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,
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,
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