Electrical Engineering Department ELECTRICAL ... retrofiiting job under new SCADA project has been...

Electrical Engineering Department

Duliajan

Annual Report

for

FY 2013-2014

ELECTRICAL ENGINEERING

DEPARTMENT

Annual Report

2013-2014


Annual Report 2013-2014

Contents

1. Overview of Electrical Engineering Department…………………………………….....….….3 - 5

2. Significant achievements and events at a glance........................................................…...5 - 7

3. Ongoing projects of Electrical Engineering Department……………………….…….…....…7 - 9

4. Technology up gradation………………………………………………………….………….....9 - 10

5. Energy conservation ……………………………………………………………….…….…..…10 - 11

6. Cost control measures …..................................................................................................11 - 12

7. Environmental protection and pollution control measures……………………………………….12

8. Significant seminars, awards received from any national or international bodies ……………13

9. Human resource………………………………………………………………………………………13

10. Acknowledgement…………………………………………………………………………………….14



Additionally we also provide electrical services for operation of passenger elevator in R&D

building and electrical services for socio-religious activities.

PREAMBLE

Electrical Engineering department is responsible for providing reliable and quality power to Fields operation, LPG

production, Housing & Civic area through its own captive power generation, transmission & distribution network. It

also provides operational and support services to various Drilling & work over rigs, Production installations and

Housing & Civic installations.

OBJECTIVES OF ELECTRICAL ENGINEERING DEPARTMENT

Generation of reliable & quality power at Duliajan Power Station and Moran Power Station.

Transmission & distribution of electrical power to various production installations, LPG plant, industrial

installations and housing and civic installations in a safe and reliable manner by regular maintenance of

overhead power lines, underground power cables and sub-stations

To provide round the clock quality operation & maintenance electrical services to drilling & workover rigs,

production installations, water treatment plant, housing & civic installations and other industrial installations

To maintain, repair, overhaul electrical equipment and to achieve high degree of availability and

reliability of all electrical equipment

To provide timely Electrical Workshop, Rig Workshop and Air-conditioning services

Procurement, installation, testing and commissioning of new electrical equipment in the field

installations, industrial, civic and housing installations

To comply with requirements of DGMS, OISD, CEA, SPCB and various other statutory bodies

ACTIVITIES OF ELECTRICAL ENGINEERING DEPARTMENT

Generation of power by operation of 2x14.45MW Gas Turbine at Duliajan Power Station since April 1977. Project activities of 20.28 MW new gas turbine at Duliajan Power Station. Dealing with matters related to QMS: ISO 9001, EMS: ISO14001 & OHSAS 18001.

Generation

Substation-Transmission and Distribution

Preventive and breakdown maintenance of 5 switchyards, 93 substations, 1

compact substation, 125 transformers, 297 OCB/VCB, 73 ACB, 534 Relays and 35

Feeder pillars.



Preventive and breakdown maintenance of the Power distribution network:

a) 33 KV Overhead Line : 19 KM b)11 KV Overhead Line : 35 KM

c) 3.3 KV Overhead Line : 20 KM d) LT Overhead Line : 42 KM

Operation and Maintenance of HT & LT overhead lines (400V, 3300V, 11000V,

33000V).Construction of new overhead lines, Installation & Maintenance of street

lighting and area lighting system. Shifting & raising of O/H lines of OIL & other

agencies. Periodic calibration and testing of relays as per PM schedules.

Fields-Operation and Maintenance

Maintenance of electrical equipments of 82 Production installations. Maintenance of electrical breakdowns in 818 bungalows and 3049 quarters of OIL township. Analysis of failure of electrical equipment. Round the clock electrical report attending. In the FY 2013-14, around 25000 reports of electrical breakdown had been attended in Housing installations and 8000 reports had been attended in Industrial and Production installations. Temporary electrification for socio-religious functions.

Maintenance of Air-conditioning and refrigeration machines.

Project, Planning and Administration

This section deals with HR related issues, budget management, materials management & asset management, contracts management, manpower enrichment through trainings, technical and energy audits. Power evacuation project is taken up to upgrade & strengthen transmission and distribution system to evacuate and distribute power from new 20.28 MW gas turbine for utilization in Housing and Industrial areas.

