Urea Monthly Operation Report [Aug-2013]

8/13/2019 Urea Monthly Operation Report [Aug-2013]

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Prepared By: MUR (E-II)

Reviewed By: SMZ (DAY ENGINEER)

Approved By: MSM/ SAK (UM/ Sr UM)

UREA PLANT OPERATIONSMONTHLY REPORT [AUG 2013]


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TABLE OF CONTENTS

Urea plant production status ......................................................................... 1

Consumption Figures ..................................................................................... 1

Total down time status ................................................................................. 2

Achievements ............................................................................................... 3

Urea Plant Highlights ..................................................................................... 4

Health Safety & Environment ......................................................................... 7

Concerns ...................................................................................................... 08

Daily Production status ................................................................................ 09

Product Quality ............................................................................................ 11

Man Power Status ....................................................................................... 13


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UREA PLANT OPERATIONS MONTHLY REPORT [AUG, 2013]

FATIMA FERTILIZER COMPANY LTD 1 Page

UREA PRODUCTION FOR THE MONTH

Target 32005 MT of Urea

Actual Production 35076.05MT of Urea

Difference +3071.05 MT of Urea

UREA PLANT AVERAGE LOAD 77.17 %

(Basis: 30.30 days)

UREA PLANT MAXIMUM LOAD 80.63 %

HIGHEST PRODUCTION DURING THE MONTH 1282.53 MTPD

CONSUMPTION FACTORS

(At 70 % Plant Load)

Design/Actual

Ammonia consumption per MT of Urea: 0.578/0.578 tons

Steam consumption per MT of Urea: 1.38/1.66* tons

CO2consumption per MT of Urea: 0.725/0.75 tons

Electrical consumption per MT of Urea: 24.5 /42.29* KWh

*Plant is running at an average of ~77.17% Load, while consumption factors are for 100% plant

Load.


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TOTAL DOWN TIME

No. of Shutdowns = 02

Total down time of the Month (Aug-13) = 16.78 Hrs

SR No ACTIVITY DATE TIME DOWN TIME TRIPPING REASON

1

Shutdown 28-08-13 07:47 hrs

10.78 Hrs

Cold Box (Rimming) leading to

Planned shutdown of NH3-Plant

backend

Startup 28-08-13 18:30 hrs

2

Shutdown 29-08-13 14:50 hrs

06 Hrs

E-102 A/B Tube rupture

Startup 29-08-13 20:50 hrs


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ACHIEVEMENTS

1. 12-Million Combined Safe Man Hours

Congratulations to all FFL employees on achieving 12 million combined (Permanent &

Contractual Employees) safe man hours on 26th

of August 2013, appreciate the efforts of all

those involved in achieving this remarkable milestone.

2. Urea Plant Injury Prevention Plan

Urea IPP prepared and presented in Executive HSE Committee meeting by SMZ, it was

appreciated by forum, and stewardship is in progress.

3. Mechanical seal failure of Steam Condensate circulation Pump (P-903 A)

During routine changeover of P-903 B to A, mechanical seal of P-903 A failed and heavy leakage

of steam condensate (~160 C) started meanwhile FSHH-1213 A/B/C timer actuated (ESD-1001

actuation time is 120 sec), board man quickly communicated to the area operator and P-903 A

stopped and flow adjusted from P-903 B. Emergency very well managed by DCS board man as it

might lead to ESD-1001 actuation and he also handle the abnormalities in plant parameters as

S.C circulation in Pool Reactor tubes reduced.

4. Urea Dust Dissolving/Recycling

Urea dust dissolving remained in progress during the month. Total dust recovered for the month

of Aug was 3585 bags i.e.; 179.25 MT of Urea. Despite of this dust recovery load, urea product

quality remained within design limits.

5. Urea Product Quality

Urea Product quality was maintained in allowable limits during humid weather and at low load,

Improvement in product fines observed after cleaning scrapper bed.

