ENGRO CHEMICAL PAKISTAN LTD

Plant-I Emergency Handling Smart Procedure

Prepared By : RdA Reviewed By : MdA/ MASd/CMA/UAf/KJ/LMM/MY/UFr/MUK Approved by : ARQ/ MAM

Engro fertilizer Ltd Daharki

Page 1

SCOPE: The e pro!ed"re are deve#op $o %"ide a opera$io& %ro"p $o $a'e i&i$ia# $ep i& fo##owi&% e(er%e&!ie ) a## o$her $ep wi## be $a'e& a per e(er%e&!y ha&d#i&% de$ai# pro!ed"re*

Ba i : F+L ,-./,0.1 para(e$er are $he ba i of $he e a!$io& $ep )

TABLE OF CONTENTS
F-2501 ID Fans Trippin !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!" !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!"
,*, $'230.- 45or$h 67 Fa& 8 $rippi&%******************************************************************************************9 ,*3 $'230.-A 4 o"$h 67 FA58 $rippi&%***************************************************************************************9 ,*9 MK230.-B 4M677L+ 67 FA58 TR6PP65:************************************************************************9

SECTION - ; SECTION 2 < SECTION - ,. SECTION - ,,

+230.0 TUB+ L+AKA:+* 65STRUM+5T A6R FA6LUR+! T= A9 power Fai#"re* T= B9 power Fai#"re

Engro fertilizer Ltd Daharki

Page 2

F-2501 ID FANS TRIPPING!

1!1 TK-250# $NORTH ID FAN % TRIPPING!
S# 1 2 3 4

ACTION STEPS
Open 30% HIC-114V in one step Close 30% HIC-1 !V in one step" F#ll Close HIC-10$V Open HIC-10!/10%V a&&ordin'l( to &ontrol F-2 01 dra)t *ed#&e )#el +&lose ,*C-111/113/1-!/1-%V. as per 100% FE/

Responsibility
F/E Boardman F/E Boardman F/E Boardman F/E Boardman F/E Boardman F/E Boardman F/E Boardman F/E Boardman F/E Boardman F/E Boardman

$ ! % 10

*ed#&e FE/ #p to 100% and &ontrol 0/1 ratio 2aintain ,I-114 a3o4e 13 0F *ed#&e pro&ess steam t5r# F*C-104/10 Open E-2 0! 1 'as side 3( pass to a4oid $0# steam 6SV pop" ,a7e BE load red#&tion steps"

1!2

TK-250#A $SO&TH ID FAN% TRIPPING!

S# 1 2 3 4

ACTION STEPS
Open 30% HIC-114V in one step Close 30% HIC-1 !V in one step" F#ll Close HIC-10!V Open HIC-10$ /10%V a&&ordin'l( to &ontrol F-2 01 dra)t *ed#&e )#el +&lose ,*C-111/113/1-!/1-%V. as per 100% FE/ *ed#&e FE/ #p to 100% and &ontrol 0/1 ratio 2aintain ,I-114 a3o4e 13 0F *ed#&e pro&ess steam t5r# F*C-104/10 Open E-2 0! 1 'as side 3( pass to a4oid $0# steam 6SV pop" ,a7e BE load red#&tion steps"

Responsibility
F/E Boardman F/E Boardman F/E Boardman F/E Boardman

$ ! % 10

F/E Boardman F/E Boardman F/E Boardman F/E Boardman B/E Boardman

1!"

