Professional Documents
Culture Documents
21
21
On
Design Training
&
Site training
ACKNOWLEDGEMENT
CONTENT
Introduction
.
..
.
.
Learnings
Conclusion
Annexures(If Any)
Inputs:
g. Wind Design
h. Skirt Design
i. Hydrotest Pressure
j. Seismic design
k.Loading data for foundation design
l. Calculation of Deflection for Wind
m. Dynamic analysis of the column
Storage Tanks:
Preface: Storage tanks constitute a substantial part of process equipment. Most of the
storage tanks are found in offsites & utilities where either feed or the products are stored.
Main types:
a) Cone roof storage tank
b) Floating roof storage tank
c) Cone cum floating storage tank
Classification with respect to storage Pressure:
a) Atmospheric & low pressure storage tanks designed with API 650
b) Pressurized storage tank designed with API 620
Heat exchangers:
Floating head
U tube
Air cooled
Advantages:
Availability
Location flexibility
No scale built up
No water treatment
Low corrosion problem
No waste water disposal
Low running cost
Disadvantages:
Type of air cooled heat exchanger: Depending on the location of fan they are
classified as
Forced draft type: Designed with tube bundle located in the discharge side of fan
Induced draft type: Designed with tube bundle located in the suction side of fan.
Forced draft type:
Advantage
Less power consumption.
Ease in maintenance.
Fans are unlikely to reach high
temperature.
Erection procedure is simple
Disadvantage
Under-slung walkway is required.
Susceptible to cross wind effect
inducing external recirculation
around the cooler.
Air flow distribution is difficult
The bundle is exposed to solar
radiation.
Plenum chamber: Provided either below or top of tube bundle for air distribution
depending upon induced draft type or forced draft type construction of air cooler.
Types of plenum chambers: 1. Conical type
2. Rectangular type
Piping department
Plant layout: It is planning the location and arrangement of various
facilities/blocks/process units etc within a available plot, as per recommended practice.
Pump
Exchanger
Air coolers
Furnace
Compressors
Clearance and accessibility
Unit piping:
Basis of unit piping:
Piping and instrument diagram(P & ID)
Equipment layout
Equipment data sheet & setting plan
Line list
Instrument data sheet
Structure & building drawings
Topography of the plant
Piping material specification
Overall plot plan
Guidelines for piping:
Pipe ways/ Rack piping
Column/Vessel piping/Control valves
Exchanger piping
Heater / Furnace piping
Pump piping
Compressor piping
Relief/Blowdown system piping
Steam piping: Piping is done as per IBR guidelines. It consist of steam supply/return
headers, stem tracing system and steam jacketing system.
Underground piping: underground piping system is designed based on the general civil
design basis for U/G services like OWS, CRWS, CBD etc.
Piping material specification (PMS): PMS gives detail about all piping items. It
consist of material details, dimension details, type of ends, schedules/thickness, branch
offs, NDT requirements, applicable code/standards etc. for all piping items.
The PMS consists of various classes, each with the following specified:
Services and corrosion allowance
Pressure and temperature rating
NDT and other special requirements
Connection details for Vents, Drains and instrument connection
Branch connection table
Design standards
API 602
API 600
BS 5352
BS 1873
BS5352
BS 1868
BS5351/API 16D
BS 5353
Testing standards
API 598
API 598
BS 6755
BS 6755
BS 6755
BS 6755
BS 6755/API 607
BS 6755
24-P-114-3301-A1A-IHInsulation Type
Piping supports: Piping supports are the mechanical devices which are used to take
the loads and reduce the concentration of stresses of the piping system.
Need of supports:
Carry weight of the piping system.
Limit the stresses in the piping system.
Limit the forces/Moments on terminal connection and Structures.
Limit the displacements.
Prevent/Minimize vibration effects.
Prevent joint leakage.
Different type of supports:
Pipe shoes/Pipe saddles: These are generally attached below pipe to rest pipe on
rack/structural supports for perfect insulation of the pipe resting on the rack/structure.
shoe support is used in smaller size pipe and saddle support is used in larger size pipe.
Low supports: Low support is a type of Y support which consist of a vertical pipe and
always comes below the pipe to support.
Guide: These are generally attached to the structure on either side of the pipe to restrain
pipe laterally on rack/structural supports.
Cross guide: These are generally attached below pipe to restrain pipe axially on
rack/structural supports.
Dummy pipe supports: It consist of a horizontal pipe element attached to pipe with in
turn rest suitably. It act always of bend/elbow.
Clamps: These consist of bent elements bolted to pipe and generally used in conjunction
with structure/other support elements to achieve a particular restraint function.
Bracket: It is a triangular or turn type structure extruded from the column to provide the
support to the pipe.
Hanger: It is used to hold the pipe and restrict deflection in downward direction.
Rigid hangers: These are generally attached above pipe to hang pipe from
Rack/Structural member. These have an advantage that they can be considered practically
frictionless for horizontal movement.
Variable spring supports: In this case spring effort increases with downward movement
of pipe and reduces with upward movement. It carries deflection due to weight not due to
pressure and temperature.
Constant spring supports: In this case spring effort remain almost constant with vertical
movement of pipe. It carries deflection due to temperature and pressure.
CEASER II:
1. Need for analysis :
Stress analysis is required for designing new piping.
To estimate the forces exerted by piping on Equipments, Pumps, Turbines.
Behavior (like wind and dynamic condition).
2. Area of applications:
Mechanical design of new piping system.
