Newsletter for Ethylene Glycol Projects

NEWSLETTER

VOL . 1, AUG’19

Welcome to the first edition of our e-Newsletter, curated specifically to keep our various
stakeholders updated about Projects involving LSTK-1 Package for “Ethylene Recovery and
Ethylene Glycol” and LSTK-2 Package for Offsite and Utilities at IOCL Paradip Refinery,
Odisha. We will endeavor to keep all of you apprised of the latest developments,
execution milestones, events, and insights concerning the two projects.
Indian Oil Corporation Limited (IOCL) is India's flagship Maharatna national oil company
with business interests straddling the entire hydrocarbon value chain - from refining,
pipeline transportation & marketing, to exploration & production of crude oil & gas,
petrochemicals, gas marketing, alternative energy sources and globalisation of
downstream operations.
Indian Oil Corporation Limited (IOCL) awarded the responsibility of setting up Mono-
Ethylene Glycol (MEG) Plant and building Intermediate and Product Storage, Dispatch
facilities & Utility facilities at IOCL Paradip Refinery, to LTHE.
The project has its own challenges in terms of complex interfaces and tough timelines. The
1
contractual Mechanical Completion is 30 months for LSTK-1 and 24 months for LSTK-2 from
the date of LOI issuance i.e. January 30, 2019.
The LSTK1 Package comprises design, engineering, procurement, supply, fabrication, construction,
inspection, testing, pre‐commissioning, start‐up, commissioning and performance guarantee run test
of the ERU, EG units along with substation and satellite rack room. The new Petrochemical Complex at
Paradip Refinery will produce 357 KTA of Glycols (including MEG ‐ 332 KTA, DEG ‐ 24 KTA, TEG ‐1 KTA).
The LSTK2 Package comprises design, engineering, procurement, supply, fabrication, construction,
inspection, testing, pre‐commissioning, commissioning and performance guarantee run test of the
four Ethylene Storage Spheres & BOG (Boil Off Gas) Package, Product Transfer Pumps, Storage Tanks,
Tanker Loading Gantry, Offsite Pipe Rack, ETP & Flare modification, Brownfield Pipe Rack modification
and Creek Bridge, TEG Barrelling Facility, Cooling Tower for EG & ER Unit, Fire Water Booster Pump
House for EG & ER Unit, Chemical House and Buildings.

While the owner has chosen M/s Toyo Engineering India Pvt Ltd., Mumbai as the Project Management
Consultant (PMC), it has signed up M/s McDermott International Inc. and M/s Scientific Design as
Licensors for Ethylene Recovery Unit (ERU) and Ethylene Glycol Unit (EG) respectively.

The refinery site is located approximately 7 km South West of Paradip Port on the North bank of the
River Kansarbatia and straddling the River Santra approximately 2 km from the shore line. The project
site is located close to the coast line. The shore runs in the northeast – southwest direction parallel to
the prevalent sea current.
The Detailed engineering for LSTK‐1 & 2 is being carried out by L&T‐Chiyoda (LTC), a joint venture
company of L&T, which has proven to be an extremely effective enterprise in our journey of
engineering excellence. LTC is working in close collaboration with the LTHE Project Management team
to deliver key deliverables in a timely manner which in turn help us achieve project completion within
the scheduled time period.

CONTRACT SIGNING CEREMONY

 KICK OFF MEETING

GROUND BREAKING CEREMONY

“Somewhere, something incredible is waiting to

be known”
IOCL PARADIP SCOPE DEMARKATION
 IOCL MEG LSTK – 1
PACKAGE FOR
“ETHYLENE GLYCOL”
 PROJECT BRIEF-LSTK1
COMPLEXITIES IN DESIGN AND CONSTRUCTION

Monoethylene Glycol (MEG) is an organic compound offering function as versatile

intermediates. It is used as an antifreeze coolant, a gas dehydration / treating agent,
and polyester resin among other things. The feed for MEG unit is Offgas from INDMAX
recovered as polymer grade Ethylene in Ethylene Recovery Unit. Further, polymer
grade ethylene is converted into Glycol streams in the Ethylene Glycol (EG) section. It
is a complex process unit which consists of a low temperature cryogenic section as
well as a high pressure – high temperature reaction section.
This being a process driven project, timely completion of engineering is a major
challenge along with performing safety studies and findings / recommendations that
will need to be incorporated without any time and cost implication.
Various other issues like the prolonged monsoon (MEG project is going to face three
monsoons at the height of civil works and mechanical works at the construction site),
local manpower constraints, changes in law etc. are expected to add to the
complexities during project execution.

