TA-2016

REPORT

Prepared By:
Mouaz Khaleeq Butt
Muhammad Aqib

Message from Vice President

The 2016 turnaround is the most important of its kind

in

Engros

history.

Involving

maintenance,

modifications, and project works, the event require

concerted efforts, collaboration and teamwork in
order to be coherent and safely implemented in time.
We must make full use of this opportunity to carry
out critical works because it is unlikely that we will
have the prospect of a total turn around for next two years.
The work to be carried out during this turnaround is vital for the Company to
meet its future business plans. More emphasis is being placed on increased
production output, whilst maintaining our excellent HSE standards.
An atmosphere of harmony and cooperation between the various work
teams, contractors and direct hire must also exist to ensure a smooth turn
around.
The work which will be carried out during this turnaround will have impact on
Engros production and its ability to meet future targets.
Meticulous

planning

and

development

of

comprehensive

turnaround

procedures put the company in a strong position and this, coupled with close
and adequate supervision, is the recipe for a successful turnaround.
I am confident that with your best efforts our turn around will be safe and
successful.

Asif Tajik
Vice President, Manufacturing
(Chairman, Manufacturing HSE)

Executive Summary

TA-2016 was planned in order to improve service factor and unavoidable scheduled
maintenance. This also provided the opportunity to carry out major and minor
maintenance and modifications to improve process safety and reliability.
Since Plant-1 TA-2016 had enormous scope of jobs, it was in no way less challenging
than the last outage owing to the time constraints. The preparations for this
turnaround were being made way ahead of the scheduled day. A comprehensive
HSE plan was formulated to ensure safe completion of the turnaround without
compromising on Health, Safety and Environment, the core focus areas of Engro.
Execution of the HSE plan in its true spirit resulted in achieving envious results with
regard to the set objectives.
From Operations standpoint the principal focus was already upon the secure
handover of process equipment/machines to the relevant interfaces for
maintenance jobs. In order to achieve this goal, extensive planning was carried out
and an effective LOTO strategy was formulated. All jobs were discussed in detail
among the shift personnel which led to the avoidance of any possible delays.
There were a few surprises which led to delays in completion of the jobs. These
include extensive maintenance jobs on furnace which were not part of the plan
initially but due to their criticality had to be completed.
Major jobs executed during TA-2016 at F-2501 were catalyst replacement, tubes
replacement, burner replacement and refractory repairs. There were numerous
miscellaneous jobs completed as well.
Apart from this, KGT-2501 overhauling was a critical path activity. The rotors of
compressor, gas turbine and steam turbine were replaced. Also extensive cleaning
of filter house was carried out.
Overhauling of K-2502 HP-case was carried out. Job scope included adjustments and
bearings replacement of IP-case to rectify the high vibrations experienced during
normal operation. Steam turbine rotor of compressor K-2503 was also replaced.
In addition to major jobs, a dedicated team was deployed to supervise the Greenlist
jobs. More than 500 Greenlist jobs at Ammonia-II were attended which in itself is a
great achievement.
Although the TURN AROUND - 16 was concluded safely without an occurrence of a
major process or safety incident, but many lessons were learnt during the time. The
lessons have been listed with the aim to help relevant personnel learn from
experience and evade their presence in the future.

HSE PLAN

Think Safety First

TA-2016 was no different from any other job executed in Engro fertilizers in
terms of safety practices. In fact, the execution of Jobs during TA-2016 was
not an easy task. The handling of such a large contract workforce and safe
execution of the jobs near active areas of plant was in itself a major
challenge. To execute jobs safely, and avoid any unforeseen circumstances,
special attention was put on safety.
Based on the hazards involved in the activities a comprehensive plan was
developed under these pointers:
1
2
3
4
5
6
7

Safe handover ofZero

equipment.
Environment Complaint
Confined
space
entries
Extensive planning ledsafety.
to Zero environmental complain during
Hose management.
TA-2016
Deployment plan of SS/SIC.
Control of running part of plant.
Learning from previous turnarounds.
Provision of explosivity neutralizing steam during steam shutdown

Zero Recordable Injury

window.
T employees, contract
personnel
and
USL
was recorded during this whole activity. However three first aid cases
8 Fire prevention.

