1. CPP:
Emergency DG (12.5MW): EDG is under Maintenance. Powerica plant at 22K EDG supplying power to SS11 and
SS14 (RWTP), SS10 (RODM), IA/PA plant.
GTG-1, Running normal at 16.4 MW Load. Running with Primary Gas Purge Valve in closed condition-Status Same
GTG-2, Running normal at 6.0 MW Load. Running on Load Clear Mode. Revised Size Orifice installed in Air Circuit.
Trial of GTG for mode change over from Primary to Lean-Lean and Lean-Lean to Primary done. Trial @ 20 MW
taken. Shared to BH Engg. Analysis awaited.
UB-1 Leakage observed from SH zone. Refractory Breaking is under progress identifying exact location of leakage.-
Status Same
UB-2 Refractory Breaking is under progress identifying exact location of leakage. Leaking Tube identified and
Welded. RT Clear.
UB-3 Pre-commissioning activities under progress-Commissioning Activities started.
HSD Road tankers unloaded, and it is continuing.
2. PROGRESS SYNOPSIS Continued
Utility:
The intake pump is running to maintain the firewater reservoir level and SBR A, G, H.
RWTP – RO I Skid D and E are in service with 85% recovery.
RWTP – Drinking water system commissioned.
RWTP –SS14 – Sinking Observed in the floor of the SS and this has caused the cable support being damaged in the cable cellar. The foundation
of the distribution transformer is also sinking. Preparation for micro pilling is in progress by civil.
SBR-B – air grid repaired. Air blower trial taken and kept in observation. After completion will go for biomass development.
RODM –RO III skid A taken in service with 80% recovery. MB A kept in service on 18.05.2023.
RODM – RO I feed water tank water filled and respective feed pumps MRT done. RO II feed water tank filling preparation is in progress.
CT-1 – Emergency CW Pump B and Main CW Pump B are in service with CPP power.
CT-2 –passivation activity completed, and restoration is in progress.
CT-4 –CW basin filling with firewater completed. Basin & sump leakages arresting and pumps MRT preparation is in progress.
LP Air Compressor A /B/C/D and Dryer C/G –are in service with CPP power. Instrument air vessel A and B is pressurized up to 20 kg/Cm2.
N2 plant – APU chain A absorber media filling is in progress.
Expander B external oil flushing is in progress.
Nitrogen storage tank vessel A PSSR completed. Preparation is going on for filling liquid Nitrogen from DFL.
• Air purification sequence program from Chain B to A is in progress.
• Flushing of LP nitrogen header with plant air is in progress.
• Fire Pump House: Diesel driven pump A and C trail run taken in presence of vendor (Cummins) and found OK .
• Electrical driven pump A and E and Jockey pump C kept in service to maintain the firewater header pressure.
ETP: SS-09 charging of EPMCC, UPS & ASB and LDB .Format 2 punch generation and sign off. Nitrogen line flushing completed.
3. ❖ The RCO MOC implementation is ongoing in Crude Area with erection close to Tank K.
❖ Leak test activity is ongoing in Zone A.
❖ The re-orientation of MOVs in crude area to ensure valve operability is ongoing.
❖ The hot loop checking for SRR-10, control valve and MOV functional test is in progress in Zone A..
❖ The pigging activity for C4 from Alkylation to Storage - 6"-P-720-3157-B1A, and Lt. cracked slop from
RFCC treatment tank to cracked slop tank - 12"-P-720-3195-A1A has been completed in zone B.
❖ Leak test activity has started in Zone C.
❖ The Solo Run test of motor 713-PA-1303A has been completed in Zone C
❖ In Zone D, 36 FO trucks were received and unloaded from 11/05/2023 - 17/05/2023.
❖ Leak test is ongoing in Jet fuel and Kerosene area in Zone D.
❖ The Solo run for 2 OWS pumps in zone D area has been completed.
❖ Pump solo run for kerosene UG pump - 732-PA-3208 has been completed.
❖ In Zone E, leak test is ongoing in diesel gantry area.
