Class Room Training for New Field Operator

Operation Department
PT Kaltim Parna Industri
Januari 2008
Compressor Sketch Drawing
Stream 1 Ammonia From V-0503
 NH3 100 mol%
 Flow (dry basis) 399.94 kg-mol/h
 Pressure 1.03 kg/cm2A
 Temperature -32.8 0C
Stream 2 Ammonia From E-0508
 NH3 100 mol%
 Flow (dry basis) 1,611.10 kg-mol/h
 Pressure 3.13 kg/cm2A
 Temperature -9 0C
Stream 3 Ammonia From E-0511
 NH3 100 mol%
 Flow (dry basis) 105.87 kg-mol/h
 Pressure 3.13 kg/cm2A
 Temperature -9 0C
Stream 4 Ammonia From E-0509
 NH3 100 mol%
 Flow (dry basis) 1,964.65 kg-mol/h
 Pressure 8.33 kg/cm2A
 Temperature 18.5 0C
Stream 5 Ammonia To E-0510
 NH3 100 mol%
 Flow (dry basis) 4,081.56 kg-mol/h
 Pressure 16.83 kg/cm2A
 Temperature 103.9 0C
Compressor Feature
Centrifugal Compressor Type – 3 stages
 Casing
 Rotor
 Impeller
 Diaphragm
 Bearing
 Sealing Device
Design Data – 1 Stage st

 Flow rate 7,762 kg/hr

 Suction Pressure 1.03 kg/cm2A
 Suction Temperature -32.8 0C
 Discharge Pressure 2.93 kg/cm2A
 Discharge Temperature 53.1 0C
 Polytropic Head 14,349 m
 Polytropic Efficiency 79.7 %
 Brake Horsepower 359 kW
Design Data – 2 Stage nd

 Flow rate 16,435 kg/hr

 Suction Pressure 2.93 kg/cm2A
 Suction Temperature 4.1 0C
 Discharge Pressure 8.08 kg/cm2A
 Discharge Temperature 92.3 0C
 Polytropic Head 15,678 m
 Polytropic Efficiency 83.0 %
 Brake Horsepower 1,881 kW
Design Data – 3 Stage rd

 Flow rate 12,598 kg/hr

 Suction Pressure 7.83 kg/cm2A
 Suction Temperature 32.2 0C
 Discharge Pressure 16.83 kg/cm2A
 Discharge Temperature 103.9 0C
 Polytropic Head 12,253 m
 Polytropic Efficiency 83.0 %
 Brake Horsepower 2,844 kW
Design Data – General
 Intercooler Outlet 45 0C
Temperature
 Inter-stage Pressure Drop 0 kg/cm2
1st discharge – 2nd suction 0.25 kg/cm2
2nd discharge – 3rd suction

1st discharge – 2nd suction

No intercooler

Total Brake Horse Power

5,084 kW
Turbine Sketch Drawing
Turbine Data – General
 Speed 9,960 rpm
 Maximum 10,458 rpm
Continuous Speed
 1st Critical
5,200 rpm
Turbine Data – Normal Condition
 Power 5,084 kW
 Speed 9,960
INLET
 Flow 97,390 kg/hr
 Pressure 110 kg/cm2G
 Temperature 510 0C
EXHAUST
 Pressure 43 kg/cm2G
 Temperature 393 0C
 Enthalpy 763 kcal/kg
Turbine Data – Rated Condition
 Power 5,592 kW
 Speed 9,960
INLET
 Flow 105,363 kg/hr
 Pressure 110 kg/cm2G
 Temperature 510 0C
EXHAUST
 Pressure 43 kg/cm2G
 Temperature 393 0C
 Enthalpy 763 kcal/kg
Equipment – TS/K-0441
 TS-0441 Steam Turbine for K-0441
 K-0441 Ammonia Compressor
 E-0441 Ammonia Intercooler
 V-0442 Ammonia Compressor 2nd Stage
KO Drum
 V-0443 Ammonia Compressor 3rd Stage
KO Drum
Equipment – Lube Oil System
 K-0431-T1 Lube Oil Reservoir
 K-0431-P1A/B Lube Oil Pump
 K-0431-TS1 Turbine for Lube Oil Pump A
 K-0431-E1A/B Lube Oil Cooler
 K-0431-F1A/B Lube Oil Filter
 K-0431-T2 Lube Oil Head Tank
Equipment – Auxiliary
 K-0441-X1 Turning Motor
 TS-0441-X1 Control Oil Accumulator
Lube Oil System
 Lube oil supply pressure 1.4 kg/cm2g
 Control oil supply pressure 9 kg/cm2g
 Control oil supply oil to governor valve.
 Auto-start system for stand-by lube oil
pump when lube oil pressure low 0.84
kg/cm2g
Dry Gas Seal
Seal Gas Supply
 Normal Operation : Ammonia Gas
 Start-up : Nitrogen
 Tandem seal, Twin seal gas filter, Differential pressure
control & flow control.
Separation Gas Supply
 Nitrogen gas should be supplied before oil circulation.
 Twin separation gas filter, pressure control valve.
Primary Leak Off
 Pressure relief device: rupture disk
Secondary Leak Off
Speed Controller
 Turbine speed is controlled by pressure
controller 1st suction PICA-0516-1 or
PICA-0507.
DCS Graphic Display
Process Flow Diagram
Refrigeration System
 Function :
Ammonia condensation
Cool purge gas, inert gas & let-down gas

