PPMAI speak Jan / Feb. 2008 1 Speak Jan-Feb.08.pdf · PPMAI speak Jan / Feb. 2008 3 ... Techincal Precision Equipments Project Director Head International Business Coordination (Chennai)

11111PPMAI speak Jan / Feb. 2008

22222 PPMAI speak Jan/ Feb. 200822222 PPMAI speak Jan/ Feb. 2008


The 43rd Annual General Meeting of theProcess Plant Machinery Association ofIndia was held on 28th September 2007 atHotel Rang Sharda, Mumbai.The Chairman, Mr. M V Kotwal calledthe meeting to order since there wasadequate quorum available. He extendeda warm welcome to the Chief Guest Mr.Prasad Chandran Chairman & ManagingDirector of BASF Limited. He alsowelcomed the guest of honors ProfessorGaitonde and Dr Malik from IIT. TheChairman also extended warm welcometo all the members.PPMAI as usual felicitated membercompanies for their outstandingperformance in the year 2006 - 07.

“M/s Thermax Limited - was awarded“Star Performer Excellence Award for2004-05” by Engineering ExportPromotion Council (EEPC). Theyreceived shield for “Star Performer” inthe product group of machinery(Electrical) & Mechanical Appliances inrecognition of their outstandingcontribution to engineering exports. Mr.Shishir Joshipura the Chairman elect ofPPMAI accepted the same on behalf ofThermax Ltd. at the hands of Mr. M VKotwal, outgoing Chairman PPMAI.

“M/s. Aker Kvaerner Powergas IndiaPvt. Ltd. - had received a “GreentechSafety Award 2006 from “GreentechFoundation”. They have been declaredwinner of silver award in service sector foroutstanding achievement in safetymanagement. Mr C M VenkateshwaranDy. Chairman PPMAI, accepted theaward on behalf of Aker Kvaerner,received the award on behalf of theircompany from the Chief Guest Mr.Prasad Chandran, CMD, BASF India Ltd.

As a gesture of appreciation to theoutstanding support and contributionrendered by member/s to the Associationin the past year, PPMAI felicitated Mr.Kevin Shah Mg. Director of KevinEnteprises a Star export house of repute,with the Chairman’s Special Award. “Mr.Kevin, a young entrepreneur, has beenDirector of PPMAI for the past few yearshad represented PPMAI at various forumsincluding CII Committee of CapitalGoods. His out of box thinking hasalways brought new ideas to the tablewhich has been appreciated in theindustry as well as in the Government”

A REPORT43rd AGM & 1st Board Meeting 2007-2008

said Mr. Kiran Kakatkar CEO PPMAI.

Mr. Kevin Shah in his response, thankedthe Chairman for conferring the Award onhim. He recalled having joined PPMAIabout seven years back and was electedto the Board within one year of hisjoining. Many small and mediumindustries when invited to join PPMAIasked whether that would get them moreorders. He said that there was certainlybetter networking due to PPMAImembership. However, more importantlymembers got various other opportunitiesto expose themselves to industry at largeand learn from the process. He madespecial mention of the opportunities hegot as a member of PPMAI Board,including giving inaugural lecture toyoung students at the Institute ofForeign Trade. He recommended thatSMEs join PPMAI in a big way to extendtheir horizon.

The outgoing Chairman, Mr. M V Kotwalin his address expressed gratitude to theboard members for the excellent supportrendered by them during his tenure asChairman. He however felt that manythings needed to be done, could be done,and there is huge potential as well. Hesaid “If we had to only organize thingsand that’s why we attempted and may bethe next person who comes in willdefinitely give a big thrust to it wouldbring formation of cluster were he canbuild groups of people, groups ofcompanies led by the medium or biggercompanies but really the strength willcome out of the number of smallsupporting companies and those clusterscan really work wonders and those are theones which will make us reallycompetitive even if the Chinesecompetition comes in”. He expressedconfidence that his successor Mr. ShishirJoshipura who is always bubbling withenergy and new ideas will give newdimension to the PPMAI activities. Headded that PPMAI is strong with lots ofpotential would be stronger under thenew leadership and assured his whole-hearted support to the new team.

1st Board Meeting 2007-2008Co-option of DirectorsMr. Kotwal invited members present asSpecial Invitees to the 1st Board Meetingand called the meeting to order. Heannounced that the first item on Agenda

was cooption of Directors for the year2007-2008. He proposed that the eightnominees may be co-opted to the Board.The proposal was accepted unanimously.(The list of Directors is given elsewhere inthe bulletin).

Election of ChairmanAs per tradition, the outgoing Chairman,Mr. Kotwal proposed the name of Mr.Shishir Joshipura, Executive VicePresident and Member ExecutiveCouncil, Thermax Limited, Pune beelected the Chairman of the Board ofPPMAI for the year 2007-2008. Theproposal was unanimously accepted by athunderous applause. He then requestedMr. Shishir Joshipura to take charge ofthe further proceedings.

Election of Dy. ChairmenChairman Mr. Shishir Joshipura then tookthe next item on the Agenda of electionof two Dy. Chairmen. He said“conventionally it is the privilege of theincoming Chairman to propose the namesfor the post. I propose Mr. C.M.Venkateshwaran, General ManagerInspection & Expediting, Aker KvaernerPowergas India Private Limited and Mr.R.Y. Kulkarni, Associate Director,Finance & Accounts, Toyo EngineeringIndia Limited to these posts”. Theproposal was accepted unanimously.

The Chairman Mr. Joshipura then invitedthe Chief Guest, Mr. Prasad Chandran,Managing Director, BASF to share histhoughts with the gathering.

Speech of Chief GuestMr. Prasad Chandran in his very specialpresentation on “Values create Values”upheld the significance and tradition ofvalues in the Indian culture and theirindelible impact on the business scenarioas well. He emphasized that “while it istruly essential to imbibe good values forsuccess one should not hesitate to do thegood and right things as his or herconscience permitted and not worry ifthings around were not so good.”

Yet another novel idea was that ofinvolving academicians’ interaction withindustry stalwarts and thus were the twoGuests of Honour Dr. Gaitonde and Dr.Malik from the IIT, Mumbai who addedglamour to the function. Former,Professor of Mechanical Engineering, IIT,

44444 PPMAI speak Jan/ Feb. 2008

Bombay, Dr. Gaitonde enlightened theaudience on “Academia & Industryrelationship with specific reference toSME’s”. Dr. Gaitonde assured theindustry that there were many areaswhere industry and educationalinstitutions like IIT’s can be partners formutual benefits. He elaborated on thetraining procedure at IIT. “I would alsolike to mention that we have recentlystarted a scheme for incubation andentrepreneurship, because for somereason the entrepreneurship bug hasbitten many of our students and faculty.We have a unit called Society forInnovation and Entrepreneurship (SINE).A few of IIT - faculty members andstudents, and a few people from outsidesuch as engineers, technocrats, fromsmall and medium industries cometogether on a new idea in some sort of

detached business environment;detached not from the real world butdetached from the normal academic trackof IIT, Mumbai. We provide themsupport so that they don’t have to worryabout overheads. They can work oninnovation and entrepreneurship andcome out with new products.

Dr. R. K. Malik, Professor of ChemicalEngineering and Dean Planning, IIT,Mumbai, shared his views on EmergingTechnologies with reference toSeparation, Simulation etc. Bothpresentations were applauded andfollowed by an effective interactivesession with overwhelming participation.He stated the similarity betweendesigning of Energy Efficient Distillationcolumns to that of Heat exchangernetworks. He further explained the

concept of Pinch Technology that haslately entered into the area of resourcemanagement, site integration, and totalplant site integration. In conclusion, heleft the audience to think on Energy,Emergy and Exergy. He also offered toassist the industry on related issueswhenever approached.

The function concluded with a HeartyVote of Thanks by Dy. Chairman C.M.Venkateshwaran and the guests weretreated to a delicious dinner thereaftersponsored by M/s. Larsen & ToubroLtd., Powai, Mumbai.

(This is not purported to be record of43rd AGM & 1st Board Meeting)

BOARD OF DIRECTORS FOR 2007-08Mr. Shishir Joshipura Mr. C.M. Venkateshwaran Mr. R.Y. KulkarniChairman Dy.Chairman Dy.Chairman(Executive Vice President & Member (General Manager - Inspection & Expediting, (Associate Director - Finance & Accounts Executive Council Thermax Ltd., Pune) Aker Kvaerner Powergas India Pvt.Ltd., Mumbai) Toyo Engineering India Ltd., Mumbai)

Mr. Anil Rairikar Mr. Shiv Shukla Mr. Suhas NayanManaging Director Chief Executive Officer Executive Director - ProcurementTUV India Pvt. Ltd., Mumbai MECS Enterprises Pvt Ltd., Mumbai Jacobs Engineering (I)Pvt Ltd., Mumbai

Mr. K. M. Panthaki Mr. Ajay Dubey Mr. Kishore MehtaManaging Director Director - Marketing Chairman & Managing DirectorBakshi Chempharma D.D. Enterprises, Pune Indus Engineering Company, MumbaiEquipments Pvt Ltd., Mumbai.

