ESSAR OIL VADINAR REFINERY Mega Turnaround Sept-Oct 2011 A Bench - - PowerPoint PPT Presentation
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
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
and requires many precautions, especially at during startup.
data
+ 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
safety record.
+ Revamp Jobs for Refinery capacity augmentation from 14 MMTPA to 18 MMTPA.
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) 13 Revamp/Expansion Execution Manager Sudhir Porichha (EPIL) 14 Overall Tie-ins Co-Ordinator Rakesh Kumar 15 Instrumentation
16 Electrical Rajeev Kumar 17 Civil Ashok Srivastava 18 EPS Dhaval Doshi 19 Security
20 Admin Geojo Paul
21
Reliability/Rotary/ Workshop
Amit Kumar N
22 Commercial J K Jani 23 RSM RSM
TR - 0 TR - 1 TR - 2 TR - 3 TR - 4
Strategic Site Turnaround Review Turnaround Work Scope Optimization Planning, Scheduling, and Integrated Plan Basis Integrated Plan Execution Techniques, T/A Management Post Turnaround Review
.
TOPTM Overview
Scope Cost Schedule Preparedness Strategic Review Workscope Review Execution Review Preparedness Rev. Close Out Review Ideal Timing Run Cycle (2)
+1 months
+ 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
+ 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…
+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.
+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
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
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)
parking area (tent by admin along with lighting. Power supply by EOL).
3) Canteen facilities for officers:.
by electrical dept.
4) Drinking Water Facilities : 5) Shutdown office: 6) Urinals & Toilets:
7) Resting Place :
as for engineer. Near Shutdown yard to avoid manpower movement. 8) First Aid office:
paramedic officer / doctor on round the clock basis and one ambulance. 9) Accommodation for Labour / Transport.
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
+Planning started with setting of Milestones for Planning activities +Compilation, discussion and finalization of Job list +Cost Estimation of S/D Jobs, Detail technical study and BOM
preparation for S/D activities, material procurement action
+Preparation of detail scope for awarding the contract +Preparation
Work packs by
and standard maintenance procedures by maintenance
+Finalization of resources, Heavy Equipments, Inspection Plans,
identifying service requirements of technical specialist & expatriate
+Organization of S/D meetings for review, micro detailing and
finalization of overall S/D schedule
Turnaround Organization - September 2011
Sr.
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) 13 Revamp/Expansion Execution Manager Sudhir Porichha (EPIL) 14 Overall Tie-ins Co-Ordinator Rakesh Kumar 15 Instrumentation
16 Electrical Rajeev Kumar 17 Civil Ashok Srivastava 18 EPS Dhaval Doshi 19 Security
20 Admin Geojo Paul 21 Commercial J K Jani 22 RSM RSM
variances due to major exigencies during the Turnaround period.
been completed : CDU & VDU (18MMTPA) & consistently will be able to process high TAN crudes , FCCU (3.7MMTPA) & FCC operation on hydro treated feed, SRU (To Improve the sulphur recovery from 99 to 99.9 wt%). Accomplishments of Turnaround which was completed on schedule in spite of lot of challenges
28 engineering days; + World tallest single crude distillation column revamped (77 trays,
90 meter height)
+ Vacuum distillation column revamped (4 bed, 60 meter height &
new vapour horn installation)
+ Major piping modifications & replacement in existing units i.e. CDU
& FCC (dismantling 75,424 inch meter & erection of 85,098 inch meter)
exchangers, 7 nos. columns & 6 nos. vessels modification, 6 nos. new ejectors erected in VDU, 29 nos. pumps modification complete & boxed-up, 4 nos. Filters modification, CDU Heater A & B, VDU Heater- A & B revamp/ modifications
Accomplishments of Turnaround which was completed on schedule in spite of lot of challenges
incident, this includes Reactor-Riser 2 nos additional Feed nozzle installation, Tie Ins Job 141 nos , Additional Exchanger installation 2 nos along with piping, 6 nos Vessels & 4 nos Pumps modification
+ All Major M & I Job completed within 21 days duration, 36
Column, DHDS reactor catalyst replacement, CCR/NHT Reactor catalyst replacement, FCCU- 6 nos. bellows replacement, Flue gas boiler tube banks replacement, MAB Surface condenser replacement, SRU MCC-1 & 2 major refractory repair, UCT & PCT 10 nos. pumps discharge line replacement, 236 Exchangers, 199 Vessels, All 6 heaters pigging, 16 Heaters maintenance, 102 PCNs (GRM & Reliability related schemes), PCN-Total INCH DIA :28624,Total INCH MTR: 32500,Steel Structure: 103MT
+ 52 Fin fan coolers, Major overhauling of over 50 Compressor/ Turbine/ Pumps. Overhauling of 297 control valves and 551 pressure safety valves, + DCS/ESD up gradation in all the units, + Capital overhauling of 145 motors, 14 Power Transformers, 45 VACUUM circuit Breakers (33 kV), 201 Vacuum circuit Breakers (6.6Kv) 198 LT Circuit Breakers. 108 obsolete relays replaced with High speed Numerical relays, + Bus bar differential protection scheme commissioned at Utility, CCR, FCCU and CDU Electrical Substations, New 33kV switchboard and 6.6 KV switchboard commissioned in CDU and Utility Substations. + Implementation of Fast Bus Transfer scheme at CDU, CCR, FCCU, DHDS, and Utility substations and many other important jobs
for movement of light weight materials as well as workmen from ground to column and Vice Versa which remarkably reduced required time frame of execution from 45 days to 35 days and all jobs were smoothly completed in scheduled timeframe. Temporary Lift, installed at CDU / VDU column
very effective for maintaining comfortable atmosphere inside column for workmen, by maintaining temperature between 28 to 32 deg C & Relative humidity was less than 65% inside the
the time mainly for huge quantum of welding / hot work inside the column. Dehumidification System in CDU & VDU column Dehumidification System for Reactor-Riser
saving by providing central Point for Cleaning of all Tube Bundles with advance Hydro jetting machines i.e. Inside/Outside Robotic machines and Inspection (Visual & Eddy Current Testing) was also carried out at same place which helped in good housekeeping and keeping ISBL unit free from Oil, Coking & Sludge and Further reduced House Keeping Job also.
