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MONTHLY

August, 2014

PRODUCTION REPORT

NH3
PLANT

GO GREEN, SAVE GREEN

Prepared By: Saqib Raouf

MONTHLY PRODUCTION HIGHLIGHTS


Sr. No.

Description

Budgeted

Actual

Production Target (MT)

40603

41915.94

Capacity Factor (%)

93

103.2

Service Factor (%)

94

91.2

Gross Energy Index (GCal / MT)

8.11

8.333

Net Energy Index (GCal / MT)

7.90

8.318

Cumulative Annual Production (MT)

305164

312981.9
(7818.9)

Credit
7

Daily Average production (MT)

1309.774

1352.127

Down Time (Hours)

48

65

Feed Gas (MMSCF)

1793

1849.34

10

Fuel Gas (MMSCF)

517

588.53

Ammonia Production Profile


1,600.00

120.00%

1,400.00

100.00%
80.00%

Production

1,000.00
800.00

60.00%

600.00

40.00%

400.00
20.00%

200.00

0.00%
1,Aug
02,Aug
03,Aug
04,Aug
05,Aug
06,Aug
07,Aug
08,Aug
09,Aug
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

0.00

Date

Ammonia Production Profile August-2014


Date

Average Load

Production

Date

Average Load

Production

1,Aug
02,Aug
03,Aug
04,Aug
05,Aug
06,Aug
07,Aug
08,Aug
09,Aug
10,Aug
11,Aug
12,Aug

102.79%
104.11%
102.64%
102.32%
102.54%
103.12%
103.29%
101.83%
102.01%
102.02%
102.03%
101.87%
101.82%
0.00%
99.67%

1,487.00
1,507.30
1,490.10
1,486.00
1,486.00
1,495.10
1,505.08
1,487.31
1,482.75
1,485.10
1,490.94
1,483.50
1,488.15
1,466.22
1,465.76

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

100.01%
100.75%
103.80%
103.85%
101.94%
101.74%
101.35%
102.44%
101.71%
100.91%
101.44%
101.36%
99.91%
68.56%
56.80%

1,457.44
1,463.22
1,485.77
1,476.68
1,486.90
1,479.27
1,487.56
1,482.80
1,483.45
1,492.08
1,482.98
1,491.40
1,488.56
262.41
0.01

31,Aug

81.72%

89.10

13,Aug
14,Aug
15,Aug

Average Load

1,200.00

Health, Safety& Environment


Incident# 1: At 1520hrs, area operator reported
heavy oil leakage from mechanical seal of lube
oil pump P-123-B of C-105.

Action Taken: Motor-driven standby pump


PM-123-A was immediately started and P-123B stopped/Isolated. Spilled oil cleaned and
pump handed over to machinery for repair.

Incident# 2: At 04:45 hrs during unloading of


CT-105 anti-surge valve FV-073A stuck at 40%
and machine tripped due to 3surges/5min
security.

Action Taken: CT-105 was tripped against 3surges/5min security.

Incident# 3: At 22:25 hrs, CT-105 actuator


position feedback ZI-105 started to fluctuate
and hunting observed in governor lift. Impact
kept on increasing and started to vary CT-105
speed due to severe hunting.

Action Taken: Isolated HP steam pressure


reduced to increase actuator AOM-1105
demand/lift opening and finally opened to
100%. Meanwhile Instrument team inspected
its JBs for suspected water ingress but no such
observation found. Now CT-105 speed control
on steam pressure and governor is not in control.

Incident Stats August-2014

3
2.5
2
1.5
1
0.5
0
NMI

PSI

FAC

Fire

Equipment Operational
Failure
Upset

Human
Error

Violation of
PSM

Series1

Safety Observations Statistics


100
80
60
40
20
0
Safety Observations Reported
Safety Observations Closed
% Close Out

