Case Studies

Client: Oman India Fertiliser Company S.A.O.C. (OMIFCO)

Project: Phase 02 & 03 / Prosafe up Gradation Project for Ammonia and Urea Plants – E&I and Cabling, Panel Installation, Loop Testing and Commissioning Works (Pre- Shut Down/Shutdown)

Client: Oman India Fertiliser Company S.A.O.C. (OMIFCO)

Project: Phase 02 & 03 / Prosafe up Gradation Project for Ammonia and Urea Plants – E&I and Cabling, Panel Installation, Loop Testing and Commissioning Works (Pre- Shut Down/Shutdown)

After successfully completion of phase 01, as a contractor AOTC became the prime option for this project, Oman India Fertiliser Company SAOC (OMIFCO) has two-train ammonia-urea fertiliser manufacturing plant at the Sur Industrial Estate in the Sultanate of Oman. The plant has the capacity to produce 1,750T/D of Anhydrous Ammonia from 2 Ammonia Plants and 2,530 T/D of granular urea from 2 Urea Plants with captive power and steam generator including plant utilities and off site facilities.

Earlier the operation and control of the complex is done from Yokogawa make CENTUM VP DCS and ESD function are implemented in ProSafe-PLC system.

OMIFCO was replaced the earlier ProSafe-PLC ESD system with ProSafe-RS system for Ammonia-12 Urea-11 and Utility sections. The old ProSafe-PLC system earlier in operation was replaced in phase wise manner.

In this phase the ProSafe-PLC ESD system for Ammonia-12 and Urea-11 was replaced.

Yokogawa was responsible to provide latest system state oft, TUV approved, capable up to SIL-3 ProSafe-RS ESD system, where AOTC was responsible for all technical calculation & execution for this project.

Following are the area covered on the replacement of ProSafe-PLC ESD system with ProSafe-RS system for Ammonia-12 & Urea-11.

Following are the area covered on the replacement of ProSafe-PLC ESD system with ProSafe-RS system for Ammonia, Urea and Utilities.

Urea - SR3 and CCR

Ammonia - SR2 and CCR

Utilities - SR1, SR5, SR6, LCR4 and CCR

AOTC got appreciation from client after successfully completion of project before time.

Repair of the overhaul, of an Alstom make, 2700 KW, 11 KV, 1489 RPM, 175.8 amps, 50 Hz, 3Ph, motor

Scope of work included visual inspection, dismantling, inspection of the stator winding, stator core, electrical static tests on the stator winding and accessories bump...

Repair of the overhaul, of an Alstom make, 2700 KW, 11 KV, 1489 RPM, 175.8 amps, 50 Hz, 3Ph, motor

After successfully bidding for the repair enquiry, AOTC was awarded a purchase order to carry out the overhaul, of an Alstom make, 2700 KW, 11 KV, 1489 RPM, 175.8 amps, 50 Hz, 3Ph, motor and it was starred externally and had an air cooled cooler. Scope of work included visual inspection, dismantling, inspection of the stator winding, stator core, electrical static tests on the stator winding and accessories bump test on the stator wedges, inspection of the rotor, bearings, bearing housing and cooler. Once the inspection was completed, new magnetic wedges were manufactured and reinserted into the stator. After which the damaged mica insulation for coil 43 was repaired and the stator was varnished. The rotor was weld repaired, machined and dynamically balanced with the fan and reinserted into the stator. The motor was tested, reassembled, painted and delivered back to the customer.

Damaged insulation at slot exit 43

Magnified view

Damaged and missing wedges

Damaged and missing wedges

Bump Test on Stator

Grooves on rotor shaft DE side

Scoring on rotor NDE side

TIR on NDE Side

TIR on DE Side

Rotor Machining

Rotor Shaft NDE side after repair

Rotor Shaft DE Side after repair

Varnished Rotor

Dynamic balancing of rotor

Wedging of Stator Slots

Insulation Repair

Varnished Stator

Painted Stator

Rotor DE Side

DE Bearings

NDE Bearing

Rotor NDE

Rotor Threaded into Stator

Bearing Housing DE

Bearing Housing NDE

Bearing Lower Half

Bearing Upper Half

Completed NDE Side

DE Side with Coupler

Repair of compressor

The compressor was transported by the customer to the AOTC repair facility on the 06th of June 2019. Upon incoming inspection, the winding was found to be completely burnt and as the customer...

Repair of compressor

The compressor was transported by the customer to the AOTC repair facility on the 06th of June 2019. Upon incoming inspection, the winding was found to be completely burnt and as the customer could not provide the original winding data, identification of the original winding data was not possible. We successfully managed to reverse engineer the winding pattern and rewound the compressor stator as a four pole machine with a two part winding pattern. The compressor was successfully tested, assembled and delivered back to the customer.

Burnt Stator winding

Burnt Stator winding

Compressor Stator

Composite Repair on the Tank shell

Customer: Oxy, Oman

Application Situation: Metal Loss in 02 Tank shell

The Tank of 39 meter diameter suffers from Metal Loss/pin hole.

Composite Repair on the Tank shell

Customer: Oxy, Oman

Application Year: April 2019

Application Situation: Metal Loss in 02 Tank shell

Problem:

The Tank of 39 meter diameter suffers from Metal Loss/pin hole.

Due to internal corrosion, the metal loss / pin hole is formed on the shell area of the tank and the client want a cold repair solution to fix the problem without long shutdown and costly replacement.

Solution:

We proposed Belzona superwrap II composite solution to restore the strength of weakened / hole material. Based on the tank UT report and the shell thickness, the Belzona superwrap II has been designed as per ISO 24817 and ASMA PCC-2 to 6 layer superwrap.

Application:

The application is carried out after Grit blasted cleaning. The Pin hole defect is repaired by bonding the plate with Belzona patch plate technique to restore its mechanical strength.

After the curing the patch plate the Belzona superwrap II system is applied.

Traveling Grate Job
Vale Csd-2019

Customer: Vale, Oman

Hse Highlights
Cold Shutdown

Customer: Vale, Oman

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