P 94 JERP Execution

P  94


JERP Execution

So far we have been seeing only technical and safety aspects of project execution in JERP. Now I am wishing to share certain human aspects and relations built which really benefited overall.

As I mentioned earlier, somehow the wavelength between me and Steve Wiggins/ Mike Beech/Bob Green matched so much that whatever I wished in terms of technical definition, schedule expediting, additional deliverable to clarify the misgivings etc. were obliged without any fuss. Of course Dilip Patel at Becrel Mumbai was completely backing me. My handling of contacts with various turn key vendors were really appreciated by the Management and Project Directorate. Mr Rajiv Gaikwad  as Project engineer from Becrel stood behind me as solid support.

Here I have to particularly mention how much I am lucky! In the beginning of 2007, when the above ground rack piping was about to pick up, my friend PBM Rao, who retired from Reliance phoned stating that Yanamandra has returned to India and looking for  a job. Without thinking a bit I responded to him stating 'ask Yanamandra to come and join'; in parallel  I phoned Sanjay Mashruwala
that I am taking Yanamandra and please request HR to regularize his  appointment immediately.
In Reliance , things used to move in flash and Yanamandra joined me next week.
Having worked with Yanamandra during Hazira project days, I knew his capacity and capabilities in piping execution. So I handed over the charge completely and forgotten the day today happenings on that front. Since Yanamandar knew Reliance style of operations, he earned the confidence of top construction management so that any drawing revisions can be routed with conviction . As always OSBL being the victim for any alterations at ISBL B/L , he could sell the changes/revisions  to Mr Dawda and seek his approval quickly. In that way he efficiently managed the OSBL area construction manager and expedited the job. He used  to take my help only for getting additional piping materials , which I used to take up with V Ganesh/Pallamraju and organize.

But in spite of these , I had two bitter incidents which almost spoiled my peace of mind.
One was ,when Becrel issued IFC drawing for utility air compressor shelter with structural column inter-distance with only 4Meters apart. When I noticed that grave error,I reacted typical of AR and told the concerned manager that he has to stop that deliverable issue as it is  and ensure undertaking review and revise. He had the audacity to state that he is from Bechtel and cannot be instructed by client project manager. That shook me up and I shouted on him. He complained the same to his boss who in turn has reported to Bechtel Project Directorate at London. They have issued complaint memo against me  seeking my removal from the project. When my management and Steve heard that, they laughed and rebutted to Bechtel. That made  Bechtel's deputy project director to realize their folly and he sought his apology to me and close.

Second was Bechtel's engineering manager at Becrel supporting the cause of ETP Indian contractor !
He was not understanding the full issue but tried to create internal politics.  Luckily my assistant NK Gupta took control then on and managed to complete the task. The management took the call for direct payment to sub vendors and got over the situation so that the main contractor  do not siphon off the payments without disbursing to their sub-contractors.

Then came out the as-built and close out.  Somehow most of the construction manpower do not realize the importance of making the as-built mark-ups and that deficiency is very much prevalent.

Key Aspects :- Accountable, Attitude,  Conviction,  Faith, Human relations, Incident analysis,
Planning, Recognition, Reputation, Ups&down 

P 93 JERP Execution

P  93


JERP Execution-Chartered Engineer audit &other experience

To ensure that everyone follow the defined design basis and it meet all the necessary/mandatory guidelines, he undertook a trip to UK to interact/interface with Bechtel LP team along with TechnoFire specialists Praful and Dilip Koimattur. Of course I was representing the client.
There were debates whether we can get away with OISD stipulation of 3 lpm/M2 for atmospheric storage tanks, what should be the inter-distance between one hydrant point to the next in OSBL and in ISBL area, what should be the criteria for arriving at pumping capacity, islanding valve arrangement in nodes etc. He even reviewed Dave Conolly's preliminary conceptual network layout
&endorsed his approach.

There after he has periodically undertaken field check visits to Jamnagar. Though in overall he was satisfied with engineering and field execution, he had a few specific observations where he insisted that unless and until they were rectified he cannot sign off  his approval. I am listing here only a few :

1) MVWS piping arrangement for auto ignition temperature  rated pumps in crude units
2) Either make provision of roof shelter for the sweet water pumping system for fire water first fill in MTF network or do not declare them as fire water pumps and take credit for fire water pumping capacity augmentation.  As we had sufficient margin with the original DTA pumping arrangement itself, we opted the choice of not taking augmentation credit.
3) Provision of riser pipe isolation valve at 1m from grade level
4) Rectification of support for HVWS piping in fin fan coolers all across JERP.
5) His insistence on provision of riser pipe with hydrants at top platform of deaerators- his argument being there are lighting cables going on top and they have to be protected.  Though the rest of the team was not convinced with his logic, there was no alternative but to implement!
6) Location selection of periphery monitors in compressor shelters.
7) Interface logic check between Honeywell supplied F&G system with deluge actuation in field as well as FM200 system in PIBs. He insisted to check the actuation of MVWS in some areas to check the throw pattern.

