Commissioning of Seal Gas Heater System

This assignment focuses on the commissioning of a seal gas heater system. It outlines the process of checking both analog and digital signals from DCS, coordinating with various departments for effective communication, and ensuring safety through mandatory trainings and toolbox talks. The document also addresses identified issues related to RCD calibration, overloading, and missing surge suppressors. It emphasizes the importance of daily progress reports, collaboration with vendors and department heads, and innovative solutions implemented during commissioning.

Competency Demonstration Report
Career Episode 3

CE 3.1 Project Information
Name of the project: Refinery off Gas Cracker commissioning.
Location of the project: Jamnagar, Gujarat, India.
Project Duration: JAN2017 to MARCH2017
Organization: Reliance Industries Ltd.
Role and Designation during the time: Electrical Engineer
CE 3.2 Project Background
CE 3.2.1 Characteristics of the project
Reliance Jamnagar Project, known as J3, is designed to increase production capacity of
ethylene and other petroleum products at the existing refining complex. This project is built on
the grass roots of existing refineries Jamnagar Export Refinery (JERP) and Domestic Tariff Area
refinery (DTA).These refineries has capacity of treating more than one million barrels of oil per
day. The third phase of ongoing development project at the site J3 includes gasification plants,
ethylene cracker complex and par xylene plant. In ROGC, turbo expander compressors were
installed for the refrigeration purposes and low pressure exhaust was again used in overall
process .To enhance the overall process efficiency, Thyristor based controlled Electrical Heaters
were installed along with Turbo expander compressors and second stage reactor. After successful
commissioning of Main Substation by me and on the basis of my work experience in previous
organisations and my diverse electrical skills, electrical heater project work was also allotted to
me by higher officials and deadline of 3 months for the project completion was declared.

CE 3.2.2 Objectives developed for the project
The main objectives identified for the development of the project are as follows:
 To regularly visit sites
 To install the control panels
 To lay the power cables, glanding and termination
 To calibrate the heat controllers
 To commission the thyristor modules
 To implement functional checking of the control panels
 To automate the checking of control panels
 To carry out system modifications as per the process requirements.
 To inspect based on quality
CE 3.2.3 My area of work
I conducted regular site visits for visual inspection of installed equipment and
commissioning activities. I attended town hall meetings with higher management to get
knowledge regarding project scope and safety guidelines. I adhered to the safety compliance and
commissioning standards during project execution. I selected the power cable by conducting
voltage drop calculations for a particular distance between source and heaters. I selected the man
power based on the special skills and carry out job specific trainings for every individual. I
carried out testing of heaters and calculated the test results for generation of records. I conducted
status update meetings with technicians, sub-contractors, vendors to understand their
requirements and problems.

Maintenance head
Electrical Head
Project Instructor
Senior Manager
CE 3.2.4 Project Group
Figure 1: People involved in the project
CE 3.2.5 My responsibilities throughout the project
I have the duty for implementation of functional checking of heater control panels by
using simulator from DCS and conducted inter-departmental meetings to ensure effective
communication and smooth co-ordination with other department’s team members. My
responsibility for the commencement of the project was to find out the design related issues and
rectify them with the use of the technical knowledge and expertise. I supervised and inspected all
commissioning related activities and carried out system related modifications for ensuring the
reliability of the equipment installed in the workplace.

CE 3.3 Distinctive Activity
CE 3.3.1 Comprehending the Theory of the project
I collected information regarding identification of thyristor units ,electrical shock
hazards associated with Solid State Relay(SSR),system’s electromagnet compatibility, radio
frequency energy emissions and its interferences with nearby electronic equipment. I carried out
visual inspection of heater control panels to check the lamps, gland plates, fixing details, tag
number verifications by referring to general arrangement documents and label diagrams. I found
some mismatches in short circuit current rating of Thyristors and fuses in seal gas heater module.
It was not acceptable, as it could invalidate the system warranty and affect the system reliability
by costing any damage to SCR .On the behalf of my short circuit current rating analysis; I made
decision to replace the over-rated power fuses with suitable range fuses. Then I checked and
verified the compliance to statutory requirements (e.g. CEA and IEC regulations etc), both
heaters were designed in accordance with flameproof Ex d and Ex e (increased safety) standards
and were suitable for installation in refinery hazardous area ZONE1 classification. I observed
some deviations from these standards in some control cables glands, which were not flame proof
and I directed the contractor for issue solving without any particular delay.
I used voltage drop calculations by considering temperature corrections, length for power
cables and short circuit current withstand capability of power cables. Then I prepared the list of
cables with number of runs to be layed from source to the system and hand over to the jointers.
Cable laying and termination work was started and completed, and in the meantime, I ensured
effective supervision of the task to eliminate work issues by suggesting experience based

