P 28 PX at PG execution

P  28

PX Execution Contd.

On request UOP mobilised 5 member team under Mr Don Bell. The leaders were Don Bell, Murphy& Richard. Richard was the instrument specialist and was in constant touch with me and my team. As PTA has been commissioned and running, we could get only DGS, Venkatesh and Baldota from the old team.So we recruited  M/S Venkateswaran, Chandra Sekhar, J Balu, Nagesh, Raja Rajan
 and strengthened Reliance team. It so happened that all of them were from MIT-some DMIT and others B Tech. We had the full co-operation from M/S  Saxena and Ashok Kumar  as well as Sh A Venkataraman for all our mechanical works.
 On technical front, usual goof-ups of DEC (here also John Brown) was very much prevalent.  My team with Richard's help took enough care to address all of them and manage. Here two important items have to be noted- 1 ) Since the control valves actuator was very large in many cases, M/S UOP have particularly recommended to go for 3/8" Cu. tubing instead of conventional 1/4 " tubing but still JB missed them out! So case by case we got them changed with mechanical department help and checked the stroke test carried  out for noting the speed of response. 2) In case of Neles Ball valve, Richard was very particular to organise the helium test done for checking zero bubble test. In central work shop Venkatesh and Saxena got them done successfully and Richard praised them very much.

During PX execution, we faced another drama!  Those days being Rule Raj existed in India, GOI issued notice to RIL stating that the clearance for PX capacity was only 75000TPA and how come the company have gone ahead with 90000TPA design in some equipment! They deployed an audit party from EIL (under Mr J Rangachari) to completely inspect our premises. The authorities in Govt. did not understand that even EIL puts design margin while specifying the equipment sizing.  Since JR being an experienced personality and having worked in L&T before joining EIL, his inspection has really benefited Reliance.

While executing PX only, AR got the opportunity to get exposed on fire fighting  systems engg. and field execution. With M/S TechnoFire (Praful Sanghrajka)as contractor, effectively  I got involved in Halon system execution for control room and A3 tank  farm  .fire water network and tank protection by MVWS/Foam injection system. In those days, since TAC were the statutory authorities to rate the insurance premium discount, got introduced to stalwarts  M/S Sanjana, TRA Krishnan, Dilip Koimattur &others.That relation still continue with TRAK and Dilip even now; of course Praful is always there.
Here I recollect three important events:
1. A sad one- Mr Verma was recruited as maintenance manager for commissioned PX and for training he was deputed to UK. There on fourth day itself he fell sick and went into coma! It is to be recorded that Reliance Management went out of way to bring him back alive by taking up with Sh Rajiv Gandhi, that time PM  to engage a chartered flight with O2 cylinders and executed that challenge.. Unfortunate that Mr Verma did not recover at all and died after several months bedridden in Hinduja hospital.
2. I have to really remember the company's commitment towards employees. Though I took the promise from the management for house loan during my final interview in Dec.'86, due to work pressure on the job, I forgot that issue completely. But the management sent a word through personnel department Sh V Venkatesh that I have completed one year in the company  and I can avail the interest free loan. That is how my first tenement at Choolaimedu , Madras was possessed.

                                                                                                                           PX  Execution contd......

Key Aspects : -Incidence analysis, Multi discipline exposure, Motivation, Opportunity, Technical issue, 

P 27 Patalganga Experience

P 27

PG Construction exposure contd.
When we took charge of PTA Purification instrumentation execution We were repeatedly cautioned about the importance and cost of one Fisher Control valve in Purification reactor bottom. Since that CV shaft and plugs were made of Zirconium it costed Rs 4 crores in 1980s itself. Mr Gordon of ICI was taking that as personal possession and did not allow any contract personnel even to hook up the copper tubing to that valve. But as commissioning and maintenance instrument engineer ,he did not think or realize that foreign particles enter in any pipeline during field fabrication. Here also such a mishap took place and created some scratch on the plug surface. It was noticed by me and DGS but could not share with ICI and John Brown team considering the involved stakes. I shared the issue only with Sh A Poddar, who was looking after material co-ordination during PTA execution. Both of us tried to contact various parties in Mumbai and New Mumbai to explore the possibility of  powder coating on the plug and shaft. We could bump on one party at Taloja who said that he does have coating facility  but do not have this relevant experience; so he was not sure to give guarantee but accepted that he can give a try and will cost Rs 11000/-. AP and me took the gamble and immediately contacted Sh RK Sundaram, who was Chief Executive-Procurement then. Over phone he concurred and asked us to go ahead. We both stood in that shop whole day and got the shaft coated by 4PM. Next day, the CV was re-assembled in instrument shop and got it erected. The Best News is that the same valve is still operational in PG PTA.- 28 years !!

