Modified Energy Management - Final

1
HPCL
BOKARO
DEPOT
SUSTAINABILITY IS THE NEW WAY OF
LIVING!
2
ENERGY
EFFICIENCY
(100 Points)
HPCL BOKARO DEPOT

3
ISO CERTIFICATE
HPCL BOKARO DEPOT

4
- Implement comprehensive
measurement, monitoring
and management systems
for energy parameters.
- Adopt progressive targets
in environmental
parameters and ensure
resource availability
towards achieving them.
HPCL BOKARO DEPOT

5
ENERGY OVERVIEW
JVBNL
750 KVA
Contract
Demand
Connected Load:
3131 KW
Contract Demand: BOKARO

750 KVA DEPOT
2500 KVA
Maximum Demand: Solar PV

DG Set
2 X 1010 KVA
464 KVA 375 kWp
1 X500 KVA
HPCL BOKARO DEPOT MANDATORY REQUIREMENT

6
MONTHLY ENERGY CONSUMPTION
17.12% 2.5%
TLF PUMPS AIR COMPRESSOR
11.5% 11.3% ADMIN+MCC+LAB

52711 TWG PUMPS
AC PANEL
JVBNL
6.1% 10.3%
EMERGENCY TAS C/R HVAC
PANEL 02
DG SETs/FE 4655
0.68% 15.49%
JOCKEY PUMP EMERGENCY
EPCC
PANEL
17514 1.03% 6.9%

VRU LIGHTS
SOLAR
3.42%
OTHERS
UNIT : KWH( 67% Fixed and 33% Variable)
7
THERMAL ENERGY - MONTHLY HSD CONSUMPTION
Equipment Average Monthly HSD Area of Application

Consumption
Fire Engine 750 Lts • Daily Testing of 2 fire
engine for 30 min
• Fire Engine running during
fire drills
• Fire Engine running during
water line leakage if any
DG 2400 Lts JVBNL Power Failure

10
ENERGY MIX
Consumption
Average DAILY
 EB
Solar- 23.4
Consumption:
4395 Units
 Solar
Generation :
Thermal-6.2 1459 units
 DG
Electrical-
70.4 Consumption:
390 Units
Electrical Thermal Solar

12
CREDIT 1. ENERGY MONITORING

SYSTEM
20 POINTS
HPCL BOKARO DEPOT

13
DISTRIBUTION OF CONSUMPTION
MFM FEEDERS(FROM) MFM FEEDERS(TO) % Substitution
Bokaro Real Energy Into the Load 100.00
Bokaro Real Energy Into the Load Bokaro Incomer
Bokaro Incomer Main Panel O/G (Bokaro) 7.04
Bokaro Incomer Emergency Panel O/G (Bokaro) 14.07
Main Panel O/G (Bokaro) MCC-1 Panel (Bokaro) 5.06
Main Panel O/G (Bokaro) LTG AC Panel-1 (Bokaro) 10.58
Main Panel O/G (Bokaro) MCC-2 Panel (Bokaro) 3.83
Main Panel O/G (Bokaro) Main Panel (Bokaro) 14.58
Emergency Panel O/G (Bokaro) Emergency Panel (Bokaro) 3.85
MCC-1 Panel (Bokaro) Bokaro.MCC_1 5.23
MCC-1 Panel (Bokaro) Bokaro.TTL_ETHANOL_PUMP-1 1.23
MCC-1 Panel (Bokaro) Bokaro.TTL_ETHANOL_PUMP-2 0.59
MCC-1 Panel (Bokaro) Bokaro.TTL_HSD_PUMP-1 2.11
MCC-1 Panel (Bokaro) Bokaro.TTL_FO_PUMP-3_MCC1 0.15
MCC-1 Panel (Bokaro) Bokaro.TTL_LDO_PUMP-1 0.00
MCC-1 Panel (Bokaro) Bokaro.TTL_LDO_PUMP-2 0.82
MCC-1 Panel (Bokaro) Bokaro.TTL_MS_PUMP-1 1.48
MCC-1 Panel (Bokaro) Bokaro.TTL_SKO_PUMP-3 0.10
MCC-1 Panel (Bokaro) Bokaro.TTL_SKO_PUMP-4 0.48
LTG AC Panel-1 (Bokaro) Bokaro.LIGHTING_AC_PANEL-1 0.58
LTG AC Panel-1 (Bokaro) Bokaro.MOV_PANEL 1.02
LTG AC Panel-1 (Bokaro) Bokaro.AIR_COMPRESSOR-2 0.51
LTG AC Panel-1 (Bokaro) Bokaro.AUTOMATION_AC 0.13
LTG AC Panel-1 (Bokaro) Bokaro.AUTOMATION_ROOM 0.26
LTG AC Panel-1 (Bokaro) Bokaro.LABORATORY_BULDING_LIGHTING_PANEL 0.08
LTG AC Panel-1 (Bokaro) Bokaro.LABOURATORY_BULIDING 0.04
MCC-2 Panel (Bokaro) Bokaro.TWD_FO_PUMP-02_MCC2 0.02
MCC-2 Panel (Bokaro) Bokaro.TWD_FO_PUMP-03_MCC2 2.78
MCC-2 Panel (Bokaro) Bokaro.TWD_HSD_PUMP-2 1.56
MCC-2 Panel (Bokaro) Bokaro.TWD_LDO_PUMP-1 0.00
MCC-2 Panel (Bokaro) Bokaro.TWD_LDO_PUMP-2 1.42
MCC-2 Panel (Bokaro) Bokaro.TWD_MS_PUMP-1 1.08
MCC-2 Panel (Bokaro) Bokaro.TWD_MS_PUMP-2 4.57
Main Panel (Bokaro) Bokaro.LIGHTING_AC_PANEL-2 0.08
Main Panel (Bokaro) Bokaro.APFC_INCOMER 0.00
Emergency Panel (Bokaro) Bokaro.JOCKEY_PUMP-01 0.28
Emergency Panel (Bokaro) Bokaro.AIR_COMPRESSOR-01 0.25
Emergency Panel (Bokaro) Bokaro.FIRE_PUMP_HOUSE 1.20
Emergency Panel (Bokaro) Bokaro.AUTOMATION 3.08
Emergency Panel (Bokaro) Bokaro.ADMIN_BUILDING 0.00
HPCL BOKARO DEPOT CREDIT 1.1 : ENERGY MONITORING SYSTEM 5 POINTS

