AAST Operation Manual Rev0

COROMANDEL INTERNATIONAL
AMMONIA STORAGE SYSTEM

LIMITED, KAKINADA
Doc No: A-6289-043-003
OPERATION MANUAL
Rev : 0 Page 1 of 103
CONTENTS Page
1. Preface 2
2. Process Description 5
3. Interlock System 14
4. System Conditioning 21
5. Start-up Procedure 34
6. Normal Operation 37
7. Shutdown Procedure 41
8. Safety Features and Measures 43
9. Plant maintenance 55
ATTACHMENTS
Annexure1- P&ID
Annexure2- Alarm List
Annexure3- Cause and Effect Diagram
Annexure4- Equipment List
Annexure5- Tank Process Data sheet
Annexure6- Control Valve Data sheet
Annexure7- Relief Valve Data sheet
Annexure8- Tie-In Point List
Annexure9- On-off Valve Data sheet
Operation Manual_Rev. 0
LIMITED, KAKINADA
Doc No: A-6289-043-003
OPERATION MANUAL
1. PREFACE
This manual has been compiled to assist those charged with the responsibility of the
initial start-up and subsequent operation of New 12500 MT Ammonia Storage System,
for Coromandel International Limited at Kakinada, Andhra Pradesh.
The primary objective in the preparation of this manual is to provide flow descriptions
and details of the processes involved with related operating principles, suggested
procedures for initial commissioning, start-up and shutdown of the plant. The contents
should be regarded as a source of information in resolving operating problems and are
not a substitute for the experience of skilled operating personnel.
It is not possible to anticipate and present all potential situations which may confront
the operator during the commissioning, start-up, normal and emergency shutdown of
the system. Consequently, this manual must be recognized as a guide and the
conditions incorporated are not rigid standards, unless specifically noted as such. The
operating skills and techniques shall be developed and improvised from actual
operating experiences. All operations shall strictly comply with safety requirements and
practices followed throughout the industry.
Therefore it is of great importance that the operator should have a full understanding
with functions, systems and layout of the process plant equipment to cope with each
and every situation. It should also be taken into consideration that the methods, data
and operating conditions described in this instruction may well have a necessity to be
appropriately amended under abnormal operating conditions or emergency situations.
Some procedures may be modified after actual operation if necessary. Standard

Operating Procedure should be written with reference to this instruction, vendor’s
instructions and others. Operators should read this manual along with Standard
Operating Procedure and other operating instructions and literature’s of special
equipment, before they actually participate in operation or maintenance activities.
Operation Manual Rev. 0

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OPERATION MANUAL
1.1 Sectional Abstract
Section 1 of the manual contains a description of the process system.
Section 2 contains description of process flows with respect to individual operations. It

also explains process and operating principles subject to each operation.
Section 3 contains a description of major equipment and elaboration of instrument

configuration loops. Vendor’s manual will be a valuable source, regarding equipment,
Instrument data sheets and instrument loop diagrams will assist in the understanding of
control and interlock schemes.
Section 4 contains a suggested procedure for conditioning all process equipment in the
preparation for initial start-up. Hydro testing, flushing and purging procedures which are
a part of system conditioning, are also explained in this section. The Equipment
Specification and vendor instruction manuals are an additional source of information
which should be referred to.
Section 5 contains a recommended starting procedure for the initial start-up and
subsequent operation of the system.
Section 6 describes a recommended Normal Operation of the system.
Section 7 contains a recommended shutdown procedure for the system.
Section 8 contains description of safety features incorporated in the system. The latter
half of this section also describes safety precautions in the handling of anhydrous
ammonia.
Section 9 contains a brief outline on activities for plant maintenance.
1.2 System Summary
This paragraph provides a brief description of the system for the storage of anhydrous
ammonia.
Function and Capacity

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There are three numbers of existing Ammonia Storage Tanks. Two tanks are of 5,000
MT capacity (10-T-01A/B) and one is 10,000 MT capacity (20-T-01) to store liquid
ammonia at a temperature of -33 degree Celsius, at near atmospheric pressure.
Another 4th new tank (30-T-01) with a storage capacity of 12,500 MT with two Ammonia
Transfer Pumps (30-P-01 A/B) of capacity 47.8 m3/h have been added to the system.
The pressure in the tanks is maintained by new Ammonia Refrigeration system
comprises of two oil lubricated screw compressors (30-K-01A/B) of suction capacity
1506 kg/hr, Ammonia condensers (30-E-01 A/B), Economizer (30-E-02) and Ammonia
Receiver (30-D-01) . New Cooling tower (30-U-01) of capacity 843 TR with Cooling
water pumps (30-P-02 A/B) are added for new Refrigeration system.
Existing plant have facility to receive ammonia from the ship and also have the facility
to transfer liquid ammonia to the DAP plant.
Liquid ammonia will be unloaded from the ship into the Ammonia Storage Tanks
through an insulated pipeline, at a rate of 550 MT/hr, temperature of (-) 31.8 0C and
pressure of 5~7 kg/cm2g. The vapour generated by flashing ammonia from these
conditions to the operating conditions of the Ammonia Storage Tanks will be sent to the
Ammonia Refrigeration System for re-liquefaction. The Re-liquefied ammonia will then
flow back to the Ammonia Storage Tanks. Liquid ammonia from the Ammonia Storage
Tanks will be pumped to the DAP plant.
The process described in this manual is for new 12,500 MT Ammonia Storage System.
For operation of the existing Ammonia Storage System the existing manuals should be
referred.

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2. PROCESS DESCRIPTION
This section describes the process description of Ammonia Storage System.
The Ammonia Storage System consist as follows
1. Ammonia Ship Unloading Section
Pre Cooling
Ship Unloading
2. Ammonia Storage and Pumping Section
Atmospheric Ammonia Storage Tank
Ammonia Transfer Pump
3. Ammonia Refrigeration Section
Ammonia Compressor
Ammonia Condenser
Ammonia Receiver
Economiser
4. Utilities and supporting Facilities
Cooling Water
Service Water
Potable Water
Plant and Instrument Air
Nitrogen
Flare
Electric power
Fire Fighting System
2.1 Ammonia Ship Unloading Section:
Liquid ammonia is brought at a temperature of -32.5 oC in refrigerated ships and

pumped ashore via the ship’s pumps through unloading arms to an unloading pipe line
to the atmospheric storage tanks. Prior to introducing ammonia from ship, unloading
line is kept cool by recirculating ammonia pumped by ammonia transfer pump. The
ammonia circulated is returned to the atmospheric storage tank.
2.1.1 Pre-cooling:

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Due to heat ingress from the surroundings the temperature of the ammonia ship
unloading line increases. The increase in temperature is proportional to the time
available between two ship unloading operations. Heat ingress depends on the
ambient temperature, and the thermal conductivity of the insulation. Pre-cooling of the
ammonia unloading-line is necessary to prevent metal stress due to achieve the
desired unloading rate of 550 MT/hr during ship unloading.
Temperature of ammonia unloading line is measured by the Temperature Indicator and

temperature recorder installed on the unloading line in the jetty area. The time required
for pre-cooling is a function of the rise in the temperature inside the ammonia
unloading line after previous unloading operation. Cold ammonia from the Ammonia
Storage Tank is pumped into the ammonia unloading line by ammonia transfer pump
(30-P-01A/B). It then flows towards the jetty through pre-cooling line and is routed back
from the jetty through an unloading line to the ammonia storage area. This line used
pre-cooling of unloading line is called the pre-cooling line. This ammonia is routed to
the Ammonia Storage Tank (30-T-01). The additional vapour generated due to pre-
cooling is drawn into the Ammonia Refrigeration Compressors (30-K-01A/B).The
progress of the pre-cooling, is indicated by the temperature indicator and temperature
recorder installed on the unloading line in the jetty area.
2.1.2 Ship Unloading:
The pre-cooling operation is one of the requirements prior to the ship unloading
operation. Commencement of the ship unloading operation is ensured by the
necessary operating instructions for the source point and the destination point of the
ammonia unloading line.
Cold ammonia delivered from the ship is pumped by the ship’s pump from the jetty to
the Ammonia Storage Tank. The additional vapour generated is principally due to
flashing of ammonia liquid, which in turn is due to difference in temperature between
the delivered ammonia and the ammonia in the Ammonia Storage Tank. This vapour is
drawn into the Ammonia Refrigeration System, where it is compressed, liquefied and
returned to the Ammonia Storage Tank.

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2.2 Ammonia Storage and Pumping Section:
2.2.1 Atmospheric Ammonia Storage Tank (30-T-01)
Ammonia is generally stored in a specially designed storage tanks at temperature of

about -33°C and pressures slightly above atmosphere (300~1200 mmWCg).
The heat leak into the various systems and a part of pumping work eventually ends up
in terms of vapour formation and subsequently rise in ammonia storage tank pressure.
The pressure in the tank is maintained by the Ammonia Refrigeration Compressors, the
detail of which is explained in the subsequent sub-section. The rise in the tank
pressure is due to the following:
1. Vapour formation due to ship unloading pipeline heat leak.
2. Rise in enthalpy due to work done by the ship pumps.
3. Vapour generated due to feed flashing inside the tank.
4. Heat ingress into the tanks.
5. Vapour formation due to heat ingress in Plant Piping.
6. Vapour displaced due to rise in liquid level in the tank.
7. Vapour formation due to minimum flow circulation of Pumps.
The Ammonia Refrigeration System is designed for the above vapour loads.
Of the above, items 4, 5 and 7 constitute the holding load. During holding operation,
one of the compressors is in operation. This compressor shall maintain the pressure of
the Ammonia Storage Tanks.
a. Tank Design & Construction
I. Type of Tank
The Ammonia Storage Tank is operated at atmospheric pressure. The tank is a double
integrity cup-in tank construction with a domed roof for the outer tank. Liquid ammonia

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from the refrigeration system is sprayed into the tank. Since, both the inner and outer
tanks are designed for the same conditions, in case of failure of the inner tank, the
outer tank acts as a perfect secondary containment chamber, confining the inner tank
contents in the outer tank. The advantages of this design are as follows:
i. Elimination of an external bund wall.
ii. Better controllability of tank pressure due to the increased vapour space,
available in annular space between the inner tank and the outer tank.
II. Tank Foundation
The foundations of the tanks are designed to prevent any differential settlement of the
tank. Also, the foundations are designed for water filling load which will occur during
hydrotesting. The foundation is raised by about one meter, to allow free circulation air
beneath the foundation.
III. Tank Bottom Design
The bottoms of the inner and outer tank are independent. The two tank bottoms are
separated by a 100 mm layer of concrete pad. 25 mm thick sand layer & 102 mm thick
two layers of closed pore cellular glass is laid between the outer tank bottom and the
concrete foundation, to conserve cold. The outer ring of insulation, on which the inner
and outer shells rest, is of perlite concrete, which is also a good insulation material.
IV. Shell Insulation
The insulation used for the shell is polyurethane, foamed in situ. The in situ application
eliminates any gaps in the insulation and leads to a more uniform insulating layer.
V. Roof Insulation
The insulating material used for the roof is glass wool. In this design, a deck of glass
wool is suspended just above the cylindrical shell of the tank and covers both, inner
and outer tanks. Necessary openings are provided in the deck for introducing nozzles
and pipes into the tank. The superheated vapour in the domed section is left relatively

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undisturbed and forms an additional insulation blanket. The suspended deck eliminates
superheating of ammonia vapour from the roof and thereby reduces the compressor
load.
VI. Tank Safety Systems
a. Safety Valves (SV 30207/30208)
The ammonia storage tank is equipped with pressure safety valves to safeguard the
tank against over pressure. The sizing criteria is that even when one safety valve is
taken out for maintenance, safety of the storage tank is not compromised, as each
safety valve is sized for 100% capacity. Safety valve is sized for rise in tank pressure,
due to external fire case. Isolation valves for safety valves are provided with
mechanical interlock.
b. Vacuum Relief (VRV 30201/30202)
The tank is provided with vacuum relief valves to protect the tank from vacuum. This
valve is sized for most severe of cases leading to drop in tank pressure, which could be
due to following combine conditions.
1. High rate of Liquid Ammonia withdrawal from the tank
2. Sudden increase in atmospheric pressure.
3. BOG withdrawal due to Compressor.
The sizing criteria is that even when one vacuum relief valve is taken for maintenance,
the safety of the tank is not compromised, as each valve is sized for 100% capacity.
c. Pressure Control Valve (PV-30203)
In addition to the safety valves, the tank is also provided with a pressure control valve
to vent the tank content in case of over pressure sensed by pressure transmitter PT-
30204.
VII. Tank Instrumentation

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The tank is provided with instruments for measurement, monitoring and control of
pressure, temperature and level. Level indication is obtained by two different types of
instruments to ensure redundancy. Additionally, a level transmitter is also installed in
the annular space, which, in normal operation should read zero. Also a level differential
transmitter is provided between inner tank and annular space.
2.2.2 Ammonia Transfer Pumps (30-P-01A/B)
Centrifugal vertical barrel type ammonia transfer pumps having capacity of 47.8 m3/hr
and discharge pressure of 25.5 kg/cm2g are provided for transferring liquid ammonia
from the ammonia storage tank to the DAP plant. Both operating and stand by pump
are identical and have a common suction and a discharge header. Each pump is
provided with an auto re-circulation control valve (ARC valve) to ensure that the pump
does not operate below its minimum flow capacity. When operating at low capacity in
the minimum flow valve re-circulates a part of the pumped liquid back to the tank thus
meeting the minimum flow requirement of the pump. Provision of piping ensures
efficient venting at the pump casing, suction and discharge, back to the vapour space
of the Ammonia Storage Tank to enable fast priming of pump and to avoid undue delay
during the starting of the pump.
2.3 Ammonia Refrigeration Section:

This section consists of the following items:
2.3.1 Ammonia Compressors (30-K-01A/B):

The net refrigeration capacity of the compressors is the total vapour load generated
inside the Ammonia Storage Tank as explained in section 2.2.1.
Two nos. of oil lubricated screw compressors having suction capacity of 1506 kg/hr
each are provided. The entire refrigeration load of the facility, including existing storage
tanks boil off gas during ship unloading load is to be handled by these two new
compressors.
2.3.2 Ammonia Condensers (30-E-01A/B)

Compressed ammonia vapour in the Ammonia Refrigeration Compressors are
condensed in the Ammonia Condensers at a condensing temperature which
corresponds to the discharge pressure of the compressors. The utility used is cooling

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water and its function is to remove superheat and latent heat from the ammonia vapour
at the condensing temperature to liquefy the ammonia. Ammonia liquid in saturated
condition is then collected in Ammonia Receiver (30-D-01).
2.3.3 Ammonia Receiver (30-D-01)

Ammonia receiver is a horizontal vessel which provides surge capacity. Ammonia
Receiver holds saturated liquid ammonia from the ammonia condensers for a hold-up
time of approximately 15 minutes.
2.3.4 Economizer (30-E-02)

Economizer is principally a heat exchanger used for sub-cooling saturated ammonia
liquid from ammonia receiver. Saturated liquid ammonia from the receiver is split into
two streams and sent to the economizer. One stream enters the tube side of the
economizer and the other enters the shell side. The latter stream enters the
economizer as vapour and liquid mixture after flashing across a control valve (LV-
30301) located at the shell-side inlet. The cold stream from shell side cools the tube
side. The vapour generated due to heat exchange on the shell-side, is sent to the
compressor intermediate port.
The temperature of saturated liquid ammonia available at the tube-side outlet is further
reduced to match ammonia storage tank conditions. This is achieved by flashing the
saturated liquid ammonia across a control valve (LV-30304).
2.4 Utilities and Supporting Facilities:
2.4.1 Cooling Water System:

A new cooling water system is provided, which includes Cooling Tower (30-U-01),
Cooling Water Circulation Pump (30-P-02 A/B) and Side Stream Filter (30-U-02).
Cooling Tower caters to the requirement of Ammonia Condensers and Ammonia
Compressor Oil Coolers, of the new facility.
Cooling Tower consists of one cell and one fan, having capacity of 843 TR. In Cooling
Tower, cooling water is cooled from 39 °C to 33 °C. Cooling water is circulated by
means of Cooling Water Pump (30-P-02 A/B). The amount of make-up water entering
the cooling water basin is controlled by an On-Off valve (XV 30801) pertaining to the

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basin level. Cooling water dosing system (Existing) is used to ensure that cooling water
quality is maintained.
Side Stream Filter (30-U-02) is used to remove suspended solids from the cooling
water system. Its capacity is 8.5 m3/hr. After a certain period of time, when the
pressure drop across the filter increases due to accumulation of sediment of
suspended solids in the cooling water, the Side Stream Filter under goes back-wash
and the water outlet resultant from the back wash is led into storm water drain.
2.4.2 Service Water:

Service water is tapped from Battery limit. Service water distribution piping is provided
from the battery limit to the various distribution points. Service water is mainly used for
cooling tower make up and for hose stations.
2.4.3 Potable water:

Potable water is tapped from Battery limit. Potable water distribution piping is provided
from the battery limit to the various distribution points. Potable water is connected to all
safety showers. Potable water stations are provided on alternate landing of stair case
and top of the tank.
2.4.4 Plant Air / Instrument Air:

Plant Air and Instrument air are tapped from Battery limit. Plant air and Instrument air
distribution piping is provided from the battery limit to the various distribution points.
Plant Air connections are provided on each landing of stair case and top of the tank for
air breathing apparatus.
2.4.5 Nitrogen:
Nitrogen gas is used for purging of Ammonia transfer pumps. Nitrogen gas is supplied
at B/L in cylinders by Coromandel.
2.4.6Flare System:
Existing flare system is used for new 12,500 MT Ammonia storage systems.
Flare system is required to facilitate the burning of ammonia vapour during the
following emergency situations:

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a. Controlling the pressure rise in the Ammonia Storage Tank (30-T-01).

b. Safety Valve discharge during external fire condition from any of the equipment
included in the system, except the Ammonia Storage Tank (30-T-01).
2.4.7 Electrical Power System:

Please refer to ‘Design Basis-Electrical (Doc. No. 6289-N-150A)
2.4.8 Fire Fighting System

Fire water ring -sprinklers (Water Curtain) system is considered for new ammonia
transfer pump and new ammonia storage tank (At the top).
Ammonia leak detectors are considered for ammonia storage tank area (2 no.) and
ammonia transfer pump area (2 no.). These leak detectors are interlocked with the
water sprinkler system in respective areas.

