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DUAL FEED CRACKER UNIT &

ASSOCIATED UNIT
OPaL ,Dahej
Prepared By : Mr.Y.A.SASTRY ,AGM

: Mr.UDAY KRISHNA
Dy.MANAGER(M)

LEPC 1, DAHEJ PETROCHEMICAL


PROJECT-6987
Write-up on DFCU & AU Plant at OPaL
Dahej
ONGC Petro Additions Ltd. (OPaL), India’s premier integrated Hydrocarbon
Company, intended to set-up an integrated grass root petrochemical complex
located in Special EconomicZone (SEZ) at Dahej, Gujarat State, India.The
complex consists of Dual Feed Cracker Unit & Associated Unit (DFCU & AU) of
1100 KTPA capacity, for cracking C2, C3, C4 and Naphtha to produce maximum
polymer grade Ethylene and Propylene as Petrochemical feed stock to the
downstream Basic Polymer Units of LLDPE,HDPE and Polypropylene by taking
feed from ONGC’s C2-C3-C4 extraction at Dahej and Naphtha from ONGC’s
plant at Uran and Hazira.

LEPC 1, DAHEJ PETROCHEMICAL


PROJECT-6987
Project Information -
• OWNER : ONGC PETRO additions LIMITED
DAHEJ PETROCHEMICAL COMPLEX,SEZ
• LOCATION :
DAHEJ BHARUCH, GUJARAT
• EIL JOB NO : 6987

Dual Feed Cracker Unit (Ethylene)-


1100KTPA/LINDE
Dual Feed Cracker Unit (Propylene)-
400KTPA/LINDE
• DESIGN CAPACITY / LICENSOR :
Pygas Hydrogenation Unit (AU)-
545KTPA/LINDE
Benzene Extraction (AU)-
149KTPA/LURGI
Butadiene Extraction (AU)-
114KTPA/LURGI
Euro 354,512,000 + USD
• CONTRACT VALUE : 365,109,000 + INR 27,088,667,000

LEPC 1, DAHEJ PETROCHEMICAL


PROJECT-6987
PROJECT TARGET DATES

DESCRIPTION SCH.DATE ACTUAL DATE

NOTICE OF AWARD 23.12.2008 23.12.2008

Mechanical Completion 23.05.2012 12.09.2012

LEPC 1, DAHEJ PETROCHEMICAL


PROJECT-6987
PROCESSES OVERVIEW

LEPC 1, DAHEJ PETROCHEMICAL


PROJECT-6987
LEPC 1, DAHEJ PETROCHEMICAL
PROJECT-6987
Major Features
The followings are the major Features of DFCU & AU:
• All utilities are provided up to battery limit by others (No boiler, cooling
tower, flare stack, etc.)
• Dual feed (= gas + liquid)  Oil Fractionation + Water Scrubbing
• No air cooler  Water cooler for surface condensers & quench section
• Spent caustic is treated by Wet Air Oxidation (35), no incinerator
• Raw gas hydrogenation -> individual C2-/C3 hydrogenation
• No expander & booster  high pressure(31.15 bar g) demethanizer
• Plate Fin type Demethanizer Condenser on the platform not on the top
of Demethanizer
• No DOX unit  Prefilter & Coalescer is installed.
• Many separation columns to export benzene and 1,3-butadiene
• No control building & maintenance shop
• Turndown: 50%
• One common lube oil skid for Ethylene and Propylene Compressors

LEPC 1, DAHEJ PETROCHEMICAL


PROJECT-6987
• The highest design pressure & temperature ~ VHP or HHP steam (116 kg/cm2g,
513 oC) Steam Drum (127 barg), CGC 5th discharge (43 barg)
• The lowest design temperature ~ Demethanizer (-165 oC @ 37 barg)
(More stainless steel was applied due to depressuring up to atmosphere.)
• Variable Frequency Driver ~ Flue Gas Fan (for 8 Furnaces)
• SQE + MOV (Cracked Gas, Decoking Gas) by LE (acc. to DOR with Annex 2)
• Furnace interface at pipe rack, junction box but P&ID
• Compressors ~ Decoking Air Compressor, Plant Air Compressor (Spent Caustic
Oxidation Unit)
•Recycle Gas Compressor (BdEU), 2nd Stage Make-Up / Recycle Compressor
(PGHU)
• No air coolers (structure)
• MP and LP steam conditions are somewhat higher than Project Design Basis.