Having seen all about fire water systems, let me touch about my dual role as primarily instrument engineer by qualification and experience added with the responsibility of safety engineering implementation. As OSBl project manager, the FW network, its pumping system and hydraulics analysis check responsibility rested with me. But when it came to Fire &Gas system, the functional responsibility was with the instrument department but the system responsibility fell on me . It was because, I was identified as safety manager in projects  and the ultimate F&G panel location placement in fire station ,  regular operation and monitoring responsibility came to fire department.
So I became internal consultant to process/instrument engineering for identification/selection of type of F&G device for various set of pumps depending on service /compressors/MCP etc.

Other than  Loss Prevention and HSE, I had several sundry roles as OSBL project manager. They are the tasks like Natural gas receipt facility interface with Gujarat State NG Pipeline Ltd, B/L Custody Transfer metering systems for export and internal transfer metering etc. So in all these cases, more than technical aspects, my responsibility enhanced with transfer logistics, identifying the mandatory customs levy,  convincing custom authorities, selection of type of custody transfer metering- coriallis type for  custody transfer for export and positive displacement turbine type for B/L transfer, routing them internally so that we do not violate DTA and SEZ line of control etc.
                                                                                                      Contd.....

Key Aspects :-  Accountable, Codes&Standard, Critical challenge, Incident analysis,
Multi discipline exposure, Responsible,Technical issue, 

P 92 JERP Execution

 P  92

JERP Execution  Fire Water System &Safety features

Though we had engineered robust fire water system , during plant commissioning trials  we faced certain tricky situations.  In spite of having sufficient hydrant points and monitors in ISBL, we faced shortage of water throw quantity during emergency or accessibility restrictions. To find resolution for those challenges, Dilip Patel of Bechtel, me combined with JMD Fire leads took  field rounds  and identified the dark spots where suitable provisions have to be made and how portable trolley arrangement with sufficient take-offs for hydrant/monitor point provisions can be made.
That resulted in development of MHO (Multiple hydrant off take ) with X'Mas tree arrangement, portable trolley with different take-off hydrants/monitors etc. These became handy when there was freak fire incident in Coker plant commissioning trials.

But still there was a major challenge when it came to addressing the coke drum structure fire protection. There were several suggestions/options and each had its own limitations! One group suggested to opt for water spray system but that was ruled out from the angle of accessibility of nozzles for maintenance and nozzle choke due to coke dust. Another group came out placing several ground monitors; that was ruled out from emergency operability angle and throw reach to 55M height. There came Larry King with an ideal resolution. He proposed to try ROOMS with remote joystick arrangement.ROOMS is nothing but an oscillating monitor mounted at 20M high, which can be adjusted for spray range/direction and angle of throw etc. by a joystick placed at remote safe area.
Considering 110X55X55M coke drum platform we have gone for 6 numbers ROOMS strategically placed on either side of the structure. That solved our major worry.

Rim Seal Fire protection for large diameter floating roof tanks :
Though in DTA we had incorporated CHUBB make poly-urethene tubed rim seal fire protection system for all large diameter floating roof tanks, unfortunately that party went out of business and we had an issue. Somehow Praful got reference from Shell Scotland about  a party named BLAZE and that was chosen. Instead of conventional sensor tubing, it had a balancing arm arrangement to sense and release the foam for fighting the rim seal fire. But it never worked at all  and it was major blow.
Luckily that was the time the statutory authorities issued the gazette to relinquish its mandatory requirement. So we escaped then.  But it is different story now,that OISD incorporated them back with specific type and made to be incorporated  retrospectively even for small diameter tanks storing Class'A' liquid products.

One should remember and thank (Late) S Narayana for his acumen to recommend to opt M/S Rosenbauer for all fire fighting vehicles in JERP. The back ground may be that he has experienced major difficulty in financing the Indian party during DTA and quality control. But his decision was blessing in disguise.

Charted Engineer Audit

Though there is no statutory obligation to carry out pre-commissioning audit of fire fighting system for a hydrocarbon processing complex, following NFPA guidelines( Jurisdiction of Authority) Reliance/TechnoFire made it as standard practice to conduct Chartered Engineer Audit for all fire fighting systems. Mr TRA Krishnan, a chartered engineer by Registration is usually contracted to carry out the audit at engineering stage in DEC office and later to undertake field inspection as well as conduct spot trials of installation. Mr Krishnan being a thorough professional with repute, will go deep into design aspects  and question the DEC/Bechtel/TechnoFire/Reliance (AR) for even minor discrepancies. Let me share some of my personal experience in his audit of JERP.
                                                                                                         Contd....