Hot thermal strains & pressure pulsation.
To estimate the excessive loads and stresses due to water hammer.
To avoid low frequency vibrations.
Relief valve thrust loads.
Earthquake loads (system to resist).
Slug flow.
Eliminating low frequency vibrations formed in existing piping system.
3. Basic theories used in CEASAR II :
Stiffness method associated with associated piping codes/standards and
regulatory guide lines (generally almost all the softwares are based on the
stiffness method where basic unknown are displacements).
Flexibility approach (forces are unknown generally not used because of
complexity).
Empirical formulas based on standards/codes/hand books.
4. Numerical techniques used :
Converting mathematical models to matrix & solving them for approximation
solutions.
Matrix properties.
Solution techniques (inverting matrix, solution through banded matrix).
Time integration scheme in time domain(for dynamics).
5. Estimation of displacements, forces & Stresses on :
Equipment (check for allowable forces/stresses as per WRC297/WRC107).
Pumps/Compressor (checking as per API 610/API 617).
Turbines/heaters (check for NEMA-SM 23).
Stresses on bends, joints of various components, computed as per required
ASME B31.1/31.3/31.4 etc.
Check above forces/stresses as per other country codes (RCC, BS, JIS, DIN
etc.)
6. Load cases :
Primary loads (sustained, pressure & forces).
Secondary loads (thermal, displacements, cold pull).
Occasional loads (wind &dynamic(sustained, thermal, operating & occasional
and their combination) ).
7. How to make the design/ system safe :
Control the pressure/temperature.
What id 3D modeling?
Integrated approach to plant design.
Design of various departments on one platform.
To the scale representation of plant in 3D with high resolution graphic
visualization.
Intelligent model components, not plain graphics.
Graphics engine
Parametric shapes.
Primitives.
Database
Specifications and catalogues.
Information regarding graphic elements (Equipment, Nozzles, Pipes, Pipe
component).
Link between graphics and database.
Query and report writing facility on database.
Drawing generation facility (isometrics, GADS, Structural drawings).
Graphics
Database
3D System
Administration
PDS 3D Modules:
Piping: Routes pipelines and places components supplied by an extensive online
database.
Equipment modeling: Provides tool to build equipments by assembling basic 3D
elements and creating composite models automatically from an extensive library.
Structural modeling: Enables designer to model Steel framing, Floors, and walls;
produce drawings; and input model geometry into a structural analysis package, such as
GT STRUDL, STAAD-III and Larsa.
HVAC modeling: Provide interactive 3D tool to layout and model ducts and other HVAC
components.
Electrical raceway: Provides interactive 3D tools to design, layout, and model electrical
cable trays, conduits, wire ways, underground duct banks and cable trenches.
Interference checking: Identifies hard(Physical) clashes between design components
and pinpoints soft clashes, such as insufficient safety clearance or maintenance access.
Pipe support: Create pipe supports in the model, and revise existing pipe support, model
graphics and database information.
Interfaces:
Pipe stress analysis: Extract information from piping models for input to third- party
pipe stress analysis products.
Isometric drawing manager: Extract Isometric drawings from piping models and to
review or plot the created isometric drawings, PDS- isogen product is used to
generate isometric from interface files.
Design review integrator: extract information to form label files for use in design
review and to review data from a design review session.
Creation of project.
Finalization of attributes, color coding etc.
Setting of seed model to be updated.
Area / Zone division to be finalized.
Criteria for model division.
Piping specs creation, through interface with IPMCS and loading.
Short description, file creation and loading.
Branch tables creation and loading.
Temperature Pressure table loading.
Physical support libraries loading.
Table checker run for all the specs individually.
Creation and models in all disciplines.
Starting of modeling.
Updation of various components in spec and their corresponding table in database,
as per requirement.
Interference check.
Border file setting for isometrics.
Continuation zone settings for isometrics.
Walk through
Visualization
Text report
PDMS Module:
Design
Isodraft
Draft
Paragon
Specon
Propcon
ADMIN
PDMS Database
Engineering
Drawings
Lexicon
Key deliverables:
The department generates the following output:
Estimate of efforts.
Engineering design basis.
Material requisitions.
Departmental input to bid packages.
Technical memorandums.
Family of compressors:
Principal of operation:
Standard followed for centrifugal compressor packages: API 610
Reciprocating compressors:
Type of reciprocating compressor:
Vertical and horizontal.
Lubricated and non lubricated.
Labyrinth diaphragm.
Single acting, Double acting.
Applicable Indian standards:
API 618 for process gas compressor (slow speed and for refineries and
petrochemicals).
API 680 for plant and instrument air (packaged type).
API 11P for high speed reciprocating compressors (for gas gathering,
boosting, fueling and injecting).
Parts of reciprocating compressor system:
Driver.
Pulsation dampeners at suction and discharge.
Distance piece purging system.
Lubricating system for frame.
Cylinder lubricating system.
Drive system (Flywheel, Gear, Coupling, V-belt etc).
Base plate/sole plate.
Control system.
MOC
CI, CS, Forged Steel
CI, CS
Teflon
Steel
Admilarity brass
SS
Typical services:
Plant and instrument air compressors.
Recycle gas compressors in PP plants.
Hydrogen compressors in LLDPE plant (diaphragm).
Make-up gas compressors in hydrocracking and hydrotreating.
Gear pumps: gear pump traps the fluid between the gear teeth on the suction side and
carry it around to the discharge side from where it forced out into the discharge pipe.