Series1

Safety Observations Reported


29

Safety Observations Closed


29

% Close Out
100

MSA Open Actions


1
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0

Series1

Equipment Machinery
0
0

Electrical
0

Instrument
0

Civil
0

TSD
0

HSE
0

Operations
0

MSA Statistics
350
300
250
200
150
100
50
0
MSA Observations
Reported

MSA Observations Closed


% Close Out

Series1

MSA Observations Reported


316

MSA Observations Closed


316

% Close Out
100

NM Open Actions
1
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0

Series1

Equipment Machinery Electrical Instrument


0
0
0
0

Civil
0

TSD
0

HSE
0

Operations
0

NM Statistics
100
80
60
40
20
0
Near Miss
Observations
Reported

Series1

Near Miss Observations Reported


0

Near Miss
Observations Closed

% Close Out

Near Miss Observations Closed


0

% Close Out
100

PTW status Department wise


Department
Equipment

Machinery

Electrical

Inspection

Civil

Instrument

CWP

HWP

CWP issued

310

HWP issued

55

CWP closed

280

HWP closed

50

CWP Closure %

90.3%

HWP Closure %

90.9%

CWP issued

117

HWP issued

CWP closed

105

HWP closed

CWP Closure %

89.7%

HWP Closure %

100%

CWP issued

19

HWP issued

CWP closed

16

HWP closed

CWP Closure %

84.2%

HWP Closure %

100%

CWP issued

HWP issued

01

CWP closed

HWP closed

01

CWP Closure %

66.6%

HWP Closure %

100%

CWP issued

19

HWP issued

02

CWP closed

11

HWP closed

02

CWP Closure %

57.8%

HWP Closure %

100%

CWP issued

87

HWP issued

CWP closed

55

HWP closed

CWP Closure %

63.2%

HWP Closure %

0%

Overall Department-wise PTW Compliance


561
600

473

400
200

84.31%
64

0
CWP Issued

CWP Closed

CWP % Close Out

HWP Issued

58

90.625%

HWP Closed
HWP % Close
Out

CWP Issued

CWP Closed

CWP % Close Out

HWP Issued

HWP Closed

HWP % Close Out

Operational Highlights
Initiatives:
Working on alarm management system
Follow up for LTDS closure

Audits carried by operation

Safety equipment audit on daily basis


Safety observation audit on daily basis
Explosivity Audit on daily basis
Routine audit on daily basis
Housekeeping Audit
Safety cabinets/PSVs car-seal audit

D-level Talk/Emergency Talk


D-level talk conducted in night shifts
Emergency talk discussed in night shifts
CM-1151A L/O and process side Delta P started decreasing sharply, so immediately
unloaded compressor to recover Delta P but in vain and compressor get tripped.
Again tried to start but cannot be started due to PM-1151A low pressure problem.
On 01-08-14 PM-121A started on low lube oil pressure logic, when checked from field
PT-121B was found de-latched, after cleaning of latching lever started again.
Cold-box bad mode problem faced on 28/08/14 so after discussion back-end outage
was planned for 60 hrs for full de-riming of cold box as well as to attend some
important jobs
Plant Start-up Activities
CT-105 drain valve steam leakage problem was rectified at 2200 hrs. After turbine
heating compressor train was rolled in first attempt at 2340 hrs.
Dryer took online at 0130 hrs (31st Aug, 2014).Cold box pressurized and which its cool
down started at 0200 hrs.
C-101 started at 0117 hrs and lined up with system at 0230 hrs after which plant front
end load increased to 75%.
C-104 startup preparations completed and compressor train rolled at 0345 hrs.
Currently machine is at 2200 rpm and will be hold here for 30~45 min. Further startup
sequence will continue afterwards.
Production resumed on 31-08-14 at around 2130 hrs

Saftey Observation Audit Complaiance


75%

75%

88%

100%

100%
80%
60%
40%
20%
0%
Shift Group A

Shift Group B

Shift Group C

Shift Group D

Routine Audit Compliance


100%

100%

100%

100%

100%
80%
60%
40%
20%
0%
Shift Group A

Shift Group B

Shift Group C

Shift Group D

Explosivity Audit Compliance


100%

100%

100%

Shift Group A

Shift Group B

Shift Group C

100%

100%
80%
60%
40%
20%
0%
Shift Group D

Ammonia Plant Multi Skill Status-2014 (To Date)