13
ENERGY METERS WISE CONSUMPTION

KWH CONSUMPTION PER
FEEDERS ANNUM % CONSUMPTION
Bokaro Real Energy Into the Load 844214.79
MCC-1 Panel (Bokaro) 230197.12 27.27
Emergency Panel O/G (Bokaro) 135062.16 16.00
LIGHTNING PANEL-1 132421.16 15.69
Bokaro.ADMIN_BUILDING 111817.21 13.25
Main Panel (Bokaro) 84896.58 10.06

Equipment >= 5% of total energy consumption
KWH CONSUMPTION PER %

FEEDERS ANNUM CONSUMPTION
MCC-2 Panel (Bokaro) 69028.94 8.18
Bokaro.MCC_1 65405.2 7.75
Bokaro.TTL_ETHANOL_PUMP-1 64379.36 7.63
Bokaro.LIGHTING_AC_PANEL-2 51873.01 6.14

13
Equipment <5% of total energy consumption
KWH CONSUMPTION PER
FEEDERS ANNUM % CONSUMPTION
Bokaro.TTL_FO_PUMP-3_MCC1 29673.68 3.51
Bokaro.LABORATORY_BULDING_LIGHTING_PANEL 23550.6 2.79
Bokaro.TWD_HSD_PUMP-2 19142.01 2.27
Bokaro.AUTOMATION 16531.52 1.96
Bokaro.TWD_MS_PUMP-1 15251.76 1.81
Bokaro.AUTOMATION_ROOM 14856.1 1.76
Bokaro.AIR_COMPRESSOR-2 13752.84 1.63
Bokaro.TTL_HSD_PUMP-1 11768.91 1.39
Bokaro.AUTOMATION_AC 9638.45 1.14
Bokaro.TTL_MS_PUMP-3 8854.74 1.05
Bokaro.VRU 119.52 0.01
Bokaro.TTL_ETHANOL_PUMP-2 7587.05 0.90
Bokaro.TTL_LDO_PUMP-1 2432 0.29
Bokaro.TTL_LDO_PUMP-2 67.26 0.01
Bokaro.TTL_SKO_PUMP-1 3.49 0.00
Bokaro.TTL_FO_PUMP-2_MCC1 227.72 0.03
Bokaro.MOV_PANEL 4511.85 0.53
Bokaro.TWD_FO_PUMP-02_MCC2 1207.45 0.14
Bokaro.TWD_FO_PUMP-03_MCC2 1359.93 0.16
Bokaro.TWD_LDO_PUMP-1 532.85 0.06
Bokaro.TWD_LDO_PUMP-2 326.25 0.04
Bokaro.TWD_MS_PUMP-2 7714.52 0.91
Bokaro.TWD_SKO_PUMP-1 220.97 0.03
Bokaro.TWD_SKO_PUMP-2 345.31 0.04
Bokaro.APFC_INCOMER 832 0.10
Bokaro.JOCKEY_PUMP-01 141.98 0.02
Bokaro.AIR_COMPRESSOR-01 4743.14 0.56
Bokaro.FIRE_PUMP_HOUSE 1703.25 0.20
Bokaro.JOCKEY_PUMP-02 125.06 0.01

14
MONTHLY ENERGY MONITORING SYSTEM

15
EQUIPMENT WISE ENERGY MONITORING SYSTEM

16
APPROACH FOR ENERGY MONITORING
Daily Equipment wise Monitoring of Energy Consumption & Corrective action being taken on daily basis
Identify major energy consuming equipments (>5% consuming equipments)
Critically monitor and control usage of major energy consuming equipments (ACs & Lights)
Carry out daily variance analysis of SEC (daily vs best)
Implementation of Demand Side management (DSM) Scheme, Load Balance initiatives.
Contract Demand reduced from 1500 KVA to 750 KVA and further to 550 KVA.
Installation of energy meters on feeders, Variable Frequency Drives (VFDs), Soft Starters, LEDs. Installation of