WEEKLY REPORT FOR OFFSITE (May 18, 2023)
4. ISBL (Primary & Secondary Blocks):
Short synopsis (Primary Unit):
CDU:
1. Leakage observed from air fin cooler 101-EA-1001 A tube bundle, to be attended. 101-EA-1004 D header plug
and 100-EA-1002 B tube leakage attended. 101-EA-1006 E vent leakage is pending due to material issue.
2. Crude column internals - UOP Inspection completed. Tray man way box up completed. RFI has been raised for
tray manhole box up.
3. TSR modification & tray fitting work is continued in light diesel stripper and heavy diesel stripper. In 101-CC-
1002, TSR welding has completed. 101-CC-1003 fit-up completed. TSR welding of 3 TSR has been completed,
Remaining 2 TSR welding job in progress. Trays installation work will commence soon.
4. CT-2 cooling water headers passivation completed. CW headers drained for installation of orifice flanges .
5. Lube oil flushing of feed gas compressor (102-KA-1002) completed. Box up of spools completed. Lube oil
flushing with bearing is balance.
6. MRT started in CDU Block. Total 25 pumps MRT done. Out of this 2 pumps are not healthy.
7. 101-P57 , 101-P51, 100-U26, 102-P27, 100-U23, 100-U20, 100-U19, 100-U08, 100-U14 leak test is in
progress.
8. LP steam header preparation for steam blowing is in progress.
9. Total 233 out of 322 no. of motors solo run completed in CDU block.
10. SRR-01 - DCS SAT, and ESD loop checking is in progress. Out of 6114 loops, 3161 loops checked till date &
2189 loops completed successfully. This week 46 loops checked & 38 loops completed.
5. MS BLOCK:
1. 40 AG piping systems is released for final box-up after completion of the flushing activity till date.
2. 41 Vessel final box up completed till date.
3. 2 Column’s manways box-up completed & 4 Column’s tray manways box-up done & 2 Column’s Chimney tray
leak test completed and 6 column’s seal pan leak test successfully carried out.
4. Lube oil flushing completed for 152-KA-1001, 151-KA-1001A/B, 155-KA-1001A/B and 152-KA-1002A/B/C
(Final lube oil flushing through bearing will be carried out after the availability of the actual service oil)
5. Hydro-test (Scope - 85) of all 85 Heat Exchangers are successfully completed on both sides whereas 6 Heat
Exchanger's tube side leak observed. Leak identification is in progress under mechanical supervision. 4/6
Heat Exchangers leak rectified.
6. Fin Fan Air Cooler Exchanger's hydrotest under progress (45/160 is completed), leakage found in 02 bundles.
6. RFCC:
1)#2 1) AG Piping Format-2s were raised to EIL; (Total Format-2s raised-1651).
2)#08 Format-2 piping loops punch points liquidation checked (Total number of liquidated Formats-2s: 1271).
3)#0 packages AG loops Format-2 raised jointly (Mech/Instr/Elec/Opr) and total number is 665.
4)#11 Format-2 package loops punch points liquidation checked (Total number of liquidated Formats-2s: 296).
5) #0 Compressor/Blower packages AG loops checked (Total number- #709)
6)#08 loops flushed this week, making a total of 502 loops flushed.
7)Expander 1-115-PZ-1001: LO flushing is completed with bearing except Rotor bearing. 6000 litre ISO VG 32 is filled in LO tank.
8)Expander-2-115-PZ-1002: LO flushing is completed with bearing except Rotor bearing. 4800 litre ISO VG 32 is filled in LO tank.
9) Aux Air comp -111-KA-1001: LO flushing is completed with bearing except Rotor bearing.
10) Aux Air comp -111-KA-1002: LO flushing is completed with bearing except Rotor bearing.
11) HPC -114-KA-1001: LO flushing is completed with bearing except Rotor bearing.
#2 number loop result found ok & waiting Lab result for balance #2 loop.
12) Main Air blower -111-BL-1001: Water and air flushing is completed. Loop1 and Loop2 lube oil flushing is completed, and sample sent to
Lab. Total no of loop -4.
