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USING ONLINE TECHNOLOGIES TO ACHIEVE

MAINTENANCE EXCELLENCE INCLUDING CASE

STUDY ON FIXING HYDROGEN LEAKAGES AT A

RUNNING PLANT

With: Rizwan Rasul

TECHNOLOGY FOCUSTECHNOLOGY FOCUS

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CONTENTS

PART I

COMPANY INTRODUCTION, PHILOSOPHY,

PERFORMANCE & ACHIEVEMENTS

PART II

ONLINE MAINTENANCE TECHNOLOGIES

PART III

CASE STUDY ON FIXING HYDROGEN LEAKAGE

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FFC INTRODUCTION

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FFC's missionFFC's mission

To sustain role as leader in industrial and agricultural

advancement of Pakistan by setting and achievingnew and higher goals, and taking initiatives

FFC is committed to ensuring safe and conducivework environment, providing high quality products

and allied services to its customers and profitable

returns to its shareholders

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FAUI FERTILIZER COMPANY LTD. incorporated in 1978.

First plant commissioned in June 1982.

Design production capacity 1,725 MeT Urea/DayUprated production capacity 2,105 MeT Urea/Day

Second plant commissioned in March 1993.

Design production capacity 1,925 MeT Urea/Day

Third plant acquired in March 2002.Design production capacity 1,740 MeT Urea/DayUprated production capacity 2,175 MeT Urea/Day

COMPANY BACKGROUND

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Operation and maintenance of facilities to:Operation and maintenance of facilities to:

Ensure safety of personnel and assets

Ensure environmental sustainability

Maximize plant efficiency by regular optimization

Ensure mechanical integrity of equipment

Ensure prompt & effective response to

emergencies

Root cause analysis to avoid recurrence

FFC PHILOSOPHY

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ONSTREAM SERVICE FACTOR (FFC-I)

50

60

70

80

90

100

82-84 85-87 88-90 91-93 94-96 97-99 00-02 03-05 06-08 09-11

Per

cent

Years

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ONSTREAM SERVICE FACTOR (FFC-II)

50

60

70

80

90

100

94-96 97-99 00-02 03-05 06-08 09-11

Perc

ent

Years

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ONSTREAM SERVICE FACTOR (FFC-III)

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CONTINUOUS ONSTREAM RECORD

PLANT AMMONIA UREA

FFC-I Syn Gas Generation 535 days 388 days

Ammonia Synthesis 204 days

FFC-II Syn Gas Generation 523 days 249 daysAmmonia Synthesis 223 days

FFC-III Syn Gas Generation 491 days 131 days

Ammonia Synthesis 143 days

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SAFETY vs PRODUCTION

1407

1507

1462

1426

1494

15161523

1459

1593

1569

1640 1638

1501

0.82

0.630.63

0.58

0.31

0.15

0.4

0.15

0.23

0.23

0.16

0.00

0.15

0

0.5

1

1200

1700

96 97 99 00 01 02 03 04 05 06 07 08 09

TRIR

UREA

PRODUCTION(X

1000)MET

YEARS

TOTAL RECORDABLE INJURY RATE VS PRODUCTION( FFC-GM 1996-2009 )

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MILLION MANHOURS WITHOUT LWI