Mr. K. Periasamy Mr. Vijay Rajpurohit Mr. P J BhounsuleDirector, Techincal Precision Equipments Project Director Head International Business Coordination(Chennai) Pvt. Ltd., Chennai Chemical Process Eqpt. Pvt . Ltd., Mumbai and M&A Larsen & Toubro Ltd., Mumbai

Mr. Y. Dharmadhikari Mr. Sadanand Hegde Mr. M. P. DhanukaVice President Chairman & Managing Director, Executive Director -MktgIndian Register of Shipping, Mumbai Filtron Engineers Limited, Pune GEE LIMITED, Mumbai

Mr. S.S. Mewawala Mr. P.K. Saxena Mr. Kevin M. ShahManaging Director Director & CEO Managing DirectorExpo Gas Containers Ltd, Mumbai Blast Carboblocks Pvt Ltd, Mumbai Kevin Enterprises Pvt. Ltd., Mumbai

Mr. N. M. Joshi Mr. Uday R Honavar Mr. Kiran B. KakatkarChairman & Managing Director Executive Director Chief Executive OfficerBakubhai Ambalal, Mumbai Honavar Electrodes Ltd, Mumbai

Mr. V.P. Ramachandran,Secretary

The Chairman & Board of Directors of Process Plant and Machinery Association of India (PPMAI) take great pleasure in informingthat the registration of their new office premises at Loha Bhavan, 91 P.D’Mello Road, Masjid East, Mumbai 400 009 has beencompleted on 29th January 2008 with the full support and assistance of Mr. Kishore Mehta, Chairman, Indus Projects Limited andDirector, PPMAI.

NEWS


43rd Annual General Meeting Photos

(L to R) C. M. Venkateshwaran, Vijay Rajpurohit,Dy. Chairman, M.V. Kotwal Chairman, Kiran Kakatkar,CEO

and V.P. Ramachandran, Secretary

Mr. Shishir Joshipura, newly elect chairman receiving amemento from Mr. M.V. Kotwal as Mr. R. Y. Kulkarni,

Dy Chairman PPMAI looks on.

Mr. Shishir Joshipura Chairman, felicitatingthe Chief Guest, Mr, Prasad Chandran.

Dr. Gaitonde, Guest of Honour from IIT,Mumbai addressing the audience

Dr. Malik, Guest of Honour from IIT Mumbaiaddressing the audience



Steel is strong, says the catchy televisioncommercial of the country’s largest steelproducer, which explains why it is thepreferred material of construction cuttingacross several product categories andindustry segments.Even in the corrosive world of chemicalprocessing, it is steel that is surprisinglythe dominant material of construction,mainly because of its robustness. In thepetrochemical and petroleum refiningsectors, where the plants are huge, asmuch as 80% of the capital goods aremade out of the humble carbon steel.Steel is inexpensive, readily available andeasy to fabricate, but process engineerswho think they can have a sound sleepafter specifying 3mm corrosion allowancecan be in for a rude shock.

Stress Corrosion CrackingThe corrosion allowance is a protectionagainst general corrosion, which occursuniformly and predictably and is thus easyto monitor and assess. Localisedcorrosion is however extremely dangerousbecause it leads to catastrophic failurewithout any warning. One of theparticularly insidious forms of localisedcorrosion is stress corrosion cracking(SCC). Equipment which has given yearsof satisfactory service can fail suddenlydue to SCC with as little as a few hours ofexposure to a particular environment.Nearly every alloy is susceptible to SCCunder a specific set of conditions, whichinclude concentration, temperature andlevel of stress. The environments thatcause SCC in various alloys are welldocumented in the publicly availablebody of literature. Some commonenvironments known to promote SCC incarbon steel are anhydrous ammonia,aqueous amines, aqueous carbonates,aqueous hydroxides and aqueousnitrates. It is important to remember thatthe environment that promotes SCC isspecific for a particular alloy. Thus the

TECHNICALSteel is Strong…but Environment Matters!

biggest bane of austenitic stainless steel,aqueous solutions of chlorides, is benignwhen it comes to carbon steel. Similarlyaqueous nitrates induce SCC in carbonsteel but not in stainless steel.

Caustic EmbrittlementTemperature and concentration play animportant role in the onset of SCC. Oneof the very well defined temperature-concentration maps pertains to carbonsteel’s susceptibility of SCC of in causticsoda environment. Depending on thecaustic concentration carbon steels arevulnerable to SCC at temperatures above50-80 0C, higher the concentration loweris the onset temperature. Since causticsoda is widely used in chemicalprocessing, carbon steel equipment andpiping in many industries are susceptibleto SCC in caustic environment, oftenunder least expected conditions. In fact,failure of steel due to causticembrittlement was first noticed in rivetsof a boiler due to localised build-up ofcaustic soda used in trace amounts forboiler feed water conditioning.Caustic SCC of carbon steel is ofteninitiated in areas of discontinuities, aresult of welding operations. Thermalstress relief is the most importantmitigating measure against caustic SCC.Post Weld Heat Treatment (PWHT) isrecommended for all welded carbon steelcomponents that are likely to be exposedto caustic soda concentrations andtemperatures which will induce SCC.Certain substances such as phosphatesand carbonates are known to inhibitcaustic SCC by altering theelectrochemical potential.

Chloride CrackingStainless steels display excellent corrosionresistance in a variety of situations, butare extremely vulnerable to SCC in achloride environment. Failure of stainlesssteel due to chloride SCC is of great

economic consequence to the chemicalindustry. The chloride environment canbe introduced in the most unlikelymanner. For example: natural dry-out of avessel after being hydrotested with watercontaining high chloride levels. Thechloride limit in water used forhydrotesting is 250 ppm and afterdraining, the surfaces should bethoroughly dried to prevent build up ofchlorides due to natural evaporation.Dosing the water or a final rinse with0.5% sodium nitrate solution is arecommended measure of mitigation.Since air or oxygen is required for chloridecracking, most failures occur only whenthe equipment is out of operation andexposed to atmosphere during shutdownfor inspection and maintenance. Thermalstress relief does not provide muchbenefit against chloride SCC and so theonly two choices are to exclude theenvironment through flushing /blanketing or opt for a superior materialof construction. Duplex stainless steelsprovide good resistance against SCC andare used in heat exchanger tubes tohandle cooling water having highchloride content.

Pitting and PassivationPitting is another very common form oflocalised corrosion experienced bystainless steel. Pits are holes of smalldiameter, usually less than 1 mm thatpenetrate deep into the metal resulting inperforation of vessel and pipe walls. Thecorrosion resistance of stainless steel is aresult of the protective oxide film andpitting is initiated at defects in thisprotective layer. Different grades ofstainless steel have varying resistanceagainst pitting and this is measured bythe Pitting Resistance Equivalent (PRE)Number, which is defined asPRE = (%Cr) + (3.3x%Mo) + (16 x %N)Higher the PRE number, higher is theresistance to pitting. Conditions that aidpitting attack include low pH and highconcentration of chlorides. Each grade ofstainless steel has a critical pittingtemperature, above which the attack islikely. Passivation treatments and controlof surface finish are the usual techniquesadopted against pitting. Passivation isusually carried out by citric acid or nitric

K. Sahasranaman is a Process Engineer with more than 28 yearsexperience in the EPC industry. He currently holds the position ofGeneral Manager - Process with UHDE India Limited and isresponsible for Process Design and Engineering functions. He hasalso worked as Engineering Manager for large size petrochemicalprojects.

Contd. Pg. 7


By Arvind Raje - Senior Consultant, ToyoEngineering India Ltd, & Author of bookon Works Contract (Sales Tax)

FISCAL POLICYBooming collection from fiscal levies(direct and indirect taxes) is symptomaticof the Industrial and technological surge.Contrasted with the immanent Indiantrait of shying off from compliance, theCorporate entities have contributedmightily to the collection bulge. May be,these entities have a repertoire of expertsto guide and advise them.True that the taxation law, hedged with‘if’, ‘but’, ‘proviso’ and clumsilystructured sows the seed of confusionand chaos leading to a leakage. Thehigher rates and harsh provisionsencourage, in fact, the tendency to keepdistance from the law. In the Federalstructure, the State enjoys legislativeautonomy on certain subjects. In thecompact country like India, there arevariables, State-to-State, in the matterof Industrial development, socio-economic conditions and humandevelopment indices. Trade andcommerce is not restricted to a particularstate or confined to that state only.People interact during Interstateintercourse. Entities situated in onestate operate in different states. It willnot be a hyperbole to say that fiscal lawsof the state do not accord in theme andobjective with the nation’s larger socialobjective. Even these states, inter-se do

TAX TALK

not present the modicum of uniformity.Voltaire, has once remarked thatdefinition should be right before we enterin to a discussion. An important reasonwhy the state fiscal laws lurch from oneinterpretation to the other is becausedefinition lapses of key terms gounnoticed even at the higheradministrative level. Consequently, Stateinitiatives on important national fiscalissues lead even the most policy makersastray.Of late, there is a definite trend toharmonise fiscal laws (direct andIndirect). Something like ‘goods andservice tax scheme’ is being thought of.A beginning has already been made tobring in Value Added Tax scheme all overthe country. Based on the concept oftaxing value added with the advantage ofInput credit, the VAT scheme has laidthe foundation of uniformity to thetaxation law throughout the country.Interestingly, the scheme like Sales Taxon the material involved in a workscontract and Sales Tax on lease rent gotmerged in the VAT scheme. Thoughover two decades have elapsed since thebirth of the subject of Sales tax in relationto works contract, confusion still reignssupreme. May be, because of want ofclarity in the law lay out and inadequateunderstanding of the concept.Attempt to rope in all sundry workscontract smacks of gluttonous approach.Ironically, colors, chemicals and dyes

used for processing fabric have attractedjudicial consideration deeming toconstitute a sale. A customs case provedto be a catalyst to set covetous eyes onall and sundry contracts. One canhowever see a silver lining in the latestjudicial consideration in the case ofBharat Sanchar Nigam Limited. A senseof discipline and order in conformity withthe legislative intention should getrestored in the near future.The material (goods value) in acomposite contract constitutes thefulcrum around which the debate,controversy and dispute revolve.Consigning the intention of the parties tothe contract to the dust bin, theingredients which have nothing to dowith the goods are sought to beentrapped. This is totally illogical,against the legislative intention andillegal.The apex court in the B.S. N. L’s casehas distinguished exceptional casesintended under the constitutionalamendment from those which wouldcontinue to be governed by the SALE OFGOOD ACT. Let us wait for theconsequential to follow.Concluding, the imminent singleenactment holding sway all over thecountry, replacing Excise Duty, Octroi,VAT, and such other Indirect taxes isexpected to result in transparency andcompliance, mitigating the vice oflitigation.

