Low Vacuum

Problem in 2nd V- 4108

Stage
Separator L- 4153

V-4108
By:
Waqqar Ahmad
App. Engr. Urea II
Contents
 Introduction
 Problem Background
 Effect on Product Quality
 Trouble Shooting
 Operational & Maintenance Activities
 Recommendations
 Q&A
Process Description
P = 0.33Kg/cm2a
P= 0.03Kg/cm2a
V-4107
E-13
1st vacuum Booster ejector
Separator V-4108 L-4153
2nd vacuum
Separator
LS
E-4114 E-4115 LS
1st vacuum 2nd vacuum
E-7
concentrator concentrator
LC
LC
Urea ~ 95%

LS

Urea melt to
L-4151 Vapors from PT
To T-4101 Pre concentrator L-4154
LS LS Urea ~ 99.8%

Urea soln from CWS

Vacuum preconcentrator CHW
Urea~ 85 %
E-4151
E-4153
L-4156
CWR
CWS
CWR
L-4152 L-4155
LS LS
CWS
CWS E-4154
E-4152
CWR E-4155
CWR CWS
CWR

T-4102

To PCT
Problem Background

Parameter Operating Value

Normal Abnormal

Vacuum of 2nd Stage (Kg/cm2a) 0.04 0.08

LS Header Pressure (Kg/cm2) 3.7 3.4

LS induction to DSTK-4101 14 07
(ton/hr)

T-4102 Level (%) ~33 >93

Effect on Product Quality

 Normal moisture in product ~ 0.34%

 Moisture in the product increased to ~ 0.4%

 Occasionally it crossed dispatch limit 0.45% due

to increase in CWS temp.
 Interim Measures to Maintain
Product Quality

 Flushing of ejector & condensers was increased

 Optimization of LS to L-4153

T-4102 level was normalized
 Vacuum improved from 0.08 to 0.06 Kg/cm2a

 Plant load decreased occasionally from 113.5 to

110%
Trouble Shooting
Probable Causes
 Water ingress from the
process flushing points
 Tube leakage of E-4153
 Low efficiency of E-4153
Actions/Remarks
 All flushing points found
OK
 E-4153/T-4102
condensate samples
were normal
 Tube side ΔT of E-4153
was 6oC (Design2.4oC)
 Trouble Shooting (Cont..)
Probable Causes
 Biuret deposition in L-4153
suction line
 Ingress of non condensable
Actions/Remarks
 Condenser, ejector &
vapor Line flushing gave
no positive effect
 V-4108 top 3” flushing,
lumps falling observed
 T4102 level inc. & steam
flow to L4153 ruled out it
Trouble Shooting (Cont..)
Probable Causes Actions/Remarks
 E-4115 tube leakage  E-4115 tube dia is 3/8”,
increase in flow was ~7tph
 Mechanical failure of  Ejector performance test
booster ejector L-4153 was carried out
 Boroscopic examination,
no observation could be
found
Trouble Shooting (Cont..)
Probable Causes Actions/remarks
 Mechanical failure of  Temp. mapping of L- 4153
booster ejector L4153 gave clear picture
(Cont..)  Vacuum measurement of
ejector steam chest & E-
4153 vapor line
 Increase in steam flow was
corresponding in case of
nozzle detachment
Conclusion

“Low Vacuum of 2nd Stage Separator”

was due to mechanical failure of
Booster Ejector L-4153
 Operational & Maintenance
Activities
 Vacuum section was by-passed to hand-over
 Two nozzles found faulty
 One nozzle found dislodged exactly at 2’O clock
position & other tilted
 Threads of nozzles & motive chest were damaged
 All nozzles were fillet welded, faulty nozzles reinforced
with sleeves
Recommendations

 Booster ejector nozzles to be further

reinforced
 Inspection of booster ejector should be
ensured in every turnaround
 PMP for all ejectors should be developed
Thank You
Query?
Temperature Mapping
53oC 60-80oC

43oC 43oC

40oC
Sampling Results

NH3% CO2% Urea % Chromate

%

T-4102 6.04 1.8 0.9 Nil

E-4153 --- --- --- Nil

 L - 4153

Steam
E-4153

V-4108

E-4115

For Prilling From V-4107

Vacuum Section Bypassing
Pressure= 0.33Kg/cm2a

V-4107 Pressure= 0.03Kg/cm2a

E-13
1st vacuum Booster ejector
Separator L-4153
V-4108
2nd vacuum
Separator
E-4114 E-4115
1st vacuum 2nd vacuum
E-7
concentrator concentrator

Urea ~ 95%

LS

LW

From
P-4109 A/B Urea melt to
L-4151 Vapors from Prilling tower
To T-4101 Pre concentrator L-4154 Urea ~ 99.8%

Urea soln from CWS

Vacuum preconcentrator CHW
Urea~ 85 %
E-4151
E-4153
L-4156
CWR

CWS

CWR
L-4152 L-4155

CWS

CWS
E-4152 E-4154

CWR
E-4155
CWR CWS
CWR

T-4102
Process
Condensate
tank To PCT
L-4153 Nozzle Assembly before
Maintenance
L-4153 Nozzle Assembly after
Maintenance
Ejector
Suction Chamber
Diffuser
Nozzle
Motive
Fluid

Low Pressure
Area

Pressure

Velocity

Length
Booster Ejector Data

L-4153 Data Design Actual

Motive steam Kg/hr 6657 7790
No. of nozzles 07 07
Flow through one nozzle Kg/hr 951 1113
Detachment of one nozzle Kg/hr -- ~7531
Total flow of motive steam Kg/hr -- 15321