"Field Operator (Process) " in Thermal Cracking Unit
Reliance Industries Limited
Total years of experience :6 years, 3 Months
1. Reliance Industries Limited- Jamnagar
Presently, I'm working with Reliance Industries Limited, at Jamnagar as
"Field Operator (Process) " in Thermal Cracking Unit.
Duration: June 2007 to till date
Plant Area: Heater, Fractionator, Gas plant & coke drum area
Company's Profile: Reliance Jamnagar manufacturing complex is the first fully integrated manufacturing complex in the world to house of petroleum refinery complex. The refinery having processing capacity of 650, 000BPSD of Crude is the world's largest grass-root refinery. Reliance processed wide range of different kind of crude. Crude complex of the Refinery has two identical trains.
Key Work Area: Thermal Cracking Unit (Coker Plant): ● Presently I'm working with world largest Thermal Cracking Unit, first unit in the world having one fractionators for 8 coke drums. This is designed by Foster Wheeler, USA. Designed to process 122 KBPSD VDU bottom. Right now processing 165 KBPSD vacuum residues. Plant also designed to process 3000 BPSD refinery slop and 1810 BPSD sludge .unit produces higher valuable products like FUEL GAS, LPG, NAPTHA, KEROSENE and GAS OIL.
● Fractionation Section: A distillation column where cracked vapour is separated and withdrawn as different product i.e. Kerosene, Light and heavy gas oil. Overhead vapour sent to gas section of unit. Column having 37.4m height, 8.8m diameter, 22 Nos. valve trays and 5 Nos. sieve trays along with 3 Nos. draw off pans.
● I handled Pump house area (Product & P/A loops), Heat Exchanger, Double volute-two stage Charge pump, Sun dyne pump, Steam turbine, Steam Generator, Fin fan coolers.
.● Cracking Section: Fractionator bottom is heated up to cracking temperature in a fired heater. The cracking reaction takes place in the coke drum. Heater having box type, twin cell and four passes, consisting of a radiant and convection. Having 72 Nos. burners, Induced draft and forced draft fans, Air pre-heaters, Soot blowers and Burner management system (BMS) panel.
● I well known of Heater start-up and shut-down, Heater pigging, ESD and Interlocks.
● Coke drum Section: There are 8 coke drums with 37 meter height and 8.84 meter dia in which cracking process occurred.
● I working with largest coke drum, ultra low recycle (5%) technology from FOSTER WHEELER, USA to minimize coke & maximize distillates.
● I familiar with coke drum related all activities like pressure test, vapour heating, switch-over, steam quenching, water quenching, heading-deheading and coke cutting ect.in 14 hrs. Cycle.
● Gas Plant (LPG recovery Section): Fractionator overhead vapour passes through condensers, liquid and vapour separates in separator drums. The vapour enters two stage 135 t/h & 50 t/h capacities Gas compressor, one is steam turbine and another is motor driven. Also Absorber, Stripper, Debutanizer, Naphtha splitter & Amine Absorber for gas recovery.
● Flare gas recovery Section: To Recover Blodown vent gases to LLP flare during steam and water quenching in coke drum we have a FGRS system. Reduced flaring from 43.7 TPD to 2 TPD by FGRS and save 15.6 Crores Rs/annum.
I hold the detailed Operational experience:- ● Gas Concentration unit for LPG Recovery and Naphtha separation.
● Fractionator Area (Pump house-Product and P/A Loops)
● Heater Area. Start-up, shut-down and pigging.
● Coke drum related all activities for 14 hrs cycle.
● Fuel gas recovery system (FGRS)
● Flare KOD, Steam turbines, Steam generator and Fin fan Area.
● successfully decontaminated Heat Ex., Hot pump, Product Loop with life guard chem.
● handled all type of emergencies like power failure, Instrument air failure, Cooling- water failure, Steam failure and Fire in the unit.
● Chemical Handling like MAPS, DORF - 410 C, Polyflow, TSP, Corrosion Inhibiter.
● Presently I have done major shutdown & start up of all Coker plant in Nov.2010.
My Responsibility Includes:-
● To supervise shift schedule and breakdown jobs with minimum downtime.
● Ensuring strict compliance with safety procedure and work with permit procedure.
● to take safe precaution for plant shutdown & start-up and during emergency.
● Continuous monitoring of throughput and all related parameters in the field.
● To handover equipment with proper isolations & decontamination during shutdown.
● monitoring the smooth and safe operation of rotating equipments like pumps, compressor, steam turbine, fin-fan coolers and ID/FD fans of heaters.
● ensuring all standby pumps are always in healthy and warm-up condition.
● Sample testing of weathering / lead acetate test for LPG and sampling of various products for laboratory testing.
● Check lube oil / seal system and oil level in reservoir in wet gas compressor & pump.
● Check firebox, burner flame pattern, air flow, steam /bfw flow, pre. & temp. in heater.
● making of punch point list and rectification of the points in co-ordination with Maint.
Special Technical Knowledge: -
● PFD, P&ID, MSDS of relevant chemicals, SOP of equipment handling.
● Plant erection, pre-commissioning and commissioning.
● Start-up and Shut-down related all activities.
● Heater start-up, shut-down, pigging of heater coils and Burner Management system (BMS), Switch over of coke drums every 4 hours.
● Exchanger's pre-cleaning, degreasing, acid cleaning and passivation.
● Hydro-test of loop and exchangers. Steam blowing of steam header and branches.
● Pneumatic test of flare header, instrument air, plant air and breathing air line.
● Pump C/O, positive isolation, safe draining, hand over to MM for seal replacement.
Safety and Environment Knowledge:-
● Familiar with all fire-fighting equipments, deluge system and fire water net work.
● Fire, smoke, gas detection DGT, DGH, DFX, DGC, DGX, DSO, DMC
● Familiar with BSC Check-list (British safety Council), LADR and regularly updating self-safety audit check-list as per annual planning.
● Put innovative efforts for ISO 9001 (2000), ISO 14000 for documentary preparation and concerned field related jobs. ISO certified by LRQA.
B.Sc. (chemistry) from Saurashtra University- Rajkot.
D.C.A. (Diploma in Computer Application) from Private computer class. B.E. Chemical Running from Indian Institute of Chemical Engineers- Kolkata