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Replacement of High Pressure Scrubber in SAFCO-II Urea Plant

Mr. Bellary Muhammad Usman Maintenance Superintendent - SAFCO Saudi Arabia


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


CONTENTS 

OBJECTIVE

PROJECT CHALLENGES

REPLACEMENT OF HIGH PRESSURE SCRUBBER

SUCCESS STORY

CONTRIBUTING FACTORS

PROJECT PHOTOS & VIDEO

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All good performance starts with clear goals.”


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.

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All good performance starts with clear goals.”


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.

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All good performance starts with clear goals.”


REPLACEMENT OF H.P. SCRUBBER

i.

PROJECT TARGET

ii.

PROJECT MILESTONES

iii.

PRE-SHUT DOWN PHASE- PLANNING

iv.

SHUT DOWN PHASE - EXECUTION

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All good performance starts with clear goals.”


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

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All good performance starts with clear goals.�


ii.

PROJECT MILESTONE (NEW SCRUBBER) 25th May 11

1st Sept ‘10

1st May ‘11

PO issued for Fabrication of New HP Scrubber

Ex-work delivery

2nd May 11

Air lift of HP Scrubber Austria to Dammam

4th May 11

11th May 11

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 Start Completion

Actual Start

Update

Engineering Material Order & Delivery Status Fabrication & Testing

15/09/2010

07/01/2011

15/09/2010

07/01/2011

11/10/2010

07/04/2011

11/10/2010

01/03/2011

07/12/2010

01/05/2011

07/12/2010

01/03/2011

Transportation

02/05/2011

02/05/2011

02.05.2011

02.05.2011

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All good performance starts with clear goals.”


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

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All good performance starts with clear goals.”


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

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All good performance starts with clear goals.”


iv.

SHUT DOWN PHASE- EXECUTION

DAILY EHSS MEETINGS

DAILY SPARES REVIEW MEETINGS

DAILY PLANNING MEETINGS 9 of 19

DAILY SHIFT CHANGE OVER MEETINGS

DAILY EXECUTION TEAM MEETINGS

All good performance starts with clear goals.”


SUCCES STORY

Before Replacing HP SF-II UREA PRODUCTION

Scrubber After replacing HP Scrubber

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1800 MTPD , Interrupted

1990 MTPD, Continuous

All good performance starts with clear goals.�

Production increase = 190 MTPD


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

All good performance starts with clear goals.”


H.P SCRUBEBR CROSS SECTION VIEW

6” x 160 Schd weld joints

Various size Bolted joints

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All good performance starts with clear goals.”


PHOTOGRAPHS- FABRICATION OF H.P.SCRUBBER

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All good performance starts with clear goals.”


PHOTOGRAPHS

-

TRANSPORT FROM AUSTRIA TO SAUDI ARABIA

01.05.2011, Austria

02.05.2011, Austria

04.05.2011, SAFCO Jubail

05.05.2011, on Vertical Stand

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All good performance starts with clear goals.”


PHOTOGRAPHS - SOIL PREPARATION

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All good performance starts with clear goals.”


PHOTOGRAPHS - OLD SCRUBBER REMOVAL

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All good performance starts with clear goals.”


PHOTOGRAPHS - NEW SCRUBBER INSTALLATION

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All good performance starts with clear goals.”


EHSS

Manufacturing Team

Contractors

SMO

THANK YOU 19 of 19

All good performance starts with clear goals.�


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