AMMONIA(NH3) STORAGE

SYSTEM PACKAGE

PRESENTATION BY
S. SILAMBU SELVA SIDDHARTHAN
ELECTRICAL
Ammonia
Manufacturing
process
(2200MTPD) in
Fertilizer &
Chemical Plant
What is the reforming process?
Processing technique by
which the molecular
structure of a hydrocarbon is
rearranged to alter its
properties.
Primary Reforming
Methane (CH4) + Steam (H2O)
Secondary Reforming
Air (O2 & N2 )
About Haber Bosch
Process?
The Haber Process is used
in the manufacturing of
ammonia from nitrogen and
hydrogen. The process
combines nitrogen from the
air with hydrogen derived
mainly from natural gas
(methane) into ammonia.
Overall plant Associated Units & Facilities
Ammonia (NH3) Urea Plant
Natural Gas(CH4) Ammonia (NH3)
Storage Tanks & (3850MTPD) &
receiving station Unit Associated facilities Prilling Tower

Bagging Unit & Common HP Captive Power

LP Flare
Wagon Loading Flare Plant

220kV Main Control

Switchyard Room
Cont.-List of Associated Units

Cooling Tower & Water Treatment

Air Separation Air Compressor
Chemical Dosing Steam Plant Plant, DM Plant,
Unit (O2 & N2 ) Unit
System Water Reservoir

Electrical
Fire Station Control Room Laboratory Warehouse
Substation

Emergency Admin and

Weigh Bridge Plant Main Entry
Workshop Medical & First Technical
Unit & Exit Gate
Aid Buildings
Cryogenic Double
Wall Storage
Tanks &
Associated
Facilities Basic
Concept
Liquid Ammonia (NH3) Parameters

Temperature: -33Deg C

Storage Liquid Pressure: 200-

700mmWC ( 0.02 to 0.07Kg/CM2)

Ammonia Purity: 99.75%,

0.25% Moisture, 3ppm (Oil)

Ammonia Density: 0.73 kg/m3

MAJOR SYSTEM IN
AMMONIA STORAGE
SYSTEM PACKAGE

• 1. DOUBLE WALL STORAGE TANKS (2x10000MT)

• 2. LP FLARE & FLAME FRONT GENERATOR SKID
• 3. BOG COMPRESSOR & REFRIGERATION
SYSTEM
• 4. AMMONIA TRANSFER PUMPS
• 5. LOADING & UNLOADING ARM STATION
• 6. FLASH VESSEL
• 7. KOD
Sub Systems

• Civil & Structural

• Mechanical
• Piping
• Electrical
• Instrumentation
• Insulation
• Painting
CIVIL
• Storage Tanks Foundation
• Base Slab
• Dyke Wall
• Column Foundation
• Pipe racks (Structure)
• Roads
• Buildings
• Storm Warm Drain
• OWS pit
• Equipment Foundations
SAMPLE PICTURE OF
CRYOGENIC STORAGE
TANK(LNG)
CONSTRUCTION PHASE

• Tanks have an inner

diameter of approximately
80m and an inner height of
37m (49.5m total overall
height of the structure). The
outer containment walls are
800 mm thick,
posttensioned vertically and
horizontally with the
cryogenically proven
• Approximately 90,000m³ of
concrete, 30,000 tonnes of
rebar and post-tensioning
steel shall be designed to
construct such type of Tanks
Types of subsystem-Mechanical (Static)

Cryogenic Double Wall

Flash Vessels Ammonia Condenser Ammonia Receiver
storage Tanks

Loading & Unloading

Economizer Knock Out Drum LP Flare
Arm, Vapour Arm

In general ( Vertical
Pressure Relief Valve Column, Exchanger,
and Vacuum Relief Pressure Vessel,CO2
Valve Adsorber, Intercoolers,
etc)
 Boil of Gas Compressor (Twin Screw Compressor)
Types of subsystem- BOG Compressor Lube Oil Auxiliary Pumps
Mechanical BOG Compressor Seal Oil Auxiliary Pumps

(Rotating) Ammonia Transfer Pumps ( Vertical , Centrifugal Pump)

Motor Operated Valves
On/Off Valves, Control Valves
Sub System
Piping

Ammonia Run down

Line ( From Ammonia Storage Tank Cooldown Storage Tank Feed Line
Plant to Ammonia Line from Run Down Line
Storage)

Ammonia Vapour
Ammonia Transfer Ammonia Pump
balancing line from
Pump Suction line from Discharge Line to Urea
Storage Tanks to Knock
Storage Tanks Plant
Out Drum, LP Flare

Unloading of Ammonia Loading of Ammonia to

Vapour Return Arm
from Tankers to Flash Tankers from Pump
from Tankers
Vessel- Storage Tanks Discharge

Vapour Arm from

Compressor Discharge
to Tankers
Cont. Sub System
Piping
• OWS lines
• Utility Lines
• Fire Water Lines
 • 1. Nitrogen (For Purging)
• 2. Fuel Gas ( For LP Flare)
• 3.Cooling Water Supply & Return ( For Ammonia
Condenser, Compressor Lube oil & Seal oil intercoolers)
• 4.Instrument Air ( For Control Valves, On/Off Valves)

