NAME: DEVVRAT THAKER ROLL NO: 505 MBA TECH (TELECOM) YEAR : 2010-11

A REPORT ON MAINTENANCE MANAGEMENT IN C&I VPCL- ESSAR PROJECTS

Vadinar Power Company ltd, is basically an captive power plant, Which is meant to provide round the clock power supply to essar oil ltd.

Essar oil ltd is involved in refining and retailing of different petroleum products It current refining capacity is 14 million tones per annum (mtpa) These refining capacity is to be expanded upto 33 mtpa, By the end of year 2012 Now the power requirement capacity of these refinery is very high, On its full load operation it requires nearly 75 Mw for 14mtpa and around 200 Mw for 33 mtpa

Now in Jamnagar we have Gujarat Electricity Board (GEB), Which provides electricity, But the capacity of GEB is not enough that it can supply power to these refineries, That is Reliance and Essar Again the power supply, Which is obtained from these government sources are not round the clock, And these can affect the refinery business badly To avoid all these and to provide an round the clock power supply, These captive power plant VPCL was established

In refinery operations, We normally use a term called Gross Refining Margins (GRM), to measure the profitability of the refinery These GRM is basically the difference between the Revenue received from the operation minus that of crude price and other operations cost GRM = Revenues (Crude price + operation expenditure) The present GRM for essar oil is $ 7.15/barrel

Now these GRM fluctuate with the price of crude, That is if the crude price increases then GRM also increases These GRM are dependent mainly on two factors 1) Type of refinery and 2) Quality of crude

Both these factors are interrelated to each other Simple refinery : A simple refinery is a one, Which seperates around 5 to 6 components, The main components are petrol and diesel. Now to operate with simple refinery, We require high quality of crude, So as to avoid the wear and tear of machineries. Here crude prices are high, But the cost of setting up a refinery is less. Essar operates on simple refinery, and crude is mainly imported from Iran.

Complex refinery : A complex refinery seperates, All the components, which are available from the fractional distillation plant The crude quality is low. Crude is cheaper but the setup cost for refinery is very high Reliance operates with these type of refinery and fuel, and they mainly import there crude from Saudi Arabia

Essar oil : $7.15/barrel Reliance industries : $10.75/barrel ONGC ltd : $ 6.15/ barrel Singapore index : $ 8.0/ barrel

In vpcl, we have 3 power plants The first power plant is an combined power plant, which operates with both gas and fuel and has a capactiy of 75Mw. The second power plant is also a combined power plant and has capacity of 2*110 Mws. The third power plant is an coal fired plant and its capacity is of 325Mw.

Now as VPCL is an captive plant, The main task is to control the cost as much as possible The first power plant is of 75 Mw and is a combined plant, Now for these plant the required oil that is High fuel oil (HFO) is obtained from the refinery as an subsidery product The gas which is required to provide ignition to these oil is obtained from the refinery, Which in turn receives these gas from petronet, Hence both the main fuel are available from refinery Now the cost of power depends on the cost of fuel, Here as it is low, The only cost required is the operational and maintenance cost

Now if we look at all the above procedures the cost of producing power comes around to approx Rs 1.5/unit, Which is around Rs. 4.5 less then the normal power Moreover these cost is mainly due to maintenance and equipment handeling Therefore from above points, we can see the maintenance is the most important part in captive plant and again as the plant is not for commercial purpose, therefore equipments can be used for an longer period of time

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The power plant works on the basic principle of Rankin cycle These is a four stage cycle : The working fluid is pumped from low to high pressure. These high pressure liquid enters in a boiler, were it is heated at constant pressure, so as to form saturated vapor. These vapor is then expanded through turbine, which generates power. The wet vapor enters condenser, So at to form liquid

The main purpose of Deaerator is to remove dissolve gases The feed water is fed through perforated trays These water is then subjected to heated steam, Which is delivered to the lower portion of dearator Now as a result of heat exchange O2 and CO2 are dissolved and vented out Here O2 gas is removed as it causes corrosion in pipelines and BFP CO2 is removed as it decreases the Ph of a liquid, Which increases the rate of corroision

