PRE-COMMISSIONING & COMMISSIONING EXPERIENCES

ON AMMONIA AND UREA PLANTS Mümin HACIMUSALAR

(Independent) Professional Commissioning

Manager / Consultant muminha@isnet.net.tr

mhacimusalar@mail.com Mobile: +905337746920

Ankara - Turkey

Presentation Update for Nitrogen + Syngas 2016

29 February - 03 March 2016 – Estrel Berlin, Germany

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Projects

1. Turkmendokunhimiya Tecen Ammonia and Urea Project, 2005, Turkmenistan

2. AlexFert Ammonia and Urea Project, 2006, Alexandria, Egypt

3. MOPCO-I Ammonia and Urea Project, 2008, Damietta, Egypt

4. Engro Ammonia and Urea Project, 2010, Daharki, Pakistan

5. Sorfert Ammonia and Urea Project, 2013, Arzew, Algeria

6. Turkmenhimiya Mary Ammonia and Urea Project, 2014, Turkmenistan

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1. Tecen Ammonia and Urea Complex Precommissioning And Commissioning Diary

600MT/day Ammonia–Uhde, 1050 MT/day Urea–Stamicarbon; Granulation-HFT

Tecen / Turkmenistan: 2002-2005

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2003 Plant Site - Turkmenistan

July 2004 Started Pre-commissioning and Commissioning

Activities

Raw Water Available (Water Intake 25 km from Plant B.L.)

Fire Water System In Operation

Temporary Cooling Tower In Operation

August 2004 Waste Water System In Operation

Instrument & Service Air Available

Nitrogen Generation Unit In Operation

Drinking Water Available

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September 2004

Water Treatment Unit In Operation

Demin Water Unit In Operation

Deaerator and Motor Driven BFW Pump In Operation

Mechanical Cleaning of Cooling Water System Before First Water Filling / Flushing

Steam Boiler Fuel Gas System Ready to Service (Awaiting Natural Gas)

Started Precommissioning of Steam Boiler

Started Air Blowing of Ammonia Plant Front-End Utilizing Desulphurization Unit As Buffer Vessel

Started Oil Flushing for Turbines/Compressor

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OCTOBER 2004

Natural Gas Available at the Metering Station (5 Km from Plant Battery Limit)

Blowing of Natural Gas Supply Line to Plant B.L. Using Natural Gas; Installed a Blow-Off Pipe to Safe Location at Plant B.L. and then Blown-Out the NG Supply Line Utilizing Natural Gas from the Metering Station

Fuel Gas System to Steam Boiler In Service Steam Boiler In Operation (45 Bar; MP Steam) Started Steam Blowing of MP Steam System Test Operation of Natural Gas/Start-up Compressor Reactors are ready to Catalyst Filling

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Blowing of Natural Gas Supply Line Using Natural Gas

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Blowing of Natural Gas Supply Line Using Natural Gas

November 2004

Steam Blowing of Ammonia Plant Going on (HP-115 barg; MP-45 barg; LP-3,5 barg)

Natural Gas/Start-up Compressor Ready to Operation

Completed Oil Flushing of Steam Turbines/Compressors

Preparation of Steam Turbines for Over-speed Tests

Ammonia Storage Tank Ready to Service

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December 2004

Reformer Combustion Air (FD) Fan and Flue Gas (ID) Fan Test Operation

Started Urea Steam System Blowing Carried out Steam Drum & WHB Chemical Cleaning

and Boiling Out Air Blowing of Ammonia Refrigeration System Reformer Fuel Gas System Tightness Test Over-speed Test of BFW Pump Turbine Cooling Water System In Operation Completed Over-speed Tests for Turbines

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January 2005

First Feed In Reformer Ammonia Plant Front-End In Operation LTS Converter Catalyst Reduction Done (But Not

Put Into Service) CO2 Removal System In Operation Blowing of CO2 Line to CO2 Compressor by Means

of CO2 from CO2 Removal System Test operation of CO2 Compressor Draw-back Process Gas to CO2 Removal System

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February 2005

Introduced Process Air to Secondary Reformer LTS Converter Catalyst Dedusting, LTS Online CO2 Removal System Online / Stabilization Methanation Online Ammonia Refrigeration System In Operation Synthesis Compressor In Operation 15 Feb. 2005: FIRST AMMONIA PRODUCTION CO2 Compressor Surge Mapping 21 Feb.2005: Completed Ammonia Converter

Catalyst Reduction 28 Feb.2005: FIRST UREA PRODUCTION

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Tecen Project PRECOMMISSIONING/COMMISSIONING PERIOD TO

FIRST UREA PRODUCTION July 2004 – Feb. 2005: 8 MONTHS

*TURN-KEY PROJECT*

(By GAP INSAAT, ISTANBUL-TURKEY)