17
DAILY VARIANCE STUDY OF KWH
1. Daily
Mean variance
Value study
= 1.1 KWH/KL
KWH/KL of Feeders carried
out.
2. Analysis done for
more than 10%
variation.
HPCL BOKARO DEPOT CREDIT 1.2 : VARIANCE ANALYSIS 5 POINTS

17
DAILY VARIANCE STUDY OF HSD NO-02
Pump Maximum
Chart Title Rating- 75 KW
100% Mean Value =1.1.1HSD Pump 2
KWH/KL
operated
90%
due to Rake
80% Unloading
70%
60%
50% HSD REGULAR PUMP- 2

Timestamp Real Power
40% 07-03-2024 00:00 0
08-03-2024 00:00 61.642
30% 09-03-2024 00:00 65.02857208
10-03-2024 00:00 0
20%
11-03-2024 00:00 62.9042511
10% 12-03-2024 00:00 0
13-03-2024 00:00 0
0% 14-03-2024 00:00 0
07.03.24 08.03.24 09.03.24 10.03.24 11.03.24 12.03.24 14.03.24
Actual Consumption Maximum Rating

17
DAILY VARIANCE STUDY OF LTG
1. HMT
Mean and=Under
Value 1.1 KWH/KL
carriage light
operated due to
Rake Unloading
LIGHTING AC LIGHTING AC
Timestamp PANEL-1 PANEL-2 Remarks
07-03-2024
00:00 64.15 332
08-03-2024 Rake
00:00 87.44 788.66 unloading
09-03-2024 Rake
00:00 115.55 840.95 unloading
10-03-2024 Rake
00:00 103.78 618.84 unloading
11-03-2024
00:00 131.055 326
12-03-2024
00:00 119.69 318.69
13-03-2024
00:00 119.79 271.58
14-03-2024
00:00 60.47 154.95

17
DAILY VARIANCE STUDY OF Ethanol Pump-01
1. Ethanol
Mean ValuePump
= 1.1 KWH/KL
insulation was found
to be low and after
cable rectification,
consumption
reduced
Timestamp Series Grouping Value
01-03-2023 14:30 ETHANOL PUMP-1 (kWh) Mar 9325.353
01-04-2023 05:45 ETHANOL PUMP-1 (kWh) Apr 5201.324
06-05-2023 17:00 ETHANOL PUMP-1 (kWh) May 6210.454
01-03-2023 14:45 ETHANOL PUMP-2 (kWh) Mar 1044.87
01-04-2023 05:45 ETHANOL PUMP-2 (kWh) Apr 673.198
06-05-2023 17:00 ETHANOL PUMP-2 (kWh) May 758.517

Rationalization of contract demand and energy RE- Credit 1.3 Points : 5
management initiatitives. Variance Analysis &
Corrective Action
 Centralized Energy Monitoring System installed at plant .
Due to this energy efficiency and efficacy improved. High to low consuming electrical
components/apparatus would be identified and corrective action taken to improve efficiency.
225 KWp solar plant commissioned in Nov,23.
Total Solar Capacity of HPCL Bokaro IRD improved to 375 KWp.
200 KW VFD for FO motors, Saving 40% of energy
 Utilization of VFDs, savings 40% and Soft starters (Reduces Peak Demand)
20
21
Case Studies with Corrective actions
after Variance Analysis
Date Issue Observed
5 April 2023 Observed insulation of Ethanol Pump is low and was drawing higher current of 55 Amps. After
replacing cables, the drawing current reduced drastically to 40-43 Amps.
Rectification:
Insulation of Ethanol pump is rectified by replacement of cables. After replacement of cables,
ethanol pump is drawing lower current which helps in lower unit consumption. A savings of Rs
5200 per month is achieved.
Date Issue Observed

09 Jan 2023 Less generation of Solar Power
Rectification:
Solae generation was monitored for the day, it was observed that due to faulty inverters, solar
generation was not happening.
HPCL BOKARO DEPOT CREDIT 1.3 : CORRECTIVE ACTION TAKEN 5 POINTS

22
OTHER INITIATIVES AND BEST PRACTICES
DEVELOPED FOR ENERGY
EFFICIENCY
 Procurement and installation of Centralised Energy for
monitoring and control of energy consumption.
 Energy Audit and compliance to the Energy Audit observations
 Load balancing and Harmonics control
 Proposal for reduction of transformer capacity from 2.5 MVA to
1.1 MVA.
 VFD installed for FO pump leading to 40% savings in energy.
 Solar Power Plant Commissioning and Monitoring
performance
 Expansion of Solar Capacity to 325 KWP
 Conversion of HMT lights to LED Lights.
 Air Compressor Pressure range 4.5 to 7 Kg/cm2, Air Leakage
arrested
 Sensitized Electrician for timely ON/OFF of Lighting load

23
Trainings to Electricians for Improvements
Training to electrician on
detecting cable fault and
corrective action to be taken.