LEPC 1, DAHEJ PETROCHEMICAL


PROJECT-6987
Furnace Schematic

LEPC 1, DAHEJ PETROCHEMICAL


PROJECT-6987
Steamdrum Steamdrum

Naphtha or
Ethane 1 C3/C4 Feed *)
1 Feed BFW
BFW 2
11 C2/C3 Feed *)
2
Convection Section 3
Convection Section 3 Dilution
4 Steam
10
4 Dilution
10
Steam 5
Quenchoil
5 11
6/7 VHP
6/7 Steam
VHP 8
Steam
8
Cracked Gas
Radiant Section
to Primary Oil
Fractionator
Radiant Section Cracked Gas
to Primary Oil
Fractionator
9 *) Only for furnaces flexible
for all feedstocks (ethane,
C3/C4 and naphtha)
9 07-F01 and 08-F01

Section Description
1 Feed Preheater
2 BFW Economiser
Section Description 3 High Temp. Convection 1A (HTC-1A)
4 Dilution Steam Superheater
1 Feed Preheater 1
5 High Temp. Convection 1B (HTC-1B)
2 BFW Economiser 1
6/7 VHP Steam Superheater (incl. BFW Injection)
3 Feed Preheater 2 8 High Temp. Convection 2 (HTC-2)
4 BFW Economiser 2 9 Radiant Coils (PyroCrack 1-1)
5 High Temp. Convection 1 (HTC-1) 10 LQE (Linear Quench Exchanger)
6/7 VHP Steam Superheater (incl. BFW Injection) 11 Quench Fitting
8 High Temp. Convection 2 (HTC-2)
9 Radiant Coils (PyroCrack 1-1)
10 LQE (Linear Quench Exchanger) LEPC 1, DAHEJ PETROCHEMICAL
11 SQE (Secondary Quench Exchanger) PROJECT-6987
Process description
Feed Preheating
Ethane Recycle and Feed - preheated up to 60 °C
ethane is used as a fuel by Ethane Start-up Evaporator 25-E16 for start-up operation
Propane and Butane feedstock - preheated up to 60 °C
Naphtha (LAN+ARN) – preheated up to 80 °C
Furnace
Feed + Process steam  cracked gas & decoking gas, VHP steam
01-F01 to 03-F01 (gas cracker) - Secondary Quench Exchangers 01-E02 to 03-E02
04-F01 to 08-F01 (liquid cracker) - direct oil injection into the transfer line w/o SQE

Oil Fractionation and Quench Oil Cycles


Two quench oil cycles of PFO (Pyrolysis Fuel Oil or Heavy Pyrolysis Oil) and
PGO (Pyrolysis Gas Oil or Light Pyrolysis Oil) are used as heat carriers
condensing the heavy ends of the cracked gas
The heat duty of the PFO is sufficient to generate approx. 60 to 80 % of the
process steam needed for cracking depending on the feedstock case.
For coke removal cyclones separate the quench oil into a fraction with a low
coke content leaving the cyclones
The largest consumer of quench water heat is the reboiler of the C3 splitter.
CBFS (carbon black feed stock) is produced from Pyrolysis Fuel Oil Stripper
(27-T02)
LEPC 1, DAHEJ PETROCHEMICAL
PROJECT-6987
Oil Fractionation and Quench Oil Cycles
Two quench oil cycles of PFO (Pyrolysis Fuel Oil or Heavy Pyrolysis Oil) and
PGO (Pyrolysis Gas Oil or Light Pyrolysis Oil) are used as heat carriers
condensing the heavy ends of the cracked gas
The heat duty of the PFO is sufficient to generate approx. 60 to 80 % of the
process steam needed for cracking depending on the feedstock case.
For coke removal cyclones separate the quench oil into a fraction with a low
coke content leaving the cyclones
The largest consumer of quench water heat is the reboiler of the C3 splitter.
CBFS (carbon black feed stock) is produced from Pyrolysis Fuel Oil Stripper
(27-T02)

Process steam system


almost all dissolved hydrocarbons are stripped off by Process Water Stripper 30-
T01.
The main heat for process steam generation is produced by cooling of pyrolysis
fuel oil. However, the heat balance is covered by condensation of MP steam.
Process water blowdown is cooled down to 45 °C in Blowdown Cooler 30-E13.