During field execution it was noticed that the DEC (John Brown) have missed out to include one integral orifice  along with DP transmitter order. The chaos and confusion was prevailing. I took the chance to explore the possibility of getting it fabricated locally. Reliance had one small time fabricator by name Sh Bachubhai. I called him and explained him the intricacies and specialty of that orifice  and requested him whether he can attempt. As he was highly dependent for Reliance interests he picked up that assignment. When he brought the finished product  the foreigners got astonished and appreciated his workmanship.

During commissioning phase of PTA, though I heard of that , H2 is potentially a dangerous gas and does not have any colour, my assistant  Arvind Patel had bitter experience. In one H2 flow transmitter
when he attempted to zero check by opening the equalizing valve in the manifold, the remnant gas in one side of impulse line  flashed on his ankle and fire emergency case arose. As it was evening 7 PM , I had the duty and responsibility to carry him to Raju Nursing Home at Panvel as emergency admission. Luckily his injury was not serious and he resumed duties in couple of days.

PG PTA plant was commissioned on 13th January'88 early hours. During that celebrations somebody posed a question to Mr PB Dighe, Site President asking what will AR do now since PTA is commissioned. He retorted saying he will jump the wall and will work in paraxylene execution.
PG PX technology licensor was M/S UOP.  As me and GS Rao  have worked with UOP in Visag.  we knew their style of functioning and punch list approach.We cautioned and advised  Reliance management  to line  up their start-up team manpower  right in the beginning itself. MDA being task oriented, understood that importance and ensured to mobilize their team immediately. That made Mr Don Bell and his team to be part of Reliance execution team for PX build up. I have faced different challenges during PX execution. GSR formed an execution team- P Garg, VLPerumallu ,Anantha narayan, Ghosh Chowdry and AR. That was the core construction team and each was given power to take the call as necessary.                                                                                          
                                                                                             PG Experience contd.......

Key Aspects :-Incident analysis, Initiative, Innovative, 

P 26 Patalganga experience

P  26

Ptalganga entry&Introduction
As per PND's directive I went to PG and  was directed to meet Sh J Sundar Raman.  For info. JSR was known to me right from my MIT student days.  I was a trainee under him in Neyveli fertilizers and later functioned as his contractor for GOP Cracker instrumentation at Baroda. So he was very familiar and cordial to me.  So on reaching his office we were discussing in general about family welfare and waited for PND's arrival. Once PND entered his cabin, he was surprised to see us moving and exchanging freely. He asked JSR how do you know him? His response was  Who does not know this bandikoot! he is well known in Instrumentation execution in India. Immediately PND left the place stating my job is over; you two manage. That is how my field exposure in Reliance originated.
In few weeks Mr GS Rao, my neighbor and EIL site chief at Visag. joined Reliance  and reported as head of construction at PG. Naturally my boss has changed from JSR  to GSR. Since I knew both of them very well transition was smooth.
In the work front, usual engineering office folly were very much there. As site instrumentation chief I have been asked to take the call and I got full recognition and co-operation from one&all. My immediate deputy was DG Sangawar under whom Arvind Patel and Vyas were there. Below them there were many engineers- Venkatesh, Godse, Vora, Chavan, Khandalkar, Rathod, Mukesh Garg, Raghavendran ,Baldota ...... PTA plant have got two distinct divisions- Oxidation and Purification. In whole of Oxidation, the main challenge was O2 monitoring and control in OXY reactor. Though John Brown personnel were there in site, it was Vyas and Vora  who addressed the finite issues and with DGS directions, managed the challenges. When it came to Purification, Arvind Patel took the initiative and tackled all the misfits in  Purification reactor and centrifuges. DGS took the call in addressing the main air compressor in PTA which had direct link with energy centre for steam turbine drive. He also personally managed the final product silo control having special pneumatic relays.
Raghavendran with Mukesh Garg and Rathod managed the energy centre and utilities block. In initial days, Baldota,Chavan, Venkatesh and Khandalkar took care of establishing the instrument maintenance shop and calibration. Later Venkatesh and Baldota shifted to Paraxylene plant execution.
Chavan took the total responsibility in establishing a robust workshop.

