Operation Manual (Toyo Ancillary) - R2

PEQUIVEN MORON FERTILIZER PROJECT
OPERATION MANUAL
FOR
ANCILLARY PLANT
PROJECT DOCUMENT NO.MTI-U-00-T6933
1,800 MTPD AMMONIA / 2,200 MTPD UREA PLANT

for
PETROQUIMICA DE VENEZUELA S.A.
in
MORON, VENEZUELA
2 Feb./28/’13 REVISED T.M S.N K.H K.H

1 Oct./15/’12 REVISED T.M S.N K.H K.H
0 Jun./30/’12 INITIAL ISSUE T.M S.N K.H K.H
REV DATE PURPOSE OF ISSUE PREPARED CHECKED APPROVED AUTHORIZED

OPERATION MANUAL
FOR ANCILLARY FACILLITY
Issued Feb. 28, 2013 Project Document No: MTI-U-00-T6933 Rev. 2 Page 2 of 39
~ Revision History ~
Rev. Date Description of Change
0 Jun./30/’12 INITIAL ISSUE
1 Oct./15/’12 Revised (Modified NH3 Storage Gas Purge Procedure)
Revised 1) Modified NH3 Storage Gas Purge Procedure 2) Deleted SWID filter section,
2 Feb./28/’13
(to incorporated in SWID operation manual)
OPERATION MANUAL
CONTENTS
SECTION 1. INTRODUCTION ........................................................................................................................................ 4

1.1 Preface ............................................................................................................................................................... 4
1.2 Operating Cautions ............................................................................................................................................ 4
SECTION 2. PROCESS DESCRIPTION ....................................................................................................................... 5
2.1 Ammonia Storage System ................................................................................................................................ 5
2.2 Fresh Cooling Water System ............................................................................................................................ 6
2.3 Instrument Air System for Bagging Unit .......................................................................................................... 7
SECTION 3. PREPARATION FOR THE INITIAL START-UP ..................................................................................... 8
3.1 General ............................................................................................................................................................... 8
3.2 Line Check.......................................................................................................................................................... 8
3.3 Line Cleaning ..................................................................................................................................................... 9
3.4 Electrical Equipment.......................................................................................................................................... 9
3.5 Vessel Inspection ............................................................................................................................................... 9
3.6 Rotating Equipment Run-in Test ...................................................................................................................... 9
3.7 Tightness Test .................................................................................................................................................... 9
3.8 Purging ............................................................................................................................................................... 9
3.9 Passivation ....................................................................................................................................................... 10
SECTION 4. START-UP ................................................................................................................................................ 11
4.1 General ............................................................................................................................................................. 11
4.2 Ammonia Storage System .............................................................................................................................. 11
4.3 Fresh Cooling Water System .......................................................................................................................... 23
4.4 Instrument Air System for Bagging Unit ........................................................................................................ 26
SECTION 5. NORMAL OPERATION ........................................................................................................................... 29
5.1 General ............................................................................................................................................................. 29
SECTION 6. NORMAL SHUTDOWN ........................................................................................................................... 31
SECTION 7. EMERGENCY SHUT-DOWN ................................................................................................................. 34
7.1 General ............................................................................................................................................................. 34
7.2 Description of the Failure ................................................................................................................................ 34
SECTION 8. SAFETY .................................................................................................................................................... 38
ATTACHMENT ................................................................................................................................................................ 39
OPERATION MANUAL
SECTION 1. INTRODUCTION
1.1 Preface
This operation instruction has been prepared for the following Ancillary Facilities in 1800MTPD
Ammonia / 2200MTPD Urea Plant for PEQIVEN at Moron, Venezuela.
- Ammonia Storage System

