ED/4/022

Issue-3
February, 2024

Contents
2.0 EQUIPMENT SECTION 3
2.1 AMMONIA UNIT 3
2.2 UREA UNIT 5
2.3 UTILITY UNIT 7

Monthly Activity Report, February 2024

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Issue-3
February, 2024

2.0 EQUIPMENT SECTION

Following equipment maintenance jobs were carried out:

2.0 AMMONIA UNIT

Following Equipment Maintenance jobs were carried out:
2.1.1 C-601A (Ammonia Ref. Compressor A)
Rectified tube connector leakage of oil separator by tightening.
2.1.2 159-F (Catacarb solution Mechanical Filter)
Removed top cover of catacarb filter and pulled out all 22 No.s cartridges for washing.
2.1.3 117-F (Catacarb lean solution filter)
Inserted blind in condensate line and removed bottom hand hole flange for carbon unloading by
process team, after this hand hole flange boxed up again.
2.1.4 1134-F (Oil Knock Out Drum)
Carried out pre fabrication of process gas line in workshop.
2.1.5 103-D (Secondary Reformer)
Performed experiment to unload catalyst from 103-D by air ejector at east side of 101-B with
collaboration of process team but could not successful.
2.1.6 102-E (CO2 Stripper)
Rectified level glass leakage of lean pan by tightening.

2.1.7 Misc-10
● Disconnected water cooler for repairing and installed at NH3 plant after repairing.

● Prepared 02 No.s steam hoses, after testing and tagging by MC shop, replaced with damage hoses
at 103-J and MOV-5.
● Repaired corroded roof sheet of air mask box No-14 by patch work.

● Fabricated and installed bolted clamp on leaky weld joint of process condensate drain line to vent
vessel near walking way to cylinder filling area.
● Fabricated 03 No.s trays for leaky oil collection of pumps and turbines in NH3 plant, required by
Machinery.

Monthly Activity Report, February 2024

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February, 2024

2.1 UREA UNIT

Following Equipment Maintenance jobs were carried out:
2.2.1 T-200 (Prill Tower)
Removed corroded roof sheets of operator cabin at 11h floor of prill tower, new sheets installed.
2.2.2 P-206 (Degasser Pump)
Cleaned suction strainer B and C.
2.2.3 TK-207A (Dissolving Tank)
Removed blinds from steam inlet and outlet lines of urea dissolving tank.
2.2.4 E-213 (Purge Condenser)
Rectified short bolting of both side channel head flanges of E-213.
2.2.5 C-201B (CO2 Compressor B)
Provided additional packing plate under N-side pedestal of 3 rd intercooler for control the
vibration, required by machinery section.
Removed 2 No.s broken studs from frame extension of 1st stage west cylinder by welding.
Installed gear box plate and fabricated electrical panel holding frame of CO2 compressor deck
overhead crane which is being modified by vendor.
Welding support of overhead crane with vendor.
Removed broken bolts of frame extension by welding.
Provided support to rigging shop for structure welding and modification of CO2 compressor
deck O/H crane which is being modified by vendor.
Tightened the pedestal bolts of 3rd inter cooler.
Checked and tightened the loss pedestal bolts of e-223B
2.2.6 P-202C (Recycle Solution Feed Pump C)
Rectified leakage of suction condensate line by welding.
Fabricated 04 No.s metallic supports for packing flushing water tubes of P-202C and installed at
site.
Installed supports of packing flushing tubes by welding.
Fabricated and replaced 05 no.s packing flushing tubes of carbamate pump c due to damage.
2.2.7 P-202B (Recycle Solution Feed Pump B)
Removed packing flushing water union leakage of carbamate pump B by tightening.
2.2.8 E-212 (Ammonia Condenser)
Rectified short bolting of channel head flanges of E-212 E & D.
2.2.9 P-202A/B (Recycle Solution Feed Pump A and B)
Replaced leaky tube connector of packing flushing water and removed 02 No.s PSV, 2 nd and 4th
flushing tube due to seat leakage and handed over to MC shop for calibration.
Cut/fabricated 12 No.s supports for packing flushing water tubes vibration rectification.
Cut packing flushing water tubing support for pump A and B and handed over to mc shop.
2.2.10 E-214 (Inert Scrubber B)
Rectified short bolting observation under Urea surveillance.
2.2.11 P-218B (HPR Absorber Pump)
Removed 06 no.s of blinds of P-218B to normalize the flow which was diverted towards P-204.
2.2.12 E-291B (Lube Oil Cooler of C-201B)
Cut/prepared baffles for new tube bundle fabrication in workshop.
Fabricated floating head sleeve of new bundle.
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Fabricated sleeve of floating head side and welded with tig welding, handed over to MC shop
for machining.
Assembled the structure of new tube bundle by fixing baffles and tie roads with tube sheet, tubes
insertion is started
2.2.13 P-237B (Urea Solution Pump)
Fabricated new coupling guard of meter, handed over to machinery section.
2.2.14 P-238B (Dissolving Tank Pump)
Cleaned suction strainer of dissolving tank pump.
2.2.15 BL-206B (Evaporator Air Blower)
Cleaned suction strainer of air blower B.
2.2.16 TK-207B (Dissolving Tank B)
Removed blinds from steam inlet and outlet lines of TK-207B and installed in TK-207A.
2.2.17 BL-206C (Evaporator Air Blower)
Cleaned suction strainers of air blouer c.

