2020

Urea-2
Machinery Package

0|Page
 MEMORANDUM
PRODUCTION DEPARTMENT
ENGRO FERTILIZERS LIMITED
DAHARKI, PAKISTAN

DATE : January 12, 2023

SUBJECT: Urea-2 Machinery Package

TO : SID,MAJ,BAf
CC : SNH, AlQ,MIK, KBM
FROM : WI

1
 PRODUCTION DEPARTMENT
ENGRO FERTILIZERS LIMITED

SUBJECT: Urea-2 Machinery Package

Prepared By : WI Issue Date : January 12, 2023

BACKGROUND
One of the biggest hurdle faced by interfaces today in maintenance of machinery is lack
of synergy amongst operations, maintenance & I&E. This is primarily due unavailability
of methodical PM & CM regimes. Operations is responsible for handing over an
equipment for PM & breakdown maintenance when demanded by the interface. But one
equipment has to undergo several PMs, involving more than one interface. For this
Operations has to handover one equipment multiple times for PM performed by different
interfaces.

In order to streamline this routine activity & reduce downtime of equipment, operations
has come with a plotted plan to eliminate discrepancies in PM & CM regimes. This will
not only reduce workload of operations team but also add to the health of equipment by
reducing multiple shut-downs & start-ups.

PROPOSAL
A plan or Job card is be developed so that for every critical machine job handover Ur-2
OPS & FM are on single page wrt to their preparedness and Job planning
ATTACHMENTS

Attachment-I: C-2C/D/E Job Package

Attachment-II: P-201’s Job Package
Attachment-III: P-202F/G,SC-241 & Conveyor jobs
Attachment-IV: Pump Breather’s cleaning list
Attachment-V:Pump Change over matrix
Attachment-VI: Preservation of Rotary Machine
Attachment-VII: Compressors/Pump Startup checklist

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Attachment-I: C-2C/D/E Job Package:

Job
Last Calibration Calibration Due Waiver
Sr # C-2C Job List Completed Remarks Resp
Date Date Status
Signature
1 C-2C overhauling FM
2 Power End & fluid end inspection FM
3 Main Packing & wiper packing leakage FM
4 E-33C tube cleaning FM
5 E-27C1/2 E-28C1/2 ,E-29C1/C2 ,E-20C1/2/3 CW side cleaning FM
6 PRV adjustment of FF lubricator FM
7 PSV inspection which are have planned inspection or on waiver FM
PSV-33___ FM
PSV-34___ FM
PSV-35___ FM
PSV-36___ FM
PSV-37___ FM
PSV-38___ FM
8 P-14C discharge C/V's inspection FM
9 5th discharge C/V inspection. FM
10 FIL-2C cleaning FM
11 Crank case cover leakages to minimize oil replenishment FM
12 C-2C all stages suc/dich valve inspection FM
13 Auto drainer fault rectification & inspection FM
14 Jacket water leakage removal FM
15 All knck out drums & pulsation bottles inspection FM
16 MP-14C & MP-16C field servicing & its breaker feeder servicing. I&E
17 C-2C all control valve PM job I&E
18 All tripping securities PM job. I&E
PLCO-87 A I&E
PLCO-90 A I&E
DPSH 100 A I&E

3
 PLCO-86 A I&E
PHCO-82 A I&E
PHCO-83 A I&E
VHCO-12C I&E
VHCO-14C I&E
LHCO-23 C I&E
19 Green List Jobs FM/I&E
20 Lube oil filters cleaning FM
21 Sump cleaning & decanting & cleaning of C-2C OPS

4
 Last Job
Calibration Waiver
Calibration Completed Remarks
Due Date Status
Sr # C-2D Job List Date Signature Resp
1 C-2D overhauling FM
2 Power End & fluid end inspection FM
3 Any Jacket water leakage or wiper packing leakage FM
4 E-33 D tube cleaning FM
5 E-27D1/2 E-28D1/2 ,E-29D1/C2 ,E-20D 1/2/3 CW side cleaning FM
6 PRV adjustment of FF lubricator FM
7 PSV inspection which are have planned inspection or on waiver FM
PSV-33___ FM
PSV-34___ FM
PSV-35___ FM
PSV-36___ FM
PSV-37___ FM
PSV-38___ FM
8 P-14D discharge C/V inspection FM
9 5th discharge C/V inspection. FM
10 FIL-2D cleaning FM
11 Crank case cover leakages to minimize oil replinshment FM
12 C-2D all stages suc/dich valve inspection FM
13 Auto drainer fault rectification & inspection FM
14 jacket water leakage removal FM
15 All knck out drums & pulsation bottles inspection FM
16 MP-14D & MP-16D field servicing & its breaker feeder servicing. I&E
17 C-2D all control valve PM job I&E
18 All tripping securities PM job. I&E
PLCO-87 B I&E
PLCO-90 B I&E
DPSH 100 B I&E
PLCO-86 B I&E

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 PHCO-82 B I&E
PHCO-83 B I&E
VHCO-12D I&E
VHCO-14D I&E
LHCO-23 D I&E
19 Green List Jobs FM/I&E
20 Lube oil filters cleaning FM
21 Sump cleaning & decanting of C-2D OPS

