P 81
Beginning of JERP
My shifting office to NHQ has coincided with start of JERP at Jamnagar. As RIL have succeeded in
executing the first refinery of such large capacity, with the favorable Government norms in developing a project under SEZ (Specified Export Zone), Reliance was the first to jump in undertaking that challenge.As they had an excellent and experienced project management and construction team, and having established worth understanding and operating relations with M/S Bechtel, the launch was smooth. The team formation took place in a jiffy with Sh Sanjay Mashruwala as Project Director and Sh. N B Deshmukh as procurement director. As PMSP became busy with the oil exploration challenge at Kakinada, this change took place; but he was given the task of project initiation and initial commitments to the tune of $1 billion before December'05 end.
As I was the project manager for OSBL- Utilities/Offsite &integration of units in the first refinery at Jamnagar, that responsibility mantle fell on me! As initial task, I was given the charge to seek the in-principle clearance for the majority of goods listing(not only OSBL but all ISBL plant equipment and all other items), from the Export Commissioner-Customs. As SEZ facility are exempt from levy of excise duty, local taxes and free import duty, my task became highly challenging. As usual , the commercial department were very possessive in sharing the data and values thereof. They were envying how come a technical person have been given this charge! But the officials in the Government Department were looking for my presence in every meeting and they made it mandatory
that I only should furnish the details and share the data. But the end result was a roaring success.
That process launched SEZ project execution procedure and operations.
By June '05 middle, the project team leads shifted their base camp to London. To start with , the management declared that all base units in the refinery shall be of the same capacity in JERP but will have additional Alkylation and Clean fuel Unit. The Alkylation got added for enriching gasolene by converting LPG from FCCU. This change has taken place since the SEZ production has to be completely exported and cannot be sold in Indian markets; in that process, USA became the main importer of that yield. Next came the importance of reduction of sulphur content in the fuel- meeting Euro 4 specification. That technology was sourced from Exxon Mobil and UOP joint efforts. The end result was that Jamnagar refining facility became the world largest refining complex.
As OSBL project manager, my first priority task was to coordinate with Bechtel layout group to develop JERP layout initial revision and seek operations/ management approval and arrive at tentative utility balance for most of the repeat units. With the supervisory directions of Dr JVK, me/Samir Karnik/Momin/Lohia/Kirit Brahmhabhatt developed the utility matrix with +30% margin for assumption errors and future developments. As we had an operating refinery at the same area, the data collection efforts became easier. But there were some major changes in the design basis. Especially, since there was no requirement of HHP steam in operating a refinery, we limited ourselves with 42 bar g steam but with Frame 9 HRSG(GE) with 110 MW capacity. With the development of higher capacity module by M/S IDE Israel, we opted for 1000M3/Hr from phase1- 260M3/Hr Desal modules. With the bitter experience of having wind velocity impact and maintainability issues, we have modified the CTs to concrete type and went in for PP tower for sea water application.
Let me narrate the various project phase experience and important milestones achieved as well as challenges faced in next issue...... Contd....
Key Aspects :- Conviction, Critical challenge, Faith, Leadership, Multi discipline exposure,
Opprtunity, Proactive approach, Responsible, Technical issue,
Beginning of JERP
My shifting office to NHQ has coincided with start of JERP at Jamnagar. As RIL have succeeded in
executing the first refinery of such large capacity, with the favorable Government norms in developing a project under SEZ (Specified Export Zone), Reliance was the first to jump in undertaking that challenge.As they had an excellent and experienced project management and construction team, and having established worth understanding and operating relations with M/S Bechtel, the launch was smooth. The team formation took place in a jiffy with Sh Sanjay Mashruwala as Project Director and Sh. N B Deshmukh as procurement director. As PMSP became busy with the oil exploration challenge at Kakinada, this change took place; but he was given the task of project initiation and initial commitments to the tune of $1 billion before December'05 end.
As I was the project manager for OSBL- Utilities/Offsite &integration of units in the first refinery at Jamnagar, that responsibility mantle fell on me! As initial task, I was given the charge to seek the in-principle clearance for the majority of goods listing(not only OSBL but all ISBL plant equipment and all other items), from the Export Commissioner-Customs. As SEZ facility are exempt from levy of excise duty, local taxes and free import duty, my task became highly challenging. As usual , the commercial department were very possessive in sharing the data and values thereof. They were envying how come a technical person have been given this charge! But the officials in the Government Department were looking for my presence in every meeting and they made it mandatory
that I only should furnish the details and share the data. But the end result was a roaring success.
That process launched SEZ project execution procedure and operations.
By June '05 middle, the project team leads shifted their base camp to London. To start with , the management declared that all base units in the refinery shall be of the same capacity in JERP but will have additional Alkylation and Clean fuel Unit. The Alkylation got added for enriching gasolene by converting LPG from FCCU. This change has taken place since the SEZ production has to be completely exported and cannot be sold in Indian markets; in that process, USA became the main importer of that yield. Next came the importance of reduction of sulphur content in the fuel- meeting Euro 4 specification. That technology was sourced from Exxon Mobil and UOP joint efforts. The end result was that Jamnagar refining facility became the world largest refining complex.
As OSBL project manager, my first priority task was to coordinate with Bechtel layout group to develop JERP layout initial revision and seek operations/ management approval and arrive at tentative utility balance for most of the repeat units. With the supervisory directions of Dr JVK, me/Samir Karnik/Momin/Lohia/Kirit Brahmhabhatt developed the utility matrix with +30% margin for assumption errors and future developments. As we had an operating refinery at the same area, the data collection efforts became easier. But there were some major changes in the design basis. Especially, since there was no requirement of HHP steam in operating a refinery, we limited ourselves with 42 bar g steam but with Frame 9 HRSG(GE) with 110 MW capacity. With the development of higher capacity module by M/S IDE Israel, we opted for 1000M3/Hr from phase1- 260M3/Hr Desal modules. With the bitter experience of having wind velocity impact and maintainability issues, we have modified the CTs to concrete type and went in for PP tower for sea water application.
Let me narrate the various project phase experience and important milestones achieved as well as challenges faced in next issue...... Contd....
Key Aspects :- Conviction, Critical challenge, Faith, Leadership, Multi discipline exposure,
Opprtunity, Proactive approach, Responsible, Technical issue,
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