P 54
JMD DTA Contd.
When that was the issue we faced for running the cooling water mains, we had an entirely different challenge when it came to main refinery fire water system! As I said in the beginning, the team assumed that there shall not be more than 5000 equivalent hydrants in DTA- including both ISBL and OSBL hydrants, Monitors etc. and went ahead designing 10X1000M3/Hr fire water pumps in pond 2 pump house. As the engineering progressed we were in for surprise shock! The total number of equivalent hydrants requirement crossed 6000 mark and it called additional pumping capacity and storage pond. When the whole team was blinking for a workable solution, Mr Bob Green ,Bechtel Civil specialist came out with a brilliant idea and a workable resolution. He identified and suggested that there is a low lying area adjacent to ETP West of road A, which happens to be about 400M only from the pond 2 area. He proposed that can be developed as additional pond and required additional fire water pump provision can be done in that. With that lead we jumped with joy. Then we went into detail and configured the new pump house orientation such that both the pump house discharge can be clubbed into single manifold. That resulted to have two fire water ponds 2&2A combined into single discharge with 16 pumps- any 10 operating with 6 stand by thus meeting TAC conditions fully. Though we implemented 16 pumps in 2 ponds, every one in the team felt we are gross over designing ;but what to do! The national rules stipulate that. Even international majors like Shell & international re-insurers M/S Munich RI commented that India is one country where empirical formula approach is prevalent. It is a different story that I have taken advantage of this excess margin while conceiving the fire water requirements in J3, which I will narrate when I address the J3 design basis.
Here I would like to emphasise that the whole management are having the wrong concept that executing ISBL projects are the biggest challenge when compared to OSBL and infrastructure build-up for a complex.They think ,specifying and designing equipment like column,reactor , exchanger are the only challenges but forget the tricky issues like utility package sizing, specification and their distribution and yard piping interconnect for process streams and tank farm and how they can make or break the smooth running of complex!
All of us think ,water is the harmless media and any Tom Dick &Harry can handle their challenge. But nobody has analysed how&what can go wrong while executing utility packages for water and how many water types come into picture in a chemical plant or hydrocarbon processing.Added to misery, since Jamnagar is dry area, we are fundamentally dependent on sea water as main water source. That adds its issue of transporting and handling water with high sodium chloride.
As OSBL project manager of DTA, though I had the main task of project engineering the main inter-connecting pipe rack and interconnect piping running into thousands of kilometers, my focus and attention has been spent mostly on water systems and its transportation. Here I would like to bring out several incidents involving water only, which literally made or broke my career in Reliance.
Contd....
Key Aspects :- Critical challenge, Incident analysis, Innovative, Multi discipline exposure,
Proactive approach, Technical issues, Ups&down
JMD DTA Contd.
When that was the issue we faced for running the cooling water mains, we had an entirely different challenge when it came to main refinery fire water system! As I said in the beginning, the team assumed that there shall not be more than 5000 equivalent hydrants in DTA- including both ISBL and OSBL hydrants, Monitors etc. and went ahead designing 10X1000M3/Hr fire water pumps in pond 2 pump house. As the engineering progressed we were in for surprise shock! The total number of equivalent hydrants requirement crossed 6000 mark and it called additional pumping capacity and storage pond. When the whole team was blinking for a workable solution, Mr Bob Green ,Bechtel Civil specialist came out with a brilliant idea and a workable resolution. He identified and suggested that there is a low lying area adjacent to ETP West of road A, which happens to be about 400M only from the pond 2 area. He proposed that can be developed as additional pond and required additional fire water pump provision can be done in that. With that lead we jumped with joy. Then we went into detail and configured the new pump house orientation such that both the pump house discharge can be clubbed into single manifold. That resulted to have two fire water ponds 2&2A combined into single discharge with 16 pumps- any 10 operating with 6 stand by thus meeting TAC conditions fully. Though we implemented 16 pumps in 2 ponds, every one in the team felt we are gross over designing ;but what to do! The national rules stipulate that. Even international majors like Shell & international re-insurers M/S Munich RI commented that India is one country where empirical formula approach is prevalent. It is a different story that I have taken advantage of this excess margin while conceiving the fire water requirements in J3, which I will narrate when I address the J3 design basis.
Here I would like to emphasise that the whole management are having the wrong concept that executing ISBL projects are the biggest challenge when compared to OSBL and infrastructure build-up for a complex.They think ,specifying and designing equipment like column,reactor , exchanger are the only challenges but forget the tricky issues like utility package sizing, specification and their distribution and yard piping interconnect for process streams and tank farm and how they can make or break the smooth running of complex!
All of us think ,water is the harmless media and any Tom Dick &Harry can handle their challenge. But nobody has analysed how&what can go wrong while executing utility packages for water and how many water types come into picture in a chemical plant or hydrocarbon processing.Added to misery, since Jamnagar is dry area, we are fundamentally dependent on sea water as main water source. That adds its issue of transporting and handling water with high sodium chloride.
As OSBL project manager of DTA, though I had the main task of project engineering the main inter-connecting pipe rack and interconnect piping running into thousands of kilometers, my focus and attention has been spent mostly on water systems and its transportation. Here I would like to bring out several incidents involving water only, which literally made or broke my career in Reliance.
Contd....
Key Aspects :- Critical challenge, Incident analysis, Innovative, Multi discipline exposure,
Proactive approach, Technical issues, Ups&down
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