 Main Equipment : Chiller 5 ea, Ammonia

Compressor, Ammonia Condenser &
Expansion Valve.
Refrigeration System
Equipment – Refrigeration
 E-0510 Ammonia Condenser
 E-0511 Inert Gas Chiller
 V-0505 Inert Gas Separator
 V-0504 Ammonia Accumulator
 E-0506 1st Ammonia Chiller
 E-0508 2nd Ammonia Chiller
 E-0509 Make-up Chiller
 E-0514 Purge Gas Chiller
 V-0503 Flash Vessel
 P-0501A/B Ammonia Product Pump
Chiller
 1st Ammonia Chiller (E–0506) & Make-up
Chiller (E–0509) : temperature 18,5 oC
(pressure 7,3 kg/cm2g)  3rd Stage
Ammonia Compressor.
 2nd Ammonia Chiller (E–0508), Inert Gas
Chiller (E–0511) & Purge Gas Chiller (E–
0514) : temperature 9 oC (pressure 2,1
kg/cm2g)  2nd Stage Ammonia
Compressor.
Ammonia Condenser
 To condense ammonia gas from Ammonia
Compressor
 Pressure 15.6 kg/cm2g
 Temperature 38.5 oC
Ammonia Product
 Flow 62,500 kg/hr
 Pressure 7.8 kg/cm2g (outlet P-0501A/B)
 Temperature -32.6 0C
Interlock System (IS-44) - Causes
 Manual trip signal from control panel
 Trip secondary reformer, IS-22
 Trip flash vessel, IS-54
 High 2nd separator (V-0442) level, LSHH-0482
 High 2nd discharge temperature, TSHH-0484
 High 3rd discharge temperature, TSHH-0487
 High 3rd separator (V-0443) level, LSHH-0484
 Trip at refrigeration compressor unit.
 Trip synthesis gas compressor, IS-43
Interlock System (IS-44) - Effect
 Trip synthesis gas compressor, IS-43.
 Action of PV-1102 let-down valve from SH to
SM line. Valve will full open at mode “manual”
during 3 seconds, then valve will open at
opening as calculated function during 2 nd 3
seconds period and then “auto” mode.
 Trip refrigeration compressor unit (TTV close).
 Controller TIC-0485, LICA-0501, LICA-0502,
LICA-0503, LICA-0504 and LICA-0505 will be
change to “manual” position with MV = 0. (TV-
0485, LV-0501, LV-0502, LV-0503, LV-0504 &
LV-0505 will close).
Trip System of Compressor Unit
 Lube oil supply header pressure low-low, 0.56 kg/cm2g
 LP comp axial position high-high, ± 0.75 mm
 Turbine axial position high-high, ± 0.75 mm
 HP comp axial position high-high, ± 0.75 mm
 Turbine radial vibration high-high, ± 80 µm
IS-54 Flash Vessel
 Causes : high level V-0503, LS-0515
 Effect : stop ammonia to V-0503 (LV-0508
close) and K-0441 trip
 Maintain level V-0503
IS-55 Stop P-0501A/B
 Causes : low level V-0503, LS-0511
 Effect : stop ammonia product, LV-0510
close
 Maintain level V-0503