Fauji Fertilizer Company Limited Date / Time

Job Follow Up System 06-April-2020 11:51:28AM

OverDue Actions Report

Organizational Unit: Inspection (MM)

Forum: Inspection Action Reporting

Sr. No Action / Recommendation Detailed Status / Remarks Priority (%) Assign / Target / Update Status
Date
1 Scope for repair of main header to be Job will be executed once handed over to Medium 02-04-2012 - 07-06-2012 - 02- In Progress
0%
finalized after inspection of main header. Inspection. Reminder sent to DM-Urea on 01-2020
20.10.14.
2 CTP # 7. Connection to be checked and Job will be executed once handed over to Medium 31-07-2012 - 30-11-2012 - 30- In Progress
0%
repaired. Inspection 12-2019
3 Anodes 120, 123, 133 and 143 to be JR to be prepared Medium 31-01-2013 - 31-03-2013 - 31- In Progress
0%
planned for replacement (identified as 12-2019
irreparable).
4 As anodes connected with AJB 10/1 are JR to be prepared Medium 31-01-2013 - 31-03-2013 - 31- In Progress
0%
inaccessible and no repair work can be 12-2019
performed, plan the replacement of these
Anodes with new ones
5 1.This internal inspection was carried out on Internal inspection of S-502 is planned in Feb Medium 06-03-2012 - 06-03-2017 - 31- In Progress
70%
M/s Force recommendations (4-5 years). - 2019. Observations related to SCC will be 12-2019
Next internal inspection shall be carried out taken in the same opportunity.
after 5-6 years interval to confirm that SCC
mitigation actions taken this year have
yielded desired results i.e. no significant SCC
is detected in the next inspection.
6 2.Non-intrusive inspection such as acoustic Internal inspection of S-502 is planned in Feb Medium 06-03-2012 - 06-03-2017 - 31- In Progress
70%
emission can be considered after next - 2019. In case no significant SCC or other 12-2019
internal inspection. That too in case no corrosion is detected in the planned
significant SCC or other corrosion is inspection, further techniques will be
detected in the next inspection. As non engaged.
intrusive inspection methods applied from
outside the sphere are not yet been widely
used by the industry because they are less
sensitive than MT.
7 02 Anodes identified as irreparable (Anode JR to be prepared Medium 31-01-2013 - 31-03-2013 - 31- In Progress
0%
# 171 and 78) to be planned for 12-2019
replacement
Production Server Data Page 1 of 32 RPT-JFS-005
 Fauji Fertilizer Company Limited Date / Time
Job Follow Up System 06-April-2020 11:51:28AM
OverDue Actions Report

Organizational Unit: Inspection (MM)

Forum: Inspection Action Reporting
Sr. No Action / Recommendation Detailed Status / Remarks Priority (%) Assign / Target / Update Status
Date
8 Inspection of pipelines to be carried out on Medium 27-07-2011 - 31-03-2015 - 31- In Progress
0%
damaged locations against any thickness 12-2019
loss,corrosion etc.
9 Re-coating / wrapping to be carried out at Medium 03-08-2011 - 31-03-2015 - 31- In Progress
0%
above locations after removal of old 12-2019
coating &proper surface preparation.
10 Holiday detection test to be done after Medium 03-08-2011 - 31-03-2015 - 31- In Progress
0%
coating and before back filling/surface 12-2019
restoration.
11 Reinforcement of line portion with reduced Medium 03-08-2011 - 31-03-2015 - 31- In Progress
0%
thickness (if any) to be carried out followed 12-2019
byDPT.
12 Insulation at marked locations to be Medium 27-07-2011 - 31-03-2015 - 31- In Progress
0%
removed for inspection of metallic pipeline 12-2019
underside.
13 Thickness to be monitored at above Medium 03-08-2011 - 31-03-2015 - 31- In Progress
0%
locations after removal of coating. 12-2019
14 Re-coating / wrapping to be carried out at Medium 03-08-2011 - 31-03-2015 - 31- In Progress
0%
above locations after removal of old 12-2019
coating &proper surface preparation.
15 Thickness to be monitored at above Medium 03-08-2011 - 31-03-2015 - 31- In Progress
0%
locations after removal of coating. 12-2019
16 Holiday detection test to be done after Medium 03-08-2011 - 31-03-2015 - 31- In Progress
0%
coating and before back filling/surface 12-2019
restoration.
17 Reinforcement of line portion with reduced Medium 03-08-2011 - 31-03-2015 - 31- In Progress
0%
thickness (if any) to be carried out followed 12-2019
byDPT.
18 Prior to any paint job, inspection is required Medium 26-09-2011 - 31-03-2015 - 31- In Progress
0%
for the surface preparation. 12-2019
Production Server Data Page 2 of 32 RPT-JFS-005
 Fauji Fertilizer Company Limited Date / Time
Job Follow Up System 06-April-2020 11:51:28AM
OverDue Actions Report

Organizational Unit: Inspection (MM)

Forum: Inspection Action Reporting
Sr. No Action / Recommendation Detailed Status / Remarks Priority (%) Assign / Target / Update Status
Date
19 Insulation of the NPS 4" LS pipeline to Medium 22-12-2011 - 01-04-2015 - 31- In Progress
0%
removed so that the soundbase metal is 12-2019
exposed. In order to restore the pipeline to
its intendedoperating condition, the sleeve
to be installed by welding on soundbase
metal after thickness monitoring.
20 Power brush cleaning of Channel head and Medium 15-02-2012 - 01-04-2015 - 31- In Progress
0%
cover. Epoxy painting tobe carried out after 12-2019
cleaning for corrosion protection.
21 Reactor to be inspected in next available Medium 17-08-2012 - 01-04-2015 - 31- In Progress
0%
opportunity. 12-2019
22 Replacement of Anodes (160, 162) with new Medium 12-07-2013 - 02-04-2015 - 31- In Progress
0%
ones to be carried out. 12-2019
23 Holiday detection test to be done after Medium 08-03-2011 - 31-03-2015 - 31- In Progress
0%
coating and before back filling/surface 12-2019
restoration.
24 Repair of partition plate to be carried out. Medium 15-02-2012 - 01-04-2015 - 31- In Progress
0%
12-2019
25 All fittings were found above retiring Medium 06-03-2012 - 01-04-2015 - 31- In Progress
0%
thickness. Fittings with thickness below 12-2019
nominal are to be kept under observation.
26 Vessel to be inspected after a service life of Medium 01-02-2012 - 01-04-2015 - 31- In Progress
0%
05 years. 12-2019
27 Vessel to be inspected after a service life of Medium 01-02-2013 - 01-04-2015 - 31- In Progress
0%
05 years. 12-2019
28 Remaining recommendations of 1st Medium 07-03-2013 - 01-04-2015 - 31- In Progress
0%
inspection report to be carried out. 12-2019
29 Eddy Current testing to be performed in Medium 31-03-2013 - 01-04-2015 - 31- In Progress
0%
next turnaround. 12-2019

Production Server Data Page 3 of 32 RPT-JFS-005

 Fauji Fertilizer Company Limited Date / Time
Job Follow Up System 06-April-2020 11:51:28AM
OverDue Actions Report

Organizational Unit: Inspection (MM)