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3. INTERLOCK SYSTEM:
Interlocks are provided to prevent the system from behaving abnormally which will
affect the safety of the personnel, plant and functioning of the equipment. Piping and
Instrumentation Diagrams indicate all the instrumentation and interlocks for the system.
Details of the interlocks are listed in cause and effect diagram.
Most of the system instrumentation is conventional in construction and application.

There may be instances where the operator may not be familiar with certain
instrumentation configuration. To aid to these situations the interlock and control
systems are explained herewith:
3.1 Ammonia Storage and Transfer Section:

(a) I-201: Ammonia Storage Tank (30-T-01) protection in connection with liquid ammonia
unloading into tank from ship:
Description:
i. The Level Transmitter LT-30201 high high signal for Ammonia Storage Tank is
interlocked with hand operated control valves HV-30201 and HV-30202 located on
14” ammonia ship unloading line and its bypass line respectively, inside the
ammonia storage battery limit.
ii. For tank over pressure, high high pressure signal from pressure transmitter
PT-30204 on Ammonia Storage Tank is interlocked with the same hand operated
control valves HV-30201 and HV-30202.
iii. Hand switch HS-30201 and HV-30202 located on PLC is interlocked with HV-
30201 and HV-30202 respectively.
Operating Logic:
i. In situation of high high liquid level in the Ammonia Storage Tank, the hand
operated control valves HV-30201 and HV-30202 should close, to prevent over
flow.
ii. In case of high high pressure in the Ammonia Storage Tank, HV-30201 and HV-
30202 should close, thereby safeguarding the tank from over pressure.
iii. In case of emergency or as per requirement HV-30201 and HV-30202 can be
closed by hand switch located on PLC.

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(b) I-202A/B: Protecting Ammonia Transfer Pump (30-P-01 A/B):

Description:
i. Level transmitter LT-30201 low low liquid level signal for Ammonia Storage Tank
(30-T-01) is interlocked with Ammonia Transfer Pump.
ii. Pressure transmitter PT-30204 low low signal on Ammonia Storage Tank (30-T-
01) is interlocked with Ammonia Transfer Pump.
iii. On-Off valve XV-30204(on 8”, pump 30-P-01 A/B suction line) limit switch ZAO-
30204 is interlocked with Ammonia Transfer Pump.
iv. Pressure differential transmitters PDT-30210 A/B (to measure pressure differential
between the suction and discharge of the pump 30-P-01 A/B) low low signal is
interlocked with Ammonia Transfer Pump.
v. Level differential transmitter LDT-30204 (to measure level differential between the
inner and outer tank) low low signal is interlocked with Ammonia Transfer Pump.
vi. Hand switch HS-30210 and HS-30211 located on PLC and field are interlocked
with Ammonia Transfer Pump.
Operating Logic:
i. In situations of low low liquid level in the Ammonia Storage Tank (30-T-01),
Ammonia Transfer Pump should trip automatically ensuring pump protection.
ii. In situations of low low pressure in the Ammonia Storage Tank (30-T-01),
Ammonia Transfer Pump should trip automatically.
iii. If XV-30204 on 8” pump suction line is not fully open, Ammonia Transfer Pump
should trip automatically ensuring pump protection.
iv. When the pressure differential across the pump is recorded low low, Ammonia
Transfer Pump should trip ensuring pump protection.
v. In situation where the level difference between inner and annular region of the
Ammonia Storage Tank (30-T-01) is low low, Ammonia Transfer Pump should trip
automatically ensuring tank protection.
vi. In case of emergency or as per requirement, Ammonia Transfer Pump can be
stopped by hand switches from field or PLC.

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(c) I-203: Ammonia Storage Tank (30-T-01) protection in connection with existing
Ammonia Compressors (10-K-01 A/B/C):
Description:
i. Pressure transmitter PT-30204 low low signal on Ammonia Storage Tank (30-T-
01) is interlocked with existing Ammonia Compressors.
Operating Logic:
i. In situations of low low pressure in the Ammonia Storage Tank, the existing
Ammonia Compressors should trip automatically.
(d) I-204: Ammonia Storage Tank (30-T-01) protection in connection with ammonia
vapour discharge to flare through existing hand operated control valve HV-10102:
Description:
i. Pressure transmitter PT-30204 high high signal on Ammonia Storage Tank (30-T-
01) is interlocked with existing hand operated control valve HV-10102.
Operating Logic:
i. In situations of high high pressure in the Ammonia Storage Tank, the existing
hand operated control valve HV-10102 should open.
(e) I-205: Ammonia Storage Tank (30-T-01) protection in connection with Ammonia
Transfer Pump (30-P-01 A/B) suction line On-Off valve, XV-30201:
Description:
i. Level transmitter LT-30201 low low liquid level signal for Ammonia Storage Tank
is interlocked with Ammonia Transfer Pump suction line On-Off valve XV-30201.
ii. Pressure transmitter PT-30204 low low signal on Ammonia Storage Tank is
interlocked with On-Off valve XV-30201.
iii. Hand switch HS-30203 A/B located on PLC and field is interlocked with On-Off
valve XV-30201.
Operating Logic:
i. In situations of low low liquid level in the Ammonia Storage Tank, the On-Off valve
XV-30201should be closed.
ii. In situations of low low pressure in the Ammonia Storage Tank, the On-Off valve
XV-30201should be closed.

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iii. In case of emergency or as per requirement, Pump suction line On-Off valve XV-
30201can be closed by hand switches from field or PLC.
(f) I-206: Ammonia Storage Tank (30-T-01) protection in connection with ammonia
vapour discharge to flare through PV-30203:
Description:
i. Pressure transmitter PT-30204 high high signal on Ammonia Storage Tank (30-T-
01) is interlocked with New Flare Subheader Butterfly valve PV-30203.
Operating Logic:
i. In situations of high high pressure in the Ammonia Storage Tank, the New Flare
Subheader Butterfly valve PV-30203 should open.
(g) I-301 A/B: Ammonia Storage Tank (30-T-01) and Economiser (30-E-02) protection in
connection with new Ammonia Compressors (30-K-01 A/B):
Description:
i. Pressure transmitter PT-30204 low low signal on Ammonia Storage Tank (30-T-
01) is interlocked with new Ammonia Compressors (30-K-01 A/B).
ii. Level transmitter LT-30303 high high liquid level signal for Economiser (30-E-02)
is interlocked with new Ammonia Compressors (30-K-01 A/B).
Operating Logic:
i. In situations of low low pressure in the Ammonia Storage Tank, the new Ammonia
Compressors should trip automatically.
ii. In situations of high high liquid level in the Economiser, the new Ammonia
Compressors should trip automatically.
(h) I-303: Ammonia Storage Tank (30-T-01) protection in connection with Open Tank Fire
Water Curtain valve (30-XV-30001):
Description:
i. Ammonia Gas Detector transmitter (AT-30201/AT-30202) high high on Ammonia
Storage Tank (30-T-01) is interlocked with Open Tank Fire Water Curtain valve (30-
XV-30001).
Operating Logic:

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i. In situations of high high Ammonia Gas concentration on the Ammonia Storage

Tank, the Open Tank Fire Water Curtain valve (30-XV-30001) should open
automatically.
(i) I-304: Ammonia Transfer Pump (30-P-01 A/B) protection in connection with Open
Pump Area Fire Water Curtain valve (30-XV-30002):
Description:
ii. Ammonia Gas Detector transmitter (AT-30203/AT-30204) high high near
Ammonia Transfer Pump (30-P-01) is interlocked with Open Pump Area Fire
Water Curtain valve (30-XV-30002).
Operating Logic:
ii. In situations of high high Ammonia Gas concentration near the Ammonia Transfer
Pump, the Open Pump Area Fire Water Curtain valve (30-XV-30002) should open
automatically.
3.2 Ammonia Refrigeration Section

(a) I-302: Ammonia Compressor (30-K-01 A/B) protection in connection with Economiser
(30-E-02) level:
Description:
i. Level transmitter LT-30303 high high liquid level signal for Economiser is
interlocked with level control valve LV-30301.
Operating Logic:
i. In situations of high high liquid level in the Economiser, the level control valve LV-
30301should close.
(b) Protecting New Ammonia Compressors (30-K-01 A/B) (Inside Vendor Package):
Description:
i. I-351: Compressor Suction pressure switch PS-30311 low low signal is
interlocked with Ammonia Compressors.
ii. I-351: Compressor discharge temperature switch TS-30312 high high signal is
iii. I-351: Compressor discharge pressure switch PS-30312 high high signal is

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iv. I-351: Primary oil separator level LT-30311 low low signal is interlocked with
Ammonia Compressors.
v. I-351: Differential pressure switch (between oil and compressor discharge) DPS-
30311 high high signal is interlocked with Ammonia Compressors.
vi. I-351: Oil manifold temperature TS-30311 high high signal is interlocked with
vii. I-351: Compressor motor bearing temperature RTD-30317 & RDT-30318 high
high signal is interlocked with Ammonia Compressors.
viii. I-351: Compressor motor current II-30310 high high signal is interlocked with
ix. I-351: Emergency stop from PLC HS-30313 signal is interlocked with Ammonia
Compressors.
x. I-352: Primary oil separator level LT-30311 more than 500 mm signal is
xi. I-352: Differential pressure across oil pump DPS-30313 more than or equal to 1.8
kg/cm2 g signal is interlocked with Ammonia Compressors.
xii. I-352: Oil separator temperature TT-30311 less than 40°C signal is interlocked
with Oil heater.
xiii. I-352: Oil separator temperature TT-30311 more than or equal to 50°C signal is
interlocked with Oil heater.
xiv. I-352: Oil separator temperature TT-30311 more than 45°C signal is interlocked
with Ammonia Compressors.
xv. I-352: Compressor load position ZT-30311 more than or equal to 12% is
Operating Logic:
i. Low low compressor suction pressure should trip the Ammonia Compressor.
ii. High high compressor discharge temperature should trip the Ammonia
Compressor.
iii. High high compressor discharge pressure should trip the Ammonia Compressor.
iv. Low low primary oil separator level should trip the Ammonia Compressor.
v. High high differential pressure between oil & compressor discharge should trip
the Ammonia Compressor.

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vi. High high oil manifold temperature should trip the Ammonia Compressor.
vii. High high Compressor motor bearing temperature should trip the Ammonia
Compressor.
viii. High high Compressor motor current should trip the Ammonia Compressor.
ix. Emergency stop from PLC should stop the Ammonia Compressors.
x. When primary oil separator level is more than 500 mm then the Ammonia
Compressor is ready to start.
xi. When Differential pressure across oil pump DPS-30313 more than or equal to
1.8 kg/cm2 g then the Ammonia Compressor is ready to start.
xii. When Oil separator temperature TT-30311 is less than 40°C then Oil heater will
on.
xiii. When Oil separator temperature TT-30311 is more than or equal to 50°C then
Oil heater will off.
xiv. When Oil separator temperature TT-30311 is more than 45°C then the Ammonia
Compressor is ready to start.
xv. Compressor load position ZT-30311 is more than or equal to 12% then the
Ammonia Compressor is ready to start.
3.3 Utility Section:

(a) I-801 and I-802: Protecting Cooling Water Pump (30-P-02 A/B):
Description:
i. Level transmitter LT-30801 high liquid level signal for Cooling Tower Basin is
ii. Level transmitter LT-30801 low liquid level signal for Cooling Tower Basin is
Operating Logic:
i. In situations of high liquid level in the Cooling Water Basin, the On-Off valve XV-
30801 should close.
ii. In situations of low liquid level in the Cooling Water Basin, the On-Off valve XV-
30801 should open.

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4. SYSTEM CONDITIONING:
Introduction
This section covers the tasks of cleaning, testing and preparation of the system for
service. The procedures described are carried out as a whole only once, at the
completion of the construction and before initial operation of the system, but
appropriate phases should be repeated after any major repair, alteration or
replacement.
Scheduling of these initial conditioning procedures should be carefully coordinated with

the construction group, in order to accomplish the most expeditious start-up possible.
Unit commissioning requires utilities that need to be commissioned and proven, to
facilitate commissioning of the system.
The ensuing discussion of conditioning is, for the most part, general in nature and does
not attempt to establish the order in which the work will be done. The best options are
determined in the field with due regard to the status of construction and the available
utilities.
Detailed blowing and flushing procedures are also best done in the field where piping
configuration as well as mechanical constraints involved at certain points may be
observed and considered.
4.1 Hydrostatic Testing
Hydrostatic tests are made on new or repaired equipment and piping to prove the
strength of materials and welds. They are conducted by filling the equipment involved
with water and building pressure with a portable test pump. These tests are not to be
confused with others, made in different ways and at less severe conditions, which may
be imposed on assembled sections of the unit before each start-up, to check the
tightness of bolted and screwed connections.
The initial hydrostatic testing required is ordinarily done by construction personnel

during the course of erection. If, for any reason, it becomes necessary for the operators
to carry out such tests, the specified hydrostatic test pressure for each item should be

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obtained from the proper source. This pressure is the highest to which the item may be
subjected under any circumstances, and must never be exceeded. Before testing a line
it is necessary to blind off any connection having lower test pressure than that of the
line being tested.
Safety Relief Valves must be removed or gagged prior to hydrostatic testing of

associated piping or equipment. In case the settings of these valves have not
previously been verified, this needs to be done before reinstallation.
Lines and equipment which are tested with media other than water must be isolated
when connected to system under hydrostatic pressure.
Instrument piping is to be disconnected from the instruments, but the piping including
manifolds, is to be tested at the same pressure as the line to which it is connected.
Suctions and discharges should be isolated or disconnected from pumps and

compressors.
It should be noted that stainless steel lines and equipment should not be contacted with
water containing more than 10 ppm chloride.
4.2 Line Blowing and Flushing
All fluid-handling equipment, particularly piping, should be thoroughly cleaned of scale

and internal debris which accumulates during construction. Thorough flushing and
blowing of all piping and equipment should follow construction, to commission the
system in operation.
Flow velocities during line blowing should be greater than normal operation flows,
approximately 125%, to the extent possible. If the pressure in the piping being blown is
maintained lower than normal operating pressure, greater velocities can be achieved
using less blowing medium.
a. Flushing Media and Techniques
All systems should be flushed or blown with “flushing media”, admitted via temporary
hose or pipe connections. Examples of flushing media are as follows:

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Water System – Flushed with water
Air System – Flushed with air or nitrogen
Systems that are not normally flushed with their normal media include:
Process Gas Systems – Flushed with air
Process Liquid – Flushed with air or water
In any system, to the extent possible, flushing media flow outlets should be at the
lowest points. The low point outlets will usually be temporary openings made by
disconnecting flanges or fittings; normal drains may be used for flush outlets provided
they are equal to or nearly close to the line size.
For optimum results, there should be no restriction at the outlet or any other point in a
line undergoing cleaning. However, if the need is to throttle the flushing flow then it has
to be done at the supply end. Effective scouring of lines is possible at higher flushing
velocities. With a limited supply of flushing medium, flushing should be avoided through
too many openings or circuits simultaneously. Flushing should be done through all
vents, drains, side connections, main channels as well as bypasses. Flushing debris
into nozzles or small bore lines where trapping can occur, it should be avoided.
Flushing should be planned so that main headers are flushed first. Branch lines and
side connections should be flushed individually after main header flushing is complete.
All control valves should be removed or rolled out until the foreign material has been
removed from their systems. Finally, the valve should be replaced and flushing should
be through the valve in normal alignment, or bypass, if the valve cannot be opened.
Short spools can be installed in place of control valves to facilitate the flushing
procedures.
All connections at pumps, compressors and drivers must be blinded while the lines
running to them are thoroughly flushed. This applies to the discharge lines. The
flushing or blowing outlet should be at some convenient point or as near to the pump or
driver as possible. Generally, it is necessary to disconnect a flange or fitting. When this

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is done on the pump or compressor side of the block valve, the open connection should
be covered to prevent the entry of debris.
In discharge lines containing a check valve immediately adjacent to the pump, a

flushing outlet may be made by removing the check valve cover plate, provided the
flapper or disc remains in place to seal off the pump itself or remove the check valve
and blind the equipment blind flange. Back-flushing through a check valve if necessary,
shall be done by removing the flapper and replacing the cover plate or by reversing the
check valve.
All connections to instruments should be isolated during flushing. Instrument air lines
must be blown with special thoroughness with clean, dry air.
4.3 Post Flushing Procedures
After the flushing, the normal piping configuration should be restored. Check valve
flappers and/or cover plates should be replaced. Lines which need further cleaning
during the start-up of pumps need not be restored completely at this time. All flanges or
connections not made up must be covered to prevent any entry of debris. Water should
be drained from all systems at the completion of flushing. During draining, to avoid
vacuum on the piping or equipment, high point vents should be kept open. All vessels
should be thoroughly cleaned internally. All normal piping at pumps, compressors and
heat exchangers should be reconnected. All control valves should be reinstalled and all
instrumentation systems should be restored to normal operating configuration.
New gaskets should be used in all flanged connections. Reuse of old gaskets will result
in leaks and costly time delays when the systems are tested for tightness.
Special care should be taken for re-installation of flow elements, control valves and
check valves which were removed for flushing. Installation procedures should be based
on the direction of normal flow in the line.
The basic utility systems, water, nitrogen and air should be put in normal working order
after they have been cleaned, so that supplies will be made available for further
flushing and commissioning procedures.

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4.4 Leak Test
The leak test is a very important work item in plant components in which the fluids are
inflammable or toxic. Hence, the leak test must be done as carefully as possible in
order to avoid fire or explosion hazard. This leak test can be done after pressure test of
each test and flushing work. The leak test of each section will be performed with air or
nitrogen at a pressure of 5 kg/cm2g or at design pressure of that section whichever is
smaller. Test is performed using soapsuds while blocking each pressurized section.
This test shall be repeated till there is no sign of bubble formation.
A. Preparation for the Operation
a. Prepare temporary piping if required.
b. Prepare scaffoldings if required for the test.
c. Confirm that flanges are not insulated for the test.
d. Confirm that test pressure shall not exceed the set pressure of safety valve or
design pressure of the equipment.
e. Provide soapsuds contained in a bottle for use in checking leakage points.
f. Confirm that all drain valves and vent valves on the process lines are closed.
B. Steps of Operation
a. It is recommended to perform leak test sequentially, starting from the lowest

pressure section.
b. Start a flow of air or nitrogen gas at the lowest section and pressurize up to the test
pressure.
c. When the pressure has reached test pressure, check for leaks of all joint parts with
soap solution.
d. Formation of bubbles at point of application of the soap suds confirms leak points.

