P 61 JMD DTA Contd.

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JMD DTA Contd.

Flare Package
While conceptualizing the flare sizing ,  no one had any idea that it will go as high as 4000MT/Hr rate!
Until that time in India,  M/S John Zink was the sole system supplier.But they could not even think of sizing the flare for this rating. That made Reliance and Bechtel to look into M/S Zeeco, an offshoot started by Mr John Zink in USA. There also, considering that there won't be a complex outage, we opted for multi riser  derrick mounted de-mountable (Foldable) type.  Then Bechtel and Zeeco  worked together  to split the HP/LP load with 3 risers  and at 400 M apart LLP  flare with 2 risers. The flare elevation came out to be 152M from ground.

Lucky for Reliance  ,Mr Rane of Petron shouldered the responsibility for the detailed engineering  and field execution of entire flare system of DTA. Touch wood, so far there is no major complaint with the flare system operations. The maintenance team have operated  and gained experience in scaling down of individual riser for inspection and maintenance.

While talking about flare system , two specific item come to my mind :
1. Outcome of hazop study recommending that  the valve handle in 84" main header has to face the earth and not the sky. This is to ensure that the accidental falling of gate in the valve should not block the flare stream.
2. Flare mains testing. There were hue and cry in the field for testing the 84" mains running on top tier of OSBL pipe rack! Hydro testing was ruled out since the pipe rack was not designed for that water load carrying. Without realizing the implications, one group was recommending for pneumatic test! As the length of these  mains was 9 Kms long, that was also ruled out.  Finally we devised a smoke test procedure and successfully carried out i.e introduce a smoking device inside and check all the weld joints with soap solution.

FM 200 system incorporation for PIBs.
 That was the time M/S Du Pont came out with FM 200 as Halon substitution for gaseous fire extinguisher system for non occupied premises and data centers.
 As JMD DTA had 33 PIB buildings having their local area control systems (Plant Interface Buildings), it was decided that we should make provisions for gaseous extinguisher system in each of them. Floating international enquiry, M/S Vijay Fire-Kidde was selected. But Reliance LP consultant(happened to be one of top official of TAC_ a statutory body) asked for one field trial and demo. before approving their system. A practical demonstration was conducted in ETP PIB and it was cleared from efficiency angle and advance warning for people evacuation lead time etc.
The contractor executed the installation in all PIBs.  Then came the big drama!

In matter of 10 days, in 7PIBs, the gas from cylinders got released even when there was no fire at all! It was mystery for projects and instrument maintenance.  After conducting a detailed investigation, it was found there was some software corruption in M/S Wormald PLC, which caused this havoc and loss! M/S Wormald was the agency who executed Fire&Gas system in whole of DTA. For info. then onward we never approved M/S Wormald make and the company has standardised with Honeywell F&G system at Jamnagar.
                                                                                             Contd.....

Key Aspects :- Critical challenge, Incident analysis, Initiative, Innovative, Lack of experience/exposure, Multi discipline exposure, Technical issue

P 60 JMD DTA Contd

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JMD DTA Story continue.....

Having seen  the various attributes of water and their implementation  story, let us touch other disciplines also.

We felt the pain in executing the small bore piping for steam tracing and location of steam traps.  On principle, Engineering did not issue detailed ISO drawings for these small bore systems. So the construction group had hell in assessing the requirements to make MIN for contractors. Contractors also did not post smart supervisors on the job and every thing was left to the field fitter's efficiency.
That caused more pressure on the management  to ensure their completion. Even the construction planning group could not give the progress status and what is left to be completed!

In that quality issue also cropped up!  As the execution team did not ensure preheating the joints/ weld rods, several nipple joints weld failure were taking place in vents and drains.There were disputes and misunderstanding between inspection and construction team. Added to misery, the construction group were refusing the seal weld of  hydro test nipples covered by threaded caps. As project manager I had the responsibility of brokering peace between them and got them addressed.