24
INITIATIVES AND BEST PRACTICES FOR
ENERGY EFFICIENCY
Individual
Installation of VFDs for each
Energy Meters pump. All
for Daily Integrated
Monitoring with Terminal
Automation
system

24
INITIATIVES AND BEST PRACTICES FOR
ENERGY EFFICIENCY
Utilization of Drives Soft Starters for Regular Pumps
Individual
Installation of VFDs for each
Energy Meters pump. All
for Daily Integrated
Monitoring with Terminal
Automation LED in Gantry
LED in Sheds
system

26
Offsetting using Solar of 150 KWp and expansion
to 325 KWp in Nov 2023
Year-1 Year-2 Year-3 Year-4
2020-21 2021-22 2022-23 2023-24*
Sr.No Description UoM Value Value Value Value
1 Renewable Plant Type On-Site - Solar PV Solar PV Solar PV Solar PV
2 Renewable Plant Capacity On-Site kW 0 150 150 375
3 Annual Generation - Renewable kWh 0 158843 149687 210172
4 Location Electrical Energy Consumption kWh 736271 685728 720971 632538
5 HSD Consumption in Fire Pump house KL 15.4 12.4 09 5.2
6 Calorific Value of HSD* Kcal/Kg 10800 10800 10800 10800
7 Density of HSD* Kg/KL 829 829 829 829
8 Conversion of Kcal to kWh - 0.0012 0.0012 0.0012 0.0012
9 Thermal Energy to Electrical Energy Conversion kWh 165455 133223 96694 55867
10 Total Annual Energy of the location kWh 901726 818951 817665 688405
% Renewable Energy Share % 0.0 19.39 18.30 30.53

27
Maintaining High Solar Performance
Maintaining Average more than 80% as per tender terms
Performance Ratio (%)

Month Jan'21 Feb'21 Mar'21 Apr'21 May'21 June'21 July'21 Aug'21 Sept,21 Oct,21 Nov'21 Dec'21
Monthly
14646 14646 14646 14646 14646 14646 14646 14646 14646 14646 14646 14646
output
Actual
Monthly 13450 14530 13330 10750 12430 14500 13890 11979 13890 12803 13230 12831
O/P
Efficiency 92% 99% 91% 73% 85% 99% 95% 82% 95% 87% 90% 88%
Monthly
14500 14500 14500 14500 14500 14500 14500 14500 14500 14500 14500 14500
output
Actual
Monthly 13830 14320 14390 13512 13753 13774 12300 12850 13555 13450 12340 14331
O/P
Efficiency 95% 99% 99% 93% 95% 95% 85% 89% 93% 93% 85% 99%
Monthly
14355 13398 14355 14355 14355 14355 14355 14355 14355 14355 14355 14355
output
Actual
Monthly 4711 11597 13514 13456 13452 8400 6926 29911 31590
O/P 13426 14353 7765
Efficiency 33% 87% 94% 94% 100% 94% 94% 59% 48% 54% 208% 220%
Monthly
14355 13398 14355
output
Actual
Monthly 30037 31224 9632
O/P
Efficiency 209% 233% 67% #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0!

29
CREDIT 2. Reduction in SEC in the past

3 years
50 POINTS
HPCL BOKARO DEPOT

30
APPROACH FOR SEC REDUCTION
Process Leverage Operational SEC

Benchmarking
Improvement Technology Efficiency Reduction
HPCL BOKARO DEPOT CREDIT 2 : REDUCTION IN SEC FOR PAST 3 YEARS 50 POINTS
31
STRATEGY FOR SEC REDUCTION
Regular
Variance Awareness Recognition
Analysis and Training Schemes
Equipment
wise Process Preventive Root Cause
Consumption Improvement Maintenance Analysis
monitoring
Explore Energy Production

Energy Efficient planning Equipment
Efficiency Equipmen based on Efficiency
Technology ts demand Improvement
32
ENERGY FLOW DIAGRAM
32
SEC AND PROJECT
PROJECT NAME BUDGET (Rs) Budget Allocation UNIT SAVED IN KWH Year SEC for the Year
Installation of Solar Plant-150 1,32,00,000 1,32,00,000 158843 2021-2022 1.87
Conversion of 2.5 inch Loading

10,00,000 10,00,000 44400 2021-2022 1.87
Line to 4 Inch
Installation of VFD for Pumps 5,00,000 5,00,000 156000 2021-2022 1.87
Replacement of Conventional 20,00,000

20,00,000 533520 2022-2023 1.80
light with LED light
Installation of additional
13000000 13000000 115028 2023-2024 1.28
225 KWP Solar Plant
Centralised Energy 13468000 13468000 90000 2023-2024 1.28