6. NP Plant Load Limitation

NP plant facing load limitation due to Low CO2flow from Urea plant, one factor contributing was

Low suction pressures at NP CO2compressor suction. By collaborative efforts between Urea and

NP operations team, pressure at NP CO2 Compressor suction increased to maintain CO2 flow

keeping Urea CO2Compressor in safe operating range.


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HIGHLIGHTS

OPERATIONAL ACTIVITIES

1. Scrapper Floor bed dry cleaning carried out.

2. IPP (Injury Prevention Plan) and FPP (Fire prevention Plan) for urea plant prepared and finalized.

3. Cooling water optimization at Urea plant remained continued during the whole month as Plant

Load varied.

4. Urea dust dissolving remained in progress during the month. Total dust recovered for the month

of Aug was 3585 bags i.e.; 179.25 MT of Urea.

5. Routine audits carried out and MWRs raised.6. Emergency talks conducted on various emergencies of urea plant during night shifts.

7. HP Ammonia Pump startup class room training conducted by M.Umar Riaz as per Technical

Training calendar urea plant for year 2013.

MAINTENANCE ACTIVITIES

1. E-102 B is handed over to maintenance for tube leakage rectification and to implement cooler by

pass installation modification. Tube bundle pulled out and inspected by Inspection team,

condition was very rusty.

Urea Dust dissolving


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2. Suction strainers of P-801 A/B, P-151 A/B, P-901 A/B, P-703 B, P-705 B, P-306 B, P-901 A/B, P-

309 A, P-903 A/B, P-802 B, P-303 B, P-951 A/B (discharge strainer) cleaned during the month.

3. P-801 A seal flush cooler cleaned, found chocked with mud.

4. Safety shower (near P-151 A/B) hand wheel problem rectified by maintenance.

5. PV-119 D/S steam trap bypass leakage rectified by maintenance.6. Gland leakages rectified at Vacuum section.

7. Prill Tower Elevator detailed maintenance carried out by maintenance team in the presence of

its vendor and it was remained out of service most of the time during the month. Now it is

working ok.

8. PSV-P363B calibrated by maintenance.

INSTRUMENT ACTIVITIES

1. AI-1261/1201 calibrated by Instrument team.

2. YT-2Y (Stage 2 Radial vibration) erratic reading problem rectified by Instrument.

3. PT-1024 and TT-1024 at 3rdstage discharge of CO2Compressor calibrated by Instrument team.

4. TT-1145 sensing cover replaced by Instrument as it was suspected that metallic pieces in G-602 B

are due this cover.

5. FSLL-1213 A/B/C Loop verified by instrument for changing ESD-1001 timer activation on HH flow

of P-903 A/B. Modification will be implemented after MOC approval.

6. LT-1024 A/B/C calibrated during shut down.

LT-146

1c

alibration

P-951 A/B discharge strainer

P-801 A seal flush cooler


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MACHINERY ACTIVITIES

1. P-903A mechanical seal replaced by machinery team.

2. G-602 A/B Mechanical cleaning carried out.

3. V-161 L.O console oil breather Mesh cleaned by machinery team.

4. G-602 B shifted to W/S after dismantling as abnormal sound observed from the bearings. NowG-602 B installed again after bearing replacement and running normal.

5. K-101 L.O replaced by machinery.

6. P-953 A/B, P-252 and P-309 A/B oil replacement/makeup carried out by machinery team.

7. K-101 and K-851 suction filter cleaned.

ELECTRICAL ACTIVITIES

1. PM-802B bearing replaced by Electrical as motor was giving abnormal sound.

2. PM-703 B bearing replaced by Electrical as motor was giving abnormal sound.

3. Abnormal sound observed from PM-703 A, problem was rectified by greasing of motor.

4. Abnormal sound observed from PM-705 A, problem was rectified by greasing of motor.5. Motor greasing and PM carried out on weekly basis.

6. Voltage measurement at KT-102 shorey/carbon brushes and K-102 gear box earthing brush

measured by electrical, declare ok.

