01-Operating Manual For 1200 MTPD Ammonia Plant PDF

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c Operating Manual
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. . .". Managers
EST/JOB NO. 5777 CLASS

CLIENT Kermanshah Petrochemicals Industries Co. DOC. NO. PROJ-PM-008
PROJECT Ammonia & Urea Complex PAGE: 1 OF 312
LOCATION Kermanshah, Iran Revision 5
K.P.I.C
Operating Manual for 1200 MTPD Ammonia Plant
c:
5 21/12/06
See Page 2 for list of revised
pages V'~
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t- I MDV
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4 6/07/05 Client Approved PCS MH CM

3 20/05/05 For Client Review PCS MH
2 10/08/04 For Internal Review XU. B ZH.G
1 Incorporating Client comments DA
0 25/06/03 For Client Approval JM RL CM
c) Rev. Date Reason for Issue By Checked
Approved
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c JOB NO. 5777 SPEC. TYPE: PAGE: 2 OF 312
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DOC NO. PROJ-PM-008 REVISION: 5
Revised Pages in Revision 5
Page Number(s) Change

1 - 11 Contents revised to reflect chanqes
13-18 Re-Formatled
123 - 125 Re-Formatled
132 -135 Re-Formatled
160 Font corrected
174 Spelling correction
180 - 181 Note inserted
190 Reference Corrected
c 216
298 - 306
Font corrected
Tables revised -- ------------- .. . ...
TABLE OF CONTENTS
1 INTRODUCTION 12
2 BASIS OF DESIGN 13
2.1 DUTY OF UNIT 13
2.2 FEED CHARACTERISTICS 13

c 2.3 PRODUCT SPECIFICATIONS 14
2.3.1 Ammonia Product ............................................................................................... 14
2.3.2 Carbon Dioxide Product ....................................................................................... 14
2.4 MATERIAL AND ENERGY BALANCES 15
2.5 BATTERY LIMIT CONDITIONS [OPERATING TEMP. & PRESSURE] 16
2.6 DESIGN FEATURES 17

2.6.1 Feed Gas Compression and Purification .............................................................. 17
2.6.2 Air Compression Section ..................................................................................... 18
2.6.3 Reforming Section ............................................................................................... 18
2.6.4 Shift Conversion .................................................................................................. 18
2.6.5 CO 2 Removal ....................................................................................................... 18
2.6.6 Methanation ......................................................................................................... 19
2.6.7 Synthesis Gas Compressor ................................................................................. 19
c 2.6.8 Synthesis Loop Section ....................................................................................... 19
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2.6.9 Refrigeration Section ........................................................................................... 19

2.6.10 Steam System ..................................................................................................... 19
2.6.11 Utilities ................................................................................................................. 20
2.6.12 Catalyst Volumes ................................................................•................................ 20
2.7 PROCESS FLOW DESCRIPTION 20
2.7.1 Introduction .......................................................................................................... 20
2.7.2 Raw Synthesis Gas Preparation .......................................................................... 21
2.7.3 Synthesis Gas Purification ................................................................................... 24
2.7.4 Synthesis Gas Compression & Ammonia Synthesis ............................................ 28
2.7.5 Ammonia Refrigeration and Recovery ................................................................. 31
c 2.7.6
2.7.7
Ammonia Purge Gas Recovery System ............................................................... 32
Ammonia Storage & Loading Facilities (OSBL) .................................................... 32
3 DESCRIPTION OF UNIT CONTROL 34
3.1 UNIT CONTROL 34

3.1.1 Natural Gas Feed Preparation ............................................................................. 34
3.1.2 Raw Synthesis Gas Preparation .......................................................................... 38
3.1.3 Synthesis Feed Gas Purification .......................................................................... 44
3.1.4 Ammonia· Production ........................................................................................... 54
3.1.5 Refrigeration And Ammonia Product Purification .................................... :............ 59
3.1.6 Ammonia Storage & Loading (OSBL) .................................................................. 65
3.2 OPERATING CONDITIONS AND PROCESS VARIABLES 66
3.2.1 Natural Gas Feed Preparation ............................................................................. 66
3.2.2 CO2 Removal ( aMDEA System) .......................................................................... 81
3.2.3 Methanation (R-21 06) .......................................................................................... 84
c 3.2.4
3.2.5
3.2.6
Ammonia Conversion ........................................................................................... 87
Ammonia Product Purification (Removal of Absorbed Gases) ............................. 98
Boiler Feed Water Deaeration (V-21 01 ) ............................................................. 101
3.3 CATALYST OPERATING CONDITIONS 103
3.3.1 Hydrogenator - R-2160 ..................................................................................... 103
3.3.2 Desulphurisers R-2108A1B ................................................................................ 104
3.3.3 Primary Reformer H-2101 .................................................................................. 105
3.3.4 Secondary Reformer R-2103 ............................................................................. 106
3.3.5 HT Shift Converter R-21 04 ................................................................................ 107
3.3.6 LT Shift Converter R-21 09 ................................................................................. 108
3.3.7 Methanator R-2106 ............................................................................................ 109
3.3.8 Ammonia Converter R-21 05 .............................................................................. 110
3.4 INSTRUMENT LIST 110
4 UTILITY I CHEMICAL REQUIREMENTS 111
c 4.1 UTILITY GENERATING CAPACITIES 111
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4.2 STEAM REQUIREMENTS 111

4.2.1 Deaerator V-21 01 .............................................................................................. 111
4.2.2 BFW Pumps P-21 04 AlB & BFW Distribution .................................................... 113
Y'-,)
4.2.3 Steam Drum - D-21 01 ........................................................................................ 114
4.2.4 H.P. Steam Distribution ...................................................................................... 116
4.2.5 M.P. Steam System (42.5 Bara) ........................................................................ 118
4.2.6 L.P. Steam System (4.5 Bara) ........................................................................... 118
4.3 STEAM CONDENSATE SYSTEMS 119
4.3.1 Surface Condenser - E-2140 ............................................................................. 119
4.3.2 Process Condensate Stripper- T-2150 ............................................................. 120
C 4.3.3 Process Condensate Drum D-2161 ................................................................... 121
4.4 COOLING WATER [SUPPLY & RETURN] 121
4.5 REFORMER COOLING WATER JACKETS 123
4.6 RAW WATER TREATMENT (OSBL) 124
4.7 SERVICE & POTABLE WATER (OSBL) 124
4.8 FLARE SYSTEM 124
4.9 AIR REQUIREMENTS 125

4.9.1 Instrument and Plant Air .................................................................................... 125
4.9.2 Combustion Air .................................................................................................. 126
4.10 NITROGEN SYSTEM 126
c 4.11 FUEL GAS

4.11.1
127
Arch Burners ...................................................................................................... 127
4.11.2 Superheater Burners ......................................................................................... 128
4.11.3 Tunnel Burners .................................................................................................. 129
4.11.4 Auxiliary Boiler Burners ...................................................................................... 129
4.11.5 H-2102 Start-up Heater ..................................................................................... 130
4.11.6 Pilot Gas Fuel .................................................................................................... 130
4.12 DIESEL FUEL REQUIREMENTS (OSBL) 130
4.13 ELECTRICAL REQUIREMENTS 130
4.14 CATALYST SPECIFICATIONS 131

4.14.1 Catalyst Specification for Hydrogenation Reactor R-2160 ................................. 131
4.14.2 Catalyst Specification for Desulphurisers R-21 08 A&B ...................................... 131
4.14.3 Catalyst Specification for H.T. Shift Converter R-21 04 ...................................... 131
4.14.4 Catalyst Specification for L.T. Shift Converter R-2109 ....................................... 131
4.14.5 Catalyst Specification for Primary Reformer H-2101 .......................................... 132
c 4.14.6 Catalyst Specification for Secondary Reformer R-2103 ..................................... 132
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4.14.7 Catalyst Specification for Methanator R-21 06 .................................................... 132

4.14.8 Catalyst Specification for Synthesis Converter R-2105 ................................... ,.. 132
4.15 CHEMICAL SPECIFICATIONS 133
4.15.1 CO2 Removal System (aMDEA) ......................................................................... 133
4.15.2 aMDEA System Antifoam Agent ........................................................................ 133
4.15.3 HP Steam System Treatment Chemicals (Estimated) ........................................ 133
4.15.4 Ammonia for Start-up ......................................................................................... 133
4.15.5 Oxygen Scavenger (such as Nalco 72100) ....................................................... 134
4.15.6 Phosphate ......................................................................................................... 134
4.15.7 Morpholine (or alternative such as Nalco 72310) ............................................... 135
c 5
4.15.8 Sodium Hydroxide [NaOH] ................................................................................ 135
PREPARATION FOR INITIAL STARTUP 137
5.1 INTRODUCTION 137
5.2 PRELIMINARY STARTUP PROCEDURES 138

·5.2.1 Unit Check-out Procedure .................................................................................. 138
5.2.2 Line Flushing Procedure .................................................................................... 139
5.2.3 Steam Blowing Procedure ................................................................................. 142
5.2.4 Air Blowing Procedure ....................................................................................... 147
5.2.5 Fuel Gas System Blow-out Procedure .............................................................. 148
5.2.6 Refractory/Heater Dry-out Procedures ............................................................... 148
5.2.7 Chemical Cleaning Procedure ........................................................................... 148
5.2.8 Catalyst Loading Procedures ............................................................................. 149
5.2.9 Catalyst Dusting Procedure ............................................................................... 149
5.2.10 Conditioning of CO 2 Removal System ............................................................... 150
c 5.2.11
5.2.12
5.2.13
Leak Testing Procedure ..................................................................................... 150
Commissioning HP Steam System .................................................................... 154
Check Relief Valve Settings ............................................................................... 155
5.2.14 Commissioning of Water Jacketing Systems ..................................................... 156
5.2.15 Precommissioning of NH3 Storage & Loading Facilities ..................................... 156
6 INITIAL START-UP PROCEDURE 158
6.2 Instrument calibration 160
6.3 Surge system checking 160
6.4 test run of the machines 161
6.5 PRELIMINARY START-UP PROCEDURES 161
C 6.6 INITIAL UNIT START-UP PROCEDURE 163
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6.6.1 Commission DeaeratorV-2101 .......................................................................... 163

6.6.2 Reformer Start Up Sequence Logic Description ................................................ 164
6.6.3 Start Auxiliary Boiler........................................................................................... 171
6.6.4 Start E-2140 Surface Condenser (Refer to the Vendor drawings for E-2150) .... 172
6.6.5 Nitrogen Heating of Hydrogenator, Desulphuriser, Primary & Secondary
Reformers and HTS Converter catalysts ............................................................ 175
6.6.6 Steam Heating of Primary, Secondary and HTS Catalysts ................................ 176
6.6.7 Reduction of Primary, Secondary and HTS Catalysts ........................................ 177
6.6.8 Establish Circulation of CO2 Removal System ................................................... 178
6.6.9 LTS Catalyst Reduction using Nitrogen as Carrier Gas ..................................... 178
6.6.10 Produce Desulphurised Feed Gas ..................................................................... 180
6.6.11 Introduce Desulphurised Feed Gas to the Primary Reformer. ............................ 181
C~ 6.6.12 Introduce Air to the Secondary Reformer and Complete Reduction and
Desulphurisation of Catalysts ............................................................................. 181
6.6.13 Commission CO 2 Removal System .................................................................... 182
6.6.14 Complete Desulphurisation of the HTS Converter Catalyst... ............................. 184
6.6.15 Commission Methanator [R-21 06] .................................................................... 185
6.6.16 LTS Catalyst Reduction using Natural Gas Feed as Carrier .............................. 187
6.6.17 Commission LTS Converter ............................................................................... 188
6.6.18 Commission Refrigeration System ..................................................................... 189
6.6.19 Start Synthesis Gas Compressor ....................................................................... 191
6.6.20 Pressure Test of Synthesis Gas Loop ................................................................ 192
6.6.21 Start Up Heater, H-2102, Sequence Logic Description ...................................... 194
6.6.22 Synthesis Converter Catalyst Reduction ............................................................ 196
6.6.23 Commission Purge Gas Scrubber [T-2103] ....................................................... 202
6.6.24 Purge and Chilldown of NH3 Storage & Loading Facilities (OSBL) ..................... 203
6.7 START-UP LINES AND REQUIREMENTS 205
c 7 NORMAL OPERATION 208
7.2 START-UP WITH ACTIVATED CATALYSTS 208

7.2.1 Hydrogenator and Desulphurisers [R-2160 & R-21 08A/B] ................................ 208
7.2.2 Primary and Secondary Reformers [H-2101 & R-2103] .................................... 208
7.2.3 HTand LT Shift Converters [R-2104 & R-2109] ................................................ 209
7.2.4 Methanator [R-2106] ....................... :.................................................................. 209
7.2.5 Ammonia Converter [R-2105] ........................................................................... 210
7.3 RESTART OF CO2 REMOVAL SYSTEM 211
7.4 OPERATION AT 60% DESIGN CONDITIONS 212
7.5 WARM [37.5°C] AMMONIA PRODUCTION 212
7.6 COLD [-35°C] AMMONIA PRODUCTION 213

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7.7 UREA PLANT OPERATION WITH AMMONIA PLANT SYNTHESIS SECTION

SHUT DOWN 213
7.8 NORMAL OPERATION OF NH3 STORAGE & LOADING FACILITIES (OSBL) 214
7.8.1 Normal Operation of NH3 Storage Tank ............................................................. 214
7.8.2 Normal Operation of Road Tanker Loading Station ........................................... 215
7.8.3 Normal Operation of Bottle Loading Station ....................................................... 215
7.8.4 Transfer of Warm NH3 Feed to Urea Unit from Storage Tank ............................ 216
7.8.5 Transfer of Ammonia to the Ammonia Unit for start-up ...................................... 216
7.9 Trouble shooting 216
C~ 8 SHUTDOWN PROCEDURE 217
8.1 NORMAL SHUTDOWN PROCEDURES 217

8.1.1 Summary of Shutdown ....................................................................................... 217
8.1.2 Reduction of Flow Rates .................................................................................... 218
8.1.3 Reduce Synthesis Section Feed Rate ................................................................ 219
8.1.4 Purge Gas Ammonia Recovery System shutdown ............................................. 219
8.1.5 Stop Ammonia Conversion ................................................................................ 220
8.1.6 Stop the Synthesis Gas Compressor [C-2103] ................................................. 221
8.1.7 Stop and Pump-out Refrigeration System .......................................................... 221
8.1.8 Depressurise and Purge Ammonia Converter .................................................... 222
8.1.9 Stabilisation of Ammonia Synthesis Catalyst ..................................................... 222
8.1.10 Methanator Shutdown ........................................................................................ 223
8.1.11 Methanator Catalyst Oxidation ........................................................................... 223
8.1.12 Shutdown of LT Shift Converter ......................................................................... 224
8.1.13 Shutdown of C02 Removal System ................................................................... 224
c 8.1.14
8.1.15
Shutdown of Process Condensate Stripper ....................................................... 225
Shutdown of Reforming Section ........................................................................ 225
8.1.16 Stop Feed to Primary Reformer ......................................................................... 226
8.1.17 Shutdown Desulphuriser Section ....................................................................... 226
8.1.18 Steam Oxidising of the Reformer Catalyst.. ....................................................... 227
8.1.19 Secure the Reformer Section .................. ,....................., .................................... 228
8.1.20 Shut Down and Secure the Steam System ........................................................ 228
8.1.21 Completing the Shutdown .................................................................................. 229
8.2 SPECIAL SHUTDOWN PROCEDURES 229
8.2.1 Removal of Ammonia Synthesis Catalyst .......................................................... 229
8.2.2 Oxidation of HT Shift Catalyst... ......................................................................... 230
8.2.3 Oxidation of LT Shift Catalyst ............................................................................ 231
9 EMERGENCY SHUTDOWN PROCEDURES 232

c 9.2 AMMONIA CONVERTER 232
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9.3 LOW TEMPERATURE SHIFT CONVERTER 233
9.4 METHANATOR 234
9.5 LOSS OF FEED GAS 235
9.6 LOSS OF STEAM TO CARBON RATIO 237
9.7 LOSS OF PROCESS AIR 237
9.8 LOSS OF BOILER FEEDWATER TO STEAM DRUM 0-2101 238
C 9.9 LOSS OF PROCESS STEAM 240
9.10 HIGH H.P. STEAM SUPERHEAT TEMPERATURES 240
9.11 LOSS OF FIRING ON PRIMARY REFORMER/AUXILIARY BOILER 241
9.12 LOSS OF STEAM PRESSURE 241
9.13 INSTRUMENT AIR FAILURE 242
9.14 ELECTRIC POWER FAILURE 243
9.15 COOLING WATER FAILURE 243
9.16 FAILURE OF WATER TREATMENT SYSTEM 244
9.17 FAILURE OF AMDEA CIRCULATION 244
c 9.18 FAILURE OF REFORMER INDUCED DRAFT FAN 245
9.19 Loss of C-2112 Arch Burner FD Fan 247
9.20 Loss of C-2111 Aux Boiler FD Fan 247
9.21 LOSS OF HYDROGEN TO THE DESULPHURISER SECTION 248
9.22 LOSS OF PURGE GAS OR EXCESS SYN GAS TO H-2101 FUEL GAS 249
9.23 GENERAL EMERGENCIES 249
9.24 PRECAUTIONS TO BE OBSERVED TO PROTECT STEAM GENERATING

EQUIPMENT 250
9.25 GENERAL PRECAUTIONS 250
c! 10 SAFETY 251

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10.2 FIRE/EXPLOSION HAZARDS 251

10.2.1 Plant Signs ........................................................................................................ 252
10.2.2 Consumables (Permits, Testing materials etc.) .................................................. 252
10.2.3 Notifications ....................................................................................................... 252
10.3 SAFETY SYSTEMS 253
10.3.1 Pressure Relief Valves ....................................................................................... 253
10.3.2 Rupture Discs .................................................................................................... 253
10.3.3 Alarms & Trips ................................................................................................... 253
(' 10.3.4 The Firewater System ........................................................................................ 254
10.4 PERSONAL SAFETY ASPECTS 255
10.5 NOISE 255
10.6 VESSEL ENTRY 255
10.7· ENVIRONMENTAL ASPECTS 256

10.7.1 Category 1- Exposure of Personnel ................................................................... 256
10.7.2 Category II - Pollution of the Environmenl... ....................................................... 256
10.8 HAZARDOUS CHEMICALS 257
10.8.1 Natural Gas ....................................................................................................... 257
10.8.2 Nitrogen ............................................................................................................. 258
10.8.3 Carbon Monoxide............................................................................................... 258
10.8.4 Carbon Dioxide .................................................................................................. 259
10.8.5 Hydrogen ........................................................................................................... 259
c 10.8.6
10.8.7
Ammonia ........................................................................................................... 259
Oxygen Scavenger(such as Nalco 72100) ......................................................... 261
10.8.8 Condensate Conditioner (Morpholine or altemative such as Nalco 72310) ........ 261
10.8.9 Steam & Condensate ......................................................................................... 262
10.8.10 Catalysts ............................................................................................................ 262
10.9 RELIEF VALVES 263
10.10 SUMMARY OF RUPTURE DISCS 265
10.11 ALARM AND TRIP SETTING 265
11 INSTRUMENTATION 266
11.2 COMPLEX LOOP INSTRUMENTATION 266
c 11.2.1 D-2101 Steam Drum Level Control .................................................................... 266
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11.2.2 HP Steam to MP Steam Letdown System .......................................................... 267

11.2.3 Auxiliary Boiler Combustion Air & Fuel Gas ControL .......................................... 269
11.2.4 Auxiliary Boiler Light-off Sequence .................................................................... 270
Arch Burner Light-off Sequence ......................................................................... 273
11.2.5 273
11.2.6 Superheater Burner Light-off Sequence ............................................................ 275
11.2.7 Tunnel Burner Light off sequence ...................................................................... 277
11.2.8 Start-up Heater Light-off Sequence ................................................................... 278
11.2.9 CO2 Absorber (T-21 01) Level Control ................................................................ 280
11.2.10 Instrumentation of the Compressor End of the Synthesis Gas Compressor ...... 280
11.3 INTERLOCKS & SHUTDOWN DEVICES 281
C_.· 11.3.1 Shutdown 21-ESD-1203/1201 Low Steam/Carbon Ratio & Low Natural Gas Feed
Rate ................................................................................................................... 281
11.3.2 Shutdown 21-ESD-1202 Low Low Process Steam Flow .................................... 283
11.3.3 Shutdown 21-ESD-21 06 Methanator Emergency Vent ...................................... 284
11.3.4 Shutdown 21-ESO-2102 Feed Gas Compressor ............................................... 285
11.3.5 Shutdown 21-ESD-21 01 Air Compressor ........................................................... 286
11.3.6 Shutdown 21-ESD-2103 Synthesis Gas Compressor ........................................ 286
11.3.7 Shutdown 21-ESD-21 05 Refrigeration Compressor........................................... 287
11.3.8 Shutdown 21-ESD-2112 Auxiliary Boiler ............................................................ 288
11.3.9 Shutdown 21-ESD-2113 Superheater Burner .................................................... 289
11.3.10 Shutdown 21-ESD-2111 Arch Burner ................................................................ 291
11.3.11 Shutdown 21-ESD-2114 Tunnel Burner. ............................................................ 293
11.3.12 Shutdown 21-ESD-2116 Startup Heater ............................................................ 293
11.3.13 Shutdown 21-ESD-1031 Fuel Gas High Calorific Value .................................... 294
11.3.14 Shutdown 21-ESD-1223 Steam Drum Low LeveL ............................................. 294
11.3.15 Interlock 21-ESD-1106 Boiler Feed Water Low Flow ......................................... 295
11.3.16 Shutdown 21-ESD-1003 Raw Gas Separator Low Level ................................... 295
c 11.3.17 Shutdown 21-ESD-1 069 Process Condensate Stripper High Differential Pressure
.......................................................................................................................... 296
11.3.18 Interlocks for Auto Start of Pumps by FCS ........................................................ 296
11.4 ANALYSERS 296
12 EQUIPMENT LIST 297
13 . LABORATORY ANALYSIS 297
13.2 GENERAL LIST OF TARGET VALUES FOR CONTROL TESTS FOR AMMONIA
PLANT AND ASSCOIATED SAMPLE AND ANALYSER POINTS 298
13.3 GENERAL LIST OF CONTROL TESTS FOR AMMONIA PLANT 303
c 13.4 CALIBRATION ROUTINES 306
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14 DRAWINGS 307
14.1 PLOT PLAN 307
14.2 PFDS & MATERIAL BALANCE TABLES 307
14.3 STEAM AND COOLING WATER BALANCES 307
14.4 PIPING AND INSTRUMENTATION DIAGRAMS 308
14.5 HAZARDOUS AREA CLASSIFICATION 308

C~ 14.6 INSTRUMENT LOGIC DIAGRAMS 308
14.7 INSTRUMENT INDEX. ALARM & SHUTDOWN SCHEDULE 308
Appendix I Correction of Orifice, Averaging Pitot Tube and Venturi Flowmeters
Appendix II Lower Heating Value (LHV) Calculations
Appendix III Density of Liquid Ammonia
,
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1 INTRODUCTION
This manual has been compiled to assist those charged with the responsibility and
supervision of the initial start-up and subsequent operation of the 1200 metric tons
per day ammonia plant for KERMAN SHAH PETROCHEMICAL INDUSTRIES
COMPANY, IRAN. It's primary objective is to provide flow descriptions and
discussions of the processes involved and related operating principles, together
with suggested guideline procedures for the initial commissioning, start-up, normal
shutdown and emergency shutdown of the plant. It may also serve as a basis for
the preparation by supervisory personnel, of detailed operating instructions, which
c should include instructions as issued by the equipment manufacturers. Under no

circumstances should operations deviate from safety regulations and practices
followed throughout the industry.
Operating conditions and techniques will evolve from actual operating experience
and it is not possible to antiCipate and present herein all potential circumstances
that may confront the operator during the commissioning, start-up, normal and
emergency shutdown of the unit. Consequently, this operating manual must be
recognised as a guide and that conditions stipulated are not rigid standards,
unless specifically noted as such.
Whilst the main objective of the unit is to produce Ammonia product by the
synthesis of nitrogen and hydrogen, it is stressed that the plant will only operate
efficiently and economically if the same attention is paid to the various
sub-sections and systems such as the HP Steam Generation and the CO2
Removal systems as is paid to the operation of the synthesis converter. Special
attention must also be paid to the quality requirements of the boiler feed water as
detailed in various sections of this manual and in ODS-148 - "Steam Generator
c Operation" included in the General Procedures Manual.
Numerical values given in this manual are design figures indicating the ranges
within which actual values may vary during normal operation and may need to be
changed as a result of experience gained in the plant. Under no circumstances
should these figures be regarded as guaranteed performance figures.
Any and all information pertinent to the aMDEA® proprietary C02 removal process
included in this Operating Instructions Manual is disclosed in confidence for use in
accordance with agreement made between KERMAN SHAH PETROCHEMICAL
INDUSTRIES COMPANY and BASF AKTIENGESELLSCHAFT and should be
treated accordingly.
-~5'-;;':·.;>·
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2 BASIS OF DESIGN
Where Block Valves are fitted on the inlet and discharge lines of unspared Relief
Valves or, in the case of Relief Valves discharging to atmosphere to the inlet lines
only, these valves must be locked open during plant operation.
It is the responsibility of the Plant Management to ensure that an

administration system is in place, which will ensure that this condition is
strictly observed
c
2.1 DUTY OF UNIT
The Ammonia Unit is designed to produce 1200 tid of Ammonia and is based on the
low energy natural gas reforming process licensed by the M.W.Kellogg Company.
1132 tid of the Ammonia product is sent as feed at approx. 37.5°C to the Urea Unit
with the balance of 68 tid being sent, at _35°C, to the offsite Ammonia storage tank.
Alternatively the Ammonia unit can produce 1200tld of cold product when the Urea
Unit is not in operation.
The Ammonia Unit is capable of producing 40% of design capacity for short periods
of time (less than 7 days). To achieve this, some equipment will need to operate on
kick-back and it will be necessary to burn some of the syngas as fuel or vent it. In
addition, a high level of experienced supervision must be in attendance throughout
this mode of operation.
The Plant is designed also to produce 1494 tid of carbon dioxide, most of which is
c exported for use as a feed to the Urea Unit.
The composition and conditions of the natural gas feedstock is given in Section 2.2.
2.2 FEED CHARACTERISTICS
The natural gas specification is as follows:

Composition volume %
CH 4 96.85
C2Ha 1.23
C3 H8 0.216
n-C4H10 0.085
i-C4H10 0.054
n-C5H12 0.042
i-C5H12 0.041
C6 and heavier 0.15
CO2 0.242
c N2 1.09
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Sulphur as organic 20 ppmv

Sulphur as inorganic 20 ppmv
Water 150 ppmv
MW 16.684
Calorific Value 11,615 kcal/kg
8645.7 kcal/Nm3
Battery limit pressure, bara
Design 17.0
Winter (minimum) 10.0
Maximum 70.0
c~ Battery limit temperature, DC
Minimum 20
Normal I design Ambient
Maximum 45
2.3 PRODUCT SPECIFICATIONS
2.3.1 Ammonia Product
The product may be warm liquid to an adjacent urea plant, or cold liquid to storage,
in any combination. The guarantee case is 1132 MTPD warm product and 68 MTPD
cold product.
Ammonia content min. 99.9 wt-%
c Water content
Oil content
max. 0.1 wt-%
max. 5 ppmw
Warm product battery limit conditions 37 DC (max) at 25.5 bara
Cold product battery limit conditions -35 DC at 4.4 bara
2.3.2 Carbon Dioxide Product
Carbon dioxide content min. 98.9 vol-O/O, dry basis

H2/N2/CH4/Ar max. 1.1 vol-O/O, dry basis
H2 content max. 0.9 vol 0/0, dry basis
Water Saturated at BL conditions
Temperature at B. L 43 DC
c Pressure at B. L. 1.8 bara

JOB NO. 5777 SPEC. TYPE: PAGE: 150F312
CLASS
2.4 MATERIAL AND ENERGY BALANCES
The Material and Energy Balances are indicated on the following Process Flow
Diagrams, steam and cooling water balances:
Air/Gas Compression &LTS Reduction Circuits DWG-060-D004

Desulphurisation, Reforming & Shift Conversion DWG-060-D005
CO2 Removal DWG-060-D006
Methanation and Ammonia Synthesis DWG-060-D007
Refrigeration (warm product case) DWG-060-D008
c Refrigeration (Cold product case)

Ammonia Storage System
Natural Gas Feed & Fuel Gas
DWG-060-D009
DWG-060-D102
DWG-060-101
Steam Balance - Warm Product Case DWG-060-B001
Steam Balance - Cold Product Case DWG-060-B002
Steam Balance - C2101 Start-up Case DWG-060-B003
Steam Balance - C2101 Restart Case DWG-060-B004
Steam Balance - C2103 Start-up Case DWG-060-B005
Steam Balance - C2103 Restart Case DWG-060-B006
Steam Balance-Emergency Shut down DWG"060-B007
Cooling Water Balance - Warm Product Case DWG-060-B008
c
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2.5 BATTERY LIMIT CONDITIONS [OPERATING TEMP. & PRESSURE]

FLOW S.G. B.L. PRES~
LINE LINE FLOWING TEMP
LINE NO. P&IONO. FROM TO RATE OR @GRAOE
SIZE SPEC MEDIUM 'C
KG/H M.W. BARA
Al000 42" lPl 62-0101 AIR ATMOS. C-2101 67890 28.6 39 0.88
A1401 6" lPl 62-0101 AIR C-2101 0·4101A 1980 28.6 39 2.03
AM1064 10" lR1B 62-0118 NH3 TK-5101A1B C-2105 1200 17.0 -11 0.9*
AM1023 6" 3Pl 62-0119 NH3 P-2113A1B P-4104A1B 47167 0.585 37 25.5**
AM1034 4" 3R1B 62-0120 NH3 P-2124A1B/C TK-5101A1B 51239 0.685 -35 4.4
C~ AM1069 3" lR1B 62-0120 NH3 0-2107 TK-4108 - - - -
AM1098 8" lPl 62-0117 NH3 E-4153 0-2122 10389 17.0 -3 3.9
B01025 3" lSl 64·0101 CONDENSATE 0-2156 V-6201 1518 0.9 148 4.5
COl 004 20" lPl 62-0122 CO2 T-2102 0-4101A 63618 42.5 43 1.8
CWR10l0 14" W2 64-0109 COOLINGWAT. HEADER OSBL - 0.992 42 3.4
CWR1013 24" W2 64-0109 COOLING WAT. HEADER OSBL - 0.992 42 3.4
CWR1016 24" W2 64-0109 COOLING WAT. E-4133 HEADER 3281000 0.992 41.8 3.4**
CWR1017 10" Wl 64-0109 COOLING WAT. E-4130 HEADER 216000 0.990 45 3.4** I
CWR1018 12" Wl 64-0109 COOLING WAT. E-4132 HEADER 224000 0.990 45 3.4**
CWR1019 14" Wl 64-0109 COOLING WAT. E·4131 HEADER 192000 0.990 45 3.4**
CWR1024 4" Wl 64·0109 COOLING WAT. C-4102 HEADER - 0.992 42 3.4

CWRll03 42" W2 64-0109 COOLING WAT. HEADER OSBL - 0.992 42 3.4
CWR1225 4" Wl 64-0109 COOLINGWAT. E-4135 HEADER - 0.992 42 3.4
CWS10l0 14" W2 64-0109 COOLING WAT. OSBL HEADER - 0.995 32 4.8
c CWS1012
CWS1016
42"
24"
W2
W2
64-0109
64-0109
COOLING WAT.
COOLING WAT.
OSBL
HEADER
HEADER
E·4133
- 0.995
3281000 0.994
32
34.4
4.8
4.8
CWS1017 10" Wl 64-0109 COOLING WAT. HEADER E-4130 216000 0.995 32 4.8
CWS1018 12" Wl 64-0109 COOLING WAT. HEADER E-4132 224000 0.995 32 4.8
CWS1019 14" Wl 64-0109 COOLING WAT. HEADER E·4131 192000 0.995 32 4.8
CWS1024 4" Wl 64-0109 COOLING WAT. HEADER C-4102 - 0.994 34.4 4.8
CWSl225 4" Wl 64·0109 COOLING WAT. HEADER E-4135 - 0.995 32 4.8
OM1000 8" W1J 62-0124 OEMIN. WATER OFFSITES E-21 06 245892 0.989 47 6.0
OR1061 4" 280X 64-0101 CONDENSATE 0-2156 A-9304 1518 0.919 148 4.5
OR1070 12" 280X 64-0106 CONDENSATE V-21 01 A-9304 - 0.935 130 2.7
ORl175 2" lP1J 62-0130 CONDENSATE 0-2161 V-6202 8100 0.972 76 0.88
OW1000 2" W2W 63-0105 DRINK. WATER OFFSITES HEADER 5000 1 Amb 4
IA1000 3" Zl 63·0105 INSTR.AIR OFFSITES HEADER 514 28.8 37 8
LPS100l 3" lSl 64-0104 LPSTEAM LP HEADER J·4107AlB/C/O 850 18.0 227 4.5
c LPS1200
LPS1305
3"
20"
lS1
lS1
64-0104
64-0104
LPSTEAM
LPSTEAM
OFFSITES
LP HEADER
LP HEADER
C-4102 IT)
-
17956 18.0
- -
227
-
4.5
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DOC NO. PROJ-PM-OOB REVISION: 5
FLOW S.G. B.L. PRESS

LINE LINE FLOWING TEMP
LINE NO. P&IONO. FROM TO RATE OR @GRAOE
SIZE SPEC MEDIUM ·C
KG/H M.W. BARA
M01019 1.5" 1P1J 62·0122 SOUR WATER T-21 02 OFFSITES · · · ·
MPS1200 10" 6S1 64·0103 MPSTEAM UTILITY PLANT MPHEAOER 50093 18.0 400 42.8
MPS1302 12" 6S1 64·0103 MPSTEAM MPHEADER C-4102T 89031 18.0 387 41.8
MPS1303 3" 6S1 64-0103 MPSTEAM MPHEAOER P-4130A (T) · 18.0 387 41.8
N1000 3" 1P1 63·0105 NITROGEN OFFSITES HEADER · · · ·
N1090 %" 1P1 63·0105 NITROGEN HEADER C-4102 · · · ·
NG1000 12" 6P1 62·0102 NATURAL GAS OFFSITES 0·2144 39114 16.7 40 17
·' ·
Cj
NG1044
PA1001
3"
2"
6P1
3P1
62·0104
62·0101
NATURAL GAS
PLANT AIR
C-2102
C-2101
N·7101A1B/C
OFFSITES 3998
16.7
28.8
142
39
43.5
14.3
PA1002 3" A1 63·0105 PLANT AIR OFFSITES HEADER · · · ·
PC1012 4" 1S1 62·0121 STRIP. CONO. E·2175 OFFSITES 52747 0.989 49 4.1
PC1034 2" 1P1J 62·0130 CONDENSATE 0-4130 0·2161 1451 0.994 39 1.7
POL.lDEMIN.
SC1003 6" 1S1 64·0105 CONDENSATE P·2112A1B U 132788 0.989 51 4.0
SC1045 1.5" 1S1 64·0105 CONDENSATE P·2112A1B E-4133 · · · ·
SC1100 6" 1S1 63·0106 CONDENSATE HEADER 0·6503 · · · ·
POL.lOEMIN.
SC4005 6" 1S1 64-0105 CONDENSATE P-4103A1B U 44172 0.989 51 4.0
SW1000 3" W2 63·0105 SERV.WATER OFFSITES HEADER · · · ·
V1046 16" 1P1 63·0104 NH3 HEADER FLARE TIP 127288 17 100 2.0
V1050 20" 1P1 63·0104 SYNGAS HEADER FLARE TIP 195432 15.7 370 2.0
* Cold Product Case

C ** Warm Product Case
2.6 DESIGN FEATURES
2.6.1 Feed Gas Compression and Purification
BIL Delivery Pressure (minimum) 10.0 bara

BIL Delivery Temperature 20-40 °c
Feed Gas Compressor Seal Loss To Fuel
Feed Gas Compressor Discharge 44.00 bara
Desulphurisation:
ColMo Inlet Temperature 371 °c
ZnO Inlet Temperature 371 °c
Heat Loss 11.0 °c
Inlet H2 2.B %
C
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2.6.2 Air Compression Section
Inlet Temperature 40 °c
Relative Humidity 49 %
Discharge Pressure 39.00 bara
Air Cooling Approach 7.0 °c
2.6.3 Reforming Section
Steam/Carbon Ratio to Primary Reformer 3.2

Crossover Temperature 605 °c
Primary Reformer A.P., Tube Exit 36.5 bara
C'
j Riser Temperature Rise 17.0 °c
Transfer Line Loss 17.0 °c
Primary Reformer Efficiency (LHV basis) 91 %
Steam to Air Coil (Molar basis) 10 %
Air Coil Exit Temperature 616 °c
Sec. Reformer Air Inlet Temperature 605 °c
2.6.4 Shift Conversion
HTS Inlet Temperature 371 °c

CO Exit LTS (dry basis) 0.3 mol%
2.6.5 CO 2 Removal
CO 2 Leakage (dry basis) 1000 ppmv

Lean Soln. Pump Efficiency 72 %
Semi-lean Soln. Pump Efficiency 72 %
C Hydraulic Turbine Efficiency
Lean Soln. Pump Capacity
75
115
%
%
CO 2 Recovery Max %
Synthesis Losses to CO2 Removal 0.3 %
c
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2.6.6 Methanation
Methanator Inlet Temperature 316 DC

CO + CO2 Leakage (dry basis) 5.0 ppmv max.
Methanator Heat Loss (wet gas basis) 10.0 kcal/kmol
H:JN2 Exit Methanator 2.99
Methane Leakage (dry basis) 0.9 mol%
2.6.7 Synthesis Gas Compressor
c Suction Pressure
Suction Temperature
First Case - Stages/Nozzles
Second Case-Stages/Nozzles
30.4
39.0
1/2
2/3
bara
DC
2.6.8 Synthesis Loop Section
Pressure Exit Last Bed 139.3 bara

Inerts at Converter Inlet 8.0 mol%
Exit Ammonia 15.75 mol%
Recycle/Effluent Approach (E-2120) 10.0 DC
Loop Pressure Drop (A.P.) 7.55 bara
Primary Separator Temperature -17.8 DC
2.6.9 Refrigeration Section
C Refrigeration Levels
Utilised Exchanger (E-2120)
Chiller Temperatures:
4
1st. Stage -35.0 DC

2nd. Stage -17.8 DC
3rd. Stage -2.2 DC
4th. Stage 16.7 DC
Warm Product Temperature 37.5 DC

Cold Product Temperature -35 DC
Warm Product 1132 Vd
Cold Product 68 Vd
Alternate Cold Product Operation 1200 Vd
2.6.10 Steam System
HP Steam Drum Pressure 125.1 bara
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HP Steam Pressure to Turbines 120.4 bara

Superheat HP Steam Temp. to Turbines 505 °c
MP Export Steam 45030 kg/h(warm case)
Surface Condenser Pressure 97 mm Hg (abs)
2.6.11 Utilities
CW Supply Temperature 32 °c
.CW Retum Temperature Rise (Overall) 10 °c
Exchanger CW Max. Outlet Temperature 50 °c
c 2.6.12 Ambient Conditions for design
Barometric Pressure
Min 851.6 mbar
Normal 877.6 mbar
Max. 881.2 mbar
Maximum Temperature 44°C

Design for air coolers, compressors and fans 40°C
Minimum ambient temperature -27°C
Design Minimum temperature -25°C
.2.6.12 Catalyst Volumes
Hydrogenation Reactor 12.2 m3

ZnO Desulphurisers 2x35.8 m3
c Primary Reformer
Secondary Reformer
High Temperature shift
24.6
25.8
48.7
m3
m3
m3
Low Temperature Shift 59.2 m3
Methanator 21.0 m3
Ammonia Synthesis Converter 68.4 m3
2.7 PROCESS FLOW DESCRIPTION
2.7.1 Introduction
The ensuing discussion will describe in detail the main process flow through the unit
together with all auxiliary systems that are pertinent to the process such as steam,
boiler feed water, etc. The Operating Conditions and Process Variables will be
discussed in detail in Section 3.0 of this manual.
For the purpose of this description the process is divided into the following sections
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and the description of the process flows through the unit will be more readily
understood if the Process Piping, Auxiliary and Utility Instrumentation Flow Sheets are
referred to during study of this section.
• Raw Synthesis Gas Preparation

• Synthesis Gas Purification.
• Purified Synthesis Gas Compression and Ammonia Synthesis.
• Ammonia Refrigeration System.
• Process Condensate Stripper and other facilities
The process is illustrated in Process Flow Diagrams 060-0004 to 060-0008 and

together with the Utility Flow Diagrams 061-B001 to 061-B008. These diagrams
c represent the operation of the plant using natural gas as feedstock to produce
1132 tid of warm product (37.5°C) plus 68 tid of cold product (-35°C). Process
flow diagram 060-0009 illustrates the alternate refrigeration operation when the
plant is producing 1200 tid of cold product. The following process description
relates to the mode of operation of the plant for the feed gas composition shown
on these process flow diagrams.
2.7.2 Raw Synthesis Gas Preparation
The raw synthesis gas is produced from natural gas in four major steps
• Compression, preheating and desulphurisation of the natural gas feed.
• Steam reforming of the hydrocarbons in the feed to an intermediate level in the

Primary Reformer furnace.
• Autothermal reforming of the steam reformer effluent in the Secondary Reformer,

where the Methane is reduced to a very low level while introducing the process air
c •
to provide Nitrogen in the proper ratio required for Ammonia synthesis.
Conversion of carbon monoxide and steam in the reformed gas to carbon dioxide
and hydrogen in a shift converter.
2.7.2.1 Supply & Compression of Natural Gas Feed
Natural Gas is used for feedstock and fuel. Natural Gas Feed from the National
Iranian Gas Company (NIGC) Metering Station enters the Offsites where a stearn
heated Feed Gas Heater (E-1 001) is provided to prevent hydrate formation in the
NH3 Unit feed gas/fuel gas and Offsites fuel gas systems.
Three control valves located downstream of the heater E-1001 control the pressure
of the Natural Gas supply to the Ammonia Unit and to the Offsites fuel gas system.
After entering the NH3 Unit, the gas is passed through the Feed Gas Knockout Drum
0-2144, where entrained liquids and solids are removed. After the Knockout Drum,
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feed and fuel streams are separated. The fuel stream provides most of the heating
requirements in the Ammonia Plant reforming furnace and auxiliary boiler.
The Natural Gas used as feed is compressed to 44 bara in a single case

centrifugal Feed Gas Compressor, C-21 02. To protect the compressor over a
wide range of operating conditions, it is provided with a Kickback Cooler, E-2133,
which allows all or part of the discharge gas to be recycled back to the suction.
When the pressure at the Ammonia Plant battery limit is above 44 bara a bypass
is provided around C-21 02 to enable it to be shut down. To assist in this operation,
Nat Gas Feed Preheater E-2171 is provided.
c 2.7.2.2 Preheating of Natural Gas Feed
A small part of the purified hydrogen-rich synthesis gas is recycled to the process
downstream of C-21 02, to give a hydrogen concentration of approx. 3% in the feed
gas. The compressed feed gas is then heated to 371°C in the convection section of
the primary reformer H-21 01, prior to sulphur removal by hydrogenation and
desulphurisation.
2.7.2.3 Hydrogenation/Desulphurisation
The heated feed gas then enters the Hydrogenation Reactor, R-2160, where the .
organic sulphur compounds are hydrogenated to H2S over a bed of CobalV
Molybdenum (Co-Mo) catalyst. Immediately downstream of the Hydrogenator are
the Zinc Oxide (ZnO) Desulphurisers, R-2108A & B. The Hydrogen Sulphide in the
gas reacts with and is retained by the Zinc Oxide producing an effluent stream
containing less than 0.1 ppm H2S by volume. Normally the Desulphurisers operate
in series, but provision is made in the installation to allow single reactor operation
during catalyst change-out while the plant remains in operation. Based upon the
c content of sulphur compounds in the natural gas the Zinc Oxide in each
desulphuriser is designed to be replaced every year.
The desulphurised feed is mixed with medium pressure (41.2 bara, 335°C) stearn
added in a ratio of 3.2 moles of steam per mole of organic carbon. The feed Gas!
steam mixture is further heated to 605°C in the convection section of the Primary
Reformer, H-21 01, using heat recovered from the furnace flue gas.
2.7.2.4 Primary Reformer
The purpose of the Primary Reformer is to begin the process of reforming the feed
gas into the hydrogen needed for ammonia synthesis. The hot steam/gas mixture
passes down through the nickel catalyst in the reformer catalyst tubes suspended in
the radiant section of the furnace. Heat for the endothermic reforming reaction is
supplied by fuel gas burners located between the rows of tubes. The down firing
furnace burners develop a reformed gas temperature near 812°C at the outlet of the
catalyst tubes. The outlet pressure of the catalyst tubes is 36.5 bara.
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The reforming furnace incorporates the use of internal manifolding at the outlet of the
catalyst section for heat conservation of the reformed gas. The reformed gas
continues to pick up heat in the risers while exiting the Radiant section. This raises
the gas temperature at the Primary Reformer exit to approximately 829°C.
The reforming furnace is designed to maximise its thermal efficiency by recovering

heat from the flue gases in the convection section. Flue gases consist of combustion
products from the radiant section of the Reformer. The recovered heat is used for the
following services:
• Steam / Gas mixed feed preheat
C' •
•
Process air / steam preheating (two coils)
Steam superheating (two coils)
• Natural gas feed 'preheat for desulphurisation
• High pressure BFW preheating
• Fuel Gas preheating
Heat is recovered from the Ammonia process by heating boiler feed water, generating
high pressure steam, superheating high pressure steam and preheating the feed and
fuel gas. The convection section and auxiliary boiler together with the Secondary
Reformer Waste Heat Boiler, E-21 01, HP Steam Superheater E-21 02 , High
Temperature Shift Effluent Waste Heat Boiler, E-21 03 , and the Ammonia Converter
Effluent/Steam Generator, E-2123, will maintain the plant in steam balance. Normally,
medium pressure steam will be exported to the Urea plant.
2.7.2.5 Secondary Reformer
The process air supply for the Secondary Reformer is provided by a two case, steam
turbine driven Air Compressor, C-21 01. The air is preheated to 616°C in order to
C transfer the maximum amount of the overall reforming conversion load to the
Secondary Reformer. A small quantity of medium pressure steam is continuously
.added to the preheat coil inlet to ensure a forward flow in the event of emergency
shutdown of the Air Compressor.
Air for the Urea Unit Hydrogen Converter and Passivation, as well as instrument and
plant air for the Complex is taken at the required pressure levels from between
compression stages of C-2101. A backup system is provided in the Utilities section
of the Complex to provide compressed air when the Ammonia Unit is not in operation.
The partially reformed gas from the Primary Reformer is mixed with the hot process
air in the Secondary Reformer in stoichiometric proportions as required for the
synthesis reaction. The combustion product is then directed downward through a bed
of nickel catalyst. The gas temperature leaving the Secondary Reformer is
approximately 994°C.
The high temperature Secondary Reformer effluent is used to generate high pressure
steam in Secondary Reformer Waste Heat Boiler, E-21 01, and to add superheat to
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the steam in HP Steam Superheater E-21 02. It exits E-21 02 at 371 cc,the
temperature required for the high temperature shift conversion. This Superheater
provides only part of the steam superheat requirements, with the remaining portion
fulfilled by a coil in the Primary Reformer convection section. A process gas bypass
arrangement is provided between these exchangers to control the division of boiling
and superheating duty according to the various operating demands of the steam
system.
2.7.2.6 Shift Converters
Downstream of the E-21 02 are the High Temperature and Low Temperature Shift
Converters, R-21 04 & R-21 09. The function of these Reactors is to convert the
c carbon monoxide in the gas stream to carbon dioxide for subsequent removal in the
aMDEA® system. .
In the shift conversion step, carbon monoxide reacts with steam to form equivalent
amounts of hydrogen and carbon dioxide. The shift reaction is reversible and
exothermic. High temperatures favour the reaction rate while low temperatures
favour maximal conversion (equilibrium). For optimum performance, two stages of
shift conversion are provided with the High Temperature Shift Effluent Waste Heat
Boiler, E-21 03, located in between to moderate the gas temperatures and efficiently
recover waste heat in the form of high pressure steam.
The two single bed shift reactors are stacked vertically to save plot space and cost.
Flow of the process gas is downward through the catalyst beds. Each shift reactor
utilises a different catalyst material and each catalyst has its own distinct advantages.
In the high temperature shift (HTS), a relatively cheap and more durable iron oxide
catalyst produces the bulk of the shift conversion. A more favourable equilibrium is
attained with the low temperature shift (LTS) copper catalyst, but it is more expensive
and susceptible to poisoning from process impurities. The low CO leakage (0.3 dry
c mol%) obtained from this combination results in a reduction in plant feed requirements
due to the more complete conversion of CO and steam to hydrogen and CO2 ,
It will be necessary to convert the oxidisedform of the LT Shift catalyst to the reduced
form at start-up with hydrogen using either nitrogen or natural gas as a carrier gas.
To assist in this operation, Start-up Cooler E-2173 has been provided.
2.7.3 Synthesis Gas Purification
Raw synthesis gas from the LTS converter is processed to remove carbon dioxide
and carbon monoxide yielding a highly pure hydrogen - nitrogen rich synthesis gas.
Bulk removal of CO2 is accomplished by an aMDEA® system. This is a proprietary low
energy process licensed by BASF.
Final removal of residual carbon dioxide and carbon monoxide is accomplished in the
Methanator by converting the carbon oxides to methane and water with hydrogen.
The hot "shifted" gases from the bottom of the low temperature shift converter are
cooled in the L.T. shift effluent train before entering the CO2 absorber T-2101. L.T.
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shift effluent gas is first cooled against boiler feed water in E-2131 and then provides
reboil heat to the aMDEA@ system G02 Stripper T-21 02 via reboiler E-21 05 with final
cooling against demineralised water in E-21 06 before entering Raw Gas Separator D-
2102 where condensed water is knocked out.
Temperature control of the L.T. shift effluent gas and heat input to the aMDEA@
solution is effected by E-2131 boiler feed water bypass. An LP steam heated reboiler
E-2111 provides further heat input to CO2 stripper T-21 02 .
2.7.3.1 D-2102 - Raw Gas Separator
c
Water vapour present in the process gas stream condensed in E-21 05 and E-21 06 is
disengaged in the Raw Gas Separator D-21 02. The condensed process steam is
withdrawn from the bottom of the separator and routed by pumps P-2121 AlB via
exchanger E-2188 to the Process Condensate Stripper (T-2150) or when off
specification or during short term upsets of D-21 02,to drain.
The raw synthesis gas passes overhead from the separator D-21 02 and is directed to
the CO2 absorber for the initial synthesis gas purification step. Pressure protection for
the D-21 02 and upstream equipment is provided by relief valve PRV-D2102 on the
Raw Gas Separator vapour outlet.
A vent in the form of a manual by-pass of relief valve PRV-D2102 is provided on the
vapour outlet from D-21 02 for start-up and emergency venting of process gas
upstream of the CO2 Absorber, T -2101. A line from the vapour outlet of D-21 02 routes
a nitrogen/hydrogen gas mixture to the Low Temperature Shift Converter inlet for
catalyst reduction during start-up (Nitrogen circulation reduction step). A takeoff from
the same line also supplies hydrogen at start-up to the suction of Feed Gas
Compressor, C-21 02.
c 2.7.3.2 T-2101 - C02 Absorber
The raw synthesis gas with most of the water removed flows through an internal
distributor into the bottom section of the CO2 Absorber column and then upward
through two packed beds. Regenerated (C02 free) aMDEA@ solution is introduced
through an internal distributor at the top of the column and flows downward through
the beds. The downward flowing solution is contacted with the up-flowing gas in the
bed packing and selectively absorbs the CO2 from the gas, the other components of
the gas stream having very low solubility in the solution. The CO2 loaded (rich)
solution collects in the bottom section of the column and exits under level control. A
further bed of packing in the base of the column minimises gas entrainment in the
solution. The rich solution at a pressure of about 32.5 bara is returned to the top of
stripping column T -2102, which operates at a pressure of about 1.8 bara. Power is
recovered from the flowing solution by passing it through a hydraulic turbine, which
assists the P-21 07A Lean solution pump drive motor. A seal loop on the gas inlet line
prevents backflow of solution in upset conditions.
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2.7.3.3 D-2103 - CO 2 Absorber Overhead KO Drum
The aMDEA® solution absorbs essentially all of the CO2 that passes through the
absorber. To knock out the bulk of any entrained solution the absorber tower also
has a demisting pad in the top through which the gas passes before leaving the
tower. The effluent gas from the absorber overhead flows to the CO2 Absorber
Knockout Drum D-21 03 for final removal of any entrained solution.
This solution is removed from the system manually to the sump system. Process
gas leaving the top of D-21 03 then passes through the shell side of E-2114
(Methanator Feed/Effluent Exchanger) before flowing to the Methanator (R-21 06)
c
top inlet.
Piping is also provided from the outlet of D-21 03 to route process gas to:
(i) Primary Reformer H-21 01 as excess synthesis gas to supplement the

• fuel gas (PG1 035-6");
(ii) to the suction of C-21 02 as start-up hydrogen (PG1038-3"), and
(iii) to R-21 09 for LTS catalyst reduction during start-up(PG1019-1.5").
2;7.3.4 T -2102 - CO2 Stripper
Regeneration of the Circulating solution by removing the absorbed carbon dioxide is

accomplished by steam stripping in the CO2 Stripper T -2102 before the solution is
recycled to the Absorber for reuse.
The rich solution from the absorber is introduced into the LP flash section of
c Stripper T -2102 and flows downward through a bed of packing. Steam generated
in the stripper section of the column passes upward through the bed and strips CO2
from the rich solution.
The semi-lean solution is pumped from the base of the LP flash section by pumps P-
2108 AlB through exchanger E-2112A1B and returned to the top of the stripping
section at boiling point.
The solution passes downwards through the beds of packing in the stripping section
and meets an upward flow of stripping steam generated by process gas reboiler E-
2105 and LP steam reboiler E-2111. The now fully regenerated solution at about
124°C exits the column through Lean/Semi Lean exchanger E-2112A1B where it is
cooled and routed to the suction of pumps P-2107A1B. Pumps P-2107A1B return
the lean solution to the top of the absorber column via exchangers E-21 09 and E-
2110 where it is further cooled to about 50°C. A slipstream is taken off the flow
through filter F-21 04 to prevent a build up of particulate matter in the system.
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stripping column through the contact cooler section and demister. This section is
supplied with cooled quench water by pumps P-2116 AlB via exchanger E-21 07 and
has a demineralised water make up line DM1102-1".
The contact cooler condenses the stripping steam and cools the CO2 to about 43°C
before the major portion is exported from the plant for use in the production of Urea
via CO2 Compressor C-41 02 located within the Ammonia Unit, with the balance
being vented to atmosphere. The contact cooler also serves to remove any
entrained aMDEA® solution from the CO2 before it is supplied to the Urea plant.
Vacuum breakers SP-009 AlBIC I D&E and rupture disc SP-008 are also provided
on the stripper overhead line.
c 2.7.3.5 Auxiliary Equipment
Auxiliary equipment for the CO2 removal system consists of a main aMDEA®
Solution Storage Tank (TK-2114) an aMDEA® Solution Sump (TK-2115) to collect
solution from various points in the system and a Collection Sump A-21 01 for
collecting accidental spillage of solution, together with contaminated rainwater and
wash water from bunded areas in the system.
TK-2i 14 is used as the main storage tank for aMDEA® solution prior to start-up and
if required to drain down the removal system during shutdowns. aMDEA® transfer
Pump, P-2111 is used to transfer the contents to the CO2 removal system with
P-21 07AlB being used to transfer from the removal system back to the tank.
It should be noted that it is extremely important to ensure that the solution is

regenerated and the Absorber depressurised before solution is transferred to
TK-2114. Before TK-2114 is opened in any way it must be purged using the
nitrogen connection at the sample point until suitable tests i.e. Drager, indicate that
any hydrogen has been purged. If the tank is to be entered, then all the necessary
c precautions described in the Safety Manual for vessel entry must be strictly
observed.
Sump Pump P-2115 is used to circulate the recovered solution through the Sump
Filter F-2115 or to transfer the recovered solution to TK-2114 either directly or via
Sump Filter F-2115.
There is also an aMDEA® Antifoam Injection System (V-21 09) for charging
anti-foam inhibitor agent to the following two locations in the CO2 Removal system
1) P-21 07A(H) discharge line (Rich solution to Stripper).