LEPC 1, DAHEJ PETROCHEMICAL


PROJECT-6987
Cracked Gas Compression
Suction pressure: approx. 0.02 barg, Discharge pressure: approx. 37.5 barg
BFW injection to compressor casing - To reduce the temperatures in the
compression process
Wash oil injection to prevent fouling of compressor
The gasoline from 31-D37 is fed to Gasoline Stabilizer 56-T01 where C4 and
lighter components are removed from gasoline and then are recycled to the
discharge side of the first stage of the cracked gas compressor.

Caustic scrubbing
the sour gases carbon dioxide (CO2) and hydrogen sulphide (H2S) are removed
from the cracked gas by washing the cracked gas with caustic. They are
converted to their respective salts.
2 NaOH + CO2 → Na2CO3 + H2O
2 NaOH + H2S → Na2S + 2 H2O
(< 1 vol ppm) of H2S and CO2 is performed in the lower and the middle
section of the caustic scrubber.
Caustic concentration of approx. 3 % in the upper cycle is adjusted by the water
flow received from the top water wash section.
The back wash water trays on top of the column are charged with BFW to
prevent any entrainment of caustic to the cracked gas compressor.
LEPC 1, DAHEJ PETROCHEMICAL
PROJECT-6987
Spent caustic oxidation
stripped with methane at low pressure to remove light hydrocarbons and
benzene
caustic is mixed with steam and air in a caustic/air/steam mixer.
sulphide and hydrogen sulphide are oxidized to thiosulphate and then to sulphate:
2Na 2 S  1.5O 2  2H 2 O  Na 2 S 2 O 3  2NaOH
(100 % conversion )
2NaHS  2O 2  Na 2 S 2 O 3  H 2 O
(100 % conversion )
Na 2 S 2 O 3  2NaOH  2O 2  2Na 2 SO 4  H 2 O
(50 - 70 % conversion depending on residence time)

Excess air separated in the neutralisation drum and vent gas from the caustic
tank are sent to the sour gas flare
Effluent suitable for Biological Treatment to be sent to OSBL (pH 7.0 by
sulphuric acid)
Sulphide content in oxidized effluent is less than 10 mg/l.
COD is reduced to 4,000 – 6,000 mg/l.

LEPC 1, DAHEJ PETROCHEMICAL


PROJECT-6987
Precooling and Drying (PFF37)
Cracked Gas Drier 37-A41 A/B/S (molecular sieve), where the water content is
reduced to the required dew point.
Cracked Gas Condensate Drier 37-A42 A/S (molecular sieve) for the removal of
the remaining water and then fed to the lower section of Deethanizer 38-T02.
Both drier stations 37-A41 A/B/S and 37-A42 A/S are regenerated automatically.
Cracked Gas Cooler II 37-E12 is in operation only during start-up of the plant
and in case of naphtha cracking only (turn down case 5).

LEPC 1, DAHEJ PETROCHEMICAL


PROJECT-6987
C2/C3 Separation (Front End Deethanizer System)
Separating all C2 and lighter components from propylene and heavier components.
C3 absorber, is operated at full cracked gas pressure above 35 bar
The deethanizer column operates at reduced pressure with a lower bottom temp.
around 80 °C

Cracked Gas C3 Absorber Deethanizer


from CGC 35 bar 25 bar

C2H6 CH4
H2 Inerts
C2- to
Hydrogenation

C3H6 26 bar
C3H6
+10°C
-38 °C
C3H6
-16 °C
- 38°C
-10 °C C2H4
- 55°C
-24 °C

Water
LP
Steam
86 °C

C3+ to
Depropanizer

LEPC 1, DAHEJ PETROCHEMICAL


PROJECT-6987
C2 Hydrogenation (Front End Acetylene Hydrogenation System)
Tubular reactor with an almost isothermal reaction. all are present in the cracked
gas.
C2H2 + H2 → C2H4
C2H2 + 2H2 → C2H6 (acetylene: 5000 ppm → 1 ppm)
CO
Analyser
Model
1 - 2 bar
- 28 °C PC
C2- to
Cold Train 65 °C
TC
CW