7. Preventive maintenance of Prill tower Elevator carried out.

8. KM-851 taken in service after winding. Now, it is running fine.

K-851(Ventilator for Scrapper)


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HEALTH SAFETY AND ENVIORNMENT

1. Congratulations to all FFL employees on achieving 12 million combined (Permanent plus

Contractual Employees) safe man hours on 26th

of august 2013.

2. Fire Break Glass unit # 126 at Prill tower top inspection carried out by Electrical, declare ok.3. Emergency Response plan Role statement discussed with shift team with reference to

preparation of mock drill planned other than routine mock drill.

4. Following Incident report (IR-01) raised during the month;

P-903A mechanical seal failure Elevator got stuck at 5thFloor Ammonia Recirculation cooler tube rupture

5. Following topics were discussed in weekly D-Level meeting;

Fire Detection and Alarm system MOC Technology Piper Alpha (Safety Beacon) Executive HSE waiver PSSR (Pre-startup safety review)

6. The oil spillage from the breather of the K-102 lube oil circuit run down tank is a constant

cause of slippery stairs / railings and unsatisfactory housekeeping in the CO2 compressor

area. Issue needs to be addressed at the earliest. Machinery team is already aware about

the problem.

7. Flash reports issued were discussed on regular basis with team.

8. HSE procedures discussion continued during night shift.

9. Management safety audit conducted as per schedule at urea plant. 07-unsafe actions and 01

unsafe condition reported. All observations status is close now.

10.19-observations related to HSE reported during the month, 14 observations status is close

now, remaining are open.


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CONCERNS

1. Compressor operating parameters are deteriorating with time, second stage pressure is high

and 3rd stage pressure is low with high temp, RPM of machine is running high at low plant

load, compressor stages efficiency as calculated by process is also low, need to investigate in

detail and rectify the root cause.

2. Flow dips observed in FT-1021 so to get margin, second antisurge valve is opened so due to

more recycling, rpm of machine is high which causes high steam consumption.

3. Oil droplets from Rundown tank are cause of high concern as it can be cause of slippage and

also a big hazard for fire.

4. E-102 B 03-leaked tubes have been plugged after SFT and hydro test. E-102 B tube bundle

pulled out and inspected by inspection, its condition is deteriorating, declared misfit for

operation, working on bypass is in progress

5. As both Ammonia recirculation coolers are unavailable due to tube rupture. So, P-102 A is

running with recycle line isolated, executive HSE waiver has been taken on the subject issue.

E-102 B is handed over to maintenance team for tube plugging and cooler by-pass

modification job. They are working on it and plugged 02 leaky tubes.

6. K-102 pinion ACP (anti-coupling) side journal bearing temperatures (at TT-2125/26)

remained high i.e.; greater than 100 C, during the month. Now, temperatures are stable at

110/114 C, problem communicated to vendor and proposed solution is still pending.

7. FT-1232 remained fluctuating, the faulty reading issue is minimized after installation of

sunlight shed at FT, but could not be completely ruled out. MOR is initialized by Instrument

team for remote display of transmitter.

8. P-301 B outboard radial vibration were high i.e. VI-2301/2302 B were 46/57 um,

respectively.

9. LT-1135 at P-401 A/B (Urea Melt Pumps) suction remained erratic during the month and LV-

1135 remained on Manual mode. These cause level fluctuations at melt pump suction and

cause disturbance in associated parameters.

10.Some Asset number/tags are missing in eAM maintenance module, end users are facing

problems in raising MWR, problem communicated to the concern.


