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    Engro'S Experience: in The Construction and Start Up of A Jumbo-Scale Plant

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    Ajay Sastry
    This document provides an overview of the EnVen 1.3 fertilizer plant project in Pakistan. Some key details include: - The plant has the largest single train urea plant and one of the largest urea complexes in the world. - Safety was a high priority, with the total recordable incident rate aimed to be less than 0.5 and extensive safety organizations and reporting. - Construction involved multiple contractors and was completed in 43 months, with commissioning taking an additional 3 months. - The plant started ammonia production within 12 days of beginning the startup process and achieved urea production within 48 hours of ammonia production.

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    Engro'S Experience: in The Construction and Start Up of A Jumbo-Scale Plant

    Uploaded by

    Ajay Sastry
    56 views43 pages
    This document provides an overview of the EnVen 1.3 fertilizer plant project in Pakistan. Some key details include: - The plant has the largest single train urea plant and one of the largest urea complexes in the world. - Safety was a high priority, with the total recordable incident rate aimed to be less than 0.5 and extensive safety organizations and reporting. - Construction involved multiple contractors and was completed in 43 months, with commissioning taking an additional 3 months. - The plant started ammonia production within 12 days of beginning the startup process and achieved urea production within 48 hours of ammonia production.

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    fertilizer

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    This document provides an overview of the EnVen 1.3 fertilizer plant project in Pakistan. Some key details include: - The plant has the largest single train urea plant and one of the largest urea complexes in the world. - Safety was a high priority, with the total recordable incident rate aimed to be less than 0.5 and extensive safety organizations and reporting. - Construction involved multiple contractors and was completed in 43 months, with commissioning taking an additional 3 months. - The plant started ammonia production within 12 days of beginning the startup process and achieved urea production within 48 hours of ammonia production.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    56 views43 pages

    Engro'S Experience: in The Construction and Start Up of A Jumbo-Scale Plant

    Uploaded by

    Ajay Sastry
    This document provides an overview of the EnVen 1.3 fertilizer plant project in Pakistan. Some key details include: - The plant has the largest single train urea plant and one of the largest urea complexes in the world. - Safety was a high priority, with the total recordable incident rate aimed to be less than 0.5 and extensive safety organizations and reporting. - Construction involved multiple contractors and was completed in 43 months, with commissioning taking an additional 3 months. - The plant started ammonia production within 12 days of beginning the startup process and achieved urea production within 48 hours of ammonia production.

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    INAMULLAH NAVEED KHAN

    VP MANUFACTURING
    ENGRO FERTILIZERS LTD
    PAKISTAN
    IN THE CONSTRUCTION
    AND START UP OF
    A JUMBO-SCALE PLANT
    ENGROS EXPERIENCE
    EnVen1.3 PROJECT OVERVIEW
    HaldorTopsoeAmmonia Plant with 2,194 MTD
    SAIPEMUrea Plant with 3,835 MTD
    Largest Single Train Urea Plant in the World
    One of the largest Urea Complex in the World
    Tallest PrillTower of the World (125 m)
    CO2Recovery (350 MTD) fromFurnace Flue Gases
    Environmentally Compliant Plant with Flare System
    TRIR & Man-hours Trend
    Statistics
    May-11
    2.2
    5.7 11.2
    20.1
    32.0
    43.0
    50.0 51.6
    0.45
    1.3
    2011

    Consciousness
    Jun-07
    Dec-07
    Jun-08
    Dec-08
    Jun-09
    Dec-09
    Jun-10
    Dec-10
    0
    0.19
    0.18
    0.16
    0.22
    0.22 0.25
    0.28
    0.27
    TRIR & Man-hours TRIR
    0.2
    8
    Man-hours
    51.6
    Jun-11
    COD
    Land Leveling
    Earth Movement
    Excavation
    Air Condition/ HVAC
    Precast Bar Bending
    Foundation work
    Concrete work
    MANNING
    H
    A
    Z
    A
    R
    D
    Refractory works
    Insulation on grounds
    Low Hazard/
    High Manning
    Low Hazard/
    Low Manning
    High Hazard/
    Low Manning
    High Hazard/
    High Manning
    Prill Tower Slipforming
    STR-101/ Concrete work at heights
    Painting & insulation at height
    Cutting
    Welding
    Grinding
    Vessel Entry
    Structure Steel Erection
    Rigging
    Startup
    Gas in
    Scaffolding at Height
    Piping erection at height
    Hydro-test
    Blowing
    Process Fluid
    2Q 07
    4Q 07
    1Q 08
    4Q 08
    1Q 09
    2Q 09
    4Q 10
    - Machinery Startup
    - Heavy Rigging
    - Electrical Circuit
    Energization
    - Prill Tower External
    Painting at Height
    - Excavations post startup of UG
    services
    1.3
    2011