A special mention here. In PG only, since the client engineers themselves supervised and managed the construction execution, the real literal ownership mentality culture was evident. My boys used to demand for corrections if they observe any thing wrong, not only in instrumentation discipline but with all allied disciplines. We used to see team work but at the same time competition among themselves.
Specific technical points while executing PTA
1. Control room system configuration
2. Purification Reactor control valve
3. Fabrication of integral orifice
4. Hydrogen flow transmitter incident

Having got experienced with two DCS system- Honeywell TDC 2000 at  Schwedt,E Germany and YEW Centum at Visag Refinery, When I first saw ABB dual mini computer system at PG, I had shock! I came to understand that BRM and Dave Walton  of John Brown only configured the system  with ICI Gordon's approval. As my deputation to PG was late, it was too late to incorporate an ideal DCS for PTA and PX at PG.  As forecasted  the issue of data share and change over were very much prevalent. Even after commissioning they continued to struggle and later changed to conventional DCS.  Another sore point was- the control room did not have false flooring! So every time if one have to check the cables, it required enormous labour to lift the steel plates.
                                                                                                     PG Experience Contd......

Key Aspects :- Delegation, Human relations, Incident analysis, Initiative, Leadership, Recognition,
Reputation, Surprise&shock, Technical issue 

P 25 Reliance Joining

P  25


Reliance Innings Begin-1987 Feb.27th

Having taken the appointment order,I thought I can join in May'87(after my first son's annual examinations at Vishaka Valley School). But PND had other ideas&asked me to report as early as possible. For that Reliance management was courteous enough to offer that I can take a rented accommodation at Visag and leave the family there until the school closure and company will reimburse the rent. All these factors gave me more confidence. So leaving the family in a rented
accommodation at Pedda Waltair,I flew to Mumbai on 26th Feb '87- since I was relieved by HPCL on 25th afternoon after due notice period formalities. As per understanding with the company, bulk of family goods were booked in a transport lorry to Navi Mumbai and they were put in a temporary housing at Vashi, since the home selected for me -20 Rohini Apartments was not available for occupation until March end. So initially I stayed in my sister-in-law house only and used to attend office at Tulsiani Chambers.

My Reliance innings started on Feb.27th,1987 and still continuing! When I began my career here I had no idea what are in store for me!!One important thing is to be noted here. I am one of the luckiest person to enjoy the experience of Reliance Growth. I got exposed to all aspects of hydrocarbon industry- Technical/Commercial/ Legal/Insurance/ Environment issues/ Material sourcing/ Logistics/
Statutory compliance/Commissioning ,Operation& maintenance/ HSE&LP including the development of Risk Register etc.  My exposure covered- right from conceptualization to steady state operations not only in in instrumentation but all facets of engineering disciplines as Project Manager/Engineering Manager in the world's largest Refinery and Petro-chemicals complex. I am proud to share that I have grown with the company  & my little contribution have played a major part in the company's development  and growth. Though I am in Reliance Industries role for the last 29 years, my employment have changed 6 times within the group set-ups.

Let me share how my life and career have evolved in all these 29 years. There were very high and low esteems during this period. I shall attempt to share and highlight my experience in Reliance by citing several incidents and challenges that I have faced..I have enjoyed all of them.

As I have mentioned earlier, when PND and KK roped me to Reliance, they had only Hazira petro-chemical plants in mind. So initially I was part of Hazira project team under Mr N Gopal sitting in Tulsiani Chambers. The project team had the task of identifying the various could-be licensor/s for
the various plants envisaged there. As the time was moving on, one day PND broached the subject
of deputing me to Patalganga to effectively participate and contribute for the  upcoming PTA plant implementation under ICI Technology ,John Brown,UK being the engineering contractor. Without hesitation I responded that it is my duty and responsibility to serve in the best of company's interest.
But they had their internal issues; Sh B R Mehta was the manager in position, who had the dual responsibility of both procurement as well as engineering/construction management. M/S ICB was the instrument contractor, managed by Sh K Chandrasekhar, another DMIT. So PND deliberated this with MDA. After few days, one fine day PND's Secy. told me that the boss wants me to be in PG and he will meet me there, as he was coming back from Delhi. That is how first field exposure in Reliance originated.                                                                     Contd.........

Key Aspects :- Multi discipline exposure, Opportunity, Proactive approach, Transfer, Ups&down 

P 24 Reliance Joining Story

P 24

Reliance Joining
As per Madras discussions, Sh PND has made sure to call me at Bombay on 7th Dec.'86. As I requested that the duration of tour to be short and the company should bear my plane ticket fares, their telegram was crystal clear. I flew from Visag, via Hyderabad on 6th Dec.and stayed at my Sister-in law residence at Ghatkopar. Me and my Co-brother Sankaran spent that evening in neighbouring joint to evaluate the pros&cons of quitting HPCL and accept to join Reliance.

