1. 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
1

2. 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
2

3. 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
3
2003 Plant Site - Turkmenistan

4. 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
4

5. 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
5

6. 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
6

7. 7
Blowing of Natural Gas Supply Line Using Natural Gas

8. 8
Blowing of Natural Gas Supply Line Using Natural Gas

9. 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
9

10. 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
10

11. 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
11

12. 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
12

13. 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
13

14. 14
First Urea Granules / Turkmenistan

15. 15
Ammonia And Urea Complex - Turkmenistan

16. 16
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

17. 17
AlexFert Ammonia And Urea Complex / Egypt

18. 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
18

19. 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
19

20. 20
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

21. 21
Mopco-I Ammonia And Urea Complex

22. 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
22

23. 23
Mopco-I Ammonia And Urea Complex
03 April 2008: Metering Station; Pigging of Natural Gas Supply Line

24. 24
Mopco-I Ammonia And Urea Complex
05 April 2008: Natural Gas Available At Metering Station

25. 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
25

26. 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)
26

27. 4. Engro Fertilizer Project
2200 MTPD Ammonia Plant/Haldor Topsoe, 3835 MTPD Urea Prilled/Snamprogetti
Daharki – Pakistan: 2009-2011
27

28. 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

29. 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
29

30. 5. Sorfert Fertilizer Project
2x2200 MT/day Ammonia–Uhde, 3450 MT/day Urea–Stamicarbon; Granulation-UFT
Arzew – Algeria: Dec 2011 – June 2013
30

31. 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

32. 6. Mary Fertilizer Project
1200 MT/day Ammonia–M.W. Kellog Limited, 1925 MT/day Urea–Stamicarbon; Granulation–UFT
Mary – Turkmenistan: 2013 - 2014
32

33. 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
33

34. Turkmenistan Mary Fertilizer Project Commissioning Progress
34

35. 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
35

36. 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 36

37. 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
37

38. 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
38

39. 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
39

40. 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
40

41. 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!
41

42. THANK YOU!