Workshop and Safety

Repair, overhauling and testing of all electrical equipment. Inspection of new electrical equipment Management of scrapped / written off material Management of safety aspects of the department

Rigs

Round the clock support service to all the Drilling and Work-over operations in NHK, Moran, Digboi and A.P. Fields. Repairing of various electronic modules/ components of the PCRs and EC Brake system. Provide support services like raising of overhead lines for ILM of rigs in and around OIL‟s operational areas in Upper Assam and EPA through either in-house service, directly through UAEDCL (erstwhile ASEB) or through contract.



+

Project-Engineering, Erection and Commissioning

Designing and preparation of electrical schematics & specifications.

Erection, testing & commissioning works of equipment and handing over.

Maintenance of all LT & HT UG cables.

Cable fault location and attending cable related breakdowns.

SIGNIFICANT ACTIVITIES AT A GLANCE

(A) Generation data of Duliajan Power Station and Moran Power Station

Total generation of DPS : 86801676 kWhr Power availability : 99.99 % Total Gas Consumption : 43,157,982 SCUM Maximum Demand : 13.6 MW at 20:15 hrs on 21st June, 2013 (Running Unit: GT No. 1)

Power Failure : 2.23 hours

Total generation of MPS : 10916000 kWhr Power availability : 99.98%

Total Gas Consumption : 4,682,001 SCUM Maximum Demand : 1.746 MW at 22:00 hrs on 15th June ,2013 (Running Unit: GT No. 1)

Power Failure : 2.07 hours

Generation and Electrical set up at Moran

Generation of power by 2x3MW Gas Turbines at Moran Power Station. Maintenance of electrical equipment of Industrial & Production installations (Housing & Civic utilities). O & M of HT & LT overhead lines Installation & Maintenance of street lighting and area lighting system Shifting & raising of O/H lines of other agencies. O&M of Electrical substations.



(B) Station Power Consumption

The total station power consumption of the power station has been maintained at 731120 kWh which is 0.84 % (as

against industrial standard of 1% to 1.5%) of the total power generation for the financial year.

(C) Life Extension of Gas Turbine Rotor

As per the life extension programme of Gas Turbine Rotor of Duliajan Power Station, reconditioned rotor of

GT#2has been placed in GT#1. The job of replacement of GT#1 rotor with the reconditioned rotor along with 9 th

major overhauling of GT#1 was carried out from March, 2013 to April, 2014. The overhauling was completed, and

unit re-commissioned with reconditioned rotor on 8th April 2013

(D) EMS 14001:2004 and OHSAS 18001:2007 certification

Duliajan Power Station has complied with requirements of EMS 14001:2004 and OHSAS 18001:2007 till 3 rd

March, 2014 and 7th March 2014 respectively. Awarding of a new contract is in process for which audit is to be

carried out for recertification

(E) Replacement of turbine oil of Gas Turbine Unit no. 1

Entire quantity of Turbine Oil (Servo Prime: 32) of Gas Turbine Unit No.1 of Duliajan power station was replaced

for the first time since commissioning of the Gas Turbines in 1977. Total 7350 Litres (35drum) of new lube oil was

used for complete replacement lube oil of GT#1.

(F) Replacement of old battery bank of Gas turbine unit no. 1

Commissioning of complete new battery bank replacing old battery bank for GTG unit No. 01of Moran power station has been done. The bank consists of 20 nos. 245 AH, Ni-Cd batteries.

(G) Installation, testing and commissioning of 500 KVA transformers has been done at different locations

500KVA dry type transformers have been commissioned at sub-station R&D and sub-station Medical. 500 KVA oil

filled transformers has been installed at sub-station Tingrai.

(H) Unitised sub-station at Tingrai

Unitised sub-station has been placed at sub-station Tingrai on 27th Dec 2013

(I) Earthing revamping of sub-stations

Earthing revamping of Bihutoli sub-station and Tingrai sub-station has been done. Replacement of all old earth

electrodes and earth strips have been done. Bentonite treatment has been done as per recommendation of CEA.

