motor Input kW 20.98 101.80 35.40
% Rated NA 46% NA
Efficiency % NA NA NA
HPCL informed that for 31 - FAN 1A , 32 FAN 1B and 32 F 1002 VFD option is
feasible to improve efficiency further.
Description Units Combination FR LR VPS PDA

11 FAN - 11 FAN - 12 FAN - 100F - KF - 4801 A
1A 3A 1C 1002 (West)
VFD HZ
RPM 884.8 884.8 884.8 884.8 884.8
Actual Parameters
Temperature 0C 32.0 32.0 32.0 32.0 32.0
Air Velocity m/s 11.1 6.3 NA NA 1.7
Cross-sectional M2 2.0 5.3 NA NA 1.5
Area
Flow rate M3/se 21.969 33.145 NA NA 2.483
c
Discharge mm 212 102.4 85 121.5 100
Pressure WG
Suction Pressure mm -25 -25 -25 -25 -25
WG
Differential mm
Head WG 237 127 110 147 125
Power - Motor kW 86.00 72.30 48.00 32.80 18.80
Input % 57% 96% 87% NA NA
Rated
Efficiency % 59.36% 57.26% NA NA 16.19%
The efficiency of some of the is marginally on the lower side. However, the
fans are provided with variable speed based control to modulate the speed
based on the operating load.

6.6 Air Conditioning/AHU performance assessment:
The Administration Bui lding is equipped with AHU -1, AHU-2 and AHU-3. The
conditioned air is supplied to the r oom/space by ducting network .
Packaged type air conditioners are provided in Annexe Building at all floors,
along with ducting network. CISF security office , Laboratories, DCS Control
rooms and MSS-10, MSS-11are also provided with water/air cooled AHUs.
The performance of machines can be evaluated by measuring
 Velocity of the return air fed to the machine along with the cross -
sectional area, to compute flow rate.
 Enthalpy of supply air by noting down the temperature and relative

humidity.
 Enthalpy of return air by noting down the te mperature and relative

humidity.
 Power consumption of the machine.

The Air Conditioning effect (TR) and specific power consumption can be
computed as under
Flow Rate of Air (kg/hr)= Average Air velocity (M/s) x Cross sectional area of the
air flow (M 2 ) x Specific Gravity of Air
Air Conditioning Effect (TR)= Air flow rate (kg/hr) x Enthalpy difference between
the air at inlet & outlet of the evaporator coil (kJ/kg) / (4.18 x 3024)
Air Conditioning Effect (kW)= Air flow rate (kg/hr) x Enthalpy difference be tween
the air at inlet & outlet of the evaporator coil (kJ/kg) / 3600= 3.512 x Air
Conditioning Effect (TR)
Specific Power Consumption (kWh/TR) =Power consumption (kW) / Air Chilling
Effect (TR)

Energy Efficiency Ratio – EER (W of cooling / W of input powe r)= Power
consumption (kW) / Air Conditioning Effect (kW) = 3.512 / Specific Power
consumption (kW/TR)
The performance of the various machines was evaluated, the details of which
are as under.
Sr. Desired
LOCATION CAPACITY POWER Load SPC Savings
No. Power Observation
TR kW TR kW/TR kW kWh
Fresh Air
Damper
Annex Building 2 - Ground Floor
closed, on
circulation
PK – 1 11 3.7 0.9 4.10 Filters
1 choked
2 PK – 2 11 7.7 1.9 4.02 Filters dusty
3 PK – 3 11 8.1 2.0 4.08 Filters dusty
PK – 4 11 8.8 2.1 4.10 Filters
4 choked
Fresh Air
Annex Building 2 - First Floor Damper
closed
5 PK – 1 11 9.2 2.2 4.10
6 PK – 2 11 9.2 2.2 4.10
7 PK – 3 11 9.6 2.3 4.09
8 PK – 4 9.92 9.5 2.3 4.11 Filters dusty
9 PK – 5 9.92 9.2 2.2 4.10
Main Gate - CISF Security
10 GF AHU – 1 16.37 6.6 5.8 1.14 Filters are
11 GF AHU – 2 16.37 5.98 7.3 0.82 choked. Near
AHU – 1 16.37 14.5 10.9 1.33 AHU no
12 insulation
Laboratory
13 TFA – 1 NA 3.6 13.6 0.27
14 TFA – 2 NA 4.25 6.4 0.66
15 TFA – 3 NA 4.37 6.8 0.64
16 TFA – 4 NA 3.72 15.3 0.24
17 TFA – 6 NA 3.74 20.5 0.18 Filters are
18 AHU – 4 NA 2.04 5.3 0.38 dusty.
GFEC SRR Fresh Air
AHU 9.7 20.7 0.47 Damper is
19 NA
closed.
DHT SRR
20 AHU – 1 NA 7.5 15.8 0.47

21 AHU – 2 NA 7.5 15.8 0.47
Combination Control Room
22 PK – 2 7.11 6.9 5.3 1.31
23 PK – 4 7.11 9.5 3.2 2.98
DCS Control Room FR
24 AHU – 1 25 2.1 7.3 0.29
25 AHU – 2 25 3.4 5.6 0.61
DCS Control Room Extension
26 AHU NA 4.8 5.4 0.89
DCS Control Room LR
27 AHU – 1 NA 2.8 4.8 0.58
28 AHU – 2 NA 1.5 4.5 0.33 Filters are
LOUPS Control Room LR dusty. Fresh
AHU 1A NA 5.4 10.2 0.53 Air Damper is
29 closed.
New Administration Building
30 AHU – 3 NA 5.89 8.3 0.71
31 AHU – 3 NA 6.9 11.5 0.60
32 AHU – 1 NA 4.9 14.0 0.35
MSS – 10
AHU SP-MSS- NA 9.9 13.1 0.76
33 3RD-02 Filters are
AHU SP-MSS- NA 8.5 7.5 1.13 choked.
34 1ST-06
AHU SP-MSS- NA 3.5 6.7 0.52 Fresh Air
35 1ST-07 Damper is
AHU SB-G-02 NA 6 3.6 1.65 closed.
36
MSS – 11
37 AHU – 1 25 9.1 6.5 1.39
38 AHU – 3 25 8.8 17.4 0.51
39 UPS Room AHU NA 8.1 4.4 1.85
Remark: Air filters needs frequent cleaning.

6.7 Refrigerator system performance:
New administration building, Laboratory and MSS -10 AHU’s are assisted with
chilled water system.
HVAC chiller performance
The performance of chiller can be evaluated by measuring
 Temperature of chilled water entering and leaving the evaporator.
 Temperature of cooling water entering and leaving the condenser.
 Flow rate of cooling water.
 Power consumption of the machine.
The chilling effect (TR) and energy efficiency ratio can be computed by indirect
method, as under:
Condenser heat removal rate (TR)= Specific heat (kCal/kg/ o C) x specific gravity x
Flow rate (M 3 /hr) x Temperature difference of water at inlet and outlet ( o C) x
1000/ 3024
Chilling effect (TR) = Condenser heat removal rate (TR) – (0.9 x Compressor
motor power) /3.516
Specific Power Consumption (kW /TR) =0.9 x Power consumption (kW) / Air
Chilling Effect (TR)
Energy Efficiency Ratio – EER (W of cooling / W of input power)= Power

consumption (kW) / Air Conditioning Effect (kW)

The performance of chiller was evaluated, the details of which are as under.
Description Unit New Admin. BUILDGING Laboratory MSS- 10

Chiller – 1 Chiller - 2 Chiller - 1 Chiller - 2
Make York York McQuay Voltas
Model YR UC UB TO 550C YR UC UB TO 550C NA NA
Type Water Cooled Water Cooled Water Cooled Water
Cooled
Motor Rating kW NA NA 178.2 NA
Specific Heat kCal/kg/oC 1.00 1.00 1.00 1.00
Specific Gravity 1.00 1.00 1.00 1.00
Motor Parameter
Power kW 74.6 75.6 54.6 52.7
Motor Load % 60% 60% 45% NA
Condenser Parameters
Inlet Temperature CW oC 26.3 26.1 30.9 28.6
Outlet Temperature CW oC 28.5 28.6 31.9 30.2
Flow Rate M3/hr 127 127 250 121
Heat Removal rate Kcal/hr 279378 317475 250000 193600
TR 92.4 105.0 82.7 64.0
Chiller Parameters
Inlet Temperature CHW oC 14.7 9.9 8.3 12.0
Outlet Temperature CHW oC 10.2 8.1 7.1 6.4
Evaporator TR TR 73.29 85.63 68.70 50.53
Overall Parameters
Chilling Effect (Indirect) TR 73.29 85.63 68.70 50.53
Specific Power Consumption kW/TR 0.88 1.02 1.13 0.86
Energy Efficiency Ratio W/W 3.97 3.45 3.10 4.07

Vapor Absorption Machine performance
The performance of vapor absorption machine is computed as follows.
Refrigeration Effect (TR)= Specific heat (kCal/kg/ o C) x specific gravity x Flow rate
(M 3 /hr) x Temperature difference of chilled water at inlet and outlet ( o C) x 1000/
3024
Description Unit MSS - 11

CP-VAM-MSS-GR-01
Design Parameters
Make Voltas
Model HAU-W-4005
Rated Output TR 260
Steam Inlet Pressure Kg/cm2 6.0
Steam Valve open % 98.0
Specific Heat kCal/kg/oC 1.00
Specific Gravity 1.00
Chilled Water Inlet Temperature oC 13.2
Chilled Water Outlet Temperature oC 9.8
Chilled Flow Rate M3/hr 210
Chillier Water inlet pressure Kg/cm2 4.9
Chiller Water outlet pressure Kg/cm2 2.5
Pressure Drop in Chiller Kg/cm2 2.4
Cooling Water Inlet Temperature oC 27.7
Cooling Water Outlet Temperature oC 31.2
Condenser C/W inlet pressure Kg/cm2 4.56
Condenser C/W outlet pressure Kg/cm2 2.1
Pressure Drop in Condenser Kg/cm2 2.46
Condensate (Steam) Quantity Kg/hr Not Possible
Refrigeration Effect TR 236.1
% Rated 91%

HVAC Cooling Towers performance
The method to evaluate the performance of cooling towers is explained in

section 6.5.1
Description Units New Admin. MSS - MSS -

Bldg. Laboratory 10 11
Chiller C.T. VAM
C.T.
Motor Rating kW 7.5 7.5 7.5 5.5 15.0
Operation 1W & 1W & 1W&1S 1W&1 1W&1
0S 0S S S
Dry Bulb Temperature 0C 27.4 27.5 30.5 28 31.5
Wet Bulb 0C 23.1 23.4 25.5 24 21
Temperature
Area M² 0.03 0.03 3.44 3.01 0.04
Water Temperature - 0C 28.5 28.6 31.9 30.2 31.2
Inlet
Water Temperature - 0C 26.3 26.1 30.9 28.6 27.7
Sump
Water Flow M3/hr 127 127 250 121 221
Power Consumption kW 2.60 2.30 6.55 NA 14.80
% 35% 31% 87% 99%
Rated
Evaporation Losses M3/hr 0.43 0.49 0.38 0.30 1.18
Drift loss M3/hr 0.032 0.032 0.063 0.030 0.055
Water consumption M3/hr 0.5 0.5 0.4 0.3 1.2
M3/day 11.0 12.4 10.7 7.8 29.7
Specific Power kW/TR 0.03 0.02 0.08 0.06
Water to air (L/G) 127.39 136.04 7.77 1.01 85.25
ratio
Actual Range oC 2.2 2.5 1.0 1.6 3.5
Actual Approach oC 3.2 2.7 5.4 4.6 6.7
Effectiveness % 41% 48% 16% 26% 34%

HVAC pumps performance
The performance of HVAC pumps is shown below.
Description Units New Admin. Bldg. MSS - 11

Condens Condens MSS-PCWP MSS-PCWP 718-CHWP 718-CHWP
er er -MTR-1 -MTR-3 -SB-G01 -SB-G02
WP-1 WP-2
Design
Parameters
Make Mather Mather KSB Pumps KSB Pumps KSB Pumps KSB Pumps
Platt Platt Ltd. Ltd. Ltd. Ltd.
Type 80/100 80/100 MEGA-G80- MEGA-G80- MEGA-G65- MEGA-G65-
BSN BSN 315 315 315 315
Type Of Fluid Water Water Water Water Water Water
Curve Y/N N N N N N N
Flow rate M3/hr 121.44 121.44 NA NA NA NA
Head M 30 30 NA NA NA NA
Specific Gravity 1.0 1.0 1.0 1.0 1.0 1.0
Motor Efficiency % 91.0% 91.0% 89.0% 89.0% 89.0% 89.0%
Motor Rating kW 18.5 18.5 11 11 15 15
Actual
Parameters
Material of the M.S. M.S. M.S. M.S. M.S. M.S.
pipe
Pipe mm 520 520 540 540 520 520
circumference
Thickness of the mm 4.8 4.8 4.8 4.8 4.8 4.8
pipe
Lining Material if NA NA NA NA NA NA
any
Lining Thickness if mm NA NA NA NA NA NA
any
Method (V or Z Z Z Z Z Z Z
method)
Transducers mm 26.94 26.94 268 268 261 261
Spacing
Flow rate M3/hr 113.98 140 98.4 102.5 105.5 104.5
% 94% 115%
Rated
Suction Pressure kg/cm NP NP 2.1 2.1 2.5 2.5
2
M 21 21.2 25.3 25.4

Discharge kg/cm NP NP 4.56 4.6 4.9 4.9
2
Pressure
M 45.6 45.6 49.0 49.2
Differential M 24.6 24.4 23.7 23.8
Pressure
Power kW 14.23 15.01 9.84 10.35 14.90 15.30
Pump Efficiency % NP NP 75.3% 74.0% 51.4% 49.8%

Description Units
Laboratory MSS - 10 D.M. Plant
Condenser Condenser DM Water Transfer Pump Degassed F W Pump
WP-1 WP-1
510 PM - 510 PM - 510 PM - 1001 510 PM -
1001B 1002B 01 C
Design Parameters
Make Beacon Mather Platt SULZER SULZER SULZER Kirloskar

Brother
Type
BCP-150/320 80/100-8SN 2F 100-3350 NA 2F-150-3250 KPD 150/400
Type Of Fluid
Water Water DM Water DM Water Sea Water Water
Curve Y/N
NA NA NA NA NA NA
Flow rate M3/hr 96.3 210 300 280 280
NA
Head M 30 90 45 68 55
NA
Specific Gravity 1.0 1.0 1.0 1.0 1.0 1.0
Motor Efficiency % 93.2% 90.0% 93.5% 93.5% 94.0% 93.5%
Motor Rating kW NA 15 90 55 90 75
Actual Parameters
Material of the pipe M.S. M.S. M.S. M.S. M.S. M.S.
Pipe circumference mm 520 520 520 520 520 520
Thickness of the pipe mm 4.8 4.8 4.8 4.8 4.8 4.8
Lining Material if any NA NA NA NA NA NA
Lining Thickness if any mm NA NA NA NA NA NA
Method (V or Z method) Z Z Z Z Z Z
Transducers Spacing mm 261 261 261 261 261 261
Flow rate M3/hr 250 121.1 171 245.5 265 282
% Rated 126% 81% 82% 95% 101%
Suction Pressure kg/cm2 0.50 0.5 1.00 1.00 0.30 0.40
M 5 5 10 10 3 4
Discharge Pressure kg/cm2 4.50 2.4 11.00 6.00 7.00 6.00
M 45.0 24.0 110.0 60.0 70.0 60.0
Differential Pressure M 40.0 19.0 100.0 50.0 67.0 56.0
Power kW 49.40 8.90 75.30 52.20 76.20 69.30
Pump Efficiency % 59.2% 78.3% 66.2% 68.5% 67.5% 66.4%

6.8 Compressed air system performance:
The detailed observation study carried out at DHDS, Nitrogen LR and Utilities
compressor system. The observations include pressure readings at inlet and
outlet of filter, dryer & receiver, inlet valve position, unload valve position,
flow rate noted down and current measurements carried out wherever
possible and feasible.
The power loss in air compressor system is computed as below:

Pressure loss= (Discharge pressure – Header pressure )-0.05*Discharge
pressure
% Pressure loss= Pressure loss *100/Discharge pressure
Power loss= Measured power * % Pressure loss
(Considering allowable 5% loss as per BEE norms)
The performance of air compressor system was evaluated, the details of

which are as under. The critical observations are mentioned in the data
sheet.
Descriptio Unit Nitrogen LR

DHDS
n Compressor Compressor
Compres Utility Compressor
sor
C- C-
87-C- 716-C- 505-CM- DHT DHT
1230 123 C4 C12 C9 C7
01-A 1011 1001 B A
D 0E
Suction
Pressure kg/cm2 NA NA NA NA NA NA NA NA NA NA NA
DP At
Filters mm WC 10 NA NA NA NA 40 130 120 110 140 300
Discharge
Pressure kg/cm2 8 7.76 7.75 7.5 7.6 7.8 7.7 7.8 7.8 7.8 8
Discharge
Temperat 0C 98 110 75 112 132 110 NA 85
ure
Dryer
Inlet kg/cm2 8 7.6 7.5 Air from receiver is
Pressure going to NA
Dryer GFEC,NFCCU,DHT
Outlet kg/cm2 6.6 7.55 NA ,NAD Dryers
Pressure
Receiver
Pressure kg/cm2 6.6 7 NA 7.5 7.5 7.5

Header
Pressure kg/cm2 6.6 LP-5.93/HP-7 6.8 7.5 7.5 7.5
Pressure
drop in kg/cm2 1.4 0.76 0.7 0.3 0.2 0.3
dryer
circuit %
2.6 3.8
Generat 17.5% 9.8% 9.3% 3.8%
% %
ed
Inlet
Valve % 100 21 48 34 100 85 100 100 46 49 73
Position
Unload
Valve % 12 13 10 0 0 0 0 0 0 0 11
Position
Flow Rate
m3/hr 940 7500 4597 NA NA NA NA NA
Current
Amp 70 105 69.56 41 36 118 64 65 110 110 65
Power 1214 658. 668. 1131 1131 668.

