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 Definition : 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 renewal. This operation involves a lot of preparations and requires many precautions, especially at during startup. Contents Turnaround Maintenance + Objective / Purpose + Process / Procedure + Strategy Followed + Organogram + Key Achievement/Highlights + Key Learning + What made it happen & final success + Major Counts at a glance + Sep’11 Cost : Budget Vs Actual + Duration Schedule Vs Actual Criteria for T/A Objectives Aligned with business goals Clear, unambiguous and prioritized Measurable, objective and monitored Based on experience , scope, knowledge and data Aggressive but achievable Deliberated and agreed to key stakeholders Turnaround Objective / Purpose + 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 Turnaround Objective / Purpose + To execute the turnaround with the highest possible + + + + safety record. To achieve the best quality of workman ship. To complete the turnaround in the shortest possible time. To complete the turnaround at the lowest possible cost. Revamp Jobs for Refinery capacity augmentation from 14 MMTPA to 18 MMTPA. CDU/VDU/SGU Revamp FCCU Revamp VBU to CDU Conversion Tie-ins. SRU Revamp Train: I integration Tie-ins. Turnaround Organization - September 2011 Sr.No. Function Name 1 2 3 4 5 6 7 8 9 Head-Refinery Chief Turnaround Manager Overall Operation Co-Ordinator Tech.Services Co-Ordinator Construction Co-Ordinator HSEF Turnaround manager Turnaround planning Co-Ordinator Turnaround-MIS-Co-Ordinator C Manoharan Narada Singh KC Swain Satheesan V N G G Mehta (EPIL) Dr Gopal Jayaraman P Rambabu D D Chaudhari / Jayanti Vagdoda 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 14 15 16 17 18 19 20 21 22 23 Revamp/Expansion Execution Manager Overall Tie-ins Co-Ordinator Instrumentation Electrical Civil EPS Security Admin Reliability/Rotary/ Workshop Commercial RSM Sudhir Porichha (EPIL) Rakesh Kumar S. Laxminarayan Rajeev Kumar Ashok Srivastava Dhaval Doshi Cmdt. Raghuraman Geojo Paul Amit Kumar N J K Jani RSM Turnaround Optimisation Program Strategic Site Turnaround Review TR - 0 Turnaround Work Scope Optimization TR - 1 Planning, Scheduling, and Integrated Plan Basis TR - 2 Integrated Plan Execution Techniques, T/A Management TR - 3 Post Turnaround Review TR - 4 Turnaround Optimisation Program . TOPTM Overview Strategic Review Scope Cost Schedule Preparedness Ideal Timing Run Cycle (2) Workscope Review - 9 months Execution Review - 6 months Preparedness Rev. Close Out Review - 3 months +1 months Mission for Shutdown From Chief Turnaround Manager {S R T C} SAFETY RELIABILITY TIME-BOUND COST-EFFECTIVE Turnaround Process / Procedure + 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 Turnaround Process / Procedure + 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… Turnaround Process / Procedure + Administrative arrangements + Security arrangements + Implementation plans + Monitoring of jobs during execution + Contingency plan for Additional resources required during turnaround + Turnaround close-out Pre Shutdown Preparation +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. Preparedness for Safe & Effective Execution +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 of executing S/D Jobs in other Refineries to the maximum extent. Preparedness for Safe & Effective Execution +Inclusion of Contract Safety System in Contractor Scope +Arrangement for Pre S/D Training to Contract Manpower +Use of only Certified Tools & Tackles +Use of Flame Arrestor for all Vehicles,Trailors, Crane & Hydra +Tool Box Talk by Engineer to Contract Manpower +Strict Compliance of Safety Work Permit System +Use of