2) P-21 07 AlB suction line.
2.7.3.6 C-4102 - CO 2 Compressor
The CO2 product from the top of T -2102 CO2 Stripper together with a small amount
of air from the 2nd stage suction of C-21 01, Air Compressor, is routed to D-41 01
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CO2 Compressor KO Drum.
C-41 02, CO2 Compressor is a turbine driven two case/4 stage compressor on which
the 1st, 2nd and 3rd stages are cooled in intercoolers and any entrained liquid
condensed in the intercoolers is automatically level controlled to D-2161 Process
Condensate Drum from separators provided downstream of each intercooler.
A Hydrogen Converter, R-41 02 is located in the 2nd stage discharge piping of

C-41 02 to remove any hydrogen present in the CO2 to less than 10 ppm(vol) by
catalytic combustion. A portion of the air injected upstream of 0-4101 is used for this
catalytic combustion.
c 2.7.3.7 Methanation
The synthesis gas from 0-2103 is heated to 316°C in the Methanator Feed/Effluent
Exchanger E-2114. This exchanger recovers the heat in the Methanator effluent by
heat exchange against the feed gas. A gas by-pass is provided around the
exchanger to permit adequate control of the feed temperature. A separate high-
pressure steam heated Methanator Feed Heater E-2172 is provided for initial
heating of the gas to normal operating temperature. E-2172 will also be required in
normal operation when the LTS Shift catalyst is fresh and the heat of the Methanator
reaction is not sufficient to provide the required temperature differential in E-2114.
The Methanator R-21 06, contains a bed of Nickel catalyst that removes the
remaining carbon oxides in the gas stream by promoting the reaction of carbon
dioxide and carbon monoxide with hydrogen to form Methane and Water. The total
amount of carbon oxides leaving the Methanator will be less than 5 ppm by volume,
and the methane content about 0.9% (dry basis). Due to the highly exothermic
nature of the methanation reactions, the synthesis gas temperature increases from
316°C at the inlet to about 347°C at the outlet.
c After heat exchange with the Methanator feed, the purified synthesis gas is air
cooled to approximately 53°C in the Methanator Effluent Cooler E-2118 and further
cooled against cooling water in E-2115 before delivery to the Synthesis Gas
Compressor Suction Drum 0-2104 at about 39°C. The small amount of process
condensate remaining in the synthesis gas, which disengages in 0-2104 and later
0-2105, is pumped to 0-2102 using the Low Pressure Condensate Pump P-2150,
and is recovered for use as BFW with the other process condensate.
2.7.4 Synthesis Gas Compression & Ammonia Synthesis
The purified synthesis gas, containing the stoichiometric ratio of hydrogen and
nitrogen for ammonia synthesis, is compressed in a turbine driven centrifugal
synthesis gas Compressor C-21 03. The compressor consists of two cases with
intercooling between cases and a separate recycle wheel in the second case.
From the discharge of the low pressure case, at approximately 67 bara a small portion
of the synthesis gas is recycled back to the Primary Reformer feed gas preheat coil to
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OOCNO. PROJ-PM-OOS REVISION: 4
provide hydrogen for the Co-Mo and ZnO desulphurisation. The make-up gas from
the first case is first cooled by heat exchange with demineralised water in the
Synthesis Gas Compressor Interstage/BFW Preheater E-2117. The gas is further
cooled to 39°C against cooling water in the Synthesis Gas Compressor Intercooler
E-2116, and then to 4.4°C with ammonia refrigeration in the Synthesis Gas
Compressor Interstage Chiller E-2129. Condensate is separated from the synthesis
makeup gas in the Synthesis Gas Compressor Interstage Separator 0-2105, and
passed through an Oil Filter F-21 02, before it is directed back to 0-2104 for recovery.
The cooled synthesis gas is compressed to the synthesis loop pressure in the makeup
gas section of the high pressure compressor case. The fresh synthesis gas is mixed
internally within the high pressure case of the compressor with recycle gas from the
c synthesis loop. After mixing, the pressure is boosted by the last wheel of the
compressor. The combined flow to the synthesis loop is discharged from the
compressor at approximately 144 bara and is cooled to 52°C in the Ammonia
Synthesis Loop Cooler E-2124.
Before the recycle gas (plus fresh feed) re-enters the converter, it is routed via E-2120
Unitised Chiller to condense out the net ammonia make produced on its previous pass
through the converter. This specially designed chiller provides refrigeration of the
synthesis gas through interchange of heat with ammonia vapours returning from the
Secondary Flash Separator 0-2106 and boiling ammonia liquid at four different
temperature levels (16.7°C, -2.2°C, -17.SoC and -35°C).
The Unitised Chiller consists of multiple concentric tubes that run through the boiling
ammonia compartments. Synthesis gas vapours from the Secondary Flash Separator
0-2106 pass counter-currently through the centre tubes and the compressor
discharge flows through the annuli. Thus, the synthesis gas is being cooled from the
outside by boiling ammonia and from the inside by recycle vapour from the Secondary
Flash Separator. The final exit temperature of the Unitised Chiller is -17.SoC and the
c liquid ammonia product is disengaged from the synthesis gas immediately

downstream.
Liquid from the Secondary Flash Separator is flashed into the Ammonia Letdown
Drum 0-2107. The flashed vapour, primarily gases released from solution, is mixed
with the refrigeration system purge gas and sent to the Purge Gas Scrubber T-21 03.
The liquid ammonia product is then split into several streams leading to E-2120 and to
the purge gas cooler section of the Refrigerant Receiver 0-2109.
The vapour from the Secondary Flash Separator 0-2106 is the Ammonia Synthesis
Converter (R-21 05) feed. It contains near 2.7 vol% ammonia and is reheated to 42°C
in the Unitised Chiller as described above. Before entering the Ammonia Synthesis
.Converter the gas is preheated to 259°C in the Ammonia Converter Feed/Effluent
Exchanger E-2121. This exchanger is provided with a feed gas bypass that controls
R-21 05 feed temperature.
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2.7.4.1 Ammonia Converter - R-21 05
Product ammonia is synthesised from the hydrogen and nitrogen in the circulating gas
stream over beds of catalyst in the horizontal, intercooled converter R-21 05. The
converter contains a removable catalyst basket within the pressure shell and
integrated with the basket is the internal heat exchanger E-2122. While there are
only two adiabatic beds,there are three catalyst sections as the second stage is split
into two sequential parts. Each catalyst bed contains a promoted iron magnetite
catalyst supported on profile wire screens. A major portion of the feed gas is passed
through the shell/basket annulus, thus preventing the pressure shell from being
heated by the reaction, and enters the shellside of the internal exchanger, preheating
c the feed against hot effluent from the first bed. The remaining portion of the feed
enters the converter via a bypass line and mixes with the other feed at the
interchanger exit. The amount of bypass is varied to control the temperature of the
process gas to the first catalyst bed.
The feed gas is directed downward through the iron catalyst. The exothermic and
equilibriurn governed reaction proceeds with a significant ternperature rise. Upon
leaving the first bed, the partially reacted gas passes through the grid supporting the
catalyst and into the space between the bottom of the bed and the basket wall. Frorn
here it is routed to the tubeside of the E-2122 Interchanger and is cooled to the proper
feed temperature to the second catalyst bed. There is no heat exchange between the
two sections of the second adiabatic bed. Hot converter effluent from the last bed
exits the converter via a special connection between the basket and pressure shell.
The heat of reaction from the ammonia synthesis is recovered by the steam system in
the Ammonia Converter Effluent Waste Heat Boiler E-2123 then used to preheat the
feed in E-2121. A small portion of the reacted gas is taken from the synthesis loop at
this point to prevent the build-Up in the synthesis loop of inert gases contained in the
purified feed (e.g. CH 4 and argon). Chilling the vapour to -17.B lowers the
c ammonia content in this high pressure purge by ammonia refrigeration in the Purge
Gas Chiller E-2125. The liquid ammonia condensed in this exchanger is removed in
the Purge Gas Separator D-21 OB, and directed to the Ammonia Letdown Drum. The
vapour from the separator is sent to the Purge Gas Scrubber T -2103, for recovery of
the remaining ammonia and then used for fuel in the Primary Reformer furnace.
A line is provided downstream of the converter effluent side of E-2121 to enable

synthesis loop gas to be used as a secondary back-up supply of desulphurisation
hydrogen in the event of a C-21 03 trip. The primary backup supply of desulphurisation
hydrogen is synthesis gas from D-21 03 routed to the suction of the Feed Gas
Compressor. The secondary back-up supply would only be required in cases when
the Feed Gas Compressor is not running and the supply would only be available for a
lirnited tirne, whilst the Feed Gas Compressor is started up, or C-21 03 is restarted. (It
should be noted that the back-up supply should be switched to the injection point
downstream of the pre-heat coil since the addition of NHs rich synthesis gas to the
cold natural gas containing CO2 , could produce carbamates and cause line blockage.
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DOC NO. PROJ-PM-OOa REVISION: 4
2.7.4.2 Start-up Heater - H-21 02
A gas fired Start-up Heater H-21 02 is provided for activating a fresh charge of
catalyst in the Ammonia Converter and for heating the catalyst up to the required
temperature during start-up.
2.7.5 Ammonia Refrigeration And Recovery
A four stage ammonia refrigeration system provides refrigeration to condense

ammonia product from the circulating gases in the synthesis loop to allow additional
ammonia synthesis on recirculation of the gas stream through the converter. It also
c
provides for recovery of ammonia from vented gases and for synthesis gas
compressor makeup gas chilling. The four refrigeration levels operate at
approximately 16.7°C, -2.2°C, -17.aoC and -35°C.
The refrigeration system consists of a two-case centrifugal compressor (C-21 05) with
two intercoolers, a refrigerant condenser, a refrigerant receiver, and evaporators.
Provision is made for contact chilling and venting of any inert gases dissolved in the
liquid ammonia from the synthesis loop. Additional provision is made to recover a
small amount of ammonia vented from the atmospheric storage to the first stage
suction of the Ammonia Refrigerant Compressor.
Ammonia vapour from the second case of the Ammonia Refrigerant Compressor
C-21 05 is cooled and condensed at 37.5° C in the Refrigerant Condenser E-2127,
then sent to the Refrigerant Receiver 0-2109. Non-condensable gases with the
residual ammonia vapour from the refrigerant receiver enter the contact chiller section
on the top of the receiver where the ammonia is condensed and drains back to the
vessel. The chilled vent gas from 0-2109 is mixed with the flash gases from 0-2107
and 0-210a before being senttothe Purge Gas Scrubber T-21 03 and ultimately to
the fuel system.
c A small portion of the liquid ammonia from the Refrigerant Receiver 0-2109 is
pumped by the Ammonia Injection Pump P-2120AlB for use as reflux to the Ammonia
Stripper, T-21 04. Under normal operation, a major portion of the product ammonia is
pumped from the receiver to the Urea unit via the Warm Product Pump P-2113A1B.
The remainder of the liquid in 0-2109 is flash cooled to 16.7"C in the Fourth Stage
Refrigerant Flash Drum 0"2123 where it provides cooling for the Unitised Chiller.
A stream is taken from the warm Ammonia product line downstream of the pumps as
cooling medium to the Urea Granulation Cooler E-4204 and Steam Condensate
Chiller E-4153. The return frorn these is to the third stage Flash drum 0-2122.
Some liquid ammonia frorn 0-2123 is used by the Synthesis Gas Compressor
Interstage Cooler, E-2129. Other liquid from 0-2123 is let-down as required to the
Third Stage Refrigerant Flash Orurn, 0-2122, flashing to -2.2°C. Liquid from the Third
Stage Drum is flashed into the Second Stage Refrigerant Flash Drum, 0-2121,
at -17.aoC.
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Liquid in the Second Stage Drum provides refrigeration directly to the second stage
chiller section of the unitised exchanger. An additional flow of liquid ammonia is taken
from this stage to provide the required refrigerant for the Purge Gas Chiller, E-2125.
The net liquid from the Second Stage Drum is flashed into the First Stage Refrigerant
Flash Drum D-2120 at -35°C. Liquid in the First Stage drum provides refrigeration
directly to the first stage chiller section of the unitised exchanger and is also sent to
the atmospheric storage tank via the Cold Ammonia Product Pump P-2124A1B/C.
The vapours generated in the four refrigeration drums are fed to the appropriate stage
of the two-case, steam turbine-driven centrifugal Ammonia Refrigerant Compressor.
The vapours are compressed, condensed, and returned to the Refrigerant Receiver,
c thus completing the refrigerant cycle. The refrigerant compressor intercoolers E-2128
and E-2167 provide cooling between the second and third stages of compression.
Boil off vapours from the ammonia storage are also routed to the first stage suction of
the refrigerant compressor. They are thus condensed by the ammonia plant
refrigeration system and a corresponding additional quantity of cold ammonia is
routed to storage.
2.7.6 Ammonia Purge Gas Recovery System
To prevent the build-up of inert gases such as argon & methane contained in the
purified feed, a side stream of purge gas is taken from the loop. The high pressure
purge gas from D-21 08, along with flashed gases from D-21 09 and D-21 07, are sent
to the Purge Gas Scrubber T-21 03. Ammonia is absorbed by a water wash in a
packed tower and the Primary Reformer burners use the low pressure absorber
overhead gases as fuel gas.
The solution leaving the absorber has an arnmonia concentration of about 11.17% wt.
c From the Purge Gas Scrubber it is pumped by the Purge Gas Scrubber Pump
P-2130AlB, and heated to about 168. 7"C in the Ammonia Stripper Feed/Effluent
Exchanger E-2161 by purified recycle water from the Amrnonia Stripper bottoms. The
heated ammonia-water solution enters the Ammonia Stripper T-21 04 below a section
of reflux packing. Liquid arnrnonia reflux to the top of the stripper column is provided
from the refrigeration system frorn the Ammonia Refrigerant Receiver D-21 09 via the
Ammonia Injection Pumps P-2120AlB. The ammonia vapour from the top of T-21 04
is vented to the Refrigerant Condenser E-2127 where it is recovered. The stripper
heat is provided by the Ammonia Stripper Reboiler, which condenses mediUm
pressure steam. A srnall amount of MP steam condensate is added to the system as
rnake up for water losses in the scrubber overhead systern.
2.7.7 Ammonia Storage & Loading Facilities (OSBL)
NOTE: The following description is based on the original Design Engineering

package and to identify any later changes or modifications, reference should be made
to the latest issue of the Offsites P&ID's.
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a) Storage Tank TK5101 is provided for the storage of Ammonia. The tank has a
capacity of 1O,OOOMT operating at a pressure of 50 mbarg and a temperature
of-35°C.
b) Although well insulated, some heat leak into the ammonia tank occurs producing
vapours, which must be removed by refrigeration. In general, refrigeration of the
storage tank involves the removal of the ammonia vapours from the vapour
space above the stored liquid ammonia by the Refrigeration Compressor,
C-21 05 in the Ammonia Unit. If C-21 OS is shut down, the package Refrigeration
Unit C-S1 01 will be in service maintaining storage tank temperature and
pressure.
c c) A Road Tanker Loading Station is provided with two Loading Arms, V-S102 A &
V-S102B each with a loading capacity of 2S000 Kg/hr. Ammonia liquid is
transferred to the loading arms using the Ammonia Transfer Pumps, P-S101 AlB
via the Ammonia Heater, E-S101 where the temperature control is set to obtain
the required ambient temperature for loading the trucks with the displaced
vapour being returned to the Ammonia Storage Tanks.
d) Facilities are also provided to depressurise and fill bottles with ammonia. The
loading is carried-out to an exact weight as specified for the bottle being filled,
using the Ammonia Bottle Weight Scales, V-S103A1B
e) A portable hydrostatic testing hand pump is provided to recertify used bottles

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3 DESCRIPTION OF UNIT CONTROL
3.1 UNIT CONTROL
This section of the manual will give the reader a clearer understanding of the unit
control and can be more readily understood if the Process Piping, Auxiliary and Utility
Instrumentation Flow Sheets are referred to during study of this section.
Note that throughout this section instruments having the same number and
designated AlBIC indicates that a two out of three voting system exists for the
c relevant interlock.
3.1.1 Natural Gas Feed Preparation
3.1.1.1 Offsite Feed Gas Heater (E-1 001)
Natural Gas Feed from the NIGC Metering Station enters the Offsites where a steam
heated Feed Gas Heater (E-1 001) is provided to prevent hydrate formation in the
NH3 Unit feed gas and Offsites fuel gas systems.
PI-1001 and TI-1001 monitor the pressure and temperature of the incoming gas. The
temperature of the natural gas downstream of E-1001 and being supplied to the NH3
Unit is sensed by a temperature indicator controller located on the Offsites fuel gas
system which resets the position of control valve PIC-1081 and regulates the flow of
LP steam to the Feed Gas Heater.
c. Should a low external supply pressure and ambient conditions allow, E-1001 can be
totally by-passed. In the event of the supply pressure being raised to 44 bara it will
be necessary to manually reset the temperature controller on the fuel gas supply line
to prevent the formation of hydrates at the higher pressure.
Three control valves located downstream of the Feed Gas Heater (E-1 001) control
the pressure of the natural gas supply to the Ammonia Unit and to the Offsite fuel
gas system. These operate under a split range pressure control system with the
actual control valve positions dependent upon the external pipeline supply pressure.
Should it be necessary to operate the system with a natural gas supply pressure in
excess of 50 bara then for downstream protection, the two control valves (PV-1084B
& C) must be blocked in and locked closed.
Should the Natural gas supply pressure approach the minimum of 10 bara the feed
gas compressor C-21 02 will not have sufficient capacity to supply both the Ammonia
plant at full rate and the Offsites gas turbines. In this situation the Ammonia plant
rate should be reduced and stabilised in good time to prevent an upset in the
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Reforming section.
For over pressure protection, high/high pressure switches PSHH-1083A1B/C are

located downstream of the pressure control assembly which in the event of an
excessive high high pressure, will actuate an interlock which will close the shut-off
valve XV-1041 on the natural gas feed line from the metering station and also the LP
Steam supply to the Feed Gas Heater, E-1001. The same interlock may be
manually actuated by the operator using shutdown switch HS-1041 located in the
main control room (HS-1042 will reset shutdown switch HS-1041). The supply line to
the Feed Gas KO Drum (0-2144) is further protected by relief valves PSV-1001A &
B, which vent to atmosphere at a safe location.
c 3.1.1.2 Feed Gas Knockout Drum (0-2144)
Natural gas from the Feed Gas Heater (E-1 001) enters the ammonia plant battery
limits on line NG-1 000-12" where the pressure and temperature of the incoming gas
are monitored by pressure indicator (PI-1074) and temperature indicator (TI-1029).
The flow is indicated on FR-1042 and integrated on FQI-1042. All these instruments
are accessible to the operators on the FCS system in the control room.
Any free water in the natural gas feed separates on entering 0-2144 Feed Gas KO
Drum from where it may be drained for disposal. A high level alarm, LAH-1 002A will
warn the operator of a high level and should the level continue to rise, LAHH-1212
on a 2 out of 3 voting system will actuate interlock ESO-21 02 which will shut down
the Feed Gas Compressor C-21 02 and open the kickback valve UV-1015. Other
causes of actuation of interlock ESO-2102 are described in detail in Section 11.3 of
this manual.
The main supply line from 0-2144, KO Drum routes feed gas to the Primary
Reformer Feed Gas Preheat Coil, either directly or via the Feed Gas Compressor
c
C-21 02, dependent on the pressure available from Offsites. There is also a branch
line FG 1002-6", which supplies natural gas as fuel gas to the various burner users on
the NHs Unit. These are described under "Utility Flows" later in this section. Another
branch line FG1 076-2" before FR-1042 supplies fuel gas to the flare system with flow
indicated on FI-1041.
The supply pressure of natural gas feed to the Feed Gas Compressor is controlled
by PRC-1187, which is provided with High and Low pressure alarms in the main
control room. High high Pressure on PT-1191A1B/C and low low pressure on PT-
1192A1B/C will actuate interlock ESO-2102 (refer Section 11.3.4 of this manual for
details) and shut down the Feed Gas Compressor should either of these conditions
occur.
3.1.1.3 Feed Gas Compression
The Feed Gas Compressor (C-21 02) is provided to compress the natural gas feed to
the required pressure for the hydrogenation and desulphurisation reactions and
subsequent reforming and conversion reactions through to the suction of the
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Synthesis Gas Compressor.
C-21 02 is a centrifugal machine consisting of a single cased multi-stage compressor

driven by a steam turbine using MP steam exhausting into the Surface Condenser
E-2140 operating at a pressure of 97 mm Hg abs.
Lubrication and governor oil for the compressor and turbine consists of a complete
system shared with C-2101 Air Compressor as described later for C-21 01 Air
Compressor. Alarms and shutdowns are also provided to alert personnel of
abnormal operating conditions and for the protection of the machine itself.
The compressor takes suction from the top of the knockout drum 0-2144 at a normal
c operating condition of 15.95 bara and 39.6°C and is discharged at 44 bara and
142°C through the feed preheat coil on Primary Reformer H-21 01.
PRC-1 01 0 at the Oesulphuriser outlet, is provided to control the pressure being

delivered from the compressor by regulating the speed of the steam turbine and
which will go to minimum speed on minimum signal from PIC-1 01 O. HS-1202 is
provided to allow manual trip of the steam turbine governor by actuating interlock
ESO-21 02, together with reset switch HS-1058. The causes and effects of Interlock
ESO-2102 are described in detail in Section 11.3.4 of this manual.
A kickback system connecting the compressor discharge to the suction is provided to

protect the machine from surging. This is controlled by FIC-1 015 on the compressor
discharge and the kickback stream is cooled in Cooler E-2133 and any moisture is
knocked-out in a piping pot fitted with a high level alarm LAH-1 077 and a manual
drain to sewer. A tie-in to the kickback line PG1034-3" from 0-2103 is provided to
supply hydrogen during start-up with flow indication by FI-1169A together with low
flow alarm FAL-1169 in FCS and the flow also can be seen on FI-1169B locally with a
manual globe valve installed in view.
c Local Indicators PI-1604 & TI-1609 together with temperature indicator (TI-1308) and
a high temperature alarm (TAH-1308) plus a pressure recorder (PR-2205) and PAH
in the main control room are provided on the compressor discharge.
Relief valves PSV-C2102A & B set at 51.5barg and 54.1 barg protect the machine
from an overpressure situation, which would relieve the compressor discharge to the
vent system.
With the possibility of natural gas being available at high pressures, a bypass round
the Feed Gas Compressor C-21 02 has been provided to enable the NH3 Unit to be
operated with this compressor shutdown. The minimum gas pressure at the battery
limits required for this operation is 44 bara. When in this bypass situation, hand
switch HS-1047A will be switched to route the signal from PIC-1 01 0, located on the
natural gas feed to the Primary Reformer, to HV-1027 thereby controlling the
pressure of natural gas to the Primary Reformer. In addition, when HS-1047A is
switched in this position, it will cancel Interlock ESO-2102 which normally shuts down
C-21 02. It is important that HS-1047 is correctly positioned when the machine is
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running to avoid running C-21 02 with the shutdown interlock ESD-2102 cancelled.
To avoid the temperature of feed gas to H-2101 is too low with C-21 02 shutdown, the
natural gas feed is preheated by LP steam in Nat Gas Feed Preheater E-2171, and
the temperature of feed gas to H-21 01 is controlled by TIC-1197 via control valve TV-
1197 on the LP steam line.
Note however that for start-up and shutdown of the NH3 Unit, the C-21 02 Feed Gas
Compressor must be in service. This will require a battery limit supply pressure of
natural gas of 14 bara to provide a sufficiently low pressure to enable the recycle of
hydrogen rich gas back to the suction of C-21 02 for process purposes.
c 3.1.1.4 Desulphurisation
In normal operation and after compression, the natural gas feed stream is ioined by a
hydrogen-rich gas stream from the first stage discharge of the Synthesis Gas
Compressor (C-21 03). This mixture flows through the feed preheater coil on the
Primary Reformer H-21 01. The flow of hydrogen-rich gas from C-21 03 is controlled
by FIC-1 022. Temperature Controller TIC-1 093 located on the feed preheater
bypass line provides a means of adjusting the inlet temperature to the Hydrogenator
R-2160. Should it become necessary to use the back-up supply of hydrogen from
the synthesis loop, then it is important to note that it should be routed downstream of
the preheat coil using the interlocked bypass provided since the addition of NH3 rich
synthesis gas to the cold natural gas containing CO2 could result in the formation of.
carbamates and possible line blockage.
During start-up and shutdown operations of the ammonia plant, hydrogen-rich gas for
desulphurisation of natural gas and the desulphurisation and reduction of the
Reformer and HTS shift catalyst, will be produced by dissociating ammonia in the
Primary Reformer (see section 6.6.7). The hydrogen-rich gas so produced will be
c routed via a start-up line PG1034-3" from D-21 03 Absorber Overhead Drum back to
the suction of the Feed Gas Compressor (C-2102).
Hydrogen gas flow from C-21 03 to H-2101 is indicated on FIC-1022 and the
combined hydrogen Inatural gas feed flow is indicated on FRC-1001. From these
two indications, the Hydrogen to Feed Ratio may be calculated.
The combined stream passes down through the Hydrogenator (R-2160) containing a
bed of Cobalt Molybdenum catalyst. This vessel is provided with temperature
indicators at the top (TI-1074), centre (TI-1075) and bottom (TI-1076) of the catalyst
bed together with high temperature alarms (TAH-1075 and T AH-1076) at the centre
and bottom of the bed. The temperature of the stream leaving R-2160 is indicated by
TI-1067 (local) and TI-1 068 (on the main control panel).
It then passes through the Desulphuriser reactors (R-21 08 A& B) containing Zinc
Oxide pellets. Local temperature indicators are located on the outlet line from each
vessel together with TI-1306 indicated on the main control panel.
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Pressure differential indicators are provided to indicate the pressure drop across
each of the Hydrogenator and Desulphuriser catalyst beds and vessels. Sampling
points are also located at intervals throughout each bed of Desulphuriser catalyst to
enable catalyst activity to be monitored.
A vent is provided on each Desulphuriser outlet line for use during start-up and
shutdown together with a start-up line from the outlet line of R-21 08B for LT Shift
catalyst reduction.
3.1.2 Raw Synthesis Gas Preparation
Reformed gas is produced in successive process steps by reforming part of the
c hydrocarbons in the primary reformer furnace and additional reforming, with air
addition for nitrogen requirements in the secondary reformer.
3.1.2.1 Primary Reformer - [H-2101]
The desulphurised gas feed is flow controlled by FRC-1 001 and then mixes with
process steam before passing to the mixed feed preheat coil located in the
convection section of the Primary Reformer (H-21 01). The MP steam flow is
controlled by FRC-1002 and both FRC-1001 and FRC-1002 are supplemented with
low flow alarms FAL-1001 and FAL-1002 respectively. A further decrease in feed
gas flow to the reformer will cause Low/low flow switch FSLL-1201 to actuate
interlock ESD-1201 and ESD-2111, which is described in detail in Section 11.3.2 &
Section 11.3.10 of this manual. Hand switch HS-1048 is provided to over-ride ESD-
1201 and ESD-2111 during start-up.
The signal from natural gas flow transmitter FT-1201 is forwarded to relay FY-1201
together with a temperature/pressure compensated signal from relay FY-1202 on the
Process Steam line. The two signals are divided to give the steam to carbon ratio
c which in the event of decreasing below a preset level and after a 5 second delay, will
actuate Low Steam to Carbon Ratio Alarm FFAL-1201 and alert the operator to this
condition. Should it decrease still further, then Lowllow Steam to Carbon Ratio switch
FFSLL-1201 will actuate Interlock ESD-1203 and ESD-1211 to be described in detail
in Section 11.3. Hand switch HS 1261 is provided as a start-up over-ride.
The combined stream of steam and feed in a ratio of 3.2 mols steam per 1 mol of
organic carbon, flows through the mixed feed preheat coil in H-2101 convection
section at the exit of the radiant section of H-2101.
When problems exist in the reforming section, HS-1202 may be used to manually
actuate interlock ESD-1203 and ESD-1211 which will shut down gas feeds to the
Primary and Secondary Reformers and open PIC-1169 vent control valve upstream
of H-2101 thus allowing continued operations of the Hydrogenator and
Desulphurisers. (HS-1059 will reset the interlock and HS-1261 over ride it on start-
up).
From the main inlet header, the steam/gas stream is distributed to four


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sub-headers (harps) which are arranged in parallel rows across the top of the
primary reformer arch. Each of the sub-headers distribute the flow via pigtail
connections downward through 52 catalyst packed tubes in the radiant section of
the primary reformer furnace. The total of 208 (4 x 52) catalyst packed tubes
constitutes the primary reforming element of the process.
The bottom of each row of 52 catalyst tubes terminates in collector headers located
near the floor of the primary reformer furnace. There are four risers (centrally
located), one on each of these collection headers, that return the flow to a water
jacketed transfer line V-2150 located over the top of the arch of the radiant box. The
transfer line directs the flow from the Primary Reformer to the process gas inlet of the
Secondary Reformer (R-21 03).
c The primary reformer has various pressure gauges, temperature indicators and
temperature recorders to observe process conditions. There is also pressure
differential indicator (Pdl-11 01) for observing the pressure drop across the tubes and
an analyser recorder (AR-1 001 A) recording the methane (CH 4) content of the
process flow leaving the primary reformer.
There are 110 fuel gas fired arch burners regulated by HIC-1 035 through 1039
located on the main panel together with 6 burners for providing additional heat to the
convection section for superheating purposes. H-2101 also incorporates an
independently fired auxiliary boiler of four burners for producing HP steam. The
control systems for these arch, superheat and auxiliary boiler burners together with
descriptions of associated shutdown devices and interlocks are contained in section
11.0 of this manual. To avoid overfiring during start-up and until normal process
conditions are reached, special attention must be paid to the lower flows of fuel gas
required until all burners are alight.
The Primary Reformer fire box draft is provided by an induced draft fan C-211 0
and regulated by the Fan drive turbine speed which is controlled by the furnace box
c pressure controller PIC-1 019 adjusting the turbine governor speed setting.
High/high pressure on PT-1 059A1B/C connected to interlocksESD-2111 ,

ESD2112andESD-2114 will shut down the arch burners, Aux. boiler burners and
tunnel burners should a high pressure occur in the furnace box.
The Aux. boiler combustion air is supplied by a turbine driven forced draft fan C-
2111. The air is supplied in ratio to the fuel by a leading air system that adjusts the
fan drive turbine governor speed setting.
PAHH-1060AlB/C located in the Aux. boiler firebox will shut down the Aux. boiler
burners via interlock ESD-2112 should a high pressure occur in the firebox.
The combustion air for the Arch burners is supplied by turbine driven fan C-2112.
The air supply is regulated by five manually operated dampers in the combustion
air ducts to the arch burners. The turbine speed is controlled by FIC-1181 , which
adjusts the governor speed setting to regular the flow of combustion air.
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High pressure switch PSH-1058 located in the Arch burner fire-box and/or High
pressure switch PSH-1057 located in the convection section at the suction of the
ID Fan, will actuate interlock ESD-1058 which will cause Air Horn PAH-1058A to
sound and Rotating Light PAH-1058B to light. These are both located in the
Reformer penthouse and interlock ESD-1058 will also be actuated by Arch burner
SID Interlock ESD-2111 and/or Aux. boiler burner SID ESD-2112 and/or tunnel
burner SID ESD-2114.
3.1.2.2 Process Air Compression
Process air for the secondary reforming operation is delivered by C-21 01, Air
c Compressor,which is a four-stage, two case centrifugal compressor driven by

turbine C-21 01 (T). C-21 01 (T) is a 6 stage, steam condensing turbine which is
exhausted and condenses into surface condenser E-2140 operating at a pressure of
97 mm Hg abs.
Lubrication, and governor oil for the compressor and turbine consist of a complete
system, rnounted in a separate console 'and shared with C-21 02 Feed Gas
Compressor. The console consists of a main reservoir together with individual
compressor lube oil rundown tanks and control oil accumulators. Turbine driven
lube oil purnps with electric motor standbys, together with coolers, filters, a
pressure control system and ancillary piping are also provided. The coolers and
filters are provided with valve linkages so that change over is accomplished without
interrupting the oil flow but it should be noted that the standby cooler and filter must
be completely filled with oil before being put into service.
C-2101 takes suction through F-2101 Air Filter to remove dust and fine particles from
the air stream. The air is compressed in the first stage of the LP case to 2.09 bara at
150°C and after being cooled in intercooler E-2141 to 39°C, enters the second stage
c
of the LP case. The air is compressed in the second stage of the LP case to 4.9 bara
at 150°C and then cooled in intercooler E-2142 to 39°C before entering the first
section of the HP case. This section compresses the air to 14.4 bara at 185°C which
is again cooled in an intercooler E-2143 to 39°C and then compressed in the final
stage to 39 bara at 189°C for delivery to the process.
The water knocked out in the intercoolers is sent to Process Condensate Drum D-
2161 for recovery.
Local pressure and temperature indicators are provided wherever necessary for
the checking of the process air conditions throughout the compressor system. A
number of alarms and trips are also provided and alarm conditions should be
corrected as quickly as possible. C-2101 may be shutdown manually by HS-1201A
in the main control room panel or by HS-1201 B local shutdown switch. (both reset
by HS-1057 in the main control room).
Shutdown interlock ESD-2101 will shutdown the machine whilst interlocks ESD-
2102 (Feed Gas Cornpressor shutdown), ESD-1201 (Low Natural Gas Feed
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Rate),ESD-1223(Steam Drum Low level) and ESD-1203 (Low Steam to Carbon

Ratio) will cause the machine to go to minimum speed. The causes and effects of
all these interlocks are described in Section 11.3. of this manual.
A supply of air to the Urea Plant is taken from the 2nd stage suction and instrument
air to the Offsites is supplied from the 4th Stage suction. A branch line from the final
discharge line is provided for line blowing and catalyst dusting during start-up.
Additional piping from the final discharge line together with a return line to the LP
case discharge line, is provided to enable circulation of nitrogen using the high
pressure case of C-2101 in order to heat up the Primary Reformer catalyst at
start-up. During these operations the LP case will be isolated from the HP case and
c vented to atmosphere from the interstage vent on the 2nd Stage discharge line.
Piping is also provided from the HP case discharge line for Low Temperature Shift
Converter reduction should it be decided to reduce the LTS catalyst using nitrogen as
the carrier gas in a closed loop circulation as opposed to a once through reduction
using desulphurised natural gas as the carrier medium. This includes a line from
C-2101 final discharge together with a nitrogen tie-in and intermediate vent to
atmosphere between the LP and HP cases. These procedures are discussed in the
Start-up Section 6.0. of this manual.
Process air flow to the Secondary Reformer from the final discharge of the
compressor is controlled by FRC-1003 which regulates the speed of the C-21 01
turbine driver and will go to minimum speed on minimum signal from FRC-1003.
FIC-1004 is an anti-surge controller provided to maintain the compressor flow above

its minimum value (surge point) by venting air to atmosphere. Process airflow may
be closed off to the Secondary Reformer by the operation of the valve HV-1006,
which is part of the reformer feed shutdown circuit. HV-1006 is a inching valve on
the 4th stage discharge line, which may be closed either by push button HS-1028
c action, or as a result of one or more of the following interlocks being actuated:
• ESD-2101 - C-2101 Air Compressor shutdown

• ESD-1201 - Low natural gas feed rate
• ESD-1223 - Steam Drum low level
• ESD-2102 - C-21 02 Feed Gas Compressor shutdown
• ESD-1203 Low Steam to Carbon Ratio.
• ESD-1202 Low Low Process steam
Any of these interlocks will also open HV-1023, the interstage vent to atmosphere and
UV-1004, the vent to atmosphere on the 4th stage discharge.
A 2-inch bypass is provided around HV-1 006 for use during initial start-up of the
Secondary Reformer, which must be tight shut off during normal operation.
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3.1.2.3 Secondary Reformer (R-21 03)
Downstream of HV-1 006,.the. process air is joined by a small flow of medium

pressure steam, which is-c~ntrolled manually by the 4-rnch bypass valve on HV-1021
and metered by FI-1044. This steam flow is necessary for the protection of the
preheat coil in the event of process air failure, with HV-1021 automated to initially
open to a preset position on hand switch HIC-1021. This then allows further manual
positioning of HV-1021 for excess cooling steam flow to the air heater coils when the
solenoid holding HV-1006 is de-energised by an interlock and closes. A control valve
(TV-1095) is located on a bypass line round the first (cold) process air preheat coil
and is positioned by TIC-1 095 controlling the temperature downstream of the second
(hot) process air coil where a high temperature alarm (TAH-1312) is also located.
c The preheated steam-air mixture enters at the top of the Secondary Reformer
(R-2103) and is directed downward through a flow insert into the combustion zone of
the reformer where the Primary Reformer effluent enters. Leaving the combustion
zone of the reformer, the flow passes through the catalyst bed to enter a chamber at
the bottom of the reformer.
There are temperature recorders located at the top (TR-1052) and bottom (TR-1053)
of the catalyst bed, and on the main outlet line from Secondary Reformer (TR-1334A
and TR-1334B). Each of these recorders is provided with High temperature alarms.
The entire vessel is encased in a water jacket with four metal temperature sensors
(TE-1333A through D) attached to the shell at various points.
Hot effluent gases from the Secondary Reformer are cooled in E-2101 (Waste Heat
Boiler) and E-21 02 (HP Steam Superheater), then pass to the inlet of the High
Temperature Shift Converter R-21 04. The temperature of the HP steam exiting
E-21 02 is controlled by TIC-1 004 via control valve TV-1 004 located in Secondary
c Reformer Waste Heat Boiler E-2101 tube side which adjust the heat area of E-2101.
The overall temperature drop across E-21 01 and E-21 02 from 994°C to 371°C is
obtained by heating the boiler water from D-2101 that is thermo-circulating on the
shell side of E-2101 and the HP steam passing through the tubes of E-21 02. The
required inlet temperature to the HT Shift Converter of 343°C - 371°C is controlled by
TIC-1010, which activates control valve TV-1010 located in the shell side of E-21 02.
High (TAH-1336) and Low (TAL-1336) Temperature alarms are provided on the
steam outlet line from E-21 02. An analyser for CH 4 (AE-1 001 B) together with a
sample point (S-028), are located on the process gas line exit E-21 02.
The primary reformer and secondary reformer systems including the waste heat
boiler and steam Superheater, are protected against over-pressuring by Relief
valves PSV-E2102A and PSV-E2102B at the "hot" outlet of E-21 02 HP Steam
Superheater.
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3.1.2.4 Shift Conversion (High and Low Temperature)
The shift converters are stacked one above the other with the upper vessel being the
High Temperature Shift converter and first in the process flow from the Secondary
Reformer.
3.1.2.4.1 R-2104 - HT Shift Converter
The process flow enters the top of the High Temperature Shift Converter, passes
through an inlet baffle and down through the shift catalyst and out through the outlet
collector at the bottom of the converter. To monitor converter conditions, a
c pressure differential indicator (PDI-111 OA in FCS and local PDI-111 OB) across the
catalyst bed together with temperature indicating points (TI-1340 through 1344) at
intervals throughout the bed, are provided on the HTS converter. Piping provision
is made for steam injection into the bottom of the HT Shift converter, which is
routed up through the catalyst bed to a vent on the inlet line from E-21 02, for use
during start-up and to keep the catalyst warm during brief shutdown periods. The
steam flow is measured on FI-11 03 with a globe valve in view.
The flow then enters the shell side of the HTS Effluent Waste Heat Boilers
(E-2103A & B) to give up heat to boiler feed water for D-2101. A vent line is located
on the process gas stream downstream of E-21 03B and is fumished to permit the
manual venting of the high temperature shift converter effluent gas at start-up and
in emergencies.
3.1.2.4.2 R-2109 - L.T. Shift Converter
After leaving the E-21 03A1B exchangers, the gas flows to the Low Temperature
c Shift Converter (R-21 09), passes through the low temperature catalyst bed and
leaves via the bottom outlet.
Analyser AR-1 022A is provided on the inlet line from E-21 03B to record the carbon
monoxide content of the gas being fed to the LT Shift Converter.
The low temperature shift converter may be bypassed during start"up or in

emergencies by operating pushbutton HS-1004 which closes MOV-1008 in the L.T.
shift inlet line and opens MOV-1009 in the bypass line. By "inching" HS-1009 or
HS-1008, the two valves may be adjusted for partial bypass operation.
The LTS inlet temperature is controlled by partial bypass of the boiler feed water to
the tube side of exchanger E-21 03B. Controller TRC-1 011 positions control valve
TV-1 011 which is located on E-21 03B tube side bypass and is used as a "forcing
valve" through the tubes.
Temperature indicators (TI-1046 through 1049) with high temperature alarm are
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OOCNO. PROJ-PM-008 REVISION: 4
provided at intervals throughout the LTS converter for monitoring of conditions

together with a high temperature alarm (TAH-1350) at the catalyst bed exit.
Temperature indicator TI-1 063 and analyser AR-1 022B located on the outlet line
respectively indicate and record the temperature and carbon monoxide content of
the gas exiting R-21 09.
3.1.3 Synthesis Feed Gas Purification
3.1.3.1 Carbon Oioxide Removal
· The hot "shifted" gases from the bottom of the low temperature shift converter are
C/
cooled in the L.T. shift effluent train before entering the aMOEA CO2 Removal
section. L.T. shift effluent gas is first cooled against boiler feed water in E-2131 and
then' provides reboiler heat to the CO2 removal solution in reboiler E-21 05 with final
cooling against demineralised water in E-21 06. Temperature control of the L.T. shift
effluent gas and heat input to the aMOEA solution is effected by E-2131 boiler feed
water bypass. A globe valve is installed on the water bypass line in view with local
TI-1355 which indicate the outlet of E-2131 tube side temperature. The outlet
temperature of E-2131 shell side is monitored on TI-1351 with TAL-1351 waming of
low temperature. Temperature indicators are also provided on outlet lines of E-21 05
and E-21 06 hot side.
3.1.3.1.1 0-2102 - Raw Gas Separator
The cooled "shifted" gases enter the Raw Gas Separator 0-2102 where any water
vapour present in the process gas stream and condensed in E-2105, E-2113 and
E-2106, is disengaged. The condensed process steam is withdrawn from the
bottom of the separator under control of LlC-1 003 and is routed directly to the
Process Condensate Stripper (T-2150) via P-2121 AlB or when off specification or
c during short term upsets of 0-2102, to drain. High and Low level alarms LAH-1003
and LAL-1003 will wam personnel of these level conditions, and high level interlock
1-1003 will automatically start whichever pump is on standby P-2121 AlB should a
high level occur.
A low/low level on 0-2102 will also actuate an interlock ESO-1205 which will close
valve LV-1003A on P-2121AlB discharge to T-2150 and close valve LV-1003B on
the disposal line to the drain. (This interlock is further described in Section 11.0 of
this manual).
The raw synthesis gas passes overhead from the separator 0-2102 and is directed
to the CO2 absorber T-21 01 for the initial synthesis gas purification step. Pressure
protection for 0-2102 and upstream equipment is provided by relief valve
PRV-02102 on the Raw Gas Separator vapour outlet.
A vent in the form of a manual by-pass round relief valve PRV-02102 is provided
on the vapour outlet from 0-2102 for start-up and emergency venting of process
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gas upstream of the CO2 Absorber T-21 01. The line PG1 034-3" from the vapour
outlet of D-2102 routes a Nitrogen/Hydrogen gas mixture to the Low Temperature
Shift Converter inlet for catalyst reduction during start-up (Nitrogen circulation
reduction step). A takeoff from the same line also supplies hydrogen at start-up to
the suction of Feed Gas Compressor C-21 02.
3.1.3.1.2 T-2101 - Carbon Dioxide Absorber
The raw synthesis gas with most of the water removed flows through an internal
distributor into the bottom section of the column and then upward through two
packed beds. The column oIJerates at about 32.5 bara, the column top and bottom
C' temperatures being about 50'C and 82'C respectively. A seal lute on the gas inlet
line prevents backflow of solution during upset conditions.
Regenerated (C02 free) aMDEA solution is pumped by P-2107A1B from stripping

colurnn T-21 02 and after cooling by E-21 09 and E-211 0 is introduced through an
internal distributor at the top of the T-1201 absorber colurnn and flows downward
through the beds. A slipstream is taken from this stream through Filter F-21 04
before it enters the column.
The flow into the column is controlled by FIC-1005. Low flow alarm FAL-1005 will
cut in the standby P2107 pump if there is not a low level in stripper T-21 02 bottom
pan i.e. LALL-1043 on T-1202 is healthy. Low Low flow alarm FALL-1205 will trip
the Methanator R-21 06 via interlock ESD-21 06 to prevent the excessive
temperature rise which would ensue if aMDEA solution flow is lost or severely
restricted.
The downward flowing solution is contacted with the upward flowing gas in the bed
packing and selectively absorbs the CO2 from the gas, the other components of the
gas stream having very low solubility in the aMDEA solution. The CO2 loaded (rich)
solution collects in the bottom section of the column and exits under level control
c LlC-1 004 with LAH and LAL. A further bed of packing in the base of the column
minimises gas entrainment in the solution. A sight glass is provided on the bottom
pan.
The rich solution at a pressure of about 32.5 bara is returned to the top of stripping
column T-21 02 which operates at a pressure of about 1.8 bara. Power is recovered
from the flowing solution by passing it through a hydraulic turbine, which assists the
P-21 07A Lean solution purnp drive rnotor via a clutch.
The level in the bottom pan is controlled by LlC-1 004, which controls LV-1004A,
and 1004-B on split range.
LV-1004A operates frorn 0.2 - 0.6 bar and LV-1004B frorn 0.6 -1.0 bar. The
hydraulic turbine P-2107(H) load is set by HIC-1 005. The hydraulic turbine load
should be adjusted such that LV-1004A has sufficient throughput to rnodulate and
control the absorber level. In the event of a hydraulic turbine trip LV-1 004A1B have
. sufficient capacity to handle the total solution flow.
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LALL-1204 will trip LV-1004A1B, HV-1005 and XV-1105 closed via manual reset
solenoids LY -1 004A1B, HY-1005 and XY-1105 to prevent breakthrough of high
pressure gas to the stripping column if the liquid seal in the absorber is lost. These .
solenoids must be reset manually in the field to resume control when the absorber
level is re-established
The differential pressure across the column is indicated on PDI-1 042, which is
provided with a high alarm. An increased DP may indicate foaming problems or
excessive liquid loading in the column.
Anti-foam injection points are provided on the rich solution return line to T-21 02 and
c 3.1.3.1.3
on the suction line to P-21 07A1B.Anti- foam is supplied from pump set V-21 09.
D-2103 - CO 2 Absorber KO Drum
The aMDEA solution absorbs essentially all of the CO2 that passes through the
absorber. The absorber tower also has a demisting pad in the top through which
the gas passes before leaving the tower, to knock out the bulk of any entrained
carbonate solution. The effluent gas from the absorber overhead flows to the CO2
Absorber Knockout Drum D-21 03, for final removal of any entrained solution.
This solution is removed from the system manually to the sump system. A high
level alarm (LAH-1132) is provided on the knockout drum to warn of an abnormal
level condition. Process gas leaving the top of D-21 03 then passes through the
shell side of E-2114 AlB (Methanator Feed/Effluent Exchanger) before flowing to
the Methanator (R-21 06) top inlet.
Pressure controller PIC-100510cated on the Process gas line from D-21 03 to

E-2114 and the Methanator will vent excess pressure to the Front End Flare.
C. Piping is also provided from the outlet of D-21 03 to route process gas to:
(i) Primary Reformer H-21 01 as excess synthesis gas to supplement the

fuel gas and the flow is controlled by FIC-1178. Low low Flow Alarm
FAL-1278 in the main control room will actuate interlock ESD-1031 which
is override by HS-1081 on start-up.
(ii) to the suction of C-21 02 as start-up hydrogen, and
(iii) to R-21 09 for LTS catalyst reduction during start-up.
3.1.3.1.4 T -2102 - Carbon Dioxide Stripper
Regeneration of the circulating solution by removing the absorbed carbon dioxide is

accomplished by steam stripping in the Carbon Dioxide Stripper T -2102 before the
solution is recycled to the Absorber for reuse.
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The rich solution from the absorber is introduced into the LP flash section of
Stripper T -2102 where the reduction in pressure causes CO 2 to flash off the
solution. The solution then flows downward through a bed of packing. Steam
generated in the stripper section of the column passes upward through the bed and
strips more CO2 from the rich solution.
Solution is pumped from the base of the LP flash section by pumps P-21 OaAlB
through exchanger E-2112 and returned to the top of the stripping section at boiling
point.
This pumped flow is normally controlled by FIC-l017 controlling FV-l017. Should,

however, the level in the draw off pan go outside the limits set by LlC-l 041, LlC-
c 1041 will override the flow controller until the level is once more within the limits. A
sight glass is provided.
High and low alarms are provided on LlC-l041. A minimum stop is provided on FV-
1017 to give minimum flow protection to pumps P-21 OaAlB. FALL-l017 low/low
flow alarm will start the stand by p-21Oa via Interlock 1-1017. FALL-1217 will trip
the Methanator via interlock ESD-21 06 to prevent excessive catalyst bed
temperature rise in the event of loss of, or restricted aMDEA solution flow.
The solution passes downwards through the beds of packing in the stripping
section and meets an upward flow of stripping steam generated by process gas
heated reboiler E-21 05 and LP steam heated reboiler E-2111. The now fully
regenerated solution at about 125'C exits the column through Lean/Semi Lean
exchanger E-2112 where it is cooled and routed to the suction of pumps P-21 07.
Flow of lean solution to the Absorber from P-21 07 is controlled by FIC-l005.
Low/low flow FALL-l 005 will autostart the spare P-21 07 via Interlock 1-1005,
however, LALL-1043 on the bottom draw off pan of the column prevents autostart
of the standby P-21 07 if there is a Low Low level in the pan. A sight glass is
c provided.
Pumps P-21 07 return the lean solution to the top of the absorber column via
exchangers E-21 09 and E-211 0 where it is further cooled to about 50'C. E-2109 is
a fin fan cooler consisting of 5 bays with 2 fans per bay. The louvers on each bay
can be opened or closed manually. The fan blade pitch will be set manually on one
fan and the pitch on the other will be controlled by TIC -1224 sensing the exit
aMDEA temperature.
A slipstream is taken off this flow through filter F-21 04 to prevent a build up of
particulate matter in the system. PDI-ll02 and PDAH-ll 02 give warning that the
filter elements need changing. Local flow indicator FI-1113B and flow indicator FI-
1113A in main control room indicate the flow through the filter. aMDEA draining
can be recovered to Sump tank TK-2115 when changing filter elements.
Seal flushing for pumps P-21 07AlB and p-210aAlB is provided from downstream of
E-2110. This flushing and also the seal flush for P-2111 and P-2112A1B can also
be supplied from BFW pumps P-2104A1B via cooler SP-167 during start up
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conditions. The normal supply to condensate pumps P-2112A1B and aMDEA

transfer pump P-2111 will always be from this source.
A pumpout line to TK-2114 MD1002-3" is provided downstream of E-211 O. This line

MUST be kept spaded off during normal operations to prevent any possibility of
over-pressurising TK-2114.
Note that the minimum stop must be taken off the block valve downstream of
pumps P-21 07AlB on MD 1020-16" when pumping out the system to prevent
pumping solution back into T-2101.
Note also that T-21 02 MUST be depressurised before removing the spade
c from pumpout line MD 1002-3" to remove any possibility of high pressure gas
entering TK-2114.
The CO2 released from the rich solution and stripping steam exit the top of the
stripping column through the contact cooler section and demister. This section is
supplied with cooled quench water by pumps P-2116A1B via exchanger E-21 07 and
has a demineralised water make up facility.
Temperature controller TIC-1 006 output adjusts the setpoint of FIC-1 016, which
controls the water flow via FV-1 016 to maintain the required temperature exit the
column. FALL-1016 Lowllow flow alarm starts the standby P-2116 pump via
interlock 1-1016. High and low temperature alarms are provided on TIC-1006.
The pump draw off pan is provided with a sight glass and level indication from
LI-1 040 that has a high and low level alarm.
The contact cooler condenses the stripping steam and cools the CO2 to about 43°C
before the major portion is exported from the plant for use in the production of Urea
c via CO2 Compressor C-41 02 located within the Ammonia Unit, with the balance
being vented to atmosphere. The contact cooler also serves to remove any
entrained aMDEA solution from the CO2 before it is supplied to the Urea plant.
Vacuum breakers SP-009A1B/CI D&E and rupture disc SP-008 are also provided
on the stripper overhead line.
The carbon dioxide flows through a demisting pad and out the top of the Stripper
(T-2102) where it can be either vented to atmosphere or sent to the Urea plant with
the stripper pressure controlled by PIC-11 04. The total flow of CO2 product to the
Urea Unit is metered by FI-1162 and FQI-1162 and is controlled by FRC-1024,
which controls the discharge flow of CO2 Compressor C-41 02 by regulating the
speed of the turbine driver. High and Low pressure alarms PAH-1104 and
PAL-1104 provide a warning of changes caused by the Urea Plant.
The stripper normally operates under 1.8 bara. at the top, and about 1.6 bara. at
the bottom and any excess pressure not absorbed in the flow to the CO 2
Compressor, will· be vented to atmosphere via PIC-11 04. The pressure drop across
the stripper internals is measured by PDI-1043, which also incorporates a High DP
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alarm (PDAH-1043).
3.1.3.1.5 Auxiliary Equipment
Auxiliary equipment for the CO2 removal system consists of a main aMDEA
Solution Storage Tank (TK-2114) and aMDEA Solution Sump (TK-2115) to collect
solution from various points in the system.
TK-2114 is used as the main storage tank for aMDEA solution prior to start-up and
if required to drain down the removal system during shutdowns. aMDEA transfer
Pump, P-2111 is used to transfer the contents to the CO2 removal system with
P-2107NBbeing used to transfer from the removal system back to the tank. P-
c 2111 can be used to circulate solution through filter F-2115 back to the tank to
clean up the system inventory.
TK-2114 is provided with a Nitrogen purge facility and vent, relief valve,
temperature and level indication and low level alarm.
It should be noted that it is extremely important to ensure that the solution is

regenerated and the Absorber depressurised before solution is transferred to
TK-2114. Before TK-2114 is opened in any way it must be purged using a nitrogen
connection at the sample point until suitable tests i.e. Drager, indicate that any
hydrogen has been purged. If the tank is to be entered, then all the necessary
precautions described in the Safety Manual for vessel entry must be strictly
observed.
Sump Tank TK-2115 is provided with a Sump Pump P-2115, which is used to
circulate the recovered solution in the Sump and to transfer the recovered solution
to TK-2114 either directly or via Filter F-2115.
c A level switchLlC-6704 with LAL and LAH is provided on TK-2115.Low level in TK-
2115 will shut down P-2115 via Interlock 1-6704 and activate low level alarm
LAL-6704 to wam the operator should this condition occur,. High level alarm
(LAH-6704) will start P-2115 via Interlock 1-6704. Local level and temperature
indications are provided.
There is also an aMDEA Antifoam Injection System (V-21 09) for charging
anti-foam inhibitor agent to two locations in the system. Anti-fo~m inhibitor injection
is routed to:
• P-21 07 NB suction line (Semi-lean solution to Absorber).

• P-21 07 A(H) discharge line (Rich solution to stripper).
3.1.3.1.6 C-4102 - CO2 COMPRESSOR (in urea plant)
C-41 02 CO2 Compressor is a 4-case/16-stage compressor with a gearbox, which

increases the speed of the 3rd & 4th stages. The compressor is driven by a 6
stage, steam condensing turbine (C-4102[T]) driven by MP steam which exhausts
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as extraction steam to 0-4110 Extraction Steam Saturator; and LP Steam

exhausting .and condensing in Surface Condenser E-4133. C-4102[T] is also
provided with a Gland Steam Condenser E-4135. Lubrication oil for the
compressor and turbine consist of a complete system, mounted in the base plate.
The console consists of a reservoir (TK-4120), a main steam driven lube oil pump
P-4130A, a motor driven standby pump P-4130B, a pair of lube oil coolers E-4134A
& B, a Lube Oil Tank Heater H-41 01, a Primary Oil Filter F-41 05 and a motor driven
Oil Purifier V-4124. An Oil Filling Pump (air driven) P-4145 together with a Lube
Oil Rundown Tank 0-4123 and a Control Oil Accumulator 0-4124 are also
provided. A pressure control system and ancillary piping are also provided. The
coolers and filters are provided with suitable valving and linkages so that change
over is accomplished without interrupting the oil flow but it should be noted that the
c standby cooler and filter must be completely filled with oil before being put into
service.
The compressor is supplied with a number of alarms and trips which function, either
to wam, or shutdown after previous warning, when potentially damaging conditions
are approached. Any alarm condition will operate a common trouble alarm in the
control room whilst the actual alarm will display on the local compressor alarm
panel. Alarm conditions should be corrected as quickly as possible, especially
those that are associated with a trip that operates if the condition is allowed to
deteriorate.
The design of the compressor is based on a mixture of Carbon Oioxide (87.9%),

Oxygen (1.4%), Nitrogen (4.8%), Hydrogen (0.45%) & Water Vapour (4.8%) being
supplied to the first stage from the CO2 Stripper T-21 02 on the Ammonia Unit
together with a small amount of air from the 2nd stage suction of Air Compressor
(C-2101).
The compressor takes suction from 0-4101 Knockout Drum at 1.7 bara and 39.8°C.
0-4101 is provided with a level controller L1C-1 003, which disposes of any knocked
c out water to Process Condensate Drum 0-2161. In the event of a high level in
0-4101, the operator will be alerted by High Level alarm LAH-1003 and should the
situation not be remedied, a High/High Level switch LSHH-1001 will actuate
shutdown interlock 1-4102C and shut down the compressor. Similarly a Low/Low
Pressure switch PSLL-1001 located on the suction line from 0-4101 will also
actuate Interlock 1-4102C and shut down C-41 02.
The compressed mixture exits the 1st stage at 6.7 bara and 177°C and after
cooling in E-4130 Compressor first stage intercooler, enters the First Stage
Separator 0-4130 where more moisture is knocked-out and disposed of by level
controller L1C-1 012 to Waste Condensate Stripper T-2125.
Again a High/High Level occurring in 0-4130 will actuate Interlock 1-4102C and shut
down the compressor. The temperature leaving Intercooler E-4130 is controlled at
40°C by TIC-1013, which regulates the flow of gas through and round the
intercooler.
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DOC NO. PROJ-PM-OOS REVISION: 4
The CO2 mixture enters the second section of the LP case at 6.4 bara and here it is
compressed to 24 bara at 1S0°C and routed to R-41 02 Hydrogen Converter where
hydrogen and other combustibles present are reduced by catalytic reduction.
Should over-reaction occur in R-41 02, then a High/High Temperature switch
TSHH-1019 will actuate Interlock 1-1019F and cause C-41 02[T] to go to minimum
speed. This interlock will be described in greater detail in a later section. In normal
operation the temperature of the gas leaving R-41 02 will have increased to 24SoC
and it is then cooled in E-4131 Second Stage Intercooler to 40°C (controlled by
TIC-1022), before entering D-4131 Second Stage Separator. Any moisture is again
knocked-out and discharged to T-2125 by Level Controller L1C-1023 and in the
event of a HigJi/High Level in D-4131, Interlock 1-4102C will shutdown C-41 02.
c The CO2 mixture then enters the first section of the HP case of the compressor
where it is compressed to 7S.5 bara and 170°C before cooling in Third Stage
Intercooler E-4132 to 50°C (controlled by TIC-1035) and moisture removal in Third
Stage Separator D-4132 prior to final compression in the 4th Stage to 146.4 bara
and 114°C for delivery to the process.
The turbine speed is controlled by FRC-1 024, which regulates the flow of carbon
dioxide from the 4th stage discharge. FRC-1024 will control the turbine speed and
on minimum signal from FRC-1024, will go to minimum speed.
C-4102 may be shutdown manually by HS-1006A in the main control room or by

local shutdown switch HS-1006B. (reset by HS-1007 in the main control room)
which actuates shutdown device Interlock 1-41 02C to be described in detail in a
later section. Valve XV-1 023 on the 4th Stage discharge line may be closed either
by push button HS-1025 action, or as a result of one or more of the following
interlocks being actuated:
• 1-4102C - C-41 02 CO2 Compressor SID

• 1-1001H - HP Ammonia Pump Shutdown
c • 1-1019T - Hydrogen Converter High Temperature
Actuation of any of these interlocks will also open the 2nd Stage Kickback to
D-4101 and 4th Stage Kickback to D-4131 ; and close the valve on the main air
supply line to the Urea Unit.
3.1.3.2 Process Condensate Drum D-2161
The condensate from the CO2 Compressor drums D-4130/1/2 together with
condensate from D-4101 CO2 • Compressor Suction Knockout Drum, the
condensate from C21 01 air compressor intercoolers and the overflow from R-21 03
water jackets is collected in Process Condensate Drum D-2161. The CO2 in the
condensate from the CO2 compressor intercoolers is allowed to flash off . The
condensate is then pumped to Offsites by pumps P-2161A1B for recovery. The level
is controlled by L1C-1098. High and Low level alarms are provided.
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3.1.3.3 Process Condensate Stripper - T-2150
Process condensate from D-21 04 (Synthesis. Gas Compo Suction Drum) and D-21 05
(Synthesis. Gas Interstage Separator) is collected in the Raw Gas Separator, D-21 02
to be recovered and reused in the Ammonia plant. Process condensate can contain
up to 1,000 ppm by wt. Ammonia; 3,000 ppm by wt. Carbon Dioxide, 500 ppm by wt.
Methanol, and a trace of amines.
Before it is exported to the offsite demineralisation plant, the condensate is stripped

by counter current contact with medium pressure steam in the Process Condensate
Stripper, T-2150. The recovered condensate will contain about 5ppmw ammonia, 5
ppmw carbon dioxide and 35 ppmw Methanol and higher alcohols.
c The condensate collected in the Raw Gas Separator D-21 02, is pumped by
Condensate Pumps P-2121AlB to T-2150 via the Condensate Feed/EOffluent
Exchanger E-2188 where it is preheated against stripped condensate leaving
T -2150. It enters the stripper through a distribution pipe above two beds of slotted
rings and heat for stripping is provided by MP Steam injection to the base of the
tower under flow control of FIC-1019.
In the event of a low/low level in D-21 02 Raw Gas Separator, sounding alarm
LALL-1205 will warn the operators and the interlock ESD-1205 will be actuated
which will close the level control valves on P-2121AlB discharge to T-2150 and on
the Offsites disposal line.
The condensate flows downward over the packing beds making intimate contact with
the counter-flowing stripping steam and vapours of ammonia, CO2 etc. are liberated
from the condensate by stripping action of the MP steam. The steam vapours exit
the tower at the top and after being mixed with additional steam, is recycled back into
the process via the mixed feed preheat coil as part of the mixed gas feed to the
c
Primary Reformer.
In the event of a high differential pressure across the two beds of slotted rings,
interlock ESD-1069 will be actuated which will close control valve FIC-1 019 on the
vapour line exiting the top of the tower. Interlock ESD-1 069 will also close the control
valve on the discharge line of condensate pumps P-2121 AlB to E-2188.
The stripped process condensate from the bottom of T-2150 flows to offsite storage
after passing through the Feed/Effluent Exchanger E-2188 and then further cooled in
Air Cooler E-2174. This flow is regulated by the stripper bottoms level controller
LlC-1025 that is provided with High level alarm LAH-1025 and Low Level Alarm
LAL-1025. An analyser AE-1017 is also provided downstream of E-2174 to indicate
the conductivity of the condensate being routed to Offsites and to alert the operator if
alarm AAH-1017 exceeds a preset limit and of the need to switch to alternative
off-specification disposal.
Air Cooler E-2174 has a one bay fitted with three fans and has a manual lever for
louver adjustment. The fan blade pitch will be set manually on one fan and controlled
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automatically on the other two by TIC-1226. High (TAH-1652) & low (TAL-1652)
temperature alarms are also provided on E-2174 outlet line.
3.1.3.4 Methanation (Conversion of Carbon Oxides)
3.1.3.4.1 R-2106 - Methanator
The preheated process gas from D-21 03 leaving the shell outlet of Methanator
Feed/Effluent Exchanger E-2114 may be further heated in Methanator Feed
Heater, E-2172 as necessary prior to entering the top inlet of the Methanator
(R-2106). On pressure increase at the inlet, the "Anti-reset-wind-up" controller
c
PIC-1005 upstream of exchangers E-2114 AlB will open and vent process gas to
the Front End Flare.
The temperature of the process gas entering the Methanator is controlled by

TRC-1012 which is split ranged between a control valve TV-1012 located on the
shell bypass of E-2114 and a control valve PV-11S0 on the HP steam supply to the
Feed Heater E-2172. E-2172 may also be used during the start-up to heat the
nitrogen being circulated during the reduction of the LT Shift catalyst. The flow
passes through the Methanator high nickel base catalyst and leaves the vessel at
the bottom outlet. If the process gas exiting the CO2 Absorber contains excess
carbon oxides the temperature in the Methanator will become too high and activate
high temperature alarms TAH-1357 through 1362. The Methanator is protected
against dangerously high temperatures by shutdown switches TSHH-1200 through
1203, which actuate shutdown interlock ESD-2106. (This interlock is described in
further detail in Section 11.0 of this manual).
Should the bed temperature exceed the set temperatures of anyone switch
TSHH-1200 through TSHH-1203,then interlock ESD-21 06 will be actuated and the
two Methanator inlet valves HV-1034 and XV-1211 will close stopping all flow to the
c Methanator. As a result the pressure controller PIC-1005 in the inlet line will open
to vent the feed gas to the Front End Flare. The Methanator trips should be set at
approximately 27"C below the maximum allowable operating temperature set by the
catalyst manufacturer.
As a further protection against high run-away temperatures in the Methanator due

to a CO2 breakthrough from the aMDEA system, Interlock ESD-2106 will also
automatically shutdown the Methanator if the lean solution flow to the CO2
Absorber drops below a preset rate as sensed by lOW/low flow switch FSLL-1205
measured on FT-1205 or if the semi-lean flow from the LP flash section of the CO2
stripper drops below the preset rate as sensed by low/low switch FSLL-1217
measured on FT-1217.
The Methanator may also be shutdown by activating push-button HS-1253 which

also actuates interlock ESD-2106 and will shut HV-1034 and XV-1211 in the
Methanator inlet line. Once tripped, the solenoid controlling XV-1211 needs to be
manually reset before this valve can be opened. If the Methanator Feed Heater
(E-2172) is in service, then interlock ESD-21 06 will also close the HP steam supply
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to the tubes.
Upon a temperature excursion trip, the Methanator catalyst is cooled down by a

manually initiated reverse nitrogen flow from the outlet line at the bottom to the
atmospheric venton the inlet line.
From the Methanator, the flow is first cooled in the tube side of the Methanator
Feed/Effluent Exchanger E-2114 and then by a one bay Methanator Effluent Air
Cooler E-2118 with 3 fans. The bay has a manual lever for louver adjustment and
the fan blade pitch will be set manually on one fan and the other two will be,
controlled automatfcally by TIC-1627 located on the outlet from E-2115 to 0-2104
on the other. Final cooling is by Methanator effluent trim cooler E-2115 using
c cooling water on the tube side. A high temperature alarm is provided on the outlet
from E-2115to 0-2104 (TAH-1618).
3.1.3.4.2 0-2104 - Synthesis Gas Compressor Suction Orum
From cooler E-2115, the flow goes to the Synthesis Gas Suction Orum (0-2104).
Entrained water vapour in the process gas is separated in 0-2104 and pumped
under level control of LlC-1008 (fitted with high and low alarms LAH/L 1008) by LP
Condensate Pump P-2150NB to the Raw Gas Separator (0-2102) for onward
treatment in the Process Condensate Stripper (T2150). Condensate from 0-2105,
Synthesis Gas Compressor Interstage Suction Orum is also routed via Oil Filter
F2102 into 0-2104. Facilities are also provided to drain 0-2104 to the oily water
sewer.
0-2104 is also fitted with LT -1208NB/C and associated High/High level alarms,
LAHH-1208NB/C. Through a voting system of 2 out of 3 of these alarms, interlock
ESO-2103 will be actuated and will shutdown C-21 03, Synthesis Gas Compressor.
(This interlock is described in further detail in Section 11.0 of this manual).
c Gas to Synthesis Gas Compressor (C-21 03) exits from the top of 0-2104 through a
demister pad. Pressure controller PRC-1006 on 0-2104 regulates C-21 03 turbine
speed and synthesis gas from 0-2104 may also be routed to the ammonia vent via
PIC-1 004 whenC-21 03 is shut-down or excess synthesis gas is vented. A manual
sample point (S-014) together with analysers for total carbon oxides (AR-1 002),
hydrogen (AR-1031), nitrogen (AR-1032) and methane (AR-1033) are located on
0-2104 outlet line to C-21 03.
Prior to entering the 1st stage of C-21 03 compressor, the process gas stream from
0-2104 is joined by the L.P. case kickback flow controlled by FIC-1007.
3.1.4 Ammonia Production
3.1.4.1 Compression of Purified Synthesis Gas
Compression of the purified synthesis gas by the Synthesis Gas Compressor

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OOCNO. PROJ-PM-OOB REVISION: 4
(C-2103) is the first step in the liquid ammonia production phase of the process.
C-21 03 compressor is a two-case mUlti-stage compressor driven by an extraction!