When talking about OSBL piping, can you imagine the width size of main rack? While designing Hazira main rack, that time management criticized the OSBL project manager for opting 6M wide three tier rack. When it came to Jamnagar, even after taking decision to route all cooling water piping underground, the main pipe rack width came to 2 X 11 M wide &three tier rack. As the overall width became 22 M span, it forced structural engineering group to divide it into 2 spans.of 3 tiers each. Then came the issue of foundation execution and casting of rack columns  and horizontal beams.
 As the total OSBL rack was 9 Kms long having column frames at every 6 M apart that too with 4 footing foundation at each frame, the speed and issue of handling the frames were challenging!
JP ( Jeetendra Prasad) was looking for finite solution but nobody had a ready made solution. Even he went to London to discuss with Bechtel experts in rack design  but no success in getting a resolution.
So the engineering issued IFC drawings for both the alternatives-  both precast frames and cast in-situ frames and left the choice selection to OSBL Chief construction manager(JP). As the job progressed, we arrived at a solution of combination- base foundation and first frame cast in-situ  and the upper frame precast. This resolution really helped to achieve speedy progress. and produced good success rate. Just for info. The average Inch Dia, of piping on the rack was 14". and the main flare pipe dia, was 84"

Air Compressor vendor selection drama:
Dr Kini of CICB has taken for granted that the utility air compressor order will go only to M/S Elliot & he is assured of his business. But both Bechtel engineers and Reliance rotary specialist have recommended to select M/S Atlas Copco make from the power efficiency(specific Power) angle. The Project management and procurement negotiated the pricing and convened the meeting with vendors on Dec. 19th , 1996 at 9.30 PM London time.  That time was chosen because Bechtel organised X'Mas get together on that evening. PMSPrasad  asked me to return back to office after that evening function. After thorough negotiations, procurement issued LOI to M/S AtlasCopco around mid-night . Dr Kini protested immediately and phoned Bombay reporting/challenging how the order can go to somebody else. Knowing the situation,PMSP did not have any option but  to hold back the issued LOI. The drama set in immediately and PMSP had to convince MDA explaining about the Specific Power factors  issue and convinced to go with Atlas Copco only. Right next day morning by 5.30 Hours, he directed procurement AK Chowdhary to remove the hold and go ahead with Atlas Copco. Then onward, in Reliance, only Atlas Copco compressors are sourced for utility air system.
                                                                                                                   Contd.....

Key Aspects :- Accountable, Critical challenge, Delegation, Incident analysis,  Leadership,
Multi discipline exposure, Planning, Technical issue

P 59 JMD DTA contd

P  59

JMD DTA Contd..

Having touched the aspect of storm disturbance, I have to highlight a few other critical issues  that really tested Reliance at JMD!
As we had several labour camps established around the complex site area which  had about 75000 people population , their safety and living conditions was our top priority task. Without any management directive or call ,M/S SC Malhotra and Mike Alaka took the responsibility on themselves. With whatever little resources available, they gathered rain coats, food packets from colony residents and ensured distribution in each camp for three days. Rather that made Mike as hero among all labour in JMD site and revered with respect then onward. Though he was a Britisher, he had the knack to converse in broken Hindi &Gujarati.

Next comes the most important  event to narrate:
As the  work progress at MTF was about 80% completion stage, this storm really took a big strike on our establishment. Many tugs and trawlers got blown away and got beached behind Western Air command area. Many small tanks which were yet to be anchored got twisted into spiral shape! But one 92 M Dia. crude tank which was also yet to be anchored got  shifted from its foundation by 11 Meters but luckily the tank shape was intact.! There was literal panic and no one was clear what to do and how to restore the situation. Then came out the heroism of Sh Kallol Patra, who was my  contractor at Hazira but here  in Reliance  rolls under PBM Rao. He volunteered to MDA and PBMR that he has got an idea and some solution! If given 2 X 125 T crane service, he can attempt to bring back in three days. As we were all desperate, we didn't have any choice but to try his suggestion.
The beauty is that he handled the task single handed and obtained full success. The management was grateful to him  and complimented him sumptuously both in terms of cash reward & Merit certificate.

While dealing on the subject of storm and drains, let me narrate a story on drain sizing!  As nobody in the world had any prior exposure to deal with sizing the drains for these large piece of land. The controversy and argument went on criticizing me and Bechtel Central civil specialist Bob Green  that we are over sizing and at the end, each drain called for cross over bridge! People without any idea were suggesting that these width can be reduced  and bridges can be got rid off. They were not understanding the basis for drain sizing factors- either the FW discharge for that concerned area or rainfall intensity of 15 minutes down pour in that defined area.
On similar lines, we had the controversy on OWS slope and the intermediate chamber nozzle elevation! People were not able to realize that  in OWS, the discharge has to pass through gravity drains only.