- SEA Water and Fresh Cooling Water System
- Instrument Air System for Bagging Unit
This instruction describes start up, shutdown and consideration for emergency for Ancillary
Facilities. The Vendor’s operating instruction for the equipment shall be read in conjunction with
this instruction.
1.2 Operating Cautions
The following rules should be carefully followed, as neglect of these cautions may cause serious
damage to personnel and/or equipment. However, attention should be paid to that operation of
the systems.
(1) Operating equipment should be checked frequently. Unusual conditions such as leakage,
vibration, overload and corrosion should be reported immediately.
(2) Monitor the pump operation regularly. (Strainer cleanliness, proper liquid levels, Vibration,
temperature, etc.)
(3) Switch pumps over regularly to assure the spares are ready whenever it is required to
start.
(4) Fully understand Vendor’s operating instructions for the equipment.
(5) Never stand directly facing any safety device, sampling valves, etc.
(6) Do not make a vacuum on equipment at any time, unless it is designed to with stand the
stresses set up under such conditions.
(7) Any work shall not be allowed unless authorized by a permit to work. If the system is
disassembled, make sure that no pressure or gas inside the piping and equipment.
OPERATION MANUAL
SECTION 2. PROCESS DESCRIPTION
2.1 Ammonia Storage System
Description
One (1) Ammonia Storage Tank (C-FB1101) of double wall full containment type is provided to
store Ammonia product at atmospheric pressure.
Tank capacity is 27,000 metric tons as working volume to accommodate approximately 15 days
of Ammonia production at the design rundown rate of Ammonia plant (75 MT/h). The condition
corresponds to the operation of Urea plant under normal capacity (51.5 MT/h).
Two Ammonia Transfer Pumps are provided, which type is a multi-stage barrel type shaft pump.
Stored Ammonia will be pumped by Ammonia Transfer Pump (C-GA1101), heated up by
Ammonia Heater (C-EA1103), and sent to Urea plant. In addition, stored ammonia can be
exported to the existing plant by Ammonia Transfer Pump (Port) (C-GA1102).
Boil off gas generated in the Ammonia Storage Tank (C-FB1101) and associated line will be
sent to the BOG Compressor Unit (C-GC1101), compressed, cooled down and returned to the
Ammonia Storage Tank (C-FB1101) as liquid phase.
Ammonia Storage Flare Stack is provided with the control system, which will operates and
monitor the flare system.
If the Ammonia Storage Tank (C-FB1101) cannot receive the product ammonia due to some
reasons, product can be sent to the existing plant directly from NH3 plant through the by-pass
line on the product rundown line to Ammonia Storage Tank (C-FB1101).
Operating Variable and Control
(1) Temperature Control of Ammonia Feed to Urea Plant
Ammonia liquid will be pumped to urea plant by Ammonia Transfer Pump (C-GA1101), heated
up by the Ammonia Heater (C-EA1103), and sent to Urea plant. Temperature control is made by
TIC-6004, which controls the LP steam flow to the Ammonia Heater (C-EA1103) shell side.
OPERATION MANUAL
(2) Pressure Control in Ammonia Storage Tank
Tank pressure is varied with Boil off gas (BOG) rate which depends on the operation condition.
Since design pressure of Ammonia Storage Tank (C-FB1101) is 1000 mm H2O and minus 100
mmH2O, it is desirable to maintain the tank pressure at about 0.02 kg/cm2g by PIC6000 which
regulates the capacity control valve of the BOG Compressor and PV6000.
2.2 Fresh Cooling Water System
Description
The heated cooling water from process units and other facilities is returned to the Fresh Cooling
Water Buffer Storage Tank (C-FB1001), and distributed to the process units and other facilities
by the Fresh Cooling Water Pump (C-GA1004A-F).
The heated cooling water is sent to the Sea Water/Fresh CW Exchanger (C-EA1001A-K), and
heat transferred between Sea Water and Fresh cooling water.
The cooled cooling water is distributed to users. Chemicals are added to the closed loop to
prevent fouling and corrosion in the system, as necessary.
The normal supply condition of the fresh cooling water is 4.5 kg/cm2g and 33 °C. Mechanical
design conditions of the system are 10 kg/cm2g and 80 °C.
Covered Drain Sump (C-AD1001) is provided to drain the Fresh Cooling Water from the Main
Header. Drained Water can be transferred to the Fresh Cooling Water Buffer Storage Tank (C-
FB1001) or Waste Water Treatment System by the Drained Fresh Water Pump (C-GA1009).
OPERATION MANUAL
2.3 Instrument Air System for Bagging Unit
Description
Dedicated Instrument air system, which consists of the Instrument Air Compressor for Bagging
Unit (C-GB1002) and the Instrument Air Dryer for Bagging Unit (C-FF1109A,B), is provided for
the Bagging Unit.
The normal supply condition of the instrument air is 7.0 kg/cm2g and ambient temperature.
Mechanical design conditions of the system are 10 kg/cm2g and 60 °C.
Two back-up systems are considered by providing the line from the Instrument Air Network and
Nitrogen Network.
Operating Variable and Control
Pressure Control is provided in the compressor package with unloading valve to maintain a
constant instrument air supply pressure of 7.0 kg/cm2g at the distribution system. Compressor
will be switched on (off) by PI2543 when the pressure of the distribution system decreases to 6.5
kg/cm2g (increases to 7.5 kg/cm2g).
OPERATION MANUAL
SECTION 3. PREPARATION FOR THE INITIAL START-UP
3.1 General
These preparation activities are very important step to start-up the plant smoothly. During the
construction phase, there are possibilities of foreign materials such as bolts, clothes, etc.,
entering into the vessel or the piping, installation error etc., of the equipment. These may result
in injury of the personnel or serious damage of the equipment, etc. Therefore these preparation
activities should be carried out carefully and thoroughly.
3.2 Line Check
In general, the line check is carried out from several points of view. For example, checking a
design point of view whether operation will be done without any trouble, conformity check with
latest drawing prior to the test and flushing, checking the plant completion to start safe
commissioning/start-up, etc.
The followings are typical examples for line checking at each stages.
(1) Before Test and Flushing (Conformity check at construction phase)
(a) "Note" written on P&I Flow Diagram.

(b) Flow direction and type (check, globe and angle, etc.) of valves.
(c) Material and class of pipe, flange, bolt and gasket.
(d) Existence of drain valves and vent valves.
(e) Installed location of instruments, flow direction of control valves and orifices.
(f) Operability of valves.
(g) Length and number of tightened bolt and completion of tightening.
(h) Incomplete work.
(2) Before Start-up
(a) Existence of steam tracing.

(b) Existence of insulation.
(c) Inclining of impulse line for instruments.
(d) Flow direction of orifice and control valves.
(e) Welding of shoes and lugs according to the rule.
(f) Installation of piping supports at the prescribed location.
OPERATION MANUAL
(g) Removing of temporary supports.

(h) Removing of pre-set pin for springs and setting of scales to c (cold) point.
(i) Providing place for piping movement by heat expansion.
(j) Not touching of high pressure line with electric cable, inflammable substance etc.
(k) Installation of spectacle according to the rule (open or shut).
(l) Line-up (Valve open/close position) is correct.
(3) After Start-up
(a) Movement of piping expansion.

(b) Scale location of support for springs (h point is right).
(c) Vibration of piping, valves, etc.
3.3 Line Cleaning
Refer to the following procedures;
- Manual Cleaning Plan for Ancillary Scope (Doc. No. CCFM-U-00-TP381)

- Line Cleaning Plan for Ancillary Scope (Doc. No. CCFM-U-00-TP382)
3.4 Electrical Equipment
Commissioning of the electrical equipment will be performed in accordance with the plant
practice by qualified electrical personnel.
3.5 Vessel Inspection
Inside of equipment such as vessel should be thoroughly checked visually.
3.6 Rotating Equipment Run-in Test
Refer to the Rotating Machine Run-in Test Procedure for Ancillary Scope (CCFM-U-00-TP384)
3.7 Tightness Test
Refer to the Tightness Test Plan for Ancillary Scope (CCFM-U-00-TP383).
3.8 Purging
Refer to the section 4.2.1.2 “Purge with Nitrogen Vapor” in this procedure.
OPERATION MANUAL
3.9 Passivation
Passivation will be done for Fresh Cooling Water System, and detail procedure shall be decided
based on the Program which the chemical Supplier will issue.
OPERATION MANUAL
SECTION 4. START-UP
4.1 General
When the preparation work such as line cleaning, tightness test, purging, etc. are completed
sufficiently, the following systems shall be started.
4.2.1 Commissioning of the Ammonia Storage Flare Stack (C-BJ1101)