condensing type turbine arranged with a drive shaft at each end connected to the two
compressor case rotors. The turbine is driven by HP steam, which exhausts to the
MP steam system with a small quantity going to the condensing stage, which then
exhausts to the surface condenser E-2140.
The compressor cases and the turbine are provided with lube oil console which
includes a turbine driven lube oil pump a motor driven auxiliary lube oil pump, a lube
oil filter and a lube oil cooler. A low lube oil pressure alarm, auxiliary pump start-up,
driver shutdown and shutdown alarm are provided. The compressor is fitled with dry
c gas seals. The compressor instruments are on a locally mounted board and in
addition, a common trouble alarm is mounted on the control room panel.
The low pressure compressor case receives gas from the suction drum 0-2104 at
about 30.4 barg and 39°C and compresses the gas to about 67 bara at 150°C. The
gas leaving the first case is cooled by BFW in preheater E-2117 and by cooling water
in inter-cooler E-2116. The gas is then subcooled by ammonia refrigerant in .
interstage chiller, E-2129 to 4.4°C before entering the high pressure case via 0-2105,
Interstage Separator at about 66.B bara where it is compressed to about 144 bara
From the last chiller (E-2129), the flow enters the Interstage Separator (0-2105)
where all condensed liquid (mainly water) is returned via LP Condensate Oil Filter
F-21 02 to 0-2104 for routing via 0-2102 to the Process Condensate Stripper and!or
offsite disposal.
0-2105 is provided with high (LAH-1011) and low (LAL-1011) liquid level alarms and
high/high level will actuate C-21 03 shutdown interlock ESO-21 03. (Oescribed in
detail in Section 11.0 of this manual).
c After passing through a demisting pad, the dry synthesis gas leaves the top of the
separator and after being joined by the synthesis gas compressor H.P. case
"kickback" flow controlled by FIC-1 OOB, enters the suction of the H.P. case machine.
Gas from 0-2105 passes through twin check valves of dissimilar type (to reduce the
likelihood of common mode failure) into the suction of the H.P. compressor case,
round which there is a bypass line with a restriction orifice. When HV-1001 and
HV-1031 trip closed, this bypass and orifice serves to depressurise the H.P. case to
L.P. case pressure after compressor shutdown.
From the top of the 0-2105 separator, a synthesis gas stream regulated by FIC-1007
directs gas back to the suction of the L.P. case machine for L.P. case "kickback"
control. FIC-1007 in conjunction with FIC-100B is provided to enable the operator to
keep the compressor out of "surge" condition by satisfying the machine's minimum
flow requirements. Both FIC-1007 and 1008 are provided with "Anti-reset-wind-up"
facilities and the line steam traced for their entire lengths to prevent condensation
occurring.
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In the H.P. case of the compressor the cooled synthesis gas (from the first stage
separator) is further compressed and is joined by the recycle synthesis gas from the
ammonia converter, which enters the side of the H.P. case machine at the 3rd Stage
inlet. Since the amount of recycle stream received from the converter is much
greater than the quantity of fresh feed, and since the instrumented kickback
FIC-1008 satisfies only the first (make-up) wheels; the last wheel depends on the
adjustment of the discharge - to - recycle bypass HIC-1030 until the compressor is
running "all-ouf'. The 2 inch by-pass around valve HV-1 001 on the discharge line to
E-2120, will be used for controlling the flow to the synthesis loop at start-up.
The main operating control for the synthesis gas compressor is via the governor of
c the driving turbine. The governor is reset by PRC-1012 which will regulate the
amount of steam letting-down through the turbine into the MP steam header to
control the HP steam header pressure; and by PRC-1 006 which adjusts the steam
valves of the condensing stage to regulate the compressor speed as necessary for
control of the pressure on the Compressor Suction Orum 0-2104.
An HP steam to MP steam by-pass system round C-21 03[T] is provided which with
the unit in normal operation, remains in a closed position. Activation of turbine trip
system will, however, cause the valve to open. This HP to MP steam letdown valve
may be actuated either automatically by Interlock ESO-2103 and ESO-21 05, or
manually by the manual indicator controller HIC-1 028 and HIC-1029 located in the
main control room during early periods of operation or unusual and emergency
conditions. This HP to MP Steam let-down station will be described in more detail in
a later section.
Particular care should be taken during the conditioning of C-21 03[T] and C-21 05[T]
turbines to be sure that the HP to MP steam let down valves are adjusted properly to
pass the required steam flow when in the tripped position.
c C-2103 may be shutdown manually by HS-1203A in the main control room or by local
shutdown switch HS-1203B. A shutdown interlock ESO-2103 is also provided and
this will be described in detail in a later section.
The combined recycle and fresh feed stream discharged from the HP case to the
synthesis loop is cooled in the tubes of the Ammonia Synthesis Loop Cooler
E-2124 and as previously mentioned, the HP case anti-surge controller FIC-1008
routes a kickback flow from downstream of E-2124 to the HP case suction when
necessary, to maintain the case suction flow above its minimum value.
The L.P. case of the synthesis gas compressor is pressure protected by PSV-02105
set at 73.0 barg located at the outlet of the first stage separator (0-2105) and the
H.P. case compressor by PSV-C2103 set at 154 barg in the discharge line of the
H.P. case machine.
The discharges of the low and high-pressure cases are provided with high
temperature alarms, TAH-1364 and T AH-1367A respectively. The synthesis recycle
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suction is provided with a high (TAH-1366) and low (TAL-1366) temperature alarm.
Pneumatically operated valves HV-1001 and HV-1 031 are provided in the H.P. case
cooled discharge and synthesis gas recycle lines respectively. They are closed by
action of C-21 03 shutdown interlock ;ESO-21 03 described in detail in Section 11.0 of
this manual. The HV's 1001 and 1031 can be manually opened or closed by push
buttons HIC-1001 and HIC-1031.
3.1.4.2 Conversion of Purified Synthesis Gas to Ammonia
3.1.4.2.1 E-2120 - Ammonia Unitised Chiller
c
The high pressure synthesis gas after leaving the E-2124 Loop Cooler is further
cooled in the "unitised" exchanger E-2120 by heat exchange with ammonia
refrigerant from 0-2120, 0-2121, 0-2122 & 0-2123 and cooled vapours from
0-2106.
In E-2120, ammonia refrigerant is routed to the four (4) shell sections from 0-2120,
0-2121, 0-2122 & 0-2123. The tube section consists of multiple concentric tubes
with vapours from 0-2106 passing through the centre tubes and the synthesis gas
and ammonia converter effluent from C-21 03/E-2124 passes through the annuli.
Thus the converter effluent is being cooled from the outside by ammonia refrigerant
and from the inside by vapour from the Secondary Flash Separator (0-2106).
3.1.4.2.2 0-2106 - Secondary Flash Separator
The chilled stream enters the Secondary Flash Separator 0-2106 via a horizontal
distributor. Ammonia from the recycle stream condenses out in the chillers and
settles in 0-2106. The Separator is provided with High (LAH-1 013) and low
(LAL-1013) level alarms and the presence of liquid can be checked locally by
tricocks. An extra high level in 0-2106 will actuate C-21 03 compressor shutdown
c interlock ESO-21 03. (Refer to Section 11.0 of this manual for further details of this
interlock).
The synthesis recycle gas passes through the demisting pads at the top of the
ammonia separator going to the ammonia synthesis system as a continuation of the
synthesis recycle gas loop and comprises feed to the ammonia converter.
Leaving the Secondary Flash Separator drum the recycle gas flow enters the tube
centre inlet of the Unitised Chiller (E-2120) to take up heat from the process flow in
the tube annuli. From the tube centre outlet of this exchanger the flow enters the
tube side inlet of the Ammonia Conv. Feed/Effi. Exchanger (E-2121) and continues
on to the inlet of the Ammonia Converter (R-21 05).
The ammonia product that is separated from the synthesis gas loop in the
Secondary Flash Separator, 0-2106, is sUb-cooled for maximum ammonia
condensation before being level controlled by LlC-1013to 0-2107. This
sub-cooling at the normal operating pressure of the synthesis gas loop will cause
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some gas (hydrogen, nitrogen, methane and argon) to be absorbed by the liquid
and results in contaminated ammonia product.
At the inlet of the tube side of E-2121, the synthesis gas is analysed for Hydrogen
(AR-1041), Nitrogen (AR-1042), Methane (AR-1043), Argon (AR-1044) and
Ammonia (AR-1045).
3.1.4.3 D-2107 - Ammonia Letdown Drum
To remove the absorbed gases from the ammonia product it is first flashed in
D-21 07, Ammonia Letdown Drum. D-21 07 receives its feed from D-21 06 where the
net ammonia make has been separated from the synthesis gas, together with a small
c import flow from the Purge Gas Separator D-21 08. LlC-1 013 regulates the flow of
liquid being letdown under pressure to D-21 07 from D-21 06.
PIC-1108 releases the flash gas leaving D-21 07 to the Purge Gas Scrubber T-21 03
for the recovery of ammonia, but is set to hold design back-pressure to prevent
over-flash. The liquid stream from D-21 07 is let down to two pOints in the
refrigeration system under the level control of LlC-1012 with the actual routing being
selected by the hand switch HS-1024. If this switch is set for "COLD" product
operation, then approximately 74% of the liquid flow from D-21 07 will be let-down to
the 1st Stage Refrigerant Flash Drum ( D-2120) with the balance being routed to
D-2123 under the control of LlC-1012. If 'WARM" product operation is selected, then
the liquid flow will be letdown to the 4th Stage Refrigerant Flash Drum ( D- 2123). In
both cases tlash vapour is routed to the Ammonia Gas Scrubber via the Refrigerant
Receiver D-21 09. (A more detailed description of the 'WARM" and "COLD" product
operations is contained in Sections 7.5 and 7.6 of this manual).
Control of the Ammonia Converter (R21 05) inlet temperature is by means of

HIC-1026 on the main control panel, which regulates the flow of synthesis gas round
c the tube side of E-2121. After receiving some preheat from the converter effluent in
E-2121, the synthesis gas enters the Ammonia Converter via main inlet valve SP-173
and bed quench valve HIC-1025. SP-006, a special rupture disc assembly, is
located around SP-173 to protect E-2121 exchanger against excessive differential
pressure if one side of the exchanger is depressurised by closure of SP-173 and/or
the converter quench valves, HIC-1025.
3;1.4.4 R-2105 - Ammonia Converter
Synthesis gas from E-2121 is introduced at one end of the external shell of the
converter and flows along the annulus between the external pressure shell and
catalyst basket towards the opposite end of the converter. This arrangement limits
the temperature to which the external shell is exposed. On reaching the opposite
end of the converter, the synthesis gas enters an opening in the end plate and flows
across the external surfaces of E-2122 tubes. After passing across the outside
surfaces of the tubes the synthesis gas enters a partitioned plenum where it is
directed to the distributor above the first bed. On exiting bed no. 1, the synthesis
gas re-enters the partitioned plenum where it is directed through the tubes of E-2122.
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The synthesis gas exits E-2122 tubes and re-enters the plenum where it is directed
through a distributor pipe to the top of bed no. 2A. The gas passes down through
bed no. 2A and is then directed to the top of bed no. 2B. A further reaction takes
place in bed 2B after which the gas exits the converter shell through an internal
piping arrangement at the feed inlet end.
Heat from the Ammonia synthesis reaction raises the gas temperature from the first
bed to around 496°C. The effluent gas flows through the tube side of the
interchanger, which cools the gas to about 387°C before passing over the second
catalyst bed. The second catalyst bed is divided into two physical beds in series to
ensure uniform flow over the catalyst. Further reaction in the second bed raises the
converter outlet temperature to about 457°C and the ammonia concentration to 15.75
c mol%. A bypass line around the converter, controlled by valve HIC-1025, is provided
to permit introduction of feed gas to the first catalyst bed without preheating for
temperature control. It is usually referred too as "quench".
The design feature of an intercooled converter has the advantages of producing a

relatively high ammonia concentration per pass and making the heat available in the
converter effluent at a temperature sufficient for the production of high pressure
steam.
3.1.4.5 H-2102 - Start-up Heater
The ammonia synthesis converter is equipped with a start-up heater (H-21 02). This
heater is used to heat the converter catalyst up to reaction temperature during the
start-up. The start-up heater feed flow is indicated on FI-1257and low/lowflow
(FALL-1257) will actuate heater shutdown interlock ESO-2116 and shut down the
heater burners. A high/high pressure on the inlet line to H-21 02 (PAHH-1196) will
also actuate interlock ESO-2116. (A full description of interlock ESO-2116 is included
in Section 11.0 of this manual)
c There is a high temperature alarm (TAH-1689) located on the heater outlet line to the
converter in addition to a high temperature alarm (TAH-1397) on the flue gas exiting
the stack. High high temperature on the heater outlet line (TI-1396) will also actuate
interlock ESO-2116 and TAHH-1396 will warn operator in main control room.
3.1.5 Refrigeration And Ammonia Product Purification
3.1.5.1 Removal of Inerts
A purge is taken from the synthesis loop to control the concentration of methane and
argon in the loop since a build-up of these components is reflected in lower ammonia
conversion. Part of the converter effluent gas exiting the shell side of E-2121 is
therefore routed as purge gas which is chilled in Purge Gas Chiller E-2125 before
entering the Purge Gas Separator 0-2108.

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3.1.5.1.1 0-2108 - Purge Gas Separator
Purge gas exiting the top of 0-2108 is flow controlled by FIC-1 013 and routed to the
bottom of Purge Gas Scrubber T-21 03. Analysers on the outlet line from 0-2108 to
T-21 03 record the Hydrogen (AR-1061), Nitrogen (AR-1062), Methane (AR-1063),
Argon (AR-1064) and Ammonia (AR-1065) contents in the gas. Liquid ammonia
from 0-2108 is pressured to 0-2107 for recovery with controller LlC-1 014 with its
associated high (LAH-1014) and low (LAL-1014) alarms controlling the liquid level
in 0-2108.
3.1.5.1.2 C-2105 - Ammonia Refrigerant Compressor
c The Ammonia Refrigerant Compressor C-21 05 is a double case (four stage)

machine with interstage coolers and driven by a non-condensing type steam turbine
C-2105(T) exhausting to the MP steam system. Lubrication and governor oil for the
compressor and turbine consist of a complete system shared with C-21 03
Synthesis Gas Compressor and as described previously for C-21 03.
The compressor speed is set by the turbine governor in response to a signal from
the compressor suction pressure controller PRC-100910cated on 0-2120 1st Stage
Refrigerant Orum.
The major duty on C-21 05 is the "unitised" exchanger E-2120 that takes up heat
from the synthesis loop. The four sections of E-2120 operate at different
pressure levels dictated by refrigerant flash drum temperature requirements. The
ammonia refrigeration requirements for each section of E-2120 being proportional
to the heat input from the synthesis gas tube side. Therefore there are
intermediate suctions to the compressor that satisfy the pressure requirements of
the 2nd (0-2121), 3rd (0-2122) and 4th (0-2123) Stage Refrigerant Orums.
c There is a heat load on the third stage flash drum 0-2122 from the ammonia
returned from the Urea Granulation cooler E-4204 and Steam condensate chiller
E-4153.
The first stage of the L.P. case recovers ammonia vapours from the 1st Stage
Refrigerant Orum 0-2120 at 0.9 bara and -35°C together with any vapours being
returned from the Storage tanks. At the entry to the second stage of the L.P. case,
the first stage discharge is joined by ammonia vapour from the 2nd Stage
Refrigerant Orum 0-2121.
The discharge of the L.P. case is first cooled in inter-stage cooler E-2167 and then
joined by the flash vapour from the 3rd stage Refrigerant Orum (0-2122) and
passes into the H.P. case for compression in the third stage. The 3rd stage
discharge is then cooled in inter-stage cooler E-2128, joined by the vapours leaving
the 4th stage Flash Orum 0-2123 and enters the compressor for 4th stage
compression and final discharge to the Refrigerant Condenser, E-2127 at about
15.6 bara.
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To satisfy the compressor minimum flow requirements and to prevent compressor

surge, a part of the compressor discharge flow must return to the flash drums
0-2120,0-2121,0-2122 & 0-2123 via the kickback controllers FIC-1012,
FIC-1011, FIC-1010 and FIC-1009 respectively. These controllers regulate
kickback ammonia vapour flows from each of the four discharge stages of the
compressor to control surge whenever the system load is considerably less than
design.
C-21 05 compressor can be shut down by interlock ESO-21 05, which is either
actuated manually by switch HS-1205A1B or automatically by various other devices
necessary for full protection of the refrigeration machine. Interlock ESO-2105 is
described in detail in Section 11 .0. of this manual.
c A similar HP steam to MP steam by-pass system to that described previously for

C-21 03 Synthesis Gas Compressor turbine is provided and described in detail in
Section 11.0 of this manual. Particular care must be taken during the start-up of
C-2105[T] and C-21 03[T] turbines to ensure that the HP to MP steam letdown
valves are adiusted properly to pass the required steam flow when in the tripped
position.
3.1.5.1.3 0-2109 - Refrigerant Receiver
The compressed flash gases (ammonia plus inerts) that leave the Ammonia
Compressor C-21 05 are sub-cooled in the Refrigerant Condenser E-2127 before
being routed into 0-2109, Refrigerant receiver. Trapped inert gases from E-2127
are vented to 0-2109 via the purge connection located on the top of the condenser
shell.
The inerts that flash from the subcooled ammonia in this drum in excess of
pressure control requirements are routed to the Purge Gas Scrubber T-21 03
c for ammonia recovery, under pressure control of PIC-11 09.
When on 'WARM" ammonia production, a fixed flow of liquid ammonia will be

pumped to the Urea Unit under control of FIC-1168 flow controller. The level in
0-2109 will then be held constant by level controller LlC-1 015 allowing the balance
to flash down to the 4th Stage Refrigerant Drum, 0-2123. High (LAH-1 015) and
low (LAL-1 015) are provided on 0-2109. On "COLD" ammonia production, the
flow to the Urea Unit will be zero with 0-2109 total level being flashed down to
D-2123. (A detailed description of the 'WARM" and "COLD" methods of operation
is described in Sections 7.5 and 7.6 of this manual).
The Ammonia Reflux Pumps P-2120AlB for the Ammonia Stripper T-21 04 also
takes suction from 0-2109. These pumps are also used during start-up to route
warm liquid ammonia to E-2124 shell inlet to prevent freezing of the water in the
process side of E-2120 Chiller since an aqua ammonia solution has a freezing point
well below the E-2120 operating temperature.
Ammonia from 0-2109 also furnishes quench (required at start-up) to the 1st, 2nd,
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c JOB NO. S777 SPEC. TYPE: PAGE: 62 OF 312
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3rd and 4th Stage Refrigeration Drums and globe valves are provided in the
individual quench lines to hand control the refrigerant flows.
3.1 .S.1.4 D-2120 - 1st Stage Refrigerant Flash Drum
This Flash Drum serves the process in three ways: first, by a deep over-flash
essentially all the inerts are removed from the ammonia product. Second, it serves
as a "head drum" for the thermal circulating refrigerant that is removing heat from
the synthesis gas loop via the "cold" section of E-2120. Third, it receives the
flashed ammonia let down from the 2nd Stage Refrigerant Drum D-2121 via the
Purge Gas Chiller E-212S.
c The pressure on D-2120 is controlled by PIC-1009, which regulates the speed of

C-21 OS compressor driver. Liquid ammonia in D-2120 is circulated by
thermoSyphon effect through the fourth section of the "Unitised" Exchanger, E-2120
. "COLD" product ammonia is routed to storage by Cold NH3 Product Pumps
P-2124A!B/C under level control of LlC-1024 on D-2120. Should a high/high level
condition occur, LAHH-1217A!B/C will activate on a 2 out of 3 voting system and
interlock ESD-210S will shut down Refrigerant Compressor C-21 OS.
3.1.S.1.S D-2121 - 2nd Stage Refrigerant Flash Drum
As with the other Flash Drums, the pressure (and resulting temperature) of D-2121
is not variable as it floats on the suction of the first stage case of the Ammonia
Compressor C-21 OS.
Liquid in D-2121 is circulated by thermosyphon effect through the third section of

E-2120. Refrigerant from D-2121 is also used to maintain a level in the shell side of
the Purge Gas Chiller E-212S under the control of level controller LlC-1116 with the
vapour being retumed to the 1st Stage Suction Drum D-2120. Excess liquid from
c D-2121 is then transferred to D-2120 under level control of LlC-1023, which

incorporates high and low level alarms. Should a high/high level occur, then LAHH-
1216A!B/C, on a 2 out of 3 voting system will actuate ESD-21OS and shutdown
C-21 OS.
3.1.S.1.6 D-2122 - 3rd Stage Refrigerant Flash Drum
Again the pressure (and resulting temperature) of D-2122 is not variable as it floats
on the suction to the second case of C-21 OS Ammonia Compressor. Liquid
ammonia in D-2122 is circulated by thermosyphon effect through the second
section of E-2120 with the level held constant by LlC-1022 routing excess liquid
ammonia to the 2nd Stage Flash Drum D-2121. LlC-1022 also incorporates High
(LAH-1022) & Low (LAL-1022) level alarms. Should a high/high level occur, then
LAHH-121SA!B/C, on a 2 out of 3 voting system, will actuate ESD-21 OS to
shutdown C-21 OS ..
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C' JOB NO. 5777' SPEC. TYPE: PAGE: 63 OF 312
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3.1.5.1.7 0-2123 - 4th Stage Refrigerant Flash Orum
All of the ammonia that is not sent to the battery limits as "WARM" product from
Refrigerant Receiver 0-2109 with the exception of the flow to 0-2120; together with
ammonia from Ammonia Letdown Orum 0-2107, is routed to 0-2123.
Liquid in 0-2123 is circulated by thermosyphon effect through the first section of

E-2120 and also supplies Synthesis Gas Compressor Interstage Chiller E-2129.
Excess liquid ammonia is transferred to 0-2122 under level control of L1C-1021 ,
which incorporates high and low level alarms. Should a high/high level occur, then
c· LAHH-1214A1B/C, on a 2 out of 3 voting system, will activate ESO-2105 and

shutdown C-21 05 and close valve LV-1 015 on the supply line from 0-2109 to
0-2123.
The ammonia converter effluent stream is cooled by heat exchange giving up heat
to boiler feed water in Waste Heat Boilers E-2123A & B, and to the converter feed
in E-2121 before returning to the Recycle Gas Compressor C-21 03 to be recycled
back to the converter. Before the recycle gas (plus fresh feed) re-enters the
converter, it is routed via the unitised chiller system to condense out the net
ammonia make produced on its previous pass through the converter.
The synthesis gas loop has all the temperature indicators and recorders, pressure
differential indicators and hand control valves (HCV's) to observe and control
process conditions within the "loop". There are also special emergency valves that
isolate the recycle compressor from the synthesis gas loop under certain
conditions. These are described in Section 11 of this manual.
3.1.5.2 Ammonia Recovery from Purge Gases
C 3.1.5.2.1 T-2103 - Purge Gas Scrubber
Purge gases from the synthesis loop containing ammonia vapours are treated in
the ammonia recovery section (T-2103 Purge Gas Scrubber and T-21 04 Ammonia
Stripper) and ammonia vapours are returned to E-2127 Refrigerant Condenser and
thus to 0-2109 Refrigerant Receiver. .
Gases from 0-2107, 0-2108 & 0-2109 are routed to the base of the Purge Gas
Scrubber (T-2103). The upflowing gases mix with a counter-current flow of water
through a packed bed of stainless steel rings. The Scrubber purge gas feed,
washed clean of arnmonia, passes through a demister pad and is routed to the Fuel
Gas Preheat Coil in the Primary Reformer convection section under pressure
control of PIC-1033.
It should be noted that the loss of this flow of purge gas to the fuel gas system will
have the effect of substantially increasing the calorific value of the feed gas being
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used by the Primary Reformer burners and will cause the tube outlet temperature to
rise. Flow indicator FI-1258 together with low flow alarm FAL-1258 is therefore
provided on the purge gas supply line to the fuel gas, which will alert the operator to
the need to reduce the arch burner firing.
Should the purge gas flow continue to fall, then interlock ESD-1 031 will be
actuated. This interlock may also be actuated by 2 out of 3 low/low pressure
switches located on the fuel gas supply line to each row of arch burners and set at
0.2 barg when firing on mixed gases.
When Interlock ESD-1 031 is actuated by either of the above conditions, it will
automatically close valve XV-1 031 on the purge gas supply line and XV-1030 on
c the excess synthesis gas supply line to H-2101 fuel gas system. At the same time
it will automatically reduce the pressure setting of PIC-1 002, the main Arch bumer
fuel gas pressure controller to 25% Note that due to the lower fuel gas supply
pressure, manual adjustment to the arch burner firing will still be necessary.
Water reflux to T-21 03 top is flow controlled by FIC-1 064 and to prevent freezing in
the base of T-21 03 in the event of loss of liquid circulation, low flow alarm FAL-1064
and low level alarrn LAL-1026 warn of these conditions for reflux flow and bottoms
level The flow from the bottom of T -2103 is measured by FT-1 065 and provides
kick-back protection for the pumps, P-2130AlB through FIC-1065 controlling a flow
back the the bottom of T-21 03. The Scrubber is also provided with high level alarm
LAH-1026, and high (PDAH-1055) and low (PDAL-1055) pressure differential
alarms across the packed bed. Over-pressure relief is provided by PSV-T2103 set
at 13.0 barg.
3.1.5.2.2 T-2104 - Ammonia Stripper
An aqueous ammonia solution from the base of T -2103 is pumped to the top
c section of stripper T-21 04 after being heated by stripper bottoms in exchanger

E-2161. This flow to T -2104 is controlled by LlC-1026 on the bottom section of
T-21 03 and a manual bypass on the bottoms (shell) side of E-2161 controls the
inlet temperature to the stripper.
In T-21 04 the ammonia vapours are steam stripped across two lower beds of
stainless steel rings. Steam for stripping is provided from a bottom reboiler E-2160
using MP steam flow controlled by FIC-1 027. The stripper bottom is provided with
a level glass together with high (LAH-1027) and low (LAL-1027) level alarms. In the
top section of T-21 04 the stripped arnmonia vapours are cooled against a manually
controlled flow of ammonia reflux pumped by P-2120AlB from D-21 09 over a third
bed of stainless steel rings.
Ammonia vapours from the top of T-21 04 are released to Refrigerant Condenser
E-2127 under pressure control of PIC-1034. Over pressure relief is provided by
PSV-T2104 set at 20.5barg.
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3.1.6 Ammonia Storage & Loading (OSBL)
When the ammonia unit is on "WARM" production, the greater part of the Ammonia
Unit production is routed directly to the Urea Unit except for a small quantity of Cold
ammonia being routed to the storage tank. When on "COLD" production, no ammonia
is routed to the Urea Unit with the entire Ammonia unit production being continuously
routed to the storage tank. Operational procedures for each of these cases are
included in Section 7.5 & 7.6 of this manual.
3.1.6.1 Ammonia Storage Tank TK- 5101
c The Ammonia Storage Tank TK-51 01 is of the "double-integrity" type with double
walls having th!'l annulus between the inner and outer tank filled with dry air. The
annulus of the tank is supplied with instrument air controlled by 51 PIC-1 002 with
associated high and low-pressure alarms. The bypass around 51 PIC-1 002 is fitted
with a restriction orifice. The annulus is also fitted with a backpressure regulator
51 PCV-1 009 venting to atmosphere.and relief valves PSV-51007/8 A high liquid
level alarm 51 LAH-1 001 and an analyser with a high NH3 in air alarrm are also
provided in the annulus to warn the operator of ammonia leakage from the inner
tank into the annulus.
A number of Temperature sensors are located on the walls of the tank and on the
under sides of the elevated concrete slabs for use during tank cool down. These
sensors are indicated on local temperature indicators.
It will be noted from Sections 7.5,& 7.6 of this manual that in both 'WARM" and
"COLD" Ammonia production cases cold liquid ammonia is routed to the storage
tank. In both cases, liquid ammonia @ -35.5°C is pumped from 0-2120 the 1st
Stage Refrigerant Flash Drum on the Ammonia unit by Cold Ammonia Product
c Pumps P-2124NB/C into Storage Tank TK-5101. The flow rate to storage is
regulated by LlC-1 024 to maintain a steady level in 0-2120 and monitored by Flow
Recorder FR-1061 and Flow Integrator FQI-1 061 located on the Ammonia unit.
The tank is equipped with two independent level indicators 51 LI-1004 and 51 LI-1005,
the former is fitted with a high and low level alarm. In addition there are two alarms,
a high/high alarm 51LAHH-1003 and a lowllow alarm 51LALL-1002. The lowllow
alarm actuates interlock ESDI-5101 which will shut down the Ammonia Loading
Pumps P-51 01 NB should tanker or cylinder loading be in progress when a lowllow
level situation occurs and the Boil Off Gas compressor, in the package unit C-5101.
The tank pressure is controlled by 51PIC-1004.Switch HS-1004 is used to direct the

Ammonia vapour from the tank to either the Ammonia Unit Refrigeration system, or
to the Boil Off Gas Compressor Package C-51 01. 51 PIC-1 004 is fitted with a high
and low pressure alarm. Highlhigh pressure is indicated by 51 PAHH-1 006.
51 PIC-1 OOB is provided to vent excess pressure to the storage flare.
A lowllow pressure switch 51 PALL-1007 is also provided which actuates interlock


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ESD-5101 to shut down the Ammonia Transfer Pumps should they be in use when a
low/low pressure condition occurs and the Boil Off Gas compressor, in the package
unit C-5101.
A signal from 51 PT-1 OOB also goes to 51 PIC-1 049. The purpose of this controller is
to cover the eventuality of a falling tank pressure when product rundown from the
ammonia unit is minimal and tanker loading or cylinder filling is in progress. Should
such a decrease in pressure occur, and to avoid ingress of air though the tank
vacuum breakers, 51 PIC-1049 will open control valve 51 PV-1049 and route warm
ammonia vapour from the outlet of Ammonia Heater E-5101.
Once the unit is in steady operation, the ammonia vapour from the storage tanks due
c to heat leaks, vapour displacement and rundown, is returned to the Ammonia Unit
Refrigeration systern for re-condensing. The Boil Off Gas Cornpressor Package,
C-5101 is then shutdown.
3.1.6.2 Arnrnonia Heater E-51 01
Liquid arnmonia frorn the storage tanks for loading tankers or cylinders is transferred
by Arnrnonia Transfer Purnps P-51 01 AlB via Arnrnonia Heater E-5101. In E-51 01 ,
Methanol is heated by LP stearn and the Methanol vapours then transfer heat to the
arnrnonia. Temperature controller 51 TIC-1 023 on the supply line to the tanker
loading arms and cylinder filling system is set to obtain the required ambient
temperature for loading or filling. It is fitted with a high and a low alarm 51 TAH/L-
1023. 51TIC-1023 will in turn resetthe pressure controller 51 PIC-1050 on E-5101,
which regulates the amount of LP steam heating the Methanol. 51 PAH-1 050 will
warn of high pressure. To avoid the Methanol pressure in E-51 01 continuing to rise
when there is no-load on the heater, 51 PIC-1050 will close the valve PV-1050 when
the Methanol pressure in the shell of E-5101 reaches 34.0 barg.
c Procedures for normal operation of the Loading arms and cylinder filling system are
included in Sections 7.B.2 & 7.B.3 of this manual. Procedures for the transfer of
warm ammonia from the storage tanks to the Urea unit and to the Ammonia unit for
start-up are also, included in Sections 7.B.4 & 7.B.5.
3.2 OPERATING CONDITIONS AND PROCESS VARIABlES
3.2.1 Natural Gas Feed Preparation
3:2.1.1 Hydrogenation (Cobalt-Moly) & Desulphurisation (Zinc Oxide)
The natural gas feed contains organic sulphur compounds, which must be removed
since sulphur is a poison to the Primary Reformer catalyst. These compounds can
best be removed by catalytic conversion to hydrogen sulphide (H2S) in the presence
of excess hydrogen and subsequent removal of the H2S by reaction with zinc oxide.
Natural gas feed, after compression to about 44 bara is mixed with a recycle stream
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of hydrogen-rich synthesis gas normally supplied from the first case discharge of the
Synthesis Gas Compressor. Note that should the back-up hydrogen supply from the
HP case recycle be used, then it should be routed downstream of the preheat coil
since the addition of NH3 rich synthesis gas to the cold natural gas containing CO2
could result in the formation of carbamates and line blockage.
The feed mixture, containing about 3.0% hydrogen first passes through the feed
preheat coil located in the convection section of the Primary Reformer furnace,
H-21 01, and then flows downward through the Hydrogenation reactor. This reactor
contains cobalt-molybdenum catalyst, where the organic sulphur compounds are
decomposed, the sulphur being hydrogenated to hydrogen sulphide ..
c The feed gas leaving the hydrogenator catalyst bed with essentially all of the
contained sulphur in the form of H2S, then flows through the Desulphurizer reactor(s)
containing zinc oxide pellets. All the sulphur that may be expected will be removed
by reaction with the zinc oxide, forming zinc sulphide.
As the feed gas may contain up to 5.0% CO2 , there is a possibility that a
"methanation" reaction may take place in the hydrogenator reactor. In order to
provide adequate design for this possibility, the operating temperature is reduced to
371°C. Particular attention for methanation should be made during start-up when
gas containing up to 18% CO2 is recycled from 0-2102.
The zinc oxide guard section is also designed to operate around 371°C with an exit
temperature in the range of 360°C.
I. Catalyst: Both the cobalt molybdate and zinc oxide catalyst are mechanically
strong and not difficult to handle. However, every effort should be made to
prevent the formation of any condensation in the reactors, particularly at
start-ups or shut-down, to avoid damaging the zinc oxide catalyst.
c II. Operating Variables: Important operating variables for the desulphuriser

are, apart from the space velocity which is fixed by the flow rate, listed below
in accordance to importance.
III. Hydrogen/feed gas ratio: This is expressed in mols of hydrogen/mole of

feed gas and design is for 0.03 mol/mol. Both the hydrogen content of the
hydrogen-rich gas and the molecular weight of the natural gas feed gas must
be known in order that the hydrogen/feed gas ratio can be accurately
determined. In general, an increase in the hydrogen to feed gas ratio will
improve the degree of desulphurisation obtained.
IV. Temperature: Design is based on an outlet temperature from the feed

preheat coil of about 371°C. Initially, and until some experience has been
acquired, this temperature should not be exceeded. Generally, a slight
increase in temperature will improve the degree of sulphur conversion.
V. Pressure: The design is for an outlet pressure from the desulphuriser
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reactor of 41.2 bara. Under normal conditions, the primary reformer pressure
level requires that this pressure level be maintained. Because the pressure is
set at the value specified, it is not to be considered as an operating variable.
However, it has been found that the higher the pressure, the better the
desulphurisation.
The only important side reaction, which might take place, is a gradual deposition of
coke on the catalyst.
3.2.1.2 Primary Reforming
After the sulphur compounds have been removed, it is desired to reform the feed gas
c under conditions that will produce hydrogen (H2 ) in an economical manner. This is .
done by contacting the feed gas on nickel catalyst in a steam atmosphere at elevated
temperature and pressure to promote (and favour) the desirable reactions. The
reaction is endothermic and requires constant heat in-put from the primary reformer
furnace to maintain the desired temperature level for proper primary reforming.
The following discussions on reforming conditions should be thoroughly understood

for the successful operation of the plant. Improper, or mal-operation at the front end
of the unit can be (and is) reflected throughout the plant.
3.2.1.2.1 Reforming Reactions
The catalysts promote two simultaneous equilibrium reactions in the primary and
secondary reformers. These reactions are steam-methane reaction (higher
homologues react in like manner):
CH 4 + H20 = CO + 3H 2
c and the carbon monoxide shift reaction:
CO + H20 = CO 2 + H2
It would be preferable if these reactions went to completion to give an overall

reaction:
CH 4 + 2H20 = CO2 + 4H2
but this is not the case and considerable CO occurs in the secondary reformer
effluent Most of this unshifted CO is oxidised to CO2 in the shift converter thus
increasing hydrogen yield.
3.2.1.2.2 Reforming Conditions
• Temperature - The overall effect of increasing reforming temperature on the

effluent gas composition is to reduce the methane and carbon dioxide content,
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and increase carbon monoxide and hydrogen content. On decreasing

reforming temperatures, the effects are reversed.
• Pressure - The pressure of the system is so essentially fixed such that

reforming pressure should be considered invariable. However, increasing
pressure has an effect similar to reducing temperatures and reformer designs
always represents a compromise in economics.
• Steam to Carbon Ratio - Beyond the vital consideration of sufficient steam to

prevent coking the catalyst, increasing steam-to-carbon ratio will shift both
above equilibrium reactions to the right with a net effect of decreased methane
and carbon monoxide and increased carbon dioxide and hydrogen in the
c reformed gas. At the same time, however, utility consumption will increase. For
other than minor deviations, the unit operation is usually most economical at
conditions closely approaching design steam-to-carbon ratio of 3.2 to 1.
Whenever there is any doubt about the true steam-to-carbon ratio entering the
furnace, the steam rate should be verified with a wet test meter method to
determine the true conditions. It is of prime importance that the steam-to-gas
ratio to the primary reformer is maintained at a value to ensure a
steam-to-carbon ratio of 3.2 to 1 at all times.
Should an operating or mechanical accident cause minor coke deposition on

the reforming catalyst, the deposit may be removed and the catalyst activity
restored by increasing steam-to gas ratio somewhat above normal for a period
of time. If the catalyst coking is considerable, it may be necessary to shut
down the unit for replacement of the catalyst.
3.2.1.2.3 Primary Reformer Catalyst
c The primary reformer tubes are packed with a nickel reforming catalyst, in the form
of rings, distributed equally to 208 tubes in the radiant section of the primary
reformer furnace. The top section of the reforming tubes are loaded with alkalised
(potash) catalyst, which will minimise the possibility of carbon laydown on the
catalyst by the heavy hydrocarbons present in the feed.
Top Section
Potash is present in the top section catalyst in the form of a mixture of potassium
aluminates and aluminosilicates such as Kalsilite (KAI Si04). In the reformer,
these compounds hydrolyse slowly to form free potassium hydroxide on the
catalyst surface. This free potash will prevent carbon deposition when reforming
feedstock with heavy hydrocarbons, and will effectively protect the normal nickel
reforming catalyst in the remainder of the catalyst tubes. Potassium hydroxide is
slightly volatile in the presence of steam and there is a small loss of potash from
the catalyst into the gas stream. This potash is replaced on the catalyst surface by
more potash from the complex potassium compounds, and this maintains
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compounds form a reservoir of potash, preventing potash loss from the surface,
and giving adequate protection over the whole catalyst life. It should be noted that
the rate of potash removal is increased by unsteady reformer operations and it is
always greater on start-up.
The hydrolysis of the potassium compounds is increased at temperatures below

700°C, and periods of steaming at such temperatures should therefore be avoided
whenever possible. During plant start-up, however, steaming the catalyst at
temperatures below 700°C is unavoidable while the plant is being heated to the
temperature at which catalyst reduction is to be carried out. The hydrolysis caused
by this steaming increases the amount of free potash in the catalyst, cau·sing a
burst of potash release when the temperature reaches a level at which the potash
c is volatile.
Transfer of potash, however, can be reduced if the process temperature, as

measured at the reformer outlet, is raised slowly beyond 700°C, the objective being
to allow recombination of free potash to take place before a temperature is
reached where the vapour pressure becomes significant. This is particularly
important if the reformer has previously been steamed for a long period below
700°C. To allow potash to recombine to the alumino-silicate form, it is suggested
that the temperature be held at slightly over 704°C for about 3 hours, after which it
is raised to 732°C for 3 hours and again raised in 28°C increments using the
preceding heating schedule. This sequence of operations is continued until the
desired steaming temperature is obtained.
A similar procedure is suggested for a shutdown. Cooling down under a steam

atmosphere below 704°C should be carried out reasonably fast, consistent with
normal safe operating practice, to avoid leaving free potash on the catalyst. If
possible, the steam should be replaced with nitrogen when the temperature
reaches 538°C. If nitrogen is not available, steam cooling may be continued to
within 38°C of the condensation temperature. If steam cooling is used, particular
c attention should be given to the soaking periods at 704°C, 732°C, and so on, on
restarting the plant.
Lower Section
Reformer (Lower Section) catalyst is a highly active steam hydrocarbon reforming

catalyst composed of supported nickel oxide and is used for the primary reforming
of methane and other light hydrocarbons in tubular reformers.
After reduction of the nickel oxide to nickel, the catalyst normally operates in the
range of exit temperatures up to 825°C, although higher exit temperatures are
possible under favourable conditions. Normally, the exit temperature should be
about 812°C at an operating pressure of 36.5 bara If a tube has abnormal
differential pressure, overheating or insufficient reforming may occur, leading to
improper operation and possible damage to radiant harp components.
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reformer) to produce hydrogen, before natural gas feed is introduced. In this way,
higher activity of the catalyst will be obtained. Before ammonia is injected into the
primary reformer, the exit temperature should be as high as possible (SOO°C or
more) to minimise the amount of ammonia which is not cracked. These
procedures will be detailed in the Start-up section of this Operating Instructions
Manual.
After loading the catalysts in the primary reformer tubes, the tubes are
mechanically vibrated to assure equal pressure drops, resulting in equal flow
distribution through each tube. If a tube has abnormal DP (pressure differential),
overheating or insufficient reforming may occur, leading to improper operation.
Carbon Formation
c" While running under normal operation conditions, primary reforming catalysts do
not produce carbon. Plant incidents, such as power failures, instrument
malfunctions and equipment failures can, however, bring about operating
conditions under which carbon can be formed. The following reactions are
possible:
2CO = c + CO2
CO + H2 = C + H20
CH 4 = C + 2H2
CH = C + H2
Carbon formation can occur in two ways. Under certain conditions in the mixture
of CO, CO2 , H2 , CH 4 and H20, free carbon is thermodynamically possible, and
c
carbon can be formed from the first two reactions set out above. This carbon is
usually referred to as thermodynamic carbon or Boudouard carbon. Carbon can
also be formed as a result of thermo-cracking of hydrocarbons as set out in the
last two reactions above.
Thermodynamic carbon can produce the most difficult problems on a plant. There
is a critical level of steam ratio depending on operating conditions, below which
carbon from this reaction is formed instantaneously in the catalyst pores. This
carbon deposit in the catalyst causes physical breakdown, and an immediate
shutdown to change the catalyst will be necessary.
The amount of carbon formed from hydrocarbon cracking depends on the relative
rates of deposition and removal of carbon. The higher the number of carbon
atoms in the hydrocarbon feed the faster the rate of decomposition, and, the
higher the steam ratio the faster the rate of removal. Thus, the likelihood of carbon
deposition occurring increases, with the molecular weight of the feedstock, and, as
the steam ratio is decreased.
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The steam ratio level at which the amount of carbon deposited becomes significant
depends on the feedstock composition. With a light feedstock, the level will be
below the normal design minimum steam ratio of 2.5. As the amounts of heavier
hydrocarbons present in the gas increases, so will the minimum operable steam
ratio. With feedstock which are almost entirely heavier hydrocarbons, higher
operating steam ratios are necessary and these levels must be maintained if long
periods of trouble-free (that is carbon deposition-free) operation are to be obtained.
Carbon, resulting from hydrocarbon cracking, does not usually form in the inner
pores of the catalyst, and total breakdown of the rings does not therefore occur.
The outer surface of the rings are, however, weakened, and the surface layers of
the rings are often removed, either during operation, or on discharge. This gives
c the rings a characteristic eroded appearance, which, after the carbon is steamed
off during operation or shutdown, is often the only indication of carbon formation.
The Potash in the reforming catalyst promotes the removal of carbon from the
catalyst, as stated previously, and this enables the catalyst to be used at steam
ratios as low as 3.0:1, if required although the normal steam-to-carbon ratio for this
unit is 3.2 to 1.
Catalyst "regeneration", to recover activity, can be accomplished by steaming the

catalyst, if only a minor amount of carbon deposition has occurred. This would be
evident by reformer tube appearance and/or increased DP through the tubes.
Reforming catalyst that has been reduced, must not be exposed to oxidising
atmospheres at elevated temperatures, except under a carefully controlled
condition. During the shutdown of the reformer the catalyst should be kept under a
steam atmosphere until the temperature of the catalyst has been reduced to
204°C. The catalyst tubes should then be purged with nitrogen to sweep out the
steam to prevent it from condensing.
( Catalyst Poisons
The poisons for primary reformer catalysts, normally encountered, are sulphur,
chlorine and arsenic (lead will also poison and ruin these catalysts). The most
common symptom is an increased reformer tube skin temperature. In very severe
cases of poisoning, the methane content of the reformer effluent gas will also rise.
If the catalyst activity is sufficiently reduced, methane cracking will occur at the inlet
of the reformer instead of steam reforming, and carbon (in the form of graphite) will
form, causing the activity of the catalyst to be lowered further.
Any sUlphur compounds that break through the zinc oxide guard chamber to enter
the primary reformer will reduce catalyst activity; however, this pOisoning is
temporary and activity may be recovered by stripping the catalyst with
sulphur - free gas. The catalyst itself may contain traces of sulphur as it is
delivered from the manufacturer, but this sulphur is removed during early phases
of the unit start-up.
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Chlorine, in small quantities, will be removed by the zinc oxide but less efficiently
than sulphur. Chlorine poisoning is reversible, but it is more difficult to remove
than sulphur. Steam stripping will remove minor amounts of chlorine, but in severe
cases, the catalyst would have to be replaced. Chlorine may be introduced by the
steam and so steam purity is especially important. In addition, cleaning solvents
. containing chlorine should be avoided around the reformer. It is not anticipated
that chlorine will be present to create any problems.
Other poisons include arsenic and lead. The effects are usually irreversible, and
the catalysts will be ruined and must be replaced, in addition to having to
elaborately clean the reformer tubes and other pipework.
c The catalyst is shipped in the oxidised state. It is pre-shrunk at temperatures

higher than those usually encountered in operation and shrinkage in service should
be negligible. If water or wet steam should suddenly cool hot catalyst, breakage
might occur, therefore this condition should be avoided.
A catalyst loading procedure is included in the General Procedures Manual under

"Catalyst Loading of Primary Reformer Tubes". The catalyst size may vary from
the standard but has no effect on the loading procedure.
NOTE: Reforming catalyst that has been activated is placed in operational use in
the reduced state and must not be exposed to oxidising atmospheres at elevated
temperatures except under carefully controlled conditions.
3.2.1.2.4 Fumace Operation
In order to obtain the packed tube outlet temperature required (about 812°C) for the
primary reforming, a flue gas temperature of about 101 OOC leaving the radiant
section will probably be necessary. The firing must be carefully regulated to avoid
c "cold" banks of tubes and/or local overheating and special attention should be
made to the note contained in Section 6.3.2.c - "Initial Start-up" of this manual.
The hot flue gases pass downward through the radiant section of the box and enter
ducts at the floor level. These ducts form the transition between the radiant and
convection sections of the fumace and serve to keep the hot flue gases in efficient
contact with the catalyst tubes, eliminating stagnant areas in the radiant section.
Tunnel bumers are installed at Furnace floor level to allow adjustment of the
furnace flue gas exit temperature to the Convection section if required.
The draft necessary to cause the flue gases to flow is induced by the Induced Draft
(I.D.) Fan, located at the base of the stack. The flue gases enter the convection
section to give up heat, successively, to the following coils:
- Mixed Feed preheat coil

- Process air (and steam) heater coil (hot leg)
- The steam Superheater (in two sections)
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- Natural Gas Feed preheat coil

Process air ( and steam) preheater coil (cold leg)
- The boiler feed water preheat coil
- Fuel Gas preheat coil
Flue gases from the auxiliary boiler enter the Auxiliary Boiler flue gas duct and join
the main convection section of the fumace upstream of the steam Superheater
coils.
Superheater burners at the top of the convection section hot leg allow adjustment of
the convection section cold leg temperatures.
c The cooled flue gases leave the convection section at a temperature of about
180°C and are discharged through the stack to atmosphere by the induced draft
fan.
Normal pressure in the radiant section of the fumace is -5 mm H20 (negative

pressure) and is regulated by PIC-l 019, which controls the speed of the Induced
Draft Fan turbine driver.
High Pressure alarm PAH-l 019 which senses the pressure in the radiant box
together with High pressure alarm, PAH-l057 measuring the pressure at the
suction of the induced draft fan, will warn the operator of a pre-determined
dangerously high pressure condition.
The Aux. boiler combustion air is supplied by a turbine driven forced draft fan C-
2111.The air is supplied in ratio to the fuel by a leading air system which adjusts
the Fan drive turbine govemor speed setting.
The combustion air for the Arch burners is supplied by turbine driven fan C- 2112
. The air supply is regulated by five manually operated dampers in the combustion
c air ducts to the arch burners. The turbine speed is controlled by FIC-1181 which
adjusts the Fan Turbine driver governor speed setting to hold a set pressure
upstream of the dampers.
The furnace has been designed to operate with excess air of 10% and a chart
"Furnace Excess Air Determination Nomograph" has been included in the General
Procedures Manual. This chart may be used in conjunction with occasional flue gas
analyses (02 , CO2 & CO) as a check on firing efficiency.
Observations of catalyst-tube skin temperatures should be made on a regular

schedule using an optical pyrometer. Hot or brightly-coloured spots sornetimes
indicate voids in the catalyst tube, or carbon deposits on the catalyst. The arch
burners must be operated to avoid flarne impingernent on the tubes, as such
mal-operation could result in early tube failure. A little experience and
experimentation will indicate the optimum draft and burner air register adjustment to
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3.2.1.3 Secondary Reforming
The partially reformed gas from the primary reformer enters the Secondary Reformer
(R-21 03) inlet chamber tangentially via a water jacketed transfer line. The
temperature at the secondary reformer inlet will be about 829°C.
The flow of gas is downward around a centrally located air inlet pipe and passes
through a fixed straightening vane to enter the combustion zone of the reactor.
Preheated process air (and steam) is introduced to the process flow through a
nozzle located just below the straightening vane. This has the effect of intimately
mixing the swirling process stream and air for rapid combustion and distributing the
c heat over the entire surface of the catalyst bed.
From the combustion zone of the secondary reformer the flow passes through a bed
of nickel catalyst to complete the reforming reaction.
3.2.1.3.1 Secondary Reformer Catalyst
The catalyst bed consists of 25.8 cubic meters of nickel catalyst. The catalyst
is supported on a bed of 25 dia. high alumina (low silica) content spheres laid
on a bed of 50 mm tabular spheres of the same material. The support spheres and
catalyst are supported by an arched brick dome located over the disengaging
section of the secondary reformer. A catalyst loading procedure is submitted in the
General Procedures Manual under "Catalyst Loading of the Secondary Reformer".
3.2.1.3.2 Secondary Reforming Operation
Maximum efficiency of the overall reforming operation requires that as much

reforming as possible be done in this partial-combustion step. Utilisation of
c combustion energy reduces the fuel gas requirement in the primary reforming
furnace. However, the amount of air charged to the secondary reforrner is set by
the nitrogen requirernents for synthesis, so the degree of overall reforrning will be
regulated by variation of prirnary reforrner temperatures. The design rnethane
content of the secondary reformer effluent stream is 0.43 mol % (dry basis).Close
control will be required on the ratio of hydrogen-to-nitrogen. If it gets very much olit
of line, difficulties will be encountered at the ammonia converter, as will be
discussed under the converter heading below. Gas analysers are provided to keep
a running check on the synthesis gas to the synthesis gas compressor and on the
gas being circulated through the synthesis loop. These instruments are normally a
major reference for operation of the primary and secondary reformers.
Sufficient air must be injected into R-21 03 to produce a HdN2 ratio of 3: 1 for the
synthesis gas stream. Whenever the process air flow is altered, temperatures in
the Secondary Reformer should be watched and compensating changes made as
necessary. Increasing the air flow will raise the temperature, and a decreased firing
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dictate. When conditions are at an optimum and a change in feed gas flow is
necessary, a proportional change (in the same direction) of the air rate will be
required to maintain the hydrogen/nitrogen balance.
Water jackets envelope the secondary reformer, transfer line, E-2101 & E-21 02 in
order to keep the metal temperature low if heat leaks develop in the internal lining.
3.2.1.4 Waste Heat Boilers E-21 01 and E-2102
Raw synthesis gas with process steam at about 994°C leaves the bottom of the
secondary reformer and is cooled bypassing through the tube sides of waste heat
boiler E-21 01 and shell side of HP Steam Superheater E-21 02, to obtain the required
c inlet temperature to the HT Shift Converter R-21 04. E-2101 and E-21 02 are
designed with "inner bypasses". The temperature of HP steam out of E-21 02 tube
side is controlled by TIC-1 004 via control valve TV-1 004 installed on E-2101 tube
side, which regulates the flow of the gas bypassing E-2101. The overall temperature
drop across the E-21 01 and E-21 02 from 994°C to 371°C, is reflected as heat input
to the boiler water from D-2101 that is thermo-circulating on the tube side of E-21 01
and to the HP steam passing through the tubes of E-21 02 respectively.
The required inlet temperature to the HTS Converter of 343- 371°C, is controlled by
TIC-1010 which activates control valve TV-1010 located in the shell side of E-21 02.
3.2.1.5 High Temperature Shift Converter [R-21 04]
The HTS and LTS shift converters are constructed as a single stacked structure with
the upper section being the HTS Converter R-21 04 consisting of one bed of high
temperature shift catalyst containing about 48.7 cubic meters of catalyst.
The High Temperature shift converter Fe30JCr203 catalyst will be either cylindrical or
c tablet form, depending on the vendor. A catalyst loading procedure is included in the
General Procedures Manual and the size may vary from that quoted, but should have
no effect on the loading procedure.
3.2.1.5.1 High Temperature Shift Converter Operation
The gas-steam process flow enters the HT section of the shift converter at about
343-371°C, where a large percentage of the CO content will be oxidised in
accordance with the following reaction:
CO+H20= CO2 + H2
This reaction is a reversible one, with "shifting" of the carbon monoxide (CO)
favoured by low temperature. However, the rate of reaction is favoured by high
temperature. To attain a specified CO conversion, the principal operating variables
are temperature and steam-to-gas ratio. It is customary to maintain the operating
temperature at design level (371°C) or lower. With new catalyst, it may be possible
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to obtain satisfactory conversion at an inlet temperature to the HT section of 343 to

357"C.
The steam-to-gas ratio is usually maintained constant. However, in the event the
LT shift converter is bypassed, and acceptable conversion has to be accomplished
in the HT section of the converter, it will be necessary to reduce the feed gas rate
to bring the steam-to-carbon ratio to the primary reformer to approximately 7.0:1.0.
Temperature: If the reaction is near equilibrium, a decrease in temperature will

likely improve conversion, and if it is not near equilibrium a temperature decrease
will reduce the shifting reaction. Conversely, if the reaction is near equilibrium, an
increase in temperature will result in a loss of conversion.
c The temperature conditions selected for the shift converter are based on a higher
temperature for the HT section to take advantage of the higher reaction rate for the
high CO content of the inlet gas, and comparatively lower temperature for the LT
section, to take advantage of favourable equilibrium conditions for the lower CO
concentrations in this section of the converter.
NOTE: The design metal temperatures for the HT and LT shift converters are
480°C and 270°C respectively. The design metal temperatures of the converters
should never be exceeded.
Steam: Increasing the steam flow results in an increase of CO shifting if

conversion is already near equilibrium, and a loss if not near equilibrium. It is
important that at least 20% steam be present in the gas passing over the catalyst
when at a temperature above 121°C, otherwise dehydration or change in the
structure of the catalyst (with a loss of physical strength) may occur. Normal
steam flows to the reforming section usually ensure this minimum steam flow to
the shift converters, so this should not pose a problem.
C 3.2.1.5.2 High Temperature Shift Catalyst Precautions
Start-up with the new, unreduced, catalyst will follow the procedure outlined in
Section 6.0. of this manual, utilising nitrogen for heating the HT shift catalyst initially
to 107"C to minimise the formation of condensate, then continuing the heating with
steam.
For all subsequent startups from a "cold" condition, nitrogen warm up of the
primary, secondary reformer and HT shift catalyst is also used. After shift catalysts
have been exposed to reducing gases (i.e. hydrogen,carbon monoxide) they are
pyrophoric and must not be exposed to oxygen (air) except under controlled
conditions. Excessive temperatures resulting from too rapid oxidation of the
reduced catalyst may cause catalyst and/or vessel damage. For this reason a
heat-up with nitrogen, circulated via C-2101 Air Compressor is used until above the
condensation temperature of steam, then steam will be used.
If the catalyst is to be removed from the vessel, or if the vessel is to be entered, at
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the client's discretion, they may subject the catalyst to a controlled oxidation
procedure to render it non-pyrophoric. However, it is recommended that oxidation
of the catalyst be carried out only when necessary. Even though the procedure is
followed carefully, some "dead spots" may occur where the oxidation was
incomplete, and some overheating may occur upon exposure to air. Further, there
is the probability that some loss of catalyst activity may occur following oxidation
and re-reduction.
A start-up with reduced catalyst must use inert gas (N 2) or a steam-gas mixture as
the heating medium, taking all precautions possible to minimise formation of
condensate, and keeping any water drained off. Water tends to weaken the binder
used in the catalyst manufacture.
c When preparing to stop operations or expose reduced shift catalyst, the general
procedures are as follows:
I. If the process gas flow is to be interrupted for only a brief period time, the
shift converter may be isolated under process gas pressure or under a
positive steam pressure, keeping any condensate drained out of the vessel.
II. If the shutdown is to be prolonged but the vessel is not to be entered or

exposed at any time to oxygen, isolate it and maintain under a positive
pressure with inert gas.
III. If the catalyst is to be inspected by looking into a top manhole only, it may
be cooled with steam to about 121°C. The steam should be purged out at
this point with nitrogen. Open the manhole for inspection. Only a slight flow
of inert gas is required to limit air diffusion. Inspectors should wear air
masks.
c IV. Should it be necessary for a man to enter the shift converter, he should be
equipped with an air or oxygen mask and a suitable hamess so that if
oxygen supply fails he may be pulled from the vessel. However, the Safety
Department of the plant should pass on the advisability of allowing a man to
enter a vessel of unoxidised catalyst in an inert atmosphere.
3.2.1.6 Low Temperature Shift Catalyst Section
The lower section of the stacked structure is the Low Temperature Shift Converter
(R-21 09) containing one bed of CulZnO/AI20 3 catalyst. The total volume of catalyst
is 59.18 cubic meters. The Low Temperature shift converter catalyst will be either
cylindrical or tablet form, depending on the vendor. A catalyst loading procedure is
included in the General Procedures Manual and the size may vary from that quoted,
but should have no effect on the loading procedure.
The top portion of this bed functions as a sulphur guard to absorb any trace amounts
of H2S that may evolve from the HT shift section and have a poisoning effect on the
LT shift catalyst. Most of the H 2S from the HT converter will be evolved during the
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first four to six hours at operating temperature. Therefore, the start-up procedure
proposed in Section 6.0. of this manual recommends venting the HT shift effluent at
the E-21 03 vent long enough to insure it is sulphur free.
Never route the HT shift effluent forward from the E-21 03 vent until it is sulphur free.
This will ensure a clean bed of top catalyst to act as a guard for the main bulk of the
LT shift catalyst in the event of a sulphur breakthrough from the desulphuriser reactor
zinc oxide guard bed during subsequent operations. During the initial start-up,
having the HT shift effluent essentially free of sulphur will help insure that the aMDEA
C02 removal solution will not be unnecessarily contaminated with an excessive
amount of H2S.
c 3.2.1.6.1 Low Temperature Shift Converter Operation
The LT shift converter will normally be operated with an inlet temperature of 202°C.
However, as Iowa temperature as possible is desirable for initial operation. Care
must be taken not to operate too close to the dewpoint of the steam/gas mixture.
Operating temperatures will be raised as the catalyst ages to sustain reaction, and
to hold the CO level down. The maximum temperature to which the LT shift
catalyst should be exposed is 260°C.
The CO conversion in the LT shift converter responds in the same direction as the
HT converter, to changes in, temperature, and steam-to-gas ratio. However, (as
previously noted), the LT converter is run at a lower temperature level. This will
ensure an effluent that is low in CO content and reduce the load on the Methanator.
The temperature at the inlet to the LT shift converter is controlled by the heat
exchange which takes place in the E-21 03 exchanger through which the HT shift
effluent gas passes giving up heat to boiler feed water for HP steam generation.
This reduces the temperature of the process gas entering the LT shift converter to
c the required'inlet temperature of 202°C.
Panel-mounted push button (HS-1004) operates valves MV-1008 & MV-1009 to

enable rapid bypassing of the LT shift converter in the event of conditions that may
lead to excessive operating temperatures. The use of this emergency bypassing of
the LT shift converter will require immediate reduction of feed gas to about 50%
and reduction of firing rate to the primary reformer. This ensures that the CO
conversion will be brought to a satisfactory level in the HT shift converter.
Caution: Do not fail to make a corresponding reduction in the process air rate to·
the secondary reformer. If the reduction in feed rate is not made immediately
before bypassing the LT shift converter, a high level of carbon monoxide (CO) will
break through to the Methanator, resulting in excessive temperatures in this reactor.
The above precautions are based on the assumption that the plant upset is of a
minor nature and CO entering the Methanator can be maintained low enough to
avoid a high temperature trip, by a rapid reduction in feed gas. However, the safest
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If the upset is due to loss of the air compressor, the latter procedure must be
followed since reaction in the HT shift will be lost due to the sudden reduction in
secondary reformer outlet temperature (HT shift feed temperature).
3.2.1.6.2 Low Temperature Shift Catalyst Precautions
Start-up with the new, unreduced catalyst or reheating the reduced catalyst will
follow the procedure outlined in Section 6.0. of this manual, using desulphurised
natural gas or nitrogen for heating the catalyst to 177"C to 190°C.
In the course of operation, particularly during the start-up stages, it may become
c necessary to purge and/or "blanket" the contents of the vessel after first isolating it.
Purging or blanketing will be accomplished by the use of nitrogen to ensure that no
''wetting'' of the catalyst occurs: The nitrogen will be introduced into the top of the
vessel and the contents displaced through the bottom reduction vent. When all
hydrocarbon has been displaced, the vessel is left standing, "bottled up", under a
positive pressure of nitrogen.
Warning: Carbon dioxide, either in its wet or dry state, must never be used for
purging and/or blanketing of the LT shift catalyst. Dry CO2 has an adverse effect
on the activity of the catalyst and this is particularly so during the stages of
activation. There is also some loss of activity, although to a somewhat lesser
degree, when wet CO2 is used.
The LT shift catalyst in the reduced stage is highly pyrophoric at any temperature,
(due to chemically absorbed and mechanically absorbed hydrogen on the catalyst).
Once reduced, therefore, the catalyst must never be exposed to, or contacted with
air (oxygen), since rapid oxidation would occur resulting in excessive temperature
and ultimate damage to the catalyst and/or the vessel.
c If the LT shift catalyst is to be salvaged it must be carefully deoxidised before

exposing the catalyst to air (02). However, this is at client's discretion and those
precautions regarding catalyst oxidation mentioned for the HT shift catalyst also
apply here. If the catalyst is to be removed from the LT shift and there are no plans
for salvaging, it may be unloaded from the shift converter under a nitrogen (N2 )
atmosphere without reoxidation. However, the catalyst should be cooled below
149°C before it is unloaded. If this latter procedure is used, the catalyst is permitted
to flow into steel drums. The catalyst should be "spray wetted" as it leaves the
converter and contacts air (02 ); this will prevent rapid reoxidation.
The operators must be thoroughly familiar with the procedures for recovery or
discarding of the catalyst.
When carrying out procedures below normal operating pressures, do not exceed
design velocities through the beds. Sudden pressuring and depressurising, and
changes in rates of flow, should be avoided, to obviate "heaving" the beds. At all
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water. Temperature of the catalyst bed should not be changed at a rate greater
than 83°C/hr.
3.2.2 CO 2 Removal ( aMDEA System)
The aMDEA CO2 removal system is a proprietary commercial process for CO2 removal
from gas streams of high CO2 concentration
3.2.2.1 Flow of Gas and aMDEA Solution
The reformed gas from the shift effluent separator enters the CO2 absorber through a
c
branch distributor and flows upward through two beds of slotted ring packing. As the
gases flow upward through the packed beds they are contacted by the downflowing
solution which absorbs most of the CO2 .
At normal design operating conditions it is expected that 773 MT/hr of the lean
solution will be pumped through the distributor above the top bed The scrubbed
gases pass through a demisting pad in the absorber top and in the overhead
separator and out the top of the drum. The temperature of the gas leaving the top is
expected to be about 50°C and the rich solution in the bottom of the tower at 82°C. It
is expected that the gas from the top of the absorber will contain about 0.1 % CO2 by
volume.
The rich aMDEA solution is stripped of the CO2 in the CO2 stripper. The rich solution
is pressured out of the absorber under level control. As the rich solution moves up
the pipe toward the stripper inlet, more and more of the CO2 is flashed from the
solution and separates from the liquid as it enters the stripper.
The solution flows down the stripper over two beds of slotted rings in the LP flash
section and into a trapout pan where the semi-lean pumps take suction. The P-21 08
c semi-lean pumps pump the solution into the stripping section of the column via
lean/semi-lean exchanger E-2112. The solution flows downwards through two beds
of packing where it contacts the upflow of steam generated by reboilers E-21 05 and
E-2111.The stripped solution is retumed to the absorber by lean solution pumps P-
2107 being cooled on route by exchangers E-2112, E-2109and E-2110
A top contact cooler section washes out entrained carbonate from the CO2 product
gas cools the stripper overhead gas and condenses the stripping steam.
3.2.2.2 Chemistry of the aMDEA Process
aMDEA (Methyldiethanolamine) solution in water removes C02 from the gas

stream by chemically bonding with the C02 to form bicarbonate. The bicarbonate
is unstable and will decompose at reduced pressures and increased temperatures.
The addition of an activator improves the rate of absorption. The quantity of
activator can be varied to vary the characteristics of the solution between that of a
physical and chemical solvent.
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The C02 is released from the solution in the stripping column by:
1. The reduction in pressure causing the C02 to flash off the solution in the LP
Flash section. This removes the bulk of the C02 from the solution without
significant heat input.
2. The addition of heat in the stripping section of the column. This

decomposes the residual bicarbonate and reduces the C02 content of the
solution to a level suitable for return to the C02 absorber for re-use.
3.2.2.3 Solvent type and solution strength
c The aMDEA Solvent Systems are delivered as premix solutions, which consist of
MDEA, the activator and a small water content. The solvent has to be diluted with
demineralised water in the gas treatment unitup to 60 %(w/w) water and 40
%(w/w) amine. During operation the amine content has to be maintained between
37 and 45 % (w/w) by adjusting the make-up water flow rate.
3.2.2.3.1 Solvent make-up
The annual solvent losses are approximately 5 to 10 % of the aMDEA premix

inventory. The solvent losses are mainly caused by mechanical problems such as
pump leakage, cleaning and change of filters or entrainment. Hence, the losses
depend strongly on the maintenance and the measures taken to avoid
entrainment.
The aMDEA premix can be used as solvent make-up. However, the activator
concentration drops slowly over months of operation since the vapour pressure of
the activator is higher than of MDEA.
c Typical annual activator losses are around 10 - 15 % of the activator inventory

which can be balanced by the addition of an enriched aMDEA make-up solution
conSisting of 40%(w/w) MDEA, 40 %(w/w) activator and 20 %(w/w) water
("aMDEA 1: 1").
The activator make-up has to be added into the solvent loop, e.g. on the suction
side of the lean solution pump.
3.2.2.3.2 Solvent storage
Nitrogen blanketing is recommended if the solvent is stored for periods longer

than three months. The continuous contact of the solvent with air turns the colour
from light yellow to brownish (degradation products in the ppm-range). The
absorption parameters of the a MDEA solvent, however, are not altered but the
foam activity can be somewhat higher.
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3.2.2.3.3 Antifoam Agent
The aMDEA solvent system is non-corrosive and therefore, no corrosion

inhibitors are required.
The only inhibitor, which has to be added to the solution, is a small amount of
antifoam agent.
The recommended defoamer is Amerel1500 .This is produced by Drew Ameroid

