P 62
JMD DTA Contd.
Having seen some of the offsite packages and main OSBL rack, let us look into RTF to MTF and vice versa pipe corridor.
This stretch is 16 Kms long passing through the entire stretch of refinery up to SH 25 and run along haul road corridor to enter MTF B/L. This pipe corridor is the life line of entire refinery operations- all the crude import or sea water intake or finished products going through marine route fall in this corridor only.. While executing this system we had a different challenge!
As there were more than 36 lines at DTA stage itself, Bechtel could easily spread the pipes on wide sleeper and run at refinery end and along the haul road; but the challenge and objection came while crossing the State High way and Railway crossing!
Without realizing the social obligations, Bechtel wanted to go ahead with over head bridge crossing.
That was summarily rejected by authorities and said that the only option left for Reliance is to go underground. Had it been a single line, we could have got away buried. Since there were so many lines in that corridor, Bechtel opted for underground culvert option. So a beatuful culvert corridor got developed with a dedicated motor way for exclusive use of Sh Dhirubhai. This was a special request of MDA. But at that time in 1997, we thought that by not providing any flange joint or any valve on those lines, we can get away without incorporating any mitigation measures within that culvert stretch of 400 M!
No one ever gave a thought that these pipelines are going to be live at all time and should be in operation during the refinery's life time. During the audit 2010, one of the insurance agency highlighted that though the designer has taken the corrosion factor into account while selecting the pipe thickness , how can one be sure of its safety without any mitigation measure? That was a major shock to all concerned and very late realization Better be late than be never. So we have formed a task force to study various options to incorporate the best sensing system in that corridor and introduce manual fire suppression system. That is one of the top priority item under safety risk study..
I am not sure whether I have already covered the Mango forest story! When we acquired the land for refinery, the front portion at SH 25 land was belonging to BPCL and they were not ready to sell. They were intending to create their own oil terminal. Maybe it was their ploy to delay Reliance to go ahead with the refinery project. So leaving 100M beyond their land limit, we drew and developed our plot plan layout and proceeded with detailing and foundation digging for tanks. After an year and half, they realized the situation and understood their plans are not feasible at all. Then they sold that to Reliance; but it was too late for us. So that plot of land was effectively utilized to develop wide green field by planting variety of mango saplings. Now we have millions of mango trees in that stretch and we also produce mango pulp.
Having addressed the refinery offsite and pipeline stretch joining MTF to RTF, let us see some important factors in MTF (marine tank farm). In the world, as the refinery source different variety of crude from various places, it is common practice to have one crude blending tank. What does that mean? The sourced crude are stored in different tank; before lining up them to refinery as feed stock, operations team used to draw the pre-calculated volume from each tank to this blending tank and prepare the mix. Once done, that will be allowed to settle for pre-calcualted time before pumping to refinery area for processing. The blend ratio will vary depending upon the available crude characteristics and the desired production pattern of finished goods (refinery yield).
Contd....
Key Aspects :- Accountable, Critical challenge, Incident analysis, Initiative, Lack of experience/ exposure, Proactive approach, Surprise&shock, Technical issue
JMD DTA Contd.
Having seen some of the offsite packages and main OSBL rack, let us look into RTF to MTF and vice versa pipe corridor.
This stretch is 16 Kms long passing through the entire stretch of refinery up to SH 25 and run along haul road corridor to enter MTF B/L. This pipe corridor is the life line of entire refinery operations- all the crude import or sea water intake or finished products going through marine route fall in this corridor only.. While executing this system we had a different challenge!
As there were more than 36 lines at DTA stage itself, Bechtel could easily spread the pipes on wide sleeper and run at refinery end and along the haul road; but the challenge and objection came while crossing the State High way and Railway crossing!
Without realizing the social obligations, Bechtel wanted to go ahead with over head bridge crossing.
That was summarily rejected by authorities and said that the only option left for Reliance is to go underground. Had it been a single line, we could have got away buried. Since there were so many lines in that corridor, Bechtel opted for underground culvert option. So a beatuful culvert corridor got developed with a dedicated motor way for exclusive use of Sh Dhirubhai. This was a special request of MDA. But at that time in 1997, we thought that by not providing any flange joint or any valve on those lines, we can get away without incorporating any mitigation measures within that culvert stretch of 400 M!
No one ever gave a thought that these pipelines are going to be live at all time and should be in operation during the refinery's life time. During the audit 2010, one of the insurance agency highlighted that though the designer has taken the corrosion factor into account while selecting the pipe thickness , how can one be sure of its safety without any mitigation measure? That was a major shock to all concerned and very late realization Better be late than be never. So we have formed a task force to study various options to incorporate the best sensing system in that corridor and introduce manual fire suppression system. That is one of the top priority item under safety risk study..
I am not sure whether I have already covered the Mango forest story! When we acquired the land for refinery, the front portion at SH 25 land was belonging to BPCL and they were not ready to sell. They were intending to create their own oil terminal. Maybe it was their ploy to delay Reliance to go ahead with the refinery project. So leaving 100M beyond their land limit, we drew and developed our plot plan layout and proceeded with detailing and foundation digging for tanks. After an year and half, they realized the situation and understood their plans are not feasible at all. Then they sold that to Reliance; but it was too late for us. So that plot of land was effectively utilized to develop wide green field by planting variety of mango saplings. Now we have millions of mango trees in that stretch and we also produce mango pulp.
Having addressed the refinery offsite and pipeline stretch joining MTF to RTF, let us see some important factors in MTF (marine tank farm). In the world, as the refinery source different variety of crude from various places, it is common practice to have one crude blending tank. What does that mean? The sourced crude are stored in different tank; before lining up them to refinery as feed stock, operations team used to draw the pre-calculated volume from each tank to this blending tank and prepare the mix. Once done, that will be allowed to settle for pre-calcualted time before pumping to refinery area for processing. The blend ratio will vary depending upon the available crude characteristics and the desired production pattern of finished goods (refinery yield).
Contd....
Key Aspects :- Accountable, Critical challenge, Incident analysis, Initiative, Lack of experience/ exposure, Proactive approach, Surprise&shock, Technical issue
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