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SAFETY PRECAUTIONS
DURING MARCH’09
SHUT DOWN
PRESENTED BY,
Mr. Jahanzeb Khan
Date: 07.03.11

KRIBHCO SHYAM FERTILISER LTD.
AMMONIA PLANT
 COMMISSIONED ON
22/11/1995
 REASSESSED CAPACITY
1520 MTPD
(w.e.f. 01/04/2000)
 TECHNOLOGY
HALDOR TOPSOE
UREA PLANT
 COMMISSIONED ON
23/11/1995
 REASSESSED CAPACITY
2 X 1310 MTPD
(w.e.f. 01/04/2000)
 TECHNOLOGY
SNAM PROGETTI

ATR- March 2009
 Duration- 19.5 Days
 Dates
-Start of shut down : 13/03/2009
-Urea one unit production : 31/03/2009
-Ammonia production : 01/04/2009
-Urea 2nd
unit start up: 01/04/2009

Ammonia Plant
-Primary reformer tube & catalyst replacement.
-Secondary reformer job
-RG Boiler job
-HTS Catalyst job
-Synthesis gas turbine overhauling
-Ammonia converter jobs
-Synthesis loop boiler Replacement
MAJOR JOBS

Energy saving Schemes
 Ammonia Product Heater installation
 PR NG Fuel pre heating
 PAC discharge line modification
 CAPH duct modification
 Ammonia Plant DCS replacement

Urea Plant
 Urea reactors and stripper inspection
 Exchangers cleaning
 Blow down and vent stack pipe replacement
 HP passivation air compressor installation
 Prilling Tower epoxy coating
 Bentley Nevada vibration monitoring system
hook up

Offsites
 CT return header shifting Job
 GTG-I Generator overhauling

Why Annual Turnarounds ????
 ATR, a planned activity- annually or biannually
 Annual turnarounds for:
-Jobs – Breakdowns, repairs, overhauls, improvements,
modifications etc
-Statutory compliances
-Cleaning of equipment
-Catalyst loading, washings, internal repairs
-Inspections and testing of equipment & machines
-Adding new equipments
-Up gradations & replacements

Shutdown job lists
 ATR job list include
-Uncompleted jobs from the previous ATR
-Jobs identified during the entire year
-Special inspections – statutory, testing,
improvements
-Jobs out of analysis reports – NDT, tech suppliers,
OEMs
-Jobs that can be only done during utilities stoppage
-Jobs on vessels for catalyst change, cleaning,
repairs etc

Jobs Planning
 Job lists reviewed on monthly basis between
departments
 Unique job number for each job which gets frozen
 All jobs are identified & tagged in field before ATR
 Each job planned – manpower, material & timelines
 Bar chart for major planned jobs
 Spacing of jobs as per vendor availability
 Risk assessment for each job by process &
maintenance
 No job done without a permit

Material / Spares planning
 Done well in advance – ATR material separately
identified
 Early orders for each critical items & OEM supplies
 All temporary lines, fittings, structures - pre fabricated
 Prior testing & overhauling of equipments like
 Cranes, forklifts, lifting tools etc
 Access equipment, hydraulic platforms etc
 Portable tools like grinders, drills, welding machines etc
 Advance availability of materials & tools from
contractors

Services planning
 Advance intimation of the ATR dates to all
 Pre visits of service providers for job understanding
 Tests for skilled workers conducted – welders,
riggers etc
 Clear guidelines for safety in job execution
 Safety training given in advance to all external work
force

Annual Turn Around – Job Cycle
Start
Preparation of ATR job list
Meetings between Production & Maintenance
functions to finalize the Shut Down Manual.
Check the Risk
Assessments
Identify the Safety Guide lines
/ PPE requirements
Inputs:
Maintenance repairs
Inspections
Process requirements
NDT recommendations
Cleaning
Carry out risk
assessment
Continued ……
YES
No

JOB CYCLE…. Continued
Include all Guide line in Shut Down
Manual against Each Job.
Hand Over the S/D Manual to all
Concerned Dept. /Section/ Persons
Stoppage, Isolation and Purging
of Equipments as Per SOP
Issue the SWP for
Maintenance crew
Return all SWP
after completing
the Job to S/I
Updation on SAP
Trial Run by
Production
Carry out the job with
full Adherence of SWP
Guidelines

