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EXECUTIVE SUMMARY
Introduction
The on-site inspection of used stationary equipment located in three separate locations in the Canada was requested by
our client Engro Pakistan Fertilizer Dharki. The inspection was conducted on 01 to 05 May, 2017 by TII inspection team.
The focus of the inspection was verification of product identification, external physical condition, general appearance of the
equipment, and certificate for residual life expectancy.
The Plant was originally built for Apache Canada and Located at the Apache Hamburg Gas Processing Complex west of
Manning, Alberta. The unit was commissioned in year 2002 and only ran for a short time before being shut in at the end of
2002. The plant consisted of two additional new amine units, dehydration, compression and ancillary equipment. The
supply gas to the plant was re-routed by the field producers to a neighboring plant so the plant was only running at ~20 to
40 % capacity. The owner decided to shut I the new expansion and wait for additional gas production. Unfortunately, no
new producers entered the Hamburg area and in 2011 the equipment was dismantled and removed from the Hamburg
Site.
The conclusion of the inspection was based on the documentation reviewed which included but not limited to Plant
maintenance records, and equipment drawings, there was no maniantence or production records available for the review
at the time of inspection. Visual inspection was limited to the extent of visual access.
Conclusion
After a thorough review of the information obtained during the inspection, it was concluded the equipment presented for
inspection, has a residual life estimated to be an average of 10 years or more, depending on regular maintenance,
upgrades, operating environment, proper utilization and repairs.
INSPECTION REPORT
CUSTOMER INFORMATION
Customer Name M/s Engro Fertilizers Project Name Assessment of Used Amine Plant
P.O. / Ref Number Contact Name M.Aqeel
INSPECTION LOCATION
Vendor : Enylen Sub-Vendor :
5509 Broadway Ave. Blackfalds, AB,
Location: Storage Yard Address :
T0M 0J0
Contact Name Mark Rajher Country :
Phone / Email
t: 403.885.9262 Vendor Order No.
ASSIGNMENT DETAILS
PO Item Serial / TAG
Qty Product Description ITP No. Activity Description
No. No.
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REPORT DATE: 08 May 2017
SCOPE OF INSPECTION
ASSIGNED SAMPLING / RESULTS*
SCOPE OF WORK CRITERIA
Y N APPLIED Sat Conf Non-C Rej Abo
Progress Monitoring
Witness Testing
Functional Performance Mechanical Run Hydro Noise Balance Electrical NDT
Other ______________
Final Visual
Packaging inspection
Pre-Shipment
Witness Container Loading
Audit
Damages inspection / Assessment
Used Equipment inspection X X
Other: NDT-Thickness Monitoring X X
2. ATTENDEES
Hamburg Plant
• The Plant was originally built for Apache Canada and Located at the Apache Hamburg Gas Processing Complex west of
Manning, Alberta. The unit was commissioned in year 2002 and only ran for a short time before being shut in at the end of
200, in 2011 the equipment was dismantled and removed from the Hamburg Site.
The equipment’s were dismantled and stored at three different location as described above
This Inspection at the Enylen Blackflad, Ponoka and Hamburg plant sit was conducted by TII inspection team, The
inspection was carried out starting from 02nd May 2017 – 05th May 2017 at all three locations.
• UT thickness measurement was dons all vessel and on random piping spools. Vessels TM shows no reportable thickness
losses. Internal examinations showed only normal corrosion with no deep or rejectable pitting of the welds or shell visible. No
internal inspection carried out on any of the referenced equipment.
• No bent piping or damage to the ladder / cage was evident.
• Vessel nameplate was found to be affixed to the vessel.
• Inspector also reviewed available documentation for the vessel (ASME U-1 form and documents from the last major activity
on the vessel, replacement of trays in 2013) and found no issues to note. No other vessel history.
• Detailed inspection of Electrical & instrumentation ws conducted there are number of instruments missing from skids the
report elaborate in detail status of instruments.
• There was no physical damage found on the instruments only atmospheric corrosion mild to heavy.
• The operationalbility of instruments remain questionable till calibration and detailed service check before putting in operations
• Pump, Motors and fan due to lack of maintenance activities or preservations shows lot of rusting and corrosion. The rotory
equipment’s required detailed inspection and checks to ensure the operability the physical condition of equipment’s can be
reviewed in detailed report.
• The structural supports, skids have surface corrosion due to external coating failures, this reuired a blasting, inspection and
paint before re-utilization.
• UT measurements taken on all vessels, tanks and piping on all accessible inspection ports.
• No notable corrosion was found when compared to design thicknesses
Manufacturer: Sulzer
Condition
• Inspection was visual only and pump was not witnessed in operation.
• Pump, motor, and piping were inspected and found with high scale and atmospheric rust.
• Surface corrosion on pump housing and bolts as coating is worn off due to exposure to weather.
• Pumps are powered by Electric motors.
• Associated piping was visually inspected.
Vendor Inspection Note
• Performed high level inspection of 2 Sulzer MSD pumps. Pumps are mounted to a skid and coupled to US Electric drive
motors.
• Coupling guards and spools were removed. 1st unit was able to rotate. 2nd unit would not rotate
• The bearing housing covers were unbolted and pulled back. 1st unit non-drive end (NDE) auto oiler glass was broken which
had allowed water to get into the bearing housing. There was some corrosion inside the housing but the bearing fits still look
ok. 2nd unit NDE bearing housing looks to be in decent shape.
• Both drive end (DE) bearing housings had some oil and looked to be in decent shape. Housings could only be pulled back
about an inch as the coupling hub is still installed.
• Both NDE bearing housings were removed. Water was drained from 1st unit. The 2nd unit was left with existing oil.
