Professional Documents
Culture Documents
August, 2014
PRODUCTION REPORT
NH3
PLANT
Description
Budgeted
Actual
40603
41915.94
93
103.2
94
91.2
8.11
8.333
7.90
8.318
305164
312981.9
(7818.9)
Credit
7
1309.774
1352.127
48
65
1793
1849.34
10
517
588.53
120.00%
1,400.00
100.00%
80.00%
Production
1,000.00
800.00
60.00%
600.00
40.00%
400.00
20.00%
200.00
0.00%
1,Aug
02,Aug
03,Aug
04,Aug
05,Aug
06,Aug
07,Aug
08,Aug
09,Aug
10,Aug
11,Aug
12,Aug
13,Aug
14,Aug
15,Aug
16,Aug
17,Aug
18,Aug
19,Aug
20,Aug
21,Aug
22,Aug
23,Aug
24,Aug
25,Aug
26,Aug
27,Aug
28,Aug
29,Aug
30,Aug
31,Aug
0.00
Date
Average Load
Production
Date
Average Load
Production
1,Aug
02,Aug
03,Aug
04,Aug
05,Aug
06,Aug
07,Aug
08,Aug
09,Aug
10,Aug
11,Aug
12,Aug
102.79%
104.11%
102.64%
102.32%
102.54%
103.12%
103.29%
101.83%
102.01%
102.02%
102.03%
101.87%
101.82%
0.00%
99.67%
1,487.00
1,507.30
1,490.10
1,486.00
1,486.00
1,495.10
1,505.08
1,487.31
1,482.75
1,485.10
1,490.94
1,483.50
1,488.15
1,466.22
1,465.76
16,Aug
17,Aug
18,Aug
19,Aug
20,Aug
21,Aug
22,Aug
23,Aug
24,Aug
25,Aug
26,Aug
27,Aug
28,Aug
29,Aug
30,Aug
100.01%
100.75%
103.80%
103.85%
101.94%
101.74%
101.35%
102.44%
101.71%
100.91%
101.44%
101.36%
99.91%
68.56%
56.80%
1,457.44
1,463.22
1,485.77
1,476.68
1,486.90
1,479.27
1,487.56
1,482.80
1,483.45
1,492.08
1,482.98
1,491.40
1,488.56
262.41
0.01
31,Aug
81.72%
89.10
13,Aug
14,Aug
15,Aug
Average Load
1,200.00
3
2.5
2
1.5
1
0.5
0
NMI
PSI
FAC
Fire
Equipment Operational
Failure
Upset
Human
Error
Violation of
PSM
Series1
Series1
% Close Out
100
Series1
Equipment Machinery
0
0
Electrical
0
Instrument
0
Civil
0
TSD
0
HSE
0
Operations
0
MSA Statistics
350
300
250
200
150
100
50
0
MSA Observations
Reported
Series1
% Close Out
100
NM Open Actions
1
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0
Series1
Civil
0
TSD
0
HSE
0
Operations
0
NM Statistics
100
80
60
40
20
0
Near Miss
Observations
Reported
Series1
Near Miss
Observations Closed
% Close Out
% Close Out
100
Machinery
Electrical
Inspection
Civil
Instrument
CWP
HWP
CWP issued
310
HWP issued
55
CWP closed
280
HWP closed
50
CWP Closure %
90.3%
HWP Closure %
90.9%
CWP issued
117
HWP issued
CWP closed
105
HWP closed
CWP Closure %
89.7%
HWP Closure %
100%
CWP issued
19
HWP issued
CWP closed
16
HWP closed
CWP Closure %
84.2%
HWP Closure %
100%
CWP issued
HWP issued
01
CWP closed
HWP closed
01
CWP Closure %
66.6%
HWP Closure %
100%
CWP issued
19
HWP issued
02
CWP closed
11
HWP closed
02
CWP Closure %
57.8%
HWP Closure %
100%
CWP issued
87
HWP issued
CWP closed
55
HWP closed
CWP Closure %
63.2%
HWP Closure %
0%
473
400
200
84.31%
64
0
CWP Issued
CWP Closed
HWP Issued
58
90.625%
HWP Closed
HWP % Close
Out
CWP Issued
CWP Closed
HWP Issued
HWP Closed
Operational Highlights
Initiatives:
Working on alarm management system
Follow up for LTDS closure
75%
88%
