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REPORT
Prepared By:
Mouaz Khaleeq Butt
Muhammad Aqib
Engros
history.
Involving
maintenance,
planning
and
development
of
comprehensive
turnaround
procedures put the company in a strong position and this, coupled with close
and adequate supervision, is the recipe for a successful turnaround.
I am confident that with your best efforts our turn around will be safe and
successful.
Asif Tajik
Vice President, Manufacturing
(Chairman, Manufacturing HSE)
Executive Summary
TA-2016 was planned in order to improve service factor and unavoidable scheduled
maintenance. This also provided the opportunity to carry out major and minor
maintenance and modifications to improve process safety and reliability.
Since Plant-1 TA-2016 had enormous scope of jobs, it was in no way less challenging
than the last outage owing to the time constraints. The preparations for this
turnaround were being made way ahead of the scheduled day. A comprehensive
HSE plan was formulated to ensure safe completion of the turnaround without
compromising on Health, Safety and Environment, the core focus areas of Engro.
Execution of the HSE plan in its true spirit resulted in achieving envious results with
regard to the set objectives.
From Operations standpoint the principal focus was already upon the secure
handover of process equipment/machines to the relevant interfaces for
maintenance jobs. In order to achieve this goal, extensive planning was carried out
and an effective LOTO strategy was formulated. All jobs were discussed in detail
among the shift personnel which led to the avoidance of any possible delays.
There were a few surprises which led to delays in completion of the jobs. These
include extensive maintenance jobs on furnace which were not part of the plan
initially but due to their criticality had to be completed.
Major jobs executed during TA-2016 at F-2501 were catalyst replacement, tubes
replacement, burner replacement and refractory repairs. There were numerous
miscellaneous jobs completed as well.
Apart from this, KGT-2501 overhauling was a critical path activity. The rotors of
compressor, gas turbine and steam turbine were replaced. Also extensive cleaning
of filter house was carried out.
Overhauling of K-2502 HP-case was carried out. Job scope included adjustments and
bearings replacement of IP-case to rectify the high vibrations experienced during
normal operation. Steam turbine rotor of compressor K-2503 was also replaced.
In addition to major jobs, a dedicated team was deployed to supervise the Greenlist
jobs. More than 500 Greenlist jobs at Ammonia-II were attended which in itself is a
great achievement.
Although the TURN AROUND - 16 was concluded safely without an occurrence of a
major process or safety incident, but many lessons were learnt during the time. The
lessons have been listed with the aim to help relevant personnel learn from
experience and evade their presence in the future.
HSE PLAN
MPT`s.
11 Noise controls during
blowing.
Safe lines
Handover
of Equipments
12
Electrical
hazards
and
prevention.
ding refresher trainings, tagging of blinds and 100% new locks ensured safe handover of equipment without an
13 Awareness and cautionary banners in the
area.
HSE COMPLIANCE
F-2501
Introduction
Primary reformer usually referred to as furnace is the heart of ammonia
plant. F-2501 is a Foster Wheeler, terrace walled furnace, and here steam
reforming of natural gas takes place over Nickel based catalyst in the radiant
tubes. It has been improvised to use the exhaust of KGT-2501 as combustion
air which in addition to not only reducing the fuel requirement, also helps in
mitigating the effects of changes in environmental conditions.
Scope of Work
The furnace was the part of the plant where most of the jobs were planned
and a major overhaul of the furnace was successfully completed in TA-2016.
Below mentioned are the most critical activities.
Catalyst Replacement
The catalyst in primary reformer was last charged in April-2000. In TA-2016
the catalyst in all (392) tubes has been replaced. The new charge of catalyst
has a layer of pre-reduced catalyst (R-67R-7H), for faster startup, at the top.
This is then followed by a bed of normal reforming catalyst (R-67-7H). The
top and bottom layers comprise 15% and 85% of bed height respectively.
The cumulative volume of the catalyst is 1230 ft3.
During the catalyst removal activity there were a few setbacks. Initially the
catalyst was to be unloaded by removing the bottom flange followed by
removal of the bottom holding cone.