Exchanger Cleaning Bay
cleaning bay for Heat Exchangers Tube bundle cleaning, Machine operating with multi jet nozzles–5 nos working simultaneously which took 1/5th times of ordinary manually tube bundle cleaning process, max pressure of 20000 PSI, due to high pressure & mobility of machines the exchanger tube bundle cleaning process was very fast and effective, and hard deposit was removed very easily, thus saving huge time in cleaning huge number of tube bundles
man, material , machines, job list and its work pack.
1. CDU/VDU column Revamping. a. We treat contract manpower as our employee and provide all the facilities like Accommodations/Food/Transport/Medical/Water/Tea-Snacks at site
b. Use of new concepts and modernized gadgets e.g. providing lifts as high as 90 Meters, Dehumidification /AC, Chemical decontamination etc. c. Maximizing the pre turnaround activities e.g. 90% scaffolding, issuing of 100% bulk material/ spares and its prefabrication/ machining and placing in position. d. Daily Review and making rolling plan for speedy execution. e. Timely supply of equipment and logistics arrangements
2. CDU/VDU Heater Modification. a. Optimise the use of Pigging machines in such a way that critical Heater handed over with in minimum possible durations. b. Use of new concepts and modernized gadgets e.g.SAF RAD Radiographic machines so that other jobs can be continued. c. Heater jobs divided in multiple zones so that welding jobs can be performed at maximum locations at a time and saved lot of time. d. Keep standby manpower for critical activities so that job shuld not suffer at any cost. 3. FCCU Reactor Refractory repairing:
electrical and instrument testing equipment etc. c. Using of skilled manpower and guidance from Refractory experts. d. Ensures Support services like inspection/process availability 24X7 on the job.
man, material , machines, job list and its work pack.
1. CDU/VDU column Revamping. a. We treat contract manpower as our employee and provide all the facilities like Accommodations/Food/Transport/Medical/Water/Tea-Snacks at site
b. Use of new concepts and modernized gadgets e.g. providing lifts as high as 90 Meters, Dehumidification /AC, Chemical decontamination, Inside/Outside Robotic Hydro jetting, SAF RAD Radiographic machines, powered torqueing/tensioning machines, Diamond cutter for refractory, Ultra-modern rotary laser based condition monitoring, electrical and instrument testing equipment etc. c. Maximizing the pre turnaround activities e.g. 90% scaffolding, issuing of 100% bulk material/ spares and its prefabrication/ machining and placing in position. d. Timely supply of equipment and logistics arrangements
finalization of overall Turnaround schedule.
motivation and support from Top Management.
productivity.
Expansion, HSEF, Security, Project/Engg, HR, CRG, IT, Warehouse, Commercial, Finance and Administration have demonstrated tireless effort and cohesive work culture towards achieving Turnaround goal.
