P 88 JERP Execution

P  88

JERP Execution

Having seen the packages, let us look at the challenges we faced in offsite ! Since JERP is placed back to back with that time existing refinery (DTA) and this being SEZ establishment, we had several restrictions in terms of routing the lines, exchange of media for intermediate processing, project capital equipment to reach its identified foundation location, custody transfer metering of fluids to go to marine etc.

Out of all these, main issue was to arrive at the pipe rack bridges elevation at main roads coming from Haul road alignment. Since the design office at London (OSBL) could not understand and appreciate the  transport hurdles. Route selection to reach that equipment final destination , equipment height, mode of transport , trailer width  with equipment placed on it etc., me along with Sh Deepak Gupta took over the responsibility.  Deepak being the OSBL Utility area construction manager and overall heavy equipment handling and erection in-charge at JMD, he had all the inputs  about the cranes to be deployed for equipment based on its weight/dimensions etc. and where the crane booms have to be mounted/ dismantled etc. So we along with his team members  studied/ analysed the routing for each equipment and its estimated time of arrival  and gave the inputs to Becrel( Bechtel- Reliance) engineering office at RCP.  Mr Jain, Civil Chief of Becrel effectively undertook the responsibility for checking the bridge elevation requirement, load distribution/transfer due to elevation change of piping etc.  Three of us jointly took the call, which are the bridges to be put on HOLD until that identified equipment reach site ,cross that alignment and which are the bridges can be executed by widening the road width on that area etc. I still remember the challenge we faced for raising the bridge bottom elevation to 13 M height, when the original pipe rack elevation was only 9M at J avenue entry. Especially in that alignment the rack had diversions and turning by 90 Deg. etc., this study became very crucial. Also we had real issue of bringing the last coke drum in F Avenue- road belonging to DTA but the equipment under SEZ. For this it took more time for us since we have to convince customs authorities but they fully cooperated once they understood the involved challenges in turning radius  of trailer/crane etc.  Here I would like to record , how important is that  the team should have open vision to pre-study these sort of challenges before designing the pipe rack bridges. By this we could achieve optimum elevation of rack bridges  and timed out the field construction to suit to equipment arrivals and foundation readiness.

As the complex size was becoming mega in size- having two refineries side by side that too one under DTA tariff and the other under SEZ( all produce have to be only exported), as offsite project group we faced innumerable hurdles. The major ones are roads, drains and fire water network.  Especially in fire water network, we had peculiar challenge! The rules called for exclusive independent network for SEZ refinery but under Disaster management criteria, it should have fall back from the neighboring network. Since I was the member-secretary of rules amendment committee under PESO , I could visualize escape route and implemented a way-out.
                                                                                                                                      Contd....

Key Aspects :-  Accountable, Communication, Critical challenge, Incident analysis, Leadership,
Responsible, Technical issue, Team building

P 87 JERP Execution

P  87

JERP Execution
Having addressed the CTs and N2 package, let us look at the mega ETP execution ! Having faced some trouble in DTA ETP operations, Bechtel/Reliance approached the issue with due care.
As first step, we ensured that a pre-treatment facility is incorporated for handling Desalter waste having phenol  in crude units before they were routed to main ETP. In ETP itself, with technology advancement we incorporated primary/secondary/ tertiary treatment. Considering enough safety margin the design was made for 4 X 500 M3/Hr. classifying HTDS and LTDS. Though the design specification was rugged, the commercial group made a mess during order commitment!In spite of the Project Director advising them not to go with X party from their experience and financial capability to handle such a large challenge, they went ahead in committing the order on that x party and made project management group to face the trouble during entire execution.

Reliance is always lucky that the technology partner for that X party was excellent , which facilitated to obtain state of art technology and equipment specifications.  But the Indian partner could not cope up with the project execution due to lack of technical manpower and financial trouble. Added to misery the engineer-in charge in Becrel ( a joint venture between Reliance and Bechtel) to take care of indigenous operations of the project  created group politics within the project management  and things went out of control.That forced Reliance Projects to take direct control of the project  and my able assistant Mr NK Gupta and his team started directly expediting the sub-ordered items and spool fabrication shop at far off places. Then came the payment issue as the main Indian partner did not have funds to remit payments and the delivery from fabrication shop/s were  getting delayed.  That forced us to make direct payments to suppliers  and accounting became a question mark! Neither Reliance commercial nor the main Indian party were coming to our rescue. Luckily , since the management was keen on timely completion of the project , they condoned and helped us; rather they appreciated our initiatives to directly take over the responsibilities and ensured timely completion.

