PANIPAT REFINERY

HIGHLIGHTS - 2010

Major Achievements

Dear Colleagues,

At the onset of the New

Year and the new
decade, I wish you and
members of your family,
Safety, health, happiness
Revamping of Panipat Refinery from 12 MMTPA to 15 MMTPA and prosperity.
has been successfully completed and commissioned in Nov'2010.
May 2011 be a year of
success and fulfillment
for each one of you .

Rajkumar Ghosh
ED(i/c)

¨Indian Oil's first Naphtha Cracker Unit at PANIPAT went on-stream

on 11th Mar'2010
 Operational Highlights

¨ Panipat Refinery successfully met the supply requirement of BS-III / IV MS & HSD as per auto
fuel policy.
¨ Highest ever Refinery distillate yield of 81.6% against previous best of 80.66% in 2009 is
expected to be achieved in 2010.
¨ Panipat Refinery has recorded highest ever production of following products in the calendar
year. The highest production numbers for the current year and the previous best achieved are
indicated below (includes projected figs. for Dec'10):

Production 2008 2009 2010

LPG 442.6 487.1 559.7

MS (Total) 855.3 1077.1 1195.9

ATF
661.2 706.8 764.6

HSD(Total) 5829.8 6283.2 6050.9

¨ Panipat Refinery has recorded highest ever T'put of following units in the current calendar year.
The highest T'put for the current year and the previous best achieved are indicated below
(includes projected figs. for Dec'10):

2008 2009 2010

HCU 1765.4 1903.2 1908.3

DHDS 675.2 759.2 865.4

433.9 541.4 544.9

CCRU

RFCCU 756.6 808.7 863.6

DHDT 2972.2 3154.8 3323.8

PTA 243.6 365.5 409.8

¨ Panipat Refinery has achieved lowest ever MBN of 54 MBTU/BBL/NRGF in the year 2010
(previous best of 57 in 2009).
Major Highlights

On 19th May'10, a major off site disaster mock drill

was carried out under the supervision of expert
representatives of “National Disaster Management
Institute, (NDMI), Nagpur”. A contingent of
ITBP also took part in the drill.

Indegenous Mangla crude from Rajasthan field of Cairns Energy delivery to refinery started
w.e.f 12th Jul' followed by successful processing at PR.

Bijwasan – PANIPAT (BPPL) dedicated Naphtha Transportation Pipeline was

commissioned on 24th April, 2010.

RLNG consumption at PR started from 6th Aug'10 in FG network of Refinery.

Two new LPG mounded bullets having capacity 2873 M3 each commissioned on
26th Aug'10.

Dedicated line for pumping PCK in pipeline for transportation of E- IV fuel

commissioned on 24th Aug'10

Former President Dr. APJ Kalam visited Panipat

Complex on 13th March 2010. Open sessions with the
Missile Man of India at MCR, Community Centre for
employees, Children and family members of Panipat
Complex were organized.
Eighth Inter School Rural sports was organized
from 14th -16th November 2010. 82 Schools of
nearby villages participated.

Padhmavibhushan Professor M.M.Sharma

interacted with chemical engineers and officers of
Panipat Complex on 21st July,2010.

15000 trees were planted along roadside for ROB

and township roads, Green Belt, Bio-drainage area
and nearby villages.

9th Flower Show was organized on 27th -28th

February, 2010

Complex comparative Analysis was carried out

with Reliance, Mitsubishi, Samsung – to
benchmark PTA product.
 Chairman's Press Conference was organized on 1st
May 2010 at the flag off of first truck polymers. Director
(R) Shri B.N. Bankapur, Director (HR) Shri V C
Agrawal and Director Pipeline Shri K.K.Jha were also
present

Bone Densitometry Camp organized at PR Hospital on 30/09/2010 in which total 100

Nos. were checked in this camp for bone density.

Popular talk on preventive aspect of heart disease was given by renowned Cardiac
Surgeon Dr. Trehan on 26/09/2010.