Mangement System
35
SEC PATTERN FOR LAST 4 YEARS
1.87
1.86
1.80 31 %
Reduction
of SEC in
1.28 2023-24.
Base 0.5% 4%
Year
31%
2020-21 2021-22 2022-23 2023-24*
35
THRUPUT PATTERN (TMT) IN LAST 4 YEARS
592.34
494.72
473.14
10%
395.79 increase by
442.9 March
2024
Till March
2024 should
reach
2019-20 2020-21 2021-22 2022-23 2023-24* 640.34
32
Details of the projects implemented to reduce specific energy
consumption
• Installation of 150 KWp On-grid Solar (Jan-2020) and 225 KWp on grid ground
mounted solar in (2023). Hence, Total 375 KWp Solar.
• Bi-Directional Meters installed for monitoring Export and import energy data.
Major Projects • Installation of Energy Meters for Monitoring (CEMS online Portal)
• Conversion of conventional lightings of all areas in LED light fittings
• Installation of VFD for 200 KW FO motor, Saving 40% of energy
• Filling rate enhancement by maximizing flow rate to 1600 LPM (Change in
Loading Arms)
• Implementing Demand Side Management Scheme (DSM)

• Load Shifting during Non-operational Hours
Optimization •
•
Utilization of VFDs and Soft Starters for regular pumps
Training imparted for employees, workmen and security personnel for better and
efficient uses for energy.
• Load Balancing of electrical feeder
• Regular monitoring of energy pattern via online CEMS portal

Process •
•
Maximum Utilization of Solar and VFDs during operational hours
Maintaining Power factor >0.95
Improvement • Preventive Maintenance schedule implementation
• Regular Critical examination of feeder like VCB M&R, ACB M&R, Vib. Analysis,
Thermography, Earthing & Continuity Checks and others followed
37
INITIATIVES DURING PROJECT
Individual VFD for pumps
High Efficiency Motors
Nozzle size increased 2.5 to 4 inch
Reduction of CD
100 % LED Lights
Solar Plant Installation
38
Savings from Reduction of CD
Details of Electricity Consumption FY-2020-21
Contract
Unit Actual
Consumption Units Demand 1500
Consumed P.F. Demand
Month KVAh KVA, Billing
KWh (KVA)
(= 75% of CD)
Saving = Rs 23.62 Lacs per annum 20-Apr 43884 46080 95 313.2 1125
20-May 45072 47232 95 115.2 1125
20-Jun 53568 55512 96 352.8 1125
20-Jul 66564 68652 97 403 1125
20-Aug 32029 33577 95 68 1125
20-Sep 71290.8 73846.8 97 327 1125
20-Oct 69552 71712 97 352 1125
energy saving
Implemented in Dec,21 20-Nov
20-Dec
75456
79956
77472
82872
97
96
316.8
316.8
1125
562.5
21-Jan 66528 69156 96 122.4 562.5
21-Feb 65988 68688 96 363.6 562.5
21-Mar 66384 68976 96 450 562.5
• Net Saving of Contract Demand 750 KVA

• Net Saving of energy charges: Rs 196875 {1125 (75 % ofCD) -562.5 (75 % of revised CD) =562.5 KVA
X Rs 350
38
Installation of Solar Plant 375 KWp
1. Solar Generations in 2021-22- 158843 KWH

2. Solar generations in 2022-23 - 149687 KWH
3. Solar Generations in 2023-24 - 210172 KWH
Saving of 518702 KW of energy
KWH
250000
200000
29.82 Lacs savings 150000
100000
50000
0
2021-22 2022-23 2023-24
Implemented in Jan 2021 and Nov,23 KWH
38
Savings from LED
High Mast Towers
Total Load Load in

Saving of 44460 Watt of energy Scenario Total NO
(Kw)
Daily ON
use
Operation Hours
monthly
Earlier 06:30PM to 06:30AM (12
528 211 12 2532
Scenario Hrs)
06:30PM to 06:30AM (12
58.5% energy saving Current

Scenerio
528 105.60 12 1050
Hrs) 12 HMT operational
daily and 09 HMT
operational during rake
operation in height hrs
for 7 hrs
Saving : 1482 unit/day (44460 unit/month)

Implemented in March 2022
41
Individual VFDs for every pump
Further , VFD operation was optimized by putting

following initiatives.
1. TAS logic of 2nd pump start updated with current
feedback of first pump causing less frequent
start of 2nd pump.
2. Turn off idle VFDs basis on actual demand saving the
wastage of passive harmonic filter.
3. Turn off VFDs after operation.
Net saving average 5.5 Kw per VFD for 10 hrs

every day
45
CEMS for controlling, monitoring and recording
VFD performance
Gross Energy Saving by Installation of VFDs and Soft Starters
Sl Rated Power Running Savings in
Particulars Savings (In KW) Remarks
No KW KW Hrs Unit/Day
Savings of 156240 KWH per Annum
HSD Pump
1 1 45 25 20 8 160 VFD
HSD Pump Without
2 2 45 32.2 12.8 6 76.8 VFD
HSD Pump Without
3 3 45 32.2 12.8 2 25.6 VFD
HSD Pump Withot
4 4 45 32.2 12.8 2 25.6 VFD
5 MS Pump 1 37 21.1 15.9 8 127.2 VFD Implemented in Feb,23

Without
6 MS Pump 2 37 23.8 13.2 8 105.6 VFD
SKO
loading is
7 SKO Pump 37 very few
520.8 Unit / Day
41
Bay Utilisation : Productivity Improvement
 16 bays are available for W/O loading