Contd. Pg.6 Steel is Strong…but Environment Matters!

acid, and the effectiveness of passivationtreatment can be established by usingelectrochemical methods.

Hydrogen AttackHydrogen is another silent killer of steel.There are several ways and mechanismsby which hydrogen attacks steel, andthese are collectively and erroneouslylabeled as hydrogen embrittlement. Asteel component may be subjected tohydrogen environment even before it hasbeen put into service, for example duringheat treating or acid pickling. Nascenthydrogen that forms as a result ofcorrosion in any aqueous environmentcan also affect steel. Reams of literature

have been devoted to the study of thesephenomena, but the mechanism remainsfar from completely understood. All thepractical experience has however beencrystallized into a chart popularly knownas Nelson Diagram, which ought to beconsulted by every engineer who specifiessteel for hydrogen service. NelsonDiagram is an invaluable guideline forselecting the right steel for hydrogenapplication as a function of temperatureand hydrogen partial pressure.One of the particularly aggressiveenvironments that encourage a form ofhydrogen attack known as hydrogenstress cracking is offered by wet H2S (sourwater), that is typical in refining and also

many petrochemical industries. Manykinds of steels are prone to failure byhydrogen stress cracking when exposedto streams containing more than 50 ppmH2S. The common method of avoidinghydrogen stress cracking is to control thehardness of weld joints through PWHT.Guidelines for this are available in NACEand API publications.The catchy slogan ‘steel is strong’ shouldbe tempered by the addendum, ‘butenvironment matters’. Engineers whospecify, design and operate equipmentbuilt of steel ought to know itslimitations and idiosyncrasies. Only thencan we get the best out of steel.


Workshop On Anti-Corrosive Linings & Composites

A two-day workshop on Anti-CorrosiveLinings & Composites was jointlyorganized by Indian Chemical Council(ICC) & PPMAI (Process Plant &Machinery Association of India on 14 &15 December 2007 in Mumbai.

Mr. Shishir Joshipura, Chairman-ProcessPlant & Machinery Association of Indiainanugurated the 2- day workshop.Professor V. V. Mahajani, Department ofChemical Engineering, Institute ofChemical Technology, MumbaiUniversity and Member of the T&EExpert Committee, ICC delivered theKey-note address.

Mr. H. S. Karangle, Chairman-Technology & Energy ExpertCommittee, ICC welcomed the delegatesand Mr. D. P. Misra, Director General-ICC proposed a vote of thanks at theinaugural function.

Following presentations were made byexperts during the two-day workshop:

EXCURSION TO BASICS - WHYCOATING?, WHY LAMINATES?- V. V. Mahajani, Professor of

Chemical Engineering, Institute ofChemical Technology, MumbaiUniversity

RUBBER LININGS - TO COMBATCORROSION AND EROSION- Ashok Jayaraman, Vice President-

Marketing, Lebracs Rubber LiningsPvt Ltd, Pondicherry

A HIGH PERFORMANCE ANTI-CORROSIVE FLUOROPOLYMER /PTFE COATINGS & LININGS

- Kirtan M. Dhami, Director (Tech. &Exports), Blinex Filter Coat Pvt.Ltd, Mumbai

DUAL LAMINATE COMPOSITES- Vijay Rajpurohit, Chemical Process

Piping Pvt,. Ltd., Mumbai

APPLICATION OF FIBER REINFORCEDCOMPOSITES IN CHEMICAL & OILAND GAS INDUSTRIES- M. Suresh, Principal Technologist

& Head-Materials Science &

Corrosion, R&D - E&C Division,Larsen & Toubro Limited, Mumbai

GLASS LINING AS ANTI-CORROSIVECOATING- Rajesh Vyas, General Manager-

Marketing, GMM Pfaudler Ltd.,Mumbai

ADVANTEX GLASS FIBER ANDEFFECT OF VARIOUS ENVIRONMENTON COMPOSITE AND CORROSIONRESISTANCE APPLICATION- Amar Tarkar, Owens - Corning India

Ltd.

Mr. H.S. Karangale delivering the welcomeaddress. Seated are: Mr. D.P. Misra, Mr.Shishir Joshipura, Chairman-PPMAI and

Professor V.V. Mahajani.

Professor V.V. Mahajani delivering the key-note address.

ANTICORROSIVE CERAMIC LININGSYSTEMS FOR SURFACEPROTECTION- S. Kartikeyan, PSK Technol-well

Linings, Mumbai

COATING ADVANCEMENTS IN THEAREA OF LININGS - CHEMICALS &PETROCHEMICAL PROTECTIVECOATINGS- Eddie Cheong, Akzo Nobel,

Singapore.

AN INTRODUCTION TO FIBERREINFORCED PLASTICS FOR ABOVEGROUND STORAGE TANK- Partha Sanyal, Manager-Technical

Services, Jotun India Pvt. Ltd.,Mumbai

CARBON & GRAPHITE ANTI-CORROSIVE LININGS ANDCOMPOSITES

- Praveen Saxena, Director & CEO,Blast Carbo Blocks Pvt. Ltd.

The Valedictory Session was chaired byMr. O.P.Goyal, Member of theTechnology & Energy Expert Committee-ICC. Mr. Eddie Cheong, Mr. K.Sahasranaman (Uhde India Ltd), Mr.Praveen Saxena, Mr. D. Majumdar & Mr.Niraj Kumar - from Heavy Water Boardparticipated in the discussions.

Mr. Shishir Joshipura, Chairman-PPMAI,inaugurating the Workshop.



LEADER SPEAK

PPMAI: What is the significance ofcaption OMEGA KEMIX?

RD: Omega is the last letter in the Greekalphabet. Similarly, we constantly worktowards being the final frontier in ourarea of operation, namely, Gas-Slurry(Gas-Induction) Reactors and alliedequipment. Kemix is a word play on Keyand Mixing. The key to Reactorproductivity is efficient mixing.

PPMAI: Please comment on theengineering strengths of OKPL.RD: For the past 10 years, we havesingle-mindedly addressed issues relatingto Gas-Liquid and Gas-Slurry reactions.Fortunately or unfortunately, there isinsufficient (and at times inaccurate)published data on Gas-Induced Impellers.As a consequence, we have developedour own design criteria, with theoreticalas well as experimental bases.Since we manufacture the entire Reactor(and not just agitators), we can carry outtrials for various impeller configurationson the equipment. For example, we arepresently manufacturing around twenty-five Hydrogenators, the largest of whichhas an operating capacity of 25000 litres,which is one of the largest of suchequipment worldwide. Here, we haveunique opportunities to try out differentimpeller/agitator configurations,resulting in frequent improvements in theperformance of our equipment.We also have substantial experience inEquipment Design, and have written ourown proprietary software for EngineeringCalculations. For our specificapplications, we claim that this softwareis more suitable than standard availablepackages.PPMAI Could you elaborate on ReactionEngineering in which your company isspecialized?

RD: Gas-Slurry Reactions are governed bymass transfer as well as reaction kinetics.If the mixing pattern is vigorous enoughto eliminate any bottlenecks due to masstransfer, the reaction will be kineticallycontrolled, and hence easy tomanipulate. Also, adequate gas-liquid

interfacial areas will aid efficient masstransfer. Further, these reactions areusually carried out in the presence ofsolid catalysts, hence, it is necessary touniformly fluidize these solidsthroughout the Reactor.Many Hydrogenation Reactions arestrongly exothermic, hence, an in-depthknowledge of Process Heat Transfer isessential. Omega-Kemix has successfullysupplied such high-exothermHydrogenators, where peak heat loadsapproach 1000 TR. Due to efficient GasInduction, process side heat transferrates approach boiling film coefficients.This factor, combined with cutting-edgemixing technology, results in isothermaloperating conditions, which, in turn,result in reduced batch times, minimalside reactions, optimum catalyst loading,and excellent batch-to-batchrepeatability.Omega-Kemix has considerableknowledge of all these Process aspects,and has been successful in translatingthese factors to full-scale operations atour end-users’ plants. This has ensuredthat without exception, our clients’projects have been successful.

PPMAI : How has your technologyimproved and facilitated the processes inProcess Industry & what are the newadditions to the product range?