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4.5 Inspection of Equipment
A. Inspection of Vessels
All vessel internals should be visually checked for cleanliness and for complete and
proper installation of internal equipment prior to the final bolting of cover plates or
manholes or loading of internals into vessels. A general check list is given below:
a. Packing support /Demister support.
b. Extended suction lines
c. Location of nozzles, slotted inlet pipes etc
d. Installation of wire mesh
e. Internal piping
f. Vortex breakers and risers
g. Internal gaskets
h. Location and range of level instruments
i. Location and length of thermowells
j. Internal floats
k. External type displacement tube cages or differential pressure nozzles for level
instrument(s)
l. Finally, each vessel should be cleaned before it is closed and then lined up.
B. Checking of Storage Tank
After completion of the hydrostatic test all water has to be drained from the tank. Once
all mechanical work is completed, the tank has to be cleaned carefully. Presumably
there will be a substantial quantity of rust in the tank. If the tank is dry, inside cleaning
can be done with broom and dust pan. Another possibility is flushing with a fire hose
and withdrawing with a submerged pump.

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All shut-off valves of the tank are to be tested for proper mechanical functioning and
any faults are to be cleared.
Control instruments are to be tested and adjusted to set point, safety valve area to be
checked for proper setting and tight closing. Liquid level indicator and temperature
recorder need special checking. All control valves and on/off valves are to be checked
with regard to their proper functioning.
During pre-commissioning and commissioning operations, care should be taken to

ensure that the tank pressure does not exceed the design limits of Full of Liquid / Liquid
head +1500 mm WCg ~ -75 mm WCg.
Whenever the tank is open to atmosphere the roof manhole and other nozzles should
always be kept open to allow proper breathing.
Whenever the tank is to be isolated it should be pressurized to a positive pressure of

500 mmWC and the tank pressure should be continuously monitored.
Always keep the tank pressure relief valve and vacuum relief valve in line.
C. Checking of Pump
The manufacturer’s operating instructions should be reviewed. A general checklist is

given below:
a. Check that the overall installation is complete.
b. Verify that the pump and driver have been aligned for cold operation. There must be
no undue strain on the pump or driver by the piping.
c. Check seal piping. Verify that all installations are correct and complete. When a
pump is furnished with mechanical seals, verify that all of the components of the
flushing system, such as strainers, separators, restriction orifices and coolers if
required, have been correctly installed and are clean. It is very important that the
flushing system is clean, as the loss of flushing fluid or dirty flush can damage the
seals.

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d. Verify that gland packing or seals are installed.
e. Check that temporary strainers in suction piping, if required, have been installed.
f. Verify that bearing housings have been cleaned prior to lubrication. If required, they
should be washed by suitable solvent.
g. Check that pump and driver are lubricated according to lubrication instructions.
h. Check rotation of electric motor drivers uncoupled from the pump.
D. Checking of Compressor
A general checklist is given below:
a. Review the Vendor’s instruction manual carefully.
b. Check the setting of relief valves and pressure, temperature and flow switch set
points.
c. Check the rotating direction of drivers including oil pump, after decoupling from the
driven equipment.
d. Check the overall installation and the proper alignment with drivers including oil
pump.
e. Check the cleanliness of lube oil piping.
f. Check the cleanliness of filters and strainers for cooling water and lubrication
system.
g. Verify the availability of cooling water, lube oil and instrument air.
h. Check the proper installation of suction strainer.
i. Check the proper installation and wiring of instruments and verify proper functioning
of the interlocking system. Check for proper functioning of output regulation and
proper installation of all measuring and control instruments.
j. Fill the lube oil system as per manufacturer’s specification.

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E. Running of machinery
a. Initial running of pumps
Complete the mechanical check items described earlier. Most pumps will not be tested
for operating conditions since service fluids for the pumps are not available at this
situation.
For water pumps, please refer to Vendor’s instruction manual. Water pump will be
started manually and checked for proper running.
b. Initial running of compressors
Complete the mechanical check items described earlier. The compressor initial run is
to be carried out with air. Compressor suction and discharge piping has to be removed
for this purpose. Refer to vendor’s instruction manual before carrying out this test.
F. Commissioning of utilities
a. Cooling water
The cooling water for Ammonia condenser and Oil Coolers is supplied by Cooling
Water system through Cooling Water pumps. The cooling water line should be
cleaned, and commissioned as early as possible during the period of preparation for
initial start-up. The conditions for cooling water supply and return are as follows:
i. Cooling Water Supply: Pressure = 3.0kg/cm2g, Temperature = 33 0 C
2 0
ii. Cooling Water Return: Pressure = 2.5 kg/cm g, Temperature = 39 C
b. Nitrogen
Nitrogen gas will be supplied at battery limit in cylinders by Coromandel for purging of
Ammonia transfer pump. It is mandatory to flush nitrogen lines with nitrogen gas, prior
to any other precommissioning activity where Nitrogen is required.
c. Instrument air

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Instrument air is supplied at battery limit at a pressure of 6.0 kg/cm2g & 40°C. All
instrument air lines shall be flushed with instrument air prior to usage.
d. Plant Air
Plant air is supplied at battery limit at a pressure of 6.0 kg/cm2g & 40°C. After flushing,
open the isolation valve at battery limit and pressurize the line at service pressure.
e. Potable water
Potable water for safety showers/eye washers is supplied at battery limit. Potable water
lines shall be flushed and charged and kept ready for service.
f. Service water
Service water for hose stations and Cooling Tower make up is supplied at battery limit.
All Service water lines shall be flushed and charged and kept ready for service.
G. Inert gas purging
Ammonia and air form an explosive mixture in range of 16-25% by volume of

Ammonia. Hence, for safety reasons, a prior displacement of air with nitrogen is
imperative. This can be achieved by purging the system with nitrogen till oxygen
content is reduced to 2% or less. Before starting purging operation the purging loops
should be planned and temporary piping required should be fabricated and kept ready.
4.6 Purging Operation
All system piping and equipment shall be purged after the storage tank purging.
4.6.1 Ammonia Storage Tank (30-T-01)
For purging of Ammonia Tank 30-T-01, close all isolation valves on tank except the
following:
i. All the instrument isolation valves shall be open.

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ii. Pressure relief valves and vacuum relief valves of tank shall be lined up after
carrying out the necessary checks. For pilot operated Pressure relief valve the pilot
connection isolation valve shall be open.
Liquid Nitrogen will be brought by tankers. Suitable vaporiser will be used. Vaporiser
will be located near the Ammonia storage tank. For purging of Ammonia Tank 30-T-01,
hose (SXH-30204) will be connected from vaporiser outlet to pipeline AGLL-30066.
Purging nitrogen supply will be through Nozzle N18 in Tank top & valve on Nozzle N6
should be closed connected to inner tank. Nitrogen exhaust will be provided from
suitable nozzles on Inner Tank and Outer Tank. Tank pressure will be maintained at
around 300 mmwcg by throttling either the tank outlet valves or nitrogen inlet valve.
The Oxygen Concentration will be measured at all outlets periodically. Nitrogen purging
will be complete when all outlet concentrations show Oxygen content less than 2%.
After Nitrogen purging valve on nozzle N18 should be closed to avoid liquid ammonia
entry in Annular space during Tank operation and valve on N6 should be opened.
After completion of nitrogen purging, the system is ready for ammonia purging.
4.6.2 Equipment and piping (excluding Ammonia Storage Tank)
For equipment purging, utility connection nozzles are provided. The equipment and
piping purging shall be carried out section by section using Nitrogen in the Ammonia
Storage Tank. Inert gas purging shall be accomplished by pressurizing and
depressurizing with Nitrogen till Oxygen content falls below 2%. Air contained in the
equipment and piping will be purged to atmosphere through vent or drain valves.
The following equipment and interconnecting piping shall be purged with nitrogen.
A. Ammonia Transfer Pump (30-P-01A/B), Drain Vessel (30-D-02) and interconnecting

piping.
B. Ammonia Compressor (30-K-01A/B), Ammonia Receiver (30-D-01), Ammonia

Condensers (30-E-01A/B), Economiser (30-E-02) and interconnecting piping.
C. Any other auxiliary vapour ammonia / liquid ammonia pipe line.

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D. Flare header piping.
The procedure for purging operation is explained below.
Open valve N4 on Ammonia Storage Tank (Line no: ALLL-30044) to connect the
Ammonia Storage tank to following equipment of Refrigeration System for Nitrogen
purging which is stored in Ammonia Storage tank.
a. Economiser (30-E-02)
b. Ammonia Receiver (30-D-01)
c. Ammonia Condensers (30-E-01A/B)
The purging of equipment listed above should be done individually and in above
sequence. The following instructions shall be followed:
1. Open the isolation valves of all instruments on the above equipment.
2. Open the connection isolation valve and the 20 NB isolation valve on vent / drain.
3. Admit nitrogen into the equipment.
4. Open the drain / vent valve in the equipment and remove air.
5. Continue the operation till the oxygen content is reduced to 2%.
When the purging of equipment is completed, use the equipment to purge the
interconnecting piping between each section of the plant like Ammonia liquefaction
system, Flare and Drain system and interconnecting ammonia lines.
While purging the interconnecting pipeline vent the air from the vent or drain points at
the end of the pipelines or from suitable flanged joints with isolation valves.
For purging of pipelines open or close the isolation valves in the interconnecting piping
for section by section purging, maintaining nitrogen pressure in the equipment by
supplying nitrogen.

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When purging of all static equipment and pipeline is completed, keep the piping and
equipment to slight positive pressure and close the vent / drain valves and nitrogen
purge valves of the utility connections.
For rotating equipment like Ammonia Transfer Pump and Ammonia Compressor (30-K-
01A/B) purging will be accomplished by connecting the Ammonia Storage Tank through
the suction line. Thus Pumps and Compressors can be purged after Ammonia Storage
Tank purging is over by using nitrogen in the tank as purging medium. For purging of
Drain Vessel 30-D-02, connect drain vessel to Ammonia Storage tank. The following
instructions shall be followed:
i. Open the isolation valves of all instruments on the above equipment.
ii. Open the utility connection isolation valve and the 20 NB isolation valve on nitrogen
hoses.
iii. Admit nitrogen into the equipment.
iv. Open the drain or vent valve in the equipment and remove air from the bottom.
v. Continue the operation till the oxygen content is reduced to 2%.

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5. START-UP PROCEDURES:
The pre-operational procedures explained in the previous section ensure the

mechanical completion of the system. The system is now ready for start-up.
This section describes initial start-up procedure for 12500 MT ammonia storage
systems. It is assumed that the existing facility is already in operation together with the
necessary utility system.
5.1 Purge out of inert gas by ammonia vapour:
5.1.1 Purging of Ammonia Storage Tank:
At first step, the inert gas present in Ammonia Storage Tank, refrigeration system and
associate pipe lines will be replaced with ammonia vapour. Ammonia vapour from
existing ammonia storage tanks, through common ammonia compressor suction line
(AGLL 30021 & AGLL 30547).
All other tank valves except PSV, VRV and instrument valves should be closed. To
start ammonia purging the 250 NB valve at TP-16 and 300 NB valve on tank top
(vapour line to ammonia compressor suction: 300-AGLL-30021-BE33-100K) is opened.
During ammonia purging, the nitrogen and ammonia mixture will be expelled from the
bottom through 4” drain of the inner tank and through annular purge ring of outer tank.
The outlet gas will be routed to flare through temporary line (100-AGLL-30104-BA31)
as shown in the P&ID. Also open isolation valve on 50-ALLL-30097-BE33-60K and
allow the gas mixture to enter the Drain Vessel (30-D-02) which will subsequently flow
back to the tank via line 50-AGLL-30098-BE33-60K.
Tank pressure is maintained at about 300 mmwcg. The refrigeration compressors will
have to be stopped in order that enough vapours are available for tank purging. The
vapour generation rate in the existing tank may be increased by unloading operation in
the existing tanks. The ammonia purging is stopped when the ammonia concentration
at both the outlets reaches 98%.
After completion of tank purging the lines and other equipments will be purged using
Ammonia connection from tank and suitable hose connection.

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5.1.2 Purging of Equipment and Piping
Vapour ammonia from Ammonia Storage Tank / from Existing Compressor will be
made available for the purging of all equipment. The purging loops described below are
indicative and can be modified at site depending on the actual pipe routings.
a. Ammonia Refrigeration Compressors (30-K-01A/B)
Close all the valves on the Refrigeration Compressor and Condenser (30-E-01A/B)
except the isolation valve for instruments. Open the isolation valve to the suction of the
Ammonia Refrigeration Compressors. Connect the line to Flare header. Check the
ammonia concentration at the vent/Drain. After purging operation close isolation valve
on the vent to flare line.
Open the isolation valve to the Discharge of the Ammonia Refrigeration Compressors.
Connect the line to Flare header. Check the ammonia concentration at the vent/Drain.
After purging operation close isolation valve on the vent to flare line.
b. Ammonia Condenser (EA-201A/B)
Open isolation valve between condenser and receiver. Purge condenser shell side by
venting ammonia through vent line of Receiver to Flare header. Check the ammonia
concentration at the drain of Condenser. After purging operation close isolation valve
on the vent to flare line.
c. Ammonia Receiver (FA-201)
Close all valves on receiver and Economiser except instrument isolation valves.
Connect Ammonia Receiver to Economiser by opening isolation valve & bypass of LV-
30301. Purge Receiver by venting ammonia through vent line of Economiser to Flare
header. Check the ammonia concentration at the drain of Receiver. After purging
operation close isolation valve on the vent to flare line.
d. Economizer (EA-101)
Close all valves on economizer and receiver except instrument isolation valves.
Connect Ammonia Receiver to Economiser by opening isolation valve & bypass of LV-

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30301. Purge Economiser by venting ammonia through drain of Economiser by

temporarily connecting drain of economiser to Flare. Vapor ammonia shall now flow
from the receiver to the shell side of the economizer and to the flare. Check the
ammonia concentration on the drain line. After completion of purging close the
isolation valve on the drain line.
e. Purging of Piping
Purge all lines in the system by venting to the Flare stack through the flare header.
The lines already purged can be connected to the Flare header by hose connections
wherever necessary.
After completion of ammonia purging for piping and equipment, proceed with purging
for the Ammonia Storage Tanks.
5.2 Tank Cool Down:
After Ammonia purging is completed the tank needs to be cooled down to make it
ready to receive liquid Ammonia. The tank’s cool down needs to be done uniformly in
order to avoid thermal stresses.
For cool down of 12500 MT Ammonia Storage Tank the 300 NB valve on tank top
(vapour line to ammonia compressor suction: 300-AGLL-30021-BE33-100K) is kept
open. The refrigeration system needs to be lined up. The return liquid from the
refrigeration system needs to be sent to the 12500 MT tank.
The tank pressure of all the three tanks will be maintained at about 450 mmWCg. As
the return liquid from the refrigeration system enters the tank through spray ring it will
initially flash and vaporise resulting in cooling of the tank. The cooling rate should
ideally be maintained between 2 to 5 Deg C per hour. The compressor loading should
be suitably maintained. During this operation some residual inerts will accumulate in
the condenser which will be vented to flare. Tank cool down will take about 12 to 16
hours. The tank cool down is considered to be over when liquid level is observed in the
tank or the tank bottom temperature reaches a steady value. After completion of cool
down of the tank, it is considered ready to receive Ammonia from ship.

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6. NORMAL OPERATION:
This section will give the reader a clearer understanding of the operation and process
principles of the system. The procedures are sequentially arranged as follows
6.1 Unloading Line Pre-Cooling Operation:
The Ammonia Transfer Pump is used for the pre-cooling operation. The start-up
procedures for this pump shall be followed as per the vendor manual. The required flow
rate is achieved by throttling the Hand Operated Control Valve located on the pre-
cooling line inside the Ammonia Storage Area. The pre-cooling flow rate should be
such that compressor system is able to handle the vapour load. The temperature in the
ammonia unloading-line shall be continuously monitored to check the effect of pre-
cooling. This shall be at the Ammonia Storage Area as well as the Jetty.
The attainment of the required temperature for the ammonia unloading-line shall
confirm the completion of pre-cooling. The existing Ammonia Transfer Pump shall be
isolated after the Pre-cooling Operation.
6.2 Ship Unloading Operation
The Ship Unloading Operation shall be subsequent to the Pre-cooling Operation. The
Marine Unloading Arm shall be purged with nitrogen to displace the air from the arm.
The arm shall be connected as per procedures specified in the vendor manual. The
pre-cooling system should be isolated from the ammonia unloading-line. The MOV
shall be opened with bypass closed and the flow shall be controlled by the Hand
Operated Valve located in the Ammonia Storage Area. The operating conditions shall
be monitored at all times and the system shall be manned continuously. The quantity of
ammonia to be accommodated in the Ammonia Tank shall be predetermined and shall
be informed to all personnel before the commencement of Ship Unloading Operation.
The rise in the liquid level in the existing Ammonia Storage Tank shall be monitored
continuously. Data communication between Jetty and Storage Area shall be fluent to
avoid any eventuality in operation. Surveying the pipeline at all points from Jetty to
Storage Area is recommended prior to the ship unloading operation.