• Both bearing housings were installed but left loose. 2nd unit was then freed up and able to rotate.
• Bearing housings were tightened up and the end covers reinstalled. Both units were still able to rotate.
• Recommendations:
• Replace auto oiler on the 1st unit NDE bearing housing or remove broken one and plug the port.
• Fill housings with preservative oil.
• Fill pump cavity with rust inhibiting product (Diesel is commonly used)
• Both pumps should be fully disassembled and inspected to determine if any further repairs are needed.
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REPORT DATE: 08 May 2017
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REPORT DATE: 08 May 2017
Condition:
• Fans, Fan housings, motors, tube sheets, Plug sheets , finned tubes all out of service with mild to medium surface corrosion
Issues:
• Tubes require cleaning due to build up of dust and debris.
• Motors Required detailed inspection after opening as motor were not preserved for longer duration.
• Fan, fan blades, shafts and other accessories have heavy rust or surface corrosion required proper cleaning and testing for
operations.
Site Condition:
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REPORT DATE: 08 May 2017
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REPORT DATE: 08 May 2017
Manufacturer: Propak
Condition:
• Shell, heads, nozzles, were inspected and found in good physical condition.
• Shell visible through inspection ports was found acceptable.
• Shell was fully insulated and only visible through inspection ports.
• Heads insulated with blanket insulation. Insulation was removed for visual inspection.
• No repair stamp.
Issues:
• Heads and head bolts were found to have minor surface corrosion due to trapped moisture under insulation blanketing.
• Vessel not accessible for internal inspection
Thickness Measurements:
• Current thickness measurements were taken and found in acceptable limit with no repotable metal losses
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REPORT DATE: 08 May 2017
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REPORT DATE: 08 May 2017
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REPORT DATE: 08 May 2017
Condition:
• Shell, nozzles, piping were inspected and found in good physical condition.
• No repair stamp.
Issues:
• Heads and head bolts were found to have minor surface corrosion.
• The associated CS piping found with heavy surface rusting no pitting or hole.
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REPORT DATE: 08 May 2017
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REPORT DATE: 08 May 2017
Recommendations:
Since the equipments are not inspected internally, therefore we would suggest conducting complete internal inspection before the
installation at site so that any internal flaw initiated during operations due to process or mechanical damage due to transportation from
USA to Pakistan can be evaluated. As per API Standard 510 (Pressure Vessel Inspection code) it is also mandatory requirement to
have complete internal and external inspection after relocation of plant, API 510 clause 6.2.2.2 stated “If both the ownership and the
location of a vessel are changed, the vessel shall be internally and externally inspected before it is reused. This inspection should
include baseline examinations for any anticipated future examinations planned as a result of the new service (e.g. if the vessel is going
into a service where stress corrosion cracking is a potential, then a baseline examination of weld cracking is advisable). Al so, the
allowable service conditions and the inspection interval shall be established for the new service”.
All pressurized stationary equipments including piping are insulated to protect from extreme cold weather and snow at Rock Spring
USA. However after relocation to Pakistan, some of equipments would not require insulation for operational purpose and thus the
insulation may cause corrosion under insulation. API RP 583 Corrosion under Insulation code and API 571 damage mechanism code
recommend removing insulation on equipment where heat conservation is not as important. Therefore we would recommend evaluating
the purpose of the insulation on equipment and piping, this can help to make decision for the permanent removal of insulation from the
equipments.
Amine contactor V-1803, which had experienced an explosion and fires at this plant back on 03 December, 2015 and during this
inspection no damage from this event was evident. However it is recommend evaluating this equipment against fire damage as per
API 579-1, Fitness for Service Assessment code. Annex 11B of this code provides comprehensive criteria for metallurgical investigation
and evaluation of mechanical properties in fire damage. A minimum, field metallography, hardness testing and if required mechanical
testing should be conducted.
8. CONCLUSION:
• Based on the visual examination and information obtained during inspection, we conclude the equipment presented for inspection,
has a residual life estimated to be an average of Ten (10) years or more, depending on regular maintenance, upgrades, operating
environment, proper utilization and repairs.
This document is issued by the Company under its General Conditions of Service accessible at http://www.tii.com/terms_and_conditions.htm. Attention is drawn to the limitation of liability,
indemnification and jurisdiction issues defined therein.
Any holder of this document is advised that information contained hereon reflects the Company’s findings at the time of its intervention only and within the limits of Client’s instructions, if
any. The Company’s sole responsibility is to its Client and this document does not exonerate parties to a transaction from exercising all their rights and obligations under the transaction
documents. Any unauthorized alteration, forgery or falsification of the content or appearance of this document is unlawful and offenders may be prosecuted to the fullest extent of the law.
In accordance with Client’s instructions, the Company’s involvement has been limited to witnessing/observing a third party’s intervention(s) at the third party’s laboratory/test house or other
facilities and installations used for the intervention(s). The Company’s sole responsibility was to be present at the time of the third party’s intervention(s) to forward the results, or confirm
the occurrence, of the intervention(s). The Company is not responsible for the condition or calibration of apparatus, instruments and measuring devices used, the analysis methods applied
the qualifications, actions or omissions of the third party’s personnel or the analysis results.
Any holder of this document is advised that the information contained hereon is limited to visual examination of the safely and readily accessible portions of the consignment only.
This report is issued by the Company under the General Conditions for Inspection and Testing Services, printed overleaf. The issuance of this report does not exonerate buyers and sellers from exercising all their rights
and discharging all their liabilities under the Contract of Sale. Stipulations to the contrary are not binding on the Company. The Company’s responsibility under this report is limited to proven negligence and will in no
case be more than three times the amount of the fees or commission. Except by special arrangement, samples, if drawn, will not be retained by the Company for more than three months.