RELIABLITY ISSUE AT CA

PREPARED BY: Ghulam Madni

Reviewed BY: Ghulam Murtaza
Outline
Reliability Issues- Categorization

Stationary Reliability Issues

Instrument reliability issues

Electrical reliability issues

Machinery Reliability issues

Civil reliability issues

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Reliability Issues - Categorization

Reliability Issues

8
Stationary

Instruement
9
Total Machinery
64 32
Civil
7
Electrical

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 Stationary Reliability Issues

www.engro.com
TREY 4
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 Issue :
• V-1010 GLG HP leg isolation valve U/S flange gasket
salt deposition.

Recommendation:
• Gasket need to be replaced

Job scope:
• Stationary

www.engro.com
TREY 5
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 Issue :
• E-1053 brine inlet line flange salt
deposition.

Recommendation:
• Tightening/Gasket replacement
required

Job scope:
• Stationary

www.engro.com
TREY 6
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 Issue :
• FCV-1014 D/S spool deposition.

Recommendation:
• Spool need to be replaced

Job scope:
• Stationary

www.engro.com
TREY 7
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 Issue :
• ST-1013 bypass valve handle
free.

Recommendation:
• Valve need to be replaced

Job scope:
• Stationary

www.engro.com
TREY 8
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 Issue :
• N-1040 B back-pulse line salt deposition.

Recommendation:
• Spool need to be replaced

Job scope:
• Stationary

www.engro.com
TREY 9
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 Issue :
• P-1014 A/B discharge line spool
is leaky near P-1024 due to
which area is looking very bad.

Recommendation:
• Spool need to be replaced

Job scope:
• Stationary

www.engro.com
TREY 10
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 Issue :
• V-1012 A/B bypass line is leak from many
points and salt deposited on it.

Recommendation:
• Spool need to be replaced

Job scope:
• Stationary

www.engro.com
TREY 11
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 Issue :
• V-1330 main out let flange having caustic
seepage. This is the long pending issue if this
leakage increases, then it have the potential of
plant Shutdown.

Recommendation:
• Leakage to be rectified

Job scope:
• Stationary

www.engro.com
TREY 12
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 Issue :
• P-1154-B discharge NRV have passing issue In this
way when we start stand by pump. This pump start
rotating in reverse direction. In order to avoid it we
have to close discharge valve of this pump.
Normally this pump was operating at AUTO MODE
( auto cut in) Now operating on Manual mode.

Recommendation:
• P-1154 B discharge NRV Need to be replaced

Job scope:
• Stationary

www.engro.com
TREY 13
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 Issue :
• V-1260 GLG LP leg valve body have
chlorinated brine leakage, this leakage was
rectified by clamp installed on TR basis this
clamp also have seepage.

Recommendation:
• Valve need to be replace with new one.

Job scope:
• Stationary

www.engro.com
TREY 14
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 Issue :
• R-1230-D valve #42 glands leakage & stem of
this valve is loose.

Recommendation:
• valve need to replaced

Job scope:
• Stationary

www.engro.com
TREY 15
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 Issue :
• PHIT 1213-B outlet valve handle
is free and valve is open
position.

Recommendation:
• Valve need to be replaced.

Job scope:
• Stationary

www.engro.com
TREY 16
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 Issue :
• R-1230-C Brine outlet sample valve handle
damage & valve is in open position.

Recommendation:
• Valve need to replaced

Job scope:
• Stationary

www.engro.com
TREY 17
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 Issue :
• PHIT 1213 –E inlet valve passing
issue .
• This valve is fully closed but due to
passing it is difficult to maintenance
PH meter temperature .

Recommendation:
• Valve need to be replaced.

Job scope:
• Stationary

www.engro.com
TREY 18
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 Issue :
• P-1314-A/B recycle valve
stem leakage.

Recommendation:
• Valve need to be replaced.