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Water from dearator first comes to BFP BFP pumps these water to HRSG as per pressure requirement of steam There are two types of BHP HHP feed pump and HP feed pump

Particulars No of pumps

HHP feed pump 3

HP feed pump 3

Speed Temperature
Suction pressure Discharge pressure Differential pressure Minimum flow

3000 Rpm 105 deg celcius

2 kg/cm sq 85 kg/ cm sq 83 kg/ cm sq 21 meter cube/hr

3000 Rpm 105 deg celcius

2 kg/ cm sq 60 kg/cm sq 58 kg/ cm sq 15 meter cube/hr

It is used to produce HHP steam by using HHP feed water from BFP Here we use oil in between the pump shaft and the motor shaft By varying the quantity of oil, We can vary rotation speed of pump shaft As a result of the above process, We can vary the pressure, as per requirement

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The main components of boiler are as follows Upper drum: It is also called as steam drum, and it is well supported by bank tubes and water well tubes. Lower drum: It supplies water from steam to furnace bottom supplies, to all the four sides of wall. Furnace: Furnace is of water cooled membrane, As it contain 3 sets of either oil/gas burners in it.

4) Burner: There are 3 burners in a boiler The burner is normally ignited with the help of LPG and the required fuel is HFO or fuel gas. The burner has following main parts. a) Air damper: It provides combustion air for burner through diffusers. b) Atomizer fuel: It breaks heavy fuel oil into fine particle, So as to make combustion faster c) Firing system: Fuel gun fires the required HFO, MP steam and LPG

TURBINE : A steam turbine is a mechanical device that extracts thermal energy from pressurized steam, and converts it into useful mechanical work. GENERATOR: The electric generator is a device that converts mechanical energy to electrical energy, generally using electromagnetic induction.

LPG SYSTEM DIESEL OIL STORAGE DIESEL OIL PUMPING FUEL OIL STORAGE FUEL OIL HEATING FUEL OIL PUMPING

Turbine speed/load is controlled through a WOODWARD 505E electronic hydraulic governing system electric single proportional to the designed speed/load change is generated by governor This signal is converted to a hydraulic single by electro-hydraulic converters The amplified signal controls the oil pressure from the control oil system to act on the turbine control valves

The term maintenance management means to keep the equipment in operational condition or repair it to its operational mode Main objective of the MAINTENANCE is to have increased availability of production systems, with increased safety and optimized cost

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As the power plant instruments are very costly, Therefore it is necessary to plan the maintenance strategies properly The following four are the main strategies that we followed at vpcl These strategies are mainly based to predict the problems, prevent it and at last to repair it The following four strategies are used in vpcl Predictve maintenance Preventive maintenance Shutdown maintenance Breakdown maintenance

It helps to determine the condition of in-service equipment in order to predict when maintenance should be performed The key to PDM is The right infromation in the right time. It helps to plan the stopage and reduce these effects In VPCL it is performed at the end of every 6 months

Oil analysis Vibrational analysis Ultrasonic analysis Thermographic analysis

It helps in minimizing the cost It helps in reducing the unsheduled maintenace Reduces the spare part inventories Optimizes machinery performance Increases the plant capacity It also helps in reducing the depreciation of capital invested through maintenance

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PM- is a time based strategy conducted at end of every 2 yrs when a piece of equipment is taken off line and inspected and based on the inspection repairs are made and the equipment on line There are 3 things, Which are of much importance while performing PM they are Planning Scheduling Continuous improvement

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PM is also called as Business Intelligence Which provides following features tracking maintenance costs cost per volume produced equipment analysis total cost of repair or replacement costs Thus the above feature can help in maintaining the balance between, Cost of maintenance and Replacement

Shut down can be defined as scheduled down period for a plant for scheduled maintenance for an extended period of time It is generally carried out at the end of 18 months It requires good plannning It generally deals with the operation parts of the refinery If it is not applied properly then it can cause huge impact on companies profits

