PROJECT PROFILE FOR RELIANCE JAMNAGAR DTA

Reliance Industries Limited (RIL) India is one of t he world’s largest producers of petroleum and petro chemical products.

Their plants spread across India are the most moder n and comparable to the best in the world. For thei r needs for setting

up water and waste water treatment plants RIL has r epeatedly reposed its trust in Vatech Wabag.

Wabag was awarded the contract for almost all their recent expansion projects, to name a few,

1. RIL Dahej-Effluent treatment Plant with Tertiary treatment (UF and RO).

2. C2 Complex- Effluent treatment plant with Tertia ry treatment (UF and RO).

3. J3 Gasification- Effluent treatment plant with T ertiary treatment (UF and RO).

4. SEZ- Effluent treatment plant with Tertiary trea tment (UF and RO).

5. Side Stream Filtration.

6. RIL Hazira- Tertiary treatment (UF and RO).

IEC (International Engineering Centre) was privileg ed to engineer and be part of all the above mention ed projects.

This project profile is for Reliance Industries L imited (RIL), which Operates the World’s large st refinery complex, at

1.34 million Bnl/Day crude processing capacity, with two refineries, one Domestic Tariff Are a (DTA) refinery and one

Special Economic Zone (SEZ) refinery, at Jamnagar, India.

The DTA gasification complex wastewater treatment f acility includes pre-treatment section, biological treatment section,

and tertiary treatment section.

Each discipline had unique challenges while executi ng engineering of this project. The complex process with multiple

treatment technologies under one roof, compressed p lot area accommodating huge civil units and equipme nt, challenges

in civil footings due to compressed layout, huge st ructures, variety of piping work and the quantum of Electrical and

instrumentation work. This case describes how this complex project Engineering was executed with the s upport of

technology tools and experience.

DTA Process overview:

Pre- treatment section

• Cyanide removal system • Iron removal • Fluoride removal system • Heavy metal removal system • Chemical Sludge treatment

Biological section

• Two stage aeration system • Biological sludge treatment

Tertiary treatment section

• Ultra filtration • Reverse Osmosis

Various influent water quality coming in DTA WWTP:

PROCESS FLOW DIAGRAM - PT

PROCESS FLOW DIAGRAM - TTP

Water Quality at outlet of PT & secondary clarifier: Water Quality at outlet of TTP:

Quantum of civil works in DTA:

Sr. no. Description Sr. no.2 Description 2

1 Guard tank (29 m Dia. x 5.5 m SWD +0.5m FB)

16 Dewatering building for Belt filter press (21x7.5x13m))

2 Equalization tank (20 m L x 20.4 m W x 4.5 m LD +0.5m FB)

17 Lime dosing system (8mx9.5mx11m height)

3 Secondary clarifier-1 (18 Dia. x 4 SWD)

18 Road and trench layout

4 Secondary clarifier-2 (18 m Dia. x 3 SWD)

19

Clarified Water Equalisation Basin (84.5m L X 12.75 m B X 4.2 m LD),

5

Flash Mixing Tank 2 & Flocculation tank & Clarifier (1.2 m L x 1.2 m W x 1.2 m LD), (4.2 m L x 4.2 m W x 3 m LD) and (14 m dia. x 4 m SWD) 20

Gas Chlorination Shed (14mx7m)

6

Anoxic basin and Aeration tank-1 (13.5 m x 1.9 m x 5.5 m LD), (28.5 m x

13.5 m x 5.5 m LD) 21 HRSCC (18 m Dia. X 3.5 m LD)

7

Flash Mixing Tank1 and Clariflocculator (1.3 m L x 1.3 m W x 1.2 m LD), (10.9 m dia. x 4.5 m SWD) 22

PIPE RACKS (150m running length)

8

Reaction Tank-I & Reaction Tank-2 (8.1 m L x 3.9 m W x 3.5 m LD), (2.5 m L x 2.5 m W x 2.8 m LD) 23

