OPERATING PHILOSOPHY CONTRACTOR ID. CODE 9294-VZ-MP-0001 PROJECT: Amionia Pan Feehtck Changeover fLocamion:Nangal [Sheet 10f446 | issue01 OPERATING PHILOSOPHY Arie 7 FIRST ISSUE Star [at Ades aaronars Rev. Description ~_ 4 Prepared | Checked | Approved DateHA rere AN net wy OPERATING PHILOSOPHY | CONTRACTOR TD. CODE 9294-VZ-MP-0001 PROJECT: Ammonia Plant Feedstock Changeover LOCATION: Nangal__—_|Shect 20f446 | Issue O1 TABLE OF CONTENTS SAFETY AND HEALTH sosesnons sss PURPOSE AND APPLICATION. PERSONNEL SAFETY crcesooon ENVIRONMENTAL SAFETY i te i EQUIPMENT SAFETY, 7 oe ‘SAFETY SYSTEMS. FACTORS THAT AFFECT QUALITY ‘GENERAL. Z PROCESS TROUBLESHOOTING, SAMPLING, RECORD KEEPING. ROUTINE OPERATOR DUTIES ROUTINE DUTIES FOR CONSOLE OPERATORS ROUTINE DUTIES FOR OUTSIDE OPERATORS. HOUSEKEEPING. OPERATING INSTRUCTIONS / LOGS, MECHANICAL BOOKS AND VENDOR IMOI Boo! OvERviEW, PROCESS DESCIIPTION. Feed Gas Compression, Preheating, and Desulfurization, Primary Reforming. Process Air Compression Secondary Reforming Shift Conversion... Carbon Dioxide Removal. Methanation Drying. Cryogente Purification... Synthesis Gas Compression Ammonia Synthesis. Purge Gas Recovery Ammonia Refrigeration.. Process Condensate Sipping. ‘Steam System: Cooling Water System (OTHER FACHLITIES.. ‘TURNDOWN OPERATION.. PROCESS OPERATING PRINCIPLE’ ‘NATURAL Gas SUPPLY FEED GAS COMPRESSION- 102-1 FEED GAS COMPRESSION - 102-1... Sealing System... DESULFURIZERS 108-DA / DB / DC. PRIMARY REFORMER, PROCESS AR COMPRESSOR: 101-I i SECONDARY REFORMER / WASTE HEAT ican iia HIGH TEMPERATURE SHIFT CONVERTER o.cecccssnesnensnnn See LOW TEMPERATURE SHIFT CONVERTERS ar ~ L1SReductionPiping e aa ete centertA verre Nine we PERAT! CONTRACTOR ID. CODE, ome sa PHIL) ‘KBR OPERATING PHILOSOPHY = 9294-VZ-MP-0001 PROJECT: Ammonia Plant Feedstock Changeover frocanos Nangal Isheot 3 0f446 | Issue OL LTS Effluent Heat Recovery. Process Condensate SYNTHESIS GAS PURIFICATION. Carbon Dioxide Removal. Process Flows Solution Flow.. @MDEA Auxiliary Equipment on ‘Methanator (Carbon Oxides Removal)... Molecular Sieves PURIFICATION... 137-L Purifier Cold Box AMMONIA SYNTHESIS. G-1701 Synthesis Gas Compressor. Synthesis Gas Conversion To Ammonia. Ammonia Refrigeration System meme AMMONIA PURGE Gas RECOVERY SYSTEM, 124-D HP Scrubber 7 123-D LP Scrubber 125-D Ammonia Distillation Column UTILITY FLOWS vows a Boiler Feedwater System . Steam Systems. STEAM CONDENSATE Jacket Water System. Cooling Water Systems Service Water System. Potable Water. : Instrument and Plant dir Systems Inert Gas System (Nitrogen). Fuel Gas System Ammonia Process Flare Front end Flare Systems. ee i Safety Showers / Eye Washes Safety Showers / Eye Washes... UNIT CONDITIONING .onune INTRODUCTION vnsennnn PRESSURE TESTING INSPECTION OF VESSELS. CATALYST LOADING. Catalyst Loading of 101-B Primary Reforme? svn Catalyst Loading of 103-D Secondary Reformer. ae Catalyst Loading of 104-D! High Temperature Shift Converter mmvmnnmonen Catalyst Loading of 104-D2 Low Temperature Shift Converter Catalyst Loading of 104-D3 LTS Guard Bed. Catalyst Loading of 106-D Methanator.. Catalyst Loading of 108-DA Hydrotreater Catalyst Loading of 108-DB and 108-DC Desulfurizers. Catalyst Loading of 109-DA and 109-DB Molecular Sieve Driers LINE BLOWING AND FLUSHING: STEAM LINE BLOWING Scope Inroduction Prerequisites to an Effective Steam Blow. ‘isomeric rst opti hana enema aaa dee crt eng mae seta ah na eet aeCONTRACTOR ID, CODE 9294-V7 -MP-0001 a Location: Nangat [sheet 406446 | Issue ot Cleaning Effect Steam Blow Preparations Steam Blow Target Acceptance Criteria. Safety and Environmental Precautions.nueuummmone INSTRUMENTS. : RUNNING-IN PUMS ‘CALIBRATING PROPORTIONING PUMES. STEAM SYSTEMS eon Sea ‘TURBINES AND COMPRESSORS. REFRACTORY DRYOUT enone Dryout of he 101-B, Primary Reformer. Dryout of the Start-Up Heater... 103-D Secondary Reformer Dryott. : 7 i SCOPE en is : a a REFERENCE DOCUMENTS .nsoenossun a Peete ete AMBIENT AIR CURING .. ce pe ee GeneRal . PREPARATION Water Jacket Dome Baffles. Stacks and Ducts Air Stream bnlet Thermocouples. Burner Requirements. Precautions Dryout Field Joints Dryout Logs Inspection and Testing... Final Preparations : AMDEA SYSTEM PREPARATION Mechanical Cleaning and Inspection Initial Circulation and Degreastigeinunnnnnninn Water Washing (Cool Water) Water Washing (Hot Water) Flushing with 3% Caustic (Sodium Hydroxide) Solution. First Condensate / Demineralized Water Flush... Second Condensate / Demineralized Water Flush. FLUSH COOLING WATER SYSTEMS... eiereaaes z PROCESS LINE BLOWING, zy : : Leak Test UNIT, AMMONIA CONCENTRATION LitditS AND BEEECTS : (CHEMICAL CLEANING OF THE HIGH PRESSURE STEAM SYSTEM... seaanae Seope. Preliminary Activities . Safety. Water Flushing. INITIAL PIPING FLUSHING PRIOR TO CIRCULATION... ALL VALVES OPENED DURING THE FLUSHING SHOULD BE RETURNED T0 THEIR CLOSRD POSITIONS BEFORE ‘CONTINUING THE PROCEDURES FOL WATER CIRCULATION FLUSH. Circuit One a ee a retrain votreA\ eon AA rt OPERATING PHILOSOPHY | CONTRACTOR ID. CODE 9294-VZ-MP-0001 PROJECT: Ammonia Plant Feedstock Changeover {LOCATION : Nangal Sheet 50446 | Issue 1 Cireuit Two. Cireuit Three Cireuit Four Circuit Five. Gircuit Six Circuit Seven Circuit Bight. Cireutt Nine, DRAIN AND FLUSH ALKALINE BOILOUT Preparation CIRCULATION FOR ALKALINE BoiLOUT.. Circuit One. Circuit Two. Circuit Three... Gireuit Fou Circuit Five Circuit Six. Circuit Seven... Cirenit Bight, Cireuit Nine DRAIN AND FLUSIE Chemical Cleaning. GENERAL. CHARGING CHEMICALS AND ESTABLISHING CIRCULATION. (CHEMICAL SOLVENT DISPOSAL. Inspection (CHEMICAL CLEANIN Scope. Preliminary Activities sn Safety Considerations. Water Flushing. Alkaline Bottout Fill, Circulate, Soak and Drain Methed. Chemical Cleaning Dryout / Final Inspection / Layup. ia CHEMICAL CLEANING OF 101-C BEFORE INSTALLATION - ALTERNATE PROCEDURE Scope. Preliminary Activities Safety Considerations... Water Flushing. Alkaline Boilout Fill, Circulate, Soak and Drain Method. Chemical Cleaning. Dryout / Final Inspection / Lay... Preliminary Action by Drawing.n.u METALLURGY... INSTRUMENTATION... : CHEMICAL CLEANING DIAGRAMS ssconsonssncnsnennnnrnnnennn START-UP PROCEDURES. 286 INTRODUCTION. Se 7 . . cad PRELIMINARY START-UP PHILOSOPHY... asi i. ca aanS INITIAL START-UP Ss oeeeee oe ote ‘ded anna enn oe oe etnies cetAA vom \ mee we mein [PBIL KBR OPERATING PHILOSOPHY | CONTRACTOR TD. CODE 9294-VZ-MP-0001 PROJECT: Ammonia Phot Feedstock Changeover |LOCATION:Nangal [Sheet 6 of 446. | Issue Ol Deacrator, F-2301 BW Water Pumps - Commission the Steam Systems 101-JTC surface condenser a Commission 101-BJ2 and 101-27 Commission 101-BJI and 101-BJIM. General. Prestart-up Conditions ee Commission Natural Gas sans Jacket Water Front End Warm-up. ‘Steam Heating 141-D/101-C/ 103- 101-C Waste Heat Boiler Circulation... ‘Steam Drum Operating Parameters. Introduction of Natural Gas. Ammonia Cracking for Hydrogenatio Commission Refrigeration Systett nsnounonnesn Commission 120-Js. atti ta ee aaa Dissociation Of Ammonia To Produce Hydrogen and Reduction For Desulfurtzation Start aMDEA Solution Circulation anv. Naiural Gas Hydrogenation & Desuifurization Process Condensate System.. ina Desulfurize Natural Gas Feed. i ‘Start Feed Gas to the Primary Reformer von.nnrnrnnsnars Reduce and Desulirize the Reformer and HT Shift Catalyst. HP Steam Letdown sora Start Air Injection to Secondary Reformer 103-D. Complete Desulfurization of HT Shift Converter Process Condensate Stripper. Start CO: Absorptio) LTS Guard Bed Reduction Procedure LTS Reduction Procedure Commission LTS Guard Bed. Commission Low Temperature Guard Bed Converter Commission Low Temperature Converter. Start Methanation. INCREASE Prep Ra’ aMDEA System Start the Hydraulic Tur Primary Reformer. Secondary Reformer Desulfurizer on Steam Systems Start the 105-J Refrigeration Compressor Start-Up Synthesis Gas Driers 109-DA / DB. Regenerate the Molecular Sieve Dryers. Cryogenic Purifier Start-up. Cryogenic Purifier Dryout. Process Gas Dryou. Purifier Cool Down ‘Start-Up Symhesis Gas Compressor G-1701 ate ee NLS agp ener cel faene pagename nee,AV veanen f\ wena PpIL) EPSIKBR OPERATING PHILOSOPHY | CONTRACTOR TD. COD: fe 9294-VZ-MP-0001 PROJECT: Ammonia Plant Feedstock Changeover LOCATION: Nangal sheet 70F446. | Issue 0! Pressure Testing of the Synthesis Loop.. SYNTHESIS CONVERTER CATALYST REDUCTION, ‘TRIM UNIT CONDITIONS AND STABILIZE ANMONIA PRODUCTION, aca START THE AMMONIA STRIPPING SYSTEM. Place 123-D, 124-D and 125-D In Service... Start Cireulation (COMMISSION PURGE GAS TO THE PROCESS OR Fubt GAS S¥S SECONDARY BURNER FIRING STARTUP AFTER EMERGENCY Service Boiler Trip. Synthesis Gas Machine Trips.a0oe 105>J Refrigeration Machine Trip. PoRIPIER TRIP METHANATOR TRIP. AMDEA SoLurion CIRCULATION Faitnd OW L685 Ov LEVEL: WN131-C1 SHIFT CONVERTERS cnn Loss oF Process Ai Loss oF FEED GAS. 1.058 oF PeocEss STrAM Loss OF BOILER FREDWATER Loss oF POWER... NORMAL STARTUP iuTDOWN SHUTDOWN PROCEDURES NORMAL SHUTDOWN PROCEDURi Introduction. Redueing Unit Throughput... PLANT SHUTDOWN veo z Normal Shutdown .. ae Purge Gas Ammonia Recovery System Shutdown ess Synthesis Section Shutdown. ‘nunonia Refrigeration System Shutdown. Purifier Shuidown. ‘Methanator Shutdown Low Temperature Shift Converter Shutdown. LTS Guard Bed Shutdown aMDEA System Shutdown eee High Pressure Condensate Stripper Shutdown. High Temperature Shift Converter Shutdown Reforming Section Shutdown. ‘Shut Down and Secure the Steam System. Shut down High Pressure BFW Pumps (G2301/62302/G2303.. Shut down 10L-JTC un EMERGENCY PROCEDURES. Introduction van a Loss of Ammonia Recovery Syste. Loss of Synthesis Loop / Synthesis Gas Compressor... Loss of 1059J Refrigeration Compress0 vv. Loss of the Purifier. Loss of Methanator, 106-D... : Loss of aMDEA Solution Circulation .. Loss of LTS Converter, 104-D2. Loss of LTS Guard Bed, 104-D3 Loss of HTS Converter, 104-DI ‘vant Mentality elie nate pl centage pel eco "rea Scape daca a espanaA eon AV rose RVA Zea PBI KBR OPERATING PHILOSOPHY | CONTRACTORID. CODE’ 9294-VZ-MP-0001 PROJECT: Ammonia Plant Feedstock Changeover [LOCATION : Nangal Isheet 80446 | Issue 01 Loss of Process Air Loss of Primeny Reformer Feed Gas. Natural Gas Failure. Loss Of Process SteaMawnnen Loss Of Steam Pressure Loss of Water - Steam Drum [41-D. Loss of Boiler Feedwvater. : Cooling Water Failure. INSTRUMENT AIR FAILURE, BLECTRIC POWER FAILURE. Emergency Load Schedule and Diesel Generator Capacity. Electrical Equipment interlocks 0.0. UPS Load Schedule and UPS Capacit tet Hiecrical Equipment with Auto Reacceleration After Power Dip. CONCLUSIONS... Removing Equipment From Service.. Returning Equipment To Service. CATALYST OXIDATION : SPECIAL INSTRUMENTATION AND CONTROL! 446 ae an eth usual poke ate sth Coan popeenotpemnacs nieta ws NWA PRI) KB A OPERATING PHILOSOPHY | CONTRACTORTD. CODE, cpa [PRIC a 9294-VZ-MP-0001 PROJECT: Ammonia Pl Feedstock Changeover LOCATION: Nangal Sheet 90446 | Issue 01 Safety and Health Purpose and Application The main purpose of this operating philosophy is to provide operator training and basic information, concerning the ammonia unit area at the TCM / National Fertilizers Nangal Punjab-India plant. The information in this operating philosophy emphasizes safe and. efficient work practices, which must be followed to produce high quality products. * Think Safe * Work Safe © Be Safe Personnel Safety It is the responsibility of each TCM / National Fertilizers employee to participate in accident prevention. Each employee has a responsibility (o their family, fellow employees, and TCM | National Fertilizers to work safely. Therefore, in the performance of all duties, every employee is expected to observe safe practices and instructions relating to the efficient and safe handling of all work tasks, Responsibilities include but are not limited to the following: * Incorporate sound safety practices into all tasks and not takes chances. * Know and follow established safety standards and use safety as a primary consideration in planning all work. * Consult a supervisor when doubt exists about the safety requirements of a task. © Report all injuries immediately and cooperate with all investigations into the causes and prevention of accidents. © Participate in safety efforts realizing that prevention is the key to personnel, environmental, and equipment safety ‘ ounnteaniowsa urn pening geal ronnie uencmngeete "re te ack age peae M4 pic) KBR OPERATING PHILOSOPHY | CONTRACTOR ID. CODE eae EEE EEE Eee 9294-VZ-MP-0001 PROJECT: Ammonia Plant Feedstock Changeover LOCATION: Nangal Sheet 10.0f 446 | Issue O1 mental Safety Environmental safety activi are mandated by Federal, State, and / or Local Authorities for all chemical process plants that handle hazardous materials. Protection of air, water, land, and surrounding life from pollution must comply with controls established by governmental regulatory agencies. Environmental safety begins with each employee. It is the responsibility of each employee to safeguard the environment, both in the interest of TCM / National Fertilizers Ltd., as well as to the communities and companies in the surrounding area. Day to day operations must be scrutinized to ensure proper handling of chemicals, and to avoid releases to the environment. Some basie examples of day to