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Sr # C-2E Job List Last Calibration Waiver Job Remarks Resp
Calibration Due Date Status Completed
Date Signature
1 C-2E overhauling FM
2 Power End & fluid end inspection FM
3 Mian packing & wiper packing leakage FM
4 E-33E tube cleaning FM
5 E-27E/28E29E/30E cw side cleaning. FM
6 PRV adjustment of FF lubricator FM
7 PSV inspection which are have planned inspection or on waiver FM
PSV-33___ FM
PSV-34___ FM
PSV-35___ FM
PSV-36___ FM
PSV-37___ FM
PRV-72 __ FM
8 P-14E discharge C/V's inspection FM
9 P-16E discharge C/V's inspection FM
10 5th discharge C/V inspection. FM
11 FIL-2E cleaning FM
12 C-2E cono filter cleaning FM
13 Crank case cover leakages to minimize oil replenishment FM
14 C-2E all stages suc/dich; valve inspection FM
15 MP-14E & MP-16E field servicing & its breaker feeder servicing. FM
16 C-2E all control valve PM job. FM
17 C-2E motor filter cleaning. FM
18 All tripping securities PM job I&E
PSL 101/6 I&E
PHCO-83E I&E
PI - 900-8 I&E
PDAH-900-10 I&E

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 TE-900-22 H I&E
TE-900-23 HH I&E
TAH-900-20 I&E
TE-900/21A I&E
TE-900/21B I&E
TE-900/21C I&E
TE-900-13 I&E
TAH-900-16 I&E
VSH-900-19/19A I&E
LHCO-23E I&E
TE-900-17-1A/1B/2A/2B/3A/3B/4A/4B/5A/5B/6A/6B/7A/7B I&E
19 C-2E motor PM job & its winding cleaning I&E
20 Green List Jobs FM/I&E
21 Sump cleaning & decanting of C-2E OPS

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 ENGRO FERTILIZERS LIMITED
MANUFACTURING DIVISION, DAHARKI
Document Type: Special Operating Originated by : WI/Mukhtiar Ali In : FEB 2020
Procedures Revision No: 0
C-2C/D/E CRANK Issue No. 1 : WI/Mukhtiar Ali In : May 2020
CASE OIL LEVEL Reviewed by : SNH In : May 2020
Document No.: PR-UR2-P4-18 Approved by : KBM In : May 2020
DRAINING & Updation due: In : May 2023

Document Status: Final / Controlled

MAKEUP
Special Operations Procedure Department : Production Unit: Urea-2 Code: PR-UR2

SECTION-18 C-2C/D/E CRANK CASE OIL LEVEL DRAINING & MAKE UP

SCOPE:
This procedure describes the actions required for draining & oil level makeup in C-2E crank
case.
TABLE OF CONTENTS

18.1 PPE’s: ....................................................................................................................................

18.3 HAZARDS AND CONSEQUENCES: ..........................................................................................
18.4 PRE-CHECKS: .........................................................................................................................
18.5 OIL DRAINING: ......................................................................................................................
18.6 OIL (USED OIL) MAKEUP IN CRANK CASE: ............................................................................

Prepared By: Reviewed By :

Signature: __________________ Signature: ________________

Name: Waqas Iqbal Name: AFB/AdM
Title: Senior Engineer (Urea-2) Title: Machinery Sup/MTS Engineer
Date: __________________ Date: ________________
Reviewed By: Approved By :

Signature: __________________ Signature: ________________

Name: Syed Najam UL-Hassaan Name: Khawaja Bilal Mustafa
Title: Manager Operation (Urea-2) Title: Production Manager
Date: __________________ Date: ________________

9
 ENGRO FERTILIZERS LIMITED
MANUFACTURING DIVISION, DAHARKI
Document Type: Special Operating Originated by : WI/Mukhtiar Ali In : FEB 2020
Procedures Revision No: 0
C-2C/D/E CRANK Issue No. 1 : WI/Mukhtiar Ali In : May 2020
CASE OIL LEVEL Reviewed by : SNH In : May 2020
Document No.: PR-UR2-P4-18 Approved by : KBM In : May 2020
DRAINING & Updation due: In : May 2023

Document Status: Final / Controlled

MAKEUP
Special Operations Procedure Department : Production Unit: Urea-2 Code: PR-UR2

18.1 PPE’S:
1. Mandatory PPE’s.
2. Cotton Gloves.

18.2 PREPARATION:
1. Arrange 12 cleaned & same oil grade oil drums.
2. Arrange foam of dimension (20cm*8cm) for sump cleaning of C-2C/D/E
3. Arrange a potable water hose having a Chicago coupling at one end & other
end is open.
4. Arrange a spare SYNCOM area operator for this activity.
18.3 HAZARDS AND CONSEQUENCES:
1. Oil may contaminate so collect oil in clean & same oil grade oil drums.
2. Oil may spill, therefore must take care to avoid slippage.
3. Explosion may occur if welding job to be done nearby.
4. P-16C/D/E1/E2 may damage if Crank Case become empty/low oil level.
5. Oil may drained while recharge in crank case so make sure that all drains &
bleeders are properly closed.
6. Oil drum may fall so special care must be required during oil charging & drums
shifting.
18.4 PRE-CHECKS:
1. Ensure oil drums are neat & clean.
2. Ensure oil drums are being used having the same oil grade.
3. Ensure all drums are properly covered & secured after oil filling in drums.
4. Caution board is used to avoid any misunderstanding.
5. Entry is restricted at the oil drums location.
6. Hose which is to be used is cleaned & physically OK.
7. Area should be cordon off before start the activity.
8. Make sure that load testing tag is installed at belts are being used for oil drums
shifting.
18.5 OIL DRAINING:
1. For C-2C/D install hose at P-16C/D discharge line Chicago coupling bleeder &
insert other end of hose in empty oil drum.
2. For C-2E install hose at P-16E1/E2 discharge line Chicago coupling bleeder &
insert other end of hose in empty oil drum.
3. Crack open the drain valve & fill the drum at about 90% by starting P-16C/D/E.

