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ESSAR OIL VADINAR REFINERY

Mega Turnaround Sept-Oct 2011

A Bench Mark in the Ref in ing sector looking

at the large Work-scope wh ich was com pleted

wi th c ompressed engineer ing days and

then fast track star t-up of the uni ts


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Definition :

In petroleum refining , turnaround means a

scheduled large-scale maintenance activity wherein

an entire process unit is taken off stream for anextended period for comprehensive revamp and

renewal. This operation involves a lot of preparations

and requires many precautions, especially at during

startup.

Turnaround Maintenance

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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

Criteria for T/A Objectives


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+ 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


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Turnaround Organization - September 2011Sr.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 S. Laxminarayan

16 Electrical Rajeev Kumar

17 Civil Ashok Srivastava

18 EPS Dhaval Doshi

19 Security Cmdt. Raghuraman

20 Admin Geojo Paul 21 Reliability/Rotary/ Workshop Amit Kumar N

22 Commercial J K Jani

23 RSM RSM


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Turnaround Optimisation Program

TR - 0

TR - 1

TR - 2

TR - 3

TR - 4

Strategic Site TurnaroundReview

Turnaround Work Scope

Optimization

Planning, Scheduling, and

Integrated Plan Basis

Integrated Plan Execution

Techniques, T/A Management

Post Turnaround Review


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.

Turnaround Optimisation Program

TOPTM

Overview Scope Cost Schedule Preparedness

Strategic Review

Workscope Review

Execution Review

Preparedness Rev.

Close Out Review

Ideal

Timing

Run Cycle (2)

- 9 months

- 6 months

- 3 months

+1 months


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Mission for Shutdown

From Chief Turnaround Manager

{S R T C}

SAFETY

RELIABILITY

TIME-BOUND

COST-EFFECTIVE


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Turnaround Process / Procedure

+ Collection of all inputs such as previous reports, procurement

lead times, job lists, own and contractor resources availabilityetc

+ 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 byexperience 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


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+ Procurement of material

+ Split between the jobs to be carried out by Companypersonnel 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…


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+ Administrative arrangements

+ Security arrangements

+ Implementation plans

+ Monitoring of jobs during execution

+ Contingency plan for Additional resources required

during turnaround

+ Turnaround close-out


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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.


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+Detailing of Scope of work for all S/D Jobs

+Preparation of Maintenance Execution Procedure & Work Pack for allS/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 crossfunctional team e.g. team involving Maintenance, Operation, Process,

Safety and Inspection

+Engaging Quality & experienced contractors having good track recordof executing S/D Jobs in other Refineries to the maximum extent.

Preparedness for Safe & Effective Execution


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+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

Preparedness for Safe & Effective Execution


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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 thecontractors 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 allthe 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 oldparking 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 supplyby electrical dept.


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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 wellas 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 byparamedic 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 andnecessary railing arrangement is being done in our workshop for safety. In addition to thispermission 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


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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 BOMpreparation for S/D activities, material procurement action

+Preparation of detail scope for awarding the contract

+Preparation of Work packs by operations and standardmaintenance 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 andfinalization of overall S/D schedule


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Turnaround Organization - September 2011Sr.

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 S. Laxminarayan

16 Electrical Rajeev Kumar

17 Civil Ashok Srivastava

18 EPS Dhaval Doshi

19 Security Cmdt. Raghuraman

20 Admin Geojo Paul

21 Commercial J K Jani

22 RSM RSM


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+ 35 days Turnaround Completed Safely ON SCHEDULE

+ Turnaround Cost within Budget as per plan. Fewvariances due to major exigencies during the Turnaround

period.

+ Tie - ins of Train - I new units & facilities with existingrefinery : ISOM, HMU, DHDT, VGO- HT, ARU, SWS, SRU,

DCU, & all OSBL/offsite tankages facilities

+ Revamp of existing units for capacity Augmentation hasbeen 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%).

Accom pl ishments of Turnaround which w as

completed on schedule in sp i te of lot of chal lenges


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+ Total Revamp (modification & reinstallation) completed in28 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/Newexchangers, 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, VDUHeater- A & B revamp/ modifications

Accom pl ishments of Turnaround which w as

completed on schedule in sp i te of lot of chal lenges


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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, 36Column, DHDS reactor catalyst replacement, CCR/NHT Reactorcatalyst 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, 199Vessels, 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


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Turnaround Key Achievement/Highlights

+ 52 Fin fan coolers, Major overhauling of over 50 Compressor/

Turbine/ Pumps. Overhauling of 297 control valves and 551pressure 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 replacedwith 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


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Turnaround Key Learning

• Dehumidification system provided in CDU & VDU column was

very effective for maintaining comfortable atmosphere insidecolumn 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. Dehum idi f icat ion System in CDU & VDU columnDehum idi f icat ion System fo r Reactor-Riser


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Turnaround Key Learning

• New idea of Exchanger cleaning bay has resulted in huge time

saving by providing central Point for Cleaning of all TubeBundles 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 Jobalso.

Exchanger Cleaning Bay


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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 etc.

c. Maximizing the pre turnaround activities e.g. 90% scaffolding, issuing of100% 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


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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.

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 beperformed 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:

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.


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•Decisive Leadership and on spot decisions.

•Micro level Turnaround planning started well in advance before 18 months forman, 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


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•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.



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Turnaround Sep’11 Cost : Budget Vs Actual

Sr.No.

Description

Budget-

Material

cost

Budget-

Service

cost

Total

Budget (

Material+

Service)

cost

Actual

MaterialCost

Actual

Service

s Cost

Total (Actual)

Justification

AMechanical/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 intakewell inside painting, Repairingand Chemical resisting coating in

pump house basin of Sea water

supply reservoir, CDU /VDU

heater main flue gas duct to stackcleaning & 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

HMaintenance

supervisor/Engineers hiring0.00 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.


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Turnaround Duration Schedule Vs Actual

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/SGU

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


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