RD: We had developed Gas-Inductiontechnology at the right time, in 1993,when the Indian Pharmaceutical industryhad just started to take off. Severalexpensive pharma molecules had amanufacturing step involving reductionby catalytic hydrogenation, whereconventional equipment were quiteinadequate. For these clients, ourtechnology was exactly what theywanted, and our products soldthemselves. Subsequently, thesereactions, particularly hydrogenation,found applications in manufacture ofspecialty chemicals, perfumery chemicals,dye intermediates, pesticides, and alliedproducts. Our technology has benefitedall these sectors of the Process Industry.Most Gas-Slurry reactions are carried out

at elevated pressures. Mechanical Sealfailures were a frequent cause of down-time. To address this issue, we embarkedon developing designs for top entrymagnetic seals. Our efforts have bornefruit, and we have recently been grantedan Indian Patent for Magnetic Seals. Weare also in the processof filing the patentin other countries. We have now suppliedseveral Gas-Induction Reactors with ourMagnetic Seals. These have been verywell accepted in the Industry, and weforesee substantial worldwide demand inyears to come. Magnetic Seals will beused on various types of rotaryequipment, and not just Reactors.

PPMAI : What was the inspirationbehind the birth of the Gas InductionReactor?RD: Actually, for a long time, I wasconvinced that conventional agitatorswere poorly qualified for gas-liquidmixing. I then visualized an impellerwhich would suck in gas from the liquidsurface and introduce it into the liquid. Imust confess that at that time, I had noidea what the impeller should look like. (Ihave a habit of imagining an objective,and then working towards it). Over a fewmonths, potential designs took shape,and my colleagues and I would try theseout in a small pilot reactor which we hadbuilt. After several false starts, we arrivedat a workable design. We have kept onimproving on this by trial and error, withinputs from end-users as well ascolleagues. I am happy to state that thishabit of incremental improvement is nowa part of my company’s culture.

PPMAI :Can you briefly explain theadvantages and working of a gasinduction reactor?RD: Gas-Liquid reactions had beentraditionally carried out in equipmentwhere an agitator was used to stir thereaction mass. This somewhat clumsymethod resulted in unsatisfactoryperformance. An Omega-Kemix Gas-Induction Reactoroffers a radical change from thisconventional approach. Instead ofchurning the reaction mass, a hollowagitator, with a proprietary impeller,draws gases from the reactor headspace,and vigorously pumps them into thebottom of the reactor, resulting in amixture akin to a boiling liquid. Gasbubbles react with the liquid as they rise.Unreacted gases which rise to the surfaceare re-induced into the liquid.PPMAI : How do you monitor quality ofyour products, your company is not ISOcertified?

Rajiv Deshpande is Managing Director of Omega-Kemix Pvt.Ltd.,India’s leading manufacturerof Gas-Slurry Reactors. He has over 35 years experience in variousfields, including Design, Process Development, Cost Estimation,Manufacturing, Project Execution, Intellectual Property, Accounts& Finance.Mr.Deshpande is a B.Tech.from IIT Bombay. He is also a memberof the Indian Institute of Chemical Engineers.Mr. Rajiv Deshpande’s e-mail: [email protected]


RD: Over 90% of our Reactors are usedfor catalytic hydrogenation, whichinvolves elevated pressures andtemperatures. Further, many of thesereactions are carried out in presence offlammable solvents, using pyrophoric(spontaneously igniting) catalysts.Operational safety is the most importantfactor in design and manufacture of suchmachinery. As a result, we are geared toexclusively manufacture such criticalequipment.It would be superfluous to add that mycolleagues in our inspection, planning,and manufacturing departments areexceptionally exacting in their approach,and our internal quality benchmarksoften exceed code requirements. Weeven have our own specifications forpacking of accessories supplied with ourGIRs.Basically, certification is an externalconfirmation of our quality processes.Our products have a CE mark, and we arein the process of ISO certification.

PPMAI : What according to you is thebest way to promote and popularize yourproduct in the industry circles?RD: The best and only way is to ensureuser satisfaction. A reactor is the heart ofa chemical plant. We recognize that ourclients’ investment will bear fruit onlywhen reactor performance meets orexceeds their specifications, consistently,and in a safe manner. We havecontinually worked towards this success,and the results have spoken forthemselves. In the final analysis, we cancall ourselves successful only when ourclient’s projects have succeeded. Itwould be worth mentioning that around80% of our work is for existingcustomers. The remaining 20% is a resultof referrals from satisfied clients.

PPMAI : Sir, we understand that yourcompany serves the Chemicals,Pharmaceuticals andAgricultural & Food Processingindustries, would you not like to spreadyour wings to cover the other industries?

RD: Actually, we cater to almost theentire range of industries which use Gas-Liquid reactions.

PPMAI: How do you rate exhibitions as apromotional medium?

RD: Exhibitions are a valuable avenue forprojecting our skills. We regularlyparticipate in specific Industrialexhibitions catering to the ProcessIndustry.

PPMAI: How do you rate your productsin the face of competition from theimported products especially from China?

RD: As a matter of fact, we export Gas-Induction Reactors to China.

PPMAI: With winds of globalization andliberalization being mantra today wouldyou like to reach the internationalbuyers?

RD: We are working towards this bybuilding a much larger manufacturingfacility, which can cater to thepotentially large internationalrequirement for our products. At present,we are hard put to satisfy the indigenousdemand.

PPMAI: What industry-friendly policyreforms you think will give a boost toprocess industry?

RD: Realistic labour laws will benefitindustry as well as workers. Today,several small and medium scalecompanies are unable to realize their

potential, due to archaic rules andregulations, particularly regardingemployment policies. Freeing theseshackles will also result in a surge inemployment. Unfortunately, the politicalleadership has not grasped this idea.

PPMAI :What prompted you to be a partof PPMAI and how has the samebenefited you?

RD: Several friends and former colleagueshold senior positions in companies whichare members of PPMAI. I have joined thisorganization on the advice of thesefriends, who had benefited from thisassociation.

PPMAI :What are your recommendationsto make our activities more industry-friendly so that we can attract moremembers to PPMAI?

RD: I would like the PPMAI to guidemembers for obtaining qualitycertification, such as ISO registrations,ASME stamps, etc. Perhaps PPMAIcould also co-opt senior retired personnelto guide members on selection of ERPpackages.

PPMAI : What is your message toPPMAI members?

RD: India’s knowledge skills are amongthe best in the world, and we Indianshave a superlative ability for innovation.Plan ahead, invest in innovation, and inthe coming decade, India can become aleading global supplier of Process Plantsand machinery.

In short, innovate, adopt globalbenchmarks, and decide where yourcompany will be five years hence. Youwill succeed.

PROCESS PLANT AND MACHINERY ASSOCIATION OF INDIA

504 Loha Bhavan, Near HP Petrol Pump, 91 P.D’Mello Road, Masjid (E), Mumbai 400 009.

Tel.: 2348 0405, 2348 0965 E-mail: [email protected]

Edited, Printed & Published by V.P. Ramachandran, Secretary,PROCESS PLANT AND MACHINERY ASSOCIATION OF INDIA,


[PPMAI conducted a “Meet the Vendor”program for their member M/s.FaingerEngineering on 16th November 2007 inMumbai. Following is a brief report of theevent].M/s. Fainger Engineering are appointedauthorized distributors for India by MuntersEuroform GmbH-Germany. The purpose ofthe presentation was to introduce MistElimination Technology for the ProcessIndustry especially for Gas Cleaning,Chemical Engineering, Oil & Gas - ProcessIndustry, Intake of Ambient Air and GasConditioning. The technology assistsseparation of liquid and contaminants fromcontinuous gas flow.Munters Euroform are world leaders in MistElimination Technology for the Process

A Report – PPMAI “Meet the Vendor”ADVANCED MIST ELIMINATION TECHNOLOGY

Industry.Technical presentation made by Mr. RomanKaiser (Vice President-Sales), Munterscovered vital aspects of the mist eliminationtechnology viz:

Function and Purpose of SeparatorsEstablished Technologies from MuntersEuroform :Candle FiltersVane Type SeparationSpin Vane SeparationWire Mesh Separation

Mr.Roman Kaiser (V.P.Sales MuntersEuroform) delivering the presentationL-R : Mr.Roman Kaiser (V.P.-Sales) Munters

Euroform,Mr.Ajey Kale (G.M.-Marketing) andMr.Sidharth Shenoy,Fainger Engineering

Specifying Separation Devices ParticleSize & Efficiency v/s Rest ContentParticle Size and its impact on EnergyConsumptionMeasuring Technologies-Efficiency ofMist Eliminators

The technical presentation followed by aninteractive session was well appreciated bythe audience. Munters have assured their fulltechnical support in solving the dropletseparation-Mist Elimination problems facedby Indian Process Industry and for flue gasdesulphurization projects.The event was well represented by Seniorofficials and Design Engineers from variousindustries like Oil & Gas, Refineries,Petrochemicals, Fertilizers, ProjectConsultants, OEMs and EPC Contractors.Established in 1975, Fainger Engineering iswell known name for valves and instrumentsin the Indian Process industry

IPVS 2007 ( Industrial Pumps, Valves &Systems Trade Fair) organized by OrbitzExhibitions Pvt.Ltd. was grandly held atthe Hitex Exhibition Centre, Hyderabadfrom the 5th to 7th October’07 with thefull support of Process Plant andMachinery Association of India (PPMAI).PPMAI members took stall presentationapart from deputing their delegates in fullstrength. PPMAI also was in theiradvisory panel for selecting the topics forthe three day conference concurrentlyheld at the exhibition. PPMAI memberssuch as M/s. Uhde India Ltd and M/s.TUV India Pvt. Ltd had presented papersand PPMAI also invited CBI Netherlands

A REPORTIPVS 2007 - Trade Fair, in Hyderabad, 5 - 7 October, 2007

to present a paper in the Exhibition.Apart from the Indian Exhibitors, therewere exhibitors from Australia, Germany,Italy, Taiwan, UK and UAE. Theexhibition was a grand success.