Company but can also be ordered via BASF. The Amerel dosing rate depends
strongly on the plant size, operating capacity and the impurities in the feed gas.
c Typical dosage rates of Amerel are as follows:
• Natural gas: 1000 mllday for a plant capacity of 350,000 Nm3/h

• Synthesis gas: 100 mllday for a plant capacity of 100,000 Nm3/h
Amerel 1500 is a suspension of surface-mcidified Si02 in silicone oil. Therefore,

it has to be stirred thoroughly before being added to the solution. The addition of
Amerel can be carried out continuouslY,batchwise or only when increased
foaming activity is predicated.
• Indications for a high foam activity are:
• High differential pressure on the columns
• Difficulties in controlling the bottom levels
• High hydrocarbon content in the acid off-gas
c •
•
High aMDEA-content in the reflux condensate or in knock-out drums
Results of the foam test outside specified range
In order to prevent foaming we recommend a regular discontinuous dosing of

Amere11500, e.g. once per shift or once per day.
For the initial start-up and when starting up after the pumps have been stopped,
an extra quantity of antifoam agent should be added.
3.2.2.3.4 Filter Operation
The filter deactivates the defoamer by the removal of the silicone particles.
Therefore the filtered stream should not be higher than actually required.
3.2.2.3.5 Regular Solvent Analyses
Solvent samples should preferably be taken from the lean solution line
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downstream the lean solution cooler. Further samples can be taken as required.
The following regular analyses are recommended (see Analysis Manual for the
BASF aMOEA Process).
Once per shift: water content by density measurement
Once per week: total amine concentration
Once per month: MOEA content and activator content
3.2.2.3.6 Reduced Load Operation
C Solution rate can be reduced proportionally to the feed gas rate.
Limitation: the liquid load of the absorber packing should be > 20 m3/m2/h
A too low liquid loading might lead to mal-distribution and to a breakthrough of

C02
3.2.3 Methanation (R-21 06)
Process gas containing about 0.1 mol % of CO2 and about 0.36 mol % CO, flows
from the top of the absorber through the absorber overhead demisting section
where any entrained moisture will be removed in passage through the demisting
pad contained therein. The gas then flows, in normal operation, to the Methanator
R-21 06 via the Absorber Overhead. drum 0-2103 and the Methanator Feed/Effluent
Exchanger E-2114 where it is preheated to 316°C.
A gas by-pass is provided round E-2114 to permit adequate control of the feed
temperature. A separate HP steam heated Methanator Feed Heater (E-2172) is
provided for the initial heating of the gas to normal operating temperature during
C start-up. It will also be required during normal operation when the LT Shift catalyst is
fresh and the heat of the methanation reaction is not sufficient to provide the
required temperature differential in E-2114.
The Absorber demisting section and the absorber overhead drum 0-2103 is
provided as an additional protection for the catalyst in the Methanator. The hot
Methanator catalyst would be damaged if contacted with liquid. Therefore, the
absorber overhead should occasionally be checked to ascertain that liquid carryover
is not excessive. Should the prospect of liquid carryover develop, steps should be
taken to vent the Methanator feed gases and to close the Methanator inlet valve.
This can be done by use of the emergency pushbutton (HS-1253) provided.
Excessive carryover may be the result of foaming of the aMOEA solution or an
excessive circulation rate of solution. Normally, the corrective step is self-evident.
The objective of the methanation reaction is to complete the removal of the carbon
oxides from the synthesis gas, since carbon oxides are pOison to the ammonia
synthesis catalyst. Removal of the carbon oxides is accomplished by their
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conversion to methane, which acts as an inert gas in the ammonia converter. The
methanation reaction is as follows:
co + 3H2 = CH. + H20 + Heat

CO2 + 4H2 = CH. + 2H20 + Heat
Both reactions are exothermic, causing a theoretical temperature rise of about 72°C for
each mol percent carbon oxide in the inlet gas. Under normal operating conditions,
with a carbon monoxide content of 0.36 mol % in the inlet gas, the expected
temperature rise in the Methanator will be about 31°C resulting in an outlet
temperature of about 347°C.
c Because of the highly exothermic nature of the methanation reaction, the Methanator
is protected by automatic high temperature actuated, feed shutoff valving. The
following temperature indicators and alarms measure the temperature at various
pOints in the catalyst bed; TAH-1357,TAH-1358, TAH-1359, TAH-1360, TAH-1361 &
TAH-1362A1B. High temperature alarms and Methanator shutoff trips TSHH-1200,
TSHH-1201, TSHH-1202 & TSHH-1203 are located at intervals throughout the catalyst
bed and are provided with thermocouple burn-out low temperature alarms.
If the bed temperature exceeds the set temperature of anyone of alarms TAHH-1200
through TAH-1203, the solenoids provided on the two Methanator inlet valves will
cause them to close, stopping all flow to the Methanator. As a result, the pressure
controller (PIC-1 005) in the Methanator inlet line will open to vent the feed gas to
atmosphere. The Methanator temperature trip should be set at a temperature of
approximately 30°C below the Methanator vessel design temperature (455 C).
As a further protection against high run-away temperatures in the Methanator due to a

CO2 breakthrough from the CO2 absorber system, the Methanator will be shut-down
automatically if the lean or semi-lean CO2 removal solution flows drop below preset
values. Low low flow on FT-1205 & FT-1217 will activate the Methanator shut-down
c system in the same manner as activation of a high temperature trip from TSHH-1200
through TSHH-1203.
If the Methanator feed valve is shut by the high temperature alarm system,
determine and correct the cause before starting feed gas to the Methanator. When
the feed gas total carbon oxides content has been reduced to normal or less, the
feed gas may be restarted to the Methanator at a low rate with the inlet valve
throttled manually. The inlet valve solenoid must be manually relatched. Gradually
increase the feed rate until the inlet valve is wide open.
Venting of the Methanator in the manner described above provides protection not only
for the methanation catalyst but eliminates any chance of having a breakthrough of CO
and CO2 into the synthesis loop which, of course, are poisons to ammonia conversion
catalyst. With regard to CO2 , it should be mentioned that besides catalyst poisoning
and degradation, this contamination can cause difficulty with the performance of the
synthesis gas compressor. With relatively large amounts of residual CO2 from the
Methanator, it is possible to deposit ammonium carbamate and/or ammonium


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carbonate in compressor internals as the result of contact with ammonia laden gases
from the second case kickback of the C-21 03 synthesis gas compressor, that is, if the
circuit is open during an emergency. This condition may create vibration problems in
the compressor and/or stress corrosion of compressor internals.
An emergency push button (HS-1253) has been provided on the control room board.
This push button may be used to actuate the Methanator inlet valve solenoid on
demand when desired.
CAUTION: Never depressurise the Methanator below normal operating pressure

while normal pressure exists upstream of the Methanator inlet valve. Such
depressurising has caused extremely high temperatures in the Methanator because of
c inlet valve leakage, increased by the higher than normal inlet valve pressure
differential. The Methanator design metal temperature is 455°C. This temperature
must not be exceeded under any circumstances.
The catalyst Loading procedures is described in the General Procedures Manual and
once the catalyst has been placed in operation or reduced, it should not be exposed to
air or to oxidising atmospheres. In a plant shutdown where Methanator entry is not
anticipated, it should always be blocked in under an atmosphere of hydrogen or
nitrogen. For removal of catalyst, it should first be at ambient temperature, then
unloaded through the dropout under an atmosphere of nitrogen. The catalyst should
be wetted down with water as it leaves the vessel to prevent rapid oxidation.
Under certain conditions, carbon monoxide and nickel may react to form nickel
carbonyl, Ni(CO)4, which is a highly toxic compound. Whenever men are going to
enter (or open) the Methanator, tests should be made to assure that carbonyls are not
present.
The most likely time for nickel carbonyl formation is during start-up or shutdown, since
these procedures involve the temperature range favourable for carbonyl formation, i.e.
c from ambient temperature conditions to about 177°C. A few simple precautions will
suffice:
3.2.3.1 Shutting Down:
The catalyst should never be permitted to cool down to ambient temperature in the
presence of CO. When the process gas contains CO, the Methanator should be
flushed with a CO-free gas before the temperature drops to 204°C.
3.2.3.2 Starting Up:
The pressure on the Methanator should be kept as low as practicable when heating up
on process gas, until the bed temperatures are above 177°C. This will help ensure a
good flow distribution during initial heating of the catalyst bed. The catalyst should be
brought up to normal operating temperature in as short a time as practicable to
minimise the possibility of nickel carbonyl formation.
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3.2.4 Ammonia Conversion
3.2.4.1 Compression of Synthesis Gas and Water Removal
The purified gas is compressed to about 67 bara in the first case of the synthesis gas
and recycle compressor (C-21 03) and then chilled in three steps: first, by boiler feed
water in the Synthesis Gas Compressor Interstage BFW Preheater E-2117; second,
by cooling water in Synthesis Gas Compressor Intercooler E-2116 and then by
ammonia refrigeration in the synthesis gas compressor interstage chiller E-2129.
This chiller cools the gas to about 4.4°C and drops out most of the water in the first
stage separator (0-2105).
c The low moisture content synthesis gas leaving the first stage separator (0-2105)
goes to the second case of C-21 03 and the pressure is increased to about 144 bara
to enter the synthesis gas loop. At an intermediate point (last wheel suction) of the
second case of C-21 03 the synthesis gas is joined by the synthesis loop recycle gas.
3.2.4.2 Precautions Relative to Synthesis Gas Compressor
The efficient operation of the Synthesis Gas Compressor, C-21 03, will require that
the quality of the process gas entering the compressor be such that the CO2 content
be maintained at the value specified (less than 10 ppm) at all times. It is important
also that the temperature of the gas entering the suction of the high pressure case
not be allowed to fall below aOc. Failure to observe these precautions when the
machine is in operation can, under certain conditions, result in the formation of
carbamate and/or ammonium carbonate at the first wheel location of the compressor
second stage. This could have a damaging effect on the operation of the machine
resulting in a progressive increase in vibration caused by an imbalance as the
deposits build up.
c To eliminate the likelihood of this occurrence the following precautions must be

followed once the compressor is in synthesis gas service:
I. The temperature of the gas entering the compressor second case must not
be allowed to fall below the aOc temperature at any time in order to avoid
conditions conducive to carbamate/carbonate formation. Formation of
carbamate/carbonate is an inverse function of temperature; that is,
decreasing temperatures increa$e the chances for formation of these
compounds. With less than 10 ppm carbon oxides in the Methanator effluent,
satisfactory operation can be expected with a compressor interstage
temperature of aOc. Similarly, extremely low temperatures at the interstage
location must be avoided because of the danger of freezing water of
saturation in the synthesis gas at compressor suction locations, which can
also cause wheel damage.
II. Flow of steam to steam tracers on kickback lines will be turned on prior to
starting. This is required in order to avoid liquid condensation in the kickback
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circuit particularly for removal of condensate to avoid situations which can

cause slugs of liquid to enter the compressor and cause wheel damage.
Prior to compressor start-up, the drains must be checked to make certain that
no liquid is present in the kickback line.
III. Operate the compressor kickback (FIC-1008) on minimum kickback flow

consistent with machine stability and, where feasible, with zero kickback.
This is particularly desirable if there has been a sudden upset in the CO2
removal system causing a somewhat higher than normal breakthrough of
CO2 from the Methanator. The second-casing kickback gas contains large
amounts of ammonia vapour and this should not be allowed to contact the
synthesis gas with a higher than normal CO2 content. If the kickback is
c closed or the kickback quantity is small during the upset, the possibility of
formation of solids in the compressor is eliminated. It should be emphasised,
however, that a breakthrough of CO2 resulting from an upset in the CO2
removal system will necessitate venting gas at the inlet to the Methanator
(PIC-1005)
IV. Satisfactory performance of the CO2 removal system requires that the
analyser (AI-1002) which continuously analyses and monitors the total oxides
in the synthesis gas stream be frequently checked and periodically calibrated.
Accurate and dependable analyses of the stream will provide an early
indication of higher than normal CO2 leakage and thus inform the operator
when venting of the gas at the Methanator inlet or the suction drum
(PIC-1004) is required.
V. A major upset in the CO2 removal system resulting in an increase in the

residual CO2 content of the gas leaving the absorber will make it necessary to
vent gas at the Methanator inlet if the CO2 breakthrough is excessive (see
"Methanation" Process and Operating Principles - Section 3.0). The push
c
button switch (HS-1253) may be used to vent the gas at any time if the
analyser recorder shows a tendency of a rise in the CO/C02 content.
VI. Always maintain the normal design temperature on the gas outlet from
E-2124. Temperature indicator (TI-1633) is installed for this purpose and the
cooling water flow to the Loop Cooler should be adjusted to yield 50°C at this
point. This will avoid condensation of ammonia and the return of liquid to the
second case suction when the machine is on kickback operation.
VII. The vibration measuring instruments should be checked frequently to

determine levels of vibration on the compressors and the results recorded in
the plant log. The vibration pattern should be checked often after an upset
has occurred to determine if an increase has followed the upset. If excessive
vibration patterns develop, the compressor must be shut down for inspection.
VIII. If the backup hydrogen supply for feed as hydrogenation is taken from the
synthesis loop, then it should be routed downstream of the preheat coil since
the addition of NH3 synthesis gas to cold natural gas containing CO2 could
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result in carbamate formation and line blockage.
If the precautions outlined above are observed, the likelihood of deposits of

carbamate and/or carbonate formation occurring on the first wheel or situations
involving build-up of liquid in the kickback circuit will be minimised.
The 2 inch bypass valve around motor operated valve HV-1001 will be used for
controlling the flow to the synthesis loop at start-up.
3.2.4.3 Conversion of Synthesis Gas to Ammonia
The synthesis converter (R-21 05) contains about 68.4 m3 of synthesis catalyst
c divided into three beds, bed no. 1 and beds no. 2A & 2B; each bed containing 22.8
3
m of catalyst.
Prior to entering the Converter R-21 05, the synthesis gas receives some preheat
from the converter effluent in E-2121. It is then introduced at one end of the
external shell of the converter at 259°C and flows along the annulus between the
external pressure shell and catalyst basket towards the opposite end of the
converter. This arrangement limits the temperature to which the external shell is
exposed. On reaching the opposite end of the converter, the synthesis gas enters
an opening in the end plate and flows across the external surfaces of E-2122
tubes. After passing across the outside surfaces of the tubes the synthesis gas
enters a partitioned plenum where it is directed to the distributor above the first
bed. On exiting bed no. 1, the synthesis gas re-enters the partitioned plenum
where it is directed through the tubes of E-2122. The synthesis gas exits E-2122
tubes and re-enters the plenum where it is directed through a distributor pipe to the
top of bed no.2A. The gas passes down through bed no. 2A and is then directed
to the top of bed no. 2B. A further reaction takes place in bed 2B after which the
gas exits the converter shell through an internal piping arrangement at the feed
c inlet end.
Heat from the Ammonia synthesis reaction raises the gas temperature from the first
bed to around 496°C. The effluent gas flows through the tube side of the
interchanger, which cools the gas to about 387"C before passing over the second
catalyst bed. The second catalyst bed is divided into two physical beds in series to
ensure uniform flow over the catalyst. Further reaction in the second bed raises the
converter outlet temperature to about 457"C and the ammonia concentration to 15.75
mol%. A bypass line around the converter, controlled by valve HIC-1025 is provided
to permit introduction of feed gas without preheating for temperature control to the
first catalyst bed, usually referred to as "quench".
The design feature of an intercooled converter has the advantages of producing a

relatively high ammonia concentration per pass and making the heat available in the
converter effluent at a temperature sufficient for the production of high pressure
steam.
The ammonia converter effluent stream at 448°C is cooled by heat exchange giving


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up heat to boiler feed water in steam generator E-2123 and to the converter feed in
E-2121 before retuming to the Recycle Gs Compressor C-21 03 to be recycled back
to the converter. Before the recycle gas (plus fresh feed) re-enters the converter, it is
routed via the unitized chiller system to condense out the net ammonia make
produced on its previous pass through the converter.
A continuous vent or high pressure purge is maintained to remove excess inerts

(mainly methane and argon) from the synthesis gas loop. This purge gas is chilled
to -29°C for initial recovery of ammonia and then passes to the ammonia absorber
for further recovery. If these inerts were allowed to build up to too high a level they
would ultimately reduce ammonia production. However, excessive venting is to be
avoided as a loss of yield by excessive loss of hydrogen/nitrogen synthesis gas will
c result.
The following are discussions of factors affecting the operation of the synthesis
converter.
3.2.4.4 Conditions Influencing the Converter Reaction
The SyntheSiS Reaction, which is promoted by the catalyst, may be illustrated by

the following equation:
N2 + 3H2 = 2NH3
The equilibrium point for this reaction is such that, at the proposed operating
conditions, the ammonia content of the reactor effluent will be about 15.75 mol
percent. The unconverted gases are recycled back through the reactor to achieve
optimum production.
3.2.4.4.1 Temperature
C The effect of a change in temperature on the ammonia synthesis reaction is a double

one, as it affects both equilibrium percentage and reaction rate. As the synthesis
reaction is exothermic, a rise in temperature lowers the equilibrium percentage of
ammonia and at the same time accelerates the reaction. This means that under
conditions far from equilibrium, temperature rise will lead to higher conversion, while
on the other hand for a synthesis system giving a conversion near the equilibrium
percentage a rise in temperature will lead to a lower conversion. Efficiency always
varies directly with temperature when catalyst deterioration. is not taken into account.
Conversion efficiency is defined as the ratio of the actual percent NH3 in the
converted gas to that theoretically possible under the conditions in question.
3.2.4.4.2 Pressure
As the synthesis of ammonia involves a decrease in volume (decrease in the number

of molecules), the equilibrium percentage of ammonia will increase with pressure. At
the same time the reaction rate is accelerated by increaSing the pressure; therefore,
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the conversion will improve with higher pressure.
3.2.4.4.3 Space Velocity
At higher process gas rates (higher space velocity in the converter) the synthesis
reaction has less time to operate and does not produce as high a concentration of
ammonia in the converter effluent as is produced when the gas is moving through
more slowly. However, the reduction in yield is far less than proportional to the
percent increase in space velocity. The increased production of ammonia, due to the
greater amount of gas put through the reaction zone, more than offsets the tendency
toward decreased production due to less complete reaction (less residence time).
Therefore, at normal or less than normal throughputs, an increase in gas rate to the
c converter will give increased production, provided that other conditions (temperature,
pressure, HJN2 ratio) are unchanged.
The usual method of changing space velocity is by altering the recycle (circulation)
rate. With more circulation (if available) the temperatures will tend to drop in the
converter beds, due to less conversion per pass; pressure will tend to drop because
of more total production of ammonia. Circulation is increased by closing in on
HIC-1030 Maximum circulation is attained when HIC-1030 is completely closed.
3.2.4.4.4 Hydrogen to Nitrogen Ratio
The fresh synthesis gas feed to the synthesis section should usually have a
hydrogen-to-nitrogen ratio of about 3:1. This is the case because the combining of
hydrogen with nitrogen to form ammonia is the ratio of 3:1. However, it should be
recognised that the hydrogen-to-nitrogen ratio within the ammonia converter can be
other than 3:1. It has been found that maximum conversion percentage is obtained
at a 2.5 to 3:1 ratio of hydrogen-to-nitrogen in the converter. The ratio in the fresh
gas feed may be altered slightly from 3:1 to obtain the optimum H2:N2 ratiO in the
c 3.2.4.4.5
combined gas feed to the converter.
Inert Gases
A continuous bleed of gas will be maintained from the recycle compressor suction
header to the purge gas system. This purge stream is required to control the
concentration of methane and other inert gases which would otherwise build up in the
synthesis circuit, resulting in lower conversion, higher pressure and reduced
production capacity.
3.2.4.4.6 Synthesis Gas Rate
Increasing the synthesis feed gas rate alone produces more ammonia and has the
following effects upon the conditions discussed above:
(1) The system pressure will increase.

(2) The catalyst bed temperature will increase.
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(3) The inert gas content will rise.

(4) The H2:N2 ratio may change.
Conversely, decreasing the synthesis gas rate will have the reverse effects.
Under normal operating conditions, the synthesis gas rate is determined by

production requirements. An increase in gas feed to the synthesis section must be
obtained by more production of gas in the front end of the plant.
3.2.4.5 Control of the Synthesis Heaction Operation
The synthesis system essentially rides on the line from the discharge of the synthesis
c gas compressor. Gas (H2 and N2 mixture of 3:1) is consumed as determined by the
operating conditions, catalyst activity, and resultant capacity of the synthesis loop. The
gas from the compressor keeps replacing the removed or converted gas. If excess
synthesis gas is available, the production increases to the limit of the compressor; then
raw synthesis gas is vented before the first stage of compression at 0-2104 suction
drum.
If there is insufficient gas, the compressor slows and the loop pressure drops until
production of ammonia is reduced and comes in balance with the gas available.
There are several variables, one or more of which may be changed to alter synthesis
loop operation. The more important controlling variables are listed below:
• Synthesis feed gas rate

• Converter feed temperature
• Synthesis gas circulation rate
• Hydrogen-to-nitrogen ratio
• HP inert purge gas rate
• Purity of feed gas
C • Converter bed temperature level
It will be noted that system pressure is not listed as a variable, which is available for
control. The pressure frequently changes as a result of the manipulation of other
conditions, but it is rare that a change would be made for the sole purpose of raising
the pressure, to the exclusion of all other effects. The system is usually so operated
that the pressure remains reasonably well below limits, while minimising the purge rate
and while maintaining converter temperatures low enough to assure long catalyst life.
Lower pressures usually indicate good operation, provided feed and purge rates are
normal and the converter temperatures are satisfactory.
Following are the factors affecting each of the synthesis loop conditions that the
operators watch to detect changes for abnormalities in the process. If these factors
are known, it is easier for an operator to explain a change in operating conditions. The
operator can then manipulate one or more variables to make the necessary correction.
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3.2.4.5.1 Converter Pressure
The main factors, which individually or collectively contribute to an increase in the

synthesis loop pressure, are:
• An increase in the synthesis feed gas rate.

• A decrease in converter temperature level.
• A change in gas composition away from the optimum of 2.5 to 3:1 ratio of
hydrogen to nitrogen in the synthesis gas loop.
• An increase in the ammonia content of the recycle gas.
• An increase in the inert gas (fixed gas) content of the circulating gas.
• A decrease in recycle gas circulation rate.
C •
•
Poisoning of the catalyst due to impure synthesis gas.
Ageing of the catalyst.
Conversely, a decrease in the pressure is caused by the reverse of the actions

above.
3.2.4.5.2 Catalyst Temperature Level
The main factors, which individually or collectively contribute to an increase in the

catalyst temperatures, are:
• An increase in the synthesis feed gas rate.

• A decrease in recycle gas circulation rate.
• A closer approach to the optimum 2.5 to 3:1 hydrogen-to-nitrogen ratio.
• A decrease in the ammonia content of the circulating recycle gas.
• An increase in converter system pressure.
• A reduction in the cold gas bypass (quench) rate to the converter.
c •
•
A decrease in the inert gas content in the circulating synthesis gas.
An increase in catalyst activity, following a temporary poisoning due to impure
synthesis gas.
Conversely, the factors causing a decrease in the catalyst temperatures are the
reverse of those mentioned above.
The best temperature for steady operation is the lowest temperature that will give
the maximum yield of ammonia product, yet high enough to provide stability in case
of pressure surges. Excessive temperatures will age the catalyst and cause rapid
reduction in catalyst activity.
3.2.4.5.3 Hydrogen-to-Nitrogen Ratio
The main factors which individual or collectively contribute to a change in the H2:N2
ratio of the circulating gas are:
• A change in the composition of the synthesis gas from the reforming and.


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purification systems
• A change in the synthesis feed gas rate.
• A change in the ammonia content of the circulating recycle gas.
• A change in the inert (fixed) gas content of the circulating gas.
The hydrogen-to-nitrogen composition of recycle gas to the converter is controlled

to maintain about 2.5 to 3: 1 ratio. A rapid change of ratio will cause a rapid
temperature change.
3.2.4.5.4 Ammonia Content of the Circulating Gas
c. Factors, which individually or collectively contribute to a change in the ammonia

content of the gas entering the converter, are:
• A change in cooling in the chillers before the ammonia separator D-21 06

• The system pressure.
It is anticipated that the ammonia concentration of about 15.75% in the converter

effluent will become 12.13% when the recycle and fresh feed gases are combined.
After chilling and separation in D-21 06, it is expected that the ammonia
concentration in the combined gas stream entering the converter will be about
2.69% after condensing out the ammonia make.
3.2.4.5.5 Inert Gas Content of Circulating Gas
The principal constituents, which contribute to the inert content of the circulating
gas, are argon and methane. These gases tend to build up and raise pressure in
the system, thus reducing the effective synthesis gas partial pressure. This is
reflected in lower conversion per pass. The inert concentration in the system is
c controlled by withdrawing a stream of purge gas via E-2125 and the purge gas
separator D-21 OS.
Design is based on an inert gas (methane and argon) content of about 1.2 mol % in
the feed gas. However, it may be found by experience that at higher
concentrations overall ammonia production can be increased by conserving
hydrogen, which would otherwise be removed from the system by excessive purge
gas rates from the synthesis gas loop.
From the preceding discussion of the ammonia synthesis operation it can be seen
that the efficiency is affected by the controllable variables listed at the beginning of
this subsection "(d)". All of these factors are interdependent and a change in one
will have an effect on the others. Consequently, good operation will be a
combination of operating experience and a recognition of the factors affecting the
operation of the system. Thus, if a drastic change in one of the operating
conditions occurs, experience will dictate those steps that should be taken to
compensate for the change, so that the system will remain in good control. Any


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changes should be made slowly when possible, so as to avoid major disturbances.
3.2.4.6 Converter Catalyst Characteristics
3.2.4.6.1 Catalyst Activation
The synthesis catalyst is made from fused iron oxides containing potassium,
calcium and aluminium oxides as stabilisers and promoters, and is charged to the
ammonia converter in the oxidised state. The catalyst must be activated before
production of ammonia will take place. The activation requires reduction of the iron
oxide to practically pure elemental iron. Reduction of the synthesis catalyst will be
c
accomplished during the initial start-up of the plant under the guidance of the
catalyst vendor's representative and careful control of conditions during catalyst
activation will result in uniform reduction which will prorr:lOte longer catalyst service.
An outlined procedure, to be used as a guide, is described in Section 6.3.18. of this

manual. During reduction, hydrogen is passed over the oxidised catalyst at
progressively higher pressures and temperatures. The hydrogen combines with the
oxygen from the iron oxide to form water. The water is removed (as much as
possible) before the gas is recycled over the catalyst. The amount of water
produced during the activation period is a good indication of the progress of the
catalyst reduction. At the start of the reduction period, a small amount of water is
formed and as reduction of the catalyst progresses, water formation increases.
The reduction of the catalyst is aided by fairly high temperatures and controlled
pressures. The water formation will reach a peak and then gradually taper off near
the end of the reduction period.
The reduction temperature should always be kept below that at which the catalyst is
going to operate, so as to avoid deactivation due to the following: (1) high
concentrations of water vapour in the circulating gas, (2) excessive heat. However,
c too Iowa temperature will cause catalyst reduction to move slowly; if temperatures
drop low enough, reduction will stop.
The effect of pressure and/or pressure change during catalyst reduction can be
critical. If each catalyst bed is not activated uniformly as reduction moves
downward, an increase in pressure may cause channelling. That is, the more
reduced catalyst areas will promote the reaction of hydrogen and nitrogen to form
ammonia in local sections of the bed. This reaction gives off heat and will cause
catalyst bed temperatures to become higher and difficult to control in these
localised areas. The pressure during catalyst reduction should be maintained at a
point where reduction is symmetrical and temperatures in a horizontal section of the
bed do not spread beyond a small range. Increasing the pressure will promote
ammonia formation; lowering the pressure will retard ammonia formation.
The catalyst can be reduced at fairly low gas rates; however, the higher the
velocities through the catalyst the shorter will be the reduction period, and
channelling through the beds may diminish at higher rates. It should also be noted
that a minimum flow rate of 50,000 kglhr must be maintained through the annulus
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to avoid excessive temperatures between the top and bottom of the converter shell.
Synthesis gas is recycled through the converter during catalyst reduction. When
the reaction has started, it is very important that the circulating gas be cooled as
much as possible to condense and remove the water vapour from the gas before
recharging to the converter. Otherwise, gas with a high concentration of water
vapour would enter the catalyst beds, which are already reduced. Water vapour will
cause deterioration or poisoning of the reduced catalyst.
In order to prevent freezing the water produced during the converter reduction, a
stream of ammonia is injected to the discharge of the HP case of the synthesis gas
compressor. This "anti-freeze" ammonia will prevent the water from freezing and
c damaging equipment. As soon as ammonia synthesis has started, the ammonia

produced will lower the freezing pOint and permit water removal from the gas
stream at lower temperatures and the ammonia injection will be discontinued.
3.2.4.6.2 Catalyst Thermal Resistance
Even when operated on pure synthesis gas, ammonia catalysts do not retain their
activity indefinitely. Some data indicate that when pure gas is being used,
temperatures below 550°C do not affect the catalyst, whereas higher temperatures
will harm the catalyst. These data also show that catalyst, which has suffered
slightly from excessive temperatures, may show a loss of activity when tried out at
400°C, whereas the activity at 500°C may be unchanged. It Should, however, be
emphasised that no definite temperature limit exists below which the catalyst is
unaffected. At a fixed temperature level but under more severe conditions of
pressure and space velocity, the deterioration of the catalyst should be expected to
develop more rapidly.
Degradation of the catalyst will first be apparent in reduced efficiency during
c
operation at lower temperatures, higher pressure and/or higher gas rates. It has
been observed that the more the catalyst activity has declined from the initial value,
the more prolonged or severe will be the treatment required to produce further
injury.
3.2.4.6.3 Catalyst Poisons
Compounds which (when present in the synthesis gas) are capable of reducing
catalyst activity and/or life are called poisons. Such substances normally form more
or less stable compounds with the active materials of the catalyst.
There are permanent poisons that cause lasting irreversible lowering of catalyst
activity. They form stable surface compounds with active parts of the catalyst.
Other poisons may cause a temporary decrease in activity; the initial effectiveness
is restored in a relatively short time after removal of the poison compound from the
gas.
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The most important group of poisons of ammonia synthesis catalyst are oxygen
compounds. These cannot be classified as temporary poisons; neither are they
permanent poisons. When an oxygen compound such as carbon monoxide is
present in small quantities in the synthesis gas, some active areas of the catalyst
combine with oxygen thus reducing catalyst activity. When the oxygen compound
is removed from the synthesis gas, the catalyst again is fully reduced, but all the
regenerated centres do not revert completely to the initial state or regain their initial
activity. So the oxygen compounds cause a strong temporary and a small
permanent decline in catalyst activity. The usual oxygen compounds that poison
the catalyst are water vapour, carbon monoxide, carbon dioxide, and molecular
oxygen. Other significant poisons are hydrogen sulphide (permanent) and oil spray
deposits, which are not real poisons as this term is used here, but which are
c 3.2.4.6.4
capable of lowering the activity of the catalyst by clogging the catalyst surface.
Catalyst Mechanical Strength
The synthesis catalyst is mechanically strong. However, the operator should not
expose it to excessive abuse. Mal-operation may cause very rapid temperature
fluctuations, resulting in catalyst breakage. During the reduction period any rapid
temperature changes should be carefully avoided; during this interval the catalyst is
thought to be particularly sensitive to mechanical crushing and quick temperature
variation A detailed catalyst loading procedure is presented in the General
Procedures Manual under "Catalyst Loading of ammonia Synthesis Converter".
Not covered in this procedure but of the utmost importance are the tests to which
the catalyst must be exposed prior to loading in the converter. As later mentioned
in the General Procedures Manual, chlorides in contact with the stainless steel
converter basket may lead to stress corrosion cracking of this intemal vessel;
therefore, the chloride content of each batch of catalyst must be checked before
loading. The catalyst should have a maximum water soluble chloride content of 10
ppm. In the case of damaged catalyst containers that might have been exposed to
c 3.2.4.7
contaminants, each container should be checked.
Separation of Anhydrous Liquid Ammonia from Synthesis Gas
The ammonia that is produced in the synthesis reactor would quickly build to a level
to interfere with the reaction so it has to be continuously removed from the synthesis
recycle gas stream going to the converter. This is done by chilling the recycle stream
via a combination of chillers/coolers in the unitized exchanger E-2120 to condense
the net ammonia product that is produced in each pass through the converter. The
temperature of the recycle gas stream is -17.SoC by the time it reaches the ammonia
separator and the condensing / subcooling of the ammonia in the synthesis gas loop
to this temperature, will reduce the ammonia in the recycle gas stream from 12.13 to
2.69%. The resulting chilled ammonia liquid collects in the ammonia separator
(D-21 06) which is under L1C control (L1C-1013) The liquid ammonia leaving D-21 06
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3.2.5 Ammonia Product Purification (Removal of Absorbed Gases)
As previously noted the liquid ammonia that is separated from the synthesis gas will
contain a certain amount of absorbed gases that would result in a contaminated
product and the purpose of the refrigeration system in the product purification step is
twofold:
First: the flash and reflash of liquid ammonia at lower pressure levels to release
absorbed gases and direct them to the fuel gas/absorber system; & second: as an
integral part of the refrigeration system, the process chillers in E-2120 remove heat
from the synthesis gas in the synthesis gas loop to sub-cool the recycle gas to -17.BoC
' for the satisfactory separation and removal of the net ammonia make from the
C/
synthesis loop. These chillers are so located in the refrigeration system to take full
advantage of the various pressure (and temperature) levels at which it is operated.
The ammonia refrigeration system is somewhat complex by nature; however, once the
system is fully understood its operation is straight-forward and should operate very
steadily. The following are descriptions of various items of equipment in the system,
what they do, and how conditions are adjusted to give the desired results. For
simplification the descriptions assume that essentially all ammonia product is
withdrawn from the refrigerant receiver D-21 09.
3.2.5.1 Ammonia Let-down Drum (D-21 07)
This let-down drum receives its feed from the ammonia separator (D-21 06) where
the net ammonia make has been separated from the synthesis gas and in addition, a
small import flow from the purge gas separator, D-210B.
The D-21 07 pressure is controlled by PIC-110B at 17.6 bara and releases to the
Ammonia Gas Scrubber, T-21 03. The liquid stream from D-21 07 is let down to two
c pOints in the refrigeration system under the level control of LlC-1 012 with the actual
routing being selected by the hand switch HS-1024. If this switch is set for "COLD"
product operation, then the liquid flow from D-21 07 will be let-down to the 1st Stage
Refrigerant Flash Drum (D-2120). If 'WARM" product operation is selected, then the
liquid flow will be let-down to the 4th Stage Refrigerant Flash Drum (D-2123). Any
flash vapour from these two let down streams is routed to the Ammonia Gas
Scrubber via the Refrigerant Receiver, D-21 09. The method of Unit Control when
producing 'WARM" or "COLD" product is further described in Sections 7.6 & 7.7 of
this manual.
3.2.5.2 First Stage Refrigerant Flash Drum (D-2120)
This flash drum serves the process in three ways: first, by a deep over-flash
essentially all of the inerts are removed from the ammonia product. Second, it
serves as a "head drum" for the thermal Circulating refrigerant that is removing heat
from the synthesis gas loop via the "cold" section of E-2120. Third, it receives the
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Purge Gas Chiller, E-2125.
From 0-2120, the ammonia circulation rate through E-2120 is directly proportional to
the heat input from the synthesis gas loop.
The pressure on the drum is reduced to about 0.9 bara by the Refrigeration
Compressor, C-21 05; pressure is controlled by PRC-1009, which regulates the
speed of the machine. The temperature in the drum will be about -35°C as a result of
the evaporating ammonia at 0.9 bara pressure.
While producing a hot ammonia product as Urea plant feed from 0-2109 a smali
portion of cold product is withdrawn from the 0-2120 to avoid an accumulation of
c water in the drum and the level in 0-2120 is held constant by level controller
LlC-1024. Cold ammonia product pumps P-2124AlB/C are used for this disposal to
the cold ammonia product system. It should be noted that when the Urea plant is in
operation i.e. the NH3 Unit is on "WARM" product operation, only one pump will be in
service with two on standby. When on "COLO" product operation, two pumps will be
in parallel service with one pump on standby.
3.2.5.3 Refrigerant Receiver (0-2109)
All of the ammonia that has been flashed in the system, compressed by C-21 05 and
sub-cooled in the ammonia condenser (E-2127) collects in this receiver.
The pressure on this drum depends (indirectly) on the temperature and volume of
cooling water flowing through the E-2127 condenser. The pressure is actually set by
PIC-1109 (14.9 bara) that releases the inert gas (LP purge) to the Ammonia Gas
Scrubber, T-21 03.
The level of the receiver is held constant by level control LlC-1 015 The major portion
c. of liquid ammonia from the refrigerant receiver is pumped by Warm Ammonia

Product Pumps, P-2113AlB to the Urea Plant at a design temperature of 32.5°C at
the battery limits. The remainder is flashed down to the Fourth Stage Refrigerant
Flash Orum, 0-2123 at 16.~C. .
3.2.5.4 Fourth Stage Refrigerant Flash Orum (0-2123)
All of the ammonia that is not sent to battery limits as product from 0-2109
Refrigerant Receiver with the exception of the previously mentioned small stream
from 0-2120, is reflashed in this drum. The pressure (and resulting temperature) of
the Fourth Stage Flash Orum (0-2123) is variable, as it "floats" on an intermediate
pressure of the second case of the ammonia compressor (C-21 05). This pressure is
expected to be about 7.6 bara and the temperature of the evaporating ammonia in
the flash drum will be about 16.~C. The level in 0-2123 flash drum is held constant
by level control LlC-1021 controlling the let-down from 0-2123 into 0-2122.
This drum serves as a "heads drum" and in addition to supplying refrigerant to

0-2122, also supplies ammonia refrigerant to two chillers: first, to the "hot" section of
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E-2120 by thermo-syphon circulation. As noted, this circulation rate is determined by

the heat input to the chiller. Second, to E-2129 at a rate depending on the pressure
differential between D-2123 and D-2122. The Interstage Chiller E-2129 is operated
at a back pressure of about 3.4 bar (1°C) on the refrigerant side in order to prevent
icing on the process side.
3.2.S.S Third Stage Refrigerant Flash Drum (D-2122)
The pressure (and resulting temperature) of the Third Stage Flash Drum is not
variable, as it "floats" on the suction to the second case of the ammonia compressor
(C-21 OS). This pressure is expected to be about 4.2 bara and the temperature of the
evaporating ammonia in the flash drum will be about -2.2°C.
c Ammonia liquid is flashed directly into the Third Stage Refrigerant Flash Drum,
D-2122 from D-2123 Fourth Stage Flash Drum by level control LlC-1021 and also via
the Interstage Chiller, E-2129. Liquid from the Third Stage Flash Drum, D-2122 is
circulated by thermosyphon effect through one of the two ''warm'' middle sections of
unitized exchanger E-2120 in the synthesis loop.
LlC-1022 controls the ammonia level in D-2122 by regulating the flow of liquid
Ammonia from the Third Stage Flash Drum into the Second Stage Flash Drum,
D-2121
3.2.S.6 Second Stage Refrigerant Flash Drum (D-2121)
As with the other flash drums, the pressure (and resulting temperature) of the
Second Stage Flash Drum is not variable, as it floats on the suction of the first stage
case of the Ammonia Compressor, C-21 OS. This pressure is expected to be about
2.7 bara and the temperature of the evaporating ammonia in the flash drum will be
about -17.SoC.
c Ammonia is also letdown from D-2121 into the First Stage Flash Drum, D-2120
through E-212S Purge Gas Chiller with the flow rate depending on the pressure
differential between D-2121 and D-2120. .
The liquid level in D-2121 is held constant by LlC-1 023, which delivers the excess to
the First Stage Refrigerant Flash Drum D-2120.
3.2.S.7 Refrigerant Compressor (C-21 OS)
The refrigeration compressor (C-21 OS) operates to serve the system in two ways:
first, to maintain the desired pressure in the First, Second, Third and Fourth Stage
Flash Drums (D-2120, D-2121, D-2122 & D-2123). This will ensure proper removal
and separation of absorbed gases from the product stream. Second, to elevate the
pressure of all flashed ammonia so the ammonia may be condensed and slightly
sub-cooled with cooling water in the ammonia condenser E-2127 (1S.6 bara as read
at PI-1641 on C-21 OS discharge.
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DOC NO. PROJ-PM-008 . REVISION: 4
The condensing ammonia in E-2127 is subcooled approximately 2.2°C below the

normal condensing temperature of ammonia as determined by the Compressor
discharge pressure. This will ensure that pressure control of the compressor
discharge is maintained by the release of absorbed gases to the Purge Gas
Scrubber via PIC-11 09. Sub-cooling the condensed ammonia below this
temperature will result in excessive absorbed gases in the refrigerant stream. On the
other hand, sUb-cooling too close to the temperature could result in excessive
ammonia in the purge gas stream.
3.2.6 Boiler Feed Water Deaeration (V-21 01)
c The preheated Demineralised water enters the top "stripping" section of the deaerator
together with recovered condensate from the desuperheater steam traps and from the
Ammonia Stripper Reboiler (E-2160) and C02 Stripper Stream Reboiler (E-2111).
· The normal operating pressure of V-21 01 i~ 2.7 bara(1.7 barg), but during start-up
however, the three preheat exchangers will not be in operation; therefore, the
deaerator at this "cold water condition" may be operated at a lower pressure.
· Oxygen content of the water can be reduced to 0.005 mg/litre or less by deaeration.
· The requirements for .accomplishing this are: .
· a) Having the water at tlie saturation condition; -i.e. at boiling temperature for the
existing pressure
b) Providing deaerator design that secures intimate contact between steam and
water.
0) Continuously venting a mixture of gases and steam from the deaerator.
c The deaerator design provides the intimatecontact of steam and water required. It is
a tray type, wherein the preheated combined stream of makeup and condensate is
sprayed into the steam compartment. -The water is spread out in a thin film as it flows
down over the trays in continual contact with the steam and is heated to approximately
saturation conditionS.
A continual surplus of steam is used so that steam and the desorbed gases can be
continually vented. This is accomplished by injecting sufficient LP steam under control
of PIC-1031 which maintains the desired 2.7 bara operating pressure on the
deaerator. The vent rate is set manually and it is sufficient that a moderate plume of
steam be maintained from the vent since the volume of non-condensible gases
desorbed is normally minute.
The deaerated water flows down from the deaeration section into the storage section
of the unit. The storage section holds water sufficient for about 20 minutes normal
operation. Low level (LAL-1030) and high level (LAH-1030) alarms will warn the
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operator should either of these conditions occur so that corrective measures can be
taken. A separate level controller L1C-1 031 is also provided which, on detection of a
higher than normal level, will actuate control valve LV-1031 to dispose of the excess to
the Equalisation Pond (A-9304) via a Blowdown pit. High/high level alarm
(LAHH-1124) is also provided together with a Low/low alarm LALL-1125 which in
addition to alerting the operator to this condition, will also actuate interlock ESD-1125
to automatically start the Offsite Deminineralised Water pump feeding the unit.
There will be a slight (perhaps immeasurable) oxygen content from even the most
efficiently operated deaerator. For this reason V-21 06 is provided to inject Oxygen
scavenger to the water in the storage section.
When boiler water is in contact with iron, some iron goes into solution as ferrous
c hydroxide. If there is no oxygen in the boiler water an equilibrium is soon reached. If

oxygen is present in the water an insoluble compound, ferric hydroxide, is formed.
Iron is lost from the system and a sediment is formed; if a continuing supply of oxygen
is available, iron or steel continues to be lost from the piping and boiler systems.
Ferrous hydroxide is an alkaline compound and its rate of solution depends upon the
pH of the water. The lower the pH of the water, the more rapidly ferrous hydroxide
goes into solution and in order to maintain the feed water at the desired pH range (8.8
to 9.2), morpholine is employed. A volume of morpholine is introduced into the
injection tank V-21 07 to which steam condensate is supplied for dilution purposes and
from where the morpholine injection pump takes suction and delivers the solution to
the suction of the feed water pumps (P-2104A1B). It is anticipated that not more than
0.5 to 0.7 ppm of morpholine will be required to maintain the desired pH range of the
BFW.
Feed water is pumped from the storage section of the deaerator to the Steam Drum
0-2101 by Boiler Feed Water Pumps P-2104A1B via the preheaVwaste heat boiler
systems as described previously.
c~ A line from P-2104A1B discharge also supplies B.FW. to the HP/MP Steam.
Desuperheaters, the HP Steam Attemperator , the MP/LP Steam Desuperheater and
desuperheater on E-2111 C02 Stripper Steam Reboiler LP steam supply.
The feed water pumps are provided with manual and automatic low flow bypasses
which retum a controlled amount of water to thedeaerator in order to avoid damage to
the pumps if the steam drum level controller should shut completely. These flows are
limited by auto recirculation valves from the pump discharge check-valves. The gate
valves on the two lines must always be car-sealed open, (CSO).
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3.3 CATALYST OPERATING CONDITIONS
3.3.1 Hydrogenator - R-2160
Stream Comgosition Unit Inlet

Methane kmol/hr 1452.4
Ethane kmol/hr 18.4
Propane kmol/hr 3.2
Butanes kmol/hr 2.1
C Pentanes
C6+
kmol/hr
kmol/hr
1.2
2.2
Hydrogen kmol/hr 45.0
Nitrogen kmollhr 31.3
Carbon dioxide kmol/hr 3.6
Argon kmol/hr 0.2
Water kmol/hr 0.1
Total Flow kmol/hr 1560.0
H2S ppmv 20
Sulphur (organic) ppmv 20
Temperature °c 371
Pressure bara 43.3
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3.3.2 Desulphurisers R-2108A1B
Stream Comgosition Units

Methane Kmol/hr 1452.4
Ethane Kmol/hr 18.4
Propane Kmol/hr 3.2
Butanes Kmol/hr 2.1
Pentanes Kmol/hr 1.2
C6+ Kmol/hr 2.2
Hydrogen Kmol/hr 45.0
Nitrogen Kmol/hr 31.3
C Carbon dioxide
Argon
Kmol/hr
Kmol/hr
3.6
0.2
Water kmol/hr 0.1
Total Flow kmol/hr 1560.0
H2S ppmv 40.0

Sulphur (organic) ppmv 0.0
Temperature °c 362
Pressure bara 42.44
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3.3.3 Primary Reformer H-2101
Stream Comj;losition Units Inlet Outlet

Methane Kmol/hr 1452.4 588.3
Ethane Kmol/hr 18.4 0
C~ Propane
Butanes
Kmol/hr
Kmol/hr
3.2
2.1
0
0
Pentanes Kmol/hr 1.2 0
C6+ Kmol/hr 2.2 0
Hydrogen Kmol/hr 45.0 3292.5
Nitrogen Kmol/hr 31.3 31.3
Carbon monoxide Kmol/hr 0 460.3
Carbon dioxide Kmol/hr 3.6 482.1
Argon Kmol/hr 0.2 0.2
Water kmoVhr 4884.5 3467.2
Total Flow kmol/hr 6444.3 8321.9
Total Flow Kg/h 113,533 113.533
Temperature DC 605 811.9

Pressure bara 39.9 36.5
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3.3.4 Secondary Reformer R-21 03
Stream Coml2osition Units Feed Air/Steam Outlet

Methane Kmollhr 588.3 0 31.6
Hydrogen Kmol/hr 3292.5 0 4141.3
Nitrogen Kmol/hr 31.3 1626.6 1658.0
Carbon monoxide Kmol/hr 460.3 0 963.1
Carbon dioxide Kmollhr 482.1 0.6 536.6
Oxygen Kmol/hr 0 437.5 0
Argon Kmol/hr 0.2 19.6 19.8
C Water
Total Flow
kmollhr
kmolLhr
3467.2
8321.9
208.4
2292.8
3940.1
11290.4
Total Flow Kg/h 113.533 64.132 177.665
Temperature °c 812 605 994

Pressure bara 35.6 36.3 35.1
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3.3.5 HT Shift Converter R-21 04
Stream Com[1osition Units Feed Outlet

Methane Kmollhr 31.6 31.6
Hydrogen Kmollhr 4141.3 4828.6
Nitrogen Kmol/hr 1658.0 1658.0
Carbon monoxide Kmol/hr 963.1 275.8
Carbon dioxide Kmollhr 536.6 1223.9
Argon Kmollhr 19.8 19.8
Water kmol/hr 3940.1 3252.8
C Total Flow
Total Flow
kmollhr
Kg/h
11290.4
177,665
11290.4
177.665·
Temperature °c 371 434.4

Pressure bara 34.2 33.9
c.

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CLASS
3.3.6 LT Shift Converter R-21 09
Stream Com[2osition, kmol/hr Inlet Outlet

Methane 31.6 31.6
Hydrogen 4828.6 5079.5
Nitrogen 1658.0 1658.0
Carbon dioxide 1223.9 1474.8
Carbon monoxide 275.8 24.9
Argon 19.8 19.8
C Water
Total Flow, kmol/hr
3252.8
11290.4
3001.9
11290.4
Total Sulphur, ppmv <0.1

Temperature, DC 206.9 229.3
Pressure, bara 33.7 33.4
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3.3.7 Methanator R-2106
STREAM COMPOSITION Units Inlet Outlet
Methane kmollhr 31.6 63.2

Hydrogen kmollhr 5071.2 4969.5
Nitrogen kmollhr 1656.5 1656.5
Carbon dioxide kmol/hr 6.8 0.0
Carbon monoxide kmol!hr 24.8 0.0
Argon kmol/hr 19.8 19.8
C Water
Total Flow,
kmol/hr
kmol/hr
27.8
6835.5
66.2
6775.2
Total Sulphur Ppmv 0

Temperature, DC 316 347.3
Pressure, Bara 31.7 31.5


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CLASS
3.3.8 Ammonia Converter R-21 05
Stream Coml2osition, vol% Units Bed 1 Inlet Bed 1 Outlet

Hydrogen kmoVhr 67.04
Nitrogen kmoVhr 22.28
Methane kmoVhr 6.06
Argon kmoVhr 1.94
Ammonia kmoVhr 2.69 11.16
Total Mole Flow kmoVhr 26037
C Total Mass Flow, kg/hr kg/hr 255059 255059

Pressure bara 141.7
Stream Coml2osition, vol% Units Bed 2A Inlet Bed 2B Outlet

Hydrogen kmoVhr 56.48
Nitrogen kmoVhr 18.75
Methane kmol/hr 6.83
Argon kmol/hr 2.19
Ammonia kmol/hr 11.16 15.75
Total Mole Flow kmol/hr 23098
Total Mass Flow kg/hr 255059 255059

Pressure bara 139.25
3.4 INSTRUMENT LIST

See Dwg 850-B2001
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4 UTILITY I CHEMICAL REQUIREMENTS
4.1 UTILITY GENERATING CAPACITIES
UTILITY CAPACITY
Instrument Ai r 1200Nm%r
Plant Air 1800 Nm%r
c
Cooling Water 24,600m%r
Service Water 25Nm%r
Drinking Water 10m%r
Firewater 600m%r
Diesel Oil 12m%r
Nitrogen 600 Nm%r
MP Steam (Boiler) 75000 kg/hr

MP Steam (HRSGS) 40000 kg/hr
3
Raw Water Treatment 813 m /hr
Demineralised Water 3m%r

Treatment
c/ Mixed Bed Polishing 410m%r
4.2 STEAM REQUIREMENTS
The Steam Balances (DWGS 061-B001 through B007) covering the steam .
requirements for various operating cases are included in Section 2 of this manual.
4.2.1 Deaerator V-21 01
The steam drum feed water makeup is deaerated demineralised water, which is
supplied from the offsite water treatment plant with the flow regulated by the deaerator
level controller LlC-1 030 which resets flow controller FIC-1 056.