“If Vision is clear, Mission is near”

 0.00
0.10
0.20
0.30
0.40
0.50
0.60
0.70
0.80
0.90
1.00

0
100000
200000
300000
400000
500000
600000
15-Jun-19 Upto Mar'19

0.00
22-Jun-19

Jun-19
29-Jun-19
06-Jul-19 Apr'19

0.00
13-Jul-19

Jul-19
20-Jul-19
27-Jul-19

Achieved
May'19

0.00
03-Aug-19 # Tool Box Talks
10-Aug-19
17-Aug-19

# HSE Training Hours

Aug-19
Jun'19

0.00
24-Aug-19
31-Aug-19
07-Sep-19
# Personnel HSE Inducted
14-Sep-19 Jul''19

0.00
21-Sep-19
# Safe MHrs (Till 30-Jun-19)

Sep-19
28-Sep-19
05-Oct-19
Aug'19

0.00
# Sr. Management walkthrough
12-Oct-19
19-Oct-19

Oct-19
26-Oct-19
Sept'19

0.00
02-Nov-19
09-Nov-19

TRIR (Total Recordable Injury Rate)

16-Nov-19

Nov-19
23-Nov-19 Oct'19

0.00
30-Nov-19
HSE Performance Indicators

07-Dec-19
14-Dec-19 Nov'19

0.00
21-Dec-19

Dec-19
28-Dec-19
04-Jan-20
Dec'19

0.00
LEADING INDICATORS

11-Jan-20
4
321
2,97,940

1,002
369

18-Jan-20

Jan-20
25-Jan-20
01-Feb-20
08-Feb-20 0.00
0.10
0.20
0.30
0.40
0.50
0.60
0.70
0.80
0.90
1.00

15-Feb-20

Feb-20
22-Feb-20
Upto Mar'19
0.00

29-Feb-20
07-Mar-20
14-Mar-20
Near Miss

21-Mar-20
Unsafe Acts &
Conditions

Apr'19
0.00

Mar-20
Case

28-Mar-20
First Aid Case

04-Apr-20
11-Apr-20
May'19
0.00

18-Apr-20

Apr-20
Medical Treatment

25-Apr-20
02-May-20
Jun'19
0.00

09-May-20
16-May-20
Lost Time Injury

May-20
23-May-20
30-May-20 Jul''19
0.00
Fatality

06-Jun-20
13-Jun-20
INJURY RATES (TRIR & LTIFR)

20-Jun-20

Jun-20
Aug'19
0.00

27-Jun-20
04-Jul-20
0
0

0
0
0

HSE KPI TRACKER (HSE S-CURVE)

11-Jul-20
135

Sept'19
0.00

18-Jul-20

Jul-20
25-Jul-20
01-Aug-20
LTIFR (Lost Time Injury Frequency Rate)

Oct'19
0.00

08-Aug-20
15-Aug-20

Aug-20
22-Aug-20
29-Aug-20 Nov'19
0.00
SAFETY PYRAMID

05-Sep-20
Planned

12-Sep-20
19-Sep-20

Sep-20
Dec'19
0.00

26-Sep-20
 HSE HIGHLIGHTS

SAFETY BRIEFING & TOOL BOX TALK

World Environment Day Celebration Welfare - Shelter For Workmen

at Site

Area Barricading HSE Committee Meeting

ENGINEERING HIGHLIGHTS
30% MODEL REVIEW
 ENGINEERING HIGHLIGHTS
3D – MODEL (ERU)
Caustic Compressor Area
Wash Binary Refrigerant Compressor
Tower De-ethylenizer
Fuel Gas Compressor
(3.8 m I.D. X 92 Ht. m)
Main Pipe-
rack