Application of gear pump:
Industrial and mobile application.
Fuel and lubrication.
Metering.
Mixing and blending (double pump).
Hydraulic applications.
Precise metering application.
Low- volume transfers.
Light or medium duty.
Steam turbine:
Working principles:
Rankine cycle is a heat engine with vapor power cycle. The common working fluid is
water. The cycle consists of four processes:
Work output of the cycle (Steam turbine), W1 and work input to the cycle (Pump), W2
are:
W1 = m (h1-h2)
W2 = m (h4-h3)
where m is the mass flow of the cycle. Heat supplied to the cycle (boiler), Q1 and heat
rejected from the cycle (condenser), Q2 are:
Q1 = m (h1-h4)
Q2 = m (h2-h3)
The net work output of the cycle is:
W = W1 - W2
The thermal efficiency of a Rankine cycle is:
The efficiency of the Rankine cycle is not as high as Carnot cycle but the cycle has less
practical difficulties and more economic.
Heat rate of turbine = (Net heat input to turbine)/(Electrical output from generator).
Turbine components:
Gas turbine: Gas turbines produce high quality heat that can be used for industrial
district heating steam requirements.Alternatively,the high temperature heat can be
recuperated to improve the efficiency of power generation or used to generate steam and
drive a steam turbine in a combined-cycle plant.
Basics of gas turbine: Gas turbine works on brayton cycle.Simple cycle gas turbines
convert a portion of input energy from the fuel to electricity and use the remaining energy
to produce heat,which is normally rejected to the atmosphere.
Starting device
Compressor
Turbine
Couplings
Starting system:Different types of starting equipments are available:
Electric motor
Diesel motor
Hydraulic motor
Items handled
Packages
Major refinery Packages/Equipments:
Equipments
Chlorinator Package
Water maker
Produced water conditioner package
Swage treatment plant
Deck Crane
Survival craft
Filter, Seperator, Coalescer
Belt conveyor
Air slides
Bridge Crane
E.O.T CRANE
HOT CRANE
Electric Hoist
Chain pully block
Lift
Mobile cranes
Fork lift truck
Start of Project:
Client
Place the order on EIL
EIL Marketing
Allocate the job no. of Project
Division
EIL Project
Allocate the Job to Concern Engineering
departments
PDS,
Revised process
documents issued for
Engineering
Preparation of
RFQ
floated
MR/T
ender
by
C&P
Packaged air-conditioners:
Range 5.5 TR to 22 TR
Air cooled and water cooled options
Scroll compressor
Microprocessor based control panel
Multi-compressor in 11 TR, 15 TR,17 TR, & 22 TR models.
Modes of Transportation:
Road tankers.
Railway tankers.
Sea tankers.
Pipelines.
Establish Requirement.
Evaluate Alternatives.
Flow tees.
Sectionalizing valves.
Pumps/Compressors.
Filters and Meters.
Seamless (SMLS).
Electric welded (EW).
Longitudinal seam submerged- Arc welded(LSAW).
Helical seam submerged-Arc welded(HSAW).
Material specifications.
Design interface:
Process.
POSD.
PFD/RED/SED.
SMMS.
ETDD.
Civil & Structures.
Electrical/ Instrumentation.
Environmental.
Inspection.
Construction.
Process, Operations & Safety.
Mechanical.
Civil & Structures.
Electrical/ Instrumentation/ Telecom/ SCADA.
Environmental.
Inspection.
Construction.
Welding/NDT Methods
Edge Preparation.
Internal / External Line-up Clamps.
Manual / Automatic Welding.
NDT (X-Ray / UT / MPI etc.).
TUBULAR
AIR COOLERS
NON TUBULAR
DOUBLE PIPE
PLATE TYPE
FIXED TUBE
SHEET
PLATE FRAME
U-TUBE
PLATE FIN
FLOATING
HEAD
HYBRID
PACKINOX
S.
No
Cleaning Possible
Fixed
Tube-sheet
U-Tube
Floating Head
1.
Inside Tube
Possible
Not Possible in
U-Bend
Possible
2.
Outside Tube
Not Possible
Possible
Possible
3.
Costing
Moderate (depending
on use of bellows)
Least Expensive
Most Expensive
S. No
Service
Type
1.
Fixed tube-sheet
2.
U-tube Exchanger
3.
Floating Head
4.
Property
Side
1.
Higher viscosity
Shell side
2.
Dirtier fluids
Tube side
3.
Tube side
4.
Tube side
5.
Corrosive fluids
Tube side
6.
Shell side
Selection of shell types: Shell and tube heat exchanger shell types designated in TEMA
are as follows:
Shell Style
E
Single Pass
Two Pass
Split Flow
Divided Flow
Kettle
Cross - Flow
Baffle design:
Types of baffles:
Longitudinal baffles: Used in F, G, and H type shells.
Cross baffles: Single segmental, Double segmental, rod baffle, helical baffle etc.
Baffling to reduce pressure drop: In order to limit the shell side pressure drop within
the permissible value, the following combination of shell and baffle style should be
considered, in order indicated:
Order
1.
2.
3.
4.
5.
6.
Combination
E shell and single segmental baffles.
E shell and double segmental baffles.
J shell and single segmental baffles.
J shell and double segmental baffles.
E shell and no-tubes in window (NTIW) baffles.
X shell
Baffles:
Baffles in condensers:
Vertical cut baffles are used in condensers to permit the separation of the
condensate from un-condensate vapor.