MW 735 1080.3 715.7 391 358
.0 5 7 .7 .7 7
Additional loss in the dryer circuit against norm of less than 5%
Pressure
loss 1.00 0.37 0.33 0.00 0.00 0.00
kg/cm2
% 0.0 0.0
12.5% 4.8% 4.3% 0.0%
Generat % %
ed
Power % Input
loss power
0.0 0.0
12.5% 4.8% 4.3% 0.0%
% %
91.9 51.8 16.9 0 0 0

KW
Loss through drain valves
No. of
Drains 1 3 2 2 2 3 3 3 3 3 3
Drain Moisture Intercool Intercoo

Location drain er drain ler Drain
after 1,2,3: LP, 1,2
cooler HP
header (New AD + Intercooler Drain 1&2, Knock out drain 1,
Old AD) cooler drain 1 (Not in use)
Remarks For high Air flow is There are 9 air compressors out of which 3
pressure not available air compressors are running, 3 air
there is for old air compressors are stand by and 3 air
booster dryer. compressors are under maintenance. The
compress dryers are common and readings provided
or. separately.
The pump-up test could not be carried out due to large capacity compressors
and continuous nature of plant operation.

The vent valve was observed to be partially open for a few of the compressors
leading to energy losses. However, as the venting is intermittent and process
safety & reliability dependent, it is not possible to estimate the present loss and
savings potential.
The possibility of installing auto -drain valve for all the vent points in the
compressor house may also be ascertained.

Dryers:
The performance of dryers , provided for utility compressors , is shown below,

considering Allowable loss in the dryer circuit against norm of less than 5% .
Description Unit Dryer for Utility Compressor

GFEC NFCCU DHT NAD
Dryer Inlet
Pressure kg/cm2 7.2 7.6 7.6 NA
Dryer Outlet
Pressure kg/cm2 6.4 6.8 6.8 NA
Pressure drop in
dryer kg/cm2 0.8 0.8 0.8 NA
%
Generated 11.1% 10.5% 10.5% NA
Flow Rate m3/hr NA 2881 3800 1246
Note: All these dryers are in common for utility compressors
Additional loss in the dryer circuit against norm of less than 5%

Pressure loss
kg/cm2 0.44 0.42 0.42 NA
%
Generated 6.1% 5.5% 5.5% NA
Power loss
% Input 5.5%
power
162.0
KW
The pressure drop in on the higher side. HPCL informed that dessicant for GFEC
air dryer has been replaced, planning done for NFCCU, DHT and DHDS dessicant
replacement.

6.9 Electric motor load analysis:
The Motor load survey involve measurement of electrical load parameters

namely volts, amperes, power factor, kW drawn.
% Motor loading= Measured power x 100 / Rated power
The load analysis for electrical motors of capacity >75kW is listed below.
Feeder no. Description Rating Voltage Current Power PF Load

KW V A KW %
MSS – 10
HT-282 (Panel)
2 WGC VFD 114-CM-3020 6250.0 6500 498.00 5488.0 0.98 88%
4 114-PM-3074 A 180.0 6500 14.50 145.0 0.89 81%
29 Air Compressor (B/H) 506-CM- 685.0 6340 66.00 644.1 0.89 94%
1002
30 114-CM-1003 (AMAB) 4905.0 6350 393.10 3930.0 0.91 80%
34 114-PM-3062B 200.0 6380 17.30 172.0 0.90 86%
36 114-PM-3074C 180.0 6370 16.70 167.0 0.91 93%
37 114-PM-3075B 320.0 6360 27.50 254.0 0.84 79%
38 114-CM-1001(MAB) 6360.0 6360 633.00 6198.0 0.89 97%
40 114-CM-1002 (FAB) 269.0 6350 24.10 238.0 0.90 88%
PCC 381 Panel
9FC 114-PM-3071B 110.0 410 108.70 72.0 0.94 65%
15FC 114-PM-3076A 125.0 415 156.00 105.0 0.94 84%
16FC 110-PM-1001C 132.0 420 181.00 101.0 0.77 77%
PCC 380 Panel
28FC 114-PM-1001C 132.0 420 200.50 125.0 0.86 95%
27FB 61-PM-1014B 132.0 415 147.00 98.0 0.93 74%
21FB 114-PM-3051B 75.0 415 82.60 54.0 0.91 72%
12FB 114-PM-3058A 110.0 410 101.00 67.0 0.94 61%
7FC 114-PM-3054B 160 410 192.00 122.3 0.90 76%
6FC 114-PM-1001B 132 410 214.00 133.1 0.88 101%
FRE PCC
1F3 31-P-12B 110 413 127.00 83.6 0.92 76%
2F3 32-P-9B 110 413 124.00 81.4 0.92 74%
3F1 31-P-11A 132 413 167.00 108 0.90 82%
4F3 31-P-7A 406 79.00 47 0.85
5F1 31-F-1B 413 83.00 50.6 0.85
7F3 31-P-6A 75 409 81.00 50.5 0.88 67%
9F1 32-F-1002 413 58.00 35.4 0.86
14F1 31-P-11B 132 458 171.00 122 0.90 92%
14F3 31-P-3C 417 77.20 47.8 0.86
17FB 32-P-7B 75 417 104.00 69.4 0.92 93%
20F3 32-F-1001 417 59.60 33.6 0.78
22F1 31-P-8B 125 417 160.00 107 0.93 86%
26F1 32-P-6B 110 412 98.50 65.3 0.93 59%
28F3 31-P-3B 412 81.30 53.6 0.93

29F1 31-P-7C 75 412 64.00 24.1 0.53 32%
MSS – 5
HT Panel (3.3KV)
1 14 C2 (C-101) 3350 260.80 1330 0.88
16 14-P-33B 180 3340 32.40 172.5 0.92 96%
6 14-C-5(B101) 4500 3360 751.00 4059.5 0.93 90%
5 95-P-01E 575 3350 93.30 470 0.87 82%
PMCC
6F1 95-CT-FAN 1 440 129.00 82.9 0.84
6F3 95-CT-FAN 2 440 134.00 86.3 0.85
10F3 14-P-28B 439 80.70 58.3 0.95
11F1 95-CT-FAN 3 440 119.00 74.1 0.82
20F1 95-CT-FAN 5 438 117.00 74.2 0.83
MSS – 7
PCC 301
2FC 101-PM-1002A 410 103.80 66.0 0.90
4FC 101-FAN-1001 410 102.30 65 0.90
5FC 102-PM-2004B 410 117.40 77 0.92
10FC 102-PM-2009B 420 185.40 126 0.94
23FC 101-PM-1003A 420 81.90 53 0.90
PCC 302
2FB 103-CM-1001A 410 170.60 111.2 0.92
3FC 103-PM-1001B 410 134.20 85.6 0.90
8FC 103-PM-2003A 410 149.60 95.4 0.90
17FB 103-PM-2006A 410 137.00 87 0.90
18FC 103-PM-2015B 410 112.00 71 0.90
21FC 103-CM-1001B 410 244.00 117.2 0.68
25FC 103-PM-2009B 410 97.00 63 0.92
HT-202 Panel (6.6KV)
9 102-CM-2001 2700 6550 271.00 2610.1 0.85 97%
12 102-CM-4090B 1000 6580 72.20 706.5 0.86 71%
14 102-CM-1001B 285 6600 29.40 281.6 0.84 99%
16 102-CM-2002A 3030 6550 25.00 232.3 0.82 8%
17 103-CM-2001A 301 6600 39.50 297.6 0.66 99%
19 103-PM-2001B 180 6570 14.70 150.3 0.90 84%
20 103-PM-2004A 6600 15.30 157.1 0.90
21 102-PM-2001A 165 6560 17.40 162.0 0.82 98%
49 102-PM-1001B 175 6590 17.00 170.5 0.88 97%
52 102-CM-4060 550 6570 45.50 475.6 0.92 86%
53 101-PM-1001B 345 6600 29.20 306.6 0.92 89%
63 505-CM-1001 740 6620 70.40 709.4 0.88 96%
MSS – 8
PCC – 330
3FC 107-PM-1003A 420 71.00 47 0.92
4FC 109-PM-1001B 420 124.00 81 0.90
12FC 105-PM-1003B 420 183.00 119 0.90
PCC – 331
2FC 501-CT-FAN5 110 410 101.00 54 0.76 49%
3FC 501-CT-FAN1 110 410 103.00 58 0.80 53%
5FC 501-CT-FAN4 110 410 101.00 55 0.77 50%
18FC 501-CT-FAN2 110 410 107.00 61 0.80 55%

20FC 501-CT-FAN3 110 410 100.10 56 0.78 51%
HT203
P6 105-PM-1001A 180 6570 16.70 171 0.90 95%
P7 105-CM-1001A 6580 53.80 336 0.55
P8 109-CM-1004A 370 6580 31.80 329 0.91 89%
P10 501-PM-1001F 645 6580 59.70 571 0.84 89%
P12 501-PM-1001G 645 6560 55.00 524 0.84 81%
P14 502-SG-10-FD FAN 1 550 6570 30.80 295 0.84 54%
P38 501-PM-1001D 645 6490 58.30 549 0.84 85%
P40 501-PM-1001H 645 6460 61.00 565 0.83 88%
P41 502-VHP-BFW-P-01-C 600 6620 38.90 387 0.87 65%
P48 502-HP-BFW-P-2B 450 6480 19.50 190 0.87 42%
P46 Reliance Motor P702B 6480 60.50 603 0.89
MSS – 11
HVSB - 2 Panel - 6.6KV
1 700-CM-1001 7170 6650 204.00 2300 0.98 32%
4 700-PM-1012B 210 6640 15.60 167 0.93 80%
9 700-FAN-M-1002 180 6620 3.40 34 0.88 19%
12 700-PM-1005B 430 6620 26.40 273 0.90 63%
15 700-PM-1003B 500 6640 25.20 270 0.93 54%
30 700-PM-1001A 1900 6600 141.30 1420 0.88 75%
34 700-PM-1005A 430 6530 26.30 270 0.91 63%
36 700-CM-1002A 4250 6600 123.00 1390 0.99 33%
3 715-C-1001B 685 6480 67.20 670 0.89 98%
6 716-C-1101 1350 6490 106.00 1060 0.89 79%
14 704-B-CM-1001A 220 6480 13.60 131 0.86 60%
39 704A-CM-1001B 220 6670 12.30 119 0.84 54%
PMCC – 1
1E 700-PM-1002B 132 422 194.00 125 0.88 95%
3E 700-FAN-1001B 160 422 15.00 6.3 0.58 4%
18E 700-PM-1004A 75 420 92.00 62 0.92 83%
19C 700-FAN-1001A 160 419 47.00 33.5 0.99 21%
PMCC – 3
08E 702-PM-1002B 132 426 166.00 111 0.91 84%
PMCC – 4
5E 714-PM-1003C 150 425 220.00 148 0.91 99%
10E 718-PM-1001C 90 425 92.00 62.3 0.93 69%
MSS – 6
PCC 302
7FB 92-P-02B 75 429 92.50 54.5 0.80 73%
1FB 73-FAN-01A (VFD 20.28Hz) 288 170.8 166.8 16 NA 6%
16FB 73-FAN-01B (VFD 20.37Hz) 288 170.7 181.3 20.7 NA 7%
17FB 73-FAN-02A 248 423 97.68 49.62 0.772 20%
2FB 73-FAN-02B 248 424.9 108.9 57.67 0.866 23%
HT Panel (6.6KV)
4 75-MK-101 280 6430 21.50 213 0.89 76%
9 71-C-01 2950 6460 161.70 1590 0.88 54%
15 71-P-01C 630 6490 46.70 467 0.89 74%
25 71-P-01B 630 6550 48.80 476 0.86 76%
26 71-P-12A 195 6500 14.80 146 0.88 75%

27 71-C-02B 880 6470 61.60 358 0.52 41%
28 87-C-01A 800 6520 70.00 735 0.93 92%
30 73P06B 230 6530 15.10 156 0.91 68%
36 71P21A 200 6530 15.10 154 0.90 77%
MSS – 2
HT Panel (3.3KV)
3 61-P-707A 280 3300 41.60 NP NP
5 81-P-01A (CT Pump-DHDS) 425 3300 86.00 NP NP
29 110-C-2001B (Oxidation Blower) 190 3300 27.70 NP NP
USSD
18FB 71P15B ( E ) 160 424 141.00 96.6 0.93 60%
18FC 81T01A (N) 120 425 77.30 45.7 0.79 38%
17FC 81-T-01B (S) 120 418 105.00 69.4 0.92 58%
4FA 61-P-917 No Display
S/S IETP
PMCC
21F1 601-K-100 2D (Aeration Blower) 424 66.60 47 0.97
26F1 601-M-1031C (TWT Pump) 423 82.00 56 0.93
3F1 601-M-1031A (TWT Pump) 424 85.00 58 0.94
2F1 601-M-1008A (RO Feed Pump) 423 101.00 72 0.98
LRS – 1
TR - 2 Panel
3 MP 1264F 6000 48.30 428.7 0.85
4 C 502 5980 26.50 241.2 0.88
6 MP 1264B 6010 46.20 398.1 0.83
TR - 1 Panel
13 MP - 101 ( E ) 5990 20.30 193 0.92
Siemens (6.6KV) Panel
4 MP - 307 C 6100 23.90 214 0.85
5 MP - 301 C ( E ) 5950 17.40 161 0.90
8 MC – 3502 5970 25.40 213 0.81
13 MP - 1264 A 5960 41.60 356 0.83
18 MP - 305 C 5980 29.00 274 0.91
20 MC – 302 5965 492.00 4570 0.90
PMCC Panel (First Floor)
2FC MC - 401C ( E ) 411 74.80 33 0.62
8FC K - 604 (A) (W) 416 159.30 85.9 0.75
12F1 P102 C 416 110.00 71 0.89
MCC - 3 Panel (Ground Floor)
8F2 MP 312A (N) 428 97.80 67.2 0.93
PMCC for TR - 3 (Ground Floor)
7F1 100 FM 1001 75 428 82.00 NP NP
7F3 MP 102A 160 428 125.00 NP NP
MCC - 4 (Ground Floor)
9F2 MP 3202 A (W) 428 90.40 60 0.90
PMCC for TR - 5 (First Floor)
1FB C 401 D 420 76.00 NP NP
3FB MP - 1202 AX 420 173.00 NP NP
2FB MP - 204 B (W) 150 420 204.00 132 0.89 88%