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Completion of the Ship Unloading Operation shall be done by stopping of the ship
pump followed subsequently by the closing of the MOV and the Hand Operated Valve
located in the Ammonia Storage Area. The Marine Unloading arm shall be purged with
nitrogen and drained completely as per manufacturer’s recommendations and the
vendor manual. After the arm attains inert condition, the ammonia unloading-line
should be isolated from the arm (by the closing the block valve) and the arm shall be
parked in position.
6.3 Holding Operation
Normal operation is a time when ship unloading or cross-country line pre-cooling

operation or cross-country line ammonia liquid evacuation is not taking place. During
this period, refrigeration system will operate on reduced loads as compared to the time
when ship unloading or pre-cooling operations or cross-country line ammonia liquid
evacuation are going on. The operator should note the following:
a) Only one Ammonia Compressor will operate
b) Flare Stack is operational
c) Air Compressor system is operating
Ammonia vapours generated in the tank mainly due to boil-off and these vapours pass
to one operating Ammonia Compressor. Based on the pressure in the tank, the
compressor will be accordingly loaded maintaining the set pressure. The operator
should continuously monitor the tank pressure to verify if the tank pressure is
maintained in the narrow band. The operator should watch if all the operating
parameters related to the compressor such as suction temperature, suction pressure,
discharge pressure and shell side of Economiser, Cooling water flow rate, lube oil
pressure, lube oil temperature etc. are within normal operating range and ensure that
no alarms are activated.
The compressed ammonia enters in Ammonia Condenser where ammonia vapours get
condensed. The condensed ammonia vapours enter Ammonia Receiver. Liquid
ammonia outlet from Ammonia Receiver is split into two streams, one stream enters

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the tube side of the Economiser to get sub-cooled and the other stream enters the shell
side of Economiser where it flashes and vaporises while absorbing the heat from the
tube-side stream and enters as a superfeed into the Ammonia compressors. The sub-
cooled tube-side stream coming out of tube side of Economiser is sent and sprayed
into Ammonia Storage tank. The liquid level in the Ammonia Receiver is maintained by
level controller LICA-30304 (maintained on AUTO mode) through control valve LV-
30304. The operator should see intermittently on DCS whether normal liquid level is
present in the Ammonia Receiver or not. If the liquid level is not close to normal level
and if Level controller is not able to maintain the level, operator should open LV-30304
by-pass valve a little to maintain the level. The liquid level in the shell side of
Economiser is maintained by level controller LICA-30301 (maintained on AUTO mode)
through control valve LV-30301. The operator should see intermittently on DCS
whether normal liquid level is present in the shell side of Economiser or not. If the liquid
level is not close to normal level and if Level controller is not able to maintain the level,
operator should open LV-30301 by-pass valve a little to maintain the level.
The ammonia compressor will maintain the pressure in the tank. In case, ammonia
compressor is not able to take the load, start the second ammonia compressor. If
pressure in the tank is under control then shut one of the compressors. If pressure in
the tank continues to rise then maintain the pressure in the tank by opening control
valve PV-30203 through pressure controller PIC-30203 to vent ammonia vapour to
flare.
6.4 Check Points for Normal Operation
6.4.1 General Check Points:
During normal operation, following points shall be checked:
a. Leakage from flange connections of low temperature process lines.
b. Leakage from man-hole covers from vessels.
c. Periodic cleaning of strainers for pumps.
d. Operability of control valves.

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e. Detection of abnormal sound from rotating machines.
f. Proper functioning of ammeters for electric machines in rotating machines.
g. Leakage of instrument air from instrument air lines or equipment.
h. Detection of abnormal vibration.
6.4.2 Ammonia Storage Tank:
Check points for Ammonia Storage Tank (FA-501) during normal operation:
a. Check all first isolation valves for liquid/vapour nozzles for the tank are in ‘OPEN’
position. However, the drain nozzles shall remain in ‘CLOSED’ position.
b. Check all tank instrument isolation valves are open. Check pilot gas line isolation
valve for the safety valves is open.
c. Check the running indication lamps for the level instrument motors are in working
condition.
d. Check conditions for all Interlocks for the tank.
e. Record the temperature, pressure and level of the storage tank at regular intervals
during each shift.
f. Check control valve (PV-30203) for flaring ammonia vapour from tank is closed.
g. Check On/Off valve XV-30204 on pump suction is in open position during the
normal operation.

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7. SHUTDOWN PROCEDURE
7.1 Normal Shutdown Procedure
The operations incorporated in this system are intermittent and hence normal shutdown
procedures are not applicable for this system.
7.2 Emergency Shutdown Procedure
Introduction
Emergency conditions may arise on the system at any time and it is obviously
impossible to present detailed instructions that would apply to all the situations.
Knowledge of the system and complete understanding of the processes involved are
the best methods operators have to safely and efficiently master any unusual
conditions which may develop. There is a need for complete understanding and
familiarity with the system alarms. All system instrumentation and alarm devices are
indicated in Piping & Instrumentation Flow Diagram. This information should be
available and learned, so that any emergency situation can be effectively handled.
Experience and understanding of the system gained over a period of time will enable
operators to modify the procedures to allow a faster recovery time when emergency
conditions arise.
Any action taken during emergency situations should satisfy the following
requirements:
1. Action taken must be one that can be performed without undue hazard to plant
personnel.
2. Action should place and maintain equipment in a safe and stable condition. This
means that no design parameters should be exceeded. These values should be
known before action is taken.
3. The action taken should permit resumption of normal operation at the earliest after
the emergency correction.

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A. Electric Power Failure
Electric Power is indicated in the control room by running indication lamps. The power
failure shall be informed by the stop indication of the continuous running motors like the
compressors. In case ship unloading is in progress the operator shall inform the ship
captain to immediately stop the ship pump to ensure system safety. In this situation,
the pressure of the Ammonia Storage Tank shall be controlled by flaring.
B. Compressor Failure
As explained in the previous chapters, the incoming liquid ammonia from the ship into
the New Ammonia Storage Tank (30-K-01) generates a considerable amount of vapour
which is liquefied by the Ammonia Refrigeration Compressors. In emergency situations
when these compressors fail, Control valve PV-30203 control the tank pressure by
flaring. Operator should monitor this situation & in these situations, this information
should be communicated to the Jetty area to stop the Ship Unloading Operation,
thereby safeguarding the system against any eventuality.
C. Instrumentation Air Failure
The philosophy used for the action of a valve when the air fails is based on system
safety requirements. For example, if instrument air fails during ship unloading then the
Hand Operated Valve located in the Ammonia Storage Area will shutdown leading to a
shutoff condition for the ship pump. The shut-off pressure as measured by the
instruments in the Jetty area shall be communicated to the ship captain to stop the ship
pump.
It is essential that the operating personnel familiarize themselves with the action that
each control valve takes in the event of air failure. This information is shown in the
P & IDs.
Conclusions
Safety of the personnel and protection of major equipment must be the primary
concerns in every emergency. All actions must be performed safely.

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8. SAFETY FEATURES AND MEASURES
8.1 Tank Safety System
8.1.1 Pressure / Temperature Control System
Normally the Pressure/Temperature in Ammonia Storage Tank is maintained between

350~550 mmWC and at a temperature of about -33 º C. The tank is provided with two
pressure transmitters ( PT-30201 , PT-30204). Readings of both transmitters are
available in control room. For Pressure / Temperature interlock description, please
refer Chapter 3 Interlock Description and Cause & Effect Diagram.
8.1.2 Tank Level System
For Tank Level interlock description, please refer Chapter 3 Interlock Description and
document Cause & Effect Diagram.
8.2 Ammonia Refrigeration Safety Systems
8.2.1 Level Control for Ammonia Receiver (30-D-01)
The receiver 30-D-01 is provided with a local level indicator (LI-30305), a level
transmitter (LT-30304) and Controller (LIC-30304). This LIC controls receiver outlet
level control valve (LV-30304) and receiver level to the set value, by operating on
control valve LV-30304. Safety is ensured by the provision of LIC high and low level
alarms, in control room.
8.2.2 Level Control for Economizer (30-E-02)
The level control system for Economizer is similar to that for the receiver. A local level
indicator (LI-30302) is provided for level measurement in the field. A level transmitter
(LT-30301) with controller LIC-30301 is also provided to control the shell side inlet
valve LV-30301 and maintain level in the economizer to set value. Additionally, level
high high alarm (LAHH-30303) is provided to trip the compressors in situations of high
high level in the economizer and close the Economiser Shell inlet valve LV-30301.

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8.2.3 Condenser and Receiver Pressure Control System
The build up of non-condensable gases would tend to increase the pressure in the
condenser and receiver thereby increasing the compressor discharge pressure. The
receiver is provided with a pressure transmitter with controller (PIC-30303). When the
pressure in the receiver exceeds the set value, the controller opens the pressure
control valve (PV-30303), located on the gas outlet for the Inert Gas to Flare stack.
This leads to passing of a mixture of non condensable gas along with traces of vapor
ammonia in condenser, to the Flare Stack.
8.3 Routine Operation Check
The following is a list of parameters which form a part of Routine Checks for Ammonia
Storage System:
a. Check operating conditions for the system
b. Check leakage from flange connections for low temperature process lines.
c. Check leakage from manhole cover for all vessels.
d. Check periodical replacement of strainers for pumps.
e. Check operability of control valves.
f. Check abnormal sound from rotating machines.
g. Check proper functioning of ammeters for all motors.
h. Check proper functioning for all panel indicators, recorders, controllers and
annunciates.
i. Check leakage of instrument air from instrument air lines or equipment.
j. Check all abnormal vibrations.

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8.4 Safety Precautions
In situations of normal and emergency operation, for the storage and handling of
anhydrous ammonia, all operators and engineers should be aware with the properties
of anhydrous ammonia.
A. General
It has been proven that anhydrous ammonia can be handled and used safely, provided
it is done with proper care, precaution and proper equipment. This requires a clear
understanding of the nature of the product, its characteristics and behaviour under
different conditions. These features are explained in the following paragraphs.
B. Properties
a. Anhydrous ammonia is a gas under atmospheric pressure and temperature. To

handle ammonia in liquid form, the liquid must be subjected to reduced temperature
or increased pressure, or a combination of both.
b. As a gas, under normal atmospheric conditions, it is colourless, lighter than air, and
has a pungent, irritating odour.
c. The boiling point of liquid ammonia at atmospheric pressure is –33.4ºC. Contact

with liquid ammonia can cause destruction of skin tissue by freezing as well as
having a caustic and dehydrating action.
d. Ammonia has a strong affinity to water. An abundant supply of water is the best
means of providing protection against the effects of contact with ammonia. Heat is
released when ammonia reacts with water. Hence, excess water is needed to
absorb this heat.
e. Liquid ammonia expands rapidly with rising temperature and it is imperative that this
be considered in the design and operation of ammonia systems. Table 8.1 lists the
various properties and characteristics for anhydrous ammonia.

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f. Anhydrous ammonia is inflammable gas. It can be ignited within a limited range of

approximately 16% to 25% by volume of ammonia vapour in the air. These
concentrations are considered difficult, but not impossible to obtain.
g. The relatively high ignition temperature of about 650ºC reduces the flammability
hazard. Formation of sparks due to friction between metals should be avoided.
C. Handling anhydrous ammonia
a. Equipment to be used shall meet the requirements of appropriate codes. Ensure

that all valves and fittings are installed and operated properly.
b. All ammonia must be removed from the system before any attempt is made to
dismantle or repair it.
c. Watch for frosting, indicating trapped ammonia. Repair leaks in equipment

immediately. Valve packing gland leaks may require only tightening nut(s). Never try
to peen or weld leaks; even pinhole size, until the equipment has been properly
purged.
d. The presence of leaks is usually detected easily by the nose, since ammonia, even
in very small quantities, is very irritating. Ammonia leaks can be located by moving
an open bottle of Hydrochloric Acid along ammonia piping. A white cloud of
ammonium chloride mist will form near the leak source.
e. Position yourself so that your head or body is not in direct line with openings of
valves and fittings.
f. The adjusting and repairing of safety relief and excess flow valves is a job for the
manufacturer.
g. Using wrenches in closing valves operated by hand wheel can damage the valve
seat and might break the valve stem.
h. Position yourself on the upwind side of ammonia leaks or transfer operations.

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i. Whenever a leak develops, all personnel shall be evacuated in the immediate

vicinity of the leak. Only trained personnel with proper protective equipment should
be allowed to approach an ammonia leak.
D. Physiological Effects
a. Ammonia is not considered poisonous. It has a cumulative toxic effect as does lead,
for example. However, it has a powerful corrosive effect on skin tissues. Exposure
to concentrations above 5000 parts of ammonia per million parts of air (5,000 parts
per million) will produce death by suffocation within minutes.
b. Anhydrous ammonia has a penetrating, intensely pungent odour. It is impossible for

a person to voluntarily remain in a seriously contaminated area. Air containing
amounts of ammonia, in which a person is willing to stand, is therefore not
particularly dangerous. Care must be taken to prevent prolonged exposures.
c. Contact with liquid ammonia will cause burns through freezing, as well as by
corrosive action.
d. Physiological effects of exposure to various concentrations of anhydrous ammonia

are shown in Table 8.2.
E. Personnel Protective Equipment.
a. Emergency or safety equipment or personal protective clothing is not an adequate

substitute for safe working conditions, or exercise of proper care by individuals.
However, if such equipment is to be effective when necessary, each workman must
be fully informed with respect to its location, use and limitations and proper
operation of the equipment.
b. A person should refrain from breathing for as long a time as possible in an area
contaminated with ammonia. While respiratory equipment is being secured and
adjusted, take only short, shallow breaths. Eyes should be closed to the extent
possible. This will minimize eye irritation. The effects of ammonia inhalation will be
lessened slightly, but only temporarily, by keeping a wet cloth over mouth and nose.

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Since ammonia vapour is lighter than air, better breathing will normally be found
close to the ground, unless liquid ammonia has been released.
c. Persons who work with ammonia and may be exposed to either the liquid or the gas
are to be provided with rubber or neoprene gloves and chemical safety glasses.
Cotton clothing should be worn as it stands up best against ammonia.
d. Gas masks (approved for ammonia service by the U.S. Bureau of Mines) with a full
face mask and green ammonia canisters (C) are to be made available in case of an
emergency. Spare canisters are to be made available. Their use is limited to brief
periods not exceeding 15 minutes in concentrations of 3%. Gradually increasing
odour of ammonia in the inhaled air will warn that the canister is exhausted.
e. Emergency equipment should be located in such places that Workers need not
move through contaminated areas to secure these.
f. No one can remain in an atmosphere with a concentration of ammonia higher than

1.5 or 2.0% for more than 15 minutes without developing severe skin burns and
blisters. Hence, in these situations, respiratory protection proves inadequate.
Exposure to heavy concentration should be made permissible only with proper
safety gloves, boots, jacket, pants made in rubber and a complete face piece gas
mask.
g. Air breathing apparatus must be worn in unknown concentrations or in

concentrations above 3%. Their useful life is determined by the size of the supply
cylinders. These are cumbersome to wear, particularly in confined spaces. Reserve
supply units are to be available.
h. Workers have to be thoroughly trained in use of personal protective equipment and

must report anything defective. All equipment must be inspected at regular intervals.
F. First Aid
1. In situations where ammonia comes in contact with skin and mucous membrane the
following measures shall be taken as first aid:

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a. All contaminated clothing should be removed as quickly as possible. Extreme care

must be exercised in removing frozen clothing. Forcible removal may tear the skin.
Hence, all clothing should be drenched with water to room temperature.
b. The affected areas should be flooded with cool water for about 15 minutes. Salves
and ointments should not be applied to skin or mucous membrane burns during a
twenty four hour period following the injury.
c. Obtain a physician’s services. In the interim, the burns should be covered with
dressings kept wet with a saturated solution of sodium thiosulfate.
d. Each worker should be acquainted with the location of each safety shower and
other source of large quantities of water.
e. Artificial Respiration Techniques
If a person is overcome by ammonia, he must be carried at once to an

uncontaminated atmosphere. If breathing has ceased, gentle and effective artificial
respiration must be started immediately.
f. Contact with the eyes
If even small quantities of ammonia enter the eyes, these should be washed
immediately and thoroughly for a minimum time of 15 minutes. A physician,
preferably an eye specialist, should be called on. If a physician is not immediately
available, the eye irrigation should be continued for a second period of 15 minutes.
After the first 15 minutes period, as a first aid measure, the eye can be treated with
two or three drops of a 0.5% pontocaine solution. Usage of oils or oily ointments as
emergency treatment should be avoided.
g. Shock
Keep the patient comfortably warm and quiet. The lower portion of his body may be
elevated slightly. Advise the doctor of any symptoms of shock, pallor, coldness of
the extremities, weak, rapid or irregular pulse, stupor and changes in the rate and
depth of respiration. Treat such symptoms only as directed by the doctor.

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h. Stimulants
The attending doctor shall determine the required stimulants.
i. First Aid Supplies
For emergency treatment of ammonia burns, first aid kits should include the
following items labelled as indicated:
i. Saturated solution of sodium thiosulphate or sterilized water.
ii. Sterile dressings or compresses.
iii. Pontocaine solution (with eye dropper).
iv. Rubber bulb syringe (for irrigating eyes with water).
G. Leak Detection Techniques
The leak detection in Ammonia Refrigeration Systems is relatively simpler due to the
pungent smell of ammonia.
The following measures can be taken to detect leaks:
a. A soap water solution is spread over doubtful spots with a brush (Nekall solution).
The formation of bubbles indicates leakage.
b. A burning sulphur paper is applied near the leaky spot. Combustion gases form
ammonium sulphate at the leaky spot indicated by white fumes.
c. SO2 blown on to the leaking points through a fine jet will cause white fumes to form.
A saturated aqueous solution of SO2 or hydrochloric acid dabbed on to the leaky
point by means of a wad of cotton wool will also cause the formation of white fumes.
d. NH3 will turn phenolphthalein paper red.
e. Alkaline ammonia will turn red litmus paper blue.
H. Safety Aspects in the handling of liquid ammonia

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1. Working in Oxygen Deficient Atmosphere during purging.
The following description pertains to recommended practice when purging operations

are under way. Recommended precautions to be observed when working in an oxygen
deficient atmosphere shall be as follows.
a. Working in an oxygen deficient atmosphere should be avoided.
b. Determine, by reliable means, the sufficiency of oxygen in the atmosphere to be

encountered.
c. If a hazard exists, suitable fresh air breathing apparatus and a safety line must be
used.
d. The possibilities of apparatus failure cannot be ruled out. Hence, preparation must
be made to prevent a catastrophe in the event of equipment failure. The individual
entering the oxygen deficient atmosphere must have all his gear situated in such a
way that in the event of loss of consciousness, he can be hoisted or dragged out of
the danger area without becoming bound on the manhole, door or to other opening.
This will require breathing apparatus that is small enough that the man can pass
through the opening with the breathing apparatus mounted on his body and
operating. A harness must be used for the safety line attachment so that the body
being raised or dragged cannot turn over and bind on the opening.
e. Sufficient manpower, plus extra persons, must be present and attentive to remove
the individual from the hazardous environment, if necessary. The extra persons
must be available for contingencies or to send more help.
f. The individual entering the oxygen deficient atmosphere and others must be
thoroughly familiar with the information contained herein and with the equipment to
be used.
g. The hazards of oxygen deficiency are listed as follows.
1. Breathing can be interrupted for only about one and one-half minutes before signs
of oxygen deficiency occur.