Overall since we introduced pre-treatment within desalter area in crude units and sourced a sound technology from M/S Waterleau, the performance of ETP was beyond our expectations and end user was very happy.

Next let us look at the challenges what we faced in main flare commissioning! When we were lining up the main flare header to the flare seal drum , which is prior to high rising stack/s , we were getting a very heavy hammering sound  and we became literally afraid! When it came to line integrity and weld  joint leak test, we carried out complete smoke test with soap water bubble test and got it 100% cleared. So there was never a doubt on that account. We took the matter with the Flare supplier M/S Zeeco , who gave seal drum design and data sheet to Bechtel/Reliance. In parallel we posed that issue to RTG-research cell for CFD study at JMD.  Fortunately, both the parties could track the defect in the interior nozzle  orientation of the seal drum and by inverting it we can get over the problem. Once that was rectified, touch wood we do not have recurrence of that problem and flare is on since then.
                                                                                                                                   Contd.....

Key Aspects :- Critical challenge, Incident analysis, Lack of experience/exposure, Responsible,
Technical issue, 

P 86 JERP Execution

P  86

JERP Execution

All the sweet water cooling towers order were ordered on M/S Hammon Shriram EPC and the sea water tower order was placed on M/S SPIG,Italy. Both the parties functioned well within the general  issues that normally prevail in any OSBL task. In case of Shriram EPC, they utilized the services of Structural specialist Dr Mannan of IIT, Chennai. That gave confidence to Reliance/Bechtel while reviewing the concrete members and civil foundation drawings for all sweet water towers. While the party has executed all the 6 towers successfully, we had one specific issue of water spilling out in CT Z 734 and the construction has to apply additional fill paste to arrest the same.

There was another major issue on top fan motor gear box for all the 7 cooling towers.  Both the vendors have opted for Premier make(Kolkatta party) gear boxes for this service  and it had a basic fundamental design defect. So seeking replacement for those gear boxes itself became a mini project for my assistant Sh NK Gupta and it went on several months to obtain them with the services of both CT vendors.

Nitrogen package execution
Since M/S Air Products,UK  executed DTA nitrogen package successfully, repeat order for 3 X 8000 Nm3/Hr order was placed on them on nomination basis. The party went ahead very fast with their package engineering  and completed entire supply in one lot. But the problem at site was foundation clearance and front availability to handle all three modules simultaneously. That made a messy situation and the construction have either lost or misplaced many of the special valves, that too for cryogenic service in cold box. That made the project functioning more difficult- one is to seek additional budget sanction and making Air Products to source these additional requirement and ship them. These are all being part of JERP, we could not take the spares from the first refinery.

Having struggled to complete mechanical completion of Nitrogen package, there was a surprise shock waiting for me. As I was on leave, KP took the application to Nagpur for seeking licence for cryogenic N2 storage vessels under SMPV Act. Though  Mr Biswas, Dy CCE  issued the licence in DTA for 10 involved vertical vessels  under SMPV Act in one licence, Dr Kaul applied the condition of maximum 6 vessels in one licence and cleared 6 only, asking KP to convey to me to seek another licence for the rest 4 vessels. By the time I restored my duty from leave, Dr Kaul was transferred on promotion and he left Nagpur. The charge for SMPV Act was taken over by Mr PC Srivastava, who was new in handling that subject.  When he went through my fresh application, he applied the condition that since Reliance have not provided dedicated individual PRVs for each vessel, it does not meet the ACT regulations and licence cannot be granted at all. That was a surprise shock for me  and panic situation set in.  I contacted Mr Biswas for advise and help.Also contacted INOX Baroda, who were the designer/ sub contractor to Air Products for these N2 vessels fabrication. Time went by but nobody could come out with any workable resolution. Then I contacted AP Project Director Mr Tony Wagstaff and posed him my panic situation. Tony,  being specialist in subject reacted immediately and confirmed that these  cryogenic N2 vessels are designed under special ASME design  termed as
ADM 2000 under ASME UG 13.3 and very much within the code conditions. With that input I reached Nagpur and put it to that time CCE Mr Nigam to look into.  Since I had excellent technical relations with the department, he convened PCS immediately and instructed to clear our licence then and there.I got relieved of my challenging tension.
                                                                                                                  Contd....

Key Aspects :-  Accountable, Critical challenge,  Incident analysis, Planning, Technical issue