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Before entering the deaerator the make-up demineralised water is preheated in LTS
Effluent Exchanger (E-21 06) and Synthesis Gas Interstage BFW Exchanger (E-2117)
to approximately 120 C.
Demineralised water make-up to V-21 01 is monitored for inlet temperature by TI-1558

located on the FCS and for conductivity by AE-1 015 provided with a high conductivity
alarm AAH-1 015 which will alert the operator to a possible tube leak in the preheat
system.
The preheated demineralised water enters the top "stripping" section of the deaerator
together with recovered condensate from the desuperheater steam traps and from the
' Ammonia Stripper Reboiler (E-2160) and CO2 Stripper Steam Reboiler E-2111.
C/ The normal operating pressure of V-21 01 is 2.7 bara but during start-up the two
preheat exchangers will not be in operation; therefore, the deaerator at this "cold water
condition" will operate at a lower pressure.
The Oxygen content of the water can be reduced to 0.005 mg/litre or less by
deaeration. The requirements for accomplishing this are:
a) Having the water at the saturation condition; i.e. at boiling temperature for the
existing pressure.
b) Providing a deaerator design that secures intimate contact between steam and
water.
c) Continuously venting a mixture of non-condensable gases and steam from the

deaerator.
The tray type of deaerator design provided produces the intimate contact of steam and
c
water required; the preheated combined stream of makeup and condensate is sprayed
into the steam compartment. Water flows down over the trays whilst the steam
bubbles through it. The mixture is thus heated to approximately saturation conditions.
The desorbed gases are continually vented by injecting sufficient LP steam under
control of PIC-1031 to maintain the desired 2.7 bara operating pressure in the
deaerator. The vent rate is set manually and it is sufficient that a moderate plume of
steam be maintained from the vent since the volume of non-condensable gases
desorbed is normally quite small.
The deaerated water flows down from the deaeration section into the storage section
of the unit. The storage section holds water sufficient for about 20 minutes normal
operation. Low level (LAL-1030) and high level (LAH-1030) alarms warn of extreme
changes in level in order that the operator can take corrective measures. A separate
on-off level controller L1C-1031 is also provided which is actuated on detection of a
high-high level by LAHH-1124. This actuates control valve LV-1031 to dispose of the
excess to the Equalisation POlJd (A-9304) via a Blowdown pit. A lowllow trip (ESD-
1125) automatically starts the standby Offsite Demineralised Water Pump feeding the
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unit.
There is always a residual oxygen content from even the most efficiently operated
deaerator. For this reason, V-21 06 is provided with Oxygen scavenger injected into
the water in the storage section.
When boiler water is in contact with iron, some iron goes into solution as ferrous
hydroxide. If there is no oxygen in the boiler water an equilibrium is soon reached.
If oxygen is present in the water an insoluble compound, ferric hydroxide, is formed.
Iron is lost from the system and a sediment is formed; if a continuing supply of
oxygen is available, iron continues to be lost from the piping and boiler systems.
c Ferrous hydroxide is an alkaline compound and its rate of solution depends upon the
pH of the water; the lower the pH, the more rapidly ferrous hydroxide goes into
solution. In order to maintain the feed water at the desired pH range (8.8 to 9.2),
morpholine is employed. The morpholine injection pump takes suction from V-21 07
and delivers the solution to the suction· of the feed water pumps (P-2104A1B) but
note the need to switch analyser and morpholine injection pOints when switching
BFW Pumps. It is anticipated that not more than 0.5 to 0.7 ppm of morpholine will
be required to maintain the desired pH range of the BFW.
It is essential that strict attention is paid to the quality of the boiler feed water being
supplied to 0-2101. Reference should be made to ODS-148 on Steam Generation
Operation contained in the General Procedures Manual, which includes the required
quality of boiler feed water together with a detailed description of the fundamentals
and recommended precautions relative to steam generation.
The quality of the Boiler Feed Water must be within the following limits:
Residuals
c" Residual Oxygen

pH:
Nalco 72100
Less than 7 ppb
8.8 - 9.2
0.8 - 1.2 ppm
4.2.2 BFW Pumps P-21 04 AlB & BFW Distribution
Feed water is pumped from the storage section of the deaerator to the Steam Drum
0-2101 by Boiler Feed Water Pumps P-21 04A1B via the following preheat/waste heat
boiler systems:
a) E-2131, LTS Effluent/BFW Exchanger followed by E-2103B/A, HTS

Effluent/Waste Heat Boilers. The BFW flow through this system is controlled by
FIC-1043 and bypass.
b) E-2123B/A, Ammonia Converter Effluent/Waste Heat Boiler. BFW flow through

this system is controlled by FIC-1020 which will be automatically closed by
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InterlockESD-2103 should the Synthesis Gas compressor trip and process gas
ceases to flow through E-2123A & B. Analyser AR-1023 located on the BFW
outlet from E-2123A will monitor the conductivity and high conductivity alarm
AAH-1023 will alert the operator to a possible leak in E-2123A1B.
c) H-2101 B.F.W. Preheater Coil. A restriction orifice is provided in the inlet block
valve bypass to the BFW Preheat Coil to ensure a minimum flow at all times.
Total flow through the above systems is indicated on FI-1006 with approximately 28%
routed via the preheat coil and the balance roughly equally split between the other two
exchanger streams. D-21 01 Steam Drum level controller L1C-11 01 controls the flow of
BFW to the drum by regulating the speed of the turbine driven Boiler Feed Water
c pump P-2104A as necessary.
In the event of a low flow of BFW to D-2101, interlock ESD-1106 will be actuated to
automatically start standby BFW Pump P-2104B and D-2101 level controller will then
regulate the flow by adjusting control valve FV-1006 on P-2104B discharge line.
D-2101 level control and P-2104A1B control will be described later in greater detail.
A line from P-2104A1B discharge also supplies B.F.w. to the HP/MP Steam
Desuperheaters, the HP Steam Attemperator, the MP/LP Steam Desuperheater and
SP-186 desuperheater on E-2111 CO2 Stripper Steam Reboiler LP steam supply.
The HP flushing medium for the aMDEA system pump seal flushes is also supplied
from P-2104A1B discharge line.
The feed water pumps are provided with manual and automatic low flow bypasses
which return a controlled amount of water to the deaerator in order to avoid damage to
the pumps if the steam drum level controller should shut completely. These flows are
limited by auto recirculation valves from the pump discharge check-valves and the
gate valves on these two lines must always be car-sealed open (CSO).
c The operators should be aware that the two-phase steam-water mixture in the piping
from the exchangers to the steam drum will decrease the rate of response of the drum
level to changes in the pump speed. Changes in pump speed will not immediately
affect the drum level as the change will be temporarily absorbed in the piping system.
Operators wishing to see immediate reaction to changes in pump speed should
observe FI-1006. This flow meter is located in the P-2104A1B discharge line and will
indicate changes in the BFW flow immediately upon any change in the pump speed.
4.2.3 Steam Drum - D-21 01
When operating under normal conditions, approximately 258000 Kg/hr of HP steam at

125 bara will be produced from D-2101 with the steam leaving the drum at about
328°C.
Total BFW flow to the Steam Drum from the BFW Pumps P-2104A1B is controlled by
level controller L1C-11 01 as described previously. It should be noted that the initiation
of steaming in E-2123A and/or E-2103A, will displace a large volume of water from the
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piping into the steam drum in a short period of time. This displacement could result in
a sudden but limited and temporary increase in the steam drum level. To avoid the
system becoming unstable, the operator should expect this level rise to occur, monitor
the condition, and let the control system slowly and smoothly correct it.
Similarly on cessation of steaming in E-2123A and/or E-2103A, water must fill the
space normally occupied by the steam in the piping. During this transition period the
steam drum level can be expected to drop and as above, the operator should monitor
the condition and again let the control system slowly and smoothly correct it.
To ensure reliable and safe operation of the steam generation system, the steam drum
is equipped with the following instrumentation:
c LT-1060 Level transmitter (Eleotric eye- hi) for level indicator L1-1 060A on
main contro!JP-~ri-vparf~ FCS ..
.-:
LT-1028 DP type Level transmitter for level indicator (L1-1 028) on the primary
FCS with low level alarm.
LT-1029 DP Level transmitter for level indicator (L1-1 029) on the primary FCS
with low level alarm.
LT-1223A1B/C DP type level transmitter (A,B & C) connected through to interlock

ESD-2112 (Auxiliary Boiler burner system) and to a low level alarm
(LA-1223)(1 out of 3) and a low/low level alarrn (LALL-1223)(2 out of
3) both located on the FCSrnain control room panel. 2 out of 3 of
these switches will also actuate Interlocks ESD-2111 &ESD-1223Lto
be described in detail in Section 11 of this manual.
LT-1001A DP type level transmitter for local level indicator (L1-1 001 C) locatedat
c
control valve FV-1006 on P-2104B discharge line, and level recorder
(LR-1 001 A with LAL) on main control room board.
LT-1001B DP type level transmitter for local level indicator (L1-1 001 D) also
located at control valve FV-1006 on P-2104B discharge line, and
level recorder (LR-1 001 B with LAH & LAL) on main control room
board.
Note: LT-1001A duplicates LT-1001 B and either may be used to
regulate the flow of BFW either directly or by "3-element control" to
be described in Section 11 of this manual.
PT-1036 Pressure transmitter for prirnary FCS indicator PI-1 036 with PAH
and PAL
PI-1750 Local pressure indicator.
MTE-1551 Metal ternperature elements (Skin thermocouples A through K)

located at various points on the steam generation system and
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connected through a common system to give individual temperature

indications on the primary FCS. These points are used to ensure
that excessive stresses do not develop in the thick walls of the steam
drum during heating and cooling cycles.
FT-1033 Flow transmitter on main steam outlet line for flow indicator (FI-1 033)
on the primary FCS and connected through to the 3-element level
control system to be described later.
FT-1006 Flow transmitter on SFW supply line to steam drum for local flow
indicator (FI-1 006) and to FRC-1006 on the primaiy FCS as part of
the 3-element control system.
c It is again stressed that careful attention must be paid to the quality of the boiler feed
water as described in section 4.2.3 and in ODS-148 - Steam Generator Operation
contained in the General Procedures Manual. The quality of the steam drum water
itself must be controlled within the following limits which includes strict pH control
necessary for the co-ordinated pH/phosphate program and to precipitate soluble iron
entering the system:
Silica Less than 0.8 ppm

Chloride Less than 2.5 ppm
Sulphate Less than 2.5 ppm
Iron Less than 0.02 ppm
Phosphate 5 -10 ppm
pH 9.5 - 9.8
Slowdown connections are provided to permit "blowing down" sediments from the low
points of the drum and the steam generators (except E-21 01) together with a
continuous blowdown mounted within the steam drum and located at what is designed
c to be the interface between the water level and the steam space. Impurities tend to
concentrate at this junction of steam and water and the continuous withdrawal of a
small amount of water and steam from this point provides the most efficient removal of
accumulated dissolved solids. Slowdown is routed to the Steam Slowdown Drum
0-2156.
Normally, on high-pressure boiler systems, the low point blow-downs will not normally·
be used. They may be used at start-up, and occasionally be used during operations
as a means of obtaining a sample of water in the shell of the steam generators.
Otherwise, since the sludge normally controlled by use of these blowdciwn valves will
not be formed, routine use of these low point blowdowns should not be required.
4.2.4 H.P. Steam Distribution
4.2.4.1 H.P. Steam System (121.1 Sara)
The Steam header from Steam Drum 0-2101, supplies HP Steam at 121.1 bara to
the main turbines. Soiler Feed Water is pumped from the Deaerator V-21 01 to the


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Steam Drum 0-2101 by BFW pumps P-21 04 AlB and is preheated enroute by
parallel passage through E-2123A1B; E-2131 and E-2103A1B; and the Boiler Feed
, Water Preheat coil located in H-2101 convection section. In addition to the main
steam generators H-21 01 CB Auxiliary Boiler and E-2101 Secondary Waste Heat
Boiler, a certain amount of steam is generated by E-2123A1B Ammonia Converter
Effluent Waste Heat Boiler (25% vapour), and E-2103A1B HT Shift Effluent Waste
Heat Boiler (25% vapour).
To prevent carry-over of water and solids when the steam drum water primes, mists
or foams, the drum contains steam scrubbing cyclones and demisters to ensure a dry
steam product and reference should be made to the vendor's drawings and literature
for particular details of the steam drum. Note that when steam generator water
c solids are carried over in the steam (e.g. silica, sodium, and chlorides), deposits can
occur in non-return and stop valves. Such deposits can also promote failure of
Superheater tubes and loss or failure of a steam turbine. It is therefore essential that
HP steam quality is maintained within the following limits:
Sodium: Less than 10 ppb

Conductivity : Less than 0.35 uS/cm2
Silica: Less than 20 ppb
Chloride: Less than 6 ppb
Sulphate: Less than 6 ppb
Total Organic Carbon: Less than 100 ppb
The steam leaving 0-2101 first passes through the tubes of HP Steam Superheater
E-21 02 on which the outlet temperature is controlled by TIC-1 004, which regulates the
temperature of process gas flowing out of from E-2101 to E-21 02. The flow is then
through two banks of super-heat tubes in the primary reformer convection section
where it is superheated to 510°C at a header pressure of 121 bara. An attemperator is
located between the two superheat coils to control the temperature of the steam
entering the Hot Superheat Coil at 462"C.
c The pressure of the HP steam header is controlled at 121 bara by PRC-1018, which
adjusts the Auxiliary Boiler firing by regulating the flow of fuel gas to the burners. The
HP Steam header is protected against over pressure by relief valves PSV-H2101 A& B
set at 132.5 barg and 136.5 barg respectively. Two relief valves PSV-D2101A & B
located on the Steam Drum 0-2101 and set at 137.9 barg and 142.0 barg respectively
are also provided.
The superheated HP steam is then routed to the turbine drivers of C-21 03 Synthesis
Gas Compressor and C-21 05 Refrigerant Compressor. In normal operation all of the
H.P. steam flows through these two turbines and exhausts to the MP steam header.
Should either or both C-2103T or C-2105T trip out and/or when either or one of them
is not operating, the H.P. steam passes through the HP/MP Letdown station to the MP
steam header under the control of PIC-1 013 located on the MP Steam header. This
letdown station is described in Section 11 of this manual.
Two desuperheaters in series each with their own independent control systems are
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included in the HP to MP letdown system. The purpose of these two desuperheaters

is to cover the eventuality of a C-21 03 and/or C-21 05 trip which if a single
desuperheater only was installed and this failed, would expose sections of carbon steel
piping in the MP steam header to higher than design temperatures.
4.2.5 M.P. Steam System (42.5 Bara)
In normal operation, the MP steam system provides the motive power for compressor
turbines C-21 01 (T), C-21 02(D and C-41 02(T) as well as pump turbines P-2104A(T)
and their seaVlube oil auxiliaries. The supply of HP Steam required for the Urea Unit
Compressor C-41 02 (T) is under the control of pressure controller PIC-1 015 that is
provided with an anti reset windup facility and a low-pressure alarm (PAL-1015).
c" MP steam is also used for heating the reboiler on the Ammonia Stripper (E-2160);
stripping steam for the Process Condensate Stripper T-2150; Process Steam to the
Primary & Secondary Reformers and purging steam to the HT Shift Converter and
various vents.
The MP steam system also provides the MP steam required for the Urea Unit pump
turbine P-4130A(T).
Turbines P-21 04A(T), C-2111 (D C-211 O(T) and C-2112(T) letdown to the LP Steam
header. The remaining turbine drivers letdown to a Vacuum Condenser E-2140.
Over-pressure protection on the MP steam system is provided by pressure controller
PIC-1 014 which vents excess MP steam to atmosphere together with relief valves
PSV-MPS1001 NB/C/D&E. PRC-1016 located on the LP Steam header provides a
letdown facility of MP to LP steam if required.
For start-up requirements, steam may be imported to the MP steam header from the
Offsites steam system. In normal operation the ammonia plant is self sufficient in
c steam requirements except that with the Urea Unit Compressor C-4102 being located
on the Ammonia Unit, its requirements exceed the Ammonia Unit's normal export by
approximately 44,000 kg/hr which is imported from Offsites.
The offsite steam-producing facilities consist of a 75 tlh package boiler V-6501

together with three heat recovery steam generators V-7101NB/C. This steam will be
employed during commissioning of the MP Steam system but once the H-21 01
Auxiliary Boiler is commissioned, the import steam will be backed out. It should be
noted that whenever the sale source of MP steam for the NH3 Plant is from Offsites,
then the superheat temperature of the MP steam generated in Offsites must be
reduced to 399°C.
4.2.6 L.P. Steam System ( 4.5 Bara)
The normal source of LP Steam is from the exhaust of the Ammonia Unit
back-pressure turbines P-2104A(T) ,C-2111(D, C-2110(T) and C-2112(T) This is
supplemented by the flash steam from the boiler blowdown drum, D-2156 and from the
LO/SO consoles of the main compressors. Makeup to the LP system can be obtained
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from the MP system via PRC-1 016 which lets down via a desuperheater and may be
required at start-up or in situations where electric motor drivers are being used instead
of the steam turbines in some services. Normally, this letdown valve is closed since
there is usually an excess of LP Steam.
Over-pressure protection on the LP system is provided by pressure controller,

PIC-1 017 which vents excess LP steam to atmosphere and is further protected by
relief valve PSV-LPS1002 set at 7.1 barg. LP Steam may also be imported from
Offsites if required.
The main user of LP steam is the CO2 Compressor (C-41 02T). Other services
supplied by the LP system are: Deaerator V-21 01; aMDEA stripper reboiler E-2111;
c Natural Gas Feed Preheater E-2171; steam ejectors at the Surface Condenser
E-2140; Urea Compressor Surface Condenser E-4133; for gland sealing; lube oil
console heating (intermittent); tank heating, etc. Purging steam for the H-21.02
Start-up Heater is also supplied from the LP system.
4.3 STEAM CONDENSATE SYSTEMS
First of all, difference between "steam condensate" and "process/waste

condensates" must be understood since the "process" and ''waste'' condensates are
not considered to be part of the steam condensate system ..
Process condensate", although it is actually condensed steam, has been exposed to

the process stream and contains impurities which would be intolerable in the steam
system. The "process condensate", from D-21 02 (which includes condensate from
D-21 04 & D-21 05), is routed to the "Process Condensate Stripper" (T-2150) to be
described later.
' 4.3.1 Surface Condenser - E-2140
C/
The Steam Condensate system consists of steam condensate formed in Surface

Condenser (E-2140) resulting from the condensing of the exhaust steam from the
driving turbines for C-21 01 , C-21 02 & C-2103.plus the small amount of steam from the
vacuum jets.
A negative pressure of 97 mmHg (abs) is maintained on E-2140 by means of the

ejectors in the Inter/After condenser E-2150. High (PAH-1068) and Low (PAL-1068)
pressure alarms are provided on the primary FCS.
E-2140 level is controlled by LlC-1019, which regulates the flow of condensate being
pumped from the surface condenser by P-2112A1B to an Offsites
Polisher/Demineralised. Unit for treatment before reuse as boiler feed water. Low
(LAL-1019) and High (LAH-1019) level alarms are provided on the primary FCS. In
the event of a Hi/Hi level in E-2140, LSHH-1128 will actuate ESD-1128L . This will
sound Hi/Hi level alarm LAHH-1128 on the primary FCS and at the same time
automatically start the standby pump P-2112B.
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Condensate from the surface condenser also furnishes the source of cooling for
jackets of the Primary Reformer transfer line (V-2150), Secondary Reformer (R-21 03),
and the top portions of the Primary Reformer risers.
Small amounts of surface condenser condensate are also diverted to:
I. TK-2114 and TK-2115 to make-up aMOEA solution

II. Start-up make-up water to CO2 Stripper T-21 02.
III. V-21 06 Oxygen Scavenger injection tank
IV. V-21 08 Phosphate mixing tank
V. V-21 07 Morpholine injection tank
c VI. V-21 09 aMOEA Anti-foam injection system

VII. Establishing start-up level in Urea Compressor Surface Condenser E-4133.
VIII. Sample cooter
A branch line from the condensate pumps P-2112A1B is used to provide steam
condensate for use as sealing medium for the atmospheric relief valves SP-179 &
SP-180 of the turbines exhausting to the surface condenser and for the surface
condenser relief valve itself.
Analyser AI-1 018 is provided to monitor the conductivity of the condensate leaving the
surface condenser. An alarm (AAH-1018) is provided in the control room to warn of
increasing conductivity of the condensate which if considered necessary, may be
diverted from the Polisher/Oemineralised Unit to the Cooling Water return header
4.3.2 Process Condensate Stripper - T-2150
Process condensate from 0-2104 (Synthesis Gas Cornp. Suction Orum) and 0-2105
(Synthesis Gas Interstage Separator) is collected in the Raw Gas Separator, 0-2102
to be recovered and reused in the Ammonia plant. Process condensate can contain
C' up to 1,000 ppm by wt. ammonia; 3,000 ppm by wt. carbon dioxide, 500 ppm by wt.
methanol, and a trace of amines.
Before it is exported to the offsite demineralisation plant, the condensate is stripped by

counter current contact with medium pressure steam in the Process Condensate
Stripper, T-2150. The recovered condensate will contain about 5ppmw ammonia, 5
ppmw carbon dioxide and 35 ppmw methanol and higher alcohols.
The condensate collected in the Raw Gas Separator 0-2102, is pumped by

Condensate Pumps P-2121AlB to T-2150 via the Condensate Feed/Effluent
Exchanger E-2188 where it is preheated against stripped condensate leaving T-2150.
It enters the stripper through a distribution pipe above two beds of slotted rings and
heat for stripping is provided by MP Steam injection to the base of the tower under flow
control of FIC-1019.
In the event of a low/low level in 0-2102 Raw Gas Separator, sounding alarm
LALL-1205 will warn the operators and interlock ESO-1205 will be actuated which
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closes the level control valves on P-2121 AlB discharge to T-2150 and on the Offsites
disposal line.
The condensate flows downward over the packed beds making intimate contact with
the counter-flowing stripping steam. Vapours of ammonia, CO2 etc. are liberated from
the condensate by stripping action of the MP steam. The steam vapours exit the tower
at the top and after being mixed with additional steam, are recycled back into the
process via the mixed feed preheat coil as part of the mixed gas feed to the Primary
Reformer.
In the event of a high differential pressure across the two beds of slotted rings,
interlock ESO-1 069 will be actuated which closes control valve FIC-1 019 on the vapour
c/ line exiting the top of the tower. Interlock ESO-1069 also closes the control valve on
the discharge line of Process Condensate Pumps P-2121 AlB to E-2188.
The stripped process condensate from the bottom of T-2150 flows to offsite storage
after passing through the Feed/Effluent Exchanger and then further cooled in Air
Cooler E-2174. This flow is regulated by the stripper bottoms level controller
L1C-1025 that is provided with High level alarm LAH-1025 and Low Level Alarm
LAL-1025. An analyser AE-1017 is also provided downstream of E-2174 to indicate
the conductivity of the condensate being routed to Offsites and to alert the operator if
alarm AAH-1 017 exceeds a preset limit and of the need to switch to alternative
off-specification disposal.
Air Cooler E-2174 has a two bay fitted with three fans and has a manual lever for
louver adjustment. The fan blade pitch will be set manually on one fan and controlled
pneumatically on the other.
4.3.3 Process Condensate Orum 0-2161
c The condensate from the CO2 Compressor drums 0-4130/1/2 together with
condensate from 0-4101 CO2• Compressor Suction Knockout Orum, the condensate
from C2101 Air Compressor intercoolers and the overflow from R-21 03 water jackets
is collected in the Process Condensate Orum 0-2161. The CO2 in the condensate
from the CO2 Compressor intercoolers is allowed to flash off . The condensate is then
pumped to Offsites by pumps P-2161 AlB for recovery. The level is controlled by L1C-
1098 . High and Low level alarms are provided.
4.4 COOLING WATER [SUPPLY & RETURN]
The water used for the cooling water system will be clarified, lime softened water. The
maximum permissible level of chlorides in the cooling water must be below 300 ppm to
avoid corrosion of materials used on the water-cooled process exchangers. The cooling
water must therefore be monitored on a regular basis and the blowdown rate must be
adjusted to keep the chloride concentration level in the circulating cooling water below
300 ppm.
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In addition, the pH of the cooling water should be neutral and free from scale, no-flow
areas and sedimentation in the heat exchangers must also be avoided. To ensure the
correct quality of the water, the system is provided with various dosing sets, which are
described in detail in the Utilities & Offsites manual:
The Cooling Water enters the battery limits via the following 42" and a 14" supply
headers and fumishes cooling media to the indicated items before retuming to Offsites
via 14", 24" & 42" retum lines:
a) 42" supply line with flow, temperature and pressure indicated in the control room
on FQI-1164, TI-1070 & PI-1185 together with Low Flow Alarm FAL-1164. All
items return via a 24" header with the temperature indicated on TI-1097, except as
c noted.
E-2127 Refrigerant Condenser [see para c) below for return line].

E-4130 CO2 Compressor 1st Stage Intercooler.
E-4131 CO2 Compressor 2nd Stage Intercooler.
E-4132 CO2 Compressor 3rd Stage Intercooler.
E-2167 Refrigeration Compressor 2nd Stage Intercooler.
E-2128 Refrigeration Compressor 3rd Stage Intercooler.
E-2133 Feed Gas Compressor Kickback Cooler.
E-2141 Air Compressor 1st Stage Intercooler.
E-2142 Air Compressor 2nd Stage Intercooler.
E-2143 Air Compressor 3rd Stage Intercooler.
E-2115 Methanator Effluent Trim Cooler
E-2110 Lean Solution Trim Cooler
E-2116 Synthesis Gas Compressor Intercooler - return supplies E-2173
Start-up Cooler via an 8" header with the temperature indicated
locally by TI-1619, and then retums via the 42" header.
Sample Cooler
c C2111/C2112 LO Console
C-2110 LO Console
C-21 03/C-21 05 LO Console
P-2107A1B LO Unit
An 8" takeoff from the main supply header supplies the following items with their return
lines tying into the 42" retum line described in c) below:
E-4135 C-41 02 Turbine Gland Steam Condenser

E-2145 C-2101 Turbine Gland Steam Condenser
C-2101/C-2102 Lube Oil Pump Turbine.
C-21 03/C-21 05 Lube Oil Pump Turbine
C-21 02 Oil Cooler
b) 14" Supply Line with flow, temperature and pressure indicated in control room by
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b) 14" Supply Line with flow, temperature and pressure indicated in control room by
FQI-1070, TI-1557, PI-1085 together with Low flow alarm FAL-1070 and all items
return to Offsites via a 14" header with the temperature indicated on TI-1096.
E-21 07 CO2 Stripper Quench Cooler

E-2175 Stripped Condensate Trim Cooler
E-2124 Ammonia Synthesis Loop Cooler.
SP-167 aMDEA Flushing System.
Cooling supply to analysers.
C-211 0(T)/C-2111 (T)/C-2112(T)
P-2104NB LO Console
C~ c) The outlet stream from the E-2127 supplies cooling water to the following items
via a 36" header with the temperature indicated locally by TI-1645. The cooling
water from all items return to Offsites via the 42" header with the temperature
indicated by TI-1250.
E-2140 Ammonia Unit Surface Condenser (and E-2150).

E-4133 Urea Unit Surface Condenser.
C-4102 LO Console
4.5 REFORMER COOLING WATER JACKETS
The Reformer cooling water jackets are divided into the following separate sections:
a) Top portions of the three Primary Reformer risers together with the Primary
Reformer Effluent Transfer line (V-2150)
( b) Secondary Reformer (R-21 03).
',J
E-2140 surface condensate is the normal supply of water to the jackets, while
demineralised water from Offsites is the emergency supply. The surface condensate is .
level controlled to each of the jackets.
All of the makeup water lines have valves located so that overflows are visible while
adjustments are made to the levels. Each of the jackets are equipped with a low-level
alarm and a level glass. A small continuous purge from the drains is maintained to
prevent build-up of dissolved material. These purges should be tested weekly for
conductivity (max 50 micromhos) and pH (max 8.0) and adjusted if necessary.
It is imperative that water jackets be maintained water filled when heat is applied to the
primary or secondary reformers. Failure to maintain adequate water levels in the water
jackets could possibly cause rupturing of the jacketing vessels. Loss of water flow from
the jackets could also cause undue stress in the transfer line piping to the secondary
reformer. A backup supply of demineralised water from Offsites is provided but in the
c event of total loss of "jacket" water, it is recommended that the reformers be taken out of
service until water jackets are again serviceable and water levels can be maintained.
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4.6 RAW WATER TREATMENT (OSBL)
Water treatment facilities are provided for the complete treatment of raw water to be
suitable for make-up of the cooling water system, make-up of boiler feed water, fire
fighting systems, potable water and service water systems.
Raw water is initially received from bore holes and stored in reservoirs which have a
3
capacity of 60000 m and is sufficient to provide the equivalent of about 70 hours of raw
water at design flows.
The facilities provided comprise treatment in two stages:

c~
a) Clarification and filtration of the raw water to be used for fire fighting, service water
systems and for cooling water make-up and potable water.
b) Demineralisation and Polishing units to produce boiler feed water.
The operation of these facilities is described in the Utilities & Offsites Operating
Manual.
4.7 SERVICE & POTABLE WATER (OSBL)
The Service & Potable Water systems use filtered clarified water from the Raw Water
Treatment Plant (V-6201) located in Offsites.
a) The SERVICE WATER is supplied from filtered Water Storage Tank TK-6201 and is
pumped to the distribution header to supply the sample point coolers and utility hose
connections within the Complex.
c b) The POTABLE WATER system is supplied from V-6201 located in the Water
Treatment Plant.
Manual.
4.8 FLARE SYSTEM
The unit is provided with various automatic vents, manual vents and drains, and relief
valves, which connect into two main headers with flare risers at the end of each header.
The two systems are known as the NH3 FLARE, V-8702 and the FRONT END FLARE,
V-8701.
Each Flare is provided with a Flare KO Drum, 0-8702 and 0-8701 respectively The flow
into each drum is measured by FQI-8701 and FQI-8702 respectively.
c 0-8701 is fitted with a with a level indicator U-8702 and high level alarm LAH-8702
there is also a high/high level alarm, LAHH-8701 both located in the Offsites/Utilities

CLASS
control room. Liquid caught in the knock out drum is drained manually.
0-8702 is fitted with a with a level indicator U-8704 and high level alarm LAH-8704
there is also a high/high level alarm, LAHH-8706 both located in the Offsites/Utilities
control room. Liquid caught in the knock out drum is drained manually.
Manual.
c 4.9 AIR REQUIREMENTS
4.9.1 Instrument and Plant Air
The instrument and plant air for the Ammonia/Urea Complex is normally supplied from
a connection downstream of the interstage cooler E-2143 on the Process Air
Compressor, C~21 01 in the Ammonia Unit, and passes to the Offsites air systems via
a flow recorder FRlFQI- 1160.
In the event of loss of C-21 01, two electric motor driven 100% air compressors are
provided on Offsites to ensure continuity of air supply. These compressors are
multi-stage centrifugal design machines with water-cooled inter-coolers and
after-coolers. An air receiver is provided prior to a combined dryer/filter unit.
The plant air connection is taken off upstream of the dryer/filter unit and although the
same storage facility is used for both plant and instrument air, it is the instrument air
which has priority over the plant air in the distribution system. In the event of low
,,-.
" pressure in the instrument air header, the plant air users and the Urea bagging plant
are shut off.
An emergency air storage system is provided Offsites as a backup for the instrument
air supply consisting of a compressor and storage vessel. This is sufficient to
maintain air for a period of approximately 30 minutes during an emergency
shutdown of the process units and Complex.
Air for the Ammonia Unit instruments passes into the main instrument air header,
which runs the entire length of the unit area. A pressure Indicator (PI-1080) is
provided in the main control room together with a low-pressure alarm (PAL-1080).
Manual.
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4.9.2 Combustion Air
Combustion air for the Auxiliary Boiler and Arch burners is supplied by the Turbine
driven Forced Draft Fans C-2111 and C-2112 respectively. The pressure in the Prirnary
Reformer firebox is controlled by PIC-1 019, which controls the speed of the induced
draft fan C-211 0 via the drive turbine governor. The flow of combustion air to the
Auxiliary Boiler is regulated by FRC-1177, which controls the speed of the Auxiliary
Boiler FD Fan via the leading air system and the drive turbine governor. The Arch
burner combustion air is controlled by FIC-11S1 which controls the speed of the
Forced Draft Air Fan C-2112 via the drive turbine governor.
In the event of a high-pressure in the Reformer Furnace box or a low flow of

(~ combustion air to the Aux. Boiler or Arch burners the Arch, Superheat and Auxiliary
Boiler burners will be shutdown by their respective interlocks. All these interlocks will
be described in Section 11 of this manual.
4.10 NITROGEN SYSTEM
l'he purity of inert gas is critical for the Ammonia Unit, which should be dry, and oil and
CO2 free, with the levels of impurities limited as follows:
02+ CO + C0 2 SO ppm by Vol. (measured as O2) max.

H2 0.5 Vol. % max.
S Zero
CI Zero
NH3 0.1 Vol. % max.
Oil Zero
The primary source of nitrogen for the Complex is from the offsite air separation plant.
c It is used for purging and heat-up during start-up and for purging the various vents and
checking the various burner systems during the light-off sequence. Nitrogen is also
supplied as purging .medium for the four Auxiliary Boiler spin-mix burners and these
valves should be car-sealed open during operation. Hose connections are supplied
and located at key items of eqUipment with permanent connections to the LTS
Converter (R-21 09) and Methanator (R-2106) for blanketing/purging purposes.
Nitrogen purge connections to the flare headers are also provided.
A secondary source of nitrogen is provided by a pressurised liquid N2 storage facility and

steam heated vaporiser. The liquid N2 facility can be either be filled directly from the air
separation unit or filled independently from road tankers. This facility will provide a
standby source of nitrogen in the event that the air separation unit is shut down and in
an emergency, liquid nitrogen can be brought in by road tanker to keep the Complex
supplied with nitrogen.
A high N2 flow is required for purging the Ammonia Storage Tanks when commissioning
and subsequently for de-commissioning, or for purging the annular space in the event of
a liquid spill from the inner to outer containers. High N2 demand can be provided by
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supplementing the output of the air separation unit with the output from the liquid storage
facility.
4.11 FUEL GAS
Fuel gas is taken from the natural gas feed downstream of the Feed Gas Knockout
Drum D-2144 and the flow is measured by FI-1040. This measurement has temperature
and pressure compensation and the total cumulative flow is measured by FQI-1040.
Pressure to the Fuel Gas header is controlled by PIC-1189 which is equipped with a
high and low alarm. The signal from the controller goes to
2 control valves on a split range control system. There is also a 4" globe valve bypass
c around the control valves located in view of a local pressure indicator, PI-1190.
There is a further line from the exit of D-2144 which supplies fuel gas as a purge to the
flare headers. This flow is measured by FI-1 041 and pressure controlled by PCV-1 041.
The flow now splits, with the fuel for the Arch and Tunnel bumers passing through the
preheat coil in the Primary Reformer convection section and the fuel for the
Superheater, Aux Boiler and H-21 02 Start-up Heater going forward under pressure
control of PIC-1 001, This controller is fitted with high and low pressure alarms.
Upstream of PIC-1001 the system is protected by PSVs-FG1 002A1B set at 13.0 bara
and exhausting to the Front End Flare.
4.11.1 Arch Bumers
Pre-heated fuel gas to H-2101 arch burners can be supplemented by excess

synthesis gas from the CO2 Absorber Overhead Drum D-21 03; and/or by purge
gases frorn the Purge Gas Stripper T-21 03. Excess synthesis gas to fuel frorn D-
2103 is controlled by FIC-1178. This is fitted with a low/low flow alarrn which
actuates ESD-1031 and trips the valve closed. Purge gas from T-21 03 is pressure
controlled by PIC-1 033. The flow of purge gas to fuel is measured by FI-1258 which
c is fitted with a low flow alarm FAL-1259. There is also a low/low flow alarm FALL-
1184 which actuates ESD-1031 and closes XV-1031 isolating the purge gas to the
Arch Burners. The effect of low flow or loss of purge gas or excess synthesis gas to
the fuel gas system would be a high calorific value fuel gas supply (natural gas). In
order to protect the Primary Reformer against overfiring, a High Calorific Value
Interlock ESD-1031 has been provided and will be described later in Section 11.
The fuel gas is distributed to 80 arch burners arranged in five (5) rows of 16 on
Primary Reformer H-21 01 , with the supply to all five rows pressure controlled by
PIC-1002. Low pressure alarms (PAL-1120) and a High pressure alarm (PAH-1121)
are provided on the main supply line to the Arch Burners together with individual High
and Low pressure alarms (PAH/PAL-1061 through 1065) located on the supply line to
each row of burners. Solenoid operated valves actuated by the light off and shutdown
interlock system are also located on the fuel gas supply, checking gas and vent lines.
The Arch burner light-off sequence together with the shutdown Interlock systemESD-
2111 will be described later in Section 11.
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that attention is paid to the low levels of fuel gas pressure required at reduced
feed and until all burners are alight. To ensure an even release of heat
throughout the furnace during start-up, burners should be carefully spaced, and
for this purpose it is recommended that burners be colour coded and/or
numbered and then lit in a specific order.
To avoid overfiring of the Primary Reformer due to changes in calorific value of the fuel
gas when using natural gas and/or mixed gases, the following series of pressure
switches have been provided on the fuel gas supply lines to each row of Arch burners
to alert the operator to high/high or low/low pressure conditions.
c
PSLL-1475/6/718/9NAlNB/NC Set at 0.04 barg when firing on Natural Gas
PSLL-1475/6/7/8/9A1B/C Set at 0.29 barg when firing on mixed gases.
PSHH-1475/6/7/8/9NAlNB/NC Set at 0.45 barg when firing Natural Gas
PSHH-1475/6/7/8/9A1B/C Set at 2.1 barg when firing on mixed gases
Note that if PSHH-1475/6/7/8/9NAlNB/NC should actuate together with Purge Gas

lowllow flow on FT-1184 for a tirned period and excess synthesis gas low low flow on
FT-1278 for a timed period, then the Reforrner will be shut down.
Catalyst tubes rnust be visually inspected at frequent intervals using an optical

pyrometer and the tube outlet temperatures and flue gas temperatures and oxygen
content carefully monitored. Immediate adjustments must be made to the burner
firing should any abnormal conditions arise.
4.11.2 Superheater Burners
c Fuel gas supply to H-2101 Superheater and Auxiliary Boiler burners and to H-21 02
Start-up Heater burners has a common pressure controller, PIC-1001 which is
provided with low pressure (PAL-1 001) and high pressure (PAH-1 001) alarms.
The fuel gas to the ten superheater burners is controlled by FIC-1031 which is reset
by TIC-1 005 measuring the temperature of the Superheated Steam exiting the Hot
Steam Superheater Coil in the Primary Reformer Convection section. Regulator
PCV-1143, in the bypass around FV-1 031, is set for minirnurn firing pressure to
ensure the burners stay alight in the event of closure of the flow control valve.
A low pressure alarm, PAL-1140 and a high pressure alarm, PAH-1141 relay fuel gas
conditions to the control room. In addition PT-1240AlB/C activates low/low pressure
alarms which, on a 2 out of 3 voting system, will actuate ESD-2113. This is also the
same for PT-1241 AlBIC which activates high/high pressure alarms.
Upon actuation of ESD-2113, trip valve XV-1240A on the superheater burner gas
supply line will close; trip valves XV-1240-1thro'10 on the gas supply line to each
superheater burner will close and trip valve XV-1240C on the vent line between the
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two trip valves will open thus providing isolation of gas to the bumers. The control for
the pilot gas to the Superheater Bumers is the same.
Flame failure devices are supplied for each main burner and each pilot burner. A
signal from any device will close only the isolation to that bumer be it pilot or main.
However, should all pilot burners fail then all the main superheater burners will trip
out.
Detailed actions of ESD-2113 will be described in Section 11.3 of this manual.
4.11.3 Tunnel Bumers
The fuel gas supply to the five tunnel burners is controlled by HIC-1568 and the flow
c rate is indicated on FI-1567. Abypass regulator (PCV-1568A) set for minimum firing
pressure is provided round the HIC control valve to ensure the bumers stay alight in
the event of closure of the HIC valve.
A low pressure alarm, PAL-1569 and a high pressure alarm, PAH-1570 relay fuel gas
conditions to the control room. In addition PT-11569A1B/C activates lOW/low pressure
same for PT-1570AlB/C which activates high/high pressure alarms.
Upon actuation of ESD-2113, trip valve XV-1565/6 on the tunnel bumer gas supply
line will close; trip valves XV-1566 on the vent line between the two trip valves will
open thus providing isolation of gas to the burners.
4.11.4 Auxiliary Boiler Burners
The fuel gas supply to the 4 Auxiliary Boiler burners is controlled by pressure
controller PRC-1 018 on the main HP Steam header which resets the flow controller
FIC-1030 on the fuel gas header to the four burners. Relay FY-1 030B then
compares on a low select basis, the signals from FIC-1030 and PIC-1030 sensing
the fuel gas pressure downstream of FV-1030, and positions control valve FV-1030
accordingly. FV-1030 is provided with a bypass pressure regulator (PCV-1133) to
c ensure that the burners remain alight in event of closure of FIC-1030 control valve.
This control system will also be described in more detail in a later section.
A low pressure alarm PAL-1130 and a high pressure alarm PAH-1131 relay fuel gas
conditions to the control room. In addition PT-1230AlB/C activates low/low pressure
same for PT-1231A1B/C which activates high/high pressure alarms.
Upon actuation of ESD-2112, trip valve XV-1230A on the Aux bumer gas supply line
will close; trip valves XV-1230-1 thro 4 on the gas supply line at the burners will close
and trip valve XV-1230C on the vent line between the two trip valves will open thus
providing isolation of gas to the burners.
There is a similar control system on the aux boiler pilot burners.
All the actions of ESD-2112 will be described in Section 11.3 of this manual
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4.11.5 H-2102 Start-up Heater
The Fuel gas supply to H-2102 Start-up Heater bumers is controlled by panel
mounted HIC-1050which is used to position control valve HV-1050 on the fuel gas
supply line to the four burners. A control valve (PCV-1153) set for minimum firing
pressure is also located on a bypass line round HV-1050.
A low pressure alarm PAL-1150 and a high pressure alarm PAH-1151 relay fuel gas
conditions to the control room. In addition PT-1250 activates a low/low pressure
alarm which will actuate ESD-2116. This is also the same for PT-1251 which
activates high/high pressure alarms.
Upon actuation of ESD-2116, trip valves XV-1250A and B on the Start up heater
c
burner gas supply line will close and trip valve XV-1230C on the vent line between the
two trip valves will open thus providing isolation of gas to the burners
There is a similar control system on the Start up heater pilot burners
All the actions of shutdown interlock ESD-2116 which will be described in section
11.3.
4.11.6 Pilot Gas Fuel
The H-2101 superheat burners, the Auxiliary Boiler burners and the start up heater
burners are fitted with pilot gas burners. Pilot gas is taken from the fuel gas header
upstrearn of each main fuel gas controller and is pressure controlled to each burner
manifold by local back pressure control valves, PCV-1144 & PCV-1134.
Downstream of each PCV are various solenoid valves and switches connected into
the same light off sequence and interlocks as described above for the main burners.
4.12 DIESEL FUEL REQUIREMENTS (OSBL)
Diesel is not required on the actual Ammonia Unit but a diesel fuel system is provided
C' on Offsites for use as back-up fuel for the Utility Steam Generators, and as a primary
source of fuel for the Emergency Generator and the Firewater Purnp. The system is
outlined on P&ID's 52D-7111712
The diesel fuel is stored in a tank at atrnospheric pressure and ambient temperature
and can be filled from road tankers. The fuel supply lines are steam traced and the
storage tank is provided with an LP steam heating coil to maintain a minimum
temperature of 5°C during periods of low ambient temperatures.
4.13 ELECTRICAL REQUIREMENTS
The electrical load requirements for the Ammonia Unit may be summarised as follows:
400 Volt 6000 Volt
Normal Operating kW 575.7 1035.8

Intermittent Operating kW 179.7 1518.4

c JOB NO.· 5777 SPEC. TYPE:

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TOTAL 755.4 @ 400V 2554.2 @ 6000V
The following Utility Data Sheets identify the various users.
701-B1021/022 6000 V Switchboard 02B-6(1)

701-B1001/002 400 V Switchboard 03U(1)
701-B1004/005 400 V Switchboard 03L1 (1)
701-B1003 Emergency 380 V Switchboard 03-L
4.14 CATALYST SPECIFICATIONS
C 4.14.1 Catalyst Specification for Hydrogenation Reactor R-2160
Type: Co-Mo
Expected Life 5 Years
Inventory Volume: 12.2m3
4.14.2 Catalyst Specification for Desulphurisers R-21 08 A&B
Type: ZnO
Expected Life 1 Year each
Inventory Volume: 35.8m3 each (x 2)
c
4.14.3 Catalyst Specification for H.T. Shift Converter R-21 04
Type: Fe/Cr/CU
Inventory Volume: 48.7m 3
4.14.4 Catalyst Specification for L. T. Shift Converter R-21 09
Type: Cu/ZnlAI

CLASS
4.14.5 Catalyst Specification for Primary Reformer H-2101
Type: Nickel
Inventory volume 24.6M3
4.14.6 Catalyst Specification for Secondary Reformer R-21 03

c Type: Nickel
4.14.7 Catalyst Specification for Methanator R-21 06
Type: Nickel
Inventory Volume: 21.0 m3
c 4.14.S Catalyst Specification for Synthesis Converter R-21 05
Type: Fe
Inventory Volume: 68.4
c
CLASS
4.15 CHEMICAL SPECIFICATIONS
4.15.1 CO2 Removal System (aMDEA)
Chemical Initial Charge Annual Consumption

(Estimated)
aMDEA Premix 140 te 20te
(1)aMDEA 1:1 Nil 7 te
c (2)Potassium Carbonate
Caustic or Tri-Sodium
30te Nil
Phosphate
Notes:
1. To maintain activator level.
2. For initial system wash.
4.15.2 aMDEA System Antifoam Agent
Type: Silicone
Supplier: Drew Ameroid/BASF
Specification Amerel1500
4.15.3 HP Steam System Treatment Chemicals (Estimated)

c Oxygen Scavenger 1200 kg/yr
Phosphate (100%) 1200 kglyr
Morpholine (100%-) 6000 kg/yr
4.15.4 Ammonia for Start-up
The estimated amount of ammonia required for start-up of the Complex is 750 Tonnes. Uses
include storage tank cool-down and minimum inventory, refrigeration initial inventory and for
hydrogen generation during initial catalyst reduction and desulphurisation.
c
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4.15.5 Oxygen Scavenger (such as Nalco 72100)
4.15.5.1 Nalco 72100
Appearance: Liquid
Odour: Musty
Colour: Clear
Viscosity @15°C: 3,Ocp.
Specific Gravity @ 15°C: 1,02
pH (Neat): 8,0
pH (@ 1% solution):
c Freezing point:
Freeze-thaw recovery:
6,7
_2°C
None
Active Constituents: Carbohydrazide
4.15.5.1.1 Storage:
NALCO 72100 has a maximum recommended in-plant storage life of one year in
factory-sealed containers. Keep container closed when not in use. The maximum
storage temperature is 50°C. At temperatures below 4°C, the product will freeze
and begins to form precipitates. Once formed, the preCipitates cannot be
redissolved and loss of product activity will occur. Bulk NALC072100 should be
stored in polyethylene, polypropylene, or stainless steel tanks.
4.15.5.1.2 Additional Information:

Breakdown Temperature: Complete at 260°C
Breakdown Products: Carbon dioxide, ammonia, water
Contribution: (ppb per ppm product)
c CI
CO 2
0,014
32
Na 0,062
NH3 (maximum) 25
Si0 2 0,001
S04 0,034
Vapour Pressure @ 24°C: 30 torr
4.15.6 Phosphate
Active Ingredient: Mixture of Tri- and Di-Sodium Phosphate
Grade: Powder or granular.
Ratio of Na to P04: 2.6
Solubility: Completely soluble in water.
Service: Scale control of 121 bara steam system.
Notes:
c 1. Vendor will advise bulk density.
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4.15.7 Morpholine (or alternative such as Nalco 72310)
4.15.7.1 Morpholine
Active Ingredient: Morpholine

Solubility: Completely miscible with water.
Service: Corrosion control/pH control of 121 bara steam
system.
Notes:
{' 1. Vendor will advise physical properties.
,,~/
4.15.7.2 Nalco 72310

Physical & Chemical
Properties:
Active Constituents: A blend of Alkanolamines

Form Liquid
Colour Clear, colourless to light yellow
Specific gravity @ 15°C 1,Ot01,04
Viscosity @ 38°C 42 SUSS
pH (Neat) 11
Pour Point -35°C
Boiling point > 93°C at atmospheric pressure
4.15.8 Sodium Hydroxide [NaOH]
c • Grade: The alkali used should be high purity, low-salt caustic (mercury cell or
rayon grade).
• Solution concentration (as used): 4 - 25% by weight.
The following is a typical rayon grade nominal 50 wt % sodium hydroxide solution

analysis:
Composition:
NaOH 51.2% bywt.
NaZC03 0.027% by wt.
NaCI 0.002% by wt.
NaCI03 30 ppm
Fe 60 ppm
NazSO. <1000 ppm
SiOz <1700 ppm
Ab0 3 370 ppm
c CaO
MgO
300 ppm
290 ppm
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Mn 7ppm
Cu 9 ppm
Pb <50 ppm
Ni 27 ppm
Sr 900 ppm
Hg 4.8 ppm
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5 PREPARATION FOR INITIAL STARTUP
5.1 INTRODUCTION
The start-up procedure presented here is for the initial start-up of the Ammonia
Unit. In the course of subsequent startups, certain of these procedures may be
eliminated or modified in whole, or in part, as may be applicable to the
particular situation.
Procedures for each section of the unit are handled separately in the write-up for
c convenience in presentation. However, it should be recognised that many of these

procedures may, and should, be performed concurrently so the unit start-up is co-
ordinated and expeditious.
The offsite facilities must be in operation and proven reliable before the start-up of the
ammonia plant is commenced. The systems in Offsites, which are directly related to the
ammonia plant, are as follows:
1. Instrument and Plant Air

2. Demineralised Water
3. Electric Generator
4. Medium Pressure Steam System
5. Cooling Water System
6. Ammonia Storage Facilities
7. Inert Gas Supply
8. Natural Gas Feed and Fuel Systems.
Steam is one of the main requirements for the process and equipment operation of the
c unit and is produced from steam generating equipment that is an integral part of the
unit. About 70 T/hr of MP steam is available from the Offsites steam generation
facilities for precommissioning and initial phase of the unit start-up.
When an adequate supply of steam is being generated in the unit's facilities, the start-
up import steam will be discontinued. The steam generating capacity within the unit is
provided mainly by the following equipment:
1. Secondary Reformer Waste-Heat Boiler E-21 01

2. HTS Effluent Waste-Heat Boiler E-2103A1B
3. Auxiliary Boiler H-21 01
4. Ammonia Converter Effluent Waste Heat Boiler E-2123A1B
Although the above items of equipment are (in the main) steam generators, there are
other items of equipment that provide preheat to the boiler feed water by recovery of
heat from the process. The items of equipment that provide boiler feed water preheat
are as follows:


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1. LTS EffluentiLP B.F.W. E-21 06

2. L.T. Shift EffluentiBoiler Feed Water Exchanger E-2131
3. Synthesis. Gas compressor Interstage B.F.W. Heater E-2117
4. B.F.W. preheat coil H-21 01 CB in Primary Reformer convection section.
Due to the fact that the steam generating equipment is an integral part of the process
equipment, the start-up has to be conducted in such a way to ensure that steam
production at each stage (or step) of the start-up is adequate to satisfy all steam
requirements of the unit. The various "Steam Balances" contained in Section 4.0. of
this manual should be referred to since these indicate the status of the steam systems
within the unit in the various stages of start-up and operation.
c As with any process unit, the ultimate operating conditions and techniques will evolve
from experience gained during the initial and subsequent start-up operations.
·Consequently, it must be recognised that the start-up presented herein is at best a
guide to help ensure an orderly initial start-up of the unit, and all conditions stipulated
are not rigid standards, unless specifically noted as such.
The following start-up is presented in two parts: first, the preliminary start-up
procedures, and second, a detailed unit start-up procedure. The start-up is a
continuous operation once initiated and is carried forward until the unit is "on stream"
producing specification product. However, certain steps require time to complete, so
down-stream equipment may be purged or commissioned during these periods to
expedite the unit start-up.
5.2 PRELIMINARY STARTUP PROCEDURES

5.2.1 Unit Check-out Procedure
Check the entire unit over for completeness and correctness of construction based on
c the P.& I. and vessel drawings. Inspect all vessels for cleanliness and correctness of
installation of any internals. Ensure that all required plugs and blinds are in place and
that all unwanted blinds have been removed, with particular attention paid to those
under safety valves.
Inspection of Vessels
Before the final bolting of the cover plates on manways, or loading of any catalyst in
vessels, the interiors of the vessels must be inspected for cleanliness, completeness,
and proper installation of internal equipment. The points checked should include the
location and length of thermowells, the location and fabrication details of distributor
piping, the location and fabrication details of internal trays, and the range of level
instrument floats or outside float cage connections.
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During the inspection of vessels, a thorough check of the primary reformer catalyst
tubes and collection headers should be made. Check all heat resistant alloy piping for
signs of paint. Paints containing zinc, copper, or lead may cause inter-granular
corrosion of this alloy piping when heated. If any is found, it must be removed before
The P&ID drawings should be used to verify piping, instrumentation, control valves,
c block valves, and drain valves. Nameplate data attached to field equipment should be
reconciled with the data sheets. Punch lists should be compiled to identify omissions
or discrepancies.
5.2.2 Line Flushing Procedure
All fluid-handling equipment, particularly piping, should be thoroughly cleaned of scale

and the internal debris, which accumulates during construction.
Operating personnel should follow up construction with the thorough flushing and
blowing required to pre-commission the unit for operation.
Most utility systems, such as water and steam, may be satisfactorily cleaned by means
of their normal media introduced through normal channels. Other systems should be
flushed or blown with "foreign" media, admitted through temporary hose or pipe
connections.
Major stearn lines will be blown to a "POLISHED ALUMINUM TARGET" until a target
c stays clean after last blowing. Norrnally, supervision in charge of line blowing will
designate those lines to be blown to targets but as a general rule, all steam turbine
inlet and main steam letdown lines will be targeted.
Vessels containing catalyst must be blinded-off to prevent wetting catalyst. To

whatever extent the lines are connected at the time, they may be flushed with water
used in hydrostatic testing. A single filling of a vessel may noi provide adequate
flushing of all lines for which it is the reservoir. In this case, a continuous or
intermittent flow of water into the vessel should be maintained. Water may be
admitted to most vessels through temporary connection to a nozzle or into the top of
the vessel by hose connection through a top entry line.
Caution must be exercised to avoid filling some large over head lines from vessels and
towers. The design of hangers, supports, or foundations may not be adequate to
the weiqht of equipment when filled with water.


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If construction has included a line or piece of equipment (with the line or equipment in
place) in their hydrostatic test, this is the ideal time to perform any required flushing. In
situations where necessary, construction will install additional temporary supports to
accommodate the weights involved in hydrostatic testing. When washing lines from a
vessel always be certain that the vessel is adequately vented to prevent vacuum
conditions from forming in the vessel.
The quality of the water to be used is of the utmost importance in all cases. Water used
to test or flush stainless steel vessels or vessels with stainless steel internals must be
"chloride free". Stress corrosion cracking could occur as a result of contacting the
c
stainless steels with chlorides. Of particular importance is the ammonia converter
basket. Every precaution must be taken to prevent water inadvertently entering or
being blown into the ammonia converter where it could contact the stainless steel
To the greatest extent possible, flush down or horizontally, and out low points. The low
point outlets will usually be temporary openings made by disconnecting flanges or
fittings. Normal drains may be used for flush outlets provided they are equal to line
size, or nearly so.
For the best results, there should be no restriction at the outlet or any other point in a
line undergoing cleaning. Where it is necessary to throttle the flushing flow, do so at
the supply end. The higher the velocity of flushing, the more thoroughly a line will be
scoured.
Following are some guides for flushing:
• Do not flush through control valves

• Do not flush through too many circuits or openings simultaneously
c
• Flush through all vents, drains and other side connections
• Flush bypasses alternately with their main channels (see remarks on control
valves)
• Avoid flushing debris into nozzles, small-bore lines, mist collectors and other
equipment where it may become lodged or trapped
So far as it can be done conveniently and economically, divert the initial flow ahead of,
or around, eqUipment until the lines upstream are clean, then flush or blow into or
through the item concerned, such as exchangers or vessels. Some instances where
this practice is particularly important are enumerated in the following paragraphs.
All control valves should be removed or rolled out until the foreign material has been
removed from their systems. Finally, replace the valve and flush through the valve in
normal alignment and / or through the bypass if the valve cannot be opened.
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::;peclal care in line blowing and flushing must be carried out for lines using noise
reducing trim control valves. The holes in the valve cages are very small, <3 mm in
diameter. The control valve will plug with rust and dirt if the lines are not very well
flushed and blown and could lead to a plant upset or shutdown. Steam control valves
should be target blown to verify cleanliness.
It is advisable to start the plant up using the bypass lines around the noise reducing
control valves if at all possible to ensure that the lines are well flushed prior to placing
the valve in service.
c
Flow meter and restriction orifices should not be installed until lines are clean. Any
orifice installed before cleaning should be removed and verified clean then replaced.
This is a good time to measure and verify orifice bores.
All connections at pumps, compressors and drivers must be closed off, blinded, or
disconnected while the lines running to them are thoroughly flushed. This applies to
the main suction and discharge lines; driving and exhaust steam; jacket cooling water;
and auxiliaries. The flushing or blowing outlet should be at some convenient point as
near to the pump or driver as possible. Generally, it will be necessary to disconnect a
flange or fitting. Where this is done on the pump or compressor side of the block
valve, the open connection must be covered to prevent entry of debris.
In discharge lines containing a check valve immediately adjacent to the pump, as is

generally the case with centrifugal pumps, a flushing outlet may be made by removing
the check valve cover plate, provided the flapper or disc remains in place to seal off
the pump itself. Where it is desirable to back-flush through a check valve, the flapper
must be removed and the cover replaced, or the check valve inverted.
c advisable to blind at the pump discharge to avoid accidental leakage back

check valves from enterina the unit.
All connections to instruments should be disconnected at the instrument and blown or

closed off during flushing.
Instrument air lines must be blown with special thoroughness with clean, dry,
preferably instrument-quality air.
By-pass steam traps until the lines are fairly clean. Check the operation of traps after
they have been opened to the condensate and remove for inspection and cleaning any
that are not working properly.
Have the fumace bumers disconnected until all lines to them are blown clean then
reconnect and blow air through the burners. Check each individual burner's orifices to
be certain each is unobstructed.
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After initial water circulation through cooler and condenser tubes, it may be advisable
to open the cooler which was flushed first in the series, or one of the first group, for
inspection and, if required, cleaning of the tube sheets. If much foreign material is
found, other units should be examined. The cooling water system is flushed with its
normally supplied water.
At the conclusion of flushing any system, check carefully to see that normal alignments
are restored, temporary connections broken, and temporary breaks reconnected.
Replace check valve flappers and / or cover plates, install orifices, etc. In the case of
lines, which will receive further cleaning during the subsequent breaking-in of pumps,
this instruction may be qualified in part.
When flushing of the process lines is finished, drain all water from the system as
c completely as possible. Provide ample top venting during the draining operation, or
whenever the level is being lowered in a vessel, to avoid pulling a vacuum on the
equipment. Blow the drained lines to effect further water removal.
The basic utility systems, steam, water, nitrogen, and air should be put in normal
working order after they have been cleaned, so that supplies will be available for
further flushing and commissioning operations. In addition from a safety point of
view the firewater system should commissioned and in operation.
5.2.3 Steam Blowing Procedure
Scope
This section identifies the minimum requirements for the cleaning of steam piping with
steam blowing.
Introduction
c The purpose'of steam blowing is to remove weld bead deposits, pipe slag and other
foreign material (iron oxides, etc.) from steam piping and the boiler (all upstream of the
turbines) to minimize the possibility of turbine damage. Particles carried by steam will
plug turbine strainers and will affect the turbine performance. Larger objects could
damage or tear the strainer and pass objects through which could result in damage to
the turbine blades and wear to its internals.
A number of Steam Blow Cycles will be required for each set of piping. Each Steam
Blow Cycle consists of heating, blowing steam through and cooling the related piping
until the steam is free of debris (a clean system is obtained). The inherent design of
the unit should allow stearn to be supplied from the boiler with the necessary
temporary piping, materials, and silencer to satisfy a steam blowing operation.
The effectiveness of cleaning is determined by the use of a polished target properly

located in temporary piping. Solid particles carried by the Steam Blow impact the
target and produce pits on the target surface. The target is then analyzed by vis,ual
observation. This observation is concerned with the amount and size of all pits on the
target. A decision is made with regard to the line being adequately clean, signifying
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the termination of that particular steam blow.
As a precautionary measure, after steam blowing, it is recommended that an

engineered fine mesh screen be attached to the coarse screen in the inlet strainer
casing at each turbine main stop and combined reheat (if applicable) valve. This fine
mesh screen is ONLY a temporary device that helps to collect foreign particles and
debris not removed by the Steam Blowing during the initial operation of the unit and
MUST be removed after full load operation is achieved (at the next shutdown of that
piece of equipment).
Prerequisites to an Effective Steam Blow:
c The necessary Steam Blowing Procedure outlining how the Steam Blows will be
conducted must be developed and reviewed with all involved personnel. It is important
that this procedure incorporate all related equipment interfaces, safety precautions,
and the Steam Blow Target Acceptance Criteria.
A summary of the calculated system pressures and velocities for each phase of the
Steam blowing operation must be included in the written procedure presented to
involved personnel. Thereby allowing verification of the pressures to be used during
the actual operation. The procedure will also serve to inform the Steam Blow
Personnel of the pressures required for adequate steam blowing of the piping at each
phase.
The Steam Blowing procedure is to include P&IDs with each phase of the steam blow
identified on them. The P&IDs will identify such things as:
• which valves are to be removed

• instrumentation to be removed
• the direction and routing of the blows
• the sequence of the blows
C •
•
amount of steam flow for each blow
the installation of temporary spools and piping
• the installation points of the silencers
• the equipment affected by the Steam Blows
• any other information deemed necessary
A sufficient quantity of polished targets (material: normally stainless steel, but

aluminum may be used) with two or more opposing sides polished to obtain multiple
uses must be available. Square stock polished on all four sides has also been used
successfully.
Cleaning Effect:
During a Steam Blow the product of the values of velocity and density of the steam at
any point in the pipe is constant according to the law of mass conservation. At the exit
of the pipe, the velocity is very high, most of the time sonic. The density is low but as
the drag force is proportional to the square of the velocity, the effect of high velocity is


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prevailing and the cleaning effect is excellent.
The Drag Force Equation's primary concem is the cleaning disturbance factor - C.
This factor is defined as follows:
C = drag force cleaning / drag force operating = p1 (V1)2 / p2(V2)2

where:
• p1 = density of cleaning medium

• V1 = velocity of cleaning medium
• p2 = density of normal operating fluid
C •
•
V2 = velocity of operating fluid during upset cases
C measures the flushing or blowing effectiveness and its value must be > 1
or ideally> 1.5
The place where the velocity and hence the cleaning effect will be at minimum is at the
point following the Throttling Valve which controls the flow during the steam blowing.
Therefore, the drag force comparison should be made at the throttling valve (within 2
to 3 meters of the valve).
The mass velocity developed during the actual Steam Blowing operation must be
verified to be correct by the recording of the system pressures at the inlet to the Steam
Blow throttling valves and at the discharge of the temporary blowdown pipe. Thereby
confirming that the proper mass velocity was attained.
The throttling valve SHOULD be located at the inlet to the pipe being cleaned, NOT at
the outlet. It should be replaced at the completion of the steam blow as it will have been
c Steam Blow Preparations
Do not blow contaminated steam through exchangers or other equipment in which

debris might become lodged. Steam should be exhausted upstream of this equipment
until clean.
Control valves, desuperheaters, or any eqUipment which might be damaged or

plugged by entrained particles in the steam flow must be removed. Pipe spools should
be fabricated and installed in their place (temporary pipe spools must conform to the
piping class of the lines being blown). Precautions must be taken to protect
equipment. Examples are:
• check valve internals removed

• orifice plates removed
• thermocouples and instrumentation removed
• strainer baskets removed


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• control valves removed - especially reduced noise trim type valves

• atomizing nozzles removed
• other equipment susceptible to steam blow damage
Steam is to be exhausted as close to the turbine inlet as possible. The trip and throttle
valve may be removed to provide a good exhaust point.
The steam is to be opened to the piping and blown at least 10 - 15 minutes after
maximum piping temperature is attained. The piping is then to be cooled to at least Y2
the maximum temperature attained during the steam blow.
Steam Blow Target Acceptance Criteria
c Acceptable discoloration is only as a result of heat discoloration (i.e., heat being

applied to cold rolled steel) and not because of black iron oxide carried in the steam.
The target is to be polished stainless steel or aluminum with a cross sectional area of
approximately 10% of the pipe cross sectional area. There must be a sufficient
number of targets available so as not to delay the Steam Blowing Procedures.
The duration of the steam blows with a target in place is to be at least 15 minutes.
The number of unraised pits allowed will be five or less. No pits resulting in raising of
metal above the target surface are permitted. '
Since turbulent flow will exist, the number of acceptable unraised pits is restricted to an
area on the target inside 0.85 of the radius (from the pipe center). That is the area on
the target experiencing greater than average velocity. Any pits outside of this area will
cause rejection of the target.
A total of five consecutive targets with less than five unraised pits per target must be
c obtained to conclude that no additional cleaning will be accomplished by continuing the

Steam Blowing Process. .
This comparison will consist of collecting THREE CONSECUTIVE TARGETS, allowing

the permanent piping to cool for a 2.4-hour period. Then reheating and finally collecting
the last TWO CONSECUTIVE TARGETS.
The targets, once removed for inspection are to be labeled with the target location, the
number of the blow taken, date, time, and the Inspectors' Name and their conclusion.
Various target bracing and securing techniques are to be approved by all of the
responsible personnel.