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2. Deficiency of oxygen in the atmosphere occurs due to displaced normal air with
nitrogen.
3. The oxygen concentration of normal air is 21% by volume. Although there is

considerable individual variation in sensitivity to oxygen deficiency, human activity is
normal at lowest oxygen as 16%. This corresponds to the oxygen content of normal
air at 3,200 m elevation above mean sea level (atmospheric pressure of 580
mmHg). At oxygen concentration below 16%, signs of oxygen deficiency occur.
Under continuous exposure, the following symptoms are observed:
12-16% - Respiration and pulse rates increase. There is general reduction in

capacity to perform physical work.
10-12% - Respiration becomes irregular, muscle coordination becomes difficult,

fatigue and emotional disturbances are obvious.
6-10% - The nervous system is affected to the point that any sudden demand for
oxygen, excitement or physical effort will result in loss of consciousness.
Below 6% - Loss of consciousness occurs very soon, followed by convulsive

movements, respiratory failure, circulatory failure and death.
At high elevation above MSL, the above effects would occur at even higher
concentrations of oxygen because of the reduced atmospheric pressure.
4. Sudden exposure to an atmosphere containing no oxygen and continuation of

normal breathing will cause almost immediate loss of consciousness (less than 1
minute). The immediate symptoms are dizziness, dimness of vision and
breathlessness. The circulation is usually stimulated at first, but if oxygen is not
soon supplied, failure of both circulation and respiration soon follow. Loss of
consciousness and subsequent death occur very rapidly and without sufficient
warning. The ability to move is often lost at about the time of the first awareness of
the precarious and dangerous situation. The reason for this is that the brain
operating on a reduced oxygen supply is suddenly aware of the situation. The
increased activity of the brain, or the excitement of attempting to correct the

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situation, calls for more oxygen from the already deficient supply. The oxygen
supply to the brain is depleted and the consciousness is lost.
5. The individual is usually revived by oxygen supply, heart massage and artificial
respiration (if the exposure has not exceeded five to fifteen minutes) depending
upon severity of oxygen depletion. If the exposure is brief, recovery may be almost
as rapid as the onset of symptoms. Prolonged exposure may lead to mental
changes (excitement, amnesia, palsied, delirium with halluniciations, apathy)
extending over many hours, and in the more severe cases, by permanent brain
damage.
6. If the exposure to an atmosphere containing oxygen exceeds 5 to 15 minutes,

permanent brain damage occurs and death ensues.
Table 8.1: Properties and Characteristics of Ammonia
Physical State Liquid Gas
Explosive limits 15 – 28
(% by volume in air)
Auto-ignition Temperature 651º C ( 1204º F)
Affinity for water Yes Yes
Boiling Point -33.35ºC
Colour Colourless Colourless
Corrosiveness Corrosive to copper, Same as liquid

copper alloys
Density (kg/m3 at -33.1ºC) 681.4 0.8898
Relative density of 0.597 (at 00C and 1 atm)

vapor(air =1)
Melting point -77.7ºC
(Freezing Point) (-107.9º F)

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Odour Pungent Pungent
Threshold limit value 25 parts per million
Table 5.2 : Physiological Effects Of Ammonia
VAPOR GENERAL EFFECT EXPOSURE PERIOD

CONCENTRATION
(ppm v/v)
25 Odour detectable by most Maximum for 8 hr working

persons period
100 No adverse effect for average Deliberate exposure for long

worker. periods not permitted
400 Immediate nose and throat No serious after exposure

infection time up to ½ hour
700 Immediate eye irritation No serious after exposure

time up to ½ hour
1,700 Convulsive coughing, Severe Could be fatal after ½ hour

eye, nose and throat irritation
2,000 Convulsive coughing, Severe Could be fatal after ½ hour

eye, nose and throat irritation
5,000 & Above Respiratory spasm, Rapid Fatal within minutes

asphyxia

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9.0 PLANT MAINTENANCE
Introduction
This instruction manual covers the general practices for maintenance of the Ammonia
Storage System. The system should be maintained for the most efficient operation and
longest equipment life. This instruction manual covers the general maintenance
checking practices for the plant operators and the maintenance personnel. The plant
management shall prepare detailed maintenance schedule for the system. For detailed
maintenance of equipment, instrument or any other device, respective Vendor
instruction manual shall be referred.
A. Maintenance
The proper maintenance of an ammonia storage installation is as important as its safe

operation. Since installations usually have a low machinery content, break down is rare
and this may lead to routine maintenance being neglected. It is recommended that
storage installations must be maintained on a regular basis. Day to day inspection can
be covered by routine operations provided that there is a satisfactory method of
reporting faults and effecting their repair. It is recommended that there should be a
comprehensive external inspection of the whole installation and report distribution
system on annual basis. Inspection may be done by a third party agency. Particular
attention must be given to corrosion, to minor gland or joint leaks and to the
completeness of the system and its allied safety and emergency equipment. The
inspector should check that any modifications to the system have been properly carried
out and recorded. He should ensure that any work arising from his report is carried out
within a reasonable time. A magnetic particle crack detection test must be carried out
covering at least 10% of the main internal welded seams, including all the T junctions.
Ultrasonic thickness testing should be carried out on pipeline branch showing any sign
of corrosion. Whilst the system is empty and safely purged, the opportunity should be
taken to make routine replacements of gland packing, gaskets etc wherever applicable.
Relief valves must receive special attention since they are usually the ultimate safety
devices fitted to guard against over pressure. All the relief valves fitted to the
installation must be tested every year. Relief valve testing devices must be kept in good

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working order. All maintenance operations carried out on an ammonia installation must
be subject to some form of permit to work system. This must take into account the
nature of the work and the potential hazard. Burning or welding operations constitute a
serious explosion hazard in pipes and vessels, which have been incompletely purged.
Care should be taken to guard against this possibility by proper purging with inert gases
before carrying out any hot work. If any wilding operations are carried out on the tank
then there must be at least local stress relief as required by the design code.
For maintenance of Pumps, vendor instructions as spelt out in vendor manuals should
be followed.
B. Inspection and Cleaning
Inspection and maintenance for all pipelines should be carried out periodically
depending on the line usage. Pressure test is necessary wherever repairs or alterations
have been made.
Every vessel which has a working pressure or less than atmospheric shall be normally
inspected every five years. Inspection by a competent authorized person is necessary
but pressure test is not obligatory. A pressure test will however be applied if repairs or
alterations have been made which may affect the strength of the vessel, where an
examination is not possible or where as a result of the examination, the Inspector
considers the results inconclusive. The checking of equipment safety valves and
inspection and maintenance should be carried out periodically.
C. Routine Check
“Routine Check” is the inspection to be carried out by the operators, who are most
familiar with the system operation status. The routine check should be classified into
weekly and the monthly checks. The check list for all routine checks shall be developed
and updated by the system operators.
The following is a list of parameters, which form a part of Routine Checks for the
Ammonia Storage System:
a. Check operating conditions for the system

LIMITED, KAKINADA
Doc No: A-6289-043-003
OPERATION MANUAL
b. Check leakage from flange connections for low temperature process lines.
c. Check leakage from manhole cover for all vessels.
d. Check periodical replacement of strainers for pumps.
e. Check operability of control valves.
f. Check abnormal sound from rotating machines.
g. Check proper functioning of ammeters for all motors.
h. Check proper functioning for all panel indicators, recorders, controllers and
annunciates.
i. Check leakage of instrument air from instrument air lines or equipment.
j. Check all abnormal vibrations.
D. Maintenance Record
Replaced, repaired or maintained parts are to be recorded by the maintenance

personnel in the system history record. It must be emphasized that the maintenance
record is important, as it is a helpful guide for future operation, maintenance and
spares inventory control. The data recorded are to be as accurate as possible.

ANNEXURE - 1
ANNEXURE - 1
ANNEXURE - 1
ANNEXURE- 1
ANNEXURE - 1
ANNEXURE - 1
ANNEXURE - 1
ANNEXURE - 1
ANNEXURE - 1
ANNEXURE - 2
TOYO ENGINEERING INDIA LTD. ALARM SET POINT LIST

Rev. 0
CLIENT: COROMANDAL INTERNATIONAL LIMITED Date 4-Nov-11
PROJECT: 1 × 12500 MT Ammonia Storage System Made HKK
LOCATION: Kakinada, Andhra Pradesh Chkd. DDP
JOB NO.: 6289 Apprvd. ASV
Doc No : B-6289-048-001 Description Preliminary
NORMAL HH H L LL
Sr No TAG P & ID No. UOM Remarks Rev.
SET POINT
INSTRUMENTS : LEVEL
mm 19500 18525 1000 583 (Note-1)
1 LIA-201 002
% 97.50 92.63 5.00 2.92 Basis : 0% = 0 mm & 100 % = 20000mm
mm 19500 18525 1000 (Note-1)
2 LIA-202 002
% 97.50 92.63 5.00 Basis : 0% = 0 mm & 100 % = 20000 mm
mm 400
3 LIA-203 002
% 1.90 Basis : 0% = 0 mm & 100 % = 21000 mm
mm 100
4 LDIA-204 002
%
mm 375 90
5 LICA-301 003
% 62.50 15.00 Basis : 0% = 0 mm & 100 % = 600 mm
mm 875 375
6 LICA-304 003
% 70.00 30.00 Basis : 0% = 0 mm & 100 % = 1250mm
mm 500
7 LIA-303 003
% 83.33 Basis : 0% = 0 mm & 100 % = 600mm
mm 1500 700
9 LIA-801 008
% 75.0 35.0 Basis : 0% = 0 mm & 100 % = 2000mm
ANNEXURE - 2

Rev. 0
NORMAL HH H L LL
SET POINT
INSTRUMENTS : PRESSURE
High Alarm set point corresponds to 83% of design pressure of tank.

1 PIA-201 002 mmWCg 1250 200.00
Low Alarm set point corresponds to 13.3% of design pressure of tank.
High -High Alarm set point corresponds to 90% of design pressure of

tank.
2 PIA-204 002 mmWCg 1350 1300 200.00 150 High Alarm set point corresponds to 86% of design pressure of tank.
Low Alarm set point corresponds to 13.3% of design pressure of tank.
Low-low Alarm set point corresponds to 10% of design pressure of tank.
Low-Low Alarm set point corresponds to 90% of pump differential

3 PDIA-210A 002 kg/cm2g 24.2 22.95 pressure.
Low Alarm set point corresponds to 95% of of pump differential pressure.
Low-Low Alarm set point corresponds to 90% of pump differential

4 PDIA-210B 002 kg/cm2g 24.2 22.95 pressure.
Low Alarm set point corresponds to 95% of of pump differential pressure.
High & low Alarm set point corresponds to 120% & 20% respectively of
5 PIA-301 003 kg/cm2g 1.35 0.9
operating pressure of Ecomiser shell side.
High & low Alarm set point corresponds to 120% & 20% respectively of
6 PICA-303 003 kg/cm2g 19.6 13.04
operating pressure of Ammonia receiver.
ANNEXURE - 2

Rev. 0
NORMAL HH H L LL
SET POINT
INSTRUMENTS : TEMPERATURE
Low Alarm set point corresponds to 20% of operating temperature of

1 TIA-301 003 °C -21.5
Ecomiser shell side.
2 TIA-304 003 °C -26.4 High Alarm set point is 80% operating temperature of Ammonia receiver.
3 TIA-801 008 °C 39 High Alarm set point is same as cooling tower inlet temperature (WR)
INSTRUMENTS : FLOW
High Alarm set point corresponds to 110% of max. flow of

FT-201
1 FI-201 002 m3/hr 46 3.8
Low Alarm set point corresponds to 90% of min. flow of
FT-201
High Alarm set point corresponds to 105% of max. flow of
2 FI-202 002 m3/hr 100.4 17.6 FT-202
Low Alarm set point is same as pump 30-P-01/B MCF flow
Notes:
1 The Level indicated are in "mm" with reference to tangent length (TL) of inner tank.
2 Set points to be reviewed based on instrument calibration range.
3 Refer vendor documents for alarm set point of Ammonia compressors (30-K-01 A/B) & for ammonia pumps seal plan (30-P-01A/B) .
ANNEXURE - 3
REV
NO
UNIT OR EQUIPMENT
1
LOGIC IDENTIFICATION NOTES:
1)After starting of the Ammonia Transfer pump ,within the Time Delay of 1 minute, if the
NOTES
differential pressure does not build up (sensed by PDT-30210A/B), then trip the running
2
pump..
2) I-203 to be connected to Existing Interlock 2 to trip 30-K-01A/B.
Existing ship unloading line motor operated valve MV-401
Open pump area fire water curtain valve (30-XV-30002)

3)I-204 to be connected to Existing Interlock12 to open the existing flare butterfly valve HV-
30-T-01Pump suction line common Isolation valve

LEGEND 10102.
A=ACTIVATE / ALARM B=BLANK
Ship Unloading Bypass Globe valve

Ship Unloading main butterfly valve
Open tank fire water curtain valve

4) Existing P&ID no: 04 (Existing interlock no to be provided by M/s Coromandel)
Existing Ammonia Compressor

Existing Flare Butterfly Valve
New Flare Butterfly Valve


C=CLOSE I=INHIBIT
Economiser Inlet valve

Ammonia Compressor
Ammonia Compressor
5) Refer fire fighting drawing no: C-6289-600-001 for details.
EFFECT
DESCRIPTION
(30-XV-30001)
N=NORMAL O=OPEN
closes
6) Permissive for opening of ship unloading line main valve (HV-30201)
P=PERMISSIVE S=START
7) To be executed through existing Interlock number I-2. Refer existing P&ID no: D-6289-
3000-04
PR=PRESET VALUE STP=STOP
8) To be executed through existing Interlock number I-12. Refer existing P&ID no: D-6289-
3000-04
R=RESET T=TRIP
9) Field start /stop local control station is default requirement for all motor driven
equipment. Hence it is not depicted in Cause and effect diagram.
DE=DE-ENERGISED
P&ID NO.
3000-002
3000-002
3000-002
3000-002
3000-006
3000-006
3000-006
3000-004
3000-002
3000-002
3000-003
3000-003
3000-003
NOTE 4
NOTE 5
NOTE 5
30-XV-30204
HV-30201
HV-30202
HV-10102
HV-30203
XV-30001
XV-30002
LV-30301
10-K-01C
30-P-01A
30-P-01B
10-K-01A
10-K-01B
30-K-01A
30-K-01B
TAG NO.
MV-401
CAUSE
10
11
12
13
13
14
15
16
17
18
19
20
21
22
23
REV NO NOTES INTERLOCK NO P&ID NO DESCRIPTION TAG NUMBER
6
7
8
9
I-201 Liquid Ammonia Unloading from Ship
3000-002 High-High Level in 30-T-01 LAHH-30201 C C C

3000-002 High -High Pressure in 30-T-01 PAHH-30204 C C C
3000-002 Soft switch @ PLC HS-30201 C
3000-002 Soft switch @ PLC HS-30202 C
6 3000-002 30-HV-30202 fully open ZSO-30202 P (6)
3000-003 Last running compressor trips -Feedback from MCC I-301 A/B C
I-202 A Ammonia Transfer Pump 30-P-01A

3000-002 Low-Low Level in 30-T-01 LALL-30201 T
3000-002 Low -Low Pressure in 30-T-01 PALL-30204 T
2 3000-002 XV-30204 NOT Fully open ZSO-30204 T
2 3000-002 XV-30204 Fully open ZSO-30204 P
3000-002 Soft switch PLC HS-30210A STP
3000-002 Note 9 HS-30210B STP
1 3000-002 Low-Low Differential Pressure between Suction & Discharge Header PDALL-30210A T
3000-002 Level Difference between Inner & Outer tank is less than 100 mm(LL) LDALL-30204 T
I-202 B Ammonia Transfer Pump 30-P-01B

3000-002 Low-Low Level in 30-T-01 LALL-30201 T
2 3000-002 XV-30204 NOT Fully open ZSO-30204 STP
2 3000-002 XV-30204 Fully open ZSO-30204 P
3000-002 Soft switch PLC HS-30211A STP
1 3000-002 Note 9 HS-30211B STP
1 3000-002 Low-Low Differential Pressure between Suction & Discharge Header PDALL-30210B T
3000-002 Level Difference between Inner & Outer tank is less than 100 mm(LL) LDALL-30204 T
CAUSE & EFFECT DIAGRAM
2 I-203 Tank low low pressure ( Note 7) 2 08-Nov-11 REVISED AS MARKED VDK DDP ASV
3000-002 Low -Low Pressure in 30-T-01 PALL-30204 T T T 1 22-Aug-11 REVISED AS MARKED VAM DDP ASV
0 03-May-11 PRELIMINARY DVK DDP RKP
3 I-204 Tank High High pressure (Note 8) REV NO DATE DESCRIPTION MADE BY CHK BY APP BY
3000-002 High -High Pressure in 30-T-01 PAHH-30204 O TOYO ENGINEERING INDIA LTD.
I-303 Fire water system PROJECT: AMMONIA STORAGE AND HANDLING

3000-002 High High ammonia concentration near Ammonia storage tank top (30-T-01) GDT-30201 O
3000-002 High High ammonia concentration near Ammonia storage tank top (30-T-01) GDT-30202 O JOB NO.:6289
2 3000-002 Soft switch @ PLC HS-30001 O
CLIENT:COROMONDEL INTERNATIONAL LTD.
I-304 Fire water system
3000-002 High High ammonia concentration near Ammonia Pump (30-P-01A/B) GDT-30203 O LOCATION:KAKINADA
3000-002 High High ammonia concentration near Ammonia Pump (30-P-01A/B) GDT-30203 O
2 3000-002 Soft switch @ PLC HS-30002 O DOC NO:B-6289-041-003
1 of 4
ANNEXURE - 3
REV NO
UNIT OR EQUIPMENT
2
LOGIC IDENTIFICATION NOTES:
NOTES
Cooling Tower Inlet (Make up water) Valve

New Flare sub header Butterfly Valve
LEGEND
Economiser Shell side Inlet Control

30-T-01 Tank Outlet Isolation valve
C=CLOSE I=INHIBIT
EFFECT
Ammonia Compressor
Ammonia Compressor
Cooling Tower Fan

N=NORMAL O=OPEN
DESCRIPTION
valve
R=RESET T=TRIP
DE=DE-ENERGISED
3000-002
3000-002
3000-003
3000-003
3000-003
3000-008
3000-008
P&ID NO.
30-U-01-PA1
XV-30204
PV-30203
XV-30801
LV-30301
30-K-01A
30-K-01B
TAG NO.
XV-3020
CAUSE
10
11
12
13
14
15
16
7
8
9
2 I-205 30-T-01 Tank outlet Valve(XV-30204)
3000-002 Soft switch @ PLC HS-30203A C
3000-002 Pushbutton in Field located at least 15m or more away from valve HS-30203B C
3000-002 Low-Low Level in 30-T-01 LALL-30201 C
3000-002 Low -Low Pressure in 30-T-01 PALL-30204 C
I-206 New Flare Butterfly Valve