Forum: Inspection Action Reporting
Sr. No Action / Recommendation Detailed Status / Remarks Priority (%) Assign / Target / Update Status
Date
30 01 Anodes identified as irreparable (Anode Medium 12-07-2013 - 02-04-2015 - 31- In Progress
0%
# 171) to be planned forreplacement 12-2019
31 A new shaft from OEM to be procured for Medium 10-10-2013 - 02-04-2015 - 31- In Progress
0%
contingency and checking mechanical 12-2019
properties.
32 Backfill carried out in front of Anode Medium 24-10-2013 - 02-04-2015 - 31- In Progress
0%
junction box. (Obs. #2) 12-2019
33 PSP values at FH # 35, 34 &30 to be kept Medium 24-10-2013 - 02-04-2015 - 31- In Progress
0%
under observation. (Obs. # 1) 12-2019
34 Reinforcement of line portion with reduced Medium 08-03-2011 - 31-03-2015 - 31- In Progress
0%
thickness (if any) to be carried out followed 12-2019
byDPT.
35 PSP values at FH # 35 to be kept under Medium 12-07-2013 - 02-04-2015 - 31- In Progress
0%
observation. (Obs. # 01) 12-2019
36 Anode # 119 (Total 01) to be rectified Medium 24-10-2013 - 02-04-2015 - 31- In Progress
0%
against no current flow. 12-2019
37 Anodes 107,139,120, 123, 133 and 143 to be Medium 24-10-2013 - 02-04-2015 - 31- In Progress
0%
planned for replacement (identified as 12-2019
irreparable).
38 Furnace tubes to be checked thru peep Medium 25-03-2013 - 02-04-2015 - 31- In Progress
0%
holes during the next startup opportunity. 12-2019
Any red hot bank will be an evidence of
blockage.
39 UT, Thickness measurement and hardness at Medium 25-03-2013 - 02-04-2015 - 31- In Progress
0%
the most sagged portions of the tube to be 12-2019
performed in the 5th tube bank in the
upcoming emergency shutdown.
40 FH # 28 Grounding to be checked and Medium 24-10-2013 - 02-04-2015 - 31- In Progress
0%
rectification to be carried out properly 12-2019

Production Server Data Page 4 of 32 RPT-JFS-005

 Fauji Fertilizer Company Limited Date / Time
Job Follow Up System 06-April-2020 11:51:28AM
OverDue Actions Report

Organizational Unit: Inspection (MM)

Forum: Inspection Action Reporting
Sr. No Action / Recommendation Detailed Status / Remarks Priority (%) Assign / Target / Update Status
Date
41 Anode # 184 to be checked against Medium 24-10-2013 - 02-04-2015 - 31- In Progress
0%
probable cable connection damage and 12-2019
fault to be rectified.
42 Re-coating / wrapping to be carried out at Medium 08-03-2011 - 31-03-2015 - 31- In Progress
0%
above locations after removal of old 12-2019
coating &proper surface preparation.
43 Based on the corrosion rate to avoid any Medium 02-02-2011 - 29-01-2016 - 31- In Progress
0%
potential leakage, above mentioned fittings 12-2019
are recommended to be replaced.
44 Audit of damaged insulation of carbon steel Medium 22-12-2011 - 01-04-2015 - 31- In Progress
0%
& low alloy piping(Temperature range -12 to 12-2019
175 deg C) and piping under
intermittentservice to be carried out. On
basis of audit following procedure will
beadopted for the damaged insulation
piping:a. Insulation removal and cleaning of
pipeline.b. Inspection of pipeline and
thickness monitoring, if applicable.c. Repair
/ maintenance of pipeline, if required.d. Re-
insulation of pipeline.
45 In order to investigate and mitigate the Medium 04-01-2012 - 01-04-2015 - 31- In Progress
0%
threat of CUI onDe-aerator (V-603), removal 12-2019
of 30% of complete insulationof De-aerator
to be carried out including
damagedinsulation area. Visual inspection
and thicknessmonitoring to be carried out
on the cleaned area afterinsulation
removal.
46 Replacement / repair maintenance of Medium 27-02-2012 - 01-04-2015 - 31- In Progress
0%
fittings (08 ea) mentioned above on priority. 12-2019
Selected fittings to be monitored again next
year.

Production Server Data Page 5 of 32 RPT-JFS-005

 Fauji Fertilizer Company Limited Date / Time
Job Follow Up System 06-April-2020 11:51:28AM
OverDue Actions Report

Organizational Unit: Inspection (MM)

Forum: Inspection Action Reporting
Sr. No Action / Recommendation Detailed Status / Remarks Priority (%) Assign / Target / Update Status
Date
47 Selected fittings to be monitored again next Medium 06-03-2012 - 01-04-2015 - 31- In Progress
0%
year. 12-2019
48 Excavation as per indications of DCVG Medium 20-12-2012 - 01-04-2015 - 31- In Progress
0%
survey (Jan, 2009) to be carriedout. 12-2019
49 Repair of above mentioned locations to be Medium 04-10-2012 - 01-04-2015 - 31- In Progress
0%
carried out. The line to be inspectedby 12-2019
inspection after the insulation is removed.
50 Cracks in acid injection lines to be removed Medium 07-03-2013 - 01-04-2015 - 31- In Progress
0%
by grinding / welding followed byDPT. 12-2019
51 Vibration Analysis of E-302 A to be Medium 31-03-2013 - 01-04-2015 - 31- In Progress
0%
performed for presence of any flow 12-2019
induced vibrations. If flow induced
vibrations were observed then eddy current
testing to be performed in the exchanger
tubes in next turnaround.
52 Thickness to be monitored at above Medium 08-03-2011 - 31-03-2015 - 31- In Progress
0%
locations after removal of coating. 12-2019
53 The decision for the repair/ replacement of Medium 26-09-2011 - 31-03-2015 - 31- In Progress
0%
any part will be taken after the cleaning & 12-2019
inspection.
54 Remaining coating defects indicated in Medium 23-01-2012 - 01-04-2015 - 31- In Progress
0%
DCVG survey to beinvestigated and 12-2019
repaired if required.
55 The Benfield circuit to be monitored again Medium 01-01-1900 - 01-04-2015 - 31- In Progress
0%
this year. 12-2019
56 Selected fittings to be monitored again this Medium 01-01-1900 - 01-04-2015 - 31- In Progress
0%
year. 12-2019
57 Sand filters to be inspected maximum at an Medium 24-12-2012 - 01-04-2015 - 31- In Progress
0%
interval of 02 years. 12-2019

Production Server Data Page 6 of 32 RPT-JFS-005

 Fauji Fertilizer Company Limited Date / Time
Job Follow Up System 06-April-2020 11:51:28AM
OverDue Actions Report

Organizational Unit: Inspection (MM)

Forum: Inspection Action Reporting
Sr. No Action / Recommendation Detailed Status / Remarks Priority (%) Assign / Target / Update Status
Date
58 DPT of cracks at partition plate to be Medium 31-03-2013 - 01-04-2015 - 31- In Progress
0%
performed in next available opportunity. 12-2019
59 Boiler to be inspected in next available Medium 31-03-2013 - 01-04-2015 - 31- In Progress
0%
opportunity. 12-2019
60 Anode # 11 and 19 (Total 02 each) to be Medium 12-07-2013 - 02-04-2015 - 31- In Progress
0%
checked against probable 12-2019
cableconnection damage and fault to be
rectified.
61 19 Anodes (71, 76, 54, 34, 35, 36, 37, 29, 31, Medium 12-07-2013 - 02-04-2015 - 31- In Progress
0%
33, 18, 2, 23 6, 9, 11, 11Aand 11B) as 12-2019
identified in observation # 2 to be rectified
against nocurrent flow.
62 Low PSP value in Observation 2 to be kept Medium 12-07-2013 - 02-04-2015 - 31- In Progress
0%
under observation 12-2019
63 Inspection of scrapper will be carried out Medium 26-09-2011 - 31-03-2015 - 31- In Progress
0%
after proper cleaning and removal of 12-2019
deposits (corrosion/paint & Urea).
Operations, to ensure timely inspection after
cleaning of every part.
64 Long Range Ultrasonic Testing (LRUT) of HDD Medium 23-01-2012 - 01-04-2015 - 31- In Progress
0%
section will be carriedout to gather the 12-2019
baseline data after one year of service. Test
to berepeated after a period of 02 years to
carry out trending and effect ofmoisture
accumulation on pipeline.
65 To gather baseline data for future Medium 23-01-2012 - 01-04-2015 - 31- In Progress
0%
reference, LRUT of the selectedportions on 12-2019
NG line is planned in 2012.
66 The Benfield circuit to be monitored again Medium 01-01-1900 - 01-04-2015 - 31- In Progress
0%
this year. 12-2019