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Turbine Manufacturers may have a recommended blowing procedure and target

specification that may vary from the above guidelines. Turbine Manufacturers
recommendations are to be STRICTLY adhered to. The above guidelines can be used
if no recommendations are
Safety and Environmental Precautions
Exhaust steam should be directed into a collection bin of substantial construction (able
. to withstand the rigors of a steam blow). It must allow the steam to vent up and any
c. condensate to drain out the bottom. Installation of temporary elbows or stacks may be
required.
Ensure that all lines are adequately braced and supported.
During initial warm-up of the piping (thermal cycle) inspect lines for any expansion
restrictions and for possible leaks.
Steam is not to be opened suddenly into a cool line. A bypass valve should be
installed to slowly warm-up the line prior to blowing. All bleed valves should be opened
to drain condensate from the line, reducing the incidence of water hammer.
The target brackets are to be designed to withstand the force of the exhaust steam at
sonic velocity.
The steam exhaust area must be roped off and access restricted. Hearing protection
must be provided in the affected area.
Temporary and uninsulated piping must be roped off and or tagged.
c 5.2.4
Steam silencers should be used at all times and locations, whenever possible.
a) Commission the water clarification and demineralisation treatment units to

produce demineralised water of the correct specification and establish an
inventory in the storage tank.
b) Carryout all necessary preparatory work on the offsite package boilers and
associated facilities and commission the boiler as required to provide steam for
pre-commissioning activities. Import MP steam from Offsites and blowout the
unit MP and LP steam systems through openings made at the extremities of the
headers.
NOTE: Whenever the sole source of MP steam is from Offsites, the superheat
temperature of the MP steam generated in Offsites must be reduced to 399°C.
It may be necessary to dismantle (or remove) valves in order to make adequate
openings for blowing. The outlets should not be restricted to effect a maximum


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velocity during the blowing stage. The laterals of each system are blown by
making openings or disconnections as necessary to effect optimum cleaning.
c) Steam lines to the large turbines are blown out to a metal target plate, the line
being declared clean when successive blowings produce no fresh marks on the
plate.
Caution: When warming up any steam system in preparation for blowing, it is to be

done very slowly to avoid any water hammer that can cause serious equipment
damage. After steam systems are blown clear, commission all steam traps from
headers to ensure that they are kept hot and free from condensate. All laterals to
various items of equipment should be kept closed until they are ready for use.
c When the steam systems appear to be acceptably clean, reassemble any equipment
which has been dismantled for blowing purposes and install all orifice plates and flow
elements. The MP and LP steam systems should then be repressurised and left
"floating" on the MP import line. This will entail commissioning PIC-1014, the
medium pressure vent to atmosphere; PIC-1 016, the medium pressure steam letdown
to the LP steam system and PIC-217 to vent excess low-pressure steam to
atmosphere.
NOTE: With the HP and LP Steam systems in service, take advantage of the time
while turbine over-speed trips, etc., are being verified to re-check the entire system to
ensure that orifice plates and restriction orifices (R.O.s') have been correctly installed.
Re-check all systems to ensure that all temporary blinds have been removed, and
pertinent blinds are installed where removed during unit conditioning. All control valves
should be checked out to ensure that all valve actions are correct in relation to their
respective controllers. Of particular importance are the turbines for the reformer
induced draft fan and boiler feed water pumps as this eqUipment is required for the
conditioning of the High Pressure steam system.
C 5.2.5 Air Blowing Procedure
With the cooling water and import steam system in service, carry out the following
activities necessary for the commissioning of the Air Compressor C-21 01 which will be
used for air-blowing purposes:
a) Commission instrument air system using import instrument air.
b) Commission electrical systems to lube oil pumps and instruments etc. on the Air
Compressor.
c) Commission Vacuum Surface Condenser E-21 04.
d) Chemically clean the compressor lube oil piping, fill with oil and circulate under
the vendor's guidance.
e) Start and run-in the process Air Compressor and its turbine under the direction of
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the vendors' representatives. Note that it is essential that the operator checks the
Filter F-2101 prior to starting the compressor to make sure that the filter packs are
not frozen and blocking the filter inlet. '
f) Using the air compressor, blow-out process lines that are normally in gas service
and finally dry-out. To achieve this, a permanent air blowing line is provided which
connects into the inlet line to the Primary Reformer and temporary piping between
the air compressor discharge and other process lines will also be required.
5.2,6 Fuel Gas System Blow-out Procedure
c
a) Isolate by blinding any systems that supplement the fuel gas system during normal
operation and disconnect all burners. Blow the fuel gas system using steam and
air alternatively to optimise rust and scale removal., Finally air blow dry and install
orifice plates and strainers.
b) Pressure test the fuel system, make tight and leave blinded off under slight
nitrogen pressure until required for service.
5.2.7 Refractory/Heater Dry-out Procedures
a) Dry-out of the Primarv Reformer as well as the Auxiliarv Boiler steam generator
lining will be carried-out in accordance with the detailed procedure "Furnace
Dry-out Procedure" [ODS-173] contained in the General Procedures Manual.
b) Great care must be taken to minimise local overheating of refractory and/or

respective catalyst tubes. Ensure that the Furnace Fans have been safely tested
and that design drafts are not exceeded in the primary or auxiliary fireboxes.
c) The refractory of the Secondarv Reformer must be dried under carefully controlled
c conditions before the catalyst is loaded to the vessel. The specifications and
procedures for the drying program that will apply are contained in the "Job
Specification" book and these will be followed in detail to conclude a satisfactory
dry-out of the equipment.
5.2.8 Chemical Cleaning Procedure
a) The High Pressure Steam system should be alkaline boiled out and chemically
cleaned in accordance with the procedure entitled "Chemical Cleaning of Steam
Generating System" [ODS-121] developed specifically for this project and
included in the General Procedures Manual.
b) As stated previously, the water treating plant located Offsites must be checked
out and commissioned. This should be undertaken well in advance of other
commissioning as to allow time for proper lining out of the system and to provide
operator training in regeneration procedures. As soon as possible, an inventory
of demineralised water must be established in the demineralised water storage

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tank for use in boil-out and chemical cleaning of the waste heat system.
c) On completion of chemical cleaning, the temporary piping will be removed. The

steam drum should then be inspected and finally buttoned-up and left under a
nitrogen blanket and/or refilled with deaerated BFW and pressure tested. All leaks
are made good and the system is then ready to generate steam for relief valve
testing, etc.
d) The chemical cleaning (degreasing) of the C02 Removal System which should
have already been charged with packing and demineralised water, can be initiated
as soon after the cleaning of the steam generating system as is convenient. The
procedure is described fully in the General Procedures Manual. On completion,
(' the aMDEA solution can be made up and retained in the storage tank. The CO2
removal system must be blanketed with nitrogen to prevent oxidation of the intemal
surfaces.
5.2.9 Catalyst Loading Procedures
a) After each vessel has been cleaned and inspected, catalyst loading may
commence. Individual standard loading procedures are contained in the General
Procedures Manual and these in conjunction with the vessel drawings should be
used to ensure proper loading.
b) Extra care should be exercised in the loading of the Primary Reformer. After
loading, pressure drops are taken on each tube and all those that fall outside the
acceptable limits are to be unloaded and recharged until all tube pressure drops
are sufficiently uniform. This is done to eliminate hot spots and high-pressure
differentials. Keep a nitrogen blanket on the Ammonia Converter after loading.
c) Actual loading of the catalysts and the packing in the CO2 removal system may
c take place during the final stages of construction or earlier. They must however be
isolated to prevent damage or entrance of contaminants.
5.2.10 Catalyst Dusting Procedure
a) The Air Compressor is used for dusting the catalysts that have been loaded to the
various reactors. During this operation, take care not to exceed the design
pressure drops over the vessels. The blow is complete when no more dust
appears in the exit air.
b) The unit will be lined up for "dusting" of the reforming and shift converter catalysts.
With the air compressor on line, the air will be routed through the start-up line into
the inlet of the mixed feed preheat coil. The catalyst in the Primary and Secondary
Reformers will be "dusted" out to atmosphere through the bottom nozzle cover of
the Secondary Reformer. Keep the compressor discharge pressure low to avoid
heat of compression and blow the catalyst dust free. When this is complete, close
up the bottom nozzle cover of the Secondary Reformer and "dust" the HTS
Converter to atmosphere by dropping out the connecting spool piece with

+ MW. Kellogg Limited Operating. Manual

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E-2103A. After the HTS Converter has been blown free of dust, replace the spool
piece and direct the airflow through the Low Temperature Shift Converter, dusting
at the 3 inch drain outlet.
NOTE: It is recommended that during the dusting and leak testing periods, no
blowdown of E-21 02 and E-21 03 items be undertaken. Hot steam generator water
could be drawn down and result in excessive air temperature to the shift
converters.
5.2.11 Conditioning of CO2 Removal System
c It is very important that the aMDEA System be properly prepared for operation by
carrying out a degreasing and descaling program. The objective is to remove oil,
grease, mill scale, rust, or other contaminants from the system that contribute to
foaming of the aMDEA solution.
Millscale in piping and towers, formed during the manufacturing and construction
phases, is potentially one of the greatest sources of sludge formation and iron that can
contribute to foaming problems when the system is placed in operation. Foaming in a
C02 removal system can result in inadequate removal of C02, pump damage,
exchanger damage, and tower internal damage.
Experience has shown that a careful cleaning of aMDEA systems is not only indicated
as good operating practice, but is mandatory to minimize foaming of the solution and
delays in the initial start-up. The time used in properly cleaning the aMDEA systems
pays large dividends later on when process gas is admitted to the system for removal
of C02. Therefore, special effort should be made to have the system as clean as
possible before start-up.
During the water wash circulation steps, instrument flushes, seal flushes, control valve,
c and instrument operation should be checked and adjusted as required for correct
operation.
a) With steam and other utilities available, the CO2 removal system will be made
ready for operation in accordance with the procedure contained in the BASF
aMDEA handbook, Part 3. The procedure necessary for preparing the aMDEA
system requires the use of either Potassium Carbonate, tri-sodium-phosphate or
Caustic washing and water flushing.
b) The exact timing for the preparation of this system cannot be defined in advance
and if the system is conditioned too early, the system must be circulated to keep
the vessels in a ''wet'' condition.
5.2.12 Leak Testing Procedure
On successful completion of the catalyst dusting operation, the equipment will be

subjected to pressure (leak) testing. This test is performed with air from the Air
Compressor and is intended to confirm that all flanges, vents, drains, other items of
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equipment, and their connections are closed and not leaking. In some cases, leak
testing is combined with nitrogen purging.
Leak testing is usually done in sections, such as desulfurization, reformers, and shift
converters, C02 removal, methanator to C-21 03, refrigeration, and synthesis.
Flanges should be carefully checked for leakage, bleed and drain valves for closure,
and manways checked. Normally 5 to 7 barg is used for leak testing. After all leaks
have been repaired, the unit should be purged with nitrogen to an oxygen content of
0.5% or less.
The Low Temperature Shift Converter, should now be blinded in preparation for
(' catalyst reduction. The Low Temperature Shift Converter, the Methanator,; and the
Ammonia Converter, should now be oxygen free, under 0.5% 02, and under a positive
nitrogen pressure.
The refrigeration system, after nitrogen purging, can be left under a pressure of about
3 barg, to be displaced with ammonia vapour during the filling of the Refrigerant
Receiver.
5.2.12.1 Natural Gas Feed, Hydrogenation & Desulphurisation Systems
I. The leak testing is done in sections, starting with the hydrogenation,

desulphurisation and natural gas feed sections. Low-pressure (5 barg) air will
be used for the leak test, using the C-21 01 Air Compressor with temporary
piping or hoses running to appropriate locations in these sections. The
following equipment should be included in this:
• Natural gas feed system from NH3 Unit limits back to the Client supply
(! point including the natural gas metering station and E-1001 Feed Gas
Heater.
• From NH3 Unit limits forward to D-2144 KO Drum; C-2102 Feed Gas
Compressor; E-2133 Feed Gas Compressor Kickback Cooler and the
Feed Gas Preheat Coil in H-2101.
• Hydrogenation & Desulphurisation System [R-2160 & R-21 08 AlB].
II. After leak testing purge the entire section with nitrogen provided at the
following connections:
• Unit side of unit limit block valve on Natural Gas Feed line.
• Suction of Feed Gas Compressor C-21 02.
• 1" drain valve on Desulphuriser outlet line to H-21 01 .
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c JOB NO. 5777

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5.2.12.2 Ammonia Plant Front End
I. Air pressure will also be used to test the Ammonia Plant front-end section
from the inlet of the Primary Reformer to the closed (and blinded) inlet to the
Methanator (R-21 06). Hand-jack closed the Methanator inlet valve (XV-1211)
and close off the upstream motorised valve. Again, use about 5 barg
pressure of air to test the system using C-21 01 as the source of air supply.
All valves and flanges must be subjected to close inspection to ascertain that
they are tight. The following items will be included in this leak test:
Primary & Secondary Reformers H-2101 & R-21 03
c
Secondary Reformer Waste Heat Boiler E-2101 (Shell side)
HP Steam Superheater E-2102 (Shell side)
HTS Effluent Waste Heat Boiler E-2103A1B (Tube side)
Low Temperature Shift Converter R-21 09
LTS Converter Effluent Exchangers E-2131/E-21 05/E-21 06
Raw Gas Separator 0-2102
CO2 Absorber T-21 01
CO2 Absorber Overhead Drum 0-2103
Methanator/Effluent Exchanger E-2114(Shell side)
Methanator Feed Heater E-2172 (Shell side)
Up to temporary test blind at Methanator inlet (R-21 06)
II. When the above system is tight, the system will be depressurised for proper
alignment for the continuation of the start-up of the equipment involved.
Note: The Low Temperature Shift Converter must now be isolated at this time
as the catalyst will be later reduced employing a low pressure reduction
method, using desulphurised feed gas or nitrogen as carrier medium. The
emergency shut-off valve (MOV-1008) in the inlet line as well as its 1" bypass
c must be blinded off to prevent the possibility of leakage into the LTS converter
before, or during the reduction procedure. The LTS converter outlet valve and
its pressure-equalising bypass will also be blinded on the converter side.
Once the Low Temperature Shift converter is isolated from the process, it must
be purged air-free with nitrogen (0.5% oxygen or lower) and the vessel
maintained under a positive pressure of nitrogen to ensure against entry of air
or process hydrocarbons into the vessel. It is important, therefore, that the
atmosphere of nitrogen be maintained on the LTS converter and it should be
frequently checked during subsequent start-up operations to ascertain that this
is the case. Because of the low cohesive strength of the copper zinc oxide
catalyst in the converter, contact with condensate or wet steam is undesirable
and all connecting lines to the vessel must be frequently checked for moisture.
5.2.12.3 Methanator
I. The Methanator will be purged with nitrogen by pressuring to about 1 barg via .
a suitable connection and depressurising to a slight positive pressure. About
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4 to 5 separate purges should clear the system of air but if the oxygen
content is not acceptable, continue purging until a satisfactory purge (0.5%
O 2 or less) has been achieved. The following equipment, up to the block
valve downstream of the Synthesis Gas Compressor Suction Drum (0-2104)
will be included in with the Methanator purge:
Methanator Effluent Air Cooler - E-2118

Methanator - R-2106
Methanator Feed/Effluent Exchanger - E-2114
Methanator Effluent Air Cooler - E-2115
Synthesis Gas Compressor Suction Drum - 0-2104
c II. Any time the system is being depressurised after a nitrogen purge, always use
the low point drains to ensure last traces of water are cleared from the system.
This is especially important during the subsequent purging of the Synthesis
Gas Loop and refrigeration systems.
III. After the Methanator and associated equipment has been purged "air free",
the system will be pressuredto 5 barg with nitrogen for a tightness test.
Inspect all flanges, valves and fittings to verify that the system is tight.
IV. Once the system is verified as tight, the system will be depressurised and the
temporary test blind aUhe Methanator inlet removed. While the system is
open, keep a slight nitrogen bleed to the reactor to keep air excluded. When
the flange is made up, the pressure on the system should be maintained at 1
barg.
5.2.12.4 Synthesis Loop
I. The synthesis loop will be purged free of air with nitrogen in the same
c manner as described for the Methanator via connections at the Ammonia

Converter (R-21 05) inlet and C-21 03 suction. The following equipment will
be included in this purge:
Synthesis Gas Compressor C-21 03

Synthesis Gas Compo Interstage Cooler E-2116 (Shell side)
Synthesis Gas Compo Interstage BFW Preheater E-2117A1B
Synthesis Gas Compo Interstage Chiller E-2129 (Tube side)
Synthesis Gas Compo First Stage Separator 0-2105
Ammonia Synthesis Loop Cooler E-2124 (Shell side)
Secondary Flash Separator 0-2106
Unitised Chiller E-2120 (Shell side)
Ammonia Converter Feed/Effluent Exchanger E-2121 (Tube side)
Synthesis Converter R-21 05
Start-up Heater H-21 02
Ammonia Converter Effluent/Waste Heat Boiler E-2123A1B (Shell side)
Ammonia Converter Feed/Effluent Exchanger E-2121 (Shell side)
Purge Gas Chiller E-2125 (Tube side)


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. Purge Gas Separator 0-2108

All inter-connecting piping for thE\8,PQve, equipment
II. In displacing air from the system, do not impose too high a pressure. A
positive pressure of 1 barg throughout the circuit will be sufficient for each
purge cycle. When tests indicate that the system is essentially air free (0.5%
O 2 or less), discontinue nitrogen introduction and leave the system under a
blanket of nitrogen.
5.2.12.5 Refrigeration System
c I. The refrigeration system will also be subjected to purging with nitrogen to free
the entire system of air. This can be accomplished through nitrogen
conneCtions being made at 0-2120,0-2121,0-2122 & 0-2123 and to the
suction and discharge circuits of C-21 05 Ammonia Refrigerant Compressor
and allowing the nitrogen to displace air to atmospheric vents. If required, in
order to expedite the purge, additional nitrogen may be introduced through
any convenient drain. Nitrogen will be steadily introduced until the system is
purged air free (0.5% O2 or less). However, the first ammonia brought into
the system must be used to sweep the nitrogen and remaining oxygen from
the system. The following eqUipment will be included in this purge:
Ammonia Let-down Orum 0-2107

4th Stage Refrigerant Flash Orum 0-2123
3rd Stage Refrigerant Flash Orum 0-2122
2nd Stage Refrigerant Flash Orum 0-2121
1st Stage Refrigerant Flash Orum 0-2120
Refrigerant Receiver 0-2109
Refrigerant Condenser E-2127 (Shell side)
Ammonia Refrigerant Compressor C-21 05
c Refrigerant Compressor 2nd Stage Intercooler

All the interconnecting piping for the above
equipment
E-2167 (Shell side)
II. The refrigeration system, including all the above associated equipment, will be
tightness tested to 3.5 barg with nitrogen. Inspect all flanges, valves and
fittings to verify that the system is tight.
III. ,The test pressure will be retained in this system so that liquid ammonia can be
later introduced to the system without the danger of overchilling eqUipment. As
a liquid level of ammonia is established in the Refrigerant Receiver vessel
(0-2109) the inerts (N2 ) will be vented as described later.
5.2.13 Commissioning HP Steam System
a) Prepare the boiler feed water treating systems and chemicals (morpholine, oxygen
scavenger and phosphate). Commission the Oeaerator and establish a low visible
water level in the steam drum using the Boiler Feed Water Pump P-2104A1B.
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Start chemical dosing units, V-21 06, V-21 07 & V-21 08 as filling commences in the
Deaerator and the Steam Drum. Lock open the boiler feed water outlet valves of
the E-2123 and E-21 03 exchangers.
b) The Primary Reformer fuel gas system previously commissioned with the controls
and shutdown circuits checked is now ready for continuous service. Purge the
firebox of the Primary Reformer with steam and start the Induced and Forced Draft
Fans, check for combustibles and fire the Auxiliary Boiler. The steam pressure
should be raised steadily until the desired pressure level is reached in accordance
with the procedure for the Heatup/Cool-down of Steam Drums (ODS-128) and
then operated as detailed in ODS-148, Operation of Steam Generatfon Equipment.
c c) The high pressure steam piping should be steam blown clean from the steam
drum to the HP/MP Letdown stations and to the inlets of the Synthesis Gas and
Ammonia Refrigerant Compressor high pressure turbines. The system should be
cooled and shocked several times to ensure all loose material is dislodged and
blown clear.
5.2.14 Check Relief Valve Settings
a) Once the piping has been cleaned and reassembled, the next step is to verify the
settings of the five relief valves protecting the high-pressure steam system and this
should be accomplished before the system is put in service.
b) Gradually increase the firing of the Auxiliary Boiler to pressures sufficient to check
each relief valve. The settings are as follows:
• PSV-D2101A 137.9 barg

• PSV-D2101B 142.0 barg
• PSV-H2101A 132.5 barg
c • PSV-H2101 B 136.5 barg
c) The verification of the fore-mentioned steam safety valves should be done under
the direct supervision of authorised persons, fully qualified, according to
established plant procedures and practices. Keep condensate drained at low
spots.
d) The high-pressure steam line should be blocked in at both upstream block valves
at the HP to MP letdown station; the inlet to C-2103(T), and the inlet to C-2105(T).
The 1 inch bypasses around the inlet block valves on both turbine inlets should be
opened and the vents just downstream of these block valves partially opened to
keep the high pressure steam line free of condensate.
e) After verification and successful operation of these safety valves and before
establishing a flow through PIC-1 013 letdown to the MP steam system, it is
recommended that the Superheater coil and the lines to C-21 03(T) and C-2105(T)
be blown with a good amount of steam to rid the lines of any contamination which
may be present. This is done by utilising the vent. These turbines may then be
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run in using air after which the steam drum pressure should be lowered to 60 barg.
Very slowly, gradually commission a flow of steam through PIC-1013. This will
require a good deal of attention in the firing of the Auxiliary Boiler of H-21 01 to
balance the load while maintaining about 60 barg steam pressure on the steam
drum. PIC-1 018 should be on manual at first so that the firing of the auxiliary
burners is as steady as possible. As conditions balance at PIC-1 013, the offsite
source of steam will be backed out of the 40 barg steam system.
5.2.15 Commissioning of Water Jacketing Systems
c Prior to plant start-up a flow of surface condenser condensate should be started to

the water jacketing system provided for the Primary Reformer Effluent Transfer Line
(V-2150), Primary Reformer Risers, Secondary Reformer (R-21 03), Secondary
Reformer Waste Heat Boiler (E-21 01) and the HP Steam Superheater (E-21 02).
Demineralised water should be used only in emergencies. The level alarm system
should be verified and in operation. This system will remain in service from this
point on. Always maintain the water jackets full at all times during plant operation. If
for any reason these jacket water levels are "lost" during operation, immediate unit
shutdown is mandatory. Starting water flow to these cooling jackets while they are
hot can result in serious equipment damage.
5.2.16 Precommissioning of NH3 Storage & Loading Facilities
Note: The following description of the Ammonia Storage & Loading Facilities is based
on the original design engineering package and reference should be made to the latest
issue of the Offsites P&ID's to identify any later changes or modifications.
a) Using P.& I. drawings, detail equipment drawings together with vendor drawings,
the NH3 Storage and Loading systems should be checked and punch listed for
c b)
completeness and correctness of construction and installation.
Internally inspect, clean and dry the Ammonia Storage Tank and associated
equipment.
c) Flow elements, restriction orifices, thermowells, relief valves, etc. must be

protected during pre-comrnissioning.
d) Flow meters on Ammonia Road Tanker loading arm supply lines should be
removed (Ensure replacement when pre-commissioning activities are
complete).
e) Ensure a record is kept listing all relief valves including those valves removed,
checked and re-installed after line cleaning.
f) Energise electrical power supply and energise and test Storage area distribution
circuits.
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g) Air blow inert gas lines to NH3 Storage area until clean and dry, then commission
inert gas generator and supply inert gas to the area.
h) Blow clean L.P. steam supply line to the NH3 Storage area and commission L.P.
Steam system.
i) Clean lube oil system on C-5101 Ammonia Refrigeration Unit and circulate oil until
clean. Run-in and trial run compressor under vendor's direction.
j) Before introducing ammonia into the storage systems, it is essential that all piping,
systems and related equipment including the outer annular spaces on both tanks;
are completely free of water and dry.
C. k) Prepare a detailed air blowing and drying procedure ensuring that the Ammonia
Storage tank is completely isolated from the associated piphig by blinding. Also
ensure that all piping inlets to compressors and Ammonia Heater (E-51 01) are
isolated and that the vapour balance line joining the two tanks is valved shut.
I) Air blow all lines using a dry filtered source of air and blow until completely clean
and dry. On completion of air blowing, make-up all joints and pressure test and
check leak free. (Exclude Ammonia Storage Tank from this test).
m) Ensure that the internals of Ammonia Heater (E-5101) have been inspected and
are clean and dry. Purge the heater shell with inert gas, then load methanol via
the hose loading connection and establish a normal working level as indicated by
the level gauge glass.
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6 INITIAL START-UP PROCEDURE
6.1 INTRODUCTION
The start-up procedure presented here is for the initial start-up of the ammonia unit.
In the course of subsequent start-ups, certain of these procedures may be eliminated
or modified in whole, or in part, as may be applicable to the particular situation.
Procedures for each section of the unit are handled separately in the write-up for
convenience in presentation. However, it should be recognised that many of these
c'
procedures may and should be performed concurrently so the unit start-up is co-
ordinated and expeditious.
As previously noted the steam requirement for the process and equipment operation
of the unit is produced from steam generating equipment that is an integral part of the
unit. However, some medium pressure' steam is available from an offsite source and
this will be used during the initial phases of the unit start-up. When an adequate
supply of steam is being generated in the unit's facilities, the start-up import steam will
be discontinued. The steam generating capacity within the unit is provided mainly by
the following equipment:
E-21 01 Secondary Reformer Waste Heat Boiler.
E-2103A1B HTS Effluent Waste Heat Boiler.
H-2101CB Auxiliary Boiler.
E-2123A1B Ammonia Converter Effluent Waste Heat Boiler.
c H-2101 BFW Coil
Although the above items of equipment are steam generators, there are other items of
equipment that provide preheat to the boiler feed water in recovering heat from the
process. The items of equipment that provide BFW preheat are as follows:
E-2131 - LTS EffluenVBFW Exchanger
E-2106 - LTS EffluenVLP BFW Exchanger
E-2117 - Synthesis Gas Interstage BFW Preheater.
Due to the fact that the steam generating equipment is an integral part of the process
eqUipment, the start-up has to be conducted in such a way to ensure that steam
production at each stage of the start-up is adequate to satisfy all steam requirements
of the unit. The unit "Steam Balances" are included in Section 4.0. of this manual.
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Whenever the sole source of MP Steam for the Ammonia Unit is from Offsites, the
superheat temperature of the MP steam generated in Offsites must be reduced to
399°C.
Prior to beginning the start-up activities, a systematic inspection should be made to

ensure that all required plugs and blinds are in place and that all unwanted blinds
have been removed, with particular attention paid to those under safety valves. Plugs
should be installed in all vents and drains. All instrument and restriction orifices
should be verified as replaced.
For the initial start-up all of the catalysts, except for one bed in the Ammonia
Converter, are in an oxidised state and must be reduced. On subsequent start-ups,
c" with catalyst maintained in the reduced state, the start-up would obviously be altered
to eliminate the reducing steps. It must also be recognised that oxygen (air} must not
be permitted to enter equipment containing reduced catalyst during start-ups.
As with any process unit the ultimate operating conditions and techniques will evolve
from experience gained during the initial and subsequent start up operations.
Consequently, it must be recognised that the start-up here presented is at best a
guide to help ensure an orderly initial start-up of the unit and conditions stipulated are
not rigid standards, unless specifically noted as such.
The initial start-up is greatly influenced by the necessity of reducing catalysts and
producing steam and that desulphurised feed must be introduced to the primary
reformer in the most expeditious manner to bring the unit on stream. The start-up
procedure is outlined briefly as follows:
a} Nitrogen is circulated for heating the primary and secondary reformers and the
HTS converter. Then use MP steam from Offsites to heat the primary and
secondary reformer and HTS catalysts.
c b} Hydrogen for reducing the LTS catalyst will be made available by dissociating
ammonia in H-21 01 primary reformer. This hydrogen is subsequently used for
hydrogenating and desulphurising the raw feed gas.
c} The air compressor and the exchangers E-2172 & E-2173 are used to circulate
and heat or cool nitrogen to supply carrier gas for reduction of the LTS converter
catalyst. Hydrogen from dissociated ammonia is used as the reducing agent.
There is also an alternative procedure in which desulphurised natural gas is used
on a once through basis using exchanger E-2173 to cool.
d} Dissociation of ammonia in the primary reformer is discontinued and the

desulphurised gas with excess hydrogen is substituted to produce hydrogen by
natural gas steam reforming. Air is injected into the secondary reformer and
temperatures raised to desulphurise the secondary reformer and the HTS
converter catalysts.
e} The CO2 removal system is commissioned and circulation of solution and removal
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of CO2 from the synthesis gas are established.
f) The LTS converter is commissioned and the synthesis gas is vented at the
Methanator inlet.
g) The Methanator is placed in service and the pure synthesis gas supply for
hydrogenation and desulphurisation can now be taken from this source.
h) The throughput is increased to generate enough steam to run the ammonia

refrigeration and synthesis gas compressors.
i) Commission the refrigeration system and start the synthesis gas compressor.
C~
j) The ammonia converter catalyst is then reduced. Specification ammonia product
is routed to storage and the plant is brought up to design throughput.
k) Commission the process condensate stripper.
The following start-up is presented in two parts. First the preliminary start-up
procedures, followed by a detailed unit start-up procedure. Once initiated, the start-up
is a continuous operation and is carried forward until the unit is "on-stream" producing
specification product. However, certain steps require time to complete, so down
stream equipment may be purged or commissioned during these periods to expedite
the unit start-up.
6.2 INSTRUMENT CALIBRATION
Before and/or during the process activation test, the following tests should be done to
C~, confirm that all the instruments work well.
This instrument test and repairing is very important. Negligence of the test may cause
serious damage to the equipment, the machine and/or personnel.
- Controller and Control valve test

- Block valve test
- Alarm test and indication on the FCS
- Trip test
- Interlock system test
These tests should be done under the instruction of the qualified instrument
personnel.
6.3 SURGE SYSTEM CHECKING

Refer to Vendor data
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6.4 TEST RUN OF THE MACHINES

Refer to Vendor data
6.5 PRELIMINARY START-UP PROCEDURES
The preliminary start-up (pre-commissioning) procedures have been described in

detail in Section 5.0 and the following is a brief summary of the principal steps:
a) With the cooling water and import steam system in service, carry-out the following:
c •
•
Commission instrument air system using import instrument air.
Commission electrical systems to lu~e oil pumps and instruments etc., on the
air compressor.
• Commission vacuum condenser equipment.
• Chemically clean compressor lube oil piping, fill with oil and circulate under
vendor's guidance.
• Start and run-in the process air compressor and its turbine under the direction
of the vendors' representatives. Note that the filter packs on Filter F-21 01
should be checked prior to starting the compressor to ensure that they are not
frozen and blocking the air inlet, and that the compressor suction line has been
thoroughly inspected and confirmed as being ciean.
• Trip test and run-in remaining compressor and pump turbines, uncoupled from
compressor/pump. The high pressure turbines of the synthesis gas
compressor and the refrigerant compressor may be run in and overspeed trip
tested using MP steam, before the HP steam becomes available.
c b) USing the air compressor, blowout process lines that are normally in gas service
and finally dry out. Temporary piping between the air compressor discharge and
process lines is required to achieve this. Note that a permanent air blowing and
catalyst dusting line is also provided to the process gas inlet line to the primary
reformer mixed feed coil.
c) Disconnect the burners, isolate and blow the fuel systems. Use steam and air
alternatively to optimise rust and scale removal. Air blow dry and install orifice plates
and strainers. Pressure test the fuel systems, make tight and leave blinded off
under a slight nitrogen pressure until required for service.
d) Flush all process lines using the medium best suited for the purpose i.e. water,
steam or air and finally dry out. Install orifice plates and control valves. Flush out
boiler feed water system, condensate system and demineralised water system and
ensure all lines are free of rust before commissioning steam traps.


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e) Prepare high pressure steam generating system for chemical cleaning. Install all
temporary pipes, etc. make up alkaline boil-out solution and then chemical cleaning
solution. The detailed procedure and the installation of temporary piping are
explained separately in procedure ODS-121 contained in the General Procedures
Manual.
f) In the absence of any recommendations by the vendor of the refractory, the

following procedure is recommended for furnace refractory dry-out for all furnaces:
• Using maximum excess air, fire off rnaximum required number of burners with
minimum sized flames and slowly raise radiant zone outlet temperature to 121°C
at approximately 15°C/hr. for 24 hours.
(' • Raise temperature to 205°C at same rate and hold for an additional 72 hours. If
fuel gas is available use maximum pilot burners and rotate main burners ...
Great care must be taken to minimise local overheating of refractory and/or

respective catalyst tubes. Ensure that 1.0. fan has been safely tested and that stack
dampers are suitably positioned so that design drafts are not exceeded in the
primary or auxiliary boiler fire boxes to avoid possible damage to floors.
g) On completion of chemical cleaning and furnace refractory dry-out, the steam

generating system temporary piping is removed. The steam drum is inspected and
finally buttoned up and left under a nitrogen blanket and/or is refilled with deaerated
BFW and pressure tested. All leaks are made good. The steam system is then
ready to generate steam when required for relief valve testing etc.
h) The CO2 removal system should already have been charged with packing and
demineralised water. The pumps are run and checked. To permit circulation at a
low rate nitrogen pressure at about 8 barg is used in the CO2 absorber. The
chemical cleaning (degreasing) of the CO 2 removal system can be initiated as soon
( after the steam generating system as is convenient. The procedure is described in
the General Procedures Manual and once done the solution can be made up and
retained in the storage tank. The CO2 removal system must be blanketed with
nitrogen to prevent oxidation of the internal surfaces.
i) If not done already, charge the catalyst in the manner described in the General
Procedures Manual to the Hydrogenator, Desulphurisers, Primary Reformer,
Secondary Reformer, High and Low Temperature Shift Converter, Methanator and
Ammonia Converter. Use vessel drawings to ensure proper loading.
j) The air compressor is used for dusting catalysts that have been loaded to the
various reactors, Each vessel is blown sequentially to atmosphere, or to a suitable
exit to remove maximum dust from the system. During this operation, care must be
taken not to exceed design pressure drops over the vessels. The blow is complete
when no more dust appears in the exit air.
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subjected to pressure (leak) testing. This test is performed with air using C-2101 Air
Compressor and is intended to confirm that all flanges, vents, drains and other items
of equipment and their connections are closed and not leaking.
I) The feed desulphurisation section, Primary and Secondary Reformers, HTS

converter and the Raw Gas Separator, are isolated from the remainder of the unit
and pressure tested as a unit. The Methanator, LTS Converter and downstream
equipment is also pressure tested and then purged with nitrogen to reduce oxygen
content to less than 0.5% by volume.
m) When tightness testing is completed on the front end, blind isolate the Hydrogenator
and Desulphurisers from the Primary Reformer to avoid hydrocarbons entering the
c Reformer before required.
n) The Auxiliary Boiler will be fired to produce steam for testing HP steam system relief
valves and also to produce HP steam. When this is completed, the Refrigeration
Compressor may be run-in on air. On completion, the steam drum pressure will be
lowered to 60 barg and let-down into the medium pressure steam system
commenced in preparation for starting up the ammonia plant.
6.6 INITIAL UNIT START-UP PROCEDURE
For the initial start-up, all catalysts have to be reduced and/or desulphurised before
fresh feed can be introduced to the unit. On this plant the reducing gas is a
hydrogen/nitrogen mixture made by dissociating liquid ammonia in the H-2101 primary
reformer.
This procedure assumes that preliminary start-up preparations as summarised in the

previous sub-section 6.2. and described in detail in the General Procedures Manual,
c have been completed and the necessary utilities have been made available.
With all systems pressure tested, purged and under nitrogen pressure, the suggested
initial start-up programme is as follows:
6.6.1 Commission Deaerator V-21 01

The V-21 01, deaerator, should be placed in service to supply water to the utility and
ammonia plant's boiler feedwater systems. Manual adjustment of the PIC-1 031
bypass valve may be required to obtain adequate steam pressure during start-up
conditions.
Start the V-21 01 as follows:

a) It is assumed that the V-21 01 has been mechanically / chemically cleaned,
flushed, piping has been flushed to the pumps, LP steam has been placed in
service and piping has been blown to V-21 01, and the unit has been inspected.
b) The oxygen scavenger, ammonia injection and boiler chemical injection systems


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should be run-in, filled, and ready to operate prior to starting the deaerator.
c) Open the deaeration section atmospheric vent valve fully to SP-032.
d) Fill the storage section with demineralized water from the offsite demineralized
storage pumps through FIC-1056 on manual control until a normal level has been
established. Fully open the bypass around E-21 06.
e) Unblock and place LlC-1031 in automatic.
f) Start a small flow of LP steam to the V-21 01 using PIC-1031 on manual.

Pressure can be verified locally on PI-6660, PI-6661 and PI-1762. As flow is
c increased, a short vapour plume should be seen coming from the atmospheric
vent.
CAUTION
Steam must be admitted slowly into the system to prevent thermal shock and water
hammer dama}<e to the deaeration section.
g) Continue increasing the steam flow slowly until the deaerator pressure reaches
2.7 bara then place PIC-1031 in automatic.
h) Reduce SP-032 isolation valve until the steam vapor plume is about 1 meter long.
i) Start the oxygen scavenger pump and test for residual chemical and oxygen
content after a short period of time.
j) Start the Ammonia Injection pump and test for pH after a short period of time.
k) Place FIC-1056 in automatic at a flow to maintain the level for a short period of
c time. Manually adjust the output of LlC-1030 to match the setpoint of FIC-1056
then put FIC-1056 in remote. Once the level is stable, place LlC-1030 in
automatic.
I) Start-Up the P-2104B pump as per the vendor's instructions and establish a low
working level in D-2101 steam drum.
6.6.2 Reformer Start Up Sequence Logic Description
This section describes the instrumentation logic controlling the interlocks and timers
associated with each set of reformer burners and should be read in conjunction with
sections 11.2.4 to 11.2.7
General Notes
a) Permissives are conditions that are checked at a particular time to confirm that an
action is allowed to proceed. Their condition has no effect except at the time they
are checked.
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b) Trips are active at all times. A trip will be initiated any time that the corresponding
variable is in the trip range, unless it is specifically over-ridden. All trips must
therefore be cleared to allow start-up and the conditions must remain good after
start-up.
c) Indication of a trip does not necessarily indicate that a complete trip of the entire
reformer or an entire burner set is initiated.
d) All indicator lamps mentioned in this description are located on the Local control
panel
6.6.2.1 Auxiliary Boiler Burners
The Aux Boiler must be started first.
c The first stage in starting the Aux boiler is to purge the entire reformer.
Permissives to start purging are: -
Aux Boiler Draft OK (21-PT-1060AlB/C)

Aux Boiler FG to main burners depressured (21-PT-1230AlB/C).
Aux Boiler FG to pilot burners depressured (21-PT-1235A1B/C).
Aux Boiler pilot gas valves closed.
Aux Boiler combustion air flow above minimum (21-FT-1177).
Aux Boiler pilot burners not lit.
Aux Boiler all main flames dark.
Arch Draft OK (21-PT-1 058A1B/C)
Arch Burners FG to burners depressured (21-PT-1475-1479NAlNB/NC).
Arch Burners FG to burners gas valves closed.
Arch Burners combustion air flow above minimum (21-FT-1181).
c Superheater FG to main burners depressured (21-PT-1240AlB/C).

Superheater FG to pilot burners depressured (21-PT-1245A1B/C).
Superheater all flames dark.
Superheater FGto main bumers gas valves closed.
Superheater FG to pilot burners gas valves closed.
Tunnel Burners FG to burners depressured (21-PT-1570AlB/C).
Tunnel Burners FG to burners gas valves closed.
Aux Boiler trips are: -
Aux Boiler Draft HH pressure (21-pt-1 060AlB/C)

Steam Drum LL level (21-LT-1223A1B/C)
ID Fan stopped (21-ZS-3401/3401 Al3401 B)
Aux Boiler Combustion Air LL pressure (21-PT-1410AlB/C)
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Aux Boiler FG to main burners HH pressure (21-PT-1231 AlB/C)- main

burners only.
Aux Boiler FG to main burners LL pressure (21-PT-1230AlB/C)- main burners
only.
Aux Boiler FG to pilot burners HH pressure (21-PT-1236A1B/C)- pilot burners
only.
Aux Boiler FG to pilot burners LL pressure (21-PT-1235A1B/C)- pilot burners
only.
Superheater steam HH temperature (21-TT-1 088/1218/1219)
Aux Boiler Main burners loss of all flames (21-BE-1 055/6/7/8)
Aux Boiler Pilot burners loss of all flames (21-BE-1005/6/7/8)
c a) Ensure that no trips (except fuel gas pressure) are active, and then reset the
trip logic by pressing 21-HS-1 044 (located in CCR).
b) When all permissives are satisfied the operator can start the purgeichecking
sequence by pressing 21-HS-1236 (on Local Panel). This starts the 20 minute
purge timer and lights the "Purging" indicator lamp (21-XL-1236A).
c) At the end of the 20 minute period the "Purge Complete" lamp «21-XL-1236B)
is lit for 30 seconds the tightness check is autornatically started.
d) The fuel gas headers to the pilot and main burners are pressurised with
checking gas (21-XV-1231A1B, 21-XV-1236A1B are opened, 21-XV-1231C,
21-XV-1236C are closed). At the same time the vent valve of the double block
and bleed on each fuel gas header is forced closed (21-XV-1230C 21-XV-
1235C) and the downstrearn block valve in the fuel gas lead to each burner is
forced open (21-XV-1230-1 to 21-XV-1230-4 and 21-XV-1235-1 to 21-XV-
1235-4) so that the burner cocks are tested, and the "Checking" lamp
«21-XL-1236C) is lit.
e) The checking gas valves remain open for 30 sec, during which the header
c pressure rises far enough to ensure that the checking permissive switches (21-
PSL-1132, 21-PSL-1137) are satisfied. The checking gas supply is then
disconnected. The pressure in the headers must be rnaintained for 90 sec
(therefore a rninimum of 60 sec after the removal of the checking gas) in order
to successfully cornplete the tightness test. If the pressure is not maintained,
the "Checking Failed" lamp (21-XV-1136D) is lit after 2 minutes and the
purge/check sequence must be restarted after the problem is cleared.
f) If the tightness check is successful, the "OK to Open Pilot FG Valves" lamp
(21-XL-1235) is lit. The operator must then press the "Start Pilots" switch (21-
HS-1235, on Local Panel) to initiate the pilots' start-up over-ride latch-up tirner
. within 140 sec from the start of the tightness test. This initiates a timed (2 - 5
minute) over-ride on the header gas pressure trips, opening the header block
valve (21-XV-1235A) and closing the header vent (21-XV-1235C). If this switch
is not pressed within the required tirne, the perrnissive is lost and the
purge/check cycle must be restarted.
g) After the timer expires, a pilot flame must be detected to allow the pilot header
gas valves to remain open.
h) Once the latch-up timer has been activated to set the over-ride, the operator

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can light off the first pilot burner by pressing the appropriate "Light Pilot Burner
No.x" switch (21-HS-1237A1B/C/D, on Local Panel) after opening the individual
pilot cock valve. This action opens the block valve in the individual pilot burner
lead, and activates the selected pilot burner's ignitor. These actions are
maintained for 15 seconds by a pulse timer. After the 15 sec period has
elapsed a flame must be detected for the gas supply to the pilot burner to be
maintained.
i} Detection of a pilot flarne and satisfactory pilot fuel gas header pressure will
light the "OK to Open Main FG Valves" lamp (21-XL-1230) and enable the
main burners over-ride latch-up timer. The first pilot flame must be detected
within the period of the pilot over-ride latch-up timer, otherwise the permissive
is lost and the purge/check cycle must be restarted.
c j) At this point the operator can decide either to continue and light the other pilot
burners or to light the main burner corresponding to the pilot that is already lit.
Since a flame at the corresponding pilot is a permissive to light a main burner,
the operator can not at this stage choose to light any other main burner.
k} If the operator decides to light the remaining pilots he proceeds by opening the
appropriate burner cocks and pressing each of the remaining "Light Pilot
Burner No.x" switches (21-HS-1237AlB/C/D, on Local Panel) in turn.
I} This condition is stable and there are no timer constraints on proceeding to
light the main burners. All trip initiators are active.
m} When the operator is ready to light the main burners he presses the "Start
Main Burners Fuel Gas" switch (21-HS-1230, on Local Panel) to initiate the
main burners over-ride latch-Up timer. This initiates a timed (2 - 5 minute) over-
ride on the header gas pressure trips to allow the fuel gas supply to be
connected and the burners to be lit.
n} The operator may then open the rnain burner cocks and press the "Light Main
Burner No.x" switch (21-HS-1238A1B/C/D, on Local Panel). This action opens
the main header FG block valve (21-XV-1230A), forces the header vent valve
(21-XV-1230C) closed, and opens the block valve (21-XV-1230-1-4) in the
individual burner lead. These actions are maintained for 15 seconds by a pulse
c/ timer. After the 15 sec period has elapsed a flame must be detected for the
gas supply to be maintained. The first burner rnust be lit within the period of
the over-ride timer, but once one flame is detected the header valves remain
open and the other burners can be lit at any time.
6.6.2.2 Arch Burners
After the Aux Boiler has been started, the next section to be lit should be the Arch
Burners.
Permissives to light the Arch Burners are: -

Arch Draft OK (21-PT-1058A1B/C)
Arch Burners FG to burners depressured (21-PT-1475-1479D/ElF).
Arch Burners FG to burners gas valves closed.
Aux Boiler FG to main burners FG valves open.
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Arch Burner trips are:-

Arch Draft HH pressure (21-PT-1059A1B/C)
Arch Burners Cornbustion Air LL pressure (21-PT-1473A1B/C)
Superheater stearn HH ternperature (21-TT-1 088/1218/1219)
Arch Burners FG to burners LL pressure (21-PT-1475-1479A1B/C/D/ElF)
Arch Burners FG to burners HH pressure (21-PT-1475-1479A1B/C/D/ElF)
Drum LL level (21-LT-1223A1B/C)
Reformer Feed LL flow (21-FT-1201A1B/C)
Reformer Feed Steam LL flow (21-FT-1202A1B/C)
c Reformer Feed Steam/Carbon LL ratio (21-FFSLL-1201A1B/C calculated)
a) Ensure that no trips are active, and then reset the trip logic by pressing
21-HS-1045 (located in CCR).
b) When all permissives are satisfied the operator can start the checking
sequence by pressing 21-HS-1221 (on Local Panel). Ensure that HIC's-1035
to -1039 are open.
c) The fuel gas leads to the burners are pressurised with checking gas (21-XV-
1270AlB are opened, 21-XV-1270C is closed)., and the "Checking" lamp
(21-XL-1221A on the local panel) is lit.
d) The checking gas valves remain open for 20 sec, during which the header
pressure rises far enough to satisfy the checking permissive switches (21-PSL-
1161-1165). The checking gas supply is then disconnected.
e) The pressure in the headers must be maintained for 90 sec (therefore a
minimum of 70 sec after the removal of the checking gas) in order to
successfully complete the tightness test. If the pressure is not maintained, the
"Checking Failed" lamp (21-XV-1221 B) is lit after 110 sec and the check
sequence must be restarted after the problem is cleared.
f) HIC's-1035 to -1039 must now be closed. PCV's-1123 to -1127 in the
c bypasses around the HIC's will open to ensure that when the burners are lit
they will be at the minimum firing position. If the tightness check is successful,
the "OK to Open FG Valves" lamp (21-XL-1220) is lit. The operator can then
press the "Open FG Valves" switch (21-HS-1220, on Local Panel) to initiate the
burner start-up over-ride latch-up timer.
g) This initiates a timed (2 - 5 minute) over-ride on the burner gas pressure trips
allowing the fuel gas valves to open and the burners to be lit. This switch must
be activated before test pressure in the headers has been lost (in the case of
the Arch Burners this would be due only to leakage). If this switch is not
pressed within the required time, the permissive is lost and the check cycle
must be restarted. Lighting of the burners is achieved by opening the individual
burner cock valves and using an ignition torch temporarily connected to the
burner fuel gas supply. There is one flame failure detector per row of Arch
burners. The burner with this device should be lit first.
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6.6.2.3 Tunnel Burners
Permissives to light the Tunnel Burners are: -

Arch Draft OK (21-PT-1058A1B/C)
Tunnel Burners FG to burners depressured (21-PT-1570AlB/C).
Tunnel Burners FG to burners gas valves closed.
Tunnel Burners checking gas valves closed.
Tunnel Burners trips are: -
Arch Draft HH pressure (21-PT-1059A1B/C)
Arch Burners tripped (initiators listed above)
c Tunnel Burners FG to burners LL pressure (21-PT-1569A1B/C, 21-PT-

1570AlB/C)
Tunnel Burners FG to burners HH pressure (21-PT-1569A1B/C, 21-PT-
1570AlB/C)
21-HS-1563 (in CCR).
sequence by pressing 21-HS-1560 (on Local Panel).
c) The fuel gas leads to the burners are pressurised with checking gas (21-XV-
1561/2 are opened, 21-XV-11563 is closed), and the "Checking" lamp
((21-XL-1560A on local panel) is lit.
d) The checking gas valves remain open for 20 sec, during which the header
pressure rises far enough to satisfy the checking permissive switch (21-PSL-
1571). The checking gas supply is then disconnected.
e) The pressure in the headers must be maintained for 90 sec (therefore a
minimum of 70 sec after the removal of the checking gas) in order to
successfully complete the tightness test. If the pressure is not maintained, the
c "Checking Failed" lamp (21-XV-1560B) is lit after 110 sec and the check
sequence must be restarted after the problem is cleared.
f) If the tightness check is successful, the "OK to Open FG Valves" lamp
(21-XL-1561) is lit. The operator can then press the "Open FG Valves" switch
(21-HS-1561, on Local Panel) to initiate the burner start-up over-ride latch-up
timer. This initiates a timed (2 - 5 minute) over-ride on the burner gas pressure
trips allowing the fuel gas valves to open (XV-1564 and XV-1565), the vent valve
to close (XV-1566) and the burners to be lit. This switch must be activated
before test pressure in the headers has been lost (in the case of the Tunnel
Burners this would be due only to leakage). If this switch is not pressed within
the required time, the permissive is lost and the check cycle must be restarted.
Lighting of the bumers is achieved by opening the individual burner cock valves
and using an ignition torch temporarily connected to the burner fuel gas supply.
supply.
6.6.2.4 Superheater Burners
Permissives to start the Superheater Burners are: -
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Arch Draft OK (21-PT-1 058A1B/C)

Superheater FG to main burners depressured (21-PT -1240AlB/C).
Superheater FG to pilot burners depressured (21-PT-1245A1B/C).
Superheater FG to rnain burners gas valves closed.
Superheater FG to pilot burners gas valves closed.
Superheater checking gas valves closed.
Superheater trips are: -
Superheater steam HH temperature (21-TT-1088/1218/1219)
Arch Draft HH pressure (21-PT-1 059A1B/C)
Aux Boiler Main burners tripped (initiators listed above)
c" Arch Burners tripped (initiators listed above)

Superheater FG to burners LL pressure (21-PT-1240AlB/C)
Superheater FG to burners HH pressure (21-PT-1241 AlBIC)
Superheater burners loss of all flames (21-BE-1 035-1 054)
21-HS-1046 (in CCR).
sequence by pressing 21-HS-1246 (on Local Panel).
c) The fuel gas headers to the pilot and main burners are pressurised with
checking gas (21-XV-1241A1B & 21-XV-1246A1B are opened, 21-XV-1241C &
21-XV-1246C are closed). At the same time the vent valve of the double block
and bleed on each fuel gas header is forced closed (21-XV-1240C 21-XV-
1245C) and the downstream block valve in the fuel gas lead to each burner is
forced open (21-XV-1240-1 to 21-XV-1240-10 and 21-XV-1245-1 to 21-XV-
1245-10) so that the burner cocks are tested, and the "Checking" lamp
c" (21-XL-1246A on the local panel) is lit.

d) If the tightness check is successful, the "OK to Open Pilot FG Valves" lamp
(21-XL-1245) is lit. The operator must then press the "Start Pilots" switch (21-
HS-1245, on Local Panel) to initiate the pilots' start-up over-ride latch-up timer
within 115 sec from the start of the tightness test.
e) This initiates a timed (2 - 5 minute) over-ride on the header gas pressure trips,
opening the header block valve and closing the header vent. If this switch is
not pressed within the required time, the permissive is lost and the check cycle
must be restarted. After the timer expires, a pilot flame must be detected to
allow the header gas valves to remain open.
f) Once the latch-up timer has been activated to set the over-ride, the operator
can light off the first pilot burner by pressing the appropriate "Light Pilot Burner
No.x" switch (21-HS-1242A-J, on Local Panel) after opening the individual
pilot burner cock valve. This action opens the block valve in the individual pilot
burner lead, allowing the operator to ignite the burner. This action is
elapsed a flame must be detected for the gas supply to the pilot burner to be


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maintained.
g) Detection of a pilot flame and satisfactory pilot fuel gas header pressure will
light the "OK to Open Main Burners" lamp (21-XL-1240) and enable the main
burners over-ride latch-up timer. The first pilot flame must be detected within
the period of the pilot over-ride latch-up timer, otherwise the permissive is lost
and the purge/check cycle must be restarted.
h) At this point the operator can decide either to continue and light the other pilot
burners or to light the main burner corresponding to the pilot that is already lit.
Since a flame at the corresponding pilot is a permissive to light a main burner,
the operator can not at this stage choose to light any other main burner.
i) If the operator decides to light the remaining pilots he proceeds by opening the
individual pilot burner cock vale and then pressing each of the remaining "Light
c Pilot Burner No.x" switches (21-HS-1242A-J, on Local Panel) in turn and

lighting the corresponding burner.
j) This condition is stable and there are no timer constraints on proceeding to
light the main burners. All trip initiators are active.
k) When the operator is ready to light the main burners he presses the "Open
Main FG Valves" switch (21-HS-1240, on Local Panel) to initiate the main
burners over-ride latch-up timer. This initiates a timed (2 - 5 minute) over-ride
on the header gas pressure trips to allow the fuel gas supply to be connected
and the burners to be lit.
I) The operator may then open the individual burner cock vale and press the
"Light Main Burner No.x" switch (21-HS-1244A-J, on Local Panel). This action
opens the main header FG block valve, forces the header vent valve closed,
and opens the block valve in the individual burner lead. These actions are
elapsed a flame must be detected for the gas supply to be maintained. The
first burner must be lit within the period of the over-ride timer, but once one
flame is detected the header valves remain open and the other burners can be
lit at any time.
c 6.6.3 Start Auxiliary Boiler
a) Establish demineralised water level in Deaerator V-21 01 and start BFW Pump
P-2104B on closed circulation to V-21 01. Establish normal operating conditions
in V-2101 and establish normal working level in Steam Drum D-21 01.
b) With induced and forced draft fans in operation and suitable draft conditions in
the Auxiliary Boiler and Primary Reformer fireboxes, light one burner in the
. auxiliary boiler and adjust firing rate to raise steam and slowly increase steam
drum pressure. Keep careful check on steam saturation temperatures as per
procedure ODS-128 - "Procedures for Heat-up/Cool-down of Steam Drums"
included in the General Procedures Manual.
c) Raise steam from D-2101 whilst increasing auxiliary boiler burner load as
necessary. Fire the Superheater burners and set the attemperator temperature
controller HIC-1007 as required to superheat the HP steam exiting the superheat
coils in H-2101 convection section, towards design.
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d) Initially use the start-up vent SP-154 to vent superheated HP steam and increase
steam drum pressure to about 60 barg before introducing steam into the MP
steam header via HV-1028 and desuperheating in SP-139A1B. As the auxiliary
boiler load increases, let down MP steam into the LP steam header via PV-1016
and desuperheat in SP-138 as necessary. Back-out the offsite MP steam
import as necessary.
e) When the steam generating system is in normal operation, the required chemical
dosing should be started to thedeaerator (oxygen scavenger and morpholine)
and the steam drum (phosphate). Steam drum blow-down should be started to
control total solids in the steam drum water and a regular sampling and
c laboratory analysis procedure must be started. It is important that strict

attention is paid to the quality of the boiler feed water and full details of
Steam Generation Operation are given in 00S-148 included in the General
Procedures Manual.
f) It should also be noted that when the unit is in normal operation, conductivity
meters and alarms are provided on various condensate streams to detect any
serious contamination from process equipment. If at any time, contamination
occu'rs and is alarmed by high conductivity, then the contaminated water stream
must be immediately routed to drain until the problem is resolved. The following
is a list of water streams so protected by conductivity meters fitted with alarms:
• AI-1 015 on demineralised water routed to deaerator from exchangers E-2106,

& E-2117.
• AI-1017 on stripped condensate stream from Process Condensate Stripper,

T-2150 routed to Offsites Demineralised. Plant.
c • AI-1018 on Condensate from E-2140 Surface Condenser normally routed to

offsite Polisher/Demineralised. plant.
6.6.4 Start E-2140 Surface Condenser (Refer to the Vendor drawings for E-2150)
NOTE
If all the steam turbines on the E-2I40 vacuum system are not ready for vacuum, install
blinds in the respective vacuum exhaust lines of the turbines upstream of the isolation
vales, if required.
The procedure for commissioning the E-2140 surface condenser, is as follows:
a) start a warming flow of LP steam to the inter and after-condenser jets as well as to the
hogging jet
b) Open cooling water to E-2127, if not already open, which is the supply cooling water of

$M.W. Kellogg Limited Operating Manual

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E-2140.
c) Open the cooling water outlet valve for E-2140 and E-2150 to establish a flow of cooling
water through the tubes. Bleed the air out of the system using the top vents.
d) Establish a level in E-2140 hot well by flowing water from the demineralized water
supply using line DM1 01 0-1.5".
e) Close the header isolation valve and the drain to the sewer downstream of LV-1 019 and
LV-1019 bypass.
h) open the seal flushing supply and return lines on both P-2112 pumps and the suction
side equalizing lines back to E-2140 for both purnps
i) place LlC-1019 in manual and closed, watch LlC-1019 and level glass LG-1619 and
stop filling when the level reaches 80% by closing the valve in line DM1 01 0-1.5".
j) close the atrnospheric relief valve, if open
k) check that the condensate lines are all isolated (if this is the first condenser started) .
I) start one P-2112 pump, and it will recycle through FIC-1032.
m) isolate the inter and after condenser shell side condensate traps and open the drains to
the sewer
c n) place the LP steam to the hogging jet, one set of inter-condenser jets and one set of
after-condenser jets in service to start pulling a vacuurn on E-2140
WARNING
When placing the jets in service, ALWAYS open the steam supply valves FIRST and
start a flow of steam to the jet THEN open the lines from the surface condenser (or
from the inter-condenser jet exhaust as the case may be).
When shutting down one set of condenser jets or the hogger jet, ALWAYS close the
eductor isolation valves FIRST - THEN close the steam supply to the jet.
Failure to do these operations in the right order will allow air to backflow into the
surface condenser causing loss of vacuum and possible plant shutdown and tnrbine
damaf(e.

<
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CAUTION
After the steam is open to the jets on the inter and after-condenser, open the eduction
line to the after-condenser jet FIRST then open the eduction line to the inter-condenser
because the supply for the after-condenser jet is the exhaust of the inter-condenser jet.
To take the jets out of service, reverse the order, inter first off, then after, then steam.
0) Put a small flow of condensate from the P-2112 discharge header to the atmospheric
relief valve seat to seal it. Only a very small trickle of water out of the overflow line is all
that is required to assure sealing.
C p) Open the bypass around the P-2112A discharge check valve to keep a flow through the
pump.
q) When the condensate from the inter and after-condenser shell drains is clear, close the
drains FIRST then open the bypasses around the traps to reclaim the water.
Commission the traps after the condensate has had some time to clean the lines back
to the condenser.
WARNING
Bypassing the condensate traps may cause a sudden loss of vacuum if air is drawn
through the jet condenser into the E-2140. It is better to isolate the trap and take the
condensate to the drain.
Failure to do these operations correctly will allow air to backjlow into the surface
condenser causing loss of vacuum and possible plant shutdown and turbine damage.
C.' r) Maintain the level by opening the line DM1 01 0-1.5" to fill.
s) The hogging jet can be taken out of service as soon as the inter and after-condenser
jets can handle the air leakage. This is not usually possible until all of the condensing
turbines are in service. The amount of air leakage is measured on a gauge on the inert
outlet line of the after-condenser.
NOTE
The hogging jet can not pull the vacuum below about 97 mm Hg (abs) and will limit the
vacuum to that amount until it is taken out of service.
t) Once a condensing turbine is placed in service, the level will rise in the surface
condenser. The water quality will NOT be good enough to use for pump seal flushing or
exporting to offsites for some time. If the level increases, open the manual drain valve
downstream of LV-1019 to the sewer and drain the condensate until the quality is
acceptable for use in other parts of the plant.
u) Watch the E-2140 vacuum on PI-106S. C-2102JT and C-2103JT turbines can be
C~ started as soon as the vacuum reaches 97mmHg
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6.6.5 Nitrogen Heating of Hydrogenator, Desulphuriser, Primary & Secondary Reformers

and HTS Converter catalysts.
a) Using the HP case of the process air compressor, circulate nitrogen around the
following circuit:
• Compressor C-21 01 discharge to the Feed Gas preheat coil via start-up line
PG 1044-6" and then to the Hydrogenation reactor R-2160, Desulphurisers
. R-2180AlB, Primary Reformer mixed feed coil and to Primary Reformer
H-2101.
c •
•
From H-2101 to the Secondary Reformer R-21 03
From R-21 03 outlet through E-2101 and E-21 02 to HTS converter R-21 04.
• From outlet of R-21 04 to E-2103A1B and then though line PG1 040-1 0" back
to the suction line of the HP case of C-2101 air compressor via the LP case
intercooler and separator package E-2142/D2142.
Other lines associated with the circuit should be closed off.
Prior to the pressuring with nitrogen, the H-2101 tube outiet headers should be
checked for water. Remove carefully the blank covers on the drains provided
and make sure any water is drained off. When completely sure free of water
replace the blank covers.
b) The system is purged with nitrogen (make up via N1 01 0-2") until the oxygen
level is 0.5% vol or less and then pressured to about 5 barg with nitrogen. Admit
steam to the turbine and start the air compressor with the LP case vented to
c atmosphere. Gradually increase the compressor speed to above the minimum

governor setting and establish circulation. Add nitrogen to the system as
required to keep the HP case suction pressure at minimum of 3 barg to prevent
ingress of air.
c) When the compressor operation is stabilised and H-21 01 furnace radiant section
is rechecked for adequate draft conditions, begin firing H-2101 burners as
required to raise the catalyst tube outlet temperatures to approximately 350°C at
30 to 40°C/hr.
NOTE: TO AVOID OVER FIRING FOR PROCESS CONDITIONS DURING

STARTUP. IT IS ESSENTIAL THAT ATTENTION IS PAID TO THE LOWER
LEVELS OF FUEL GAS PRESSURE REQUIRED UNTIL ALL BURNERS ARE
ALIGHT.
TO ENSURE AN EVEN RELEASE OF HEAT THROUGHOUT THE FURNACE

DURING STARTUP. BURNERS SHOULD BE CAREFULLY SPACED AND


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FOR THIS PURPOSE IT IS RECOMMENDED THAT BURNERS BE COLOUR

CODED ANDIOR NUMBERED AND THEN LIT IN A SPECIFIED ORDER.
CATALYST TUBES MUST BE VISUALLY INSPECTED AT FREQUENT

INTERVALS USING AN OPTICAL PYROMETER AND THE TUBE OUTLET
TEMPERATURES AND FLUE GAS TEMPERATURES AND OXYGEN
CONTENT CAREFULLY MONITORED. IMMEDIATE ADJUSTMENTS MUST
BE MADE TO THE BURNER FIRING SHOULD ANY EXCESSIVE
TEMPERATURE DIFFERENTIALS OCCUR.
d) The catalyst in the secondary reformer will be heated by the nitrogen flow.
c
E-21 01 and E-21 02 will be warmed up and then the HTS converter will be
heated.
e) HTS converter catalyst must not be dry heated above 150°C. With the steam
drum in operation there may be some heat pick up from E-2101/E-21 02, if
this is the case, TIC-1004 and/or TIC-1 01 0 may be manipulated to control
the temperature entering the HTS.
f) During the above steps, cooling water flows will be started to the water
jackets on the Secondary reformer R-21 03 and Primary Reformer Effluent
Transfer Line V-2150.
6.6.6 Steam Heating of Primary, Secondary and HTS Catalysts
a) When the primary reformer tube outlet temperatures reach approximately 350°C,
MP steam will be introduced to the mixed feed coil via the normal 12" process
steam line MPS-1006-12". Note that whereas the feed gas preheat coil is
designed for zero flow, some MP steam will be admitted to the steam/air coil via
MP steam line MPS1 004-8" to keep outlet Jemperature below the coil design
c temperature.
b) The process air compressor will be shut down as soon as the steam flow to the
mixed feed coil has been started at the rate of 15 to 20 MT.hr., going to vent at
the inlet of the HTS converter. Start a warming steam flow through MP steam
line MPS1003-4" to the outlet line of the HTS converter and put a flow of steam
back up through the bed holding the back pressure at 7 to 10 barg by throttling
the HTS inlet vent. With the steam flow established, condensate accumulated in
E-21 01, E-21 02 and the HTS outlet line must be drained off.
c) Start to increase primary reformer firing rate so that the tube outlet temperature
o
increase at 30 to 40 C/hr. until 750°C is reached. [Refer to NOTE on previous
pageof this section]. At the same time the steam rate is slowly increased
through FRC-1002 to 25,000 kg/hr. Reformer temperature and pressure design
limitations should not be exceeded.
d) The steam side of the primary waste heat boiler E-2101 must be closely watched
by monitoring the inlet and outlet temperatures across the boiler. If circulation


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has not started when the outlet temperature of the secondary reformer (TR-
1334NB) has reached 540°C, this temperature must be held and not exceeded
until circulation is established. When boiler is circulating steadily, the steam
drum pressure is slowly raised to approximately 125 barg.
e) The primary reformer outlet temperatures will be held at 750°C for 6 to 8 hours in
order to allow the potash that has been evolved to recombine with catalyst. At
the end of this period, the tube outlet temperatures will be raised to
approximately 815°C for catalyst reduction.
6.6.7 Reduction of Primary, Secondary and HTS Catalysts.
c a) When the primary reformer outlet temperatures reach 815°C, reduction of the
primary, secondary and HTS catalysts will be carried out using hydrogen
produced by dissociating liquid ammonia in the primary reformer.
b) Warm liquid ammonia will be supplied from the offsite heater E-5101 at 31.5°C
into Refrigerant Receiver D-2109. This transfer should be carefully monitored to
ensure that D-21 09 design minimum temperature is not exceeded. From
D-21 09 it will be injected via the start-up line AM1 065-2" between P-2120NB
discharge line and the primary reformer mixed feed coil inlet at an initial flow rate
of 500 to 1,000 kg/hr and a supply pressure of at least 12 barg The ammonia
will dissociate and flow, mixed with the steam, through the H-2101 catalyst filled
tubes and R-2103 catalyst bed to the vent V-1 005-18" at the HTS converter inlet.
Over a period of about one hour, gradually increase the ammonia injection rate
to 2,100 kg/hr. This will give the required steam to ammonia ratio of 12 to 1 over
the primary reformer catalyst, which is equivalent to a 7.5: 1 steam/H 2 ratio
required for the reduction of Primary Reformer catalyst. Use both ammonia
reflux pumps to attain this rate. [Refer to ODS-100 in the General Procedures
Manual which is a description of the NH3 cracking procedure]
c c) Maintain the back pressure at the HTS converter inlet in the range of 7 to 10
barg (PI-1194). When the CO2 Stripper circulation is in operation and when the
gas at the inlet of the HTS converter contains 1 ppm or less of H2S; the gas can
be slowly cut through the HTS converter, E-2103A, E-2103B, R-21 09 bypassing
line PG1022-12", E-2131, E-21 05, and E-21 06, then venting through the start-up
vent line V1 008-14" downstream of D-21 02, still holding the same back pressure.
The steam to the outlet of the HTS converter will be stopped.
d) Reduction and Desulphurisation of the reforming catalyst should be

accomplished in about 12 to 24 hours. Complete desulphurisation of the HTS
catalyst will probably not take place until desulphurised natural gas feed is
started to the reformer and the HTS converter heat of reaction elevates the
catalyst temperature. The inlet temperature of the shift converter should be
increased to 343°C to 371°C if possible, during the ammonia dissociation phase,
and then reduced to 316°C to prevent the release of any more sulphur.
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6.6.8 Establish Circulation of CO 2 Removal System
Establish a high level of aMDEA solution in Stripper column using P-2111 pumping
from TK-2114. If standard Premix solution is being used dilute to about 40% with
water in TK-2115 before pumping to the system.
The aMDEA Sump PUMP P-2115 is used pumping prepared aMDEA solution from
TK-2115 to TK-2114 through aMDEA Filter F-2115. Commission aMDEA Sump
Filter F-2115.
Ensure that the differential pressure across the filter does not exceed the maximum
permissible (see vendor details).
c: Commission BFW flushing cooled in SP-167 from P-21 04 discharge to P-21 08, P-
2107 and P-2111 seals. Pump from Stripper to absorber with P2107 pump. When a
liquid seal is established in the' Absorber pressure up with Nitrogen to maximum
available pressure(approx 8 bara). Continue adding solution to the system until
sufficient inventory is established in both towers to allow continuous circulation with
P-2107 at a low rate.
When draw off pan level is established in the LP flash section of the stripper start a
P-21 08 at a low rate. Exchanger E-2109 Fans.and E-211 0 Cooling water should be
off at this time. Note that when flushing is applied to the solution pump seals a slow
dilution of the aMDEA solution will commence which will continue until reboil is
started.
Begin Antifoam addition to the system. Start to warm up system with LP steam using
E-2111. Establish water level in contact cooler section and commence circulation
with P-2116 pumps when boil off starts. Commission E-21 07 when required
Commission E-21 09 and E-211 0 as solution temperature rises. Adjust solution
c strength to about 40% using water/solution make up as required. Pump seal flushes
should remain on BFW until system is stabilised at normal pressures.
Add antifoam . For the initial start-up a content of antifoam of about 50 ppm (w/w) is
required. After a plant shut-down, i.e. when the solution pumps were stopped, about
one third of the initial amount of antifoam should be added prior to starting-up again.
Commission aMDEA Solution Filter F-21 04 as per F-2115.
6.6.9' LTS Catalyst Reduction using Nitrogen as Carrier Gas.
a) If it is decided to reduce the LTS catalyst using nitrogen a carrier gas, then the
following procedure is a generic description, which may be modified by the
catalyst vendor's representative on site to reflect actual conditions experienced
during the LTS catalyst reduction. If it is decided to use Desulphurised Natural
Gas as carrier on a once through basis, then the following procedure will still be
followed in conjunction with the circuit described in SUb-section 6.6.16 of this
manual.
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b) The following circuit which must be blind isolated from the rest of the system and
pressure tested until tight, will be used using the high pressure case of the
process air compressor to circulate nitrogen:
• Air compressor discharge via start-up lines PG 1046-8" to the inlet of the
Start-up Cooler, E-2173 (via NG1022-8") and Methanator Feed Heater,
E-2172 (via PG1048-8").
• From E-2172 & E-2173 via line NG1 024"8" to inlet of LTS Converter, R-21 09.
• From outlet of R-21 09 through start-up line PG 1042-10" to the suction of the
c HP case on the Air Compressor, C-2101 via the intercooler and separator on
the LP case discharge.
c) Nitrogen (make up via N1010-2") must be allowed to purge the circuit until the
oxygen content is 0.5% by volume or less. When purging is completed the entire
circuit is pressured with nitrogen to approximately 5 barg using a connection into
the HP suction line of C-21 01.
d) The air compressor is then started as per the vendor's instructions venting air
from the LP case to atmosphere. Run the compressor at a speed that will give a
flow of 28,000 NM 3/hr. and add nitrogen as necessary to maintain the suction
pressure at approximately 4 barg. Loss 0 f nitrogen will be due mainly to
leakage through the air compressor seals.
e) Heat the LTS catalyst to 120°C at a rate of not more than 50°C/hr using heat of
compression. If the heating rate actually obtained is greater than 50°C/hr the
start-up cooler E-2173 should be used. If the heating rate is low, or 120°C
cannot be reached, use the start-up lines to the Methanator heater, E-2172.
c f) The inlet temperature to the suction of the air compressor HP case will be held at
30°C via the suction intercooler and any liquid drained from the intercooler
separator pot.
g) When the catalyst is stabilised at 120°C, hydrogen being produced by

disassociating ammonia in H-2101 will be routed from the outlet of the Raw Gas
Separator, D-21 02 via PG1019-1.5" to the inlet of the LTS converter R-21 09 to
give a hydrogen concentration of 0.5% by volume. The hydrogen Flow meter FI-
1101 and FI-11 02 are provided with different range to indicate the flow of
hydrogen. Throughout the reduction, the hydrogen concentration at the inlet and
outlet of R-21 09 will be monitored.
h) Watch the catalyst bed temperature and shut off hydrogen injection if no reaction
is evident or there is a sudden temperature rise in the bed.
i) Check the converter inlet and outlet monitors to see if hydrogen is consumed. If
hydrogen is not consumed do not allow the concentration of hydrogen in the
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stream to exceed 0.5%.
j) When conditions have stabilised at 180°C and hydrogen is being consumed, the
hydrogen concentration can be slowly raised to approximately 1.5% by volume in
the inlet gas. As the hydrogen concentration to the LTS converter inlet
increases, the catalyst temperature will increase but it must not be allowed to
exceed 230°C in any part of the catalyst bed at any time during the reduction. If
this temperature is exceeded, the hydrogen flow must be stopped.
k) As the reduction proceeds, the maximum catalyst temperature will fall so

allowing the inlet temperature to be increased to 200°C. The hydrogen
concentration can be gradually increased to approximately 3% by volume without
C' exceeding the maximum catalyst temperature of 230°C
I) When the reduction appears complete the inlet temperature should be increased
to approximately 225°C and the inlet hydrogen concentration increased in the
range of 6 to 20%. The reduction can be considered to be complete when the
whole catalyst bed is about 225°C and the hydrogen concentration difference
between the inlet and outlet of R-21 09 has been less than 0.5% by volume for
more than four hours.
m) At the end of the catalyst reduction, the circulation of nitrogen/hydrogen mixture

will continue until the catalyst has been cooled down to ambient at the rate of
approximately 50°C/hr. At the end of this period, the circulation will be stopped,
the system purged with nitrogen and the LTS converter left isolated under a
nitrogen pressure of at least 0.5 barg higher than in the HTS converter.
n) Gradually reduce the air compressor speed. Vent the excess gas from the loop
as the compressor is slowed down to avoid excessive suction pressure. Shut
c down the air compressor.