Horizontal cut baffles may be used in partial condensers where the two- phase
stream leaves together.
Baffles in vaporizers:
There is always a problem of phase separations and flow oscillations. Hence it is
advantageous to vaporize on tube side.
Never use vertical cut baffles for vaporization on shell side.
Fouling: Fouling is a general term that include any kind of deposit of extraneous
material that appears upon the heat transfer surface during the life time of heat exchanger.
It results in undesirable decline in heat transfer and/or an increase in pressure drop. It is
inescapable consequences of the process of indirect heat transfer across a building wall.
Air coolers: Air cooler heat exchangers (ACHEs) are heat transfer equipment usually
employing finned tubes where ambient air is forced across the outside of the tubes in
order to cool and/or condense the fluid inside the tubes.
The basic components are one or more tube bundles served by axial flow fans, fan
drivers, speed reducers and an enclosing and supporting structures.
Types of Air Coolers:
Forced draft: Air cooled exchangers are classified as forced draft which uses axial
flow fans to force the air across the finned tube bundle. The fans are positioned
below the bundle thus not exposing the mechanical section to hot exhaust air flow.
Forced draft is generally preferred as maintenance is much simpler. Here the tube
bundle is located on the discharge side of the fan.
Induced draft: In induced draft, the tube bundle is located on the suction side of the
fan, since ID fans throw the air to higher altitude than the FD fans. Induced draft is
preferred when difference between the process fluid outlet temperature and air inlet
temperature is low, say 7 degree Celsius.
Mass transfer
Equipment handled:
TRAY
Packing
Packings: 1. Random
2.Structured
Application of packings:
Mass transfer.
Heat transfer.
Potential to handle high throughput at high efficiency.
Extensive use in revamp application.
Offer low p/Unit theoretical stage.
Purpose of distributors:
Distributor:
Required when external liquid flow is introduced.
Provides uniform flow over the bed.
Liquid redistributor:
Remix liquid phase before the next bed.
Intercept all liquid flowing down the column.
Liquid
redistributor
Spray type
distributor
Gravity distributor
Purchase
Methods of purchase:
International competitive bidding (ICB)
Domestic competitive bidding
Limited enquiry
Crash procurement
Basic Requirements for issuing RFQs:
Projects Input Sheet along with Material requisition (MR) which contains
delivery period, cost estimate, type of MR (India / Foreign / Global) and other
special requirements.
Contracts:
Type of Contracts
Item Rate
EPCC:
Engineering, Procurement, Construction, Commissioning.
Utility Packages:- such as Cooling Tower, DM Plant, Raw Water Treatment Plant,
Waste Water Treatment Plant, Captive Power plant, etc.
Process Packages: - Where whole Unit / Offsite are executed on EPCC mode like
Panipat Naphtha Cracker Project, MRPL Phase-III.
One Lump sum Price with Break-up of Prices for Engineering, Procurement and
Construction
Proposal Forms
Technical section:
Job Specifications
Schedule of Rates-Detailed description (in case of item rate tenders)
Technical Specifications
Standards Specifications applicable for the work
Inspection Test Plan applicable for the work
Datasheets/Drawings
Integrity Pact:
Bidding document shall also include Integrity Pact as per procedure. Integrity
pact porforma shall be provided by Owner.
2. INSPECTION AND EXPEDITING:
INSPECTION:
EIL inspection department provides specialized inspection and expediting
services for EILs own projects in the field of
Petroleum Refining
Petrochemicals
Pipelines
Onshore Oil & Gas
Offshore Oil & Gas
Mining & Metallurgy
Terminals & Storages
Infrastructure
10 Regional procurement offices (RPOs) across India and three foreign inspection
offices at London, Milan and Shanghai.
Commercial
Directorate
Inspection
PDD
Shipping
Inspection /
Expediting
Service portfolio:
Source Inspection.
Site fabrication Inspection.
Project
Monitoring &
Expediting
Surveillance Audit.
Expediting and Monitoring.
Vendor evaluation - Capability and capacity assessment.
Inspection is needed:
To ensure quality of material / equipment before dispatch to site.
Last but not the least, inspection helps to put a check to avoid deviations
which as a human being sometimes we tend to take lightly.
Inspection Methodology:
On satisfactory inspection/document review, inspection engineer issues Inspection
certificate.
Head Inspection
at H.O.
Head RPO
Inspection
engineer
Monitors RPOs,
Sets Quality
Objectives for
the Department,
implements the
same through
RPOs
Deploys
inspector, selects
inspector by
competency
analysis,
Monitors quality
of Inspection
Services of RPO
Inspects , stamps
items with Unique
identification
stamp
Inspection Service:
Inspection at Supplier works, Yards, Offshore Platforms and onshore Project:
Source Inspections are tailored to meet a specific need and may include
Review and Approval of QAP / ITP
Discipline
% age Weightage
Engineering
3-5 %
Ordering
12-15%
Tendering
8-10%
Manufacturing /Delivery
35-45%
Construction
20-25%
Commissioning
2-3%
Client
Monitor /
Central
Coordinator
at HO
Expediting
visits by
RPO
Engineer
MSR /
Constrai
nt
Reports
Expediti
ng
Reports
SCHEDULING:
MONITORING CYCLE:
As the project is executed as per set targets, periodically, say, every month the
actual progress is compared with the schedule and in case of slippages/ holdups,
preventive/ corrective actions are highlighted for resetting the targets till the
project is completed.