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 ENGRO FERTILIZERS LIMITED
MANUFACTURING DIVISION, DAHARKI
Document Type: Special Operating Originated by : WI/Mukhtiar Ali In : FEB 2020
Procedures Revision No: 0
C-2C/D/E CRANK Issue No. 1 : WI/Mukhtiar Ali In : May 2020
CASE OIL LEVEL Reviewed by : SNH In : May 2020
Document No.: PR-UR2-P4-18 Approved by : KBM In : May 2020
DRAINING & Updation due: In : May 2023

Document Status: Final / Controlled

MAKEUP
Special Operations Procedure Department : Production Unit: Urea-2 Code: PR-UR2

4. Close the drain valve after oil drum filling & capped the drum.
5. Shift maximum oil from crank case in drums by keep an close eye on P-16C/D/E
discharge pressure.
6. For C-2D Remove hose from P-16C/D discharge bleeder & installed at suction
bleeder of P-16C/D
7. For C-2E Remove hose from P-16E1/E2 discharge bleeder & installed at suction
bleeder near E-30E for complete oil draining.
8. Marked the drums clearly.
18.6 SUMP CLEANING FOR C-2E
1. Ensure C-2E is LOTO
2. Ensure Vessel Entry prerequisite is done for Confine space permit Requirements
3. During lube oi removal from crank case use pack of foam sponge to soak the
residual of oil to empty out crank case & squeeze the sponge in tray OR bucket.

Do not use Lattha or lint material in cleaning of Sump for C-2C/D/E

as it causes cloth strands to remain in sump which eventually clog in Cono
filter upon circulation
18.7 OIL (USED OIL) MAKEUP IN CRANK CASE:
1. Make sure that all jobs in crack case are completed & work permits returned.
2. Make sure that all suction & discharge drains/bleeders of P-16E1/E2 are closed.
3. Install crank case top covers except last one (P-14E side).
4. Shift all the drums on compressor deck which will be charged in C-2E crank case.
5. Install mesh at crank case cover to ensure that there is no impurity in oil.
6. Charged the oil in crank case.
7. Install remaining top cover of crank case.
8. Remove empty oil drums from area to lube oil station

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Attachment-II:P-201’s Job Package
Last Job
Calibration Calibration Waiver Completed Remarks
Sr # P-201B/C/E/F s Job List Date Due Date Status Signature Resp
1 P-201's crank case Overhauling (if required) FM
2 P-201's packing/manifolds replacement (if required) FM
3 Crank case & gear box lube oil cooler cleaning FM
P-201's suction , discharge ,casing & Lube oil PSV's
4 inspection FM
P-201 B PSV's FM
PSV-204___ FM
PSV-269___ FM
PSV-204___ FM
PSV-201___ FM
5 P-201's suction & discharge pulsation bottle inspection FM
6 P-201's gear box inspection or replacement (if required) FM
7 P-201's oil filter cleaning. FM
8 All instrumentation PM job FM
Instrumentation Inst
PTX/PHCO-419___ Inst
TAH/THCO-419___ Inst
PSL-423___ Inst
PLCO-427___ Inst
9 Lube oil motor PM job Inst
10 P-201,s flushing BFW FI's fault rectification. Inst
11 Motor field servicing & breaker feeder servicing Elec
12 Green List Jobs FM/I&E

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Requirement of FM team in Handing over of P-201’s
1. P-201’s Suction hogger installation for removal of trapped ammonia
2. P-201’s suction blind installation
3. N2 connection while pressurization of Uraca
4. Presence of FM team while pressurizing Uraca’s with Ammonia

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Attachment-III:P-202’s & SC-241 Job Package
Sr # P-202G's Job List Waiver Status Job Completed Remarks Resp
Signature
1 L.O filter replacement/cleaning. FM
2 BFWstrainers are cleaned . FM
3 Gear box inspection FM
4 Check Free Shaft Rotation FM
5 E-208 G1/G2 Lube oil exchangers cleaning FM
6 Safety Critical Securities PM I&E
PHCO-125G I&E
PSLL-122G I&E
PT-122G I&E
THCO-126G I&E
TE-137G I&E
FSLL-121G I&E
FSLL-122G I&E
VHCO-121G/GA I&E
VHCO-122G/GA I&E
VHCO-123G/GA I&E
7 Main & aux. motors servicing (Field/breakers) I&E
8 Temperature Indication PM I&E
TE-126G I&E
TI-136G I&E
TE-117 G I&E
TE-118 G I&E
TE-119 G I&E
TE-120 G I&E
TE-125 G I&E
TE-126 G I&E
TE-121G I&E
TE-123G I&E
TE-124 G I&E

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 (TE-1/2/3/4/5/6) I&E
9 PLC check up I&E

Sr # P-202F's Job List Resp

For Quarterly Checkup
1 L.O filter replacement if > 5psi. FM
2 Cleaning of P-251 suction strainer and discharge filter . FM
3 CWS both strainer should be cleaned FM
4 Coupling guard Removal for Free Shaft Rotation FM
5 Vibration panels indication should be OK and green FM
6 All temperature & pressure parameter should be Ok FM
7 Lube oil exchanger cleaning FM
8 Securities PM Inst/OPS
9 Mian & aux. motors servicing (Field/breakers) Inst/OPS

Sr # SC-241 & Conveyor Job List Resp

1 Scrapper bull gear inspection or replacement FM
2 Scrapper belts replacement. FM
3 Scrapper gear box oil replacement or oil make up FM
4 CO-241 conveyer belt replacement FM
5 CO-241 motor belts/roller replacement FM
6 CO-241 motor field servicing & its breaker feeder servicing Elec
7 Scraper motor field servicing & its breaker feeder servicing Elec
8 CO-241 RPM probes PM Inst
9 Pull chord PM Inst
10 Scrapper RPM prob pm Inst
11 CO-241 Plug chute indication PM Inst
12 Scrapper floor washing. Ops
13 PLC test & PM. Inst/OPS