0) When the system is depressurised, isolate R-21 09 from the system and return all
other blinds to the positions required for normal operation.
6.6.10 Produce Desulphurised Feed Gas
a) Before the end of the catalyst reduction period the feed gas desulphurisation
section will be prepared ready to desulphurisenatural gas feed.
b) Nitrogen purge the system including the feed gas compressor, piping,
hydrogenator and desulphurisers. If required, commission the feed gas
compressor on kick-back operation and then route natural gas through the
system to vent at the desulphuriser outlet via line V1000-8". NOTE that the Feed
Gas Compressor is fitted with dry seals. Bottled N2 is provided for the seals at
start up and shutdown. The supply of N2 should be isolated once the machine is
running normally. Local pressure indicator PI-1683, gate valve with spectacle
blind and a 4" globe valve are provided on this line. Increase forward gas flow to
vent to about 20% design and pick up heat from the feed gas preheat coil.
c Slowly increase system pressure to design and with gas flow at 40% of design,
adjust TIC-1 093 to attain 377°C throughout the hydrogenator and desulphuriser
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catalysts. Introduce a hydrogen/nitrogen mixture from 0-2102 to the suction of

Feed Gas Compressor, C-21 02 and establish a hydrogen flow as indicated on
FI-1169 of 4 - 5% of the feed gas flow as indicated on FR-1042.
Note: High temperature alarms at the centre (TAH-1075) and exit (TAH-1076)
of R-2160 catalyst bed are provided to alert the operator to a methanation
reaction which is possible during start-up when gas containing 18% CO2 is
recycled from 0-2102. The catalyst bed upper temperature is indicated on TI-
1074.
c) Ensure that HIC-1027 valve is closed, since at this phase of the start-up, use of
c natural gas by-pass round C-21 02 is not required.
d) Analyse the desulphuriser effluent for sulphur and when this effluent gas
contains less than 0.5 ppm sulphur, it may be introduced to the primary reformer.
6.6.11 Introduce Oesulphurised Feed Gas to the Primary Reformer
a) Increase natural gas feed to the desulphuriser section to approximately 40%

design and stabilise at design pressure (on PI-1683).
b) Adjust ammonia injection to H-2101 and hydrogen/nitrogen make-up to C-21 02

suction to obtain about 1% hydrogen excess in the sulphur free gas venting at
the desulphuriser outlet.
c) Increase process steam to the primary reformer to about 70% design and steam
to the steam/air coil to 100% design and hold the primary reformer tube outlet
temperature at 760 to 780°C with a back pressure of about 18 barg (on PI-1692).
c d) Introduce desulphurised feed gas to the primary reformer at about 40% feed and
70% steam which should give a 5 to 1 steam to gas ratio.
e) ~iscontinue ammonia injection to the primary reformer feed line to the mixed
feed coil but continue the flow of hydrogen rich gas to the suction of the feed gas
compressor from the outlet of 0-2102 Raw Gas Separator, taking into
consideration the CO/C0 2 content of this recycle gas and the possibility of a
methanation reaction in the hydrogenator.
6.6.12 Introduce Air to the Secondary Reformer and Complete Reduction and
Oesulphurisation of Catalysts.
a) Adjust primary reformer tube outlet temperatures to give a methane content of

the primary reformer effluent gas of 5 mol % minimum. Ensure that the inlet gas
temperature to the secondary reformer from H-2101 is 650°C minimum before
introducing the process air to R-21 03.
c b) Prior to starting the air compressor C-21 01, the motor drive for the compressor
air filter F-21 01 will be started, water flow to compressor intercoolers checked
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and lube oil system commissioned. Start the compressor and bring up to
minimum governor speed and vent to atmosphere via UIC-1 004. Increase the
speed of C-21 01 (T) until discharge pressure recorded on PR-10S0 is slightly
higher than the R-21 03 inlet pressure. Slowly open the 2" globe valve in the
by-pass round ball valve HV-1006 to introduce a low rate of air to R-21 03.
Ignition will be verified by an immediate temperature rise in top of the Secondary
Reformer bed (TR-10S2). If ignition is. not immediate, cut all air and wait for the
system to purge itself before trying again at a higher temperature.
c) When ignition is established, open HV-1006. fully and adjust FRC-1 003 to
increase air rate to obtain the required hydrogen to nitrogen in the process gas
stream. Ensure the 2" bypass valve round HV-1006 is Car Sealed closed after
c start-up.
d) In order to complete the desulphurisation of the HTS catalyst, the inlet

temperature will be raised to 360°C. It will probably be necessary to completely
bypass E-21 02 (controlled by TRC-1 01 0) in order to achieve this. When the
sulphur content at the outlet of the HTS converter is 1 ppm or less, the HTS inlet
temperature will be lowered in the interests of prolonging catalyst life.
6.6.13 Commission CO 2 Removal System
a) With aMOEA solution circulation previously established at 20 - 30% flow and

the sulphur content of the process gas at the HTS converter outlet at 1 ppm or
less, process gas will be put through the CO2 absorber T-21 01. Stop any
pressuring nitrogen flow to the absorber and gradually adjust the vent valve on
0-2102 outlet line as needed while opening the valve in the absorber inlet.
b) Verify all the flows, levels, pressures and temperatures are stable, slowly open
the 1" bypass valve in line PG101S-16" gate valve. As the CO2 removal system
c pressure is increasing, monitor the levels, temperatures and pressures

throughout the system as adjust flows as necessary to stabilize the process.
When the 1" bypass valve is fully open slowly start opening the gate valve.
When the gate valve is fully open and pressure in T-21 01 is equal to the
pressure at PI-1692, close the 1" bypass of the gate valve.
c) Allow some time for the aMOEA circulation to line out and settle and the
absorber to equalise with the pressure of the process gas under control of
PIC-100S at the Methanator inlet vent. Increase the circulation rate to 70 - 80%
as Absorber pressure allows
d) Venting at the outlet of the HTS Converter will be gradually stopped and process
gas will go to vent at the Methanator inlet via V1 013-14". As condensation of
steam takes place, there will be an accumulation of process condensate in the
Raw Gas Separator, 0-2102 which will be disposed off to the Process
Condensate Stripper, T -21 SO under control of level controller LlC-1003.Gas rate
through the system should be kept akSO% initially.
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e) Check that all aMDEA solution streams are at required temperature and flow
rates and that the CO 2 concentration of the process gas leaving the Absorber is
0.1 mol % of CO 2 on a dry basis. Check for foaming. Check the solution
strength.
The feed gas rate of the aMDEA process can be increased to 25% of the design
value within less than 15 minutes if the temperature of the regenerated solution
. is adjusted before the feed gas enters the absorber. Therefore, the time for
starting up the cold plant to 25 % capacity will depend essentially on the time for
heating-up the solvent and the equipment. A rough calculation can be
performed on the basis of the reboiler heat duty, the solvent inventory and the
weight of the equipment.
c During the first start-up the capacity should be increased to 100 % in four steps:
• To about 50 % within 30 minutes,
• From 50 to 80 % within 30 minutes,
• From 80 to 90 % within 15 minutes,
• From 90 to 100 % within 30 minutes.
When a smooth operation of the plant is observed (absence of any foam-active

components like carboxylic acids), changes in capacity can be performed within
a very short time, e. g. from 0 to 100 % within less than 1 hour.
f) With the Stripper Reboiler, E-21 05 and E-2111 providing heat, reboiling of the
C02 Stripper, T-21 02 will commence. Dispose of carbon dioxide from T-21 02 to
atmosphere via the vent using pressure controller PIC-1104 set at 0.8 barg.
c Then as and when required, Carbon Dioxide may be routed to the Urea Plant
using the CO2 Compressor C-41 02 and under flow control of FIC-1024, which
controls the discharge flow by regulating the speed of the compressor.
g) Adjust contact cooler quench flows from CO2 Stripper Quench Pump P-2116A1B
so that the CO 2 product after separation, is cooled to 43°C. When all available
gas has been routed through the CO2 removal system increase the gas feed to
50% of design and the process steam rate to 100% of design of the primary
reformer.
h) The process air to R-21 03 is also increased to maintain the hydrogen to nitrogen
ratio. Maintain a back pressure at R-2106 inlet at 18 barg.
i) With a carbon oxide free hydrogen/nitrogen mixture now available from the
Absorber overhead drum, D-21 03, this gas may be used in the desulphurisation
section. Route a slip stream of gas from D-21 03 to C-21 02 Feed Gas
Compressor suction via the start-up line PG1019-3", PG1038-3" and PG1034-3"
to supply the front end hydrogen requirements.

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j) When the level is established in the Process Condensate Stripper, T-2150, admit
MP stripping steam. As tower conditions are stabilised, route the overhead
vapours mixed with additional steam as part of the mixed gas feed to the primary
reformer to MP process steam. The stripped process condensate can be sent to
the offsite demineralised water plant via the Feed/Effluent Exchanger, E-2188
and the Stripped Condensate Air Cooler E-2174, and the Stripped Condensate
Trim Cooler E-2175.
Note:
New catalyst in LT shift reactor in ammonia and synthesis gas plants: When a new
catalyst is charged to the LT shift reactor the dust from the catalyst pellets can be
(' blown with the synthesis gas into the C02 removal section. The particles are then
washed out in the absorber and the high particle content in the solution can result in
severe foaming problems in the aMDEA unit. In order to avoid these problems the
synthesis gas should be put to flare after an exchange of the LT shift catalyst for a
couple of hours. Afterwards, when the dust content of the synthesis gas is low
enough the synthesis gas can be fed to the absorber.
6.6.14 Complete Desulphurisation of the HTS Converter Catalyst.
a) Effluent gas from the HTS converter will again be tested for sulphur by laboratory
analysis. Total sulphur from primary and secondary reformers and HTS
catalysts will be detected, although sulphur in reformer catalysts is negligible.
Increase the HTS converter inlet temperature to 371°C, or higher if possible,
since it is usually good practice to try to increase the inlet temperature above its
normal operating temperature to ensure complete desulphurisation of the
catalyst. if the catalyst is desulphurised at a temperature less than design, some
additional sulphur will be removed when temperatures approach or exceed
design conditions.
c b) To aid in the complete desulphurisation of the HTS converter catalyst, gradually

increase the process steam rate to 100% of design and the unit feed rate to 75%
of design.
c) Increase the process air rate to R-21 03 Secondary reformer as the feed gas
rate is increased to 75%
d) Raise the feed gas compressor discharge to about 40 barg by adjusting the
speed of the turbine using PRC-1010 to get the desired pressure. Increase the
back pressure on the unit being held at PIC-1005 to about 21 barg.
e) Increasing the plant throughput will add duty to E-21 02 and may make it possible
to achieve 371°C at the HTS converter inlet and also ensure good distribution to
the HTS converter to ensure complete desulphurisation of the catalyst.
f) As the unit pressures are increased, the Slip-stream of hydrogen rich synthesis
gas from D-21 03 should be adjusted to the hydrogenator and desulphurisers as
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required.
IMPORTANT NOTE: The "hydrogen" recycle to the hydrogenator and

desulphurisers should be carefully controlled to ensure adequate desulphurisation
(less than 0.5 ppm sulphur at R-2108A1B outlet) and minimum (1% or less) excess
hydrogen in R-2108A1B effluent stream. THIS IS IMPORTANT IF R-2108A/B
EFFLUENT STREAM IS USED AS "CARRIER" GAS FOR THE LTS CONVERTER
CATALYST REDUCTION.
Natural gas as a "carrier" for LTS catalyst reduction will only be used if:
c
• Sulphur compounds in the gas feed are non-organic (H 2S) and may be absorbed
by the Zinc Oxide catalyst in R-21 08 AlB Desulphurisers without the requirement
for 3% hydrogen content to attain desulphurisation of the feed gas AND:
• Feed gas does not contain heavy hydrocarbons (non-condensables) which could
tleposit on the LTS catalyst thus reducing its activity, performance and life.
NOTE: A significant increase in heat of reaction will be noted once the shift
converter inlet temperature passes 343°C. Although it is not anticipated that there
will be any chance of runaway, conditions should be adjusted carefully and the
catalyst temperature should not be allowed to exceed 482°C at any location.
g) When the sulphur content of the HT Shift converter effluent gas is consistently
less than 1 ppm as verified by several samples taken over a period of a few
hours, the feed gas rate is cut back to 40% of design in preparation for the
activation of the Methanator catalyst.
6.6.15 Commission Methanator [R-21 06]
c a) To place the Methanator in service, a steam to gas ration of approximately 8:1

will be required which will produce an HT Shift effluent containing less than 2%
CO. The 2% CO is a maximum figure as 1% CO will cause a 72°C temperature
rise in the Methanator and therefore, 1% CO would be an ideal figure if possible.
A process steam rate of 100% of design and a feed gas rate of 40% to 45% of
design will produce an acceptable CO content at the HT Shift converter effluent
to place the Methanator in service.
After confirming that the Carbon oxides (CO + CO2 ) content of the gas that will
be introduced to the Methanator is less than 2.0%, the Methanator may be put
into service.
NOTE: The total carbon oxides actually influence the total temperature rise
across the Methanator. The normal amount of CO2 in the process stream
leaving the CO2 Absorber is not expected to be a problem. However, if there is a
break-through of CO 2 from the absorber, high Methanator temperatures can be
experienced even though the CO level is normal.


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b) The Methanator, including its effluent system, E-2114, E-2118 and E-2115 and
up to and including the synthesis gas compressor suction drum 0-2104 is being
maintained under a nitrogen pressure. Discontinue N2 purge at this time.
c) Open butterfly valve XV-1211 and gradually open the 1Y2' by-pass valve around
HV-1034 block valve, then slowly equalise the pressure in the Methanator with
the 0-2103 pressure. With PIC-1004 on 0-2104 closed on the control panel,
fully open HV-1034. With the Methanator pressure thus floating on the upstream
system pressure gradually open PIC-1004 allowing the Methanator inlet pressure
controller PIC-1 005 to move towards closed to compensate. When PIC-1005 is
closed, put PIC-1 004 on automatic at approximately 21 barg and move PIC-1 005
c index upward to close the valve tight.
d) Route the process gas through Methanator Feed Heater, E-2172 and manually
ititroduce HP steam to start raising the Methanator inlet temperature towards
design operating of 316°C at a rate which will heat up the Methanator catalyst
not faster tnan 114°C/hr. As the outlet temperature rises, the inlet process gas
will begin to pick-up heat from the Methanator effluent in E-2114 and split range
controller TRC-1012 should be commissioned. The maximum allowable outlet
temperature for the Methanator is 399°C with a maximum metal temperature of
454°C.
e) As the Methanator catalyst temperature is raised, there is a temperature range

(38 - 177°C) through which minute amounts of highly toxic Nickel Carbonyl may
be formed. ALL PERSONNEL SHOULD BE AWARE OF THIS POSSIBILITY
AND STAY WELL AWAY FROM THE METHANATOR EFFLUENT GAS UNTIL
THE BED TEMPERATURES HAVE REACHED 204°C. The presence of water
vapour on the oxide coating of the catalyst hinders the formation of the carbonyl.
Therefore, the first start-up of the Methanator may be less hazardous than
c subsequent start-ups with reduced catalyst. A Methanator catalyst should never

be permitted to cool down to ambient temperatures in the presence of carbon
monoxide.
f) As the catalyst bed is heated to the design operating temperature of 347°C at

the Methanator outlet, the catalyst will be gradually reduced and should exhibit
catalytic activity, which will be manifested by a temperature increase across the
converter. When the differential temperature across the bed is proportional to
the carbon monoxide in the gas (i.e. 1.0% CO will cause a 72°C rise), the
catalyst has reached full activity. Approximately 6 hours of operation at near
design operating temperature is generally sufficient to fully activate the catalyst,
after which the Methanator inlet temperature is adjusted to give the required (10
ppm or less) carbon oxides in the outlet gas.
NOTE: To protect E-2172 exchanger from differential thermal expansion and

possible tube sheet failure if the process flow through E-2172 is stopped quickly,
as in the case of an automatic high temperature shut-off; the HP steam through
the tubes of E-2172 should be discontinued immediately. This is accomplished


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automatically by interlockESD-21 06which trips PIC-1180 controlling the flow of

HP steam to the tubes.
g) As the catalyst is being reduced, the following analysers installed at the outlet of
D-21 04 should be activated to monitor the quality of the synthesis gas to C-21 03:
AR-1002 records the total carbon oxides [CO + CO 2) in the Methanator effluent.
AR-1033 is expected to indicate approximately 0.9 mol% of methane [CH 4 )

when in normal operation. If a higher methane content is indicated, it is likely
(assuming the hydrogen/nitrogen ratio to be normal), that a higher severity of
reforming is required in the primary reformer.
c AR-1031 records the hydrogen [Hi! content of the stream leaving D-2104 and
should range between 72 and 75%, depending primarily on the air introduced to
the secondary reformer. Adjustment of the H2 content will be made by making
small changes in the Process air introduced to R-21 03. If the per cent H2 is too
high, additional air is required and vice versa.
AR-1032 will indicate the nitrogen [N 2) content of the stream (approx. 24.9%).·
6.6.16 LTS Catalyst Reduction using Natural Gas Feed as Carrier
a) If it was decided not to reduce the LTS catalyst using nitrogen as carrier gas as
outlined in section 6.6.8. then reduction using natural gas as the carrier gas will
take place at this point in the start-up. Natural gas will only be used as a carrier
provided it is suitable viz.: sulphur and hydrocarbon components conform to
requirements specified in 6.6.13f) above.
b) The following approximate flow conditions will apply to the front end of the unit at
c this stage:
• Process Steam Rate (FRC-1002) 100%

• Natural Gas Feed Rate (FRC-1001) 40% to 45%
• Process Air Rate (FRC-1003) 50%
• Pressure at D-21 04 (PIC-1004) 21 kg/cm2g.
c) Up to this time, the LTS converter has been kept isolated from the rest of the
process under a nitrogen atmosphere of sufficient pressure to prevent any
process gas leakage into the converter. The nitrogen purge may now be
stopped and the catalyst reduced as detailed below.
d) The reformer feed rate is still at 40% to 45% of normal and the auxiliary boiler
should be firing at 85% of normal. The feed gas will be gradually increased to
about 100%, which will be distributed 50% to the reformer as feed, and 50% to
the LTS converter via line NG1 022-6" as carrier gas. During catalyst reduction
the hydrogen recycle to the desulphurisers should be discontinued since it would
not be possible to control the Hydrogen content in the Natural Gas carrier with
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any accuracy if the carrier gas already had a hydrogen content which would be
varying with any change in sulphur content of the incoming gas. This method of
LTS reduction should therefore not be attempted if Organic Sulphurs are present
in the feed gas.
e) The reduction of the LTS catalyst may be accomplished at any time after the
sulphur content of the HTS effluent as indicated at 0-2102, shows a negligible
amount of sulphur, preferably less than 1 ppm.
f) Start a flow of desulphurised natural gas from the outlet of Oesulphurisers

R-2108NB via the start-up line NG1022-6" to Start-up Cooler E-2173, to the LTS
converter and through the LTS converter outlet vent. Control the required
c temperature for the reduction by adjusting E-2173 cooler.
g) Hydrogen rich gas for reduction will be introduced to the LTS converter inlet from
0-2103 via the start-up line. From this point the reduction steps will be as
already detailed in sub-section 6.6.8.f) through 0). On completion of reduction,
the LTS converter will be placed in service as per the next step.
6.6.17 Commission LTS Converter
a) After reduction of the LTS converter catalyst using natural gas as a carrier,
reduce the feed gas rate to 50% and re-establish the hydrogen recycle to the
desulphurisers.
b) Initiate a purge by dilution-pressuring with nitrogen to remove combustible gas

and maintain an outlet of nitrogen at the openings as blinds are removed from
the inlet and outlet lines. Purging .procedure should only be continued as long as
necessary to obtain an acceptable atmosphere for blind removal so as to
minimise the cooling effect on the catalyst beds. The nitrogen may contain trace
c amounts of oxygen and could cause partial re-oxidation of the catalyst if

continued for an excessive period.
c) When the blinds have been removed prepare to heat the LTS catalyst to a
temperature above the dew-point of the process gas from the HTS converter.
The heating medium for this step is a slip-stream of process gas feed to the
Methanator via a start-up line PG 1058-8" to the LTS inlet line and to the vent at
the LTS converter outlet.
d) Carry-out the warm-up at low pressure (about 3.5 barg) and heat the catalyst at
a maximum rate of 55°C/hr. In order to avoid temperature shock to the catalyst,
the differences in temperature between the catalyst and the heating medium
should not exceed 190°C.
e) The first re-heat of the LTS catalyst must be done with care to prevent runaway
temperatures. If an increase in temperature (TI-1346 through TI-1350) across
the catalyst bed is observed during the heating, reduce the flow of heating
medium until the temperatures stabilise (flow reduction will decrease the amount

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C JOB NO. 5777 SPEC. TYPE: PAGE: 1B90F312
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of hydrogen contacting the catalyst).

f) Once the catalyst temperature is above the dew point of the process gas from
the HTS converter (190 - 210°C) the HTS effluent may be routed through the
LTS converter. Check that the sulphur content of the HTS effluent is less than 1
ppm. The CO content of the HTS effluent will probably be 1% or less at this
stage but it should be checked to ensure that it is less than the design value of
3.5% (dry gas basis).
g) Drain all condensate from both sides of MOV-100B at the LTS converter inlet.
Partially open the 1" by-pass around MOV-100B and shut-off the heating stream
from the Methanator inlet line. Once a heat of reaction is noticed, hold these
conditions for about 1 hour i.e. do not increase flow through MOV-100B by-pass
C' valve. When conditions are stable, gradually increase the MOV-100B by-pass
until it is wide open. Adjust the temperature of the gas to theLTS converter
(TIC-1 on) to obtain 205°C or as near as possible at TI-1345.
h) Gradually close in the outlet vent until the converter outlet pressure is a little
lower than the inlet pressure. Then slowly drain condensate from both sides of
the LTS converter outlet valve before opening wide and at the same time closing
the outlet vent valve.
i) Place the LTS converter in service by opening inlet valve MOV-100B and closing
by-pass valve MOV-1 009. Adjust LTS converter and Methanator inlet
temperatures to give the required gas analyses. Good operating practices
require that the inlet temperatures be kept as low as possible consistent with
stable operation in order to attain long catalyst life.
j) With the primary reformer feed rates at 50% design and aMDEA solution
circulation rates at 100% design it is not anticipated that there would be any
significant change in the carbon dioxide at the Absorber (T-21 01) inlet caused by
placing the LTS converter in service. However, CO2 at the Methanator outlet
C should be monitored.
k) Stabilise unit operation with the LTS converter and Methanator in service venting
process gas at the Synthesis Gas Compressor Suction Drum, D-21 04 via PIC-
1004. Check that the design differential pressures across the catalyst beds are
not exceeded.
6.6.1B Commission Refrigeration System
a) In preparation for commissioning the Refrigeration and Synthesis Gas

Compressors, Increase gas feed to the primary reformer to 75% with the
corresponding increase in the process air to the secondary reformer to hold the
hydrogen to nitrogen ratio. As the gas feed rate to H-2101 is increased, the
back pressure on D-21 04 (PIC-1 004) can be increased to 23 barg. Increasing
the feed and air rates will assist in the production of steam necessary to start-up
C-21 03 and C-21 05 compressors. Adjust D-2101 steam drum pressure to 120
barg.


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b) The refrigeration system will have previously pressure tested at 3.5 barg with
nitrogen. After repairing any leaks found, purge the entire system with nitrogen
to an oxygen content of 0.5 - 1.0% by volume and left at the test pressure so that
liquid ammonia can be introduced into the system without overchilling the
equipment.
c) Introduce WARM ammonia from Offsites to the Refrigerant Receiver 0-2109 as

previously outlined in subsection 6.6.7. Oisplace the nitrogen from the remainder
of the system by allowing ammonia to distribute from 0-2109 through the four
flash drums and the compressor system. The nitrogen is displaced to
c atmosphere via equipment vents and drains until the ammonia fumes become
objectionable, at which time the vents and drains will be closed. A pressure will
then be imposed in the system at the pressure equivalent to the vapour pressure
of ammonia at the ambient temperature.
d) All of the kickback control valves FIC-1009/1010/1011 & 1012 will be wide
open. The Refrigeration Compressor C-21 05 is then started according to
vendor's instructions with steam being admitted to the driving turbine without
upsetting the steam system and the machine brought up to minimum governor
speed bringing it through the critical speeds.
e) A survey of the compressor inlet temperatures should now be made and quench
(further ammonia imported) as required to hold down the temperatures. Set the
suction pressure controller PRC-1009 on 0-2120 to hold the pressure at about
3.5 barg. PRC-1009 will be "over-ranged" on the pressure for this operation, so
operate PRC-1009 on manual. This setting should result in the compressor
running at just over its minimum governor speed. As an aid in developing
discharge pressure, throttle the kickback valves as much as possible without
c getting into a surge condition.
NOTE: Extreme caution must be observed whenever quench is introduced and

added to the circulating stream. A close watch must be maintained on the
temperature in the drums to ascertain that over-quenching is not taking place.
This is to be avoided, because excessive quenching could result in a "reverse
flow" of liquid ammonia into any or all of the sections of the unitized exchanger
E-2120.
Refrigerant in any of E-2120 shell sections is undesirable at this time because of

the impending warm-up operation which must be undertaken prior to leak testing
of the synthesis loop, and to prevent freezing of the water of saturation in the
fresh synthesis feed gas which is passing through the process side of E-2120.
Try to add only enough quench to maintain compressor discharge temperatures
at or near normal, and avoid establishing levels in the refrigeration drums at this
time.
f) Non-condensables that remain in the system will accumulate in 0-2109 and in

c the shell of E-2127. Continue to vent these vapours until the pressure in the


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receiver 0-2109 corresponds to the receiver temperature (see NH3 vapour

pressure curve in the General Procedures Manual).
NOTE: If it is intended that a fresh charge of ammonia converter catalyst is to

be reduced entirely under recycle conditions then, an inventory of ammonia
should be kept in 0-2109. This ammonia received from 0-2109 will be used to
inject into the ammonia converter effluent stream upstream of E-2124 to prevent
water formed during the catalyst reduction from freezing in the chilling section.
The liquid ammonia will be injected by pump P-2120AlB.
g) Compressor C-21 05 is now in operation on total kickback; its temperatures are

controlled by quench and no liquid levels have been established in 0-21201
c 2121/2122 & 2123.
6.6.19 Start Synthesis Gas Compressor
a) The synthesis loop will be standing under nitrogen pressure, having been purged
to an oxygen level of 0.5% by volume. If not already done so, the feed rate to
the primary reformer will be increased to 75% of design, with the air rate
increased in proportion to the feed rate. The steam rate should be at 100% of
design. Pressure on the Synthesis Gas Compressor Suction Orum, 0-2104,
should be raised to design.
b) When the analysis of gas being vented at 0-2104 shows the gas to be
acceptable for feed to the ammonia converter (maximum 10 ppm total oxides),
preparations will be made to start the Synthesis Gas compressor. The
preliminaries required for starting this machine will be observed such as tuming
water on the intercooler E-2116 and Ammonia Synthesis Loop Cooler, E-2124
and starting the lube oil system.
c c) Ensure that the synthesis loop is isolated by closing motorised valves HV-1001
and HV-1031 before pressurising C-2103. Ensure ALL kickback valves are fully
open.
d) The gas is admitted by carefully cracking open the 2" by-pass around the
isolating valve in the suction line between 0-2104 and the compressor. Pressure
the system slowly to 0-2104 pressure. Close the 2" inlet valve by-pass and
depressurise the compressor and 0-2105 to about 1 barg via 0-2105 vent and
compressor blowdowns to displace nitrogen to atmosphere with synthesis gas.
Repeat this procedure until the stream within the compressor shows a
composition similar to that of the synthesis gas. Repressurise the compressor
and associated piping to the pressure of 0-2104. Open the compressor suction
valve fully prior to starting the machine.
e) Assuming that all preliminaries for starting the machine have been carried-out
and lube oil systems are in operation, proceed as follows:
• Check the C-21 03 kickback valve (HV-1030) and the minimum flow


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controllers UIC-1007 and UIC1008 are fully open. Leave HV-1001 on the
discharge line downstream of E-2124 and its 2" by-pass closed off as the
machine will be started on total kickback.
• Ensure that steam has been routed to the turbine seals and begin to slowly
admit HP steam to the high pressure turbinewith the turbine casing drains
open. Do not commence rotation until no further condensate is observed,
then close drains and start the compressor according to the vendor's
instructions. Bring the compressor speed up to about 5,000 RPM, then bring
it swiftly through the critical speeds to about 6,500 RPM.
c • This should bring the machine safely above the critical speeds for both the
HP and LP cases. If this can be done on the HP turbine it should not disturb
the steam balance. If not, it may be necessary to pick-up part of the load
gradually with the condensing turbine, taking the jumps in the speed on the
HP turbine when going through the critical speeds.
• Gradually bring the compressor speed to the minimum governor setting.

These increases. in speed will be accomplished as far as possible with the
HP turbine. If, when the inlet valve to this turbine is fully open, the
compressor is not up to the minimum speed, it will be necessary to open the
condensing turbine inlet valve until the compressor reaches the desired
speed.
f) The above, combined with starting the Refrigeration Compresso~, C-21 05,
should bring the changeover on the steam system from letting down from HP to
MP steam via PIC-1013 to letting-down via the HP turbine on C-21 03.
g) When the compressor operation has stabilised, start a small flow of synthesis
gas from the LP case discharge takeoff upstream of E-2117 via FIC-1022 as the
c hydrogen source for the desulphuriser and shut down the flow from D-21 03 to
the suction of Feed Gas Compressor, C-21 02.
6.6.20 Pressure Test of Synthesis Gas Loop
a) The pressure test of the synthesis gas loop entails gradual and stepwise
incremental pressure changes of 14 barg per hour to 70, 105 and 140 barg and
checking for leaks. The H-21 02 Start-up Heater and associated piping is to be
included in the test.
b) The synthesis gas compressor is on total kickback operation with no flow

through the synthesis converter. The synthesis loop will now be aligned
preparatory to carrying out an operator leak test.
NOTE: The converter shell has been impact tested at -10°C and converter
pressure at a temperature lower than -12°C shall not be more than 40% of
design (i.e. 61.6 barg) until the metal temperature is brought above -12°C.
Attention is also called to the fact that at no time should the Secondary
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OOCNO. PROJ-PM-OOS REVISION: 4
Flash Separator (0-2106) and the Ammonia Letdown Drum (0-2107) be

pressured up to their operating pressure at metal temperatures of -23°C or
lower.
c) Prepare for pressure testing the synthesis loop by aligning the loop as follows:
o Leave HV-1 001 and its 2" by-pass closed, also HV-1031
o Open SP-173 wide (main inlet valve to converter R-2105).

o Open wide the two "car-sealed open" valves on the differential rupture disc
SP-006 which is set to rupture at 20 barg and is provided to protect E-2121
c •
against an excessively high pressure differential between the tubes and shell
sides.
Close the quench inlet valve HIC-1 025 and tlie butterfly valve on the inlet line
to Start-up Heater, H-21 02.
o Close all outlet valves on 0-210S, Purge Gas Separator. (There are block
and by-pass valves on controllers FIC-1013 and LlC-1014).
o Start ammonia to E-2129 from 0-2123 and set pressure controller PIC-1114
at a minimum of 3.5 barg to prevent freezing water in this exchanger on the
synthesis gas side.
d) With the synthesis loop aligned as described above, and using the 2" by-pass
around the compressor discharge valve (HV-1001) to regulate the flow, slowly
admit synthesis gas into the system. As the system pressure (as indicated on
the PI-1632 substitute gauge), approaches 3.5 barg start opening the vent valve
upstream of HV-1 031 on the compressor recycle suction line. Control the
quantity of gas being admitted to the loop using HV-1001 by-pass until the
c pressure in the system as indicated on PI-1632 has reached 14 barg
e) Start a flow of ammonia using pumps P-2120AlB to C-21 03 discharge to E-2124.

The purpose of this ammonia injection is to make aqueous ammonia of the water
of saturation entering the synthesis loop in the fresh synthesis gas, thereby
lowering the freezing point of the solution to prevent freezing in the 0-2122,
0-2121 & 0-2120 sections of the Unitized Chiller E-2120 which operate
at -2.2°C, -17.SoC & -35°C respectively. This aqueous solution should be
sampled at Chiller E-2120 to determine its ammonia concentration. About 25
wt% ammonia solution should be established before E-2120 unitised exchanger
sections are chilled down to their normal operating temperatures. This ammonia
injection must be maintained until ammonia in the recycle gas performs the
same function.
f) Once the system has been aligned as above, start the leak test by increasing the
pressure at the converter outlet in 14 barg increment to 70 barg by regulating at
the HV-1001 by-pass and adjusting C-21 03 discharge pressure and the vent as
necessary.


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g) Replace the low range substitute pressure gauge with its normal high range
gauge. Even with kick-back valves wide open, considerable discharge pressure
is developed by the compressor at these conditions due to restrictions offered by
the valving and piping; therefore, exercise caution when regulating the flow. In
this connection, attention is directed to the fact that the tube assembly in the
Converter Feed/Effluent Exchanger, E-2121 is designed for a maximum
differential pressure of 24 barg The pressure increments must be applied and
reduced uniformly to both shell and tube sides to prevent the SP-006 disc from
rupturing. The 24 barg differential pressure across E-2121 must not be
exceeded at any time.
c h) Continue the test by increasing loop pressure in 14 barg per hour increments,
inspecting and repairing as required after each 35 barg increase. Work the
synthesis loop pressure up to approximately 140 barg or the maximum attainable
by throttling the kick-back valves to the minimum settings above the compressor
surge pOint and by gradually increasing the compressor speed to the maximum
attainable with available steam. If necessary, throttle down on the vent on the
compressor recycle line, but do not close completely.
i) When the converter system is deemed tight, cut back on the feed to this system
by reducing compressor speed. PIC-1004 on 0-2104 will vent the excess gas.
Reduce the synthesis loop to 84 barg in preparation for synthesis catalyst
reduction.
NOTE: Attention is called to the fact that any future hydrostatic strength
test of the converter will require the shell metal temperature be at a
minimum of 38°C before the strength test is applied.
6.6.21 Start Up Heater, H-21 02, Sequence Logic Description
c This section describes the instrumentation logic controlling the interlocks and timers
associated with each set of reformer burners and should be read in conjunction with
section 11.2.8
General Notes
a) Permissives are conditions that are checked at a particular time to confirm that
an action is allowed to proceed. Their condition has no effect except at the time
they are checked.
b) Trips are active at all times. A trip will be initiated any time that the corresponding
variable is in the trip range, unless it is specifically over-ridden. All trips must
therefore be cleared to allow start-up and the conditions must remain good after
start-up.
c) Indication of a trip does not necessarily indicate that a complete trip of the entire
reformer or an entire bumer set is initiated.
d) All indicator lamps mentioned in this description are located on the Local control
panel

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The Start-up Heater is a natural-draft heater firing natural gas only. Pre-ignition
purging is a manually-controlled operation carried out using steam.
First stage in starting the Start-up Heater is to purge the firebox.
Permissives to start the purge/checking sequence are: -

Start-up Heater FG to main burners depressured (21-PSLL-1250).
Start-up Heater FG to pilot burners depressured (21-PSLL-1263).
Start-up Heater FG to rnain burners gas valves closed.
c Start-up Heater FG to pilot burners gas valves closed.

Start-up Heater checking gas valves closed.
Start-up Heater trips are: -

Start-up Heater FG to main burners HH pressure (21-PSHH-1251)- main
burners only.
Start-up Heater FG to main burners LL pressure (21-PSLL-1250)- main burners
only.
Start-up Heater FG to pilot burners HH pressure (21-PSHH-1262)- pilot burners
only.
Start-up Heater FG to pilot burners LL pressure (21-PSLL-1263)- pilot burners
only.
Start-up Heater Main burners loss of all flames (21-BE-1020/21/22123) - main
burners only.
Start-up Heater Pilot burners loss of all flames (21-BE-1 026/27/28/29) - pilot
c burners only.
Start-up Heater Syngas feed LL flow (21-FT-1257)
Start-up Heater Syngas feed HH pressure (21-PT-1196)
Start-up Heater Syngas outlet HH temperature (21-TT-1396)
a) Ensure that no trips (except fuel gas pressure) are active, and then reset the
trip logic by pressing 21-HS-1 050 (located in CCR).
b) When all permissives are satisfied the operator can start the purge/checking
sequence by pressing 21-HS-1254 (on Local Panel). This starts the 20 minute
'purge' timer and lights the "Purging" indicator larnp (21-XL-1251 A). In order to
have a purge of the firebox, the operator must manually initiate a flow of steam
through it
c) At the end of the 20 minute period the "Purge Complete" lamp (21-XL-1251 B)
is lit for 30 seconds and the tightness check is automatically started.
d) The fuel gas headers to the pilot and main burners are pressurised with
checking gas (21-XV-1251A1B, 21-XV-1263A1B are opened, 21-XV-1251C,
21-XV-1263C are closed), and the "Checking" lamp ((21-XL-1251C) is lit.


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e) The checking gas valves remain open for 20 sec, during which the header
pressure rises far enough to ensure that the checking permissive switches (21-
PSL-1152, 21-PSL-1155) are satisfied. The checking gas supply is then
disconnected. The pressure in the headers must be maintained for 90 sec
(therefore a minimum of 60 sec after the removal of the checking gas) in order
to successfully complete the tightness test. If the pressure is not maintained,
the "Checking Failed" lamp (21-XL-1151D) is lit after 110 sec and the
purge/check sequence must be restarted after the problem is cleared.
f) If the tightness check is successful, the "OK to Open Pilot FG Valves" lamp
(21-XL-1249) is lit. The operator must then press the "Open Pilot Valves"
switch (21-HS-1249, on Local Panel) to initiate the pilots' start-up over-ride
timer. This initiates a timed (2 - 5 minute) over-ride on the Pilot Bumer gas
c pressure trips and opens the fuel gas valves, allowing the burners to be lit after
opening the individual pilot burner cock valve. This switch must be activated
before test pressure in the headers has been lost (in this case this would be
due only to leakage). If this switch is not pressed within the required time, the
permissive is lost and the check cycle must be restarted. g) Lighting of the
burners is a manual action using an ignition torch temporarily connected to the
burner fuel gas supply.
h) After the timer expires, a flame must be detected to allow the pilot header gas
valves to remain open.
i) Once all the Pilot Burners are indicating that they have a flame, the "OK to
Open FG Valves" lamp (21-XL-1250) is lit and the main burners' start-up over-
ride timer is enabled. To light the main burners the operator opens the
individual burner cock valve and presses the "Open FG Valves" switch (21-HS-
1250, on Local Panel).
6.6.22 Synthesis Converter Catalyst Reduction
a) The following procedure is only a generic description of the reduction of the
c Ammonia Converter catalyst, which will normally be carried out under the
direction of the catalyst vendor's representative who may call for certain
modifications to the procedure.
b) To maintain adequate gas velocity in the converter annulus, the catalyst

reduction is to be effected in the "recycle" operating mode from the start. The
loop can be put into recycle service once the unit has been pressured and flows
set using the recycle gas circuit with a small make-up flow of fresh synthesis gas
venting upstream of HV-1031.
c) Throughout the reduction process water is produced and the water vapour
concentration in the gas leaving the ammonia converter should not be allowed to
exceed 3,000 ppm by volume. Water vapour is a catalyst poison and is removed
from the recycle gas by chilling in the refrigeration section where it is condensed
and appears as an ammonia-water mixture continuously increasing in ammonia
strength. This Ammonia water mixture accumulates in the Ammonia Separator,
0-2106 and is let down to 0-2107. From 0-2107 it is initially routed to the
Ammonia-Water Tank TK-41 08 located on the Urea Unit and diluted to <20%


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NH3 strength with de mineralised water injected into the transfer line. On
reaching a strength of 80% ammonia in D-21 07, it will be routed to the Offsites
Ammonia Storage Tank and at 95% NH3 strength it may be let down to the
refrigeration system.
d) The amount of water formed during the activation of pre-reduced catalyst is only
approximately 20 kg/MT of catalyst loaded. A large part of this water is already
released when the catalyst is heated up through the range 204 - 302°C.
Un-reduced catalyst will produce about 280 kilograms of reduction water per
metric tonne of catalyst. The last part of the water given off, probably the last
10 - 20 percent, will be found as small water content in the ammonia produced
during approximately the first week of operation.
c e) The ammonia reflux pump, P-2120 will be used to provide a small flow of
ammonia to the inlet of E-2124 as described in subsection 6.3.17.e) above.
f) Following the pressure testing of the synthesis loop, synthesis gas will be
passing into the loop through the HV-1001 by-pass valve and being vented
upstream of HV-1031 The synthesis gas compressor will be on full recycle
operation with a discharge pressure of about 80 barg.
g) Increase the loop pressure to equal the compressor L.P. case discharge
pressure by increasing the flow through HV-1001 by-pass and reducing the flow
through the vent upstream of HV-1031 The loop inlet valve HV-1001 can then
be opened fully and the by-pass closed.
h) Slowly open wide HV-1031 while closing the vent. All adjustments should be
made gradually and in small increments while observing the effect each
adjustment has on the flow through the ammonia converter. Considerable
recycle will be established as soon as HV-1 031 is fully opened.
c i) The output from C-21 03 compressor should then be divided into two flows: one
going to the converter shell for cooling and the other through Start-up Heater,
H-21 02, to heat the catalyst.
j) The ammonia converter normal inlet valve, SP-173 will be open with the
interchanger by-pass, HIC-1025 closed. The butterfly valve on the inlet line to
H-21 02 will be fully opened.
Notes:
1. To avoid excessive temperature differentials between the top and
bottom of the converter shell, a minimum volumetric flow rate of 2,000
m3/h should be maintained through FI-1105 on the converter inlet. (This
flow meter is for use during catalyst reduction or loop restart and will indicate
over scale during normal plant operation when FR-1059 on C-21 03 discharge
will measure the loop flow).
2. When H-2102 is in operation, valve HIC-1025 must be shut. This valve


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should only be opened when the outlet temperature of H-21 02 is the

same as the temperature upstream of the HIC-1025 valve otherwise cold
gas via HIC-1025 will enter the quench line upstream of the junction
with the H-2102 outlet line.
k) When firing H-21 02, all plant safety procedures concerning furnace firing should
be followed. After purging the firebox for about 15 minutes with the stack
damper wide open, the damper should be set about two thirds open when
lighting the burners. Before firing a burner, check the draft visually with a piece
of tissue paper at the furnace peep doors. Light and adjust the start-up heater
burner firing to increase the outlet temperature as necessary. Increasing the
temperature is the first step in phase one (1) of the reduction procedure.
c NOTE:
The furnace is designed for FULL loop pressure, but with nil flow and no
heat from burners. When fired, the synthesis loop must be at a reduced.
pressure and a burner interlock pressure connection on the inlet line to H-21 02
is provided to prevent lighting of burners if loop pressure is at full pressure.
I) The stabilisation process consists of a skin oxidation of the catalyst whereby it

takes up an amount of oxygen corresponding to about 2 wt.%. The stabilisation
makes the catalyst non-pyrophoric at temperatures up to about 93°C. At higher
temperatures it will oxidise in the presence of air and heat up further by itself
m) Operating conditions during the start-up cannot be fixed exactly and the
procedure given below should not be considered a set of instructions, which
must be strictly adhered to. It has been chosen because a schedule is the most
practical way to illustrate how a combined charge of pre-reduced catalyst should
be treated during activation.
c n) Phase 1 : Inlet Temperature Ambient to 343°C - With the start-up heater fired
and gas flow established through the converter, the basic objective of phase 1 is
to heat the catalyst in bed no.1 to a top of bed temperature of 343°C at
approximately 25 - 30°C per hour. Note that bed No.1 will have been loaded
with pre-reduced catalyst. Many variables will have to be adjusted during this
period and it is impossible to outline every step in its proper time sequence.
What will be presented is a broad outline with emphasis on the overall procedure
and how it is to be accomplished.
The following operating conditions should be maintained:

• Loop pressure should be held at approximately 84 barg at the converter
outlet, controlled by the amount of purge. During reduction, the loop
pressure must be stabilised at 84 barg and would be more stable if HV -1001
is wide open and the pressure riding on the compressor discharge.
• The rate of temperature rise should be held at 30 - 50°C per hour as

indicated on temperature indicators TI-1383/1384/1385 & 1386, all located in
the plenum section between the catalyst support grid and the basket shell at

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the base of bed No.1.
• The inlet valve to H-21 02 is always wide open with the flow raised or lowered
using SP-173 at the converter inlet whilst maintaining the minimum flow rate
of 50,000 kg/hr through FI-11 05 but without overloading the start-up heater.
The pressure-temperature limitations and the design flue gas exit
temperature from the convection temperature on H-21 02 should not be
exceeded.
• As flow and temperature are increase, the start-up heater will be firing at
near design rate. After design heat output has been reached, any need for
additional outlet temperature will be met by decreasing the flow of gas
c •
through the heater coils. The flow at this time will be decreased by opening
the valve at the converter inlet.
Flow changes through the heater and converter require balancing
adjustments around the synthesis gas compressor. Kickback flows must be
varied as required to maintain stable conditions at all times.
0) Start-up Heater (H-21 02) Precautions: Overheating of the start-up heater coils
is prevented by the flow of gas through it. If, for any reason, the synthesis
compressor is shut down, then the fires in the heater will be extinguished
immediately. If this emergency should arise, a small flow of gas through the
heater coil may be maintained by including a flow of gas to vent upstream of
HV-1031. This flow of gas will provide some cooling for the heater coil, and the
drop in the loop pressure will serve to keep the start-up heater within its safe
operating zone and limitations.
It is unlikely that the heater coil will need any cooling flow after the loop pressure
has dropped to a level approaching that of the compressor suction. Under these
reduced flow conditions the temperature of the gas leaving the heater will rise
c sharply but the heat absorbing capacity of the piping, the converter basket, and
the catalyst beds will prevent any appreciable temperature rise in the catalyst
bed itself.
NOTE:
Low synthesis gas flow through H-21 02 detected by FT-1257 will actuate
interlock ESD-2116, which trips the fuel gas solenoid valves and closes fuel gas
block valves XV-1250A & B and open XV-1250C. If the Synthesis Gas
Compressor has to be shut down or trips during the reduction procedure, the first
step is to verify that the fires in the start-up heater have been extinguished.
Continue a flow of gas through the heater and converter until the converter
catalyst temperatures have been reduced approximately 35°C below the existing
reduction temperatures. If the interruption is for a prolonged period and the shell
temperatures of the converter fall below 3SoC, the system must be gradually
depressurised to a maximum of 14 barg. If the synthesis gas pressure is totally
lost on the loop for any reason, the loop must be kept under a positive nitrogen
atmosphere.


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p) Phase 2 : Hot Spot from 343°C to 410°C. Water formation from the catalyst
starts at a relatively low temperature (about 220°C) but to initiate the synthesis
reaction, the catalyst has to be heated to around 410°C. Thus, during phase 2,
the location of the hot spot is normally found at the top of bed No.1, and the
reduction temperature at the plenum thermocouples, should be raised at a rate
of 2° to 3°C per hour to the 410°C temperature level. Towards the end of this
period the pressure will be raised towards 105 barg in 3.5 barg increments.
As the pressure is raised and the temperature approaches the target 410°C,
ammonia synthesis will begin. Oevelopments should be observed closely and
ammonia percentages should be determined at the converter inlet and outlet.
Water vapour analyses should also be made on the gas at the converter outlet.
c [Refer to 00S-172 in the General Procedures manual for a description of the

procedure for determining H20 at the converter outlet and the necessary
apparatus and chemicals should be on site and ready for use when required].
The water vapour concentration at the converter outlet should not be allowed to
exceed the catalyst vendor's recommendations, i.e. 3,000 ppm by volume.
Should the analyses exceed these recommendations, the rate of temperature
and pressure increase should be slowed somewhat.
Ouring this period of catalyst reduction, it will probably be necessary to reduce

the flow rate through the start-up heater in order to increase the heater outlet
temperature without "overfiring" the burners. Adjustment of the cooling flow
through the annular space of the converter must be made as required to keep
the shell temperatures, top and bottom, as equal as possible using the SP-173
valve with due regard for the simultaneous effect on the gas flow through the
heater.
At some point in the catalyst reduction, the ammonia produced will be in
c sufficient quantity to combine with the reduction water and produce an aqua
ammonia solution. An aqua ammonia solution of 21% has a freezing point of
approximately -40°C.
The reduction gases from the converter, containing water vapour and some
ammonia vapour are cooled in the ammonia converter effluent steam generator
E-2123 in heat exchange with boiler feed water, and in the converter
feed/effluent exchanger E-2121.
As the catalyst reduction progresses, increased conversion will take place,

producing more ammonia, which must be condensed for recovery in the 0-2106
Flash Separator. Ammonia refrigerant was previously established in 0-2109
Refrigerant Receiver and it will now be possible to establish levels in the 0-2120,
0-2121,0-2122 & 0-2123 Flash Orums as more ammonia is produce in the
R-21 05 converter, if these levels have not been established earlier.
As the level builds-up in 0-2106 Ammonia Separator, the aqua ammonia

produced will be level controlled by LlC-1013 into 0-2107 Letdown Orum. From
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p) Phase 2 : Hot Spot from 343°C to 410°C. Water formation from the catalyst
starts at a relatively low temperature (about 220°C) but to initiate the synthesis
reaction, the catalyst has to be heated to around 410°C. Thus, during phase 2,
the location of the hot spot is normally found at the top of bed No.1, and the
reduction temperature at the plenum thermocouples, should be raised at a rate
of 2° to 3°C per hour to the 410°C temperature level. Towards the end of this
'period the pressure will be raised towards 1'05'barg in.3.5 barg increments.
As the pressure is raised and the tempe'rature approaches the target 410°C,
. C\mmohia synthesis will begin .. Developments should be observed closely and
. ammonia percentages should be determined at the converter inlet and outlet..
Water vapour analyses should also be inadeon the gas at the converter outlet.
c [Refer to ODS-172 in the General Procedures manual for a description of the

procedure for determining. H2 0 at the converter outlet and the necessary
apparatus and chemicals should be on site and ready for use when required].
The water vapour concentration at the converter outlet should not be allowed to
exceed the catalyst vendor's recommendations, i.e. 3,000 ppm by volume.
Should the analyses exceed these recommendations, the rate of temperature'
and pressure increase should be slowed soni'ewhaf.·
During this pe(iod of catalyst reduction, it will probably be necessary to reduce

the flow rate tbrough the start"up heater in or.der to increase the heater outlet
temperature without "overfiring" the bumers:. Adjustment of the cooling flow
through the annular space of the converter must be made as required to keep
the shell temperatures; top and bottom; as equal as possible using the SP-173
valve with due r.egard for the simultaneous effect on the gas flow through the
heater. .
At some point in the cata.lyst reduction, ttie ammonia produced will be in
c sufficient quantity to combine with the reductibnwater and produce an aqua

ammonia soluiion. An aqu.aammonia solution of 21 % has a freezing point of
.approximately -40°C. . .
The reduction gasesJrom ilie converter, cont~i~ng water vapour and some
ammonia vapour are cooled in the. ammonia converter effluent steam generator
E-2123 in heat exchange with boiler feed water, and in the converter
feed/effluent exchanger E-2121. .
As the catalyst reduction progresses, increased conversion will take place,

producing more ammonia, which must be condensed for recovery in the D-2106
Flash Separator. Ammonia refrigerant was previously established in D-21 09
. Refrigerant Receiver and it will now be possible to establish levels in the D-2120,
D-2121, D-2122 & D-2123 Flash Drums as more ammonia is produce in the
R-21 05 converter, if these levels have not been established earlier.
As the level builds-up in D-21 06 Ammonia Separator, the aqua ammonia

produced will be level controlled by L1C-1013 into D-21 07 Letdown Drum. From


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0-2107 the water formed during the converter catalyst reduction will be drawn off
as described in para. 6.3.18.c) above.
Continue sampling and confirm operation of the ammonia injection pump P-2120
to ensure the aqua ammonia concentration is maintained at no less than 20% to
prevent freezing of water in the gas as it passes through the refrigeration flash
drums.
q) Phase 3 : Continuing Reduction to 427°C & Decreasing Heater Load. Hold

the No.1 inlet temperature at 410°C to 427°C as required for reaction. As a
result of the synthesis reaction in bed No.1, temperatures at the inlet of bed No.2
will gradually increase to approximately 416°C. Ultimately the reaction in the
c converter beds will provide all the heat needed and it will be possible to reduce
the start-up heater firing. As this is done, the converter pressures may be
gradually increased, which will tend to improve the stability of the reaction. The
pressure can now be increase incrementally by 3 to 5 barg per hour towards 125
barg at the converter outlet and held after each step so that conditions can be
lined out.
Since the temperatures have a tendency to increase during the transition period,
the flow of gas through the main converter inlet SP-173 should be increased as
the firing of the heater is reduced. When this has been done a number of times,
the point will be reached where gas coming from the heater is appreciably cooler
than the gas that has been warmed in the converter annular space. Eventually,
gas flow through the heater can be used as quench for the control of bed No.1
inlet. The converter (annular space) bypass (HIC-1025) will serve as quench
(when necessary) after flow has been stopped through the heater.
r) Phase 4 : Moving Towards Full Production It is desirable to take the heater

off line over a period of 3 to 4 hours so that the temperature of the castable is
c reduced to a point when flow~hrough the heater can be stopped soon after the
fires are extinguished. When the. gas flow through the heater is stopped, shut
the heater inlet butterfly valve. Verify that the fuel gas block valves have been
closed and isolate the header from the natural gas line.
Over the next few hours of operation, the converter conditions should be moved
towards normal design values. The catalyst bed No.1 inlet should be
somewhere between 399°C and 427°C. The converter pressure will stabilise at a
point where, all of the available feed is being consumed by the ammonia
synthesis loop, the ratio is 3 to 1 hydrogen to nitrogen, and the converter bed
temperatures are lined out at their optimum production values. Purge will be
required to control excessive inert build-up.
During the first days of operation of a new catalyst charge, it is always desirable
to keep the operating temperatures relatively low. Holding the temperature down
for the first five days to a week will limit the production, but it is expected to
achieve optimum catalyst activation. The catalyst is fully reduced when the
water content of the product becomes nil at any condition of operation ..
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('
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During this phase, the aqua ammonia concentration being controlled into D-21 07
will gradually reach 95% ammonia. At this point, the liquid will be let down to the
refrigeration system instead of being disposed of via the temporary start-up
connection provided at the FIC-1171 flow control valve. As the levels in the
refrigeration system increase, ammonia will be directed to storage from D-2120
under level control of LlC-1 024.
s) Line out Unit Conditions. Inerts in the loop should be controlled at 8%

maximum (Methane + Argon) in the converter feed. Up until now the purge gas
has been routed through Scrubber T-21 03 by-pass to atmospheric vent. The
purge gas recovery section is now commissioned as outlined in following
c subsection 6.3.19.
Adjust unit conditions so that the desired hydrogen/nitrogen ratio is obtained in

the synthesis section. Maintain the highest circulation rate possible in the
synthesis section within the limitations of stable converter temperatures. This
will yield maximum ammonia production as the overall plant throughput is
increased to yield 1,200 tid ammonia.
The ammonia product should be analysed on a routine basis for water and oil.
The oil content will gradually decrease over the first two weeks of operation
. down to virtually zero.
Synthesis gas for the desulphurisers continues to be taken directly from C-21 03
interstage .. When there is no further need for use of start-up hydrogen rich gas
to the suction of the Feed Gas Compressor, C-21 02 , C-21 02 can be shut down.
At the same time direct natural gas feed must be established using HIC-1027 to
carefully coincide with C-21 02 shutdown. Note that should it be necessary to
operate the system with a natural gas supply pressure in excess of 50 barg then
c for downstream protection, the control valves (PV-1087A1B) must be blocked in.
6.6.23 Commissiori Purge Gas Scrubber [T-21 03]
As ammonia production increases, the purge gas rate should be adjusted to

maintain the inert gas content of the converter feed stream at about 8%. Initially,
T-21 03 will be valve isolated and the purge gas should be directed entirely to the
ammonia vent via T-21 03 by-pass SG1 033-6" and control valve PV-1033B. As
converter conditions stabilise, purge gas will be routed into T-21 03 Scrubber and
T-21 04 Ammonia Stripper will be put into service.
Establish a high level of condensate water in the bottom of the Scrubber via the 1'h"
start-up water connection on the bottom outlet line. Start P-2130AlB pump and
establish a high level in Stripper T -2104, then shut down pump. MP steam flow will
then be started to E-2160 Ammonia Stripper Reboiler and the temperature increased
towards design. Ammonia reflux from pump P-2120 will then be established to the
top of T-21 04.
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With design pressure established on T-21 04, circulation flows between T-21 03 and
T-21 04 will be established. Purge gas will initially be routed to the NH3 vent and
eventually to H-21 01 Reformer fuel gas. Note that in the event of loss or low flow of
purge gas to the fuel gas system, low flow alarm FAL-1258 will alert the operator to
the need to reduce the Arch burner firing on the Primary Reformer. Should this
reduction not be immediate or sufficient, then low/low flow on FT-1258 will actuate
interlockESD-1031 which will close block valves XV-1031 on the purge gas and
XV-1030 on the Synthesis Gas connections to the fuel gas. At the same time it will
reset PIC-1 002 pressure controller on the fuel gas supply line to 25% of its nominal
value.
" Ammonia from T-21 04 will be routed to 0-2109 via E-2127 and controlled by
C"
PIC-1034, with the water inventory in the base of T-21 04 maintained as required by
adding condensate from the outlet of E-2160 Reboiler tubes.
The feed flow to the converter should be increased at a rate proportional to the limit
of available synthesis gas. The converter effluent steam generator E-2123 is in
service and steam production will be increased as feed to these items increases.
The blowdown rates should be adjusted to control the solids in the system and
conserve chemical usage.
6.6.24 Purge and Chilldown of NH3 Storage & Loading Facilities (OSBL)
a) Inert Gas for purging will be introduced via the tie-in with the Ammonia Unit
rundown line and into the tank via the dip pipe. Alternatively nitrogen supplied
from road tankers may be tied-in to the connecting point located on the Ammonia
Unit rundown line and adjacent to the access road.
b) The air from the tank will then be displaced by inert gas until the gas at the 3
inch top atmospheric vent (nozzle K) is at a maximum of 3.0% Oxygen.
C Care must be taken during this procedure that the design pressure (0.15
barg) of the tan k is not exceeded.
c) On completion of the Inert Gas purge, the tank will be pressured to a maximum
of 0.1 barg and all flange connections soap tested and checked leak free.
d) Connect-up a supply of ammonia from a road tanker to the 3 inch start-up,

connection on the Ammonia liquid inlet line. Line-up this supply to the internal
dip pipe at the bottom of the tank.
e) Bleed-in a small amount of liquid ammonia which will vaporise at the dip pipe.
The vaporised ammonia will then displace the inert gas.
f) Continue the ammonia injection to the dip pipe on the tank until the oxygen
content at the high point vent is below 0.5%.
g) Cooling down of the ammonia storage tank must be done gradually and


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uniformly, over an extended period of time to avoid thermal stresses of the tank
walls, floor and roof. The tank must be cooled from ambient temperature to the
normal operating temperature of -35°C at a maximum cool down rate t!lf 14°C per
hour as described in the following procedure:
h) Start dry instrument air purge to the outer annular space on pressure control and
place the pressure controlled vent to atmosphere in service.
i) Resume the liquid ammonia injection to the tank for cooling purposes, but
switch from the dip pipe to the internal spray ring.
j) As pressure starts to build-up in the tank, the Ammonia Refrigeration Unit
c~ (C-51 01) must be started. This will remove the flashed ammonia vapour and
maintain the tank below the design pressure of 0.15 barg Any residual nitrogen
should be vented at the refrigeration unit until minimal.
k) Continue to supply the liquid ammonia to the internal spray ring but staying
within the limit of the compressor operation whilst achieving the cool-down rate
at maximum of 14°C per hour.
I) During the cool-down, a log must be kept to record all floor temperature sensors,
metal temperatures, tank pressure and tank internal temperatures initially at 30
minute intervals, then hourlY. Differential temperatures between sensors in
excess of 20°C must be avoided.
m) When the tank is down to design temperature, liquid ammonia will start to
accumulate. Continue to import sufficient ammonia into the tank to build
sufficient inventory to be available for Ammonia Unit start-up and the
commissioning of the truck loading facilities.
c n) At this stage the Ammonia Refrigeration Unit (C-51 01) will be set on automatic
control to maintain the Storage Tank at the operating pressure. Once the
Ammonia Unit is in steady operation, the amrnonia vapour from the storage tank
due to heat leaks, vapour displacement and run down, is returned to the
Ammonia Unit refrigeration system for reccondensing. C-5101 may then be shut
down.
0) The entire loading system from the Ammonia Transfer Pump suction header
back to the atmospheric relief valve by-pass vent on the return vapour line from
the tanker loading hoses will be inert gas purged. The by-pass lines provided
between the tanker loading hoses and the vapour return lines at the loading
station will be used.
p) Then purge the same system with ammonia vapour until the oxygen level at the
vent is less than 0.5%. This is effected by bringing in a small amount of liquid
ammonia into the pump suction header from the storage tanks and allowing to
vaporise.


