UREA PLANT OPERATIONS

MONTHLY REPORT [AUG, 2013]

Prepared By: Reviewed By: Approved By:

MUR SMZ

(E-II) (DAY ENGINEER)

MSM/ SAK (UM/ Sr UM)

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

UREA PLANT OPERATIONS MONTHLY REPORT [AUG, 2013]

UREA PRODUCTION FOR THE MONTH

Target Actual Production Difference

32005 MT of Urea 35076.05 MT of Urea +3071.05 MT of Urea

UREA PLANT AVERAGE LOAD (Basis: 30.30 days) UREA PLANT MAXIMUM LOAD HIGHEST PRODUCTION DURING THE MONTH

77.17 %

80.63 % 1282.53 MTPD

CONSUMPTION FACTORS (At 70 % Plant Load)

Design/Actual Ammonia consumption per MT of Urea: Steam consumption per MT of Urea: CO2 consumption per MT of Urea: Electrical consumption per MT of Urea: 0.578/0.578 tons 1.38/1.66* tons 0.725/0.75 tons 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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UREA PLANT OPERATIONS MONTHLY REPORT [AUG, 2013]

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

Shutdown 1 Startup

28-08-13

07:47 hrs 10.78 Hrs

Cold Box (Rimming) leading to Planned shutdown of NH3-Plant backend

28-08-13

18:30 hrs

Shutdown 2 Startup

29-08-13

14:50 hrs 06 Hrs

E-102 A/B Tube rupture

29-08-13

20:50 hrs

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UREA PLANT OPERATIONS MONTHLY REPORT [AUG, 2013]

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 CO2 flow from Urea plant, one factor contributing was Low suction pressures at NP CO2 compressor suction. By collaborative efforts between Urea and NP operations team, pressure at NP CO2 Compressor suction increased to maintain CO2 flow keeping Urea CO2 Compressor in safe operating range.

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UREA PLANT OPERATIONS MONTHLY REPORT [AUG, 2013]

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.

Urea Dust dissolving

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.

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UREA PLANT OPERATIONS MONTHLY REPORT [AUG, 2013]

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, P309 A, P-903 A/B, P-802 B, P-303 B, P-951 A/B (discharge strainer) cleaned during the month.

P-951 A/B discharge strainer

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

P-801 A seal flush cooler

4. 5. 6. 7.

Safety shower (near P-151 A/B) hand wheel problem rectified by maintenance. PV-119 D/S steam trap bypass leakage rectified by maintenance. Gland leakages rectified at Vacuum section. 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. 2. 3. 4. AI-1261/1201 calibrated by Instrument team. YT-2Y (Stage 2 Radial vibration) erratic reading problem rectified by Instrument. PT-1024 and TT-1024 at 3rd stage discharge of CO2 Compressor calibrated by Instrument team. 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-1461 calibration

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UREA PLANT OPERATIONS MONTHLY REPORT [AUG, 2013]

MACHINERY ACTIVITIES
P-903A mechanical seal replaced by machinery team. G-602 A/B Mechanical cleaning carried out. V-161 L.O console oil breather Mesh cleaned by machinery team. G-602 B shifted to W/S after dismantling as abnormal sound observed from the bearings. Now G-602 BCOMPANY installed again FATIMA FERTILIZER LTD after bearing replacement and running normal. 5 Page 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. 1. 2. 3. 4.

ELECTRICAL ACTIVITIES
1. 2. 3. 4. 5. 6. PM-802B bearing replaced by Electrical as motor was giving abnormal sound. PM-703 B bearing replaced by Electrical as motor was giving abnormal sound. Abnormal sound observed from PM-703 A, problem was rectified by greasing of motor. Abnormal sound observed from PM-705 A, problem was rectified by greasing of motor. Motor greasing and PM carried out on weekly basis. 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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UREA PLANT OPERATIONS MONTHLY REPORT [AUG, 2013]

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 5th Floor 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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UREA PLANT OPERATIONS MONTHLY REPORT [AUG, 2013]

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 LV1135 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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UREA PLANT OPERATIONS MONTHLY REPORT [AUG, 2013]

PRODUCTION PROFILE
Sr No
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

Date
1 Aug, 2013 2 Aug, 2013 3 Aug, 2013 4 Aug, 2013 5 Aug, 2013 6 Aug, 2013 7 Aug, 2013 8 Aug, 2013 9 Aug, 2013 10 Aug, 2013 11 Aug, 2013 12 Aug, 2013 13 Aug, 2013 14 Aug, 2013 15 Aug, 2013 16 Aug, 2013 17 Aug, 2013 18 Aug, 2013 19 Aug, 2013 20 Aug, 2013 21 Aug, 2013 22 Aug, 2013 23 Aug, 2013 24 Aug, 2013 25 Aug, 2013 26 Aug, 2013 27 Aug, 2013 28 Aug, 2013 29 Aug, 2013 30 Aug, 2013 31 Aug, 2013

