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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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