When it came to valve selection  and piping execution for underground systems, the controversy is still on even after 17 years! Unfortunately, for some political reasons, the order for butterfly valves were placed on M/S TYCO- keystone make where the integrity in rubber ring to disc were not assured! In every CT commissioning or fire network charging, these rubber rings in butterfly valves gave way, choking the downstream ROs and valve passing even in closed state.

We had nightmare  while dealing with foundation/ flooring in Acid/Alkali storage and handling areas.
Especially while dealing with Hcl or diluted H2SO4, the base slab  used to blow bubbles  in spite of epoxy lining or using protective paving blocks! Only by repeated trial and error only we could get over these challenges.                                                                               Contd....

Key Aspects:-  Attitude, Codes& Standard, Communication, Conviction, Critical challenge,
Incident analysis, Initiative,  Lack of experience/exposure, Multi discipline exposure, Proactive approach, Responsible, Technical issue, 

P 58 JMD DTA Contd.

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JMD DTA Contd.

As I recollect the happenings during execution of DTA infrastructure/utilities and offsite, the story goes on like Hanuman tail!

Next I plan to narrate the happenings with respect to Cooling water system

On my first entry to Bechtel London office, I had the shock! After officially getting introduced to Reliance top management team then(M/S Mike Kinny and Maurice Banniyan),as OSBL PM, they gave me to review the cooling water pump data sheet , which has to be included  in MR for floating enquiry to market. I don't know what made me to look at the head value and temperature even before looking at the pump capacity in that data sheet!  To my surprise ,Bechtel process engineer for Utilities and Offsite  has indicated that as 9.5 Kg/cm2 g whereas it should have to be of the order of 4-6 Kg/cm2 g only.. None in the group have realized  or were able to understand what could be the implication if that  pressure value has been retained as such! Every one thought that since I am not a chemical engineer by qualification and only a project manager from India, my proposition should not be considered at all.
That forced me to carry out a detailed calculation for the potential loss in energy consumption, which came to Rs 1.2 Crores/day only on cooling water transfer from CT to plant area for circulation   and return back to top of the CT.and threatened them that if they are not ready to review my suggestion, I shall write to MDA by fax and report to him. Typical of Mike Kinny, he threatened me that he will throw me from the stairs and complained to D Murali.  DM in his own style tried to convince me to keep quiet and forget; but since it was in company's long term interest, I did not relent and made Bechtel to realize the fault.  That made Tony Kerren and Pratap Patel to check the data from fundamentals and then they negotiated with me to agree for 5.1 kg/cm2 g keeping some cushion in hand.

For  information, in DTA we had 7 C Ts each having 3 X 6000 M3/Hr cooling water pumps and my check has saved 7 X 3 X 500 KW /hour power consumption=10500 KW/Hr i.e 10.5 MW/Hr. These pumps run as long as the the user plant/s  are on line.

Minor issue: While carrying out the detailing engineering, the U/G to A/G, piping group had confusion in the provision of equalizing manifold at plant B/L  and difficulty in tracing the supply line vs return line. As in those days since 3D modelling was not in vogue, the piping group had difficulty in identifying line numbers  to release Isometrics.

DTA faced one of the biggest challenge before plant commissioning.  There was an unprecedented storm of about 180 km/hr wind velocity and all wooden cooling tower internals flew away in air.  Though Reliance could claim advance Loss of Profit from insurance company,on SOS basis we had the services of M/S Paharpur Cooling Towers to re-build all the disturbed towers and restore normalcy. Fortunately that has not delayed the commissioning of main plants
                                                                                                                                    contd....

Key Aspects :- Conviction, Critical challenge, Faith. Initiative, Surprise& shock, Technical issue

P 57 JMD DTA contd.

P  57

JMD DTA Contd.

As I said earlier, my water story during DTA days continued at different angles!

On my return from Chennai, with the help of Jamnagar engg. group I got the sacrificial anode introduced at all en route manholes in that 3 X 16 Km long sea water supply lines and return brine line and got over the mess.  Afterwards we never had any problem at all and all these lines are in service without any break for the last 17 years. Touch wood!