3000-002 High -High Pressure in 30-T-01 PAHH-30204 O
I-301A Ammonia Compressor

3000-003 High High level in economizer (30-E-02) LAHH-30303 T
I-301B Ammonia Compressor

3000-002 Low -Low Pressure in 30-T-01 PALL-30204 T CAUSE & EFFECT DIAGRAM
3000-003 High High level in economizer (30-E-02) LAHH-30303 T
I-302 Economiser Level

3000-003 High-High Level in 30-E-02 LAHH-30303 C 2 08-Nov-11 REVISED AS MARKED VDK DDP ASV
1 22-Aug-11 REVISED AS MARKED VAM DDP ASV
I-801 Cooling Tower Basin Level 0 03-May-11 PRELIMINARY DVK DDP RKP
2 3000-008 High Level in Cooling tower Basin LAH-30801 C REV NO DATE DESCRIPTION MADE BY CHK BY APP BY
TOYO ENGINEERING INDIA LTD.
I-802 Cooling Tower Basin Level PROJECT: AMMONIA STORAGE AND HANDLING
2 3000-008 Low in Cooling tower Basin LAL-30801 O JOB NO.:6289
2 I-803 Cooling Tower Fan LOCATION:KAKINADA
2 3000-008 High High Vibration in Cooling tower fan VAHH-30801 T DOC NO:B-6289-041-003
2 of 4
ANNEXURE - 3
REV NO
UNIT OR EQUIPMENT LOGIC IDENTIFICATION
NOTES:
NOTES
1. HOLD will be removed after confirmation of data from compressor package
vendor M/s Johnson control. DELETED.
LEGEND
C=CLOSE I=INHIBIT
N=NORMAL O=OPEN
EFFECT
DESCRIPTION
R=RESET T=TRIP
DE=DE-ENERGISED
P&ID NO.
TAG NO.
CAUSE
10
11
12
13
14
15
16
1
2
3
4
5
6
7
8
9
2 1 I-351A YORK INDIA DOC NO. RF/6/11/002-01 Ammonia Refrigeration Compressor 30-K-01A
REFER : ANNEXURE -1
COMPRESSOR VENDOR M/s JOHNSON CONTROLS
CAUSE AND EFFECT DIAGRAM
2 1 I-352 A YORK INDIA DOC NO. RF/6/11/002-01
2 08-Nov-11 REVISED AS MARKED VDK DDP ASV

REV NO DATE DESCRIPTION MADE BY CHK BY APP BY
PROJECT: AMMONIA STORAGE AND HANDLING
JOB NO.:6289
LOCATION:KAKINADA
DOC NO:B-6289-041-003
3 of 4
ANNEXURE - 3
NOTES REV NO
UNIT OR EQUIPMENT LOGIC IDENTIFICATION
NOTES:
1. HOLD will be removed after confirmation of data from compressor package

vendor M/s Johnson control. DELETED.
LEGEND
C=CLOSE I=INHIBIT
N=NORMAL O=OPEN
EFFECT
DESCRIPTION
R=RESET T=TRIP
DE=DE-ENERGISED
P&ID NO.
TAG NO.
CAUSE
10
11
12
13
14
15
16
1
2
3
4
5
6
7
8
9
2 1 I-351B YORK INDIA DOC NO. RF/6/11/002-01 Ammonia Refrigeration Compressor 30-K-01B
REFER : ANNEXURE -1
COMPRESSOR VENDOR M/s JOHNSON CONTROLS
CAUSE AND EFFECT DIAGRAM
2 1 I-352 B YORK INDIA DOC NO. RF/6/11/002-01
2 08-Nov-11 REVISED AS MARKED VDK DDP ASV

REV NO DATE DESCRIPTION MADE BY CHK BY APP BY
PROJECT: AMMONIA STORAGE AND HANDLING
JOB NO.:6289
LOCATION:KAKINADA
DOC NO:B-6289-041-003
4 of 4
ANNEXURE - 3
DOCUMENT : CAUSE AND EFFECT DIAGRAM
ANNEXURE -1 TOYO ENGINEERING INDIA LIMITED
CLIENT : COROMANDEL INTERNATIONAL LTD.
CONTRACTOR : TOYO ENGINEERING INDIA LTD. YORK
Doc INDIA
No.: DOC NO. RF6/11/002-I-02
RF6/11/002-I-02
VENDOR YORK INDIA LTD.
VENDOR: LTD (A JOHNSON CONTROLS CO)
PLANT : 1 x 12500 MT AMMONIA STORAGE SYSTEM LOCATION : KAKINADA, ANDHRAPRADESH, INDIA Sheet 2 Rev. 2
30-KM-01A 30-KM-01A-P1 30-KM-01A 30-K-01A-H1/2 SOV 30312 SOV 30311
INDIVIDUAL
SR.NO. DESCRIPTION TAG NO. STATUS SET POINT START LUBE COMPRESSOR OIL HEATER
ALARM COMPRESSOR UNLOADING LOADING
OIL PUMP READY TO ----------------------
MOTOR TRIP SOV SOLENOID
MOTOR START ON OFF
Low (+) 0.020 X

1 Compressor Suction Pressure Switch (Kg/cm2 g) PS 30311 L
2
2 Compressor Suction Pressure Switch (Kg/cm g) PS 30311 LL
Low Low (+) 0.010 X X X
0 Low (-) 35 X
3 Compressor Suction Temperature Switch ( C) TS 30311
0 High 87 X
4 Compressor Discharge Temperature Switch ( C) TS 30312
High High 93 X X X
High 18.2 X
5 Compressor Discharge Pressure Switch (Kg/cm2 g) PS 30312
High High 19 6
19.6 X X X
Low 500 X
6 Primary Oil Separator Oil Level (mm) LT 30311 Low Low 450 X X X
>500 X
2 <1.8 X
7 Differential Pressure Across Oil Pump (Kg/cm g) DPS 30313
>=1.8 X
2 High 1 X
8 p
Differential Pressure Across Duplex Oil Filter ((Kg/cm
g g) DPS 30312
High 1.5 X
9 Differential Pressure between Oil & Disch. (Kg/cm2 g) DPS 30311
High High 2 X X X
0 0 High
g 60 X
10 O Manifold
Oil f Temperature S
Switch ( C) TS 30313
High High 65 X X X
0 High 80 X
11 Compressor Motor Bearing Temperature ( C) RTD 30317 & 30318
High High 85 X X X
0 High 85 X
12 Compressor Motor Winding Temperature ( C) RTD 30311 & 30316
High High
High 90 X
13 Compressor Motor Current (%) II 30510
High High 95 X X X
ON X X X
14 Emergency Stop (From PLC) HS 30310
OFF X
High 93 X
Low 30 X
0
15 Oil Separator Temperature transmitter ( C) TT 30311 ON <40 X
OFF 50>= X
>45 X
16 Compressor vibrations high (mm/sec) VT 30311 & VT 30312 High > 2.5 X
17 Compressor shall be at minimum load position (Compressor no load situation) ZT 30311 12% >= X
18 C
Compressor M
Motor
t H Healthy
lth Signal
Si l ffrom MCC H lth
Healthy X
19 All process alarm & trip parameters are healthy Healthy X
2 Load (-) 0.023 + DB X
20 Tank Pressure transmitter for compressor loading / unlaoding (Kg/cm g) PT 30201
Unload ((-)) 0.023 - DB X
Start X X
21 Compressor
Stop X X X
TOYO INDIA DOC NO: B-6289-041-003 REV 2

ANNEXURE - 3
DOCUMENT : CAUSE AND EFFECT DIAGRAM TOYO ENGINEERING INDIA LIMITED
CLIENT : COROMANDEL INTERNATIONAL LTD. ANNEXURE -1
CONTRACTOR : TOYO ENGINEERING INDIA LTD. Doc
YORKNo.: RF6/11/002-I-02
INDIA DOC NO. RF6/11/002-I-02
VENDOR: YORK INDIA LTD. ((A JOHNSON CONTROLS CO))
PLANT : 1 x 12500 MT AMMONIA STORAGE SYSTEM LOCATION : KAKINADA, ANDHRAPRADESH, INDIA Sheet 3 Rev. 2
30-KM-01A 30-KM-01A 30-KM-01A XL-30312 XL-30301 30-KM-01A-P1 30-KM-01A-P1 XL-30324 XL-30326 PIC-30201 SOV 30312 SOV 30311
Compressor
COMP OIL PUMP
& oil pump
SR.NO. DESCRIPTION TAG NO. STATUS SET POINT COMP COMP MOTOR REMOTE OIL PUMP MOTOR REMOTE
COMP FAILS OIL PUMP operation UNLOAD LOAD
MOTOR MOTOR RUNING MODE MOTOR RUNING MODE
TO START MOTOR STOP under tank SOV SOLENOID
START STOP INDICATION SELECTED START INDICATION SELECTED
pressure
p
ON PLC ON PLC
control
Local/Remote switch for compressor motor on LCS Local mode HS-30301 Local
1 X X
AND Start command for compressor motor from LCS HS-30315 Start
Local/Remote switch for compressor motor on LCS Remote mode HS-30301 Remote
2 AND Auto/Manual switch in PLC on Manual mode HS-30302 Manual X X X
AND Start command for compressor motor from PLC HS 30311

HS-30311 St t
Start
Local/Remote switch for compressor motor on LCS Remote mode HS-30301 Remote
3 X X
AND Auto/Manual switch in PLC on Auto mode HS-30302 Auto
Local/Remote switch for oil pimp motor on LCS Local mode HS-30326 Local
4 X X
AND Start command for oil pump motor from LCS HS-30321 Start
Local/Remote switch for oil pimp motor on LCS Remote mode HS 30326
HS-30326 Remote
5 AND Auto/Manual switch in PLC on Manual mode HS-30302 Manual X X X
AND Start command for oil pump motor from PLC HS-30322 Start
Local/Remote switch for oil pump motor on LCS Remote mode HS-30326 Remote
6 X X
AND Auto/Manual switch in PLC on Auto mode HS-30302 Auto
Time gap between oil pump running and compressor running feedback is
7 Timer in PLC > set pt 10 X X
above set point (Sec)
8 Time gap after compressor running feedback above set point (Sec) Timer in PLC > set pt 10 X
9 Time gap after compressor running feedback below set point (Sec) Timer in PLC < set pt 120 X
Auto/Manual switch in PLC on Manual mode HS-30302 Manual
10 AND Load command from PLC HS-30304 Load X
AND Time gap after compressor running feedback above set point (Sec) Timer in PLC > set pt 120
Auto/Manual switch in PLC on Manual mode HS-30302 Manual
11 AND Unload command from PLC HS-30305 Unload X
Auto/Manual switch in PLC on Auto mode HS-30302 Auto
>= (-) 0.023

12 Tank Pressure above set point (Kg/cm2 g) PT 30201 Load X
+ Dead band
Auto/Manual switch in PLC on Auto mode HS-30302 Auto
2 < (-) 0.023

12 Tank Pressure below set point (Kg/cm g) PT 30201 Load X
- Dead band
TOYO INDIA DOC NO: B-6289-041-003 REV 2

ANNEXURE - 4 <Security Level 2>
EQUIPMENT LIST
NO.
ITEM NO. SERVICE TECHNICAL DATA MOC REMARKS
O S
30-T-01 1 - Ammonia Storage Tank Type : Double Integrity Cup In Tank Shell, Bottom & Roof : LTCS
Capacity : 12,500 MT Insulation:
Size : Outer Shell: PUF
OuterShell ID : 37000 mm Bottom : Foam Glass with sand &
perlite concrete
Inner Shell ID : 35400 mm
Outer Shell Height : 21000 mm Suspended deck : Glass Wool
Inner Shell Height : 20000 mm
Operating Pressure :
Outer Tank : 300~1200 mm WCG
Inner Tank : Liquid Head
Operating Temperature :
Outer Tank : -33 0C
Inner Tank : -33 0C
Design Pressure :
Outer Tank : Liquid Head + 1500 mm WCG / -75 mm WCG
Inner Tank : Liquid Head
Design Temperature :
Outer Tank : -40/60 0C
Inner Tank : -40/60 0C
PROJECT: CKAS
ABBREVIATIONS JOB NO. : 6289
O: OPERATING CLIENT: COROMANDEL INTERNATIONAL LTD
S : STANDBY PLANT: 12500 MT AMMONIA STORAGE SYSTEM
ID : INTERNAL DIAMETER LOCATION : KAKINADA, ANDHRA PRADESH
TL: TANGENT LENGTH TOYO ENGINEERING INDIA LTD.
MOC : MATERIAL OF CONSTRUCTION MUMBAI , INDIA
Doc no : A-6289-047-01 Rev. 1 Page1 of 6
FORM A-G33.011-1/6 - (Sep-1999)

EQUIPMENT LIST
NO.
O S
30-D-01 1 - Ammonia Receiver Type: Horizontal Cylindrical Vessel Shell & Head : LTCS
Capacity: 3.58 m³
Size:
Vessel ID : 1250 mm
Vessel TL : 2500 mm
Operating Pressure: 16.3 kg/cm2g
1
Operating Temperature (Nor./ Min.): 43 / -33 0C
Design Pressure: 22.5 kg/cm2g
Design Temperature: -40 / 150 0C
30-D-02 1 - Ammonia Drain vessel Type: Horizontal Cylindrical Vessel Shell & Head : LTCS
Capacity: 0.53 m³
1
Size:
Vessel ID : 387.36 mm (16 " NB pipe)
Vessel TL : 4500 mm
Operating Pressure: 0.075 kg/cm2g 1
Operating Temperature (Nor. / Min.): 15.5 to 46 / -33 0C

Design Pressure: 22.5 kg/cm2g
Design Temperature: -40 / 60 0C
PROJECT: CKAS
ID : INTERNAL DIAMETER LOCATION: KAKINADA, ANDHRA PRADESH
Doc no : A-6289-047-01 Rev. 1 Page 2 of 6
FORM A-G33.011-2/6 - (Sep-1999)

EQUIPMENT LIST
NO.
O S
30-P-01 A/B 1 1 Ammonia Transfer Pump Type: Vertical Centrifugal Barrel Pump Barrel: LTCS
Capacity: 47.8 m³/hr Impeller: SS
Discharge Pressure: 25.5 kg/cm2g
Pumping Temperature: -33 0C
30-P-02 A/B 1 1 Cooling Water Pump Type: Horizontal Centrifugal Pump Casing: CI
Capacity: 425 m³/hr Impeller: CI
1
Pumping Temperature: 33 0C
30-K-01 A/B 2 - Ammonia Compressor Type: Oil Flooded Screw Compressor Casing : Cast steel
Capacity: 1506 kg /hr (each compressor )
Discharge Temperature: 82 0C
PROJECT: CKAS
Doc no : A-6289-047-01 Rev.1 Page 3 of 6
FORM A-G33.011-3/6 - (Sep-1999)

EQUIPMENT LIST
NO.
O S
30-E-01 A/B 2 - Ammonia Condenser Type: AEM (Horizontal) Shell : LTCS
Duty: 1.1422 x 1.5 MMkcal / hr Tubes : LTCS
1
Shell Side Data:
Fluid : Ammonia
Operating pressure : 16.56 kg/cm²g
Operating Temperature: 100 0C (Vapor In ) / 43 0C (Liquid Out)
Design pressure: 22.5 kg/cm²g
Design Temperature: 150 0C / - 40 0C
1
Tube side data:

Fluid : Cooling Water
Operating pressure : 3.0 kg/cm²g
Operating Temperature: 33 0C (In) / 39 0C (Out)
Design Temperature: 55 0C / - 40 0C
1
PROJECT: CKAS
FORM A-G33.011-4/6 - (Sep-1999)

ANNEXURE - 4
<Security Level 2>
EQUIPMENT LIST
NO.
O S
30-E-02 1 - Economizer Type: BKU (Horizontal) Shell : LTCS
Duty: 0.1879 x 1.2 MMkcal / hr Tubes : LTCS
Insulation : PUF
Shell side data:
Fluid : Ammonia Vapor
Operating pressure: 1.1 kg/cm²g 1
0
Operating Temperature: -17.7 C (In) / -17.7 °C (Out)
Design Temperature : -40/60 0C
Tube side data :

Fluid : Liquid Ammonia
Operating pressure: 16.3 kg/cm²g
Operating Temperature: 43 0C (In)/-11.7 0C(Out)
Design Temperature: -40/60 0C
30-U-01 1 - Cooling Tower Type: Induced Draft Casing: FRP

Capacity: 843 Ton of Refrigeration (TR) 1 Filling: PVC
0
Water Temperature: 33 C (Cooling Tower Outlet)
/ 39 0C (Cooling Tower Inlet)
30-U-02 1 - Side Stream Filter Type: Valveless automatic bakwash gravity type Shell: CS
Capacity : 8.5 m³/hr
PROJECT: CKAS
FORM A-G33.011-5/6 - (Sep-1999)

EQUIPMENT LIST
NO.
O S
30-Z-01 A/B 1 1 N2 Cylinder Manifold Capacity: 1 NM³/ HR
1 1
30-J-01 1 - HOT Crane for Compressor Capacity: 7.5 T

House Span: 11 M
Lift: 6.5 M
1
30-X-01 1 - CPB for Transfer Pump Capacity: 2 T
House Lift: 7.65 M
PROJECT: CKAS
O: OPERATING CPB: CHAIN PULLY BLOCK CLIENT: COROMANDEL INTERNATIONAL LTD
S : STANDBY 1 PLANT: 12500 MT AMMONIA STORAGE SYSTEM
FORM A-G33.011-6/6 - (Sep-1999)

ANNEXURE - 5
ANNEXURE - 5
ANNEXURE - 5
ANNEXURE - 5
ANNEXURE - 6
<Security Level 2>
Coromandel
CLIENT : International Limited REV DATE MADE CHKD APPD
TOYO ENGINEERING INDIA LIMITED PLANT / UNIT : Ammonia storage 0 18-May-11 DVK DDP RKP
LOCATION : Kakinada, India 1 25-Apr-11 DVK DDP RKP
WORK NO. : 6289-CKAS 2 12-Oct-11 DDP/HKK ASV ASV
Doc NO A-6289-049-001
Control Valve Process Datasheet Revision Index
Revision
Sr No Tag Number REMARKS
Rev-0 Rev-1 Rev-2 Rev-3
1 LV-30301 18-May-11
2 LV-30304 18-May-11
3 PV-30303 18-May-11
Revised
4 PV-30203 20-Apr-11 25-Apr-11 12-Oct-11
5 HV-30201 11-May-11
6 HV-30202 11-May-11
Newly added
7 HV-30205 12-Oct-11
TOYO ENGINEERING INDIA LTD. CONTROL VALVE

