PAT ees ee Eee LEADER SPEAK Lam writing to you at the most exciting, challenging and critical stage of J3 project. Civil works are ‘almost complete now and the focus is on ramping- up the mechanical phase, which will culminate with pre-commissioning activities. More than 1.38 lac pairs of boots are working on-ground everyday to realize the J3 dream. For the first time in RIL's history, we have mobilized more than one lac direct workers on a single project and we are still counting the numbers. Additionally, the team has assigned 3500 workers to the township and more than 7600 contract workers to work alongside the M5 RPMG army of 4600 engineers and other stat. All contracts and contractors have been lined up, except for new and revamp projects. Performance of contractors is being regularly reviewed against signed-off execution plans to help them achieve the targets, which in turn will aid in commissioning the project on time, safely and within budget. A Self Perform Group (SPG)is being rapidly developed as a contingency pian, besides having stand-by Contractors on the panel, The infrastructure, including labor camps and roads, is. already in place Ensuring coordinated mobilization of machinery, materials and manpower with the right skil-sets requires effective contract management. Further, itinvolves ensuring productivity and meeting production targets in line with the project schedule and making quick corrections, in case of delays or gaps. Moving forward, round-the- clock work with resource optimization will help us meet deadlines. With reduced uncertainties, the key differentiator will be the generation of mechanical work fronts, efficiently coordinated logistics for material management ‘and worker movement to increase the wrench time on actual worksite. Huge quantities of scaffold / staging systems have been mobilized to support timely execution of construction activities. The Six Sigma initiative has helped in enhancing utilization of construction plant and machinery. We have encountered a few obstacles in our journey so far, but, history has taught us that winners encounter heartbreaking obstacles before triumphing, | am confident that we can make ithhappen together, proving once again that Jamnagaris the true ‘Jewel'in the crown of Reliance. ‘The price of success is high but so are the rewards, AK Garg Head—Construction Contracts, RPMG Memo DearColleagues, India's per capita polymer consumption is at an alltime high. This enables RIL to not only scale its production and meet the surging demand but also create employment ‘opportunities for the youth. Read our ‘Constituents’ section to get a feel of 43's another crucial and challenging project. As our Construction ‘Contracts Head AK Garg points out, the J3 Project team is working round the-clock with resource optimization tomeet stingentdeadiines. ‘The ‘News’ section has interesting updates on Jamnagar's heaviest single-lift equipment. Flip over to know more. And finally, the ‘J3 in pictures’ section brings you splendid progress pictures. Deepak Dattaw pO tanta News Colerastarnts LLDPE plant at J3 inear Low Density Polyethylene (LLDPE) and High Density Polyethylene (HDPE), commonly used for ‘making thin tims for applications ranging from food to hygiene to automotive sectors, have been receiving increased levels of attention. The polymers’ versatility and high tensile strength and puncture resistance make them leaders in the commodity polymer segment and are the key drivers of product demand. ‘The global growth of LLDPE and HOPE together is 5% and, their domestic demand is 6%. Both the polymers have @ bright demand outlook and RIL is setting up a world scale LLDPE and HOPE manufacturing facility at the J3 site, Jamnagar. The facility will dd nearly 560 KTA to an existing 890 KTA of LLDPE & HDPE produced at Hazira, Dahej ‘and Nagothane. “LLDPE plant is a complex technology but, well proven and established. The team has weathered the challenges in engineering and procurement and, the ‘construction is progressing ahead of the schedule rapidly. The C&P Building is the tallest technology structure in J3, has gathered momentum and is nearing civil completion. Upon casting the fith and final floor next month, it will pave way for the structural steel module erection,” shares Kiran Shinde, Project Director, C2 Complex. He further adds, “The selection of right suppliers for equipment