day environmental concerns are: ‘* Proper disposal of chemicals © Efficient use of the storage and process flare systems © Unit monitoring for fugit isi © Prevention of unwanted runoff onto the sewer system Equipment Safety Equipment safety refers to verifying that a tool or piece of machinery is safe to use and that cach person’s knowledge of using the equipment meets approved operating standards, This is accomplished through training, calibrating, and maintaining mechanical and electrical systems so that they function as intended. Safety Systems Safety systems are provided as a function of the process design. Relief valves protect vessels, piping, and equipment from over pressurization, and fail-safe valves assume their designed positions in the event of failure of automatic positioning, electrical power, or instrument air pressure, These features provide protection against over pressurizing operating systems and loss of process chemicals to the atmosphere, which could impact personnel safety and the environment. Depending on the design application, relief valves are used for the following: ‘* Overpressurization * Thermal relief ‘Alarm are installed at specific point in the process to monitor parameters critical to the proper operation of the unit. These alarms provide operators with a warning of conditions that, if left LA ne ee Raga cen Stem,wy pit) OPERATING PHILOSOPHY | CONTRACTOR ID. CODE = oa i 9294-VZ-MP-0001 PROJECT: Ammonia Plant Feedstock Changeover LOCATION: Nangall ISheet 11 of 446 | Issue.01 uncorrected may activate specific automatic process flow failure responses. Some typical examples of failure responses are: Relief valve opening to vent. (Resulting in product loss to vent and possible environmental impacts) Activation of automatic shutdown systems. In addition, certain interlocks are provided to perform specific automatic actions, such as opening/closing valves, and/or shutting down pumps or compressors. (Results in down time and in most cases product loss to the vent). Safety systems not related to the process that is just as vital are: © Safety showers / eye wash stations ‘* Fire monitors / fire water system «Emergency Lighting * Radio, Telephone, or Intercom Communication Devices Personnel Protective Equipment such as Breathing Air SystemsA esas Atte we TONTRACTOR 1D. CODE ea PDIL KBR OPERATING PHILOSOPHY a 9294-VZ-MP-0001 PROJECT: Ammonia Plant Feedstock Changeover Jessi nana ISheet_ 12 0f446 | Issue 01 Factors That Affect Quality General While many clements must be considered when quality of a final product is discussed, two ‘major areas are typically examined in the investigation of process problems: 1. Operator Error 2. Equipment Failure In order to maintain high quality products, operators must be trained to recognize acceptable process control parameters and be able to make adjustments as necessary. Equipment must always be in good working order to maintain and indicate the proper operating limits, Process Troubleshooting Troubleshooting is a method of solving problems. Once the problem is identified, a cause can be attached to it, Careful analysis should be made such that the identified cause is truly the cause and not a symptom. Once the cause is identified, remedies or solutions can be implemented, Generally the problem solving technical sequence of steps is as follows: Step (1) Identify the Problem Step (2) Gather Information That Relates To the Problem Step (3) Identify the Root Cause Step (4) Formulate the Solution Step (5) Test the Solution Step (6) Implement the Solution Step (7) Measure Effectiveness of the Corrective Action If The Problem Persist Return to Step 1, which is to identify the Problem Obviously, the identification of problems cannot take place unless standards of control limits are declared. Sampling, record keeping, monitoring, and the use of calibrated instrumentation are key factors in the assessment of process problems. SamplingMA reson Arc CONTRACTOR 1D. CODE s% P DIL) KBR OPERATING PHILOSOPHY 9294-VZ-MP-0001 13 of 446 sheet Issue 01 PROJRCT: Ammonia Plant Feedstock Changeover |LOCATION : Nangal Sampling is q fundamental part of produet verification and good process operation, A sample should be taken to ensure that process and product specifications are being met. Avoid catching samples from low flow or stagnant points. Allow adequate movement of the product prior to catching the sample. Refer to the Material Safety Data Sheet (MSDS) book to determine any required precautions necessary to safely collect specific chemical samples. Take samples only from designated sample locations. It is very important to always wear the proper personal protective equipment (PPE) when taking samples. The following is a general checklist for sampling in the ammonia unit, Obtain sample container for specific sample to be taken Locate sample point Inspect sample point for proper working condition Using proper PPE equipment to catch sample Isolate sample point and remove sample Fill out sample tag and attach to sample or use a pre-labeled sample container ‘Take sample to designated lab pick-up point or to the lab directly Log sample and results in the operators log book eI ae eee Refer to the TCM / National Fertilizers Ltd. normal operation procedures covering sample procedures for detailed instructions. Record Keeping Record keeping is a means to document quality, measure inventories, and generally track notable activities which could indicate trends before serious consequences result. Shipping, Receiving, Daily Production Logs, Environmental Reports, Operator Reading Log Sheets, and Safety Records are some examples of records which are maintained for production, business, and legal reasons. Some concerns, which are inherent to record keeping in general, include: Allocation Of Time To Keep Records Storage Space For Records Retrieval Of Records After Storage Length Of Time To Keep Stored Records Other quality control records include equipment inspection reports, calibration / test reports for relief valves, interlock systems, flow meters, temperature indicators, and pressure gauges, ete, ‘Rhsovarioush cnet Nina's guroulghens neat rauleramdeeytnad a tae ctor, eR etree ed ener ccel ea eames ong wescAY water \neinee wy NZ PpiL| KBR OPERATING PHILOSOPHY | CONTRACTOR ID. CODE mem [Pate 9294-VZ-MP-O001 Location : Nangal Isheet 14 of 446 | Issue 01 [ Proynicr:Avmorn Pw Reock Gagne Hand written records such as Daily logbooks should be clear, concise, and to the point. Take a few minutes to think about the main points of the event you are writing about before you start, Always leave out personal opinions, only state the facts. Records that are not retrievable are useless. Check with the unit supervisor to determine record retention times, and storage locations as required, to keep records current and useful. The key to record keeping is consisteney. Try to take readings at the same time each day for continuously operated equipment. This will help negate the effect of varying outside factors on your data, Environmental records as opposed to production records must be maintained to comply with federal, state, and local government regulations. This data must be accurate, For more details on how and when to record environmentally sensitive data consult the Environmental Deaprtment or the unit supervisor. : ae ie aa iy seat Ser SSpopecagmenaea see me9294-VZ-MP-0001 % cei KBR OPERATING PHILOSOPHY | CONTRACTOR ID. CODE Ss Pear ence eae eee PROJECT: Ammonia Plant Feedstock Changeover LOCATION: Nangal_ Sheet 15.0446 | Issue 01 Routine Operator Duties Routine Duties for Console Operators In performing the normal job duties in the ammonia unit operations, control console operators will be required to: © frequently monitor DCS and other consoles for safe and efficient operations * make necessary adjustments to keep process running smoothly * print and retrieve DCS generated reports © Record selected unit information on log sheets at pre-set intervals. Control console operators should always communicate with the outside operators using clear and precise instructions. In performing the normal job duties in the ammonia unit operations, outside operators will be required in part to: Climb ladders Climb stairs Open and close valves of all sizes Work around hot and cold equipment Work in clevated areas of the unit Lift various tools and small equipment Use hoses of varying services and sizes Handle chemicals Record selected unit information on log sheets Operators should pay special attention to, proper lifting techniques and proper body positioning when operating valves, to prevent back injuries, and the proper use of fall protection when working on elevated platforms or ladders. This does not preclude any or all of the other safe work standards, but simply highlights some of the hazardous areas of the normal job duties that sometimes are taken for granted and cause the worst injuries, ema create One ey daasalccely satay pape perwmewauee eetN canon Anema BIL KBB OPERATING PHILOSOPHY | CONTRACTOR ID. CODE 9294-VZ-MP-0001 PROJECT: Ammonia Plant Feedstock Changeover | LOCATION : Nangall sheet 16 0f446 | Issue Ot ‘The safest process operator is a well-trained and observant operator that applies all safe work practices and standards in performance of every task required, Operators should always take the time necessary to read or review the Material Safety Data Sheets, MSDS, and procedures for the task to be preformed, and use the proper personal protective equipment, PPE, and tools, wy Housekeeping Housekeeping is an area of concern that must be addressed because of its direct impact on safety in the workplace and morale of the employees. Keeping an area clean and orderly can provide the basis for positive attitudes and efficiency in operations and other related departments. Housekeeping must be applied not only to equipment maintenance where the need is obvious during or after maintenance work, but also to routine activities such as eating, smoking, and keeping break areas clean and orderly. ‘The use of appropriate cleansers to clean soiled areas and putting items back in their proper place of storage after use, are major elements in the implementation of a good housekeeping program, Operators should write work orders for clean up activities that fall outside the scope of their responsibility. Examples of tasks that may fall into this eategory are: ‘© Removing scaffolds from process areas * Disposal of insulation Operators should always be aware of housekeeping; it takes a conscientious effort from everyone involved to accomplish a successful housekeeping program. Operating Instructions / Logs, Mechanical Books and Vendor IMOI Books Operators can not properly operate a plant if they can not find the appropriate vendor information to refer to. A complete set of as-built P&IDs and other drawings, mechanical catalogs, vendor instructions books and engineering data should be accessible to the operators at all times. These items should be stored in the contro] room in a controlled environment and available for anyone who requires information at anytime of the day or night. a Te esas eae Us mcm nee,\ A vest AA nee , “Z v t ‘CONTRACTOR ID. CODE sea (PBIL] KBR OPERATING PHILOSOPHY 9294-VZ-MP-0001 PROJECT: Ammonia Plant Feedstock Changeover {LOCATION Nangal Sheet 17 0f446 | Issue 01 Overview This operating philosophy has been compiled to assist those charged with the responsibility of the initial startup and subsequent operation of the 950 metric tons per day ammonia plant for TCM / National Fertilizers Ltd, in Nangal Punjab-India, Its primary objective is to provide flow descriptions and discussions of the processes involved and related operating principles, suggested procedures for the initial commissioning, and suggested procedures for startup and shutdown of the plant, The contents should be regarded as a source of reference for information in resolving operating problem NOTE Tt is not possible to anticipate and present herein all potential circumstances, which confront the operators during the commissioning, startup, normal, and emergency shutdown of the unit. Consequently, this operating philosophy must be recognized as a GUIDE and that conditions stipulated are NOT rigid standards, unless specifically noted as such, The operating conditions and techniques will evolve from actual operating experiences, Under no circumstances should operations deviate from safety regulations and practices followed throughout the industry. ae Te reeceMA rein A annie My ese PBL) KBR OPERATING PHILOSOPHY | CONTRACTOR ID. CODE 9294-VZ-MP-OO01 PROJECT: Ammonia Plant Feedstock Changeover - [LOCATION :Nengal Isher 18 0f446 | Issue Ot Process Description ‘The front end of the ammonia plant is based on KBR Purifier™ technology, which is a low energy natural gas steam reforming based process that is offered and licensed by KBR. The new front end is combined with the existing synthesis loop to produce 950 MTPD of ammonia, The plant design and performance are based on lean natural gas composition, which is the design case. However, the plant will also be able to operate and achieve the nameplate capacity with the rich natural gas composition as well, ‘The ammonia plant process design for the lean gas case at end-of-run conditions is