ESSAR OIL VADINAR REFINERY Mega Turnaround Sept-Oct 2011 A Bench Mark in the Refining sector looking at the large Work-scope which was completed with compressed engineering days and then fast track start-up of the units
Turnaround Maintenance Definition : In petroleum refining , turnaround means a scheduled large-scale maintenance activity wherein an entire process unit is taken off stream for an extended period for comprehensive revamp and renewal. This operation involves a lot of preparations and requires many precautions, especially at during startup.
Contents Turnaround Maintenance + Objective / Purpose + Process / Procedure + Strategy Followed + Organogram + Key Achievement/Highlights + Key Learning + What made it happen & final success + Major Counts at a glance + Sep’11 Cost : Budget Vs Actual + Duration Schedule Vs Actual
Criteria for T/A Objectives Aligned with business goals Clear, unambiguous and prioritized Measurable, objective and monitored Based on experience , scope, knowledge and data Aggressive but achievable Deliberated and agreed to key stakeholders
Turnaround Objective / Purpose + Make plant safe to operate till next outage. + Improve efficiency & throughput of plant by suitable modification. + Reduce routine maintenance costs + Perform Regulatory Inspection + Increase reliability / availability of equipment during operation + Re-establish Plant Capacity . + Upgrade technology by introducing modern equipment & Technology + Complete corrective /preventive maintenance & project work
Turnaround Objective / Purpose + To execute the turnaround with the highest possible safety record. + To achieve the best quality of workman ship. + To complete the turnaround in the shortest possible time. + To complete the turnaround at the lowest possible cost. + Revamp Jobs for Refinery capacity augmentation from 14 MMTPA to 18 MMTPA. CDU/VDU/SGU Revamp FCCU Revamp VBU to CDU Conversion Tie-ins. SRU Revamp Train: I integration Tie-ins.
Turnaround Organization - September 2011 Sr.No. Function Name 1 Head-Refinery C Manoharan 2 Chief Turnaround Manager Narada Singh 3 Overall Operation Co-Ordinator KC Swain 4 Tech.Services Co-Ordinator Satheesan V N 5 Construction Co-Ordinator G G Mehta (EPIL) 6 HSEF Dr Gopal Jayaraman 7 Turnaround manager P Rambabu 8 Turnaround planning Co-Ordinator D D Chaudhari / Jayanti Vagdoda 9 Turnaround-MIS-Co-Ordinator Hembala Dixit 10 Operation Co-Ordinator ISBL: SKM Rahman/Utility: Chitti Babu/PIT/COT: Ajay Veer 11 Engineering & Inspection Ramesh Kumar 12 Revamp/Expansion Project Manager Ramakrishna Paramhans (EPMCL) Revamp/Expansion Execution 13 Sudhir Porichha (EPIL) Manager 14 Overall Tie-ins Co-Ordinator Rakesh Kumar 15 Instrumentation S. Laxminarayan 16 Electrical Rajeev Kumar 17 Civil Ashok Srivastava 18 EPS Dhaval Doshi 19 Security Cmdt. Raghuraman 20 Admin Geojo Paul Reliability/Rotary/ Workshop 21 Amit Kumar N 22 Commercial J K Jani 23 RSM RSM
Turnaround Optimisation Program Strategic Site Turnaround TR - 0 Review Turnaround Work Scope TR - 1 Optimization Planning, Scheduling, and TR - 2 Integrated Plan Basis Integrated Plan Execution TR - 3 Techniques, T/A Management TR - 4 Post Turnaround Review
Turnaround Optimisation Program . TOP TM Ideal Overview Scope Cost Schedule Preparedness Timing Strategic Review Run Cycle (2) - 9 months Workscope Review - 6 months Execution Review - 3 months Preparedness Rev. +1 months Close Out Review
Mission for Shutdown From Chief Turnaround Manager {S R T C} SAFETY RELIABILITY TIME-BOUND COST-EFFECTIVE
Turnaround Process / Procedure + Collection of all inputs such as previous reports, procurement lead times, job lists, own and contractor resources availability etc + Gathering information from the previous turnaround by way of group discussions, reviewing previous plans and turnaround reports + Finalization of job list and freezed after challenging by experience multi disciplinary Challenging Team + Setting of turnaround run lengths and approximate turnaround duration + Preparation of work scope for next turnaround + Critical review of work scope + Breakdown jobs into specific activities + Review implementation option and resource requirement + Prepare an achievable plan and well integrated level I, II, III schedule
Turnaround Process / Procedure + Procurement of material + Split between the jobs to be carried out by Company personnel and contractor + Contract Planning + Resources for running units + Check the jobs for pre-requisites such as scaffolding, insulation removal, blinds, etc + Pre-shutdown fabrication + Progressive hand over of the execution portion to the field co-ordinators, planners, field engineers, contractor supervisors + Ensure availability of tools and construction equipment + Ensure adequate infrastructure facilities like, labour colony, canteen / space for eating for workman, medical facilities, transportation, drinking water, toilet facility etc …
