INAMULLAH NAVEED KHAN

VP MANUFACTURING
ENGRO FERTILIZERS LTD
PAKISTAN
IN THE CONSTRUCTION
AND START UP OF
A JUMBO-SCALE PLANT
ENGROS EXPERIENCE
EnVen1.3 PROJECT OVERVIEW
HaldorTopsoeAmmonia Plant with 2,194 MTD
SAIPEMUrea Plant with 3,835 MTD
Largest Single Train Urea Plant in the World
One of the largest Urea Complex in the World
Tallest PrillTower of the World (125 m)
CO2Recovery (350 MTD) fromFurnace Flue Gases
Environmentally Compliant Plant with Flare System
TRIR & Man-hours Trend
Statistics
May-11
2.2
5.7 11.2
20.1
32.0
43.0
50.0 51.6
0.45
1.3
2011

Consciousness
Jun-07
Dec-07
Jun-08
Dec-08
Jun-09
Dec-09
Jun-10
Dec-10
0
0.19
0.18
0.16
0.22
0.22 0.25
0.28
0.27
TRIR & Man-hours TRIR
0.2
8
Man-hours
51.6
Jun-11
COD
Land Leveling
Earth Movement
Excavation
Air Condition/ HVAC
Precast Bar Bending
Foundation work
Concrete work
MANNING
H
A
Z
A
R
D
Refractory works
Insulation on grounds
Low Hazard/
High Manning
Low Hazard/
Low Manning
High Hazard/
Low Manning
High Hazard/
High Manning
Prill Tower Slipforming
STR-101/ Concrete work at heights
Painting & insulation at height
Cutting
Welding
Grinding
Vessel Entry
Structure Steel Erection
Rigging
Startup
Gas in
Scaffolding at Height
Piping erection at height
Hydro-test
Blowing
Process Fluid
2Q 07
4Q 07
1Q 08
4Q 08
1Q 09
2Q 09
4Q 10
- Machinery Startup
- Heavy Rigging
- Electrical Circuit
Energization
- Prill Tower External
Painting at Height
- Excavations post startup of UG
services
1.3
2011

Technology
Project Executive
SOC Chairman
Sub
SOC
(P)
Sub
SOC (M)
Sub
SOC
(I&E)
Sub
SOC
Civil
Sub SOC
Environment
Sub
SOC
IRRC
Safety
Advisor
Safety Engineer (1)
Safety Facilitator with
Construction Dpt. (35)
Safety Supervisor (1)
Safety Facilitator (11)
Descon HSE Team
Manager (1)
Engineer (20)
Officers/ Sup (40)
Assistant (20)
Doctor (1)
Paramedic (2)
HSE Or gani zat i on
Pr oj ect SOC & Sub SOCs
Saf et y sect i on r ol e and
r esponsi bi l i t i es
Cont r act or s Saf et y
Or gani zat i on
Saf et y f aci l i t at or f or ever y
const r uct i on j ob
I ndi vi dual Char t er f or SOCs
avai l abl e
HSE Organization
PROJECT
EXECUTIVE
PLANNING &
CONTRACTS
MANAGER
ENGINEERING
MANAGER
CONSTRUCTION
MANAGER
AMMONIA, UREA
CONSTRUCTION
MANAGER
UTILITIES
SAFETY
ADVISOR
Planning,
Contracts &
Procurement
Engineers
Process, Project
Machinery,
Civil, I&E
Engineers
Project,
Inspection,
Civil, Machinery
Safety
Engineers
CEO
OPERATIONS &
START-UP
MANAGER
Operations
Engineers &
Supervisors
CONSTRUCTION
MANAGER
I & E
I & E Engineers
Project,
Inspection,
Civil, Machinery
I&E Engineers
SENIOR ADVISOR
QA/QC
QA/QC
Engineer
ENGINEERS: 85
OPERATORS &
TECHNICIANS: 152
TOTAL: 237

ENVEN 1.3 PROJECT CONTRACTING

STRATEGY
Overall Project Management
EP
Ammonia, Urea
Selected Utilities
Saipem
Engineering
SP Netherlands
Purchase & Supply
Of Equipment
Saipem, Madeira
Limited Construction
SupervisionSaipem, Italy
CONSTRUCTION
Ammonia, Urea
Utilities & PM&S
Descon
EP
Utilities,PM&S
EFERT
LSTK
Offsite Facilities
Descon
EPC
CO2 Recovery Project
Descon
EP-WLGE
CONS-Descon
Ammonia Storage Proj
1
Based on Schedule
Descon
35%
EFERT
Engineering &
Procurment
15%
Saipem
Engineering &
Procurement
45%
Commissioning
5%
1