(J) Retrofitting

Relay retrofiiting job under new SCADA project has been completed at SS#A, SS#E, SS#W-80, SS#OCS-3,

SS#GCS-6 and SS#GCS-5 on 19th Jan 2014.New VCB retrofiiting job has been completed at New water supply

on 8th August 2013. BOCB retrofiiting job with new Schneider make VCB has been completed at New water supply

on 17th August 2013. Numerical relay retroffing job has been done at SS#Jaipur and SS#G on 17th Jan 2014.



a

(K) Electrification of new GET Hostel and new TDX bunglows

Power supply and internal electrification of the new Gents GET hostel and 42 nos new TDX bunglows has been

completed.

(L) Installation of new PCC panel at GCS-1 B Compressor station

The power supply system of GCS-1 B installation was renovated with the installation of a new PCC panel. The

feeders of the new PCC panel were fitted with MCCBs and earth leakage protection devices for protection against

various electrical faults, which were not there in the earlier CFS type panel board

(M) NIA Cement handling plant area substation

Power supply to NIA cement handling plant area loads have been now given from the new substation. With this,

the new substation at NIA cement plant is now commissioned

(N) Power supply arrangement to RTU buildings under new SCADA project and CMT building

Power supply arrangement from existing power sources to 22 nos. of RTU buildings (newly constructed) under

new SCADA project has been carried out.

Power supply to CMT building has been given from the feeder pillar at Water injection station 21 with laying of new

cable and commissioning of a new panel at CMT switch room

(O) Tengakhat GCS

Electrification and illumination arrangement has been made for newly constructed Tengakhat GCS

(P) Cable laying jobs

Major cable laying jobs were completed in this period: namely, replacement of portions of GCS-4 feeder, power

supply cables (HT & LT) from new TDX substation, power supply cables to Gents GET hostel, sub-station 6 to

Tingrai feeder cable replacement, laying of cables under Power evacuation project, G sub-station to Tie-line

feeder new isolator, Sub-station 4 feeder upgradation, Bihutoli sub-station feeder upgradation, Medical sub-station

new transformer cable replacement, power supply cable to Electrical Engg. Deptt. new building etc.

(Q) Achievement of service level agreement between Production (Oil) and Electrical Engg Department

Service level agreement between Production (Oil) and Electrical Engg Department with target of 97% was

achieved for the financial year.

(R) Achievement of service level agreement between Production (Gas) and Electrical Engg Department

Service level agreement between Production (Gas) and Electrical Engineering Department with target of 97% was

achieved for the financial year.

(S) Achievement of service level agreement between Drilling and Electrical Engg Department

Service level agreement between Drilling and Electrical Engineering Department was 100% achieved for the

financial year.



MAJOR ONGOING PROJECTS OF ELECTRICAL ENGINEERING DEPARTMENT

(A) 20.28 MW Gas Turbine Power Plant

LSTK contract has been awarded to Bharat Heavy Electricals Limited & execution is under progress. Major

equipment has been delivered at site and various construction, erection and testing of equipments & sub-plants are

currently in progress. The Gas Turbine was put on ratchet on 30 Mar 14 and was subsequently cranked up to a

speed of approximately 430 rpm on 31 Mar 14.Presently, various sub-contractors and vendors of M/s BHEL (LSTK

contractor) are engaged at site for completion of balance jobs.

Progress of work as on 31st March 2014

Supply of materials and equipments: 92%

Civil Construction works: 84%

Erection works: 70%

(B) Power Evacuation Project

Power evacuation project is taken up to upgrade & strengthen transmission and distribution system to evacuate and distribute power from new 20.28 MW gas turbine for utilization in Housing and Industrial areas. The project comprises of three phases. Phase I: Evacuation of power from the power plant to load centre switchrooms It includes construction of 2 nos 11KV switchrooms and laying of HT Cable from Duliajan power station to switch rooms through pucca cable trench. It includes installation and commissioning of the switch rooms with required HT and LT switchgear panels and transformers.60 % of the job has been completed. Phase II: Upgradation of 3.3KV sub-stations to 11 KV sub-stations and LT distribution system in housing, industrial and civic areas. It includes construction and commissioning of 6 No. 11KV substations to replace existing 3.3KV substations in domestic distribution network. It also includes construction and commissioning of 1 No. 11KV switch room, upgradation of 2 nos 11 KV sub-stations inside industrial area, installation and commissioning of 19 nos. feeder pillar using ACB, MCCB with upgraded protection and 6 nos. RMU in housing, industrial and civic areas. It also includes pre-fabricated 11KV substation inside Industrial area. 10 % of the job has been completed.



