P 112
Deluge Optimization in J3
When we initiated J3 project Loss Prevention engineering in 2011/12, nobody had an iota of the job quantum for the loss prevention piping , but had only the lesson learnt during the execution of J1&J2. Added to injury, the Chief Electricity Authority of India have introduced the mandatory requirement of spray water fire protection for all transformers having rating of >10 MVA and 2000 lts. of oil tank in a transformer. This addition came in picture with the Act Amendment in Oct.2010.
But every DEC went ahead with engineering based on original Design basis what we developed in-house, based on NFPA and our back ground experience in the existing refineries.
When we took stock of total involved quantity of piping both above ground and under ground in C2 complex, it was coming to more than 400 Kms Run ! This does not include the requirement of transformer spray piping. When we took the account for transformers in 2014, the requirement was for 165 transformers coming in C2 complex,PX IV, DTA Refinery-new upcoming plants, DTA/SEZ Gasification complex. At that moment, the construction management started crying looking at the total quantum of fire water piping and reported to Apex management to explore the possibility of optimizing and reduce the quantum of scope as much as possible. Moreover, with the bitter experience of deluge valve downstream piping corrosion (due to normally empty line with wet surface), we changed the piping specification to hot dip galvanization . All these things stirred the situation and there was utter chaos.
Moreover, none of the DEC engineering personnel could visualize and appreciate the necessity of splitting the Isometric drawings into workable spools with break flanges for undertaking the galvanization in outside shop at Rajkot /Ahmedabad. That time Sh.HRM called me and asked to have a re-look at all the DEC IFC deliverable and optimize as much as possible in all the project areas.
But the issue was, we have already sourced all the deluge valve requirement ( imported )and available in stores. Also at that stage,we did not realize the absolute requirement of deluge arrangement for electrical transformers across all project areas. So this surprise assignment has even shaken me in the start. I formed a working level task force drawn from RPMG/TechnoFire and JMD Fire team.
Fortunately,I had the services of M/S Dilip Koimattur,Aravind Induchoodan, Chattopadhyay & Ms Leena Thomas of my team.
Dilip &Leena being chemical engineers by qualification, they could discuss and analyze where they could cut down or where high sensitivity can cause trouble etc. Firstly, the task force deliberated and took the decision to avoid the spray water pipe routing on cold insulated vessels , where ground level monitor/hydrant can be utilized to fight the fire emergency. Since we had the deluge valve supply executed already , the team went to each and every DEC office to review the layout and 3D model to explore the possibility of combining the deluge supply for several equipment in one area retaining the deluge valve of largest size in that area and eliminating other valves and make them as spare. Aravind,having the field experience in handling fire emergency situations, did the task of identifying the use of already engineered hydrant and ground monitor in that domain area. Wherever, they found gap, they introduced new hydrant or monitor as essential. In these ,I played more the role of project manager than Loss Prevention manager.
By carrying out this exercise, they have reduced the scope of field piping from 400 Kms to 280Kms
in whole C2 complex itself and got about 65 deluge valves 3"/4"as spare from original 650 valves sourced from M/S Inbal,Israel. That I utilized for all the transformers in C2 complex and required to top-up the transformer requirement only in DTA/SEZ gasification complex, which was about 65 in number. At that stage, since the Israel party wanted price escalation, I thought it fit to go with indigenous sourcing from M/S HD Fire that too hydraulically balanced instead of pneumatic type.
As HD Fire MD himself is a technical expert in designing the system, he endorsed my decision and supplied the top-up requirement for transformers in Gasification complex.
Yes, there was problem in field execution since the concerned DEC engineer could not differentiate the piping arrangement between pneumatic type to hydraulically balanced type. With field engineering the situation was overcome.
Also by re-engineering all the isometrics with break flanges, we have eliminated the requirement of hot dip galvanizing in external shops.
Happy to note,all these fire water systems are completed and plants are commissioned without any hitch.