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 Attachment-IV: List of Breathers

Sr # Syncom Sr # Recovery & Decomposition

1 C-2C Crank Case 35 P-274A
2 C-2D Crank Case 36 P-274B
3 C-2E Crank Case 37 P-264A
4 C-2C Pedestal Bearing 38 P-264B
5 C-2D Pedestal Bearing 39 B-221
6 C-2E Pedestal Bearing 40 P-265A
7 P-201B Crank Case 41 P-265B
8 P-201C Crank Case 42 P-267B
9 P-201D Crank Case 43 P-267C
10 P-201E Crank Case 44 P-280A
11 P-201F Crank Case 45 P-280C
12 P-201B Gear Box 46 P-244A
13 P-201C Gear Box 47 P-244B
14 P-201D Gear Box 48 P-244C
15 P-201E Gear Box Sr # Finishing
16 P-201F Gear Box 49 P-242A
17 P-202B Torque Converter 50 P-242B
18 P-202C Torque Converter 51 P-342A
19 P-202E Torque Converter 52 P-342B
20 P-202B Ist gear box 53 P-243A
21 P-202C Ist gear box 54 P-243B
22 P-202E Ist gear box 55 P-243C
23 P-202B 2nd gear box 56 P-243D
24 P-202C 2nd gear box 57 P-254A
25 P-202E 2nd gear box 58 P-254B
26 P-202F Oil sump 59 P-254C
27 P-202G Oil Sump 60 P-254D
Sr # ACES 61 P-255
28 P-205A 62 P-255A
29 P-204 63 P-241A
30 P-263C 64 P-241B
31 P-298A 65 P-299A
32 P-298B 66 P-299B
33 P-203A 67 P-299D
34 P-266C

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Attachment-V Urea-2 Pump change over Matrix

Urea-2 STAND BY PUMPS OPERATION CHECK UP MATRIX 2Q-2020

Month April May June Remarks
Week 1w 2w 3w 4w 1w 2w 3w 4w 1w 2w 3w 4w
Category-1: Pump change over on quarterly basis
P-202 F (Plan wrt to SS Checklist)
P-11C
P-256B
P-16E1
P-264B
P-242A
P-247A
P-267C
P-264A
P-253C
P-262B
P-261A
P-261B
P-241B
P-202E
P-265B
P-205A
P-266A

17
 Urea-2 STAND BY PUMPS OPERATION CHECK UP MATRIX 2Q-2020
Month April May June Remarks
Week 1w 2w 3w 4w 1w 2w 3w 4w 1w 2w 3w 4w
Category-1: Pump change over on quarterly basis
P-266B
P-265A
P-280C
P-16E2
P-205B
P-255A
P-263A
P-280 A
P-274B
P-243D
P-244C
P-11D
P-274A
P-202B
P-241A
P-267B
P-262A
P-243A
P-243C

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 Urea-2 STAND BY PUMPS OPERATION CHECK UP MATRIX 2Q-2020
Month April May June Remarks
Week 1w 2w 3w 4w 1w 2w 3w 4w 1w 2w 3w 4w
Category-1: Pump change over on quarterly basis
P-256A
P-242 A
P-255
P-202C
P-263B
P-243B
P-247B
P-242B
Category-2 Pump operation will be checked on half yearly basis or Standby pump to be put in operation
in case of Startup/Shutdown
Month Jan Feb March April May June July Aug Sept Oct Nov Dec
Week 3w 3w 3w 3w 3w 3w 3w 3w 3w 3w 3w 3w
P-254A/B
P-254C/D

Guidelines:
1. P-202 F to be start on 1st Wednesday of each Quarter (Jan, April,July,October)
2. Tuesday morning shift SS to ensure standby pump operation checkup as per matrix and sign the matrix

19
3. Category-1 pump operation will be checked and line up in system on quarterly basis as per scheduled matrix.
4. Category-2 pump operation will be checked on half yearly basis or Standby pump to be put in operation in case of Plant
startup/Shutdown. This category Pump has to be started on Tuesday (Working day)
5. In case the pump changeover is not possible pen down the reason on the pump matrix

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Attachment-VI PRESERVATION OF ROTORY MACHINES
Engro Fertilizer Ltd.
Effective by : March 2020 Urea-2 plant
Prepared by : Asad Saifullah Lube Oil Circulation Checklist
Reviewed by :WI (Applicable when plant is shut down for
more than 1 month) Revision No : 2
Approved by : SNH Updated On:
Com pressor post checklist to be filled in Morning Shift and Synthesis post checklist to be filled
in Evening Shift on 15th of Every m onth
Date:__________________

Post Description Yes No Remarks

Bar over for 30 Min
and continue lube oil
Compressor C-2C / D/ E q q pump running for
2~3hrs
Operate lube oil pump
P-201B/C/D/E/F q q for 30min
Synthesis
Operate lube oil pump
P-202B/C/E/F / G q q for 30min

POST COMPRESSOR SYNTHESIS

OPERATOR:_________________________

SUPERVISOR:______________________________ UNIT MANAGER:__________________________

21
Engro Fertilizer Ltd.
UREA-2 plant
Effective by : March 2020
Oil Cup Monitoring Checklist
Prepared by : Asad Saifullah

Reviewed by : RdA
(Applicable when plant is shut down for more Revision No : 2
Approved by :SNH than 1 month) Updated on:
Date:__________________

Check for presence of water in oil cup and replace lube oil if required. This audit to be carried out on
15th of every month in Night Shift.

