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AV-04 Case Study:CF Industries - Utilizing Avantis toManage Turnarounds

Presenter: Mark Dubreuil

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CF Industries is a global leader in fertilizer manufacturing anddistribution, the second largest nitrogen fertilizer producer in theworld and the third largest phosphate fertilizer producer amongpublic companies. CF Industries owns and operates world-scalenitrogen and phosphate plants and serves agricultural and industrialcustomers through its best-in-class distribution system.

Donaldsonville Nitrogen Complex

• Donaldsonville operates:

– 5 Ammonia Plants

– 4 Urea Plants

– 3 Nitric Acid Plants

– 2 UAN Plants

• CF Industries' nitrogen complex atDonaldsonville, LA is North America’slargest and, in many respects, itsmost flexible nitrogen operation.

• It can produce and ship approximately 5 million tons of nitrogen foragricultural and industrial uses each year.

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• Donaldsonville operates:

– 5 Ammonia Plants

– 4 Urea Plants

– 3 Nitric Acid Plants

– 2 UAN Plants

• CF Industries' nitrogen complex atDonaldsonville, LA is North America’slargest and, in many respects, itsmost flexible nitrogen operation.

• It can produce and ship approximately 5 million tons of nitrogen foragricultural and industrial uses each year.

Outage Cycle Strategy

• To improve flexibility, outage cycles have been extended to multipleyears, resulting in the ability to capture various continuous runrecords:

– Ammonia 4 achieved a 995 day continuous run record which at the time wasa world record for a Kellogg ammonia plant.

– Urea 4 established a 936 day continuous run record which was only daysshort of the world record for a Stamicarbon urea plant.

• But even the best maintenance and operating plans couldn’tovercome…

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• To improve flexibility, outage cycles have been extended to multipleyears, resulting in the ability to capture various continuous runrecords:

– Ammonia 4 achieved a 995 day continuous run record which at the time wasa world record for a Kellogg ammonia plant.

– Urea 4 established a 936 day continuous run record which was only daysshort of the world record for a Stamicarbon urea plant.

• But even the best maintenance and operating plans couldn’tovercome…

Hurricane Gustav

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Over time, Turnaround Cycles have lengthened considerably

• Ammonia Plants are scheduled for major outages every 5 years

• Urea/UAN/Nitric plants are scheduled on a 4 year cycle

CF’s Turnaround Cycle Progression

1 year 4 years 5 years

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28 days10 days 21 days

1 year 4 years 5 years

Outages have expanded from 10 to 28 days as a result

Long Cycles Result in Lots of Work

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Avantis Schedules Define Included Tasks

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Avantis Schedules are ExportedUsing the Custom Extension Feature

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Exports Create/Update Microsoft Project

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Breaking Down the Time Line

Major Outage – Entire Time Line

Pre-Turnaround Turnaround Post -Turnaround

Locate, Verify, & TagPre-stage materialsBuild ScaffoldsPre-Fabricate ItemsRemove InsulationPrep Worksites

Replace InsulationTear Down ScaffoldsWork Site Clean-upStow TemporaryEquipment

Install BlindsRemove PipingOpen VesselsPull Valves for Inspection and Repair

Equipment InspectionsMisc RepairsClean Vessels

Found WorkReplace ValvesClose VesselsReplace PipesRemove Blinds

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Locate, Verify, & TagPre-stage materialsBuild ScaffoldsPre-Fabricate ItemsRemove InsulationPrep Worksites

Install BlindsRemove PipingOpen VesselsPull Valves for Inspection and Repair

Equipment InspectionsMisc RepairsClean Vessels

Found WorkReplace ValvesClose VesselsReplace PipesRemove Blinds

Breaking Down by AreaSchedule Plant Plant Operating Area Tasks

18794-Urea 2 T/A 2009 (Not Assigned) 718794-Urea 2 T/A 2009 Nitric Acid Plant Process Piping & Vessels 218794-Urea 2 T/A 2009 UAN Plant Steam System 118794-Urea 2 T/A 2009 Urea Plant 6118794-Urea 2 T/A 2009 Urea Plant Atmospheric Absorption 1618794-Urea 2 T/A 2009 Urea Plant Boiler Feed Water 5118794-Urea 2 T/A 2009 Urea Plant Clean Condensate System 3518794-Urea 2 T/A 2009 Urea Plant CO2 Compression 13018794-Urea 2 T/A 2009 Urea Plant Cooling Water 5118794-Urea 2 T/A 2009 Urea Plant Desorption 2518794-Urea 2 T/A 2009 Urea Plant Effluent 418794-Urea 2 T/A 2009 Urea Plant Evaporation 65

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18794-Urea 2 T/A 2009 Urea Plant Evaporation 6518794-Urea 2 T/A 2009 Urea Plant Granulation 22718794-Urea 2 T/A 2009 Urea Plant High Pressure Synthesis 10418794-Urea 2 T/A 2009 Urea Plant Instrument Air & Plant Air 2118794-Urea 2 T/A 2009 Urea Plant Low Pressure Reflux 26

18794-Urea 2 T/A 2009 Urea Plant Low Pressure Synthesis (Recirculation) 7418794-Urea 2 T/A 2009 Urea Plant NH3 Buffer Tank & Piping 518794-Urea 2 T/A 2009 Urea Plant NH3 Compression 3718794-Urea 2 T/A 2009 Urea Plant Package Boiler 6718794-Urea 2 T/A 2009 Urea Plant Safety 718794-Urea 2 T/A 2009 Urea Plant Steam System 184

Breaking Down by Work Category

Schedule Work Category Tasks

18794-Urea 2 T/A 2009 (Not Assigned) 14

18794-Urea 2 T/A 2009 Fixed Equipment 119

18794-Urea 2 T/A 2009 I&E 525

18794-Urea 2 T/A 2009 Misc Maint 230

18794-Urea 2 T/A 2009 MOC 17

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18794-Urea 2 T/A 2009 MOC 17

18794-Urea 2 T/A 2009 Paint 2

18794-Urea 2 T/A 2009 PSO 230

18794-Urea 2 T/A 2009 Rotating 63

Export Default Linking Behavior

Work Order

Work Task w/o Activities

Work Task w/Activities

Activity

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Work Task w/Activities

Activity

Activity

Activity

Activity

Export Default Schedule Rollups

Schedule

Plant

Plant Operating Area

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Work Task / Activity

Plant Operating Area

Entity

Work Order

Resources

Assigning Phase, Category,and Plant Operating Areas

Operating Area of Plant

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Phase of Outage

Work Category

Alternate Phase Specification forActivities

Activity Type is used toOverride the Phase of theoutage when Activities aredefined for a work task

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Specifying Labor Requirementson Tasks

Crew Size and PlannedHours are entered aslabor requirements onTasks w/o Activities.

If a task has Activities,these entries summarizethe total need from allactivities for the task

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Crew Size and PlannedHours are entered aslabor requirements onTasks w/o Activities.

If a task has Activities,these entries summarizethe total need from allactivities for the task

Specifying Labor Requirements onTasks with Activities

A ‘creative’ use ofthe downtime tabfor activities isused to record thenumber of hours,trade, and crewsize needed

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Selecting Parameters for Export

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Specifying Phased Start Dates

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Monitoring the Export

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Example Output

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Example Output

Custom Columns are used to ‘Store’exported identifiers and groupings

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Using Auto-Filter to Get Sub-Sets

Auto-FilterToggle

Filter Selection

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Getting a ‘Punch List’ of Work

Show IncompleteWork Only

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Filter Selection toSub-set desired

Default Linking Provided by Export

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Questions?

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