    Technology
    Project Executive
    SOC Chairman
    Sub
    SOC
    (P)
    Sub
    SOC (M)
    Sub
    SOC
    (I&E)
    Sub
    SOC
    Civil
    Sub SOC
    Environment
    Sub
    SOC
    IRRC
    Safety
    Advisor
    Safety Engineer (1)
    Safety Facilitator with
    Construction Dpt. (35)
    Safety Supervisor (1)
    Safety Facilitator (11)
    Descon HSE Team
    Manager (1)
    Engineer (20)
    Officers/ Sup (40)
    Assistant (20)
    Doctor (1)
    Paramedic (2)
    HSE Or gani zat i on
    Pr oj ect SOC & Sub SOCs
    Saf et y sect i on r ol e and
    r esponsi bi l i t i es
    Cont r act or s Saf et y
    Or gani zat i on
    Saf et y f aci l i t at or f or ever y
    const r uct i on j ob
    I ndi vi dual Char t er f or SOCs
    avai l abl e
    HSE Organization
    PROJECT
    EXECUTIVE
    PLANNING &
    CONTRACTS
    MANAGER
    ENGINEERING
    MANAGER
    CONSTRUCTION
    MANAGER
    AMMONIA, UREA
    CONSTRUCTION
    MANAGER
    UTILITIES
    SAFETY
    ADVISOR
    Planning,
    Contracts &
    Procurement
    Engineers
    Process, Project
    Machinery,
    Civil, I&E
    Engineers
    Project,
    Inspection,
    Civil, Machinery
    Safety
    Engineers
    CEO
    OPERATIONS &
    START-UP
    MANAGER
    Operations
    Engineers &
    Supervisors
    CONSTRUCTION
    MANAGER
    I & E
    I & E Engineers
    Project,
    Inspection,
    Civil, Machinery
    I&E Engineers
    SENIOR ADVISOR
    QA/QC
    QA/QC
    Engineer
    ENGINEERS: 85
    OPERATORS &
    TECHNICIANS: 152
    TOTAL: 237

    ENVEN 1.3 PROJECT CONTRACTING


    STRATEGY
    Overall Project Management
    EP
    Ammonia, Urea
    Selected Utilities
    Saipem
    Engineering
    SP Netherlands
    Purchase & Supply
    Of Equipment
    Saipem, Madeira
    Limited Construction
    SupervisionSaipem, Italy
    CONSTRUCTION
    Ammonia, Urea
    Utilities & PM&S
    Descon
    EP
    Utilities,PM&S
    EFERT
    LSTK
    Offsite Facilities
    Descon
    EPC
    CO2 Recovery Project
    Descon
    EP-WLGE
    CONS-Descon
    Ammonia Storage Proj
    1
    Based on Schedule
    Descon
    35%
    EFERT
    Engineering &
    Procurment
    15%
    Saipem
    Engineering &
    Procurement
    45%
    Commissioning
    5%
    1

    ENVEN 1.3 PROJ ECT
    SAFETY
    TRIR <0.5
    PSRM& PSM
    PHA / HAZOP
    Project Specific
    Systems
    Contractor Safety
    Monitoring &
    Reporting
    Incident Investigation
    QUALITY
    FATs & SATs
    Construction Quality
    Quality Assurance
    Checklists
    Hold point concept
    Internal quality
    reviews
    Limited Construction
    supervision
    COST
    Regular
    Monitoring
    Independent
    Reporting
    Monthly &
    Quarterly
    Variance
    reports
    InterimReviews
    SCHEDULE
    Integrated Team
    Use of modern softwares
    for monitoring & reporting.
    Monthly & Quarterly Reports
    Proactive Approach to
    mitigate
    Positive variance
    InterimReviews
    0
    10
    20
    30
    40
    50
    60
    70
    80
    90
    100
    M
    a
    r
    -
    0
    7
    A
    p
    r
    -
    0
    7
    M
    a
    y
    -
    0
    7
    J
    u
    n
    -
    0
    7
    J
    u
    l
    -
    0
    7
    A
    u
    g
    -
    0
    7
    S
    e
    p
    -
    0
    7
    O
    c
    t
    -
    0
    7
    N
    o
    v
    -
    0
    7
    D
    e
    c
    -
    0
    7
    J
    a
    n
    -
    0
    8
    F
    e
    b
    -
    0
    8
    M
    a
    r
    -
    0
    8
    A
    p
    r
    -
    0
    8
    M
    a
    y
    -
    0
    8
    J
    u
    n
    -
    0
    8
    J
    u
    l
    -
    0
    8
    A
    u
    g
    -
    0
    8
    S
    e
    p
    -
    0
    8
    O
    c
    t
    -
    0
    8
    N
    o
    v
    -
    0
    8
    D
    e
    c
    -
    0
    8
    J
    a
    n
    -
    0
    9
    F
    e
    b
    -
    0
    9
    M
    a
    r
    -
    0
    9
    A
    p
    r
    -
    0
    9
    M
    a
    y
    -
    0
    9
    J
    u
    n
    -
    0
    9
    J
    u
    l
    -
    0
    9
    A
    u
    g
    -
    0
    9
    S
    e
    p
    -
    0
    9
    O
    c
    t
    -
    0
    9
    N
    o
    v
    -
    0
    9
    D
    e
    c
    -
    0
    9
    J
    a
    n
    -
    1
    0
    F
    e
    b
    -
    1
    0
    M
    a
    r
    -
    1
    0
    A
    p
    r
    -
    1
    0
    M
    a
    y
    -
    1
    0
    J
    u
    n
    -
    1
    0
    J
    u
    l
    -
    1
    0
    A
    u
    g
    -
    1
    0
    S
    e
    p
    -
    1
    0
    O
    c
    t
    -
    1
    0
    N
    o
    v
    -
    1
    0
    D
    e
    c
    -
    1
    0
    %