Milestone
BAR CHART:
Bar Chart
It does not show the logical relationships between the various activities.
Network
Float
. The difference in time between an activitys earliest and latest dates
Critical Path
Sequence of activities through a network from start to finish, the sum of
whose durations determines the overall project duration. It is the longest
continuous path of activities through the network.
Critical activity
Activity lying on critical path.
Software Used:
4.PROJECT:
Zero Date:
This is the date from which EIL is committed to complete the project. This can be either
the date of clearance given from the government, signing of contract between EIL&
client, signing of contract between client & process licensor or receipt of process package
from licensor or the date specified by the client.
Start Date:
This is the date when the client asks EIL to start the job.
Pre Commissioning:
This is the preparation of the plant for commissioning after mechanical completion. This
includes mainly flushing & cleaning of pipes, loading of catalysts, loops checking & trial
run of auxiliary systems.
Commissioning/Start Up:
The commissioning activity will start with the introduction of raw materials and will
terminate with satisfactory completion of guarantee runs by licensor
Project execution methodology:
CONVENTIONAL METHOD
LSTK METHOD
OBE:
Final commissioning
Stage 1
effective date upto conversion date
stage 2
conversion date upto completion of the work
Project is awarded to the contractor based on its lump sum price of
services/ various mark up fees, contractor and company collaborate to
develop the open book estimate
Mrs/ sub-contracts are floated & awarded in the first 10-12 months of the
project (stage 1- OBE phase). The LSTK price of the project is based upon
the value of finally awarded pos/ sub-contracts. The LSTK price is fixed
at the end of the OBE phase (conversion date)
For the items for which engineering could not be completed during the
stage 1 (OBE phase) or no formal enquiries issued for any material, eqpt
or works the price is based on in-house data/ budgetary quotes to finalise
the lst price, contingencies on these items are fixed in consultation with
the company
Bidding time is drastically cut contractor estimates its services for the project
like any consultancy job
Time required by client to select an PMC & EPC contractor is fruitfully utilised in
engineering & project execution
Risk & reward on account of market volatility on price are transparent and both
client & contractor derive the benefit of the same
This mode also permits mid course corrections upto first 6 to 8 months of
engineering which otherwise is difficult due to contractual commitments with
EPC contractor
Client has the benefits of both the modes of project execution (conventional as
well as LSTK)
(16-PSV-1421, 18-CV-1118).
Bulk materials Piping, Electrical / Instt. cables,
Manufacturing/ Delivery:
Receipt at site:
Receipt
Report)
Allocation to agencies:
Issuance to contractors:
Reconciliation of materials:
5. COST ESTIMATION:
An estimate is " an evaluation of all costs of the elements of a project or effort as defined
by an agreed upon scope ".
Estimation is required:
Establishing feasibility and initial budget for project
Location
Cost control
Execution Philosophy
Process Description
Equipment List with Capacity, technical specs Utilities & Off-sites Requirement
Site training
Introduction:
PROJECT BACKGROUND:
In 2002 , GAIL (India) Limited commissioned Engineers (India) Ltd to prepare a
per-feasibility report for setting up a petrochemical complex at Assam, based on
the OIL & ONGC gas as feed stock, and converting the existing LAKWA LPG
plant into C2+ recovery plant and setup a 160000 TPA gas cracker complex along
with one downstream polymer unit.
Based on the pre-feasibility report and as directed by MPO&NG in AUG-2004,
GAIL has decided to prepare a detailed feasibility report for setting up an ethylene
cracker based on the gas available in Assam supplemented with naphtha.
FEED SCENARIO:
The feed commitment available for the complex is as under:
6 MMSCMD Natural Gas with C2+ content of 7.02 mole% Approx from OIL
INDIA LTD Duliajan.
1.35 MMSCMD Natural Gas with C2+ content of 7.74 mole% Approx from
ONGC at LAKWA up to 2012 and 1.0 MMSCMD thereafter.
160000 TPA Naphtha from Numaligarh Refinery.
Based on the above feed availability which can produce 220000 TPA Ethylene & 60000
TPA Propylene, the detailed feasibility report has been prepared for a configuration of a
220000 TPA & 60000 TPA cracker complex.
OIL
DULIAJAN
LLDPE /HDPE
220,000 TPA
NAPTHA
160,000 TPA
12,500 TPA
280,000 TPA
TECHNOLOGY SELECTION:
UNIT
CAPACITY
LICENSOR
6.0 MMSCMD
EIL
C2 + SEPARATION UNIT
6.0 MMSCMD
EIL
220,000 TPA
220,000 TPA
POLYPROPYLENE UNIT
GERMANY
60,000 TPA
A. AT LEPETKATA
LUMMUS TECHNOLOGY,
INEOS, UK
LUMMUS NOVOLEN,
EIL
B. AT LAKWA
GAS SWEETENING UNIT
1.35 MMSCMD
EIL
EIL
C. AT DULIAJAN
GAS DEHYDRATION UNIT (GDU)
6.0 MMSCMD
EIL
EIL
D. PIPELINES
1. C2+LIQUID PIPELINE (4 - 47 KM) LAKWA TO LEPETKATA
EIL
EIL
BCPL has appointed EIL as EPMC consultant. Project management services cover all the
activities leading to the execution of a project by carrying out engineering, procurement
and managing construction at site. The efforts of various agencies such as licensors,
vendors, clients, contractors / sub contractors and EIL's different departments are brought
together in a logical pattern to result in fruitful culmination of the project.
