P 109
Hydraulic Study of FW network
When it came to SEZ we had the fundamental problem of shortfall ,having 50% standby pumping capacity while considering two largest fire demand that too@10.2 lpm/ M2 for tankage surface area and 1 lpm/M2 for land area! Under the expanded refinery plot,introducing new PX IV, its tank farm required @6000 M3/Hr. Considering Reliance own design basis, two simultaneous demand factors were-FCCU@6000 M3/Hr+ PX IV tank farm calling for 6000 M3 /Hr=12000 M3/Hr. but we had only 12 X 1000 M3/Hr. pumping..So there was virtually no standby pumping capacity. But when we counter-checked these under OISD design factors, we had more than 50% spare pumping capacity since OISD call for only @3lpm/M2 surface area in a tank against Reliance standard of 10.2 lpm/M2 surface area. At that stage, the team deliberated about the absolute requirement of incorporating additional pumps in the existing pump house to meet Reliance own standards.But the limitation arose from the space angle and pond volume! So the idea was dropped but recordings are kept for reference in future.
As the same network has been extended to cater to SEZ gasification complex also, a similar analysis
like DTA was carried out. Here the various scenario were:
In refinery area alone-2 simultaneous demand factors were- FCCU &PX IV tank farm
In Gasification complex,-2 simultaneous demand factors were-one gasifier module &AGR plant
In combined Refinery&gasification complex-2 simultaneous demand factors were- FCCU or PX IV tank farm with AGR plant.
As already explained, the analysis results with respect to OISD stipulations were comfortably met. Even under Reliance design basis, we were getting remote point remnant pressure more than 8 kg/cm2 g. That settled the issue,
When it came to C2 complex,issue was different. Since that was in green field, it called for a new infrastructure itself. At the start of J3, since I was the project manager -OSBL J3 as well as Loss prevention manager, the onus for conceptualizing the system fell on me. With the help of M/S Steve Wiggins &Bob Green of M/s Bechtel , I could identify the low lying area in the plot to develop as fire water pond in C2 complex. Then came the issue of identifying 2 largest demand areas in C2 complex to arrive at the fire water pumping capacity..Naturally the ROGC plant area was the largest but the plot plan was not frozen!More so since Reliance ROGC was one of the first in the world to develop
technology for producing Ethylene utilizing off gas from refinery as feed stock,With the involvement of RTG,M/S Technip-France went on developing the plot plan for ROGC but frozen the periphery FW ring main network sizing factor as 36" dia.. Finally the developed plot plan was 700M X 500M and it is not right to consider the entire plot as one single area for simultaneous demand consideration. So there was continuous exchange and debate with Technip-Delhi as well as France.
Finally we arrived at considering to split the plot into 3 segment ,giving merit of fire break of 36 M between each segment. That came to a demand of 7600 M3/Hr in the largest demand area. By that time, since all other ISBL boundary limits were frozen, we could easily identify that IIR/HIIR would be the second largest demand area in C2 complex land. Considering these two largest demand factors we arrived at the figure of approx. 10000 M3/Hr main pumping capacity. Then came my dilemma of making 50% spare pumping capacity that too the total should be an even number for equal split between electric motor driven and diesel drive. My conscience and gut feeling prevented me to opt for 6 number standby pump provision. I discussed the issue with SM and decided to go with FMEA analysis to arrive at the standby provisions taking credit for Reliability factors,MTBF/MTTR etc.
With complete analysis and logic, I concluded to go with only 4 standby pumps for the main 10 pumps demand. So a total of only 14 pumps have been implemented. All involved stake holders
including RTG,Operations &Fire Department appreciated the same and an exclusive design basis document was generated. Even the statutory authorities PESO felt that this should be the approach instead of going with empirical formula for large complex like C2 complex. Then onward M/S Yanamandra and Raguraman Seshadri took over the responsibility of executing the same.
Though at a later stage, one of the PESO authority took objection for catering FW to IIR complex from this FW pump house, that plant being another joint venture undertaking,we could technically justify and convince the authorities and sort out.
In case of MTF, we did not have any issue ,since the overall land area got frozen right at the beginning in 1996 itself and largest dyke factor for crude tanks did not alter at all.
It may not be wrong to note that JMD has got the maximum number of Fire water pumping capacity=
76 X 1000 M3/Hr split into 6 different land areas catering to 16000 acres land having world largest refinery/petrochemical complex.at Jamnagar.
Having successfully handled JMD FW hydraulic analysis, we ventured to undertake that exercise one by one for all manufacturing complex locations under Reliance.
Contd.....