9 Deputation of dedicated operations resources.

10 Multiple training of area operators &

MPT`s.
11 Noise controls during
blowing.
Safe lines
Handover
of Equipments
12
Electrical
hazards
and
prevention.
ding refresher trainings, tagging of blinds and 100% new locks ensured safe handover of equipment without an
13 Awareness and cautionary banners in the
area.

Safe Confined Space Entry

aining courses of vessel entry protocol for trade apprentices and standby personnel ensured safe execution of ve

HSE COMPLIANCE

Safe execution in Live Area

supplying gas to Plant-2. Vigilant operation and continuous explosivity checks performed by operations team le

F-2501
Introduction
Primary reformer usually referred to as furnace is the heart of ammonia
plant. F-2501 is a Foster Wheeler, terrace walled furnace, and here steam
reforming of natural gas takes place over Nickel based catalyst in the radiant
tubes. It has been improvised to use the exhaust of KGT-2501 as combustion
air which in addition to not only reducing the fuel requirement, also helps in
mitigating the effects of changes in environmental conditions.
Scope of Work
The furnace was the part of the plant where most of the jobs were planned
and a major overhaul of the furnace was successfully completed in TA-2016.
Below mentioned are the most critical activities.
Catalyst Replacement
The catalyst in primary reformer was last charged in April-2000. In TA-2016
the catalyst in all (392) tubes has been replaced. The new charge of catalyst
has a layer of pre-reduced catalyst (R-67R-7H), for faster startup, at the top.
This is then followed by a bed of normal reforming catalyst (R-67-7H). The
top and bottom layers comprise 15% and 85% of bed height respectively.
The cumulative volume of the catalyst is 1230 ft3.
During the catalyst removal activity there were a few setbacks. Initially the
catalyst was to be unloaded by removing the bottom flange followed by
removal of the bottom holding cone.
But during the execution the bottom holding cones broke This left the cones
stuck inside the tubes with no other means to remove the catalyst from
bottom it was decided by the process team that vacuum machines would be

used

to

suck

the

catalyst

CATALYST STUCK INSIDE CONES

out

from

the

top

flanges.

OLD AND NEW CONE

CATALYST REMOVAL INPROGRESS USING VACUUM MACHINES

This unprecedented problem delayed the catalyst removal activity

considerably but did not lead to any delays as far as startup timeline was
concerned.
Tubes Replacement
In TA-2016, 25 radiant tubes (15 of Cell-I and 9 of Cell-II) of F-2501 were also
replaced as a prior assessment by Konam declared these tubes as D-Class
(the ones requiring immediate replacement).

CATALYST TUBE BEING INSTALLED IN PLACE

This activity was executed flawlessly without encountering any major

problem.

NEW CATALYST TUBES AFTER CATALYST LOADING

OLD CATALYST TUBES

Burners replacement
The burners in F-2501 are post mix where fuel and air are introduced
separately and in TA-2016 all burners have been replaced. This is done in
order to reduce the back pressure generated by the older burners which had
smaller diameter holes, this led to issues of flame lift off resulting in
reduction in furnace efficiency.
Carburized plates of the burners were also replaced as required.

OLD BURNER

NEW BURNER

Refractory Repair
Refractory inside the furnace was damaged due to prolonged operation,
resulting in escapeof heat. To minimize the heat losses refractory repairs at
various places inside the fire box were completed. In addition to this peep
doors internal refractory, burners and air duct insulation was also replaced.

REPAIRED PEEP DOOR

REPLACED INSULATION BRICKS IN FIREBOX

Bull Noses were also inspected and repaired or replaced as required in TA2016.

REPAIRED BULLNOSE (Convection Section)

As a result of these repairs steam spargers would no longer be needed

during normal operation.

REPAIRED REFRACTORY INSIDE FIREBOX

Sealing Baskets Replacement

Sealing baskets were replaced in TA-2016 resulting in better isolation of
furnace internals from the atmosphere.
Transfer Line Replacement
In 2014 a bulge in transfer line was observed due to internal refractory
damage and it was boxed up then by repairing the refractory as required but
it was planned to replace the whole S portion of transfer line as soon as
possible.

