Challenges Faced & Lessons Learnt from the … · BPCL –Kochi Refinery C.K. Soman DGM (Power & Utilities), BPCL KR ... directly related to the main project but combined with it,

Kochi Refinery

BPCL –Kochi Refinery

C.K. Soman

DGM (Power & Utilities), BPCL KR

Jaikishen C Nath

SM(Power & Utilities), BPCL KR

Challenges Faced & Lessons Learnt from the Commissioning and Stabilization of MS & HSD Quality up gradation Units

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

Road Map

Kochi Refinery

The Refinery that was; circa 2006

CDU 1 CDU 2 FCCU DHDS

GT 1 19MW STG 12MW GRID 4MW TOTAL 35MW

Kochi Refinery

The Capacity Expansion & Modernisation Project (CEMP II)

CDU 1 CDU 2 FCCU DHDS

GT 1 19MW STG 12MW GRID 4MW TOTAL 35MW

NHT CCR VGO DHS CDU2 Augmentation

Others

GT 2 34MW 220kV Yard 33kV &6.6kV levels

Kochi Refinery

Improve product quality to Euro III/ IV levels

Enhance refining capacity by 2MMTPA

Flexibility for further product quality up gradation

Objectives of the Project

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

Process Units Added as part of CEMP II

Kochi Refinery

Addition of 34MW GTG

Augmented grid backup through 220kV substation

Replacement of obsolete 11kV Generation bus

33kV Distribution

6.6kV Utilisation

Changes in Electrical System

Kochi Refinery

220kV grid backup system slated for completion in first quarter of 2012

Load doubling to 60MW

New GTG in the commissioning stage

Process units commissioned ahead of power system elements

Challenges -Post CEMP II Electrical System

Kochi Refinery

Lin

k 2

KS

EB

2

KS

EB

1

ST

G

GT

1

Pre CEMP II Electrical Distribution System

Lin

k 1

11kV

11kV

66/11kV 66/11kV

Kochi Refinery

Load Growth Since Jan 2010

36 35

36 37 37

38 37

38

42 44

48 48

51 51

56 55

56

51

56

Jan

10

Fe

b 10

Ma

r 10

Ap

r 10

Ma

y 10

Jun

10

July

10

Au

g 10

Se

p 10

Oct 10

No

v 10

De

c 10

Jan

11

Fe

b 11

Ma

r 11

Ap

r 11

Ma

y 11

Jun

11

July

11

Plant load recorded Jan-10 to Jul-11

Peak load recorded Linear (Peak load recorded)

Kochi Refinery

Parallel operation was chosen for augmenting reliability

Or Run all the generators in parallel with the grid

Run the new units with power from the GTG being commissioned

Operation Philosophy

Kochi Refinery

VGO HDS,NHT

CCR,CDU2 New

Tie

4 T

ie 2

Tie

1

UTILITY,DHDS,

FCCU,CPP

AUX,CDU1 Lin

k 2

K

SE

B2

KS

EB

1

Te

mpora

ry L

ink

CDU2 Old, PRU,

ARU,PIBU, N/R,

Colony

ST

G

GT

1

GT

2

Lin

k 1

33kV,

25MW

HT 101

23MW

2101

11MW

Implementation of the chosen mode

Kochi Refinery

66kV grid backup designed for 20 MVA; other industries also fed from this line

Outage of New GTG, loads the grid lines to 28MVA approx

Load shedding turns off when in parallel

Old units also affected

Challenges -Post CEMP II Electrical System

GTG1

33%

GTG2

47%

STG

10%

KSEB IMPORT

9%TG

1%

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.

Tiding over and Learning

Kochi Refinery

Reliability issues faced

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.

Kochi Refinery

Reliability issues faced

Flash caused by arcing of insulating material

Material found arcing even while meggering at 5000V.

Same material used all through, had to be removed

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

Tiding over and Learning

Kochi Refinery

Major Failures

Input transformer of RGC motor in CCR UNIT burnt.

6.6MVA transformer was supplied by Transfor, Switzerland

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.

Tiding over and Learning

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

Learnings in a Nutshell

Kochi Refinery

Thank you

Thank you