Over drinks we analysed the matter thread bare and the points of discussion were as follows:
 Is it right on my part to leave Public sector firm D Grade manager position  and join a private firm?
The said firm is full of controversy especially being targeted by M/S VP Singh,Bhurelal and Gurumoorthy of Indian express. Mr VP Singh was the finance Minister of India under Mr Rajiv Gandhi,PM.
Had the wrong notion that Ambanis are Sindhis ;though I have several Sindhi friends I personally don't trust them
Being a small company, whether I will get paid my salary dues every month ?
But at the same time, I have been called by PND after KK telling good about me. So we were trying to find some good excuse route to wriggle out!
The house loan became the moot point.  In that year only I became eligible to avail a loan of Rs 2 Lacs @2% interest( an employee must have completed five year of services in Govt.undertaking). So we closed the night considering that I will table that point during final interview and if at all they considered that favorably, then only I should accept the deal.
Next day,7th Dec. when I went to Tulsiani chambers for interview PND was not there; but he has left instructions with his PA Mr Ramachandran and HR Mr V Venkatesh to receive me and take to Mr N Gopal, then GM-Projects for discussions . So from 10.30 to 2 PM, me and Mr Gopal were discussing.
You know what subject?- as me and Gopal hailed from the same school at Triplicane Hindu High School, we did detailed analysis about each and every teacher of that school- their characterization /mannerisms, special attributes both positive and negative etc. Lastly when PND came at 2 PM, he gave direct instructions to Venkatesh to line up my medical check-up on next morning. Then he told me to complete that formality and wait for him in the afternoon. I frankly asked him whether I can go ahead with confirming my return journey booking, which he okayed. Next day interview meeting was a story by itself.
As he was arriving, he asked his secretary to line up two plates of idly/vadai for him and me  and took me in. I was very keen to raise the house loan subject so that I can wriggle out. But he started the dialogue differently.  He repeated that this interview is only formality  and declared that I have been selected as Instrument manager for the upcoming Hazira project. Then he asked me to refer some names to lead construction as chief manager and inspection manager. Keeping Mr GS Rao of EIL in mind, I responded that the person is too senior compared to me and only personality like KK can approach. That  he noted and thanked. I was getting nervous to put my requirement on the table.
Then looking at the wall- where Goddess Kamakchi with Periya Periaval  photo frame was there, I broached the subject of house loan citing HPCL rules and my eligibility factor etc. His reaction was
with caution.He explained that this is private company and there is no such practice etc. Then I responded then my joining Reliance is getting ruled out. Immediately he stopped me and dialed MDA ( Mukesh Ambani). He answered that it can be considered only after one year successful completion. Then we both exchanged and that ruling was entered in my personal  file.                           Contd.....

Key Aspects :- Communication, Conviction

P 23 End of Visag Innings

P 23

Visag Innings Closure

During my tenure in HPCL Visag, though I have achieved the distinction of One of the FIRST to introduce DCS in India, life was not easy. Though I enjoyed the job assignment fully with the support of my team, there was full of politics- Bombay Vs Visag differentiation. After VREP completion, none of the project team members were assigned any definite role/ responsibility. I took advantage of that  period in completing my Hindi Rashtra Basha examinations and got first class.

 In Aug. '86 I was deputed for one week training course at Khandala/Lonawala- Training For Trainers  conducted by HPCL Training Head Mr Harry D' Silva. That outing in Hill Station that too during Maharashtra monsoon gave me complete relief.  Out of 27 attendees( drawn from all over India) I stood first in the training & final presentation project , got the shield. My return journey to Visag via Bombay/Hyderabad changed the course of my life and career!

I left the training camp by noon and traveled to Bombay by share taxi ; then caught the Bombay-Hyderabad IA flight. The plane was delayed and reached Hyderabad only around 8 PM. When I got down and after claiming the baggage, climbing up the staircase to get out, somebody from behind
shouted my name. When I looked back, it was Sh KK( K Krishnamurthy, former Chairman,HPCL) who called me. He queried that as it is already late, why not we have coffee in the stall and chat for few minutes. Since I have respect for elders like him I readily agreed and went with him.  Initially he enquired about the CO Boiler incident, plant operation conditions and about the welfare of my colleagues. Then he changed the subject asking me, " Is it not time for you to change the job?" After that he asked me to give my CV and said he will look for one. I was taken by surprise shock and queried- are you saying  a change of job in India  or something in abroad? He responded it may be anything but you do not have future in HPCL to grow under the changed management. His was a plain talk exposing the real truth. Since I was on  official tour, I did not keep the CV copy.He understood that and gave me his personal visiting card and asked me to post my CV to his home address at Chembur. On reaching Visag I discussed this subject with my wife. She immediately reacted that since KK and his wife Mrs Naglakshmi are our well wishers, we should send the CV immediately, which I did in August itself and forgotten then. To everybody's surprise, by end November I get a phone  trunk call from KSV & Mrs Kamala Vaidyanathan stating that I should
positively meet Mr PN Devarajan at Madras. On that day evening, when I went to recreation club, my another boss- who retired that week only, said in chaste Telugu- Emira,Elluthava, tappakonda Dr PND meet chai.  In the night about 10.30PM DHPR phoned and advised me to go and meet PND.
So without any hesitation I traveled to Madras to meet PND. When I called on him at Taj Coramandal hotel, he recollected that he has met me earlier! I responded to him saying yes- at Chemplast interview in 1969. Then he said that Sh KK has briefed him enough about me and stated that I will be called for final interview at Mumbai for regularisation and medical test etc. Since I lost my father that year July only, I requested that the final interview date should not fall on 25/26th Dec.,being 6th month ceremony dates. He acknowledged and confirmed that it will not be so late and will be in first week of December itself. I was called to fly out on 7th December'86 for final interview formalities at Bombay.   That is how my Visag innings came to end; Rest is History..........

