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Performance Highlights (Refineries Division)
Last Updated: April 04, 2008
IndianOil Refineries - Setting New Standards of Excellence
IndianOil Refineries achieved highest ever output of 47.4 MMT during the year 2007-08, registering a growth of 7.7% in crude processing over last year, surpassing 100% capacity utilisation. This feat has been achieved by the collective support of Corporate Office, Marketing Division and Pipelines Division through highest ever evacuation of the products.
During the year, three of our Refineries, namely Barauni, Gujarat and Panipat achieved highest-ever crude throughputs of 5640 TMT, 13715 TMT and 12830 TMT respectively.

To enhance GRM, IndianOil Refineries processed highest ever 48.8% of High Sulfur crude in 2007-08 as against previous highest of 43.7% in 2006-07. Barauni, Gujarat, Mathura and Panipat Refineries have improved upon their HS crude processing. Similarly, IndianOil Refineries processed highest ever 9.4% of heavy crude in 2007-08 as against previous highest of 3.0% in 2006-07.

Our committed efforts towards efficient Energy Conservation has resulted in reduction of overall energy consumption to 67 MBTU/BBL/NRGF (MBN) during 2007-08 against the earlier lowest of 71 MBTU/BBL/NRGF in 2006-07.

The Commendable performance of the Refineries was suitably acknowledged with a number of awards during the year 2007-08, notably in the fields of Energy Conservation, Safety & Environment Management. IndianOil's Mathura and Panipat Refineries have won two prestigious awards for their Energy Conservation efforts from the Centre for High Technology (CHT).

The awards were presented by Hon'ble Union Minister of Petroleum & Natural Gas, Mr. Murli Deora at the CHT Refinery Technology Meet at Thiruvananthapuram on 20th September 2007.

Scaling Greater Heights
Operations
IndianOil Refineries achieved record overall production of LPG, MS, ATF, SKO, HSD, LAB and Bitumen in 2007-08.
Products 2007-08 Previous Best (2006-07)
LPG 1627 1491.9
MS 4300 3906.5
MS (Euro-III) 1403.7 1238.8
ATF 2135 1827.1(2006-07)
SKO 3775 3659.3 (2006-07)
HSD 19510 17859.3 (2006-07)
HSD (Euro-III) 3975 3626.2 (2006-07)
LAB 133.0 121.8 (2006-07)
BITUMEN 2212 2050.6 (2006-07)
Figs. in TMT

Beyond limits
  • Barauni Refinery achieved highest ever crude throughput of 5640 TMT during the year surpassing the previous best of 5553.2 TMT in 2005-06.

  • Gujarat Refinery achieved highest ever crude throughput of 13715 TMT during the year surpassing the previous best of 12953.1 TMT in 2006-07.

  • Panipat Refinery achieved highest ever throughput of 12830 TMT during the year surpassing the previous best of 9434.3 TMT in 2006-07.

  • " All refineries have either remained at par or improved upon their earlier best in Specific Energy Consumption, as listed in the table.


    • Refineries Year 2007-08 Previous Best
    GUWAHATI 71 77 (2006-07)
    BARAUNI 70 72 (2005-06)
    GUJARAT 69 70 (2003-04)
    HALDIA 71 (2006-07) 70
    MATHURA 67 67 (2006-07)
    DIGBOI 92 92 (2006-07)
    PANIPAT 63 67 (2005-06)
    IOC 67 71 (2006-07)

    As a result, overall Specific Energy Consumption has improved to 67 MBTU/BBL/NRGF in 2007-08 from 71 MBTU/BBL/NRGF in 2006-07. As part of continued efforts towards Energy Conservation, more than 20 schemes were implemented during the year resulting in savings to the tune of 24000 SRFT/year.

    Towards better capacity utilisation
    Action has been taken for allocating 0.2 MMTPA of additional imported crude to BRPL and to distribute equivalent Assam crude to Guwahati and Digboi in following proportion: G = 0.15 MMT and D = 0.05 MMT. This has facilitated in enhancing capacity utilisation of Guwahati and Digboi Refineries.

    GRM Improvement through stream sharing
    SRGO transfer from Gujarat to Panipat and Mathura
    Total 41 TMT HS-SRGO dispatched to Panipat Refinery through KVSSPL and MPCPL during Aug 07 &
    Dec 07 to enable Gujarat Refinery to increase crude processing by utilizing spare capacity of Panipat DHDT. Similarly, SRGO transfer from Gujarat to Mathura Refinery by Tank wagon to the tune of 190 TMT done during 2007-08 to utilize spare capacity of Mathura DHDT.

    SRGO transfer from Haldia to Barauni
    As a new initiative, 2.5 TMT of SRGO was transported by rake from Haldia to Barauni Refinery on 24th Feb 08 for processing in Barauni DHDT utilizing its spare capacity. This enabled Haldia to enhance its crude processing level. To extend this new avenue further, 8 TMT of SRGO was transported through HBPL from Haldia to Barauni Refinery on 10th March 08.

    LSHS transfer from Gujarat to Panipat.
    Total 60 TMT TEC grade LSHS transfer to Panipat Refinery done for use as IFO. This has enabled Panipat Refinery to increase their distillate yield by upgrading part of Vacuum Slop, otherwise used as IFO.

    Isomerate transfer from Mathura to Panipat
    Panipat Refinery received 6.0 TMT of Isomerate produced at Mathura during the year 2007-08 for production of Euro-III MS for feeding NCR through the Panipat-Rewari pipeline.