RO FEED TANK, RO PRODUCT TANK, FILTER FEED BASINS AND PUMP AREA (20 m L X 9.25 m B X 5.5 m LD), (20 m L X 9.25 m B X 5.5 m LD), (35 m L X 20 m B X 3.2 m LD)

9 Solid contact clarifier-I (8 dia. x 4.5 m SWD)

24 Analyser Rooms 2 & 3

10 Aeration tank-2 (29 m x 12 m x 5.5 m LD)

25 Road Crossing Bridges

11

Chemical sludge sumps (2 m x 2 m x 3 m LD +4.6 m FB) , 4.1 m x 4.1 m x 3 m LD +4.6 m FB 26

RCC /Structural details of Electrical Cable Tray Rack near PEB shed

12 Chemical sludge thickener (8.5 m Dia. x 3.5 m SWD)

27 Paving

13 Bio Sludge sump and Supernatant sump for Bio sludge, Chemical Sludge Supernatant sump and service water Tank. (4.1 m x 4.1 m x 3 m LD), (5 m x 5 m x 3 m LD), (4 m x 5 m x 3 m LD), (3.5 m x 3 x 2.5 m LD) 28

Pipe /E& I Supports

14 Bio Sludge thickener (8 m Dia x 3.5 m SWD)

29 Chemical house (40mx25mx11.5m Height)

15 Chemical unloading area (40mx11m)

30 PEB Shed (80mx20mx4.7m)

Quantum of civil works in DTA:

Challenges in civil design:

One of the most critical challenges faced while designing civil structures was the design of pipe bridge footing where space was a constraint. The huge civil tank for clarified water storage (84.5x12.75), with its raft coming in the way of column footing of bridge was a challenge with respect to foundation of bridge. Conventionally such foundation footings are done with combined footing, this consumes lot of concrete. With our expertise we designed it for combined strip footing which consumes concrete much less as compared to combined footing. Overall considering steel and concrete together the average saving is around 20%.

This design is a composite methodology viz. combination of combined footing and stripped beam leading to combined strip footing.

Below snap shows the combined strip footing 3D model view:

The third one was the critical design of structural bridge for pipes and cable trays. You can see the snap of a structural bridge as below. The design involved 21 load cases for which the structural analysis was to be carried out. Main loads comprised of dead load, Pipe frictional load, Wind and Seismic load in various directions, test load etc. The structure is about 15 m in height. The analysis was done using STAAD-PRO software.

Fourth case was for RO shed, here we used prefabricated plated sections of structural members over the conventional structural

members. Here the saving in kg/m2 was approximately 50% against the conventional structures. The plated sections are having

variable cross sections with respect to its length. This helps in maintaining the cross section comparative to the load reducing the

total weight. The Structural graphical model for prefabricated shed can be seen as below.

Varyingcrosssectionofplated

sections.

DTA Layout:

The layout area was one of the order wining criteria for this project. No EPC contractor was in a position to fit the Equipment layout in given area of

approximately 34500 sq m that too in a odd shape. The required area by competition was almost 15 to 20 % higher. That is where innovative ideas from

Wabag helped. Entire RO shed of 3500 sq m was placed on a equilization tank to fill the area deficit coming in fitting the equipment layout.

Pipe Routing: The entire piping model is done in PDS software. Stress analysis of high pressure piping in duplex and non metallic GRE piping is

done using Caesar to take care of adequate supporting and stress proof pipe routing. There were around 1250 plus isometrics with materials

like GRE, CS, GI, SS, Duplex, CPVC, etc. Total piping is around 27km in length. Pipe sizes range from 15NB to 600NB and the total inch dia. of

52000 and inch meter of 60000. Although there was a space constraint, special care was taken from ease of operation and maintenance point

of view. The operation and maintenance space can be seen in below pump piping arrangment snap.

Valves sizes ranging from 50mm to 450mm with wide range of material of construction like UPVC, PP, Carbon steel with both lined and

unlined types, SS 316L, Brass and Duplex stainless steel. The quantity of valves is around 3000 nos. with pressure class upto 800 pounds.