and packages was a crucial aspect and, due diligence was carried out to the minutest detail. The team is also geared up fo execute some of the most critical lts in J3 Projects including, the ~630MT product purge bin, to be installed at a height of 85m. The deep dive is taken into construction schedule through a number of interactive sessions. Contractor's safety compliance is regularly ‘monitored through site walk downs and reviews.” Plant Statistics The Plant features the latest and most preferred UNIPOL Polyethylene technology. Licensed by M/s Univation Technologies, LLC, the plant features: plant capacity inthe industry, + Simple production process with fewer ertical and rotating ‘equipment, namely Cycle gas compressor, Vent recovery ‘compressor and Pelleting system, + Strategic flexibility of product mix that enable tailored grades or customers, + Lower operating costs, + Proven acceptance of products forall major applications including specialties and commodities, + Lower capital investment confirmed by engineering studies, competitive bids and consultant studies, and Globally proven operating performance and long- termreliabiity. ‘The LOPE plant willinclude a catalyst manufacturing faclty ‘and a pilot plant for development and production of Dry ZN catalyst, which is essential for production of the LLOPE. Bosides providing self- sufficiency in catalyst supply, the Plant will also provide Opex advantage and product competitiveness inthe global market. + Predominantly LLDPE with capability to produce HDPE on need basis + 550 KTA + Fluidized bed Reactor process + Diy and slurry ziegler-natta catalysis + Chrome catalyst +Other specialty catalyst systems + Flexibilly for packaging in 25K, Intermediate Bulk containers and Sea Bulk containers roe Producing LLDPE Raw Material Supply and Purificatio Liquid co-monomers and other raw materials from the battery limits are fed directly into their respective degassing columns(en far T that are mounted on surge tank, equipped with tempered water-cooled condenser and steam heater reboiler, The Palleting System 1B Rasin Storage Etaing |. Raw material purification 3. Fluldized Bed Reactor 3. Direct Catalyst injection Product Discharge System Rosin degassing for monomer removal Monomer recovery unit ‘Additivation Product Pelletization ‘bottom product from surge tank then passes through cooler, sulphur removal bed and dryer before it is sent to the Reaction System. Reaction System: ‘The reaction system begins when resin is produced by polymerisation ofreactants in a fluidized bed reactor at~24.6 Kglem2g pressure and ~ 80-100°C (grade specific) temperature. An extremely cool cycle of reactant gas fluidizes the reactor bed and removes the exothermic heat caused by the reaction. The product then flows intermittently {from the reactor into two pairs of Product Discharge Systems, which consist of product chamber and product blow tanks land operate in a sequentially altemating mode. Granular Resin and Reaction gas gets separated in Product Chamber. Gas is vented to the top of the Reactor and Resin flows by gravity to Product Blow Tanks, from which itis high pressure ‘conveyed to Product Purge Bin. ‘The Reaction system majorly consists ofthe folowing: + Reactor: A vertical reactor with distributor plate at bottom ‘and an expanded dome on top. + Cycle gas compressor: A package for fluidization and assisting reaction exotherms removal. This is a single ‘stage, motor driven, fixed speed compressor equipped with suction IGV. + Cycle gas cooler: A shell and tube exchanger that helps removing reaction exotherms by circulating cooled DM water (tempered water). + Tempered water cooler: Assists in the heat exchange process between tempered water and cooling water. Product Purge Bin, Compounding & Pelletizing: ‘At this stage, the resin from Reactor (Product Discharge System) enters the product purge bin (PPB) through four transfertines, Resin Degassing: Resin degassing removes hydrocarbons from resins for recoverylrecycie and deactivates residual catalyst / alkyls before sending itfor pelltization PPB consists of two sections: the upper section for purging of hydrocarbons and the lower section for hydrolysing,Vent Recovery System: The vent recovery system improves overall monomer ‘efficiency by compressing and condensing comonomers (Butene-1 or Hexene-1) and Induced Condensing Agent (ICA) from the PPB purge stream. The