MK-250#' $MIDDLE ID FAN% TRIPPING! Page 3

Engro fertilizer Ltd Daharki

S# 1 2 3 4

ACTION STEPS
Open 0% HIC-114 V" Close 0% HIC-1 !V Close ,*C 111/113/1-!/1-% as per FE/ %0%" F#ll Open HIC-10$/10! F#ll Close HIC-10% V

*esponsi3ilit( F/E Boardman

F/E Boardman F/E Boardman F/E Boardman

$ ! % 10 11 12

*ed#&e FE/ to %0%" *ed#&e pro&ess air to &ontrol 01 ration at 1"3 t5r# 6*C33 8 F*C-11! *ed#&e pro&ess steam t5r# F*C-104/10 to &ontrol S0 ratio at 3"%/3"! F#ll open 3(pass o) E-2 0!1 ot5er9ise 6SV o) E-2 0! 1 9ill pop *ed#&e Flo9 o) F*C-12 /124 *ed#&e :-2 02 Speed; in&rease p#r'e )lo9 ; open anti s#r'e to &ontrol s#&tion press#re *ed#&e 6*C-1 2 set point 200#

F/E Boardman F/E Boardman F/E Boardman F/E Boardman F/E Boardman B/E Boardman B/E Boardman

SECTION ( 2

PARTIAL 'F) FAIL&RES

Page 4

Engro fertilizer Ltd Daharki

2!1
S# 1 2 3 4

MP-2515C OR MP-2515D ONL* ONE P&MP TRIPPING! ACTION STEPS

F#ll Close HIC-1110V to stop BF< &ir&#lation In)orm =t(-2 6ost Operator to ,rip 02 )ans o) C,-2 )rom S0* In)orm 6#ri)i&ation operator a3o#t trippin' o) 26-2 1 C or 26-2 1 > and to start 26-2 1 1" I) p#mps start t5en normali?e all &onditions" I) 26-2 1 1 does not start; t5en Immediatel( red#&e FE/ #p to ! @%0% 7eepin' in 4ie9 >-2 0 /11 le4el" 1&t#ate I-4 i) le4el de&rease does not stop $ ,a7e a&tion steps o) Ba&7 end trippin'"

Responsibility
F/E Boardman =t(-2 6ost Operator SIC F/E Boardman F/E Boardman F/E Boardman / B/E Boardman

2!2
S# 1 2 3

TP-2515' TRIPPING! ACTION STEPS

F#ll Close HIC-1110V to stop BF< &ir&#lation In)orm =t(-2 6ost Operator to ,rip 02 )ans o) C,-2 )rom S0* in)orm 6#ri)i&ation operator a3o#t trippin' o) 26-2 1 C or 26-2 1 > and to start 26-2 1 1 I) 26-2 1 1 does not start; t5en Immediatel( red#&e FE/ #p to -0@100% 7eepin' in 4ie9 >-2 0 /11 le4el" ,a7e lo9 load a&tion steps as mentioned"

Responsibility
F/E Boardman =t(-2 6ost Operator SIC SIC

B/E Boardman

2!"
S# 1 2 3 4 $

E-2525 PSD R&PT&RE RES&LTING IN 'F) FAIL&RE! ACTION STEPS

1&t#ate I-1 Isolate 1ll prote&tion steams Isolate /*C-11%1/B; /*C-1221/B; Close CB> 4al4es and 1n'le 4al4es o) steam dr#ms C-2 0$/12 >onAt open an( 6ro&ess side and Steam side Vent Stop 26-2 1 C and ,6-2 1 B to a4oid C-2 22 le4el /oss *ed#&e BF< press#re 'rad#all( and 0et t5e 6S> isolated

Responsibility
F/E Boardman *EF" Operator *EF" Operator F/E Boardman F/E Boardman F/E Boardman

SECTION ( "
"!1

TOTAL 'F) FAIL&RES

MP-2515C+D TRIPPING D&E TO TOTAL PO)ER FAIL&RE Page

Engro fertilizer Ltd Daharki

S# 1 2 3

ACTION STEPS
1&t#ate I-1 2an#all( &lose /*C-11%1/B and /*C-1221/B Close all prote&tion steams o) F-2 01;and Be4er open an( 4ent o) 'as side and steam side" Isolate all a#to 4al4es &losed )rom C/*; Close CB> 4al4es and an'le 4al4es o) steam dr#m"

Responsibility
F/E Boardman F/E Boardman F/E Boardman

*e)ormin' post operator

SECTION ( #
#!1

LOSS OF COOLING )ATER

P-25201S ONL* ONE P&MP A,AILA'LE! Page !