Cold Box

3D – MODEL (EGU)
Substation (SS315N) Satellite Rack Room
(SRR822)
Main Pipe
Rack

Waste Heat
Boiler Area

Wash Tower Compressor Area

EO Reactor (6m I.D. X 97m Ht.) Reclaim Compressor
(Approx 8 m I.D. X MEG/DEG
Recycle Compressor
23 m Ht.) Tank Area
H.P. and M.P Nitrogen
Compressor
 PROCUREMENT HIGHLIGHTS
MANUFACTURING PIPE/FITTINGS & FLANGES

UG PIPE DISPATCH FROM RATNAMANI

PROCUREMENT HIGHLIGHTS
UG PIPE STACKING YARD
 PROCUREMENT HIGHLIGHTS
MFF- HAZIRA, COLUMNS SHELL ROLLING WORK

MFF- HAZIRA, REACTORS SHELL ROLLING WORK

 CONSTRUCTION HIGHLIGHTS
SITE PROJECT OFFICE WORK IN PROGRSS

BATCHING PLANT COMMISSIONED

 CONSTRUCTION HIGHLIGHTS
PROJECT STORE SET UP IN PROGRSS

CONSUMABLE STORE WORK

 CONSTRUCTION HIGHLIGHTS
CENTRAL QUALITY LAB INAUGURATION

OPENING CEREMONY DURGA POOJA

FRONT VIEW DEMONSTRATION

INSIDE VIEW
 CONSTRUCTION HIGHLIGHTS
SPOOL FABRICATION SHOP

CASTING OF 1ST PILE CAP FOUNDATION

OF ERU PIPERACK
 CONSTRUCTION HIGHLIGHTS

STONE COLUMN WORK IN PROGRSS

CONSTRUCTION HIGHLIGHTS
PILING WORK IN PROGRESS
 IOCL MEG LSTK – 2
PACKAGE FOR
“OFFSITE AND UTILITIES”
 PROJECT BRIEF-LSTK2
COMPLEXITIES IN DESIGN AND CONSTRUCTION
Complexities
 Stringent Project Schedule mandating completion of LSTK-2 Package within 25
months (24 months mechanical completion + 1 month commissioning).
 Geographically wide project area (running roughly 4 km across the refinery).
 Majority of work will have to be carried out inside a running plant (Brownfield).
 Obtaining native files from the Owner for the existing facilities.
 Adequacy check of existing facilities like ETP, Flare, Creek Bridge and Brownfield pipe
rack and modifications as required and guaranteeing the performance.
 Presence of UG facilities across the Pipe rack.
 Execution of approx. 150 Tie-Ins.
 Construction and erection of 2.9 km long pipe rack.
 Working with exotic P-91 piping material.
 Uncertain weather conditions with frequent rains, storms, possible cyclones and local
IR factors.

Uniqueness
Adequacy check, revamping and enhancement of existing facility like ETP, Creek Bridge,
Flare & Brownfield Pipe rack.
Liquefaction potential prone site due to which a unique foundation concept combining
stone column & piling has been adopted.
LSTK Package – 2 for Offsite & Utilities Project
Paradip Refinery, Odisha
 LEADING INDICATORS SAFETY PYRAMID
Fatality 0
# Safe MHrs (Till 30-Jun-19) 2,04,089
Lost Time Injury 0
# Tool Box Talks 544
Medical Treatment 0
# Personnel HSE Inducted 726 Case
First Aid Case 0
# HSE Training Hours 938
Near Miss 1
# Sr. Management walkthrough 9
HSE Performance Indicators Unsafe Acts & 180
Conditions

INJURY RATES (TRIR & LTIFR)

1.00 1.00
0.90 0.90
0.80 0.80
0.70 0.70
0.60 0.60
0.50 0.50
0.40 0.40
0.30 0.30
0.20 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.20 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.10 0.10
0.00 0.00

Upto Mar'19

Jun'19

Jul''19

Sept'19

Dec'19
May'19

Aug'19

Oct'19
Apr'19

Nov'19
Jun'19

Jul''19
Upto Mar'19

Sept'19

Oct'19
May'19

Aug'19

Dec'19
Apr'19

Nov'19

TRIR (Total Recordable Injury Rate) LTIFR (Lost Time Injury Frequency Rate)