    C
    u
    m
    m
    u
    l
    a
    t
    i
    v
    e

    P
    r
    o
    g
    r
    e
    s
    s
    0
    1
    2
    3
    4
    5
    6
    7
    8
    %

    M
    o
    n
    t
    h
    l
    y

    P
    r
    o
    g
    r
    e
    s
    s
    Monthly Planned Baseline
    Monthly Planned Forecast 4
    Monthly Revised Actual Progress
    Monthly Planned Progress (August
    2009)
    Cummulative Planned Progress
    Baseline
    Cumulative Planned Forecast 4
    Cumulative Revised Actual Progress
    Cummulative Planned Progress (August
    Planned : 100.00%
    Actual : 99.96%
    1.- 2010
    1
    Engg&Procurement
    Snamprogetti
    ECPL
    Const / Mechanical Completion
    Utilities
    Ammonia
    Urea
    Critical Path Items
    Cooling Water Pumps
    Process Air Compressor
    Ammonia Piping
    Primary Reformer
    Sub-Critical Path Items
    Offsite EPC Contracts
    Ammonia Storage
    Commissioning
    Pre-Commissioning
    Commissioning
    Production
    end-Aug 2009
    end-March 2010
    17 J an 2010
    25 April 2010
    18 J une 2010
    31 Oct 2009 mid-Aug 2009
    15 April 2010
    mid-Oct 2009
    mid-May 2008
    25 April 2010
    06 April 2010 end-Aug 2008
    01 J uly 2007 30 May 2009
    mid-May 2007
    J une 2009
    May 2009
    Oct, 2010
    J an 2010
    Dec, 2010
    Increase in construction quantities.
    De-watering Surprise on start of Civil Works
    Industrial peace issues & their impact
    Unprecedented rains & floods in 2010.
    Failure of weld joints on critical path systems towards the end.
    Commissioning delay by 22 days due to fire at syncomp.
    COD delays due to non-availability of gas
    PWHT machines must be audited properly before acceptance.
    Construction contractor must not be given full authority on QA/QC
    QA/QC functions must be directly reporting to Project Executive
    Average experience of QA/QC team must be around 10 years
    Work on radiography scope from the initial phase of construction
    Killed carbon steel material must be marked before fabrication
    Welding of heavy thickness piping must be done first
    N
    o
    .