Key Aspects :-Accountable, Attitude, Incident analysis, Initiative, Leadership, Technical issue, Team building
Hydraulic Study of FW network
When it came to SEZ we had the fundamental problem of shortfall ,having 50% standby pumping capacity while considering two largest fire demand that too@10.2 lpm/ M2 for tankage surface area and 1 lpm/M2 for land area! Under the expanded refinery plot,introducing new PX IV, its tank farm required @6000 M3/Hr. Considering Reliance own design basis, two simultaneous demand factors were-FCCU@6000 M3/Hr+ PX IV tank farm calling for 6000 M3 /Hr=12000 M3/Hr. but we had only 12 X 1000 M3/Hr. pumping..So there was virtually no standby pumping capacity. But when we counter-checked these under OISD design factors, we had more than 50% spare pumping capacity since OISD call for only @3lpm/M2 surface area in a tank against Reliance standard of 10.2 lpm/M2 surface area. At that stage, the team deliberated about the absolute requirement of incorporating additional pumps in the existing pump house to meet Reliance own standards.But the limitation arose from the space angle and pond volume! So the idea was dropped but recordings are kept for reference in future.
As the same network has been extended to cater to SEZ gasification complex also, a similar analysis
like DTA was carried out. Here the various scenario were:
In refinery area alone-2 simultaneous demand factors were- FCCU &PX IV tank farm
In Gasification complex,-2 simultaneous demand factors were-one gasifier module &AGR plant
In combined Refinery&gasification complex-2 simultaneous demand factors were- FCCU or PX IV tank farm with AGR plant.
As already explained, the analysis results with respect to OISD stipulations were comfortably met. Even under Reliance design basis, we were getting remote point remnant pressure more than 8 kg/cm2 g. That settled the issue,
When it came to C2 complex,issue was different. Since that was in green field, it called for a new infrastructure itself. At the start of J3, since I was the project manager -OSBL J3 as well as Loss prevention manager, the onus for conceptualizing the system fell on me. With the help of M/S Steve Wiggins &Bob Green of M/s Bechtel , I could identify the low lying area in the plot to develop as fire water pond in C2 complex. Then came the issue of identifying 2 largest demand areas in C2 complex to arrive at the fire water pumping capacity..Naturally the ROGC plant area was the largest but the plot plan was not frozen!More so since Reliance ROGC was one of the first in the world to develop
technology for producing Ethylene utilizing off gas from refinery as feed stock,With the involvement of RTG,M/S Technip-France went on developing the plot plan for ROGC but frozen the periphery FW ring main network sizing factor as 36" dia.. Finally the developed plot plan was 700M X 500M and it is not right to consider the entire plot as one single area for simultaneous demand consideration. So there was continuous exchange and debate with Technip-Delhi as well as France.
Finally we arrived at considering to split the plot into 3 segment ,giving merit of fire break of 36 M between each segment. That came to a demand of 7600 M3/Hr in the largest demand area. By that time, since all other ISBL boundary limits were frozen, we could easily identify that IIR/HIIR would be the second largest demand area in C2 complex land. Considering these two largest demand factors we arrived at the figure of approx. 10000 M3/Hr main pumping capacity. Then came my dilemma of making 50% spare pumping capacity that too the total should be an even number for equal split between electric motor driven and diesel drive. My conscience and gut feeling prevented me to opt for 6 number standby pump provision. I discussed the issue with SM and decided to go with FMEA analysis to arrive at the standby provisions taking credit for Reliability factors,MTBF/MTTR etc.
With complete analysis and logic, I concluded to go with only 4 standby pumps for the main 10 pumps demand. So a total of only 14 pumps have been implemented. All involved stake holders
including RTG,Operations &Fire Department appreciated the same and an exclusive design basis document was generated. Even the statutory authorities PESO felt that this should be the approach instead of going with empirical formula for large complex like C2 complex. Then onward M/S Yanamandra and Raguraman Seshadri took over the responsibility of executing the same.
Though at a later stage, one of the PESO authority took objection for catering FW to IIR complex from this FW pump house, that plant being another joint venture undertaking,we could technically justify and convince the authorities and sort out.
In case of MTF, we did not have any issue ,since the overall land area got frozen right at the beginning in 1996 itself and largest dyke factor for crude tanks did not alter at all.
It may not be wrong to note that JMD has got the maximum number of Fire water pumping capacity=
76 X 1000 M3/Hr split into 6 different land areas catering to 16000 acres land having world largest refinery/petrochemical complex.at Jamnagar.
Having successfully handled JMD FW hydraulic analysis, we ventured to undertake that exercise one by one for all manufacturing complex locations under Reliance.
Contd.....
Key Aspects :-Accountable, Attitude, Incident analysis, Initiative, Leadership, Technical issue, Team building
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