HSE KPI TRACKER (HSE S-CURVE)

800000

Planned

700000

600000

500000

400000

300000

200000

100000
Achieved

0
20-Jul-19

21-Mar-20
29-Jun-19
06-Jul-19
13-Jul-19

27-Jul-19

05-Oct-19
12-Oct-19
19-Oct-19
26-Oct-19

04-Jul-20
11-Jul-20
18-Jul-20
25-Jul-20
07-Sep-19
14-Sep-19
21-Sep-19
28-Sep-19

04-Jan-20
11-Jan-20
18-Jan-20
25-Jan-20

07-Mar-20
14-Mar-20

28-Mar-20

05-Sep-20
12-Sep-20
19-Sep-20
26-Sep-20
15-Jun-19
22-Jun-19

01-Feb-20
08-Feb-20
15-Feb-20
22-Feb-20
29-Feb-20

11-Apr-20

06-Jun-20
13-Jun-20
20-Jun-20
27-Jun-20
07-Dec-19
14-Dec-19
21-Dec-19
28-Dec-19

04-Apr-20

18-Apr-20
25-Apr-20
02-May-20
09-May-20
16-May-20
23-May-20
30-May-20
03-Aug-19
10-Aug-19
17-Aug-19
24-Aug-19
31-Aug-19

01-Aug-20
08-Aug-20
15-Aug-20
22-Aug-20
29-Aug-20
02-Nov-19
09-Nov-19
16-Nov-19
23-Nov-19
30-Nov-19

Jun-19 Jul-19 Aug-19 Sep-19 Oct-19 Nov-19 Dec-19 Jan-20 Feb-20 Mar-20 Apr-20 May-20 Jun-20 Jul-20 Aug-20 Sep-20
 Tool Box Talks

Field HSE Highlights

Crane Inspection and Load Test

National Safety Day World Environment

Weekly Meeting with
4th March 2019 - Day 5th June 2019 – Site Safety Induction
RCM
Safety Pledge Sapling Plantation

Driver’s Training Welfare - Shelter For

HSE Committee Meeting
Workmen

World Environment Day (5th

June 2019) – Sapling Team Talk Regarding Load test Activity
Planting
 ENGINEERING HIGHLIGHTS
30% MODEL REVIEW (23rd to 25th of May 2019)
ENGINEERING HIGHLIGHTS
COOLING TOWER AREA

SPHERE AREA
 ENGINEERING HIGHLIGHTS

EG STORAGE AREA

TEG BARRELING
AREA

EG GANTRY AREA
ENGINEERING HIGHLIGHTS
HAZID STUDY
PROCUREMENT HIGHLIGHTS
PIM AT VENDOR WORKS

PETALS MANUFACTURING
 PROCUREMENT HIGHLIGHTS
MANUFACTURING- PIPES & FLANGES

PIPE DISPATCH FROM RATNAMANI

AHMEDABAD
 SITE PHOTOGRAPHS
SITE PROJECT OFFICE CIVIL WORK

SITE CONSUMABLE STORE - COMPLETED

31
 SITE PHOTOGRAPHS
UG PIPE FABRICATION ACTIVITY

LAYDOWN AREA DEVELOPMENT WORK

32
 SITE PHOTOGRAPHS
STRUCTURAL MATERIAL RECEIVED SITE

EXCAVATION WORK IN PROGRESS FOR ROAD

33
 SITE PHOTOGRAPHS
FENCING WORK IN PROGRESS

BATCHING PLANT COMMISSIONED

34
 SITE PHOTOGRAPHS
TESTING PILE CHIPPING WORK IN PROGRESS – SPHERE AREA

PILE RIG ASSEMBLED IN SPHERE AREA

35
 SITE PHOTOGRAPHS
REBAR CAGE FABRICATION WORK IN PROGRESS

WORKING STONE COLUMN WORK – COOLING TOWER AREA

36
 SITE PHOTOGRAPHS
TEST STONE COLUMN WORK – IOTL AREA

WORKING PILE WORK PROGRESS IN PR-01 AREA

37
THANK YOU