P 116
J3 PPE Implementation
That Hazop point issue has got nothing to do with implementation of PPE-Breathing Air but became a fundamental process issue! That was a vent stack of 110 M tall which may emit vapors containing 600 ppm of CO, 2000 ppm of CO2 when there is process upset in Methanation in AGR. To start with, the operations team got frightened with, that this much CO2 content in air which will form ice in cold box and ASU operations cannot sustain at all.When Reliance took up the matter with M/S Linde questioning why they have not tabled this point during plot plan review of AGR and ASU, both being executed from the same office at Munich, that party coolly responded that these are two independent contract from Reliance and they are not responsible for this mess. When Reliance carried out consequential analysis post noting this, it showed that CO of 600ppm may be prevalent up to 500 M radii from that stack whereas the gap between AGR and ASU is only 81M in field.
Immediately EJames deployed one of his able process analyst to study how to get over this challenging situation. After carrying out CFD, she came out with decreasing temperature profile with raise in elevation and ensure to eliminate the impact of CO2 in atmosphere. This output was reviewed by M/S Linde and they concurred in principle. Then the plant process team and projects took up with Linde Baroda and incorporated steam ring arrangement at the bottom of that stack.
There were many bottlenecks in arriving at the source point for pure air, where&how to make provisions for air quality analysis during BA distribution, how any field personnel will access this provision during field operations/ maintenance&wear the harness assembly, emergency switch over
provision to a bottled pure air when air quality deteriorate etc.
When it came to utility compressor air quality, one group of operations and safety queried, whether we are right in opting to utilize process air which may contain some moisture even after trap, instead to look for dry instrument air having Du Point of -40 Deg. That led us to take up with the world best refinery building agency M/S Bechtel as well carry out study of basic stoichiometry for air. We got convinced that we are in order with respect to selection &continued to choose plant air only for this service.
Having got over the breathing air source in principle, from the respective refinery utility air compressor system for respective refineries and their corresponding gasification complex, we decided to utilize C2 area utility compressor for that complex exclusively. To assure the continuous monitoring of breathing air feed from utility air compressor system in respective area, we introduced
a three element(sensors) in-line analyzer module with a cut-off valve for monitoring CO/H2S/%O2 in the air distribution header. This was supplied by M/S MSA under brand name ULTIMA.
But unfortunately I came to understand now that the concerned OSBL DEC has not completed its engineering yet , but respective user plants are up&running for the last one year or so!
For arriving at the quantity of BA take-offs, in 2015 I conducted field meetings with respective end stake holder in operations of each plant and went through their layout and plant 3D model. In the initial exercise it came out to +410 in DTA and +450 in SEZ . Here I have to highlight one specific issue ! When I completed this task, Mr Pandian of AGR was still not happy and looked for more.
When I discussed with him one to one, he brought out one major technical deviation taken by equipment and column supplier while sizing the man hole cover ! It seems they have opted for 18" hole size when international approved standard call for 24" hole size; With 18" hole, a human being cannot enter any column with SCABA set with cylinder at his back &harness assembly ! So he was looking for relief through these BA Stn take-off points. We shall come to know of its effective use only after full commissioning of gasification complex/s.
Contd.......
Key Aspects:- Incident analysis, Technical issue,Attitude
J3 PPE Implementation
That Hazop point issue has got nothing to do with implementation of PPE-Breathing Air but became a fundamental process issue! That was a vent stack of 110 M tall which may emit vapors containing 600 ppm of CO, 2000 ppm of CO2 when there is process upset in Methanation in AGR. To start with, the operations team got frightened with, that this much CO2 content in air which will form ice in cold box and ASU operations cannot sustain at all.When Reliance took up the matter with M/S Linde questioning why they have not tabled this point during plot plan review of AGR and ASU, both being executed from the same office at Munich, that party coolly responded that these are two independent contract from Reliance and they are not responsible for this mess. When Reliance carried out consequential analysis post noting this, it showed that CO of 600ppm may be prevalent up to 500 M radii from that stack whereas the gap between AGR and ASU is only 81M in field.
Immediately EJames deployed one of his able process analyst to study how to get over this challenging situation. After carrying out CFD, she came out with decreasing temperature profile with raise in elevation and ensure to eliminate the impact of CO2 in atmosphere. This output was reviewed by M/S Linde and they concurred in principle. Then the plant process team and projects took up with Linde Baroda and incorporated steam ring arrangement at the bottom of that stack.
There were many bottlenecks in arriving at the source point for pure air, where&how to make provisions for air quality analysis during BA distribution, how any field personnel will access this provision during field operations/ maintenance&wear the harness assembly, emergency switch over
provision to a bottled pure air when air quality deteriorate etc.
When it came to utility compressor air quality, one group of operations and safety queried, whether we are right in opting to utilize process air which may contain some moisture even after trap, instead to look for dry instrument air having Du Point of -40 Deg. That led us to take up with the world best refinery building agency M/S Bechtel as well carry out study of basic stoichiometry for air. We got convinced that we are in order with respect to selection &continued to choose plant air only for this service.
Having got over the breathing air source in principle, from the respective refinery utility air compressor system for respective refineries and their corresponding gasification complex, we decided to utilize C2 area utility compressor for that complex exclusively. To assure the continuous monitoring of breathing air feed from utility air compressor system in respective area, we introduced
a three element(sensors) in-line analyzer module with a cut-off valve for monitoring CO/H2S/%O2 in the air distribution header. This was supplied by M/S MSA under brand name ULTIMA.
But unfortunately I came to understand now that the concerned OSBL DEC has not completed its engineering yet , but respective user plants are up&running for the last one year or so!
For arriving at the quantity of BA take-offs, in 2015 I conducted field meetings with respective end stake holder in operations of each plant and went through their layout and plant 3D model. In the initial exercise it came out to +410 in DTA and +450 in SEZ . Here I have to highlight one specific issue ! When I completed this task, Mr Pandian of AGR was still not happy and looked for more.
When I discussed with him one to one, he brought out one major technical deviation taken by equipment and column supplier while sizing the man hole cover ! It seems they have opted for 18" hole size when international approved standard call for 24" hole size; With 18" hole, a human being cannot enter any column with SCABA set with cylinder at his back &harness assembly ! So he was looking for relief through these BA Stn take-off points. We shall come to know of its effective use only after full commissioning of gasification complex/s.
Contd.......
Key Aspects:- Incident analysis, Technical issue,Attitude
No comments:
Post a Comment