shown on Process Flow Diagrams FD-1, 2, 3, 4, along with steam balance on FD-5, cooling water balance on FD-6 and CO2 chiller unit on FD-7. Similarly, the ammonia plant process design for the rich gas case at end-of-run conditions is shown on Process Flow Diagrams FD-1A, 2A, 3A, 4A, steam balance on FD-5A, cooling water balance on FD-6A and CO2 chiller unit on FD-7A, This Process Description refers to the lean gas case, end-of-run operation. It should be noted that NFL equipment tag numbers are maintained for existing equipment while all new equipment have KBR equipment tag numbers. ‘The feed and fucl to the ammonia plant is natural gas with the following compositions and conditions: Composition, dry mol% Lean Gas Rich Gas CHs 84.50 Kea z [9.00 7 CoHs 3.00 Cato 2.00 Csthe 0.25 CO2 0.00 Ne 1.25 Total 100.00 LHV (keallkgy a 34 Total Sulfur (as H2S and organic sulfim), ppmv <10 Pressure at Plant Battery Limit, kg/em2(a) 41 ‘Temperature, °C 30.0 seit enn,AA reron— etna wy epic KBR OPERATING PHILOSOPHY | CONTRACTORID. CODE 9294-VZ-MP-0001 PROJECT: Ammonia Plant Feedstock Changeover LOCATION : Nangal Isheet 19 of 446 | Issue 01 ‘The main process steps are as follows: Feed Gas Compression, Preheating and Desulfurization Primary Reforming Process Air Compression Secondary Reforming Shift Conversion Carbon Dioxide Removal CO? gas chilling Methanation Drying Cryogenic Purification Synthesis Gas Compression Ammonia Synthesis Purge Gas Ammonia Recovery Ammonia Refrigeration Process Condensate Stripping Steam System Cooling Water System Feed Gas Compression, Preheating, and Desulfurization Natural gas for feed and fuel is supplied at the plant battery limit at 30 °C and 41 kg/om™(a) at metering station, Natural gas first goes through the Feed Gas Knockout Drum (174-D), where any entrained liquids (or solids) are removed. Part of the natural gas sent to the primary reformer furnace as fuel. The rem natural gas is compressed to 57.3 kg/em*(a) in the Feed Gas Compressor, 102-I which is driven by an electric motor, 102-IM. To allow the compressor to operate over a wide range of operating conditions without going into surge, it is provided with a kickback line and a Kickback Cooler, 143-C. This allows some of the compressor discharge gas to be recycled back to the compressor suction through 174-D. This is typically required during plant start-up and turndown conditions when the feed gas flow is much lower than normal After compression in 102-J, natural gas feed is niixed with a small amount of synthesis gas recycled from the synthesis loop, This provides the required hydrogen for the downstream hydrotreater. If the synthesis loop is not in operation, the hydrogen recycle stream can be taken from the Methanator Effluent Separator (144-D) overhead and added at the suction of 102-J. It is also possible to produce hydrogen by ammonia cracking in the primary reformer. An ammonia injection line upstream of the primary reformer is provided for this. ‘The mixture of natural gas and hydrogen is heated to 371 °C, first using condensing LP a ii ans agptn ateuantonl fcr aypapesebsaeemeee mena,ae NA PRAT CONTRACTOR ID, CODE mam (PPIt) KBR OPERATING PHILOSOPHY 9294-VZ-MP-0001 PROJECT: Ammonia Phant Feedstock Changeover | LOCATION : Nangal Isheet 20 of 446 | tssue OF steam in the LP Steam/Eced Gas Preheater (190-C), and then in the Feed Gas Coil located in the convection section of the Primary Reformer (101-B). The hot gas then enters a two step desulfurization system. In the first step, the hot gas passes through a Hydrotreater (108- DA), which contains cobalt /molybdenum (CoMo) catalyst, The catalyst ensures hydrogenation of organic sulfur compounds such as mercaptans (RSH) and carbonyl sulfide (COS), if present in the feed gas, and converts them to hydrogen sulfide. RSH + H2= RH + HS COS + Ho= CO + ERS In the second step, hydrogen sulfide in the feed gas is removed in two Desulfurizers, (108- DB/DC). Each Desuifurizer contains a bed of zine oxide. Hydrogen sulfide reacts with the zine oxide and is retained as zine sulfide, thereby producing an effluent stream containing less than 0.1 ppmv of sulfur. HS + ZnO = Zn$ + H20 The two desulfurizer vessels are arranged in series, in a lead-lag configuration such that either vessel can be taken out of service to replace the zine oxide while the other vessel remains in service and plant operation is not interrupted. Each vessel contains enough zine oxide to last for at least one year of continuous service at the design inlet sulfur concentration of 10 ppmy (max,) hydrogen sulfide in the feed gas, Primary Reforming Desulfurized feed gas is mixed with process steam from the MP steam header and the overhead of the Process Condensate Stripper (130-D) to give a steam to organic carbon molar ratio of 2.7:1. The feed gas flow is controlled by ratio to the process steam flow, This feature protects the reforming catalysts in case of loss of process steam. The mixture is preheated to about 495 °C in the convection section of the Primary Reformer (101-B). The preheated mixed feed is distributed over tubes packed with reforming catalyst and suspended in the radiant section of 101-B. Steam reforming reactions take place over the nickel based reforming catalyst in the radiant tubes to form carbon monoxide, carbon dioxide and hydrogen. Steam reforming reaction for any hydrocarbon can be written as: Cy Hy + 2 H20 = n CO + (2ntm)y/2 He For methane the above reaction becomes: “Ds doves anda once ete annem moe al opt ns “Tar aang chaser ea geSeneer papooseOPERATING PHILOSOPHY | CONTRACTOR ID. CODE 9294-VZ-MP-0001 PROJECT: Ammonia Plant Feedstock Changeover _LocaTton : Nangal Isheet 21 0f446 | Issue 01 CHa + E20 =3 H2 + CO The water gas shift reaction converts carbon monoxide to carbon dioxide and additional hydrogen: CO + H2O =CO2 + Ha The 101-B effluent gas at 48.0 kg/em?(a) and 721 °C contains about 29.87 mol% (dry basis) of unreacted methane, The 101-B effluent is sent to the Secondary Reformer via the Primary Reformer Effluent Transfer Line (107-D). Heat for the endothermic steam reforming reactions in 101-B is supplied by the combustion of fuel gas in burners located at the top of the furnace. The burners are located between the rows of catalyst tubes and are downward firing. Thus, the heat flux is highest at the top of the tubes, where the process temperatures are the lowest and most of the reforming reaction, is being done. The outlet manifolds and riser tubes are located inside the radiant box for heat conservation. The primary reformer uses the latest refractory and insulation technology. Ceramic fiber lining in the radiant section provides rapid thermal response due to low heat storage. Super duty hard refractory is used where flames may contact the sidewalls, The reformer is designed with 2% oxygen (dry basis) in the flue gas at the outlet of the radiant section. This ensures complete combustion of the fuel in the burners. The Purifier process uses excess air in the secondary reformer. This feature reduces the size of the primary reformer furnace by about one third, and lowers the process gas outlet temperature from the reformer substantially, as compared to a conventional ammonia plant. The lower outlet temperature results in longer tube and catalyst life. ‘The primary reformer is designed to obtain maximum thermal efficiency by recovering heat from the flue gas in the convection section. The heat recovered is used for the following services: *Mixed Feed Preheating Process Air Preheating # Steam Superheating #Feed Gas Preheating © Combustion Air Preheating ree eta eee cmeAN restos Nanas Mw sti ‘TING CONTRACTOR ID. CODE cada {PDIL KBR OPERATING PHILOSOPHY 9294-VZ-MP-0001 PROJECT: Ammonia Plant Feedstock Changeover LOCATION: Nangel _|Sheet_ 22 0F 446 | Issue O1 Process Air Compression Process air is drawn in through an Air Filter (101-L) that removes any dust particles. Process air is then compressed in an integrally geared Process Air Compressor (101-J) to a pressure of 50.8 kg/em2(a). Inter-stage cooling and condensate separation is provided in 101-J, 101-J is controlled to maintain a constant pressure drop across the downstream process air control valve, During plant startup or tudown operation, enough compressed s vented to maintain the minimum load on the compressor to prevent it from going into surge. Compressed process air is then preheated to about 510 °C in the Air Preheat Coils located in the convection section of 101-B, and sent to the secondary reformer. Steam is continuously added to the process air at the inlet of the coil. This feature prevents backflow of hot gas from the Secondary Reformer in the event of a 101-J trip. 101-J also provides plant and instrument air required for the entire plant from 3rd stage discharge of the compressor. Secondary Reforming Hot compressed process air and primary reformer effluent are sent to the top section of the Secondary Reformer (103-D) where spontaneous combustion occurs. The resulting hot gas mixture then flows down through a bed of nickel based reforming catalyst in the lower section of 103-D, The heat released from the combustion reactions in the upper section supplies the heat for the steam reforming reactions in the lower section, converting methane to more carbon oxides and hydrogen, The unreacted methane content in the gas leaving 103-D is about 1.77 mol% (dry basis). In @ conventional ammonia plant, the amount of process air introduced in the secondary reformer is controlled carefully to produce a stoichiometric 3:1 molar ratio of hydrogen to nitrogen at the inlet to the ammonia converter. In the Purifier process, about 50 percent excess air is used in the secondary reformer with the excess nitrogen being removed in the Purifier coldbox. The excess air produces additional combustion heat for the reforming reactions in the secondary reformer. ‘Thus the reforming load is shifted from the primary reformer to the secondary reformer. This feature lowers the primary reformer outlet temperature and furnace duty. In addition, the methane leakage from the reforming section is relaxed as the unreacted methane is removed in the Purifier cold box. This reduces the overall reforming severity and lowers the secondary reformer outlet temperature to about 906 °C. The lower outlet temperature results in milder conditions for the downstream waste heat boiler as compared to conventional plants, ‘The heat in the 103-D effluent is recovered by generating HP steam (104 kg/em?g) in the i a et cna ee fae Un,A seme A\ nate pit) KBR OPERATING PHILOSOPHY | CONTRACTOR ID. CODE: 9294-VZ-MP-0001 PROJECT: Ammonia Plant Feedstock Changeover | LOCATION : Nangal sheet 23 of 446 | Issue O1 Secondary Reformer Waste Heat Boiler (101-C). 101-C is a KBR proprietary design. It is vertical, water-tube, thermosyphon boiler. For safety reasons, 103-D, 107-D, and 101-C are provided with water jackets. The water Jackets keep the metal walls cooler and provide an early warning system against any possible refractory failure which allows for an orderly shutdown of the plant in such a scenario. Shift Conversion The cooled Secondary Reformer effluent is sent to the High Temperature Shift (HTS) Converter (104-D1) reactor. Here, the gas flows over a bed of HTS catalyst where the carbon monoxide reaets with steam to form carbon dioxide and hydrogen via the water gas shift reaction, CO + H20 =CO2 + Ha About 72% of the carbon monoxide is shifted to carbon dioxide in the HTS converter. The carbon monoxide content in the HTS effluent is about 2.87 mol% (dry basis). The water gas shift reaction is exothermic, The gas leaving the HTS converter is cooled by generating HP steam in the HTS Effluent/Steam Generator (103-C), and by heating HP boiler feed water in the HTS Effluent/BFW Preheater (186-C). The gas then passes through a LTS Guard Bed (104-D3) which is packed with LTS catalyst. 104-D3 catalyst volume is based on 2.5 years of catalyst life. 104-D3 effluent is cooled against Boiler Feed Water (BFW) in the LTS Guard Bed Effluent/BF W Preheater (187-C) and is then sent to the Low Temperature Shift (LTS) Converter (104-D2) at about 208 °C. Most of the remaining carbon monoxide is shifted to carbon dioxide in the LTS, leaving a residual carbon monoxide content of about 0.25 mol% (dry basis) in the LTS effluent, LTS effluent is cooled against BFW in the LYS EffluenBFW Preheater (131-C) and by producing LP steam in the LTS Effluent/LP Steam Generator (131-Cl). The gas is then sent to the CO2 Stripper Reboiler (105-C) and further cooled in the LTS Efflueny/DMW Exchanger (106-C) to about 70 °C. The process condensate is separated out in the Raw Gas Separator (142-D1) and pumped to the Process Condensate Stripper. The overhead of 142- D1 is sent to the Carbon Dioxide Removal unit, Carbon Dioxide Removal The Carbon Dioxide Removal unit uses a two stage aMDEA® process licensed by BASF. The process gas enters the bottom of the CO2 Absorber (121-D) at about 70 °C. It is contacted counter-currently with semi-lean aMDEA solution in the lower section of 121-D. rene a uit uaa Compre cuaeonltpecaniroypapewca paramere nomenai$ at Fei KBR OPERATING PHILOSOPHY | CONTRACTOR ID. CODE 9294-VZ-MP-0001 PROJECT: Ammonia Plant Feedstock Changeover |LOCATION : Nangal iSheet 24 of 446 | Issue OL The gas then flows upward into the top section of 121-D where it is contacted with lean aMDEA solution, The gas then passes through a wash water section and demister pad before being sent to the CO2 Absorber Overhead Knockout Drum (142-D2) to remove any traces of entrained aMDEA solution. The treated gas leaving the top of the absorber contains less than 500 ppmv (dry basis) of carbon dioxide and is sent to the methanation section, Rich aMDBA solution from the bottom of 121-D is first passed through a power recovery Hydraulic Turbine (107-JAHT). The power recovered in the hydraulic turbine is used to drive one of the Semi-Lean Solution Pumps (107-JA). The rich aMDEA solution is then sent to the High Pressure (IP) Flash (126-D) where most of the dissolved inerts are flashed from the rich solution. This ensures a high purity carbon dioxide product that is low in inerts, Since the flash gas from 126-D contains a fair amount of carbon dioxide, this gas is further scrubbed with a slipstream of lean aMDEA solution in the HP Flash Gas Scrubber (127-D) to recover almost all the carbon dioxide. The overhead from 127-D is routed to the fuel system, The 127-D bottoms are mixed with 126-D bottoms and sent to the top of CO2 LP Flash (122-D1). The LP flash operates at about 1.8 kg/em?