Having touched intake sea water, let us see what all difficulties we faced in sea water storage after the filtration unit  in MTF area. As nobody has carried out the engineering and execution  of this large capacity- 10500M3/Hr. of sea water intake, Reliance was forced to go with experimenting for filtration package selection. Not to take any chance at all, Bechtel went ahead with conventional classifier arrangement and placed the turn key order on M/S UEM, a Delhi party. Though it was one man show, Mr Bhatia put his heart and soul in execution of the same. Though he faced lot of financial constraints, Reliance backed him to ensure successful completion.

As good engineering practice and to take double benefit, the team conceived the filter water pond of 6 hours water capacity as reserve and utilize the same as fire water pond for Marine tank farm FW use. Typical of fixing the quantum for Fire Water at the bottom , the raw water level was on the top. So we ended with the storage volume of more than 100000 M3. For fire water objective, we used 10 X 1000 M3/Hr pumps standardized KBL model. It so happened that in all Reliance JMD tank farm, the MVWS spray requirement for the largest dyke called for 6600M3/Hr, keeping NFPA spec. of @10.2 lpm /M2 surface area. To meet TAC condition of 150% pumping capacity, it so happened that we ended with 5 Motor and 5 Diesel everywhere. There came the catch ! As  the order was placed for standard pump  meeting sea water service conditions, we did not realize that the vertical immersion of shaft height  in the pump house built within pond can come as an issue! It fell short by 1 1/2 M and we took up with KBL for necessary rectification. As we have an excellent working relationship even up to their chairman level, Mr Sanjay Kirloskar got involved personally , took up that challenge and executed as task force. Since then we do not have any issue at all in that aspect.

While dealing with fire water pumping and network- both in tank farms/ and refinery, it is absolutely important that I should share some of the inherent problems we faced.
1. Interface engineering did not envisage the valve pit size Vs interior arrangement to make provisions for split spools to drop&re-erect butterfly valves in the valve pit
2. Provision of necessary puddle flange in valve pits were goofed up during detailed engineering.
3. To take short cuts  and to meet the committed time schedule , the construction group raising SER to go with service test instead of hydro test of mains has caused more damage than benefit. The network system was never flushed to get rid of construction debris.
4. As the sourced butterfly valve disk end rubber rings were not properly embedded, they gave way during commissioning  and that has become a bitter truth even now.
5. In DTA days, Bechtel has also missed out the provision of flushing connection for under ground fire water network.                                                                           Contd......

Key Aspects :-Attitude, Codes& Standard, Critical challenge, Faith, Incident analysis, Technical issue 

P 56 JMD DTA Contd.

P  56

JMD DTA Contd.

When the MTF and Utility operations took over and attempted to commission, we were getting water fountains at all places and every one started blaming me. Rather it went to that extent , the management got the inputs suspecting my integrity! They all thought that I have colluded with the contractor and overlooked the job.  So keeping me out, the site construction management formed emergency task force. I was cursing my luck and fate.Their set task was to send people inside with brooms and torches and mark the holidays wherever observed. As the line size was 42" Dia., people movement was easy &flexible and they completed this update inspection as well as rectification in 28 days for all the three lines. By that time it was Oct./Nov.'99 and every one was under extreme pressure with time constraint.

Then came the chaos! When they restarted the system, once again the fountains were there. Though it was set back for commissioning, as an individual I got relieved from my mental tensions. Then only people understood my position and some people even came to the extent of consoling me.Sh MDA understood the seriousness of the situation- sea water transportation is life-line for the refinery operations; Immediately he called up his classmate Sh Raju Narayanan and sought his emergency attention. For info. Raju after his chem. engineering degree at UDCT, migrated to London, specialized in underground service and corrosion technology.

