Mr. Bellary Muhammad Usman Maintenance Superintendent - SAFCO Saudi Arabia

Transcription

1 Replacement of High Pressure Scrubber in SAFCO-II Urea Plant Mr. Bellary Muhammad Usman Maintenance Superintendent - SAFCO Saudi Arabia

2 REPLACEMENT OF HIGH PRESSURE SCRUBBER AT SAFCO UREA PLANT, JUBAIL, SAUDI ARABIA SLIDES - 19 v

3 CONTENTS OBJECTIVE PROJECT CHALLENGES REPLACEMENT OF HIGH PRESSURE SCRUBBER SUCCESS STORY CONTRIBUTING FACTORS PROJECT PHOTOS & VIDEO 1 of 19

4 OBJECTIVE To Share SAFCO experience in, Replacing old H.P. Scrubber with new one to Enhance SF-II Urea Plant Reliability. Events captured during successful replacement of new High Pressure equipment is shared to the benefit of all SABIC Plants. 2 of 19

5 CHALLENGES IN HAND Manufacture and transport new H.P. Scrubber from Austria to SAFCO. Replace the old H.P Scrubber with new one at 80mtr elevation. Remove and restore Connected Piping and Structures to facilitate replacement of H.P. Scrubber. 3 of 19

6 REPLACEMENT OF H.P. SCRUBBER i. PROJECT TARGET ii. iii. PROJECT MILESTONES PRE-SHUT DOWN PHASE- PLANNING iv. SHUT DOWN PHASE - EXECUTION 4 of 19

7 i. PROJECT TARGET This Project is a sequence of unique, complex and connected activities having one goal and that must be completed within Planned duration, within budget and meeting all specifications. GOAL QUALITY CONTROL MONITOR TIME SAFE EXECUTION SET OBJECTIVES/ DELIVERABLES PLAN /ORGANIZE 5 of 19

8 ii. PROJECT MILESTONE (NEW SCRUBBER) 25 th May 11 1 st Sept 10 1 st May 11 2 nd May 11 4th May th May 11 PO issued for Fabrication of New HP Scrubber Ex-work delivery Air lift of HP Scrubber Austria to Dammam HP Scrubber delivered at SAFCO Jubail Urea Plant Shut down to replace Scrubber HP Scrubber replacement project completed and plant production resumed Project Status Activity Contractual Actual Start Completion Start Update Engineering 15/09/ /01/ /09/ /01/2011 Material Order & Delivery Status 11/10/ /04/ /10/ /03/2011 Fabrication & Testing 07/12/ /05/ /12/ /03/2011 Transportation 02/05/ /05/ of 19

9 iii. PRE-SHUTDOWN PHASE PLANNING LOGISTIC PLAN TECHNICAL REPORT FOR STRUCTURAL REMOVAL DESIGN OF VERTICAL STRUCTURE FINALIZATION OF ELECTRICAL AND INSTRUMENTATION SCOPE FINALIZATION OF MECHANICAL SCOPE QUALIFICATION OF CONTRACTOR RIGGING PLAN EHSS PLAN SOIL TREATMENT FOR CRANE FOOTING 7 of 19

10 PRE-SHUTDOWN PHASE PLANNING Contd NEW SCRUBBER PREPARATION HEAVY LIFT CRANE ASSEMBLY WELDERS QUALIFICATION CRANE AND RIGGING TOOLS CERTIFICATION EXECUTION TEAM MEETINGS QUALITY ASSURANCE PLAN APPROVAL 8 of 19

11 iv. SHUT DOWN PHASE- EXECUTION DAILY EHSS MEETINGS DAILY SPARES REVIEW MEETINGS DAILY SHIFT CHANGE OVER MEETINGS DAILY PLANNING MEETINGS DAILY EXECUTION TEAM MEETINGS 9 of 19

12 SUCCES STORY SF-II UREA Before Replacing HP Scrubber 1800 MTPD, Interrupted Production increase PRODUCTION After replacing HP Scrubber 1990 MTPD, Continuous = 190 MTPD 10 of 19

13 CONTRIBUTION FACTORS: SABIC VALUES Contributing factors for the successful story as below, but not limited to these. MOTIVATION AND ENCOURAGING THE EXECUTION TEAM AND CONTRACTORS. UNDERSTANDING THEIR INDIVIDUAL CAPACITIES. CREATED HEALTHY ENVIRONMENT AND ENSURED ENGAGEMENT OF EXECUTION TEAM AND CONTRACTOR THROUHOUT. READY AVAILABILITY OF MANUFACTURING TEAM FOR SUPPORT AND APPROVING INITIATIVES OF EXECUTION TEAM. UNDERSTANDING OF SMT EXPECTATIONS TO DELIVER IN TIME AT OPTIMUM COST. 11 of 19

14 H.P SCRUBEBR CROSS SECTION VIEW 6 x 160 Schd weld joints Various size Bolted joints 12 of 19

15 PHOTOGRAPHS- FABRICATION OF H.P.SCRUBBER 13 of 19

16 PHOTOGRAPHS - TRANSPORT FROM AUSTRIA TO SAUDI ARABIA , Austria , Austria , SAFCO Jubail , on Vertical Stand 14 of 19

17 PHOTOGRAPHS - SOIL PREPARATION 15 of 19

18 PHOTOGRAPHS - OLD SCRUBBER REMOVAL 16 of 19

19 PHOTOGRAPHS - NEW SCRUBBER INSTALLATION 17 of 19

20 Manufacturing Team EHSS SMO Contractors 19 of 19 THANK YOU