C2- from
Deethanizer
Methanol
- 36 °C 65 °C
Startup
Heater

°C
Methanol
80 Vapor Pressure
73 °C
70

60

1 1.1 1.2 1.3 1.4 bar

LEPC 1, DAHEJ PETROCHEMICAL


PROJECT-6987
Low Temperature Section
C2minus fraction is cooled in several stages until all ethylene, ethane, and methane is
condensed. The remaining gas consists of 81 mol % hydrogen.
40-D31(-55°C), 40-D32(-78 °C), 40-T01 (-108 °C),
C2 Absorber 40-T01 (-128 °C), 40-D33 (-140 °C)
Gas stream  H2 fraction (81 mol% H2, feed to PSA) & CH4 fraction (96 mol% CH4)
 mixed as a fuel gas
Liquid stream  to Demethanizer 41-T01
C1/C2 Separation
Operating pressure of 31 barg
Methane, hydrogen and carbon monoxide are recovered overhead.
Bottom C2 fraction is fed to C2 Splitter
Methane recycle is expanded to 7 barg corresponding to a temperature of -129 °C for C2
recovery.
Open Loop C2 Fractionation System
C2 Splitter overhead product is heated then pressurized in the 3rd stage of C2 ref.
compressor.
Further compression in the 4th stage and the balance stream is cooled against the cold
overhead vapours and condensed in the reboiler of the C2 splitter
- mainly subcooled and used as a reflux
- others are condensed against propylene refrigerant and stored in Ethylene Collecting
Drum

LEPC 1, DAHEJ PETROCHEMICAL


PROJECT-6987
Temperature levels of ethylene refrigerant :
Low pressure (LP) C2 refrigeration: -101 °C
Medium pressure (MP) C2 refrigeration: -80 °C
High pressure (HP) C2 refrigeration: -57 °C
Heat Pump System
Refrigerant System
I II III IV
Shared by both

Product compression
CW CW CW

Ethylene
Product (vap)

LP
C2 Feed C2H4

HP MP
C2H4 C2H4

LP
C3H6

Ethane
Recycle
Ethylene
Product (liq)

LEPC 1, DAHEJ PETROCHEMICAL


PROJECT-6987
Propylene Refrigerant Cycle
Intermediate temperature range between cooling water and ethylene refrigerant
Temperature levels of propylene refrigerant :
Low pressure (LP) C3 refrigeration: -38 °C
Medium pressure (MP) C2 refrigeration: -20 °C
High pressure (HP) C3 refrigeration: +10 °C

PSA Plant
Pure hydrogen is delivered to
- C3-Hydrogenation (PU 52)
- Gasoline Hydrogenation I and II (PU 61 and 64)
- Regeneration of reactors
- Export to BL

LEPC 1, DAHEJ PETROCHEMICAL


PROJECT-6987
 Process description • PGHU: 61, 62, 63, 64, 65
• BdEU: 58
• BzEU: 67 (numbering based on Proposal)

Downstream Separation of Deethanizer Bottom


Light hydrocarbon recycle

C3 Hydrog. (52-R01)
C3 (27 bar, 16 oC) C3= (propylene) C3= Liquid to B.L.
Deethanizer
bottom C3 Splitter (55-T01)
(26 bar, 89 oC) C3 Stripper (54-T01) (18 bar, 43 oC)
(14 bar, 31 oC) C3
C3+
C3- Propane recycle to furnaces
Butadiene
Depropanizer (51-T01) C4 Extraction 1,3-Butadiene to B.L.
(8.6 bar, 15 oC) (58-Y01)
C5 C5 recycle to furnaces

Gasol. Hydrog.II Depentanizer (65-T01)


C5-C6 (64-R01A/S ~ 29 (5 bar, 92 oC)
C4+ bar, 275 oC)

C6 Bz. Ext.
Debutanizer (57-T01) Gasol. Hydrog.I (67-Y01) Benzene to B.L.
(5.6 bar, 68 oC) (61-R01A/S ~ 30
bar 86 oC)
C5+ Pyrolysis Gasoline to B.L.
C7-C8
C7+
C6/C7 Separation (62-T01) Deoctanizer (63-T01)
(1.7 bar, 80 oC) (1.9 bar, 144 oC)

C9+ C9+ Product to B.L.


