Reliance Industries, India
Integrating new plant into existing installations
Reliance Industries Limited, (RIL), is a Fortune 500 company and the largest private sector corporation in India. Its activities range from hydrocarbon exploration and production, to petroleum refining and marketing, petrochemicals, retail and telecommunications.
The RIL Dahej Manufacturing Division’s chemical plant, located 45 km from Bharuch in Gujarat, manufactures various products including caustic soda, polyvinyl chloride, high density polyethylene, monomethyl glycol, ethylene oxide, PTA and PET.
RIL’s Hazira complex in Gujarat is situated in approximately 1,000 acres of land near the banks of the River Tapi. The plant manufactures a wide range of polymers, polyesters, fiber intermediates and petrochemicals.
The two facilities currently use gas turbines and auxiliary boilers based on power plant designs that meet the plants’ existing power and steam requirements. RIL is switching to coal and petroleum coke to reduce power and steam costs at the sites. As part of this process, RIL is establishing Coal Captive Power Plants, (CCPP), a process that is well advanced. The challenges center around how to integrate the CCPP into the existing sites, and ensure that steam and electrical supply is of high quality and availability.
The mission of the project was to establish operating strategies and control system settings for the new CPPS at Hazira and Dahej, so that all foreseeable operating conditions and upset conditions are managed without causing costly outages.
The project was carried out by the following studies:
- Integrated steam and power studies for islanded and grid connected operations. For upset conditions in the steam and power systems, effects were studied on steam and power system in synchronized mode and islanding
- Relay co-ordination and load flow studies were conducted of the entire network
- Transient stability study and validation of PSS tuning of the new CCPP
- Island operation testing and tuning of turbine and generator control
- Electrical power system stability study for island operation
This was a multi-discipline project, involving most of our areas of expertise: process engineering, power systems, and control engineering were applied extensively throughout the project.
The analysis and test packages carried out by Solvina helped RIL to speed up the start-up of the CCPP, and thereby switch to the new power and steam sources sooner. Plant control systems were well-tuned, and efficient operating strategies were developed.
Our involvement saved RIL substantial amounts of capital investment in terms of a smooth, timely start-up of the new CCPP; it reduced the number of outages, and ensured stable and efficient operations at both plants.