13) Main Air blower-111-BL-1002: Water flushing, and Air flushing is completed.
14) Wet gas compressor 113-KA-1001A and 1001B: No activity.
11)Cooling Water System- Supply and Return valves closed after completing cleaning and passivation
12)HP/LP flare systems flushing towards OSBL side completed. LP flare line 66” line OSBL flange towards OSBL Gasket replaced. Leak test to be
done.
13) OWS system flushing in progress with service water.
14) VHP steam line hydrotest completed for Main header & MAB branch headers @ 256 bar (g).
15) DM water return line pipe replaced & leakage again found during leak test
7. RGDU
1. Format 2 checking of piping loops & equipment in progress. Completed for 856 loops out of 858 . Liquidation of format
2 punch points also in progress. On shore manpower is very less.
2. 284 loops flushing completed till date.
3. 29 out of 33 Heat Exchangers both sides hydro test completed. Tube side leakage found for 3 no. of heat exchangers.
4. Format-3 files, System wise checking in progress ,21 number of system files received with lots exceptions, its under
review. 2 system accepted with exception.
5. RGC Compressor Lube oil Flushing in progress.
8. HGU
1. Format 2 checking of piping loops & equipment in progress . Completed for 713 loops out of 722. Liquidation of format 2
punch points also in progress.
2. Piping loop flushing for 572 loops completed till date.
3. Exchanger hydro test started. 32 out of 35 Heat Exchangers both sides hydrotest completed. One heat exchanger leak
found.
4. Format-3 files system wise checking in progress, 42 systems received with lots exception , its under review, 20 AG &1 UG
systems accepted with exception & structure accepted with exception 10.
5. N2 start up compressor lube oil flushing completed.
6. Unit-161 Rformer-1 refractory work under progress out of 533 Ton 36 Ton refractory work remain
7. 160 KA-0002B lube oil circulation on going.
8. At SRR -6 Instrument hot loop checking started.
9. FO/FG
• Total 64 loop flushing done out of 65.
• Format-3 files system wise checking in progress, 2 AG system accepted with exceptions.
• FG header OSBL side flushing completed and pressure test in progress.
• FO supply and return line electrical tracing job under progress.
10. PROGRESS SYNOPSIS Continued
SRU:
1. Format 2 checking of piping loops is I/p. Completed for 817 out of 823 offered. Liquidation of format 2 punch points I /p.
2. Piping loop flushing/blowing continued. 614 loops flushing completed till date.
3. Motor Solo Run in progress. 32/126 Completed.
4. Hydrotest of 28/32 fin fan tube bundles completed. Heat Exchangers/Steam Generators Hydrotest for 35/53 Completed.
7. MP/HP/LP steam header preparation for steam blowing is in progress.
8. Stripped water non-phenolic Header from OSBL site air flushing completed.
9. CWS/CWR ISBL system passivation preparation i/p.
10. The hot loop checking for SRR-08 is in progress (Total 4172 loop, completed 1278).
FLARE:
1. JNK contractor manpower mobilized at site on 11.04.2023. Balance work in progress.
2. Flare PSSR audit done.
3. The hot loop checking for SRR-08 is in progress (Flare total 251 loop, completed 90).
4. 24-inch Flare Pilot flame lit up done successfully at 12.18 hrs.
CT04:
1. CWS/CWR pipes welding job completed at OSBL Piperack near N2 plant.
4. CT4 motors 634-PM 1001D pumps coupling & alignment job i/p.
5. CWS/CWR FT’s tapping welding work i/p .
11. PPU:
1. Format 2 checking of piping loops under progress. Completed for 505 loops out of 505 offered. Liquidation of format
2 punch points under progress.
2. Piping loop flushing/blowing continued. 248 loops flushing completed till date. 95 loops reinstated.
3. 15 piping system format-3 Accepted with exception.
4. 11 equipment cleaning, internal inspection and agitator fixing job completed. Liquidation of format 2 punch points
under progress.
5. 48 Equipment format-3 Accepted with exception.
6. ISBL Service water system flushed and keep in charged condition.
7. ISBL Drinking water system flushed with service water, then isolated from Battery limit.
8. ISBL DM water system flushed, then isolated from Battery limit, drained and dried.
9. ISBL Plant air system floating with OSBL header and keep in charged condition.
10. Reactor mechanical seal job: PPU train-A 1st and 2nd reactor, Train-B Reactor mechanical seal installation completed.
12. MHC
ALKYLATION
1. Format 2 checking of piping loops & equipment i/p. Completed for 1057 AG piping loops out of 1059 offered.
2. Liquidation of format 2 punch points also i/p.
3. Exchanger hydro test started. 38 out of 71 Heat Exchangers both side hydro test successfully completed .
4. Piping Loop flushing and blowing continued. 571 loops flushing completed till date.
5. SAR Plant Combustion Chamber Refractory Dry out completed. Final inspection balance.
1. Format 2 checking of piping loops & equipment i/p. Completed for 905 AG piping loops out of 905 offered (
905 loops completed by cross functional team)
2. Piping loop flushing/blowing continued. 745 loops flushing completed till date.
3. 890 loops released for box up. Among these 823 loops are boxed up.
4. 65 loop leak tests completed. Including 4 system are leak test completed.
5. 196/197 Equipment format 3 completed.
6. 5/5 column, 23/37 vessels, 45/45 Exchangers boxup done.
7. 10 OSBL lines pigging is done. 6 18” lines are pending.
8. Nitrogen preservation of 11 Heat Exchangers done
9. 71/92 Air Fin Cooler hydrotest is completed.
10. 6/10 OSBL line pigging done. 4 nos of 18” lines are pending.
13. INSTRUMENTATION HIGHLIGHTS AS ON 19 May 2023 ( TOP PRIORITY TAGS )
1. RODM CR06 Hot Loop checking 1009 out of 5839 completed.
2. RWTP CR08 Hot Loop Checking 3063 out of 3855 completed.
3. GTG#1 hot loop checking 783 out of 800 completed. Remaining pending for ECS .
4. GTG#2 hot loop checking 767 out of 800 completed –now running at around 20 MW
5. GTG#7 hot loop checking : Hot Loop checking 710 out of 800 completed.
6. GTG#8 hot loop checking : 270/ 800 completed
7. Trading Facility SRR11 Hot Loop checking 1097 out of 2556 completed.
8. CPP CR02 UB1 BMS and DCS Hot Loop Checking 459/459 & 573/581completed
9. CPP CR02 UB2 BMS and DCS Hot Loop Checking 459/459 & 572/581 completed
10. CPP CR02 UB3 BMS and DCS Hot Loop Checking 359/459 & 500/581 completed. 179 loops for Soot Blowers also completed. Start up preparation in progress
11. CPP CR02 HRSG1 BMS and DCS Hot Loop Checking 240/240 & 490/490 completed. Soot blower loops checks completed. Start up preparation in progress.
12. CPP CR02 HRSG2 BMS and DCS Hot Loop Checking 235/240 & 488/490 completed. Soot Blower loops checks completed.
13. CPP CR02 HRSG3 BMS and DCS Hot Loop Checking 66/730 completed
14. CPP CR02 HRSG7 BMS and DCS Hot Loop Checking 286/730 completed
15. CPP CR02 HRSG8 BMS and DCS Hot Loop Checking 49/730 completed
16. CPP BOP related priority Hot Loop Checking 1814 out of 3137 completed
17. CDU/SRR1 Hot Loop Checking 3968 out of 6114 Completed
18. SRU/SRR8 Hot Loop Checking 1236 out of 4172 Completed
19. N2/Air Hot Loop Checking 1409/ 1842 Completed.
DCS/ESD/GDS Panel Installation V03 Modification SRR/CR System Power ON Status
BUILDING TOTAL INSTALLED BALANCE SCOPE COMPLETED BALANCE SCOPE COMPLETED BALANCE
SRR/CR/SS 2038 1841 193 975 850 125 20 12 08