Job scope:
• Stationary

www.engro.com
TREY 19
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 Issue :
• E-1312 gasket side leakage

Recommendation:
• Exchanger Maintenance required

Job scope:
• Stationary

www.engro.com
TREY 20
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 Issue :
• P-1294 discharge valve stem leakage

Recommendation:
• Need tightening/maintenance

Job scope:
• Stationary

www.engro.com
TREY 21
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 Issue :
• FCV-1265 U/S drain bleeder
valve body deposition.

Recommendation:
• Valve replacement required

Job scope:
• Stationary

www.engro.com
TREY 22
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 Issue :
• PCV-1466 U/S isolating valve is stuck at 30%
valve opening.

Recommendation:
• Valve need to be replaced
Job scope:
• stationary

www.engro.com
TREY 23
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 Issue :
• P-1444-A discharge valve flapper issue when
we increase vale from 30% pump looses flow
and ampere.

Recommendation:
• valve need to removed and checked and
rectified the issue.

Job scope:
• stationary

www.engro.com
TREY 24
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 Issue :
• P-1494-A discharge NRV gets stucked at open
position. In this way when we start stand by pump.
This pump start rotating in reverse direction. In
order to avoid it we have to close discharge valve of
this pump.
• if A pump trips and we start B pump. Due to
NRV stucking. Flow will start circulation
between two pumps insufficient flow to tower
will lead to chlorine release from C-1495.
• Recommendation:

• NRV issue need to be resolved.

Job scope:
• stationary

www.engro.com
TREY 25
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 Issue :
• P-1434-A & P-1424 A/B P-1447 A discharge bleeder
extended lines are not available. This create odd
situation during priming and draining pressuring
of pump. This can lead to Acid exposure.

Recommendation:
• Proper extended line to be provided.

Job scope:
• stationary

www.engro.com
TREY 26
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 Issue :
• Spent acid loading arm drain line and fresh acid
hose drain line are badly damage. Due to this
floor is being damage. In order to drain we use
bucket and then take it channel for draining of
H2so4 this can cause Acid exposure.

Recommendation:
• Proper drain line to be installed with proper
supports and slope.

Job scope:
• stationary

www.engro.com
TREY 27
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 Issue :
• V-1491 A/B main 4” outlet and inlet valve are hard
and have very small size gearbox handles which is
very difficult to operate.

• This can lead to back ache and mixing of hypo

batch.

Recommendation:
• Valve Gearbox handle need to replaced and valve to
be checked.

Job scope:
• stationary /machinery

www.engro.com
TREY 28
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 Issue :
• ZV-1661 A/B upstream Cl2 gas purging to hypo
system is disconnected for couple of years
which should reconnected as we are facing
problems during R-1660A/B start up.

• Trapped(120Kpa) Cl2 gas between ZV-1661A/B

and FV-1662A/B  will lead to a blast in R-1660A/B
of R-1660A/B during R-1660A/B light up.

Recommendation:
• Line need to be connected.

Job scope:
• stationary
www.engro.com
TREY 29
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 Issue :
• PCV-1466 bypass valve is blinded due to passing
issue this valve is not available to take PCV-1466
on bypass during malfunction & unavailability
of PCV-1466.

• Recommendation:
• Valve need to replaced/Overhauled

• Job scope:
• stationary

www.engro.com
TREY 30
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 Issue :
• E-1412 Insulation and cladding is badly
damaged.

Recommendation:
• New insulation & cladding installation

Job scope:
• Stationary

www.engro.com
TREY 31
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 Issue :
• N2 lines toward 1690 & 1670 A/B is badly
damaged and corroded.

Recommendation:
• Line replacement required.

Job scope:
• stationary

www.engro.com
TREY 32
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 Issue :
• XE-1743 steam leakage from exchanger
gaskets.

Recommendation:
• Exchanger gasket replacement required

Job scope:
• stationary

www.engro.com
TREY 33
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 Issue :
• Area 1700 first floor railing is damage.

Recommendation:
• Repairing work required

Job scope:
• stationary

www.engro.com
TREY 34
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 Issue :
• Safety shower 1800 area near by loading
station its drain line is chocked. It is
disconnected and water goes in dyke which
creates slippery hazard.

