from the Commissioning and Stabilization of MS & HSD Quality up - PowerPoint PPT Presentation

BPCL – Kochi Refinery Kochi Refinery Challenges Faced & Lessons Learnt from the Commissioning and Stabilization of MS & HSD Quality up gradation Units C.K. Soman Jaikishen C Nath DGM (Power & Utilities), BPCL KR SM(Power & Utilities), BPCL KR

Road Map Kochi Refinery Growth Map of BPCL- KR through the years 2006-12 Challenges faced in bringing units online Major failures during the initial phase Learnings from the project

The Refinery that was; circa 2006 Kochi Refinery CDU 1 GT 1 19MW CDU 2 STG 12MW FCCU GRID 4MW DHDS TOTAL 35MW

The Capacity Expansion & Modernisation Project (CEMP II) Kochi Refinery CDU 1 NHT CCR GT 1 19MW GT 2 34MW CDU 2 VGO DHS STG 12MW 220kV Yard FCCU CDU2 Augmentation GRID 4MW 33kV &6.6kV DHDS Others TOTAL 35MW levels

Objectives of the Project Kochi Refinery Improve product quality to Euro III/ IV levels Enhance refining capacity by 2MMTPA Flexibility for further product quality up gradation

Process Units Added as part of CEMP II Kochi Refinery VGO-Hydro-desulphurisation (VGO-HDS) unit of 1.7 MMTPA capacity (M/s. UOP LLC, USA) Continuous Catalytic Regeneration Reformer (CCR Reformer) of 0.85 MMTPA and Naphtha Hydro-Treater (NHT) Unit of 0.85 MMTPA capacity (M/s. UOP LLC, USA) Revamp of Crude Distillation Unit II (CDU – II) from 3.0 MMTPA capacity to 5.0 MMTPA 100 TPH Utility Boiler, 72 TPH HRSG and matching offsite & other facilities

Changes in Electrical System Kochi Refinery Addition of 34MW GTG Augmented grid backup through 220kV substation Replacement of obsolete 11kV Generation bus 33kV Distribution 6.6kV Utilisation

Challenges - Post CEMP II Electrical System Kochi Refinery Process units commissioned ahead of power system elements Load doubling to 60MW New GTG in the commissioning stage 220kV grid backup system slated for completion in first quarter of 2012

Pre CEMP II Electrical Distribution System Kochi Refinery KSEB2 KSEB1 66/11kV 66/11kV 11kV Link 1 Link 2 GT1 STG 11kV

Load Growth Since Jan 2010 Kochi Refinery Plant load recorded Jan-10 to Jul-11 Peak load recorded Linear (Peak load recorded) 56 56 56 55 51 51 51 48 48 44 42 38 38 37 37 37 36 36 35 Jan 10 Feb 10 Mar 10 Apr 10 May 10 Jun 10 July 10 Aug 10 Sep 10 Oct 10 Nov 10 Dec 10 Jan 11 Feb 11 Mar 11 Apr 11 May 11 Jun 11 July 11

Operation Philosophy Kochi Refinery Run the new units with power from the GTG being commissioned Or Run all the generators in parallel with the grid Parallel operation was chosen for augmenting reliability

GT2 Implementation of the chosen mode 33kV, 25MW Kochi Refinery VGO HDS,NHT CCR,CDU2 New Tie 1 Tie 2 Tie 4 STG GT1 HT 101 23MW UTILITY,DHDS, Link 2 FCCU,CPP Temporary Link AUX,CDU1 2101 11MW Link 1 CDU2 Old, PRU, KSEB1 ARU,PIBU, N/R, Colony KSEB2

Challenges - Post CEMP II Electrical System Kochi Refinery 66kV grid backup designed for 20 MVA; other industries also fed from this line KSEB IMPORT Outage of New GTG, loads 9% TG the grid lines to 28MVA 1% approx STG GTG1 10% 33% Load shedding turns off when in parallel GTG2 47% Old units also affected

Tiding over and Learning Kochi Refinery Shed the new units in tandem with the GTG outage to avoid overloading the grid lines Utility systems to stabilise before the process units.

Reliability issues faced Kochi Refinery Revamp of old 11kV generation bus also included in CEMPII BHEL commissions the panel as part of GTG package. Flash over in May 2011 All units affected as the generator bus had tripped.

Reliability issues faced Kochi Refinery Flash caused by arcing of insulating material Material found arcing even while meggering at 5000V. Same material used all through, had to be removed

Tiding over and Learning Kochi Refinery Material issues and other rectifications to be addressed by BHEL during annual turn around Concept of mixing revamps with unrelated projects to be reviewed

Major Failures Kochi Refinery Input transformer of RGC motor in CCR UNIT burnt. 6.6MVA transformer was supplied by Transfor, Switzerland

Tiding over and Learning Kochi Refinery Several teams were formed under an umbrella leadership. Division of jobs coupled with group synergies of being under umbrella leadership brought back the plant by sourcing and commissioning a new transformer within a short span of 16 days.

Learnings in a Nutshell Kochi Refinery Commissioning and stabilisation of the power system elements like generators, substations etc to be completed prior to the process unit commissioning The revamp and such other jobs not directly related to the main project but combined with it, shall be reviewed and monitored separately

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