Storm water and Chemical drainage system: In open chemical area where draining both chemical spillages and rain water in isolated way was

bit tricky. Both the drainages had to be sent to different destinations viz. chemical spillage to nearby by chemical sump and rain water to

storm water drain trench. A special arrangement with a provision of valve was made such that if the valve is in closed position only chemical

spillages can be collected and transferred to chemical sump and in case of transfer of rain water the valve was to be opened and the this would

enable transfer of rain water to nearby storm water trench.

Typical single UF skid seen in isolation. Total 7 nos. of such UF skids are arranged side by side in RO-UF shed.

Typical RO skid seen in isolation. Total 14 nos. each with back to back arrangement of 2 stages.

Various Piping Materials Handled

Glass reinforced epoxy

Carbon Steel

Galvanized iron

Duplex stainless steel

Stainless steel 316

Poly tetra flouro ethyelene

High density poly ethylene

Carbon Steel rubber lined

Chlorinated poly vinyl chloride

Electrical and Instrumentation Design:

Cable Rack at Termination point Pipe and Cable Rack inside the plant

DTA electrical works involved arround 330 km of power and control cabling. With 286 motors for different duties ranging from 0.37kw to

132KW out which 48 nos. are with variable frequency drive. The complexity of cable routing can be seen in above snap containing a 9 meter

high cable rack containing 22 no. of power and control cables trays.

There are about 550 number of intruments with various types of analyzers (Ph, ORP, Dissolved oxygen, Cyanide, Flouride, Nitrate, etc). These

were special analyzers and were used rarely. Special care was taken while doing the selection of these analyzers. This also demonstrated our

capability to do something new with additional efforts with right first time.

Instrumentation: In tools (an Intergraph

software for instrumentation and control)

was used for this project. Intools is

integrated softwares for control and

instrumentation. All engineering data

sheets are to be made through In Tools.

The software is such that any change in

any of the data sheet will automatically

update the respective documents. For eg.

any change in instrument details once

updated will get automatically updated in

Instrument index, I/O list. Below is the

snap of DTA In Tools index for

instrumentation. This ensured that the

final documentation is inline with all

respective documents and error free. The

software used was third party.

The Sampling sysetm: The sampling panels for various analyzers in

the plant are located at remote locations due to space constraint. Due

to the long distance sampling pumps were used to transfer sample to

the analyzer panels. The arrangement for sampling was such that

different concentration levels were measured separately at given

point of time. This was achieved by using systematic valve

arrangement. An eg. of Cyanide analyzer sampling sequence can be

seen in below snap. Similar type of arrangement is done for all types

of analyzers used in this project.

Safety Features:

Liquid retaining structures are provided with a positive isolation in

order to do easy maintenance of civil storage tanks. In case of

maintenance of tank after emptying it although there is provision of

isolation gate, special attention is given to the safety of person

working in tank by providing redundant isolation so that nothing can

come from inlet sump to the empty side.

The PLC:

Although the plant does not fall under hazardous area classification, being located inside a refinery other PLC’s were falling under hazardous

area classification and client wanted interchangeability of spares and to maintain uniformity in the plant, so it was insisted by client to have

SIL2 PLC system and intrinsicaly safe field instruments.

Here the PLC is with SIL2 (safety integrity level 2) feature with channel to channel isolation/barriers.

Moving from SIL 1 to SIL 2 to SIL 3 places higher demands on the safety system. The average probability of having a dangerous failure is 10

times lower for SIL 2 than it is for SIL 1.

Conclusion: In conclusion it can be seen that the engineering works done for this project was not only vast but it was also a complex system

when it comes to different Process schemes under one package, Equipment layout, Piping and cable routing, usage of engineering softwares,

safety aspects, , innovative ideas for cost optimization and much more. Various softwares handled while engineering this project shows our

ability to work with latest engineering softwares mostly used by leading Engineering consultants like Flour Daniel, Bechtel, Jacob etc.

efficiently. Our engineering team always aim to reach excellence in any discipline of engineering we handle.