Production MT 1246.37 1271.45 1275.54 1275.78 1245.32 1169.16 1131.14 1160.55 1276.47 1062.45 1046.89 1098 1201.56 1282.53 1195.33 1123.88 1124.22 1124.05 1125.43 1122.49 1124.39 1123.70 1122.66 1124.39 1123.70 1087.02 1056.40 574.39 786.50
1192.04 1202.25

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1400

200

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UREA PLANT OPERATIONS MONTHLY REPORT [AUG, 2013]

PRODUCTION PROFILE

Production Profile
Month of Aug, 2013

Production MT

1 Aug, 2013 2 Aug, 2013 3 Aug, 2013 4 Aug, 2013 5 Aug, 2013 6 Aug, 2013 7 Aug, 2013 8 Aug, 2013 9 Aug, 2013 10 Aug, 2013 11 Aug, 2013 12 Aug, 2013 13 Aug, 2013 14 Aug, 2013 15 Aug, 2013 16 Aug, 2013 17 Aug, 2013 18 Aug, 2013 19 Aug, 2013 20 Aug, 2013 21 Aug, 2013 22 Aug, 2013 23 Aug, 2013 24 Aug, 2013 25 Aug, 2013 26 Aug, 2013 27 Aug, 2013 28 Aug, 2013 29 Aug, 2013 30 Aug, 2013 31 Aug, 2013

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UREA PLANT OPERATIONS MONTHLY REPORT [AUG, 2013]

UREA PRODUCT QUALITY ANALYSIS

Date
1 Aug, 2013 2 Aug, 2013 3 Aug, 2013 4 Aug, 2013 5 Aug, 2013 6 Aug, 2013 7 Aug, 2013 8 Aug, 2013 9 Aug, 2013 10 Aug, 2013 11 Aug, 2013 12 Aug, 2013 13 Aug, 2013 14 Aug, 2013 15 Aug, 2013 16 Aug, 2013 17 Aug, 2013 18 Aug, 2013 19 Aug, 2013 20 Aug, 2013 21 Aug, 2013 22 Aug, 2013 23 Aug, 2013 24 Aug, 2013 25 Aug, 2013 26 Aug, 2013 27 Aug, 2013 28 Aug, 2013 29 Aug, 2013 30 Aug, 2013 31 Aug, 2013

Moisture (%)
0.36 0.37 0.39 0.39 0.40 0.36 0.36 0.36 0.37 0.37 0.40 0.39 0.35 0.41 0.42 0.36 0.42 0.35 0.34 0.38 0.38 0.34 0.35 0.39 0.34 0.38 0.37 0.37 0.35 0.39 0.39

Biuret (%)
1.05 1.01 0.96 1.06 1.03 1.04 1.0 1.01 1.0 1.05 1.04 1.02 1.04 0.98 0.98 1.10 1.02 1.07 0.97 0.99 1.05 1.04 1.05 1.08 1.05 1.06 1.08 1.02 1.05 0.98 1.06

APS (mm)
2.11 2.07 2.12 2.06 2.09 2.11 2.11 2.11 2.09 2.12 2.13 2.11 2.10 2.17 2.08 2.14 2.12 2.11 2.10 2.15 2.10 2.10 2.11 2.13 2.10 2.12 2.12 2.10 2.13 2.20 2.12

Fines (%)
0.6 1.0 0.9 0.6 0.6 1.0 0.3 0.6 0.5 0.6 0.4 0.4 0.7 0.4 0.9 0.6 0.5 0.5 0.2 0.8 0.8 0.9 1.3 0.5 0.7 0.7 0.7 0.6 0.6 0.3 0.7

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0.5

1.5

2.5

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UREA PRODUCT QUALITY ANALYSIS

UREA PRODUCT QUALITY ANALYSIS

Month of Aug, 2013

UREA PLANT OPERATIONS MONTHLY REPORT [AUG, 2013]

1 Aug, 2013 2 Aug, 2013 3 Aug, 2013 4 Aug, 2013 5 Aug, 2013 6 Aug, 2013 7 Aug, 2013 8 Aug, 2013 9 Aug, 2013 10 Aug, 11 Aug, 12 Aug, 13 Aug, 14 Aug, 15 Aug, 16 Aug, 17 Aug, 18 Aug, 19 Aug, 20 Aug, 21 Aug, 22 Aug, 23 Aug, 24 Aug, 25 Aug, 26 Aug, 27 Aug, 28 Aug, 29 Aug, 30 Aug, 31 Aug, Fines (%) APS (mm) Biuret (%)

Moisture (%)

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UREA PLANT OPERATIONS MONTHLY REPORT [AUG, 2013]

MAN POWER STATUS MANAGEMENT

Sr. No 1 2 2 3 5 Sr. UM

Designation

No of Employees 1 1 1 3 1 1 8 7

UM Sr. Engr Engineer I Engineer II GTE Total Manpower

Total Permanent Manpower

STAFF
Sr. No 1 2 2 3 4 5 6 7 Sup I Sup II *Sup III Opt I *Opt II Opt III Manpower on contract Apprentices Total Total Permanent Manpower Designation No of Employees 3 1 4 0 7 3 0 1+4 23 18

*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.

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