(Refer to Vendor P&ID: MTI-U-BA082110-AXBJ020-505)
(1) Confirm all the Ammonia Storage System has been purged with nitrogen prior to
any ignition.
The ignition system must not be operated until the Ammonia Storage
System is thoroughly purged.
(2) Continuously purge the Ammonia Flare Header 10 V 38042 A1Q2 with nitrogen
from 2 N 35503 ANA2, and adjust flow rate at 10 Nm3/hr by FI6001.
(3) Confirm that the pilot/ignition gas is available up to the Flame Front Generation
(FFG) System.
(4) Turn the Power On/Off switch to “On” position.
(5) Open the first valve (BV-100) on the ignition side of FFG, and make sure that other
valves (BV-200 and BV-300) are closed.
(6) Open the valves of air and natural gas. (BV-101, BV-102 and BV301), and confirm
that the pressure shown at PI-100, PI-200 and PI-300 is 8 psig.
(7) Wait approximately one minute to replace the ignition line with natural gas.
(Consider one minute for every 100’)
(8) Press the Manual Spark switch on the local panel to fire the FFG. Confirm a
momentary blue flash visible through the sight glass in the Ignition Chamber.)
OPERATION MANUAL
(9) When the first pilot ignites and the thermocouple controller detects 250°C, the Pilot
#1 “On” indicator will come on.
(10) Switch the valve (BV-200 and BV-300) and repeat same steps (7) to (9) for other
pilots.
(11) When all pilots are on, close the valves (BV-100, BV-200, BV-300, BV-101 and
BV-201), and kept these valves closed. Pilot line valve (BV-301) remains open.
4.2.2 Initial Purging and Cooling Down
This instruction shall be read in conjunction with Vendor’s operating

instruction “PURGE & COOL DOWN PROCEDURE (Doc. No. MTI-U-
AXFB003-945)”
The purge and cooling down consists basically of 4 separate phases as follows;
- Purge with nitrogen vapor

- Purge with ammonia vapor
- Cool down with liquid ammonia
The first few hours in the cool down operation are the most critical time,
therefore proceed slowly to avoid the quite erratic condition such as the
overpressure or vacuum.
At any time during the purge or cool down of the tank, pressure shall not
exceed the design pressure of the inner or outer tank of 0.1 kg/cm2G.
At any time during the purge or cool down of the tank, vacuum shall not
exceed 20 mmH2O.
At any time during the purge or cool down of the tank, temperature shall
not be less than minus 40 °C when the material contact with product.
Do not use any mercury devices around the tank.

OPERATION MANUAL
4.2.2.1 Pre-Purge Check List
(1) Safety personnel should be aware and present at site
(2) Working area around the storage tank shall be loped off as necessary to prevent
unauthorized personnel entering the area.
(3) Tool, material, etc., not suitable for explosive atmosphere should be removed from
the area.
(4) All pressure vacuum safety devices shall be in place and operational.
(5) All the piping connection shall be physically isolated from the tank.
(6) Open 12” purge vent nozzle (N14) in the center of the tank and any other valves
for purging (if available).
(7) Remove blinds and install valves on nitrogen purge nozzles (N-35A/B/C/D)
(8) Put water manometer to the tank to read the tank pressure accurately during
purging.
(9) A sample point shall be prepared at each location for venting.
(10) Prepare an essential record sheet for purging and cool down.
(11) Arrange the meeting for Schedule and Emergency communication
(12) Arrange the continuous nitrogen supply.
(13) Confirm the tank has been tested, cleaned and dried prior to any purging.
4.2.2.2 Purge with Nitrogen Vapor
General
OPERATION MANUAL
(1) The following is a brief listing for purging end point (including 20% safety factor).
Product % by Volume
Oxygen 12.0
If the purpose of purging is preservation, oxygen content must be

reduced to approximately 1%.
(2) Nitrogen should be introduced to the piping system and tank until the oxygen
concentration of the mixture being vented is below the value listed above.
(3) Total quantity if nitrogen required to reach the purge end point is equivalent to
about two (2) to three (3) times the total tank volume of 58439 m3.
Procedure
(1) Nitrogen will be admitted to the piping system (Refer to the attachment 4.2.2 -1)
from the utility station to purge connection on pump suction. Purging will be done
with pressurizing and depressurizing cycle.
(2) Nitrogen will be admitted to the tank through the connection (N-31A) on inner shell
4” drain (Refer to the attachment 4.2.2 -2). Valve on the utility station can be used
to throttle the nitrogen flow to the tank.
(3) Admit nitrogen vapor to the tank at approx. 300 Nm3/hr for about 2 hours. Keep
the nitrogen temperature higher than the air in the tank to avoid condensation.
(4) After 2 hours, increase the flow rate in steps of 300 Nm3/hr unless limited by vapor
supply or tank pressure. (i.e. venting rate)
(5) As the nitrogen purge path is from bottom to top, temperature of incoming nitrogen
can be lowered than air in the tank, and less mixing will occur due to large density
difference.
(6) Take and Record the reading every two (2) hours.
(7) After the purge end point has been reached, the venting from (N-14) can be
stopped. Start annular space purge. Slowly open 2” valves on purging nozzles (N-
OPERATION MANUAL
35A/B/C/D) and watch closely for perlite particle flow caused by excessive nitrogen
flow through the perlite. If perlite flow occurs, throttle the nitrogen supply valve
(utility station) and annular purge valves (2”) until the perlite flow stop. Monitor the
tank pressure closely and adjust the nitrogen flow rate within the specific range.
(8) After the purge end point has been reached at each purge point, associated valves
can be closed. To prevent the overpressure in the tank, nitrogen gas supply rate
shall be reduced when closing any valves.
(9) Once the purge is complete, a positive pressure should be maintained on the inner
tank to prevent air entering the tank prior to ammonia vapor purging. The pressure
shall be kept by make-up nitrogen between the limit of 0.1 kg/cm2g and 20
mmH2O.
4.2.2.3 Purge with Ammonia vapor
After the nitrogen gas purging, the tank and piping shall be purged with ammonia gas
by using the liquid ammonia which is supplied from the existing plant.
General
(1) The following is a brief listing for purging end point.
Product % by Volume
Ammonia between 80 – 90 (or further requirement from licenser)
Oxygen less than 5
(2) Extreme caution must be used because gases escaping from any opening may
become explosive.
(3) Introduction of liquid ammonia into the tank can result in temperature lower than
the tank design temperature. Therefore, nitrogen purge shall be followed by a
purge with ammonia vapor.
(4) Ammonia vapor is heavier than air and will tend to drift towards the ground.
Therefore, check the downwind side of the tank when ammonia is purged.
OPERATION MANUAL
(5) As ammonia is lighter than nitrogen and will form a pocket in the top of the tank,
purge the tank from top to bottom. Slowly piston the nitrogen out through the inner
shell 4” drain and, achieving a displacement purge rather than a dilution purge.
Procedure
Cold liquid ammonia supplied from the existing plant will be heated up by the ammonia
heater C-EA1103 in order to produce the hot liquid ammonia. Ammonia gas will be
produced under the lower pressure by regulating the 2” cool down valve prior to the
ammonia storage tank C-FB1101 (Refer to the attachment 4.2.2 -3)
(1) Input the following set point
PV-6000 (Pressure control at FB-1101): 0.07 kg/cm2g