Post Description Yes No Remarks

P-203A q q Bearing hosing oil level
P-206 A/B q q Bearing hosing oil level
P-262A q q Glycol Level

P - 266A/ B / C q q Bearing hosing oil level

SYNTHESIS
P - 263 C q q

P-205 A/ B q q Bearing hosing oil level

P-204 q q
P-298 A / B q q
P-267 A/ C q Bearing hosing oil level
B-221 q q Bearing hosing oil level
P-280 A/ C q q Bearing hosing oil level

DEC / REC P-274 A /B q q

P-265 A/ B q q
P-244 A/ B/ C q q
P-264 A / B q q
P-255 / A q q
P-254 A/ B / C / D q q
P-243 A/ B / C / D q q
FINISHING
P-241A/B q q
P-242A/B q q
P-342A/B q q Bearing hosing oilevel
ACES/ SYNTHESIS DEC / REC FINISHING
POST OPERATOR :________________________

SUPERVISOR: _______________________ UNIT MANAGER : _____________

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Attachment-VII: Compressors/Pump Startup checklist
Engro Fertilizers Ltd.

Effective on : July 2017 Document No : 107-Chk

CO2 COMPRESSOR (C-2 C / D)
Prepared by : Asghar Ali Kanju Issue No : 03
STARTUP CHECKLIST
Reviewed by : ZuA/ MASm/ TH/ AA Revision No : 00

Approved by : BQ Updation Due : July 2020

Date: C-2______ Time:

Sr. No. DESCRIPTION YES NO REMARKS

1 Ask Supervisor to initiate electrical supervisor / engineer call out through URUT-1

2 All maintenance jobs completed and work permits returned, house keeping carried out.
3 Ensure following utilities are available

i Power to ASGR (P-9 MCC & P-10 MCC are energized)

ii 48V DC power for C-2____ excitation panel in ASGR is ON

iii 48 DC power for C-2____ trip panel in ASGR is ON

iv 125V DC control power supply is ON from HTSGR

v Main breaker in MSGR is rackin, on remote & reset

vi 11KV Breaker in ASGR is rack-in & on Remote

4 Local / Excitation panel Lamp test done and no bulb is fuse.

5 Instrument air to all instruments is commissioned.

Ensure all alarms and tripping securities isolation is removed and are in service at local panel
6
PSLL86____, LHCO23____, PSHH82____, PHCO83____, PSLL87____, PSLL-90____

7 Check c.water pressure is normal ( 40# - 45# ) and is in service to all coolers.

8 175# steam is in service to E-38.

TK-5A level is 1-2 glass of the GLG, start P-11____ check auto cut in and line up jacket water to
9
all cylinders jacket.

Crank case oil level is 50% of high low mark at the side glass, lube oil pump (P-16____) is
10
running and oil pressure is normal (35-40 psig)

11 TK-207 and TK-6A are in service.

12 Ensure 2nd, 3rd, 5th stage vent valves are fully open.

13 5th stage both discharge valves and cross over valve are fully closed.

14 All pulsation bottles and K.O drums drain valves are crack open.

15 HIC-44____ is fully open from local panel.

16 Isolation is removed of PIC-43C, PIC-45____, TIC-43____, FIC-43____

17 Check physically TIC-43____ is fully closed and inform to boardman.

18 CO2 from NH3-2 is available, PIC-43C is open 40% with 7# S.P. and PIC-45____ with 3# S.P.

19 Start P-14____, check FF.Lubricator drops & bar over the compressor for 15min. then stop P-14____

Start P-14____, before starting compressor and check process trips healthy indication is 'ON' at
20
local panel.

21 Inform to Ur-2 Boardman, Amm-2, UR-1 control room and start the compressor.

22 After startup check the compressor for any abnormality at any stage and pressurize the compressor.

NOTE: During pressurizing the compressor, ensure that E-30's gas outlet temperature is above 120°F, before 4th discharge pressure increases beyond 800#.

NOTE: Ensure C-2____ motor anti condensate heater and cylinder lube oil heater are off.

Checked By Area Operator Verified By Shift Supervisor Authorized By Shift Incharge

23
Engro Fertilizers Ltd.

Effective on : Dec. 2018 Document No : 108-Chk

CO2 COMPRESSOR (C-2E)
Prepared by : Imran Anjum Issue No : 03
STARTUP CHECKLIST
Reviewed by : AAb Revision No : 00

Approved by : BQ Updation Due : Dec. 2021

Date: Time:

Sr. No. DESCRIPTION YES NO REMARKS

1 Make sure that all maintenance job are complete & all work permit have been returned.

2 Housekeeping has been carried out in comp. hall & surrounding area.

3 Ensure C-2E local panel and excitation panels are energized in ASGR

4 CB-10 at MSGR for C-2E is ON, Rack in and Put on Trip position

5 Ensure compressor control select is on local (local panel).

6 Ensure primary lube oil pump select is on A/B (local panel).

7 Ensure lube oil pump A/B select A=hand, B=Auto (local panel).

8 Ensure cylinder lube oil pump is on Hand (local panel).

Ensure Lube oil pressure is more than 50 Psig, on lube oil header end PI. If lube oil pressure is
9
less than 50 Psig then Oil sump inlet filter to be cleaned by FM.