Turnaround Process / Procedure + Administrative arrangements + Security arrangements + Implementation plans + Monitoring of jobs during execution + Contingency plan for Additional resources required during turnaround + Turnaround close-out
Pre Shutdown Preparation + Keep end blinds /spectacles near line flanges as per positive isolation plans indicating required date for readiness on tags. + Keep adequate numbers of Testing Spools, temporary Connections for connecting pressure gauges & drains/vents for testing of Heat Exchangers (Both Shell & Tube side) + Fabrication of Spool Pieces for Heater Pigging Jobs. + Erection of scaffolding wherever possible e.g. For Heat Exchanger, inaccessible Blind locations, control Valve s, safety valves, etc. + Lifting and shifting arrangement for control valves , Safety Valves, etc. + Provision of Power supply points at planned locations e.g. laying of additional cable if any for welding, Hydro jetting and Hydro testing M/C. + Arrangement of temp. lift and Dehumidification at defined locations.
Preparedn ess for Safe & Effective Execution + Detailing of Scope of work for all S/D Jobs + Preparation of Maintenance Execution Procedure & Work Pack for all S/D Jobs + Preparation of TBRA for all Critical S/D activities e.g. Hot jobs, Modification job, work at height or any other confined space jobs + Assignment of specific job responsibilities to a group of cross functional team e.g. team involving Maintenance, Operation, Process, Safety and Inspection + Engaging Quality & experienced contractors having good track record of executing S/D Jobs in other Refineries to the maximum extent.
Preparedn ess for Safe & Effective Execution + Inclusion of Contract Safety System in Contractor Scope + Arrangement for Pre S/D Training to Contract Manpower + Use of only Certified Tools & Tackles + Use of Flame Arrestor for all Vehicles,Trailors, Crane & Hydra + Tool Box Talk by Engineer to Contract Manpower + Strict Compliance of Safety Work Permit System + Use of General & Specific PPE’s e.g. Life line belt, Fall Arrestor + Certified Lifting plan for heavy lift + Certification of Scaffolds & use of “Safe to use” Tag
Facilities and Services (F & S) 1) Contractor office space / working area – Space for contractor’s offices have been provided in the S/D yard. Some of the contractors will have to be located inside the units (from logistic point of view). 2) Canteen facilities for contractor SAB : Own arrangement – Space will be provided by EOL. ECIL : Own arrangement – Space will be provided by EOL. Other contractors: Tea will be served at work place as free of charge to all the contract labour at 01.00 hr, 4.00 hrs, 7.00 hrs, 10.30 hrs, 15.30 hrs, 16.30 hrs (incl W/s & utility) Two sheds are being constructed. One at shutdown yard, & another tent in old parking area (tent by admin along with lighting. Power supply by EOL). Required tables, chairs, etc will be arranged by Admin. Lighting arrangement in tin sheds will be provided by elect dept. 3) Canteen facilities for officers:. Location will be at area in between CCB & LAB. Tables, chairs, carpet & lighting is being organized by Admin and power supply by electrical dept.
Facilities and Services (F & S) 4) Drinking Water Facilities : 5) Shutdown office: 6) Urinals & Toilets: Sufficient no of toilets and urinals have been constructed in shutdown yard. 7) Resting Place : Separate tents arranged for Dining and Rest room for different contract manpower as well as for engineer. Near Shutdown yard to avoid manpower movement. 8) First Aid office: Central first aid tent will be located in front of Lab near E-W road. It will be supplemented by paramedic officer / doctor on round the clock basis and one ambulance. 9) Accommodation for Labour / Transport. Accommodation for 10000 Labours have been booked in Labour colony. For transporting Labours from labour colony to refinery, our trailers will be used and necessary railing arrangement is being done in our workshop for safety. In addition to this permission will be given for walking from labour gate to workplace on the fixed route. 10) Office space for foreign expatriates : 11 Timing: Working time: 08.00 to 20.00 & 20.00 to 8.00 hrs. Lunch time: 12.30- 13.30 hrs in two batches (30 min break) Dinner: 22.00 to 23.00 hrs In two batches Radiography timing : It will be declared on time to time & followed
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