Production Server Data Page 7 of 32 RPT-JFS-005

 Fauji Fertilizer Company Limited Date / Time
Job Follow Up System 06-April-2020 11:51:28AM
OverDue Actions Report

Organizational Unit: Inspection (MM)

Forum: Inspection Action Reporting
Sr. No Action / Recommendation Detailed Status / Remarks Priority (%) Assign / Target / Update Status
Date
67 Long Range Ultra Sonic Inspection (LRUT) of Medium 08-09-2011 - 31-03-2015 - 31- In Progress
0%
the selected portions ofthe line to be 12-2019
carried out in order to assess threat of
internalcorrosion.
68 Scope for repair, if any, and frequency of Medium 04-11-2012 - 01-04-2015 - 31- In Progress
0%
inspection will be finalized after inspection. 12-2019
69 Selected thickness monitoring to be done Medium 24-05-2012 - 01-04-2015 - 31- In Progress
0%
after 2 years of service. 12-2019
70 During the past few turnarounds, the Medium 31-03-2013 - 01-04-2015 - 31- In Progress
0%
refractory had been repeatedly found 12-2019
dislodged at overhead locations and trend
seems to be rising e.g., refractory directly
above E-201 coil was replaced in TA-2011
due to occurrence of large hot spots
(above 5000C). In view of this, following
actions are recommended;a.
Thermography of the overhead refractory
locations to be performed (already
planned in June & Dec 2013).b. Refractory
repairs of overhead areas to be planned
accordingly in TA-2014.
71 Bulging measurements to be performed in Medium 25-03-2013 - 02-04-2015 - 31- In Progress
0%
TA-2014 for trending. 12-2019
72 01 most sagged tube to be removed for Medium 25-03-2013 - 02-04-2015 - 31- In Progress
0%
micro structural evaluation in TA-2014. 12-2019

Production Server Data Page 8 of 32 RPT-JFS-005

 Fauji Fertilizer Company Limited Date / Time
Job Follow Up System 06-April-2020 11:51:28AM
OverDue Actions Report

Organizational Unit: Inspection (MM)

Forum: Inspection Action Reporting
Sr. No Action / Recommendation Detailed Status / Remarks Priority (%) Assign / Target / Update Status
Date
73 Re-coating/wrapping to be carried out at Medium 23-09-2013 - 02-04-2015 - 31- In Progress
0%
above locations with following steps:a. 12-2019
Removal of old coating & proper surface
preparation (Careful power brush cleaning)
and thickness monitoring.b. Reinforcement
of line portion with reduced thickness (if
any) to be carried out followed by DPT.c.
Holiday detection test to be done after
coating and before back filling/surface
restoration.
74 Urea solution recovery tank to be inspected Medium 01-01-1900 - 30-06-2016 - 01- In Progress
0%
during next turnaround 01-2020
75 Shell to be pulled for inspection of tube Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
bundle in next turnaround. 01-2020
76 Ammonia Knock out drum to be inspected Medium 02-09-2015 - 30-06-2016 - 01- In Progress
0%
after 5 years. 01-2020
77 Steam drum of auxiliary boiler to be Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
inspected in next turnaround. 01-2020
78 Combustion chamber of B-602 to be Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
inspected during next turnaround. 01-2020
79 Column to be inspected in next TA. Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
01-2020
80 Bent weir plate as per observation no. 5 to Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
be kept under observation during next 01-2020
inspection.
81 Vessel to be inspected in next TA. Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
01-2020

Production Server Data Page 9 of 32 RPT-JFS-005

 Fauji Fertilizer Company Limited Date / Time
Job Follow Up System 06-April-2020 11:51:28AM
OverDue Actions Report

Organizational Unit: Inspection (MM)

Forum: Inspection Action Reporting
Sr. No Action / Recommendation Detailed Status / Remarks Priority (%) Assign / Target / Update Status
Date
82 Cleaning and painting of test posts to be Only excavation of Test post # 7 is pending Medium 13-04-2015 - 31-03-2016 - 01- In Progress
80%
carried out against external corrosion. Test due to high water table and same will be 01-2020
posts locks to be repaired. Additionally, executed by March 2016.
excavation of the test post no. 7 to be
carried out to verify the connection.
83 PSP values at FH # 35 to be restored to Medium 30-04-2015 - 30-10-2015 - 01- In Progress
0%
recommended limits. (Obs. #1) 01-2020
84 Malfunctioning anode # 05, 07 of east side Medium 14-02-2015 - 01-06-2015 - 01- In Progress
0%
ground bed and Anode # 03, 05 of west 01-2020
side ground bed to be repaired.
85 Low PSP value at V-602 Near opt cabin to Medium 11-02-2015 - 01-06-2015 - 01- In Progress
0%
be kept under observation (as per Obs. 01-2020
#01)
86 De-aerator to be inspected during next Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
turnaround. 01-2020
87 Top dish head blind nozzles to be opened Medium 06-03-2013 - 02-04-2015 - 31- In Progress
0%
and offered for inspection. 12-2019
88 Steps for reducing leakage rate (observed Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
during water fill test) to be finalized. 01-2020
Correspondence is already underway with
SAIPEM for the probable use of thicker hold
downgrid plate (around 20-25mm) in order
to exert more down-force onto the ferrules
for propersealing/ elimination of solution
bypassing.
89 Excavation to be carried out at FH # 15 and Medium 12-04-2014 - 02-04-2015 - 31- In Progress
0%
condition of coating / wrapping to be 12-2019
checked. (Ref Obs. # 1)
90 Grounding of FH¿s # 30, 31, 33, 34, 35, 76 to Medium 11-02-2015 - 01-06-2015 - 01- In Progress
0%
be removed by providing coat wrap on the 01-2020
fault locations.
Production Server Data Page 10 of 32 RPT-JFS-005
 Fauji Fertilizer Company Limited Date / Time
Job Follow Up System 06-April-2020 11:51:28AM
OverDue Actions Report

Organizational Unit: Inspection (MM)

Forum: Inspection Action Reporting
Sr. No Action / Recommendation Detailed Status / Remarks Priority (%) Assign / Target / Update Status
Date
91 Urea distillation tower to be inspected in Medium 09-02-2015 - 31-10-2017 - 01- In Progress
0%
next turnaround opportunity. 01-2020
92 3rd & 4th Beds to be inspected in next T/A. Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
01-2020
93 UT Inspection of all tube to tubesheet welds Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
to be planned for next turnaround. 01-2020
94 Grounding of FH¿s # 60, 62 to be removed Medium 02-05-2015 - 02-11-2015 - 01- In Progress
0%
by providing coat wrap on the fault 01-2020
locations.
95 Thickness monitoring of HP Loop circuit to Medium 11-06-2014 - 02-04-2015 - 31- In Progress
0%
be performed in two years on-stream to 12-2019
monitor against any aggravation in
thickness reduction.
96 Vessel to be inspected in next Turnaround. Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
01-2020
97 Exchanger to be inspected and repairs to Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
be performed in next available opportunity. 01-2020
98 Vessel to be inspected in next Turnaround. Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
01-2020
99 Anodes # 03,11, 19 (Total 03) to be rectified Medium 30-04-2015 - 30-10-2015 - 01- In Progress
0%
against nil current flow. (Obs. #2) 01-2020
100 Ampere meter to be rectified at TR #01 (Ref: Medium 02-05-2015 - 02-11-2015 - 01- In Progress
0%
Obs. #04) 01-2020
101 Full length Eddy Current Testing of tubes in Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
outer periphery to be planned for next 01-2020
turnaround.Tubes with defects of 40% or
more to be plugged.
102 Flue gas duct of auxiliary boiler to be Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
inspected in next Turnaround. 01-2020