Engro fertilizer Ltd Daharki

S# 1 2 3 4

ACTION STEPS
1s7 =tilities post operator to open C<S C#mp o4er 4al4e o) =rea-II to 1mmonia-II ,rip =rea-2 and as7 to isolate all C< s#ppl( 4al4es" *ed#&e FE/ #p to %0% 6in&5 t5e dis&5ar'e 4al4e o) *#nnin' C< 2otor dri4en p#mp as per 1mps" limit ,rip :-2 03 and :-2 02 i) 4a&&#me drops 3elo9 - DH2o

Responsibility
F/E Boardman SIC F/E Boardman =t(-2 6ost Operator B/E Boardman S(nt5esis 6ost Operator F/E Boardman

$ !

Immediatel( pin&5 C<S o) E-2 3 #p to -0% and isolate; E-2 1%;E-2 22" C5e&7 :-2 01 intersta'e temp" I) in&reases #p to 3%0F ,rip :-2 01

#!1
S# 1 2 3 4

A-- P-25201S NOT A,AILA'LE! ACTION STEPS

,rip =rea-2 and as7 to isolate all C< s#ppl( 4al4es" ,rip :0,-2 01 and :-2 03 Open E#mp O4er 4al4e o) 1mm-2 and =rea-2 Immediatel( Isolate E-2 3 /3$;E-2 1%/22;2 0-C Conne&t )ire 9ater s#ppl( 9it5 20-set $ C5e&7 EBCO6 'as dis&5ar'e and l#3e oil temp and )#rt5er isolate C< eF&5an'ers i) reG#ired"

Responsibility
SIC F/E and B/E 3oardman =t(-2 6ost Operator S(nt5esis 6ost Operator *e)ormin' 6ost Operator SIC

SECTION - 5 C-2515 PSD R&PT&RE $ N.isan/0 %

Sr"# 1 2 3 4

ACTION STEPS
In)orm =rea-1/2 a3o#t CO2 press#re de&rease 1s7 area operator to isolate 6S> 1s7 area Operator to Open 1st to 4rt5 &ompartment C#mp o4er o) >-2 1 In&rease openin' o) /*C-!21 i) not )#ll open . *ed#&e )lo9 at F*C-12 to maintain le4el in >-2 1

Responsibility
SIC F/E Boardman F/E Boardman F/E Boardman F/E Boardman

N120: I3 PSD r.p2.r0 is 4.0 21 Gas si40 E5/6an 0r -0a7a 08 260n 41n2 2r9 21 is1-a20 i2! A/2.a20 I-: an4 s6i32 as a2 PIC-10#, SECTION ( : MAIN MACHINES TRIPPING :!1 KGT-2501 TRIPPING Page "

Engro fertilizer Ltd Daharki

Sr"#

ACTION STEPS

Responsibility

Engro fertilizer Ltd Daharki

Page #

1 2 3 4

open HIC-110 to letdo9n steam Control F-2 01 dra)t 3( &losin' HIC-10$/10!/10% In&rease % # steam t5r# F*C-10*ed#&e 6*C-31-V set point )rom -3 to %3 8 also &lose ,*C 111/113/1-!/1-% ,ill ,I-114 sta3le a3o4e 12 0F *ed#&e FE/ to -0% to maintain ,I-114 sta3le a3o4e 12 0F

F/E Boardman F/E Boardman F/E Boardman F/E Boardman F/E Boardman F/ E Boardman F/E Boardman F/E Boardman F/E Boardman F/E Boardman

$ ! % 10

B( pass /,SC *ed#&e pro&ess steam t5r# F*C-104/10 to &ontrol S0 ratio at 3"0 pl#s ,a7e 3e&7 end trippin' a&tion steps F#ll open E-2 0!1 'as 3(pass *ed#&e )lo9s F*C-124/12

