SAFETY PRECAUTIONS DURING MARCH’09

SHUT DOWN

PRESENTED BY,

Mr. Jahanzeb Khan

Date: 07.03.11

KRIBHCO SHYAM FERTILISER LTD.

AMMONIA PLANT COMMISSIONED ON 22/11/1995

REASSESSED CAPACITY 1520 MTPD (w.e.f. 01/04/2000)

TECHNOLOGY HALDOR TOPSOE

UREA PLANT

COMMISSIONED ON 23/11/1995

REASSESSED CAPACITY 2 X 1310 MTPD

(w.e.f. 01/04/2000)

TECHNOLOGYSNAM PROGETTI

ATR- March 2009

Duration- 19.5 Days Dates

-Start of shut down : 13/03/2009

-Urea one unit production : 31/03/2009

-Ammonia production : 01/04/2009

-Urea 2nd unit start up : 01/04/2009

Ammonia Plant

-Primary reformer tube & catalyst replacement.

-Secondary reformer job

-RG Boiler job

-HTS Catalyst job

-Synthesis gas turbine overhauling

-Ammonia converter jobs

-Synthesis loop boiler Replacement

MAJOR JOBS

Energy saving Schemes

Ammonia Product Heater installation PR NG Fuel pre heating PAC discharge line modification CAPH duct modification Ammonia Plant DCS replacement

Urea Plant

Urea reactors and stripper inspection Exchangers cleaning Blow down and vent stack pipe replacement HP passivation air compressor installation Prilling Tower epoxy coating Bentley Nevada vibration monitoring system

hook up

Offsites

CT return header shifting Job GTG-I Generator overhauling

Why Annual Turnarounds ????

ATR, a planned activity- annually or biannually Annual turnarounds for:

-Jobs – Breakdowns, repairs, overhauls, improvements, modifications etc-Statutory compliances-Cleaning of equipment

-Catalyst loading, washings, internal repairs -Inspections and testing of equipment & machines -

Adding new equipments -Up gradations & replacements

Shutdown job lists

ATR job list include -Uncompleted jobs from the previous ATR

-Jobs identified during the entire year-Special inspections – statutory, testing, improvements-Jobs out of analysis reports – NDT, tech suppliers, OEMs-Jobs that can be only done during utilities stoppage-Jobs on vessels for catalyst change, cleaning, repairs etc

Jobs Planning

Job lists reviewed on monthly basis between departments

Unique job number for each job which gets frozen All jobs are identified & tagged in field before ATR Each job planned – manpower, material & timelines Bar chart for major planned jobs Spacing of jobs as per vendor availability Risk assessment for each job by process &

maintenance No job done without a permit

Material / Spares planning

Done well in advance – ATR material separately identified

Early orders for each critical items & OEM supplies All temporary lines, fittings, structures - pre fabricated Prior testing & overhauling of equipments like Cranes, forklifts, lifting tools etc Access equipment, hydraulic platforms etc Portable tools like grinders, drills, welding machines etc Advance availability of materials & tools from

contractors

Services planning

Advance intimation of the ATR dates to all Pre visits of service providers for job understanding Tests for skilled workers conducted – welders,

riggers etc Clear guidelines for safety in job execution Safety training given in advance to all external work

force

Annual Turn Around – Job Cycle

Start

Preparation of ATR job list

Meetings between Production & Maintenance functions to finalize the Shut Down Manual.

Check the Risk Assessments

Identify the Safety Guide lines / PPE requirements

Inputs:

Maintenance repairs

Inspections

Process requirements

NDT recommendations

Cleaning

Carry out risk assessment

Continued ……

YES

No

JOB CYCLE…. Continued

Include all Guide line in Shut Down Manual against Each Job.