OLD TRANSFER LINE

OLD TRANSFERLINE
COLD COLLECTOR
TRANSFERLINE JOINT
COLDWITH
COLLECTOR
JOINT

NEW TRANSFER LINE RIGGING IN-PROGRESS

Misc. Jobs:

DAMAGED AIR DUCTS

CONVECTION SECTION COILS INLET REFRACTORY REPAIR

KGT-2501
STEAM INLET HEADER (New)

Since its continuous operation for past 18 years, this machine was in dire
need of maintenance. During TA-2016, KGT-2501 inspection and Rotors
replacement were carried out. In terms of its scope as well as being a critical
path activity, this was one of the most major jobs.
Upon inspection, its rotor, impellers and guide vanes, bearings, were found
damaged and were replaced. This includes Steam Turbine (KT-2501) rotor
replacement, HP, LP air compressor (K-2501) rotor replacement, KGT-2501
rotor replacement and maintenance.

Job Scope

Starting steam turbine Overhauling

Rotor Replacement
Bearing Inspection / Replacement
Compressor Section Inspection
Combustion section Inspection
Turbine section Inspection
Coupling inspection & Alignment

OLD AND NEW HP CASE ROTOR

HP CASE DAMAGED INLET

GUIDE VANES

DAMAGED BEARING

Besides
rotors
replacement of HP,
LP, Steam turbine
and gas turbine
other
parts
including
IGVs,
Bearings, nozzles
and Buckets were
found
damaged.
Extensive
maintenance work
was performed on
KGT-2501 in this
context

HP CASE ROTOR

Steam turbine Rotor was inspected and was found damaged. First stage
nozzles, Thrust bearing, journal bearing conditions was also not healthy.

Gas turbine rotor assembly, consisting of axial compressor rotor combined

with gas turbine rotor, was replaced totally along with its other parts
STEAM
TURBINES
DAMAGED ROTOR
inspection
and
replacement.
1ST STAGE DAMAGED
NOZZLES

TK-2501 DAMAGED ROTOR

FIRST STAGE NOZZLES

Inspection carried out revealed thinning of axial compressor blades and

damaged buckets of Gas turbine wheels. Axial compressor Stator blades
were replaced. Gas turbines 1st and 2nd stage shrouds and nozzles were found
damaged and were also replaced.

CARBORIZED SHROUDS

AXIAL COMPRESSOR DAMAGED BLADES

1ST STAGE DAMAGED

BUCKETS

2nd STAGE DAMAGED BUCKETS

AXIAL COMPRESSOR NEW STATOR BLADES

K-2502
Introduction

It is the synthesis gas compressor where mixture of nitrogen and hydrogen in

stoichiometric ratio of 1:3 is compressed from 350 psig to 3150 psig in four
stages. This compressor is driven by a 37,500 BHP steam turbine. This is
done because the ammonia conversion reaction equilibrium is favored at
high pressures.
Job Scope
During its Run, this compressor IP case showed high vibrations and also, its
HP case overhaul was last done in 2005 and was due. After shutdown, the
syn-compressor seals, bearings, couplings were inspected and were found
damaged,
Syn machines HP case was completely overhauled including guide vanes
diaphragm and rotor assembly.

HP CASE NEW ROTOR AND GUIDE VANES ASSEMBLY

On inspection IP case bearing was found to be clogged with oil, thrust

bearing was also found damaged.
Signs of sludge, oil, and damage were seen.

SYN O/B JOURNAL BEARING

SYN IP CASE THRUST BEARING OIL SLUDGE

SYN LP THRUST COLLAR

DAMAGED

SYN LP CASE TRHUTS BEARING WITH OIL SLUDGE

K-2503
Introduction
K-2503 is an integral part of the refrigeration loop at backend. It is a
horizontally split centrifugal compressor with two cases having seven and six

stages respectively. It is a steam turbine driven compressor that compresses

the ammonia vapors (refrigerant) to 210-230 psig, which are condensed and
recovered in the refrigeration receiver as liquid. This compressor is driven by
a steam turbine.
Job Scope
Since 1998, its steam turbine rotor hasnt been overhauled. Moreover, no
inspection is carried out since then.
After its disassembly, steam turbine rotor inspection was carried out., it was
decided to use the same rotor after its sandblasting, and minor repairs
because its health was found to be satisfactory. Also, new refurbished rotor
had a damaged bucket along with minor pitting which led to use of the old
rotor.