About The Conference:-In conjunction with the event, aconference was also organized at HICC(Hyderabad International ConventionCentre), near Hitex Exhibition Centre,Hyderabad. The theme of the conferencewas ‘IPVS Prospects and Initiatives for2020.’ Presentations at the conferencewere given to foresee the emerging trendsand outline prospects and initiatives for

the coming 10-12 years in the fields ofindustrial pumps, valves and systems.

The conference was a techno-economicconference. Delegates to the conferencegot a glimpse of the emerging world orderin the field of IPVS. Some of therenowned speakers were; Roselin Reidy,Editor, Pump Analyst, ElsevierTechnologies, UK; Rudiger Nagel,Editor, Delta-P Global, NagelPublications, Germany; R K Srivastava,Kirloskar Brothers Ltd., Pune, India andAnil Rairikar, MD, TUV India, & Head,TUV NORD, South Asia.



TECHNICALHOT TAPPING

Mr. V. Devendranath is a Mechanical Engineer and Senior Manager,Inspection & Expediting, Aker Kvaerner Powergas Private Ltd. Hehas a total of eighteen years experience and the major part of it inAker Kvaerner. He has attended various training programs onRadiography Testing, ISO Internal Auditors Training Course,Welding Inspectors, Air Compressors, HSE Leadership Programs etc.

Hot Tapping allows for safe cutting intopressure lines and vessels and is primarilyused to isolate equipment and to prevent shutdown of a unit of a plant.The forgoing pages describe our recentexposure on Hot Tapping carried out atHPCL, Mahul site during which Hot Tappingwas carried out on 100 site fabricated tanks.This experience could possibly serve as aguideline for taking up similar activities.

Refer : S:/Insp/Technical/Hot Tapping /Folder-1 FOR Visual Clipping Of Hot TapActivity

INTRODUCTION :1.0 What is Hot Tapping ?Hot tapping is the technique of attaching amechanical or welded branch fitting to pipingor equipment in service, and creating anopening in that piping or equipment bydrilling or cutting a portion of the piping orequipment within the attached fitting. Hottapping is usually performed when it is notfeasible, or it is impractical, to take theequipment or piping out of service, or topurge or clean it by conventional methods. Ahot tap connection can often be safely madewithout interfering with the process operation.

2.0 Metal Thickness And Testing2.1 The piping or

equipment base metal thicknessmust provide support for the newconnection and the hot tappingmachine. Alternatively,reinforcing pads or auxiliarysupport of the hot tappingmachine may be provided. Thebase metal must be free oflaminations, hydrogen attack, orstress corrosion cracking.Imperfections which might preventa sound weld from being mademust be evaluated by a competentperson.

2.2 A minimum base metal thicknessof 4.8mm (3/16") isrecommended for most applicationof welding and hot tapping (API2201, September 1995)

2.3 Ultrasonic testing will be used forthe above inspection.

3.0 Prevention of Burn-through, whilewelding nozzle and reinforcement padand correct fittings.3.1 The risk of burn-through can be

minimised if the equipment isproperly inspected for adequatewall thickness and absence ofdefects, if controlled weldingtechniques are done by qualifiedand experienced welders to preventoverheating, and if otherappropriate safety procedure arefollowed.

3.2 To minimise the possibility ofburn-through, the first weld passto the equipment or piping shouldbe made with a 2.4mm (3/32")diameter welding electrode. Theremaining passes should be madewith electrodes not to exceed3.2(1/8") diameter, if actualthickness does not exceed12.8mm(1/2"). (As a furtherprecaution against burning-through, the welder may test theamperage of the welding machineon a sample piece of metal of thesame thickness as the equipmentto be welded)

3.3 Welders must be qualified inaccordance with applicable codeand specifications.

3.4 They should be thoroughlyfamiliar with welding equipmentand procedures to be used.

3.5 A competent supervisor shouldoversee welding operation toensure proper procedures arefollowed, welding machine andaccessories are in good conditionand operated correctly.

3.6 A detailed Welding ProcedureSpecification (WPS) should beprepared and adhered to.

3.7 Care should be taken to select the

proper fitting for the hot tapconnection. Connection should bedesigned to the applicable code.Be sure the fitting is the propersize to accommodate the hot tapmachine.

3.8 Exercise care to see that the fittingis properly positioned to, beforewelding, so that misalignment ofhot tap machine will not occur.

3.9 It may be desirable to reducemoisture content in the weld area(presently monsoon). Moistureinclusion could result in weldporosity and under-bead cracking.

4.0 Requirement To Be Completed PriorTo Start Of Hot Tapping4.1 A hot work and safety permit is

obtained from the owner.

4.2 The conditions stipulated in thepermit are complied with.

4.3 A competent companyrepresentative during the hot tapprocedure must be present.

4.4 All lines to the tank are blinded,including heating coils and waterdraw-off.

4.5 To ensure that the hydrocarbonliquid level inside the tank is2M(6') above the point of hot tap,it is necessary to take an actualdip by the owners representative,gauge ticket filled and a copy ofthe gauge ticket issued to the HotTapping Agency.

4.6 A competent person having currentcertificate from the Hot TappingParent Agency, trained by themand has adequate experience in hottapping of tank in-service, shouldbe in charge of Hot TappingOperation.

4.7 The area to which a connection isto be made has been identified andphysically marked.

4.8 The metal thickness has beenmeasured and absence of metalimperfections is verified.

4.9 A competent supervisor ofWelding Agency should beavailable at site during the welding

Contd. Pg. 16



operation.

4.10 Necessary signs and barriersshould be placed.

4.11 Provide fire-fighting equipment atsite.

4.12 The personnel at hot tapping siteshould be conversant with the useof extinguisher and firewater hose.If necessary, training should bearranged for them.

4.13 In addition to fire fightingequipment as above provided, theowner may deploy specialised firefighting equipment such as foammaking equipment, foamcompound and foam tender, as pertheir requirement.

4.14 It is desirable that the ownerprovides a Process Standby withcombustible Gas indicator to takeperiodical Gas test and to ensurethat there is no oil or gas leakagein the vicinity. In case of any suchemergency, the process standbywill immediately stop the hot workand contain the emergency also byappropriate action.

4.15 While every effort should be madeby all concerned to avoid anyemergency, still it is desirable toprepare an Emergency Procedureto combat any emergency such asoil leak, fire or explosion. As theowner would have their ownEmergency Organisation andProcedure, this may be done bythe owner.

4.16 The attached check list must becompleted prior to Hot Tapping.

5.0 Inspecting The Weld Prior ToAttaching Hot Tap Machine5.1 The welded attachment should be

inspected during and after weldingand before hot tap machine isinstalled.

The weld joint shall be checkedwith dye penetrant/ultrasonic andfor ensuring proper quality of weldjoint. These procedures should notbe relied upon to replacehydrostatic/air testing.

5.2 While testing the reinforcementpad, since the test pressure is low,ensure that there is properarrangement to restrict thepressure, not to exceed testpressure.

6.0 Hot Tapping Machine Stability6.1 A Hot Tap machine can be

considered suitable if the pressureand temperature of the medium

inside the tank walls within theworking limits of the hot tapmachine.

6.2 The seals and materials of the hottap machine must be compatiblewith the hydrocarbons inside thetank

6.3 The material of the drill or cuttermust be suitable for effectivepenetration of the tank shell plate.

6.4 Before hot tapping is attempted,the machine, cutter and pilot bitshould be carefully inspected toensure that they are in satisfactorycondition and capable of being leftin service, if necessary, in the eventof mechanical problems or hot tapvalve leakage.

7.0 Installation Of The Hot Tap Machine7.1 The hot tap valve to be used must

be of adequate size, propermetallurgy, and be a full openingvalve. It should be tested for seatleakage prior to installation. (SeeAPI Standard 598)

7.2 During installation, the valveshould be centered on the nozzleflange.

7.3 Run the boring bar through thevalve opening to be sure the cutterdoes not jam or drag.

7.4 Carefully calculate the travel ofthe cutter to ensure that the tapcan be completed within thosedimensional limits, that the cutwill be stopped before the cuttertouches the opposite sides of thetapped pipe, and the cutter can beretracted far enough to allowunimpeded closure of the tappingvalve.

7.5 Check the bleed-off valve will holdpressure and is not plugged.

7.6 Ensure that precautions have beenestablished for safe bleed-off anddisposal of the material collectedin the machine above the hot tapvalve.

8.0 Testing The Weld And Hot TapMachine8.1 The welded attachment and hot

tap machine should be testedbefore cutting is started.

8.2 Bolts, packing and packing nutsshould conform to appropriatestandards.

8.3 Check tightness of bolts, packing,packing nuts and bypass line, ifrequired, to avoid possible leakage.

8.4 If the current temperature of theline or vessel will permit, ahydrostatic test should beconducted in accordance withapplicable code. The new weld andthe tapping machine should bepressure tested simultaneously.

The test pressure should be atleastequal to the operating pressure ofthe tank to be tapped, but it shouldnot exceed the present internalpressure by more thanapproximately 10% in order toavoid possible internal collapse ofthe tank. The temperature of themetal should be considered toprevent brittle fracture.

8.5 Air or nitrogen with soap solutionon the weld can be substituted fora hydrostatic test if thetemperature precludes hydrostatictest. At elevated temperatures, airshould be used only after carefulconsideration to avoid thepossibility of a combustiblemixture.