But during the execution the bottom holding cones broke This left the cones
stuck inside the tubes with no other means to remove the catalyst from
bottom it was decided by the process team that vacuum machines would be
used
to
suck
the
catalyst
out
from
the
top
flanges.
Burners replacement
The burners in F-2501 are post mix where fuel and air are introduced
separately and in TA-2016 all burners have been replaced. This is done in
order to reduce the back pressure generated by the older burners which had
smaller diameter holes, this led to issues of flame lift off resulting in
reduction in furnace efficiency.
Carburized plates of the burners were also replaced as required.
OLD BURNER
NEW BURNER
Refractory Repair
Refractory inside the furnace was damaged due to prolonged operation,
resulting in escapeof heat. To minimize the heat losses refractory repairs at
various places inside the fire box were completed. In addition to this peep
doors internal refractory, burners and air duct insulation was also replaced.
Bull Noses were also inspected and repaired or replaced as required in TA2016.
OLD TRANSFERLINE
COLD COLLECTOR
TRANSFERLINE JOINT
COLDWITH
COLLECTOR
JOINT
Misc. Jobs:
KGT-2501
STEAM INLET HEADER (New)
Since its continuous operation for past 18 years, this machine was in dire
need of maintenance. During TA-2016, KGT-2501 inspection and Rotors
replacement were carried out. In terms of its scope as well as being a critical
path activity, this was one of the most major jobs.
Upon inspection, its rotor, impellers and guide vanes, bearings, were found
damaged and were replaced. This includes Steam Turbine (KT-2501) rotor
replacement, HP, LP air compressor (K-2501) rotor replacement, KGT-2501
rotor replacement and maintenance.
Job Scope
DAMAGED BEARING
Besides
rotors
replacement of HP,
LP, Steam turbine
and gas turbine
other
parts
including
IGVs,
Bearings, nozzles
and Buckets were
found
damaged.
Extensive
maintenance work
was performed on
KGT-2501 in this
context
HP CASE ROTOR
Steam turbine Rotor was inspected and was found damaged. First stage
nozzles, Thrust bearing, journal bearing conditions was also not healthy.
CARBORIZED SHROUDS
K-2502
Introduction
K-2503
Introduction
K-2503 is an integral part of the refrigeration loop at backend. It is a
horizontally split centrifugal compressor with two cases having seven and six
NEW AND
OLDcompressor
ROTOR. CRACK
ON NEW ROTOR
4TH STAGE were
(Right found
side)
On inspection,
Refrig
turbines
2 diaphragms
cracked.
Mechanical OST:
After its maintenance and overhauling, following standard protocol, K-2503s
mechanical OST was tested.
After bypassing electronic OST, Machine was ramped up to almost 9000
RPMs but mechanical OST didnt actuate. Machine had to be tripped
manually. After cleaning of OST pin assembly, and its spring replacement,
2nd OST attempt was made but the result was same.
Taking into account that rotor has been in use for 18 years, it was
decided to take wavier of mechanical OST and rely on electronic OST
alone.
Heat exchangers
Several Exchangers inspection, cleaning hydro-testing was done. The major
exchangers attended during TA-2016 are as follows:
E-2518, E-2522, E-2528, E-2523A/B, E-2526, E-2524, E-2506, E2502/3/4, E-2514, E-2509C, E-2511 A-H, E-2501A/B, E-2539, E-2538
A/B andE-2537A/B/D
GREENLIST
During TA-2016 around 513 Greenlist jobs were attended. The other major
categories of jobs attended include:
Temporary Repairs.
PSVs Calibration.
Projects Jobs.
140
Control Valves.
126
120
97
100
80
72
60
46
40
31
20
0
Total
%
Completion
Complet
ed
405
29
120
4
5
2
95%
62%
87%
75%
40%
50%
385
18
104
3
2
1
Inspection
Overall
1
566
0%
91%
0
513
APS Modificaiton
APS is installed to provide automatic startup
of standby pumps in case of deviation of
Process variable from set point or tripping of
one of the pumps. This system was by design
pneumatic, with total control in field. During
TA-2016, APS modification which was
planned in 2004 has been implemented,
making this an electronic system. The new
system provides indication on TDC in control
room making it much simpler and user
friendly, while making emergency handling easier.
