Metafrax has improved the efficiency and reliability of its equipment

Metafrax Chemicals carried out a shut–down maitenance of methanol production and integrated Ammonia–Urea-Melamine (AUM) Complex. This annual comprehensive event makes it possible to strengthen current capacities and create a foundation for future development.

One of the main tasks in the production of methanol was to replace the catalyst in the once-through unit. In addition, the specialists replaced two sections of pipelines, installed a steam heater, and carried out routine maintenance: inspections, cleaning, technical expertise of industrial safety of the equipment, diagnostics, and valve inspection.

The steam boiler and compressor in the process preparation shop were upgraded at the AUM Complex with maximum load mode. The specialists also repaired two compressors in the ammonia production plant.

Some operations on the equipment of the AUM Complex were performed using a reverse engineering process. We took measurements and 3D-scanned the parts of the units in the ammonia production plant.

- Equipment is completely disassembled into its component parts. Then each of them is scanned using high-precision measuring equipment and translated into 3D images. After that, drawings are made, according to which exact copies of these parts can be made in the future," explained Alexander Eske, Deputy Technical Director for Maintenance, Repair and Overhaul Activities.

The maintenance works involved employees of all repair services of the enterprise - repair work shop, power supply workshops, automation repair shop, process personnel of the production plants, as well as specialists from about 20 contracting organizations. At the same time, thanks to the previously performed expansion of the valves' inspection division in the Repair work shops the inspection of all involved shut-off and control valves was carried out through the own employees of the Repair work shops this year.

- Thanks to the high level of organization and careful preparation, the maintenance works were carried out at a high level. I would like to note the high readiness of all the repair services of the enterprise, which were responsible for the elimination of the main and additional defects that were discovered during the work, and these defects were promptly eliminated without failure and extension of the maintenance repair dates," said Albert Khudaibirdin, Managing Director for Production at Metafrax Chemicals.