NEW AND
OLDcompressor
ROTOR. CRACK
ON NEW ROTOR
4TH STAGE were
(Right found
side)
On inspection,
Refrig
turbines
2 diaphragms
cracked.

Mechanical OST:
After its maintenance and overhauling, following standard protocol, K-2503s
mechanical OST was tested.
After bypassing electronic OST, Machine was ramped up to almost 9000
RPMs but mechanical OST didnt actuate. Machine had to be tripped
manually. After cleaning of OST pin assembly, and its spring replacement,
2nd OST attempt was made but the result was same.
Taking into account that rotor has been in use for 18 years, it was
decided to take wavier of mechanical OST and rely on electronic OST
alone.

Heat exchangers
Several Exchangers inspection, cleaning hydro-testing was done. The major
exchangers attended during TA-2016 are as follows:
E-2518, E-2522, E-2528, E-2523A/B, E-2526, E-2524, E-2506, E2502/3/4, E-2514, E-2509C, E-2511 A-H, E-2501A/B, E-2539, E-2538
A/B andE-2537A/B/D

GREENLIST
During TA-2016 around 513 Greenlist jobs were attended. The other major
categories of jobs attended include:

Temporary Repairs.

PSVs Calibration.

Projects Jobs.


140

Control Valves.
126

120
97

100
80

72

60

46

40

31

20
0

Greenlist Status at the end of TA-2016

Department
Stationary
Machinery
Instrument
Projects
Electrical
Process

Total

%
Completion

Complet
ed

405
29
120
4
5
2

95%
62%
87%
75%
40%
50%

385
18
104
3
2
1

Inspection
Overall

1
566

0%
91%

0
513

APS Modificaiton
APS is installed to provide automatic startup
of standby pumps in case of deviation of
Process variable from set point or tripping of
one of the pumps. This system was by design
pneumatic, with total control in field. During
TA-2016, APS modification which was
planned in 2004 has been implemented,
making this an electronic system. The new
system provides indication on TDC in control
room making it much simpler and user
friendly, while making emergency handling easier.

A total of 14 loops were implemented. Their logics were checked in actual

and the possible scenarios were tested online to verify their actual operation.

Trainings of Operation personnel were conducted on this modification to

familiarize them with the new system. Before startup, simulations were
conducted to give board-men better understanding of new system.

HIC-2411 logic implementation

After redundancy of NGBC, feed and fuel gas to Plant-1 and feed gas to Plant2 is supplied through ENCOP 1 & 2 common manifold. Also, Power network
(Gas Turbines) at URUT-1, have also been shifted at compressed fuel through
ENCOPs discharge.
Because of whole site integrated gas network, either ENCOP 1 or ENCOP 2
tripping can cause plant 1 & 2 tripping and worst case scenario can result
into total site black out because of power network failure.
To protect site from total power cut out, HIC-2411 (previously PRC-2411) is
installed on AMM-2 feed line that will actuate automatically in case of
Tripping.
Scenario
ENCOP-1 Trip
ENCOP-2 Trip
ENCOP 1 &2 Trip

LOGIC
HIC-2411 closed
HIC-2411 closed
HIC-2411 close with total site
blackout

In case some job needs to be done on ENCOP-1 or 2, or ENCOP-1 or 2 is to be

manually shut down for maintenance, these logics can be bypassed from
TDC at AMM-2.
In case of normal/bypass, following indication will be displayed on TDC.
Green color indicates normal operation or Active logic status
ENCOP
-1

ENCOP
ENCOP
-1
ENCOP

Purple Color Indicates Bypassed logic

CATACARB NVD TEST RUN

History:
Because of decrease in the quantity of gas available to Engro fertilizers Ltd.
Operation of both plants at optimum operating capacity was not possible. A
study (namely CATACARB NVD project) was carried out to use purification
unit of AMM-2 to Increase methane content of gas which will increase the
maximum capacity of ENVEN which is designed on higher BTU gas.
Test Run:
During TA-2016, a low pressure CATACARB run was carried out. Purpose of
this low pressure run was to check the feasibility of operation of Absorber
and stripper at low pressure up to 200 psig and 7 psig respectively. Several
parameters were monitored during operation to check the efficiency at low
pressure run.
The results were satisfactory as the run was completed without major
setbacks and problems.
Recommendations:
Although, this test run was successful, but still further study needs to be
carried out before actual operation is carried out as the hydrodynamics of
the absorber at lower turndown ratio and lower pressure will be changed
resulting in operational difficulties.
Secondly, due to presence of Sulphur, the modification of solution and cost
incurred with it needs to be analyzed for profitable operations.
Also, unavailability of spares of lean solution pumps and hydraulic turbines
make operation of this process unreliable.