PROJECT KEY DATES
ZERO DATE :
09.04.2007
23.11.2009
08.04.2012
CONTRACTUAL :
22.11.2013
(48 months from the date of receipt
of Licensor Package for Ethylene Cracker
Unit)
PROJECT DURATION
TARGET :
SCHEDULE DURATION :
53 Months
CONTRACTUAL DURATION :
Learnings
Construction department
Construction management services comes under directorate projects
Total management of the project system is controlled by directorate project.
Total no. of construction site EIL has right now = 44 and 891 working people.
EIL is ISO 9000 company in quality point of view and ISO 14000 in
environmental aspect.
ISO 18000 company in quality, environment and health.
OSA- Observation and safety aspect.
OQA-Observation and quality aspect.
HSE objectives:
Based on the HSE policy, the HSE objectives derived areas under
To maintain an HSE management system conforming to the principles of ISO
14001 and with guidelines as per BS 8800, and ensure its availability to all
parties of interest and compliance at all levels.
To promote the highest standard of safety and health and care of environment to
comply with all applicable laws, regulations and codes of practice.
To design and construct the plant and Equipment which is and does not have any
unacceptable impact on health, Environments and meets or exceeds customer
requirement for HSE.
To provide resources for employees essential for implementation, control and
improvement of HSE management system.
To strive for continual improvement by periodical reviews based on feedback
from performance measurement and monitoring trends in international HSE
system.
Reference documents:
EIL HSE manual : 1-0000-0011, REV 0.
EIL standard specification: 6-82-0001, Rev 4.
HSE procedure:5-1940-1940, Rev 4.
EIL procedure for technical audits: 5-1940-8020, Rev 3.
Safety aspect with owner/Contract between EIL and Customer.
General condition of contract(GCC).
Special case of contract (SCC).
Statutory requirements.
Few Definitions:
Safe: An entity is provisionally categorized as safe if its risk are deemed knownand, in
the light of that knowledge, judged to be acceptable.
Risk: The cumulative effect of the chances of predictable/unpredictable occurrences
which will adversely affect project activities.
Hazard: A set of condition which has potential of causing damage to property, injury of
person, or to environment.
Incident: Something occurring by chance, without intention, which interrupts the normal
line of events in process or construction activities.
Pile foundation: Pile foundations are the part of a structure used to carry and transfer
the load structure to the bearing ground located at more depth below ground surface.
These are used in case of Soft/Silty/Clayey type of soils. These are pipe shaped:
When the load is tremendous high, most foundations are pile foundation.
I beam:
The web resists shear force while the flanges resist most of the bending moment
experienced by the beam.
ISMB: Indian standard medium weight beam.
Grouting: Grouting involves injecting a grout material into generally isolated pore or
void space of which neither the configuration or volume are known and is often referred
to simply as grouting. The grout may be a cementitious, resinous or solution chemical
mixture material.
The greatest use of grouting is to improve Geomaterial (Soils and Rocks).
The purpose of grouting can be either to strengthen or reduce water flow through
a formation.
It is also used to correct faults in concrete or masonry structures.
Grouting has been performed on the foundation of virtually every one large
dams, in order to reduce the amount of leakage through the rock, and sometimes
to strengthen the foundation to support the weight of the overlaying
Structure/Equipment
contact with the earth. Posts and beams that come in direct contact with the earth will rot
more quickly and ultimately weaken the structure. Footing also prevent frost heave.
Nito bond: For bonding fresh wet cementitious materials to existing cementitious
surfaces.
Can be applied on to dry or damp substrates.
Exhibits high mechanical strength.
Positive adhesion-exceeds that of the tensile strength of the host concrete.
Slow curve allows time to erect steel reinforcement and formwork.
Solvent free- can be used in enclosed locations.
Admixtures: Admixtures are natural or manufactured chemicals which are added to
the concrete before or during mixing. The most often used admixtures are air-entraining
agents, water reducers, water reducing retarders and accelerators.
Admixtures are used to give special properties to fresh or hardened concrete.
Admixture may enhance the durability, workability or strength characteristic of a
given concrete mixture.
Admixtures are used to overcome difficult construction situations, such as hot or
cold weather placements, pumping requirements, early strength requirements or
very low water-cement ratio specifications
Key terminology:
Construction Network: Construction network is an extension of the overall project
schedule for construction part of the project.
Overall construction schedule: Based on the overall project schedule, site planning,
engineers develop an overall construction schedule Unit/Area wise and tender wise.
Workload for various tender is converted to equivalent man-hour using standard manhour productivity data from available data bank and skill factor for various elements.
The progress on the bars at any point of time multiplied by the weighted
value percentage shall provide overall construction progress curve (S-curve).
Contractor schedule: The contractor schedule is also prepared as soon as the contract
is awarded and as per signed and agreed document. Individual work items would be
assigned with weighted value in the same way as defined in the overall construction
schedule.
Quality plan:
Purpose: The purpose of this service is to describe the methodology to befollowed for
field planning services as per planning manual.
HO planning role:
Identification of requirement / MTO stage.
Requisition stage.
Ordering stage.
Manufacturing/delivery stage.
Site warehouse role:
Receipt of material
Generating of DPR, MRR, OSRD report and issuance of the same to client, EIL
HO and site planning.
Monthly bulk material receipt status to be sent to site planning for generating
monthly progress report.