(a). At this low pressure, most of the carbon dioxide from the rich aMDEA solution is flashed. ‘The solution flows down through a packed bed where it is contacted with rising vapor coming from the CO2 Stripper (122- D2), The CO2 stream from the top of the LP Flash Column is cooled to 38 °C by the CO2 LP Flash Overhead Condenser (107-C). Condensate is separated in the CO2 LP Flash Overhead Knock Out Drum (180-D) and pumped by the CO2 LP Flash Reflux Pump (116- JINJA) to provide wash water for 121-D, 122-D1 and 127-D. The make-up water required for the CO2 Removal Unit is also added to the suction of 116-J/JA. Semi-lean aMDEA solution is drawn from the bottom of the LP Flash, Most of the semi- lean solution is pumped by 107-JA/JB/JC to the bottom section of the CO2 Absorber. About 17% of the semi-lean solution is pumped by the Semi-Lean Solution Circulating Pumps (117-J/JA), heated to about 100 °C in the Lean/Semi-Lean Solution Exchanger (112-C), and then sent to the CO2 Stripper (122-D2), LTS effluent gas supplies heat to the CO2 Stripper Reboiler which is used to strip carbon dioxide from the aMDEA solution, The stripped carbon dioxide flows up the stripper and is sent to the LP Flash. Lean aMDEA solution is drawn from the bottom of 122-D2. The lean solution is cooled by exchanging heat against semi-lean solution in 112-C, It is further cooled to about $0 °C using cooling water. The cooled Jean aMDEA solution is then pumped by the Lean Solution Pumps (108-J/JA) to the top section of the CO2 Absorber and a ee eae maceA reocen A Veins NA ti ‘CONTRACTOR ID, CODE wa PpIL) KBR OPERATING PHILOSOPHY 9294-VZ-MP-0001 PROJECT: Ammonia Plant Feedstock Changeover | ocaT1oN : Nangal Isheet 25 0f446 | Issue 01 to the HP Flash Gas Scrubber. The carbon dioxide removal unit is designed with a slightly negative water balance. To maintain the concentration of aMDEA solution in the system, a continuous make-up of about 220 kg/hr of demineralized water is required. This design eliminates the discharge of any aMDEA solution from the system which avoids any expensive effluent treatment, and minimizes the aMDEA solution loss, Given the composition of the natural gas (both lean and rich), the steam reforming front-end does not produce sufficient carbon dioxide i.e, 1240 MTPD as 100% CO2, when producing synthesis gas sufficient for 950 MTPD of ammonia, Hence, additional feed gas needs to be reformed and passed through the carbon dioxide removal unit to meet the carbon dioxide production requirements, As a result, the synthesis gas production is more than what is required for 950 MTPD of ammonia, Surplus synthesis gas, which represents about 3% of the total synthesis gas produced, is sent to the fuel system, It is worth noting that due to the use of excess air in the secondary reformer, the Purifier process generates proportionately more carbon dioxide than other conventional steam reforming processes. This reduces the amount of surplus synthesis gas “wasted” to the fuel system, as compared to other conventional processes. Methanation ‘The vapor from the CO2 Absorber Overhead KO Drum is preheated to the methanation reaction temperature, using methanator effluent in the Methanator Feed/Effluent Exchanger (114-C), and using condensing HP steam in the Methanator Start-up Heater (172-C). The preheated gas then flows through the Methanator (106-D) where carbon oxides in the gas are converted to methane by reaction with hydrogen over a nickel catalyst. Residual carbon oxides leaving the methanator are less than 5 ppmy (dry basis). CO2+ 4 H2=CHa + H20 CO +3 H2=CHs + 120 The methanation reactions above are highly exothermic and could potentially overheat 106- D. This could occur if an upset in the shift (LTS/HTS) or carbon dioxide removal systems causes a breakthrough of carbon monoxide or carbon dioxide to 106-D. An automatic shutdown system is provided to prevent overheating. ‘The exothermic methanation reactions cause a temperature rise across 106-D. At end-of-run of the LTS catalyst, the feed to 106-D will contain about 0.30 mol% (dry basis) carbon monoxide and about 500 ppmv (dry basis) carbon dioxide. However, when the LTS catalyst is new, the carbon monoxide content will be lower, resulting in less temperature rise across 106-D. At this time, heating in 172-C is essential to maintain the inlet temperature to 106-Da OPERATING PHILOSOPHY | CONTRACTOR ID. CODE 9294-VZ-MP-0001 PROJECT: Ammonia Plant Feedstock Changeover | LOCATION: Nangal sheet 26 of 446 | Issue Ot at 300°C, Drying In preparation for drying, the methanator effluent is cooled by heat exchange with methanator feed in 114-C to 79 °C, and against cooling water in the Methanator Effluent Cooler (115-C) to 38 °C. The methanator effluent then combines with recycle synthesis loop purge gas from 124-D and the mixture is chilled using ammonia refrigerant in the Methanator Effluent Chiller (130-C) to about 4 °C, ‘The chilled gas is then sent to the Methanator Effluent Separator (144-D) where process condensate is separated out. ‘The overhead from 144-D is then sent to the Molecular Sieve Driers (109-DA/DB). There are two driers packed with Zeolite based desiccant and operate cyclically. Each drier is sized to remove traces of ammonia, residual carbon dioxide, and water in a 24-hour drying cycle. The drier regeneration facilities are designed for a nominal 20 hour heating and cooling cycle to provide a comfortable safety margin of 4 hours of stand-by time. Regeneration and cooling of the driers are done using waste gas ftom the Purifier. During drier regeneration, the waste gas is heated to 265 °C in the Molecular Sieve Regeneration Heater (183-C) by condensing steam from the 63.0 kg/em’g steam header, Cryogenic Purification Dried, raw synthesis gas is then sent to the cryogenic purification section. The gas is cooled by heat exchange with make-up synthesis gas and with purifier waste gas in the top section of the Purifier Feed/Effluent Exchanger (132-C), The gas then flows through the Purifier Expander (131-IX), where work is removed to provide the net refrigeration duty required for the Purifier. The expander energy is recovered by generating clectricity in the Purifier Expander Generator (131-JG). The expander effluent is further cooled and partially condensed in the bottom section of 132-C and enters the Purifier Rectifier (137-D) at -171 °C. Liquid from the bottom of the rectifier is partially evaporated at reduced pressure in the shell side of the Purifier Rectifier Condenser (134-C) and provides cooling for the condenser and reflux for the column, The Rectifier bottoms contain the excess nitrogen, most of the methane, and some of the let argon, The partially evaporated liquid leaving the shell side of 134-C is reheated and vaporized in 132-C and leaves as Purifier waste gas. The waste gas is used as carrier gas to regenerate the Molecular Sieve Driers and then sent to the fuel system. The make-up synthesis gas from the top of 134-C, is reheated in 132-C and sent to the ree eae crs Tests peer wematconly oheran Faprewae arenes TS=< CKBA OPERATING PHILOSOPHY | CONTRACTOR ID. CODE 9294-VZ-MP-0001 a LOCATION: Nangal Isheet 27 of 446 | Issue O1 existing Synthesis Gas Compressor at 1.8 °C. The operation of the Purifier is controlled by a hydrogen analyzer on the synthesis gas, to maintain an exact molar ratio of hydrogen to nitrogen of 3:1. The only other impurities in the make-up synthesis gas are about 0.32 mol% argon and less than $0 ppmv of methane. Synthesis Gas Compression ‘The process description for the synthesis gas compression and ammonia synthesis sections of the plant are identical to the existing plant, except for a new mechanical refrigeration system and a purge gas ammonia recovery system. All the existing equipment in the synthesis gas compression and ammonia synthesis sections are reused. ‘The existing Converter Effluent Cooler (B-1804) has been replaced, The putified synthesis gas is compressed in a four stage, steam turbine driven Synthesis Gas Compressor (G-1701). Reeyele gas is added to the synthesis gas before the fourth stage suction, and the combined flow leaves the compressor at about 197.2 kg/om?(a). Ammonia Synthesis Ammonia is produced in a fixed-bed, vertical converter. Make-up and recycle gas mixture from the synthesis gas compressor is preheated by heat exchange with converter effluent in the Heat Exchanger (E-1803). It then flows to the Ammonia Converter (D-1801). Ammonia concentration in the feed to the converter is about 2.76 mol%, Ammonia is synthesized in two adiabatic beds provided with an intercooler and an aftercooler. ‘The converter effluent containing about 17.70 mol% ammonia is at about 453 °C. It is cooled by generating HP steam in the Synthesis Loop Waste Heat Boiler (E-1801) and by heating boiler feed water in the Converter Effluent BFW Preheater (E-1802). After heat recovery, the converter effluent is cooled to 59°C by heat exchange with converter feed in E-1803. The converter effluent is further cooled to 38 °C by cooling water in Converter Effluent Cooler (E-1804). The existing E-1804 exchanger has been replaced with a new design, The converter effluent is then sent to the Cold Exchanger (E-1805) where it is chilled by heat exchange with the recycle gas. ‘The gas is finally chilled to about -4 °C against ammonia refrigerant in the Ammonia Chiller (E-1806). Liquid ammonia is separated out from the converter effluent in the Separator (F-1801) while the vapor is recycled to the last stage of the Synthesis Gas Compressor via E-1805. A small fraction of the vapor stream from F-1801 is purged from the synthesis loop to control the inerts (methane plus argon) concentration inlet to the ammonia converter at 3.20 mol%. ‘The high pressure purge stream is sent to the purge gas ammonia recovery section. aa een emceesae a CONTRACTOR ID. CODE yy aaa PD Fe KBA OPERATING PHILOSOPHY 9294-VZ-MP-0001 PROJECT; Ammonia Plant Feedstock Changeover LOCATION: Nangel_ sheet 28 0f 446 | Issue 01 Liquid ammonia from F-1801 is depressurized to about 37.0 kg/om*(a) in the Flash Dram (F-1802), This reduction in pressure releases most of the dissolved gases in the ammonia. ‘The flashed vapor is sent to the ammonia recovery system. Liquid ammonia from F-1802 is, ‘ed with recovered ammonia from the ammonia recovery system and sent to the existing Horton Sphere as produet ammonia. The expected ammonia product purity is about 99.9% on dissolved gas free basis. The Horton Sphere operates at about 4,2 ke/om*(a) pressure and is provided with a dedicated package refrigeration system. Liquid ammonia from the Horton Sphere is pumped using existing transfer pumps to E-2403 where the ammonia is heated to 10 °C and sent as product to the urea plant. E-2403 is an existing exchanger and uses ammonia refrigerant as the heating medium, Purge Gas Recovery The high pressure purge gas from the synthesis loop is sent to the HP Ammonia Scrubber (124-D) in the ammonia recovery section. The gas is scrubbed with water to recover the ammonia, The overhead from 124-D contains about 25 ppmv of ammonia. This gas, almost free of ammonia, is recycled upstream of 130-C to recover the hydrogen and nitrogen. A small amount of 124-D overhead is also recycled to the desulfurization section to provide the hydrogen required for hydrotreating, Flash vapor from F-1802 is sent to the LP Ammonia Scrubber (123-D) where it is scrubbed with water to recover most of the ammonia. The overhead from 123-D is sent to the fuel system, ‘The 123-D and 124-D bottom streams contain water with dissolved ammonia, These aqua- ammonia solutions are combined and sent to the Ammonia Distillation Column (125-D) to recover the ammonia, Reboiling duty for 125-D is provided by the Ammonia Distill Column Reboiler (160-C) which uses condensing 32.0 kg/cm’g steam as the heating medium, The overhead vapor from 125-D goes to the Ammonia Distillation Column Reflux, Condenser (163-C) where the ammonia is condensed out against cooling water. The condensed ammonia is then pumped by the Ammonia Distillation Column Reflux Pumps (120-W/JA), Part of the 120-J/JA discharge is sent as reflux to 125-D, while the remaining is sent as recovered ammonia to the Horton Sphere. Ammonia Refrigeration ‘The ammonia refrigeration section supplies ammonia reftigerant to two chillers: the Methanator Effluent Chiller (130-C) and the Ammonia Chiller (E-1806). Ammonia refrigerant is stored in the Ammonia Refrigerant Receiver (109-F). From here it is sub- cooled in E-2403 by heating the product ammonia to urea, The subcooled ammonia refrigerant is sent to E-1806 from E-2403 and from 109-F to 130-C. The refrigerant vapors “peter onni neti nnn ep ec eg eteA seinen Nant y PDIL| KBB OPERATING PHILOSOPHY | CONTRACTOR ID. CODE iz 9294-VZ-MP-0001 PROJECT: Ammonia Phat Feedstock Changeover [LOCATION : Nangal Isheet 29 of 446 | Issue OF from these exchangers are routed to the Ammonia Refrigeration Compressor (105-J) via the Ammonia Refrigeration Compressor Suction Drum (120-F). 