FILTERED FUEL TO F-2501

History:

Mari wells are depleting resulting in a decrease in battery limit pressure.

Moreover, depletion in these wells resulted in an increase in carryover of
salts and impurities which ultimately led to heavy choking of furnace fuel
control valves (TRC-111 and TRC-113) and fuel lines. Although, fuel knock out
drums are installed, but due to increase in impurities and carryover (with the
passage of time), these K.O. drums are at their capacity limit.
Modification:
To avoid such an issue in the future, filtered fuel from ENCOPs suction line
(at upstream of PRC-2401) is taken and used as furnace fuel. Being much
cleaner, and free from foreign matter, this fuel is currently supplied to
furnace.

Startup Highlights
Smooth start
up
Safe Start up
in
first
attempt
without any
problems or
failures.
Major delays

Catacarb Run

CATACARB RUN

Catacarb run
that
was
Catacarb
run
planned pre
that
was
shutdown
planned
initially pre
was
shutdown
of 4 hours
initially
4
but was ofgot
extended
for
hours
but got
more thanfor
10
extended
hoursthan 10
more

hours

Steam circuit
lineup
Steam circuit
was lined up
without issues
of hammering

F-2501catalyst
F-2501CATALYST
unloading

UNLOADING

Difficulty
encountered in
Difficulty
Catalyst
encountered
in
unloading due
Catalyst
unloading
to bottom
cones
due
to
bottom
damage
and
cones
damage and
vacuum
machinemachine
vacuum
inefficiency
inefficiency
let to let
a
to
a
slight
set
slight set back
back

No natural
gas leak
Effective
LOTO
Strategy,
Trainings
ensured
safe start
up
and
shutdown
F-2501
F-2501
unplanned
UNPLANNED
maintenance
jobs
MAINTENANCE
Besides
JOBS
major
jobs
Besides major
that
were
jobs
that
were
planned
at
planned
at
furnace,
furnace,
severalseveral
jobs
jobs
came
thatthat
came
on
and
onspotspot and
weren'tpartpart
weren't
of
of
the
the timeline.
timeline.

Lessons learnt
Although TA-2016 concluded safely without any injury or fatality but there
were a few close calls endangering not only the personnel but also posing
serious threats to the property and equipment. Keeping in view the policy of
Engro to learn from such incidents below is a brief summary of the incidents
and their learnings to prevent such issues from occurring again.
E-2534 vapor outlet flange leakage:
Ammonia level transfer was in progress from Ammonia reservoir (D-2528) to
ammonia chiller (E-2534) and approximately after 5 to 10 minutes, E-2534 vapor
outlet line flange leakage started. Tube cleaning of E-2534 was carried out during TA2016. Approximately 20 persons were working on compressor deck and they felt
ammonia smell as wind direction was from TK-200 to airport gate. One of the
instrument person got ammonia exposure in eyes, while he was helping another
scaffolder who was coming down from compressor deck, as a result of that he
panicked and got his harness entangled in stairs

While handling hazardous services as ammonia, double check need to be

performed from all relevant interfaces to avoid such incidents.
There were almost 20 people working on the compressor deck. During lineup
of ammonia, natural gas or any other hazardous services, area must be
vacated to avoid any potential hazard.
Nitrogen purge test should be done at higher pressures to check for any
leakage in the circuit.
Transfer line incident:
During rigging activity of Secondary reformers transfer line, 100 ton crane with
hanging load (15 Ton) started tilting towards one side when the load almost reached at
its location as the floor caved (~ 2 inches) under one of the out riggers. Load was
carefully secured using multiple chain blocks and subsequently the crane was released
safely.