Award of HonorAward of Honor 1616

First Place AwardFirst Place Award 0505

Second Place AwardSecond Place Award 0404

Award of MeritAward of Merit 0404

Outstanding Safety Award 02Outstanding Safety Award 02

Perfect AwardPerfect Award 0303

Industry Leader Award 03Industry Leader Award 03

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MAINTENANCE PHILOSOPHY

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CHANGE FOR THE BETTER

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NIPPING OF PRIMARY REFORMER

CATALYST TUBES

ONSTREAM OFF-TAKES BY HOT TAPPING

ONLINE MAINTENANCE OF VALVE

ACTUATORS

ONLINE LEAKAGE RECTIFICATION

ONLINE TECHNOLOGIES

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CATALYST TUBE NIPPING

TECHNIQUE TO ISOLATE BLOCKED ORLEAKING TUBE FROM PROCESS STREAM

HAZARDOUS ACTIVITY WITH POSSIBLITY

OF SUDDEN TUBE FAILURE

REQUIRES PRACTICE, PRECISION AND

EFFECTIVE COMMUNICATION BETWEEN

EXECUTION TEAMS

AVOIDS EXPENSIVE TOTAL COMPLEX

SHUTDOWN OF AT LEAST 3 DAYS

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INLET HEADERHAIR PIN

CATALYST TUBE

PIG TAIL

HOT COLLECTOR

Nipping point for inlet hairpin

Nipping point for outlet pigtail

LEAKING POINTLEAKAGE STOPPED

CATALYST TUBE NIPPING

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BEFORE NIPPING

TUBE IS GLOWING

CATALYST TUBE NIPPING

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AFTER NIPPING PIG

TAIL IS DARK

CATALYST TUBE NIPPING

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ONSTREAM OFF-TAKES BY HOT TAPPING

HOT TAPPING ON

VACCUM SERVICE

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ONLINE MAINTENANCE OF VALVE ACTUATORS

PROBLEMATIC

VALVE ACTUATOR

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ONLINE MAINTENANCE OF VALVE ACTUATORS

CLAMP FOR HOLDING

VALVE STEM

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ONLINE MAINTENANCE OF VALVE ACTUATORS

CLAMP INSTALLED

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METHODOLOGYMETHODOLOGY

ASSESSMENT AND EXTENT OF LEAKAGE

INITIATION OF ONLINE LEAKAGE

RECTIFICATION CHECKLIST

INSPECTION CHECKS SUCH AS

THICKNESS MONITORING AT THEPERIPHERY OF LEAKAGE

ONLINE LEAKAGE RECTIFICATION

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METHODOLOGYMETHODOLOGY OPTIONS FOR ARRESTING LEAKAGE

PEENING & WELDING

PAD INSTALLATION

CLAMP INSTALLATION

WITH SEALANT INJECTION WITHOUT SEALANT INJECTION

APPROVAL OF SAFE OPERATIONS COMMITTEE

MONITORING OF PARAMETERS DURING JOB

EXECUTION

ONLINE LEAKAGE RECTIFICATION

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HYDROGEN LEAKAGE

Service : 60% Hydrogen

11% Methane

Temperature : 790 C

Pressure : 32 kg / cm2

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HYDROGEN LEAKAGE

DIA 1800 mm

CLAMP INSTALLED

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Flange Size : 8 1500 lbs

Temperature : 50 C

Pressure : 90 kg / cm2

CO2 LEAKAGE

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CO2 LEAKAGE

CLAMP INSTALLED

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Service : 60% H219% CO2

Temperature : 260 C

Pressure : 32 kg / cm2

HYDROGEN LEAKAGE

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HYDROGEN LEAKAGE

WELDED BOX-UP

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VERY HIGH PRESSURE STEAM LEAKAGE

Flange Size : 8 2500 lbs

Temperature : 500 C

Pressure : 103 kg / cm2

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Service : MDEA + CO2

Temperature : 75 C

Pressure : 62 kg / cm2

MDEA LEAKAGE ON COLUMN

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MDEA LEAKAGE ON COLUMN

WELDED BOX-UP

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Service : MP Steam

Temperature : 220 C

Pressure : 23 kg / cm2

MP STEAM LEAKAGE

MP STEAM LEAKAGE

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MP STEAM LEAKAGE

WELDED BOX-UP

LIQUID AMMONIA LEAKAGE

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Service : 100% Liquid NH3

Temperature : 29 C

Pressure : 19 kg / cm2

LIQUID AMMONIA LEAKAGE

LIQUID AMMONIA LEAKAGE

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PREPARATION & PRE-ARRANGEMENTS