system with its distinct design improves overall monomer efficiency by recovering Butene or Hexene comonomer together with ICA from Product Purge Bin. Resin additive handling: Various additives are added to granular resin before palletisation to preserve and impart properties required for downstream processing and final use. atier Blending i oo q Extruderand pelletizing: ‘The extruder and pelletizing section converts granular resin and additive mixture to pellet shape. This process provides the required flexibility for product packaging. ‘Seodbed Storage: ‘Seedbeds help in starting the reaction after every shut down. ‘Seedbed storage facilities include moving granular resin from resin surge/vent hopper, storage bin, recirculation in storage bin and charging the reactor. The process uses Nitrogen (N2)as a conveying agent. LLDPE Feed Stock & ProductSlate J3-ROGC- Refinery off Gas Cracker will provide 550 KTA Ethylene, the sole feed stock to LLOPE unit, The plant will produce fast moving and special product grades besides various conventional ones Representing Reliance ‘The project management team is led by Kiran Shinde Constituent Units wo resto Cd be W ocaarti rd (Project Director) and comprises of Tridib Raj Borthakur {Senior Project Manager), Gopinath Deshpande (Project, Manager), Vivek Bhatia and Satish Kumar (Project Engineers). The task force includes discipline engineers ‘Sumathi Mani (Process), Sandeep Darvesh (Civil), Bidyut Barua and Nilesh Dandekar (Piping), Mahesh Pawar (Mechanical), Rajesh Thakur (Electrical), Kishorkumar Lad ‘and Jibin Jacob (Instrumentation.) The project controls team is led by Sandeep Grover (Complex Project Controls Manager) and supported by Haricharan Lakkavathri (Project Controls Lead). Project Procurement Manager Sandeep Karkare, leads the procurement team on the project. ‘The team has Suketu M Vakil as Technology Sponsor and ‘AniruddhaD Deshpande as Technology Manager. Operations manager is KM Udupa ‘The Construction team includes Complex Construction Manager VL Perumallu, Construction Area Manager Malay Verma, Construction Manager Senthilnathan Swamy and Project Controls Lead Pradeep Jagnani, supported by discipline leads. Maintenance team comprises of Sunil Chowdhury (Mechanical), K Karthikeyan (Electrical), Jaideep Bhandari (Instrumentation), Amish Shah represents the Business Team. Licensor & Detailed Engineering The Process Design Package was developed at Univation’s Houston Office, Texas, USA. Jacobs carried out the Basic Engineering ofthe project from its Portsmouth office and took forward Licensor’s PDP package into Basic Engineering Design Package. Aker Power Gas carried out the Detail Engineering of the project, consisting of development of Jacob's BED package, into full ‘Approved for Construction’ design package. Detailed Engineering Completed as of ‘April2015. Value Engineering The team implemented various initiatives as part of ValueEngineering, such as: + Recovery of valuable monomers from waste stream by using membrane separation technology, + Optimization of motors rating selection for Pneumatic Conveying Package, resulting in lower Capex and Opex, Conversion of cerlain structures and pipe racks from steel toconcrete and optimization of piperack elevations, + Optimisation of number of pits in the underground (UIG) network to reduce excavation quantity, and Maximisation of the use of repeat plant concept for faster delivery of engineering and pre- procurementdeliverabies. Critical Success Factors ‘There are several factors that are contribute to the success of the project. Some of these are’ + Maintaining a high level of HSE awareness among all team members, + Following One Team Approach to maintain transparency and close co-operation between RIL, Jacobs and Aker Power Gas during the engineering phase, + Effective interface co-ordination with Vendors and OSBL, + Effective quality management with a right-first-time approach, and + Implementing several lessons learned from previous relevant projects and during the Engineering phase. Key Equipmentand Highlights ‘There are 226 Tagged Mechanical Equipment and Packages €on J3-LLDPE Project, of which 27 fall under the Super Over Dimensional Consignment category. ‘Compounding and Pelletizing(C&P) Building is going to be the tallest technological structure in J3 with an elevation of up to 102m. The Building will be built with RCC of up