FROM PROJECT EFFECTIVE DATE TO FIRST UREA PRODUCTION

March 2002 – February 2005: 36 MONTHS

PROJECT TARGET SCHEDULE TO FIRTS UREA PRODUCTION

31 MONTHS PROJECT DELAY: 5 MONTHS

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First Urea Granules / Turkmenistan

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Ammonia And Urea Complex - Turkmenistan

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2. AlexFert Ammonia And Urea Complex

1200 MT/day Ammonia–Uhde Technology 1925 MT/day Urea–Stamicarbon Technology

Granulation–Stamicarbon Technology

2005 – 2006 Alexandria / Egypt

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AlexFert Ammonia And Urea Complex / Egypt

AlexFert Ammonia And Urea Complex / Egypt Commissioning Milestones

01 Nov. 2005: Started Precommissioning And Commissioning Activities

24 Jan.–10 Mar. 2006: Precommissioning And Commissioning of Steam Boiler

04–28 Mar 2006: Steam Blowing of Ammonia Plant 02 May 2006: FIRST FEED IN REFORMER 18 June 2006: FIRST AMMONIA PRODUCTION 25 June 2006: Completed Catalyst Reduction 28 June 2006: Shutdown Ammonia Back-End Due to Heavy

Leakage on Ammonia Separator Level Transmitter 09 July 2006: Urea Synthesis Water Run with CO2 (~140 bar) 12 July 2006: FIRST UREA PRODUCTION

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AlexFert Project PRECOMMISSIONING/COMMISSIONING PERIOD TO

FIRST UREA PRODUCTION: 01 Nov 2005 – 12 July 2006: 8.5 MONTHS

*TURN-KEY PROJECT*

(By Krupp Uhde GmbH, Germany)

FROM PROJECT EFFECTIVE DATE TO FIRST UREA PRODUCTION:

December 2003 – July 2006): 32 MONTHS

PROJECT TARGET SCHEDULE TO FIRTS UREA PRODUCTION 34 MONTHS

PROJECT EARLY COMPLETION: 2 MONTHS

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3. Mopco-I Ammonia And Urea

Complex

1200 MT/day Ammonia–Uhde Technology 1925 MT/day Urea–Stamicarbon Technology

Granulation–Uhde Fertilizer Technology (UFT)

2007 – 2008 Damietta / Egypt

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Mopco-I Ammonia And Urea Complex

MOPCO-I Ammonia And Urea Complex Commissioning Milestones (1)

September 2007 To April 2008:

Carried out Precommissioning And Commissioning of Off-Sites & Utilities

Flushing / Air Blowing of Ammonia Units

*** 3 Months Delay In Providing Natural Gas ***

03 April 2008: Pigging of Natural Gas Line to Metering Station

05 April: Natural Gas Available At the Plant B.L.

07 April: Ignition of Steam Boiler Burners And Commissioning

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Mopco-I Ammonia And Urea Complex 03 April 2008: Metering Station; Pigging of Natural Gas Supply Line

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Mopco-I Ammonia And Urea Complex 05 April 2008: Natural Gas Available At Metering Station

MOPCO-I Ammonia And Urea Complex Commissioning Milestones (2)

21 April–05 May 2008: Steam Blowing (HP/MP/LP) 24 May: FIRST FEED IN REFORMER, Catalyst Reduction 21 June: P. Air Compressor Test Operation, Blowing and

Surge Mapping 24 June: Power Generator Test Operation 09 July: Ammonia Refrigeration Compressor Test Operation 28 July: Synthesis Gas Compressor Test Operation 29 July: CO2 Compressor Test Operation 04 Aug: Started Ammonia Catalyst Reduction 06 Aug: FIRST AMMONIA PRODUCTION 10 Aug: CO2 Compressor Surge Mapping 11 Aug: Urea Synthesis Water Run With CO2 (~140 Bar) 13 Aug: Completed Ammonia Converter Catalyst Reduction 14 Aug 2008: FIRST GRANULE UREA PRODUCTION

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Mopco-I Project PRECOMMISSIONING/COMMISSIONING PERIOD TO FIRST UREA

PRODUCTION: SEP 2007 – AUG 2008: 11 MONTHS

FROM NATURAL GAS PROVISION TO FIRST UREA GRANULE

(03 APR–16 AUG 2008) : 4 MONTHS

*TURN-KEY PROJECT* (By Krupp Uhde GmbH, Germany)

FROM PROJECT EFFECTIVE DATE TO FIRST UREA PRODUCTION:

SEP 2005 – AUG 2008: 35 MONTHS

PROJECT TARGET SCHEDULE TO FIRTS UREA PRODUCTION 33 MONTHS

PROJECT DELAY: 2 MONTHS (Due To 3 Months Delay On N.G. Provision)