solutions to the workforce. Once SSR checking work was completed, I proceeded towards
testing of heaters and heater control panels. I carried out inspection of testing equipment and
checked the calibration reports of such devices before starting testing activities. I developed
testing and functional checking procedures for effective implementation of testing activities.
Then, I conducted full load test, harmonic test, element assembly resistance, and insulation
resistance (cold), and high voltage flash test on heaters and calculated the test results by
employing some simple mathematical calculation by adhering to the IEC stipulations.
CE 3.3.2 Engineering Knowledge and Skills applied in the project
I carried out voltage drop calculations with the consideration of the length of the power
cables, short circuit currents and the temperature corrections. I carried out thermostat based relay
trip settings calculations and set the thermostats accordingly .By using PACT ware configuration
software; I configured temperature controllers by scaling the current output, programming
high/low alarms as per operational requirements and selected the particular measured values to
be displayed on LC display. Then I used calibrated IR tester and multi meter for power cables
insulation resistance and continuity checking. I assessed these measuring tools to reduce the risk
of misreading due to scaling, ranging or other errors.
CE 3.3.3 Accomplishment and task performed
Once over temperature devices checking completed, I moved on to the next step that was
interface checking with DCS system. First of all I conducted inter-departmental meeting to
discuss the process department requirements and their interfacing related issues. Then I
constructed discussion oriented system nomenclature and shared with instrumentation
department for automation checking. I assisted, interacted and supported other departments to
ensure safe completion of commissioning activities. In interface functional testing, I checked

both analog and digital signals from DCS by coordinating with both process and instrumentation
departments by using walkie- talkie sets for effective communication. As I was accountable for
the safety of commissioning workforce, I attended all mandatory safety trainings in Learning
Centre and carried out tool box talks for sub-contractors and technicians. Then I organized
training sessions for team members for prevention and protection from gas leakage,
electrocution, fire etc.
CE 3.3.4 Identified issues and their solutions
CE 3.3.4.1 Issues
The fault and safety of the system are the main issues for the development of the project.
I faced problem during the calibration of the residual current device (RCD) for limiting the
magnitude and duration of the earth fault currents. The test results was required to be aligned
with the project for increasing the efficiency and safety of the users. Overloading can cause
permanent damage to the system and thus it should be avoided and act as a problem in the
project.
CE 3.3.4.2 Solution
I carried out daily progress reports and circulated to the relevant departments for effective
communication. I constructed power point presentations by adding pictures of design issues,
work flow charts, technical matter, and new ideas to display in the town hall meetings. I also
discussed my work issues with the department heads and tried to solve such issues on the basis
of their valuable suggestions. My active participation in these meetings helped me to gain
knowledge to effectively mobilize and made better utilization of commissioning manpower.

CE 3.3.5 Plan to produce creative and innovative work
In seal gas heater control panel, I observed that low voltage surge suppressor was not
installed in the control panel which was crucial for protection of equipment from both internal
and external overvoltage spikes. It was also not mentioned in the wiring schematic, so it was a
design related issue. I discussed the issue with company vendor in a brief meeting and suggested
him for installation of surge suppressor of appropriate rating. I also communicated all such issues
found during commissioning activities to my senior manager. Calibration of multi-function meter
(MF)installed in heater power distribution board was still pending; I carried out electrical fault
setting calculations such as over current, short circuit, earth fault, over voltage, under voltage etc
by developing some simple calculation techniques from complex mathematical derivations, and
also by adhering to IEC stipulations.
CE 3.3.6 Collaborative work
I witnessed the functional check for the temperature panels in remote and manual modes
and changed the set points of the temperature. I checked the heater panels by communicating
with the process department and found that within 4 hours of full load trial, seal gas heater
tripped at DEVICE OVER TEMP fault. I thoroughly analyzed the issue and observed dust
coating on the surface of heat sink and due to this heat dissipation was not proper. After cleaning
the heat sink, I also applied thermal transfer grease paste at the interface between drive’s
processor and heat sink and turned on the heater panel supply. I observed the SSR for next 4
hours during full load condition and device temperature was normal in the meantime.

CE 3.4 Project review
CE 3.4.1 Project overview
The project is important for me because it was a challenging project and critical
controllers should be used for the management of the sensors installed in the work site. For the
configuration of the sensor more knowledge was gained by me and this helped me to attain new
height in future. It helped me to develop the critical thinking and the resources that should be
used for troubleshooting the device are used for the development of the project.
CE 3.4.2 My contribution to work
In this project, I utilized my restricted time and worked hard to meet deadlines. My
seniors were satisfied with my work and I was appreciated for my hard work, capabilities to
handle any project individually and my dedication towards work.