Ammonia Operation Monthly Report August-2014

8/10/2019 Ammonia Operation Monthly Report August-2014

1/18

GO GREEN, SAVE GREEN

MONTHLY

PRODUCTION REPORT

August, 2014NH3

PLANT

Prepared By: Saqib Raouf


2/18

Sr. No. Description Budgeted Actual

1 Production Target (MT) 40603 41915.94

2 Capacity Factor (%) 93 103.2

3 Service Factor (%) 94 91.2

4 Gross Energy Index (GCal / MT) 8.11 8.333

5 Net Energy Index (GCal / MT) 7.90 8.318

6 Cumulative Annual Production (MT)

Credit

305164 312981.9

(7818.9)

7 Daily Average production (MT) 1309.774 1352.127

8 Down Time (Hours) 48 65

9 Feed Gas (MMSCF) 1793 1849.34

10 Fuel Gas (MMSCF) 517 588.53

MONTHLY PRODUCTION HIGHLIGHTS


3/18

0.00%

20.00%

40.00%

60.00%

80.00%

100.00%

120.00%

0.00

200.00

400.00

600.00

800.00

1,000.00

1,200.00

1,400.00

1,600.00

1,

ug

02,

ug

03,

ug

04,

ug

05,

ug

06,

ug

07,

ug

08,

ug

09,

ug

10,

ug

11,

ug

12,

ug

13,

ug

14,

ug

15,

ug

16,

ug

17,

ug

18,

19,

20,

21,

ug

22,

ug

23,

ug

24,

ug

25,

26,

ug

27,

ug

28,

ug

29,

ug

30,

ug

31,

ug

Production

Date

Ammonia Production Profile

Ammonia Production Profile August-2014

Date Average Load Production Date Average Load Production

1,Aug 102.79% 1,487.00 16,Aug 100.01% 1,457.44

02,Aug 104.11% 1,507.30 17,Aug 100.75% 1,463.22

03,Aug 102.64% 1,490.10 18,Aug 103.80% 1,485.7704,Aug 102.32% 1,486.00 19,Aug 103.85% 1,476.68

05,Aug 102.54% 1,486.00 20,Aug 101.94% 1,486.90

06,Aug 103.12% 1,495.10 21,Aug 101.74% 1,479.27

07,Aug 103.29% 1,505.08 22,Aug 101.35% 1,487.56

08,Aug 101.83% 1,487.31 23,Aug 102.44% 1,482.80

09,Aug 102.01% 1,482.75 24,Aug 101.71% 1,483.45

10,Aug 102.02% 1,485.10 25,Aug 100.91% 1,492.08

11,Aug 102.03% 1,490.94 26,Aug 101.44% 1,482.98

12,Aug 101.87% 1,483.50 27,Aug 101.36% 1,491.4013,Aug 101.82% 1,488.15 28,Aug 99.91% 1,488.56

14,Aug 0.00% 1,466.22 29,Aug 68.56% 262.41

15,Aug 99.67% 1,465.76 30,Aug 56.80% 0.01

31,Aug 81.72% 89.10


4/18

Health,Safety&EnvironmentIncident# 1:At 1520hrs, area operator reported

heavy oil leakage from mechanical seal of lubeoil pump P-123-B of C-105.

Action Taken: Motor-driven standby pump

PM-123-A was immediately started and P-123-

B stopped/Isolated. Spilled oil cleaned and

pump handed over to machinery for repair.

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

CT-105 anti-surge valve FV-073A stuck at 40%

and machine tripped due to 3surges/5minsecurity.

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

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

position feedback ZI-105 started to fluctuate

and hunting observed in governor lift. Impact

kept on increasing and started to vary CT-105

speed due to severe hunting.

Action Taken: Isolated HP steam pressure

reduced to increase actuator AOM-1105

demand/lift opening and finally opened to

100%. Meanwhile Instrument team inspected

its JBs for suspected water ingress but no such

observation found. Now CT-105 speed control

on steam pressure and governor is not in control.