:!2
Sr"# 1 2 3 4

K-2502 TRIPPING ACTION STEPS

Open HIC-110 V Close F*C 1$0V Control H6//6 BF< 6ress#res Close /*C-3$$/3$%V/3$2/3$3/101! Close HIC-141/142/143/144

Responsibility
F/E Boardman F/E Boardman F/E Boardman B/E Boardman B/E Boardman B/E Boardman B/E Boardman

$ ! %

Close F*C-14!/HIC-14!V *ed#&e 6*C-1 2 Set point #p to 1%0# and t5en Slo9l( red#&e *62 o) ,:-2 03 :eepin' in Vie9 Hst s#&tion press#re Open ,*C-3!0V to &ontrol inter sta'e temperat#re o) :2 03

B/E Boardman

:!"
Sr"# 1

K-250" TRIPPING ACTION STEPS

Bormal Stop :-2 02

Responsibility
B /E Boardman

Engro fertilizer Ltd Daharki

Page $

2 3 4

Open HIC-110 V Close F*C 1$0V Control H6//6 BF< 6ress#res Close /*C-3$$/3$%V/3$2/3$3/101!/101%/3 -

F/E Boardman F/E Boardman F/E Boardman B/E Boardman B/E Boardman B/E Boardman B/E Boardman

$ ! % -

Close HIC-141/142/143/144/101% Close F*C-14!/HIC-14!V Close ,*C-3!0V and its 3( pass Close 2OV-1010 and HIC-1011V

B/E Boardman

:!#
Sr"# 1 2 3 4

MG SET TRIPPING ACTION STEPS

1&t#ate I-$ Immediatel( s5i)t pro&ess 'as 4ent to 6IC-104V and partiall( at 6IC-103V BO,EI 4ent is 7ept at 6IC-104 to a4oid &r(stalli?ation o) Cata&ar3 sol#tion in E-2 0%1/B/C/> Open 0% HIC-114 V" Close 0% HIC-1 !V Close ,*C 111/113/1-!/1-% as per FE/ %0%"

Responsibility
F/E Boardman F/E Boardman F /E Boardman F/E Boardman F/E Boardman F/E Boardman F/E Boardman F/E Boardman

$ ! % -

F#ll Open HIC-10$/10! F#ll Close HIC-10% V ,a7e B/E trippin' a&tion steps *ed#&e FE/ #p to ! %

:!5
Sr"# 1 2

MP-250"' TRIIPPING ACTION STEPS

F#ll open HIC-1-3 V 6IC-104 #p to 2 % in 1st step

Responsibility
F/E Boardman F/E Boardman

Engro fertilizer Ltd Daharki

Page 1%

3 4

In)orm 1re operator to Start stand 3( 6H,-2 03/1 I) Stand 3( 6H, starts s#&&ess)#ll( t5en optimi?e FE/ as per Semi lean )lo9 Control C-2 1- le4el

F /E Boardman F/E Boardman F/E Boardman B/E Boardman F/E Boardman F/E Boardman

$ ! %

Control S(n 2a&5ine S#&tion 6ress#re 1dC#st steam/BF< press#re a&&ordin'l( t5ro#'5 HIC110 8 6*C-334/HIC-1110 I) stand 3( 6H,-2 03 does not start; t5en )#rt5er de&rease FE/ #p to %0% and a&t#ate I-% i) ,emp" O) >-2 20 rises #p to !30F"

:!:
Sr"# 1 2 3

MP-250#;A 'OTH P&MPS TRIIPPING ACTION STEPS

1&t#ate I-% +I-10 9ill a&t#ate &onseG#entl(. Immediatel( s5i)t pro&ess 'as 4ent to 6IC-104 7eepin' HIC-1-3 FC BO,EI 4ent is 7ept at 6IC-104 to a4oid &r(stalli?ation o) Cata&ar3 sol#tion in E-2 0%1/B/C/> ,a7e a&tions o) BE trip

