Project Overview

The Client wanted to revamp their fertilizer production operations to adapt to shifting business needs. The west train of one of their plants produced ammonium sulphate (AS), while the east train produced monoammonium phosphate (MAP). Rally was asked to participate in a project to convert the east (MAP) train of the plant to match the west train (AS) process, using as much existing and surplus equipment as practically possible. The project also provided an ideal opportunity to make strategic upgrades and improve product quality.

MAP Plant Conversion to AS main MAP Plant Conversion to AS first MAP Plant Conversion to AS second

Concept Validation & Design Development

Concept Validation
After a few months of confidential development work, Rally Engineering delivered a design basis memorandum (DBM) to the Client establishing a high-level feasibility plan for converting the east train of the plant from producing MAP to AS, while minimizing the impact to ongoing operations.

Design Development
Rally then spent the next five months refining the plan. The design team took a more detailed look at how each system would need to be modified to achieve the target production rate of 60 tonnes per hour with a recycle rate of 6:1. While some new piping and equipment needed to be purchased, Rally identified many opportunities to use surplus equipment and modify in situ machinery.
With the Client’s endorsement of a Class III ‘total installed cost’ (TIC) estimate and a consolidated design basis, the design team proceeded to the final phase of engineering.

Detailed Deliverables

Working from existing plant data, site visit notes, and extensive laser scanning, Rally produced a wide variety of deliverables throughout the detailed engineering phase.
Rally created material requisitions (MRs), equipment data sheets, and detailed fabrication drawings. Procurement support was provided for many MRs simultaneously.
Construction work packages (CWPs) were split out by engineering discipline for execution by mechanical, piping, civil, structural, electrical, and instrumentation contractors. More importantly, the CWPs were individually tailored for construction during brief plant outages over a six-month period. This minimized the impact of revamp work on regular operations.
The east train of ammonium sulphate production is now up and running, and regularly out-performs its 60 tonnes/hour nameplate design rating.

Download PDF