KeyAspects :- Attitude, Conviction, Incident analysis, Initiative, Innovative, Technical issue, Team building 

P 91 JERP Execution

P  91

JERP Execution- Fire water System &safety Features

Having seen about the OSBL &ISBL Network, let us see the specific specials what we have incorporated in JERP .  Having experienced several difficulties in DTA with respect to throw height, accessibility,  throw quantity requirement, distribution in demand area, safety of hydrant point in heavy traffic/crane  movement spot etc. Bechtel/TechnoFire/Reliance went on configuring several new developments and succeeded to overcome those hurdles.  Some of them are explained here:

Our  senior construction manager Charles D'Souza came up with a fantastic improvisation of protecting the hydrant point from being damaged by crane movement in plant ISBL area. He suggested to add an additional spool below grade and place the hydrant point in built concrete pit.
His suggestion was to construct the  hydrant take-off point in that pit but defer erecting the spool as well as the hydrant point until all the heavy crane movement completion in that area. To allow free movement of crane, he got that pit filled with sand and put a concrete slab cover. Once the heavy equipment erection and crane movement was over, he arranged to clean the sand from the pit and fixed the spool and hydrant point and carried out service test for testing the integrity. His idea was revelation to all concerned in the industry.

With standard ground based monitor placed about 20M apart from the target object, when the network operating pressure at that point was  about 9-9,5 kg/cm2g, the discharge throw height reach was only about 35M height, whereas in refinery the tall columns are about 45/72M and some are even nearing 90M also. This handicap was highlighted by JMD fire team during the engineering stage; Reliance projects and Bechtel took that as a challenge  and searched for suitable solution in the market. One party  M/S Stang claimed to have hi-rise monitor that too mounted at grade level. Both Bechtel and Reliance believed their data sheet and committed an order for 50 numbers on that party.
But good sense prevailed on us and JMD fire team insisted to have a field sample trial for testing its performance. The party has agreed to carry out the same and asked Reliance/Bechtel to develop test rig with inflow orifice, inline flow meter and pressure gauge etc. with scaffolding arrangement . The whole thing was engineered and developed fully; the party's MD with specialist consultant turned up with two test pieces of monitors. The full battalion  of JMD Fire team, Reliance OSBL project members including me, Technofire represented by  Praful and Dilip Koimattur, Dilip Patel of Bechtel, M/S Stang' s representatives assembled at 3PM to conduct the field trial test. We simulated the throw quantity and requisite pressure at nozzle throat to test the samples; but to our utter surprise the throw reach height was not even crossing 18M elevation, when an adjacent fixed ground monitor of another make was giving at least 34M! the party tried to change another nozzle and adjusted its throw alignment etc. but could not improve it at all. The whole exercise went on until night 2AM and then we gave up. The party MD could not face us , he went away without telling anybody and later wrote to cancel the order. We were back to square one!

To my luck, that was the time Mr Larry King of M/S TFT was interacting with me and JMD fire team to promote their monitors for JMD. When I personally discussed with him about the possibility of utilizing their standard monitor mounted at high elevation, he also jumped with joy and agreed to carry out field trials.  Then came the challenge about mounting them at high elevation but at the same time to keep the safe distance of 20M away from target object. We took up with structural and piping group of Jamnagar engineering( Anil Chaudhary )&NR Prakash . They came out with two propositions-1) to design self standing tower of 13.5M high&mount the monitor on top, 2) strategically locate the monitor in already available structural platform in rack area and in both cases
route the riser pipe with an isolation valve at 1M from grade level. These were welcomed by one and all and the field trial was a roaring success. The only limitation is that the monitor focus is fixed and one has to climb through monkey ladder to adjust/change its direction. But that handicap was acceptable to the end user  and that has become Reliance standard for Hi-Rise monitor arrangement.


KeyAspects:-   Communication, Critical challenge, Faith, Incident analysis, Initiative, Innovative,
Multi discipline exposure, Technical issue

P 90 JERP Execution

P  90


JERP Execution-Fire water System and Safety features

Network drain arrangement and valves

As JERP  underground fire water network was about 300Kms in overall length, we realized the need for drain valve provisions at strategic locations in overall OSBL network. That became essential since the network is always filled with water under 10.5 kg/cm2g pressure, that too stagnant water is prone to develop bacteria , bad odor and lead to corrosion of header. There came the controversy!
The end user-JMD Fire department marked about 250 number of points in the overall network drawing and gave it to projects for engineering and incorporation. But the site construction management questioned its need that too for this much quantity of drain take-offs. As usual I played the role of mediator and concluded to opt for about 120 points.Took the responsibility of field marking the strategic requirements and got it engineered by Becrel. The end result, all members got satisfied.