Process Planning – Shutdown Manual
 A Comprehensive Process Handbook which includes:
 Schedule of shutdown & start up
 Detailed job lists (Area wise) & Bar chart for major jobs
 Risk assessment of each activity
 Procedures for Shutdown of each section
 Special activities - hydro testing, catalyst replacement,
cleaning
 Purging of sections & checklist of major maintenance jobs with
sketches
 Critical inspections & vessel entry
 Start up of utilities & each sections

Safe Work Procedures
A safe work procedure can be defined as the
written instruction of a task/activity outlining
the preferred method whilst emphasizing
ways to minimise any risk(s) of harm. A safe
work procedure outlines the hazards, risks
and associated controls measures to be
applied to ensure the task/activity is
conducted in a way to reduce the risk of
injury.

DEVELOPMENT
Safe work procedures should be developed
for all tasks/activities, processes, and the
operation of equipment and machinery,
where a risk assessment identifies the
requirements as a suitable control measure
to reduce the risk of injury.

PROCESS STEPS
To aid in the development of a safe work
procedure the following steps should be
followed:
Step 1. Observe the task or process;
Step 2. Record the sequence of basic job steps
Step 3. Assess potential hazards of each steps
Step 4. Review associated legislative
requirements

Step 5. Assess the risk of Hazards;
Step 6. Suggest ways of eliminating and controlling
the hazards;
Step 7. Test the procedure by consultation and
verify relevant issues are documented
Step 8. Obtain approval of the procedure from a
supervisor or manager.

In determining potential hazards in a task
or process the following factors could be
considered
 Is there exposure to noise, fumes or dust?
 How can equipment fail in any way?
 Is the work physically strainers?
 Is the work made harder by external factors ( climate,
noise etc.)?
 Is there enough space to move about?
 Can the person be caught in, on or between anything

 Can the person be struck by or contacted by anything
while doing this step of the job
 Do loads need to be lifted/or handled?
 Can the person slip or trip or fall
 What level of supervision is required?
 Is the work made harder by the way it is organised ?
 Is there any requirement specified in relevant legislation?

PRIORITIES
It is recognized that, in some areas, the preparation of
safe work procedures may take some time.
The priorities for the preparation of safe work
procedure should be:
 All new task where there is a high to medium risk
should have safe work procedures prepared before
they are put into general use;
 For existing processes, safe work procedures for high
risk tasks should be prepared first, followed by
medium and low risk tasks;

Safety Systems in ATR
 Safety of Man, Machine & Equipment – Top Priority
 No job without Risk assessment & Scheme / procedure
 No job without Safety Permit
 All class 1 permits - Inspected by Safety officer
 Additional process people posted as safety officers
 Safety observers – Internal & External
 Cross functional inspection teams for entry & box up of
each Vessel
 Check lists and sign-offs for each inspection
 Registers for blinds / vessel entry with sign-offs

Safety in ATR
 Training
 Communication of safety norms to all personnel
 Safety talk every morning & before start of each job
Contractors
 Medical tests before jobs
 Training & tests on job execution
 Checking & certification of all new equipment brought to
site
 100% adherence to use of PPEs
 Proper arrangements for rescue - availability of crane,
 ambulance & constant watch on working personnel inside
the vessel

Checking of Safety Systems & Logics
 Each component of safety logic is checked
 Trip switches, transmitters, vibration probes & other
key elements are removed, calibrated & installed
back
 After installation all Trip interlocks cross checked
through manual simulation
 Stroke checking of ALL control valves
 Calibration of all critical PSVs
 Hydro test of all critical exchangers

Start up
 Systematic leak check - initially with IG at lower
pressure then at operating pressure
 For each activity like purging, filling, start up etc
 A documented procedure cum check list
 Optimum utilization of trained manpower for different
activities
 Comparison of efficiencies – machines, reactors,
 exchangers, catalysts performance etc

Shutdown Report & Records
 Shutdown report includes:
 Planned vs. actual timings for major activities
 Details of key jobs done
 Section wise observations of inspections & repairs
 Surprises
 Analysis & improvements achieved
 Observations regarding safety & environment lapses
 Identification of area of improvements
 Learning & best practices observed

AFTER ATR
 AMMONIA PLANT CAPACITY : 1725 TPD
 UREA PLANT CAPACITY : 2825 MTPD
 ON STREAM DAYS : 350
 ANNUAL UREA PRODUCTION : 988750 MT

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