 Normalisation of indents across TOD
 Issues faced
 Higher energy consumption due to over
time.
 Small Nozzle Size Low flow rate
 High Cycle time.
 Bay configuration was modified to maximise
utilisation
 All loading through bottom loading TTs
44400 KWH savings per annum
 Nozzle size increased from 2.5inch to 4
inch
 Flow rate increased to 1600 LPM
 Cycle time reduced from 45 to 25mins
(Productivity Improvement)
48
CREDIT 3. Equipment wise efficiency

improvement
15 POINTS
HPCL BOKARO DEPOT

Daily Monitoring of Equipments
CREDIT 3.1 : EQUIPMENT WISE EFFICIENCY MONITORING AND

HPCL BOKARO DEPOT
IMPROVEMENT
10 POINTS
ETHANOL PUMP RECTIFICATION Monthly
Consumption
Ethanol Pump
2
30 KW
Series 1
Drawing
Maximum Rating of Pump-30 KW Higher power
due to low
insulation.
42.00 Rectified
01.11.21 27.00
01.12.21 29.00
37.00 01.01.22 25.00
01.02.22 28.00
01.03.22 27.00
01.04.22 26.00
29.00 28.0027.00 28.00 28.0029.00 29.00 28.0028.00 01.05.22 28.00
27.00 26.00 26.00 26.00 27.00 01.06.22 26.00
25.00 25.0024.00 25.00 25.0026.00 01.07.22 28.00
23.00 01.08.22 29.00
01.09.22 25.00
01.10.22 24.00
01.11.22 0.00
01.12.23 23.00
01.01.23 29.00
01.02.23 37.00
01.03.23 42.00
01.04.23 25.00
01.05.23 26.00
01.06.23 28.00
01.07.23 28.00
0.00 01.08.23 25.00
1 1 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 01.09.23 26.00
1.2 2.2 1.2 2.2 3.2 4.2 5.2 6.2 7.2 8.2 9.2 0.2 1.2 2.2 1.2 2.2 3.2 4.2 5.2 6.2 7.2 8.2 9.2 0.2 01.10.23 27.00
.1 .1 .0 .0 .0 .0 .0 .0 .0 .0 .0 .1 .1 .1 .0 .0 .0 .0 .0 .0 .0 .0 .0 .1
01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01.11.23
01.12.23
27.00
26.00
01.01.24 28.00
01.02.24 26.00
Series 1

HPCL BOKARO DEPOT
IMPROVEMENT
10 POINTS
LIGHTNING LOAD RECTIFICATION
Conventional Light LED LIGHT
55.4% reduction in KWH unit
Particular Total fittings KWH KWH
consumed.
HMT 528 2534.4 1406.59 20.34 lacs Savings per
MCC2 14 3.4 1.8 annum.
Conference Room 12 9.5 5.2
Control Room 24 13.8 7.5
Lab 32 38.01 18.75
Admin Building 89 40.78 23
TT IN-OUT 48 5.184 3
Total Per Day 2645.074 1465.84

Per year 793522.2 439752

HPCL BOKARO DEPOT
IMPROVEMENT
10 POINTS
POWER FACTOR RECTIFICATION
Month Power Fcator Remarks
Power Factor
Savings of 4050 Units /2.5 lacs 01.06.21
01.07.21
91.98
98.00
Power Factor 01.08.21 95.00
100.00 01.09.21 93.00
01.10.21 94.00
Harmonic Filter found to be
98.00 not working. The same
01.12.21 88.00 rectified.
96.00 01.01.22 95.00
01.02.22 95.00
01.03.22 98.00
94.00 01.04.22 98.00
01.05.22 98.00
01.06.22 98.00
92.00 01.07.22 98.00
01.08.22 97.00
90.00 01.09.22 96.00
01.10.22 97.00
01.11.22 97.00
88.00 01.12.23 97.00
01.01.23 97.00
01.02.23 97.00
86.00 01.03.23 97.00
01.04.23 97.00
01.05.23 97.00
84.00 01.06.23 98.00
01.07.23 98.00
82.00 01.08.23 98.00
21 21 21 22 22 22 22 22 22 23 23 23 23 23 23 24
01.09.23 98.00
. . . . . . . . . . . . . . . . 01.10.23 97.00
. 06 . 08 . 10 . 01 . 03 . 05 . 07 . 09 . 11 . 01 . 03 . 05 . 07 . 09 . 11 . 01 01.11.23 97.00
01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01.12.23 97.00
01.01.24 97.00
01.02.24 97.00

HPCL BOKARO DEPOT
IMPROVEMENT
10 POINTS
49
Energy intensity of various critical feeders

HPCL BOKARO DEPOT
IMPROVEMENT
10 POINTS
50
Distribution of energy matrix in major Pump Feeders
and daily monitoring.