LOGIC
HIC-2411 closed
HIC-2411 closed
HIC-2411 close with total site
blackout
ENCOP
ENCOP
-1
ENCOP
Startup Highlights
Smooth start
up
Safe Start up
in
first
attempt
without any
problems or
failures.
Major delays
Catacarb Run
CATACARB RUN
Catacarb run
that
was
Catacarb
run
planned pre
that
was
shutdown
planned
initially pre
was
shutdown
of 4 hours
initially
4
but was ofgot
extended
for
hours
but got
more thanfor
10
extended
hoursthan 10
more
hours
Steam circuit
lineup
Steam circuit
was lined up
without issues
of hammering
F-2501catalyst
F-2501CATALYST
unloading
UNLOADING
Difficulty
encountered in
Difficulty
Catalyst
encountered
in
unloading due
Catalyst
unloading
to bottom
cones
due
to
bottom
damage
and
cones
damage and
vacuum
machinemachine
vacuum
inefficiency
inefficiency
let to let
a
to
a
slight
set
slight set back
back
No natural
gas leak
Effective
LOTO
Strategy,
Trainings
ensured
safe start
up
and
shutdown
F-2501
F-2501
unplanned
UNPLANNED
maintenance
jobs
MAINTENANCE
Besides
JOBS
major
jobs
Besides major
that
were
jobs
that
were
planned
at
planned
at
furnace,
furnace,
severalseveral
jobs
jobs
came
thatthat
came
on
and
onspotspot and
weren'tpartpart
weren't
of
of
the
the timeline.
timeline.
Lessons learnt
Although TA-2016 concluded safely without any injury or fatality but there
were a few close calls endangering not only the personnel but also posing
serious threats to the property and equipment. Keeping in view the policy of
Engro to learn from such incidents below is a brief summary of the incidents
and their learnings to prevent such issues from occurring again.
E-2534 vapor outlet flange leakage:
Ammonia level transfer was in progress from Ammonia reservoir (D-2528) to
ammonia chiller (E-2534) and approximately after 5 to 10 minutes, E-2534 vapor
outlet line flange leakage started. Tube cleaning of E-2534 was carried out during TA2016. Approximately 20 persons were working on compressor deck and they felt
ammonia smell as wind direction was from TK-200 to airport gate. One of the
instrument person got ammonia exposure in eyes, while he was helping another
scaffolder who was coming down from compressor deck, as a result of that he
panicked and got his harness entangled in stairs
Although, previous rigging during transfer line removal was done under
similar condition, but base plates were not present beneath the crane out
riggers to evenly distribute load.
Also, a survey prior to rigging should be conducted in rigging area, to ensure
the health of floor/space on which rigging needs to be carried out.
Fire cloth should be placed properly near the hot job area.
KGT-2501:
After KGT-2501 startup, when machine was ramped up to 3537 RPM, people in the
field heard explosion sounds (2 explosions) inside KGT exhaust plenum. Immediately,
the machine was tripped from Control room. After tripping, very high (987 OF) exhaust
temperature along with erratic vibrations probes readings were observed.
Area Personnel being vigilant and present were able to detect this event on
time. This type of vigilance and presence should be shown in operating area
especially during startups and shutdowns.
Because of machine overhauling, maintenance, and modifications; its
performance parameter should have been re-evaluated to implement
necessary change.
PIC-131 condensate splash:
Absorber vent upstream flange was being opened by standing underneath the same
flange. Suddenly, condensate started showering from flange. Luckily the person was
saved because condensate didnt shower on him. (Permit was given for drain /
depressurized condition. He was not using Face Shield / Splash suit).
This kind of incident goes to show how important PPEs are and how their
violation can result in injury. So the importance of PPEs cannot be over
emphasized as they are the last line of defense against any potential injury.
Also, sharp edges of scaffolding should be covered with cloth.
E-2514 BLIND OPENING:
A blinded flange at inlet of E-2514 gas side was opened by DESCON workers during
Hydrotesting activity. The upstream end of the flange was pressurized with ~10psi
nitrogen. Opening of the flange resulted in loud sound and release of gas which is a
violation of issued permit. The work was being performed un-supervised at Catacarb
post during lunch hours