3FB MP - 202 A (N) 420 88.00 NP NP
LRS – 2
HT Panel (6.6KV)
7 MP - 4120 A 740 6490 42.40 414 0.87 56%
10 C – 4502 6480 27.60 232 0.75
11 MP - 4121 A 250 6480 14.40 133 0.82 53%
12 44-C-02B (FGRS Motor) 420 6490 32.10 317 0.88 75%
27 MP - 4101 B ( E ) 280 6690 24.30 231 0.82 83%
30 MC - 1230 E 6690 35.40 365 0.89
33 44-C-02A (FGRS Motor) 420 6690 31.70 319 0.87 76%
LRS – 4
HT 900 Panel
99-PM-1264G (SCW CT Pump 575 6730 56.80 556 0.84 97%
LOUP)
6 99-PM-11A (HP Lean Amine 6700 30.30 312 0.89
Pump)
10 99-CM-01A (Make up gas 1050 6690 136.00 1180 0.75 112%
Compressor)
11 99-CM-02A (Recycle gas 1000 6700 121.00 1023.5 0.73 102%
compressor)
19 99-PM-02B (Feed Charge Pump) 6740 46.80 497 0.91
24 99-CM-1230F (Air Compressor) 418 6760 37.50 386 0.88 92%
PMCC - 901 (First Floor)
5FB 99-PM-07A 75 413 57.00 37.86 0.93 50%
8FB 99-PM-10A 160 412 227.00 147.1 0.91 92%
21FB 99-PM-05B 75 420 72.00 48.3 0.93 64%
LRS – 3
PMCC - 301 Panel (Ground Floor)
6F3 MP - 4103 A (W) 132 437 116.00 72.6 0.82 55%
7F2 MP - 201 B (W) 125 437 150.00 102 0.90 82%
14F3 MK - 4101 B ( E ) 160 424 178.00 117 0.89 73%
PMCC - 401 Panel (First Floor)
2B MP - 3204 A ( E ) 419 232.00 145 0.86
4C P - 3201 ( E ) 419 146.00 NP NP
8C CT FAN 3 (LR CT) 419 105.00 61 0.80
9C 99 FAN 04A (LOUP SCW Fan A) 419 127.00 66.8 0.72
PMCC - 311 Panel (First Floor)
13FB MP - 4204 A (W) 110 419 222.00 88 0.55 80%
MP - 4453 B (S) 125 419 173.00 103.75 0.83 83%
22FB MP - 4202 B ( E ) 75 419 100.00 58.5 0.80 78%
MSS 1
USS A PMCC
6F1 11-P-11A 150.0 419.7 183.7 115.8 0.87 77%
7F2 11-P-6B 75.0 419.1 108.0 37.4 0.48 50%
5F1 11-P-12B 90.0 419.3 209.4 95.4 0.63 106%
3F1 THP 12B West 150.0 419.7 192.6 138.6 0.99 92%
EP 1
2F1 11-P-2D 430.3 129.0 86.5 0.88
3F3 11-P-2A 433.0 77.1 52.6 0.91
PF 1
2F1 11-P-2D 432.0 67.5 47.5 0.93

SUB I
2FA 11-P-11B 160.0 409.3 192.9 135.0 0.99 84%
HT Panel (3.3KV)
8 11-P-1C 3307.0 84.7 436.5 0.91
9 95-P-01B 575.0 3307.0 109.3 563.6 0.88 98%
11 11-P-1B 3307.0 83.0 427.9 0.90
20 95-P-01A 575.0 3307.0 98.7 497.4 0.88 87%
26 95-P-01D 575.0 3307.0 122.7 576.2 0.82 100%
MSS 4
HT Panel (3.3KV)
4 95-P-01G 575.0 3310.0 109.0 548.0 0.88 95%
7 31-P-14A 400.0 3300.0 72.7 361.0 0.87 90%
18 31-P-1C 355.0 3300.0 69.4 357.0 0.89 101%
33 31-P-14B 400.0 3320.0 71.2 352.0 0.86 88%
42 95-P-01I 575.0 3310.0 107.0 531.0 0.87 92%
45 31-P-1E 350.0 3320.0 79.3 406.0 0.89 116%
CPP Substation 1
HT Panel (3.3KV)
6 P-7102B 220.0 3356.0 38.4 198.7 0.89 90%
CMCC Panel
2F1 CPP005A 125.0 440.0 175.0 125.3 0.94 100%
CPP Substation 3
PMCC 503
CPP005F(N) Boiler Feed Pump 125.0 436.0 169.0 119.0 0.94 95%
13FA (N)

Underloaded Motors:
The drop in motor efficiency is just 1 to 3% till an operating load of around 50%;
but the drop becomes steep as the load start falling below 50%. Depending on
the actual load, the motor consumes 5 to 15% additional power while operating
at smaller loads.
The following motors were observed to be loaded below 50% of the rated
capacity.
Feeder Description Rating Voltage Current Power P F Load

no. KW V A KW %
MSS – 10
FRE PCC
29F1 31-P-7C 75 412 64.00 24.1 0.53 32%
MSS – 8
PCC – 331
2FC 501-CT-FAN5 110 410 101.00 54 0.76 49%
5FC 501-CT-FAN4 110 410 101.00 55 0.77 50%
HT203
P48 502-HP-BFW-P-2B 450 6480 19.50 190 0.87 42%
MSS – 11
1 700-CM-1001 7170 6650 204.00 2300 0.98 32%
9 700-FAN-M-1002 180 6620 3.40 34 0.88 19%
36 700-CM-1002A 4250 6600 123.00 1390 0.99 33%
PMCC – 1
3E 700-FAN-1001B 160 422 15.00 6.3 0.58 4%
19C 700-FAN-1001A 160 419 47.00 33.5 0.99 21%
MSS – 6
PCC 302
1FB 73-FAN-01A (VFD 20.28Hz) 288 170.8 166.8 16 NA 6%
16FB 73-FAN-01B (VFD 20.37Hz) 288 170.7 181.3 20.7 NA 7%
17FB 73-FAN-02A 248 423 97.68 49.62 0.772 20%
2FB 73-FAN-02B 248 424.9 108.9 57.67 0.866 23%
HT Panel (6.6KV)
27 71-C-02B 880 6470 61.60 358 0.52 41%
MSS – 2
USSD
18FC 81T01A (N) 120 425 77.30 45.7 0.79 38%
PMCC - 901 (First Floor)
5FB 99-PM-07A 75 413 57.00 37.86 0.93 50%

As seen from the above table 16 numbers of motors are under loaded out of
which 2 numbers of motors are connected with VFD’s. 4 numbers of HT motors
are also found to be loaded less than 50%. For balance 10 numbers LT motors , a
detail analysis needs to be done for a longer duration such as six months to
check the trend, power consumption and various other operational factors (plant
thruput, etc.) affecting the performance .
HPCL opined that for various identified pumps, motors, specific limitation is
occurring due to low unit through put during survey, revamp study is in progress
in a few units, etc. HPCL informed that VFD can be implimented for motors of
31 P1C and E (FRE) , 32P7A , review shall be done by them for FR - 12 P9 A/B,
GFDS - 101-PM-1001A, 101-PM-1002A, 101-PM-1003A, 102-PM-1001B, 102-PM-
2001B, 102-PM-2004A, 103-PM-2001A, 103-PM-2004A, 103-PM-1001B, 103-PM-
2003A, 103-PM-2006A, 103-PM-2009A, 107-PM-1003A, 109-PM-1001A. For
these identified motors, the unit is undergoing revamp and post revamp flow
requirements will change. It was informed that for pump 105-PM-1003 A /B ,
both pumps were operating during survey, however in normal condition only one
pump operates with 90% valve opening. For 107 -PM-1003 A and 107-PM-1001A
plant is operating at lower thruput since revamping activities. For LR block MP -
305C, 307 C and MP 312 A PDU current feed rate is low , however in future it
may increase to design level. Trimming o f impeller option shall be studied for
short duration savings. For MP -4121A , PDA unit is designed to run both BS and
Cat fee dmode. During Cat feed mode , recycle comes down. Hence VFD option
is not required. For other, pumps are running as per process r equirement,
demand of various grades, throughput etc.

6.10 Lighting system:
The illumination in the plant is provided with the help of 125/ 160 / 230 / 400
W MVL and SVL at most of the places along with LED of 45 W at some place s.
The measurements are listed below.
Location Illumination (Lux) Type of Fitting

1 2 3 4 5 Type Flame Watts
Proof
Plant Area
Centralised Caustic Storage & Supply Unit
110-TK-2004 45 64 51 63 55 M.V.L. Yes 125
110-TK-2004 39 44 52 60 49 M.V.L. Yes 125
110-TK-2006 A 60 58 54 62 65 M.V.L. Yes 125
110-TK-2006 B 74 81 99 106 61 M.V.L. Yes 125
PT Plant Ground Floor
110-E-2001 Influent Cooler 22 44 36 52 39 M.V.L. Yes 125
Poly Aluminium Chloride 44 51 37 46 57 M.V.L. Yes 125
tank
Oxidation Tank 82 84 73 15 88 M.V.L. Yes 125
Oxidation Blower 14 15 21 26 27 M.V.L. Yes 125
Clarifier East 83 55 26 89 65 M.V.L. Yes 125
Clarifier West 91 72 62 51 54 M.V.L. Yes 125
LPG & Propane Mounted Bullet
East 88 84 51 44 61 M.V.L. Yes 125
North 66 54 62 26 39 M.V.L. Yes 125
West 52 31 44 56 49 M.V.L. Yes 125
South 51 36 34 56 42 M.V.L. Yes 125
Pump Area 64 65 45 45 38 M.V.L. Yes 125
Flare LPG Knock Out Room 23 43 49 49 39 M.V.L. Yes 125
LR Pump Area 24 34 31 18 15 M.V.L. Yes 125
FR-OMCC
61-P-901 25 29 31 26 39 M.V.L. Yes 125
61-P-903 40 44 49 51 23 M.V.L. Yes 125
61-P-905 26 28 37 41 39 M.V.L. Yes 125
61-P-907 44 46 49 32 21 M.V.L. Yes 125
61-P-909 55 56 24 36 41 M.V.L. Yes 125
61-P-911 55 60 59 49 42 M.V.L. Yes 125
61-P-913 25 23 31 37 41 M.V.L. Yes 125
61-P-917 45 25 55 26 38 M.V.L. Yes 125
73-P-03-B 65 69 40 58 55 M.V.L. Yes 125
71-P-15-A 54 51 49 59 43 M.V.L. Yes 125
14-LS-HS D/S 23 41 42 32 38 M.V.L. Yes 125
Asphalt Bulk loading Gantry
Bay No 1 84 76 55 74 64 M.V.L. Yes 460

Bay No 3 81 56 91 42 66 M.V.L. Yes 460
Bay No 5 46 49 54 61 57 M.V.L. Yes 460
Bay No 7 64 69 55 44 49 M.V.L. Yes 460
Bay No 9 51 56 71 52 66 M.V.L. Yes 460
Bay No 11 56 69 51 59 63 M.V.L. Yes 460
Asphalt Tank Area
TK 755 24 21 18 28 23 M.V.L. Yes 160
TK 756 26 26 27 38 33 M.V.L. Yes 160
TK 757 22 17 15 31 28 M.V.L. Yes 160
TK 750 34 27 25 22 29 M.V.L. Yes 160
Asphalt Transformer 45 51 61 54 42 M.V.L. Yes 160
Pump Slab 40 35 26 31 21 M.V.L. Yes 160
Old Tank 754 45 36 25 31 46 M.V.L. Yes 160
Old Tank 751 41 32 28 25 37 M.V.L. Yes 160
DHT Pump Area
718-PM-1001A 25 15 30 31 36 M.V.L. Yes 125
718-PM-1001B 39 41 25 21 19 M.V.L. Yes 125
718-PM-1001C 18 29 32 36 26 M.V.L. Yes 125
TF 1 Pump Slab
61-P-1007B 25 27 31 25 26 M.V.L. Yes 125
61-P-1008B 39 36 31 25 36 M.V.L. Yes 125
61-P-1009B 35 32 30 34 27 M.V.L. Yes 125
571 Tank Area
61-PM-1014 A 61 31 39 41 44 M.V.L. Yes 125
61-PM-1013 B 48 41 46 51 44 M.V.L. Yes 125
TF 2 Pump Slab
61-P-1011A 40 54 37 29 51 M.V.L. Yes 125
61-P-1012B 42 39 37 49 56 M.V.L. Yes 125
61-P-1012A 54 48 19 24 36 M.V.L. Yes 125
61-P-1006A 26 29 39 28 39 M.V.L. Yes 125
DHDS Area
Cooling Tower Area 27 28 36 32 41 M.V.L. Yes 125
Pump Area 41 51 49 43 37 M.V.L. Yes 125
BCW Pump House 46 32 38 41 51 M.V.L. Yes 125
Compressor Area 57 58 61 64 69 M.V.L. Yes 125
DM Plant
GFEC Storage Tank Area 1 55 68 71 79 58 M.V.L. Yes 125
GFEC Storage Tank Area 2 56 36 41 39 49 M.V.L. Yes 125
GFEC Pump Area 58 61 71 52 63 M.V.L. Yes 125
DHT Pump Area 76 91 98 85 64 M.V.L. Yes 125
DHT Tank Area 218 174 136 202 198 M.V.L. Yes 125
HM Unit
Heat Exchanger 63 74 81 58 49 M.V.L. Yes 125
Pump Area 36 37 39 54 41 M.V.L. Yes 125
Old Boiler
Pump Area 62 68 71 96 85 M.V.L. Yes 125

Passage Area 14 18 31 39 24 M.V.L. Yes 125
NFCCU Air Drier 36 38 41 39 50 M.V.L. Yes 125
DHT Drier Area 51 62 38 40 49 M.V.L. Yes 125
DHT Cooling Tower
Pump Area 91 68 85 78 61 M.V.L. Yes 125
Cooling Tower Area 80 66 69 68 71 M.V.L. Yes 125
FRE VPS Area
Pump Area 64 68 71 78 89 M.V.L. Yes 125
FRE APS Area
Pump Area 51 41 49 52 63 M.V.L. Yes 125
Nitrogen Plant
Receiver Area 91 116 114 121 98 M.V.L. Yes 125
Combinational Area
Pump Area 41 51 69 72 64 M.V.L. Yes 125
DHT Sub Plant
Pump Area 41 68 52 58 39 M.V.L. Yes 125
FRE Cooling Tower
Pump Area Sea Water 71 68 59 49 70 M.V.L. Yes 125
Pump Area BCW 61 63 69 54 85 M.V.L. Yes 125
GFEC
GFEC Prime G
Furnace 12 13 8 6 5 M.V.L. Yes 125 / 400
Pump Slab 15 14 28 16 21 M.V.L. Yes 125 / 400
Compressor 52 27 42 20 15 M.V.L. Yes 125 / 400
Reactor 10 11 7 15 26 M.V.L. Yes 125 / 400
SWSU
Plant Area 32 15 16 40 36 M.V.L. Yes 125
ARU
109E Heat Exchanger 11 7 9 4 3 M.V.L. Yes 125
Tower 11 13 6 15 19 M.V.L. Yes 125
109 & 1007 15 3 4 9 14 M.V.L. Yes 125
ATF
New Boiler S-12
Pump Area 16 21 32 21 23 M.V.L. Yes 175
FD Area 14 16 14 9 52 M.V.L. Yes 160
Day Tank 3 5 7 12 9 M.V.L. Yes 125
CBD Tank 12 16 9 16 8 M.V.L. Yes 125
Drum A.H.E. 12 16 14 9 4 M.V.L. Yes 125
Boiler Heater Area 12 3 20 7 6 M.V.L. Yes 125

CCR
Furnace Area 35 34 26 31 24 M.V.L. Yes 160
Cycle Max 32 26 30 16 24 M.V.L. Yes 160
Lift Tower 15 16 7 9 11 M.V.L. Yes 160
Pump Slab 8 9 20 21 37 M.V.L. Yes 160
Compressor Shed 17 15 19 10 16 M.V.L. Yes 160
Mixing Drum 8 9 11 16 14 M.V.L. Yes 160
IOD
ISOM
Pump Slab 30 28 26 21 19 M.V.L. Yes 160
Reactor 14 12 10 8 21 M.V.L. Yes 160
Furnace 33 12 23 19 12 M.V.L. Yes 160
PDA Plant
Tank Area 20 25 21 23 19 S.V.L. Yes 400
High Mast Tower 60 54 84 61 161 S.V.L. Yes 400
Compressor Shed 28 24 74 54 31 M.V.L. Yes 400 / 160
Pump Slab 78 35 42 51 40 M.V.L. Yes 125 / 160
Furnace 10 11 15 16 42 M.V.L. Yes 125 / 160
Tower 41 31 48 33 40 M.V.L. Yes 125 / 160
NMP-3 Plant
Tank Area 75 74 51 19 15 M.V.L. Yes 400
Tower 23 30 20 21 19 M.V.L. Yes 160 /125
Reactor 34 33 23 26 30 M.V.L. Yes 125 / 160
Furnace 23 51 31 108 58 M.V.L. Yes 160
Pump Slab (near tank area) 10 15 13 21 16 M.V.L. Yes 125
Pump Slab 91 81 70 66 82 M.V.L. Yes 125
Drum 52 59 61 21 15 M.V.L. Yes 160
H.E. Area 4 3 2 5 0 M.V.L. / No 400
S.V.L.
LOB Plant
High Mast Tower near NMP- 80 57 54 109 55 M.V.L. / No 400
3 S.V.L.
Compressor Shed (first 104 120 139 110 201 M.V.L. Yes 250 / 400
Floor)
Compressor Shed (Ground 124 107 15 92 86 LED / M.V.L Yes 45 / 125 /
Floor) 160
Pump Slab 110 150 104 151 170 LED Yes 45
Reactor 152 57 109 128 103 M.V.L. Yes 125 / 160
Furnace 129 19 88 120 94 M.V.L. Yes 125 / 160
Tower 52 57 39 81 125 M.V.L. Yes 125 / 160
Drum 121 104 600 95 101 LED / M.V.L Yes 45 / 160 /
125
High Mast Tower 98 104 85 45 93 S.V.L. No 400
BCW Plant

