1.220 Million $ Cost Optimization in ADGAS plant Maintenance By applying creative ideas (kaizen)

• Done by:

• Ahmed Al Ali

• SIE (Process)

• 30.01.2016 1

New back up air line Removal of redundant VRU panel Replace corroded SOV boxes at plant 19 Replace pump well pressure control valves limit

switches Replace Sulphur shore slop tank RTD junction

boxes Replacement of SOV at LNG jetty entrance Sulphur loading line skin temperature Sulphur loading arm control panel LNG tank D-103 deluge valve cable fault How much we have saved?

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As UAE government has announced 2015 as innovation year and inline with ADGAS innovation strategy (kaizen) we have implemented creative ideas.

During day to day maintenance activities we came across many break downs and repeated problems.

These repeated problems consumes a lot of man hours and materials.

To rectify these problems we have implemented many innovative solutions that resulted in plant reliability and cost optimization by using internal resources.

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Disadvantages of not having back up air header line:

Un availability of Instrument & plant air during compressor shutdown in utility plant.

Consume more energy while using portable air compressor.

Delay the ship loading due un availability of air during utility compressor trip.

Maintenance of loading pumps lifting jobs and all control valves will be delayed.

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Before

6

After

New Air

header

line

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Advantages of new back up air header line:

Continuous availability of instrument air and plant air during air compressors shutdown in utility plant.

Saving Energy, so no need for portable air compressor during shortage of plant & instrument air

Increase the reliability of STOREX instruments while ship loading

Avoid ship delaying time ( Two times plant 28 air compressor failed, Operations used the instrument air backup line and resumed the Sulphur ship loading ).

Easy loading pump lifting maintenance.

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Description cost

Manpower (10

person)

50,000 $

Engineering 20,000 $

Scaffolding 10,000 $

Safety standby 5,000 $

Materials 60,000 $

Ship delay charge 40,000 $ per year

Total 185,000 $

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• Disadvantages of Old panel:

The VRU compressor was tripping due to

panel purge which was not required as

almost all loops were transferred from local

panel to control room during SCSU project.

Space occupied by the panel un-necessary.

Consuming energy for the panel which was

not in use.

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Before

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After

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Advantages of Removal of the panel:

VRU compressor is more reliable and not

tripping.

Enough space is available now for major

shutdown maintenance of compressor.

Energy saving by isolating the power

which was used by redundant panel.

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Description Cost

Manpower 40,000 $

Mobilization 10,000 $

Materials 20,000 $

Accommodation &

food

10,000 $

Production loss per

year

20,000 $

Total 100,000 $

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• Disadvantages of old SOV boxes:

1- Pilot flare Auto Ignition system some

times fail to operate due to corroded & old

tubing's.

2- Difficult to remove SOV’s for

maintenance.

3- Difficult to replace the faulty SOV’s.

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Before

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After

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Advantages of new modification:

1- Easy maintenance.

2- Long life working condition of the

solenoid valves.

3- Pilot flare Auto Ignition system is

reliable.

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Description cost

Manpower 40,000 $

Mobilization 10,000 $

Materials 20,000 $

Accommodation &

food

10,000 $

Total 80,000 $

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Disadvantages of Old mechanical lever operated limit switches:

Un availability of valves feedback indication due to mechanical lever getting stuck.

Frequent failure of mechanical levers due to corrosive atmosphere.

Consume more materials for the maintenance.

Consume more man hours for repair and replace the limit switches.

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Old mechanical

lever operated

limit switches

Before

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New magnetic

operated limit

switches

After

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Advantages of new magnetic limit switches:

Maintenance free due to no mechanical moving parts (lever).

Saving Man hours. Increase the reliability of the pump pressure

control valves. Saving cost of Materials. More efficient system for Operations to

confirm the valves position.

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Description cost

Manpower (6

person) for 60 days

80,000 $

Engineering 20,000 $

Safety standby 5,000 $

Materials 70,000 $

Total 175,000 $

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Disadvantages of Old RTD JB’s:

Getting corroded and damaging frequently since it was metal JB’s affected by corrosive atmosphere.

Located inside confined space which is always required safety standby for maintenance.