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4. Engro Fertilizer Project 2200 MTPD Ammonia Plant/Haldor Topsoe, 3835 MTPD Urea Prilled/Snamprogetti

Daharki – Pakistan: 2009-2011

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Engro Project – Pakistan Precommissioning / Commissioning Milestones

No MAJOR PROJECT EVENTS Completion

Date Duration

(Day)

1 Started Pre-commissioning 1-Jun-2009 1

2 Raw Water Available & Plant Effluent System Ready (Owner Scope)

1-Oct-2009 122

3 Natural Gas Available at Site (Owner Scope) 6-Nov-2009 158

4 Commissioning of Gas Turbine and & Power Generation (Owner Scope)

25-Nov-2009 177

5 Commissioning of HRSG (Heat Recovery Steam System; Owner Scope)

2-Jan-2010 215

6 P. Air Comp. Commissioning and Surge Mapping & Ready For Air blowing

29-Jun-2010 393

7 Commissioning of KS/HS Steam Systems and Boiler Blow Down System

4-Nov-2010 521

8 FEED IN REFORMER 11-Nov-2010 528

9 UREA SYNTHESIS LEAK TEST 21-Nov-2010 538

10 Ammonia Synthesis Loop & ARU Pneumatic Test 22-Nov-2010 539

11 FIRST AMMONIA PRODUCTION 26-Dec-2010 573

12 FIRST UREA PRODUCTION 29-Dec-2010 576

ENGRO FERTILIZER PROJECT DAHARKI/PAKISTAN

PRECOMMISSIONING/COMMISSIONING PERIOD TO FIRST UREA PRODUCTION:

Jun 2009 – Dec 2010: 19 MONTHS

*EP+LIMITED SUPERVISION CONTRACT* (By SAIPEM S.p.A., Italy)

FROM PROJECT EFFECTIVE DATE TO FIRST UREA

PRODUCTION: April 2007 – December 2010: 45 MONTHS

PROJECT TARGET SCHEDULE TO FIRTS UREA PRODUCTION

37 MONTHS PROJECT DELAY: 8 MONTHS

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5. Sorfert Fertilizer Project 2x2200 MT/day Ammonia–Uhde, 3450 MT/day Urea–Stamicarbon; Granulation-UFT

Arzew – Algeria: Dec 2011 – June 2013

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SORFERT FERTILIZER PROJECT / Arzew–ALGERIA

TRAIN-1: AMMONIA 1 / UREA AND GRANULATION

PRECOMMISSIONING AND COMMISSIONING PERIOD TO FIRST UREA PRODUCTION: Nov 2010-May 2012; 19 MONTHS

*EP+SUPERVISION CONTRACT* (By Krupp Uhde GmbH, Germany)

FROM PROJECT EFFECTIVE DATE TO FIRST UREA PRODUCTION: (June 2007 – May 2012) 59 MONTHS

PROJECT TARGET SCHEDULE TO FIRTS UREA PRODUCTION: 42 MONTHS

PROJECT DELAY FOR TRAIN 1: 17 MONTHS

AMMONIA TRAIN-2

PRECOMMISSIONING PERIOD: (April 2012–December 2012) 9 MONTHS (*)

(*) READY FOR GAS FEED IN / INITIAL START UP as of Dec. 2012 WAITING FOR ALGERIAN AUTHORITY–ARH–OPERATION PERMIT

Ammonia Production: September 2013 Project Realization Time to First Ammonia Production : September 2013 ; 75

months from project start date with 27 months delay

6. Mary Fertilizer Project 1200 MT/day Ammonia–M.W. Kellog Limited, 1925 MT/day Urea–Stamicarbon; Granulation–UFT

Mary – Turkmenistan: 2013 - 2014

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Turkmenistan Mary Fertilizer Project

PRECOMMISSIONING/COMMISSIONING PERIOD TO FIRST UREA PRODUCTION:

(15 July 2013 – 20 September 2014) 14 MONTHS

*EP+SUPERVISION CONTRACT* (By Kawasaki Heavy Industries, Kobe-Japan)

FROM PROJECT EFFECTIVE DATE TO FIRST UREA

PRODUCTION: (January 2011 – September 2014) 45 MONTHS

PROJECT TARGET SCHEDULE TO FIRTS UREA PRODUCTION:

42 MONTHS PROJECT DELAY: 3 MONTHS

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Turkmenistan Mary Fertilizer Project Commissioning Progress

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Projects Summary / Overviews

Project Name, Location, Plant Size and Year

Contract Type

Pre / Commissioning

Time (M)

Time to First Urea Granule

(M)

Project Target Urea (M)

Time Deviation

(M)

Tecen, Turkmenistan 600 MTPD Ammonia;1050 MTPD Urea (2002 – 2005)