Pump Slab & Drum 185 120 80 111 92 M.V.L. Yes 160
Pump Room 92 43 181 350 41 M.V.L. / TL No 400 / 36
NMP-2 Plant
Pump Slab 29 40 29 91 32 M.V.L. Yes 160 / 400
Drum 29 44 56 59 39 M.V.L. Yes 160
Furnace 5 7 11 10 9 M.V.L. Yes 160
Tower 11 5 6 8 11 M.V.L. Yes 160
Tank Area 7 11 6 8 9 M.V.L. Yes 160
DWA Plant
Pump Slab 16 20 21 11 12 M.V.L. Yes 160
PDU Plant
Filter Area 11 8 14 16 7 M.V.L. Yes 160
Pump Slab 24 20 30 32 36 M.V.L. Yes 125 / 160
Tower 35 40 8 11 28 M.V.L. Yes 125 / 160
NMP-1 Plant
Compressor 20 25 47 35 31 M.V.L. Yes 125 / 160
Pump Slab 45 35 38 31 49 M.V.L. Yes 125
Tower 42 15 38 26 35 M.V.L. Yes 125 / 160
High Mast Tower 68 61 64 71 54 S.V.L. No 400
VPS-LR
Pump Slab 15 32 59 71 8 M.V.L Yes 250
High Mast Tower 71 82 79 82 45 S.V.L. No 125 / 400
Drum 190 200 35 76 112 M.V.L. Yes 125
Hydrogen Plant
Furnace-1 13 21 36 42 51 M.V.L. Yes 125
Furnace-2 11 12 14 15 17 M.V.L. Yes 160
Furnace-3 14 13 29 24 22 M.V.L. Yes 160
Pump Slab 29 31 28 24 26 M.V.L. Yes 160
Boiler House
Compressor 42 36 49 55 51 M.V.L. Yes 125 / 160 /
400
Pump Slab 100 55 54 81 92 M.V.L. Yes 125
ARU+SWS+SRU+GTU
Pump Slab-1 16 49 53 94 81 M.V.L. Yes 230
Pump Slab-2 11 30 18 48 77 M.V.L. Yes 230
Pump Slab-3 62 27 64 22 34 M.V.L. Yes 230
DHT
Pump Slab 74 173 98 104 81 M.V.L. Yes 125
Furnace 84 92 51 102 67 M.V.L. Yes 125 / 250
Heat Exchanger 6 8 16 50 49 M.V.L. Yes 125 / 250
Compressor Shed-Ground 151 68 36 64 41 M.V.L. Yes 125 / 250
Floor
Compressor Shed-First Floor 102 119 145 132 144 M.V.L. Yes 125 / 250 /
400

GTG Plant Area
HRSG-IV 21 27 34 39 8 M.V.L. Yes 160
HRSG-III 4 5 9 11 10 M.V.L. Yes 160
HRSG-II 3 5 10 9 16 M.V.L. Yes 160
HRSG-I 11 9 13 10 15 M.V.L. Yes 160
The street light illumination requirement is fulfilled with 250 W SVL at all the
places.
The measurements are listed below.
Location Substation Pole Illumination (Lux) Type of Fitting

No 1 2 3 4 5 Type Flame Watts
Proof
Street Light
O Street MSS 7 1 82 36 23 20 39 S.V.L No 250
2 17 7 3 10 12 S.V.L No 250
3 32 18 26 17 36 S.V.L No 250
MSS 8 4 22 17 19 25 24 S.V.L No 250
5 39 27 17 19 23 S.V.L No 250
6 10 35 12 7 5 S.V.L No 250
7 23 36 20 29 34 S.V.L No 250
MSS 6 8 7 19 9 11 15 S.V.L No 250
9 14 10 12 16 17 S.V.L No 250
10 20 46 26 41 17 S.V.L No 250
Avenue 4 57 23 31 46 51 S.V.L No 250
H 5 30 11 13 26 41 S.V.L No 250
6 45 55 19 24 39 S.V.L No 250
7 9 10 11 12 16 S.V.L No 250
8 4 5 15 21 34 S.V.L No 250
9 6 7 21 46 34 S.V.L No 250
MSS 6 10 33 21 16 26 29 S.V.L No 250
11 12 9 10 22 26 S.V.L No 250
12 4 6 12 18 15 S.V.L No 250
13 16 17 19 21 14 S.V.L No 250
14 6 16 14 11 9 S.V.L No 250
15 17 9 8 12 14 S.V.L No 250
DSG 11 1 70 61 84 54 65 S.V.L No 250
3 21 47 35 39 41 S.V.L No 250
4 9 8 11 16 21 S.V.L No 250
5 24 54 46 60 59 S.V.L No 250
6 9 6 47 34 26 S.V.L No 250
7 23 40 41 23 27 S.V.L No 250
8 51 50 16 24 39 S.V.L No 250
9 3 4 9 7 12 S.V.L No 250
10 17 53 27 17 23 S.V.L No 250

11 16 52 38 41 46 S.V.L No 250
12 33 60 47 52 39 S.V.L No 250
13 7 15 63 51 38 S.V.L No 250
14 7 8 40 38 27 S.V.L No 250
15 63 56 16 42 34 S.V.L No 250
16 9 22 17 48 39 S.V.L No 250
17 55 68 7 8 42 S.V.L No 250
18 15 25 16 42 35 S.V.L No 250
19 12 51 36 64 29 S.V.L No 250
20 42 52 32 21 39 S.V.L No 250
21 67 49 28 22 38 S.V.L No 250
22 35 46 71 44 63 S.V.L No 250
23 15 69 54 42 27 S.V.L No 250
24 19 68 54 47 26 S.V.L No 250
IETC 1 26 16 15 19 24 S.V.L No 250
2 21 36 30 27 29 S.V.L No 250
3 7 13 22 28 34 S.V.L No 250
4 22 56 17 4 12 S.V.L No 250
5 16 6 8 21 24 S.V.L No 250
6 16 19 27 29 36 S.V.L No 250
8 15 14 10 21 29 S.V.L No 250
Avenue MSS 2 7 15 11 10 9 7 S.V.L No 250
C 6 4 5 6 9 15 S.V.L No 250
5 3 10 17 22 27 S.V.L No 250
4 11 6 24 27 32 S.V.L No 250
3 22 19 17 11 6 S.V.L No 250
2 21 36 19 14 10 S.V.L No 250
1 6 8 16 15 20 S.V.L No 250
5 Street MSS 2 3 16 19 4 9 14 S.V.L No 250
2 23 41 38 51 32 S.V.L No 250
1 6 8 16 15 27 S.V.L No 250
Asphalt B Side 4 3 16 17 21 9 S.V.L No 250
5 62 46 22 36 44 S.V.L No 250
6 5 10 16 43 65 S.V.L No 250
7 33 14 21 36 19 S.V.L No 250
8 57 38 82 65 73 S.V.L No 250
9 61 8 32 54 43 S.V.L No 250
11 23 51 52 49 37 S.V.L No 250
12 3 6 7 19 21 S.V.L No 250
13 17 73 39 45 58 S.V.L No 250
Avenue MSS 10 8 86 69 55 71 42 S.V.L No 250
E 7 85 47 69 55 59 S.V.L No 250
6 9 4 18 51 42 S.V.L No 250
Asphalt B Side 9 23 35 9 14 28 S.V.L No 250
10 26 24 16 7 19 S.V.L No 250
11 42 68 22 16 7 S.V.L No 250
12 26 21 45 19 37 S.V.L No 250

6th Asphalt B Side 9 7 3 4 16 22 S.V.L No 250
Street 8 15 10 9 21 14 S.V.L No 250
7 54 12 36 42 35 S.V.L No 250
6 12 25 55 29 41 S.V.L No 250
5 46 51 38 22 14 S.V.L No 250
MSS 2 4 35 21 14 18 24 S.V.L No 250
3 56 31 25 41 45 S.V.L No 250
2 10 16 24 30 36 S.V.L No 250
1 23 26 44 64 51 S.V.L No 250
Avenue MSS 5 7 12 8 13 21 17 S.V.L No 250
A 6 42 31 38 6 14 S.V.L No 250
5 13 4 8 16 14 S.V.L No 250
4 22 16 13 14 18 S.V.L No 250
3 10 6 16 28 14 S.V.L No 250
2 67 51 8 14 19 S.V.L No 250
1 11 10 54 51 31 S.V.L No 250
Street 1 MSS 5 1 82 70 20 12 45 S.V.L No 250
2 32 78 61 16 49 S.V.L No 250
3 31 40 12 19 28 S.V.L No 250
4 11 56 44 9 19 S.V.L No 250
5 15 26 8 38 42 S.V.L No 250
6 7 51 62 41 37 S.V.L No 250
7 8 19 29 31 42 S.V.L No 250
Avenue MSS 5 1 56 47 45 61 33 S.V.L No 250
B 2 56 51 47 22 25 S.V.L No 250
3 6 12 20 54 43 S.V.L No 250
4 8 14 39 30 13 S.V.L No 250
5 21 25 26 6 18 S.V.L No 250
MSS 10 6 42 43 11 26 34 S.V.L No 250
7 5 8 169 26 17 S.V.L No 250
8 14 28 16 32 24 S.V.L No 250
Street 3 MSS 10 1 17 16 26 24 29 S.V.L No 250
2 31 43 26 25 27 S.V.L No 250
3 10 23 21 32 29 S.V.L No 250
4 31 29 26 24 17 S.V.L No 250
5 13 6 7 9 16 S.V.L No 250
Avenue Asphalt B Side 4 10 8 12 26 19 S.V.L No 250
D 3 36 37 19 6 21 S.V.L No 250
2 3 14 33 36 27 S.V.L No 250
1 3 7 16 28 26 S.V.L No 250
Street 8 MSS 2 1 24 21 16 17 12 S.V.L No 250
2 12 9 16 17 21 S.V.L No 250
3 8 13 10 5 9 S.V.L No 250
4 15 17 21 24 29 S.V.L No 250
Avenue CPP 35 98 94 48 57 61 S.V.L No 250
J 34 28 20 35 21 24 S.V.L No 250
33 22 17 36 11 21 S.V.L No 250

32 8 9 14 16 34 S.V.L No 250
31 6 10 16 10 15 S.V.L No 250
30 8 7 18 21 17 S.V.L No 250
29 58 61 18 42 39 S.V.L No 250
MSS 6 28 67 58 21 24 39 S.V.L No 250
27 3 20 13 29 16 S.V.L No 250
26 3 10 13 11 21 S.V.L No 250
25 7 5 16 9 21 S.V.L No 250
24 9 3 9 26 17 S.V.L No 250
23 10 12 16 17 5 S.V.L No 250
22 16 21 14 10 9 S.V.L No 250
21 16 21 14 10 7 S.V.L No 250
20 15 17 19 39 27 S.V.L No 250
19 8 18 24 34 19 S.V.L No 250
18 36 20 34 19 12 S.V.L No 250
17 30 23 24 14 10 S.V.L No 250
16 8 9 17 21 24 S.V.L No 250
15 7 17 14 21 19 S.V.L No 250
14 22 21 13 17 19 S.V.L No 250
13 6 8 11 17 26 S.V.L No 250
12 15 16 17 14 10 S.V.L No 250
11 30 32 17 21 14 S.V.L No 250
10 21 13 19 10 8 S.V.L No 250
9 13 18 41 20 28 S.V.L No 250
8 20 13 14 18 9 S.V.L No 250
7 44 38 36 27 21 S.V.L No 250
6 50 46 57 21 39 S.V.L No 250
5 42 41 34 29 24 S.V.L No 250
4 17 59 34 43 33 S.V.L No 250
3 15 4 16 8 19 S.V.L No 250
1 3 6 16 11 24 S.V.L No 250
Avenue PST -11 1 23 24 39 31 29 S.V.L No 250
G 2 18 5 16 17 19 S.V.L No 250
3 17 21 14 12 19 S.V.L No 250
4 8 7 19 15 27 S.V.L No 250
5 36 13 29 19 21 S.V.L No 250
6 9 18 44 53 31 S.V.L No 250
8 31 23 17 19 24 S.V.L No 250
The illumination measurement was carried out in the Administrative building

and plant DCS. The measurements are listed below.
Sr Location Length Width Illumination (Lux)

No
M M I II III IV V VI VII VIII IX X Max Min Avg

Administration Building
First Floor
1 Room No. 102 6.0 3.0 495 460 432 471 468 489 467 445 462 481 495 432 467
2 Room No. 103 6.0 3.0 494 482 471 489 486 468 472 479 459 475 494 459 478
3 Room No. 108 6.0 3.0 495 468 437 469 482 439 467 459 471 472 495 437 466
4 Room No. 111 6.0 3.0 412 398 368 385 389 410 402 378 381 377 412 368 390
5 Room No. 113 5.4 3.6 120 129 139 147 121 118 135 145 128 152 152 118 133
6 Room No. 119 5.4 4.8 163 144 151 149 164 158 162 167 152 159 167 144 157
7 Room No. 121 5.4 3.6 393 408 397 412 389 372 410 409 394 381 412 372 397
8 Room No. 122 5.4 3.6 358 408 352 348 349 359 356 365 364 368 408 348 363
9 Room No. 124 5.4 3.6 313 323 351 361 323 346 335 339 342 348 361 313 338
10 Room No. 127 5.4 3.6 228 217 221 235 230 231 225 234 231 209 235 209 226
11 Room No. 128 9.0 4.8 213 230 219 239 215 231 224 229 218 245 245 213 226
12 Room No. 131 5.4 3.6 321 342 303 337 312 324 331 329 315 311 342 303 323
13 Room No. 133 5.4 3.6 222 205 246 248 229 245 234 231 237 234 248 205 233
14 Room No. 135 5.4 3.6 225 230 238 268 229 258 239 254 249 251 268 225 244
15 Room No. 136 5.4 3.6 223 225 308 287 224 265 268 275 279 261 308 223 262
16 Room No. 137 5.4 3.6 238 268 254 245 246 235 338 246 249 261 338 235 258
17 Room No. 139 5.4 3.6 313 298 258 254 256 267 254 256 261 303 313 254 272
18 Room No. 140 5.4 3.6 316 342 331 325 331 316 319 324 312 298 342 298 321
19 Room No. 144 5.4 3.6 264 262 256 249 246 254 259 256 261 241 264 241 255
20 Room No. 146 5.4 3.6 398 341 361 352 356 384 359 364 345 348 398 341 361
21 Room No. 147 5.4 3.6 367 349 356 372 346 349 354 356 356 354 372 346 356
22 Room No. 148 5.4 3.6 375 382 368 379 364 368 375 378 364 365 382 364 372
23 Room No. 149 5.4 3.6 346 313 356 349 346 316 345 346 339 352 356 313 341
24 Room No. 150 3.0 2.4 248 268 279 268 256 268 276 271 269 269 279 248 267
25 Room No. 152 5.4 3.6 289 238 301 298 239 241 254 246 267 261 301 238 263
26 Room No. 155 6.6 3.6 238 268 289 299 289 298 275 268 264 301 301 238 279
27 Room No. 159 4.8 3.6 400 473 421 458 423 435 425 426 406 441 473 400 431
Second Floor
1 Room No. 203 6.0 3.0 425 437 413 419 415 410 428 425 426 439 439 410 424
2 Room No. 206 6.0 3.0 183 193 384 394 212 235 356 361 264 250 394 183 283
3 Room No. 210 6.0 3.0 470 350 357 402 346 359 364 379 365 425 470 346 382
4 Room No. 211 6.0 3.0 319 249 258 301 265 254 287 259 285 267 319 249 274
5 Room No. 217 5.4 3.6 213 287 203 225 215 264 235 246 259 266 287 203 241
6 Room No. 218 5.4 3.6 168 187 213 203 179 198 201 212 176 198 213 168 194
7 Room No. 220 5.4 3.6 285 350 439 387 356 365 389 312 410 314 439 285 361
8 Room No. 223 5.4 3.6 276 321 305 310 286 298 285 279 309 278 321 276 295
9 Room No. 225 5.4 3.6 208 256 230 247 246 235 249 257 210 212 257 208 235
10 Room No. 226 5.4 3.6 208 210 225 252 210 245 248 236 237 198 252 198 227
11 Room No. 227 3.6 2.4 273 252 230 280 256 249 243 256 261 255 280 230 256
12 Room No. 229 5.4 3.6 360 368 390 331 356 364 354 359 361 289 390 289 353
13 Room No. 231 5.4 3.6 250 226 252 241 235 256 249 235 239 233 256 226 242
14 Room No. 232 5.4 3.6 196 270 256 238 229 235 259 245 256 183 270 183 237
15 Room No. 233 5.4 3.6 350 312 357 389 356 345 359 368 375 319 389 312 353
16 Room No. 235 3.6 2.4 273 280 283 243 256 249 259 267 249 261 283 243 262
17 Room No. 236 5.4 3.6 256 308 313 289 259 284 287 289 294 263 313 256 284
18 Room No. 237 5.4 3.6 347 312 328 331 336 349 315 324 334 355 355 312 333
19 Room No. 238 5.4 3.6 203 230 258 281 210 245 265 278 279 271 281 203 252
20 Room No. 239 5.4 3.6 253 270 249 252 265 251 267 261 259 261 270 249 259
21 Room No. 240 5.4 3.6 350 313 298 320 312 324 336 326 310 337 350 298 323
22 Room No. 241 5.4 3.6 177 160 158 147 156 154 168 157 149 163 177 147 159
23 Room No. 242 5.4 3.6 282 256 242 273 279 278 268 269 257 233 282 233 264
24 Room No. 245 5.4 3.6 385 346 358 399 365 354 359 358 368 349 399 346 364