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PRODUCTION PROFILE

Sr No Date Production MT

1 1Aug, 2013 1246.37

2 2Aug, 2013 1271.45

3 3 Aug, 2013 1275.54

4 4 Aug, 2013 1275.78

5 5Aug, 2013 1245.32

6 6Aug, 2013 1169.16

7 7 Aug, 2013 1131.148 8 Aug, 2013 1160.55

9 9 Aug, 2013 1276.47

10 10 Aug, 2013 1062.45

11 11 Aug, 2013 1046.89

12 12 Aug, 2013 1098

13 13 Aug, 2013 1201.56

14 14 Aug, 2013 1282.53

15 15 Aug, 2013 1195.33

16 16 Aug, 2013 1123.8817 17 Aug, 2013 1124.22

18 18 Aug, 2013 1124.05

19 19 Aug, 2013 1125.43

20 20 Aug, 2013 1122.49

21 21 Aug, 2013 1124.39

22 22 Aug, 2013 1123.70

23 23 Aug, 2013 1122.66

24 24 Aug, 2013 1124.39

25 25 Aug, 2013 1123.7026 26 Aug, 2013 1087.02

27 27 Aug, 2013 1056.40

28 28 Aug, 2013 574.39

29 29 Aug, 2013 786.50

30 30 Aug, 2013 1192.04

31 31 Aug, 2013 1202.25


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PRODUCTION PROFILE

Production Profile

Month of Aug, 2013

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Production MT


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UREA PRODUCT QUALITY ANALYSIS

Date Moisture (%) Biuret (%) APS (mm) Fines (%)

1Aug, 2013 0.36 1.05 2.11 0.6

2Aug, 2013 0.37 1.01 2.07 1.0

3 Aug, 2013 0.39 0.96 2.12 0.9

4 Aug, 2013 0.39 1.06 2.06 0.6

5Aug, 2013 0.40 1.03 2.09 0.6

6Aug, 2013 0.36 1.04 2.11 1.0

7 Aug, 2013 0.36 1.0 2.11 0.3

8 Aug, 2013 0.36 1.01 2.11 0.6

9 Aug, 2013 0.37 1.0 2.09 0.5

10 Aug, 2013 0.37 1.05 2.12 0.6

11 Aug, 2013 0.40 1.04 2.13 0.4

12 Aug, 2013 0.39 1.02 2.11 0.4

13 Aug, 2013 0.35 1.04 2.10 0.7

14 Aug, 2013 0.41 0.98 2.17 0.4

15 Aug, 2013 0.42 0.98 2.08 0.9

16 Aug, 2013 0.36 1.10 2.14 0.6

17 Aug, 2013 0.42 1.02 2.12 0.5

18 Aug, 20130.35 1.07 2.11 0.5

19 Aug, 2013 0.34 0.97 2.10 0.2

20 Aug, 2013 0.38 0.99 2.15 0.8

21 Aug, 2013 0.38 1.05 2.10 0.8

22 Aug, 2013 0.34 1.04 2.10 0.9

23 Aug, 2013 0.35 1.05 2.11 1.3

24 Aug, 2013 0.39 1.08 2.13 0.5

25 Aug, 2013 0.34 1.05 2.10 0.7

26 Aug, 2013 0.38 1.06 2.12 0.7

27 Aug, 2013 0.37 1.08 2.12 0.7

28 Aug, 2013 0.37 1.02 2.10 0.6

29 Aug, 2013 0.35 1.05 2.13 0.6

30 Aug, 2013 0.39 0.98 2.20 0.3

31 Aug, 2013 0.39 1.06 2.12 0.7


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Month of Aug, 2013

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31Aug,

Moisture (%)

Biuret (%)

APS (mm)

Fines (%)


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MAN POWER STATUS

*Congratulation to Mr. Ch. Akbar for his promotion to Sup-II. *Congratulation to Mr. Naeem, Mubeen, Dewarka and Arslan for their promotion to Opt-II.

MANAGEMENT

Sr. No Designation No of Employees

1 Sr. UM 1

2 UM 1

Sr. Engr 1

2 Engineer I 3

3 Engineer II 1

5 GTE 1

Total Manpower 8

Total Permanent Manpower 7

STAFF

Sr. No Designation No of Employees

1 Sup I 3

2 Sup II 1

2 *Sup III 4

3 Opt I 0

4 *Opt II 7

5 Opt III 3

6 Manpower on contract 0

7 Apprentices 1+4

Total 23

Total Permanent Manpower 18

Documents

Urea Monthly Operation Report [Aug-2013]