    Stream Sharing between BRPL to Guwahati Refinery
    DHDT feedstock from BRPL to Guwahati Refinery continued throughout the year 2007-08 to enable BRPL to process Assam crude in absence of DHDT. 162.5 TMT of DHDT feedstock was transferred to Guwahati during 2007-08 against the previous best of 154 TMT in 2006-07. 4.4 TMT of LSHS was also transferred from BRPL to Guwahati. As a new beginning, CLO transfer from Guwahati to BRPL started in Nov 07 for production of Needle Coke at BRPL. 985 MT of CLO has been transferred in 2007-08.

    Stream sharing between Digboi and Guwahati
    During the year 2007-08, Reformer Naphtha from Guwahati (12.8 TMT) was transferred to Digboi for processing in its CRU while 17.0 TMT INDMAX feed, and 4.8 TMT of Naphtha from Digboi was transferred to Guwahati for processing. Transfer of Reformate from Digboi to Guwahati started from 18th August 2007 as a new stream sharing and 4.4 TMT of Reformate has been transferred this year.

    Product Export
    Making foray into new markets, beyond the national boundaries to sustain the crude output and profitability, IndianOil Refineries exported following products:
    Figs in TMT
    Products Year 2007-08*
    Naphtha 1743.4
    Furnace Oil 48.8
    Bitumen 40.2
    Paraxylene 17.4
    Total Export 1849.8

    *provisional
    The exports during the year 2007-08 as above, are the highest from IndianOil Refineries, the previous best being 1666.1 TMT in year 2006-07.
    New facilities commissioned/inaugurated

    State-of-the-Art LPG Storage Facility at Gujarat
    The Minister of State for Petroleum and Natural Gas, Mr. Dinsha Patel inaugurated the advanced state-of-the-art storage technology comprising six mounded bullets with a capacity of 1500 cubic meter each at Gujarat Refinery on 13th June 2007.

    Plant-wide Real-Time Database System
    Plant-wide Real-Time Database System was commissioned at Guwahati, Barauni, Haldia, Digboi and Panipat Refineries.

    Retrofitting of DHDS for VGO processing at Mathura
    DHDS unit of Mathura Refinery was retrofitted with in-house expertise for processing high sulfur VGO to profitably utilize available surplus capacity of the unit. As a part of the project, Refinery came up with an innovative design of Winterizing device (on product rundown air-cooler) for quick and inexpensive implementation. The modifications were executed during July'07 shutdown and successful trial run was carried out on VGO mode during 14th to 18th Nov 2007. Processing of high sulphur feed stock (desulphurised by DHDS route) in FCCU helps in increasing cheaper HS crude processing in the Refinery.

    New projects approved

    MS Quality Upgradation Project
    The Board approved MS Quality Upgradation Project at Mathura and Panipat Refineries at an estimated investment of Rs. 348 crore and Rs.1131 crore respectively on 31st Jan'08 with targeted commissioning by Dec'09. Implementation of this project will improve the quality of MS to Euro - III / IV equivalent.

    New projects approved in principle

    Distillate Yield Improvement Project (Coker) at Haldia
    In principle approval of the project was accorded by the Board for Distillate Yield Improvement Project at Haldia Refinery on 31st Jan'08.
    Setting up of Facilities for Production of Para-Xylene at Gujarat Refinery
    In principle approval of the project was accorded by the Board for Setting up of Facilities for Production of Para-Xylene at Gujarat Refinery on 28th Dec'07.

    Projects under implementation - important milestones
    Environmental Clearance / Licensor Selection / Process Packages
  • Environmental Clearance (EC):

    • EC obtained for Paradip Refinery Project (PDRP) in July 2007 for updated Refinery & Petrochemical configuration of 15 MMTPA.
  • Licensor Selection:

    • MS Quality Improvement Projects:
  • M/s Axens, France for Fluidised Catalytic Cracking Gasoline Desulphurisation (FCC- GDS) unit at Panipat & Mathura Refineries

  • M/s Axens, France for Naphtha Hydrotreater Unit (NHTU), Isomerisation (ISOM) & FCC-GDS at Barauni Refinery

  • M/s Axens, France for ISOM, NHT & Naphtha / Indmax Splitter unit at Guwahati / Digboi Refinery.

    • Paradip Refinery Project:
  • ABB, EMRE for Alkylation Unit

  • UOP for Straight Run LPG Treater Unit

  • Merichem, USA for FCC Light Naphtha Treater, FCC LPG Treater Unit

  • Consolv, Canada for Flue Gas Desulphurisation Unit (FGDU),

  • MECS, USA for Spent Acid Regeneration Unit (SARU),

  • Black & Veatch, USA for Sulphur Recovery Unit (SRU)

    • Final Process Packages delivered in the Financial Year:
  • Coker & ISOM units of Gujarat Resid Upgradation Project

  • Process units (ISOM, Naphtha Hydrotreater & FCC Gasoline Desulphurisation) of MS Quality Improvement projects at Panipat, Mathura, Barauni, Guwahati & Digboi Refineries

  • Fifteen packages viz. VGO-HDT, DCU, HGU, FCC Unit, DHDT, ER/EB/SM, ATF / KERO, FCC LT Naphtha Treater, FCC LPG Treater, SR LPG Treater, Coker LPG Treater, Alkylation, Polypropylene including PRU, PX-Complex, FGDU units for Paradip Refinery Project.