25 Room No. 246 5.4 3.6 421 415 398 425 397 425 421 416 409 433 433 397 416
26 Room No. 247 5.4 3.6 412 390 357 397 359 384 394 398 401 402 412 357 389
27 Room No. 248 5.4 3.6 270 268 252 247 251 256 259 268 259 263 270 247 259
28 Room No. 251 5.4 3.6 251 235 245 259 269 265 254 245 244 269 269 235 254
29 Room No. 259 6.6 3.6 220 185 210 229 228 225 231 234 219 237 237 185 222
Third Floor
1 Room No. 304 8.0 8.0 514 477 659 553 498 468 512 658 481 460 659 460 528
2 Room No. 305 8.0 8.0 341 314 319 367 324 326 319 358 326 345 367 314 334
3 Room No. 306 8.0 8.0 410 425 440 467 445 446 457 459 461 398 467 398 441
4 Room No. 307 8.0 8.0 354 366 376 399 378 375 389 385 376 374 399 354 377
5 Room No. 308 8.0 8.0 303 318 530 280 346 316 325 456 465 471 530 280 381
6 Room No. 314 5.4 3.6 250 235 222 241 245 246 235 239 226 233 250 222 237
7 Room No. 319 5.4 3.6 309 305 317 351 345 326 339 349 326 333 351 305 330
8 Room No. 330 5.4 3.6 304 340 321 354 316 346 368 357 341 371 371 304 342
9 Room No. 332 5.4 3.6 350 317 354 319 326 345 354 351 339 325 354 317 338
Control Room
1 LR DCS 20 8 114 130 128 89 121 125 119 126 129 110 130 89 119
2 LR Server Room 20 8 210 239 310 212 235 226 229 231 220 221 310 210 233
3 FR DCS 25 9 251 257 287 278 265 259 261 254 259 241 287 241 261
4 FR Server Room 25 9 370 360 364 348 359 369 358 354 351 352 370 348 359

Light Fittings:
The details of light fitting is as under.
Location Tube light CFL MH HPMV

36 W 36 W 400 W 125 W 160 W
LR substations 1012
Workshop, LR Admn 186
Workshop, LOUP SRR, LR canteen
LR DCS
Workshop, Substation, DCS, SRR 69
LOUP 792
LOUP
BH 47
Hydrogen unit 74
VPS 79
NMP-1 105
NMP-2 165
NMP-3 168
PDU 231
PDA 340
Boundary wall
Lattec LTG Tower
high mast LTG Tower
Watch Towers
Street Lights
Total 1012 186 69 1954 47
Location LED HPSV

15 W 20 W 48 W 150 W 250 W 400 W
LR substations
Workshop, LR Admn
Workshop, LOUP SRR, LR canteen 370
LR DCS 45
Workshop, Substation, DCS, SRR
LOUP 100
LOUP
BH
Hydrogen unit
VPS
NMP-1
NMP-2
NMP-3
PDU

PDA
Boundary wall 264
Lattec LTG Tower 42 373
high mast LTG Tower 984
Watch Towers 19
Street Lights 223
Total 45 370 100 264 265 1376

6.11 Capacitors:
The capacitor banks are fitted in the feeder of MSS 1, 4, 5, 7, 8, and 11.
KVAR rating of capacitors was not available.
The ampere measurements of capacitor banks are shown in the following
table.
Description Rating Current (Amp) Remark
kVAR Amp R Y B
MSS 4 - HT Panel 3.3KV
Capacitor Bank II - Feeder 31 0.0 279.0 277.0 277.0
Capacitor Bank I - Feeder 27 0.0 180.0 178.0 178.0
Capacitor Bank - Feeder 17 0.0 72.3 72.3 72.3
MSS 7 - HT202 Panel 6.6KV
Capacitor Bank I 0.0 130.3 134.2 131.8
Capacitor Bank II 0.0 96.7 91.0 93.7
MSS 8 - HT203 Panel 6.6KV
Capacitor Bank I 0.0 126.8 127.2 127.4
MSS 11 HVSB 2 Panel 6.6KV
MSS 11 HVSB 2 Panel 6.6KV
LRS 1 - TR2 Panel 6.6KV
Capacitor Bank - Feeder 9 0.0 106.1 117.5 117.7
LRS 2 - 6.6 KV Panel 6.6KV

6.12 Transformers:
The transformer loading is computed as below.

Transformer loading (%)= Measured KVA/Rated KVA
The performance analysis of transformers is shown in the following table.
Feed Description Rated Values Power PF Loa Avg.

er d Energy
KVA KV Amp KW KVA % KWH
MSS 1
3.3KV Panel
TR 42 Incomer 2 to 2000.0 3.3 83.0 427.0 474.4 0.90 24
4 MSS7 % NP
TR 44 Incomer 3 to 2000.0 3.3 106.0 530.0 588.9 0.90 29
19 MSS7 % 605.7
SUB A Transformer 1500.0 3.4 124.0 636.0 722.7 0.88 48
3 % 621.29
SUB HM Transformer 1000.0 3.4 59.0 299.0 343.7 0.87 34
1 % 318.73
SUB B 1500.0 3.4 33.0 175.0 192.3 0.91 13
22 % 177.82
SUB I 1600.0 3.4 42.0 197.0 243.2 0.81 15
24 % 196.7
USSA PMCC
SUB A MSS 1 TR Sec 1500.0 0.4 960.0 620.0 704.5 0.88 47
11 % 615.3
SUB I MSS 1 TR Sec 1600.0 0.4 292.0 181.0 212.9 0.85 13
1FA % NP
MSS 4
3.3KV Panel
TR 2 (Admin Supply) 3000.0 3.3 98.0 450.0 555.6 0.8 19
6 % 301.03
FRE TR1 (MSS 10) 2000.0 3.3 201.0 980.0 1139.5 0.86 57
19 % 959.87
MSS 4 Incomer 1 (TR N 15000. 3.3 1130. 6200.0 6458.3 0.96 43
21 Sec.) 0 0 % 5560.17
TR 5 (MSS5) 2000.0 3.3 35.0 170.0 200.0 0.85 10
29 % 170.83
SUB M TR 1600.0 3.3 83.0 390.0 469.9 0.83 29
35 % 463.08
FRE TR2 (MSS 10) 2000.0 3.3 126.0 640.0 727.3 0.88 36
38 % 604.93
FRE TR3 (MSS 10) 2000.0 3.3 75.0 370.0 430.2 0.86 22
43 % 413.02
MSS 10

HT 282 Panel
2000.0 6.5 86.0 770.0 939.0 0.82 47
11 TR 84 % 768.24
Incomer 1 - TR 80(Sec) 31000. 6.5 660.0 7100.0 7553.2 0.94 24
13 0 % 7074.32
TR 85 2000.0 6.5 76.0 710.0 845.2 0.84 42
14 % 727.7
Incomer 1 - TR 81(Sec) 31000. 6.3 1270. 12400. 13932. 0.89 45
20 0 0 0 6 % 12695.96
TR 82 2000.0 6.4 64.0 610.0 717.6 0.85 36
23 % 672.29
31 TR 87 2000.0 6.4 13.0 120.0 146.3 0.82 7% 123.76
PCC 381 Panel
Main Incomer 1 0.4 1151. 706.0 784.4 0.9
1FB 0 NP
31FB Main Incomer 3 0.4 196.0 103.7 126.5 0.82 NP
PCC 380 Panel
Main Incomer 1 (TR 82 2000.0 0.4 980.0 591.0 671.6 0.88 34
2FB Sec) %
Main Incomer 3 (TR 84 2000.0 0.4 1275. 744.2 875.5 0.85 44
32FB Sec) 0 %
FRE PCC Panel
FRE Main Incomer 1 2000.0 0.4 1300. 816.0 927.3 0.88 46
11F2 0 % 861.01
FRE Main Incomer 3 2000.0 0.4 658.0 412.0 473.6 0.87 24
25F2 % 455.19
MSS 5
3.3KV Panel
Main Incomer 1 (TR 1 15000. 3.4 1210. 6600.0 7021.3 0.94 47
7 Sec) 0 0 % 5379.549
New Adm Bldg S/S TR 3.4 103.0 NP NP NP
13 Feeder NP
22KV Panel
22 KV Incomer 1(MSS7) 22. 200.0 7160.0 7782.6 0.92
1 4 6008.675
TR 1 (Incomer 1) 15000. 22. 187.0 NP NP NP NP
3 0 4
PMCC Panel
Main Incomer 1 (TR 5) 2000.0 0.4 267.0 171.0 201.2 0.85 10
7F3 % 203.47
Main Incomer 3 (TR 3) 2000.0 0.4 801.0 538.0 611.4 0.88 31
15F3 % 613.19
MSS 7
HT 202 - 6.6KV Panel
TR24 (Heater Load Only) 2000.0 6.6 96.7 16.0 1112.0 1.00 56
2 % NP
3 TR27 2000.0 6.6 50.4 NP NP NP
26F TR33 2000.0 6.6 53.3 NP NP NP

Incomer 1 (TR21 Sec) 31000. 6.6 831.0 NP NP
11 0 NP
Incomer 2 (TR22 Sec) 31000. 6.5 259.0 2854.0 2912.2 0.98 9%
33 0 NP
Incomer 3 (TR23 Sec) 31000. 6.6 572.0 NP NP
40 0 NP
42 TR26 2000.0 6.6 42.4 NP NP NP
43 TR29 2000.0 6.5 54.0 NP NP NP
45 TR35 2000.0 6.6 32.0 NP NP NP
22KV Switchboard (HT201)
Incomer 1 - HT201 (TR1 22. 660.0 24200. 25473. 0.95
6 Sec) 3 0 7 26075.43
Incomer 2 - HT201 (TR2 22. 560.0 19100. 21460. 0.89
14 Sec) 2 0 7 18634.1
TR21 31000. 22. 249.0 8800.0 9462.4 0.93 31
4 0 3 % 9046.36
TR22 31000. 22. 77.0 3000.0 3092.8 0.97 10
9 0 3 % 3185.6
TR23 31000. 22. 172.0 6000.0 6593.4 0.91 21
16 0 2 % 5612.25
PCC 301
TR26 Sec (I/C 3 PCC 301) 2000.0 0.4 961.0 651.0 700.0 0.93 35
26F % NP
TR24 Sec (I/C 1 PCC 301) 2000.0 0.4 1417. 927.0 1007.6 0.92 50
7F 0 % NP
PCC 302
TR27 Sec (I/C 1 PCC 302) 2000.0 0.4 975.0 577.0 678.8 0.85 34
1F % NP
TR29 Sec (I/C 3 PCC 302) 2000.0 0.4 861.0 500.0 595.2 0.84 30
26F % NP
MSS 8
PCC 330
Incomer 1 TR36 Sec 2000.0 0.4 618.0 392.0 440.4 0.89 22
2F % NP
Incomer 1 TR37 Sec 2000.0 0.4 780.0 463.0 551.2 0.84 28
10F % NP
PCC 331
Incomer 1 TR38 Sec 2000.0 0.4 473.0 264.0 322.0 0.82 16
1FB % 232.06
Incomer 3 TR40 Sec 2000.0 0.4 318.0 179.0 218.3 0.82 11
28F %
HT 203 Panel
TR36 2000.0 6.6 40.6 403.0 463.2 0.87 23
P3 % NP
TR38 2000.0 6.6 29.3 271.0 330.5 0.82 17
P4 % NP
P19 Incomer 1 - HT203 6.6 263.0 2888.0 2946.9 0.98 NP
P22 Incomer 2 - HT203 6.7 308.0 3028.0 3520.9 0.86 NP

P29 TR40 2000.0 6.6 17.0 141.0 180.8 0.78 9% NP
TR37 2000.0 6.6 50.4 454.0 560.5 0.81 28
P32 % NP
MSS 11
HVSB 1 (22KV Panel)
TR5A 25000. 21. 90.0 3400.0 3434.3 0.99 14
5 0 5 % 2869.57
TR5B 25000. 22. 90.0 3400.0 3434.3 0.99 14
8 0 1 % 3173.9
Incomer 1 (TR03 GIS 22. 160.0 6300.0 6363.6 0.99
3 Sec) 4 5826.1
Incomer 2 (TR04 GIS 22. 110.0 4400.0 4444.4 0.99
9 Sec) 3 3913.04
TR6A 22500. 21. 74.0 2800.0 2857.1 0.98 13
2 0 4 % 2869.6
TR6B 22500. 22. 21.0 800.0 888.9 0.90 4%
11 0 0 698.69
HVSB 2 (6.6KV Panel)
TR7 3150.0 6.6 33.0 320.0 390.2 0.82 12
6 % 313.04
Incomer 1 (TR5A Sec) 25000. 6.7 290.0 3300.0 3367.3 0.98 13
17 0 % 2823.1
Incomer 2 (TR5B Sec) 25000. 6.6 310.0 3600.0 3636.4 0.99 15
33 0 % 3188.66
TR8 3150.0 6.6 31.0 320.0 351.6 0.91 11
23 % 343.6
HVSB 3 (6.6KV Panel)
TR11 3150.0 6.5 34.0 330.0 370.8 0.89 12
16 % 376.17
TR13 3150.0 6.5 44.0 430.0 483.1 0.89 15
18 % 394.62
Incomer 1 (TR6A Sec) 22500. 6.5 250.0 2800.0 2857.1 0.98 13
19 0 % 2914.8
20 TR9 3150.0 6.5 19.0 150.0 217.4 0.69 7% 157.3
TR14 3150.0 6.7 47.0 420.0 560.0 0.75 18
23 % 408.07
24 TR12 3150.0 6.7 21.0 200.0 250.0 0.80 8% 215.246
Incomer 2 (TR6B Sec) 22500. 6.7 70.0 800.0 879.1 0.91 4%
33 0 717.49
PMCC - 1 Panel
Incomer 1 (TR7 Sec) 3150.0 0.4 536.0 321.0 386.7 0.83 12
12 % 305.66
Incomer 2 (TR8 Sec) 3150.0 0.4 482.0 321.0 348.9 0.92 11
17 % 336.36
PMCC - 2 Panel
1 Incomer 1 (TR9 Sec) 3150.0 0.4 273.0 137.0 198.6 0.69 6% 136.34
PMCC - 3 Panel

Incomer 1 (TR11 Sec) 3150.0 0.4 525.0 353.0 392.2 0.90 12
12 % 368.18
17 Incomer 2 (TR12 Sec) 3150.0 0.4 300.0 182.0 222.0 0.82 7% 195.45
PMCC - 4 Panel
Incomer 1 (TR13 Sec) 3150.0 0.4 647.0 426.0 478.7 0.89 15
6 % 381.82
Incomer 2 (TR14 Sec) 3150.0 0.4 741.0 409.0 545.3 0.75 17
11 % 399.08
MSS - 6 LT
PCC -301 Panel
Incomer 1 (TR121 Sec) 2500.0 0.4 716.0 406.0 506.2 0.80 20
4FC % 377.59
14FC Incomer 2 (TR122 Sec) 2500.0 0.4 198.0 103.0 128.6 0.80 5% 121.51
PCC -302 Panel
3FC Incomer 1 (TR123 Sec) 2500.0 0.4 269.0 200.0 202.2 0.99 8% 220.667
Incomer 2 (TR124 Sec) 2500.0 0.4 406.0 290.0 292.3 0.99 12
13FC % 283.76
PCC -303 Panel
Incomer 1 (TR125 Sec) 2000.0 0.4 1063. 668.0 703.2 0.95 35
3FC 0 % 526.676
MSS - 6 HT
HT 6.6KV Panel
TR124 2500.0 6.5 27.4 292.0 301.0 0.97 12
23 % 291.34
11 TR123 2500.0 6.5 19.8 209.0 211.1 0.99 8% 219.77
TR125 2000.0 6.5 48.9 437.0 475.0 0.92 24
12 % 520.78
MSS – 2
22KV Panel
CPP TR 2 9000.0 22. 76.0 2400.0 3038.0 0.79 34
NA 5 % 2274.85
3.3KV Panel
1 TR45 ( E ) 2000.0 3.3 31.0 NP NP NP
2 IETP TR1 (S) 2500.0 3.3 61.0 NP NP NP
USS D1 TR 3 (S) 1000.0 3.3 88.0 380.0 513.5 0.74 51
12 % 314.16
SUB Mahul TR 750.0 3.3 14.5 83.6 84.4 0.99 11
15 % 51.88
Incomer 2 CPP TR 2 Sec 15000. 3.4 510.0 2440.0 2939.8 0.8 20
31 0 % 2377.91
22 TR 46 (W) 2000.0 3.4 16.2 70.0 92.1 0.76 5% 48.699
USS D2 TR 4 (N) 1000.0 3.4 34.9 146.0 189.6 0.77 19
23 % 157.23
TR 2 (IETP) 2500.0 3.2 90.0 400.0 500.0 0.80 20
24 % 320.02
MSS – 9
PCC351 Panel
3FB Incomer 1 (TR45 Sec) 2000.0 0.4 228.3 137.0 169.1 0.81 8% NP