Recommendation:
• Line de-choking required

Job scope:
• Stationary

www.engro.com
TREY 35
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 Issue :
• V-1810 top railing is badly damage chances
are this can fall one someone.

• Recommendation:
• Repairing work required

• Job scope:
• Stationary

www.engro.com
TREY 36
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 Instrument Reliability Issues

www.engro.com
TREY 37
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 Issue :
LCV-1284 have chlorinated brine leakage from its
glands, outlet valve towards T-1310 have passing
issue.

Recommendation:
• Leakage to be rectified

• Manual valve to be replaced.

Job scope:
• Stationary/instrument

www.engro.com
TREY 38
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 Issue :
• Lcv-1310 passing issue. & due to this facing
controlling issue at T-1310 level we are controlling
the level of V-1310 through LCV-1310 isolation
manual valve this create extra work load.

Recommendation:
• Need overhauling

Job scope:
• Instrument

www.engro.com
TREY 39
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 Issue :
FCV-1029 is stuck at close position. Then we are
controlling the flow of Ferric chloride through
manual valve of V-1029 Outlet which is present at
Brine Area 5th Floor this create the work overload
of Post A Area engineer.

Recommendation:
• Valve overhauling Required

Job scope:
• instrument

www.engro.com
TREY 40
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 Issue :
LCV-1420 is under Instrument for Overhauling.

Recommendation:
• Valve overhauling Required

Job scope:
• instrument

www.engro.com
TREY 41
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 Issue :
• FG-1012 is faulty due to which we
have facing issue to adjust flow.

• Recommendation:
• Need to be replaced

• Job scope:
• Instrument

www.engro.com
TREY 42
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 Issue :
• R-1230-A Caustic header PG faulty .

Recommendation:
• PG need to be replaced

Job scope:
• Instrument

www.engro.com
TREY 43
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 Issue :
• PG 1154-A Faulty

Recommendation:
• Need to be replace

Job scope:
• instrument

www.engro.com
TREY 44
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 Issue :
• V-1690-A high level switch conduit is hanging
with any support.

Recommendation:
• Proper support to be installed on it

Job scope:
• instrument

www.engro.com
TREY 45
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 Electrical Reliability Issues

www.engro.com
TREY 46
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 Issue :
• A-1100 Pipe rack cable trays are too much
corroded these cable trays may be fell down
and cause the personnel injury.

Recommendation:
• Cable trays need to be replaced

Job scope:
• Electrical

www.engro.com
TREY 47
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 Issue :
• P-1336 A motor Fan is damage need to be
replaced with new one.

Recommendation:
• motor fan to be replaced.

Job scope:
• Electrical

www.engro.com
TREY 48
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 Issue :
• Near P-1024 light is faulty.

Recommendation:
• Light need to be rectified.

Job scope:
• Electrical

www.engro.com
TREY 49
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 Issue :
.A-1600 third, Fourth and fifth floor all lights are
faulty need to replace on urgent basis

Recommendation:
• Lights need to be rectified.

Job scope:
• Electrical

www.engro.com
TREY 50
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 Issue :
.A-1400 second floor floor all lights are faulty need
to replace on urgent basis

Recommendation:
• Lights need to be rectified.

Job scope:
• Electrical

www.engro.com
TREY 51
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 Issue :
• 1400 Area pumps LCS are in poor
condition and not covered with
sheet.

Recommendation:
• Servicing & polythene covers to be done on
all LCS.

Job scope:
• electrical

www.engro.com
TREY 52
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 Issue :
• P-1666-A/B ,C-1620-A/B ring pump ,P-
1447-A/B & P-1484A/B flexible conduit
PVC insulation is damage.

Recommendation:
• Line need to be replaced.

• Conduit replacement required

Job scope:
• Electrical

www.engro.com
TREY 53
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 Issue :
• P-1824-A hypo loading pump motor
installation issue is pending for long time. 1
motor is high watt and other one is not
fitting in due to alignment issue.