    • Lining up of Project Management Consultant (PMC) / Engineering, Procurement, Construction Management Consultant (EPCM):
    PMC/EPCM contracts worth Rs.226 crore awarded during the year. Project-wise details are as under:

    Residue Upgradation and MS & HSD Quality Improvement Project at Gujarat (Resid-J):
  • M/s Jacobs Engineering as EPCM for Diesel Hydrotreater Unit (DHDT) & Hydrogen Generation Unit (HGU).

  • M/s UHDE India as EPCM for Vacuum Gas Oil-Hydrotreater Unit (VGO-HDT).


    • MS Quality Improvement Projects:
  • M/s Jacobs as EPCM for FCC Gasoline Desulphurisation Unit (FCC GDS) at Mathura Refinery

  • M/s PDIL as PMC for Licensor, Engineering, Procurement & Construction Management (LEPCM) job for Hydrogen Generation Unit at Barauni Refinery

  • M/s Toyo India as PMC for ISOM, FCC GDS and associated offsite & utilities of Barauni Refinery

  • M/s Lurgi India as PMC for ISOM units & associated offsite facilities at Guwahati & Digboi Refineries


    • Preparation of DFR for High Sulphur (HS) Crude Maximisation Project at Barauni Refinery:
  • M/s EIL has been awarded the job of preparation of detailed Feasibility Report for High Sulphur (HS) Crude Maximisation Project at Barauni Refinery on 25th May'07. Completion period is 44 weeks from date of award of job.


    • Award of major LSTK contracts:
    LSTK contracts and packages worth Rs. 5231 crore (approx.) were awarded during the year. Project-wise details are as under:
    Naphtha Cracker Project at Panipat:
  • Spent Caustic Treatment Plant (EPCC-1A) to M/s Toyo in September 2007

  • Propylene Separation Unit revamp (EPCC-14) to M/s Nicco in October 2007


    • Residue Upgradation and MS & HSD Quality Improvement Project at Gujarat (Resid-J):
  • Balance DCU (Package-3A) to M/s Punj Lloyd in December 2007

  • Coker Heater (Package-3C) to M/s L&T in October 2007

  • Isomerisation & NSU (Package-4) to Technip, KTI in Jan'08

  • Sulphur Recovery Unit (Package-5) to M/s L&T in October 2007

  • Utilities & Offsite comprising Quality related facilities (Package-6A): to M/s IOTL in July 2007

  • Gas Turbine with Heat Recovery Steam Generation (Package-7) to M/s BHEL in June 2007

  • Coke Handling (Package-8) to M/s FFE Mineral in August 2007

  • Cooling Tower (Package-9) to M/s Gammon Cooling Tower in July 2007

  • Mounded Bullets (Package-10) to M/s VTV in April 2007

  • Caustic Oxidising Plant (Package-11) to M/s Linde in January 2008

  • Reformer package of HGU to M/s Heurty Petro-Chem, France.

  • PSA facilities package of HGU to M/s UOP, India.


    • Improvement in Diesel Quality & Distillates Yield (Hydrocracker) Project at Haldia Refinery (OHCU-H):
  • Cooling Tower (Package-5) to M/s Gammon Cooling Tower in July 2007

  • ETP, DM / RO Plant (Package-6) to consortium of Hindustan Dorr Oliver & Doshion Ltd. in June 2007


    • Paradip Refinery Project:
  • Dredging & Reclamation of balance land to Joint Venture of M/s Dharti and M/s Hung Hua Construction Co. Ltd. in October 2007.


    • MS Quality Improvement Projects
  • ISOM Unit at Panipat Refinery to M/s L&T in July 2007

  • FCC-GDS Unit at Panipat Refinery to M/s Toyo in January 2008


    • Additional Funds for MS Quality Improvement Projects:
    The Board approved the provision of funds totaling Rs. 1343 crore for procurement of long delivery critical equipment & award of contracts for all MSQ improvement projects in Panipat, Mathura, Barauni, Guwahati & Digboi Refineries in view of very short execution time available for these projects.

    Procurement of Long Delivery Critical Items:
    To reduce the schedule risk of Resid-J and MS Quality projects, pre-procurement of long delivery items was given strategic push. Procurement of following long delivery critical items has been taken to reduce the execution time of various projects.
  • RESID-J: Reactor of VGO-HDT, PSA & Reformer Package of Hydrogen Generation Unit, Coke Drum, Coke Cutting System, Coker Heading / De-heading System, Wet Gas Compressor of Coke Drum System Package.

  • MSQ Projects: Reactor & Compressors for Barauni, Guwahati, Digboi and Mathura Refineries and FCC Gasoline Desulphurisation of Panipat Refinery clubbed together. The action would help in saving time.

    • Benefits of this strategy has already started accruing and few examples are:
  • M/s UHDE as EPCM Consultant accepted challenging completion schedule of VGO-HDT of 26 month because reactors were pre-ordered

  • M/s Punj Lloyd has accepted 28 months completion schedule (including 4 months for commissioning) of DCU of Gujarat Resid Upgradation Project as Coke Chambers have been pre-ordered


    • Centralized Procurement Cell (CPC):
  • CPC formed for procurement of bulk items at competitive rates for projects as well as Refinery Additional Facility (AF) jobs / maintenance jobs. The section started functioning w.e.f 15th June, 2007. Materials worth Rs.21.14 crore has been ordered through CPC. Action for Rate Contract for Bearings, GT spares & Cables has started materializing. In subsequent months lead-time of procurement will improve.