12FB Incomer 2 (TR46 Sec) 2000.0 0.4 111.3 65.2 82.5 0.79 4% NP
IETP Substation
Incomer 1 (TR1 Sec) 2500.0 0.4 380.0 240.0 282.4 0.85 11
8F1 % 254.32
Incomer 2 (TR2 Sec) 2500.0 0.4 570.0 370.0 430.2 0.86 17
17F1 % 331.6
LRS 1 (First Floor )
6.6KV Jyoti Panel
TR 1 (Sec) 6300.0 6.0 64.1 618.8 665.4 0.93 11
14 % 613.25
TR 2 (Sec) 6300.0 6.0 67.3 619.0 665.6 0.93 11
1 % 609.14
6.6KV Siemens Panel
Incomer 1 (TR6(S) Sec) 6300.0 6.0 208.0 2030.0 2071.4 0.98 33
6 % 2182.81
Incomer 2 (TR7(M) Sec) 6300.0 6.0 192.0 1910.0 1949.0 0.98 31
11 % 2097.25
Incomer 3 (TR8(N) Sec) 6300.0 6.0 200.0 2000.0 2040.8 0.98 32
15 % 2184.82
PMCC Panel
Incomer 1 (TR9 Sec) 1800.0 0.4 453.0 281.0 342.7 0.82 19
3F2 % 282.01
Incomer 2 (TR5 Sec) 1800.0 0.4 434.0 261.0 314.5 0.83 17
6F3 % 260.94
Incomer 3 (TR4 Sec) 2000.0 0.4 1030. 670.0 752.8 0.89 38
10F2 0 % 696.53
Incomer 4 (TR3 Sec) 2000.0 0.4 1170. 702.0 806.9 0.87 40
14F3 0 % 678.04
LRMSS
LR 1 Panel
TR5 1800.0 22. 9.2 274.5 321.4 0.85 18
3 0 % 272.25
TR6 6300.0 22. 57.5 2160.0 2222.2 0.97 35
4 0 % 2094.24
TR7 6300.0 22. 57.8 2100.0 2167.2 0.97 34
5 0 % 2094.24
TR8 6300.0 21. 58.9 2180.0 2254.4 0.97 36
6 9 % 2094.24
TR9 1800.0 21. 10.1 323.0 374.7 0.86 21
7 9 % 209.78
LR 1 Tata Incomer KV 21. 199.0 7200.0 7523.5 0.96
8 9 8391.02
LR 2 Panel
CPP Incomer 21. 151.0 5290.0 5858.3 0.90
1 5 4195.5
TATA Incomer 21. 210.0 6645.0 7637.9 0.87
6 0 NP

TR 1 22. 64.0 NP 650.0 NP NP
8 3
9 TR 2 NP NP NP NP NP
TR 3 22. 21.0 710.0 816.1 0.87
15 3 664.14
TR 4 22. 20.0 650.0 730.3 0.89
15 3 685.16
TR 21 22. 66.0 2270.0 2550.6 0.89
17 5 2261.45
18 TR 22 NP NP NP NP NP
TR 92 10000. 22. 26.0 887.5 1002.8 0.9 10 NP
20 0 1 %
TR 91 10000. 22. 89.1 2800.0 3461.1 0.81 35
21 0 1 % 3285.53
LRS 2
6.6KV Panel
15 TR 23 2000.0 NP 55.4 NP NP NP
16 TR 25 2000.0 NP 32.5 NP NP NP
17 TR 27 2000.0 NP 40.8 NP NP NP
19 Incomer 1 (TR21 Sec) 6.5 224.0 2200.0 2444.4 0.90 2296.28
24 Incomer 2 (TR22 Sec) 6.7 146.0 1570.0 1688.2 0.93 1661.504
25 TR 24 2000.0 NP 37.5 NP NP NP
NA TR 26 2000.0 NP 31.3 NP NP NP
HT 900 Panel
TR 93 2500.0 6.7 63.0 640.0 780.5 0.8 31
13 % 719.6
Incomer 1 (TR91 Sec) 10000. 6.7 341.0 3300.0 3793.1 0.87 38
12 0 % 3340.86
Incomer 2 (TR92 Sec) 10000. 6.8 88.0 900.0 1046.5 0.86 10
17 0 % NP
PMCC 901 Panel
Incomer 1 (TR91 Sec) 10000. 0.4 970.0 610.0 701.1 0.87 7%
1FB 0 703.62
LRS 3 (Ground Floor )
PMCC 301 Panel
Incomer 1 (TR24 Sec) 2000.0 0.4 641.0 408.0 491.6 0.83 25
8F2 % 387.05
Incomer 2 (TR23 Sec 2000.0 0.4 835.0 505.0 608.4 0.83 30
17F3 % 524.65
PMCC 401 Panel
Incomer 1 (TR27 Sec) 2000.0 0.4 569.0 342.0 412.0 0.83 21
03B % 352.98
PMCC 311 Panel
10FA TR 26 (Sec) 2000.0 NP NP 310.0 NP NP
12FA TR 25 (Sec) 2000.0 NP NP 360.0 NP NP

CPP Substation 1
3.3KV Panel
9 TR 512 2000.0 3.3 14.2 45.8 81.6 0.56 4% 58.25
TR 9 1000.0 3.3 27.5 139.8 154.6 0.90 15
8 % 154.6
Panel Incomer TR 10 5000.0 3.4 120.1 559.8 726.1 0.77 15
5 (Sec % 564.9
11KV MES Panel
TR 1 15000. 11. 250.0 4700.0 5465.1 0.86 36
NA 0 2 % 4284.61
TR 2 15000. 11. 250.0 4700.0 5465.1 0.86 36
NA 0 2 % 4381.54
TR 5 1000.0 11. 5.0 90.0 96.8 0.93 10
NA 2 % 100.97
TR 6 1000.0 11. 10.0 120.0 193.5 0.62 19
NA 2 % 149.51
TR 7 1000.0 11. 5.0 80.0 97.6 0.82 10
NA 2 % 97.08
GTG 4 (TR 4 & TR 8) 11. 280.0 4800.0 5393.3 0.89
NA 2 4893.2
22KV Siemens Panel
TR 1 (Sec) 15000. 22. 118.3 4592.2 4606.1 0.99 31
10 0 5 7 % NP
TR 2 (Sec) 15000. 22. 121.0 4240.0 4726.9 0.90 32
7 0 6 % 4271.85
TR 4 (Sec) 15000. 22. 134.7 4800.0 5286.3 0.91 35
12 0 6 % 3913.89
TR 10 5000.0 22. 18.5 575.9 705.8 0.82 14
5 5 % 581.73
NA TR 511 5000.0 NP NP NP NP NP
Load Centre
NA TR 5 (Sec) 1000.0 0.4 180.0 NP NP 102.4
NA TR 6 (Sec) 1000.0 0.4 210.0 NP NP 151.55
NA TR 7 (Sec) 1000.0 0.4 150.0 NP NP 98.3
CPP Substation 3
3.3KV BHEL Panel
7 TR513 2000.0 NP NP NP NP NP
PMCC 503 Panel
5FA Incomer 1 (TR512 Sec) 2000.0 0.4 70.0 40.8 53.0 0.77 3% 76.4
Incomer 2 (TR513 Sec) 2000.0 0.4 260.0 170.0 195.4 0.87 10
14FA % 154.89
GT MCC Panel
Incomer 1 (Unit Aux 0.4 254.0 161.9 192.7 0.84
2FA Trans) 167.84

6.13 Electricity Bill:
The electricity is procured from Tata Power Ltd as well as through Open access,
the details of the consumption is as under.
Description Unit Apr-16 May-16 Jun-16 Jul-16 Aug-16 Sep-16

Consumer Name - HPCL Mumbai Refinery, Chembur ( E ),Mumbai.
Consumer No. - 9000 0000 1511
Category - HT I - Industry Sanctioned Demand- 42136KVA
Meters No. - 10102235 , 2037405
Consumption KWH 5261920 3432000 1670720 819520 4473920 1168960

0
Reactive Power KVAR 1585120 984960 362880 20800 1360960 3474880
H
Power Factor (PF) 0.957 0.961 0.977 1.000 0.957 0.959
PF Penalty/Incentives Rs -519770 -357771 -601028 - -449736 -
885714 1052192
5 0 7 9 5 4
Bill Amount Rs 5755610 3957170 2169807 131410 4978196 1167625
9 0 8 92 8 82
Consumer Name - HPCL (100KV) Mumbai Refinery, Chembur ( E ),Mumbai.
Consumer No. - 9000 0002 1997
Contract Demand 57500 KVA 37500 KVA 17500
KVA
Total Consumption KWH NA NA NA NA NA 3010738
2
Open Access Units KWH NA NA NA NA NA 2557946
1
(Billed Units) 1 2 7 92
Tata Units - existing CD KWH NA NA NA NA NA 3410468
Tata Units - above existing KWH NA NA NA NA NA 1117454
CD
Lapsed Energy at KWH NA NA NA NA NA 7120
Consumer Meter
Reactive Power KVAR 6174078
H
Power Factor (PF) 0.98

PF Penalty/Incentives Rs - - - - - -
3663965 5545154 4166115 323614 1734517 1945913
existing CD 3
Energy Charges - above Rs 0 0 0 0 0 1318595
existing CD 7
Bill Amount Rs 2105106 2105697 2380117 172299 1142636 1067154
91 83 44 66 33 72
Description Unit Oct-16 Nov-16 Dec-16 Jan-17 Feb-17 Average

Consumer Name - HPCL Mumbai Refinery, Chembur ( E ),Mumbai.
Consumer No. - 9000 0000 1511
Category - HT I - Industry Sanctioned Demand- 42136KVA
Meters No. - 10102235 , 2037405
Consumption KWH 156012 123300 859904 876512 910528 7431680

80 80 0 0 0 .00
Reactive Power KVA 435696 417648 186848 233152 185792 2034632
RH 0 0 0 0 0
5
Power Factor (PF) 0.963 0.947 0.977 0.966 0.980 0.968
PF Penalty/Incentives Rs - 0 - - - -
129601 248884 168805 280115 1103661
1 3 0 7
320 20 60 80 20 6
Bill Amount Rs 144108 132578 902552 926710 101443 7814251
532 172 30 04 235 8
Consumer Name - HPCL (100KV) Mumbai Refinery, Chembur ( E ),Mumbai.
Consumer No. - 9000 0002 1997
Contract Demand 17500 KVA
Total Consumption KWH 371386 386350 361508 379734 352209 3587104
08 68 40 54 00 2
Open Access Units KWH 279164 281768 291472 289505 266380 2773477
70 08 48 66 80 2
(Billed Units) 8 60 2 9 0 1
Tata Units - existing CD KWH 809853 966084 675078 879323 858282 7549449
9 6 6 7 0
Tata Units - above existing KWH 112359 797414 252806 229652 0 586820
CD 9

Lapsed Energy at KWH 0 197432 7972 8022 0 36757
Consumer Meter
Reactive Power KVA 877297 105809 799989 899349 964875 8695022
RH 2 34 6 6 6
2
Power Factor (PF) 0.97 0.96 0.98 0.97 0.96 0.97
PF Penalty/Incentives Rs - - - - - -
263268 145414 367651 303009 129456 2678843
5 0 5 4 3
80
existing CD 93 89 07 20 63 8
Energy Charges - above Rs 797755 566163 179492 163052 0 2750055
existing CD 3 9 3 9
Bill Amount Rs 191166 210838 184455 216889 191929 1720528
460 906 367 419 586 21

6.14 Solar Hot Water System for canteen:
It is observed LPG is utilized to generate hot water for use in canteen & worker
amenities areas.
The possibility of installing solar hot water system to generate hot water for
both the canteen & worker amenities areas. The capacity of the hot water (at
60 o C) system for canteen can be around 5000 litres per day based on the
present load.
The possibility of installing solar hot water system may be ascertained.

Chapter-VII
E v a l u a t i o n o f E n e r g y M a n a g e m e n t S y s t e m
7.1 Energy management policy :
HPCL's Mumbai Refinery use energy in various forms viz., fuel, steam,
electricity, etc. in different processing units to convert crude oil to
valuable petroleum products. Most of these refinery processes are
energy intensive and use part of the finished products produced in the
refinery to derive their energy requirement. Thus any reduction in
consumption of energy directly results in higher availability of finished
products, which in turn results in higher profit. Hence, energy
conservation has direct impact on refinery's profits.
The approved energy policy of HPCL, MR is stated below.
ENERGY POLICY of HPCL, MR
“We in HPCL- Mumbai Refinery commit ourselves to continual

improvement in energy performance and strive to become the
benchmark in Refinery sector by ”:
 Considering energy management aspects as an integral part of our
activities related to refinin g, storage, and dispatch of petroleum
products by close engagement with our stakeholders.
 Improving energy performance by efficient management of energy
resources and its conservation, analyzing the gaps and setting
objective targets and action plan.
 Remaining at the technological forefront through continuous up -
gradation of in -house expertise and absorption of latest technologies
in energy management, supporting the purchase of energy efficient
products and services.
 Encouraging the use of renewable energ y/recovered energy.

 Complying with all applicable legal and other requirements related to
use of energy.
 Fostering the spirit of participation by all employees and its
stakeholders in energy conservation efforts through regular training
and communication t o create awareness on efficient use of energy.
Effective energy management is not only good for industry, but also
becoming a requirement. It is best achieved with ISO 50001. The
international standard outlines energy management practices that are
considered to be the best, globally. HPCL MR is in the process of
implementing ISO 50001 at their refinery.
7.2 Energy management monitoring system:
Skyrocketed energy and demand costs significantly impact any

industry's balance sheet. To control energy cost, the consumer must
gain answers to these questions:
1. How much energy is used?
2. What are the major loads?
3. When and where electrical energy is used the most?
4. How much does it cost?
HPCL MR has prioritized Energy Conservation (ENCON) activities by

delegating energy conservation responsibilities to Managers and
Engineers for monitoring ENCON measures on regular basis through
Management Information System . To optimize utilization of energy,
several research and development initiatives have been undertaken to
achieve the optimal level.
Establishing Energy Management System in HPCL -MR
Establishment of Energy Management Monitoring System in HPCL-MR

combines best practices in project management, energy monitoring,

and energy awareness along with an energy policy that will govern
corporation’s approach towards energy use and performance.
Dedicated ENCON Cell had been established since last few decades
under the Energy Management Policy. The employees across all ranks
in HPCL-MR are well educated and trained to improve the knowledge
on the ENCON improvement activities. Also , ongoing and upcoming
projects are tailored to be compatible with the organization’s ener gy
efficiency standards.
What is an Energy M anagement Monitoring system?

An energy management system (EMS) is a system of computer-aided
tools used by operators of electric utility grids to monitor, control, and
optimize the performance of the generation and/or
transmission system.
An Energy Management Monitoring System (EMMS) is a systematic

process for continually improving energy performance.
HPCL-MR has established ISO 50001 and following activities initiated :

 Develop and implement an energy management policy
 Identify main energy users
 Set energy objectives and measurable targets
 Implement and operate programmes to meet these objectives and
targets
 Check and take corrective action as required
 Review the system continually and improve where possible
Main benefits of an EMS/EMMS to HPCL -MR are listed below:
 Embeds best-practice energy management in day -to-day operations

 Improves refinery’s performance and productivity
 Reduces refinery’s energy costs

 Ensures to maintain a process of continual improvement
 Ensures that top management of HPCL -MR commit to energy efficiency
and that all staff play a role in the process
 Helps refinery to comply with its energy -efficiency and emission -
reduction obligations
7.3 Bench marking:
The benchmark and target values are set annually for energy
consumption (as a fraction of crude processed) based on past data as
well as consumption of other refineries.
The values are monitored at regular interval and deviations, if any, are
studies and remedied, wherever possible and feasible.

