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Kochi Refinery
BPCL –Kochi Refinery
C.K. Soman
DGM (Power & Utilities), BPCL KR
Jaikishen C Nath
SM(Power & Utilities), BPCL KR
Kochi Refinery
from the Commissioning and Stabilization of MS & HSD Quality up - - PowerPoint PPT Presentation
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 &
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Kochi Refinery
The Refinery that was; circa 2006
CDU 1 CDU 2 FCCU DHDS GT 1 19MW STG 12MW GRID 4MW TOTAL 35MW
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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
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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
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Kochi Refinery
VGO-Hydro-desulphurisation (VGO-HDS) unit
- f 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
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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
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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
- f power system elements
Challenges -Post CEMP II Electrical System
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Kochi Refinery
Link 2 KSEB2 KSEB1 STG GT1
Pre CEMP II Electrical Distribution System
Link 1
11kV 11kV 66/11kV 66/11kV
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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 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
Plant load recorded Jan-10 to Jul-11
Peak load recorded Linear (Peak load recorded)
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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
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Kochi Refinery
VGO HDS,NHT CCR,CDU2 New Tie 4 Tie 2 Tie 1 UTILITY,DHDS, FCCU,CPP AUX,CDU1 Link 2 KSEB2 KSEB1 Temporary Link CDU2 Old, PRU, ARU,PIBU, N/R, Colony STG GT1 GT2 Link 1 33kV, 25MW HT 101 23MW 2101 11MW
Implementation of the chosen mode
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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%
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Kochi Refinery
Shed the new units in tandem with the GTG outage to avoid
- verloading the grid lines
Utility systems to stabilise before the process units.
Tiding over and Learning
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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.
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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
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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
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Kochi Refinery
Major Failures
Input transformer of RGC motor in CCR UNIT burnt. 6.6MVA transformer was supplied by Transfor, Switzerland
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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
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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
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Kochi Refinery