CAREER EPISODE 3

a. Introduction
CE 3.1 This career episode is based upon my engineering activity as an employee at
XXXXXXXXXXXXX Limited. In this project, I worked as a Mechanical section
head and worked on the project of the refurbishment of Unit-A21 which lasted for
1 year and 8 months.

CE 3.2

CHRONOLOGY

Project Title

Dates for the Project

Duration +

Name of the Organization

Location

My Role

(b) Background

CE 3.3 Found in 1959, XXXXXXXXXXXX Ltd known for their range of adhesives like
Fevicol, Fevikwik, M-seal ,Cyclo, Hobby Ideas, and Acron. With their corporate
office in Andheri (East), Mumbai, the manufacturing facilities are located in
Mahad (Maharashtra),Baddi (Himachal Pradesh),Vapi (Gujrat) etc. incorporates
subsidiaries in Brazil & Middle East and has started the manufacturing operations
in Egypt,Thailand, Bangladesh, and the Middle East.

CE 3.4 The overall objective of the project was to reduce the breakdowns/downtime
related to equipment's and pipeline leakages (utility & process). As the unit is a
continuous manufacturing facility so any failure leads to a loss of production. To
re-establish the process it requires 8 hours to achieve the desired purity levels and
production rate.Unit- A21 was started in late 80's and was manufacturing facility
for vinyl acetate monomer. Main input raw materials were ethylene and acetic
acid. As ethylene price increased the profit margins started becoming narrow.
Finally, in 2008 VAM production was stopped. Since the plant was not
 operational fully for a couple of years, it was difficult to maintain the plant by
investing capital in a sick plant. In 2013 IPAc (Isopropyl acetate) production
started by using part of the existing VAM plant.
CE 3.5 The responsibilities which I carried out as a Mechanical section head, during this
project included:
1. Monitoring and controlling maintenance cost.
2. Reviewing with maintenance personnel, proposing technical
improvements and job plan optimization.
3. Ensuring that the equipment is performing effectively and efficiently.
4. Organize/manage project labour and the delivery of materials, and
equipment.
5. Planning out mechanical verification and validation.
6. Establishing work measurement programs and analyzing work samples to
develop standards for labour utilization.
7. Working with process team in the modification of plants and equipment to
ensure the operating capacity of the plant.
8. Co-coordinating for repair activities in the event of serious damage to
equipment in the area of responsibility.

CE 3.6 Figure 1 gives the organizational chart of my project with my position in purple.

Limited

Section Head - Mechanical

Insulation team
Fabrication team

Technicians Technicians
 Figure 1 CE-1 Project Organizational Chart

(c) Personal Engineering Activity

CE 3.7 During the project, the major task was to control leakages in the corroded
pipelines which were mainly steam, steam condensate, nitrogen process water and
cooling water. As the plant was operational for 20 days in a month, I took
necessary approvals and planned replacement of corroded pipelines one by one.
SinceI initiated the project to replace the majority of the service lines in the plant,
it was my duty to plan the budget in phase manner for the purchase of pipeline,
fittings and spares.
a) Nitrogen line- 600 meters (Sch 40 seamless pipeline CS)

b) Process water pipeline 800 meters (ERW pipelines Class -C, CS)

c) Cooling water pipeline 600 meters (ERW pipelines Class -C, CS)

d) Flare header pipeline 120 meters (SS304, 250nb sch10)

e) Boiler feed water line- 100 meters

f) Steam condensate line 300 meters

g) Steam line- 300 meters

CE 3.8 The other problem we faced was with thedust collection system for coal handling
system was not in operation and this lead to heavy dust accumulation in the coal
handling plant. Dust, in turn, used to settle on the rotating parts like bearings and
at the bottom bed of the bucket elevators. To address this problem both, from
pollution and maintenance prospective, equipment details were studied and all
damaged parts such as solenoid valves, bags, cages were ordered and the system
was restored.

CE 3.9 Reciprocating type air compressors procured from KG Khosla were used for
pressurizing propylene and propane gas. This equipment was initially in service
 for compressing ethylene. OEM supplied packing were not able to seal the gas
and significant leakage of gas was observed. This was primarily contributing to
unsafe condition. The loss of the gas due to the leakage was another primary
concern. Existing design was a plate and ring design which did not prove effective
in long run. I approached Hoerbiger India Private limited to design packing which
would meet our requirement.