7.4 Development and establishment of procedures include energy
efficiency possibilities
The energy monitoring system has been incorporated and religiously

implemented. The critical parameters of major consumers are
maintained within the limits.
The performance evaluation of major consumers is periodically

undertaken to assess the performa nce and identify opportunities for
energy conservation.
The compressed air leak testing, trap testing is also carried out at
periodic interval to identify and rectify loss -point.
The life cycle cost is considered while procuring any major energy
consuming equipments / systems.
7.5 Training to staff responsible for operational and associated

processes:
Training needs are identified and addresses through periodical

assessment, effectiveness of the corrective actions is monitored.
7.6 General audit review:
A comprehensive and effective energy management system is in place,

and is formalize with effective incorporation of th e energy
management system based on ISO -50001.
7.7 Conform to Act, rules and regulations framed there under:

The guidelines and requirements under PAT schemes are religiously
and strictly adhered to.
7.8 Strength and weaknesses of the designated consumer:
Strengths:
 Energy Conservation has been inoculated in the every sphere of

activities like purchase, operations & maintenance.
 Incorporated Energy Management System in early stages; which is

continually improved upon.
 Energy audit as well as equipments studies are carried out

periodically and economically viable suggestions are taken up for
implementation
 Competent and trained manpower.
Weakness:
 Fluctuating crude oil prices
 Partially administered price mechanism
 Stringent quality requirements

Chapter-VIII
E n e r g y C o n s e r v a t i o n M e a s u r e s a n d
R e c o m m e n d a t i o n s
Recommendations of Energy saving measures :
8.1 Reducing pressure drop in the compressed air dryers :
The pressure drop is higher in many of the dryers as discussed earlier.
The possibility of replacing the adsorbent medium so as to reduce the

pressure drop to 0.2 to 0.3 kg/cm 2 .
The saving potential as economics is as under.
Description Unit Value
Operation Hr/year 7920.0

Cost of power Rs/KWH 8.0
Present pressure drop kg/cm 2 0.8 to 1.4
Present loss due to higher pressure KW 160.6
Typical pressure drop kg/cm 2 0.2 to 0.3
Projected savings % 75%
KW 120.5
Annual Savings MWH/Year 954.0
L Rs/year 76.3
Approximate Investment L Rs 120
Payback period Months 18.9

8.2 Optimizing p erformance of chillers :
The performance of some of the chiller is on the lower side; which may be
improved through improved maintenance practices.
Description Unit Values

Total Cooling Effect TR 278.2
Present power KW 257.5
Present Specific power KWH/TR 0.93
Projected Specific powerKWH/TR 0.75
Projected savings KW 48.9
% 19%
L Rs/year 15.5
It is suggested to review the present maintenance practices and incorporate

energy performance parameters to ensure effective servicing the machines
and other components.

8.3 Replacing lamps with LED lamps
The various lamps may be replaced with LED lamps.
Location Units CFL MH HPMV

36 W 400 W 125 W 160 W
Rating of the lamp Watt 36 400 125 160
Rating of the switchgear Watt 4 4 15 15
Power consumption of the lamp Watt 40 404 140 175
Number of lamps No 1012 186 69 1954
Operating period Hr/Month 360 360 360 360
Total consumption kW 40.48 75.14 9.66 341.95
kWh/Month 14573 27052 3478 123102
Alternative Lamp: LED Lamp
Rating of the lamp Watt 18 150 50 60
Rating of the switchgear Watt 2 2 2 5
Power consumption of the lamp Watt 20 152 52 65
Number of lamps No 1012 186 69 1954
Operating period Hr/Month 360 360 360 360
Total consumption kW 20.24 28.27 3.59 127.01
kWh/Month 7286 10178 1292 45724
Saving Potential
Cost of power Rs/kWh 8.00 8.00 8.00 8.00
Energy Saving kWh/Month 7286 16874 2186 77378
MWH/Year 87.4 202.5 26.2 928.5
Rs/Month 58291 134991 17487 619027
Rs L/Y 6.99 16.20 2.10 74.28
Economics
Investment Rs L 11.00 17.00 2.00 70.50
Payback period Month 18.9 12.6 11.4 11.4

Location Unit HPSV
150 W250 W 400 W
Rating of the lamp Watt 150 250 400
Rating of the switchgear Watt 16 15 20
Power consumption of the lamp Watt 166 265 420
Number of lamps No 100 264 265
Operating period Hr/Month 360 360 360
Total consumption kW 16.6069.96 111.30
kWh/Month 5976 25186 40068
Alternative Lamp: LED Lamp
Rating of the lamp Watt 75 125 200
Rating of the switchgear Watt 5 5 5
Power consumption of the lamp Watt 80 130 205
Number of lamps No 100 264 265
Operating period Hr/Month 360 360 360
Total consumption kW 8.00 34.32 54.33
kWh/Month 2880 12355 19557
Saving Potential
Cost of power Rs/kWh 8.00 8.00 8.00
Energy Saving kWh/Month 3096 12830 20511
MWH/Year 37.2 154.0 246.1
Rs/Month 24768 102643 164088
Rs L/Y 2.97 12.32 19.69
Economics
Investment Rs L 4.50 20.00 32.00
Payback period Month 18.2 19.5 19.5

8.4 Installing Solar Hot Water System for canteen
A 5000 LPD solar hot water system may be installed to meet the hot water
requirements of various canteen and convenience areas.

Water consumption kg/day 5000
Temperature - inlet oC 30
Temperature - outlet oC 60
Fuel Natural Gas
Cost of fuel Rs/SCM 35.0
GCV of fuel kCal/SCM 9400
Efficiency % 85%
Consumption SCM 18.77
Solar System
Operation Day/year 270.0
Saving SCM/Year 5068.8
L Rs/Year 1.8
Economics
Savings L Rs/Year 1.8
Investment L Rs 3.75
Payback Month 25.4

8.5 ENERGY AND COST SAVINGS BY REPLACING GRID POWER BY
ROOFTOP SOLAR PV SYSTEM
BACKGROUND AND PRESENT SYSTEM
The policy of Government of Maharashtra allows installation of solar roof top

systems under a policy of net metering. In the course of energy audit while
examining the buildings of “HPCL” for energ y efficiency potential, an assessment
is also made on the availability of roof top space with shadow free area. The
following buildings are found to have suitable space for installing solar roof top
system:
PROPOSED SYSTEM AND RATIONAL
a) ADMIN BUILDING_NEW
CAPEX MODEL
The facility can install 170 kWp (Thumb rule 1 kWp occupies 100 Sq. ft and for
shadow clearance and walk way we considered 20 Feet thereby for 1 kW we
require 120 Sq. feet) solar roof top system (Solar PV system) with net metering
facility to reduce the energy consumption. Irradiation level in Mumbai region is
5.05 sun hours. Therefore, tentatively a 170 kWp solar PV system generates
2,48,200 kWh per annum (as the solar plant will be active on sunny days only,
considered 365 days per year) i.e. ,680 units per day. Considering Rs. 65 per watt
peak, 170 kWp system costs around Rs. 1,10,50,000. Based on DISCOM tariff of
Rs. 6/ kWh, the payback period works out to 8 years and Return on Investment
(ROI) is 71.55% with an IRR of 6%. The detailed calcul ation is presented as
Annexure-2 to this report. HPCL informed that roof top solar for admin building
is under consideration.
b) ADMIN BUILDING_OLD
CAPEX MODEL

73,000 kWh per annum (as the solar plant will be active on sunny days only,
considered 365 days per year) i.e.,200 units per day. Considering Rs. 65 per watt
peak, 50 kWp system costs around Rs. 32,50,000. Based on DISCOM ta riff of Rs.
6/ kWh, the payback period works out to 8 years and Return on Investment (ROI)
is 71.55% with an IRR of 6%. The detailed calculation is presented as Annexure -
2 to this report.
c) ELECTRICAL BUILDING
CAPEX MODEL
The facility can install 25 kWp (Thu mb rule 1 kWp occupies 100 Sq. ft and for
facility to reduce the energy consumption. Irradiation level i n Mumbai region is
peak, 25 kWp system costs around Rs. 16,25,000. Based on DISCOM tariff of Rs.
2 to this report.
d) BUILDING BESIDE OLD ADMIN BUILDING
CAPEX MODEL

1,46,000 kWh per annum (as the solar plant will be active on sunny days only,
is 71.55% with an I RR of 6%. The detailed calculation is presented as Annexure -
2 to this report.
e) LR&LOUP CONTROL ROOM

CAPEX MODEL
6/ kWh, the payback period works o ut to 8 years and Return on Investment (ROI)
1 to this report.
COST BENEFIT ANALYSIS
CAPEX Model: Cost Benefit Analysis is presented under Annexure -1.

8.9 Low Efficiency of HRSG 1, HRSG 3, and HRSG 5
Present Condition
The HRSG exhaust temperature is very high as compare to design and industry standard. This is primarily due
to insufficient heat transfer in the steam generator. All the sections of HRSG 1 and HRSG 3 have poor heat
transfer. This includes high Pinch point. There is a need of improving the HRSG heat transfer by improving
the performance for all the sections. This will leads to increase the efficiency of HRSG by 20%. Therefore, it
is recommended to do the detailed HRSG internal tubes inspection and take corrective action including
cleaning/ replacement of the tubes. The HRSG 5 has high flue gas inlet temperature and has very poor
superaheater section performance. The tuning of the GT exhaust temperature/ checking the Superheater
tube deposits will help in improving the section performance. HPCL informed that chemical cleaning
procedure of the boilers as done in past will be followed in future. The expected performance may be as
follows:
HRSG Poor Efficiency

Parameter UoM HRSG 1 HRSG 3 HRSG 5
Efficiency % 57.42% 59.08% 75.08%
Expected Efficiency Improvement with boiler
measures % 80% 80% 82%
heat transfer from the Boiler kj/s 13098 13244 41398
Improvement in thermal Energy gain with boiler
measures kj/s 18249 17934 45216
Increase in Thermal Energy kj/s 5151 4690 3818
Total Gain Yearly Kj yearly 146878347036 133708568093 108853852869
Total Gain Yearly, kcal yearly 35104767456 31957114745 26016695236
MTOE MTOE 3510 3196 2602
8.10 Dry Flue Gas loss in Boiler SG-12 and Boiler SG-10
The Boiler SG10 and Boiler SG12 both have high dry flue gas loss. This is primarily due to excess air flow in
the boiler and insufficient heat transfer in the boiler. With the inspection , checking tubes, maintanence /
cleaning tube deposits , etc. the performance will be increase. HPCL informed that inspection, cleaning of
boiler is done periodically in refinery as planned schedule. The expected performance may be as follows:
Flue Gas Loss in Boiler SG-12 and Boiler SG-10

Parameter UoM Boiler SG-12 Boiler SG-10
Exhaust temp Degree C 151.73 185.66
Optimized Temperature Degree C 130 130
Page 135 of 151

% improvement with Reduce in Flue
gas temp % 1.0% 2.2%
Increase in thermal output with

kCal/hr 420770 1371031
increase in efficiency
Energy Gain Yearly kCal 3332499612 10858567611
MTOE 333 1086
8.11 Replacement of VHP BFP Pump of Boiler SG12 with small size pump
The VHP BFP of Boiler SG-12 is operating at very low efficiency. Currently , pump is designed for the 164 TPH
flow with an efficiency of 72%. The combined efficiency of the pump is 33%. Therefore, even the pump is
giving only 64 TPH as per need but motor loading is 92%. That is why there is a need of small size pump, the
efficiency can be improved upto 70%. With the introduction of new pump the option will be flexible as in low
load , the small size pump will be used which have the same dynamic pressure as existing above. HPCL
informed that VFD is in line for this BFP pump motor, hence power consumption and other parameters will
be reviewed again by HPCL. The Encon Calculations are given below.
Parameter UoM Design Operating
Pump Efficiency % 72.75% 33.19%
Flow TPH 164 64
Power Consumption kW 359 331
Expected power consumption with pump
curve kW 225.00
Pump hydraulic power kW 110
Power Saving with new 200 kW pump kw 131
Yearly Saving in kW kWh 1039470
Yearly saving in Rs Rs 8315757
Investment Rs 5,000,000
Payback month 7
8.11 Use of Plate Heat Exchanger instead of Fin Fan Coolers for Generator Lub Oil Cooler water and
cleaning of suction filter of fan
The Generator lub oil is cooled by closed circuit water which flows through the fin fan coolers then passess
through the Lub Oil cooler and transfer energy. With the present system the maximum cooling can be
achieved only upto the ambient dry bulb temperature. With the use of Plate heat exchanger where the
Cooling Tower water will be used for cooling the Closed circuit DM water. GT-1 water requirement calculated
as 270 m3/hr, GT-2 as 157.5 m3/hr, GT-5 as 189 m3 /hr , total requirement as 616 m3/hr. HPCL opined that
this much additional raw water avialibility is not possible. The scheme is given below
Page 136 of 151

Present Scheme
Lub Oil to Bearing Cold Water Air In

Lub Oil Air Out
Hot Return Oil
Cooler Fin Fan
Hot Water Cooler
Proposed Scheme
Cold Water Cooling water In
Lub Oil to Bearing
Lub Oil Cooling
Hot Return Oil
Cooler Plate Heat
Hot Water Water Out
Exchanger
With the implementation following saving can be occurred
Parameter UoM GT 1 GT 3 GT 5
Present Power Consumption by Fin Fans kW 36 36.9 75.10
Cooling Water Inlet Temp oC 55 55 55
Cooling Water Outlet Temp oC 38.70 41 44
Effectiveness of Fin Fans % 49.4% 42.4% 33.3%
Saving with Replacing the GT Fin Fan
Coolers with Plate Heat Exchanger kw 36 37 75
Yearly saving in kW by replacing Fin Fans
and Pump kWh 285120 292248 594792
Yearly saving considering 8 Rs/Unit Rs 2280960 2337984 4758336
Investment Rs 5000000
Payback Month 6
8.12 Installation of VFD for FD Fan of Boiler SG-10 & SG-11
The FD Fan of Boiler SG-10 is operating in a part load with there is a yearly variation in the Air flow
requirement of the Boiler. The FD Fan efficiency comes very low to 37%. Therefore, to save the power from
yearly operations variations the VFD is recommended for the FD Fan for SG-10 and similarly , for SG-11 as
informed by HPCL. The encon savings are given below.
Page 137 of 151

Installation of VFD for Boiler SG 10 FD Fan
Parameter UoM Data
Present FD fan Efficiency % 37%
FD Fan Operating flow kg/hr 102958
Proposed efficiency with 60% efficiency % 60%
Power Consumption kW 136
Power Consumption with VFD kW 84
saving in kW kW 52
Saving in kW yearly kWh yearly 412896
Yearly Saving considering 8 Rs/Unit Rs 3303168
Payback Month 7
Installation of VFD for Boiler SG 11 FD Fan
Parameter UoM Data

FD Fan Operating flow kg/hr 102958
Proposed efficiency with 60% efficiency % 60%
Power Consumption with VFD kW 84
saving in kW kW 52
Payback Month 7
Page 138 of 151

8.13 Replacement of FD Fan Suction Filters of SG-12
During the field visit it is observed that all the suction filter of the FD fan is choked. The suction velocity is
hardly .1 to .5 m/s. It is also damaged in many places. During the data collection and analysis the FD Fan
efficiency comes very low. The reason predicted is Fan motor is working hard to deliver the Air to the boiler
but at the same time as the suction filters are choked therefore it is consuming extra kW to achieve the
desired need of the boiler. HPCL informed that action has been iniated and replacement planned for both
SG-10 and SG-12 FD fan suction filters. The Encon saving calculations are given below
Replacement of FD Fan Suction Filter of SG-12 boiler
Parameter UoM Data
hydraulic Power needed kW 14.5
Fan efficiency Improvement after replacing suction filter % 60%
Fan Discharge pressure mmWc 71.57
Fan discharge pressure with improved condition mmWc 300
Hydraulic Power needed with improved condition kW 58
Power Consumption after improvement considering 60% Fan efficiency kW 100
Saving in Power consumption kW 67
Payback Month 6
Page 139 of 151

8.14 VHP water Header Interconnection for SG-10, Sg-11 and SG-12 Boilers
At Present the VHP water Header is not interconnected. The Individual pump is running for
the boilers SG-10 and SG-12. In both the boilers the Pump is operating in part load operation
at close to 50%. With the interconnection of the header the 1 pump can be stopped in one of
the boilers. HPCL informed that the scheme is under consideration. The encon calculation is
given below
Parameter UoM Data
Present Power consumption of both the boilers kW 640.62
The total BFW water needed for boilers TPH 172.97
the capacity of 1 VHP BFW Pump TPH 192
Power Consumed by SG-12 VHP Pump kW 331
Saving with stopping 1 VHP Pump kWh 331
Yearly saving kWh 2621520
Yearly Saving in Rs Rs 20972160
Payback period Months 6
Page 140 of 151

8.15 Replacing IETP blowers with Turbo blowers
There are 6 numbers of SBR blowers (lobe type) in WWTP , out of which 4 are running and
two are stand by. 3 running blowers are provided with VFD and one non VFD blower. Four
lobe type blowers can be replaced with high efficiency turbo blower (PM motor, airfoil
dynamic centrifugal type). HPCL informed that the scheme is being worked out with the
help of vendor.
The expected consumption of one turbo blower is 45 kw ( 50%) as compared to present

blower of capacity of 90 kw.