105-J is driven by a condensing steam turbine (105-JT) supplied with 32,0 kg/em’g steam. The discharge from 105-J is condensed against cooling water in the Ammonia Refrigerant Condenser (127-C). ‘The condensed ammonia is returned to 109-F. Process Condensate Stripping Process condensate from the Raw Gas Separator (142-D1) is sent to the process condensate stripping section. Here the condensate is first preheated in the Condensate Stripper Feed/Effluent Exchanger (188-C) and is sent to the Process Condensate Stripper (130-D). In 130-D the process condensate is stripped of dissolved impurities, such as hydrogen, nitrogen, methane, argon, carbon monoxide, carbon dioxide, methanol, and amines using live MP stripping steam, The stripped condensate, free of impurities, leaves the bottom of 130-D and is cooled in 188-C and in the Stripped Condensate Cooler (174-C). The cooled stripped condensate is sent to the offsite polisher to recycle the water as demineralized water. The stripping medium for 130-D is MP steam. The overhead from 130-D is mixed with the main process steam and sent to the primary reformer. Thus the impurities contained in the process condensate are sent to the reformer where they are destroyed at the high temperatures. Steam System ‘The steam system of the ammonia plant is shown on the steam balance flow diagram FD-5. ‘The ammonia plant uses steam at five pressure levels, The normal expected steam header conditions are as follows: [Header [Pressure, kg/ em? g [Temperature, °C essure (HS) 190.0 [500 Pressure (MS)___(63.0__ ~ Hea 2 kg/em?g Header B2.0 386 a = 10 kg/em"g Header 10.0 32 [2.5 kg/cm’ Header bs i146 Superheated HS steam produced in the ammonia plant is combined with the import steam from the offsite service boiler and admitied to the existing Synthesis Gas Compressor “iadanweunataarueeate state Sopcacaing Kg eyane mation tein poeaN KBR OPERATING PHILOSOPHY | CONTRACTOR ID, CODE 9294-VZ-MP-0001 [momen Ammonia Phat Feedstock Changeover LOCATION: Nangal ‘sheet 30 0f 446 | Issue 01 Steam Turbine (GT-1701). The turbine is a combination extraction and condensing type machine. In GT-1701, MS steam is extracted at 63 kg/om’g to supply steam to the Process Air Compressor Steam Turbine (101-JT), ID Fan Steam ‘Turbine (101-BJ2T), BFW Pump Turbine (GT-2301), Mol sieve regeneration heater (183-C), LTS start up heater (175-C), in addition to supplying process steam to the condensate stripper and to the process air coil. MP steam is also exported to the urea plant to the CO2 Compressor Turbine. 101-IT has extraction steam at 32.0 kg/em?g and a condensing section. Also, 10.0 ke/om2g steam is injected into this turbine. The extraction steam from 101-IT is used in the ‘Ammonia Refrigeration Compressor Steam Turbine (105-JT), and is also exported to the urea plant. 105-JT is a condensing type steam turbine. A common surface condenser (101- ITC) is used for 101-JT and 105-IT. The 10 kg/em”g steam is generated by extracting steam from the BFW pump turbine. Extracted 10 ka/em’g steam is supplied to 101-JT, to the ejectors for the surface condensers and as gland steam to 105-JT, 101-JT. lOkg/em2g steam also exported to other plants. 2.5 kg/em?g LP steam is generated by the LP Steam Generator (131-Cl). It is used in the deaerator, LP Steam Feed Gas Heater (190-C), heat tracing, 2.5kg/em2g steam also goes to APH steam coil, The steam condensates from the surface condensers are sent to the offsite polisher and recycled as demineralized water. Demineralized water fiom offsite is pre-heated in 106-C and then sent to the deaerator. The deacrator is operated at 0.2 kg/em?g, Deacrated water is pumped by BFW pumps G-2301/2302/2303 and supplied to three parallel exchangers: 131- C, 187-C/186-C and E-1802, The deaerated BFW for LP steam generation in 131-C is supplied by the LP BFW Pumps (190-J/JA). HP BFW from the BFW pumps flows to the BFW Preheater, E-1802 to recover heat from ammonia converter effluent, ‘The HP BFW then splits into two streams. Most of the BFW goes to ammonia converter waste heat boiler, E-1801 to generate 100% saturated steam and the balance of the BEW flows to the steam drum, 141-D, Preheated BFW from 131-C and 186-C are mixed and supplied to the steam drum, 141-D, and to the offsite service boiler. The steam drum produces HP saturated steam which is superheated in the steam superheat coil in 101-B and in the service boiler superheat o: The service boiler produces HP superheated steam. In the ammonia plant, high pressure steam is generated by process heat recovery in three steam generators, one at the outlet of the secondary reformer in 101-C, the outlet of the HTS reactor in 103-C and the outlet of the synthesis converter in E-1801. HP saturated steam produced by 101-C and 103-C are sent to the steam drum, while HP steam generated by E-1801 is sent to the superheat coils. tas epee ene pew pm amenAA seximen wy i PE CONTRACTOR ID. CODE SZ. BIL) KBR OPERATING PHILOSOPHY = 7 9294-VZ-MP-0001 PROJECT: Ammonia Phat Feedstock Changeover |LOCATION: Nangal ISheet 31 of 446 | Issue 01 Cooling Water System The cooling water system is shown on FD-6, The CW supply is at 33 °C, Individual exchanger exit water temperatures are limited to about 43 °C, The overall mixed return temperature is limited to 43 °C. The combined surface condenser 101-JTC is in series with the ammonia refrigerant condenser 127-C. All other exchangers are in parallel. Other Facilities a) Gas-fired Start-up Heater C-1801 is part of the existing plant and provides for activating a fresh charge of catalyst in the ammonia converter and for heating the catalyst up to the temperature at which the reaction is self-sustaining during start-up of the plant. b) The following are provided for the CO2 Removal System: aMDEA Solution Storage ‘Tank, 114-F aMDEA Solution Sump, 115-F aMDEA Transfer Pump, 11 1-J , aMDEA Sump Pump, 115-J vy, aMDEA Solution Filter, 104-L vi, aMDEA Antifoam Injection System, 109-L vii, aMDEA Sump Filter, 115-L ©) For the protection of the high pressure steam system, a set of chemical injection pumps and metering devices are provided. These include; © 108-L, the Phosphate Injection system for seale control. ae eta eda aoe case eeoiney pr wanAA rete AA vt M PDL KBR OPERATING PHILOSOPHY | CONTRACTOR ID. CODE: fet 9294-VZ-MP-0001 PROJECT: Ammonia Phint Feedstock Changeover |LOCATION :Nangal Isheet 32 0f446 | Issue O1 Turndown Operation ‘The ammonia unit can be turned down to about 70 percent of design capacity while operating at essentially the design energy consumption per ton of ammonia produced. Below this capacity, compressors begin to require recycle to avoid surge. To keep a compressor out of surge, some of the discharge stream is recycled back to the suction, or in the case of the air compressor, vented to atmosphere. This increases the energy consumption per ton of ammonia produced, but it permits the unit to operate at rates below 70 percent. The lower limit of operation is about 60 percent of capacity. One advantage of the KBR Purifier ProcessTM during turndown operation is the ability to uuse more air in the secondary reformer to keep steam production higher. a Ne seg eyes arpa mene,epic) KBR OPERATING PHILOSOPHY | CONTRACTOR ID. CODE 9294-VZ-MP-0001 PROJECT: Ammonia Plant Feedstock Changeover | LOCATION Nangal Isheet 33 0446 | Issue 01 Process Operating Principles Natural Gas Supply. NOTE Ti should be noted that the expected case for the operation of the National Fertilizers T.td. ‘Facility is that the design conditions listed in the following sections are based on End of Run (usually meaning end of catalyst life) conditions unless stated otherwise. The case shown is for the normal mode of maximum warm ammonia production unless otherwise stated. Operating conditions described are for Lean Gas case unless stated otherswis The inlet design natural gas compositions are as follow: san Case Rich Nz = 0.10% 1.25% CHt = 97.97% 84.50% CoH 1.79% 9.00% CH 0.14% 3.00% Cato 0.00% 2.00% CsHia 0.00% 0.25% CO2 0.00% 0.00% HO = 0.00% 0.00% S< 10 ppmv (as H28 and organic sulfur) same as Lean Natural gas, which is used for feed is available from offsites and has a battery limit isolation valve with a figure ‘8" blind installed.. 21,107 kg / hr of feed gas and 2,883 kg/hr of fuel gas at 30°C and 39.5 ke/em%(a) enter the Feed Gas Knockout Drum 174-D, where any entrained liquids are removed. The total inlet gas stream is DCS instrumented for monitoring using: FI-1042 = compensated flow PI-1074 — - pressure with a low alarm TI-1029- temperature ‘aeons ab et ono eet eee “etyremcun nett onan weOPERATING PHILOSOPHY | CONTRACTOR ID. CODE’ 9294-V7-MP-0001 [ PRorEcr: Ammons Pn Fest Cingeove ILOcATION: Nangel Sheet 34 of 446 ‘The flow is compensated for pressure and temperature in the DCS function block FN-1042 and is totalized on FQI-1042. A local pressure indicator PJ-1602 is also provided, FE-1042 is a Ultra sonic type flow element. A manual DCS molecular weight block FN-1042A has also been included as a part of the compensation calculation. Locally, PI-1700 shows the line pressure with TI-1905 showing the temperature, DCS controller PIC-1041 controls the pressure to the 174-D drum and has a high and low alarm. The valve fails last on loss of instrument air and will open on loss of signal. It is equipped with isolation valves and a bypass for manual control. The upstream bypass valve will have figure ‘8? blind for positive isolation. Prior to the gas entering the 174-D knockout drum, there are take-off’s upstream of the 174- D isolation valve which is the gas supply to two places: 1 101-B Primary Reformer Fuel - line NG5034-4” 2, 102-J bypass line for LTS start-up line NG1080-8” All of the lines can be isolated at the take-off point as well as individually. The process line is equipped with figure ‘8° blind. This source can be used during start-up until 102-1 is available for operation, AT-1008 gas chromatograph measures 6 components: CHa shown on the DCS on AI-1008A C2Hs shown on the DCS on AI-1008B C3Hs shown on the DCS on AI-1008C Ca shown on the DCS on AI-1008D Nz shown on the DCS on AI-1008E_ COzshown on the DCS on AI-1008F It has two DCS alarms, XA-XXXX for power failure, and AAL-1008 for Instrument / gas chromatograph failure. There is a manual sample point on the source line. 174-D has an inlet isolation valve located downstream of the natural gas take off line NG1043 and upstream of the start up hydrogen line PG1053, There is a 1” pressurizing bypass line around the isolation valve, Both valves contain a figure ‘8? blind. Between the inlet isolation valve and the 174-D is a nitrogen purge line, This line has a double block and bleed with a non-return valve and a figure *8? blind, It is used to pressure purge the 174-D and associated systems. Local pressure indicator PI-1629 shows the nitrogen purge pressure. earnenas "pata Spy unsteusbpenrpapsonermannestAA reson Vas & eam (PRI KBR OPERATING PHILOSOPHY | CONTRACTOR ID. CODE 9294-VZ-MP-0001 PROJECT: Ammonia Phat Feedstock Changeover | LOCATION : Nangal ISheet 35 0f446 | Issue O1 ‘There is an additional line NG2016-6” upstream of 174-D. This line is a part of the 102-J antis urge system and will be described in detail later. There is also a bypass line, NGSOO1- 4°, with a double block and bleed between the 174-D outlet line going to the three fuel gas lines, This allows the fuel gas to be separated in 174-D before going to fuel and will be the normal fuel gas supply after start-up. ‘There is also line NGS002 with a double block and bleed to the 102-J bypass line for the same reason, The 174-D drum contains an inlet gas sparger nozzle and a demister pad covering the vapor outlet nozzle. A local level glass L.G-1602 can be used by the field operators to monitor the level. Normal operating level is actually to run the vessel near empty. The level of the 174-D is indicated by DCS monitored LI-1212A/B/C, with a high level alarm. If a high-high level occurs, SIS LT-1212A/B/C will activate, alarm LAHH-1212 which will sound in the DCS and the 102-J Feed Gas Compressor will be tripped if 2003 show high-high level. XA-1052A/B/C will alarm in the DCS if the associated LT-1212A/B/C fails. There is also SIS to DCS level indications on LI-1212A/B/C each with a high alarm. Any level that accumulates in the drum will be manually drained to the front end flare header using a double block and bleed valve arrangement with the final valve being a globe-type valve (with bypass) for control. The drum is protected from overpressure by, safety relief valve PRV-I74DA/B (1 Working/1 standby) which relieves at 61.9 kg/em?g to the front end flare header. ‘The relief valve has a double block and bleed bypass line for depressuring and purging and this line has a figure ‘8” blind for positive isolation. A local pressure indicator, PI-1690, has also been installed. Feed Gas Compression 102-J 102-J takes suction from the top of the feed gas knockout drum 174-D through line NG1001-10". This line has a lock open (LO) isolation valve with a pressuring bypass, 21,107 kg / hr of natural gas at 39.5 kg/em? (a) and 30°C is compressed by 102-J to 57.3 kg/em?