P 61
JMD DTA Contd.
Flare Package
While conceptualizing the flare sizing , no one had any idea that it will go as high as 4000MT/Hr rate!
Until that time in India, M/S John Zink was the sole system supplier.But they could not even think of sizing the flare for this rating. That made Reliance and Bechtel to look into M/S Zeeco, an offshoot started by Mr John Zink in USA. There also, considering that there won't be a complex outage, we opted for multi riser derrick mounted de-mountable (Foldable) type. Then Bechtel and Zeeco worked together to split the HP/LP load with 3 risers and at 400 M apart LLP flare with 2 risers. The flare elevation came out to be 152M from ground.
Lucky for Reliance ,Mr Rane of Petron shouldered the responsibility for the detailed engineering and field execution of entire flare system of DTA. Touch wood, so far there is no major complaint with the flare system operations. The maintenance team have operated and gained experience in scaling down of individual riser for inspection and maintenance.
While talking about flare system , two specific item come to my mind :
1. Outcome of hazop study recommending that the valve handle in 84" main header has to face the earth and not the sky. This is to ensure that the accidental falling of gate in the valve should not block the flare stream.
2. Flare mains testing. There were hue and cry in the field for testing the 84" mains running on top tier of OSBL pipe rack! Hydro testing was ruled out since the pipe rack was not designed for that water load carrying. Without realizing the implications, one group was recommending for pneumatic test! As the length of these mains was 9 Kms long, that was also ruled out. Finally we devised a smoke test procedure and successfully carried out i.e introduce a smoking device inside and check all the weld joints with soap solution.
FM 200 system incorporation for PIBs.
That was the time M/S Du Pont came out with FM 200 as Halon substitution for gaseous fire extinguisher system for non occupied premises and data centers.
As JMD DTA had 33 PIB buildings having their local area control systems (Plant Interface Buildings), it was decided that we should make provisions for gaseous extinguisher system in each of them. Floating international enquiry, M/S Vijay Fire-Kidde was selected. But Reliance LP consultant(happened to be one of top official of TAC_ a statutory body) asked for one field trial and demo. before approving their system. A practical demonstration was conducted in ETP PIB and it was cleared from efficiency angle and advance warning for people evacuation lead time etc.
The contractor executed the installation in all PIBs. Then came the big drama!
In matter of 10 days, in 7PIBs, the gas from cylinders got released even when there was no fire at all! It was mystery for projects and instrument maintenance. After conducting a detailed investigation, it was found there was some software corruption in M/S Wormald PLC, which caused this havoc and loss! M/S Wormald was the agency who executed Fire&Gas system in whole of DTA. For info. then onward we never approved M/S Wormald make and the company has standardised with Honeywell F&G system at Jamnagar.
Contd.....
Key Aspects :- Critical challenge, Incident analysis, Initiative, Innovative, Lack of experience/exposure, Multi discipline exposure, Technical issue
JMD DTA Contd.
Flare Package
While conceptualizing the flare sizing , no one had any idea that it will go as high as 4000MT/Hr rate!
Until that time in India, M/S John Zink was the sole system supplier.But they could not even think of sizing the flare for this rating. That made Reliance and Bechtel to look into M/S Zeeco, an offshoot started by Mr John Zink in USA. There also, considering that there won't be a complex outage, we opted for multi riser derrick mounted de-mountable (Foldable) type. Then Bechtel and Zeeco worked together to split the HP/LP load with 3 risers and at 400 M apart LLP flare with 2 risers. The flare elevation came out to be 152M from ground.
Lucky for Reliance ,Mr Rane of Petron shouldered the responsibility for the detailed engineering and field execution of entire flare system of DTA. Touch wood, so far there is no major complaint with the flare system operations. The maintenance team have operated and gained experience in scaling down of individual riser for inspection and maintenance.
While talking about flare system , two specific item come to my mind :
1. Outcome of hazop study recommending that the valve handle in 84" main header has to face the earth and not the sky. This is to ensure that the accidental falling of gate in the valve should not block the flare stream.
2. Flare mains testing. There were hue and cry in the field for testing the 84" mains running on top tier of OSBL pipe rack! Hydro testing was ruled out since the pipe rack was not designed for that water load carrying. Without realizing the implications, one group was recommending for pneumatic test! As the length of these mains was 9 Kms long, that was also ruled out. Finally we devised a smoke test procedure and successfully carried out i.e introduce a smoking device inside and check all the weld joints with soap solution.
FM 200 system incorporation for PIBs.
That was the time M/S Du Pont came out with FM 200 as Halon substitution for gaseous fire extinguisher system for non occupied premises and data centers.
As JMD DTA had 33 PIB buildings having their local area control systems (Plant Interface Buildings), it was decided that we should make provisions for gaseous extinguisher system in each of them. Floating international enquiry, M/S Vijay Fire-Kidde was selected. But Reliance LP consultant(happened to be one of top official of TAC_ a statutory body) asked for one field trial and demo. before approving their system. A practical demonstration was conducted in ETP PIB and it was cleared from efficiency angle and advance warning for people evacuation lead time etc.
The contractor executed the installation in all PIBs. Then came the big drama!
In matter of 10 days, in 7PIBs, the gas from cylinders got released even when there was no fire at all! It was mystery for projects and instrument maintenance. After conducting a detailed investigation, it was found there was some software corruption in M/S Wormald PLC, which caused this havoc and loss! M/S Wormald was the agency who executed Fire&Gas system in whole of DTA. For info. then onward we never approved M/S Wormald make and the company has standardised with Honeywell F&G system at Jamnagar.
Contd.....
Key Aspects :- Critical challenge, Incident analysis, Initiative, Innovative, Lack of experience/exposure, Multi discipline exposure, Technical issue
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