Allocation of material: Material is allocated to the contractors from the available logical
stock of material by site planning after following consideration/analysis:
Priorities of different activities based on:
Availability of related drawing and access.
Balance material to be allocated to the individual contractor in line with monthly
program which is reviewed by EIL engineer.
Priority of different jobs.
Indents are handed over to respective contractor for lifting the material from ware
house after authorization and signing of each indent by respective area
coordinator.
Issuance of material to contractor: Warehouse issues the requisitioned material
to contractors after receiving the indent, duly authorized by area coordinator.
Detail of issued quantity is filled up by warehouse and copies are marked to
client, area coordinator & site planning.
Return on material: All unused material both usable and non usable are returned by
contractor to warehouse through MRVs.
Stock verification: Ware house periodically verify the physical stock of material by
comparing actual quantities available in the stock with the quantities indicated in bin
card. Discrepancy if any is reconciled by warehouse with vendor.
Electrical
Substation transfers power through panel boards which then transfer the power through
the feeder pillar boards.
There are three different types of clearance required for electrical items:
A- inspection at site/workshop
B- dispatch clearance
C- Verification of documents
ARMOUR (GI)
OVERALL SHEET
Above shown is the insulation design of the conductors. Three conductors are kept in a
triangular fashion to reduce the space between the conductors. The three conductors are
then surrounded by a PVC sheet for insulation. On the periphery of the PVC sheets we
have a mesh of GI called the armour over which we have a sheet of PVC again.
In case of XLPE, there is a thin semiconductor screen/film around the main conductor
which is again surrounded with copper film.
There are again two phases for conduction
TP: three phase: three-phase electric power systems have at least three
conductors carrying voltage waveforms that are 120offset in time.
a
b
c
d
e
f
Electrical characteristics :
Current-DC
Amp (range) 80-110 A
Voltage(range) 22-24 V
Tungsten electrode 2 mm
Welding positions: The welding progression, (vertically upwards or downwards), must
always be stated and it is an essential variable for both procedures and performance
qualifications.
Welding Positions For Groove welds:Welding Position
Test Position
Flat
1G
Horizontal
2G
3G
3G
Overhead
4G
5G
6G
6G
Test Position
1F
Horizontal
2F
Horizontal Rotated
2FR
3F
3F
Overhead
4F
5F
E7018:
E7016:
Code of welding:
IS 7307- Qualification of welding procedure.
IS 7310- Qualification of welders.
IS 9595- Joint design
For civil and structure work because in IS qualification for a single position does not
qualify WPS or the welder for other positions. WPS for horizontal position, qualified for
horizontal position only.
ASME welding code : ASME section 9 for qualification of welding procedure and
welder- both for Welding and Brazing.
ASME section II part A- For ferrous material.
ASME section II part C- For welding consumables.
ASME section V for (non destructive test)
NDT Radiography
Ultrasonic testing
Dye penetration test
Magnetic particle testing
Penetrate testing
Eddy current testing
Hydro testing
For flare line Pneumatic testing (at low pressure).
Pneumatic testing pressure- 1.1 times of design pressure.
Radiography: To locate the defect and measure the defect for acceptance of welded
joint.
Radiography and dye penetration test is done at site.
Radiography acceptance criteria for piping ANSI 31.3
Acceptance criteria for welder on the basis of joint welded by welder is given in ASME
section 9.
Radiograp
hy
Gamma
Ray
X- Ray
Undercut:
II.
Porosity:
III.
Incomplete fusion:
IV.
Overlap:
V.
Underfill:
VI.
Spatter:
VII.
Cracks are not allowed in welding. Generally cracks develop in Alloy Steel.
Instrumentation
Role of Instrumentation:
I.
II.
Differential pressure flowmeter: Fluid flow rate by reading the pressure loss across a
pipe restriction is most commonly used flow measurement technique.
Flow rate is directly proportional to square root of differential pressure.
Signal conditioning : signal conditioning means manipulating an analog signal in such
a way that it meets the requirement of the next stage for further processing. Signal
conditioning can include amplification, Filtering, Converting, Range matching, Isolation
and any other processes required to make sensor output suitable for processing after
conditioning.
Flow measuring Devices: Flow orifice, Pitot tube, Venturimeter, Turbine flow meter,
Coriolis mass flow meter and ultrasonic flow meter.
Displcer: A Displcer is a device is a device based on the Archimedes principle. The
displacer rod, which attached to a measuring spring using a chain, immerse into the
liquid and is subjected to buoyant force proportional to the mass of the displaced liquid.
Every change in the weight of the rod corresponds to the change in the length of the
spring and is therefore a measure of the liquid level.
Level measuring devices: Differential pressure transmitter, Displacer, Radar.
Simple programming
Program changes without system intervention (no internal rewiring)
Smaller, cheaper and more reliable than corresponding relay control system.
Simple, low cost maintenance.
the same position regardless of changes in value differential pressure, stem friction,
diaphragm hysteresis and so on.
Unit no.
Tag no.
FV- Flow valve
II- Instrument Index
LAH- Level Alarm high
TE- Temperature element
LG- level gauge
LT- level transmitter
LAL- level alarm low
AI- analyser indicator(gas detector)
Mother equipment of Instrument index is P&ID.
For corrosive liquid we use pressure type filter.
Transmitter is installed at 1.5 m from the equipment.
For gas- Transmitter is installed above the vessel.
For liquid- Transmitter is installed below the vessel.
Duct: In duct we can put one wire over another.
Cable tray: one wire at a time.