ENVEN 1.3 PROJ ECT
SAFETY
TRIR <0.5
PSRM& PSM
PHA / HAZOP
Project Specific
Systems
Contractor Safety
Monitoring &
Reporting
Incident Investigation
QUALITY
FATs & SATs
Construction Quality
Quality Assurance
Checklists
Hold point concept
Internal quality
reviews
Limited Construction
supervision
COST
Regular
Monitoring
Independent
Reporting
Monthly &
Quarterly
Variance
reports
InterimReviews
SCHEDULE
Integrated Team
Use of modern softwares
for monitoring & reporting.
Monthly & Quarterly Reports
Proactive Approach to
mitigate
Positive variance
InterimReviews
0
10
20
30
40
50
60
70
80
90
100
M
a
r
-
0
7
A
p
r
-
0
7
M
a
y
-
0
7
J
u
n
-
0
7
J
u
l
-
0
7
A
u
g
-
0
7
S
e
p
-
0
7
O
c
t
-
0
7
N
o
v
-
0
7
D
e
c
-
0
7
J
a
n
-
0
8
F
e
b
-
0
8
M
a
r
-
0
8
A
p
r
-
0
8
M
a
y
-
0
8
J
u
n
-
0
8
J
u
l
-
0
8
A
u
g
-
0
8
S
e
p
-
0
8
O
c
t
-
0
8
N
o
v
-
0
8
D
e
c
-
0
8
J
a
n
-
0
9
F
e
b
-
0
9
M
a
r
-
0
9
A
p
r
-
0
9
M
a
y
-
0
9
J
u
n
-
0
9
J
u
l
-
0
9
A
u
g
-
0
9
S
e
p
-
0
9
O
c
t
-
0
9
N
o
v
-
0
9
D
e
c
-
0
9
J
a
n
-
1
0
F
e
b
-
1
0
M
a
r
-
1
0
A
p
r
-
1
0
M
a
y
-
1
0
J
u
n
-
1
0
J
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l
-
1
0
A
u
g
-
1
0
S
e
p
-
1
0
O
c
t
-
1
0
N
o
v
-
1
0
D
e
c
-
1
0
%

C
u
m
m
u
l
a
t
i
v
e

P
r
o
g
r
e
s
s
0
1
2
3
4
5
6
7
8
%

M
o
n
t
h
l
y

P
r
o
g
r
e
s
s
Monthly Planned Baseline
Monthly Planned Forecast 4
Monthly Revised Actual Progress
Monthly Planned Progress (August
2009)
Cummulative Planned Progress
Baseline
Cumulative Planned Forecast 4
Cumulative Revised Actual Progress
Cummulative Planned Progress (August
Planned : 100.00%
Actual : 99.96%
1.- 2010
1
Engg&Procurement
Snamprogetti
ECPL
Const / Mechanical Completion
Utilities
Ammonia
Urea
Critical Path Items
Cooling Water Pumps
Process Air Compressor
Ammonia Piping
Primary Reformer
Sub-Critical Path Items
Offsite EPC Contracts
Ammonia Storage
Commissioning
Pre-Commissioning
Commissioning
Production
end-Aug 2009
end-March 2010
17 J an 2010
25 April 2010
18 J une 2010
31 Oct 2009 mid-Aug 2009
15 April 2010
mid-Oct 2009
mid-May 2008
25 April 2010
06 April 2010 end-Aug 2008
01 J uly 2007 30 May 2009
mid-May 2007
J une 2009
May 2009
Oct, 2010
J an 2010
Dec, 2010
Increase in construction quantities.
De-watering Surprise on start of Civil Works
Industrial peace issues & their impact
Unprecedented rains & floods in 2010.
Failure of weld joints on critical path systems towards the end.
Commissioning delay by 22 days due to fire at syncomp.
COD delays due to non-availability of gas
PWHT machines must be audited properly before acceptance.
Construction contractor must not be given full authority on QA/QC
QA/QC functions must be directly reporting to Project Executive
Average experience of QA/QC team must be around 10 years
Work on radiography scope from the initial phase of construction
Killed carbon steel material must be marked before fabrication
Welding of heavy thickness piping must be done first
N
o
.

