ACTIVITY SCHEDULE CHART FOR RFCL, Ramagundam SD-Feb'24

Process Engineering Dept. (TS) Date: 09.02.24

Day 1 2 3 4 5 6 7 8 9 10 11 12 13
Date Day 1 Day 2 Day 3 Day 4 Day 5 Day 6 Day 7 Day 8 Day 9 Day 10 Day 11 Day 12 Day 13
6am 10am 2pm 6pm 10pm 2am 6am 10am 2pm 6pm 10pm 2am 6am 10am 2pm 6pm 10pm 2am 6am 10am 2pm 6pm 10pm 2am 6am 10am 2pm 6pm 10pm 2am 6am 10am 2pm 6pm 10pm 2am 6am 10am 2pm 6pm 10pm 2am 6am 10am 2pm 6pm 10pm 2am 6am 10am 2pm 6pm 10pm 2am 6am 10am 2pm 6pm 10pm 2am 6am 10am 2pm 6pm 10pm 2am 6am 10am 2pm 6pm 10pm 2am 6am 10am 2pm 6pm 10pm 2am
Hours 0 4 8 12 16 20 24 28 32 36 40 44 36 40 44 48 52 56 60 64 68 72 76 80 108 112 116 120 124 128 132 136 140 144 148 152 156 160 164 168 172 176 180 184 188 192 196 200 204 208 212 216 220 224 228 232 236 240 244 248 252 256 260 264 268 272 276 280 284 288 292 296 300 304 308 312 316 320

Ammonia Plant Start-up Urea Plant Start-up

Day 9, 6:00 to Day 12, 08:00 (66 hrs.) Day 12, 08:00 am to Day 12, 10:00 pm (14 hrs.)
S.No Description
Load Reduct & IS-1 Purging & Force Cooling
HP Steam Super heater coil (E-203-1) manifold leakage rectification (162 hrs)
(06:30 -17:02 pm) (17:10 pm - 08:00 pm) Starts at '2 pm Reformer Feed In at 02 am)
Insulation
1 Pri. Reformer Marking /Cutting Grinding for Edge Preparation Preheating/Buttering PWHT Elbow fit up Preheating, Welding of Elbow & NDT Purging Reformer Heating
Removal
10.5 27 7 24 24 36 24 14 40 12 24

HTER Feed In ( 03 am)

2 HTER

(Purging & Force Cooling)

Process Air Line up ( 7 am)
3 Sec. Reformer Air Inlet NRV gasket replacement

(Purging & Force Cooling)

LTG & LTS Heating at 08 pm) LT G & LTS line up ( 10 am)
4 CO Shift Section Heating
14 3
(Purging)
CO2 removal section CO2 Availabilty at 02 pm

5 CO2 Removal Section FV3032-1 plug replcement CO2 Absorber Inlet PSV-3092-2 & 3
8 4

Methanator line up at 08 pm
6 Methanator
6

IS-7 Back end start up

(4:30 pm) 08 am (Ammonia Production at 08 am, Day 12)

7 Synthesis Section Syn gas line PSV replacement

(Stopped at 17:02 pm)

8 PAC

(Stopped at 04:30 pm)

9 ARC

(Stopped at 04:30 pm) SGC Start-up at 08 pm

10 SGC

Feed Cut Draining and Flushing ( 46 Hrs) Urea production at 10 pm

07:00 am) (07:00 am to 05:00 am) Heating CO2 rolling & Ammoniation

11 Urea Plant / Bagging CO2 Compressor Dry Gas seal replacement

8 8 6
HRSG & GTG Stop UB STOP Feed-in at 4 pm
(05:15 pm to 05:40 pm) (05:00 am) UB start up at 06:00 am GTG & HRSG start-up at 09:00 pm
12 GTG/HRSG/UB UB leak rectification
8 4

Depressurisation Steam charging at 02:00 pm

13 HP Steam Header
6

Depressurisation Steam charging at 02:00 pm

14 MP Steam Header
6

Depressurisation Steam charging at 02:00 pm

15 LP Steam Header
6
Total Ammonia Production Loss 255 Hours (10.63 Days ) …. Production stopped at Day 1 at 1700 hrs and production anticipated on Day 12 at 08:00hrs.
Total Urea Production Loss 279 Hours (11.63 Days)…. Production stopped at Day 1 at 07:00 hrs and production anticipated on Day 12 , at 22:00 hrs.