Production Server Data Page 11 of 32 RPT-JFS-005

 Fauji Fertilizer Company Limited Date / Time
Job Follow Up System 06-April-2020 11:51:28AM
OverDue Actions Report

Organizational Unit: Inspection (MM)

Forum: Inspection Action Reporting
Sr. No Action / Recommendation Detailed Status / Remarks Priority (%) Assign / Target / Update Status
Date
103 Internal Inspection and repair of hot spot Medium 02-09-2014 - 02-04-2015 - 31- In Progress
0%
locations indicated in thermography report. 12-2019
104 V-401 to be inspected during the next Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
turnaround. 01-2020
105 Survey to be repeated after 3 years Medium 13-04-2015 - 01-10-2015 - 01- In Progress
0%
frequency. 01-2020
106 Replica metallography of 1st row non- Medium 16-07-2014 - 01-06-2015 - 31- In Progress
0%
leaking tubes (to be performed after coil 12-2019
removal).
107 Following reliability work of urea reactor is Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
short listed. However, the actual priority of 01-2020
jobscope to be finalized prior to next
inspection / maintenance opportunity.a.
Rehabilitation of welds of 1994 relined
segment.b. Replacement of Support ribs
with new approved design. The priority is to
remove thesesupports from 1992 & 1994
relined segments.c. Replacement of
interruption strips with circular corner design.
Currently, 1994 relinedsegment and bottom
segments have square shaped interruption
strips.d. Segregation of relined segments of
1994 / 1995. Communication paths of weep
holesto be verified by unit.e. Relining of Shell
course no. 31 & Bottom dome.f.
Replacement / Repair of Ammonia and
Carbon dioxide inlet pipe subject to
condition.
108 Tank to be inspected in next turnaround Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
opportunity. 01-2020

Production Server Data Page 12 of 32 RPT-JFS-005

 Fauji Fertilizer Company Limited Date / Time
Job Follow Up System 06-April-2020 11:51:28AM
OverDue Actions Report

Organizational Unit: Inspection (MM)

Forum: Inspection Action Reporting
Sr. No Action / Recommendation Detailed Status / Remarks Priority (%) Assign / Target / Update Status
Date
109 Material availability to be ensured for the Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
replacement of low thickness trays (as 01-2020
found duringprevious inspections). However,
replacement is subject to results of
inspection findings.
110 Probable cable connection damage Medium 12-04-2014 - 02-04-2015 - 31- In Progress
0%
(during new foundations construction) to be 12-2019
checked and fault to be rectified at base of
V-250 K.O Drum.
111 Bulging in 1M nozzle to be kept under Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
observation. 01-2020
112 18 Anodes (71, 76, 54, 34, 35, 36, 37, 29, 31, Medium 24-10-2013 - 02-04-2015 - 31- In Progress
0%
33, 18, 2, 6, 9, 11, 11A and 11B) as identified 12-2019
in observation # 2 to be rectified against no
current flow.
113 Equipment to be inspected in next Turn Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
around opportunity. 01-2020
114 Need of RFT and bundle inspection to be Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
evaluated before next turnaround. 01-2020
115 H-Scan on catalyst tubes to be performed in Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
next turnaround. 01-2020
116 Low PSP value at FH #22, V-1001, SS #6 West Medium 12-04-2014 - 02-04-2015 - 31- In Progress
0%
side planning car parking shed to be kept 12-2019
under observation (as per Obs. #01)
117 PSP values at FH # 15 to be restored to Medium 30-04-2015 - 30-10-2015 - 01- In Progress
0%
recommended limits. (Obs. #1) 01-2020
118 The internal surfaces of the sight glass and Medium 06-03-2013 - 02-04-2015 - 31- In Progress
0%
its seating area to be offered forinspection 12-2019
once the sight glass is removed.

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 Fauji Fertilizer Company Limited Date / Time
Job Follow Up System 06-April-2020 11:51:28AM
OverDue Actions Report

Organizational Unit: Inspection (MM)

Forum: Inspection Action Reporting
Sr. No Action / Recommendation Detailed Status / Remarks Priority (%) Assign / Target / Update Status
Date
119 Blow down vent stack to be inspected Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
during next turn around. 01-2020
120 Vessel to be inspected in next TA. Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
01-2020
121 (IR#1127)Rec.#2 Anode # 184 to be Medium 04-05-2016 - 30-11-2017 - 01- In Progress
0%
checked against probable cable 01-2020
connection damage and
122 18 Anodes (172, 71, 76, 54, 34, 35, 36, 37, 29, Medium 12-04-2014 - 02-04-2015 - 31- In Progress
0%
31, 33, 18, 2, 6, 9, 11, 11A and 11B) to be 12-2019
rectified for nil current flow (as per Obs. #02)
123 Bed no. 2 & 3 to be inspected in next Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
turnaround. 01-2020
124 Comprehensive rehabilitation plan needs to Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
be prepared for ensuring vessel integrity 01-2020
prior tonext Turnaround.
125 Repeated corrosion phenomenon at Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
previously repaired areas to be kept under 01-2020
observation.Belzona application to be
considered in next opportunity based upon
Inspection findings.
126 Ammonia Accumulator to be inspected Medium 02-09-2015 - 30-06-2016 - 01- In Progress
0%
after 5 years. 01-2020
127 Anodes #119,121, 126,132 (Total 04) to be Medium 11-02-2015 - 01-06-2015 - 01- In Progress
0%
rectified against nil current flow. 01-2020
128 Replacement of Urea stripper vapor outlet Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
line to be planned in next turnaround. 01-2020
Detailedscope shall be provided by
Inspection.
129 Vessel to be inspected in next turn around. Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
01-2020
Production Server Data Page 14 of 32 RPT-JFS-005
 Fauji Fertilizer Company Limited Date / Time
Job Follow Up System 06-April-2020 11:51:28AM
OverDue Actions Report

Organizational Unit: Inspection (MM)

Forum: Inspection Action Reporting
Sr. No Action / Recommendation Detailed Status / Remarks Priority (%) Assign / Target / Update Status
Date
130 Low pressure inert washing tower is to be Medium 09-02-2015 - 31-10-2017 - 01- In Progress
0%
inspected during the next turnaround 01-2020
opportunity.
131 The flash drum is to be inspected after 5 Medium 02-09-2015 - 30-06-2016 - 01- In Progress
0%
years. 01-2020
132 Economizer of auxiliary boiler to be Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
inspected in next Turnaround. 01-2020
133 Tank to be inspected after a service life of Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
seven years. 01-2020
134 Temperature monitoring of the hot spot to Medium 16-04-2015 - 16-07-2015 - 01- In Progress
0%
be performed to check for any 01-2020
aggravation.
135 Locations marked on the isometric may be Medium 02-10-2015 - 31-03-2016 - 01- In Progress
0%
traced after removal of insulation, to 01-2020
pinpoint the exact welds and the repairs
made to address the recurrent leakages
stemming from them. Visual inspection of
these repairs may be carried out for
verification and subsequently tagged on
the external cover of the insulation for ease
of identification at a later stage.
136 Exchanger to be inspected and repairs to Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
be performed in next available opportunity. 01-2020
137 Super heaters are to be inspected during Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
next turnaround. 01-2020
138 Natural gas pre heater to be inspected Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
during the next turnaround. 01-2020
139 Low PSP value at V-602 Near opt cabin to Medium 01-01-1900 - 02-11-2015 - 01- In Progress
0%
be kept under observation (as per Obs. 01-2020
#01)

Production Server Data Page 15 of 32 RPT-JFS-005

 Fauji Fertilizer Company Limited Date / Time
Job Follow Up System 06-April-2020 11:51:28AM
OverDue Actions Report

Organizational Unit: Inspection (MM)