The intranet based portal e-suggestion module has been developed and launched on
4th Feb.'10 during the suggestion fortnight celebration

TPM relaunched on Jan 21st -2010 for next

higher level award.
 Energy conservation schemes/measures
implemented during the current year:

ŸCondensate recovery with interconnection of

condensate drain header of UB SCAPH to
condensate recovery tank of IPP Air Cooled
Condenser (5 MT/hr condensate).
ŸCondensate recovery from CPP, MCR, Adm. Bldg.
& SS-28 VAMs condensate drain.(8 MT/hr
condensate).
ŸVarious Energy conservation schemes viz. Flare gas
recovery system for PR/ PX PTA and PREP flares,
Mass flow meter installation in transfer line of HPS
and Bitumen, ETP Biogas Recovery in SRU
Incinerator etc were implemented.
Operational Improvement Measures

Ÿ Revamp of side cut naphtha circuit in AVU-1 to cater increased feed

processing post P15 Implemented during P15 revamp shutdown.

Ÿ HP Breech Lock Exchanger leak Rectification (05-EE-HP-05A/B)

Ÿ Replacement of Vacuum column packing in OHCU

Ÿ
Ÿ Modification of Stripper Reboiler Draw-off well

Ÿ M&I inspection of units AVU-I, DCU, PX-1, PX-2, PTA, PR- sulfur
block & other inspection activities during P-15 revamp shutdowns of
OHCU, DHDT & PRE-HGU carried out within stipulated schedule.

Ÿ Reliability improvement of Crude Heater in CDU-I by carrying out

replacement of entire damaged ceramic fiber lining and corroded
casing plate in radiation zone.

Ÿ Remaining life assessment of (Boiler-2) was carried out after a service

life of around 12years.

Ÿ Comprehensive inspection & failure analysis of both the Parex

Chambers were carried out through expert agency during recent M&I
shutdown.
Ÿ Technical Study / preparation of technical specification for advanced
cooling water & fire water treatment through expert consultant : Study
completed.

Ÿ On-line health assessment of bottom

plates of 03nos. Crude Oil Tanks
through AET ( Acoustic Emission
Testing): AET of Crude oil tank #
302, 304 & 308 carried out to assess
condition of bottom plates.

Ÿ Inspection & testing of 2nos. Propylene Horton Spheres (HS-8 & HS-9)
as per SMPV rules carried out.
Ÿ Installation of new skin thermocouples in heater in PX-1: 24 nos. of
Extracto pad type skin thermocouple were installed in Platformer
heaters for the first time for proper monitoring of skin temperature.
Ÿ Reliability improvement through up gradation of metallurgy

Ÿ Augmentation of Inspection Archives and gadgets

Ÿ The Intranet based portal e-suggestion module has been developed and
launched on 4th feb’10 during the suggestion fortnight celebration. The
module has been implemented throughout the Refineries Division.

Ÿ Intranet based form flow applications (e-Suvidha) were developed and

implemented during the calendar year 2010 including festival advance
reqistration of TPM and Kaizen etc.
 Awards

Indira Gandhi National Award for Hindi Implementation.

¨Panipat Refinery has been awarded the Jawaharlal Nehru Centenary award
(first Prize group 1) for 2009-10(insittuated by MOP&NG) for Energy
Performance in the category of Refineries (including private sector) having
composite Energy Factor >5

The 'Naphtha Cracker Project – Panipat' team has been selected as joint winner
for the 'Petrotech' Project Management (Team) Award – 2010
 Panipat Naphtha Cracker was honoured with “Shrestha Suraksha
Puraskar” for Project Construction.

Ÿ The Refinery has won prestigious OISD award (first prize) for refinery
category for the year of 2009-10 and individual category to two employees
performing outstanding job in safety.

Ÿ Second Prize towards Furnace /Boiler Insulation effectiveness in the

category of furnace having heat Duty 500 MMKcal/hr during Oil and Gas

Panipat Refinery received Safety awards-2009 “Prashansha Patra Award (in

the manufacture sector category) from National Safety Council, India

Panipat Refinery won “Greentech Gold Safety Award” at National

Conference organized at Goa.