8.6 Ensure that there are noconnections through which aircould enter.

9.0 Completion9.1 It is often possible to tell when the

cut is complete by the reducedresistance to the hand cracking orby the speed of the drive motor.The manufacturer’s instructionsshould be followed when retractingthe bore and closing the valve.

9.2 If the blank or coupon is lost, noattempt should be made to reachfor it.

10.0 Hot Tapping Should Not Be DoneUnder Following Conditions10.1 Tank wall thickness is below the

minimum recommended (vizJ4.8mm (3/16") and has beenfound to have any defects.

10.2 The oxygen level within theequipment must be controlled toprevent the formation of avapour/air mixture within theflammable or explosive ranges. Inaddition, contents of the line orvessel is being hot tapped mustnot contain :

Hydrogen

Vapour/air or vapour/oxygenmixtures within flammable orexplosive ranges.

Contd. Pg. 14 HOT TAPPING

Contd. Pg. 18


www.uhdeindia.com ThyssenKrupp

Uhde IndiaA company of ThyssenKrupp Technologies

Over 3 decades of Service to theChemical and allied industries -in India & Abroad

With over 30 years' experience indesigning and constructing plantsfor the chemical industries in Indiaand abroad, we are ideally placedto fully understand our Clients'requirements. Just as weunderstand them having come toexpect nothing but the very bestfrom us.

Our plants are a tribute to oureconomical processes,comprehensive services,technology portfolio, experienceand unique working methods.Energy-efficient, environment-friendly and operationally reliable,they stand out for their productquality, high yields and safetyconsiderations. And they comebacked by the technologicalcompetence of Uhde GmbH,Germany and its groupcompanies.

Needless to say, we undertakeeverything from pre-projectactivities to plant commissioningand operation. All of whichunderscores our pre-eminentposition as a leading contributor tothe Chemical & allied industries inIndia & abroad.

Uhde House, LBS MargVikhroli(W), Mumbai 400 083IndiaTel. : 91-022-6796 8000Fax : 91-022-2578 4327E-mail : [email protected]

Pune Office -Dugal Plaza,Prem Nagar, Bibwewadi RoadPune 411 037IndiaTel. : 91-020-6608 1100Fax : 91-020-6608 1300E-mail : [email protected]

Uhde India Limited


Acids, chlorides, peroxides orother chemicals likely todecompose or before hazardousfrom the heat of welding.

Caustic or amine, if theconcentration and temperatureare such that the fabricationspecifications calls for stressrelieving.

10.3 Certain unsaturated hydrocarbonsthat may experience exothermicdecomposition reaction, (ehtylene,for example) if the metaltemperature from hot tappingcould initiate such as reaction atthe maximum expected pressure.Such reactions could havepotential for causing localized hotspots on pipe walls that could leadto failure.

10.4 Hydrocarbon liquid level above thehot tapping point is less than 1m.

10.5 No attempt should be made to hottap atmospheric pressurepetroleum storage tank above theliquid level, i.e., in the vapourspace or on the roof, because ofthe danger of explosiveatmospheric inside the tank.

10.6 Hot work should not be permittedon the deck of a floating roof tankin service.

10.7 Hot tapping should not be done onequipment which requires stressrelieving because of metallurgy orthickness of metal.

PPMAI welcomes the following members .who newly joined the association and look forward to their prolonged association andactive participation in all our programmes.

Welcome New Members!

Sr. No. Name of the company Contact Person Activity1 Amar Equipments Pvt . Ltd. Mr. V N Shah Manufacturer of Hoses and Expansion

6 Parmar Indl. Estate, Director joints and the new generationBail Bazar, Kurla -W, Mumbai - 400 070. Composite hoses for 1st time in India.Ph: 25111540, 25140169, 65753028Fax: 25109565. Email: [email protected]

2 Chemtrols Samil India Pvt Ltd., Mr. P Rajendran Nair Manufacturers of Level gauges,R 587/1 TTC Indl Area,, level switches, Quarter Turn valves,Rabale MIDC, Thane Belapur Road Air Header, Sample Cooler,Navi Mumbai - 400 701. Ph: 6514 1120 Instrument Valves etc.Fax : 022 - 2769 9063. [email protected]

3 HYDRO PROKAV PUMPS INDIA PVT. LTD.,, Mr. S Giri, Manufacturers & Suppliers of Positive170/2, & 170/3 SIDC Pvt Indl. Estate Director Marketing Displacement Pumps, TwinCoimbatore - 641 021. Tel: 0422 - 324 2220/ 2679 624 Screw Pumps, Triple Screw Pumps,Fax: 0422 - 2679 476. Email: [email protected] Internal Gear Pumps & Internal LobeWebsite : www.hppumps.com Pumps

4 Intercontinental Development & Engg. Mr. C N Sapthasayee, Engineering Consultancy services forAE & E Pvt. Ltd. (IDEA) Managing Director Power Process, Oil & Gas, Structural Steel,5th Floor Apex Plaza, 3, Nungambakkam Inspection, Construction, Supervision &High Road, Chennai - 600 034, Commissioning Assistance.Ph: 9144- 2822 5363. Fax: 9144- 2825 7134Email: [email protected]. Website: www.aee-idea.in

5 R M Applied Engineers Mr. Kashinath Sagumale Manufacturers of Metallic and Non MetallicD-37 Addl. M.I.D.C. AMBERNATH - EAST Proprietor Hydraulic Hoses and Rubber andDist. Thane. Tel.0251-2621575 Metalic and Non Metallic ExpansionEmail: [email protected] Joints (Bellows)Website: www.rmapplied.com

6 Laxmi Hydraulics Pvt. Ltd, Mr. Sharad Krishna Thakre Manufacturers of Special Pumps, GearedB-11 MIDC, Chincholi Managing Director Motors, Crane Duty Motors, Flame ProofSOLAPUR - 413 255 Motors including increased safety motorsTel. +91-217-2357001/2/3/4/5 Mr. Satish N. Gunje and all other types of motorsFax: +91-217-2357006 Manager-QAEmail: [email protected]: [email protected]

11.0 Conclusion11.1 Hot tapping is done on pipelines or

equipment in service containingconsiderable quantity offlammable/combustible liquid.Hence, this operation calls forextreme caution, vigilance,alertness and continuoussurveillance from all the personnelconcerned with hot tapping.

11.2 Needless to mention, every stageof hot tapping should be properlydocumented.

Contd. Pg. 16 HOT TAPPING


TECHNICALHydrogen Induced Cracking (Hic) &Sulphide Stress CorrosionCracking (Sscc)

Mr.K Periasamy,Technical Director,and M/s. Precision Equipments (Chennai) Pvt. Ltd, ChennaiDirector of PPMAI

Introduction

Nascent Hydrogen (H+) (which is alwayspresent in wet H2S medium) in thepresence of strong oxidising agents like Cl-, Br -, I etc. tend to get into steel andmake the steel hard and brittle, therebyinitiating cracking along the rollingdirection of the Steel. This phenomenonis called Hydrogen Induced Cracking(HIC). Presence of impurities like S, P inthe steel accelerates the process of HIC.

Presence of sufficient concentration ofH2S results in cracks when the materialsare subjected to stress and thisphenomenon is called Sulphide StressCorrosion Cracking( SSCC ).

The ProcessWhen atomic Hydrogen enters thematerials, it fills in the gap between thegrains.

When two Hydrogen atoms cometogether, they form H2 Gas and this inturn results in volume increase. Whenmore and more Hydrogen gas is formed, itmakes the steel to bulge locally, formingblisters. These blisters can burst andbecome active sites for further corrosion.

Nascent Hydrogen concentration isappreciable whenever we have Hydrogenand wet Hydrogen Sulphide above certainlevels. Hence, HIC is invariablyassociated with processing of petroleumproducts, especially sour crude, whichcontains Sulphur bearing compounds likeMercaptans.

NACE SpecificationsNational Association of CorrosionEngineers (NACE), a US basedorganisation has carried out extensiveresearch on the behaviour of materialsunder various concentrations of elementsresponsible for hardness pickup andfurther cracking. Based on their research,they have given generalrecommendations on materials for use in

sour services, and it is given in NACEspecification - MR-01-75. They havealso formulated Test Reagents (TR) forvarious material tests. The relevantMaterial Test Methods and TestReagents applicable for Resistance toHydrogen Induced Cracking are given intheir Specification NACE - TM -02-84and NACE - TM -01-77 respectively.

All sour service requirements specific toPetroleum Refineries have been compiledin NACE-MR-01-03.

It should be borne in mind that thesespecifications specify only details likerecommended materials, Test specimenpreparations, the test methods to beadopted, reagents to be used, etc. Theydo not spell out any acceptance criteriafor the material based on these tests. It isupto the users to decide on theacceptance levels for the various testresults.