ADOPTION OF NEW TECHNOLOGY, INNOVATIONS AND PERFORMANCE OF EXCELLENCE WITH

RESULTANT BENEFITS

The existing PLC control System with MS-DOS based control system of Gas Turbine Generators is now

considered obsolete, and hence, it needs to upgrade the control system of Gas Turbine Generators with the new

generation MS-Window based control system. The procurement process for Up-gradation of PLC based control

system for 2 nos. 14.45 MW Gas Turbine Generators of Duliajan Power Station is under progress.

(A) Up gradation of PLC based control system

(B) Up gradation of electrical equipments of production installations

Electrical power supply systems of most of the Production-oil and gas installations are quite old and are not

adequate/well-equipped for stringent safety requirements of today. Specifications for panel boards (power and

motor control centres) for these installations have been updated as per Central Electricity Authority (Measures

Relating to Safety and Electric Supply) Regulations, 2010, and DGMS directives.

The specifications take into account latest state of the art technology like incorporation of intrinsic safety

barriers (between hazardous and non-hazardous areas of oil mines), safety measures such as 30 Volt remote

push button stations, earth leakage protection in each feeder etc. Action plan regarding revamping of

electrical power supply system of these installations has been drawn up, to be carried out in a phase-wise manner.

Budget for six such installations, namely, Joypur OCS/GCS, OCS-4, GCS-4, OCS-8 and Makum OCS has already

been sought.

(C) Adoption of energy efficient fittings

Energy efficient SON fittings had been commissioned in New TDX

area, MTDC, Main road at NIA, Well 21 and CMT.1 no. of 70W SON

new Luminaries ,25 nos of 150W SON new Luminaries and 26 nos

of 400W SON Flood light luminaries had been installed.

Phase III: Upgradation of11KV HT sub-stations and LT distribution substations in housing, industrial and civic areas.

It includes upgradation of 7 Nos. LT/HT substations in housing and industrial area, construction and commissioning of 1 no. 11KV switch room, construction of cable trench from GCS 5 to R&D complex, installation and commissioning of 16 nos. feeder pillar using ACB and MCCB with upgraded protection in housing, industrial and civic areas. It also includes revamping of power distribution system of oil market and E&F Type bungalow areas and installation of automatic power factor improvement system in all new substations.



(D) Major modification of LT OH distribution line

A total of 7 nos LT feeder has been modified and 4 nos of new LT feeder has been erected which has led to the following benefits in the network distribution.

1. Load balancing of different feeders.

2. Reduction of load to a safer value to avoid OH line breakdown

3. Clear distinction of zones of different feeder power supply areas for safe identification.

4. Isolation of offices, school and other utility power supply from housing loads

5. Arrangement of New TDX B’low and GET hostel power supply.

(E) Up gradation of LT OH line and Up gradation of UG power cable

Up gradation of LT overhead lines conductors

(approximate: 5000m) with higher current carrying

capacity from rabbit to dog ACSR conductors in the

areas of substation-7, SS-4, B-Type SS &New TDX

substation has been carried out.

(F) Introduction of digital scroll compressor

Old PILC cable has been replaced with the latest

technology XLPE 240sqmm (2000m) underground

cable in 11KV Ring Main System.

The digital scroll compressor in the field of air conditioning and refrigeration system has been introduced which

has led to energy efficiency and also automatic setting of consumption of only required electrical power at a

particular time.

(A) Generation data of Duliajan Power Station and Moran Power Station

ENERGY CONSERVATION WITH RESULTANT BENEFIT:



(B) Gas consumption trend of Duliajan Power Station and Moran Power Station

(C) Consumption of petroleum products for industrial use

Note: Total 7350 Litres (35drum) of new lube oil was used for complete replacement lube oil of GasTurbine#1 in the

month of November 2013.