Forum: Inspection Action Reporting
Sr. No Action / Recommendation Detailed Status / Remarks Priority (%) Assign / Target / Update Status
Date
140 (IR#1127)Rec.#3 Ammeter to be rectified at Medium 04-05-2016 - 30-11-2017 - 01- In Progress
0%
TR #01. (Ref: Obs. #04) 01-2020
141 Grounding of FH¿s #29, 30, 31, 33, 34, 35 to Medium 12-04-2014 - 02-04-2015 - 31- In Progress
0%
be removed by providing coat wrap on the 12-2019
fault locations.
142 Equipment to be inspected in next Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
turnaround opportunity. 01-2020
143 Ammonia Separator to be inspected after 5 Medium 02-09-2015 - 30-06-2016 - 01- In Progress
0%
years interval. 01-2020
144 Super heater of auxiliary boiler to be Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
inspected in next Turnaround. 01-2020
145 (IR#1127)Rec.#1 PSP values measured Medium 04-05-2016 - 30-11-2017 - 01- In Progress
0%
below the recommended limit are to be 01-2020
restored. (Ref: Obs. # 01)
146 (IR# 1128)Rec.#3 Anodes # (107, 139, 120, Medium 04-05-2016 - 30-11-2017 - 01- In Progress
0%
123, 133 & 143) to be planned for 01-2020
replacement (identified as irreparable).
(Ref: Obs. # 04)
147 Anode identified as irreparable (Anode # Medium 12-04-2014 - 02-04-2015 - 31- In Progress
0%
78 & 171) to be planned for replacement 12-2019
148 Anodes #107, 139, 120, 123, 133 and 143 to Medium 11-02-2015 - 01-06-2015 - 01- In Progress
0%
be replaced (identified as irreparable). 01-2020
149 Backfilling needs carrying out in front of Medium 11-02-2015 - 01-06-2015 - 01- In Progress
0%
Anode junction box. 01-2020
150 Vessel to be inspected in next TA. Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
01-2020
151 Air duct of boiler to be inspected in next Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
Turnaround. 01-2020

Production Server Data Page 16 of 32 RPT-JFS-005

 Fauji Fertilizer Company Limited Date / Time
Job Follow Up System 06-April-2020 11:51:28AM
OverDue Actions Report

Organizational Unit: Inspection (MM)

Forum: Inspection Action Reporting
Sr. No Action / Recommendation Detailed Status / Remarks Priority (%) Assign / Target / Update Status
Date
152 MPI of complete shell welds seams and Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
nozzles to be carried out in next inspection. 01-2020
153 Equipment to be inspected in next TA Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
01-2020
154 The pitted area in the bottom of the vessel Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
to be kept under observation. 01-2020
155 Backfilling needs carrying out in front of Medium 30-04-2015 - 30-10-2015 - 01- In Progress
0%
Anode junction boxes. 01-2020
156 Grounding of FH¿s # 30, 33, 34, 35, 76 to be Medium 30-04-2015 - 30-10-2015 - 01- In Progress
0%
removed by providing coat wrap on the 01-2020
fault locations.
157 As per our past experience on titanium Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
stripper, restoration of damaged tube ends 01-2020
(due tosolution bypassing) by machining in
next turnaround to be looked into.
158 Re-coating / wrapping to be carried out at Medium 21-04-2015 - 29-01-2016 - 01- In Progress
0%
above locations with following steps:a. 01-2020
Excavation around the line of at least 350
mm depth. Removal of old coating, visual
inspection, proper surface preparation
(Careful power brush cleaning) and
thickness monitoring.b. Reinforcement of
line portion with reduced thickness (if any)
to be carried out followed by DPT.c. Holiday
detection test to be done after coating and
before back filling/surface restoration.
159 PSP values at FH # 35 to be restored to Medium 11-02-2015 - 01-06-2015 - 01- In Progress
0%
recommended limits. (Obs. #1) 01-2020

Production Server Data Page 17 of 32 RPT-JFS-005

 Fauji Fertilizer Company Limited Date / Time
Job Follow Up System 06-April-2020 11:51:28AM
OverDue Actions Report

Organizational Unit: Inspection (MM)

Forum: Inspection Action Reporting
Sr. No Action / Recommendation Detailed Status / Remarks Priority (%) Assign / Target / Update Status
Date
160 Option of blowing to remove any left-over Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
blockage may be considered in case 01-2020
repetitivesagging will be observed in
replaced tubes.
161 Sagging data to be measured in next Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
available opportunity. 01-2020
162 Interconnecting nozzles to be replaced in Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
next Turnaround owing severe internal 01-2020
thicknessloss.
163 Hardness and Radiographic testing of the Medium 01-01-1900 - 31-03-2016 - 01- In Progress
0%
weld rehabilitated in the chassis plate of the 01-2020
P & H crane # 43944 is to be undertaken in
accordance to its WPS. Arrangements for
undertaking these NDT¿s are also to be
made.
164 Reduce the load of T/R in 18 area as per Medium 14-02-2015 - 01-06-2015 - 01- In Progress
0%
external audit report. Inspection will re- 01-2020
check PSP of all test posts after the activity.
165 Cracks visible in painting, requires cleaning Medium 01-10-2012 - 02-04-2015 - 31- In Progress
0%
and re-inspection. (Ref. obs #15) 12-2019
166 Blow down vent stack to be inspected Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
during next turnaround. 01-2020
167 Urea waste water tank to be inspected Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
during the next turnaround. 01-2020
168 Vessel to be inspected in next TA. Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
01-2020
169 Air duct of auxiliary boiler to be inspected in Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
next Turnaround. 01-2020
170 Anodes #119,121, 126,132 (Total 04) to be Medium 30-04-2015 - 30-10-2015 - 01- In Progress
0%
rectified against nil current flow. 01-2020
Production Server Data Page 18 of 32 RPT-JFS-005
 Fauji Fertilizer Company Limited Date / Time
Job Follow Up System 06-April-2020 11:51:28AM
OverDue Actions Report

Organizational Unit: Inspection (MM)

Forum: Inspection Action Reporting
Sr. No Action / Recommendation Detailed Status / Remarks Priority (%) Assign / Target / Update Status
Date
171 (IR#1118) 6.Thickness of epoxy paint is to be Medium 03-11-2016 - 31-03-2017 - 01- In Progress
0%
measured. It should equal 300 microns in 01-2020
total
172 Sand filters to be inspected maximum at an Medium 22-04-2014 - 02-04-2015 - 31- In Progress
0%
interval of 03 years. 12-2019
173 Grounding of FH¿s # 4, 7, and 3 to be Medium 11-02-2015 - 01-06-2015 - 01- In Progress
0%
removed by providing coat wrap on the 01-2020
fault locations.
174 Anodes # 11, 14, 17, 19 (Total 04) to be Medium 11-02-2015 - 01-06-2015 - 01- In Progress
0%
rectified against nil current flow. (Obs. #2) 01-2020
175 Distributor tray of 1MF manway to be Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
replaced in next T/A. 01-2020
176 Option of tubes' life assessment to be Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
evaluated before next turnaround. 01-2020
177 Steam drum of the boiler is to be inspected Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
during next turnaround. 01-2020
178 Cracks # 01 and # 02 in the ring bearing Medium 01-01-1900 - 31-03-2016 - 01- In Progress
0%
(turn table) of crane # 43943 are pending 01-2020
removal and repair. Arrangements for the
accessibility to and inspection of the
bearings¿ inner race may also be
considered to ensure the reliability of such a
vital component.
179 (IR#1121) 2. Thickness monitoring of Medium 15-04-2016 - 31-12-2017 - 01- In Progress
0%
complete circuit to be carried out in 2017. 01-2020
180 Anodes #119, 126 (Total 02) to be rectified Medium 12-04-2014 - 02-04-2015 - 31- In Progress
0%
against nil current flow. 12-2019
181 Tank to be inspected in next turnaround Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
opportunity. 01-2020