EIL Specifications for HICBased on their research, experience andrelated research works by other agencies,the consultants have recommended thegenerally acceptable materials withcertain restrictions for various productforms like Plates, Pipes, Forgings, etc.The requirements specified by EIL forHIC tested steel are given below : (Ref:Cl. 2.2.1 (e) of Spec. No.: 6-15-0001)

1. C < 0.23 %

2. C.Eq.< 0.40%.

3. Ni < 0.2%

4. S < 0.002% for Plates and <0.01% for Pipes, Forgings

5. a) Hardness of Plates andPipes shall not exceed 200BHN and that of Forgings 187BHN.

b) Plates shall be SA 516 Gr.60only.

c) Plates shall contain Calcium

(or) other Rare Earth elementsto create spherical inclusionsinstead of stringers.

d) Plates shall be tested inaccordance with NACE - TM -02 - 84 using Test Solution ‘A’of NACE -TM-01-77.

e) The acceptance criteria: CLR <10% (CLR -Crack LengthRatio)

The EIL Specification discussed above isa general one and some modifications aremade to this specification by otherconsultants / users for individualprojects. Some of the modificationsgenerally made are:

1. The Specification can read“The Steel shall be HICResistant” and it shall meet aparticular specification of theConsultants. For example, EILSpec No.: 6-79-0013. Thisimplies that the steelmanufacturer shall produce thesteel, keeping in mind that thissteel is meant for sour service,thereby implying thatimpurities like S and P are keptlow, inclusions of Sulphurbearing impurities are inspherical form (which otherwisewill form stringers) and therequired HIC tests areconducted in the Mill itself andreported in Mill T.C.

Please note, without specifying theapplicable spec. of consultants, there isno meaning for “HIC Resistant Steel”

Generally, getting HIC Resistant steeldirectly from the Mill is difficult unlessgood quantities are involved.

2. The specification can read “The steelshall be HIC tested with followingrequirements”:

a. S < 0.002% (Target 0.001%)

b. P < 0.02%

c. Carbon Equivalent < 0.40%\

d. Calcium to be used to get

Spherical inclusions, with restrictions onCa/S ratio ( 2 to 3).


Pressure Vessel Design

Chief Guest Mr. C. M. Venkateshwaran,Dy. Chairman, PPMAI inaugurating the Workshop andintroducing Mr. B. J. Shenoy, Faculty to the audience.

Mr. B. J. Shenoy receiving a memento from Chief Guest,Mr. C. M. Venkateshwaran.

Mr. B. J. Shenoy Honoring the Chief Guest,Mr. C.M. Venkateshwaran by handing over a memento.

Mr. B. J. Shenoy receiving a mementofrom Mr. C. M. Venkateshwaran.

Mr. V. P. Ramachandran, Secretarydelivering the vote of thanks.

Mr. P. J. Bhounsule Director, PPMAIreceiving a memento from Mr. B. J. Shenoy.


HiTech Workshop on PressureVessel Design, ASME Section VIII,Divn.1, conducted on 9/10th

January 2008 at Larsen & ToubroLtd, Powai, Mumbai

PPMAI has always been keepingabreast of the latest developmentsin the engineering industry andtrying to address industry relatedtopical issues through its variouseducational programmes with thetechnical assistance and valuedinputs of its esteemed members.

The Global Oil & Gas sector seeingphenomenal growth in investmentswith major projects on drawingboards and under implementationright from exploration & refining todownstream petrochemicals. Withthe resultant shortage of Qualityand knowledgeable suppliers, andEngineering talent projectauthorities and global customersare now inclined towards newsuppliers confident of meeting therequirements of technicaladequacy, quality , prompt andtimely delivery. One of the keyelements to achieve this isthorough knowledge of applicationengineering for the equipmentsupplied.

The most widely used code for thedesign and manufacture of staticequipment of the process plants isASME Boiler and Pressure VesselCode, divided into 12 sections. It isimportant to know the exactinterpretation of each and everysection and the clauses therein,exact applicability of variousclauses to the specified designconditions and interpretation of theresults obtained by calculations

A ReportPressure Vessel Design

using the same.

With this background PPMAI,relentlessly serving the cause ofProcess Industry for over fourdecades, organized a two daycourse to train designers in the useof ASME Boilers and PressureVessels code.

The Course Director Mr. B JShenoy a respected practicingdesigner for over 35 years indesigning equipment for diverseindustries - right from chemicalplants, fertilizer plants,petrochemical plants, refineries,thermal power plants to nuclearpower plants had speciallydesigned the two - day course forthe PPMAI members.

The course was well received by themember companies which wasevident from their overwhelmingresponse. Interestingly there werealso participants from non membercompanies as well.

Curtains were raised for the twoday event with a warm welcomeextended to the delegates andother dignitaries by the PPMAISecretary, Mr. V P Ramachandran.Mr. C M Venkateshwaran, GeneralManager, Inspection & Expediting,Aker Kvaerner Powergas Ltd andVice Chairman PPMAI graced theoccasion as the Chief Guest. Mr.Venkateshwaran has had anillustrious career spanning over twodecades in Design, Procurement,Inspection and Construction was anapt choice to initiate deliberations.Introducing Mr. Venkateshwaran,popularly CMV to the PPMAIfaternity, Mr. V P Ramachandran,Secretary lauded latter’s

encouragement, support andguidance rendered to all PPMAIactivities and his noble gesture ofsparing time amidst busypreoccupations to be the guest forthe day.

CMV in his response stated that “ASME Code has always exciteddesigners, production engineers,inspection engineers, surveyors andusers and interpretationsdiscussions all have been part ofthis excitement. He further addedthat journey of understanding thecode is a continuous process.Engineering talent in the countryshadowed by the IT boom is now inhuge demand. He further addedthat Pressure Vessels being anengineering marvel still remain anexcellent avenue tickling one’sdesign engineering skills.”

Introducing the learned faculty, Mr.Venkateshwaran praised Mr. B JShenoy’s willingness to share hisknowledge with the delegates. Healso recalled his interaction withMr. Shenoy years back on a certainproject. Further he described Mr.Shenoy as a practical trainer and agood teacher that will enhance thequality of the workshop.

Finally, it was the turn of Mr. P JBhounsule, Director PPMAI todeliver the valedictory address. Healso gave away certificates to thedelegates and Curtains lowered onthe two day event that concludedwith a hearty vote of thanks by theSecretary, Mr. V P Ramachandranwho requested participants’feedback and asked them to sendtheir queries to PPMAI which hesaid will be replied by Mr. Shenoy.


Mr. M. P. Dhanuka, Executive Director(Marketing), Gee Limited, MumbaiThane - 400 004

1.0 IntroductionWelding today, has become one of themost important tools for efficientmaintenance of plants and qualityfabrication in industry.It has come to play a vital role in thegrowth and development of a variety ofimportant sectors of the economy such asthermal, hydro, nuclear and wind powergeneration, petrochemicals, off-shoredrilling, steel plants, industrial machinery,heavy engineering, ship building,transportation fertilizers, oil & waterpipelines, etc.Welding Technology today is not merelya joining method but it is effectively usedfor cladding, hard-surfacing, cutting andfor variety of other applications.Most of the time welding engineers orinspectors think that weld metal qualitydepends largely on either skill of thewelder or on the quality of weldingconsumables used for depositing weldmetal. However, there is a thirdimportant variable/factor which doescontribute to the quality of depositedweld metal and that important variable/factor is quality or type of power sourceused, while depositing the weld metal.In order to derive maximum benefits interms of productivity and quality,welding engineers/supervisors shouldstudy the latest trends in weldingprocesses and consumables available forvarious arc welding processes, so thatthey can derive maximum benefits andcan become globally competitive.

2.0 TRENDS IN WELDINGCONSUMABLES:Last year i.e. during the year 2006-2007,steel production in India was about 49.0million tons.Consumption pattern of the steel showsthat growth is more confined to longproducts, which are mainly used forconstruction activities. As far as weldingis concerned, there has been growth ofabout 8 to 10% as compared to previousyear.Last few years have seen distinct changetowards MIG/MAG welding from SMAW(MMAW) process. However, the changeis confined to large and medium

TECHNICALLatest Development In Welding Consumables For Special Steels

fabricators. The consumption figures of welding consumables available form theindustries are tabulated in Table 1.

TABLE 1(All Figures in Metric Tons)

Sr. Manual Metal MIG/MAG Submerged TIG TotalNo. Arc Welding Welding Arc Welding Welding1. Deposited weld 138000 61000 18000 3000 220000

metal (2006-2007)2. Electrodes/Wire 216000 63000 18000 3000 300000

(2006-2007)

During 2006-2007, in our country, about62 percent of weld metal was depositedby using SMAW process whereas about28 percent weld metal was deposited byusing MIG/MAG process. The trend isobviously to use more and more MIG/MAG process, using solid, flux cored ormetal cored wires for increasing overallproductivity in the shopfloor.

3.0 TRENDS IN SMAW WELDINGCONSUMABLES :With the global competition, ourfabricators have become more qualityconscious. Many of them have receivedISO-9000 certification and ASTM-UStamp. The welding engineers stipulatetheir requirements of weldingconsumables by preparing specifications,which are usually based on ASME SectionII Part ‘C’ specification.The latest trends of welding consumablesfor welding special steels observed are asunder:

4.0 IMPROVED QUALITY OF SOLIDWIRES FOR MIG/MAG WELDINGFew manufacturers of welding wires,produce CO2 grade wires, grade ER 70S-6, ER 70S-G, ER 80S-G etc in whichcopper coating is carried out byelectroplating process. Such wires whenused give following advantages:A. Uniform copper coating - which

results in better feedability.

B. No flaking of copper becauseadherence of copper on the wireis100%.

C. Current transfer is more consistant.

D. Less fumes with the even andconsistant copper coating.

4.1 USE OF METAL CORED WIRESFOR MIG/MAG WELDINGFor welding high tensile, low alloy andcreep resisting steels, welding engineershave started switching over to metalcored wires instead of fluxcored wires.4.11 Distinct advantages of Metal coredwires are as under:a) Possible to produce small batch.b) Deposited weld metal has lower

impuritiesc) Arc stability is excellent and wetting

characteristic of the weld to theparent metal is very good whichresult in 100% radiographic qualitywelds.

d) Lower diameter metal cored wirescan be used in (1.0 mm dia)positional welding.

