DEAERATOR C-EG1001

IPS- Pequiven Moron Fertilizer Project

TRAINING COURSE DEAERATOR C-EG1001

General Consideration Operating Condition Equipment Description Erection Star-Up Maintenance

TRAINING COURSE DEAERATOR C-EG1001

General Consideration Deaerator is mainly used to eliminate the oxygen, carbon dioxide and other non-condensable gas from the water. Operation: the water is sprayed-down inside deaerating tower and heated by the steam flowing in upward direction. The water reaches the saturation temperature at working pressure and release the dissolved gas.

TRAINING COURSE DEAERATOR C-EG1001

TRAINING COURSE DEAERATOR C-EG1001

Process Design Condition 180C

INLET Make-up water Mass Flow Rate(kg/h) Temperature C Pressure (kg/cm2 g) 260000 80 10 L.P Condensat e 10830 125 10 Heating Steam 15450 180 5 BFW from Ammonia Plant 52200 160 10 BFW OUTLET Vent (air + steam) 500 120 1

337980 120 1

Process Design Condition 225C

INLET Make-up water Mass Flow Rate(kg/h) Temperature C Pressure (kg/cm2 g) 260000 80 8.7 L.P Condensate 10830 100 4 Heating Steam BFW from Ammonia Plant 52200 130 2.5 BFW OUTLET Vent (air + steam) 500 120 1

18100 225 4

340600 120 1

TRAINING COURSE DEAERATOR C-EG1001

Normal Operating Condition

Flow (kg/h) Make-up Water L.P Condensate BFW from ammonia 260000 10830 52200 Temperature (C) 80 125 160 Pressure(kg/cm2 g) 10 10 10

DEAERATOR

Flow (kg/h) Make-up Water L.P Condensate BFW from ammonia 260000 10830 52200

Temperature (C) 80 125 160

Pressure(kg/cm2 g) 10 10 10

TRAINING COURSE DEAERATOR C-EG1001

GUARANTEE PERFORMANCE

O2 Content

7 ppb

CO2 Content undetectable

TRAINING COURSE DEAERATOR C-EG1001

Equipment Description

Tower Spray Valve Trays Holding Tank

TRAINING COURSE DEAERATOR C-EG1001

DEAERATOR GENERAL ARRANGMENT

Tower Shell material Trays/Spay Valve Design Pressure Design Temperature Stripping Steam Sa 240 Gr. 304L S316/316L 5/FV kg/cm2 g 350C Holding tank SA 516 Gr. 70 N 5/FV kg/cm2 g 160C NCG

Make-Up water Holding Tank Tower

Start-Up heating steam

Deaerated Water

TRAINING COURSE DEAERATOR C-EG1001

DEAERATOR TOWER

Internal Diameter Cylindrical Length

2024 x 12 mm 2940 mm

TRAINING COURSE DEAERATOR C-EG1001

DEAERATOR DETAILS-SPRAY VALVES

NInstalled Spraying Nozzle size 15 3mm

SPRAY VALVES HEADER

TRAINING COURSE DEAERATOR C-EG1001

DEAERATOR DETAILS-TRAYS

Model Installed quantity

WT-A 4x3x12

TRAINING COURSE DEAERATOR C-EG1001

DEAERATOR DETAILS-HOLDING TANK

Internal Diameter Cylindrical Length Volume

3028 x 14 mm 14000 mm 106 m3

OPERATING LEVEL High Level ( HL) Normal Level ( NL) Low Level (LL) Low Low Level (LLL) 2561 mm 2360 mm 938 mm 351 mm

TRAINING COURSE DEAERATOR C-EG1001

DEAERATOR DETAILS-HOLDING TANK

TRAINING COURSE DEAERATOR C-EG1001

ERECTION PRECOMMISSIONING & COMMISSIONING

TRAINING COURSE DEAERATOR C-EG1001

ERECTION

The following prescription is intended as a general giudance for the execution of the main activities to be carried out during site erection. NOTE: DEAERATOR IS ASME CALCULATED FOR PRESSURE AND VACUUM OPERATION,THEREFORE MODIFICATION OF ANY PART OF THE VESSEL ARE STRICTLY FORBIDDEN.
Check that no internals and auxiliaries have been broken during the transport or lifting. During the erection phase, the nozzles of vessels and equipment must be protected with wooden matching flanges or plugs, to avoid any damage to the surfaces in case of accidental impacts. The correct orientation of equipment nozzles must also be checked to ensure correct location of the equipment. Supports shall be checked.