C3/C4 Separation
Operating pressure: 7.9 barg
Top product of C3 fraction is sent to C3 Hydrogenation Unit
Bottom product of C4+ fraction is sent to Debutanizer.
C4/C5 Separation
Debutanizer 57-T01
Top product  Lurgi’s Butadiene Extraction Unit
Bottom product (C5+)  Gasoline Hydrogenation Unit 1  62-T01 C6/C7 Separation
Column
top (C5-C6 fraction) is bottom  63-T01 Deoctanizer

C3 Hydrogenation & C3 Stripping


Conversion of MAPD (methylacetylene and propadiene) to propylene and
propane
Hydrogenated C3 fraction is fed to C3 Stripper 54-T01, where all light
components are removed.
Stripped overhead gas is fed to the 4th suction drum of CGC
Bottom stream is pumped by 54-P71 A/S to C3 Splitter 55-T01.
C3 Splitter 55-T01
Top: propylene liquid product
Bottom: propane recycle to furnace

LEPC 1, DAHEJ PETROCHEMICAL


PROJECT-6987
CONSTRUCTION HIGHLIGHTS
Health Safety & Environment (HSE)
•Total 41,890,404 Safety Man-hours (up to 15 Oct 2012)
•Set-up of free medical facilities at site for workers by deploying
permanent doctor & nursing staff which are capable of handling
emergency & trauma medicine.
•Availability of Ambulance equipped with first aid treatment facility.
•Medical checkup of all works & staffs was carried out at the time of HSE
induction training and induction card issued.
•Regular Health-checkups was organized.
•Work Permit System implemented effectively by involving execution
staff.
•Rigorously Tool Box Talk conducted on daily basis before starting job.
•Promotional activities were conducted to motivate workers by awarding
certificates and prize for following safe practice.
•Top management actively participated in activities like mass
housekeeping, site walk through etc.
•Hanging scaffolding provided at pipe racks which helps to expedite work
on different elevation at same location simultaneously in safe manner.
LEPC 1, DAHEJ PETROCHEMICAL
PROJECT-6987
Mechanical Work
• Total 627 corresponding 17,134 MT of equipment erection.
• Major Equipment are as follows:

SL. EQUIPMENT Nos.


NO.
1 TOWER 6
2 COLUMN 23
3 REACTOR 7
4 VESSELS 86
5 HEAT EXCHANGERS 168
6 COMPRESSOR (Turbine 3
Driven)
7 COMPRESSOR (Electric 6
motor Driven)
8 PUMPS 200

LEPC 1, DAHEJ PETROCHEMICAL


PROJECT-6987
• Tallest tower C3 Splitter (124m, 1231 Tons), was erected
The single piece erection had been done for column with 124.5m height & 1231 MT weight.
It is the tallest column in petrochemical industry in India.
Tower Capacity – 1800 MT

LEPC 1, DAHEJ PETROCHEMICAL


PROJECT-6987
Piping Work
• Area wise job execution for better control
• About 1.1 Million inch Dia. for AG Piping, conceding more than 342,000
joints excluding
furnace piping.
• Largest pipe size 128” used for carrying cracked gas from Oil Fractionators
to Quench
Tower.
• Auto welding machines were used at fabrication shop.
• More than 300 piping welders were deployed at field during peak time.
• Less than 3% repair rate
• System wise piping completion for testing and flushing utilizing piping
design integration
system.
• 2335 AG Piping pressure test package (process), corresponding more than
15 Million Inchmeter.