o
f

W
e
l
d
s
Techniques Used
Team Build-up
Procedures development
More than 530 procedures were developed for operational activities
Training
400 man hours per person thru following trainings;
In house classroom training
Similar technology plants
Training by technology licensors
Training on Operator Training simulator (OTS)
Pre-commissioning
High pressure test of Synthesis loop at 200 Kg/cm
2
in addition to normal activities
Commissioning & Start-up
Frontend commissioned in 05 days
Back-end commissioned in 07 days
Urea on-spec achieved with-in 48 hours of ammonia production
Same vendor was selected for DCS & OTS
A number of potential shut downs were saved by
OTS trained operators
Front end was normalized in record 05 days
Malfunctions & Controller behaviors were well-
understood upfront and fixed.
OTS HALL
Control Room
OTS HALL
Control Room
System-wise requirements audit
Pre-startup Safety Reviews (PSSR) recommendations closure
Temporary gaskets audit
Piping conformity audit by SAIPEM for frontend
Instrument air leakage audit
Pre-startup PHA recommendations closure
Audit for completion of permissive for feed-in
Housekeeping & Combustible Material Audit
OTS HALL
Control Room
CW low
pressure
on pump
change-
over
A wrong
signal was
generated by
cooling water
pumps ESD
which
resulted in
nuisance I-1
Control
Power
failure to
reformer
ID fan
speed
probes
due to
tripping of
power
distribution
cabinet.
I-1 was
manually
activated due
to fire at
synthesis
machine.
Air
compressor
tripped and
protection
steam in air
convection coil
was not
established in
time due to
slow response
of protection
steam flow
control valve.
DATE MONTH Milestones / Activities
4-Apr-2007 0 Effective date of contract
19-Dec-2009 32
nd
Start of Steam blowing
12-Jun-2010 39
th
Air compressor commissioned
20-Aug-2010 41
st
Ammonia storage commissioned
11-Nov-2010 43 m 7 days Feed-in to Primary Reformer
16-Nov-2010 43 m 12 days Frontend Normalized in 05 days
17-Nov-2010 43 m 13 days Backend start-up heldback due to gas limitation
29-Nov-2010 43 m 25 days Fire at SynCompressor
20-Dec-2010 44 m 16 days Restart of Synthesis Compressor
26-Dec-2010 44 m22 days AmmoniaProduction
29-Dec-2010 44 m25 days Urea Production
GAS CONSUMPTION DURING PRE-COM& COMMISSIONING
Energy for Pre-commissioning 550,000 G cal
Energy for commissioning & startup 650,000 G cal
Total Energy consumption 1,200,000 G cal
Front end Startup & normalizationfrom feed in 05 days
Backend startup & Production 07 days
Effective Ammonia plant startup time barring thegas 12 days
outage & Syn comp incident
Total waste water generated 26 Million US Gal
Construction completion timefrom effective date of contract 43 months 22 days

EmergencyResponse
The machine was immediately shutdown by using
fieldmanual switch.
The fire was extinguished immediately by operating
delugesystem(water sprinkler).
RemedialMeasures
Carried out quality assurance checks of all thermo-
wells &instrument hook-ups on all critical / hazardous
systemsandseal welded.
Install all thermo-wells as per standard practice given
inANSI StandardonNPTthreads.
Background
During pressurization of syncompressor, thermocouple
at recycle suction dislodged.
Dislodging of a thermo-well resulted in Fire.
Flames from the fire hit air compressor turbine.
Faulty installation of threadolet, which didnt allowed the
thermo-well to be fully tightened.
Excessive root penetration hindered thermo-well
insertion
Thredolet 3
rd
Suction Line after Flame Impingement
Ammonia feed pump, P-01B tripped on high vib
security, restarted but tripped again.
Ebara responded proactively & impeller hub was
shortened.
Similar modification was done at the other pump
CO2compressor surging on 02 occasions
Min governor speed was changed from 5693 to
6476 rpm
Extensive training of manpower and well-structured utilization of
Thorough and once through pre-commissioning
Several layers of audits performed
All circuits pressure tested
Synthesis loop was tested at 200 Kg/cm2 pressure with nitrogen
All critical circuits were pressure tested with nitrogen / air.
Frontend was pressure tested with nitrogen and soap test was carried out.

April 2007
November 2010
Apr 2007 Sep 2007
Oct 2007 Nov 2007 Dec 2007
Jan 2008
Feb 2008 Mar 2008
Apr 2008
May 2008
Jun 2008 Jul 2008
Furnace in Operation
Purification Post at Night
450 Tons Synthesis Converter Reactor Rigging by 1200T Crane
365T Urea Reactor (R-01) erected using 1200T Crane
165T LP/HP Flash Drum (V-301/302) erected using 1200T Crane
385T CO2 Absorber (C-302) erection using 1200T Crane
450T Prill Tower Truss Structure lifted to 109m Elevation
Ammonia Storage Tank Commissioned
5000 MT NH3Capacity
Double-Walled Tank
Men @ Work
Men @ Work
Men @ Work
Safety Talk
DAHARKI EXPANSION