TIC-6004 (NH3 temp. at C-EA1103 outlet): 25 degC
TA-6006 (NH3 temp. at C-EA1103 outlet): LL = 10 degC
(2) Slightly open 1st valve (2”) and fully open 2nd valve (2”) on cool down line (2NHL-
38120) of C-FB1101.
(3) Crack open FV-6000 (LP Steam to C-EA1103) by manual, and introduce the steam
into the C-EA1103. Condensate will be drained out from the drain valve at
upstream of LV-6002.
(4) Slowly Introduce NH3 from the existing plant to the new complex through the
interconnecting.
Ammonia gas purge between existing and new plant shall be started
same time as one system.
(5) Monitor the temperature at the outlet of C-EA1103. When the temperature starts to
drops, adjust FV-6000 by manual (or put into auto mode). Adjust the outlet
temperature of C-EA1103 at 25 degC.
Supply pressure from the existing plant shall be less the 10 kg/cm2g
(Design pressure). This pressure shall be controlled at existing plant
side.
OPERATION MANUAL
(6) Admit the ammonia vapor to the tank at slow rate (Approx. 300 to 500 Nm3/hr) for
initial 2 hours.
Monitor the wall temperature and pressure on C-FB1101 within limit. 1st
valve (2”) on cool down line shall be adjusted, as required.
(7) After confirming the positive pressure inside the tank, open the inner shell 4” drain
(N-31A) to establish a slow flow through the temporary vent.
(8) After 2 hours, increase the flow rate to between 1000 and 3000 Nm3/hr unless
limited by vapor supply or tank pressure. (i.e. venting rate)
(9) Take and Record the reading every two (2) hours.
(10) When the gas composition from the inner shell 4” drain (N-31A) reaches 90%
ammonia, close the inner shell 4” drain valve (N-31A) and slightly open PV-6000 to
flare. Put PV-6000 on auto at the set point of 0.07 kg/cm2g,
(11) Continue venting until the end point of 90% of ammonia and 5% of oxygen at all
the purge points.
(12) Maintain a positive pressure of 0.07 kg/cm2g on the tank to avoid air entering into
the tank.
After NH3 Storage tank was purged with NH3, purge the piping system. (Refer to the
attachment 4.2.2 -4)
(13) Piping system will be purged through the drain and vent valve to the equalizing
line.
(14) Vapor outlet is connected to the flare through the temporary hose.
(15) Continue venting until the end point of 90% of ammonia and 5% of oxygen at all
the purge points.
4.2.2.4 Cool down with liquid ammonia
General
OPERATION MANUAL
(1) Extreme caution must be used because gases escaping from any opening may
become explosive.
(2) Prior to cool down
- All the instrumentation is calibrated and operational.

- All the piping are connected and purged.
- Pressure vacuum vents are operational
- The refrigeration system shall be checked out and operational
Procedure
(1) Prior to introduction of liquid ammonia, the refrigeration system should be started in
accordance with 4.2.4. Once the system is operating properly, the tank pressure
will begin to drop. The tank pressure shall be maintained by BOG control system.
Or the tank pressure must be controlled by PV-6000 with releasing the gas to flare.
Refer to the Vendor’s operating instruction for BOG Compressor.
(2) The liquid flow rate to the tank must be carefully controlled, especially first few
hours (Refer to the attachment 4.2.2.-5)
It is estimated that a liquid ammonia flow rate of approx. 3m3/hr will