Hand Over the S/D Manual to all Concerned Dept. /Section/ Persons

Stoppage, Isolation and Purging of Equipments as Per SOP

Issue the SWP for Maintenance crew

Return all SWP after completing

the Job to S/I

Updation on SAP

Trial Run by Production

Carry out the job with full Adherence of SWP

Guidelines

Process Planning – Shutdown Manual

A Comprehensive Process Handbook which includes: Schedule of shutdown & start up Detailed job lists (Area wise) & Bar chart for major jobs Risk assessment of each activity Procedures for Shutdown of each section Special activities - hydro testing, catalyst replacement,

cleaning Purging of sections & checklist of major maintenance jobs with sketches Critical inspections & vessel entry Start up of utilities & each sections

Safe Work Procedures

A safe work procedure can be defined as the written instruction of a task/activity outlining the preferred method whilst emphasizing ways to minimise any risk(s) of harm. A safe work procedure outlines the hazards, risks and associated controls measures to be applied to ensure the task/activity is conducted in a way to reduce the risk of injury.

DEVELOPMENT

Safe work procedures should be developed for all tasks/activities, processes, and the operation of equipment and machinery, where a risk assessment identifies the requirements as a suitable control measure to reduce the risk of injury.

PROCESS STEPS

To aid in the development of a safe work procedure the following steps should be followed:

Step 1. Observe the task or process;Step 2. Record the sequence of basic job stepsStep 3. Assess potential hazards of each stepsStep 4. Review associated legislative

requirements

Step 5. Assess the risk of Hazards;

Step 6. Suggest ways of eliminating and controlling the hazards;

Step 7. Test the procedure by consultation and verify relevant issues are documented

Step 8. Obtain approval of the procedure from a supervisor or manager.

In determining potential hazards in a task or process the following factors could be considered

Is there exposure to noise, fumes or dust? How can equipment fail in any way? Is the work physically strainers? Is the work made harder by external factors ( climate,

noise etc.)? Is there enough space to move about? Can the person be caught in, on or between anything

Can the person be struck by or contacted by anything while doing this step of the job

Do loads need to be lifted/or handled? Can the person slip or trip or fall What level of supervision is required? Is the work made harder by the way it is organised ? Is there any requirement specified in relevant legislation?

PRIORITIES

It is recognized that, in some areas, the preparation of safe work procedures may take some time.

The priorities for the preparation of safe work procedure should be:

All new task where there is a high to medium risk should have safe work procedures prepared before they are put into general use;

For existing processes, safe work procedures for high risk tasks should be prepared first, followed by medium and low risk tasks;

Safety Systems in ATR

Safety of Man, Machine & Equipment – Top Priority No job without Risk assessment & Scheme / procedure No job without Safety Permit All class 1 permits - Inspected by Safety officer Additional process people posted as safety officers Safety observers – Internal & External Cross functional inspection teams for entry & box up of

each Vessel Check lists and sign-offs for each inspection Registers for blinds / vessel entry with sign-offs

Safety in ATR

Training Communication of safety norms to all personnel Safety talk every morning & before start of each job

Contractors Medical tests before jobs Training & tests on job execution Checking & certification of all new equipment brought to site 100% adherence to use of PPEs Proper arrangements for rescue - availability of crane, ambulance & constant watch on working personnel inside the

vessel

Checking of Safety Systems & Logics

Each component of safety logic is checked Trip switches, transmitters, vibration probes & other

key elements are removed, calibrated & installed back

After installation all Trip interlocks cross checked through manual simulation

Stroke checking of ALL control valves Calibration of all critical PSVs Hydro test of all critical exchangers

Start up

Systematic leak check - initially with IG at lower pressure then at operating pressure

For each activity like purging, filling, start up etc A documented procedure cum check list Optimum utilization of trained manpower for different

activities Comparison of efficiencies – machines, reactors, exchangers, catalysts performance etc

Shutdown Report & Records

Shutdown report includes: Planned vs. actual timings for major activities Details of key jobs done Section wise observations of inspections & repairs Surprises Analysis & improvements achieved Observations regarding safety & environment lapses Identification of area of improvements Learning & best practices observed

AFTER ATR

AMMONIA PLANT CAPACITY : 1725 TPD

UREA PLANT CAPACITY : 2825 MTPD

ON STREAM DAYS : 350

ANNUAL UREA PRODUCTION : 988750 MT

THANK YOU