TRAINING COURSE DEAERATOR C-EG1001 The following main erection phases shall be considered:
Positioning of holding tank, tightening the fixed saddle Positioning of deaerating tower and connecting downcomer and internal steam balance nozzle, tightening the relevant bolts; Tightening of tower supporting saddles; Installation of platform and ladders; Positioning of piping, supports and other equipment; Installation of electrical/instruments; Installation of deaerating tower internal parts

NOTE: INTERNAL PARTS TO BE INSTALLED AFTER FLUSHING

TRAINING COURSE DEAERATOR C-EG1001

TRAYS INSTALLATION (1)
Tray modules shall be carefully handled for introduction and assembling to avoid any damage. The tray modules introduction shall be done through the manhole which is on the external deaerator head. Before introduction check that tray modules and fixing accessories are clean. If necessary wash (with soft water) and dry them. Check that the tray support frames inside the tower are perfectly horizontal and free from any obstructing matters. Put crosswise over them adequate walking wooden planks. Introduce each tray module and pile them inside the deaerator as per IOM. Remove step by step the walking wooden planks. Once the last modules have been fitted, it will be advisable to tighten definitively the bolts of the fixing packaging modules accessories getting in and moving on the package only after having placed suitable wooden boards in order to prevent damaging and deformation of the modules.

TRAINING COURSE DEAERATOR C-EG1001

TRAYS INSTALLATION (2)

Long side Short side Long side

TRAINING COURSE DEAERATOR C-EG1001

SPRAY VALVES INSTALLATION Valves are delivered already properly fixed and no controls are recommended

TRAINING COURSE DEAERATOR C-EG1001

START-UP & SHUT DOWN

TRAINING COURSE DEAERATOR C-EG1001

Normal procedure to be followed Check that level indicator valves are open if any. Release condensate water, slowly in the holding tank increasing flow up to the design level. Release start up steam slowly in the holding tank until the deaerator temperature reaches the required value. Release steam into the deaerating tower. Release condensate water into the deaerating tower, increasing flow up to the design conditions. Check that steam reaches and maintains the foreseen pressure value. Should some bangs been heard, reduce water flow rate.
START-UP AND OPERATION

TRAINING COURSE DEAERATOR C-EG1001 Shut down

WHEN THE DEAERATOR MUSTS BE PUT OUT OF COMMISSIONG, THE DUTY HAS TO BE REDUCED GRADUALLY, IN ORDER TO AVOID WATER HAMMERING.

TRAINING COURSE DEAERATOR C-EG1001

Fault finding
A

Excess of oxygen content (or improper sample Collecting) Inlet water flow-rate higher than design data Temperature below/above design data Inlet steam pressure below design data

Perform an additional measurement. Check that no air leakage is present before sampling point (to be evaluated and checked in their correctness). Check the control system of relevant valve. Synchronize working time with the steam regulation valve. Make sure that no obstructive matters or scale prevent the normal working. Check the temperature of condensate at a point very next to the deaerator and make the necessary adjustments to the up-stream equipment. Check the control system of the relevant valve, comparing its pressure with the one given on the tower pressure gauge. Make sure that the steam regulation valve does never open completely; if this occurs, may be that steam sometimes is insufficient. Check that seats are clean not encrusted or worn out. Make sure that the valve stem slides free inside the shutter Make sure that the inside distribution valves have no obstructive matters, ags, etc. Check the springs tension and release the relevant bolts, if necessary. Make sure that vent pipes both inside and outside the degassing tower are not obstructed. Make sure that the regulation of the condensate flow is smooth and that storage tank volume can meet the possible fluctuations; sudden changes in working conditions may cause an insufficient venting.

The inlet water through the spray valves is insufficient

An insufficient venting may cause the retention of non condensable gasses Working fluctuations

TRAINING COURSE DEAERATOR C-EG1001

MAINTENANCE

TRAINING COURSE DEAERATOR C-EG1001

REGULAR AND PREVENTIVE MAINTENANCE
MAINTENANCE

Regular and preventive maintenance is the periodic check of the equipment working conditions during normal operation and the removal of defects and inconsistencies observed during equipment operation. Checking vibrations of machinery, temperature/pressure of equipment, etc. Providing maintenance recommended by instruments manufacturers Replacing or cleaning spray valves and similar equipment Checking correct operation and readings of instruments Replacing gaskets Eliminating leaks