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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
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.
Turnaround Maintenance
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
 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
+ 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
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 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
Turnaround Optimisation Program
TR - 0
TR - 1
TR - 2
TR - 3
TR - 4
Strategic Site Turnaround
Review
Turnaround Work Scope
Optimization
Planning, Scheduling, and
Integrated Plan Basis
Integrated Plan Execution
Techniques, T/A Management
Post Turnaround Review
.
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
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.
+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
Preparedness for Safe & Effective Execution
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 and standard
maintenance 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 and
finalization of overall S/D schedule
Turnaround Organization - September 2011
Sr.
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
+ 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
Accomplishments of Turnaround which was
completed on schedule in spite of lot of challenges
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. 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 of
100% 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
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 be
performed 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.
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
•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.
What made it happen(from 45 to 35 Days)
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 35 days
Total engineering duration 26 days
Total no of blinds provided for plant handover 3924 Nos
Turnaround Budget 74.66 Cr
Turnaround Expenditure 74.69 Cr
Major Contractor involved 70 Nos
Turnaround Manpower (Officer + Workman+ OEM Experts) 15000 Nos
Essar Officers (In 12hrs Shift Rota) 846 Nos
OEM & Expatriate 20 & 5 Nos
Cranes (250T,200T,150T ,135T,130T,120T,110T,100T& 60T) 57 Nos
Hydra 39 Nos
Fork Lift 10 Nos
Trailer 33 Nos
Exchanger tube bundle pullers 05 nos
Hydro-jetting machines 26 Nos
Hydro-testing machines 50
Insitu Machining sets 12
Rotomol cleaning machine 2
Stress relieving machine 20
Air compressors 09 Nos
Pigging machine 06 Nos
Hydraulic torque tightening m/c 12
Transformer oil filtration machine 3
Heating oven for motors 2 nos
Transformer oil heating and vacuum m/c 3
Mobile lighting tower 2 nos
Fire Blankets 3500 Nos
Total no. of Revamp Major jobs executed 1618 Nos
Total no. of Major M&I jobs executed 2492 Nos
Turnaround Sep’11 Cost : Budget Vs Actual
Sr.
No.
Description
Budget-
Material
cost
Budget-
Service
cost
Total
Budget (
Material+
Service)
cost
Actual
Material
Cost
Actual
Service
s Cost
Total (
Actual)
Justification
A
Mechanical/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 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
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
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
TOTAL COST (Rs in Cr.) 74.66 73.96
Rs in Cr.
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/S
GU
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
THANK YOU

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TAround Present.pdf

  • 1. 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
  • 2. 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. Turnaround Maintenance
  • 3. 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
  • 4.  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
  • 5. + 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
  • 6. 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.
  • 7. Turnaround Organization - September 2011 Sr.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
  • 8. Turnaround Optimisation Program TR - 0 TR - 1 TR - 2 TR - 3 TR - 4 Strategic Site Turnaround Review Turnaround Work Scope Optimization Planning, Scheduling, and Integrated Plan Basis Integrated Plan Execution Techniques, T/A Management Post Turnaround Review
  • 9. . 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
  • 10. Mission for Shutdown From Chief Turnaround Manager {S R T C} SAFETY RELIABILITY TIME-BOUND COST-EFFECTIVE
  • 11. 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
  • 12. 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…
  • 13. 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
  • 14. 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.
  • 15. +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
  • 16. +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
  • 17. 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.
  • 18. 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
  • 19. 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 and standard maintenance 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 and finalization of overall S/D schedule
  • 20. Turnaround Organization - September 2011 Sr. 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
  • 21. + 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
  • 22. + 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 Accomplishments of Turnaround which was completed on schedule in spite of lot of challenges
  • 23. 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
  • 24. 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
  • 25. 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
  • 26. 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
  • 27. 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
  • 28. 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
  • 29. 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 of 100% 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
  • 30. 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 be performed 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.
  • 31. 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
  • 32. •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. What made it happen(from 45 to 35 Days)
  • 33. 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.
  • 34. Turnaround Sep’11 : Major counts at a Glance Total Turnaround duration 35 days Total engineering duration 26 days Total no of blinds provided for plant handover 3924 Nos Turnaround Budget 74.66 Cr Turnaround Expenditure 74.69 Cr Major Contractor involved 70 Nos Turnaround Manpower (Officer + Workman+ OEM Experts) 15000 Nos Essar Officers (In 12hrs Shift Rota) 846 Nos OEM & Expatriate 20 & 5 Nos Cranes (250T,200T,150T ,135T,130T,120T,110T,100T& 60T) 57 Nos Hydra 39 Nos Fork Lift 10 Nos Trailer 33 Nos Exchanger tube bundle pullers 05 nos Hydro-jetting machines 26 Nos Hydro-testing machines 50 Insitu Machining sets 12 Rotomol cleaning machine 2 Stress relieving machine 20 Air compressors 09 Nos Pigging machine 06 Nos Hydraulic torque tightening m/c 12 Transformer oil filtration machine 3 Heating oven for motors 2 nos Transformer oil heating and vacuum m/c 3 Mobile lighting tower 2 nos Fire Blankets 3500 Nos Total no. of Revamp Major jobs executed 1618 Nos Total no. of Major M&I jobs executed 2492 Nos
  • 35. Turnaround Sep’11 Cost : Budget Vs Actual Sr. No. Description Budget- Material cost Budget- Service cost Total Budget ( Material+ Service) cost Actual Material Cost Actual Service s Cost Total ( Actual) Justification A Mechanical/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 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 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 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 TOTAL COST (Rs in Cr.) 74.66 73.96 Rs in Cr.
  • 36. 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/S GU 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