10 Ensure 1st stage (both cylinder), 2nd, 3rd, 4th, and 5th stage cylinder all capacities are unloaded.

11 Open isolating valve of PIC-45E and control suction pressure 6#.

12 Ensure that TIC-51 is in service with jacket water temp of 130°F.

13 Check all bulbs on local panel lights and alarms are OK and no bulbs are fused.

14 PIC-45E, TIC-43E, HIC-43E, PIC-37E, FIC-43E control valves stroke checked.

15 Instrument air for all instruments individual valves are open.

16 Check CW pressure is normal & cooling water is open to all coolers

Check crank case oil level is normal, start lube oil pump (P-16E1, E2) & standby pump is "on auto
17
cut in". Ensure that lube oil circuit pressure is more than 35#. (set pressure of cutout is = 15#).

Start JW pump (P-11C/D) & standby pump is "on auto cut in". Open JWS & JWR v/v to C-2E
18 each stage & Check visible JWR flow in sight glasses. TK-5A JW tank level is normal (02
glasses).
19 Ensure that PIC-37V and its u/s isolating valve is open and reset its solenoid valve.

20 Ensure that HIC-44E is full open and check physically.

21 Ensure CO2 is available from Amm-2 and PIC-43C is 70% open with set point of 7.1psig

22 Ensure that all electrical securities are in service

23 Ensure that all instrument & tripping securities are in service

24 Ensure both 5th discharge block valves & FIL-2E bypass valve are closed.
25 Ensure that 1" vent valves of 2nd, 3rd & 4th stages are open .

26 All suction / discharge pulsation bottles & K.O. drum drain valves are crack open.

27 TIC-43E 10% open on manual from control panel.

28 Start F.F lubricator pump & check lubricator drops as per list.

Engage pneumatic barring gear machine by maintenance person & start barring over the
29
compressor for 15 minutes. Disengage the barring gear.

30 Inform UR-2 boardman, Uty-1 and Ammonia-2 control rooms.

Check ready to start indication in ON on local panel & no flag is appearing (Now start the main
31
motor of comp.) by pushing both button simultaneously.

32 Check thoroughly abnormal sounds from any stage & see that all F.F lubricator are working properly.

NOTE: 1) 2nd, 3rd, 4th and 5th stages capacities to be loaded when their discharge temp. increased.

2) If any inter stage temperature rised to 300°F then first unload the stage otherwise trip the compressor.

3) Ensure cylinder lube oil heater breaker is off. 4) If the machine does not start immediately initiate trip signal, rectify the cause.

Checked By Area Operator Verified By Shift Supervisor Authorized By Shift Incharge

24
Engro Fertilizers Ltd.
Effective on : June 2019 CARBAMATE RECYCLE PUMPS Document No : 110-Chk
Prepared by : Asghar Ali Kanju JSW (P-202 B / C / E) Issue No : 012
Reviewed by : ZuA/AA STARTUP CHECKLIST Revision No : 00
Approved by : BQ Updation Due : June 2022

Date: P-202____ Time:

Sr. # DESCRIPTION YES NO REMARKS

1 Check that all maintenance jobs are completed and work permits returned.
2 Check that 48V power supply for tripping securities is 'ON' in ASGR.
3 Check that power supply of breaker for control panel is on in D.B. room.
4 Check that EE-242/245 panel in MCC Room are energized.
Check that local control panel is energized and all indication bulbs are
5
available and working 'OK'.

Check crankcase oil level is normal & lube oil pump is running with discharge
6
pressure of 60 psig. Lube oil filters are clean and one is on stand by.
7 Check cooling water for lube oil cooler & Tarque convertor are in service.
8 Check gear box oil level is 50% of the glass.
9 Check oil flow in sight glass by priming auxiliary gear pump.
Check torque convertor oil level is 50% of the low high mark at dip-stick and its
10
cooler is in service.
11 Check HP lubricator oil pump is running and F.F lubricators are giving drops.
12 Check LP lubricator oil pump is running and F.F lubricators are giving drops.
Check flushing water for plungers is in service and flow through return line
13
sight glass is visible.
14 Check isolating valve of PHCO is open.
15 Check isolating valve of discharge PI is open.
16 Check stroking of SIC control valve on torque convertor.
17 Check no oil slippage.
18 Check that discharge drain valve is open.
19 Check Main motor breaker is racked-in in MCC Room.

Checked By Area Operator Verified By Shift Supervisor Authorized By Shift Incharge

25
Engro Fertilizers Ltd.

Effective on : July 2019 CARBAMATE RECYCLE PUMP Document No : 111-Chk

Prepared by : Asghar Ali Kanju SUNDYNE (P-202F) Issue No : 02

Reviewed by : ZuA/AA STARTUP CHECKLIST Revision No : 00

Approved by : BQ Updation Due : July 2022

Date: Time:
Sr. No. DESCRIPTION YES NO REMARKS

1 Check that all maintenance jobs are completed and work permit returned.

2 Check steam tracing of suction and discharge lines is in service.

3 Check steam jackets of FIC-222V & HIC-221V is in service.

4 Check that 48V power supply for tripping securities is 'ON' in auxiliary switch gear room.

5 Check that power supply of breaker for local control panel is 'ON' in auxiliary switch gear room.

6 Check that local control panel is energized and all indication bulbs are available and working 'OK'.
Check cooling water in lube oil cooler is in service. Both strainers on cooling water lines are clean
7
& one is standby.

8 Check level of oil sump is normal.

9 Check auxiliary lube oil pump is on line on auto cut-in mode with oil pressure of 40 psig.

10 Check bursting discs on glands seal flushing lines are not ruptured.

11 Check seal flush water pump is running normal.

12 Check P-261 A/B is running normal.

13 Check stroking of HIC-221V & FIC-222V checked from local panel & is 'OK'.

14 Check isolating valve of discharge and suction lines PI's are open.

Check oil level in menzel oil pump is full and pump is running normal to feed oil to suction and
15
discharge PI's.

