P 36
Hazira Ph1 C2 Terminal contd.
3.Sulzer Boil-off compressor Coupling miss out. This is one more case where the supplier as well as the purchaser have missed out to include this while packing the consignment at the factory in Zurich!
But this item was reflected in packing list and we at site searched for it in the field throughout night.
Self, PBMR and Charles D'Souza read the drawing and conveyed to field workers to search for something equivalent to a pair of flanges coupled. The effort and exercise for search went on until 3.30AM that night and then we abandoned. Next day early morning we requested Sh PS Desai to get in touch with Sulzer factory and order for a replacement on SOS basis. LGA also deputed their person for expediting the same. The funniest thing was that the original coupling after third party inspection was neatly packed for shipment to India but left out in factory and stored. The factory regretted for this lapse and arranged air freighting immediately. As usual we had to struggle to convince customs authorities during clearance.
4. Now comes the famous C2 cryogenic piping issue from Terminal to jetty and back.
In basic engg. LGA designed them as A312 8" Dia. line with re-circulation of same diameter for vapour balancing and to keep the line cool at all times. As the detailed engineering was in L&T scope
they did not issue the piping specification. L&T being turn key contract ,went ahead sourcing the pipe as well as fabricated fittings from indigenous source( M/S Rathnamani). Pipe laying , supporting using M/S Swastik developed supports and radiography progressed very fast. Parallelly cold insulation job also started by M/S Lloyd Insulations. As good practice ,Reliance had the system of reporting daily progress and inspection reports to concerned. Mr P Ethiraj, that time chief of Inspection noticed in Mr Vyas daily reports that some fabricated elbows have failed in radiography and the field replaced them. After seeing the repetition for 2/3 days , he raised an alarm and Sh KKM
viewed that very seriously and brought to attention of MDA. Panic was set-in since L&T have gone ahead with fabricated longitudinal weld pipe and elbows out of them. KKM demanded that only seamless pipe should have been used for this service and L&T have taken us for a ride. Here also I became a target victim.When MDA have asked AM Naik and BN to substitute them with seamless pipe, they both responded that it will cost Rs 7Crores and Reliance has to bear the cost and delay.
Then PMSP was asked to get in touch with international majors like Lummus, Shell etc. and find out their methods and practice for handling cryogenic C2. His feedback collection only saved the situation. Then a management decision was taken that L&T will strip open all the insulation so far done and carry out 100% radiography of all the longitudinal welds also. During that crisis situation we had the Radiography shots interpretation expertise non availability in India to manage such quantum . As God's gift, Kuwait war took place and many inspection engineers of Indian origin
were returning via Bombay. VVB was asked to place personnel at airport to identify and pick up the qualified personnel directly on landing. Reliance was lucky to get Mr Bhattacharya ,Lakshmipathy and two others. On crash basis the whole inspection exercise was carried out in flat 40 days. Meanwhile Sh NR Prakash was asked to check the pipe supports design. Dr N Srinivas of Lloyd insulation came out with precast puff insulation. Meanwhile as basic inspection requirement, Reliance asked L&T to furnish the source Factory heat certificates for the billets from which plates were rolled.. MrBambani of L&T did not understand the seriousness of the situation and was fooling around. Moreover M/S Rathnamani had some IT raids in their factory and godown and they have destroyed all the records/ certificates. So once again chaos set in. Finally AMN got himself involved
and found out these plates were sourced from Salem Steel plant and he could get certificates from their records. Then only hydrotest of complete loop could be performed.
Contd........
Key Aspects :- Accountable, Critical challenge, Incident analysis, Technical issue, Ups &down
Hazira Ph1 C2 Terminal contd.
3.Sulzer Boil-off compressor Coupling miss out. This is one more case where the supplier as well as the purchaser have missed out to include this while packing the consignment at the factory in Zurich!
But this item was reflected in packing list and we at site searched for it in the field throughout night.
Self, PBMR and Charles D'Souza read the drawing and conveyed to field workers to search for something equivalent to a pair of flanges coupled. The effort and exercise for search went on until 3.30AM that night and then we abandoned. Next day early morning we requested Sh PS Desai to get in touch with Sulzer factory and order for a replacement on SOS basis. LGA also deputed their person for expediting the same. The funniest thing was that the original coupling after third party inspection was neatly packed for shipment to India but left out in factory and stored. The factory regretted for this lapse and arranged air freighting immediately. As usual we had to struggle to convince customs authorities during clearance.
4. Now comes the famous C2 cryogenic piping issue from Terminal to jetty and back.
In basic engg. LGA designed them as A312 8" Dia. line with re-circulation of same diameter for vapour balancing and to keep the line cool at all times. As the detailed engineering was in L&T scope
they did not issue the piping specification. L&T being turn key contract ,went ahead sourcing the pipe as well as fabricated fittings from indigenous source( M/S Rathnamani). Pipe laying , supporting using M/S Swastik developed supports and radiography progressed very fast. Parallelly cold insulation job also started by M/S Lloyd Insulations. As good practice ,Reliance had the system of reporting daily progress and inspection reports to concerned. Mr P Ethiraj, that time chief of Inspection noticed in Mr Vyas daily reports that some fabricated elbows have failed in radiography and the field replaced them. After seeing the repetition for 2/3 days , he raised an alarm and Sh KKM
viewed that very seriously and brought to attention of MDA. Panic was set-in since L&T have gone ahead with fabricated longitudinal weld pipe and elbows out of them. KKM demanded that only seamless pipe should have been used for this service and L&T have taken us for a ride. Here also I became a target victim.When MDA have asked AM Naik and BN to substitute them with seamless pipe, they both responded that it will cost Rs 7Crores and Reliance has to bear the cost and delay.
Then PMSP was asked to get in touch with international majors like Lummus, Shell etc. and find out their methods and practice for handling cryogenic C2. His feedback collection only saved the situation. Then a management decision was taken that L&T will strip open all the insulation so far done and carry out 100% radiography of all the longitudinal welds also. During that crisis situation we had the Radiography shots interpretation expertise non availability in India to manage such quantum . As God's gift, Kuwait war took place and many inspection engineers of Indian origin
were returning via Bombay. VVB was asked to place personnel at airport to identify and pick up the qualified personnel directly on landing. Reliance was lucky to get Mr Bhattacharya ,Lakshmipathy and two others. On crash basis the whole inspection exercise was carried out in flat 40 days. Meanwhile Sh NR Prakash was asked to check the pipe supports design. Dr N Srinivas of Lloyd insulation came out with precast puff insulation. Meanwhile as basic inspection requirement, Reliance asked L&T to furnish the source Factory heat certificates for the billets from which plates were rolled.. MrBambani of L&T did not understand the seriousness of the situation and was fooling around. Moreover M/S Rathnamani had some IT raids in their factory and godown and they have destroyed all the records/ certificates. So once again chaos set in. Finally AMN got himself involved
and found out these plates were sourced from Salem Steel plant and he could get certificates from their records. Then only hydrotest of complete loop could be performed.
Contd........
Key Aspects :- Accountable, Critical challenge, Incident analysis, Technical issue, Ups &down
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