produce a cool down rate of approx. 5°C /hr. Do not exceed the cool
down rate of max 5°C /hr.
In any case the rate if cool down should be controlled to ensure that the
tank design pressure is not exceeded, and the temperature difference
between any two points on the tank does not exceed about 30°C.
(3) Take and Record the reading every one (1) hour.
(4) The cool down should be continued until a liquid level appears in the tank, or until
the design fill rate can be maintained, whichever occurs first. Then cool down can
be considered as complete.
OPERATION MANUAL
(5) When the liquid level reached to XXX mm (XX %), liquid inlet valve can be opened
slowly. After the liquid inlet valve is opened fully, then close 2” filling valve. (Refer to
the attachment 4.2.2.-6)
4.2.3 Ammonia Transferring
4.2.3.1 Ammonia Transfer to Urea Plant
(1) Pressurize in Ammonia Heater C-EA1103 tube side up to 4 ~ 5 kg/cm2G with the
nitrogen gas.
(2) Pump can be cooled down as follows;
a) Lead the Ammonia fluid into the pump casing from the casing bottom through
the barrel drain pipe (3/4 NHL 38087/38088 A1Q2).
b) Open 1” vent valves on the pump casing and discharge line while the pump
casing is cooled down.
c) Approximately 2 hours after the above step-a), slightly open the main suction
valve, and after that open it fully.
d) When the end of the vaporization inside the pump and the pump is fully filled up
with the liquid, cooling down can be completed.
(3) Ensure that all the gas has been removed from the pump casing and discharge
line. Then close the vent valve on the pump discharge line.
(4) Clack open the pump discharge valves, and open FV6001A,B.
(5) Start the Ammonia Transfer Pump (C-GA1101A,B).
Initially, main flow is returned from C-GA1101A,B to the Ammonia Storage tank (C-
FB1101) through 3 NHL 38011 A1Q2 with FV6001A or 3 NHL 38079 A1Q2 with
FV6001B.
If the discharge pressure rises once and the lower almost to the suction
pressure, stop the pump immediately. Remove the gas again from the
pump casing, restart the pump.
Keep open the pump suction valve and equalizing line valve of the stand-
by pump.
OPERATION MANUAL
(5) Deliver the liquid Ammonia as follows;
C-GA1101A,B => C-EA1103 => XV6003 => 4 NHL 38009 B1A2 => Urea Plant
(6) Slowly open 4" pump discharge valve and build up ammonia pressure in U-EA1103
up to normal conditions (PIA6004: 22 kg/cm2G).
XV6002 open position
(7) Supply SLL steam to C-EA1103 and slowly increase the temperature of liquid
ammonia up to between 25°C and 30°C by controlling FV6000 manually.
During lower load of C-EA1103, the condensate level will increase due to
low temperature, and pressure of condensate which cannot be drained
out, even if LV6002 is opened. Nitrogen can be supplied to C-EA1103
shell side to keep the pressure for condensate drain out, if necessary.
(PG6006)
(8) Increase flow rate of the liquid ammonia to Ammonia Reservoir (U-FA104) by
slowly opening 4" B.L valve and LV131, which are located inside urea plant.
(9) Adjust the TIC6004 (or FIC6000) at 30°C and put it on automatic position.
(10) Check LV6002 and if the condensate level in the Ammonia Heater (U-
CEA1103) is stabilized, put it on auto.
Check temperature of TIC6004 (more than 25°C).
4.2.3.2 Ammonia Transfer to Existing Storage Tank
(1) Pump can be cooled down as follows;
a) Lead the Ammonia fluid into the pump casing from the casing bottom through
the barrel drain pipe (3/4 NHL 38089/38090 A1Q2).
b) Open 1” vent valves on the pump casing and discharge line while the pump
casing is cooled down.
OPERATION MANUAL
c) Approximately 2 hours after the above step-a), slightly open the main suction
valve, and after that open it fully.
d) When the end of the vaporization inside the pump and the pump is fully filled up
with the liquid, cooling down can be completed.
(2) Ensure that all the gas has been removed from the pump casing and discharge
line. Then close the vent valve on the pump discharge line.
(3) Clack open the pump discharge valves, and open FV6002.
(4) Start the Ammonia Transfer Pump (C-GA1102A,B).
Initially, main flow is returned from C-GA1102A,B to the Ammonia Storage tank (C-
FB1101) through 3 NHL 38013 A1Q2 with FV6002.
If the discharge pressure rises once and the lower almost to the suction
pressure, stop the pump immediately. Remove the gas again from the
pump casing, restart the pump.
Keep open the pump suction valve and equalizing line valve of the stand-
by pump.
(5) Deliver the Cold Liquid Ammonia as follows;
C-GA1102A,B => FV6003 => 6 NHL 38007 A1Q2 => Existing Storage Tank
(6) Slowly increase the flow rate of the liquid ammonia to the existing storage by
opening FV6003.
(7) Check FV6003, and then put it on auto if the flow rate is stable.
4.2.4 Start-up of BOG Compressor Unit
4.2.4.1 Vacuum Drying
(1) Confirm that the system has been leak tested, and any leaks have been repaired.
OPERATION MANUAL
(2) On the refrigeration side, check that all valves to drain, atmospheric vents and N2
lines are closed except for hoses connected for depressurization.
(3) On the refrigerant circuit, open all valves including inlet block valves for relief
valves, by-pass valves, instrument isolation valves, etc.,
(4) Check pressure in the system and allow to be released until at a nominal 0 kPag.
(5) Close all valves for depressurization.
(6) Fit vacuum pumps to the Ammonia Liquid Receiver C-GC1101FA2 and/or the Oil
Separator C-GC1101FD2.
(7) Pumps should be operated as per manufacturer’s instruction, and 24 hr/d.
(8) Measure vacuum at a location remote from the vacuum pump.
(9) When vacuum reaches approximately – 5 ℃ wet bulb or 2600 micron Hg when
measured at least 2 locations of the unit. Pumps can be isolated and switched off.
(10) When pumps are switched off, monitor vacuum. If vacuum increase to about
3500 microns Hg in 2 minutes it indicates that there is moisture in the system still
evaporating.
If vacuum increases slowly to 3500 microns Hg, the system could be leaking.
If vacuum increase to only 2800 to 2900 microns Hg after 2 minutes and stays
relatively constant the evacuation can be considered finished.
(11) The length of time is dependent on the moisture within the system and the
number of pumps used, but could be from 3 days to 10 days duration.
4.2.4.2 Initial Charge of System with Ammonia Refrigeration Unit

OPERATION MANUAL
(1) All Internal valves on the refrigeration side should be open after evacuating the
system. This should include by-pass valves around level control valves LCV6937
and LCV6938.
(2) Ensure all pre-commissioning checks have been undertaken, including correct oil
level, appropriate valve have been closed for operations.
(3) Under the supervision of Vendor Representative, introduce the Ammonia vapor
from the Ammonia Storage Tank to the compressor suction line manually.
(4) Start the initial purge and vent to the safe location.
(5) Close LCV6937 and LCV6938 by-pass valves.
(6) Under the supervision of Vendor Representative, control the compressor loading to
achieve required liquid in the receiver, level to be determined by the site
representative.
(7) Start compressor under automatic operation.
a) Check the level in the oil tank

b) Check that all necessary gas, oil and water valves are open.
c) Start the lubricating oil pump motor from local panel.
d) Ensure the capacity control valve is in the fully unloaded position. Adjust the
volume ration VI screw to the required setting. (VI type only). (Turning fully
clockwise sets Vi=2.2). Refer to graphs under 6.3 for number of turns.
e) After the oil pump has been running for approximately 15-20 seconds, start the
drive unit and check that all gauges are indicating normal readings.
f) Load the compressor – oil to outer end cylinder ports activates compressor slide
valves to go “on load “position.
4.3.1 Start-up of the Fresh Cooling Water Pump (C-GA1004A-F)