5/18

0

0.5

1

1.5

2

2.5

3

NMI PSI FAC Fire Equipment

Failure

Operational

Upset

Human

Error

Violation of

PSM

Incident Stats August-2014

Series1

0

20

40

60

80

100

Safety Observations Reported

Safety Observations Closed

% Close Out

Safety Observations Reported Safety Observations Closed % Close Out

Series1 29 29 100

Safety Observations Statistics


6/18

0

50

100

150

200

250

300

350

MSA Observations

Reported MSA Observations Closed% Close Out

MSA Observations Reported MSA Observations Closed % Close Out

Series1 316 316 100

MSA Statistics

00.10.20.30.40.50.60.70.80.9

1

Equipment Machinery Electrical Instrument Civil TSD HSE Operations

Series1 0 0 0 0 0 0 0 0

MSA Open Actions


7/18

0

20

40

60

80

100

Near Miss

Observations

ReportedNear Miss

Observations Closed % Close Out

Near Miss Observations Reported Near Miss Observations Closed % Close Out

Series1 0 0 100

NM Statistics

00.10.20.30.40.5

0.60.7

0.8

0.9

1

Equipment Machinery Electrical Instrument Civil TSD HSE Operations

Series1 0 0 0 0 0 0 0 0

NM Open Actions


8/18

0

200

400

600

CWP IssuedCWP Closed

CWP % Close OutHWP Issued

HWP ClosedHWP % Close

Out

561473

84.31%

64

58 90.625%

Overall Department-wise PTW Compliance

CWP Issued CWP Closed CWP % Close Out HWP Issued HWP Closed HWP % Close Out

Department CWP # HWP #

Equipment

CWP issued 310 HWP issued 55

CWP closed 280 HWP closed 50

CWP Closure % 90.3% HWP Closure % 90.9%

Machinery



CWP Closure % 89.7% HWP Closure % 100%

Electrical




Inspection




Civil




Instrument




PTW status Department wise


9/18

Operational Highlights

Working on alarm management system

Follow up for LTDS closure

Initiatives:

Audits carried by operation Safety equipment audit on daily basis

Safety observation audit on daily basis

Explosivity Audit on daily basis

Routine audit on daily basis

Housekeeping Audit

Safet cabinets/PSVs car-seal audit

D-level Talk/Emergency Talk

D-level talk conducted in night shifts

Emergency talk discussed in night shifts

CM-1151A L/O and process side Delta P started decreasing sharply, so immediatel

unloaded compressor to recover Delta P but in vain and compressor get tripped

Again tried to start but cannot be started due to PM-1151A low pressure problem.

On 01-08-14 PM-121A started on low lube oil pressure logic, when checked from field

PT-121B was found de-latched, after cleaning of latching lever started again.

Cold-box bad mode problem faced on 28/08/14 so after discussion back-end outag

was planned for 60 hrs for full de-riming of cold box as well as to attend some

important jobs

Plant Start-up Activities

CT-105 drain valve steam leakage problem was rectified at 2200 hrs. After turbin

heating compressor train was rolled in first attempt at 2340 hrs.

Dryer took online at 0130 hrs (31st

Aug, 2014).Cold box pressurized and which its coo

down started at 0200 hrs.

C-101 started at 0117 hrs and lined up with system at 0230 hrs after which plant fron

end load increased to 75%.

C-104 startup preparations completed and compressor train rolled at 0345 hrs

Currently machine is at 2200 rpm and will be hold here for 30~45 min. Further startu

sequence will continue afterwards.

Production resumed on 31-08-14 at around 2130 hrs
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10/18

0%

20%

40%

60%

80%

100%

Shift Group A Shift Group B Shift Group C Shift Group D

75% 75% 88% 100%

Saftey Observation Audit Complaiance

0%

20%

40%

60%

80%

100%


100% 100% 100% 100%

Explosivity Audit Compliance

0%

20%

40%

60%

80%

100%


100% 100% 100% 100%

Routine Audit Compliance


11/18

0

10

20

3040

50

60

70

80

90

100

Planned Skills Actual Skills Done % Compliance

Series1 1 1 100

NH3 Plant Cross Training Status Till Aug-2014

Series1

Skill Status 2013 2014Cumulative

2013

Cumulative

2014

1 One Post 27 23 38 39

2 Two Post 6 9 11 16

3 Three Post 2 4 5 7

4 Four Post 3 3 3 3

5 Five Post 0 0 0 0

6 Six Post 0 0 0 0

7 Seven Post 0 0 0 0

8 Eight Post 0 0 0 0

Ammonia Plant Multi Skill Status-2014 (To Date)