Key Aspects  :- Surprise & shock, Training, Transfer, Ups&down

P 22 Visag Innings Contd

    P22

Visag innings Contd...
During VREP commissioning we have come across a freak incident. Without realising the importance of flare flame continuity, one of the operations engineer opened the steam valve  in the flare header and put off the flare flame! The whole project&operations team were blinking with crossed fingers. Mr Rama Sundaram, No. 2 of EIL team took a bold initiative to face that challenge.He caught hold of a village urchin and asked that boy to shoot alighted torch  tied with an arrow from his bow, standing on a nearby tall structure. Being a small boy, he was not aware of the seriousness of the situation and shot the arrow.The flare header got re-lit and we were relieved.

In VREP days, though I was Instrument manager by designation I had the opening and opportunities to deal other discipline subjects also.One of it was CO boiler selection. HPCL management( Sh KK) asked me to get in touch with Mr SR Setlur( who was the first Indian Covenanted officer of Burmah Shell , ex CMD of BRPL,  and even presently functioning as adviser to Reliance- aged 84 years) and seek his inputs /recommendations in conceptualizing CO boiler configuration in FCCU-VREP.I called on him at his Janpath office and off hand he has given various tips to ensure what factors to be addressed and DOs & Donts. Utilizing them when we posed those factors to EIL and finally to the selected bidder, they were astonished &fully accepted to incorporate them.
But it is a different fact that after 1 1/2 years of  successful operation, there was a blast in that CO Boiler due to mal-operation. That caused requirement of additional 6 steam control valves IBR certified.
In 1985 August I was on emergency leave  at Madras to attend to my father who had brain cancer  and surgery  carried out. During that time DHPR( DHP Rathnaswamy) phoned me and queried whether I can make an emergency trip to IL Palghat to get these valves on SOS basis.When I responded that I do not have any relevant papers and no money in hand, management convinced me that they will fax the data sheets and specifications to EIL office at T Nagar and travel advance will be extended by Mr Abhraham ,Regional manager, HPCL Madras. Since my brother Venkhat has some contacts in S Rly. he could get me a first class berth in West Coast Express immediately. The funniest part  was that my assignment got over as soon as the train departed from Madras Central.
My co-passenger in that coupe was none other than Mr Kini, GM IL Palghat factory. As we discussed about this emergency requirement during train journey itself, next morning when he dropped me in GH, he asked me to come leisurely and meet Mr GK Pillai.  IL Palghat staff were so cooperative, that Pillai had worked out all details and waited for my arrival.  They said that they can divert valves from NFL Panipat order subject to HPCL agree to pay a premium of 10% cost, which HPCL management readily agreed. The beauty was that the valves arrived at site even before my return to visag.

Naphtha Pump Fire accident burning rack cables:.On one fine morning( some time in peak summer 1985) one gland packing in naphtha pump gave way& a major fire broke out. Though the fire team fought and brought under control, the fire rage burnt all rack signal cabling connected to DCS. Refinery came to crash shut down. As nobody has forecast such freak scenario, no spare cable was available in stock. Immediately the whole company looked for SOS assistance; luckily MRL had that cable in stock. I was flown to Madras to contact Mr AV Krishnan, GM Projects and seek his help. I took the responsibility of getting the cables  issued on replaceable basis and arranged transport.The whole exercise was completed fast and the refinery recommissioned in 3 days flat and production achieved in 5 days.                                                                   Visag innings Contd.....

Key Aspects :-Conviction,  Initiative, Innovative, Multi -Discipline exposure, Technical issue