PowerPoint Presentation

[Virtual Presenter] Good morning everyone. I am here to present our proposed solution to provide backup in case of a problem with one of the MLPUs. We will discuss how our VFD scheme with interoperability of VFDs in SMPL-Viramgam's VC-28 will address the shutdown situation and the lack of a backup plan. Let's begin our presentation..

[Audio] This slide will focus on the inter-operability of Variable Frequency Drives (VFDs) at Viramgam, WRPL Rajkot location. We will examine the current VFD Scheme and the problem statement that will lead us to the proposed VFD Scheme..

SMPL VC28. 01.

[Audio] SMPL VC28 is the most critical crude oil pipeline in WRPL Viramgam. It has a designed throughput of 9.3MMTPA and two MLPUs are kept running at all times while a third is kept as a standby. VC28 has an average flowrate of about 1800Kl/hr, and it is essential to maintain the requisite discharge head/pressure. If one of the pumps trips, VC28 may experience an instantaneous shutdown if a second pump is not activated promptly..

[Audio] The fifth slide shows the inter-operability of the Variable Frequency Drives (VFDs) in VC-28 at the SMPL-Viramgam location of the WRPL Rajkot. This includes three MP-01 pumps, two MP-02 pumps, and three MP-03 pumps. The VC 24 mainline pumping units and the ex-Vadinar operation of VC 24 have a pump/engine make of Ruhrpumpen/Allen, with a rated flow of 1025 kl/hr, a rated head of 316 m, a rated RPM of 3025, and an engine BHP of 3146. The VC 28 mainline pumping units and the ex-Viramgam operation of VC 28 have the same specifications..

[Audio] We are setting up Variable Frequency Drives (VFDs) for three motors at SMPL-Viramgam WRPL Rajkot. Each motor is 6.6kV, 1600kW, and has been supplied by M/s. Nidec from Italy. The VFD systems are provided by M/s. Siemens with a rating of 6.6KV/1745KW. That concludes this slide..

Present VFD Scheme. 02.

[Audio] The slide describes the arrangement of Variable Frequency Drives (VFDs) in the VC-28 at SMPL-Viramgam. It is evident that each Motor Load Power Unit (MLPU) can either be operated by a VFD mode or Bypass mode. This is due to the high inrush current and damage which Bypass mode is likely to cause. Furthermore, the output of each VFD is connected directly to its respective MLPU by an isolator. Unfortunately, there is no facility to enable the interoperability of VFDs with other MLPUs..

[image] Scheme VC28 MLPIJ WD B 6.60'. MP-7. MP-8.

Problem Statement. 03.

[Audio] This case study discusses the potential risks associated with inter-operability of Variable Frequency Drives (VFDs) in the VC-28 at the SMPL-Viramgam location in WRPL Rajkot. In this case a VFD7 fault in MLPU7 posed a serious risk of both MLPU7 and MLPU8 being unavailable. Specifically, the situation arose where the VFD fault caused both a motor/pump fault in MLPU8. Therefore, proper maintenance of VFDs needs to be taken into account when keeping the inter-operability of MLPUs running. These types of risks must be identified and minimized in order to prevent any potential system failures..

Proposed VFD Scheme. 04.

[Audio] In this slide, we discuss a proposal to facilitate the flow of power from Variable Frequency Drives (VFD) to the MLPUs, through the use of isolator switches. This proposal will allow for the interchanging of VFDs and MLPUs in VC-28, which eliminates the bottleneck problems during maintenance and when multiple defects occur. In total, there are 9 isolator switches which are grouped into 3 sets of 3 switches each, and the output of the VFD is connected to the junction box. To facilitate the exchange between MLPU-07 and VFD-09 and MLPU-08 and VFD-08, isolator 7c and 8b should be switched on..

[image] wpu h•pass. MP-7. MP-8. MP-9.

[image] MLPU-7 lined up with VFD-8. MP-7. MP-8. MP-9.

Implementation. 05.

[Audio] This slide looks at the inter-operability of VFDs in VC-28 at SMPL-Viramgam Location WRPL Rajkot, scheduled for 28.11.2023. To ensure the inter-operability requirements are met, there needs to be mechanical castell key interlocking in each of the 9 isolator switches. This interlock only allows one switch, a, b or c, to be ON at a time, and each switch set must be lined up with only one VFD. Additionally, modifications need to be made to the bus bar and their feedback needs to be extended to SCADA. Finally, 3 additional HT Junction Boxes need to be procured and installed with 3 Nos of HT cable jointing done between VCB and VFDs, and 3 Nos of HT cable joints need to be done at VFD output cable. This, combined with 3Cx400Sqmm HT cable and 12C CU control cable, should complete the inter-operability requirements..

[Audio] The slide displays a table with the details of the modification of the MLPU line up scheme in SCADA for logical interlock for the Viramgam location. The table includes the switch tag, status, and activity for each of the MLPUs and VFDs. Ensuring all of the switches are correctly lined up is important for the system to operate correctly..

Benefits. 06.

[Audio] I would like to discuss the cost-benefits of inter-operability of VFDs in VC-28 at SMPL-Viramgam. Having more MLPUs running together can lead to a drastic reduction in downtime. This also minimizes the loss of throughput that could have been otherwise incurred. For example, if two MLPUs are running, the flow rate in SMPL VC-28 is 1850 KL/hr. However, if only one MLPU is running, the flow rate reduces to 900KL/hr, resulting in a loss of Rs. 11,00000/hr. The estimated cost of this project is Rs. 15.00 Lakhs, as per quotes received from various vendors..

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