Maintenance team exposure to toxic gases. Required scaffolding whenever routine or

break down jobs there.

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Before

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After

New FRP

junction

boxes outside

confined space

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Advantages of new RTD junction boxes:

No toxic gases exposure for maintenance team

Easy maintenance because we have shifted the JB’s outside the slop tank pit.

Scaffolding not required. Safety standby not required. New JB’s not getting corroded very fast,

since we have used FRP material.

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Description cost

Manpower per

year

20,000 $

Scaffolding 10,000 $

Safety standby 5,000 $

Total 35,000 $

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Disadvantages:

1- Difficult to maintain the SOV’s.

2- Isolation valves were seized and difficult

to operate for replacement of faulty SOV’s.

3- Delay the ship loading during SOV

failure.

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Before

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After

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Advantages of new isolation valve and Mounting plate:

1- Easy maintenance. 2- Made the LNG & LPG loading Process more reliable. 3- Avoid unwanted ESD. 4- New SOV by pass valves provided for immediate resuming of loading / circulation in case of SOV failure.

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Disadvantages of Sulphur loading line without skin temperature indication: Line getting frequently chocked which

was causing delay Sulphur ship loading. Difficult to trace out the Sulphur blockage

in the loading line. Consuming more manpower and time. More energy consumption to remove the

chock from the line.

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Before

Sulphur

Loading line

without Temp.

points

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New Temp.

Control

Panel

New Temp.

Element with

SS conduit

New Temp.

Element

JB

After

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Advantages of new skin temperature ( 36 points) in Sulphur loading line: Sulphur loading line not getting frequently chock

as Operations having now facility to monitor the temperature and take action immediately.

Easy to identify the location of the blockage in the loading line.

Saving manpower and time. Saving energy. Saving the cost of the cables for new system by

using excess cables from old projects which were lying in the salvage yard.

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Description cost

Manpower 20 technicians X

30 days = 55,000 $

Mobilization 20,000 $

Materials 115,000 $

Accommodation &

food

10,000 $

Total 200,000 $

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Description:

An incident had taken place when

Sulphur ship hit jetty #5 during berthing.

This incident caused the damage of the

control panel.

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Disadvantages of giving contract to

replace the control panel:

High cost to bring the vendor.

Long time to finish all the formalities to

bring the vendor on site which will delay

the ship loading.

Consuming more manpower and

materials.

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Before

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Before

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After

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Advantages of Replacement of control panel with new using internal resources: Saving the cost of the vendor and labour. Save the time by fabricating new panel with

internal wiring and fixing on site. Saving manpower and time. Save the cost of material by using available

materials in our stock and some from non movable items.

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Description cost

Manpower 50, 000 $

Mobilization 20,000 $

Panel 100,000 $

Accommodation &

food

10,000 $

Total 180,000 $

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Disadvantages:

Non availability of deluge valve during

fire emergency.

To rectify this fault it was required to

replace 250 meter underground control

cable which can be done through outside

contractor which means high cost for

material and manpower.

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Before

D-103 Deluge valve faulty cable

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After

New Junction

box installed

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Advantages of new modification: Continuous availability of Deluge valves. Rectified Long standing cable fault. Deluge valve ( fire water system ) put back

on service which was not operate able for long period.

Saved the cost of replacing 250 meter multi core underground control cable.

Saved the cost of CIVIL work ( Opening / closing trenches, excavation, remove and relaying cable ).

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Description cost

Manpower (15

person)

40,000 $

Engineering 10,000 $

Scaffolding 20,000 $

Safety standby 10,000 $

Materials 100,000 $

Civil works 100,000 $

Total 280,000 $

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Description Cost

New back up air line

185,000 $

Removal of redundant VRU panel 100,000 $

Replace corroded SOV boxes at

plant 19

80,000 $

Replace pump well pressure

control valves limit switches

175,000 $

Replace Sulphur shore slop tank

RTD junction boxes

35,000 $

Sulphur loading line skin

temperature

200,000 $

Sulphur loading arm control panel 180,000 $

LNG tank D-103 deluge valve

cable fault

280,000 $

Total 1,220,000 $

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Thank you