(a), 356 kg / hr of hydrogen-rich synthesis gas is needed to convert the organic sulfur in the 108-DA. The design hydrogen in the gas stream is 1.943 vol. %. The normal source comes from 124-D and is controlled by FIC-1029 in the DCS passing through a non-return and isolation valve to the discharge line of the 102-J before 190-C. The valve is a fight shutoff class that fails closed if instrument air or control signal is lost and comes with isolation valves. FIC-1029 comes with both high and low flow alarms to alert the operators to those conditions. The valve position is indicated in the DCS on FZI-1029. It will be a ee a nee cocoate,AA cies tA eines ‘CONTRACTOR ID. CODE 7 Pele KBR OPERATING PHILOSOPHY 9294-VZ-MP-0001 .mmonia Plant Feedstock Changeover Nangal Isheet 36 0f446 | Issue 01 tripped closed through interlocks I-102J or 1-101 should trips occur. FYV-1029 line is protected from overpressure by safety relief valve PRV-101BA/BB (1 Working/1 standby) which relieves at 61.9 kg/em2g to the front flare header. It is equipped with a double block and bleed bypass with a downstream globe valve for control and a figure ‘8’ blind for isolation. Hydrogen can also be supplied during start-up and partial shutdown conditions using hydrogen from either: © 142-D1 CO2 Absorber Inlet Knockout Drum © 142-D2 CO2 Absorber Overhead Knockout Drum * 144-D Methanator Effluent Separator Outlet. The flow from 142-D1 is controlled by DCS mounted FIC-1011 which has a low flow alarm, The valve fails closed if instrument air or control signal is lost and comes with isolation valves. This hydrogen flow is directed to the 174-D on the suction of 102-J through two non-return and isolation valves. Both the source and final isolation valves have figure *8” blinds for positive isolation. The control valve position is indicated in the DCS on PZI-1011, It will be tripped closed through interlocks 1-101 & I-102J should a trip occur. DCS switch FHS-1011 will reset the trip. A grab sample point is available. ‘The flows from 142-D2 and 144-D are controlled by DCS FIC-1023 which has a low flow alarm. The valve fails closed if instrument air or control signal is lost and comes with isolation valves. Each hydrogen flow is directed to the 174-D on the suction of 102-J through non-return and isolation valves. The final isolation valves have figure ‘8? blinds for positive isolation. The control valve position is indicated in the DCS on FZI-1023. It will be tripped closed through interlocks 1-101 & 1-102] should a trip occur. DCS switch FHS-1023 will reset the trip. ‘The gas stream can be grab-sampled for lab analysis. Feed Gas Compression - 102-J 102-J takes suction through an in-line strainer from the exit the knockout drum, 174-D, through line NG1001-10". The strainer has a DCS pressure drop indication on PDI-1241 with a high alarm, The gas is controlled by a vendor PIC-1202. The Controller is a suction pressure controller but is to be operated where the output of PIC-1202 on the discharge of 102-J will set the suction pressure to maintain the desired discharge pressure. PIC-1202 will "merece pees ue peepee magn pmo eetwe Big KBR OPERATING PHILOSOPHY | CONTRACTOR ID. CODE’ 9294-VZ-MP-0001 PROJECT: Ammonis Plant Feedstock Changeover LOCATION: Nangal_-_—_‘[Sheet_ 37 of 446 | Issue 01 have to be closed as indicated by DCS PZLC-1202 from the vendor as a start permissive for the motor. PV-1202 valve fails open on loss of signal and instrument air and has a handjack for manual operation, A bypass line NG1080-8” is provided around 102-J for start-up when the suction pressure is higher than the required system backpressure pressure and 102-I is not required to be in service. The line is equipped with non-return, source and destination isolation valves and ties-in downstream of the 102-J discharge isolation and non-return valves. 102-J, a motor driven compressor, discharges to the feed preheat coil of the 101-B primary reformer furnace at 57.3 kg/cm? (a) and at a temperature of about 67°C. This temperature is dependent on suction temperature and compression ratio and will be lower if the suction pressure to the compressor is higher. The compressor is furnished with a vendor antisurge controller, FIC-1030, which maintains a constant flow through the compressor by recycling a preset flow back to the suction at 174-D through the kickback cooler 143-C to keep the compressor out of surge. FV-1030 is a tight shutoff class (TSO) that fails open upon loss of instrument air or control signal, It has isolation valves and a handjack for manual operation. The valve position is reported to the DCS on FZI-1030. 143-C cools the 67°C discharge temperature to 50°C , which can be seen on DCS TI- 1621, TI-1621 is provided with high alarm. 102-J has a number of local instruments which indicate: 1, suction temperature, T1-1619 2. suction pressure, PG-5025; 3. discharge pressure, PG-5026 4. discharge temperature, TI-1620 There are also a number of DCS indications: TI-1205 suction temperature TI-1206 discharge temperature PI-1201 suction pressure PI-1202 discharge pressure F1-1030 compressor flow veerr a sas ennA erro Vries CONTRACTOR ID, CODE PpIL| KBR OPERATING PHILOSOPHY eat PROJECT: Ammonia Plant Feedstock Changeover 9294-VZ-MP-0001 LOCATION : Nangal ISheet 38 of 446 Hand switches HS-1602, locally, or HS-1402, in the control room, will shutdown 102-5 through Interlock I-102J when activated Vendor trip interlock X8-102J will also trip the machine as will SIS interlock I-101B on a reformer trip. The feed gas compressor is driven by a fan-cooled motor 102-JM. Sealing System 102-J uses dry gas seals on the compressor. See the vendors information for a description of their seals components and operation, The 102-J vendor's P&IDs need to be accessed for all of the details on instrumentation, piping, driver, anti-surge protection, intercooling, knockout, overpressure protection and other relevant equipment. The Compressor is protected from overpressure by safety relief valve PRV-102J that relieves at 61.9 kg/em’g to the front end flare header. The relief valve has a double block and bleed bypass line for depressuring and purging with a figure ‘8’ blind... Desulfurizers 108-DA /DB /DC The inlet and outlet design gas compositions are as follows: Inlet Outlet 1.95% 1.95% 0.75% 0.75% 95.31% 95.31% 0.12% 0.12% 0.00% 0.00% 1.74% 1.74% 0.14% 0.14% 0.00% 0.00% 0.00% 0.00% 10 ppmv (as H2S and organic Sulfur) s< <0.1 ppmy The natural gas feed first flows through 190-C gas preheater where it is heated to 120.5°C against low-low pressure steam, The temperature is DCS indicated on TI-1207 which has both high and low alarms. SSS as een Capps canteen enPumas menteSZ, Fe KBR OPERATING PHILOSOPHY | CONTRACTOR ID. CODE’ om 9294-VZ-MP-0001 PROJECT: Ammonia Plant Feedstock Changeover LOCATION :Nangal Isheet 39 of 446 | Issue 01 ‘The condensate formed in 190-C is collected in a horizontal 18” collection pipe and level controlled by DCS LIC-1007 to the deaerator. LIC-1007 has high and low alarms. LV-1007 fails open on loss of instrument air / signal and has a handwheel and isolation valves with a bypass. Locally, the level can be seen on LG-1607. ‘There is a local grab sample point for the gas after the hydrogen mixing tie-in The gas then flows to the feed preheat coil, of the 101-B primary reformer to the inlet of the 108- DA Hydrotreater. A temperature control bypass valve TV-1305 is provided around the feed preheat coil to provide a means of controlling the temperature of the feed gas entering the hydrotreater at 371°C. There is a high and low temperature alarm with this DCS TIC-1305 controller. The valve Will fail closed if control signal or instrument air is lost and a hand jack, a bypass and isolation valves are furnished for manual operation. The temperature directly out of the preheat coil can be seen in the DCS on TI-1612 and has a high alarm. The coil and the downstream piping to the TV- 1305 tie-in are designed for 401°C at 64.7 kg/em2g, The heated feed gas then enters the Hydrotreater Vessel, 108-DA, where any quantities of organic sulfur compounds are hydrogenated to hydrogen sulfide, H2S, in a bed of cobalt / molybdate (Co-Mo) catalyst. There is a block valve with a 2” bypass at the inlet of 108-DA and both are furnished with figure °8" blinds, The H2$ in the gas reacts with and is retained in a bed of zine oxide (ZnO), producing an cffluent stream containing less than 0.1 ppmy sulfur by volume, ‘There are two ZnO beds in this unit, 108-DB and 108-DC, The zine oxide in each desulfurizer will need replacement in 1 year based upon the sulfur compounds absorption on the catalyst from the natural gas at 100% of normal flows for every day of the year. If the sulfur content in the gas is less, the catalyst (absorbent) will last longer. The Co-Mo catalyst has an approximate 5 year lifetime, ‘The 108-Ds all have inlet and outlet gas distributors. The outlet distributor is screen covered to avoid loss of catalyst and support material to the process, There is one bed of catalyst, Cobalt - Molybdate, in 108-DA and a bed of adsorbent, Zine Oxide, in each 108-DB and 108-DC vessel. Each vessel also has a catalyst dropout chute to unload the catalyst. Loading and unloading of the catalyst will be discussed later in this manual The 108-DA has a local pressure indicator as well as a DCS pressure differential indicator. 108-DA is monitored locally by P1-1721 for pressure and in the DCS on PDI-1105A with a high alarm for pressure differential, DCS TI-1304 with a high alarm and DCS TI-1306 have been placed in the vessel to monitor catalyst temperature. A sample point has also been placed on the outlet line that ties into a common line going to a sample cooler for grab sampling. The line has an upstream gate valve for isolation and a downstream needle valve ‘i iontnaahisluaensa sees ete Hot mle eyoleceneecmtaalingeghoieUS cnt meet "SASSI SporeA reset A \ ne Va CONTRACTOR 1D. CODE (PB) KBR OPERATING PHILOSOPHY 9294-VZ-MP-0001 PROJECT; Ammonia Plant Feedstock Changeover [LOCATION : Nangal Isheet 40 0f446 | Issue 01 for sample flow control with a bleed in between to prevent cross-contamination of samples. The 108-DB and 108-DC have local pressure indicators as well as a DCS pressure differential indicator. 108-DB is locally monitored by PI-1722 for pressure and PDI-110SB in the DCS with a high alarm for pressure differential. 108-DC is monitored by PI-1723 locally for-pressure and PDI-1105C with a high alarm for pressure differential in the DCS. There are local outlet temperature indicators with TI-1602 on 108-DB and TI-1603 on 108- DC. Sample connections are located on each of the vessels for taking manual samples of the gas at the upper-point, mid-point and lower-point of each ZnO bed with a sample point also located on the common outlet line that ties into a common line going {o a sample cooler SC- 103 for grab sampling, Each line has an upstream gate valve for isolation and a downstream needle valve for sample flow control and a needle bleed valve in between for positive isolation to prevent cross-contamination, There is also a manual sample connection of the common line, Normally, the Desulfurizers operate in series, but provision is made in the installation to allow single reactor or even parallel operation during catalyst change out while the plant remains in operation. The piping arrangement allows for either vessel to be the leading or the following vessel in the series operation. Each vessel has an inlet and outlet isolation valve as well as inlet and outlet crossover valves. Each of these vales has a figure ‘8° blind for positive isolation, The inlet isolation valve have 2” pressurizing valves. Each of the three vessels is also piped with a double block and bleed nitrogen purge line with a non-return valve and figure ‘8? blind that ties in just upstream of the outlet isolation valve, Each vessel is also equipped with a double block and bleed vent line that goes to the front end vent system. NGS007-1,S” for 108-DA, NGS008-1.5” for 108-DB and NGSO17- 1.5” for 108-DC. Maintenance blinds are provided inlet, outlet, and on the crossover lines to each of the three vessels. The common Desulfurizer outlet line also has a DCS controlled vent valve HIC-1108 in line RV1090-12” to the front end flare header. This line will be used for start-up and shutdown activities only. HV-1108 valve is a tight shutoff class (TSO) valve that closed if control air or signal is lost. There is also an upstream isolation valve. HY-1108 enable HIC-1108 to vent 