General & Specific PPE’s e.g. Life line belt, Fall Arrestor +Certified Lifting plan for heavy lift +Certification of Scaffolds & use of “Safe to use” Tag Facilities and Services (F & S) 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 SAB : Own arrangement – Space will be provided by EOL. ECIL : Own arrangement – Space will be provided by EOL. Other contractors: Tea will be served at work place as free of charge to all 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) Two sheds are being constructed. One at shutdown yard, & another tent in old parking area (tent by admin along with lighting. Power supply by EOL). Required tables, chairs, etc will be arranged by Admin. Lighting arrangement in tin sheds will be provided by elect dept. 3) Canteen facilities for officers:. Location will be at area in between CCB & LAB. Tables, chairs, carpet & lighting is being organized by Admin and power supply by electrical dept. Facilities and Services (F & S) 4) Drinking Water Facilities : 5) Shutdown office: 6) Urinals & Toilets: Sufficient no of toilets and urinals have been constructed in shutdown yard. 7) Resting Place : Separate tents arranged for Dining and Rest room for different contract manpower as well as for engineer. Near Shutdown yard to avoid manpower movement. 8) First Aid office: Central first aid tent will be located in front of Lab near E-W road. It will be supplemented by paramedic officer / doctor on round the clock basis and one ambulance. 9) Accommodation for Labour / Transport. Accommodation for 10000 Labours have been booked in Labour colony. For transporting Labours from labour colony to refinery, our trailers will be used and 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 Detailed Shutdown Planning +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 of Work packs by operations maintenance procedures by maintenance and standard +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. Function No. 1 2 3 4 5 6 7 8 9 Head-Refinery Chief Turnaround Manager Overall Operation Co-Ordinator Tech.Services Co-Ordinator Construction Co-Ordinator HSEF Turnaround manager Turnaround planning Co-Ordinator Turnaround-MIS-Co-Ordinator Name 11 Engineering & Inspection C Manoharan Narada Singh KC Swain Satheesan V N G G Mehta (EPIL) Dr Gopal Jayaraman P Rambabu D D Chaudhari / Jayanti Vagdoda Hembala Dixit ISBL: SKM Rahman Utility: Chitti Babu PIT/COT: Ajay Veer Ramesh Kumar 12 Revamp/Expansion Project Manager Ramakrishna Paramhans (EPMCL) 10 Operation Co-Ordinator 13 14 15 16 17 18 19 20 21 22 Revamp/Expansion Execution Manager Overall Tie-ins Co-Ordinator Instrumentation Electrical Civil EPS Security Admin Commercial RSM Sudhir Porichha (EPIL) Rakesh Kumar S. Laxminarayan Rajeev Kumar Ashok Srivastava Dhaval Doshi Cmdt. Raghuraman Geojo Paul J K Jani RSM Accomplishments of Turnaround which was completed on schedule in spite of lot of challenges + 35 days Turnaround Completed Safely ON SCHEDULE + Turnaround Cost within Budget as per plan. Few variances due to major exigencies during the Turnaround period. + Tie - ins of Train - I new units & facilities with existing refinery : ISOM, HMU, DHDT, VGO- HT, ARU, SWS, SRU, DCU, & all OSBL/offsite tankages facilities + Revamp of existing units for capacity Augmentation has 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 + Total Revamp (modification & reinstallation) completed in 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) + Revamp completed- 36 Nos. Exchangers - Modifications/New 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 Turnaround Key Achievement/Highlights + FCCU all revamp job completed within schedule without any 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 Turnaround