Production Server Data Page 19 of 32 RPT-JFS-005

 Fauji Fertilizer Company Limited Date / Time
Job Follow Up System 06-April-2020 11:51:28AM
OverDue Actions Report

Organizational Unit: Inspection (MM)

Forum: Inspection Action Reporting
Sr. No Action / Recommendation Detailed Status / Remarks Priority (%) Assign / Target / Update Status
Date
182 Vessel to be inspected in next turnaround. Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
01-2020
183 Vessel to be inspected in next TA. Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
01-2020
184 All locations to be excavated for inspection Medium 13-04-2015 - 31-03-2016 - 01- In Progress
0%
/ repair of external coating. Defects in Mari 01-2020
gas battery limit to be prioritized.
185 (IR# 1128)Rec.#2 Anodes # (107, 119, 120, Medium 04-05-2016 - 30-11-2017 - 01- In Progress
0%
121, 123, 126, 128, 132, 133, 139, 142, 143) to 01-2020
be rectified against nil current flow. (Ref:
Obs. # 02)
186 Anode # 184 to be checked against Medium 12-04-2014 - 02-04-2015 - 31- In Progress
0%
probable cable connection damage and 12-2019
fault to be rectified (Ref: Obs. #02
187 Malfunctioning anode #03, 05, 07 of ground Medium 15-04-2014 - 02-04-2015 - 31- In Progress
0%
bed to be repaired. 12-2019
188 Blow down vent stack to be inspected Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
during next turnaround. 01-2020
189 MPD to be inspected in next turnaround. Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
01-2020
190 Equipment to be inspected in next TA. Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
01-2020
191 Exchanger to be inspected and repairs to Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
be performed in next available opportunity. 01-2020
192 Startup furnace to be inspected in next Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
available opportunity. 01-2020
193 De-super heater of auxiliary boiler to be Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
inspected in next Turnaround. 01-2020

Production Server Data Page 20 of 32 RPT-JFS-005

 Fauji Fertilizer Company Limited Date / Time
Job Follow Up System 06-April-2020 11:51:28AM
OverDue Actions Report

Organizational Unit: Inspection (MM)

Forum: Inspection Action Reporting
Sr. No Action / Recommendation Detailed Status / Remarks Priority (%) Assign / Target / Update Status
Date
194 Anodes #107, 139, 120, 123, 133 and 143 to Medium 12-04-2014 - 02-04-2015 - 31- In Progress
0%
be replaced (identified as irreparable). 12-2019
195 Equipment to be inspected in next Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
Turnaround Opportunity. 01-2020
196 De-super heater to be inspected in next Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
turnaround. 01-2020
197 Complete Eddy Current Testing of Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
exchanger to be planned for next 01-2020
turnaround.
198 Tubes external indentation due to baffle Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
hammering and striking of sharp corners of 01-2020
stiffenersto be kept under observation.
Additionally, soft material (Aluminum and
Teflon) to bearranged for inserting stiffeners
in next turnaround opportunity.
199 Exchanger to be inspected in next Turn Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
around opportunity. 01-2020
200 An audit for such observations to be carried Medium 24-07-2015 - 24-01-2016 - 01- In Progress
0%
out on similar piping near PD pumps. 01-2020
201 Anode # 160 /162 to be replaced. (Ref: Medium 12-04-2014 - 02-04-2015 - 31- In Progress
0%
Obs. #02) 12-2019
202 PSP values at FH # 35 to be restored to Medium 12-04-2014 - 02-04-2015 - 31- In Progress
0%
recommended limits. (Obs. #1) 12-2019
203 Anode identified as irreparable (Anode # Medium 11-02-2015 - 01-06-2015 - 01- In Progress
0%
78 & 171) to be planned for replacement 01-2020
204 Ammonia let down vessel to be inspected Medium 02-09-2015 - 30-06-2016 - 01- In Progress
0%
after 5 years. 01-2020

Production Server Data Page 21 of 32 RPT-JFS-005

 Fauji Fertilizer Company Limited Date / Time
Job Follow Up System 06-April-2020 11:51:28AM
OverDue Actions Report

Organizational Unit: Inspection (MM)

Forum: Inspection Action Reporting
Sr. No Action / Recommendation Detailed Status / Remarks Priority (%) Assign / Target / Update Status
Date
205 SAIPEM has suggested the use of liquid Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
Teflon in conjunction with Teflon gaskets at 01-2020
all thetube-ferrule interfaces during the next
available opportunity. This option /
recommendation isto be evaluated with
regards to the suitable method of liquid
Teflon application, itseffectiveness, type of
product to be used and the curing time
involved etc.
206 RT of mid height joints of all bulged tubes to Medium 03-03-2014 - 02-04-2015 - 31- In Progress
0%
be performed in upcoming Turnaround for 12-2019
integrity assessment of the welds.
207 Equipment to be inspected in next Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
Turnaround opportunity. 01-2020
208 ECT of tube bundle to be repeated in next Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
turnaround. 01-2020
209 Grounding of FH¿s # 60, 62 to be removed Medium 11-02-2015 - 01-06-2015 - 01- In Progress
0%
by providing coat wrap on the fault 01-2020
locations
210 07 Anodes (78, 65, 54, 29, 31, 33, 18) to be Medium 11-02-2015 - 01-06-2015 - 01- In Progress
0%
rectified for nil current flow (as per Obs. #02) 01-2020
211 Random thickness of shell and nozzles to be Medium 06-03-2013 - 02-04-2015 - 31- In Progress
0%
carried out 12-2019
212 Inlet nozzle and shell area near Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
impingement plate to be kept under 01-2020
observation.
213 Vessel to be inspected during next turn Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
around. 01-2020
214 Vessel to be inspected in next Turnaround. Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
01-2020

Production Server Data Page 22 of 32 RPT-JFS-005

 Fauji Fertilizer Company Limited Date / Time
Job Follow Up System 06-April-2020 11:51:28AM
OverDue Actions Report

Organizational Unit: Inspection (MM)

Forum: Inspection Action Reporting
Sr. No Action / Recommendation Detailed Status / Remarks Priority (%) Assign / Target / Update Status
Date
215 Anodes #107, 139, 120, 123, 133 and 143 to Medium 30-04-2015 - 30-10-2015 - 01- In Progress
0%
be replaced (identified as irreparable). 01-2020
216 Internal epoxy painting of the shell to be Medium 16-07-2015 - 16-01-2016 - 01- In Progress
0%
carried out after thorough cleaningand 01-2020
repair.
217 Degassifier to be inspected in next TA. Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
01-2020
218 Acid injection lines to be removed and Medium 06-03-2013 - 02-04-2015 - 31- In Progress
0%
offered for inspection. 12-2019
219 Option of blowing to remove any left-over Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
blockage may be considered in case 01-2020
repetitivesagging will be observed in
replaced tubes.
220 E-208A to be inspected in suitable Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
opportunity. 01-2020
221 This vessel is to be inspected after 5 years. Medium 02-09-2015 - 30-06-2016 - 01- In Progress
0%
01-2020
222 (IR#1119) 3. All fittings are to be monitored Medium 11-05-2016 - 31-12-2018 - 01- In Progress
0%
after an interval of 03 years. 01-2020
223 01 Anodes identified as irreparable (Anode Medium 24-10-2013 - 02-04-2015 - 31- In Progress
0%
# 171 and ) to be planned for replacement 12-2019
224 (IR# 1128)Rec.#1 PSP value at FH # 15 to be Medium 04-05-2016 - 30-11-2017 - 01- In Progress
0%
restored to recommended limits. (Ref: Obs. 01-2020
# 01)
225 Vessel to be inspected in next Turn around Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
opportunity. 01-2020
226 Manway sealing surface to be kept under Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
observation. 01-2020