HPCL BOKARO DEPOT
IMPROVEMENT
10 POINTS
51
Equipment consuming 80% of the total energy consumption in the plant & steps
for Equipment Wise Efficiency Improvement
Initiatives taken to monitor and improve efficiency of major energy consuming equipments
High masts and other lights:
• Optimum use of high masts lighting during operational and non-operational Hours.
• Turning on only emergency lights of TT pump houses and gantry.
Product Pumps:
• Operation through VFDs regular pump and Soft Starters
• Demand based pumping
• Vibration analysis of product pumps
• Regular oil checking and top up
• Installation of soft starter to reduce high initial current.
• Installed energy meters on pump feeders for monitoring energy consumption.
• Installation of drive for 200 KW motor
Admin Building
• Install Energy Meter on Feeder
• Convert existing conventional lights with LED
• Optimum Use of Lights and AC
Control Room
• Optimum Use of Lights and AC
Vapor Recovery System (VRU)
• Max. Utilization of VRU system for recovery and extraction of MS from Vapor
Green Energy Usages
Installation of On-grid Solar of 225 KWp in 2023 and 150 Kwp in 2020.

HPCL BOKARO DEPOT 50
IMPROVEMENT
10 POINTS
52
Using best available market equipments
E quipm e E xis ting E xis ting
S no B es t Market
nt m ake equipm ent
1 L E Ds B AJ AJ 0.98 power fac tor B es t in the market
2
T ank T ruc k
K IR L O S AK R IE 2 - 94.5% IE 3 - 95.4%
Approx 80%
P ump Motors
3
T ank Wag on
K IR L O S AK R IE 2 - 94.5% IE 3 - 95.4%
equipment used are
P ump Motors
4 VF D L &T
VF D + Invertor
B es t in the Market
best available in
T ec hnolog y
5
H ig h Mas t
B AJ AJ 0.98 power fac tor B es t in the market
market
T owers
6 J oc key P ump K IR L O S K AR IE 2 - 93.8% IE 3 - 95.4%
7 UP S 20 K VA HITACHI H IT AC H I B es t in the market
8 C C TV INF INO VA VP 130-A220C 762 B es t in the market
9 LE D S AMS UNG Q E 55T B es t in the market
10 AC B L &T B es t in the market
C AP AC IT O R
11 L &T B es t in the market
B ANK
12 F IR E E NG INE K IR L O S K AR B es t in the market
E L E C T R IC AL
13 L &T B es t in the market
P ANE L
14 S olar Inverter P ower O ne B es t in the market
15 Air C ompres s or S ullair B es t in the market
16 Air C onditioner 5 s tar rated B es t in the market
17 F ANS Normal F ans B L D C F ANS
18 HC D G E L T R O NIX B es t in the market
19 H VL R AK R O N B R AS S B es t in the market
20 C B AC G O DR E J B es t in the market
CREDIT 3.2 : At least 50% of the energy intensive equipment used in the
HPCL BOKARO DEPOT
factory is of best available market efficiency
5 POINTS
56
Other Energy Saving Equipments
50 8 no
NEW VFD
Pumps
62 MOTION
SENSORS
NEW
ENERGY
METERS
5 STAR
RATING AC
PF AND CAPACITOR
MANAGEMENT
HPCL BOKARO DEPOT
5 POINTS
58
High Efficiency (IE2) Motors and Pumps in Tank
Truck and Wagon Loading
HPCL BOKARO DEPOT
5 POINTS
60
CREDIT 4. Energy Benchmarking

15 POINTS
HPCL BOKARO DEPOT

61
SEC Comparison with other PAN India locations of
similar capacity FY 2023-24
SEC
1.9 2.6
1.4
1.28
1.0
Raipur Depot Patna Depot Guwahati Depot Haldia Terminal Kolkata Terminal
HPCL BOKARO DEPOT CREDIT 4.1 : Internal Energy Benchmarking 5 POINTS

63
Energy Audit Dec 2021
HPCL BOKARO DEPOT CREDIT 4.2.1 : Energy Audit 2 POINTS

64
Total 3 Complied
Compliance Status Points 3 Points
100%
1. To Improve P.F. to 0.99 by

revamp / reapir of existing
CB : Corrective action taken and
Replacing Conventional gantry lights with LED faulty capacitors were removed
Lights and revamping done. Now, P.F is
>0.95 (In addition. E20 Projects
are under process so the
Major consumption pattern is uneven.

But plant has maintained the P.F.
Improvements >0.95
2. Replacing Conventional gantry
contributing conventional nights with LED

Lights: Replacement of
to SEC Conventional Lights to LED lights

done for all Sheds and process
Installation of Occupancy Sensors
improvement areas.
3. Replace non-star Air
Conditioners with BEE 5 star
rated inverter Acs: 4-5 Acs
were replaced with 5 star rated
Acs.Optimum use of Acs is
ensured during operational hours
and officers were sensitize for
efficient use of Acs during
working hrs.
HPCL BOKARO DEPOT CREDIT 4.2.2 : Implementation of Energy Audit Recommendations 3 POINTS
65
SEC Comparison with Competitors
3
2.69
Bokaro Depot
2.5
has lowest SEC
in comparison to
its counterparts 2
situated in same
place and under 1.33
1.5
same
environmental 1.28
condition. 1
0.5
0
IOCL Jasidih BPCL POL BOKARO HPCL POL BOKARO
Series 1
HPCL BOKARO DEPOT CREDIT 4.3 : External Benchmarking 5 POINTS