Key Achievement/Highlights + 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 Turnaround Key Learning • Temporary Lift was installed at CDU & VDU column, 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 Turnaround Key Learning • Dehumidification system provided in CDU & VDU column was 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 columns. This facility has remarkably contributed in reducing the time mainly for huge quantum of welding / hot work inside the column. Dehumidification System in CDU & VDU column Dehumidification System for Reactor-Riser Turnaround Key Learning • New idea of Exchanger cleaning bay has resulted in huge time 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 Turnaround Key Learning • Robotic Hydrojetting machine made available at exchanger 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 Robotic Tube bundle cleaning Machine What made it happen(from 45 to 35 Days •Decisive Leadership and on spot decisions. •Micro level Turnaround planning started well in advance before 18 months for man, material , machines, job list and its work pack. • Defined all critical jobs : 1. CDU/VDU column Revamping. a. b. c. d. e. We treat contract manpower as our employee and provide all the facilities like Accommodations/Food/Transport/Medical/Water/Tea-Snacks at site only. Use of new concepts and modernized gadgets e.g. providing lifts as high as 90 Meters, Dehumidification /AC, Chemical decontamination etc. Maximizing the pre turnaround activities e.g. 90% scaffolding, issuing of 100% bulk material/ spares and its prefabrication/ machining and placing in position. Daily Review and making rolling plan for speedy execution. Timely supply of equipment and logistics arrangements What made it happen(from 45 to 35 Days) 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. Use of new concepts and modernized gadgets e.g.SAF RAD Radiographic machines so that other jobs can be continued. Heater jobs divided in multiple zones so that welding jobs can be performed at maximum locations at a time and saved lot of time. Keep standby manpower for critical activities so that job shuld not suffer at any cost. b. c. d. 3. FCCU Reactor Refractory repairing: a. Providing of Dehumidification /AC. b. Using SAF RAD Radiographic machines,Diamond cutter for refractory, 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. What made it happen(from 45 to 35 Days) •Decisive Leadership and on spot decisions. •Micro level Turnaround planning started well in advance before 18 months for man, material , machines, job list and its work pack. • Defined all critical jobs : 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 only. 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 What made it happen(from 45 to 35 Days) •Engaged best contractor and resources and skilled/ specialized man power. Optimum deployment & effective utilization of resources •Organization of Turnaround meetings for review, micro detailing and finalization of overall Turnaround schedule. •Compliance of Systems and Procedures, Strong belief in team work, motivation and support from Top Management. •Caring of the Employees and Workmen resulted in excellent overall productivity. •All disciplines viz- Maintenance, Operation, TS/Process, Inspection, 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. The Success : 100% Planned jobs completed along with last minute surprises •It is worth highlighting that not only 100% planned jobs have been completed effectively but many important jobs came at last moment which could be also completed within this Turnaround period. •Last minute surprises and exigencies were also handled effectively- CCR Recycle gas compressor major maintenance due to