1. BPCL experience in Benchmarking and Performance improvement.
BPCL Mumbai Refinery
Pre-Conference on “Benchmarking in Downstream Industries”.
BPCL experience in Benchmarking and Performance improvement.

2. BPCL Mumbai Refinery.
Capacity : 12 MMTPA.
Crude Units : 3
FCC’s : 2 , MTBE : 1
Hydrocracker : 1
Diesel Hydrotreater : 1
Integrated LOBS with hydrocracker unit – First of its kind capable of producing Gr-II Base Oils.

3. Performance Evaluation(Traditional)
MOU parameters
Crude Thru' put.
Distillate yield.
Fuel & Loss.
Specific Energy Consumption.
Safety.

4. Performance Evaluation
Participated in the Asia-Pacific Fuels Refinery performance Analysis conducted by M/s Solomon Associates Inc. in
1996 & 1998.

5. Performance Evaluation
M/s Solomon parameters
Process Parameters
a) Refinery Utilization
b) Hydrocarbon Inventory
c) Volumetric expansion Index.
2. Energy Parameter
a) Energy Intensity Index(EII)

6. Performance Evaluation
M/s Solomon parameters
Personnel Parameters
a) Equivalent personnel per EDC.
b) Personnel cost Index in US $/EDC.
4. Maintenance Parameters
a) Maintenance Index

7. Performance Evaluation
M/s Solomon parameters
Financial Parameters
a) Cash operating Expenses.
b) Return on Investment

8. Performance Evaluation
M/s BPCL ranking
1st quartile performance in
Refinery Utilization
Volumetric Expansion index
Operational availability of units
Return on Investment
2nd quartile performance in
Inventory
Maintenance Index
Mechanical availability of units.

9. Performance Evaluation
M/s BPCL ranking
3rd quartile performance in
Total cash operating expenses
Net cash margin
4th quartile performance in
Energy Index
Number of personnel

10. Performance Evaluation
Participated in the Operational Benchmarking of Indian PSU refineries conducted by M/s Shell Global Solutions Inc. in
2003/04 & 2004/05. (Through Centre for High Technology)

11. Performance Evaluation
M/s SGS parameters
Energy & Hydrocarbon Loss Management
Site CEL Index
Energy Index
Generation Index
Fuel & loss Index
Refinery Hydrocarbon Loss(% wt on Intake)
2. Human Resources Management
Overall Shell Personnel index
Operations Personnel index
Maintenance Personnel index
Own staff Overtime % of Standard Activities
Contractors % of Standard Activities
Labour Costs (US $ millions/NSP)

12. Performance Evaluation
M/s SGS parameters
Maintenance Performance, Reliability & Availability Optimization
Site maintained availability (%)
Crude Distiller Unplanned Downtime (%)
Maintenance Cost (US $/MUc)
Maintenance Effort (Hour/MUc)
4. Environmental Performance
CO2 Emission (T/T of Crude + Feedstock)
VOC Emission (% Wt. on Crude + Feedstock)
Oil discharge to Environment (ppm)
Oil discharge at Refinery Fence (g/T C+F)

13. Performance Evaluation
M/s SGS parameters
Financial Performance
Site Gross Margin (US $/bbl)
Site total Operating Cost (US $/bbl)
Site Energy Costs (US $/bbl)
Cash Operating Expense (US $/bbl)
Site Net Margin (US $/bbl)

14. Performance Comparison

18. Comparison of Solomon and Shell benchmarking

19. Shell Benchmarking advantage :
Recommendations of Shell benchmarking
Shell Benchmarking advantage :
Comparison with other PSU refineries in similar duties and operational conditions.
Recommendations for reduction of Gap.
Unit wise energy comparison with best.
Function wise manpower comparison helps.
Cross functional team for finalizing the Shutdown scope.
Steam letdown – Pressure reducing turbine being put up.
Strengthening of Advisory / Inspection Dept.

20. Performance Evaluation
Benefits of Benchmarking :
Streamlining of the Data collection.
Compare with the Regional and Global Peers.
GAP identification.
GAP reduction by performance improvement.

21. BPCL Mumbai Refinery
Thank You