69
Thank You!
The more we become energy efficient nation,

the less we need to develop additional energy
sources !
“Information contained in this presentation is confidential and should not

be reproduced, distributed without prior consent of HPCL.”
HPCL BOKARO DEPOT

Modified Energy Management - Final

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1

HPCL BOKARO DEPOT

HPCL BOKARO DEPOT

HPCL BOKARO DEPOT

Contract Demand: BOKARO

Maximum Demand: Solar PV

HPCL BOKARO DEPOT MANDATORY REQUIREMENT

11.5% 11.3% ADMIN+MCC+LAB

17514 1.03% 6.9%

Equipment Average Monthly HSD Area of Application

DG 2400 Lts JVBNL Power Failure

HPCL BOKARO DEPOT MANDATORY REQUIREMENT

Electrical Thermal Solar

HPCL BOKARO DEPOT MANDATORY REQUIREMENT

CREDIT 1. ENERGY MONITORING

HPCL BOKARO DEPOT

HPCL BOKARO DEPOT CREDIT 1.1 : ENERGY MONITORING SYSTEM 5 POINTS

ENERGY METERS WISE CONSUMPTION

ENERGY METERS WISE CONSUMPTION

KWH CONSUMPTION PER %

HPCL BOKARO DEPOT CREDIT 1.1 : ENERGY MONITORING SYSTEM 5 POINTS

HPCL BOKARO DEPOT CREDIT 1.1 : ENERGY MONITORING SYSTEM 5 POINTS

HPCL BOKARO DEPOT CREDIT 1.1 : ENERGY MONITORING SYSTEM 5 POINTS

HPCL BOKARO DEPOT CREDIT 1.1 : ENERGY MONITORING SYSTEM 5 POINTS

Identify major energy consuming equipments (>5% consuming equipments)

Carry out daily variance analysis of SEC (daily vs best)

Implementation of Demand Side management (DSM) Scheme, Load Balance initiatives.

HPCL BOKARO DEPOT CREDIT 1.1 : ENERGY MONITORING SYSTEM 5 POINTS

HPCL BOKARO DEPOT CREDIT 1.2 : VARIANCE ANALYSIS 5 POINTS

50% HSD REGULAR PUMP- 2

Actual Consumption Maximum Rating

HPCL BOKARO DEPOT CREDIT 1.2 : VARIANCE ANALYSIS 5 POINTS

HPCL BOKARO DEPOT CREDIT 1.2 : VARIANCE ANALYSIS 5 POINTS

Timestamp Series Grouping Value

01-03-2023 14:30 ETHANOL PUMP-1 (kWh) Mar 9325.353

01-04-2023 05:45 ETHANOL PUMP-1 (kWh) Apr 5201.324

06-05-2023 17:00 ETHANOL PUMP-1 (kWh) May 6210.454

01-03-2023 14:45 ETHANOL PUMP-2 (kWh) Mar 1044.87

01-04-2023 05:45 ETHANOL PUMP-2 (kWh) Apr 673.198

06-05-2023 17:00 ETHANOL PUMP-2 (kWh) May 758.517

HPCL BOKARO DEPOT CREDIT 1.2 : VARIANCE ANALYSIS 5 POINTS

 Centralized Energy Monitoring System installed at plant .

225 KWp solar plant commissioned in Nov,23.

Total Solar Capacity of HPCL Bokaro IRD improved to 375 KWp.

200 KW VFD for FO motors, Saving 40% of energy

Date Issue Observed

HPCL BOKARO DEPOT CREDIT 1.3 : CORRECTIVE ACTION TAKEN 5 POINTS

HPCL BOKARO DEPOT CREDIT 1.3 : CORRECTIVE ACTION TAKEN 5 POINTS

HPCL BOKARO DEPOT CREDIT 1.3 : CORRECTIVE ACTION TAKEN 5 POINTS

HPCL BOKARO DEPOT CREDIT 1.3 : CORRECTIVE ACTION TAKEN 5 POINTS

Utilization of Drives Soft Starters for Regular Pumps

HPCL BOKARO DEPOT CREDIT 1.3 : CORRECTIVE ACTION TAKEN 5 POINTS

2 Renewable Plant Capacity On-Site kW 0 150 150 375

3 Annual Generation - Renewable kWh 0 158843 149687 210172

4 Location Electrical Energy Consumption kWh 736271 685728 720971 632538

5 HSD Consumption in Fire Pump house KL 15.4 12.4 09 5.2

6 Calorific Value of HSD* Kcal/Kg 10800 10800 10800 10800

7 Density of HSD* Kg/KL 829 829 829 829

8 Conversion of Kcal to kWh - 0.0012 0.0012 0.0012 0.0012

% Renewable Energy Share % 0.0 19.39 18.30 30.53

HPCL BOKARO DEPOT CREDIT 1.3 : CORRECTIVE ACTION TAKEN 5 POINTS

Performance Ratio (%)

HPCL BOKARO DEPOT CREDIT 1.3 : CORRECTIVE ACTION TAKEN 5 POINTS