    • Limited Tender Facility of IndianOil web site:
  • For the first time in IndianOil, the Limited Tender Enquiry facility of IndianOil web has been started for faster finalization of tenders.


    • Plot Plan Review of PDRP by Multi Disciplinary Team :
  • A pool of engineers was mobilized from various Refineries and their valuable experience on plant operation and maintenance were obtained. Further, a multi-disciplinary team was sent to FWEL, Reading, UK to review and incorporate the same in the plot plans jointly with FWEL experts in Dec.'07. This has helped FWEL in getting +10% cost estimate on schedule i.e. by March' 08 as they are now in position to make MTOs of Piping and Cables.


    • Forming a Multi Disciplinary Team to verify the FEED & Estimating Methodology of PMC (FWEL, UK):
  • In order to get world class FEED for various PDRP facilities and sound +10% cost estimate, a multi disciplinary IOCL Team has been mobilized to FWEL, Reading, UK.

    • Award of N2 / O2 package of PNCP on Build Own & Operate (BOO) basis:
  • BOO concept has been introduced in IndianOil, which is found very attractive from cost point of view. The job has been awarded to M/s Air Liquide, Belgium on BOO basis with a completion schedule 29 months for 1st delivery of product gases.


    • Lining up of M/s Shell Global Solution for "Project Advisory and Technical Support Services" - PNCP Project
  • M/s SGS, who are having vast experience of construction & commissioning petrochemical plants across the world, has been lined up for providing us advisory services & technical support during project execution and building the roadmap for safe & flawless startup/commissioning of the complex of PNCP.


    • Involvement of external expert for Hazop review and 3-D modeling:
  • In view of limited expertise in the field of Naphtha Cracker Unit, External specialist were involved during Hazop review of Cracker (SGS) and downstream polymer units. M/s Shell Global Solution were involved for Cracker Unit & retired personnel from industry was involved for polymer units. External specialist were also involved during 3-D model review


    • Review of 3-D model for offsite & underground system for PNCP:
  • For the first time 3-D model review of Offsite/Utilities and underground piping was carried out in Naphtha Cracker Project. This helped in efficient designing of the offsite and underground piping network in the complex, future planning for expansion and better constructability


    • Contracts
  • Review of LSTK GCC of Refinery Division completed and many standard terms & condition modified to align it with market.


    • New products launched
  • Paraxylene despatch started from August 2007. About 17.3 TMT has been dispatched during 2007-08.


    • Milestones
    Shipping
  • Record quantity of 46.114 MMT of imported crude has been lifted during 2007-08 as against 42.682 MMT in 2006-07. This includes crude imported for CPCL also.
  • Govt. of India conveyed the approval during May 2007 for continuation of direct chartering by IndianOil.
  • VLCC tankers are being utilized wherever possible to reduce the freight cost of crude transportation to our refineries. 116 nos of VLCC tankers were fixed during 2007-08 to transport 30.932 MMT as against 110 nos of VLCC for a qty of 29.410 MMT in 2006-07.

    • Clean Development Mechanism (CDM) Project
    One Clean Development Mechanism (CDM) Project at each Refinery was identified and action was initiated for getting the benefit through United Nations Framework Convention for Climate Change (UNFCCC). In 2007-08 Host Country Approval obtained for Phase-I projects at Guwahati, Haldia, Digboi and Panipat. All seven projects in Phase-I are under various stages of validation. Additional twelve projects have been identified in Phase-II at Barauni, Haldia, Gujarat, Mathura and Panipat.

    System improvement
    Creation of In-house Knowledge Portal:     In-house knowledge portal "Abhiyan Gyan Drishtee" launched on 11th April 2007 aimed at optimizing the use of intellectual capital of IOCians to excel in various areas including Project Management, Operations, Maintenance & Inspection, Production, HR, Finance and other operational areas.

    Safety Foundation Building
    As an effort towards Foundation Building for Safety Culture, M/s DuPont completed the safety foundation building exercise in Gujarat, Haldia and Mathura Refineries and their observations / recommendations are under various stages of implementation.

    Cutting edge technologies adopted
    Step-less Control System for Hydrocracker MUG compressor at Mathura     Mathura became first IndianOil Refinery to implement Step-less Capacity Control System for power savings. The device has been installed in Makeup Gas Compressor of Hydrocracker Unit and has been in operation since 17th April, 2007. With the installation of the system, compressor spill back valve could be completely closed and thereby resulting in a fuel savings of 1500 MT of fuel/year.

    Dry running Non-contacting Mechanical Seal at Gujarat Refinery
    Dry running Non-contacting Mechanical Seal was installed for the first time in Dumad LPG Transfer Pumps, which has helped in eliminating existing flushing fluid arrangement .

    Data Reconciliation and Yield Accounting Package at Mathura
    DRYA (Data Reconciliation and Yield Accounting Package), first of its kind in IndianOil Refinery implemented for working out Daily Production Balance using real time process data. The system was formally inaugurated on 1st October 2007. Data reconciliation and re-validation enables quick identification and rectification of erroneous flow indications apart from reliable material balance of Refinery units.

