Replacement of High Pressure Scrubber in SAFCO-II Urea Plant

Mr. Bellary Muhammad Usman

Maintenance Superintendent - SAFCO

Saudi Arabia

v

REPLACEMENT OF

HIGH PRESSURE SCRUBBER AT

SAFCO UREA PLANT,

JUBAIL, SAUDI ARABIA

SLIDES - 19

CONTENTS

OBJECTIVE

PROJECT CHALLENGES

REPLACEMENT OF HIGH PRESSURE SCRUBBER

SUCCESS STORY

CONTRIBUTING FACTORS

PROJECT PHOTOS & VIDEO

All good performance starts with clear goals.”1 of 19

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.

All good performance starts with clear goals.”2 of 19

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.

All good performance starts with clear goals.”3 of 19

i. PROJECT TARGET

ii. PROJECT MILESTONES

iii. PRE-SHUT DOWN PHASE- PLANNING

iv. SHUT DOWN PHASE - EXECUTION

All good performance starts with clear goals.”

REPLACEMENT OF H.P. SCRUBBER

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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.

i. PROJECT TARGET

GOAL

QUALITY CONTROL

MONITOR TIME

SAFE EXECUTION

PLAN /ORGANIZE

SET OBJECTIVES/DELIVERABLES

All good performance starts with clear goals.”5 of 19

ii. PROJECT MILESTONE (NEW SCRUBBER)

PO issued for

Fabrication of New HP Scrubber

Ex-work delivery

1st Sept ‘10 1st May ‘11 2nd May 11

Air lift of HP

Scrubber Austria to Dammam

4th May 11

HP Scrubber delivered at SAFCO

Jubail

25th May 11

HP Scrubber replacement

project completed and plant

production resumed

11th May 11

Urea Plant Shut

down to replace

Scrubber

All good performance starts with clear goals.”6 of 19

ActivityProject Status

Contractual ActualStart Completion Start Update

Engineering 15/09/2010 07/01/2011 15/09/2010 07/01/2011Material Order & Delivery Status 11/10/2010 07/04/2011 11/10/2010 01/03/2011

Fabrication & Testing 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

RIGGING PLAN EHSS PLANSOIL TREATMENT

FOR CRANE FOOTING

FINALIZATION OF ELECTRICAL AND

INSTRUMENTATION SCOPE

FINALIZATION OF MECHANICAL

SCOPE

QUALIFICATION OF CONTRACTOR

LOGISTIC PLAN

TECHNICAL REPORT FOR STRUCTURAL

REMOVAL

DESIGN OF VERTICAL

STRUCTURE

iii. PRE-SHUTDOWN PHASE PLANNING

All good performance starts with clear goals.”7 of 19

NEW SCRUBBER PREPARATION

HEAVY LIFT CRANE ASSEMBLY

WELDERS QUALIFICATION

CRANE AND RIGGING TOOLS CERTIFICATION

EXECUTION TEAM MEETINGS

QUALITY ASSURANCE PLAN

APPROVAL

PRE-SHUTDOWN PHASE PLANNING Contd ▪ ▪ ▪

All good performance starts with clear goals.”8 of 19

iv. SHUT DOWN PHASE- EXECUTION

All good performance starts with clear goals.”9 of 19

DAILY EHSS MEETINGS

DAILY SHIFT CHANGE OVER

MEETINGS

DAILY EXECUTION

TEAM MEETINGS

DAILY PLANNING MEETINGS

DAILY SPARES REVIEW

MEETINGS

SF-II UREA

PRODUCTION

Before

Replacing HP

Scrubber

1800 MTPD ,

InterruptedProduction

increase

=

190 MTPD

After

replacing HP

Scrubber

1990 MTPD,

Continuous

All good performance starts with clear goals.”

SUCCES STORY

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MOTIVATION AND ENCOURAGING THE EXECUTION TEAM AND CONTRACTORS.UNDERSTANDING THEIR INDIVIDUAL CAPACITIES.

Contributing factors for the successful story as below, but not limited to these …………………….

CONTRIBUTION FACTORS: SABIC VALUES

All good performance starts with clear goals.”11 of 19

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.

H.P SCRUBEBR CROSS SECTION VIEW

6” x 160 Schd weld joints

Various size Bolted joints

All good performance starts with clear goals.”12 of 19

All good performance starts with clear goals.”

PHOTOGRAPHS- FABRICATION OF H.P.SCRUBBER

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PHOTOGRAPHS - TRANSPORT FROM AUSTRIA TO SAUDI ARABIA

All good performance starts with clear goals.”

01.05.2011, Austria 02.05.2011, Austria

04.05.2011, SAFCO Jubail 05.05.2011, on Vertical Stand

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PHOTOGRAPHS - SOIL PREPARATION

All good performance starts with clear goals.”15 of 19

PHOTOGRAPHS - OLD SCRUBBER REMOVAL

All good performance starts with clear goals.”16 of 19

PHOTOGRAPHS - NEW SCRUBBER INSTALLATION

All good performance starts with clear goals.”17 of 19

Manufacturing Team

EHSS

ContractorsSMO

THANK YOUAll good performance starts with clear goals.”19 of 19