Major Achievements-1
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Local development of spare parts for rotary equipment at Dawood Hercules Chemicals saved an average of Rs. 5-6 million per month from 1999-2002. Refurbishment of critical equipment at Weir Services Dubai for Byco Oil Pakistan Ltd was completed on time and under budget, saving over $1 million through reverse engineering and repairs. The establishment of a Reliability Section at Byco Oil Pakistan Ltd through training and documentation improved plant efficiency and reliability by identifying issues and preventing unplanned shutdowns that could have cost millions. Major repairs on critical urea reactors at Dawood Hercules Chemicals increased their life, efficiency, and reliability, saving millions of rupees daily.
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The Importance of Integration of subsurface with surface facilities design
Major Achievements-1
- 1. MAJOR ACHIEVEMENTS Enormous savings thru Local Development of High Cost Imported (OEM) Spares of Rotary Equipments (at Dawood Hercules Chemicals): Average Monthly Savings thru local development amounted about Rs 5-6 Million (during 1999-2002). Local development of complete 2nd stage of Ingersoll Rand recip air compressor saved over Rs 6 Million (year 2000). Local development of Cooling Water Pump impeller saved about Rs 2.5 Million (year 2002). Local development of various pumps’ shafts saved about Rs 0.5-1.5 Million each. Average difference between local versus imported spares cost ranged from 10 to 20 times. Local development of High Pressure Urea Letdown Valve body saved about Rs 15 Million (year 2002). Spares rebuilding/repairs/reclamation saved enormously about 95% of the OEM cost. Successful & Cost Effective Refurbishment of Critical Rotary Equipments at Weir Services Dubai (at Byco Oil Pakistan Ltd): The project was independently handled & completed on time within budget despite big hurdles. Over 01 Million USD was saved thru reverse engineering & specialized repairs of critical spares at Weir W/Shop, Dubai and by effective commercial/technical negotiations without compromising quality. Almost all the critical rotary equipments were successfully commissioned & are now running satisfactorily without any major repairs which truly proved successful refurbishment. Reverse engineering of various compressor parts, pumps’ impellers, shafts & Laser Cladding of compressor crankshaft were few of the major jobs. The most challenging & significant achievement was successful refurbishment of 4.5 MW Siemens Turbo-Compressor which included extensive repair of compressor rotor (in U.K). This mainly consisted of replacing two impellers by development/reverse engineering & extensive repairs on rotor by HVOF Coating (High Velocity Oxy Fuel) at Weir Turbo-Machinery W/Shop, U.K. Also, had a unique experience of witnessing High Speed Balancing at the General Turbo W/Shop in Bucharest, Romania. During post repair inspection of rotor in Romania, pointed out flaws in shaft sizing & metal coating which was admitted by Contractor & the rotor was sent back to W/Shop in U.K for rectification. Thus, saved about USD 100,000 for
- 2. additional repairs and achieved enormous saving (in Millions of USD) in terms of plant downtime & resultant production loss. Successful Development of Reliability Section (at Byco Oil Pakistan Ltd): Reliability Section was effectively established which included in-house training of manpower & development of ISO/IMS Controlled Documents like Plans, SOP’s & Work Instructions. Successful implementation resulted in finding root causes of various chronic & serious issues related to rotary equipments thru detailed investigations thus, contributed as key player towards increasing plant efficiency & reliability. This in fact, started to improve the operation & maintenance culture of the refinery. Timely identification of issues resulted in saving many sudden/unplanned shutdowns & saved Millions of USD of production loss besides emergencies and other associated losses. Successful completion of major repairs at highly critical Urea Reactors which resulted in increased life, efficiency & reliability of the reactors (at Dawood Hercules Chemicals): Increase in reactors’ efficiency saved Millions of Rupees daily besides saving the high cost reactors from damages/deterioration.