108-DB/DC to the front end flare header with at signal from 1-101 and [-102J. The valve position is DCS indicated on HZI-1108, The overall reaction in the Desulfurizers is exothermic but a heat loss of 11°C has been Ln enn ree an US ocean nim,we SZ, epi) KBR OPERATING PHILOSOPHY | CONTRACTOR ID. CODE nats 9294-VZ-MP-0001 | PROJECT: Ammonia Plant Feedstock Changeover | LOCATION; Nangal ‘Sheet 41 of 446 | Issue O1 used for design purposes thus the exit temperature at 360°C but the actual temperature should follow within just a few degrees of the inlet temperature. Locally, the pressure can be monitored using Pi-1626. Sulfur exit the 108-Ds is monitored in the DCS on Al-1004 with a high alarm and DCS alarm AAL-1004 will sound upon a failure of the analyzer. Primary Reformer The inlet and outlet design gas compositions (dry basis) of the radiant section at the end of run catalyst life are as follow: Inlet Outlet Ha 1.95% 54.92% Ne 0.75% 0.34% CHa 95.31% 29.87% Ar 0.12% 0.05% CO = 0.00% 4.30% COz 0.00% 10.52% CrHe 1.74% 0.00% Cis = 0.14% 0.00% The Primary Reformer, 101-B, is a gas fired, processing furnace containing radiant and convection sections, Processing occurs in catalyst packed tubes contained in the radiant section, The desulfurized feed is mixed with 406°C medium pressure steam, part of which was used fo strip the process condensate beforehand. The steam is added in a ratio of 2.7 ‘moles of steam per mole of organic carbon and 2,98 to 1 steam to gas weight ratio. The desulfurized natural gas flow rate to the 101-B radiant section is 21,464 kg / hr and is controlled by DCS controller FIC-1001. FIC-1001 is pressure and temperature compensated in a DCS function block FN-1001 using DCS PI-1200 pressure and TI-1204 temperature. The flow is also compensated for molecular weight using a DCS manual input from FN- 1001A. FIC-1001 is furnished with low alarm. All of these instruments are monitored in the DCS, PI-1605 is the local pressure indication. Interlock I-101J will set FIC-1001 to automatic and the setpoint at 6500 kg/hr (to be confirmed during commissioning) when initiated, FV-1001 valve will fail closed in case of a loss of instrument air or the control signal and has DCS valve position indication on FZI-1001. It can also be isolated upstream and ee a ae a te en eet,A\ sestoun Vrs mmm [baw wy PDIL} KBR OPERATING PHILOSOPHY | CONTRACTOR ID. CODE: S 9294-VZ-MP-0001 PROJECT: Ammonia Plant Feedstock Changeover LOCATION: Nangal [Sheet 42.0F 446 | Issue 01 downstream, Solenoid valves FY-1001A/B will trip the valve closed upon activation of any of the interlock I-101 OR 1-1025 trip signals and must be DCS reset to regain control using. handswitch FHS-1001. It comes with a start-up 3” bypass line with flow control valve FV- 1100. Flow is DCS indicated and controlled on FIC-1100, FV-1100 valve will fail closed in case of loss of instrument air or the control signal and has DCS valve position indication on FZI-1100.The bypass has a double block and bleed valving arrangement with the downstream valve a globe-type for control. This will be used to slowly bring gas into the reformer at start-up then MUST BE isolated once control has been switched to FIC-1001, There is also a DCS pressure drop indication across FV-1001 on PDI-1204. The gas flow meter run is physically located on the discharge line.of the 102-I Feed Gas Compressor upstream of the 108-DA with FV-1001 located inlet the feed preheat coil to 101- B. A compensated flow signal from FT-1201 is also sent to the DCS on FI-1201. This signal is temperature compensated in the SIS PLC function block FN-1201 using TY-1307 and pressure compensated using PY-1111, These indications are sent to the DCS on TI-1307 with both high and low alarms. XA-1072 will alarm in the DCS if TT-1307 fails, XA-1060 will alarm on PT-I111 failure and XA-1066 alarms on FT-1201 failure. The signal is also molecular weight compensated using a manual input from the DCS FN-1201B in FN-1201 Low-low process gas flow will sound FALL-1201 in the DCS and initiate an 1-101) trip from SIS FSLL-1201 control room handswitch HS-1251 can also be used to trip. The results of this trip are: # close 101-J discharge MOV-1006 «close FV-1003B, process air control valve * FIC-1044, purge MP steam to the secondary reformer by tripping solenoid valve FY- 1044 to manual bumpless operation * FIC-1044 trip open automatically after 30 seconds For other action refer interlock description ‘The steam to carbon ratio to the primary reformer is measured by comparing the compensated process steam flow from FN-1202 and the process gas flow from FN-1201, ‘The process gas flow is calculated to carbon flow using SIS function block FN-1201A. The resulting ratio is sent to the DCS by SIS FFSL-1201 to FFI-1201 and will sound an alarm of FFAL-1201 if the ratio becomes low. ‘This takes the process air out of 103-D Secondary Reformer. FFSLL-1201 Steam-To-Carbon Ratio is the trip circuit ratio monitor. If the ratio signals “Rison eeepc aid lA pee raneAA rumen AN eons CONTRACTOR ID, CODE 9294-VZ-MP-0001 Feedstock Changeover OcAy weal eet 43 of 446 | Issue OF show low-low, it will initiate a DCS alarm on FFALL-1201 and trips in the 1-101 and I- 101B logic will occur that initiates: * close 101-J discharge MOV-1006 * close FV-1003B, process air control valve FIC-1044, purge MP steam to the secondary reformer by tripping solenoid valve FY- 1044 to manual bumpless operation FIC-1044 trip open automatically after 30 seconds FY-1001 mix feed flow valve trip close FY-1100 FV-1001 Start up bypass valve close XYV-1063 NG to mix feed flow valve trip close FV-1029 H2 to NG trip close FV-1023 start-up H2 (0 NG valve closed FV-1011 start-up H2 to 174-D valve closed XYV-1064 NG to vent valve open XY2-1001 AE-1001 Sampling valve trip close XY2-1130 AE-1030 Sampling valve trip close XY2-1131 AE-1031 Sampling valve trip close XY2-1132 AE-1032 Sampling valve trip close HY2-1108 A/B Enable HIC-1108, 108-DA/DB/DC effluent to flare Activates I-104D2 to bypass the LTS 1-G1701 activates a synthesis gas compressor shutdown, initiate interlock I-101B which will: « trip valves XV-1220A/B closed stopping fuel gas to the main arch bumers 0 trip valve XV-1220C open venting fuel gas to the main arch burners « trip valves XV-1222A/B closed stopping fuel gas to the secondary arch burners o trip valve XV-1222C open venting fuel gas to the secondary arch burners « trip valves XV-1240A/B closed stopping fuel gas to the tunnel arch burners « trip valve XV-1240C open venting fuel gas to the main tunnel burners DCS alarm HA-1251 will sound when this trip occurs. The gas stream line contains XV-1063. XV-1063 is an open or closed valve that can be activated by interlock I-101 & I-102J. XV-1063, on the DCS, has indications showing the valve is in the open or closed position. The XV-1063 isolation valve and the FV-1001 flow ‘senting ar i erected eA eanA reraan Vrain ti CONTRACTOR 1D. CODE, (PBIL) KBB OPERATING PHILOSOPHY 9294-VZ-MP-0001 PROJECT: Ammonia Plant Feedstock Changeover [LOCATION : Nangal Sheet 44 0f446 | Issue 01 controller are a part of the reformer shutdown logic circuitry tripping on 1-101 & 1-1025, interlock logi XV-1064 is provided in between FV-1001 and XV-1063 to vent off hold up natural gas in emergency shut down, Downstream of FIC-1001 control valye, the gas stream is joined by 63,984 kg / hr of medium pressure steam controlled by DCS flow controller FIC-1002 with a low alarm after it passes through a blindable non-return valve, A sample cooler SC-107 has been installed downstream to allow for getting samples of the mixed stream, There is also a permanently piped nitrogen purge line tied in downstream of XV-1063 through a double block and bleed system with a non-return valve and a figure eight blind for purge the front end after a shutdown or to help supply nitrogen during the warm- flow. FIC-1002 is a biased signal from the compensated steam flow signal FI-1002 through DCS function block FN-1002A. This block compensates for the extra / consumed steam from / to the stripped condensate in the 130-D Process Condensate Stripper. ‘This system will be explained later in more detail, FI-1002 is pressure and temperature compensated using DCS PI-1090 and TI-1008 through a function block FN-1002. FIC-1002 controls two vatves using a split-range control scheme. FY-1002A opens first as the controller signal goes from 0% to 30% followed by FV-1002B from 30% to 100%. Both FV-1002 valves fail open when instrument air pressure or the control signal is lost and have handjacks for manual operation, The flow meter run for the process steam is physically located upstream of the MP steam line to the Process Condensate Stripper 130-D. The line can be isolated with a double isolation lock open (LO) valves that has a 1” double block valve pressuring bypass. The process steam and gas feed to the primary reformer is controlled by a lead / lag control system that is designed to maintain the steam to carbon ratio during upsets. The FN-1002 steam flow signal is directed to FFI-1001 DCS division function block to calculate the steam to carbon mol ratio. It is also directed to division block FFN-1001A where it is divided by the manually set desired steam to gas ratio as input on DCS FFN-1001. The output of EFN-1001 is directed to FFN-1001B low select function block where the lower of that signal or the signal from the manually set desired plant rate is input on HIC-1001 after passing through a ramp rate controller block HN-1001 will go to FIC-1001 as the remote setpoint. Corrected feed gas flow from FN-1001 is directed to two function blocks — where it is multiplied by the gas carbon number as input manually then on to F "Nese at ane Sata eoeslocnipan opens loa eenamreee meeAA seta CONTRACTOR ID, CODE ws E P en FO KBR OPERATING PHILOSOPHY 9294-VZ-MP-0001 PROJECT: Ammonia Plant Feedstock Changeover | LOCATION: Nangat Isheet 45 0f446 | Issue OI determine the steam to carbon mol ratio. Secondly, to the high selection function block FFN-1001C. The higher of this signal or the signal from HIC-1001 desired plant rate is passed through a ramp rate block HN-1001 is sent to FEN-1001D which multiples the gas signal by the desired ratio setting on FFN-1001 and forwards that signal to FIC-1002 as a remote setpoint. This system has been designed to react to automatically reduce the gas flow should the steam flow be reduced for any reason to protect the reformer from coking the catalyst. An increase in steam rate for any reason other than an increase on the HIC- 1001 plant rate control will not increase the gas rate. In addition, an increase in gas flow to the reformer for any reason other than an inerease on HIC-1001 will result in an increase of the steam flow to protect the reformer but a decrease in gas will have no effect on the steam, All of the previously mention function blocks and manual input blocks for the lead-lag system are in the DCS. ‘The normal steam to gas weight ratio for this plant is 2.98. The design steam to carbon molar ratio for the plant is 2.7 Process steam flow from FT-1202 is pressure and temperature corrected in the SIS PLC function block FN-1202 using PY-1053 for pressure and TY-1024 for temperature. The corrected flow is indicated in the DCS on FI-1202. The temperature and pressure are also shown in the DCS on TI-1024 and PI-1053, respectively. DCS transmitter failure alarm XA-1071 will sound on a TT-1024 failure with XA-1062 alarming on a PT-1053 failure and XA-1053 used for a FY-1202 failure, PI-1606 is a local prossure gauge on the medium pressure steam line, Locally, PI-1733 indicates the pressure downstream of the 130-D steam tie-in on the line to the mixed feed coil. The temperature of the process steam to the reformer is shown in the DCS on TI-1656 with a low alarm. Upstream of the 101-B mixed feed preheat coil is a line tied into the line containing the mixed process gas and steam. Line A 1002-4" is from the 101-J, air compressor, discharge and will be used during precommissioning only to blow the process lines with air. This line has a non-return valve and removable gate valve that will be blinded after use. There is an ammonia line from 120-J/JA, NH-1021 that ties into the gas line to the mixed feed coil, This ammonia injection can be used during start-up to provided hydrogen by cracking ammonia with the steam in the reformer. This hydrogen is then sent to the front end of the plant for hydrogenation of the natural gas for sulfur removal until sulfur-free feed gas can be admitted and hydrogen produced by reforming... The line has a double isolation “he tenetcnsenal man scenes en rare ae cee,A reste AA rae we fe PBI) KBR OPERATING PHILOSOPHY | CONTRACTORID. CODE 9294-VZ-MP-0001 PROJECT: Ammonia Plant Feedstock Changeover Location :Nangal_ ——_|heet_ 46 of 446 | Issue O1 with figure ‘8? blind for positive isolation and a non-return valve, Local rotameters FI-2800 & FI-2800A are used to control the amount of ammonia injected. The combined gas and steam flow at 386°C, as indicated on TI-1310 which has a high temperature alarm, flows through the mixed feed preheat coil of the 101-B convection section, The temperature, after preheating is 495°C, is shown on TI-1313 which has associated high and low temperature alarms. Mixed feed pressure is shown in the DCS on