Production Server Data Page 23 of 32 RPT-JFS-005

 Fauji Fertilizer Company Limited Date / Time
Job Follow Up System 06-April-2020 11:51:28AM
OverDue Actions Report

Organizational Unit: Inspection (MM)

Forum: Inspection Action Reporting
Sr. No Action / Recommendation Detailed Status / Remarks Priority (%) Assign / Target / Update Status
Date
227 Vessel to be inspected in next turnaround Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
opportunity. 01-2020
228 Vessel to be inspected after 5 years of Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
service. 01-2020
229 Rubber lining of the vessel to be completely Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
rehabilitated after removal of old lining. 01-2020
(Recommendation since TA-2005). Base
metal to be cleaned and inspected before
installationof new lining to check for any
corrosion damage.
230 Carbamate Separator to be inspected in Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
next turnaround. 01-2020
231 Vessel to be inspected in next TA. Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
01-2020
232 Corrosion deposits observed on the metallic Medium 15-12-2015 - 31-12-2016 - 01- In Progress
0%
plates to be cleaned followed by inspection 01-2020
and repainting as per specification.
233 Vessel to be inspected in next TA. Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
01-2020
234 Combustion Chamber of auxiliary boiler to Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
be inspected in next Turnaround. 01-2020
235 Inspection of mixing tee to be carried out in Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
next Turnaround. 01-2020
236 Hardness on weld joint of tube no. 19C & Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
16E to be kept under observation. 01-2020
237 The 05 welds of Section III (P & H Crane # Medium 01-01-1900 - 31-03-2016 - 01- In Progress
0%
43944) which were found to have 01-2020
contained defects like undercuts and
pinholes are to be repaired and
subsequently inspected.
Production Server Data Page 24 of 32 RPT-JFS-005
 Fauji Fertilizer Company Limited Date / Time
Job Follow Up System 06-April-2020 11:51:28AM
OverDue Actions Report

Organizational Unit: Inspection (MM)

Forum: Inspection Action Reporting
Sr. No Action / Recommendation Detailed Status / Remarks Priority (%) Assign / Target / Update Status
Date
238 Anode # 160 /162 to be replaced. (Ref: Medium 11-02-2015 - 01-06-2015 - 01- In Progress
0%
Obs. #02) 01-2020
239 Vessel to be inspected in next turnaround. Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
01-2020
240 Vessel to be inspected in next TA. Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
01-2020
241 Low PSP value at FH # 22,T-902, SS6 West Medium 24-10-2013 - 02-04-2015 - 31- In Progress
0%
side planning car parking shed to be kept 12-2019
under observation
242 Economizer to be inspected during the next Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
turnaround. 01-2020
243 When the header is offline, metallography, Medium 02-10-2015 - 31-03-2016 - 01- In Progress
0%
hardness testing and PMI should be 01-2020
performed at its problematic sections to
assist in ascertaining the root cause of these
leakages.
244 Vessel to be inspected in next turnaround. Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
01-2020
245 Supports inside Mari gas battery limited to Medium 13-04-2015 - 31-03-2016 - 01- In Progress
0%
be removed for inspection and repair work 01-2020
against external corrosion. Additionally,
coat wrap at NG line entrance point to be
exposed for inspection.
246 The remaining 03 defected lacings Medium 01-01-1900 - 31-03-2016 - 01- In Progress
0%
comprising the Section II (P & H Crane # 01-2020
43944) are to be replaced and
subsequently tested through VT, MPI (before
load test) and DPT (before and after load
test).

Production Server Data Page 25 of 32 RPT-JFS-005

 Fauji Fertilizer Company Limited Date / Time
Job Follow Up System 06-April-2020 11:51:28AM
OverDue Actions Report

Organizational Unit: Inspection (MM)

Forum: Inspection Action Reporting
Sr. No Action / Recommendation Detailed Status / Remarks Priority (%) Assign / Target / Update Status
Date
247 Extensive ongoing thickness monitoring Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
program outside turnaround and 01-2020
radiography of jointsduring turnaround to
be continued.
248 The equipment to be inspected during next Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
turnaround. 01-2020
249 Gas outlet side of Product Gas Cooler to be Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
inspected in next turnaround. 01-2020
250 Flue gas duct of auxiliary boiler to be Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
inspected at next Turnaround. 01-2020
251 Corrosion of the gasket seating surface to Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
be inspected in next Turnaround for 01-2020
anyaggravation.
252 Holiday detection to be performed at the Medium 06-03-2013 - 02-04-2015 - 31- In Progress
0%
bottom portion of vessel after drying ofthe 12-2019
vessel.
253 Auxiliary Super heater to be inspected in Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
next turnaround. 01-2020
254 V-425 to be inspected in the next Medium 02-09-2015 - 30-06-2016 - 01- In Progress
0%
turnaround. 01-2020
255 Vessel to be inspected in next Turnaround. Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
01-2020
256 Anode identified as irreparable (Anode # Medium 01-01-1900 - 02-11-2015 - 01- In Progress
0%
78 & 171) to be planned for replacement 01-2020
257 For ruling out any in-adequacy in gas flow Medium 03-03-2014 - 02-04-2015 - 31- In Progress
0%
pattern, temperature profile of the tube 12-2019
banks at one and three turn valve openings
to be performed at Plant-I start-up furnace.

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 Fauji Fertilizer Company Limited Date / Time
Job Follow Up System 06-April-2020 11:51:28AM
OverDue Actions Report

Organizational Unit: Inspection (MM)

Forum: Inspection Action Reporting
Sr. No Action / Recommendation Detailed Status / Remarks Priority (%) Assign / Target / Update Status
Date
258 Inspection/ DPT of drum welds on available Medium 16-07-2014 - 02-04-2015 - 31- In Progress
0%
opportunities till the completion of 12-2019
recommendation # 2 above.
259 PSP values at FH # 62 to be restored to Medium 11-02-2015 - 01-06-2015 - 01- In Progress
0%
recommended limits. (Obs. #1) 01-2020
260 Scope of repair/replacement to be finalized Medium 16-12-2014 - 02-04-2015 - N/A In Progress
0%
after inspection.
261 Exchanger to be inspected and repairs to Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
be performed in next available opportunity. 01-2020
262 ECT of tubes to be repeated in next Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
turnaround. 01-2020
263 All repaired locations on process side and Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
corrosion near seal welds to be kept 01-2020
underobservation.
264 Medium pressure absorber to be inspected Medium 09-02-2015 - 31-10-2017 - 01- In Progress
0%
during next turnaround. 01-2020
265 Primary reformer to be inspected in next Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
turnaround. 01-2020
266 Solution Inlet nozzle (sacrificial) liner to be Medium 09-02-2015 - 31-10-2017 - 01- In Progress
0%
kept available. However, a possible 01-2020
switching ofliner material from titanium to
zirconium to be explored with SAIPEM for
better protectionagainst erosion.
267 Temporary fasteners, nuts, studs, tie-rods Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
etc. of titanium material were generally 01-2020
observed tobe worn-out. Their replacement
(where possible) with the suitable material
to be looked into.