PROCESS DATA SHEET
Job No.: 6289 Revision 0
Process: Ammonia Storage System App By RKP
Customer: Coromandel Intl. Ltd. Chkd By DDP
Location: Kakinada, Andhra Pradesh Made By DVK
Date 18/05/2011
Doc. No: A-6289-049-001
1 Tag No. LV-30301(Case-1) LV-30301(Case-2)
2 Quantity 1 1
3 Service From Ammonia Receiver From Ammonia Receiver
(30-D-01) to shell side of (30-D-01) to shell side of
Economiser 30-E-02 Economiser 30-E-02
4 Line Size (NB.) 50 50
5 Line Class BE33 BE33
6 Fluid Name Ammonia Ammonia
Case Case-1 Case-2
7 Fluid State Liquid Liquid
8 Flow & Pressure Unit kg/hr kg/cm2 kg/hr kg/cm2
9 Flow Rate and Maximum 908 749
Pressure Drop Normal 756 14.95 624 10.21
Minimum 378 312
10 Pressure (kg/cm2G) Normal 16.364 11.52
11 Pressure (kg/cm2G) Des. 22.5 22.5
12 Temperature (ºC) Oper Des. 43 60/-40 33 60/-40
13 Maximum dp shut off (kg/cm2) 22.5 22.5
14 Operating Density (kg/m3) 576.7 594.6
15 Operating Viscosity ( cP ) 0.11 0.11
16 Molecular Weight ( Flashed Vapor) 17.035 17.035
17 Compressibility Factor
18 Specific Heat Ratio
19 Critical Pressure (kg/cm2Abs.) 115.2 115.2
20 Critical Temperature (Deg C.) 132.4 132.4
21 % Flash 22 18
22 Vapour Pressure(Kg/cm2 Abs.) 17.364 12.52
23 Actuator Fail Position Close Close
24 Special Type Body Jacket
25 Required Sheet Tightness
26 Special Material Body LTCS LTCS
Seat & Plug
27 Applied Code & Law
28 Handwheel Required
29 Accessories
30 Notes 1 1
31 P & I Drawing No. 3000-003 3000-003
Notes :
1. Cold Insulation to be provided .
FORM A-KE10.002-1/1 - (Sep-1999)


PROCESS DATA SHEET
Date 18/05/2011
Doc. No: A-6289-049-001
1 Tag No. LV-30304(Case-1) LV-30304(Case-2)
2 Quantity 1 1
3 Service From Economiser(30-E-02) From Economiser(30-E-02)
tube side to NH3 Storage tube side to NH3 Storage
Tank (30-T-01) Tank (30-T-01)
Case Case-1 Case-2
Minimum 1506 1566
12 Temperature (ºC) Oper Des. -11.7 60 /-40 -14.5 60 /-40
14 Operating Density (kg/m3) 655 659
16 Molecular Weight ( Flashed Vapor) 17.035 17.035
20 Critical Temperature (Deg C.) 132.4 132.4
21 % Flash 7 6
22 Vapour Pressure(Kg/cm2 Abs.) 2.773 2.469
Seat & Plug
29 Accessories
30 Notes 1 1
31 P & I Drawing No. 3000-003 3000-003
Notes :
1. Cold Insulation to be provided .
FORM A-KE10.002-1/1 - (Sep-1999)


PROCESS DATA SHEET
Date 18/05/2011
Doc. No: A-6289-049-001
1 Tag No. PV-30303 PV-30303
2 Quantity 1 1
3 Service Inert Gas to Flare Inert Gas to Flare

6 Fluid Name Nitrogen/Inerts Nitrogen/Inerts
Case Case-1 Case-2
7 Fluid State Vapour Vapour
Minimum
12 Temperature (ºC) Oper Des. -15 60 /-40 -15 60 /-40
14 Operating Density (kg/m3) 18.11 13.66
16 Molecular Weight ( Flashed Vapor) 28 28
17 Compressibility Factor 0.99 0.99
18 Specific Heat Ratio 1.45 1.45
20 Critical Temperature (Deg C.) -147 -147
21 % Flash
22 Vapour Pressure(Kg/cm2 Abs.)
Seat & Plug
29 Accessories
30 Notes
31 P & I Drawing No. 3000-003 3000-003
Notes :
FORM A-KE10.002-1/1 - (Sep-1999)


PROCESS DATA SHEET
Job No.: 6289 Revision 0 1 2
Process: Ammonia Storage System App By RKP RKP ASV
Customer: Coromandel Intl. Ltd. Chkd By DDP DDP ASV
Location: Kakinada, Andhra Pradesh Made By DVK DVK DDP / HKK
Date 20/04/2011 25/04/2011 12/10/2011
Doc. No: A-6289-049-001
1 Tag No. PV-30203 (Note 2,3 4) 2
2 Quantity 1
30-T-01 vent to Existing flare
3 Service header
4 Line Size (NB.) 200

5 Line Class BE33
6 Fluid Name Ammonia
Case
7 Fluid State Vapour
8 Flow & Pressure Unit Nm3/hr kg/cm2
9 Flow Rate and Maximum 1474.4
Pressure Drop Normal 363.5
Minimum
10 Pressure (kg/cm2G) Normal 0.075
11 Pressure (kg/cm2G) Des. 0.15(Note1)
12 Temperature (ºC) Oper Des. -20 60 / -40
13 Maximum dp shut off (kg/cm2) 0.15(Note1)
14 Operating Density (kg/m3) 0.836
15 Operating Viscosity ( cP ) 0.0086
16 Molecular Weight ( Flashed Vapor) 17.035
17 Compressibility Factor 0.99
19 Critical Pressure (kg/cm2Abs.)
20 Critical Temperature (Deg C.)
21 % Flash
23 Actuator Fail Position Close
25 Required Sheet Tightness TSO
26 Special Material Body
Seat & Plug
28 Handwheel Required YES
29 Accessories Handwheel
2
30 Notes 5, 6
31 P & I Drawing No. 3000-002
Notes: 2
1 PV-30203 to be designed for rating of 300#.

2 PV-30203 is Line size valve with negligible pressure drop.
3 No Cu bearing material is to be considered for this valve.
4 Valve with Motorized actuator as per client information.
5 Butterfly type control valve. 2
6 This valve is client scope of supply.
FORM A-KE10.002-1/1 - (Sep-1999)

<SECURITY LEVEL 2>
ANNEXURE - 6

PROCESS DATA SHEET
Process: Ammonia Storage Tank App By RKP
Customer: Coromadel International Ltd Chkd By DDP
Location: Kakinada Made By DVK
Date 11/05/11
Doc. No: A-6289-049-001
1 Tag No. 30-HV-30201 30-HV-30202
2 Quantity 1 1
3 Service Ship Unloading Line By-Pass Line
to Tank 30-T-01 of HV-30201
(ALHL-30001) (ALHL-30004)
4 Line Size (mm) 350 50

8 Flow & Pressure Unit Kg/hr Kg/cm2 Kg/hr Kg/cm2
9 Flow Rate and Maximum 550000 0.2 10000 0.5
Pressure Drop Normal
Minimum
10 Pressure (kg/cm2G) Oper Des. 8 32.5 8 32.5
12 Temperature (ºC) Oper Des. -33 -40/60 -33 -40/60
13 Operating Density (kg/m3) 680 680
15 Molecular Weight (Flashed Vapor) 17.03 17.03
19 % Solids
20 % Flash 0.3 0.3
21 Actuator Fail Position FC FC
Seat & Plug
26 Handwheel Required Yes No
27 Accessories
28 Notes 1 2
29 P & I Drawing No. D-6289-3002 D-6289-3002
Notes :
1. Butterfly type control valve.
2 Globe type Control valve

PROCESS DATA SHEET
Process: Ammonia Storage System App By ASV
Location: Kakinada, Andhra Pradesh Made By DDP / HKK
Date 12/10/2011
Doc. No. A-6289-049-001
1 Tag No. HV-30205
2 Quantity 1
Pre-cooling ammonia to
3 Service ship unloading line
4 Line Size (NB.) 80

5 Line Class BE33
Case
7 Fluid State Liquid
8 Flow & Pressure Unit kg/hr kg/cm2
Pressure Drop Normal
Minimum 2862 23
10 Pressure (kg/cm2G) Normal
11 Pressure (kg/cm2G) Des. 32.5
12 Temperature (ºC) Oper Des. -33 -40/60
13 Maximum dp shut off (kg/cm2) 32.5
14 Operating Density (kg/m3) 681.3
15 Operating Viscosity ( cP ) 0.251
16 Molecular Weight ( Flashed Vapor)
20 Critical Temperature (Deg C.)
21 % Flash
23 Actuator Fail Position Close
26 Special Material Body LTCS
Seat & Plug
28 Handwheel Required YES
29 Accessories Note 1
30 Notes 2
31 P & I Drawing No. 3000-002
Notes:
1 Open-close limit switch and solenoid valve
2 Globe type control valve.
FORM A-KE10.002-1/1 - (Sep-1999)

ANNEXURE - 7
TOYO ENGINEERING INDIA LTD. SAFETY RELIEF VALVE

PROCESS DATA SHEET
Job No. : 6289 Revision 0 1 2
Process : Ammonia Storage System Approved RKP RKP ASV
Customer : Coromandel International Ltd. Checked RKP RKP DDP
Location : Kakinada, India Made DDP DVK NAK
Date 13/5/2011 25/05/2011 20/07/2011
1 Tag No. SV-30207 /30208 VRV-30201/30202
2 Quantity 1 Operating +1 Standby (Note 3) 1 Operating + 1 Standby (Note 3)
3 Service Ammonia Storage Tank 30-T-01 Ammonia Storage Tank 30-T-01
4 Line Size (mm.) Inlet/Outlet 200 /250 300/ -

5 Line Class Inlet/Outlet BE31 / BA31 BE31 / -
6 Code or Law API-2000 API-2000
7 Sizing Basis External Fire Case Vacuum relief
8 Fluid Name Ammonia Air (Note 1)
9 Fluid State Vapour Gas
10 Required Capacity Vap. 8972 2374
Liq. -
Unit kg/hr Nm3/hr
11 Pressure Nor. 0.075 750
Set 0.145 (-)44
Unit kg/cm2g mmWCg
12 Overpressure(%) 21 -
13 Temperature Nor. -33 -33
Discharge -31
Unit °C °C
14 Superimposed Back Press. (I) Type Constant
Max. Note 4
Nor.
Min.
Unit kg/cm2g
15 Built-Up BackPress.(II) 0.001
16 Total BackPress.(I+II) Note 4
Unit kg/cm2g
17 Viscosity Liq.
Unit cP cP
18 MW 17.03 29
19 Cp/Cv 1.31 1.4
20 Z 0.98
20 Sp. Gr.
21 % Flash
22 Body Material
23 Trim Material
24 Equipment Design Press. mmWC (G) (Full of Liquid+1500) & -75 -75
25 Accessories
26 P & ID No. D-6289-3000-002 D-6289-3000-002
27 Remarks
EXTERNAL FIRE GAS EXPANSION
a. Specific Heat( )
LIQUID EXPANSION
b. Coefficient of Thermal Expansion( )
c. Heat Duty ( )
d. Specific Heat( )
TUBE FAILURE
e. Tube outside Diagram( )
f. Tube Thickness( )
g. Operating Pressure High Pr. Side( )
f. Design Pressure Low Pr. Side( )
EXTERNAL FIRE VAPORIZATION
i. Latent Heat ( ) 326 kcal/kg
Notes : 1. Air from Atmosphere to the Tank.
2. No Copper or Copper bearing alloys should be used for any part of the relief valves.
3. DELETED
4. Relief to atmosphere.
ANNEXURE - 7

PROCESS DATA SHEET
Date 13/5/2011 25/05/2011 04/08/2011
1 Tag No. SV-30201 SV-30204
2 Quantity 1 1
3 Service Ship Unloading Line From 30-T-01 outer tank drain to Ammonia
Transfer Pump 30-P-01A / B suction line
4 Line Size (Inch.) Inlet/Outlet 3/4 "/ 1" (Note 2) 3/4 "/ 1" (Note 2)
5 Line Class Inlet/Outlet BE33 / BE33 BE33 / BE33
7 Sizing Basis Liquid Expansion Liquid Expansion
10 Required Capacity Vap.
Liq.
Unit kg/hr kg/hr
11 Pressure Nor. 8 0.075
Set 32.5 10.5
Unit kg/cm2g kg/cm2g
12 Overpressure(%) 10 10
13 Temperature Nor. -32 Amb ~ (-)33
Discharge -33 (-)33
Unit °C °C
14 Superimposed Back Press. (I) Type Variable Variable
Max. 2.06 2.06
Nor. 0.03 ~ 0.145 0.03 ~ 0.145
Min. 0.03 0.03
15 Built-Up BackPress.(II) - -
16 Total BackPress.(I +II ) 2.06 2.06
17 Viscosity Liq. 0.251 0.251
Unit cP cP
18 MW 17.035 17.035
19 Cp/Cv
20 Z
21 Sp. Gr. 0.681 0.681
22 Flashing service Yes Yes
23 Body Material LTCS LTCS
24 Trim Material SS316 SS316
25 Equipment /Line Design Press kg/cm2g 32.5 12.5
26 Accessories
27 P & ID No. D-6289-3000-002 D-6289-3000-002
28 Remarks
a. Specific Heat( )
LIQUID EXPANSION
c. Heat Duty ( )
d. Specific Heat( )
TUBE FAILURE
i. Latent Heat ( )
Notes : 1. No Copper or Copper bearing alloys should be used for any part of the relief valves.
2. Thermal relief valve size is 3/4" x 1 "
ANNEXURE - 7

PROCESS DATA SHEET
Job No. : 6289 Revision 2
Process : Ammonia Storage System Approved ASV
Customer : Coromandel International Ltd. Checked DDP
Location : Kakinada, India Made NAK
Date 8/4/2011
1 Tag No. SV-30209 SV-30210
2 Quantity 1 1
3 Service Precooling line Drain Vessel 30-D-02
4 Line Size (Inch.) Inlet/Outlet 3/4 "/ 1" (Note 2) 3/4 "/ 1" (Note 2)
Liq.
Unit kg/hr kg/hr
11 Pressure Nor. 8.0 0.075
Set 32.5 22.5
Discharge -33 -33
Unit °C °C
Max. 2.06 2.06
Nor. 0.03 ~ 0.145 0.03 ~ 0.145
Min. 0.03 0.03
Unit cP cP
18 MW 17.035 17.035
19 Cp/Cv
20 Z
21 Sp. Gr. 0.681 0.681
25 Equipment /Line Design Press kg/cm2g 32.5 22.5
26 Accessories
27 P & ID No. D-6289-3000-002 D-6289-3000-002
28 Remarks
a. Specific Heat( )
LIQUID EXPANSION
c. Heat Duty ( )
d. Specific Heat( )
TUBE FAILURE
i. Latent Heat ( )
ANNEXURE - 7

PROCESS DATA SHEET
Job No. : 6289 Revision 0
Process : Ammonia Storage System Approved ASV
Customer : Coromandel International Ltd. Checked DDP
Location : Kakinada, India Made NAK
Date 11/1/2011
1 Tag No. SV-30211
2 Quantity 1
3 Service 3 Precooling line
4 Line Size (Inch.) Inlet/Outlet 3/4 "/ 1" (Note 2)

5 Line Class Inlet/Outlet BE33 / BE33
6 Code or Law API-520
7 Sizing Basis Liquid Expansion
Liq.
Unit kg/hr
11 Pressure Nor. 25 ~ 28
Set 32.5
Unit kg/cm2g
12 Overpressure(%) 10
13 Temperature Nor. -32
Discharge -33
Unit °C
14 Superimposed Back Press. (I) Type Variable
Max. 2.06
Nor. 0.03 ~ 0.145
Min. 0.03
Unit kg/cm2g
15 Built-Up BackPress.(II) -
16 Total BackPress.(I +II ) 2.06
Unit kg/cm2g
17 Viscosity Liq. 0.251
Unit cP
18 MW 17.035
19 Cp/Cv
20 Z
21 Sp. Gr. 0.681
22 Flashing service Yes
23 Body Material LTCS
24 Trim Material SS316
25 Equipment /Line Design Press kg/cm2g 32.5
26 Accessories
27 P & ID No. D-6289-3000-002
28 Remarks
a. Specific Heat( )
LIQUID EXPANSION
c. Heat Duty ( )
d. Specific Heat( )
TUBE FAILURE
i. Latent Heat ( )
ANNEXURE - 7

PROCESS DATA SHEET
Date 13/5/2011 25/05/2011 04/08/2011
1 Tag No. SV-30205 SV-30202 / SV-30203 / SV -30206
2 Quantity 1 1/1/1
3 Service Ammonia Transfer Pump 30-P-01A/B Ammonia Transfer Pump 30-P-01A/B
suction line discharge line
4 Line Size (Inch.) Inlet/Outlet 3/4 " / 1 " (Note 2) 3/4" / 1" (Note 2)
Liq.
Unit kg/hr kg/hr
Set 10.5 32.5
Discharge -33 -33
Unit °C °C
Max. 2.06 2.06
Nor. 0.03 ~ 0.145 0.03 ~ 0.145
Min. 0.03 0.03
Unit cP cP
18 MW 17.035 17.035
19 Cp/Cv
20 Z
21 Sp. Gr. 0.681 0.681
25 Equipment Design Press. kg/cm2g 12.5 35
26 Accessories
27 P & ID No. D-6289-3000-002 D-6289-3000-002
28 Remarks
a. Specific Heat( )
LIQUID EXPANSION
c. Heat Duty ( )
d. Specific Heat( )
TUBE FAILURE
i. Latent Heat ( )
ANNEXURE - 7