Although, previous rigging during transfer line removal was done under
similar condition, but base plates were not present beneath the crane out
riggers to evenly distribute load.
Also, a survey prior to rigging should be conducted in rigging area, to ensure
the health of floor/space on which rigging needs to be carried out.

HIC-1110 by-pass sudden opening:

During startup, to maintain pressure of BFW circuit and keep HIC-1110 in operation
control range, HIC-1110 by pass was cracked opened. Due to great difference in
pressure at its upstream and downstream (almost 700# delta), very high force was
exerted on this valve which resulted in its opening on its own. This opening resulted in
indication of low BFW pressure on TDC. Because of excessive force and vibrations,
bolt above valve wheel went flying away. Fortunately, this opening was spotted by
operation team soon when valve was just 3-4 turns open and was manually held in
place to prevent further opening. A mechanical technician nearby was called
immediately and Bolt was tightened. Then gradually the valve was closed.

When high difference in pressure exists, manual valves need to be operated

carefully as there is a chance of such an event.
An operator should have been present there to monitor the valve opening, as
there have been reports of such an incident in the past.
This bypass cannot be declared redundant because of its application. In
future if this manual bypass needs to be operated, then an operator must be
present there as long as this valve is being operated.
E-2515a a plug on head cover came off:
During startup process, the backend circuit was being lined up and venting was shifted
at PIC-132. During pressurization, as the pressure reached 20psig, a plug came out
from E-2515A tube side head cover which resulted in syn-gas leakage and that was
indicated by sudden decrease in pressure at PIC-132. Area operator reported
immediately and flow was stopped from that exchanger towards backend.

Considering the hazard associated with hydrogen service, all necessary

checks should be performed while doing box-ups.
Purge test at higher pressure should be done to detect leakages prior to
actual line ups.
Fire on cold insulation of LIC-367
Fire was observed on cold insulation of valve LIC-367 and its u/s d/s line near E2539A. Further investigation revealed that a welding job at a distance of 3-5 feet was
carried out.

Prior to welding or any hot job surrounding area should be inspected

for presence of any flammable material i.e. cold insulation in above
case.

Fire cloth should be placed properly near the hot job area.
KGT-2501:
After KGT-2501 startup, when machine was ramped up to 3537 RPM, people in the
field heard explosion sounds (2 explosions) inside KGT exhaust plenum. Immediately,
the machine was tripped from Control room. After tripping, very high (987 OF) exhaust
temperature along with erratic vibrations probes readings were observed.

Area Personnel being vigilant and present were able to detect this event on
time. This type of vigilance and presence should be shown in operating area
especially during startups and shutdowns.
Because of machine overhauling, maintenance, and modifications; its
performance parameter should have been re-evaluated to implement
necessary change.
PIC-131 condensate splash:
Absorber vent upstream flange was being opened by standing underneath the same
flange. Suddenly, condensate started showering from flange. Luckily the person was
saved because condensate didnt shower on him. (Permit was given for drain /
depressurized condition. He was not using Face Shield / Splash suit).

During first flange break, there is quite a high chance of occurrence of

unseen events. This was a similar situation when condensate showered. In
anticipation of these events, proper precautions must be taken along with
usage of necessary PPEs, Face shield, Splash suit etc. First flange break
should take place in the presence of Operations personnel.
Superficial cut to FSR at backend
On compressor Deck at AMM-2 backend, an FSR, Mr. Salahuddin received a
superficial cut on his left hand palm while holding a rough scaffolding plank with his
bare hands. Investigation revealed that he was supervising the coupling removal
activity where he was holding a rough plank. He was sent to Clinic and the injury was
reported as FAC.

This kind of incident goes to show how important PPEs are and how their
violation can result in injury. So the importance of PPEs cannot be over
emphasized as they are the last line of defense against any potential injury.
Also, sharp edges of scaffolding should be covered with cloth.
E-2514 BLIND OPENING:

A blinded flange at inlet of E-2514 gas side was opened by DESCON workers during
Hydrotesting activity. The upstream end of the flange was pressurized with ~10psi
nitrogen. Opening of the flange resulted in loud sound and release of gas which is a
violation of issued permit. The work was being performed un-supervised at Catacarb
post during lunch hours

Flange breaking activity should be done in supervision of operations

personnel. During lunch hours, such activities should not be performed.