LEPC 1, DAHEJ PETROCHEMICAL


PROJECT-6987
Modern Techniques used at Piping Fabrication Shop
􀂾 Sliding and overhead gantry girder: This method was used for easy handling of
Pipe spools which includes big bore fittings etc. during joint fit-up. This arrangement
was also useful to take out big pipe spools after fabrication. It was the safest and time
saving method.
􀂾 Flux Cored Arc Welding Method: This is semi automatic welding machine and was
implemented at site. This has an advantage over conventional welding in terms of
production rate and quality.
􀂾 Multiple Nozzle argon supply arrangement for TIG welding: Argon Gas was filled
in tank & then argon was supplied through piping & provided for welding through
hoses.
􀂾 Pipe Shifting arrangement: Tower crane (1 nos.) of radius 60m and height of 50m.
Installed in pipe fabrication yard for easy shifting of pipe spools to radiography bunker
to take radiography of weld joints. This method was very fast and provided with no
blockage of passage due to movement of vehicle / Hydra / Forklift etc.
􀂾 Pipe Auto Welding System: PAWS900 (SAW) Welding Machine was used at piping
fabrication shop. This machine was able to weld pipe of dia. 12” to 36” having
thickness up to 25mm. Time required for welding of 12” pipe having 10mm wall
thickness was 30min. Whereas using conventional welding method, a welder takes
nearly 90 min. welding time.
􀂾 Pipe Facing Machine: TUBE 400(MODEL) was used at piping fabrication shop. This
machine was able to make a bevel from 3” to 16” dia. in 10 sec and 30 sec
respectively. Whereas using conventional method it takes approx. 10- 20 minutes.
􀂾 Metal Cutting Band Sawing Machine: This machine was able to cut the pipe from ½”
to 16” dia. of any thickness. The time taken for cutting 2” pipe of 10mm thickness is 3
min. and 16” pipe of 15 mm is 15 min, which is much faster than conventional method.
􀂾 CNC Pipe Coaster: (CPCM-4N-900A) Model- This machine was helpful to make 90
degree branch and lateral branch from size 4” to 36”. Cutting and beveling of pipe was
done simultaneously. LEPC 1, DAHEJ PETROCHEMICAL
PROJECT-6987
LEPC 1, DAHEJ PETROCHEMICAL
PROJECT-6987
Pre –Insulated Tube for Steam Tracing both supply & return line.
Steam supply & return line insulation to manifold is done with Pre-Insulated tube.
For insulation SS tube (A269 Gr.TP304SMLS PE 0.90mm) has been used in DFC & AU
Project. Due to this material, no welding is required. The advantages of this material are
•Easy handling
•Time saving,
•Easy modification of the lines
•Easy bending
•Because there is no welding requirement, it saves welding repairs time and man
power.

LEPC 1, DAHEJ PETROCHEMICAL


PROJECT-6987
Steel Structure Work
• Total Structure Quantity- 14,434 MT
• Total Structures – One Common Pipe Rack from HU to AU area (1820 MT)
14 other Pipe Racks
26 Equipment Structures
5 Shelters including 3 main Compressor Shelters
Chemical Storage Building (CSB)
Modern Techniques for Structural Erection
􀂾 Bolting method was adopted instead of Welding for connection of different
Structural
members which saved time.
􀂾 Final Coat painting was applied at Painting yard with Airless spay which
gives better
aesthetic appearance as compare to brush application.
􀂾 Module assembly was easier and safer as it was done at ground level and
erected with
using crane.
􀂾 Structural members after fabrication & Final Painting ate structural
fabrication shop
were shifted to site for erection.
􀂾 Base plate template was made at ground level and an Erection of Structural
member
was done by assembling all the members into a single unit, i.e. Module.
􀂾 Faster Erection as compared to Traditional method of erection.

LEPC 1, DAHEJ PETROCHEMICAL


PROJECT-6987
LEPC 1, DAHEJ PETROCHEMICAL
PROJECT-6987
Civil Work
• No. of Piles- 8735
• Under-reamed (300mm, 400mm & Driven)
• 26 Equipment structures spread in plant
• Concrete – 53309 M3
Building Work
• No. of Buildings- 6 nos.
• Description - DFCU Substation,
AU Substation
RIB-1
RIB-2
RIB-3
Chemical Storage Building (CSB)
• Concrete – 9942 M3
Precast Pipe Rack Erection: Both concrete and structural type Pipe racks are
used.Pre- fabricated concrete pipe rack up to 13 meter height used for carrying pipes
were framed structure cast at grade level with columns, transverse and longitudinal
beams.Total 287 number of Precast Pipe rack were cast and erected for 13 nos. of
pipe rack of total length of approx.1744 meters.
•It saves pipe rack erection time.
•It reduces site welding and bolting.
•It does not require any fire proof work.
•It provide with good structural safety through rigid connection.

LEPC 1, DAHEJ PETROCHEMICAL


PROJECT-6987
Electrical Work
• Two sub-stations in DFCU & AU area respectively, for optimized load distribution throughout the
plant.
• 66 KV Switch yard for feeding 6.6 KV power supply to AU substation through step down
power transformer, DFCU taking feed from AU substation.
• Diesel generator of 1820 KVA for emergency power supply.
• UPS for 3 Remote Instrument Buildings (RIB), with storage batteries 54AH~471AH, &
battery charger having output rating from 5.5KVA~55.5KVA.
• More than 450,000 RM power cable (HT/LT) pulling ranging from 1.1 KV to 6.6 KV.