Cathodic Protection and Corro-Coat application.
 We did not think the absolute necessity of  cathodic protection of DTA underground fire water network,  thinking  that three layer wrapping and coating will take care of &eliminate underground pipe wall corrosion. But towards the end of DTA project stage we observed some deterioration of headers. When we consulted Raju Narayanan for his expert advice, he recommended its incorporation both for the old DTA systems as well as for new JERP headers. Rather he took the responsibility of engineering the same and we got it executed by M/S Corrosion Controls Ltd.
More or less, that was the time M/S Kirloskar Brothers came out with Corrosion-Coat application, an upgraded substitute for conventional coal tar coating and wrapping. Reliance tried with a sample and got convinced about its excellent properties. Since then that has become Reliance Standards and made sure that KBL opened a permanent application shop within our site premises.

Having addressed the overall OSBL FW Network system, let us look into the specifics what we faced in interface between OSBL and respective ISBL headers. As engineering for various ISBL were distributed across various Bechtel offices globally, interface issue was challenging! That was very high when it came to Coker plant since that engineering was under responsibility of M/S Foster Wheeler Houston whereas OSBL was engineered at London/Mumbai offices.

Here one specific aspect has to be highlighted! As the OSBL and ISBL Fire water network and internal distribution  were engineered in different geographical location offices, we ended in having two independent network  with tie points ! That made us to end up with adjacent hydrant points and monitor points at 1 or2 M intervals, which I termed them as Laurel and Hardy. We could not remove/get rid off them because each party had its own logic and technical justification. But with involvement of Bechtel, TechnoFire specially Praful and Dilip Koimattur, the team envisaged to develop an overall integrated co-ordinates matched  complete JERP Network including OSBL and ISBL fire water network distribution. That task responsibility was undertaken by Mr Dilip Patel of Bechtel.With lot of constraints and without their own management support, Dilip took up that challenge and performed tremendously. Our ultimate customer-JMD Fire Department are extremely satisfied and enjoying the fruits of his labour.
                                                                                                                 Contd......

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

P 89 JERP Execution

P  89

JERP Execution- Fire water&Safety systems

As said, with my past exposure and technical contacts, I could effectively interface with Mr Steve Wiggins of Bechtel when it came to fire water systems engineering.  Steve being one of the experts in systems definition and conceptual basic engineering, we had an excellent understanding  in converting our thoughts and vision effectively.

When it came to meeting the disaster management requirement of having full back -up sourcing of fire water from DTA to SEZ, vice versa, though that aspect was restricted item from SEZ angle, we could get  away by taking up with the District Magistrate ( Chief Revenue Authority for the District ,at the same time Disaster management Chief for the District). So we could get royal tie-in with isolation valve put in closed condition during normal operation. But when it came to SEZ tank farm fire water network, there was no neighboring fire water source pond for back-up! There came Steve's brilliance ; he  came out with an idea of taking 20" pipe manifold with isolation valves taken from 66"/60" sea water intake lines for JERP. As these lines were passing adjacent to SEZ tank farm, the execution became easy and effective.  So in this case, since the tank under fire may require very large
quantity of fire water that too for extended period( maybe 2/3 days continuously) we decided to go with sea water as worst case emergency back-up.

Here I have to particularly mention Dave Conolly's name. Though on first look ,one may conclude that he is  disinterested man and may not contribute any value, he was the best asset for fire water engineering of JERP. All his pipe diameter selection for each node in JERP fire water network, both in refinery area and tank farm went through successfully in first pass itself. His first and only hydraulic check calculations were appreciated by one and all. He was one person who could assimilate all the IFs andBUTs of various applicable laws and meet all of them comprehensively.

Having seen about the overall fire water network integrity, let us go in detail about various pin pricks of JERP fire water system.
To start with, let me narrate the issue about network isolating  valves selection,  valve pits dimensions to suit the valve and distance piece, network drain valve qty in numbers and location , valve status position indicator etc.

Valve type selection: Considering overall cost aspect and space/operability, avoiding muck settling in valve body, project team opted to go with sandwich type butterfly valves from M/S L&T valves. But JMD site management and operations were bitter to accept selection of butterfly valves since they had miserable experience of using TYCO butterfly valves in DTA network, which never isolated the node what they wanted to isolate for maintenance. After long deliberations, project team convinced the end user to accept and go with L&T butterfly valves that too type tested for positive shut-off.

Typical of interface mismatch between piping and civil discipline when it came to internal piping configuration and the overall pit dimensions to accomodate the zig zag piping arrangement. Each engineering discipline was taking stand and it became project manager's responsibility to mediate and resolve.      
                                                                                                                 Contd......

Key Aspects :- Accountable, Incident analysis, Leadership, Multi discipline exposure,
Proactive approach, Technical issue, Team building