PROCESS DATA SHEET
Process : Ammonia Storage System Approved RKP ASV ASV
Customer : Coromandel International Ltd. Checked RKP DDP DDP
Location : Kakinada, India Made DDP NAK VDK
Date 13/5/2011 25/05/2011 04/08/2011
1 Tag No. SV-30303/30304 SV-30301/30302
2 Quantity 1 Operating +1 Standby (Note 2) 1 Operating +1 Standby (Note 2)
3 Service Ammonia Receiver 30-D-01 Economiser 30-E-02
4 Line Size (Inch.) 2" / 3" 3 2" / 3" 3

5 Line Class Inlet/Outlet BE 33 / BA 31 BE33 / BA 31
7 Sizing Basis External Fire Case External Fire Case
Liq.
Set 22.5 22.5
Unit kg/hr kg/hr
13 Temperature Nor. 43 -17.7
Discharge 22 22
Unit °C °C
14 Superimposed Back Press.(I) Type Variable Variable
Max. 0.145 0.145
Nor. 0.075 0.075
Min. 0.03 0.03
15 Built-Up BackPress. (II) 1.91 1.91
15 Total BackPress. (I+ II) 2.055 2.055
16 Viscosity Liq.
Unit cP cP
17 MW 17.035 17.035
18 Cp/Cv 1.31 1.31
19 Z 0.98 0.98
20 Sp. Gr.
21 % Flash - -
24 Equipment Design Press. kg/cm2g 22.5 22.5
25 Accessories
26 P & ID No. D-6289-3000-003 D-6289-3000-003
27 Remarks
a. Specific Heat( )
LIQUID EXPANSION
c. Heat Duty ( )
d. Specific Heat( )
TUBE FAILURE
i. Latent Heat ( ) kcal/kg 237 237
2. Size & number of PSVs required to be confirmed by instrument / Vendor.
3
ANNEXURE - 7

PROCESS DATA SHEET
Process : Ammonia Storage System Approved RKP ASV ASV
Customer : Coromandel International Ltd. Checked RKP DDP DDP
Location : Kakinada, India Made DDP NAK VDK
Date 13/5/2011 25/05/2011 04/08/2011
1 Tag No. SV-30307/ 30308 SV-30305/ 30306
2 Quantity 1 Operating +1 Standby (Note 2) 1 Operating +1 Standby (Note 2)
3 Service Ammonia Condenser 30-E-01 A Ammonia Condenser 30-E-01 B
3 3
4 Line Size (Inch.) 2/3 2/3
5 Line Class Inlet/Outlet BE 33 / BA 31 BE 33 / BA 31
7 Sizing Basis External Fire Case External Fire Case
Liq. - -
Unit kg/hr kg/hr
Set 22.5 22.5
13 Temperature Nor. 43 43
Discharge 22 22
Unit °C °C
Max. 0.145 0.145
Nor. 0.075 0.075
Min. 0.03 0.03
15 Built-Up BackPress.(II) 1.91 1.91
16 Viscosity
Unit cP cP
17 MW 17.035 17.035
18 Cp/Cv 1.31 1.31
19 Z 0.98 0.98
20 Sp. Gr.
21 % Flash
24 Equipment Design Press. kg/cm2g 22.5 22.5
25 Accessories
26 P & ID No. D-6289-3000-003 D-6289-3000-003
27 Remarks
a. Specific Heat( )
LIQUID EXPANSION
c. Heat Duty ( )
d. Specific Heat( )
TUBE FAILURE
i. Latent Heat ( ) 237 237
2. Size & number of PSVs required to be confirmed by instrument / Vendor.
3
ANNEXURE - 7

PROCESS DATA SHEET
Date 13/5/2011 25/05/2011 04/08/2011
1 Tag No. SV-30310 / 30309
2 Quantity 1/1
3 Service CW return lines from condensors
30-E-01 A/B
4 Line Size (Inch.) Inlet/Outlet 3/4" / 1" (Note 2)

5 Line Class Inlet/Outlet BB31 / BB31
6 Code or Law API-520
7 Sizing Basis Liquid Expansion
8 Fluid Name Cooling Water
Liq.
Unit kg/hr
11 Pressure Nor. 3
Set 6
Unit kg/cm2g
12 Overpressure(%) 10
13 Temperature Nor. 39
Discharge 39
Unit °C
14 Superimposed Back Press. (I) Type Constant
Max. Note 3
Nor.
Min.
Unit kg/cm2g
15 Built-Up BackPress.(II) Negligible
16 Total BackPress.(I +II ) Note 3
Unit kg/cm2g
17 Viscosity Liq. 0.8
Unit cP
18 MW 18
19 Cp/Cv
20 Z
21 Sp. Gr. 1
22 % Flash
23 Body Material CS
24 Trim Material
25 Equipment Design Press. kg/cm2g 6
26 Accessories
27 P & ID No. D-6289-3000-003
28 Remarks
a. Specific Heat( )
LIQUID EXPANSION
c. Heat Duty ( )
d. Specific Heat( )
TUBE FAILURE
i. Latent Heat ( )
3. Relief to atmosphere
ANNEXURE - 8
Document No: B-6289-044-001
TOYO ENGINEERING INDIA LTD. TIE-IN POINT LIST REVISION NO DATE MADE BY CHECKED BY APPROVED BY
JOB NO: 6289

CUSTOMER: COROMANDEL INTERNATIONAL LTD.
LOCATION: KAKINADA, INDIA 1 25-08-2011 VAM DDP ASV
DOCUMENT NAME: TIE-IN POINT LIST 0 05-04-2011 DVK DDP RKP
Operating Condition Design conditions
Tie in Line Size Piping Fluid Fluid Pressure 0 Pressure O Insulation

Issue Stream Description(Line no) LINE ROUTINE Temperature C Temperature C Remarks
Number (mm) Spec. Code State kg/cm2g kg/cm2g
From P&ID NO To P&ID NO Min Nor/Max. Min Nor/Max. Hot Cold Legend Thickness, mm
NEW AMMONIA COMPRESSOR SUCTION
LINE TO EXISTING AMMONIA COMPRESSOR
0 TP-16 250 BE33 AGLL V 300-AGLL-30021-BE33-100K 3000-003 250-AGLL-10228-BE33T-K100 3000-006 0.075 -33 22.5/ (-75 mm WC) 60 -40 K 100
SUCTION
(250-AGLL-30547-BE33-100K)
REFRIGERATED LIQUID AMMONIA FROM
0 TP-17 200 BE33 ALLL L NEW SYSTEM TO EXISTING SYSTEM 200-ALLL-30044-BE33-100K 3000-003 150-ALLL-10106-BE33T-K100 3000-006 1.37 -33 22.5/ (-75 mm WC) 60 -40 K 100
(200-ALLL-30547-BE33-100K)
PRECOOLING RETURN HEADER FROM

1 TP-18 100 BE33 ALHL L+V EXISTING SYSTEM TO NEW SYSTEM 100-ALHL-10149-BE33T-K60 3000-004 350-ALHL-30001-BE33-100K 3000-002 8 -33 32.5/ (-75 mm WC) 60 -40 K 60
(100-ALHL-30041-BE33-60K)
NEW AMMONIA PUMP (30-P-01A/B)
DISCHARGE TO EXISTING AMMONIA PUMP 35 (Hold)
1 TP-19 150 BE33 ALHL L 150-ALHL-30048-BE33-100K 3000-002 100-ALHL-20036-BE33-60K 3000-004 25 -33 60 -40 K 100
DISCHARGE HEADER 32.5
(150-ALHL-30048-BE33-100K)
FROM EXISTING AMMONIA PUMP DISCHARGE
35
1 TP-20 150 BE33 ALHL L HEADER TO NEW STORAGE TANK 200-ALHL-10505-BE33T-K100 3000-004 350-ALHL-30001-BE33-100K 3000-002 25 -33 60 -40 K 100 DELETED
(150-ALHL-30047-BE33-100K)
(Hold)
SHIP UNLOADING LINE FROM EXISTING

0 TP-21 400 BE33 ALHL L SYSTEM TO NEW SYSTEM 400-ALHL-20001-BE33-100K 3000-005 30-T-01 3000-002 8 -33 32.5/ (-75 mm WC) 60 -40 K 100
(400-ALHL-30001-BE33-100K)
NEW SYSTEM FLARE SUBHEADER TO

100
1 TP-22 BA31 AGLH V EXISTING FLARE HEADER 100(HOLD)-AGLH-30100-BA31 3000-002 200-AGLH-10141-BA31 3000-004 0.1 15.5 ~ 46.0 3.5 60 - - - -
(Hold)
(100(HOLD)-AGLH-30100-BA31)
AMMONIA VAPOUR FROM 30-T-01 TO

1 TP-23 200 BA31 AGLH V EXISTING FLARE HEADER 200-AGLH-30105-BA31 3000-002 200-AGLH-10141-BA31 3000-004 0.1 15.5 ~ 46.0 3.5 60 - - - -
(200-AGLH-30105-BA31)
NEW COMPRESSOR DISCHARGE TO

1 TP-24A/B 100 BA33 AGHH V EXISTING COMPRESSOR DISCHARGE 150-AGHH-30512-BA33-30P 3000-003 80-AGHH-10268-BA33T-P30 3000-006 17.2 100.0 22.5 150 - P 30 -
(100-AGHH-30549-BA33-30P)
TEMPORARY LINE FOR PRECOMMISIONING TEMPORARY

1 TP-25 100 BA31 AGLL V FROM NEW TO EXISTING SYTEM 30-T-01 3000-002 PRECOMMISIONING LINE OF 3000-005 0.1 15.5 ~ 46.0 3.5 60 - - - -
(100-AGLL-30104-BA31) 20-T-01
AMMONIA CONDENSER AND RECEIVER
INERT GAS VENT FROM NEW SYSTEM TO
1 TP-26 25 BA31 AGLH V 25-AGHH-30517-BE33 3000-003 25-AGLH-10145-BA31 3000-006 0.1 15.5 ~ 46.0 3.5 60 - - - -
EXISTING SYSTEM
(25-AGLH-30545-BA31)
SERVICE WATER FROM EXISTING HEADER

1 TP-27A 50 BB31 SW L EXISTING HEADER 3000-009 50-SW-30623-BB31 3000-009 5.5 15.5 ~ 46.0 6 60 - - - -
TO NEW SYSTEM
SERVICE WATER FROM EXISTING HEADER

1 TP-27B 50 BB31 SW L EXISTING HEADER 3000-009 50-SW-30625-BB31 3000-009 5.5 15.5 ~ 46.0 6 60 - - - -
TO NEW SYSTEM
DRINKING WATER FROM EXISTING HEADER

1 TP-28A 40 RE31 DW L 40-DW-20091-RE31 3000-009 40-DW-30624-RE31 3000-009 2.5 15.5 ~ 46.0 6 60 - - - -
TO NEW SYSTEM
DRINKING WATER FROM EXISTING HEADER

1 TP-28B 40 RE31 DW L 50-DW-10340-RE31U 3000-009 40-DW-30628-RE31 3000-009 2.5 15.5 ~ 46.0 6 60 - - - -
TO NEW SYSTEM
PLANT AIR FROM EXISTING HEADER TO

1 TP-29A/B 40 BB31 PA V EXISTING HEADER 3000-009 40-PA-30626-BB31 3000-009 6 40.0 8 60 - - - -
NEW SYSTEM
PLANT AIR FROM EXISTING HEADER TO

1 TP-29B/C 40 BB31 PA V EXISTING HEADER 3000-009 40-PA-30630-BB31 3000-009 6 40.0 8 60 - - - -
NEW SYSTEM
INSTRUMENT AIR FROM EXISTING HEADER EXISTING HEADER 40-IA-30631 -BB31

1 TP-30A 40 EB31 IA V 3000-009 3000-009 6 40.0 8 60 - - - -
TO NEW SYSTEM (40-IA-10380-EB31) 40-PA-30636-BB31
SHEET 1 OF 2
ANNEXURE - 8
Document No: B-6289-044-001
TOYO ENGINEERING INDIA LTD. TIE-IN POINT LIST REVISION NO DATE MADE BY CHECKED BY APPROVED BY
JOB NO: 6289

CUSTOMER: COROMANDEL INTERNATIONAL LTD.
LOCATION: KAKINADA, INDIA 1 25-08-2011 VAM DDP ASV
DOCUMENT NAME: TIE-IN POINT LIST 0 05-04-2011 DVK DDP RKP
Operating Condition Design conditions
Tie in Line Size Piping Fluid Fluid Pressure 0 Pressure O Insulation

Issue Stream Description(Line no) LINE ROUTINE Temperature C Temperature C Remarks
Number (mm) Spec. Code State kg/cm2g kg/cm2g
From P&ID NO To P&ID NO Min Nor/Max. Min Nor/Max. Hot Cold Legend Thickness, mm
INSTRUMENT AIR FROM EXISTING HEADER EXISTING HEADER

0 TP-30B 40 EB31 IA V 3000-009 40-IA-30630-EB31 3000-009 6 40.0 8 60 - - - -
TO NEW SYSTEM (40-IA-10380-EB31)
COOLING WATER FROM NEW COOLING

WATER SUPPLY HEADER TO EXISTING 3000-006 3
1 TP-31 200 BB31 WS L 300-WS-30613-BB31 200-WS-10310-BB31 3000-006 33.0 6 55 - - - -
COOLING WATER SUPPLY HEADER 3000-008 3.5
(200-WS-30614-BB31)
COOLING WATER FROM EXISTING
COOLING WATER RETURN HEADER TO
0 TP-32 200 BB31 WR L 200-WR-10302-BB31 3000-006 300-WR-30613-BB31 3000-006 2.5 39.0 6 55 - - - -
NEW COOLING WATER RETURN HEADER
(200-WR-30614-BB31)
INSTRUMENT AIR FROM EXISTING HEADER EXISTING HEADER 3000-002

1 TP-30C 15 EB31 IA V 3000-009 15-IA-30650-EB31 6 40.0 8 60 - - - Newly Added
TO NEW SYSTEM 3000-009
INERT GAS FROM INERT GAS REMOVER TO

1 TP-36 25 BA31 AGLH V EXISTING FLARE HEADER. 25-AGLH-10145-BA31 3000-004 200-AGLH-10141-BA31 3000-004 0.1 15.5 ~ 46.0 3.5 60 - - - Newly Added.
(25-AGLH-10145-BA31)
SHEET 2 OF 2
ANNEXURE - 9
ON-OFF VALVE
PROCESS DATA SHEET
Job No.: 6289 Revision 0 1
Process: Ammonia Storage Tank App By RKP ASV
Customer: Coromadel International Ltd Chkd By DDP DDP
Location: Kakinada Made By DVK HKK
Date 11/05/2011 20/10/2011
Doc. No: B-6289-049-002
1 Tag No. 1 XV-30204 XV-30801
2 Quantity 1 1
3 Service Inner Tank Outlet Make up Water
Line to Pump Suction To Cooling Tower
4 Line Size (mm) 200 50

5 Line Class BE33 BB31
6 Fluid Name Ammonia Service water

2 2
8 Flow & Pressure Unit Kg/hr Kg/cm G Kg/hr Kg/cm G
Pressure Drop Normal 32566 8000
Minimum
10 Pressure (kg/cm2G) Oper Des. 0.075 12.5 5.5 6
12 Temperature (ºC) Oper Des. -33 -40/60 AMB 60
11 Maximum dp shut off (kg/cm2) 12.5 6
13 Operating Density (kg/m3) 681.3 990
15 Molecular Weight ( Flashed Vapor)
19 % Solids
20 % Flash
21 Actuator Fail Position FC FO
24 Special Material Body LTCS CS
Seat & Plug
26 Handwheel Required Yes NO
27 Accessories
28 Notes 1 1
29 P & I Drawing No. D-3000-002 D-3000-008
Notes:
1. Ball type Valve

AAST Operation Manual Rev0

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COROMANDEL INTERNATIONAL

AMMONIA STORAGE SYSTEM

Some procedures may be modified after actual operation if necessary. Standard

Operation Manual Rev. 0

1.1 Sectional Abstract

Section 1 of the manual contains a description of the process system.

Section 2 contains description of process flows with respect to individual operations. It

Section 3 contains a description of major equipment and elaboration of instrument

Section 6 describes a recommended Normal Operation of the system.

Section 7 contains a recommended shutdown procedure for the system.

Section 9 contains a brief outline on activities for plant maintenance.

1.2 System Summary

Function and Capacity

Operation Manual Rev. 0

Operation Manual Rev. 0

2.1 Ammonia Ship Unloading Section:

Liquid ammonia is brought at a temperature of -32.5 oC in refrigerated ships and

Operation Manual Rev. 0

Temperature of ammonia unloading line is measured by the Temperature Indicator and

2.1.2 Ship Unloading:

Operation Manual Rev. 0

2.2 Ammonia Storage and Pumping Section:

2.2.1 Atmospheric Ammonia Storage Tank (30-T-01)

Ammonia is generally stored in a specially designed storage tanks at temperature of

1. Vapour formation due to ship unloading pipeline heat leak.

2. Rise in enthalpy due to work done by the ship pumps.

3. Vapour generated due to feed flashing inside the tank.

4. Heat ingress into the tanks.

5. Vapour formation due to heat ingress in Plant Piping.

6. Vapour displaced due to rise in liquid level in the tank.

7. Vapour formation due to minimum flow circulation of Pumps.

a. Tank Design & Construction

Operation Manual Rev. 0

i. Elimination of an external bund wall.

II. Tank Foundation

III. Tank Bottom Design

IV. Shell Insulation

Operation Manual Rev. 0

VI. Tank Safety Systems

a. Safety Valves (SV 30207/30208)

b. Vacuum Relief (VRV 30201/30202)

1. High rate of Liquid Ammonia withdrawal from the tank

2. Sudden increase in atmospheric pressure.

3. BOG withdrawal due to Compressor.

c. Pressure Control Valve (PV-30203)

VII. Tank Instrumentation

Operation Manual Rev. 0

2.2.2 Ammonia Transfer Pumps (30-P-01A/B)

2.3 Ammonia Refrigeration Section:

2.3.1 Ammonia Compressors (30-K-01A/B):

2.3.2 Ammonia Condensers (30-E-01A/B)

Operation Manual Rev. 0

2.3.3 Ammonia Receiver (30-D-01)

2.3.4 Economizer (30-E-02)

2.4 Utilities and Supporting Facilities:

2.4.1 Cooling Water System:

Operation Manual Rev. 0

2.4.2 Service Water:

2.4.3 Potable water:

2.4.4 Plant Air / Instrument Air:

Operation Manual Rev. 0

a. Controlling the pressure rise in the Ammonia Storage Tank (30-T-01).

2.4.7 Electrical Power System: