1. ELECTRICAL MAINTENANCE IN HPCL
INDUSTRIAL TRAINING REPORT

2. 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.

3. ● 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

4. 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

5. What is electrical maintenance?

6. Types of Maintenance
● Breakdown Maintenance
● Periodic Preventive Maintenance
● Predictive or condition-based
Maintenance
● Pro-active Maintenance

8. 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.

9. 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

10. 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

11. LOCATING UNDERGROUND
CABLE FAULTS
TOOLS and EQUIPMENT
●Surge Generator
●Cable Tracer

12. ● Fault Locator
● Continuity Tester

13. 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

14. Meter control centre
(MCC)
Power control centre
(PCC)

15. Ingress Protection

16. Gas Insulated Substation

17. 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%)

18. 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

19. Visual comparison between AIS
& GIS components

21. UNINTERRUPED POWER
SUPPLY
BLOCK DIAGRAM OF UPS

22. Types of ups:
● Offline / standby
● Line-interactive
● Double-conversion / online
● Ferro-resonant
● DC power
● Rotary DRUPS (diesel rotary UPS)

23. Normal operation

25. Operating on alternate mains input

27. Thank You!...