OPERATION MANUAL
This procedure can be applied for flushing, passivation and commissioning of the
Fresh Cooling Water System.
Passivation program shall be discussed with chemical supplier separately, and

procedure shall be prepared based on the program submitted by the chemical
supplier.
(1) Confirm that Polished Water from Y&V (or Emergency Back-up Water from PQV)
is available.
(2) Line-up the system as follows;
a) Open 56” Outlet valve on the Buffer Tank

b) Close 48” return and 3” drain valves around the Buffer Tank.
c) Close 4” drain valve from 48” return header to the Covered Drain Sump (C-
AD1001).
d) Close the pump suction / discharge valves.
e) Close inlet / outlet valves of the Sea Water/Fresh CW Exchanger (C-EA1001A-
K).
f) Open 16” circulation line 16 CW 34045 AAA21
g) Isolate the chemical dosing pot.
(3) Confirm that safety devices (Breather) on the Buffer Tank is operational.
For flushing of the Fresh Cooling Water System, huge amount of water
may be discharged from the tank. Therefore 24” M/H shall be kept
opened to avoid the overpressure and vacuum of the tank. If the flushing
is completed, M/H can be closed.
(4) Confirm that the chemicals are loaded to the dosing pod.
Chemical for corrosion inhibitor can be mixed by using Covered Drain

Sump (C-AD1001) and Drain Fresh Water Pump (C-GA1009) as per
chemical vendor’s instruction.
OPERATION MANUAL
(5) Confirm that continuous nitrogen purge to the Buffer Tank is in service.
(6) Receive the Polished Water from Y&V. (or Emergency Back-up Water from PQV)
up to the, and fill-up the water up to ＸＸＸＸＸmm at LI2401.
During the water filling, check the leakage from the flange connection.
(7) Fill-up the water into the pump casing by opening the pump suction valves.
(8) Slightly open the pump discharge valve and fill up the pump discharge line by
gravity.
Do not allow the pump rotated by grabity flow.
(9) Confirm that no air inside the system at each high point vent.
(10) Start the Fresh Cooling Water Pump (C-GA1004A-F) from local switch.
(11) Gradually open the pump discharge valve and adjust the discharge pressure.
Do not continue the operation with small valve opening (less tank 20%
opening) of the butterfly valves to avoid the damage of the valves.
(12) Once the pump operation is stable, fill-up the Fresh Cooling Water System by
opening the isolation valves from the pump discharge side. Vent the air from all
the high point, start the circulation operation through the complex. Close the 16”
circulation valve fully.
If the circulating water flushing is completed and the turbidity of

circulation water becomes specified value, pass the cooling water
through the all coolers.
(13) Start other pumps and increase the flow to the normal operating point
- Total normal flow: 11590 Ton/hr

OPERATION MANUAL
- Each pump: 2318 Ton/hr
(14) Adjust the normal flow rate to each unit as follows;
a) Ancillary Plant: 489 Ton/hr (FT2401)

b) Ammonia Plant: 4806 Ton/hr (FT2402)
c) Urea Plant: 6295 Ton/hr (FIQ733)
Adjust the flow rate, temperature, etc. at start-up period of the complex.
4.4.1 Instrument Air Compressor for Bagging Unit
The start-up steps below should be read in conjunction with the figure of control panel
shown hereafter.
(1) Switch the power on and check (6) “Voltage on LED” lights up.
(2) Press (1) “Start Button”. The compressor will start running with unloading condition.
(3) Check (8) “automatic operation LED” lights up.
(4) After approximate.25 seconds, the compressor will be loaded automatically.
(5) Regulate the Cooling Water flow rate with compressor load.
Control panel
OPERATION MANUAL
4.4.2 Instrument Air Dryer for Bagging Unit
(1) Close the air supply valve to the Dew Point sensor.
(2) Isolate the air supply from the air compressor by closing the valve on 3 PA 35401
ABA2.
(3) Start the air compressor, and wait for pressuring.
(4) Slowly open the inlet valve shown (2) above, and pressurize the dryer unit.
(5) Check the leakage and repair if necessary.
(6) Supply the power to the dryer.
(7) Switch the dryer on by pushing button
(8) Check the dryer operation with the dryer outlet valve closed.
To Start-up the dryer first time or after a long term shutdown, keep
running for several hours before opening the outlet valves.
(9) Gradually open the dryer outlet valve.

OPERATION MANUAL
(10) Open the air supply to the Dew Point sensor.

OPERATION MANUAL
SECTION 5. NORMAL OPERATION
5.1 General
5.1.1 Alarm Set Point
Refer to the table 5.1 “Alarm Set Point List for Ancillary Facility”
5.1.2 Interlock Logic
Refer to the Preliminary Interlock Description for Ancillary Facility

(Doc. No.; MTI-U-00-T2085)
5.2.1 BOG Compressor Unit (U-GC1101)
(1) Check the bearing temperature, vibration, noise, etc.
(2) Check the proper oil level in the reservoir.
(3) Monitor the pressure, temperature in the Tank.
5.2.2 Ammonia Transfer Pump (U-GA1101 & 1102)
(2) Check if the suction filter is clogged by suction pressure gauge.
(3) Monitor the level, pressure, temperature in the Tank.
(4) Frequently, switch the running pump and stand-by pump to check the healthy.
5.3.1 Fresh Cooling Water Pump (C-GA1004A-F)