12/18

0

20

40

60

80

100

120

140

160

Total No. of

Standing

Alarms

No. of

Standing ESD

Alarms

No. of

Standing

DCS Alarms

No. of

Standing

DCS Alarms

Issues

Resolved

No. of

Standing ESD

Alarms

Issues

Resolved

% of

Standing

Alarms

Issues

Resolved

Series1 142 17 133 85 0 60

Ammonia Standing Alarms Statistics

01020

30405060

7080

90100

Incidents

Reported

Recommendations

Marked to

Operation

Operation

Recommendation

Closure

Compliance

Overall Closure

Compliance

Series1 3 0 100 100

Incidents Recommendation Closure Compliance


13/18

0

20

40

60

80

100

Shift Group A

Shift Group B

Shift Group CShift Group D


Series1 100 100 100 100

Emergency Talk Compliance

0

50

100

Shift Group AShift Group B

Shift Group C

Shift Group D


Series1 100 100 100 100

D-Level Talk Compliance


14/18

DESCRIPTION UM JulyDesign

Consumption

Cumulative

2013

Cumulative

2014

Catacarb WBU

(Polyglycol)Litre 40 22.5 315 168

Catacarb 400 DM 3 1 30 37

Catacarb 72-S Litre 0 As Required 113 0

Catacarb 922

(V2O5)m3 0 0.225 10 11

Potassium

Carbonate

(K2CO3)

MT 03 1.85 21.075 26

Bulab-9564

(Na3PO4)Kg 50 86.6 575 275

Hydrazine

(N2H4)Liter 75 52.7

Oil Drums

Turbo-32DM 0 As Required

Oil Drums

Turbo T-32DM 14 As Required

Oil Drums

Tellus + ClavusDM 0.5 As Required

Oil &Chemical Consum tion


15/18

Maintenance Highlights

E-108 GLG leakage rectified by replacing its glass.

E-145A3 old bundle hydro-jetting/Hydro-testing and

chemical cleaning done.

P-420 suction strainer cleaned

E-222 and its associated piping painting done

P-110A discharge valve gland leakage rectified

Insulation provision at MS-116 inlet line and E-093

associated lines done

Insulation provision at E-118 and associated line done

FH-051 isolation valve handle provided

D-143 inlet/outlet lines thickness monitoring done

PM of safety showers carried out

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

E-228/229/123/130 painting job done

Platform provision at E-240A/B unapproachable valves

D-208/E-114/116/216 associated insulation removal and

thickness monitoring done

FIL-103B/D/E cleaning done

FM#04 nozzle free problem rectified

Pin-hole leakage rectified at Rota-meter of PT-104

D-132 both man-ways removal and blinds installation for

charge replacement

New windsocks installed at TK-102/1101

Tie-ins were taken for CT-105 gland condenser

New tie-ins for CWS/CWR taken for E-145

FIL-104A/B cleaning done

E-182A/B and E-151 cleaning and hydro-testing done
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16/18

Machinery Highlights

PM-1151A low pressure problem rectification remained

I/P

PT-1501B CW jacket get de-blocked

General oil make up and area surveillance

P-1504B gland leakage rectified

C-102 breathers cleaning done

PM-9345A/B suction strainers cleaning done

TK-115 portable centrifuges cleaning done

P-118 anti-foam pump diaphragm replaced for low

pressure problem leakage rectification

FIL-102 primary/secondary filters cleaning done

C-104 LPC to turbine side oil leakage rectification done

C-105 I/B and O/B bearings inspection done

C-104 control oil filters cleaning done

C-106 portable centrifuge cleaning done

BT-201 lube oil filters cleaning done

PT-101B seal leakage rectified

CGT-102 ventilation fan filters cleaning done

P-145B seal leakage rectification


17/18

Electrical & Instrumentation Highligh

PDC-1182 inspection done and declared ok

Conductivity analyzer CI-103 calibration done

FI-042 LP leg replaced, found blocked

ZI-1180 IOP problem rectified

TE-397 replaced with new one at E-182A/B O/L

C-105 O/B AP-014 fluctuation observed, health foundok

PT-022 calibration as per PM plan

PT-478/480A calibration done

FI-158/159/005 calibration done

MOV-058 limit switches adjusted

Fused lights replaced due to low light issue

Motors greasing done

PSL-135A/B/C calibration done

Natural gas latest composition incorporated in DCS

PSL-134/76B/87C calibration done as per PM plan

FV-063 glands repacking done

FV-932 flow limitation problem rectification done

MOV-150/151 limit switches adjustment done

D-118 sam le oint tubin re laced


18/18

Position Available Approved

Unit Manager 1 1

Day Engineer 1 1

Shift In-charge 4 5

Area Engineer 3 5

Back End Board Man 2+3(Sub-Engineers) 5

Front End Board Man 3+1 5

Operators (Permanent) 31 32

Apprentice Operators 6

Annual Contract 1 Annual Contract

Helpers 8 Annual Contract

Documents

Ammonia Operation Monthly Report August-2014