Total Turnaround duration 35 days Total engineering duration 26 days Total no of blinds provided for plant handover 3924 Nos Turnaround Budget 74.66 Cr Turnaround Expenditure 74.69 Cr Major Contractor involved 70 Nos Turnaround Manpower (Officer + Workman+ OEM Experts) 15000 Nos Essar Officers (In 12hrs Shift Rota) 846 Nos OEM & Expatriate 20 & 5 Nos Cranes (250T,200T,150T ,135T,130T,120T,110T,100T& 60T) 57 Nos Hydra 39 Nos Fork Lift 10 Nos Trailer 33 Nos Exchanger tube bundle pullers 05 nos Hydro-jetting machines 26 Nos Hydro-testing machines 50 Insitu Machining sets 12 Rotomol cleaning machine 2 Stress relieving machine 20 Air compressors 09 Nos Pigging machine 06 Nos Hydraulic torque tightening m/c 12 Transformer oil filtration machine 3 Heating oven for motors 2 nos Transformer oil heating and vacuum m/c 3 Mobile lighting tower 2 nos Fire Blankets 3500 Nos Total no. of Revamp Major jobs executed 1618 Nos Total no. of Major M&I jobs executed 2492 Nos
Sr. No. Description Budget- Material cost Budget- Service cost Total Budget ( Material+ Service) cost
Actual Material Cost
Actual Service s Cost Total ( Actual)
Justification
A Mechanical/Operations (Sub total) 15.86 40.10 55.96
18.49 35.79
54.63 B Electrical 2.52 2.22 4.74
2.01 1.90 3.91
C Instrument 2.99 0.99 3.98
1.64 1.26 2.90
D Civil 0.50 2.99 3.49
1.70 5.58 7.27
Additional Job of Sea water intake well inside painting, Repairing and Chemical resisting coating in pump house basin of Sea water supply reservoir, CDU /VDU heater main flue gas duct to stack cleaning & inspection, Insulation, Scaffolding
E Inspection 1.80 1.80
0.00 1.53 1.53
F Fire & Safety 0.30 0.35 0.65
0.37 0.18 0.55
G Admin & Canteen facilities, Vehicles, OHC & IT 0.00 1.51 1.51
0.09 2.34 2.43
H Maintenance supervisor/Engineers hiring 0.00 2.53 2.53
0.00 1.47 1.47 Total shutdown Budget (in
crores). (Addition of A to H)
22.17 52.48 74.66 24.30 50.04 74.69 TOTAL COST (Rs in Cr.)
74.66 73.96
Rs in Cr.
UNIT PLANNED STOPPAGE DATE & TIME ACTUAL FEED CUT OFF STOPPAGE DATE & TIME PLANNED START- UP DATE & TIME ACTUAL FEED CUT IN START UP DATE & TIME CDU/VDU/S GU
18/09/11 & 08:00 hrs 18/09/11 & 04:45 hrs 23/10/11 & 08:00 hrs 24/10/11 & 11:08 hrs
VBU
19/09/11 & 02:00 hrs 19/09/11 & 00:30 hrs 24/10/11 & 08:00 hrs 24/10/11 & 19:15 hrs
TREATERS
20/09/11 & 08:00 hrs 19/09/11 & 00:30 hrs 23/10/11 & 08:00 hrs 23/10/11 & 18:00 hrs
FCCU
19/09/11 & 08:00 hrs 19/09/11 & 09:10 hrs 23/10/11 & 08:00 hrs 23/10/11 & 10:25 hrs
NHT
18/09/11 & 20:00 hrs 18/09/11 & 21:15 hrs 22/10/11 & 08:00 hrs 23/10/11 & 16:35 hrs
CCR
18/09/11 & 20:00 hrs 18/09/11 & 21:35 hrs 21/10/11 & 08:00 hrs 27/10/11 & 05:25 hrs
DHDS
18/09/11 & 20:00 hrs 18/09/11 & 20:00 hrs 24/10/11 & 08:00 hrs 29/10/11 & 16.00 hrs
ARU
21/09/11 & 08:00 hrs 19/09/11 & 09:00 hrs 23/10/11 & 08:00 hrs 23/10/11 & 21:00 hrs
SWS
21/09/11 & 12:00 hrs 21/09/11 & 08:15 hrs 23/10/11 & 08:00 hrs 24/10/11 & 04:00 hrs
SRU train-1 20/09/11 & 08:00 hrs 19/09/11 & 06:45 hrs
23/10/11 & 08:00 hrs 28/10/11 & 19:10 hrs
SRU train-2 20/09/11 & 08:00 hrs 18/09/11 & 09:00 hrs
23/10/11 & 08:00 hrs 31/10/11 & 12:00 hrs
UTILITY- UCT
29/09/11 & 08:00 hrs 27/09/11 & 17:00 hrs 11/10/11 & 08:00 hrs 13/10/11 & 16:00 hrs
UTILITY- PCT
26/09/11 & 08:00 hrs 25/09/11 & 00:00 hrs 13/10/11 & 08:00 hrs 15/10/11 & 10:00 hrs
H2S Flare
26/09/11 & 08:00 hrs 26/09/11 & 11:30 hrs 14/10/11 & 08:00 hrs 15.10.11 & 18.45 Hrs
HC Flare
30/09/11 & 08:00 hrs 26/09/11 &11:30 hrs 15/10/11 & 08:00 hrs 12/10/11 & 20:30 hrs
N2 Plant
01/10/11 & 08:00 hrs 06/10/11 &18:00 hrs 05/10/11 & 08:00 hrs 15/10/11 & 06:00 hrs
Steam
01/10/11 & 08:00 hrs 04/10/11 &08:30 hrs 05/10/11 & 08:00 hrs 10/10/11 & 09:00 hrs