OPERATION MANUAL
(2) Check if the suction filter is clogged by PDG-2401A-F.
(3) Monitor the level, pressure, temperature in the Tank.
(4) Frequently, switch the running pump and stand-by pump to check the healthy.
5.4.1 Instrument Air Compressor for Bagging Unit
The steps below during operation should be read in conjunction with the figure of
control panel shown in section 4.4.1.
5.4.2 Instrument Air Dryer for Bagging Unit
As regular intervals, check the PDP temperature. If the PDP temperature is too high,
let the dryer regenerate by closing the outlet valve.
OPERATION MANUAL
SECTION 6. NORMAL SHUTDOWN
6.1.1 BOG Compressor
(1) Stop the drive unit
(2) After the compressor stops, the control system should be operated to move the
slide valve into the off load position, unless the control system does this
automatically.
(3) After the compressor stops rotating, stop the lubricating pump motor.
If the compressor is shut down for the extended period, the suction and
discharge valves should be closed and the lubricating oil pump should
be run approximately 10 minutes per week to distribute oil through the
unit. Turn the compressor shaft a few times every week by hand.
Maintain the cooling water flow to the exchanger to prevent frost
damage.
If the compressor is shut down for more than 3 months, follow same
procedure above. In addition, the compressor unit should be run for one
hour every three months.
6.1.2 Ammonia Transfer Pump
(1) Slowly close the control valve at downstream on the pump discharge line, and
divert the flow to the Ammonia Storage Tank with minimum flow rate.
(2) Stop the pump from the local switch
(3) If the pump is left unused, fully close the pump suction valve, discharge valve and
minimum flow line valve, then release the gas from the pump.
(4) Stop cooling, flushing and sealing. Do not stop the quenching line of the pump
operated at low temperature (Nitrogen gas quenching)
OPERATION MANUAL
6.2.1 Shutdown of the Fresh Cooling Water Pump (C-GA1004A-F)
The cooling water system can be shutdown only when all the plant has no users.
(1) Gradually close the pump discharge valve to be stopped. When the discharge
valve is almost closed, stop the pump from the local switch.
(2) Close the pump suction valve.
(3) Repeat the same steps (1) and (2), and stop other pumps.
(3) While reducing the total flow rate, gradually close the 48” return valve to the Fresh
CW Buffer Storage Tank (U-FB1001).
Some users in urea plant are located at higher elevation than 48” return
nozzle on the Fresh CW Buffer Storage Tank (U-FB1001). Therefore, 48”
return valve should be closed when the cooling water system is
shutdown to avoid a vacuum on equipment at any time, unless it is
designed to with stand the stresses set up under such conditions.
(4) If the draining is required in the main header, drain the water to the Covered Drain
Sump (C-AD1001), and return the drained water to the Buffer Tank.
(5) Do not stop the continuous nitrogen purge to the Buffer Tank.
6.3.1 Back-up System of Instrument Air
The instrument air is consumed for positioners and control valves regardless use or
non-use. Even if the users in Bagging Unit are shutdown, the required quantity of
instrument air should not be reduced as much as possible.
OPERATION MANUAL
Therefore, communicate with Ancillary plant to prepare the back-up Instrument air
from the ancillary facility through the back-up line (3” IA 34539 ABX2) before the IA
Compressor for Bagging Unit is shutdown.
In addition, back-up nitrogen can be used through the back-up line (3” N 35505 ANA2)
in case that no instrument air is available.
6.3.2 Shutdown of Instrument Air System for Bagging Unit
(1) Shutdown the Instrument Air Dryer for Bagging Unit (C-FF1009A/B) and isolate the
Dryer Unit from the instrument air header.
(2) Simultaneously connect the back-up instrument air (or nitrogen) from the ancillary
facility by opening 3” isolation valves.
(3) Stop the Instrument Air Compressors for Bagging Unit (C-GB-1002).
(4) Depressurize the Instrument Air Compressor for Bagging Unit (C-GB-1002) and
Instrument Air Dryer for Bagging Unit (C-FF1009A/B), if necessary.
OPERATION MANUAL
SECTION 7. EMERGENCY SHUT-DOWN
7.1 General
Following are some of the general consideration which should be considered during Emergency
shutdown period.
Operators shall recognize an emergency situation and to take appropriate actions immediately.
For assuring best preventive and preservation type of operative actions during emergency or
shutdown situations, the prompt knowledge of plant equipment, instrumentation, controls and
interrelationships among the various sections of the plant is very important. The actions to be
taken for the most common emergencies should be studied in advance, by all personnel
associated with the Systems, so that they can be implemented without delay when necessary.
This section describes the actions to be taken for the Ammonia Storage System, Cooling Water
System and Instrument Air System for Bagging Unit.
7.2 Description of the Failure
7.2.1 Electric Power Failure
Main Electric Power supply for the facilities is provided from the existing Main Sub-
station. In case of power failure all plants are taken into emergency shutdown
operation.
Emergency power is supplied from Emergency Diesel Engine Generators (DEG) in a

complex. DEG will supply power to the selected items for the safe plant shutdown. All
the plants should be restarted smoothly after main power supply is recovered.
Major instrumentation power is supplied from uninterrupted power supply (UPS) unit.
UPS can supply power continuously for a few hours after power failure and UPS can
be charged again after power supply is re-established.
Even if instrument power fails, fail safe position of valves and instrumentation can
keep facility safe.
OPERATION MANUAL
Service Action in DCS Action at Field

Ammonia Storage (a) If the pressure accumulates in the (a) If the pressure accumulates in the
tank, operate PV6000 from DCS. to tank, operate PV6000 by hand wheel to
release the pressure. release the pressure. (If UPS power is
no available.)
Cooling Water N/A Close all the isolation valves, such as

pumps, heat exchanger, tanks, as
required and prepare for re-starting.
IA System N/A If required, supply back-up Instrument Air

(for Bagging) or Nitrogen by opening the manual
isolation valve.
7.2.2 Steam Failure
Steam failure is most probably caused by the failure of Boiler Unit.
If the steam is not recovered, operator shall take the following action as necessary.

Ammonia Storage (a) Close XV-6002 and XV-6003. (a) Stop the Ammonia Transfer pump (U-
GA1101) if shutdown become long
period.
Cooling Water N/A N/A
IA System N/A N/A

(for Bagging)
7.2.3 Cooling Water Failure
Cooling water failure is most probably caused by the following situation.
- Power Failure
- Mechanical Failure
First, the operator shall identify the cause of failure and correct it. Otherwise, operator
shall take the following action as necessary.

