The Minimac team successfully completed a critical flushing project in a big fertilizer company with a capacity of 4000 tonnes in Jharkhand.

Synopsis

An installation project was ongoing at the fertilizer plant’s premises. Newly built lube pipelines and tanks were to be flushed to remove the welding debris and other components left inside while fabricating the pipelines. The entire project was delayed due to a very slow flushing process. Minimac Operations and Maintenance Service (MOMS) team evaluated the situation and came out with a solution to expedite the flushing process. The project required flushing their two main compressors, i.e., PSE processed air compressor and carbon dioxide compressor

Problems

Proper flushing had to be done as the pipeline was newly fabricated; otherwise, it would have led to a major breakdown of the compressor, as the impurities would choke the blades and erode/damage the compressor. Other issues were to ensure proper calculation for variable pipe diameters, and if the oil goes to the rundown tank and overflows, 60-65 degree oil will fall, causing a huge mishap.

Client’s Requirement

• Fast completion of the job to meet the project timeline.

Solutions

• Minimac Systems examined the pipeline, which consisted of a low-pressure pipeline, high-pressure pipeline, and run-down tank.


• A proper calculation was done as the work was a bit critical; any negligence could become a mishap


• All parameters must be considered, including segment-wise flushing, hammering, thermal showering, etc.


• At the end of the flushing, a mesh was installed to check if any impurities were present


• Completing the flushing project was ensured as per ISO 18/15/12

Cost Saving

This plant managed to save:

• Cost of import caused due to deficit of fertilizer.

CO2 e Saving

1,44,000 kg of CO2 e / 0.144 gigagrams of CO2 e

Benefits

1. The reliable operation of the system and trouble-free operation of machines.
2. Sustainable performance of manufacturing process.
3. Elimination of new compressor cost.
4. Avoiding the risk of fire and explosion.
5. Reduction in the possibility of product degradation due to lack of proper flushing
6. Timely execution.

Feedback

As a result of Minimac's excellent work, another assignment of a similar nature was assigned to them. Minimac achieved the OEM's request for no debris in the mesh.

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