ELECTRICAL MAINTENANCE IN HPCL INDUSTRIAL TRAINING REPORT

ABOUT HPCL

● VISAKH Refinery was commissioned with an installed capacity of 0.65 Million Metric Tonnes Per Annum (MMTPA) by Caltex Oil Refining (India) Ltd. in 1957.

● Leading Jet fuel supplier in India

Hindustan Petroleum (as ESSO and Caltex prior to 1974) has been providing aviation refueling (Aviation Turbine Fuel - ATF) services at various airports in India for more than half a century.

Exploration & Production section "HP-E&P is world class and technically proficient, with global presence delivering superior returns from a sustainable balanced portfolio with highest commitment to HSSE* and Society

Alternate Energy Being an energy company, HPCL has been in

the forefront in experimenting with alternate sources for harnessing of renewable energy resources. It has an installed capacity of 50.5 MW of Wind Power as of 31st. March 2011

Refinery Performance (Last 5 years)

The Crude Oil processed by the refineries, during the previous 5 years (in MMTPA) is shown below Refinery Crude Thruput (MMTPA)

Year 05-06 06-07 07-08 08-09 09-10 Mumbai Refinery 6.25 7.42 7.36 6.65 6.97 Visakh Refinery 7.57 9.24 9.41 9.15 8.79 Total 13.82 16.66 16.77 15.8 15.76

What is electrical maintenance?

Types of Maintenance

● Breakdown Maintenance  ● Periodic Preventive Maintenance

● Predictive or condition-based Maintenance

● Pro-active Maintenance

Methods used in predictive maintenance at HPCL

Infrared THERMOGRAPHY

Thermographic inspections of electrical equipment detect hot-spots well before problems occur. Here's how the latest infrared scanning systems at a major hospital work and fit into a typical electrical preventive maintenance program.

Dissolved Gas Analysis

DGA consists of three steps.

● Oil Sample Tube ● Extraction of Fault

Gases using Multiple Gas Extractor

● Quantitative determination and analysis of Fault gases

Motor current signature analysis

The applications appear to be almost endless.

● AC Motors and Alternators ● IDC Motors and Generators ● Single and Three phase systems ● Eddy-Current drives ● Variable Frequency Drives

● Incoming power quality

LOCATING UNDERGROUND CABLE FAULTS

TOOLS and EQUIPMENT

●Surge Generator

●Cable Tracer

● Fault Locator

● Continuity Tester

Electrical equipment at a glance in HPCL

● LT Motors 1910 ● HT Motors 119 ● MOVs 275 ● EHT Panels 49 ● EHT tapes(kms) 80 ● Lighting System ● HT Panels 40 ● LT Panels 112 ● HT Breakers 381 ● LT Breakers 347 ● PA Exchange 06 ● PA Call Stations 178

Meter control centre (MCC)

Power control centre (PCC)

Ingress Protection

Gas Insulated Substation

Space allocation of AIS/HIS/GIS

AIS H-GIS GIS

Area(m2) 5696(100%) 3776(66%) 882(15%)

Volume(m2) 227840(100%) 151040(66%) 12348(5%)

Why we need GIS ● GIS has small ground space requirements. ● Gas insulated Substations have easy

maintenance( nearly zero Maintenance Less field erection time & less erection cost.

● For underground powerhouse of Hydro electric power project where space constraint is a major issue.

● For Fast Growing Major Cities where land availability is costlier.

● Non-Flammability & Non-Explosive , Oil-free & Less Pollution

Visual comparison between AIS & GIS components

UNINTERRUPED POWER SUPPLY

BLOCK DIAGRAM OF UPS

Types of ups:

● Offline / standby ● Line-interactive ● Double-conversion / online ● Ferro-resonant ● DC power ● Rotary DRUPS (diesel rotary UPS)

Normal operation

Operating on alternate mains input

Thank You!...