16 Make sure that no security is bypassed on local panel.

17 Confirm carbamate circulation valve D/S of RO-400 is fully open.

Check low pressure oil cutout switches (PA-122) & low pressure auxiliary oil pump cutin switch
18
(PA-131) are in service.

19 P-202F shaft is rotating freely as checked by machinery staff.

20 Tag sent to Urea-1 & main motor breaker in MSGR is racked in with breaker switch at trip
position.
21 Ensure following block valves are closed.

i- Suction line I/V. ii- FIC-222V down stream I/V. iii- P-202F discharge line I/V to ACES.

22 Start seal flush pump (P-251).

Open seal flush water for 1st stage to maximum and check water is coming out from discharge
23
line drain.

24 Close seal water to first stage.

Open seal flush water for 2nd stage to maximum and check water is coming out from discharge
25
line drain.

26 Keep seal flush water open to both stages.

27 Start P-204 (LPFW pump).

28 Flush discharge line, ensure it is clear and close drain valve.

29 Open FIC-222 from Control Panel.

30 Flush circulation line, ensure it is clear and close drain valve.

31 Close FIC-222 from Local Panel OR DCS .

32 Close LPFW to P-202F suction.

33 Open suction valve of pump.

34 Open circulation valve of pump.

35 Adjust seal water flow in seals.

Open FIC-222V 80% on manual. Flow indication from FIC-222 will show flow has established
36
through the pump towards E-261 recycle line & line d/s of FIC-222V is clear.

37 Close P-251 circulation valve.

38 Put main motor breaker on remote and reset in MSGR-1. Pump is ready to start now.

NOTE: 1) Reset diagnostic switch after main drive started. 2) Check for any leakage

Checked By Area Operator Verified By Shift Supervisor Authorized By Shift Incharge

26
Engro Fertilizers Ltd.

Effective on : Jan-2019 CARBAMATE RECYCLE PUMP Document No : 113-Chk

Prepared by : ZuA EBARA (P-202G) Issue No : 01

Reviewed by : AA STARTUP CHECKLIST Revision No : 01

Approved by : BQ Updation Due : Jan.2022

Date: Time:

Sr. No. DESCRIPTION YES NO REMARKS

1 Check that all maintenance jobs are completed and work permits are returned.
2 Check all instruments are in service.
3 Send HPAC sample to LAB and make sure concentrations are with in range. (Urea conc.15~25%)
4 Check steam tracing of suction and discharge lines is in service.
5 Check steam jacketing of HIC-222A is in service.
6 Check that 220V power supply of breaker for local control panel is on in DB room (EE-284 A / B).
7 Check that local control panel & panel view is energized and working normal.
8 Check cooling water of lube oil cooler is in service.
9 Check oil level is normal in oil sump (05 bolts).
10 Check auxiliary lube oil pump is running normal and selector switch is on "Auto".
11 Ensure positive oil flow through oil sight glass of each bearing.
Check BFW is available and pressure is normal 25Kg (355 psig) and temperature is running
12
around 100~110F.
13 Check BFW line strainers are clean and one is standby.
Check that P-261A/B are running normal (discharge pressure 300#). If pressure is low ensure
14
anticorrison air is open in HP circuit
Reset SOV of HCV-222A after Bypassing SOV from Local panel or from HMI in C/R & check
15
stroking of HIC-222A from control room is OK.
16 Confirm carbamate circulation valve d/s of RO-400 is fully open.
Check low pressure oil cut-out switch (PS-122G) & low pressure auxiliary lube oil pump cutin
17
switch (PS-123G) and DPI are in service.
Electrical tag sent & P-202G main motor breaker trolley in MSGR is racked in with breaker switch
18
trip position.
19 Ensure following block valves are closed.
i Suction line block valves.
ii HIC-222A down stream block valve.
iii Balance line block valve.
iv 2nd discharge valve.
20 Open discharge line drain valve.
21 Start P-204 (LPFW pump).
22 Flush LPFW line from 2nd bleeder of double block and bleed before opening into P-202G suction line.
Open LPFW valve to P-202G suction and drain LPFW from bleeder on suction line u/s of suction
23
stainer.
24 Flush discharge line,ensure positive flow by keeping pump discharge drain open for 20 minutes.
25 Open HIC-222A from control room.
26 Flush circulation line, ensure it is clear and close drain valve.
27 Close HIC-222A from control room.
28 Flush balance line, ensure it is clear and close drain valve.
29 Close LPFW to P-202G suction.
30 Open HIC-222A 80% from control room.
31 Ensure P-202G shaft is rotating freely as check by machinery staff.
32 Open suction valve of pump.
33 Open balance valve of pump.
34 Open circulation valve of pump.
35 Adjust BFW flow in seals & ensure that flow to each seal is not less than 7 Liters/min.
36 Ensure pump ready to start indication appeared at local panel view & HMI in C/R.
37 Inform to board man, SIC Ammonia-2/Urut-1 before pump start up.
38 After startup of Ebara main motor check all conditions are normal.
39 Put HIC-222A SOV in service before opening discharge valve to ACES.
40 Stop Auxiliary oil pump while keeping the switch on auto before opening discharge valve to ACES.

