3_C.K. Soman.pdf - World Petroleum Council

Objectives of the ProjectKochi RefineryImprove product quality to Euro III/ IVlevelsEnhance refining capacity by 2MMTPAFlexibility for further product quality upgradation

Process Units Added as part of CEMP IIKochi RefineryVGO-Hydro-desulphurisation (VGO-HDS) unitof 1.7 MMTPA capacity (M/s. UOP LLC, USA)Continuous Catalytic Regeneration Reformer(CCR Reformer) of 0.85 MMTPA andNaphtha Hydro-Treater (NHT) Unit of 0.85MMTPA capacity (M/s. UOP LLC, USA)Revamp of Crude Distillation Unit II (CDU – II)from 3.0 MMTPA capacity to 5.0 MMTPA100 TPH Utility Boiler, 72 TPH HRSG andmatching offsite & other facilities

Changes in Electrical SystemKochi RefineryAddition of 34MW GTGAugmented grid backup through 220kVsubstationReplacement of obsolete 11kVGeneration bus33kV Distribution6.6kV Utilisation

Challenges -Post CEMP II Electrical SystemKochi RefineryProcess units commissioned aheadof power system elementsLoad doubling to 60MWNew GTG in the commissioningstage220kV grid backup system slated forcompletion in first quarter of 2012

KSEB1Pre CEMP II Electrical Distribution SystemLink 1STGGT1Link 2KSEB2Kochi Refinery66/11kV66/11kV11kV11kV

Load Growth Since Jan 2010Kochi RefineryPlant load recorded Jan-10 to Jul-11Peak load recordedLinear (Peak load recorded)5655565648 4851 5151424436353637 37383738July 11Jun 11May 11Apr 11Mar 11Feb 11Jan 11Dec 10Nov 10Oct 10Sep 10Aug 10July 10Jun 10May 10Apr 10Mar 10Feb 10Jan 10

Operation PhilosophyKochi RefineryRun the new units withpower from the GTG beingcommissionedOr Run all the generators inparallel with the gridParallel operation was chosenfor augmenting reliability

Challenges -Post CEMP II Electrical SystemKochi RefineryKSEB IMPORT9%TG1%STG10%GTG247%GTG133%66kV grid backup designedfor 20 MVA; other industriesalso fed from this lineOutage of New GTG, loadsthe grid lines to 28MVAapproxLoad shedding turns offwhen in parallelOld units also affected

Tiding over and LearningKochi RefineryShed the new units in tandemwith the GTG outage to avoidoverloading the grid linesUtility systems to stabilisebefore the process units.

Reliability issues facedKochi RefineryRevamp of old 11kV generationbus also included in CEMPIIBHEL commissions the panel aspart of GTG package.Flash over in May 2011All units affected as thegenerator bus had tripped.

Reliability issues facedKochi RefineryFlash caused by arcing ofinsulating materialMaterial found arcing evenwhile meggering at 5000V.Same material used allthrough, had to beremoved

Tiding over and LearningKochi RefineryMaterial issues and otherrectifications to be addressed byBHEL during annual turn aroundConcept of mixing revamps withunrelated projects to bereviewed

Major FailuresKochi RefineryInput transformer ofRGC motor in CCR UNITburnt.6.6MVA transformerwas supplied byTransfor, Switzerland

Tiding over and LearningKochi RefinerySeveral teams were formed under anumbrella leadership.Division of jobs coupled with groupsynergies of being under umbrellaleadership brought back the plant bysourcing and commissioning a newtransformer within a short span of 16days.

Learnings in a NutshellKochi RefineryCommissioning and stabilisation of thepower system elements like generators,substations etc to be completed prior tothe process unit commissioningThe revamp and such other jobs notdirectly related to the main project butcombined with it, shall be reviewed andmonitored separately

Thank youThank youKochi Refinery