Turn-key 8 M 36 M 31 M 5 M delay

AlexFert, Egypt 1200 MTPD Ammonia; 1925 MTPD Urea (2003 – 2006)

Turn-key 8,5 M 32 M 34 M 2 M early

Mopco, Egypt 1200 MTPD Ammonia; 1925 MTPD Urea (2005 – 2008)

Turn-key 11 M (*) 35 M 33 M 2 M delay

Engro, Pakistan 2200 MTPD Ammonia; 3835

MTPD Urea (2007 – 2011)

EP + Limited Supervision

19 M 45 M 37 M 8 M delay

Sorfert, Algeria 2x2200 MTPD Ammonia; 3450

MTPD Urea (2007 – 2013)

EP+ Supervision

Train-1: 19M Train-2: 27M

(**)

Train-1: 59M Train-2: 75M

Train 1: 42M Train 2: 48M

17 M delay 27 M delay

Mary, Turkmenistan 1200 MTPD Ammonia; 1925

MTPD Urea (2011 – 2014)

EP+ Supervision

14 M 45 M 42 M 3 M delay

(* ) 3 months delay in providing natural gas supply (**)Train 2: Precommissioning was conducted within 9 months. However due to environmental and export permits issue from local authorities the commissioning of the plant was suspended for 16 months. M: Month

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Conclusions / Observations (1) • Only 1 out of 6 projects, a turn-key project; AlexFert, Egypt, was completed

earlier than expected.

• It is stated that turnkey contract projects were completed faster than EP contracts.

The most common causes of delay observed on the projects can be identified as follows depending on the project location and countries:

1. Visa provision for expatriates

2. Language, lack of English speaker

3. Lack of Experienced manpower of owner, contractor or consultant

4. Frequent change of labor or staff; Contractor, Subcontractor, Owner

5. Poor HSE (Health, Safety and Environment) management

6. Provision of operation spare parts

7. Poor Communication / coordination in the workplace and among the project team members and parties

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Conclusions / Observations (2)

8. Insufficient task priority assignment, project tracking to determine the Critical Path & Expected Completion Time

9. Unqualified subcontractor(s)

10.Poor site management, supervision of EP Contractors

11. Shipping and supply delays; material procurement / delivery, import or export formalities

12.Extreme climatic conditions; weather disruptions or natural disasters, unexpected rains & floods

13.Design errors, design change

14.Change orders or deviation order; by EP Contractor or Owner

15.Unforeseen ground conditions for implementation of projects, faulty soil investigation report, de-watering

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Conclusions / Observations (3)

16.Conflicts between owner and other Stakeholders of Project

17.Bureaucracy in owner’s organization

18.Improper Factory Acceptance Test (FAT)

19.Local industrial peace and labor issues, public demonstrations

20.Poor inspection and testing techniques methods

21.Delay in obtaining permissions & approvals from Local Authorities

22.Financial Constraints of contractor / owner

23.Improper storage / preservation conditions of materials leading to damaged material when necessary

24.Unnecessary restrictions to access at site

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Recommendations (1)

1. The most common causes of delay observed on the projects were listed in the previous section; need to be improved

2. Project on Turnkey Basis (EPC Contract; minimize project schedule)

3. Availability of Mechanical Completion and Project Progress Monitoring and Control Systems (ICAPS, WinPCS, …)

4. Work on non-destructive testing (NDT) methods from the initial phase of construction

5. Availability of Detailed –STEPWISE-Pre-Commissioning Procedure to guide Construction / Erection / Pre-commissioning / Commissioning

6. CONTRACTOR’S and OWNER’s Organization Chart corresponding to each other in terms of Pre-commissioning / Commissioning and Normal Operation Responsibilities

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Recommendations (2) 7. Assignment of expert Operators / Engineers for all disciplines

(Operation, Electric, Instrumentation, Machinery, Mechanic and Administrative) as well as new trainees.

8. A Dedicated Operation Team should be assigned for each system or Unit (Continuity is important; do not change team members).

9. Sometimes, extended or unusual work shifts are required during pre-commissioning / commissioning and start-up

10. Pre-commissioning / Commissioning period is the right time for training of Owner’s Operation team who will operate the plant: They can learn a lot only during pre-commissioning and commissioning phases.

11. Task Force Teams can be formed for the systems / subsystems or units which has high priorities

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Recommendations (3)

12. Owner's close follow up is necessary for any activities at plant site. Project Manager / Unit Managers / Engineers / Operators should study their lessons (procedures, operating manual, P&ID etc.)

13. Close communication and coordination between all project parties are always essential.

14. Availability of Temporary Cooling Tower for Initial Start Up (to be used for Nitrogen generation, Instrument- Service Air, Steam Boiler / BFW)

15. Commissioning Spares / Operation Spares Availability

16. Respect people; no matter who they are. Treat them properly!

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THANK YOU!