Plant Utilities • 5.Service Water (For Common)

• 6.Plant Air ( For Maintenance Purpose)
• 7.LP Steam ( During Pre commissioning & Commissioning)
• 8.Drinking Water ( For Safety Shower)
SUBSYSTEM
Painting & Insulation

Sand Blasting
Primer Coating
First coat painting
Final Coat painting
Insulation
Hot Insulation
Cold Insulation
SUB SYSTEM-ELECTRICAL

Substation Equipments
(Transformer, Busduct,
HV/LV Switchgears, DC
Switchyard Cathodic Protection System Diesel Generators
System, UPS System, Cable
Cellar Trays, Lighting Trf,
WDB, Panels, SCADA)

Driven Motors Electric Heater Cabling Cable Trays

Control Panels & Junction FA System ( Manual Call

PA System MOV
Boxes, LCS Point)

Plant Earthing & Lightning

Lighting System EOT
Protection System
SUBSYSTEM
INSTRUMENTATION
• FIELD ANALOG & DIGITAL INSTRUMENTS (PRESSURE, TEMPERATURE, LEVEL,
FLOW)
• CONTROL VALVES
• TANK FARM MANAGEMENT SYSTEM
• MACHINE MONITORING SYSTEM, LCP
• IMPULSE TUBING
• PLC/DCS
• UPS SYSTEM
• FIRE & GAS DETECTION
• VIBRATION SENSORS (CASING & AXIAL DISPLACEMENT FOR COMPRESSOR)
• CCTV
• PANELS & JB
• CABLES, CABLE TRAY, CABLE DUCT
• STATIC EQUIPMENT (LOW PRESSURE DOUBLE WALL
STORAGE TANKS)
Cryogenic
Storage Tanks
General
Arrangement
Sample Picture
STATIC EQUIPMENT (LOW PRESSURE DOUBLE
WALL STORAGE TANKS) STANDARD API-620
LIQUID AMMONIA RECEIVED FROM AMMONIA PLANT IS STORED IN
THE AMMONIA STORAGE TANK HAVING A NET / EFFECTIVE
CAPACITY TO STORE 2x10000 MT OF LIQUID AMMONIA EXCLUDING
VAPOR SPACE AND DEAD LEVEL OF PUMPS SUCTION.
THE STORAGE TANK IS DOUBLE WALLED, DOUBLE INTEGRITY TYPE,
ALSO KNOWN AS "CUP-INTANK". THE TANK CONSISTS OF CUP
INSIDE WITH OUTER SHELL INSULATED FROM OUTSIDE. THE
ANNULUS BETWEEN THE CUP AND OUTER TANK NORMALLY
CONSISTS OF AMMONIA VAPOR. THE ROOF IS BARE AND PAINTED
OUTSIDE. SUSPENDED DECK WITH INSULATION IS PROVIDED INSIDE
TANK. THE OUTER TANK SHELL IS DESIGNED FOR FULL STRENGTH TO
HOLD LIQUID AMMONIA AT (-)33°C FOR DOUBLE SAFETY.
THE OUTSIDE OF THE TANK IS INSULATED WITH RIGID
POLYURETHANE INSULATION FOAMED IN-SITU (PUF) AND COVERED
WITH ALUMINIUM CLADDING. THE BOTTOM HAS FOAM GLASS ,
WHICH IS A LOAD BEARING INSULATION. THE CUP IS COVERED
WITH SUSPENDED DECK WITH RESIN BONDED GLASS WOOL
INSULATION.
THE TANK IS EQUIPPED WITH TWO PILOT
OPERATED PRESSURE RELIEF VALVES AND TWO
VACUUM RELIEF VALVES TO SAFEGUARD THE
TANK AGAINST OVERPRESSURE OR VACUUM.
(ISOLATION VALVES ARE PROVIDED WITH
SUITABLE MECHANICAL INTERLOCK).
THE TANK RESTS ON ELEVATED FOUNDATION
SLAB SUPPORTED ON CONCRETE COLUMNS TO
PERMIT FREE AIR PASSAGE BELOW THE TANK AND
AVOID FREEZING BELOW GROUND.
THE TANK IS PROVIDED WITH A LADDER FOR
GOING INSIDE THE CUP. A STAIRCASE TOWER
WITH PLATFORM LEADING TO TANK TOP IS
PROVIDED FOR APPROACH TO THE NOZZLES
STATIC EQUIPMENT
(LOW PRESSURE
DOUBLE WALL
STORAGE TANKS)
• INNER TANK (LTCS)
• OUTER TANK (LTCS)
• DOME ROOF (LTCS)
• SUSPENDED DECK (ALUMINIUM)
• INSULATION IN BETWEEN INNER AND
OUTER TANK(BUFF)
• DECK INSULATION (WOOLEN GLASS )
• NOZZLES (INSTRUMENTS, PRV/VRV,
DOME ROOF VENT, NITROGEN
(N1&N2) FEED, VENT, COOLING
DOWN,PUMP SUCTION, VAPOUR
BALANCING )
STATIC EQUIPMENT
(LOW PRESSURE
DOUBLE WALL
STORAGE TANKS)
• FLASH VESSEL
• OPERATING PLATFORM
• INSTRUMENTS (COOLDOWN TEMPERATURE
SENSORS, INNER SHELL TEMPERATURE
SENSORS, LEVEL TRANSMITTER (RADAR &
SERVO),PRESSURE TRANSMITTER,
TEMPERATURE ELEMENT, FLARE CONTROL
VALVE, ANALOG INSTRUMENTS (PRESSURE &
TEMPERATURE TRANSMITTERS, FLOW
TRANSMITTER)
• SAFETY VALVES (PRESSURE RELIEF VALVE
(1500mmWC), VACCUM RELIEF VALVE
(-20mmWC)
STATIC EQUIPMENT
(LP FLARE)
START-UP FLARING
NITROGEN FREEING OF STORAGE TANKS
NITROGEN FREEING OF PROCESS PIPELINES
FLARING OF KOD & SEPARATOR GAS PRIOR TO COMPRESSOR START
AMMONIA TRANSFER PUMP STARTUP
EMERGENCY DEPRESSURISATION / BLOWDOWN
DURING NON-AVAILABILITY OF BOG COMPRESSOR
MANUAL VENTING
FINAL DEPRESSURISATION OF VESSEL PRIOR TO PURGING AND ENTRY
AUTOMODE VENTING THROUGH SET POINTS
FLARE CONTROL VALVE SET POINT SHALL BE 600MMWC OF TANK PRESSURE
STATIC EQUIPMENT
(LP FLARE)
A Flare System is an arrangement of piping
and specialized equipment that collects
hydrocarbon releases from relief valves,
blowdown valves, pressure control valves
and manual vents and disposes of them by
combustion at a remote and safe location
A flame front generator is a system in which
a gas/air mixture is introduced at ground
level and flows up a one-inch line to the
pilot burner. After filling this line with the
mixture it is ignited by a spark. The
resulting flame travels to the top of the
flare where the pilot burner is ignited.
ROTATING
EQUIPMENTS
(PUMPS)
To Transfer Ammonia from
Storage tanks to Urea Plant
Vertical Transfer pumps
envisaged.
The pumps can also transfer
liquid Ammonia from one tank to
another tank through Ammonia
run down line.
For Loading the Liquid Ammonia
to Road tankers through Transfer
pumps and Loading Arm system
ROTATING
EQUIPMENTS
(PUMPS)
PUMP DATA
Boil Off Gas Compressor & Refrigeration
system
Ammonia continuously evaporates, creating a gas called
boil-off gas (BOG).