LIQUID AMMONIA LEAKAGE

LIQUID AMMONIA LEAKAGE

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LIQUID AMMONIA LEAKAGE

WELDED BOX-UP

PROCESS GAS LEAKAGE

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PROCESS GAS LEAKAGE

BFW PRE-HEATER

Flange Size : 2000 mm

Temperature : 300 C

Pressure : 38 kg / cm2

SEGMENTAL CLAMP

CASE STUDY OF UNIQUE LEAKAGE

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CASE STUDY OF UNIQUE LEAKAGE

GOVERNING FACTORS

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GOVERNING FACTORS

PLANTS ARE AGING

ENDEAVOR TO EXTRACT MAXIMUM LIFECYCLE OF EQUIPMENT

LONG TURNAROUND CYCLES

SUB-SURFACE DEFECTS DURING ERECTION

INSPECTION AND REPAIR OF EVERYTHING IS

NOT POSSIBLE

PROCESS FLOW DIAGRAM

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PROCESS FLOW DIAGRAM

PG from

F-201

Secondary

ReformerR-203

From AirCompressor

E-208A

E-208B

HT CO Shift

Convertor

R-204

H2 = 55.4%

N2 = 22.19%

CO = 11.7%

CO2 = 9.74%

CH4 =0.77%

H2O = 82450

H2 = 55.4%

P = 31.8 Kg/cm2

T = 378 oC

FACTS

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FACTS

No isolation valve or bypass line available

Line size 24 inch D/S of WHB E-208

Piping material Ferritic Alloy-Steel (A-335 Gr. P-I)

No Pre-heating, Post heating & Post Weld HeatTreatment Possible

INFLUENCING FACTORS

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MAJOR SAFETY HAZARD

Explosivity 100%

POTENTIAL PLANT DOWN TIME

Elbow replacement activity would require

complex shutdown of 108 hrs

Online welding on Process Gas with 55.4% H2 was

not attempted before.

INFLUENCING FACTORS

PREPARATION & PRE-ARRANGEMENTS

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Job Execution Sequence Reviewed on

Appropriate Forums Job Safety Analysis Carried out

Consensus of Execution Team Developed

Motto: DONT FORCE YOUR TEAM

PREPARATION & PRE ARRANGEMENTS

PREPARATION & PRE-ARRANGEMENTS

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Special Scaffold Platform with Multiple

Escape Routes Provided Operations crew on standby to Shutdown

the Plant

Rescue Squad on Standby

PREPARATION & PRE ARRANGEMENTS

ONLINE BOXUP IDEA

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ONLINE BOXUP IDEA

Installation of Box-up clamp in two halves

Installation of ejectors (Qty: 02 Ea) on the clamp to

prevent accumulation of explosive gas inside the clamp

Supply of Nitrogen from opposite side to ejectors to

purge out remained traces of gas

Monitoring of vacuum inside the clamp through Vacuum

Gauge

Welding of clamp after explosivity test

CLAMP DESIGN

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CLAMP DESIGN

Detail A

CLAMP DESIGN

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Detail A

PIPE TO ELBOW WELD JOINT

REINFORCEMENT

PIPE TO ELBOW WELD JOINT

REINFORCEMENT

OVALITY OF PIPE & ELBOWOVALITY OF PIPE & ELBOW

CLAMP DESIGN

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CONNECTIONS FOR

STEAM EJECTORS

CONNECTION FORNITROGEN SUPPLY

CONNECTION FOR

VACUUM GAUGE

ESCAPE PLATFORM

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R-204

R-203

ACTIVITY SEQUENCE

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Steam supplyto ejector

NitrogenSupply

Vacuum gauge

Complete welding of box-up clamp

ACHIEVEMENT

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Job completed successfully within ONE week

of reported leakage

Major achievement in Safety Preparedness

Clamp remained in service for1 Years

Improved confidence for arresting similar

leakages

TREES REQUIRE FERTILIZER

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THEY MAY ALSO REQUIRE CLAMP

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FLOURISHING EVEN TODAY

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