    o
    f

    W
    e
    l
    d
    s
    Techniques Used
    Team Build-up
    Procedures development
    More than 530 procedures were developed for operational activities
    Training
    400 man hours per person thru following trainings;
    In house classroom training
    Similar technology plants
    Training by technology licensors
    Training on Operator Training simulator (OTS)
    Pre-commissioning
    High pressure test of Synthesis loop at 200 Kg/cm
    2
    in addition to normal activities
    Commissioning & Start-up
    Frontend commissioned in 05 days
    Back-end commissioned in 07 days
    Urea on-spec achieved with-in 48 hours of ammonia production
    Same vendor was selected for DCS & OTS
    A number of potential shut downs were saved by
    OTS trained operators
    Front end was normalized in record 05 days
    Malfunctions & Controller behaviors were well-
    understood upfront and fixed.
    OTS HALL
    Control Room
    OTS HALL
    Control Room
    System-wise requirements audit
    Pre-startup Safety Reviews (PSSR) recommendations closure
    Temporary gaskets audit
    Piping conformity audit by SAIPEM for frontend
    Instrument air leakage audit
    Pre-startup PHA recommendations closure
    Audit for completion of permissive for feed-in
    Housekeeping & Combustible Material Audit
    OTS HALL
    Control Room
    CW low
    pressure
    on pump
    change-
    over
    A wrong
    signal was
    generated by
    cooling water
    pumps ESD
    which
    resulted in
    nuisance I-1
    Control
    Power
    failure to
    reformer
    ID fan
    speed
    probes
    due to
    tripping of
    power
    distribution
    cabinet.
    I-1 was
    manually
    activated due
    to fire at
    synthesis
    machine.
    Air
    compressor
    tripped and
    protection
    steam in air
    convection coil
    was not
    established in
    time due to
    slow response
    of protection
    steam flow
    control valve.
    DATE MONTH Milestones / Activities
    4-Apr-2007 0 Effective date of contract
    19-Dec-2009 32
    nd
    Start of Steam blowing
    12-Jun-2010 39
    th
    Air compressor commissioned
    20-Aug-2010 41
    st
    Ammonia storage commissioned
    11-Nov-2010 43 m 7 days Feed-in to Primary Reformer
    16-Nov-2010 43 m 12 days Frontend Normalized in 05 days
    17-Nov-2010 43 m 13 days Backend start-up heldback due to gas limitation
    29-Nov-2010 43 m 25 days Fire at SynCompressor
    20-Dec-2010 44 m 16 days Restart of Synthesis Compressor
    26-Dec-2010 44 m22 days AmmoniaProduction
    29-Dec-2010 44 m25 days Urea Production
    GAS CONSUMPTION DURING PRE-COM& COMMISSIONING
    Energy for Pre-commissioning 550,000 G cal
    Energy for commissioning & startup 650,000 G cal
    Total Energy consumption 1,200,000 G cal
    Front end Startup & normalizationfrom feed in 05 days
    Backend startup & Production 07 days
    Effective Ammonia plant startup time barring thegas 12 days
    outage & Syn comp incident
    Total waste water generated 26 Million US Gal
    Construction completion timefrom effective date of contract 43 months 22 days

    EmergencyResponse
    The machine was immediately shutdown by using
    fieldmanual switch.
    The fire was extinguished immediately by operating
    delugesystem(water sprinkler).
    RemedialMeasures
    Carried out quality assurance checks of all thermo-
    wells &instrument hook-ups on all critical / hazardous
    systemsandseal welded.
    Install all thermo-wells as per standard practice given
    inANSI StandardonNPTthreads.
    Background
    During pressurization of syncompressor, thermocouple
    at recycle suction dislodged.
    Dislodging of a thermo-well resulted in Fire.
    Flames from the fire hit air compressor turbine.
    Faulty installation of threadolet, which didnt allowed the
    thermo-well to be fully tightened.
    Excessive root penetration hindered thermo-well
    insertion
    Thredolet 3
    rd
    Suction Line after Flame Impingement
    Ammonia feed pump, P-01B tripped on high vib
    security, restarted but tripped again.
    Ebara responded proactively & impeller hub was
    shortened.
    Similar modification was done at the other pump
    CO2compressor surging on 02 occasions
    Min governor speed was changed from 5693 to
    6476 rpm
    Extensive training of manpower and well-structured utilization of
    Thorough and once through pre-commissioning
    Several layers of audits performed
    All circuits pressure tested
    Synthesis loop was tested at 200 Kg/cm2 pressure with nitrogen
    All critical circuits were pressure tested with nitrogen / air.
    Frontend was pressure tested with nitrogen and soap test was carried out.

    April 2007
    November 2010
    Apr 2007 Sep 2007
    Oct 2007 Nov 2007 Dec 2007
    Jan 2008
    Feb 2008 Mar 2008
    Apr 2008
    May 2008
    Jun 2008 Jul 2008
    Furnace in Operation
    Purification Post at Night
    450 Tons Synthesis Converter Reactor Rigging by 1200T Crane
    365T Urea Reactor (R-01) erected using 1200T Crane
    165T LP/HP Flash Drum (V-301/302) erected using 1200T Crane
    385T CO2 Absorber (C-302) erection using 1200T Crane
    450T Prill Tower Truss Structure lifted to 109m Elevation
    Ammonia Storage Tank Commissioned
    5000 MT NH3Capacity
    Double-Walled Tank
    Men @ Work
    Men @ Work
    Men @ Work
    Safety Talk
    DAHARKI EXPANSION

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