Responsibility
F/E Boardman F/E Boardman B/E Boardman

:!<
Sr"# 1 2 3 4 $ ! %

MP-25#<;A 'OTH P&MPS TRIIPPING ACTION STEPS

Stop 6-200C )rom &ontrol room Stop ammonia )rom ,-3001 ,rip 6rism =nit Isolate /6/H6 6#r'e &5illers 1dC#st load at =*E1 as per ammonia prod#&tion *ed#&e FE as 9ell as BE load + red#&e speed o) ,:2 02. Isolate /*C-3$!+E-2 2-. 8 /*C-3!4+E-2 34. to stop inp#t in >-2 30

Responsibility
B/E Boardman B/E Boardman B/E Boardman B/E Boardman SIC B/E Boardman B/E Boardman

:!=

MP-250>;A 'OTH P&MPS TRIIPPING

Engro fertilizer Ltd Daharki

Page 11

Sr"# 1 2 3 4

ACTION STEPS
Stop 6-200C )rom &ontrol room /ine =p 1mmonia )rom ,-3001 to =rea-1/2 Control >-2 2% /e4el" Start Bot5 6-2 4!As"

Responsibility
B/E Boardman SIC B/E Boardman B/E Boardman

SECTION ( < E-2501 A!;' $ )ASTE HEAT 'OILER% E?CESSI,E T&'E LEAKAGE
Sr"# 1 2 3 4

ACTION STEPS
1&t#ate I-1 ,rip :-2 03 S5i)t Vent at 6IC-103V at 300# 3a&7 press#re" Close 2OV-2 10" :eep on de&reasin' %% # steam press#re to de&rease >, 3et9een steam/pro&ess side "*ed#&e t5is >, to 0#"

Responsibility
F/E Boardman F/E Boardman F/E Boardman F/E Boardman

F/E Boardman F/E Boardman *e)ormin' 6ost Operator" F/E Boardman

$ ! %

95en %% # steam press#re red#&es to 300# F#ll open >-2 0 lo&al 4ent and Isolate /*C-11%1/B C#t steam to F-2 01 Open E-2 01C 'as side drains and E-2 011/B BF< side >rains

Engro fertilizer Ltd Daharki

Page 12

SECTION ( = E-2505 $ )ASTE HEAT 'OILER% E?CESSI,E T&'E LEAKAGE

Sr"# 1 2 3 4

ACTION STEPS
1&t#ate I-2 S5i)t Vent at 6IC-104V at 3 0# 3a&7 press#re" Close /,SC 2OV- 04/0 /0$" Slo9l( >e&rease $00# steam press#re #p to 4 0#" 1&t#ate I-1 and t5en Immediatel( s5i)t Vent at 6IC-103V and Isolate /*C-1221/B and Stop 6-2 01

Responsibility
F/E Boardman F/E Boardman F/E Boardman F/E Boardman F/E Boardman

SECTION ( > INSTR&MENT AIR FAIL&RE

Sr"# 1 2 3 4

ACTION STEPS
1&t#ate I-1 and I-$ Open 6IC-103V on 5and Ca&7 to &ontrol 3a&7 press#re #p to 2 0# " 6in&5 F*C-104/10 /10- to &ontrol prote&tion steam )lo9 Control >-2 0 /11 le4el on B( pass and Isolate /*CAs" Open HIC 110 3( pass to &ontrol steam 5eader press#re"

Responsibility
F/E Boardman *e)ormin' 6ost Operator *e)ormin' 6ost Operator *e)ormin' 6ost Operator *e)ormin' 6ost Operator *e)ormin' 6ost Operator 6#ri)i&ation 6ost Operator *e)ormin' 6ost Operator

Cra&7 Open 6*C-102V B( pass )or &oil prote&tion"

Control BF< 5eader press#res on 3( pass"

Control all Steam 5eader press#res on B( pass"

Engro fertilizer Ltd Daharki

Page 13

10

Control C-2 22 le4el on B( pass" ,a7e BE trippin' steps"

6#ri)i&ation 6ost Operator B/E Boardman

Engro fertilizer Ltd Daharki

Page 14