Number of Blowers No 4.0
Present power of each blower KW 90.0
Projected Power for one Turbo
blower KW 45.0
Projected savings for each KW 45.0
blower % 50%
Total savings for 4 blowers KW 180.0
L Rs/year 114.0
Page 141 of 151

ANNEXURE-1: COST SAVINGS BY REPLACING GRID POWER BY ROOFTOP SOLAR PV SYSTEM (CAPEX
MODEL)
A) ADMIN BUILDING_NEW
List of Assumptions
Particulars/ Name of item Value Unit
Year wise % Increase in the Savings 5.0% Percentage
Year wise % Increase in the Operation cost 5.0% Percentage
Discount factor 10.0% Percentage
Operating cost as % investement 1.0% Percentage
Project Economics:
Project Year 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Investment ₹ 110,50,000.00 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Savings /Year 0 ₹ 14,89,200.00 1563660.00 1641843.00 1723935.15 1810131.91 1900638.50 1995670.43 2095453.95 2200226.65 2310237.98 2425749.88 2547037.37 2674389.24 2808108.70 2948514.14 3095939.84 3250736.84 3413273.68 3583937.36 376
Cost of Operation
0 110500.00 116025.00 121826.25 127917.56 134313.44 141029.11 148080.57 155484.60 163258.83 171421.77 179992.86 188992.50 198442.12 208364.23 218782.44 229721.56 241207.64 253268.02 265931.43 279
/Year
Net Savings 0 1378700.00 1447635.00 1520016.75 1596017.59 1675818.47 1759609.39 1847589.86 1939969.35 2036967.82 2138816.21 2245757.02 2358044.87 2475947.12 2599744.47 2729731.70 2866218.28 3009529.20 3160005.65 3318005.94 348
Discounted Cash
-11050000.00 1253363.64 1196392.56 1142011.08 1090101.49 1040551.42 993253.63 948105.74 905010.02 863873.20 824606.24 787124.14 751345.77 717193.69 684593.97 653476.06 623772.61 595419.31 568354.79 542520.48 517
flows
NPV of Savings 18955828.76
Simple Payback
8.0
Period (Years)
NPV of the
7905828.76
Project
ROI (%) 71.55
IRR (%) 6%
Page 142 of 151

B) ADMIN BUILDING_OLD
List of Assumptions
Project Economics: Fig : Rs.
Project Year 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
Investment ₹ 32,50,000.00 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Savings /Year 0 ₹ 4,38,000.00 459900.00 482895.00 507039.75 532391.74 559011.32 586961.89 616309.99 647125.48 679481.76 713455.85 749128.64 786585.07 825914.32 867210.04 910570.54 956099.07 1003904.02 1054099.22 1106804.19 1162144.39 1220251.61 1281264.20 1345327.41 1412593.78
Cost of Operation
0 32500.00 34125.00 35831.25 37622.81 39503.95 41479.15 43553.11 45730.76 48017.30 50418.17 52939.08 55586.03 58365.33 61283.60 64347.78 67565.17 70943.42 74490.60 78215.13 82125.88 86232.18 90543.78 95070.97 99824.52 104815.75
/Year
Net Savings 0 405500.00 425775.00 447063.75 469416.94 492887.78 517532.17 543408.78 570579.22 599108.18 629063.59 660516.77 693542.61 728219.74 764630.73 802862.26 843005.38 885155.65 929413.43 975884.10 1024678.30 1075912.22 1129707.83 1186193.22 1245502.88 1307778.03
Discounted Cash
-3250000.00 368636.36 351880.17 335885.61 320618.08 306044.54 292133.42 278854.63 266179.42 254080.35 242531.25 231507.10 220984.05 210939.32 201351.17 192198.84 183462.53 175123.33 167163.17 159564.85 152311.90 145388.63 138780.06 132471.87 126450.43 120702.68
flows
Simple Payback
8.0
Period (Years)
NPV of the
2325243.75
Project
ROI (%) 71.55
IRR (%) 6%
Page 143 of 151

C) ELECTRICAL BUILDING
List of Assumptions
Project Year 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
Investment ₹ 16,25,000.00 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Savings /Year 0 ₹ 2,19,000.00 229950.00 241447.50 253519.88 266195.87 279505.66 293480.95 308154.99 323562.74 339740.88 356727.92 374564.32 393292.54 412957.16 433605.02 455285.27 478049.53 501952.01 527049.61 553402.09 581072.20 610125.81 640632.10 672663.70 706296.89
Cost of Operation
0 16250.00 17062.50 17915.63 18811.41 19751.98 20739.58 21776.55 22865.38 24008.65 25209.08 26469.54 27793.01 29182.67 30641.80 32173.89 33782.58 35471.71 37245.30 39107.56 41062.94 43116.09 45271.89 47535.49 49912.26 52407.87
/Year
Net Savings 0 202750.00 212887.50 223531.88 234708.47 246443.89 258766.09 271704.39 285289.61 299554.09 314531.80 330258.39 346771.30 364109.87 382315.36 401431.13 421502.69 442577.82 464706.71 487942.05 512339.15 537956.11 564853.92 593096.61 622751.44 653889.01
Discounted Cash
-1625000.00 184318.18 175940.08 167942.81 160309.04 153022.27 146066.71 139427.31 133089.71 127040.18 121265.62 115753.55 110492.02 105469.66 100675.58 96099.42 91731.27 87561.66 83581.59 79782.42 76155.95 72694.32 69390.03 66235.94 63225.21 60351.34
flows
Simple Payback
8.0
Period (Years)
NPV of the
1162621.88
Project
ROI (%) 71.55
IRR (%) 6%
Page 144 of 151

D) BUILDING BESIDE HR BUILDING
List of Assumptions
Project Year 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
Investment ₹ 65,00,000.00 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Savings /Year 0 ₹ 8,76,000.00 919800.00 965790.00 1014079.50 1064783.48 1118022.65 1173923.78 1232619.97 1294250.97 1358963.52 1426911.69 1498257.28 1573170.14 1651828.65 1734420.08 1821141.09 1912198.14 2007808.05 2108198.45 2213608.37 2324288.79 2440503.23 2562528.39 2690654.81 2825187.55
Cost of Operation
0 65000.00 68250.00 71662.50 75245.63 79007.91 82958.30 87106.22 91461.53 96034.60 100836.33 105878.15 111172.06 116730.66 122567.19 128695.55 135130.33 141886.85 148981.19 156430.25 164251.76 172464.35 181087.57 190141.95 199649.04 209631.50
/Year
Net Savings 0 811000.00 851550.00 894127.50 938833.88 985775.57 1035064.35 1086817.56 1141158.44 1198216.36 1258127.18 1321033.54 1387085.22 1456439.48 1529261.45 1605724.53 1686010.75 1770311.29 1858826.86 1951768.20 2049356.61 2151824.44 2259415.66 2372386.44 2491005.77 2615556.05
Discounted Cash
-6500000.00 737272.73 703760.33 671771.22 641236.17 612089.07 584266.84 557709.26 532358.84 508160.71 485062.49 463014.20 441968.10 421878.64 402702.34 384397.69 366925.06 350246.65 334326.35 319129.70 304623.80 290777.26 277560.12 264943.75 252900.85 241405.36
flows
Simple Payback
8.0
Period (Years)
NPV of the
4650487.51
Project
ROI (%) 71.55
IRR (%) 6%
Page 145 of 151

E) BUILDING BESIDE HR BUILDING
List of Assumptions
Project Year 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
Investment ₹ 39,00,000.00 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Savings /Year 0 ₹ 5,25,600.00 551880.00 579474.00 608447.70 638870.09 670813.59 704354.27 739571.98 776550.58 815378.11 856147.02 898954.37 943902.08 991097.19 1040652.05 1092684.65 1147318.88 1204684.83 1264919.07 1328165.02 1394573.27 1464301.94 1537517.03 1614392.89 1695112.53
Cost of Operation
0 39000.00 40950.00 42997.50 45147.38 47404.74 49774.98 52263.73 54876.92 57620.76 60501.80 63526.89 66703.23 70038.40 73540.32 77217.33 81078.20 85132.11 89388.71 93858.15 98551.06 103478.61 108652.54 114085.17 119789.43 125778.90
/Year
Net Savings 0 486600.00 510930.00 536476.50 563300.33 591465.34 621038.61 652090.54 684695.07 718929.82 754876.31 792620.13 832251.13 873863.69 917556.87 963434.72 1011606.45 1062186.77 1115296.11 1171060.92 1229613.97 1291094.66 1355649.40 1423431.87 1494603.46 1569333.63
Discounted Cash
-3900000.00 442363.64 422256.20 403062.73 384741.70 367253.44 350560.10 334625.55 319415.30 304896.42 291037.50 277808.52 265180.86 253127.18 241621.40 230638.61 220155.04 210147.99 200595.81 191477.82 182774.28 174466.36 166536.07 158966.25 151740.51 144843.21
flows
Simple Payback
8.0
Period (Years)
NPV of the
2790292.50
Project
ROI (%) 71.55
IRR (%) 6%
Page 146 of 151

C e r t i f i c a t i o n
 The data collection has been carried out diligently and truthfully;
 All data monitoring devices are in good working condition and have been
calibrated or certified by approved agencies authorized and no tempering of such
devices has occurred;
 All reasonable professional skill, care and diligence had been taken in preparing
the energy audit report and the contents thereof are a true representation of the
facts;
 Adequate training provided to personnel involved in daily operations after
implementation of recommendations; and
 The energy audit has been carried out in accordance with the Bureau of Energy
Efficiency (Manner and Intervals of Time for the Conduct of Energy Audit)
Regulations, 2010.
Signature
Name of the accredited energy auditor
Accreditation details
Seal
Page 147 of 151

ABBREVIATIONS
C Degree Centigrade
A Ampere
APFC Automatic Power Factor Controller
Avg. Average
CHW. Chilled Water
cm. Centimeter
Cr. Crores
CT Cooling Tower
CW Cooling Water
DBT Dry Bulb Temperature
DG Diesel Generating
Dia. Diameter
Effn. Efficiency
gm. Gram
hr. Hour
Ins Insulated
HPCLMR Hindustan Petroleum Corporation Ltd
Mumbai Refinery
Kcal Kilo Calories
Kg. Kilogram
KL Kilo Liter
KV Kilo Volt
kVA Kilo Volt Ampere
kVAr Kilo Volt Ampere Reactive
kW Kilo Watts
kWh Kilo Watt Hour
lit Liters
lt Liters
Ltd. Limited
M or m Meter
Max. Maximum
MD Maximum Demand
Min. Minimum
Mm Millimeter
MT Metric Ton
MW Mega Watts
No. Number
OLTC Online Tap Changer
PCRA Petroleum Conservation Research
Association
p.a. Per Annum
PF Power Factor
Rpm Revolutions per minute
Rs. Rupees
Sec. Second
SEC Specific Energy Consumption
Temp. Temperature
TPH Tones Per Hour
TR Tons of Refrigeration
V Voltage
Page 148 of 151

Abbreviations in CPP and Utiltities boilers
APC : Auxiliary Power Consumption
APH : Air Preheater
BEP : Best Efficiency Point
BFP : Boiler Feed Water Pump
CEP : Condensate Extraction Pump
DC : Designated Consumer
DCA : Drain Cooler Approach
DEA : Deaerator
ECM : Energy Conservation Measure
FW : FeedWater
GCV : Gross Calorific Value
FD Fan : Forced Draft Fan
kCal : kilo Calorie
kWh : kilo Watt Hours
LHV : Lower Heating Value
MT : Metric Tons
NCV : Net Calorific Value
PF : Power Factor
SEC : Specific Energy Consumption
SLD : Single Line Diagram
SPC : Specific Power Consumption
TPA : Tonnes per Annum
TPD : Tonnes per Day
TTD : Terminal Temperature Difference
UoM : Unit of Measurement
Page 149 of 151

Form 2 for Hindustan Petroleum Corporation Ltd, Refinery Mahul, Mumbai
Sr. Energy Saving Measures Investment Life Annual Energy savings Payback
No Cycle NG Oil Electricity Amount
Rs Lac Year KSCM MT MWH Lakh Month
Rs
1 HRSG 1 Efficiency improvement 5 3511.7 877.9
2 HRSG 3 Efficiency improvement 5 3195.6 798.9
3 HRSG 5 Efficiency improvement 5 2602 634.6
4 Dry flue gas loss in Boiler SG10 improvement 10 333.3 75.7
5 Dry flue gas loss in Boiler SG12 improvement 10 1086 246.8
Replacement of VHP BFP Pump of Boiler SG12 with small
6 size pump 50 10 1039.47 83.1 7
Use of Plate Heat Exchanger instead of Fin Fan coolers for
7 Generator Lub Oil Cooling for all Gas Turbines 50 10 1172.16 93.77 6
8 FD Fan Suction choked Filter replacement 20 10 530 38.5 6
9 VFD for FD Fan of SG-10 & SG-11 66 10 412 34.4 14
Interconnection of VHP BFW Header of Boiler SG-10, SG-11,
10 and SG-12 100 10 2621.47 209.8 6
11 Thermal Insulation loss reduction in CPP HRSG 10 497.8 124.5
Reducing pressure drop in various dryers by replacing the
12 decissicant 120 10 954 76.3 18.9
13 Improving & maintaining performance of chillers 12 10 193.6 15.5 9.3
14 Replacing various lamps with LED lamps 157 10 1681.9 134.6 14
Replacing one SBR blower (lobe type) with high efficiency
15 turbo blower (centrifugal), total 4 blowers 128 10 1425.6 114 13.5
Installing solar hot water system for canteen hot water
16 applications 3.75 25 5.07 - 1.8 25.4
Installing solar PV systems on Admin Building, Old Admin
Building, Electrical Building, Old Admin Building and LR&
17 LOUP Control Room (total 405 KW) 263.25 25 486 38.9 81.3
970 5.07 11225.97 10930 3606.97
Signature Signature
Name of energy manager Name of accredited energy auditor
Name and full Company a ddress Accredat ion details and seal
Page 150 of 151

Single Line Diagram of HPCL Refinery
Page 151 of 151

HPCL MEA REPORT 6 June 2017 Submitted

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

HPCL MEA REPORT 6 June 2017 Submitted

Uploaded by

Copyright:

Available Formats

Report On

MANDATORY ENERGY AUDIT

Petroleum Conservation Research Association

MEA 2017 HPCL Refinery Mumbai Page 1

4. ENCON MEASURES ..........................................................................................................................................

4.2 LOW EFFICIENCY OF HRSG 1, HRSG 3, AND HRSG 5 .......................................................................................... 135

MEA 2017 HPCL Refinery Mumbai Page 2

Team of HPCL, Mumbai Refinery:

M/s. Petroleum Conservation Research Association

MEA 2017 HPCL Refinery Mumbai Page 3

MEA 2017 HPCL Refinery Mumbai Page 4

MEA 2017 HPCL Refinery Mumbai Page 5

17 Installing solar PV systems on Admin Building,

Conversion from 10930 MWH = 10930000/5164 = 2116.6 MTOE

= 11225.97 MTOE + 2116.6 MTOE

Total MT of Oil Equivalent (MTOE) savings = 13342.57 MTOE

MEA 2017 HPCL Refinery Mumbai Page 6

HPCL’s Mumbai Refinery was established in 1952. Through progressive

1 Name of the Unit Hindustan Petroleum Corporation Ltd

2 The sector in which unit falls Petroleum Refinery (PSU)

(b) Year of establishment 1952

4 Registered office address with telephone, fax numbers and

5 Name, designation, address, mobile, telephone, fax Ms Jolly Sony

MEA 2017 HPCL Refinery Mumbai Page 7

Name of the Unit Installed Capacity

CDU-PG 4000 TMTPA

CDU-BH (Expansion) 3500 TMTPA

VDU-PG (FR) 21200 BSD

VDU-BH 27170 BSD

Propane Unit 12.35 M3/hr

Hexane Manufacturing unit 71.7 M3/hr

Hexane Treating unit (NMP) 14.7 M3/hr

DHDS 2275 TMTPA

Diesel Hydro-Treating (DHT) 1760 TMTPA

Hydrogen Unit 14.5 TMTPA

DHDS-SRU 2X65 TPD

DHT-SRU 2X65 TPD

FCCU 1000 TMTPA

New FCCU (check case) 1456 TMTPA

New FCCU (Design case) 1276 TMTPA

ATF Treating Unit 11000 BSD

VDU-PG (LR) 21130 BSD

Solvent Extraction Unit-I 5358 BSD

Solvent Extraction Unit-II 5358 BSD

Solvent Extraction Unit-III 5358 BSD

Propane Dewaxing Unit 335 TMTPA LOBS

Propane De-Asphalting Unit 755 TMTPA

LOUP UNIT (GR-II LOBS) 227 TMTPA

MEA 2017 HPCL Refinery Mumbai Page 8

NHT/CCR 545 TMTPA

NHT/ISOM 250 TMTPA

Prime-G+ 475 TMTPA

SWSU 120 M3/hr

ARU 260 M3/hr

LTU 439 TMTPA

MEA 2017 HPCL Refinery Mumbai Page 9

The detail of the study team including Designation, Professional qualification

Sr No Name Qualification Designation Experience

MEA 2017 HPCL Refinery Mumbai Page 10

MEA 2017 HPCL Refinery Mumbai Page 11

The monthly expenses sheet is shown in the following table.

1.3 Major energy use areas :

The major consumers of energy resources include