Hoerbiger India private limited proposed a cup type design over the plate and ring
design. Suitable sealing material was selected considering the compatibility to
ensure a life of 10000 hrs run.

Tungsten carbide coating was done on the piston rods to protect it from getting
corroded by the carried over acid traces in crude propylene.

CE 3.10 During this project, since there was no data available for the dust collector so it
was getting difficult to get the right bags for the coal dust collection system. To
solve this problem, I approached sales cum service team of Rieco bag filters.
They analyzed the system and came up with the right selection.

CE 3.11 During this project, I was responsible for calculating the line size flow capacity
based on the present utility load. I made sure that all the measurements were
accurate and precise.
CE 3.12 While working with the pipes I made sure that all the work was done according to
the Piping ASTM and ASME codes so that the work was as per standards.
CE 3.13 During this project,I received valuable knowledge about managing time and using
standards in execution. I always received valuable guidance from my team mates
and took support from the internet for fetching technical information. Internet
 gave me useful links of vendors who supplied bags for coal dust collection
system. This practically solved my problem in getting suitable for my system.
CE 3.14 Since the pipelines were almost 20 years old and heavily corroded, there were line
leakages and punctures every now and then. Equipment's failure though can be
addressed later on considering standby availability. But in case of leaking pipeline
online repairs were not possible every time. For a single repair production loss of
min 6 hours counted. In such a scenario I preferred to prioritize the service lines
based on severity. For example, cooling tower circulation water was an important
requirement for the process, whose failing would have caused huge losses. Most
of the piping was fabricated and erection on the pipe rack was done and only
minimum field joints were welded availing clearance. The same strategy was
followed throughout the job.
CE 3.15 I used many different software in order to carry out my responsibilities in the
project. I used AutoCAD,for modeling and planning purposes. It helped me get a
clear picture and solve all the problems that I faced during the project.
CE 3.16 I ensured safety and protection at all levels during this project. Personnel
protective equipment were a compulsion while undertaking any job. All lines
were drained and properly isolated. Work permits were availed and all necessary
requirement had to be fulfilled before a worker was allowed to enter the site area.
Hydro test of lines was carried out before erection. For working on equipment,
first lock out and tag out was carried out to make sure that it was safe to be
around. The weekly meeting was the forum to discuss the site clearance and
safety compliance requirement and it was made sure that all the safety codes were
properly adhered to.
CE 3.17 During this project, I learned and developed a lot of management skills as well.
Yes,since all projects were initiated by me so I had to closely monitor inventory,
work progress, safety, quality and make sure that the timeline was being followed.
Since it was a self-initiated project which helped me to be mature and competent
to handle projects independently.As the site team and local fabrication contractor
were involved in the project so work scheduling and monitoring was done on
daily basis. The main task was to get clearance from production department for
which weekly meetings were conducted to overcome such situations which can
hamper work.
CE 3.18 In this project, I actively participated in the meetings with the supervisors and the
team to discuss the progress of the project. Apart from the weekly meetings that
discussed the safety procedures and site clearance, I also had to inform the heads
of the progress, usually on daily basis. Since I was working for a service
department in this case so, I had to inform the production manager and the unit
head for isolation of pipelines.
CE 3.19 At the end of the project, apresentation was made on the overall project which
reflected the overall progress and activities. I prepared a monthly review
presentation which covers production and engineering achievements and
breakdowns included the refurbishment plan and also reflected the drop in
frequently occurring breakdowns and losses. I also prepared a file which
contained test certificates and hydro test reports.
CE 3.20 While working on this project I got a chance to integrate theoretical knowledge
with professional knowledge. Understanding the working principle of
reciprocating compressors helped me to understand the root cause of the gland
failures. During this project,engineering knowledge of piping helped me to
materialize the right grade of pipe considering the service requirement.
(d) Summary

CE 3.21 In this project, I developed a lot of skills that helped me improve as a team player
and helped with my personal growth as well. The project was a great success as it
eliminated the breakdowns to zero from line leakages and suppressed the leakage
of propylene gas from the glands. The equipment was running for more than 6000
hrs. and would definitely perform up to 10000 hrs. as claimed. Pipeline
replacement project was completed on time and proved beneficial because it
eliminated irregular breakdowns such as punctures and leakages. We all worked
to complete the project on time. I utilized all my engineering knowledge and skills
to accomplish the objectives and goals of the project. I proposed clear technical
solutions and operational solutions independently. I recommended modifications
within adequate safety conditions.