Instrumentation Work
• Three Remote Instrument Buildings (RIB) were constructed at site.
• RIBs are equipped with system/marshalling/power cabinets, UPS systems, MMS and F&G
system
• Honeywell’s DCS System with C300 controllers with Field bus Interface Modules (FIM) and
Process Manager I/O Processers are implemented, to permit centralized operation of plant.
I/O Modules segregated as follows :
o RIB 1 - Furnace(1~8) & Quench Area
o RIB 2 - Compressor & Cold Area
o RIB 3 - BdEU, BzEU & PGHU Area
• ESD and F&G, SIL3 complied and TUV certified. Interfaced with DCS system supplied by
Honeywell.
Analyzer System, CCTV, MMS are other main highlights

LEPC 1, DAHEJ PETROCHEMICAL


PROJECT-6987
ACHIEVEMENT OF THIS PROJECT
Schedule date of Mechanical completion of this Project (without Pre comm..)
was 23.05.12(Project award date:23.12.2008) and actual mechanical
completion achieved on date 12.09.2012 ,which is almost as per schedule. This
was the major achievement.
HOW IT COULD BE POSSIBLE?(LESSON LEARNT)
1. MULTIPLE SUB-CONTRACTORS: Dependency over one sub contractor for all
construction was avoided, instead more than 50 sub contractors were contracted for
the construction work. This helped easy replacement, if any sub contractor is not
performing good and more efficient control over work progress.
2. MAINTAINING PROJECT SCHEDULE:
•Notice of Award:23.12.2008
•Engineering:
Start date-06.03.2009 End date-13.01.2011
•Ordering & Sub-Contracting:
Start date-14.04.2009 End date-30.12.2010
•Manufacturing & Delivery (Piping materials, Equipments & Instruments, etc.):
Start date-01-08.2010 End date-24.10.2011
•Construction:
Start date-13-07.2009 End date-02.08.2012

LEPC 1, DAHEJ PETROCHEMICAL


PROJECT-6987
Contractor had continued to develop and maintain the project schedule throughout the
engineering,procrument and construction period. The overall project schedule was used
by contractor as the prime vehicle for constructability planning exercises. The extent of
detailing of the overall project schedule was such that the effect of any significant delay
or change in the course of the execution of the any activity was clearify,explained
,evaluated and controlled. This include immediate mobilisation of workman/sub
contractor, additional supervisor/engineer and Machines as and when required.

3.MODERN TECHNIQUES USED: Modern techniques were used at piping and


structure fabrication shop,such as Sliding and over head gantry grider,Flux cored arc
welding, Multiple nozzle argon supply arrangement for tig welding, Auto welding
system, Pipe facing machine ,metal cutting machine,CNC pipe cuter.
Tower crane (3 nos.) with capacity 2-10MT,25m height & radius 20 mtr was installed
for DFCU work for shifting and lifting of pipe spools and structure members, small pump
etc.
Tower crane(1 nos.) installed in Pipe Fabrication Yard for shifting of pipe spools .
Special Radiography bunker was made near fabrication shop to facilitate RT works in
day time also to expedite production and clearance of spool from Fabrication Shop.

LEPC 1, DAHEJ PETROCHEMICAL


PROJECT-6987
4. INSPECTION METHODOLOGY: Field inspection Notice(FIN) system used for
inspection. Contractor was giving FIN one day before to PMC for inspection. Piping
test packages after mechanical and NDT clearance from contractor were submitted to
PMC for the same through document transmittal. Its minimize the time between M/c
and NDT clearance as well as rework.
5. DEPLOYMENT OF PROJECT & ENGINEERING TEAM AT SITE: When about 90%
of engineering work had been done, project and engineering team of contractor was
shifted to site for better control of engineering work, quick communication with
construction team at site, incorporating actual site condition in to design and minimizing
the revision work.
6. WELFARE ACTIVITY FOR WORKER/SUBCONTRACTOR AND EMPLOYEE:
•Monthly award system for contractor’s engineers, supervisor, sub contractor and
workers for motivation.
•Free canteen facility for contractor employee ,including dinner at night for those
working late.

LEPC 1, DAHEJ PETROCHEMICAL


PROJECT-6987
LEPC 1, DAHEJ PETROCHEMICAL
PROJECT-6987

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