Recommendation:
• Motor installation required

Job scope:
• Electrical

www.engro.com
TREY 54
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 Machinery Reliability Issues

www.engro.com
TREY 55
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 Issue :
• P-1024A seal is leak and corroded
pump casing .

Recommendation:
Seal leakage need to be rectified.

Job scope:
• Machinery

www.engro.com
TREY 56
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 Issue :
• P-1425 seal is badly leak .

Recommendation:
Seal leakage need to be rectified.

Job scope:
• Machinery

www.engro.com
TREY 57
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 Issue :
• R-1230-A hydraulic manifold valve
issue whenever we try to adjust
pressure valve don't do fine
controlling .

Recommendation:
• Hydraulic manifold maintenance
required

Job scope:
• Machinery

www.engro.com
TREY 58
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 Issue :
• P-1364-A pump Low Flow issue

Recommendation:
• Pump overhauling

Job scope:
• Machinery

www.engro.com
TREY 59
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 Issue :
• N-1822 Hypo loading arm manual isolating
valve gear box is under machinery and valve
is being operated by fitting wheel directly on
valve.

Recommendation:
• Gearbox installation required

Job scope:
• Machinery

www.engro.com
TREY 60
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 Issue :
• Sulfite dosing in 32 NaoH facility is out of
services for couple of months due to dosing
pump low flow issue.

Recommendation:
• New dosing pump installation required

Job scope:
• Machinery

www.engro.com
TREY 61
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 Issue :
• R-1660A/B top vent valves handle are
corroded and have sharp edge.

• This can cause hand injury during operation.

Recommendation:
• Valve gearbox need to replaced

Job scope:
• machinery

www.engro.com
TREY 62
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 Civil Reliability Issues

www.engro.com
TREY 63
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 Issue :
• cell room ground floor concrete ceiling plaster
started fell down near by R1230D DCDS +ve bus
bar. This concrete material containing iron is clear
visible now.

Recommendation:
• Proper assessment with civil expert or lineup
external source analyze the situation and then
rectify the issue.

Job scope:
• Civil

www.engro.com
TREY 64
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 Issue :
DCDS room cemented wall have cracked at
multiple locations, and cell room ground floor
bus bar side wall also have cracks .

Recommendation:
• Wall repairing to be done ASAP.

Job scope:
• Civil

www.engro.com
TREY 65
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 Issue :
Brine building north side cemented wall have
cracked at multiple locations, need to be Repair.

Recommendation:
• Wall repairing to be done ASAP.

Job scope:
• Civil

www.engro.com
TREY 66
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Issue :
V-1020 pillars have too much big cracks
need proper assessment with civil
specialist.

Recommendation:
• Pillars repairing to be done ASAP.

Job scope:
• Civil

TREY
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 Issue :
V-1010 west side pipe rack cemented cantilever
beams have multiple cracks.

Recommendation:
• cantilever beams repairing to be done ASAP.

Job scope:
• Civil

www.engro.com
TREY 68
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 Issue :
V-1010 west side pipe rack cemented pillars
have multiple cracks.

Recommendation:
• Pillars repairing to be done ASAP.

Job scope:
• Civil

www.engro.com
TREY 69
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 Issue :
• 1400 Area drain channel near 1447 & 1425 is
badly damaged

• This is also internally leaking to spent unit

dyke

Recommendation:
• Channel Civil work required.

Job scope:
• Civil

www.engro.com
TREY 70
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 Issue :
• Steam condensate line towards utility its
sample point space is confined and it is hard to
take sample from it

• Recommendation:
• Around this point beak channel and make it
wider so it is easy to take sample

• Job scope:
• Civil

www.engro.com
TREY 71
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 Issue :
• 1700 area drain Channel covers are not
fitting in properly. Due to width of channel

Recommendation:
• Tiling and civil work required

Job scope:
• Civil

www.engro.com
TREY 72
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ThankYou

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