There are three satellite rack room and one control room for every unit.
Smart instrument gives more data.
Pipeline works
Natural gas, LPG, ores can be transported from one place to another by pipeline.
Duliajan to BCPL Lepetkata twin pipeline 18 pipeline, thickness 6.4, 7.1, 8.5 mm
and length 47.04 km.
Raw water pipeline- River to site 6.2 km and diameter 28.
Naphtha from numaligarh-5.2 km and 20 diameter.
Thickness of line pipe from lakwa to BCPL Lepetkata 7.1 mm.
In survey three routes are proposed for the pipeline, away from the village.
20 m land is taken into acquisition.
Right of use (ROU) 10 % of land cost is given to owner.
Right of way (ROW) Land is bought.
Typical ROU (right of use):
Anti-corrosive coating:
Coal tar ENAMEL coating (BS 4164, AWWA C203):
Primer
Two layer of coal tar enamel and glass fibre inner rap
One layer of coal tar impregnated outer wrap.
Coating thickness 4.7 mm.
Peel test:
Done to check the adhesion of coating.
Should be done for every 50 joints or for coating done in one day whichever is
least.
Lowering activity hold point
For normal land depth of pipe from the ground level should be 1 m and for road
crossing it is 1.2m.
Only cropping should be done on the land from where pipeline is passing.
Crawler crane having side boom is used to lower the line pipes.
25 kv current is used for holiday test (5.5 mm thick layer).
Lowering should not be done at night but for road crossing activity it should be done
at night.
Concrete coating pipe:
Used for river crossing, concrete balance the buoyant force.
2 mm of wire mesh is used in this case and after that 70 mm of concrete coating
is done.
Two SV station in Duliajaan pipeline route and four SV station in Lakwa route.
Number of SV station in a Particular pipeline route depends on the population and
land in that route
Inspection test plans (ITPs): It provides the details of activities for various works,
sequentially and indicates the stage wise roles of verification/inspection by contractor,
PMC/owner and the records/formats to be maintained.
Types of Verification/Inspection:
WC: 100% Examination by contractor.
RW (Random vigilance): Review of contractors documentation.
Mechanical
Two major activities: 1. Piping (consists above ground and underground)
3. Equipment
All process lines are above ground.
Utility lines are underground. E.g.- Cooling line, OWS, CWS, CBD line.
Underground piping is done during civil works and is under Structural scope.
Corrosion protection is done by either of the two methods:
1. Wrapping coating
2. Cathodic protection (Done for pipelines)
A3AMaterial of construction
Pressure rating
Piping specification A1A, A2A, A10A
1st character:
A 150 #
D 600 #
G 2500 #
B 300 #
E 900 #
J 150 # (for GI pipe)
C 400 #
F 1500 #
2nd character:
A Carbon Steel
D one quarter chrome moly (alloy Steel)
3rd character:
1-10 non corrosive Hydro-carbon.
2- IBR
5 Hydrogen
4- Cryogenic
16 NACE
3- non corrosive utilities (Air, nitrogen)
20 jacketed line (Steam tracing to Keep the process fluid hot)
On the basis of services, lines are classified as:
IBR
Non IBR
Process fluid having pressure more than 3.5 kg/cm2 is termed as IBR service fluid.
Jacketing does not come under IBR, only parts upto tapping come under IBR.
Mechanical Drawings, Specifications and Works:
1. Piping material specifications (PMS).
2. Isometric Routing, Dimension, Material, in 3-D picture.
II.
Elevation
Alignment: level and verticality by
Hanging a plumb
Thredolite
Rotating equipment:
I.
Elevation of nozzle and orientation of nozzle.
II.
Grouting of pocket.
III.
Pump and motor is aligned with the help of dial gauge.
IV.
Entire grouting.
V.
Final alignment
With pipe
Without pipe
Single skid pump: Pump and motor in one package.
Double skid pump: Pump and motor in two package.
Assembly of compressor is done at site.
Column internals:
Trays:
Used in fractionation columns.
Trays supporting rings (TSR) are used to support the trays.
Trays are bolted to TSR.
Drawing used:
1 Isometric (3D).
2 P&ID (piping and instrument diagram)
3 PFD (process flow diagram)
4 GAD(general arrangement drawing)
Standard length of fabricated pipe 6 m
For beams, structural steels and pipe of smaller diameter like 2 and below we can
find pipe having length 12 m.
Flanges: Flanges shall be in accordance with the following codes except where otherwise
noted
Upto 24 (150# - 1500#) ASME B16.5
Upto 12 2500#
- ASME B16.5
Above 24
- ASME B 16.47series
Spectacle blinds are used for complete isolation.
PCV Pressure control valve
TRV- Temperature regulating valve
PRV Pressure regulating valve
PDT Pressure differential transmitter
Priority 1 work before Hydrotest
Priority 2 work after hydrotest
Volume of Naphtha tank 5000 kilolitre
Naphtha is pumped to ECU from Naphtha tank.
Naphtha tank diameter 18 m
Height 11.5 m
Five core of primer is used in tank. Two core of Epoxy primer and three core of final
primer.
Alcometer is used to measure the thickness of the primer.(Dry film thickness (DFT))
Tank :
Bottom-full radiography
Sides-10% radiography
In case of tank fabrication of tank is done on site and blasting is done after welding (of
all the material including tank plates).
Because of rain problem, overhead cabeling is suggested for the Lepetkata site.
We should do fire proofing of steel structure which is used in RCC structure.