Oil & Natural Gas Corporation’s(ONGC) Uran Processing Complex , near Mumbai , India was Commissioned in 1981. It is the first landfall point of Bombay Offshore field of Oil /gas & handles approximately 16 Million Metric Tons per Annum (MMTPA) of Oil & 12 Million cubic Meter per day (MCMD) of natural gas along with 1400 Cubic meter per day (CMD) of condensate. .This is around half of domestic production of Oil & Oil Equivalent Gas(OEG). After extracting some value added products like Ethane Propane(C2C3) ,Liquefied Petroleum Gas(LPG),Light Aromatic Naptha(LAN),the Plant Caters Lean gas(lighter Hydrocarbon) to various consumers. Rich gas is also fed to some preferred consumers in & around Mumbai. The crude oil is dispatched to refineries after maintaining required Basin Sediment & Water(BS&W). The utility area of this strategic plant contains one of the first Gas Turbine Generator(GTG) based cogeneration plants of the country .Two GE Frame-V GTG’s (2X20MW) each with a Bharat Heavy Electrical Ltd(BHEL) supplied Heat Recovery Steam Generator(HRSG:2X75Tons/hr) were commissioned in 1984.The facility was further upgraded with additional of 3rd gas Turbine(20MW)&HRSG boiler(90Tons/hr) in 2000. While the control system of the first GTG was Speedtronic (Mark-II) with pneumatic boiler control system, the new turbine was provided with latest Triplex Speedtronic(Mark-V) control that interfaces with Honeywell PLC/DCS The present paper focuses Instrumentation & Control system & its maintenance with specialties of new one. It also highlights our previous experience, relative merits & de-merits of two different technologies & challenges faced by operation & the maintenance (O&M) team of the plant. With this knowledge, O&M team is capable of carrying out any type of challenging activity related to a typical gas based captive power plant not only in India but also to any part of the world .
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