2.2.18 Misc-20
● Carried out area surveillance of recovery section

● Rectified short bolting of E212F which was found during surveillance

● Carried out area surveillance of prilling section

● Replaced corroded bottom sheet of air mask box no. 30 in area 220 by welding

● Carried out area surveillance of synthesis section

● Provided support to workshop for welding the structure of CO2 compressor deck overhead crane
which is being modified from manual to electrical operation by vendor.
● Carried out area surveillance of old decomposition section.

● Carried out area surveillance of new decomposition section.

● Repaired damaged boxes of air mask station no.25, 26,27 at uera plant old decomposition section
by patch work.
● Installed back windsock with metallic pole at the top of V-2231 after repairing in workshop

2.2 UTILITY UNIT

Following Equipment Maintenance jobs were carried out:
2.3.1 CT-401 (Cooling Tower)
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Installed new fabricated pipelines and its supports in cooling tower cell c for fire water sprinkler
system by vendor.
New fire water line pressure tested at 230PSI
Rectified leakage of gear box lube oil level make up line by reinstallation.
Adjusted and tightened the supports of gear box oil makeup line of cell H.
Carried out lines flushing of fire water sprinkler system at cooling tower cell A, B C, D, E and F
by vendor.
Installed nozzles of fire water sprinkler system in all cells after flushing.
Rectified leakage of make up line by runner wrapping near east side of cooling tower.
New railing for east side walkway of cooling tower is being fabricated in workshop.
Deblocked fire water sprinkler pipeline of cooling tower cell G and H by vendor.
2.3.2 TP-423 (Turbine for Lube Oil Pump)
To open and remove suction discharge flange
2.3.3 B-401A/B (Boilers A/B)
Removed flame arrestor of boiler, shifted in workshop, leaned by steam and installed at site.
Clean 21 no.s prep hole glass and replaced 03 no.s glass due to broken.
Cleaned 21 hole glass and replaced 03 no glass due to broken.
2.3.4 TK-416 (Alum Tank)
Prepared the surface of alum tank with grander for thick ness measurement by inspection
2.3.5 P-413 (Caustic Soda Feed Pump)
Replaced pump body drain valve due to seat leakage.
2.3.6 V-411 (Caustic Soda Process Vessel)
Repaired broken sling wire of dip stick.
2.3.7 DR-501A (Instrument Air Dryer)
Replaced steam trap due to not working.
2.3.8 P-406A (Turbogenerator condensate pump for TG-401A)
Opened and removed discharge spool and NRV.
2.3.9 P-406B (Turbogenerator condensate pump for TG-401B)
Rectified leakage of water line from P-406B to agricultural land by installing bolted clamp.
2.3.10 P-431B (Sulphuric Acid Pump)
Open suction and discharge flanges of H2SO4 pump and connected again after pump
replacement by machinery section.

2.3.11 Misc-40
● Removed corroded rain protection shed from E-side of DCS room. Also new shed is being
fabricated in workshop
● Installed structure of room shed at E-side of DCS room which was newly fabricated in
workshop.
● Replaced inlet valve of H2SO4 day tank due to seat leakage.
● Installed foot valve of peter engine at canal water.
● Installed upper shed of DCS room.
● Made pipe nipples for general use.
● New pipeline 2” x 360’ long as being fabricated in workshop for raw water from WTS Utility to
Urea plant.
● Fabricated raw water line at workshop.
● New pipeline dia 2’’ (CS) is being fabricated in workshop for replacement of corroded raw
water line of utility plant.

Monthly Activity Report, February 2024

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● Replaced Cl2 cylinder.

● DCS room East side lower room protection shed is being installed.
● Removed hoses from portable compressor PC-2 which was placed at utility plant.
● Fabricated patch plate dia 6” x 12” long for leakage rectification of fire water line near CT-401.
● DCS room east side lower shed is being installed.
● Welded patch plate for fire water line rectified leakage.
● Repaired damaged cradle of rigging section by welding in workshop.

2.3.12 Misc-70
● Modified 3 no.s birds cages in colony near the boundary wall of E-type houses west side by
cutting and welding.
● Replaced filters of drinking water coolers at fair price shop, D-type , E-type and musjid in colony

● To installed drain channel of bird cages

● Made pipe nipples for general use

● Repaired broken hook of portable air compressor PC-3 by welding in workshop

● Carried out preparation of pipe PCs four welders test.

● Repaired water tap of washroom in control room

● Replaced faulty door closer of issue counter of material warehouse

● Installed coupling on spare rotor of TP-402 by heating in workshop

● Installed rotor tip body of TP-402 by heating in workshop

● Fabricated 02 no.s goal post for futsal game

● Repaired leaky hot water under ground pipeline by welding in D-Type houses

● Carriedout installation of cable tray on the roof of top of control room by welding

● Installed new drinking water cooler in canteen

● Cleaned the filters of drinking water cooler in control room

● Removed faulty electric geyser of TP building washroom and installed new one

● Conducted the welders test in workshop and test PCs have been handed over to inspection

● Repaired 2 no.s of foot pedestals of bags saving machine by tig in workshop

● Checked the pressure of 10 no.s oxy and 10 no.s D/A cylinder in warehouse, found ok

● Repaired guard plate of drill machine by welding in mc shop. also repaired pump body of H2SO4
pump by welding in workshop
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● Repaired canopy of fire hose box no.1 by patch plate welding

● Repaired jammed door of fire hydrant no.10

● Replaced 3 no.s empty breathing air cylinder with filled one outside control room

● Removed 7 no.s pump impellers of P-406A by heating in workshop

● Carried out house keeping of equipment section , load scrap material in trolly and shifted at main
scrap yard near ware house.

Monthly Activity Report, February 2024

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