Increasing Yield & Reducing Energy Losses in an Ammonia Production Plant
- Fertilizer Production
- Mid-sized manufacturer operating a 20-year-old ammonia plant
- North Africa
Seamless Startup of a Greenfield Ammonia-Urea Complex with Zero Critical Failures
- Fertilizers
- State-backed fertilizer company
- Greenfield ammonia-urea complex in North Africa
Obstacles Our Experts Have Transformed into Opportunities
A national fertilizer company was nearing mechanical completion of a new ammonia-urea complex but lacked a structured plan for commissioning and startup:
Unclear Handover Ownership
The handover process between EPC and operations was unclear, creating ownership gaps
Manual Commissioning Tracking
Commissioning sequences and punch list tracking were being done in Excel, with no version control
Operator Training Gap
Operators were unfamiliar with the plant’s systems, and no structured training program had been deployed
Missing Performance Tests
No performance guarantee test protocols were in place, risking contractual penalties
Uncoordinated System Energization
Critical equipment and systems were being energized with limited coordination between OEMs, contractors, and the client team
Startup Readiness at Risk
The risk of a failed or delayed startup loomed large—with operational readiness and safety on the line.
TEEC’s Expert-Led Solution
Our Experts activated its Commissioning, Startup & Operational Readiness service to orchestrate a structured transition from construction to operations:
What Our Experts Did
Developed a Ready-for-Startup (RFSU) framework, covering mechanical completion, commissioning, pre-startup safety reviews, and punch list closeout
Aligned commissioning plans with EPC and OEMs across all units (reformer, reactor, granulation, utilities)
Delivered a full training and competency program for operations and maintenance teams, including SOPs, emergency drills, and control room simulations
Designed and facilitated Performance Guarantee Test protocols in alignment with licensors and EPC warranties
Supported go-live with technical advisors embedded on-site through startup and stabilization
TEEC ensured not just that systems were ready, but that people, procedures, and processes were ready too.
Execution Approach by Teec’s Experts
- Developed a Ready-for-Startup (RFSU) Master Plan aligned with mechanical completion, commissioning, and handover milestones
- Defined system-level commissioning packages and linked them to the project schedule and punch list closeout
- Created digital checklists for subsystem readiness, including utilities, process units, and E&I systems
- Embedded TEEC commissioning engineers in control rooms and field teams to oversee energization, flushing, and loop checks
- Coordinated start-up sequencing across OEMs, EPC, and client teams to avoid overlaps and equipment stress
- Resolved interface issues in real-time and managed commissioning logs, checklists, and sign-offs digitally
- Delivered structured training programs including classroom, simulator, and field sessions
- Developed SOPs, emergency response protocols, and critical procedures tailored to the new plant
- Conducted Operator Competency Assessments and certification prior to handover
- Designed and executed performance test procedures in coordination with licensors and off-takers
- Monitored startup KPIs including ramp-up curve, emissions, yield, and energy consumption
- Handed over a fully validated startup report and post-commissioning optimization plan
Results & Impact
Plant achieved first ammonia product within 9 days of gas-in, 2 weeks ahead of plan
Zero major incidents during commissioning across utilities and process units
Operator readiness improved dramatically, with 38 staff certified and deployed pre-startup
All performance guarantees met on the first testing cycle, with no rework or commercial penalties
Integrated Value Through Teec’s Data-Driven Solutions
Data-Driven Solutions
BPM Solutions
With this integration, TEEC turned the startup from a high-risk black box into a transparent, trackable, team-driven success story.