(D) Energy conservation by adoption of various measures

Measures

Equivalent energy in kWhr

1. A total of 300 Nos. of analog type ceiling fan regulators are replaced with

electronic regulators. A total of 16 nos. of 100 watt bulbs at old & new water

supply stations are replaced with 15 watt CFL.

11112 kWhr

3. A total of 36 nos. of old air conditioners with energy efficient (3 star rated)

window type air conditioners in buy back scheme were replaced. A total of

13 nos. of old window type air conditioners with energy efficient (3 star

rated) split type air conditioners were replaced. A total of 8 nos. energy

efficient (3 star rated) window ACs and 6 nos. split ACs were installed.

14537.50 kWhr

Various measures taken for the conservation of energy during the year 2013-2014, have resulted in an annual energy saving of 25649.50 kWhr



COST CONTROL MEASURES

(A) In Moran power station, a distilled water plant is in use to meet the high volume of distilled water requirement for

regular turbine-compressor cleaning which has resulted in cost saving of power station.

(B) In Moran power station, use of lube oil demister equipment resulted in cost saving by reducing lube oil and air

inlet-filter-elements consumption.

(C) Strict monitoring of overtime & vehicle mileage were exercised during the financial year in the department.

ACTIVITIES RELATED TO SAFETY, DGMS, ENVIRONMENTAL PROTECTION AND POLLUTION CONTROL

(A) Used / burnt lube oil generated during different maintenance activities of Gas Turbines is collected in drums and

kept at Duliajan Power Station premises. 46 drums of such burnt / used lube oil has been despatched to authorised

recycler of used / burnt lube oil M/s East End Petro- Chemicals (P) Ltd. via Materials Department for onward action as

per policy of OIL.

(D) A contract has been awarded to M/S Nanak Engineering Works, P.O. Parbatpur, Namrup, Assam for inspection,

load testing & issue of test certificates for EOT crane and other lifting tools of Electrical Engineering Department.

Accordingly, the party has carried out inspection, load testing of EOT Cranes & other lifting tools of Duliajan Power

Station and certificate has been issued to Duliajan Power Station for the mentioned jobs by authorised person as per

statutory norms.

(B) Installation of 2 nos. of energy efficient split air conditioners with green refrigerant using R410A has been done..

Installation of 1 no. precision AC with R407C refrigerant has been done. These refrigerants are used as an alternative

to R22 which has adverse effect on environment.

Kilometerage of Electrical Engineering department for the FY 2013-2014



SIGNIFICANT SEMINARS AND AWARDS

(A) Duliajan Power Station won 2nd position in internal safety audit during the year (Category -process plant).

(B) Longest accident free employees award

Shri Manik Chandra Gogoi and Shri R. Borah of Electrical Engineering department had been awarded as longest

accident free employees during safety week held by Safety department.

HUMAN RESOURCE

MANPOWER

Total executives strength of the department : 46 (Including Moran-Electrical) Total employees strength of the department : 385 (Including Moran- Electrical)

ENRICHMENT OF HUMAN RESOURCE

A total of 12 executives of the department attended various in-house training and 23 executives of the department

attended in-country training to enrich their knowledge in specific areas. A total of 2 executives of the department

were given overseas training to enhance their skill in the area of operation.

A total of 101 work persons of the department attended in house training and 21 work persons of the department

were sent to in country training to enhance their skill.

Electrical Engineers working in SCR panel

Progress of new Gas turbine project



ACKNOWLEDGEMENT

It gives me immense pleasure to congratulate the workforce of Electrical Engineering Department

for the commendable job they have put up during the financial year 2013-2014 to achieve the

targets. We acknowledge our indebtedness for the valuable guidance and support received from

Resident Chief Executive, local management and General Manager (Engineering). We gratefully

acknowledge the support received from corporate management for efficient functioning of the

department. The department also sincerely acknowledges various departments of OIL for their

continued support towards fulfilling its objectives and achieving the goals of the department despite

various constraints.

A C Patowary Head-Electrical

Date: 25.04.2014

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