PI-1607 after exiting the mixed feed coil. The mixed feed leaves the coil, where a double block drain valve is incorporated for use during start-up to drain any condensate, then flows to the top of the radiant section where it is split into three equal and parallel sub-headers. The 3 sub-headers distribute the flow to 132 tubes packed with two sizes of nickel reforming catalyst. The tubes extend downward through the radiant section of the reformer to a horizontal collection header. Each tube has a multi-holed eatalyst support plate in the bottom of the tube that the reforming catalyst rests upon, These 132 catalysts packed tubes constitute the primary reforming element of the process. Each of the 3 collection manifolds contains a centrally located riser pipe that returns the flow upward through the radiant fire box to the Primary Reformer Effluent Transfer Line, 107-D. The transfer line is a refractory lined, water jacketed transition piece connecting the primary reformer with the Secondary Reformer, 103-D. Each of the collection headers has a double blocked drain for start-up only if steam is used for start-up in place of the normal nitrogen flow. ‘The heat for the endothermic reforming reaction is supplied by fifiy six (56) fuel gas burners located on either side of the rows of tubes with fourteen (14) burners in cach of the four rows, There are two sizes of burners in the reformer arch section. The burners located between the rows have a higher heat release capability. The burners between the furnace wall and the outer rows of tubes have a lower capability. The outer row bumers are designed smaller than the inner row burners, taking into account that they only supply direct radiation to tubes in one direction, while the inner row burners supply direct radiation in two directions. Both natural gas and purge gas fuels will be used for normal operation. The burners are designed for design heat liberation for either natural gas or purge gas combined, or for natural gas alone. Note that these two fuel gas streams will not be combined prior to the bumers, but will have separate burner connections. The furnace arch burners operate firing down and develop a reformed gas temperature of 721°C at the outlet of the catalyst tubes. A sr Og py ed tiene Seay peeAA rein Nemes wy CONTRACTOR ID, CODE a cei KBR OPERATING PHILOSOPHY =m 9294-VZ-MP-0001 PROJECT: Ammonia Plant Feedstock Changeover LOCATION: Nangal sheet 47 of 446 The normal end-of-run pressure at the outlet of the catalyst tubes is 48 kg/em?(a). The reforming furnace incorporates the use of internal manifolding (outlet manifolds) at the outlet of the catalyst tube leading (o riser tubes that direct the reformed gases to the transfer line for heat conservation of the reformed gas and balanced coil expansion. The reformed gas continues to pick up heat in these risers and collector pipes while exiting the radiant section, This raises the gas temperature at the primary reformer exit by 17°C to approximately 737°C, The primary reformer is instrumented for monitoring the temperatures and pressures of the process and the flue gases. The effluent process stream is continuously analyzed for the following contents by the on-stream gas chromatograph: AI-1001 - Methane A manual sample cooler $C-105 has been added to the stream to the analyzer for grab sampling the gas stream. Each row of tubes has two temperature indicators located on each side of the riser tube- TI- 1315A through TI-1315C and TI-1316A through TI-1316C. All of the temperatures are indicated on the DCS and all have high temperature alarms. Pressure drop across radiant coil, including the crossover piping on the inlet, is measured by PDI-1607 in the DCS with a high alarm attached. There are also two DCS pressure indications, PI-1607 showing inlet pressure and PI-1608 on the outlet, ‘The reforming furnace is designed to attain greater than 93.3% thermal efficiency by recovering heat in the convection section from the flue gases. Flue gases consist of combustion products from the radiant section of the reformer. The flue gases are continually analyzed for oxygen content by analyzers AI-1010A and AI-1011A with associated low oxygen alarms and combustibles by analyzers Al-1010B and Al-1011B with high combustibles alarms located on the side of the convection section and are displayed on the DCS, The expected excess oxygen in the flue gasses is: Mol% O2 Mol% O2 Wet Basis Dry Basi Radiant Exit. 1.42 2.00 Combustion air is provided by the 101-BJ1, Forced Drafi, FD, Fan. The fan is motor driven at 980 rpm and takes suction through a screen protected suetion plenum, It is designed to ee ia sata arena a asst eee mmAN ruins AN acne OPERATING PHILOSOPHY | CONTRACTOR ID. CODE 9294-VZ-MP-0001 PROJECT: Ammonia Plant Feedstock Changeover [LOCATION : Nangal Isheet 48 of 446 | Issue OF provide 140,197 kg/hr with a normal flow of 111,296 kg/hr at a static pressure of 329 mmHa0. The discharge goes into a duct leading to the 101-BC, Combustion Air Preheater. Full load current for the 3300 volt motor is 71 amperes, The fan bearings are water cooled and have flow glasses, for visually monitoring the water flows from the bearings. Here, the air is preheated by exchanging heat first with low-low pressure stream in an internal steam coil to the preheater then with the hot flue gases coming from the convection section of the primary reformer through the use of an open channel air preheater exchanger. Low-low pressure steam is manually controlled to the steam coil with an inlet globe valve, ‘The condensate formed collects in a level pipe on the coil outlet which is DCS level controlled using LIC-1010 with a high alarm associated. The condensate is sent to the 101- JTC surface condenser through LV-1010 which has a handjack for manual operation, can be isolated and has a bypass line. ‘The preheated air continues through additional duct work to the tunnel burners and to the primary reformer arch burners, There are four individual preheated air ducts each going to a row of arch burners, Each of the rows has an adjusting damper with a manual gear driven operator. In addition, each individual burner has an air adjustment as well. Each damper has a minimum stop set at 10% open to provide a minimum of 10% of the maximum air flow. ‘An induced draft fan, 101-BJ2, supplies the draft required to pull the flue gases through the convection section and push them out of a stack to the atmosphere. Pressure in the combustion air duct is sensed and controlled downstream of the 101-BC by PIC-1855 at about 120 mmH20 and has low alarm, The controller operates a set of inlet dampers to the forced draft, FD, fan since the fan is motor driven and runs at a fixed speed, These vanes will fail last if instrument air is cut off for any reason and fail open on signal loss, Their position is reported to the DCS on PZI-1855 indicator. The dampers are forced closed by interlock I-101BJ1 if the ID or FD fan is shutdown for any reason to avoid putting a high positive pressure on the reformer. The damper actuator has a handjack for manual operation. ‘There is a local pressure indicator on the discharge side of the FD fan, PI-1193 as well as DCS indications with low alarms on PI-1197A/B. Pressure is also locally measured downstream of the air preheater on PI-1196 and individually on cach end of the arch burners rows using PI- 1890, PI-1891, PI-1892 and PI-1893. These pressures are expected to be about 75 to 100 mmk20. Air doors capable of passing YY,YYY ACFM (cold door) provided upstream of the combustion air preheater and YY,YYY ACEM each (hot doors) are provided in the combustion air duct downstream of the 101-BC preheater to allow for continued reformer operation if the FD fan mca rece eee ets coxtA sera AAs PDI KBR OPERATING PHILOSOPHY | CONTRACTOR ID. CODE zl 5 i 9294-VZ-MP-0001 PROJECT: Ammonia Phat Feedstock Changeover | LOCATION: Nangal (Sheet 49 0f 446 | Issue OL should fail as sensed by the SIS FD fan motor low current alarm, ISLL-101BJ1 and alarmed in the DCS on IALL-1808. A 2003 voting logic using SIS pressure signals (PT-1197A and PT- 1197B) and current indication ISLL.-101BJ1 any two failure will trip the air doors open. The FD fan motor current is shown in the DCS on II-1808 and has a low alarm, ‘The motor also has a DCS run indication, When the combustion air duct pressure falls to —Y.YY inH20, as sensed by either PT- 1197A/B and alarmed in the DCS on PALL-1197, the hot and cold air doors automatically open through interlock 1-101BJ1 if the FD fan motor current is low, YY amps or less. All of the doors have an open / close transition time of less than 5 seconds. The hot air doors have a DCS position indication XZSO-1005 and XZSO-1006, All of the doors fail last on loss of instrument air, The reformer is capable of continued operation at approximately 70% of design capacity without the FD fan as long as at least one hot air door is open. If both air doors fail to open at the same time, the reformer firing will trip. When restarting the FD fan, following operation with air doors open, the hot air doors will automatically close upon clearing of PALL-1197. The cold air door are first closed by operators by using HIC-1015 after operating the password-keyed handswitch, HS-1015, to enable the controller. The ambient combustion air temperature is monitored in the DCS just at the fan discharge on T1-1327, after the low pressure stream coil on TI-1326 and also after the preheater on TI-1325 at 228°C. The pressure drop across the combustion air side of the air preheater is indicated on the DCS on PDI-1195 and has a high alarm. The design allowable pressure drop is 150 mmE20. The combustion air flow divides between the arch burners and the tunnel burners and flows through the burners, mixes with the fuel gas, combusts to provide heat for the reforming reaction to take place and becomes hot flue gas in the radiant section of the reformer, These gases are pulled through the reformer by the Induced Draft, ID, Fan, 101-BJ2. The ID fan is driven by a medium pressure steam turbine, 101-BJ2T. Electric motor 101-BJ2M is provided as stand by driver, and pulls the hot flue gases through the radiant and convection sections of the reformer then exhausts them to the atmosphere through a stack. 101-BJ2T is an extracting turbine letting down steam from 63 ke/em2g pressure to the 32 kg/em2g steam header pressure. The turbine speed is indicated on the DCS SI-1005. DCS PIC-1019A /B sense the pressure in the radiant box and controls PV-1019 through PHS 1019.. ‘The turbine fails {0 maximum sped upon loss of a control signal. aa ne eT anno erentowy = PDL) KBR OPERATING PHILOSOPHY CONTRACTOR ID. CODE 9294-VZ-MP-0001 PROJECT: Ammonia Plaat Feedstock Changeover | LOCATION: Nangal ISheet 50 of 446 | Issue 01 Inlet medium pressure steam flow to the turbine is measured on the DCS on FI-1125 after being, temperature compensated by DCS TI-2660 through function block FN-1125. TI-2660A is, provided for local as well as DCS indication, The steam passes through an inlet double isolation valve set with a 0.75” double valve warm-up bypass line..A double block warm up line with a globe valve for control is provided to a silencer SP-102, A local temperature indicator, TI-2662A, has been provided in the exhaust line with a DCS indication on TI-2662A. TI-2662 is also provided for DCS indication, The exhaust line is protected from overpressure by a relief valve PRV-101BJ21 set to relieve at 35.3 kg/em’g to the atmosphere, The turbine letdown steam to the MLP steam header passes through a non- and can be isolated. The isolation valve has a 1” double block and bleed bypass ing the pressure on both sides of the valve, The turbine is also equipped with a seal steam leakage system which goes gland steam condenser. The flow is DCS indicated on FI-2713 with the temperature shown on TI-2311. Handswitch HS-1205 in the DCS or HS-1005 locally can be used to stop the turbine by tripping the inlet steam valve Through interlock I-101BJ2T. The vendors internal protection trips from XS-101BJ2T will also act through this interlock, DCS alarms will sound for common alarm on XA-2607 and XL-101BJ2T and locally these will sound on 1005. Trip alarms will sound in the DCS on XA-1205 and HA-120S and in the control room on UA-1205. Hot flue gases are normally pulled by the ID fan from the radiant section of the reformer exiting through four tunnels, The tunnels, and the openings that allow the flue gases into them, are designed to give an equal flow throughout the radiant box of the reformer. The hot flue gases flow through the convection section across various coils giving up heat to the fluids in the coils so that as much heat as possible is recovered to make the reformer more efficient. The design Lower Heating Value, LHY, efficiency of the reformer is 93.3% minimum, The flue gas heats the following coils in the order listed: Coil Design Case ‘Temperature Pressure Radiant section catalyst tubes TC 48.1 kg/om’g Radiant section riser tubes B8°C 47.0 kg/em’g Mixed Feed Coil 537.6°C 61.9 kg/em’g Hot Process Air Coil 538°C 54.8 kg/em’g HP Hot Steam Superheater Coil 533°C 1143 kg/em’ HP Cold Steam Supetheater Coil 423.4°C 1143 kglem’g Feed Gas Preheat Coil BLPC 61.9 kglem’g Cold Process Air Coil 420°C 54.8 kg/em’g, ‘itnnews Scolar ean CL