to 48m and thereafter 54m of Structural Stee! Modules. ‘The Stee! Structure will house the world’s largest Product Purge Bin, weighing 630 MT. the Purge Bin will be located at the top ofthe structure at aheight of 85m. ‘The Structure is designed to be lifted as modules, some of them weighing more than 400 MT. ww Constituents News pew ota ry ‘A massive crane of more than 3000 Tonnes is being ‘mobilised forthe erection of modules and Product Purge Bin. ‘The LLDPE - Reactor is the heaviest equipment in LLDPE, weighing 650 MT. C&P building also houses one of the largest Extruder Package and has the capacity of pelletizing 4100tonnesihr. Project Schedule Setting a challenging target for itself, the team aims to commission the plant along with upstream ROGC plant. The team has taken several initiatives to support aggressive project completion, such as: + Timely availabilty of FC drawings and materials, + Saturation of construction manpower by deploying multiple contractors, + Extended shifis for selected activities, + Outsourcing of structural steel, and + Active participation by Original Equipment Manufacturers during construction for better planning, quality and faster execution. Procurement LLDPE plant contributes to 2 Super Heavy Lift in C2- Complex - Reactor and Product Purge Bin. All major equipment including static, rotary and packages are ordered considering vendor experience and worldwide sourcing. Of the 225 equipment and packages, 90% have been dispatched and majority are already available at sit. Balance Equipment ate being aggressively expedited to ensure schedule targets are met. Equipment Quality Surveillance has been a major focus area of J3-Program. Reliance, Detailed Engineering Contractor ‘and reputed third party inspection agencies have been relentlessly pursuing with vendors to ensure that the equipment supplied meets the required technical specifications and standards. Construction The LLDPE Engineering, Procurement and Construction teams are working in coordination to ensure seamlessprogress of construction activities, “Regular, effective and clear communication within group has enabled the LLDPE construction team to develop a sound understanding of their roles and responsibilities besides assisting them in comprehending the major challenges ahead,” shares Malay Verma, Area Construction Manager. He further adds, “Safe and productive operation of construction in LLDPE is distinctly evident from safety performance indicators, such as Zero Fatality and less than 1% Total Recordable cases against completion of 3 million-MH and 38 % Construction Progress. The team takes great pride in these ratings and strives diligently to ensure that there is ever a let-down in safety, quality or performance in their daily duties. With a strengthened labour force of nearly 1,200, the construction activities in LLDPE have picked pace. Even as the construction team is putting all efforts for speedy completion of civil and UG piping works, they have also ‘commenced structural steel and AG piping works. While there stil lies a colossal task of completing C&P building, the construction team is in full swing to meet the aggressive schedule, Another challenge ties in mobilizing the required and experienced resources for the next six to eight months and installing critical core plant equipment and piping works. ou A) eee Constituent UnitsNEWS J3 team installs Jamnagar’s heaviest column The J3 team has installed Jamnagar’s heaviest single-lift colurnn - the Sulphur Methanol wash column ~ in the Acid Gas Recovery Unit of Gasification Complex. This Super Over Dimensional Consignment (SODC) measuring 91-meter in length and 6,3-meter in diameter with a fabricated weight of 4464MT was lifted using a3200MT Sarens crane. However, maneuvering the crane in a limited space was a challenge for the team as there were multiple construction activities in progress within close proximity. Subsequently, the team worked out an alternative by dressing up the SODC con ground before erection, This minimized activities, such as insulation and platform erection at height and ensured safety of workers, The SODC also marks a significant milestone for completion of the Gasification complex as important work fronts have been released for construction, id Erne ie ie aol) LO)Project in pictures as on July 31, 2015Refrigération - Piperack Meise— am of a ee: es ihe 2rd tne