Key Aspects:- Communication, Critical challenge, Delegate, Incident analysis, Leadership, Proactive approach, Responsible, Technical issue, Team building
Deluge Optimization in J3
When we initiated J3 project Loss Prevention engineering in 2011/12, nobody had an iota of the job quantum for the loss prevention piping , but had only the lesson learnt during the execution of J1&J2. Added to injury, the Chief Electricity Authority of India have introduced the mandatory requirement of spray water fire protection for all transformers having rating of >10 MVA and 2000 lts. of oil tank in a transformer. This addition came in picture with the Act Amendment in Oct.2010.
But every DEC went ahead with engineering based on original Design basis what we developed in-house, based on NFPA and our back ground experience in the existing refineries.
When we took stock of total involved quantity of piping both above ground and under ground in C2 complex, it was coming to more than 400 Kms Run ! This does not include the requirement of transformer spray piping. When we took the account for transformers in 2014, the requirement was for 165 transformers coming in C2 complex,PX IV, DTA Refinery-new upcoming plants, DTA/SEZ Gasification complex. At that moment, the construction management started crying looking at the total quantum of fire water piping and reported to Apex management to explore the possibility of optimizing and reduce the quantum of scope as much as possible. Moreover, with the bitter experience of deluge valve downstream piping corrosion (due to normally empty line with wet surface), we changed the piping specification to hot dip galvanization . All these things stirred the situation and there was utter chaos.
Moreover, none of the DEC engineering personnel could visualize and appreciate the necessity of splitting the Isometric drawings into workable spools with break flanges for undertaking the galvanization in outside shop at Rajkot /Ahmedabad. That time Sh.HRM called me and asked to have a re-look at all the DEC IFC deliverable and optimize as much as possible in all the project areas.
But the issue was, we have already sourced all the deluge valve requirement ( imported )and available in stores. Also at that stage,we did not realize the absolute requirement of deluge arrangement for electrical transformers across all project areas. So this surprise assignment has even shaken me in the start. I formed a working level task force drawn from RPMG/TechnoFire and JMD Fire team.
Fortunately,I had the services of M/S Dilip Koimattur,Aravind Induchoodan, Chattopadhyay & Ms Leena Thomas of my team.
Dilip &Leena being chemical engineers by qualification, they could discuss and analyze where they could cut down or where high sensitivity can cause trouble etc. Firstly, the task force deliberated and took the decision to avoid the spray water pipe routing on cold insulated vessels , where ground level monitor/hydrant can be utilized to fight the fire emergency. Since we had the deluge valve supply executed already , the team went to each and every DEC office to review the layout and 3D model to explore the possibility of combining the deluge supply for several equipment in one area retaining the deluge valve of largest size in that area and eliminating other valves and make them as spare. Aravind,having the field experience in handling fire emergency situations, did the task of identifying the use of already engineered hydrant and ground monitor in that domain area. Wherever, they found gap, they introduced new hydrant or monitor as essential. In these ,I played more the role of project manager than Loss Prevention manager.
By carrying out this exercise, they have reduced the scope of field piping from 400 Kms to 280Kms
in whole C2 complex itself and got about 65 deluge valves 3"/4"as spare from original 650 valves sourced from M/S Inbal,Israel. That I utilized for all the transformers in C2 complex and required to top-up the transformer requirement only in DTA/SEZ gasification complex, which was about 65 in number. At that stage, since the Israel party wanted price escalation, I thought it fit to go with indigenous sourcing from M/S HD Fire that too hydraulically balanced instead of pneumatic type.
As HD Fire MD himself is a technical expert in designing the system, he endorsed my decision and supplied the top-up requirement for transformers in Gasification complex.
Yes, there was problem in field execution since the concerned DEC engineer could not differentiate the piping arrangement between pneumatic type to hydraulically balanced type. With field engineering the situation was overcome.
Also by re-engineering all the isometrics with break flanges, we have eliminated the requirement of hot dip galvanizing in external shops.
Happy to note,all these fire water systems are completed and plants are commissioned without any hitch.
Key Aspects:- Communication, Critical challenge, Delegate, Incident analysis, Leadership, Proactive approach, Responsible, Technical issue, Team building