Few examples of popular metal coredwires which are being used by fabricatorsare as under:1. E 70C-3C2. E 70C-G3. E 70C-6M4. E 80C-G

4.12 Welding of galvanized steels:Low carbon and low alloy galvanizedsteels are used in the structure of ships orin the field of automobile manufacturing.For welding galvanized steel sheets orpipes, a new grade of metal cored wiretype E 70C-G has been developed. Thewire is being used in large quantities forwelding of galvanized steel sheets andpipes.

Contd. Pg. 25



4.2 FLUX CORED WIRES FOR MIG/MAG WELDING:In the recent years, depending uponapplications, flux cored wires have beendeveloped for welding low-alloy hightensile steels, weathering steels,cryogenic steels, etc. These wires areusually rutile as well as basic type and areavailable in diameter 1.20 mm or 1.60mm.

4.3FLUX CORED WIRES FORHARDFACING APPLICATION OR FORRECLAMATION WELDING:Variety of flux cored wires either self-shielded or gas shielded are now beingused in increasing quantity for hardfacing /reclamation welding. Fewexamples are reclamation of cement millrolls, pulleys. Caterpillar tracks rollers,crusher jaws, excavator parts, etc.

5.0 CELLULOSIC ELECTRODES FORPIPE LINE WELDINGEven today for laying cross-countrypipelines, cellulosic electrodes arepreferred. These consumables help toincrease the productivity and are nowsupplied in tin containers, which arehermetically sealed.Such containers retain moisture in theflux coating of electrodes, which is anessential feature for obtaining desiredpenetration and performance whilewelding. For welding of cross-countrypipelines, the pipe line designers havestarted specifying following cellulosicelectrodes for welding:a) E7010-P1b) E8010-P1c) E8010Gd) E9010G

EX010-P1 (pipeline) electrodes havebeen designed primarily for weldingtypical high strength, pipe butt joints inthe vertical welding position withdownward or upward progression. Thesespecially formulated cellulosic electrodesare best suited for achieving fullpenetration and radiographic quality.Usually E7010 - P1 is recommended forwelding of APl-5L-X52 and E 8010-P1electrode for APl-5L-X65 pipingassemblies respectively. Even today, fewfabricators use cellulosic electrodes, typeE7010-G and E8010-G for similarapplications.

6.0 HYDROGEN CONTROLLED, MOISTURE RESISTANCE ELECTRODES :With the revision of AWS/SFA 5.1 and AWS/SFA 5.5 specifications, weldingengineers could be more specific while writing their requirements of weldingconsumables. The revised specifications allow users to mention what type of hydrogencontrolled electrodes are required and whether they are looking for moisture resistanttype basic coated electrodes.

TABLE 2, gives information on how welding engineers could stipulate their require-ments, depending on the job specifications/ critical application. Welding consumablesmanufacturers usually supply moisture resistant electrodes in hermetically sealed tincontainers or in vacuum pouches. The use of moisture resistant electrodes eliminateexpensive drying before use and eliminate or reduce post weld heat treatment for manyapplications. ]

Type of basic coated Same type with Same type with requirementselectrode requirementsof diffusible of diffusible hydrogen in

hydrogen in the weld metal the weld metal and moistureresistant coatin specification

E 7018 E7018-H4 E 7018-H4RE 7018-H8 E 7018-H8R

E 7016-1 E 7016-1 H4 E 7016-1 H4RE 7016 -1 H8 E 7016-1 H8R

E 8018-B2 E 8018-B2 H4 E 8018-B2 H4RE 8018-C1 E 8018-C1 H4 E 8018-C1 H4RE 9018 M E 9018 M H4 E 9018 M H4RE 11018 M E 11018M H4 E 11018M H4R

7.0 E7018/E7018-1ELECTRODES FOR OFF-SHORE FABRICATIONS �PROCESSPLATFORMS INVOLVING WELDING OF NACE STEEL.NACE specification for such special types of E7018/E7018-1 electrodes is given inTable No. 3

TABLE 3Type of electrodes Max. ‘Mn’ Max. ‘S’ Max. ‘P’ Content

Content (%) content (%)E 7016 )E 7016-1 ) 0.010 0.012E 7018 ) -1.40E 7018-1 )

)

8.0 E7018/E7018-1 ELECTRODES WITH HIGH IMPACT VALUES AT SUBZEROTEMPERATURES :For specific applications such as critical parts of steel plants, off-shore platforms, fewdesigners stipulate very high impact requirements at sub-zero temperatures. Theserequirements are given in Table 4.Type of Electrodes Impact requirements at sub - zero temperature

E 7016-1 100 Joules at minus 460CE 7018-1 100 Joules at minus 460C

Designers are of the opinion that the weld metal deposited from such high qualityelectrodes, has unique property of ‘resistance to ageing’ and thus under severe serviceconditions, the weld metal does not fail and thus helps to achieve continuous desiredproductivity year after year.

9.0 NEWLY DEVELOPED WELDING CONSUMABLES FOR WELDING OF T/P 92MATERIAL.Designers of power plants have started recommending T/P 92 grade alloyed steel in

Contd. Pg. 22 Latest Development In Welding Consumables For Special Steels


place of T/P 91 for following benefits :a) 30% gain on the admissible stress at6000C .b) A significant reduction in thicknesscan be obtained. Weight reduction givesbenefit of overall cost reduction of thepower plant.

C) Time of fabrication can be reduced.

d) Improved creep properties as well astoughness properties.CHEMICALANALYSIS OF ASTM A 355 � GRADEP 92.

Chemicals %C 0.07-0.13Mn 0.30-0.60S 0.010 maxP 0.020 maxSi 0.50 maxCr 8.50-9.50Mo 0.30-0.60V 0.15-0.25N 0.03-0.07Ni 0.40 maxAl 0.04 maxNb 0.04-0.09W 1.50-2.00B 0.001-0.006

MECHANICAL PROPERTIES OF P/T -92 MATERIAL.UTS - 620 Mpa Minimum0.2% Proof Stress - 440 Mpa MinimumElongation - 15% Minimum(L=5d)

9.1 NEWLY DEVELOPED WELDINGCONSUMABLES FOR P92/T-P 92Basic type electrode E9018-G has beendeveloped with controlled BORONcontent in the weld metalCHEMICAL PROPERTIES OF THEWELD METAL (E 9018-G) are as under:

Chemicals %C 0.10Si 0.30Mn 1.0Cr 9.0Mo 0.50V 0.2Co 1.0Nb 0.05N 0.04W 1.7B 0.003Al 0.010 maxCu 0.05

9.2 SAW WELDING CONSUMABLESFOR P92/MATERIAL.Suitable metal cored wire Aluminate -Fluoride basic type flux have beendeveloped.

DEPOSITED WELD METALCHEMISTRY IS AS UNDER (SAW) :

CHEMICALS %

C 0.10SI 0.30MN 1.0CR 9.0MO 0.50CO 1.0V 0.2NB 0.05N 0.04W 1.7B 0.002AL 0.02 MAXCu 0.05 max

Contd. Pg. 19 Hydrogen Induced Cracking (Hic) &Sulphide Stress Corrosion Cracking (Sscc)

to be Contd ....

e. Crack Length Ratio (CLR) <10%

f. Crack Sensitivity Ratio (CSR) <5%

In this case, the steel havingthe above mentioned chemistrylevel is tested by taking samplesas specified in NACE - TM - 02 -84. As per NACE -TM- 02 -84,test specimen shall be taken atthe mid of the width side (2500mm side) of the plate. Thelongitudinal axis of the testspecimen shall be parallel to theprinciple rolling direction of theplate.

It is observed that most of the plateswhich comply with the impurityrestrictions (S, P) pass the HIC tests.

Some Clients simply specify “The steelshall meet NACE requirements” (or) “Wet Hydrogen Sulphide requirements”.

These are vague statements, since there isnothing like “NACE requirements” unlessthe applicable NACE specifications are

spelt out with acceptance criteria.Similarly, depending on the level of H2Scontent and the type of equipment,different consultants select differentmaterial testing requirements andacceptance criteria. It is not unique.

Wherever possible, we can substituteForgings / Pipes in place of Plates, ifprocurement of small quantities isdifficult. Examples are:

a) Floating Head Dish / Shellcover Dish / Channel CoverDish

b) Shell cover Barrel / ChannelBarrel of small dia (~ 400mm)

c) Tube Sheets

d) Nozzle necks

Production / Quality ControlDepartments shall be aware of thefollowing with respect toNACE / HIC Equipments:

1.HIC / Hydrogen service equipmentswill always be subjected toHardness restrictions. Hence, heat

inputs during welding shall be keptto the bare minimum and also weldrepairs shall be kept low by carefulWelding practices.

2.For HIC equipments, the bevelededges shall be MP tested for 20mmfrom the edges, apart from theregular DP test of beveled edges toensure that the plates are nothaving any lamination, at least nearthe welding Zone, which otherwisewill develop further after welding.

3.HIC equipments are subjected to100% RT, on the HIC side. If shellside is HIC. then the Floating Headof AES / AKT /BKT exchangersare made of Lipped Construction sothat the Dish to Flange joint canalso be subjected to 100% RT.

4.HIC equipments are sometimessubjected to Wet FluorescentMagnetic Particle Test (WFMT) asan additional NDT apart from PT&RT. This can detect microfissures in welding area.


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