ABC meeting with plant head Modification/ Inventory work to enhance plant reliability Material inspection at warehouse and local store 100% Compliance of history card for any instrument finding 100% Compliance of daily planning and progress report Ensure 100% protection during heavy rain and Zero failure Instrumentation maintenance audit by internal agency Reliability audit and finding implementation

A power plant in which we capture and store carbon dioxide to mitigate the annual carbon credit goals, In order to prevent global warming is called as an Carbon captive power plant There are 3 processes which are mainly being used Post combustion capture Oxy-fuel combustion Pre expansion combustion

TRANSPORT : Pipeline is the main source It provides end to end connectivity, with a very little CO2 loss STORAGE : The processes normally used are Geo logical storage Ocean storage Mineral storage

The majority of profit in Carbon captive power plants are obtained by following sources Selling of CO2 to Oil and Gas fields Carbon market

Depleting Oil and Gas fields require infusion of CO2 As time passes the natural gas surrounding the oil field starts depleting The above mentioned threat is an profit making opportunity to Carbon Captive Power Plant, As it mainly serves two purposes 1) We can store CO2 in place of natural gas 2) It helps in providing cushion to the oil fields, to keep the surrounding conditions in oil field normal Being in Gujarat these option is very much profitable with lots of oil and gas fields located here

An Carbon market is a specific market which is designed for the sale of green house gases like carbon dioxide and methane The standardized unit which is being used for transaction is CARBON CREDIT CARBON CREDIT: Carbon credit is a certificate or permit to transfer one ton of Carbon dioxide 1 Carbon Credit unit = 1 ton of CO2

Few days before UN , certified Reliance powers 3 ultra mega power project, for saving 48.5 million carbon units ,for a period of 10 years By saving these carbon credit units, they are about to earn some 5,000 Crore Rs during these period of 10 yrs Another example is of British petroleum, which entered in India so as to buy and save carbon units by starting an subsidary company Thus it can be said that Carbon Credit can serve as highly efficient source of revenue in future

It is a natural gas , which is produced from Shale Deep inside the sea, At a depth of around 3,000 mts , there are some shale rocks, which consist of mature petroleum Due to intense heat and pressure these petroleum gets converted into natural gas, called as the shale gas

Since the year 2000, the consumption of Shale gas or the natural gas has been replace by shale gas upto 35% in USA As a result of these reserves , there dependence for natural gas on Russia and Arabic countries have been reduced to considerable amount They have the largest reserve in world, which will eventually help them to reduce the electricity prices All the Euro-zone countries have started looking towards the shale gas as the future fuel, In order to avoid increasing cost of natural gas from Arabic countries

India has potential of being the worlds largest Shale gas producer to support its Super power operations Recently ONGC founded a gas block in West Bengal, with an area over 12,000 sq km Another potential sites are at Cambay province, KG basin and Kutch sector Reliance Industries and RNRL are some of the other companies involved in its extraction In these fiscal year Reliance acquired some 40-49% share in Atlas co, in marschellus shale gas field, Which is eventually the largest producer of shale gas

An Mou being signed between USA and India, during Barack Obamas visit to India, To produce environmental friendly energy Based on these Mou, India denied for the use of TAPI gas line Reliance industries during these year reported a fall of 5 mmct of gas in KG basin Reliance are about to enter in a strategic alliance with British Petroleum, for shale gas exploration in KG basin All these may eventually help India for its monopoly in Natural gas like the Arab countries

It requires methods for controlling methane emissions USA is working to reduce these emissions Now if we look the effect of methane gas, than the effect of 0.2% of methane is almost equivalent to 6% of CO2 gas The emission of methane takes place only when there is a leakage during its extraction procedure

It was a great experience to work with a company having operations worth Rs. 45,000 crore Seeing the operations of such a company and consulting them was great It helped me in developing my skills, That is to propose new products or research at such an large level Moreover it helped me in getting professional