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 Fauji Fertilizer Company Limited Date / Time
Job Follow Up System 06-April-2020 11:51:28AM
OverDue Actions Report

Organizational Unit: Inspection (MM)

Forum: Inspection Action Reporting
Sr. No Action / Recommendation Detailed Status / Remarks Priority (%) Assign / Target / Update Status
Date
268 Grounding of FH¿s # 4, 5, 7, and 3 to be Medium 30-04-2015 - 30-10-2015 - 01- In Progress
0%
removed by providing coat wrap on the 01-2020
fault locations.
269 Anode # 184 to be checked against Medium 02-05-2015 - 02-11-2015 - 01- In Progress
0%
probable cable connection damage and 01-2020
fault to be rectified (Ref: Obs. #02)
270 07 Anodes (78, 65,68, 54, 29, 31, 33, 18) to Medium 01-01-1900 - 02-11-2015 - 01- In Progress
0%
be rectified for nil current flow (as per Obs. 01-2020
#02)
271 Backfilling needs carrying out in front of Medium 12-04-2014 - 02-04-2015 - 31- In Progress
0%
Anode junction box. (Obs. #2) 12-2019
272 Anode # 160,184,158 to be checked Medium 11-02-2015 - 01-06-2015 - 01- In Progress
0%
against probable cable connection 01-2020
damage and fault to be rectified (Ref: Obs.
#02)
273 Bulging data to be taken for trend analysis. Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
01-2020
274 Accumulator to be inspected during next Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
turnaround. 01-2020
275 UT Inspection of all tube to tubesheet welds Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
to be planned for next turnaround. 01-2020
276 Evaluation for the possibility of ToFD Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
examination on 2nd circumferential weld 01-2020
seam of Bed no.4 to be carried out prior to
next turnaround.
277 Vessel to be inspected in next TA. Medium 09-02-2015 - 30-06-2016 - 01- In Progress
0%
01-2020

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 Fauji Fertilizer Company Limited Date / Time
Job Follow Up System 06-April-2020 11:51:28AM
OverDue Actions Report

Organizational Unit: Inspection (MM)

Forum: Plant Reliability Task Force
Sr. No Action / Recommendation Detailed Status / Remarks Priority (%) Assign / Target / Update Status
Date
1 For inspection and critical structure repairs Vendors with such expertise related to civil High N/A - N/A - 12-12-2019 In Progress
60%
expertiseshould be identified and hired from structures have been contacted.
market.
2 Provision of sleeves to be done with proper A survey of coat wrap of piping has been High N/A - N/A - 12-12-2019 In Progress
40%
insulation afterdigging the line till healthy carried out. Remedial actions are to follow
portion in all over the plant. now.
3 Develop mechanism to check the CUI in all High N/A - N/A - 29-01-2019 In Progress
0%
critical plantpiping.
4 Piping segments with two phase flow and High N/A - N/A - 29-01-2019 In Progress
0%
high velocities tobe identified and included
in inspection plan.
5 Dead ends (for corrosive services in High N/A - N/A - 29-01-2019 In Progress
0%
particular) andInjection/mixing points to be
identified and included ininspection plan.
6 Piping segments with harsh operating High N/A - N/A - 29-01-2019 In Progress
0%
conditions to beidentified and included in
inspection plan.
7 Audit of paint damage on piping to be High N/A - N/A - 29-01-2019 In Progress
0%
carried out for properrepair
8 Painting of piping to be carried out only High N/A - N/A - 29-01-2019 In Progress
0%
after propersurface cleaning and
inspection of base pipe. Awarenesssession
on this observation to be made part of
trainingmodule.
9 In order to have idea of equipment’s High N/A - N/A - 29-01-2019 In Progress
0%
external condition it isrecommended to
remove insulation of Back End 2nd
chillerCold insulation in TA and carry out
inspection. (Based onobservation further
line of action may be defined)

Production Server Data Page 29 of 32 RPT-JFS-005

 Fauji Fertilizer Company Limited Date / Time
Job Follow Up System 06-April-2020 11:51:28AM
OverDue Actions Report

Organizational Unit: Inspection (MM)

Forum: Plant Reliability Task Force
Sr. No Action / Recommendation Detailed Status / Remarks Priority (%) Assign / Target / Update Status
Date
10 External inspection of the vessels to be High N/A - N/A - 29-01-2019 In Progress
0%
included in pressurevessel inspection plan
including inspection of externalcoating /
insulation, piping connections, skirt,
foundation andassociated structure.
11 Inspection of conveyor belts structure to be High N/A - N/A - 29-01-2019 In Progress
0%
included ininspection plan.
12 Structure on corrosive service should be High N/A - N/A - 29-01-2019 In Progress
0%
inspected / auditedfor their reliability and
mechanical integrity as per
definedfrequency may be 10 or 15 years.
13 All davits at the plant to be inspected and High N/A - N/A - 29-01-2019 In Progress
0%
their design to beimproved.
14 Enlist piping which has vibration problems High N/A - N/A - 29-01-2019 In Progress
0%
especiallythose adjacent to reciprocating
machines and their healthto be checked.
15 Review supports with the pad especially on High N/A - N/A - 29-01-2019 In Progress
0%
the lineshaving high vibrations.
16 Fresh review of PMP on the basis of current High N/A - N/A - 29-01-2019 In Progress
0%
observations isrequired to include missing
jobs, update equipmentsreplaces,
frequency based on experience and
actionassigned to correct agency.
17 Material availability status to be update by High N/A - N/A - 29-01-2019 In Progress
0%
P&S on quarterlybasis for reliable planning
of jobs through concerned.
18 Target date should be marked in all High N/A - N/A - 29-01-2019 In Progress
0%
recommendations

Production Server Data Page 30 of 32 RPT-JFS-005

 Fauji Fertilizer Company Limited Date / Time
Job Follow Up System 06-April-2020 11:51:28AM
OverDue Actions Report

Organizational Unit: Inspection (MM)

Forum: Plant Reliability Task Force
Sr. No Action / Recommendation Detailed Status / Remarks Priority (%) Assign / Target / Update Status
Date
19 There should be a written closing note to High N/A - N/A - 29-01-2019 In Progress
0%
close assignedaction signed by in-charge of
the executing unit with theconsent of
initiating unit. System similar to SR closing
note tobe followed.
20 The recommended approach is to High N/A - N/A - 29-01-2019 In Progress
0%
conclude reports afterRCA so that actions
are realistic.
21 Actions assigned in reports to be mutually High N/A - N/A - 29-01-2019 In Progress
0%
agreed andreviewed by all concerned.
22 Any action which is against SOP or unusual High N/A - N/A - N/A In Progress
0%
without givingconsideration of
consequential outcome should
beinvestigated and RCA to be done.
Accordingly report to beissued.
23 All units to develop training modules and High N/A - N/A - 29-01-2019 In Progress
0%
separate “on-thejob”and customize training
subjects.
24 Training module should cover all subjects/ High N/A - N/A - 29-01-2019 In Progress
0%
activitiesrelated to functions of a unit.
Practical demonstration/handsontraining of
small job activities to be carried out
atdepartmental level before assigning
independent jobswherever applicable.
25 Shutdown opportunities to be used to train High N/A - N/A - 29-01-2019 In Progress
0%
people on all suchactivities. Include in
training manual of unit’s.
26 Training plans to be developed on the basis High N/A - N/A - 29-01-2019 In Progress
0%
of individualstraining needs and
observations in performance appraisal.
Include in training manua

Production Server Data Page 31 of 32 RPT-JFS-005

 Fauji Fertilizer Company Limited Date / Time
Job Follow Up System 06-April-2020 11:51:28AM
OverDue Actions Report

Organizational Unit: Inspection (MM)

Forum: Plant Reliability Task Force
Sr. No Action / Recommendation Detailed Status / Remarks Priority (%) Assign / Target / Update Status
Date
27 Level of junior management up to DE may High N/A - N/A - 29-01-2019 In Progress
0%
be fixed to ensurecompletion of five basic
mandatory training programs
beforepromotion to DE level. Same to be
included in trainingmanual.
28 RCA should be made part of basic High N/A - N/A - 29-01-2019 In Progress
0%
mandatory training for allEngineers. Include
this in working procedure of unit’s.
29 Coils bulging assessment to be carried out High N/A - N/A - 29-01-2019 In Progress
0%
for replacement ifrequired. Also its thermal
expansion support to be clean asper TMP
plan.
Forum: Sub SOC (M)
Sr. No Action / Recommendation Detailed Status / Remarks Priority (%) Assign / Target / Update Status
Date
1 Vibration problem of Lube oil Pumps P-309 Very High 12-10-2017 - 31-12-2017 - N/A In Progress
0%
A/B to be studied in detail.

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