Raju Narayanan & Bechtel's corrosion specialist Trevor Osborne  landed in Jamnagar on Dec. 17th 1999. This day has some importance in my life as well, which will be disclosed as the flow goes. The team from UK came to site directly after lunch and I was asked to receive them at MTF.  On reaching MTF limits, even from a distance of 50 M , Raju uttered to me in chaste Tamil saying " Ramanathan, nobody can help the situation: It is the blunder of basic engineering  ; that people have not cared to notice the electrolysis effect  of valve shaft nobel metal with that of CS pipe internal lining be it cement lining or enamel coating." No inspection or holiday check can solve the issue for ever. Then ,as reaction , I questioned him, are there no solution at all for this impasse.  He asked me the details about the agency and contractor who has undertaken this coating contract.   As soon as I mentioned the name PSL, he asked me to call  Ahuja  to have direct talks. As Raju is in marine corrosion study business, he was aware that PSL deal with sacrificial anode also. He made Ahuja to talk to their Kandla factory and enquire the stock availability of sacrificial anodes and its type with dimensions. Things worked in lightning speed. Then the whole team moved to Desalination module area in utilities block. There M/S Sinhal, RM Shah and PB Patel received us and  they started narrating their bitter experience. Raju asked them to demonstrate the water movement in that local manifold. Things were no different from that of MTF end. That made Raju to come to firm conclusion. Once Ahuja got the input data from Kandla by fax, Raju generated  a hand sketch for suspending this sacrificial anode from the 42" dia. pipe manhole at every 250 M apart. By the time all these were over, it was 7.30 PM and we came to my office to wind up the day. Then came the bad news phone call from my wife at 7.45 PM- stating my mother has breathed her last at 7.25 PM at Chennai and rush back. Raju only controlled my grief and escorted me to guest house for moving to Chennai via. Ahmedabad that night.                                                                                                                                                                                               Contd......

Key Aspects :-Communication, Critical challenge, Human relations, Incidence analysis, Initiative,
Lack of experience/exposure, Surprise&shock, Reputation, Ups&down

P 55 JMD DTA Contd.

P  55

JMD DTA Contd.

Though my exposure and experience  with project engineering dealing with water can run into several volumes, I shall limit with 10 incidents only, which may give the reader the whole picture !

 In DTA days, the estimated consumption of fresh water was 3100 M3/Hr and this whole requirement has to be generated only out of sea water . In those days, there was no other source for fresh water in Padana area and even Narmada water availability at Sikka came only in the beginning of new millennium. As the Reverse Osmosis technology development has not taken place then ,membrane availability was scarce and the power consumption rate too high for RO process, the projects team opted for Desalination process and identified  the company IDE from Israel. Even on date, that is the company who are world leaders in Desalination technology.In DTA days, we have limited ourselves with 5 X 500 +1 X 600 M3/Hr desalination modules.  That party carried out the sea water analysis , its TDS etc. and specified the quantity and quality requirement of sea water for operating their modules in the refinery area.  Sea water requirement was 10500 M3/Hr. Bechtel/Reliance ordered turn key responsibility to IDE for setting up the desalination modules.

As sea water is so corrosive, all sections and tubing of desal modules are made of Titanium.
Though given as turn key responsibility, all of us were jittery because of Israel's local conditions- Gaza Border  fight between Israel and Palestine! But somehow IDE managed the situation  by undertaking all the fabrication in open yard near the sea coast and shipped them without causing any delay. We must say the whole credit should go to Mr Henry of IDE and at field end Mr Tuvia took all the care. On lighter side, Mr Tuvia can seek Indian citizenship as he has completed more than 20 years at Jamnagar- he has continued to stay here for Reliance DTA, then Essar, followed by Reliance SEZ and now J3.

Let us look into the messy /tricky issue what we have faced in handling/transporting sea water.
Here I have to narrate my bitter experience.Keeping the company's interest and cost saving as primary objective, I was the hero who vouched for internal epoxy coating against conventional cement lining. My colleague ( experienced in marine projects- civil engineer) Mr Gopalan was vouching for 1" thick cement lining Vs AR recommending Epoxy coat of 1.5 mm layer.  The said epoxy was developed by Dr Kurtz of Germany and that was the chemical used for coating the inner aspects of English Channel- London  Dover to Paris. My recommendation basis justification was to choose 3 X 42" dia. CS pipe of 16 Kms. long each  instead of  cement lined 3 X 48" dia. CS pipe of 16 Kms long each . Naturally everybody agreed with my recommendation  and the field execution- internal coating with jigs and mandrels, contract was placed on M/S PSL.  At the beginning ,to set the process in motion, Dr Kurtz himself was present in the field. From PSL side M/S Sehgel and Ahuja were the job managers and the field installation went smooth.  As per the process and procedure, coating inspection went on ,holiday identification and rectification process  went on. Unfortunately in midway schedule Dr Kurtz died. The whole system were boxed up and cleared for commissioning .
Nobody was aware and ready for surprise shocks!                                             Contd....

Key Aspects :- Accountable, Critical challenge, Incident analysis, Responsible,Ups&down