100%
100%
80%
60%
40%
20%
0%
Shift Group A
Shift Group B
Shift Group C
Shift Group D
100%
100%
100%
100%
80%
60%
40%
20%
0%
Shift Group A
Shift Group B
Shift Group C
Shift Group D
100%
100%
Shift Group A
Shift Group B
Shift Group C
100%
100%
80%
60%
40%
20%
0%
Shift Group D
2013
2014
Cumulative
2013
Cumulative
2014
One Post
27
23
38
39
Two Post
11
16
Three Post
Four Post
Five Post
Six Post
Seven Post
Eight Post
100
90
80
70
60
50
40
30
20
10
0
Series1
Planned Skills
1
% Compliance
100
Series1
Incidents
Reported
Recommendations
Marked to
Operation
Operation
Recommendation
Closure
Compliance
100
Overall Closure
Compliance
100
Series1
Total No. of
No. of
Standing
Standing ESD
Alarms
Alarms
142
17
No. of
Standing
DCS Alarms
133
No. of
Standing
DCS Alarms
Issues
Resolved
85
No. of
Standing ESD
Alarms
Issues
Resolved
0
% of
Standing
Alarms
Issues
Resolved
60
Series1
Shift Group A
100
Shift Group B
100
Shift Group C
100
Shift Group D
100
Series1
Shift Group A
100
Shift Group B
100
Shift Group C
100
Shift Group D
100
UM
July
Design
Consumption
Cumulative
2013
Cumulative
2014
Catacarb WBU
(Polyglycol)
Litre
40
22.5
315
168
Catacarb 400
DM
30
37
Catacarb 72-S
Litre
As Required
113
Catacarb 922
(V2O5)
m3
0.225
10
11
Potassium
Carbonate
(K2CO3)
MT
03
1.85
21.075
26
Bulab-9564
(Na3PO4)
Kg
50
86.6
575
275
Hydrazine
(N2H4)
Liter
75
52.7
Oil Drums
Turbo-32
DM
As Required
Oil Drums
Turbo T-32
DM
14
As Required
Oil Drums
Tellus + Clavus
DM
0.5
As Required
Maintenance Highlights
E-108 GLG leakage rectified by replacing its glass.
E-145A3 old bundle hydro-jetting/Hydro-testing and
chemical cleaning done.
P-420 suction strainer cleaned
E-222 and its associated piping painting done
P-110A discharge valve gland leakage rectified
Insulation provision at MS-116 inlet line and E-093
associated lines done
Insulation provision at E-118 and associated line done
FH-051 isolation valve handle provided
D-143 inlet/outlet lines thickness monitoring done
PM of safety showers carried out
charge replacement
New windsocks installed at TK-102/1101
Tie-ins were taken for CT-105 gland condenser
New tie-ins for CWS/CWR taken for E-145
FIL-104A/B cleaning done
E-182A/B and E-151 cleaning and hydro-testing done
Machinery Highlights
PM-1151A low pressure problem rectification remained
I/P
PT-1501B CW jacket get de-blocked
General oil make up and area surveillance
P-1504B gland leakage rectified
C-102 breathers cleaning done
PM-9345A/B suction strainers cleaning done
TK-115 portable centrifuges cleaning done
O/B glands
tightening
donereplaced for low
P-106C
P-118 anti-foam
pump
diaphragm
Position
Available
Approved
Unit Manager
Day Engineer
Shift In-charge
Area Engineer
2+3(Sub-Engineers)
3+1
Operators (Permanent)
31
32
Apprentice Operators
Annual Contract
Annual Contract
Helpers
Annual Contract