high vibrations, DHDS Recycle gas compressor unplanned overhauling due to coking in rotor, Damage of 4th Bed layers of packing in VDU column, Shifting of HP steam line from support, Last moment receipt of CDU/VDU heater tubes & prefabrication, Cracks in CDU Heater supports and many more……., created a huge pressure. Turnaround Sep’11 : Major counts at a Glance Total Turnaround duration Total engineering duration Total no of blinds provided for plant handover Turnaround Budget Turnaround Expenditure Major Contractor involved Turnaround Manpower (Officer + Workman+ OEM Experts) Essar Officers (In 12hrs Shift Rota) OEM & Expatriate Cranes (250T,200T,150T ,135T,130T,120T,110T,100T& 60T) Hydra Fork Lift Trailer Exchanger tube bundle pullers Hydro-jetting machines Hydro-testing machines Insitu Machining sets Rotomol cleaning machine Stress relieving machine Air compressors Pigging machine Hydraulic torque tightening m/c Transformer oil filtration machine Heating oven for motors Transformer oil heating and vacuum m/c Mobile lighting tower Fire Blankets Total no. of Revamp Major jobs executed Total no. of Major M&I jobs executed 35 days 26 days 3924 Nos 74.66 Cr 74.69 Cr 70 Nos 15000 Nos 846 Nos 20 & 5 Nos 57 Nos 39 Nos 10 Nos 33 Nos 05 nos 26 Nos 50 12 2 20 09 Nos 06 Nos 12 3 2 nos 3 2 nos 3500 Nos 1618 Nos 2492 Nos Turnaround Sep’11 Cost : Budget Vs Actual Rs in Cr. BudgetMaterial cost Sr. Description No. Mechanical/Operations total) (Sub Total Budget- Budget ( Actual Actual Total ( Service Material+ Material Service Actual) cost Service) s Cost Cost cost 15.86 40.10 55.96 18.49 35.79 54.63 B Electrical 2.52 2.22 4.74 C Instrument 2.99 0.99 3.98 2.01 1.64 1.90 1.26 3.91 2.90 A D Civil 2.99 3.49 1.70 5.58 7.27 1.80 1.80 0.30 0.35 0.65 0.00 0.37 1.53 0.18 1.53 0.55 0.50 E Inspection F Fire & Safety 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 74.66 73.96 TOTAL COST (Rs in Cr.) Justification 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 Turnaround Duration Schedule Vs Actual UNIT CDU/VDU/S GU VBU TREATERS FCCU NHT CCR DHDS ARU SWS SRU train-1 SRU train-2 UTILITYUCT UTILITYPCT H2S Flare HC Flare N2 Plant Steam PLANNED STOPPAGE DATE & TIME ACTUAL FEED CUT OFF STOPPAGE DATE & TIME PLANNED STARTUP DATE & TIME ACTUAL FEED CUT IN START UP DATE & TIME 18/09/11 & 08:00 hrs 18/09/11 & 04:45 hrs 23/10/11 & 08:00 hrs 24/10/11 & 11:08 hrs 19/09/11 & 02:00 hrs 19/09/11 & 00:30 hrs 24/10/11 & 08:00 hrs 24/10/11 & 19:15 hrs 20/09/11 & 08:00 hrs 19/09/11 & 00:30 hrs 23/10/11 & 08:00 hrs 23/10/11 & 18:00 hrs 19/09/11 & 08:00 hrs 19/09/11 & 09:10 hrs 23/10/11 & 08:00 hrs 23/10/11 & 10:25 hrs 18/09/11 & 20:00 hrs 18/09/11 & 21:15 hrs 22/10/11 & 08:00 hrs 23/10/11 & 16:35 hrs 18/09/11 & 20:00 hrs 18/09/11 & 21:35 hrs 21/10/11 & 08:00 hrs 27/10/11 & 05:25 hrs 18/09/11 & 20:00 hrs 18/09/11 & 20:00 hrs 24/10/11 & 08:00 hrs 29/10/11 & 16.00 hrs 21/09/11 & 08:00 hrs 19/09/11 & 09:00 hrs 23/10/11 & 08:00 hrs 23/10/11 & 21:00 hrs 21/09/11 & 12:00 hrs 21/09/11 & 08:15 hrs 23/10/11 & 08:00 hrs 24/10/11 & 04:00 hrs 20/09/11 & 08:00 hrs 19/09/11 & 06:45 hrs 23/10/11 & 08:00 hrs 28/10/11 & 19:10 hrs 20/09/11 & 08:00 hrs 18/09/11 & 09:00 hrs 23/10/11 & 08:00 hrs 31/10/11 & 12:00 hrs 29/09/11 & 08:00 hrs 27/09/11 & 17:00 hrs 11/10/11 & 08:00 hrs 13/10/11 & 16:00 hrs 26/09/11 & 08:00 hrs 25/09/11 & 00:00 hrs 13/10/11 & 08:00 hrs 15/10/11 & 10:00 hrs 26/09/11 & 08:00 hrs 26/09/11 & 11:30 hrs 14/10/11 & 08:00 hrs 30/09/11 & 08:00 hrs 26/09/11 &11:30 hrs 15/10/11 & 08:00 hrs 12/10/11 & 20:30 hrs 01/10/11 & 08:00 hrs 06/10/11 &18:00 hrs 05/10/11 & 08:00 hrs 15/10/11 & 06:00 hrs 01/10/11 & 08:00 hrs 04/10/11 &08:30 hrs 05/10/11 & 08:00 hrs 10/10/11 & 09:00 hrs 15.10.11 & 18.45 Hrs THANK YOU