Skill Status

2013

2014

Cumulative
2013

Cumulative
2014

One Post

27

23

38

39

Two Post

11

16

Three Post

Four Post

Five Post

Six Post

Seven Post

Eight Post

NH3 Plant Cross Training Status Till Aug-2014

100
90
80
70
60
50
40
30
20
10
0
Series1

Planned Skills
1

Actual Skills Done


1
Series1

% Compliance
100

Incidents Recommendation Closure Compliance


100
90
80
70
60
50
40
30
20
10
0

Series1

Incidents
Reported

Recommendations
Marked to
Operation

Operation
Recommendation
Closure
Compliance
100

Overall Closure
Compliance

100

Ammonia Standing Alarms Statistics


160
140
120
100
80
60
40
20
0

Series1

Total No. of
No. of
Standing
Standing ESD
Alarms
Alarms

142

17

No. of
Standing
DCS Alarms

133

No. of
Standing
DCS Alarms
Issues
Resolved
85

No. of
Standing ESD
Alarms
Issues
Resolved
0

% of
Standing
Alarms
Issues
Resolved
60

D-Level Talk Compliance


100
50
0
Shift Group A
Shift Group B
Shift Group C
Shift Group D

Series1

Shift Group A
100

Shift Group B
100

Shift Group C
100

Shift Group D
100

Emergency Talk Compliance


100
80
60
40
20
0
Shift Group A
Shift Group B
Shift Group C
Shift Group D

Series1

Shift Group A
100

Shift Group B
100

Shift Group C
100

Shift Group D
100

Oil &Chemical Consumption


DESCRIPTION

UM

July

Design
Consumption

Cumulative
2013

Cumulative
2014

Catacarb WBU
(Polyglycol)

Litre

40

22.5

315

168

Catacarb 400

DM

30

37

Catacarb 72-S

Litre

As Required

113

Catacarb 922
(V2O5)

m3

0.225

10

11

Potassium
Carbonate
(K2CO3)

MT

03

1.85

21.075

26

Bulab-9564
(Na3PO4)

Kg

50

86.6

575

275

Hydrazine
(N2H4)

Liter

75

52.7

Oil Drums
Turbo-32

DM

As Required

Oil Drums
Turbo T-32

DM

14

As Required

Oil Drums
Tellus + Clavus

DM

0.5

As Required

Maintenance Highlights
E-108 GLG leakage rectified by replacing its glass.
E-145A3 old bundle hydro-jetting/Hydro-testing and
chemical cleaning done.
P-420 suction strainer cleaned
E-222 and its associated piping painting done
P-110A discharge valve gland leakage rectified
Insulation provision at MS-116 inlet line and E-093
associated lines done
Insulation provision at E-118 and associated line done
FH-051 isolation valve handle provided
D-143 inlet/outlet lines thickness monitoring done
PM of safety showers carried out

Cold insulation provided at PM-1101A/B/C associated lines


E-228/229/123/130 painting job done
Platform provision at E-240A/B unapproachable valves
D-208/E-114/116/216 associated insulation removal and
thickness monitoring done
FIL-103B/D/E cleaning done
FM#04 nozzle free problem rectified
Pin-hole leakage rectified at Rota-meter of PT-104
E-190/191
cleaning
& hydro-test
done
D-132 bothchemical
man-ways
removal
and blinds installation
for

charge replacement
New windsocks installed at TK-102/1101
Tie-ins were taken for CT-105 gland condenser
New tie-ins for CWS/CWR taken for E-145
FIL-104A/B cleaning done
E-182A/B and E-151 cleaning and hydro-testing done

Machinery Highlights
PM-1151A low pressure problem rectification remained
I/P
PT-1501B CW jacket get de-blocked
General oil make up and area surveillance
P-1504B gland leakage rectified
C-102 breathers cleaning done
PM-9345A/B suction strainers cleaning done
TK-115 portable centrifuges cleaning done

O/B glands
tightening
donereplaced for low
P-106C
P-118 anti-foam
pump
diaphragm

pressure problem leakage rectification


FIL-102 primary/secondary filters cleaning done
C-104 LPC to turbine side oil leakage rectification done
C-105 I/B and O/B bearings inspection done
C-104 control oil filters cleaning done

C-106 portable centrifuge cleaning done


BT-201 lube oil filters cleaning done
PT-101B seal leakage rectified
CGT-102 ventilation fan filters cleaning done
P-145B seal leakage rectification

Electrical & Instrumentation Highlights

PDC-1182 inspection done and declared ok


Conductivity analyzer CI-103 calibration done
FI-042 LP leg replaced, found blocked
ZI-1180 IOP problem rectified
TE-397 replaced with new one at E-182A/B O/L
C-105 O/B AP-014 fluctuation observed, health found
ok
PT-022 calibration as per PM plan
PT-478/480A calibration done
FI-158/159/005 calibration done

MOV-058 limit switches adjusted


Fused lights replaced due to low light issue
Motors greasing done
PSL-135A/B/C calibration done
Natural gas latest composition incorporated in DCS
PSL-134/76B/87C calibration done as per PM plan
FV-063 glands repacking done
FV-932 flow limitation problem rectification done
MOV-150/151 limit switches adjustment done
D-118 sample point tubing replaced
FT-028A HP valve I/V gland leakage rectified

Position

Available

Approved

Unit Manager

Day Engineer

Shift In-charge

Area Engineer

Back End Board Man

2+3(Sub-Engineers)

Front End Board Man

3+1

Operators (Permanent)

31

32

Apprentice Operators

Annual Contract

Annual Contract

Helpers

Annual Contract