Ammonia Storage (a) BOG Compressor (U-GC1101) is
tripped.
OPERATION MANUAL
(c) Control the pressure of Ammonia

Storage Tank (U-FB1101) by adjusting
PV-6000.
Cooling Water N/A Start the Stand-by pump, as necessary.
IA System N/A Supply back-up Instrument Air or Nitrogen

(for Bagging) by opening the manual isolation valve.
7.2.4 Instrument Air Failure
Instrument Air Failure will be triggered by the following situation.
- Power Failure
- Cooling Water Failure
- Mechanical Failure
In principle, instrument air is used to energize controllers and actuators in a manner

that loss of instrument air results in de-energization of actuators and controller. Even if
instrument air fails, fail safe position of valves and instrumentation can keep facility
safe.
First, the operator shall identify the cause of failure and correct it. Otherwise, operator
shall take the following action as necessary.

Ammonia Storage (a) Ammonia Storage Tank (C-FB1101) (a) If the pressure accumulates in the
will be isolated. tank, operate PV6000 by hand wheel to
release the pressure.
- HV6000 Close (NH3 Tank Feed)
- XV6000 Close (Tank Outlet)
- XV6001 Close (Tank Outlet)
- PV6000 Close (Vent gas to Flare)
- FV6001 Open (Pump min. flow)
- FV6002 Open (Pump min. flow)
- FV6003 Close (Pump discharge)
- XV6002 Close (NH3 heater Inlet)
- XV6003 Close (NH3 heater outlet)
- XV6004 Close (Steam inlet)
- XV6005 Close (Condensate outlet)
(b) Ammonia Transfer Pump (U-GA1101

& U-GA1102) will be tripped by
interlock sequence, if the suction MOV
is closed
(c) BOG Compressor will shutdown.
Cooling Water No Action No action

OPERATION MANUAL
IA System No action Supply back-up Instrument Air or Nitrogen

(for Bagging) from the network by opening the manual
isolation valve.
7.2.5 Natural Gas Failure
Natural Gas supply for the Ammonia Flare Pilot is provided from the existing Plant. In
case of Natural Gas failure, the following action should be taken.

Ammonia Storage No action Use Back-up LPG Cylinder for the flare pilot.
Cooling Water No Action No action
IA System No action No action

(for Bagging)
OPERATION MANUAL
SECTION 8. SAFETY
Refer to the Operation Manual for Urea Plant (MTI-U-50-T6932), Section 9 “Safety” of the
manual.
OPERATION MANUAL
ATTACHMENT
ATTACHMENT-4.4.2-1: Purging with Nitrogen (Piping)
ATTACHMENT-4.4.2-2: Purging with Nitrogen (Tank)
ATTACHMENT-4.4.2-3: Purging with NH3 Vapor (Piping)
ATTACHMENT-4.4.2-3: Purging with NH3 Vapor (Tank)
ATTACHMENT-4.4.2-5: Cooling Down with Liquid NH3
ATTACHMENT-4.4.2-6: Liquid NH3 Filling

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PEQUIVEN MORON FERTILIZER PROJECT

PROJECT DOCUMENT NO.MTI-U-00-T6933

1,800 MTPD AMMONIA / 2,200 MTPD UREA PLANT

2 Feb./28/’13 REVISED T.M S.N K.H K.H

REV DATE PURPOSE OF ISSUE PREPARED CHECKED APPROVED AUTHORIZED

Rev. Date Description of Change

0 Jun./30/’12 INITIAL ISSUE

1 Oct./15/’12 Revised (Modified NH3 Storage Gas Purge Procedure)

SECTION 1. INTRODUCTION ........................................................................................................................................ 4

- Ammonia Storage System

1.2 Operating Cautions

(4) Fully understand Vendor’s operating instructions for the equipment.

SECTION 2. PROCESS DESCRIPTION

2.1 Ammonia Storage System

Operating Variable and Control

(1) Temperature Control of Ammonia Feed to Urea Plant

(2) Pressure Control in Ammonia Storage Tank

2.2 Fresh Cooling Water System

2.3 Instrument Air System for Bagging Unit

Operating Variable and Control

SECTION 3. PREPARATION FOR THE INITIAL START-UP

3.2 Line Check

(1) Before Test and Flushing (Conformity check at construction phase)

(a) "Note" written on P&I Flow Diagram.

(2) Before Start-up

(a) Existence of steam tracing.

(g) Removing of temporary supports.

(3) After Start-up

(a) Movement of piping expansion.

3.3 Line Cleaning

Refer to the following procedures;

- Manual Cleaning Plan for Ancillary Scope (Doc. No. CCFM-U-00-TP381)

3.4 Electrical Equipment

3.5 Vessel Inspection

Inside of equipment such as vessel should be thoroughly checked visually.

3.6 Rotating Equipment Run-in Test

3.7 Tightness Test

Refer to the Tightness Test Plan for Ancillary Scope (CCFM-U-00-TP383).

4.2 Ammonia Storage System

4.2.1 Commissioning of the Ammonia Storage Flare Stack (C-BJ1101)

(4) Turn the Power On/Off switch to “On” position.

4.2.2 Initial Purging and Cooling Down

This instruction shall be read in conjunction with Vendor’s operating

- Purge with nitrogen vapor

Do not use any mercury devices around the tank.

4.2.2.1 Pre-Purge Check List

(1) Safety personnel should be aware and present at site

(9) A sample point shall be prepared at each location for venting.

(11) Arrange the meeting for Schedule and Emergency communication

(12) Arrange the continuous nitrogen supply.

4.2.2.2 Purge with Nitrogen Vapor

If the purpose of purging is preservation, oxygen content must be

4.2.2.3 Purge with Ammonia vapor

(1) The following is a brief listing for purging end point.

(1) Input the following set point

PV-6000 (Pressure control at FB-1101): 0.07 kg/cm2g

4.2.2.4 Cool down with liquid ammonia