    Enhancing profitability
    New Imported Crude Processed     In order to widen the crude basket, new imported crude oils were processed by various Refineries during 2007-08 such as Essider (Origin: Libya), Kissanje (Origin: Angola), Azeri Light (Origin: Azerbijan), Brass Light (Origin: Nigeria), Kole (Origin: Angola), Hout (Origin: Neutral Zone), Ratawi (Origin: Neutral Zone), Oriente (Origin: Equador), Soroosh (Origin: Iran), Ceiba (Origin: Equatorial Guinea) and Zafiro (Origin: Equatorial Guinea).
  • Barauni: Essider, Ceiba, Azeri Light, Brass Light and Zafiro

  • Gujarat: Kissanje, Azeri Light, Kole and Hout

  • Haldia: Essider, Ceiba, Azeri Light and Zafiro

  • Mathura: Kissanje, Azeri Light, Kole and Hout

  • Panipat: Kissanje, Azeri Light, Kole, Hout, Ratawi, Oriente and Soroosh

    • Over and above, two new crude oils, namely Palanca (Origin: Angola) and Kikeh (Origin: Malaysia) have been procured for processing in IndianOil Refineries.

    Shell Global Integrated Business Improvement Programme at Mathura
    Mathura Refinery successfully completed assessment phase of Shell Global Integrated Business Improvement Programme during May-Jun'07. Implementation of 16 PFI, with mutual acceptance, is in progress for expected GRM improvement of 16.4 Million US$/Yr. (28.1 cents/bbl)
    LSHF HSD despatch by BTPN rake at Gujarat
    Low Sulfur High Flash Diesel despatch by BTPN rake at Gujarat started on 1st September 2007 converting the existing LDO handling facilities. This will help in reducing DHDS load and thereby allowing increased crude processing in the refinery and better GRM.

    SKO transfer from Barauni Refinery to Guwahati Refinery
    SKO transfer from Barauni Refinery to Guwahati Refinery started since Sep'07 to cater to Guwahati fed area to maximize ATF production of Guwahati for better GRM.

    Awards for Excellence
    Energy Conservation     National Energy Conservation award - 2007 from Ministry of Power
    H.E. President of India presented the Certificate of Merit to Guwahati Refinery as the winner of National Energy Conservation Award - 2007 (Certificate of merit) in the Refining sector, instituted by Ministry of Power on 14th December 2007. This distinction has come after commendable efforts in Energy Conservation by the Guwahati Refinery throughout 2006-07.
    Jawaharlal Nehru Centenary awards instituted by CHT
  • Mathura Refinery received "Jawaharlal Nehru Award" (2nd prize) for lowest Specific Energy Consumption during the year 2006-07. The prestigious award was given away by Hon'ble Union Minister of Petroleum & Natural gas on 20th September 2007 during XIV RTM in Kovalam, Thiruvananthapuram.

    • Department of Renewable energy Government of Haryana
  • Panipat Refinery has been awarded the second prize for excellence in the implementation of Energy conservation measures under State level Industrial Sector-HT category during the year 2006-07 by Department of Renewable energy, Government of Haryana on 18th December 2007.

    • Oil & Gas Conservation Fortnight (OGCF)-2007 award from MOP&NG
  • Panipat Refinery received Oil & Gas Conservation award 2007 from MOP&NG on 20th September 2007 for being third lowest Steam leaks Refinery of the country based on joint surveys conducted during OGCF. The Insulation Effectiveness of Furnace/Boiler survey was conducted simultaneously at all Refineries in Dec 2007 by the CHT team during OGCF-2007.

    • Shri Anil Raj Trophy for the year 2006-07
  • Haldia Refinery was awarded "Shri Anil Raj Trophy" on 18th September 2007 for the year 2006-07 for achieving maximum reduction in Energy consumption and hydrocarbon loss amongst IndianOil Refineries over the previous best performance.


    • Safety & Environment Management
    Oil Industry Safety Directorate Award 2006-07 for Safety Performance (Refinery Category) by OISD
  • Mathura Refinery has been declared winner of the "Oil Industry Safety Directorate Award" (First Position) for safety performance for the year 2006-07. The award was presented by Petroleum Secretary, Mr. M S Srinivasan in Mumbai on 29th September 2007.

    • Shri AV Ogale Shield for safety in operations
  • Panipat Refinery and Mathura Refinery jointly received Shri A V Ogale Shield on 11th July 2007 for the year 2006-07.

    • Golden Safety Award from National Safety Council
  • Panipat Refinery received Golden Safety Award - 2006 from National Safety Council for its PTA project for leadership role in guiding & motivating the contractors to improve the safety at project site. Haryana State Safety Award

  • Panipat Refinery bagged Haryana State Safety Award for the year 2006 for lowest accident frequency rate & longest accident free period among chemical (large scale) factories.

    • Other Awards
    Rajbhasha Shield for Panipat
  • Panipat Refinery received Rajbhasha Shield Pratham Puraskar (1st Prize) for the year 2006-07 from Official Language Deptt., Ministry of Home Affairs for commendable work in Hindi implementation in

    • Town Official Language Implementation Committee. (TOLIC).
    Kaizen award
  • Panipat Refinery is once again among the top five winning companies at National Kaizen Conference held in October 2007 under the auspices of TPM Club India (CII), at New Delhi. This is the second time that an IndianOil refinery or a PSU has won the Kaizen award at a national level competition.


    • Suggestion Scheme Corporate Awards
    Refineries Division has made great contribution through a unique initiative to harness creativity and innovation for higher productivity through the Suggestion Scheme. The Suggestion Scheme Corporate Awards for the year 2006-07 were given away during 44th IndianOil day celebrations on 1st September, 2007.
    Refineries Division is the proud recipient of four corporate awards as under:
    The Best Suggestion Award
  • The team of suggestors from Barauni Refinery of Mr. Asis Das, SMIS and Mr. S.K. Pandey, SISO were felicitated for being the winner of the Best Suggestion of the year for their suggestion on "Replacement of Existing OT Management System with a Web based Form Flow System".

    • The Best Suggestor of the Year Award
  • Mr. Tarun Chandra Thakuria, MLE of Guwahati Refinery was felicitated for winning the Best Suggestor of the year 2006-07. This Award for the Best Suggestor is presented to the employee who contributes the highest number of accepted suggestions in a year. Mr. Thakuria received the award in recognition of his contribution of 42 accepted suggestions during the year.

    • The Most Frequent Suggestor Award
  • Mr. Tarun Chandra Thakuria, MLE of Guwahati Refinery also received the Most Frequent Suggestor of the Year Award.

    • The Best Coordinator Award
    Mr. Aniruddha Chatterjee, Officer (A&W) of Barauni Refinery was felicitated for winning the Best Coordinator of the Year 2006-07, for steering the scheme at his location to generate the highest number of accepted suggestions in a year i.e. 546 number of award winning suggestions and implementing 199 number of suggestions.

    Inspired IOCians
    • Common Wealth Power Lifting Championship at New Zealand
      • Mr. Girish Joshi , Master Operator and Prasant Patel , S/o of Mr. Harbhan Patel , Technician Grade I of Mathura Refinery (sponsored by IndianOil) participated in the Common Wealth Power Lifting Championship Competition held at New Zealand from 6th to 8th Dec.'07. Both the participants have bagged four Gold Medals each in Master II and Sub-Junior Group categories respectively.
    • PetroFed Oil & Gas Industry Award 2007
      • MSQ Project of Gujarat was adjudged best under Project Management category (500 - 5000 crore) of PetroFed Oil & Gas Industry Award 2007. The PetroFed awards were given away by Hon'ble Union Minister of Petroleum & Natural gas on 21st March 08 in Mumbai.
      • Mr. Naba Kumar Kalita, Master Technician of Guwahati Refinery was awarded the PetroFed Award under the category "Innovator of the Year - Individual" in recognition to his innovative in-house development of Mechanical Seal in crude auto-sampling system. He received a citation and cash award of Rs. 2 lakhs.
      • Mr. Kalita, was also declared winner of "Shram Veer Award-2007" by Assam Productivity Council during Productivity Week Celebrations - Feb'08 held at Guwahati Refinery.
    Refinery-wise Highlights
    Guwahati
    • No lost time accident in the financial year , completed 1563 days equivalent to 16.8 MMH since 20.12.03 without any lost time accident.
    • Highest ever HDT output of 623 TMT in the year 2007-08 against previous best of 582.8 TMT in 2005-06.
    • New PLC based Automatic Load Shedding scheme implemented in ABB Ac160 PLC system condemning trouble prone August CS300 PLC. Logic developed for both steam & power load shedding. System put on line and inaugurated on 28.07.07.
    • Continuous Emission Monitoring System (SO2/NOx Analyzers) of CDU commissioned and inaugurated on 03.11.07.
    • 6 Nos. of state-of-the-art Nucleonic type Interface level instruments for Coke drum R1A & B commissioned on 21.07.07.
    • Guwahati Refinery won the Bronze Trophy for its electronic newsletter GR E-news awarded by Association of Business Communicators of India ABCI, Mumbai.
    • Town Official Language Implementation Committee (TOLIC) (PSU) under the Chairmanship of ED, Guwahati Refinery won the First Prize among TOLICs of North Eastern Region for best performance in Official Language Implementation.
    Barauni
    • In addition to highest ever crude throughput (2007-08: 5640 TMT, 2005-06: 5553 TMT), Barauni processed highest ever 12.8% HS crude as against 11.3% in 2003-04. It also processed highest ever HS crude in a month (76.6 TMT, 14.4% on crude) in June'07. Barauni also achieved highest ever MS production in a month of 69.5 MT in Dec 07.
    • Barauni achieved highest ever RFCCU and DHDT throughput of 1445 TMT and 2405 TMT respectively in 2007-08 surpassing its previous best of 1383 TMT and 2345 TMT respectively in 2005-06.
    • Successful execution & commissioning of Yield & Energy Optimization project in AVU I and AVI-II was done in Feb/Mar'08 and Sep-Oct 07 respectively. The implementation of the projects resulted in improvement in preheat of Crude from 225 to 275 deg C and also improvement in distillate yield.
    • Replacement of Coke cutting Kelly system of Coker-A was done in Oct'07 with the help of German technology.
    • Commissioning of 3 new pumps for reuse water service at Barauni Refinery in April'2007. They were needed as backup for the existing 3-reuse water pumps. The pumps can discharge either into the reuse water line or to the river Ganga . The installation of these 3 new pumps of head 65 meters and capacity 360 M3/hr has helped in augmentation of effluent water reuse.
    • Commissioning of new LPG Treatment Unit (LTU) was done in Dec'07. This unit will help in increasing HS crude processing at Barauni.

    Gujarat
    • Gujarat Refinery achieved record unit throughputs and production of various products as indicated below:
      • Figs in TMT
      Unit outputYear 2007-08 *Previous Best
      LAB812750(2006-07)
      HCU15201437(2006-07)
      ProductsYear2007-08Previous Best
      LPG410407 (2006-07)
      Total MS1202918(2006-07)
      LAB 133133122(2006-07)
      HSD total52605088(2006-07)
      BITUMEN594542 (2003-04)

      * (Provisional)

    • FCCU, HCU, DHDS and LAB were operated at 114 %, 127 %, 123 % and 113 % of the design capacities respectively in order to maximize crude processing and thereby improving GRM.

    • DHDS Unit throughput increased to 255m3/hr (1.7 MMTPA) from 245 m3/hr after implementing the process scheme for reducing the excess Recycle gas ratio.

    • With additional NG/RLNG supply, the NG/RLNG firing in GTs have been increased to 175.5 TMT in 2007-08 compared to 151.6 TMT in 2006-07. The has helped in improving GRM of Refinery.

    • Improved shutdown management - saved 7 days shutdown duration in FCCU resulting in GRM improvement of Rs 24 Crores. VBU shutdown completed ahead of schedule by 1.5 days in April'07.

    • Commenced first ever dispatch of Black oil (Furnace Oil) through BTPN rake. The 1st rake was loaded on 25.07.2007 after carrying out successful modification in the BTPN Tank Wagon Loading gantry for FO loading.

    • First rake of LSHF despatched by BTPN rake on 01.09.07 converting the existing LDO handling facilities. This will help in reducing DHDS load and thereby allowing increased crude processing in the Refinery.

    • Dispatched Px-feed (2.4 TMT) to Panipat Refinery in May'07 during Mathura Refinery shutdown period for sustaining their plant operations.

    • PSA unit of MSQ was commissioned successfully on 20th May 2007.

    • Successfully commissioned the scheme relating to recovery of Hydrogen from CCRU off gases on 13th April 2007. Saving estimated Rs. 19.50 crores per annum.

    • Achieved fire free period of 1020 days (from 16th June 2005 to 31st March'08) during the year 2007-08.

    Haldia
    • Record production of Bitumen of 438 TMT (previous best 434 TMT in 2006-07) and record production of ATF of 316 TMT (previous best 282 TMT in 2006-07) has been achieved in 2007-08.

    • Facility for Ethanol Blending in MS has been completed in April 2007.

    • As a part of modernization of Tank Wagon gantry no - 1, the existing loading hoses have been replaced with loading arms and BTPN rake loading facilities. FO BTPN rake loading has been done successfully.

    • Conversion of Tk-870 (LOBS tank of 5000KL) to Bitumen service for higher export parcel size (present 8 TMT from that of 3 TMT earlier) for increased Bitumen production and higher profitability. First parcel has been exported in Sept'07 from this tank.

    • Haldia Refinery was selected as Nodal Refinery for implementation of Cenvat Accounting in SAP including Common Chemicals. Help provided in implementation in Mathura, Barauni, Guwahati and Gujarat for implementation of the same.

    • Haldia Refinery implemented SAP Leave module and integrated with the legacy system on 10th May 07.

    • Replacement of 2.0 KM of HP, LP and H2s flare headers was completed along with 34 nos. of supporting columns during shutdown of Sep-Oct 07. Replacement of Hydrocarbon Flare Tip (Incoloy-800H Metallurgy) & Acid Flare Tip (Inconel-625 Metallurgy) along with Retention Ring and Flame Stabilizer was also carried out during the shutdown of Sep-Oct 07.

    • CS Flue gas stack (100 m) of RFCCU has been replaced with newly designed SS-316L stack in Oct'07 to combat severe corrosion leading to frequent perforation of shell.

    • Organized training on CDWU commissioning & operation for Petronas (Malaysia) personnel in three batches (14 nos per batch) of 21 days each with active support of IMA. Haldia Refinery also imparted training to the personnel of National Oil Company, Libya on Environment Management System during Jan'08 - Mar'08.

    Mathura
    • Highest Ever Crude output in a month of 818.4 TMT during Nov-07 against previous best of 795.96 TMT in Dec-96.

    • Highest ATF production of 75.8 TMT during Dec-07 against previous best of 69.8 TMT in Sept'06.

    • Highest ever HS crude processing of 59.4% done in 2007-08 against earlier best of 56.5% in 2005-06.

    • Highest Bitumen production of 711 done in 2007-08 against previous best of 677.9 TMT in 2006-07.

    • First IndianOil Refinery to install APH in Visbreaker furnace. New glass-lined APH, ID/FD fans and low NOx burners were installed as a part of the project. The facilities were hooked up during June-July-07 shut down and commissioned in Aug-07.This has resulted in fuel savings of 2000 MT/year.

    • Taking a cue from Shell Business Improvement Programme study, steam-heated Feed heater was installed in FCCU feed service on a fast track. A redundant re-boiler was reengineered in-house and redeployed in new service. The scheme helped achieving higher throughput in Debutaniser section, which was earlier limiting. CDU main fractionator pressure reduced from 1.3 to 1.0 kg/cm2 for achieving energy savings to the tune of 640 thousand US$/Yr. Also, steam generation load shifted from Boiler to HRSG by operating the Boiler near turn down load for overall benefit of around 74 thousand US$/Yr under the Shell PFI.

    • Replacement of Circulating Water headers in AVU done for the first time since the commissioning of Refinery. The massive replacement job included pre-fabrication of 2100 In-dia piping (8" ~ 40" NB), extraction of the existing supply & return headers from the intermediate pipe-rack (total approx 200 metre long pipe-rack), re-insertion of new pipes (using cranes and electrical winches) and in-situ welding of 1100 India,

    • Modernisation of campus wide network from ATM (Asynchronous Transfer Mode) to Gigabit Ethernet technology with creation of VLANs (Virtual LAN), incorporation of redundant routes for all the critical locations, and activation of STP (Spanning Tree Protocol) between redundant links has been accomplished and network with improved reliability commissioned on 5th March 2007.

    Digboi
    • Digboi Refinery completed 1848 Fire Free days as on 31.03.08

    • Steam Trap Management and Condensate Recovery: Study carried out by M/s Forbes Marshall, Pune and the defective steam traps (438 out of 458 nos) repaired/replaced by them. A saving of 2.8 MT/Hr of steam has been achieved.

    • Model based Multi-variable Advanced Process Control has been commissioned in Solvent Dewaxing Unit in August 2007.

    • Contract Section of AOD was the 1st amongst all the IOCL refineries to release on-line Purchase Order in SAP.

    Panipat
  • In addition to highest ever crude output of 12.83 MMTPA, Highest ever OHCU/HCU, DHDS/DHDT outputs achieved during the year 2007-08:
    • Figs. In TMT
    UnitsYear 2007-08Previous Best (Year)
    OHCU/HCU35002342.9 (2006-07)
    DHDS/DHDT35002431.3 (2006-07)

  • Highest ever production of the following products was achieved during the year 2007-08 as detailed below:
    Unit outputPrevious Best
    LPG426.7287.9 (2006-07)
    Naphtha815.9593.4 (2006-07)
    ATF682.9491.3 (2005-06)
    HSD5942 4097.6 (2006-07)
    HSD (Euro-III)1748.4 1198.3 (2006-07)
  • Panipat processed highest ever 78.8% High Sulfur crude, exceeding their earlier best of 70.2% in 2006-07. This has enabled GRM improvement.
  • Panipat Refinery achieved the unique distinction of being the first PSU Refinery in India to successfully complete On-Line Spalling of Heater tubes in Coker Unit.
  • CII selected Kaizen presentation on reduction of MTBF with installation of vortex breaker using refractory bricks inside the channel box of 55/56-E-102 to stop frequent equipment failure resulting un-interrupted PREP Sulphur unit operation. This Kaizen was presented in National Kaizen conference at Delhi on 9th-10th October 2007.
    • Enabling Efficiency - HR Initiatives
    • Recruitment Exercise for selection of 350 Engineers/Officers in various disciplines for IndianOil through All India Open Advertisement successfully handled by the Refineries Division. Another exercise to recruit 200 experienced engineers initiated in December/Jan'08 and selection process to be completed in April 2008.

    • e-Enabled workflow based on line application for processing "Medical Reimbursement" introduced on intranet w.e.f. 19th November 2007.

    • E-mail server upgraded from Exchange 5.5 to Exchange 2003. This has resulted in better Server Up time, higher reliability and Better Manageability, improved web access of e-mail, easy backup and improved Security.

    • The Performance Management System (PMS) Data Bank has been developed and implemented at RHQ and seamlessly integrated to all Refineries through Intranet. This has enabled archiving and sharing of Refinery performance data for last 20 years across all Refinery units for performance analysis and benchmarking.

    • SAP HR Time Management Module implementation completed at all Refinery locations/Ref. Hqrs, Kolkata and Mumbai offices, in June 2007.

    • In Jan'08, COIS conveyed acceptance of Refinery Division's decision of November 2006 to replicate Haldia Refinery Leave Management Module at all Refinery Division locations and Pipelines Division Leave Module at all Marketing and Pipelines locations and R&D Center with online updation provision on SAP HR Time Management Module.

    • Updated Personnel Manual uploaded on Headquarters Intranet.

    • Induction Training for newly joined officers to the Division was completely revamped with subject-wise module, field visit and management interaction in appropriate proportions. First batch underwent the redesigned module in September-October 2007 at Gujarat and Mathura Refineries.

    • Partnering with Government of India in reconstruction of Iraq by imparting training to Petroleum Sector officials of Iraq as a Corporate Business Development initiative - 8 batches completed in 2007-08.

    • 'Srijan' - Knowledge Management Portal consisting 'Manage Mentor' (HR articles ) and 'From the Legal Desk' (Quarterly judgements of CIC and other important judgements) introduced on HR Page of Headquarters intranet.

    • 'Non-Monetary Recognition Scheme' - 'Pratibha Samman' (Individual recognition) and 'Samuhik Uplabdhi Puruskar' (Group recognition) introduced for recognizing the extraordinary contributions of the employees of Refinery Units of the Refineries Division.

    • Specialized 8 weeks course on Petroleum Refining technology for the fresh batches for Chemical engineer at IIP-Dehradun was redesigned and conducted in two batches during Dec 2007 - Jan 2008 and Feb - March 2008.

    • Designed specialized training courses for non-chemical engineers; 18 Civil engineers, 12 Instrumentation engineers and 18 Electrical Engineers exposed at identified selected venues.

    • Key Process technologies and their expert faculty have been identified and virtual classrooms started and one programme on HGU module carried out in July'07.

    • Specialized training on Refinery Operations and Maintenance imparted to foreign clients from Libya, Malaysia and ENOC at Haldia and Panipat Refineries.

    • EPMS - KRA/KPI clean up exercise completed for all disciplines for assessment year 2007-08.

    • Launched superior-subordinate MOU Scheme for officers for focused Performance Management.

    • First programme to felicitate ex-IOCians (of 75 years and above age) organized at India Habitat Center, New Delhi.

    • The Corporate Communications homepage on the R-HQ Intranet, developed in-house, was launched by Director (Refineries) on the occasion of the 44th IndianOil Day.

    • Dr. Ajit Pathak, CM(CC) inducted as Media Advisor to Central Information Commission (CIC).
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