BOG leads to an increase of the pressure in the tanks and

losses of ammonia through LP flare which could have an
impact to economic and safety problems.

To maintain a constant pressure inside the storage tanks

and to reduce losses over the ammonia supply chain the
ammonia gas is continuously compressed and
recondensed by a customized screw compressor skid and
Refrigeration skid where BOG is re-liquefied and sent back
to the tanks. The screw compressor skid has been
designed for operation in a hazardous zone.
Boil Off Gas Compressor & Refrigeration
system
• The ammonia vapour is compressed by a screw compressor vapour suction
through KOD (Knock Out Drum) to protect compressor from droplets of liquid.
• Discharge vapour from compressor transferred to condenser. Vapour ammonia
is liquefied through Cooling water in tube side.
• The liquid ammonia (+30 Deg C) is collected into a receiver vessel. From the
receiver, liquid ammonia temperature and pressure will be reduced through heat
exchanger ( Economizer). From Economizer outlet liquid Ammonia (-10Deg C)
will be further directed to Control valve (Globe type) to achieve the Liquid
Ammonia temperature (-30 to -33 Deg C) and send back towards the storage
tank.

To increase availability of the system the most important parts of the system are
redundant – compressor unit with oil circuits, oil pumps, oil filters, oil coolers,
ammonia condensers.

Inorder to minimize the pollution of process ammonia with the compressor oil
skid is equipped with specially designed efficient oil separator that guarantees
oil carry over not more then 5 ppm.
 • Unloading Arm: Ammonia from Road tankers will be unloaded and
LOADING, transferred to storage tanks through Flash vessel (Intermediate vessel to
connect both storage tanks)
UNLOADING, • Loading Arm: Ammonia from Storage tanks shall be pumped through
VAPOUR RETURN transfer pump and filling of Ammonia road tankers

ARM STATION • Vapour Return Arm: Taking vapour from Road tankers during Unloading and
Pressurize the road tanker during loading
CONSTRUCTION, PRECOMMISSIONING,
COMMISSIONING SEQUENCE FOR PIPING
1. SPOOL
FABRICATION &
2. FITUP 3. WELDING
PIPING SUPPORT
FABRICATION

5. HYDROTEST, DP 6. CARDBOARD
4. RADIOGRAPHY
TEST BLASTING

7. PIPELINE 8. INTEGRATED
ERECTION AS PER LEAK TESTING AND 9.INSULATION
ISO & P&ID NITROGEN PURING

11. LINE GASSING

10.STENCILING
UP
Thank You