Checked By Area Operator Verified By Shift Supervisor Authorized By Shift Incharge

27
Engro Fertilizers Ltd.
Effective on :Feb 2020 Document No : 109-Chk
P-261,s
Prepared by : Abid Ali Issue No : 01
STARTUP CHECKLIST
Reviewed by : WI Revision No : 00
Approved by :SNH Updation Due : July 2023

Date: P-261____ Time:

Sr.# DESCRIPTION YES NO REMARKS

1 Check that all maintenance jobs are completed & work permits returned.
2 Check all locks are removed,breaker is rack in & reset.
3 Check that all instruments and securities (FI & PI) are in service.
4 Check that pump discharge filter is installed & cleaned
5 Check that pump is flush and its suction , discharge lines are clear.
6 Check that seal water change over LPFW valve is closed.
7 Check that seal water is lined up and flow is 6 div & pressure is 110~140Psig.
8 Ensure that FAL-422A/B seal water low flow alarm is rest from C/R.
9 Check pumps discharge line and FILL-261A/B drain valves are closed
10 Check LPFW valve in pump suction is closed
11 Check that E-261 (HPAC) level is minimum 60%.
12 Check suction valve is open.
13 Check pump discharge valve is crack open.
Inform Boardmen & start the pump.Line up pump gradually by opening its
14
discharge valve
15 After pump started & linedup.Check for any abnormality.

Checked By Area Authorized By Shift

Verified By Shift Supervisor
Operator Incharge

Engro Fertilizers Ltd.

Effective on :July 2020 Document No : 113-Chk
P-264's
Prepared by : Abid Ali Issue No : 01
STARTUP CHECKLIST
Reviewed by : WI Revision No : 00
Approved by :SNH Updation Due : July 2023

Date: P-264____ Time:

Sr.# DESCRIPTION YES NO REMARKS

1 Check that all maintenance jobs are completed & work permits returned.
2 Check all locks are removed,breaker is rack in & reset.
3 Check that all instruments and securities (FI & PI) are in service.
4 Check that pump suction strainer is installed .
5 Check that cooling water in bearing housing is in service.
6 Check oil level in oil cup. It should be 50% min.
7 Check that pump is flush and its suction , discharge lines are clear.
8 Check that seal water is lined up and flow is 6 div & pressure is 110~140Psig.
9 Ensure that FAL-423A/B seal water low flow alarm is rest from C/R.
10 Check pump drain valve is closed.
11 Check TW in pump suction is closed
12 Check that LPA-B (E-262B) level is normal about 55% or more .
13 Check suction valve is open.
14 Check pump discharge valve is crack open.
Inform Boardmen & start the pump.Line up pump gradually by opening its
15
discharge valve
16 After pump started & linedup.Check for any abnormality.

Checked By Area Operator Verified By Shift Supervisor Authorized By Shift Incharge

28
Engro Fertilizers Ltd.
Effective on :July 2020 Document No : 114-Chk
P-274 's
Prepared by : Abid Ali Issue No : 01
STARTUP CHECKLIST
Reviewed by : WI Revision No : 00
Approved by :SNH Updation Due : July 2023

Date: P-274____ Time:

Sr.# DESCRIPTION YES NO REMARKS

1 Check that all maintenance jobs are completed & work permits returned.
2 Check all locks are removed,breaker is rack in & reset.
3 Check oil level in oil cup. It should be 50% min.
6 Check that RO is installed at seal water line option from P-274's discharge
7 Check that pump is flush and its suction , discharge lines are clear.
8 Check pump drain valve is closed.
9 Check that pump m/seal drain line valve is closed.
10 Check TW in pump suction is closed.
11 Check that LPA-A (E-262A) level is normal about 55% or more .
12 Check suction valve is open.
13 Check pump discharge valve is crack open.
Inform Boardmen & start the pump.Line up pump gradually by opening its
14
discharge valve
15 After pump started & linedup.Check for any abnormality.

Checked By Area Operator Verified By Shift Supervisor Authorized By Shift Incharge

Engro Fertilizers Ltd.

Effective on :July 2020 Document No : 115-Chk
P-254 's
Prepared by : Abid Ali Issue No : 01
STARTUP CHECKLIST
Reviewed by : WI Revision No : 00
Approved by :SNH Updation Due : July 2023

Date: P-254____ Time:

Pre-Checks: YES NO REMARKS

1 Ensure no job is in progress at standby pump

2 Ensure standby pump's motor breaker is racked-in in MCC Room
3 Ensure standby pump's bearing oil cup level is normal
4 Ensure standby pump's suction and discharge lines are clear and pump shaft is rotating freely
5 Ensure 4.92 kg/cm2 (70 psig) steam is open in suction line and coming from discharge drain
6 Crack open 4.92 kg/cm2 (70 psig) steam in standby pump's jacket and line up condensate
7 Open 4.92 kg/cm2 (70 psig) steam in pump mechanical seal
Pump Start-Up
Inform board man and isolate steam in suction line and open drain point at pump suction to drain
1
condensate
2 close the suction and drain open suction valve of Pump slowly by coordinating with Boardmen
3 Ensure Urea solution is coming from discharge drain and standby pump is primed properly
Keep discharge drain valve crack open of standby pump located at CV D/S of the pump which to be
4
started
5 Inform the board man to keep close focus on TK-241 level and start standby pump
6 Open discharge valve slowly and mean while close full discharge drain of started pump
7 Inform the board man and ask for TK-241 level stability and pump pressure is normal
8 Check the pump which is started for any abnormality
If pump is quite smooth, inform board man & start closing discharge valve to minimum of the pump which
9
has to be shutdown
10 Stop the pump and close discharge valve of the pump.
11 Close suction valve of the pump which is off-lined
12 Wide open the discharge drain located at CV D/S to displace urea of the shutdown pump
13 Ensure free rotation of the shaft
14 Open 4.92 kg/cm2 (70 psig) steam in pump suction and displace Urea thru discharge drain
15 Ensure pump suction / discharge lines are clear and steam is flowing thru discharge drain
16 Flush the shutdown Pump with P-204 by changing steam option to LPFW

Checked By Area Operator Verified By Shift Supervisor Authorized By Shift Incharge

29