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q) On completion of the above purge, trial run both Ammonia Transfer Pumps by
circulating liquid ammonia back to the storage tank. At this point the vapour
return system from the loading arms may be lined-up back into the storage tank.
6.7 START-UP LINES AND REQUIREMENTS
a) Line A-1002-4" is provided from the discharge line of C-21 01 Air Compressor
and connects to the inlet line to the primary reformer mixed feed coil. Its
purpose is for the line blowing and dusting of the Primary Reformer, Secondary
Reformer and HT Shift catalysts during pre-commissioning and an isolation valve
and two blinds are provided which should be in the closed position after use.
c b) Chemical cleaning nozzles and blank ends are provided throughout the steam
generating system for chemical cleaning purposes. These will enable the
installation of temporary piping for chemical cleaning by the sub-contractor as
per the note made on each steam system drawing. On completion of chemical
cleaning all temporary cleaning lines will be removed and blank ends replaced.
c) Start-up Vent V-1019-6" is a high pressure steam vent located at the outlet of
H-2101 steam superheat coil and is used for commissioning the auxiliary boiler
and steam generating system. [Refer to Unit Start-up procedure subsection
6.6.2d). This vent enables the venting of steam first produced on firing the
Auxiliary boiler when the HP steam pressure is slowly raised by shutting in of this
vent until steam can be let down into the MP steam header and the vent valve
then finally closed.
d) For the nitrogen pre-heating of the Hydrogenator, Desulphurisers, Primary and

Secondary Reformers and HT Shift catalysts; the air compressor C-21 01 2nd
stage discharge is blanked shut with the 2nd stage start-up vent to atmosphere
wide open. The following start-up lines are also used for circulating nitrogen:
('
• . PG-1044-6" from the 4th stage discharge of Air Compressor C-21 01 to the
inlet of H-2101 Primary Reformer Feed Gas Preheat coil is used at start-up
for the nitrogen heating of the catalysts. .
• PG-1040-10" from the outlet of the HT Shift converter and returning to the
3rd stage suction of C-21 01 Air Compressor via the inter-cooler inlet. This
also enables cooling of the returning nitrogen stream. It should also be
noted that a return nitrogen flow from the outlet of the LT Shift converter is
also tied into the same line (PG-1042-10").
• N-1010-2" from the nitrogen supply system ties-in to the 3rd stage suction of
the Air Compressor C-21 01 to provide make-up nitrogen.
e) AM-1065-2" supplies liquid ammonia to the inlet to the Primary Reformer mixed
feed coil for the dissociation of liquid ammonia to provide hydrogen. Ammonia is
pumped from the Refrigerant Receiver, D-21 09 using the Ammonia Reflux
(
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Pumps, P-2120 AlB which can both be run together at maximum rate to obtain
sufficient supply if required.
f) PG-1046-8" and NG-1024-8" are start-up lines from the 4th stage discharge of
C-2101 to the inlet line of the LT Shift converter R-21 09 via Start-up Cooler
E-2173 (or via E-2172 Start-up Heater) and are used to reduce the LT Shift
catalyst when using nitrogen as the carrier. The air compressor will be lined up
as described previously for nitrogen circulation, with start-up lines PG-1042-10"
& PG-1040-10" retuming the nitrogen from the LTS converter outlet to the 3rd
stage suction via the intercooler.
g) Hydrogen for desulphurisation and/or LTS Reduction can be produced by

(' cracking ammonia in H-2101. It is supplied from the Raw Gas Separator,
0-2102 via PG-1034-3" which is connected to the Feed Gas Compressor suction
for desulphurisation; or via PG-1019-1%" to the LTS converter inlet line by line
pG-1034-3" for catalyst reduction.
h) When 0-2103 gas is used as hydrogen recycle for desulphurisatibn, it is routed

to C-21 02 suction via PG-1038-3" and PG-1034-3". Should it be used for LTS
catalyst reduction then it will be routed to the LTS converter inlet via
PG-1019-1%".
i) NG-1022-6" supplies natural gas from the outlet of R-21 08 AlB Oesulphurisers
to the inlet of the LT Shift converter via the Start-up Cooler, E-2173 when using
natural gas as the carrier for the reduction of the LT Shift catalyst. Natural gas
carrier is then vented from the outlet of the LT Shift converter via start-up vent
V-1006-10" and V-1007-16" to the Front End Vent.
j) AM-1050-1%" is a start-up line from 0-2109 to the inlet of the Ammonia

Synthesis Loop Cooler, E-2124 using pumps P-2120 AlB. It is used as an
c ammonia injection point to prevent freezing in the E-2120 Unitised Chiller during
the initial aqueous ammonia make from catalyst reduction.
k) SG-1041-1%" is the back-up hydrogen supply for desulphurisation from C-21 03

3rd Stage Suction line and which connects back to the Feed Gas Preheat Coil
inlet line.
I) PIC-1169 is a vent located on the outlet from Oesulphurisers R-21 08 AlB to the.
front end vent via V-1090-10", and is used to vent natural gas during heating of
catalysts prior to start of desulphurised feed gas to the primary reformer.
m) Vent line V-1005-18" located on the inletto HT Shift converter R-21 04 is used
during start-up to heat-up the catalyst by back-flowing MP steam from the
converter outlet to the front end vent.
n) Vent line V-1007-16" at the inlet to the LT Shift converter, R-21 09 and used
during commissioning when venting process gas to the front end vent, prior to
starting flow through the C02 system exchangers.

$JM.w. Kellogg Limited Operating Manual

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0) Vent line V-1006-10" on outlet from LT Shift converter, R-2109 and ties-in to
vent line V-1007-16". This vent is used for the nitrogen purging of LT Shift
catalyst after shut-down, with the nitrogen being introduced to the converter inlet
line via a hose connection.
p) Vent line V-1008-14" located on the outlet line from 0-2102 to the CO2 Absorber
is used to vent process gas prior to routing through the Absorber.
q) PIC-100S located on the inlet to the Methanator, R-2106 and is used to vent
process gas to the front end ventvia V-1013-14''', prior to start of Methanator.
Also on emergency trip and closure of the Methanator inlet valves, this vent will
c/ r)
open and vent the process gas.
PIC-1004 is located on the outlet line from Synthesis Gas Compressor Suction
Orum, 0-2104 to compressor, C-21 03 and is used to vent process gas to the
Ammonia ventvia V-1012-14", prior to the start-up of the synthesis loop. It will
also vent the process gas on synthesis loop shutdown.
s) Vent line V-1017-10" to the Ammonia vent is located on the return line to the
3rd stage of the Synthesis Gas Compressor, C-21 03 from E-2121 and is used
for the initial purging and pressuring of the synthesis loop and during the
Converter catalyst reduction period prior to going onto the recycle flow reduction.
This vent can also be used after an emergency shut-down if the converter
differential metal temperatures top to bottom exceed maximum design, when it
can be opened to establish a flow of gas through the converter by slowly venting
down the synthesis loop towards atmospheric pressure.
t) NG-102S-1%,' from the start-up lines from the Oesulphuriser outlet downstream
of E-2173and tying-in to T-21 01 Overhead line and is used to pressure the CO 2
c Absorber with natural gas at start-up.
u) .Ammonia may be imported to the Ammonia Unit for start-up by warming product
in Offsites heater E-51 01 and pumping back up lines AM-S1039-4", AM-1039-4",
AM-1023-4" and AM-1080-2" into 0-2109.
Cold ammonia may also be imported from Offsites storage by using line
AM-S104S-4" connected to P-51 01 AlB discharge and backing-up ammonia
along the rundown lines AM-S1001-4" & AM-1034-4" and jumping into 0-2109
via AM-1D42-3".
Note: When importing ammonia from Offsites, great care must be taken to
ensure that 0-2109 deSign minimum temperature is not exceeded.
v) AM-1066-3" form 0-2109 outlet to 0-2120/2121/212212123 supplies quench

ammonia described in 6.6.17.e) at start-up.


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7 NORMAL OPERATION
7.1 INTRODUCTION
a) The start-up procedures presented in Section 6.0 are for the initial start-up of the
Ammonia unit and in subsequent start-ups, certain of these procedures may be
eliminated or modified in whole, or in part, as may be applicable to the particular
situation. .
c b) Subsequent start-ups of the front end will employ a closed nitrogen

circulation to accomplish the heating to above condensation temperature.
c) Normal operation and control of the unit with operating conditions and
variable adjustments when necessary will be as outlined in Section 3.0 of
this manual with the following modifications:
7.2 START-UP WITH ACTIVATED CATALYSTS
7.2.1 Hydrogenator and Desulphurisers [R-2160 & R-2108A/B]
These vessels are nitrogen purged at shutdown and maintained under a

nitrogen blanket. Restart is effected by "once through" flow of feed gas
followed by hydrogen injection as for the initial start-up.
7.2.2 Primary and Secondary Reformers [H-2101 & R-21 03]
c a) Catalysts in the primary and secondary reformers are partially

re-oxidised by steam at each shut-down, and are reduced during
the subsequent start-up by feed introduction with excess hydrogen.
b) Cold catalyst should not be subjected to steam re-heating as the

condensation and evaporation physically damages the catalyst The
re-start therefore involves heating the catalysts under a closed-loop
nitrogen circulation, up to about 204°C, or above the condensation
temperature of 40 barg MP steam which is then introduced as described
for the initial start-up.
c) During brief shut-downs of the Ammonia plant, the primary and

secondary reformers may be kept warm by "once-through" steam
flow and firing of the H-2101 burners until such time as feed may
be introduced.


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7.2.3 HT and LT Shift Converters [R-21 04 & R-21 09]
7.2.3.1 HT Shift Converter
• During a brief shutdown the HT Shift catalyst is kept hot with a flow of
steam. Take all precautions possible to minimise formation of
condensate and keep any water well drained off. Water tends to
weaken the binder used in the catalyst manufacture. During
re-starting, the process stream from the secondary reformer is put
through the converter when the effluent temperature from E-21 02 is
the same as that in the HT Shift catalyst bed.
C
/
• The converter is then placed on stream as outlined previously in the
"Initial Start-up" section. After a prolonged shutdown, the catalyst will
be re-heated by nitrogen circulation also as outlined in the Initial Start-
up procedure.
7.2.3.2 LT Shift Converter
• Prior to a brief shutdown the converter was purged with inert gas as it
was taken out of service to sweep steam out of the vessel ensuring a
reasonably dry atmosphere.
• If the catalyst bed has not cooled below 180°C (if restarted at 50%
design pressure) the feed can be turned through the converter using
the principals given previously.
• After a prolonged shutdown and if the catalyst has cooled below

180°C, the catalyst will have to be reheated with Methanator feed gas.
c
With Methanator R-21 06 inlet shut, Methanator feed gas will be
directed via start-up lines PG1030-12" through the Methanator Feed
Heater, E-2172 and then to the inlet of the LT Shift converter via
PG1050-8", venting at the outlet of R-21 09. Once the temperature is
above 180°C the feed may be turned through the converter using the
principals given previously.
NOTE: The above re-start of the LT Shift converter assumes that the
catalyst is in a completely reduced start. If this converter was purged on
shutdown with an inert gas containing trace amounts of O2 , partial
re-oxidation may have taken place. In this event the LT Shift catalyst
should be re-reduced as noted in the initial start-up as a precautionary
measure.
7.2.4 Methanator [R-21 06]
This reactor is "bottled up" on a shutdown and pressure maintained with

synthesis or inert gas to keep air excluded. The feed may then be tumed
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through the activated catalyst as note for the initial start-up.
7.2.5 Ammonia Converter [R-2105]
a) Following a brief shutdown during which the converter catalyst

temperature remains between 370 to 400°C, it is usually possible to
regain the synthesis reaction without recourse to the start-up heater.
• Synthesis gas is introduced very slowly through the normal inlet.

The circulation rate is held very low at first and is increased as
rapidly as the reaction will allow without depressing the converter
temperatures. High converter pressure will aid in regaining the
c synthesis reaction. NOTE: To avoid excessive temperature

differentials between the top and bottom of the converter shell, a
minimum volumetric flow rate of 2,000 m'lh should be maintained
through FI-11 05 on the converter inlet as outlined in Section 6.3.1B.
of this manual.
• The BFW supply valve FV-1020 to E-2123 exchangers must be

manually reset in the field and the BFW flow to E2123A1B gradually
restored as the converter exit temperature rises.
• Once the converter temperatures begin to increase as a result of the

heat of reaction, the cold feed inlet and the quench flows may be
re-established as required to develop a normal temperature profile
through the converter. Quench flow should be established
cautiously, since the usual tendency is to overquench and smother
the reaction.
b) Following a prolonged shutdown during which the converter catalyst
c temperature has cooled below 370°C, the synthesis reaction may not
start upon resumption of synthesis gas feed flow and it will be necessary
to raise the catalyst temperatures to the level at which the synthesis
reaction will start.
• When it is necessary to use the heater, the system will be aligned

for circulation with the start-up heater in the circuit as in the case of
Phase 1 of the catalyst reduction procedure. (It will not be
. necessary to use the venting procedure, except as required for
inerts control). The refrigeration system will be in full operation.
• Do not exceed the temperature/pressure limitations for H-21 02

start-up heater.
• As the converter temperatures begin to increase, more feed gas

must be admitted through the converter normal inlet to control the
converter shell temperatures. This division of flow permits a higher
circulation rate. Maintain maximum flow through the heater and


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reduce the rate of temperature increase at the heater outlet as the

converter temperatures approach 370°C.
• The BFW supply valve FV-1020 to E-2123A1B exchangers must be

manually reset in the field and the BFW flow to E-2123A1B gradually
restored as the converter exit temperature rises.
• When the converter temperatures reach a level at which the

synthesis reaction starts (usually about 370°C) the heat of reaction
will cause an increase.in the rate of heating of the catalyst beds and
fresh synthesis gas must be added to the system to maintain
constant system pressure. As this effect becomes obvious, gas flow
c must be increased through the converter normal inlet whilst

maintaining flow through the start-up heater to protect the coil.
Converter temperatures must be watched closely while the heater
firing is reduced as rapidly as possible consistent with the thermal
stability of the converter.
• The start-up heater should be removed from service in the

same manner as that outlined in Phase 4 of the catalyst
reduction procedure.
• Cold feed flow and quench flow should be started at conservative

rates to avoid over quenching and temperature cycles in the
converter.
• Gradually increase circulation rates towards maximum, and as liquid

accumulates in the ammonia separator, the liquid level controller for
the separator should be placed in service to discharge the product to
0-2107. Purge gas flow may be started as the system inerts content
c •
dictates.
Feed flow to the converter should be increased at a rate consistent

with constant operating pressure up to normal ammonia production
rate or to the limit of available synthesis gas.
7.3 RESTART OF CO2 REMOVAL SYSTEM
If the plant has been shut down for a short period only due to an upset it may
have been possible to keep the C02 system circulating in which case it is
only necessary to reintroduce gas to the absorber and line out the solution
flows and temperatures. Reboil rates should be restored reasonably slowly to
avoid the possibility of disturbing the column packing.
A longer shut down would require recommissioning as described in section

6.6.12


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7.4 OPERATION AT 60% DESIGN CONDITIONS
a) Natural gas rate will be adjusted to 60% process design. Hydrogen rich
gas from C-21 03 will be adjusted down towards the 60% rate depending
on required sulphur outlet analysis from the Desulphuriser section.
b) Process steam to the primary reformer should be slowly decreased to

the rate of 57000 kglhr - approximately 65% design rate.
c) Steam to the steam/air coil will be kept at the 100% design rate of 3558
kg/hr.
c d) Process air rate to the secondary reformer will be adjusted towards the
60% design rate and adjusted for the required nitrogen to hydrogen ratio
for synthesis loop operation.
e) Primary reformer tube outlet temperatures will be adjusted to give

the required methane outlet design from the primary reformer and the
minimum methane slip from the outlet of the secondary reformer.
f) C02 system solution rates will be kept at approximately 100% design

to keep loading on the towers for efficient CO2 removal. .
g) On reduction in rates the kickback flows for anti-surge settings will

adjust the control valves as required on the C-21 01 Air Compressor,
C-21 02 Feed Gas Compressor, C-21 03 Synthesis Gas Compressor and
C-21 05 Ammonia Refrigerant Compressor.
h) Purge gas flow from the synthesis loop will be adjusted as required for
design synthesis loop inerts level.
c 7.5 WARM [37.5°C] AMMONIA PRODUCTION
When making warm ammonia product, the refrigeration system will operate
as follows:
a) A fixed amount of D-2107 liquid will be routed to D-2120 under the control
of FIC-1171 to satisfy the level and refrigerant requirements associated
with this system. Then with selector switch on D-21 07 level controller
LlC-l012 in the ''WARM PRODUCT" position, the balance of D-21 07 level
will be routed to D-2123 under the control of LlC-l 012 with a small
amount of flash vapour being routed manually as ammonia wash to
D-21 09.
b) Hot ammonia from D-21 09 is pumped by the Warm Ammonia Product Pumps,
P-2113 AlB under pressure control of PIC-l 028 to the Urea Plant and metered
by integrator FR & FQI-l060 located on the Ammonia Unit. The temperature of


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the product leaving the ammonia unit is indicated by TI-1 084 and a sample point
(S-017) is provided for final product quality control.
c) UC-1015 will then control 0-2109 level by routing to 0-2123 the excess
not being pumped by P-2113 AlB, although a small amount of 0-2109
liquid is routed as reflux to Ammonia Stripper, T-21 04 using NH3 Reflux
Pumps P-2120AlB.
d) UC-1021 on 0-2123 will operate control valve LV-1021 directing excess

ammonia to 0-2122. Similarly, UC-1022 on 0-2122 will direct excess
ammonia to 0-2121, and UC-1023 on 0-2121 will direct excess ammonia
c
to 0-2120.
e) UC-1024 on 0-2120 will operate control valve LV-1024AlB on P-2124

AlBIC discharge line, and with one pump on line, will send a small excess
of "Cold" ammonia to the offsite storage tank, thereby avoiding any
accumulation in 0-2123.
7.6 COLD [-35°C] AMMONIA PROOUCTION
When making cold ammonia product, the refrigeration system will operate as
follows:
a) With selector switch HS-1024A on 0-2107 level controller UC-1012 in

the "COLO PROOUCT" position and switch HS-1024B suitably
positioned, 0-2107 liquid level will be routed to 0-2120 via control valve
FV-1171 under the control of UC-1012 on 0-2107. No liquid will be
routed to 0-2123 in the cold product case but a small amount of flashed
vapour will continue to be routed manually as ammonia wash to 0-2109.
c b) Warm Product Pumps, P-2113 AlB will be shut down and UC-1015 will
control 0-2109 level by letting down ammonia to 0-2123.
c) UC-1021 will control 0-2123 level by letting down to 0-2122;

UC-1022 will control 0-2122 leVel by letting down to 0-2121 and
UC-1023 will control 0-2121 level by letting down to 0-2120.
d) UC-1024 on 0-2120 then operates the control valve directing the

discharge flow from P-2113 AlBIC to the offsite storage tanks to control
0-2120 level. This will require two pumps in service and the cold
ammonia stream is metered by FQI and FR-1061.
7.7 UREA PLANT OPERATION WITH AMMONIA PLANT SYNTHESIS SECTION SHUT
OOWN
The Urea Plant will be supplied with warm ammonia from the storage tank via the


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heater E-51 01 located at the storage tank. The Ammonia Plant warm product pumps
will be shut down and the warm ammonia line closed at the battery limits and isolated
from the Urea Plant.
The Granulation Unit and Urea Plant chillers E-4204 and E-4153 will be supplied with
warm ammonia chilling from the HP Ammonia Pumps' common suction line on the
Urea Plant.
Ammonia vapours from the above chillers will be retumed to the Ammonia Plant
Refrigeration Section 3rd Stage Ammonia Flash Drum (0-2122) and thence to the
Refrigeration Compressor. .
c The Refrigeration Compressor will be in service at the speed required to handle the
load provided by the vapours from the Urea PlanVGranulation Unit chillers and retum
these vapours as Cold Ammonia at -35 degC to the Storage Tank from Drum 0-2120
with the Cold Ammonia product pumps.
The Refrigeration Compressor will be operating with kick-back flows as required by

each stage and liquid quench from 0-2109 as required for temperature control.
Ammonia Plant front-end feed rates will be adjusted to meet the Urea Plant C02 feed
requirements and the Synthesis Gas vented at the Synthesis Gas Compressor
Suction Drum vent.
Steam requirements under these circumstances will be no more than those for the
start-up case of the Synthesis Gas Compressor with the Refrigeration Compressor on
stand-by at minimum governor speed and total kick-back.
As the Ammonia to the Urea/Granulation chillers is provided from the

Storage Tank which contains minimum inerts, there will be minimum
c venting required from 0-2109. 0-2109 vented gases (if any) should be
routed directly to the Ammonia Flare and the Ammonia Recovery system
(T-21 03/T-21 04! P-2130NB) may be shut down.
7.B NORMAL OPERATION OF NH3 STORAGE & LOADING FACILITIES (OSBL)
7.B.1 Normal Operation of NH3 Storage Tank
Note: The following description of the Ammonia Storage & Loading

Facilities is based on the original design engineering package and reference
should be made to the latest issue of the Oftsites P&IO's to identify any later
changes or modifications.
a) With the Ammonia Unit in normal operation, liquid ammonia at -35°C is

rundown to the Storage Tank.


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b) Once the Ammonia Unit is in steady operation, the ammonia vapour

from the storage tank due to heat leaks, vapour displacement and run
down, is returned to the Ammonia Unit refrigeration system for
re-condensing. The offsite refrigeration unit (C-S1 01) is then shut-down.
7.8.2 Normal Operation of Road Tanker Loading Station
a) Ammonia liquid is transferred to the Ammonia Road TankerArms using

the Ammonia Transfer Pumps (P-5101 AlB) via the Ammonia Heater
(E-51 01) where the temperature control is set to obtain the required
ambient temperature for the tanker loading of liquid ammonia.
c b) The Road Tanker Loading Station is provided with two loading arms
each with a loading capacity of 25000 Kg /hr. Trucks will be loaded at
ambient temperature and pressure with the displaced vapour from the
road tanker being returned to the ammonia storage tank. The road
tankers are kept under a back pressure by a control valve located in this
return line set at the pressure dependent upon the ambient loading
temperature required.
NOTE: If road tanker being loaded did not previously contain ammonia
then it may be necessary for it to be purged to ensure contaminated
vapour is not routed into the storage tanks. This may be done by initially
routing the displaced vapour via the relief valve by-pass located on the
vapour return line to the tanks.
c) On completion of loading a road tanker, the isolation valves upstream

on both the loading and vapour return arms are closed. The pressure in
the two lines is then equalised by opening the balance lines between
them. The loading arm to the tanker should remain open to allow free
c draining of any liquid ammonia remaining in the loading arm. The

loading valve and vapour return valve at the road tanker may then be
closed and the hoses carefully disconnected.
To avoid the methanol pressure in E-5101 continuing to rise when no load,

PT-1050 will trip the steam control valve PV-1050 when the methanol
pressure reaches 35.0 kg/cm2g.
7.8.3 Normal Operation of Bottle Loading Station
a) Before loading a bottle, it should be depressurised down to

approximately atmospheric pressure via a knockout pot connected to
the vapour balance lines between the storage tanks. Note: To avoid
possible contamination of the storage tanks, only bottles previously
containing ammonia should be used. A portable hydrostatic testing
hand pump is provided to recertify used bottles when necessary.
b) The bottle to be loaded is then filled with liquid ammonia with the

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b) The bottle to be loaded is then filled with liquid ammonia with the
ammonia heater set at the required ambient temperature. The loading
is carried-out to an exact filling weight as specified for the bottle being
filled, using the ammonia bottle weight scales (V-5103)
7.B.4 Transfer of Warm NH3 Feed to Urea Unit from Storage Tank
When the Ammonia Unit is shut-down, it may be required to supply warm

liquid ammonia from the Storage Tank to the Urea Unit. This will be done
by commissioning the Ammonia Transfer Pumps and the Ammonia Heater
c (E-51 01) set at 35.2°C, and routing the warm liquid ammonia to the Urea
Unit via the connecting line located on the ammonia supply line to the road
tanker station.
7.B.5 Transfer of Ammonia to the Ammonia Unit for start-up
During the start-up of the Ammonia Unit it is necessary to provide an

inventory of ammonia for the refrigeration system via a line from the
discharge of the Ammonia Transfer Pumps back to Refrigerant Receiver
(0-2109). This vessel however is not impact tested and the import of NH3
should be carried-out slowly to allow it to warm-up in the line with the
temperature of the vessel being carefully monitored to ensure 0-2109
design minimum temperature is not exceeded.
7.9 TROUBLE SHOOTING

Troubleshooting is a method of solving problems. Once the problem is
(
,~_/ identified, a cause can be attached to it. Careful analysis should be made
such that the identified cause is truly the cause and not a symptom. Once
the cause is identified, remedies or solutions can be implemented.
Generally the problem solving technical sequence of steps is as follows:
Step (1) Identify the Problem

Step (2) Gather Information That Relates To the Problem
Step (3) Identify the Root Cause
Step (4) Formulate the Solution
Step (5) Test the Solution
Step (6) Implement the Solution
Step (7) Measure Effectiveness of the Corrective Action
If The Problem Persist Return To Step 1, Which Is To Identify the

Problem.
Obviously, the identification of problems cannot take place unless
standards of control limits are declared. Sampling, record keeping,
monitoring, and the use of calibrated instrumentation are key factors in the
(, assessment of process problems.
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8 SHUTDOWN PROCEDURE
8.1 NORMAL SHUTDOWN PROCEDURES

8.1.1 Summary of Shutdown
a) The following instructions apply to a normal shutdown of the plant, undertaken for
production requirements or for periodic maintenance and inspection of equipment.
In this sort of shutdown, as opposed to one forced by an emergency condition, it is
assumed that all parts of the plant are in good order and that the operation may be
c
performed without any element of urgency. Preparatory to reduction of the plant
feed rates, all interested parties must be notified of the coming reduced utility
demand.
b) The shutdown procedures for various sections of the plant are covered separately
here for convenience, although in a definite sequence. However, it should be
recognised that some of the operations can and should be carried out
concurrently. In the case of a shutdown for maintenance purposes, certain items
of equipment should be steamed prior to opening-up - the usual procedures being
to valve isolate, purge, blind isolate and then steam equipment before equipment is
opened and entered by those issuing the necessary "gas free" certificate. In any
event, the works safety regulations and procedures must be observed. In the case
of the various reactors, the relevant sections of this manual should be referred to
before vessels are opened to the air and oxidation procedures carried-out where
applicable. Care must be taken to ensure effective isolation between vessels and
lines to be steamed, and vessels containing catalysts that could be destroyed or
impaired on contact with water. All vessels that contain catalysts in the reduced
state must be maintained under a positive pressure of nitrogen to prevent ingress
of air.
c c) As each section of the plant is shutdown, gas analyser instruments will be taken
out of service and handed over to the instrument department for inspection and
servicing, while control instruments and recorders will also be passed on for
maintenance once they are out of service and no longer required for operational
purposes.
However. where reactors are to stand during the shutdown under pressure. with
catalysts in the reduced state. the appropriate temperature points throughout the
catalyst beds where installed, should always be available for reference and to this
end either a temperature recorder or indicator should always be in service.
d) It must be borne in mind that as each section of the plant is shut down, overall
steam production will fall due to the loss of heat as various effluent exchangers are
taken out of commission. However, stearn production will be maintained by the
increased firing of the auxiliary boiler burners and by increasing the prirnary
reformer furnace draft until the completion of reformer catalyst oxidation, or, if that
operation is not to be carried-out, before cutting feed out of the plant. If necessary,
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import steam can be used to supplement the unit's production.
e) During the period of increased convection draft, the temperature of the waste heat
coils must be watched carefully if flows are reduced and maximum tube skin
temperatures must on no account be exceeded. As reactors come off line, as with
the start-up, every effort must be made to avoid pressure and temperature surges
that might disturb the catalyst beds.
f) Since the amount and type of maintenance work to be carried-out will vary each
shutdown, no attempt will be made here to describe procedures for vessel
preparation as· these will of necessity be arranged to meet each individual case.
However, where the extent of maintenance requirements is known, every effort
( should be made to have the equipment ready to hand over as quickly as possible
after the item is shut down. Forward planning can be of considerable help in
accomplishing a quick handover.
8.1.2 Reduction of Flow Rates
a) The first step in the unit shutdown should be the stepwise reduction of the natural
gas feed rate to the minimum compatible with stable plant operation. This
minimum rate should be about 60% to 75% design rate.
b) The process steam rate to the Primary Reformer should be maintained at a greater
than normal steam to gas/steam to carbon ratio value whilst the feed rate is being
reduced. In any case, the steam should not be reduced below 45 tonnes/hour until
after natural gas has been taken out completely. It would be advantageous to hold
the steam to carbon ratio at 4 to 1 when the feed rate has been reduced to 60%.
However, the ability to do this depends on the quantity of steam, which is available.
c) The firing of the primary reformer and the process air rate to the secondary
c/ reformer should be reduced to maintain the product composition of the reforming

section near design. Process air will be reduced prior and proportionally to the
feed gas, but the hydrogen to nitrogen ratio is the determining factor. The air
preheat coil outlet temperature must be kept within design temperature limits. If
the temperature becomes too hot, more steam will be added into the coil.
d) The aMDEA solution circulation rate may be reduced slightly, assuming that CO2
leakage remains constant, but the rate should be kept as high as the availability of
heat for solution regeneration allows.
e) The temperature controllers must be watched to confirm that they remain on

control. It will be necessary to reposition the hand controlled butterfly valves
where these are worked in conjunction with temperature controlled butterfly
valves. The inlet temperatures to the high temperature shift, low temperature
shift, methanator, and ammonia converter should be maintained at their normal
values to maintain normal outlet gas compositions.


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8.1.3 Reduce Synthesis Section Feed Rate
a) As feed rate is reduced to the reforming section, synthesis loop feed rate will also
fall by action of the synthesis gas compression system controls. The reduction in
natural gas feed must be controlled so that the synthesis section suffers no drastic
temperature or pressure fluctuations.
b) As feed rates are reduced the synthesis gas compressor will tend to slow down by
the action of PRC-1006. Kickback controllers UIC-1007, UIC-1008 and HIC-l030
should ensure that a surge condition does not d.evelop at the reduced speed.
c
c) As the compressor slows it may be necessary to inch open the kickback valve
HIC-l030 to satisfy minimum flow requirements of the recycle stage. Ultimately,
the compressor will reach minimum governor speed after which the suction drum
D-21 04 pressure will tend to fall off as feed reduction is continued in the
reforming section.
d) When fresh synthesis gas rate reduction begins there will be less heat of
reaction in the synthesis converter and less cold quench and cold feed will be
required to maintain normal temperatures. The quench and cold feed controllers
must be adjusted to control the rate of temperature decrease in the converter.
e) The total recycle rate will also be reduced and kickback flow will increase.
f) Continue to remove purge gas from the synthesis loop pro-rata with front end feed.
g) The hydrogen supply for desulphurisation from D-21 03 will be switched to the
suction of Feed Gas Compressor, C-21 02.
NOTE: If the natural gas feed has been on direct supply via the compressor by-pass
c using HV-1027, start the Natural Gas Compressor C-21 02 and shut down the by-pass
flow.
8.1.4 Purge Gas Ammonia Recovery System shutdown

a) Prior to shutdown of the purge gas recovery unit, any purge to the fuel gas
system from PV-l033A should be taken out of service and purge gas vented to
the NH3 flare system through PV-l033B. PV-l033A should be placed in manual
and closed if open.
b) Once the purges from D-21 07, D-21 08 and D-21 09 are stopped, the ammonia
recovery system can be shutdown.
c) Continue normal circulation of the system until all of the ammonia has been
scrubbed and returned to the refrigeration system. This can be determined by
lab analysis.
d) Reduce and stop the steam flow to E-2160 to cool T-21 04 and the circulating
water.


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e) Once the water has cooled, circulation can be stopped by shutting down the P-
2130 pumps.
f) Levels can be maintained in the vessels, if desired, unless the system or

individual vessels need to be drained or transferred for maintenance purposes.
8.1.5 Stop Ammonia Conversion
a) Reduction of temperature in the synthesis converter will lead to loss of converter.

reaction. When this occurs, the temperature profile of the vessels will turn rapidly
downwards. Circulation through the converter must be reduced rapidly by opening
c the kick-back valve HIC-l030 and finally terrninated by closing the valves HIC-
1001 and HIC-l 031 and fully opening HIC-l 030. This termination of flow is for
controlling the speed of ternperature loss through the converter.
Note: When an ammonia converter is shutdown with no annular flow of

cooling gas, the heat in the beds rises and causes the metal temperature of
the top surface of the converter shell to increase and become hotter than the
bottom. In this situation it is normal for the converter to bow but during a
shutdown, close attention must be paid to the converter shell metal
temperatures. The design temperature of the converter shell is 325°C but in
a shut-down situation the metal temperatures may be allowed to exceed
325°C provided the following rules are adhered to:
• Depressurise to 98 bara if:
I.any metal temperature exceeds 350°C or
II. metal temperatures have exceeded 325°C for more than 3 days.
c • Depressurise further to 49 bara if metal temperatures have exceeded

350°C for more than one day.
• Depressurise to 15 bara if any metal temperature exceeds 370°C.
b) The converter may be cooled to about 50 to 75°C by continuing circulation of

synthesis gas if this is required. Usually no work on the converter will be required
and for long shutdowns the vessel might be cooled to about 160°C and then left
under synthesis gas pressure. For brief shutdowns every effort is made to
conserve heat in order to expedite the restart. In this latter case, recycle gas
circulation is discontinued as soon as possible in order to conserve heat remaining
in the catalyst beds.
c) As the reaction is lost in the converter, consumption of the make-up gas will
cease and the pressure on the suction of the compressor will tend to rise. The
vent on the Compressor Suction Drum, D-21 04 will open via PIC-l 004 due to the


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increase in pressure.
d) It should be borne in mind that steaming in E-2123A will cease and water must fill
the space normally occupied by the steam in the piping to the steam drum. During
this transition period the stearn drum level can be expected to drop and to avoid
the system from becoming unstable, the operator should monitor the condition and
let the control system slowly and smoothly correct for it.
e) Drain all ammonia from the separator D-21 06 to the Ammonia Letdown Drum
D-21 07 and from there to the 4th stage refrigerant flash drum, D-2123 in
preparation for shutting down the refrigeration system. Be alert for
auto-refrigeration taking place in vessels containing ammonia.
c 8.1.6 Stop the Synthesis Gas Compressor [C-21 03]
a) With the synthesis gas compressor on total kickback at minimum governor speed,
the machine may be shut down. The machine should be at minimum governor
speed or less (using as little steam to the extraction turbine as possible) in order to
minimise the effect on the steam system when it is shut down. Shutting down the
compressor should be carried-out in accordance with vendor's instructions.
b) When the turbine governor is tripped to stop the machine, the high pressure steam
that had been entering the HP turbine is diverted through the linked by-pass valve
HIC-1028 and PIC-1013 into the rnedium pressure steam line while the steam to
the condensing turbine is shut off.
c) The outlet from the Synthesis Gas Suction Drum, D-21 04 should be blocked. The
compressor should then be depressurised and nitrogen purged.
d) The inlet temperature to the HT and LT Shift converters should be maintained by
c/ adjusting the flows through and around E-21 01 , E-21 02 and E-2103A1B.
8.1.7 Stop and Pump-out Refrigeration System
a) With the synthesis gas compressor stopped, no further cooling is required from the
refrigeration system therefore C-21 05 may also be shut down.
b) The compressor will have gone on total kickback automatically as the synthesis
loop circulation ceased. The kickback lines enter the flash drums via distributors
below the liquid level of ammonia and thus keep the vapour returns to the C-21 05
compressor cool. In case of low levels of ammonia in the Flash Drums, the liquid
ammonia should be started to the 1st, 2nd, 3rd & 4th stage kickback lines.
c) Remove ammonia from the flash drums and if required the Refrigerant Receiver,
D-2109 but be ready to increase the pressure as necessary to prevent
auto-refrigeration. The refrigerant compressor C-21 05 may be slowed and
stopped when the steam input to the machine has been reduced to a point where
taking it off line will cause little or no disturbance to the steam system.


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d) At shutdown, the system pressure will equalise and the ammonia can be pumped
out to storage. The vapours remaining in the flash drums D-2120, D-2121, D-2122
& D-2123 may be blown down to the NH3 vent header. If no work is to be
carried-out on the system, it should be left under pressure ready for restarting. In
the event that the system is to be opened, then ammonia vapours must be
removed by purging with nitrogen until residual ammonia vapour is low.
8.1.8 Depressurise and Purge Ammonia Converter
a) If it is desired to clear the converter of synthesis gas for maintenance
c
requirements, the following procedure is recommended:
• Continue recycle gas flow until the converter is cooled to about 50°C.
• Depressurise the synthesis loop to approximately 0.5 barg after C-21 03 is

shutdown.
• Isolate and nitrogen purge to required level and maintain system under positive
pressure.
8.1.9 Stabilisation of Ammonia Synthesis Catalyst
a) If the ammonia converter is to be opened for inspection, it is normal practice to

maintain a constant bleed of nitrogen through the beds to prevent oxidation.
Personnel entering the vessel should be provided with closed loop breathing
apparatus.
b) Catalyst oxidation is seldom or ever used if the vessel is to be unloaded and the
catalyst discarded. However, the following is a procedure for controlled
c stabilisation, which may be used if the catalyst is to be retained.
• Cool the converter to below 65°C and purge the synthesis loop and synthesis
gas compressor with nitrogen containing less than 100 ppm of oxygen.
• Pressure the system to approximately 2.0 barg with nitrogen and circulate at
maximum rate.
• With maximum nitrogen circulation established, introduce air to the suction of

the recycle wheel of the compressor at a rate which results in an oxygen
content of not more than 0.2 mol% at the converter.
• Limit catalyst bed temperatures to 100°C by reducing air input to the loop.
c) A temperature wave should progress through the beds from first to last as
oxidation progresses. Air injection should be stopped as soon as the last bed
outlet temperatures peaks and begins to cool.


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d) Oxygen will be consumed completely by the reaction so that oxygen will appear in
the converter outlet when stabilisation of the lowest bed is completed. When
converter inlet and outlet oxygen concentrations are equal, cool the catalyst to
below 50°C and then shut down the compressor, depressurise the system and
prepare the vessel for inspection and maintenance.
e) This procedure requires great care and most plants prefer to dump the catalyst
un-oxidised, deluging it with water.
8.1.10 Methanator Shutdown
c" a) Gas from the outlet of the Methanator is being vented via PIC-1004 at the
Synthesis Gas Suction Orum 0-2104. First, change the source of hydrogen for
desulphurisation from C-21 03 1st stage to the outlet of 0-2102.
b) Slowly reduce the temperature of the gas flowing to the Methanator to between
230°C to 260°C. This is done by manipulation of TRC-1 012 so that the desired
temperature is obtained while still keeping TRC-1012 in controllable range.
c) Gradually lower the set pOint of PIC-1005 Methanator inlet vent while
simultaneously adjusting PIC-1 004 set point upward, maintaining approximately
the same system pressure. (This pressure was set in proportion to reformer
section feed reduction when shutting down the synthesis gas section). This will
change the system pressure control and the gas flow will be released upstream
of the Methanator. Use the board mounted HIC-1 034 to close the Methanator
inlet valve HV-1034 followed by manually closing butterfly inlet valve XV-1211.
d) Start a nitrogen purge to the outlet line of the Methanator, allowing the excess
pressure created to be reduced by PIC-1004. Crack open the 2" manual vent
c valve on the inlet line to R-2106. The object is to displace the carbon oxides from
the vessel while it is still hot.
e) After purging, pressure up the Methanator to a pressure slightly higher than that
being held by PIC-1005
8.1.11 Methanator Catalyst Oxidation
a) If the catalyst is to be removed from the vessel it should first be subjected to

controlled oxidation. It is important that the catalyst not be oxidised unless
absolutely necessary since it is likely that catalyst activity will be impaired during
the oxidation operation.
b) A general oxidation procedure is as follows:
• Start a flow of nitrogen through the bed sufficient to attain a space velocity of
100 to 200 standard volumes per volume of catalyst per hour. The pressure
flow of nitrogen should be such as not to exceed the design linear velocity


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through the catalyst beds.
• Cool the catalyst to 70°C, purging with nitrogen before the temperature is
below 150°C. Add 0.5 mol% of air to the nitrogen. If after one hour the
temperature rise does not exceed 83°C, increase the air rate to give 2.0 mol%.
Continue the oxidation until an analysis of the effluent gas shows not more
than 10 -20% of oxygen is being consumed.
• Increase the air to 5% and continue the oxidation for a further six hours.
Check the effluent gas for oxygen consumption and if this proves satisfactory
and catalyst bed temperatures continue to fall, the catalyst may be cooled to
near ambient temperature and removed.
c c) If at any time during oxidation any catalyst bed temperature approaches 250°C the
quantity of air being added should be reduced and, if necessary, shut off altogether
until temperatures are once again under control.
d) Once manways have been removed from the vessel a close check must be kept
on the beds for areas of local overheating or dead spots which may not have been
fully oxidised during the foregoing procedure. If no attempt is to be made to
salvage the catalyst for reuse, steam my be substituted for nitrogen in the above
procedure.
e) In fact, it is seldom, if at all, that any catalyst is subjected to air oxidation.

Normally, if the catalyst is to be dumped, it is allowed to cool and unloaded into
drums being sprayed with water to prevent pyrophoric action. The vessel is
maintained under a nitrogen blanket during unloading.
8.1 .12 Shutdown of LT Shift Converter
c a) Bypass this vessel by actuating HS-1004, which fully opens the bypass MOV-1009
and then closes the inlet MOV-1008, then manually close the vessel outlet valve.
b) Purge the process gas from the vessel using nitrogen. If the catalyst performance
has been satisfactory and no maintenance is required on the vessel, the vessel
should be kept boxed in under a positive pressure of nitrogen.
c) If it is necessary to inspect the vessel by observation through the top manway, the
catalyst should be cooled with nitrogen and the top manway opened while
maintaining a flow of nitrogen through the beds. Inspecting personnel must
wear air masks
8.1.13 Shutdown of C02 Removal System
a) Back gas out of the CO2 Absorber by opening the vent on D-21 02 and allowing
PIC-1 005 to close, then close the absorber inlet valve
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be routed via the vent upstream of the LT Shift bypass valve MOV-1 09 holding 18
to 20 barg at this point.
c) Change pump seal flushing to BFW
d) Maintain solution temperatures and continue the circulation for at least 45 minutes
and preferably for two to three hours to ensure complete solution regeneration
after gas has been discontinued. When the solution regeneration is complete,
continue to vent all process gas at D-21 02 and the LT Shift inlet vent to ensure
supply of hydrogen rich gas to the Desulphuriser section.
e) If the solution inventory is to be stored in TK-2114 boil off levels to reduce volume.
c f) Purge the absorber tower with nitrogen through the Methanator inlet vent and
leave the entire system under pressure. If the towers are to be opened it will be
necessary to transfer solution to TK-2114 .
NOTE: The solution should onlY be run-down to TK-2114 after it has been full
regenerated in the Stripper and the Absorber is depressurised. If it is required to
open TK-2114, then it should be purged with nitrogen via the connection provided
at the sample point until suitable tests Le. Drager indicate any hydrogen has been
purged. If the tank is to be entered, then the precautions such as steam purging,
etc. described in the Safety Manual for vessel entry must be strictly followed.
g) If the towers are not to be opened no further action is necessary. If tower entry is
required the system should be water washed to flush residual aMDEA from the
packing.
8.1.14 Shutdown of Process Condensate Stripper

a) When venting is switched to PIC-1032, process condensate from D-21 02 to T-
c 2150 will cease. T -2150 can be taken out of service at this time.
b) Isolate the condensate to offsites and open the upstream drain to the sewer.
c) Stop the P-2121 pumps and isolate. Condensate from D-21 02, if any, will be
directed to the sewer through LV-1003B.
d) Slowly reduce the setpoint on FIC-1019 while watching the flow on FIC-1002.
The FIC-1002 flow should continue to control at the setpoint as FIC-1 019 is
reduced. Isolate FV-1019 once it is fully closed.
e) Be sure the level remains near normal in the bottom of the T-2150 during this
time to avoid blowing MP stem through to the drain. Isolate LV-1025.
8.1.15 Shutdown of Reforming Section
a) At this point all process gas is being vented from D-2102 and the vent on the inlet
line to the LT Shift converter. During the reduction of feed rates to the Primary
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Reformer, the process air to the Secondary Reformer will have been progressively
cut back to maintain a reducing atmosphere through the catalyst bed.
b) Prior to stopping the gas flow to the Primary Reformer, the process air flow to the
Secondary Reformer should be stopped to avoid the possibility of having excess
air in the gas from the Secondary Reformer.
c) Reduce the process air flow progressively so that the Secondary Reformer outlet
temperature decreases at a rate of 55°C per hour, until the air flow is finally
stopped.
' d) Watch the outlet temperature on the steam-air pre-heat coil as the air rate is
C-"
reduced and increase steam flow to the coil inlet as required to prevent
overheating the coil.
e) Before shutting down the Air Compressor, ensure that the standby offsite
instrument air compressor is in service first. Then shut down the normal
instrument air supply. The Air Compressor can then be shut down.
8.1.16 Stop Feed to Primary Reformer
a) When the air flow to the Secondary Reformer has been discontinued, keep
reducing the gas flow at a rate of about 15% per hour. Keep an excess of process
steam flow to the reformer throughout the feed reduction and do not go below say
50% of normal design rate (44000 kg per hour).
b) A start may be made on redUCing the feed flow during the period when the process
air is being withdrawn if desired and if made in small increments. Gradually reduce
the pressure on the steam drum to 60 barg during the above steps.
c_ c) Adjust the furnace firing throughout this period to hold a fumace outlet temperature
of 788 - 816°C or such other temperature a necessary to hold the secondary
reformer catalyst temperatures at 760°C minimum. Firing of the auxiliary boiler
may have to be manually controlled and also adjust the firing of the Superheater
burners as required.
8.1.17 Shutdown Desulphuriser Section
a) Reduce firing on H-2101 as the gas flow is decreased but ensure a high steam to
carbon ratio at the inlet to the primary reformer throughout this period. Do not
reduce the process steam rate below about 44000 kg/hr.
b) During this period of reduction of feed rates, less and less steam will be produced
in the waste heat boilers and more steam from the auxiliary boiler will be required.
Stop gas feed and hydrogen to the reformer, and route the effluent from the
desulphurisers to vent using PIC-1169. With H-2101 catalyst tube outlets of about
760°C, continue steaming for approximately eight hours to steam oxidise the
catalysts. Continue to vent at the HTS outlet vent. Stop the gas feed to the


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hydrogenator R-2160 and desulphurisers and stop venting process gas at 0-2102
vent as soon as hydrogen rich gas is no longer required for the desulphurisers.
c) Purge both hydrogenator and desulphurisers with nitrogen by introducing nitrogen

at the purging points on the outlet lines and purging back through the beds to the
vents on each reactor inlet line
d) With the gas feed to the reformer isolated, pressure of the reformer system may
gradually be reduced to about 19 barg by operation of the vent valve.
8.1.18 Steam Oxidising of the Reformer Catalyst
c a) Maintain the process steam flow through the reformer to the vent upstream of the
HT Shift converter R-21 04 at about 50% of design rate (Le. 44000 kg/hr.)
b) Fire the primary reformer furnace so that the catalyst temperatures in the
secondary reformer are 760°C or better if possible. This actually constitutes steam
oxidation of the reformer catalyst.
c) Continue the steam oxidation of the reformer catalyst until the steam
leaving the secondary reformer contains essentially no non-condensables.
This may reguire eight hours or more.
d) At temperatures above 760°C, steam will oxidise much of the reduced nickel in the
catalyst to nickel oxide, with the formation of hydrogen, which appears as a
non-condensable gas in the effluent stream. If the catalyst in the secondary
reformer can be held at about 760°C during the eight hours steaming period and
until essentially no non-condensables are found in the effluent stream, it is safe to
assume that about 70 to 80% of the nickel has been oxidised.
c. e) At the end of the primary reformer steam oxidising period, reduce the catalyst tube
outlet temperatures at 60°C per hour to about 350°C. During this period prepare
the system for nitrogen circulation of the primary reformer, secondary reformer and
HT Shift converter using the second case of the process air compressor.
Gradually reduce steam to the primary reformer to 25% of design.
f) When the primary reformer tube outlets reach 350°C discontinue the steam flow,
pressure up the circulation system with the HP nitrogen and start circulation. As
long as the temperature in the HT Shift converter is above 150°C, put a small flow
of steam (approximately 5 tonneslhour) into the outlet and to the vent on the inlet
line to prevent catalyst dehydration.
g) Continue reducing the primary reformer tube outlets to 250°C and hold at this
temperature for 2 to 3 hours, then reduce the tube outlet temperature to 150°C and
stop nitrogen circulation. Stop steam to the HT Shift converter and leave under a
nitrogen pressure.


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8.1.19 Secure the Reformer Section
a) Steam flow to the reformer will be discontinued when the catalyst temperatures
have been reduced as discussed above. The air compressor C-21 01 can be
shut-down when no longer required. Be sure the stand-by instrument air is
available to supply instrument air before C-21 01 is shut down.
b) After all burners are out in the radiant section of the furnace, double block and
bleed burner lines, open some furnace burner air registers to facilitate cooling this
portion of the furnace for later entry. The auxiliary boiler section must be
considered as this is done so as not to disturb the draft in this section. When the
c
final cooling of the reformer tubes is achieved, open blank ends on outlet header
and check all water drained out and then replace.
c) The flow of steam to the HT Shift converter can be stopped and the vessel
blanketed under a nitrogen atmosphere.
8.1 .20 Shut Down and Secure the Steam System
a) It must be assumed that operation of the auxiliary boiler will be continued for
sometime after the actual shutdown of the ammonia unit and this item will be fired
on manual control to provide whatever steam is required for maintaining heat
where necessary on vessels, purging, boiler feed water pump, etc. and to carry out
any of the catalyst oxidation procedures mentioned below.
b) Following the shutdown of the air compressor, the steam drum pressure can be
further reduced by reducing the firing until steam production falls off to meet the
demand. As firing is reduced in the auxiliary bailer, it will probably be necessary to
remove burners - one at a time - in order to maintain controllable firing. The
auxiliary boiler may be maintained in this condition, furnishing steam for the
c services required for catalyst stabilisation, oxidation etc., until there is no further
demand for steam production within the battery limits.
c) The steam production will fall off to a point where it will be necessary to import MP
steam from Offsites, but it should be noted that when MP steam is imported from
Offsites, the superheat temperature of the MP steam generated on Offsites should
be reduced to 3990 C. When down to one burner and the import steam is being
used for services within the battery, the last burner may be extinguished. It will
probably be necessary to make adjustments to the H-2101 draught control to
maintain a moderate draft.
d) When the steam drum pressure has dropped to about 1.5 barg and the boiler is to
be opened, then the vent should be opened. If not, open nitrogen to the boiler
system to maintain positive pressure as the system cools. The normal water level
will remain. This nitrogen introduction will stop air from entering the equipment and
prevent oxidation of the metal, which can be harmful to good operation of the 125
bar steam system. When all bumers are extinguished, double block and bleed
burner lines.


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e) During below freezing temperatures, the boiler drum and associated equipment
should be drained of water and held under nitrogen pressure.
f) Keep in mind that the cooling of the boiler system must be carried,out under
limitations of the heating and cooling procedure outlined in Procedure ODS-128
contained in the General Procedures Manual.
8.1 .21 Completing the Shutdown
a) When all furnace firing is discontinued, the fuel supply piping to the furnaces is
c
blinded off to ensure against inadvertent entrance of cornbustibles to the
furnaces.
b) The supply of water to the reformer jackets is discontinued and the jackets drained
if required.
c) The Furnace fans are shut down when the fumaces have cooled sufficiently.
d) Cooling water is shut off to users when not required. This depends on weather
conditions. If freezing weather is forecast, cooling water flows must be maintained
through all equipment that cannot be drained. On all coolers, by-passes are
installed between the inlet and outlet cooling water lines and should be used to
maintain flows if cooling water is shut to equipment. Steam tracing on shutdown
equipment should also be checked frequently during cold weather.
8.2 SPECIAL SHUTDOWN PROCEDURES
8.2.1 Removal of Ammonia Synthesis Catalyst
c a) If the ammonia converter catalyst is to be retained and not removed from the
converter basket, it must be oxidised under controlled conditions before air is
permitted to enter the synthesis section. However, this oxidation procedure is
seldom, if ever, required. It is customary to maintain a strong positive pressure of
nitrogen on the vessel after it has been depressurised and purged free of
combustible material - replenishing as frequently as necessary to ensure the
exclusion of air from the system. The vessel may be kept "bottled up" in this
condition until the resumption of plant operation.
b) If maintenance work is required on the converter, this can be accomplished by

maintaining a sufficient flow of nitrogen over the catalyst to ensure the exclusion of
air, making oxidation of the catalyst unnecessary. If the catalyst is to be discarded,
the catalyst is dumped and immediately quenched with water whilst maintaining a
nitrogen purge on the converter.

c JOB NO.' 5777 SPEC. TYPE:

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8.2,2 Oxidation of HT Shift Catalyst
a) If the HT Shift catalyst is to be inspected by looking into the top manhole only, it
may be cooled with steam to about 121°C. The steam should be purged out at this
point with nitrogen and the vessel thus cooled further if required. While
maintaining a slight positive bleed of nitrogen, open the manhole for inspection.
Only a slight flow of inert gas is required to limit air diffusion. Inspectors should
wear air masks
b) Should it be necessary for a .man to enter the shift converter, he should be

equipped with an air or oxygen mask and a suitable harness so that if oxygen
supply fails, he may be pulled from the vessel. However, the Safety Department of
C: the plant should advise on the advisability of allowing a man to enter a vessel of
unoxidised catalyst.
c) If inspection reveals that only the top bed of catalyst should be removed due to
solids collection or catalyst breakage and it is desirable to avoid oxidation of
catalyst; the catalyst can be removed via the manway provided, whilst maintaining
the bleed of inert gas on the bottom of the bed. The discharged catalyst should
be dumped into steel drums and wet down as necessary to prevent development
of high temperatures.
d) If it is desired to oxidise all the catalyst before unloading or opening the shift
converter, the following procedure may be used. Prior to initiation of oxidation, the
converter bed temperatures should be adjusted to about 288°C and the process
gas stream cut out. The vessel should be isolated and lined-up to the oxidation
vent. A flow of regeneration steam should be established and 3 to 4 mol% air
added.
e) The temperature rise during oxidation will probably not exceed 83°C so long as the
c concentration of air does not go above 3 to 4 mol%. The temperature should not
be allowed to exceed 427"C; if it should rise to that point, air injection should be
discontinued until the temperature is again under control.
f) When the oxygen content of the non-condensable gas leaving the shift converter
exceed 15 mol%, raise the air rate to give 6 mol% for two hours. If there is no
increase in bed temperatures, increase the air rate to give 8 mol% and so on in
2% increments until 15% air is reached.
g) If there is no further evidence of oxidation the stearn may be slowly reduced and
the air content of the stearn/air mixture can be increased to 75% during cooling of
the catalyst to ensure complete oxidation. When the temperature of the catalyst
bed has decreased to about 121°C, the steam supply may be shut off.
h) The bed may be further cooled using air, but continue to observe the catalyst
temperatures and if there is any indication of temperature rise, re-introduce the
steam. After the catalyst has cooled to about 50°C it may be dropped out.


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i) When carrying out oxidation procedures below normal operating pressures, care
should be taken not to exceed design velocities through the beds. Sudden
pressuring and depressurising or rapid increases in flow are to be avoided as
"heaving" of the beds may result in mechanical damage to the catalyst and
channelling. Do not exceed design metal temperature of 482°C on the high
temperature shift converter vessel.
j) At all times particularly when the catalyst is hot, it should be protected from liquid
water. Temperatures should not be changed at a rate greater than 83°C per hour.
8.2.3 Oxidation of LT Shift Catalyst
c a) The LT Shift catalyst may be rendered inert using either of the following
procedures but it is not recommended that it be oxidised and the catalyst vendor
should be contacted for special instructions:
b) The catalyst can be cooled to about 177°C and then cooled with a stearnlair
mixture, keeping a close watch on temperature points in the catalyst bed. Do not
exceed deSign metal temperature of 302°C on the vessel.
c) The catalyst may be cooled to below 177°C with steam. Then it can be dumped
and flooded with water if there is any tendency for it to heat on exposure to air.


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9 EMERGENCY SHUTDOWN PROCEDURES
9.1 INTRODUCTION
a) Emergency conditions may arise on the unit at any time and it is quite obviously
impossible to present detailed instructions that would apply to all situations.
Knowledge of the unit and a complete understanding of the unit process
involved are the best guarantees that the operators of the unit have to safely
and efficiently cope with any unusual conditions which might develop. The
following are guidelines of the actions to be taken in the event of the more common
emergencies and more detailed operating procedures will be prepared by the plant
c supervisory personnel based on personal and actual site experience.
b) Complete understanding and familiarity with the unit emergency condition alarms
and warning devices should be a "must" for all personnel concerned with the
successful operation of the plant. Operators should review all the alarms on the
plant using data furnished elsewhere as a guide to location, etc. They should
educate themselves to the function of these alarms and then go through the mental
exercise of what action to take in the event an alarrn sounds.
c) In every instance the action taken should satisfy the following requirements:
• The action taken must be one that can be performed without hazard to plant
personnel. The operator should not jeopardise the safety of himself or others.
• The action taken should place and maintain the unit equiprnent in a safe
condition. Design pressures. temperatures and flows should not be
exceeded. Prompt action demands thaHhese values be known
beforehand.
c • The action taken should be such as will permit resumption of norrnal operation
as quickly as possible after the ernergency has been corrected.
d) Certain emergency conditions of the plant result in the automatic action of controls
to prevent harm to catalyst vessel or equipment. However, this does not in any
way relieve the operator from the responsibility to be cognisant of and to take
immediate corrective action for the unusual condition.
9.2. AMMONIA CONVERTER
a) If the Synthesis Gas Corn pressor has tripped out, it will not be possible to carry-out
the usual cooling down of the converter and catalyst beds.
b) The pressure in the synthesis loop should be held as long as possible to enable a
rapid restart if required.
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c) If the synthesis loop is to remain shut down for a period of time, depressurise via the
purge gas system and follow this with nitrogen and leave under nitrogen pressure.
This pressure should be checked at frequent intervals to ensure that no ingress of
air takes place.
NOTE: At temperatures lower than -12°C, the converter pressure must not exceed
40% of its design and further increases in pressure shall take place only after the shell
temperature has reached or exceeded -12°C.
9.3 LOW TEMPERATURE SHIFT CONVERTER
c a) Possible temperature upsets in the secondary reformer effluent system, or in the E-

2103A/B heat recovery circuit joining the high and low temperature shift converters
can cause high temperatures in the low temperature shift section. Excessive
temperature rise in the LT Shift section can cause a decline of catalyst activity or
permanent catalyst damage, or vessel damage. The most likely cause of this will be
a BFW flow upset caused by a HP steam system or D-2101 level upset reducing the
BFW flow to the E-2103A/B. Excessively low temperatures will cause a loss of
reaction and a breakthrough of CO
b) Special remote operated valving is provided to enable by-passing of the LT shift

converter in the event of conditions leading to high temperatures during normal
operation. This bypassing can be done by using HS-1004 to open MOV-1009
bypassing the LTS then closing MOV-1008 isolating the LTS inlet. To completely
isolate the LT shift converter, the LTS outlet isolating valve and its bypass valve
will also have to be manually closed by operators.
c) Immediate reduction of inlet temperatures and reduction of feed rate (to increase the
steam/carbon ratio and residence time in the high temperature shift converter) is
then necessary to prevent high carbon oxides from being carried into the
c Methanator, perhaps resulting in high reaction temperatures in that vessel.
d) Immediate actuation of HS-1253 is also necessary. This hand switch will isolate the
R-21 06 methanator by closing XV-1211 and HV-1034 preventing the possibility of
high carbon oxide (CO) containing process gases from entering the vessel resulting
in a temperature run-away. Process gas will vent at PIC-1005.
e) After the cause of the emergency has been rectified, the low temperature shift
converter can once again be brought into the circuit and rates may be increased and
worked slowly to the desired throughput. Adjust the heat recovery circuits joining
the high temperature and low temperature shift converters to optimum.
Sulphur content of the gas leaving the high temperature shift should be below 1 ppm
before attempting to go through the low temperature shift converter.
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9.4 METHANATOR
a) Any upset at the front end of the unit, particularly the shift converter or CO2
removal system, will likely result in excessive carbon oxides concentration in
the Methanator feed. This will most likely be caused by a circulation failure I
upset in the C02 removal system or possibly due to a LTS temperature
upset .These excessive carbon oxides will cause sudden and high
temperatures to develop in the Methanator because of the highly exothermic
nature of the methanation reaction. A theoretical average temperature rise of
about 66°C occurs for each mol percent carbon dioxide in the inlet gas.
c b) Automatic upstream venting of the Methanator at PIC-1005 activated by the

temperature recorder alarms and high, high temperature trips located in the
Methanator catalyst beds, have been provided. However, if the Methanator
catalyst temperatures start to climb rapidly and it is evident that an emergency
condition is impending, it is best to remove the feed from the Methanator at
once (using the push-button HS-1253, to close the inlet valve) and not wait for
high, high temperature trips. This is true because of the time lag in
temperature transmission.
When HV-1034 is closed by a methanator emergency, the C-21 03 compressor

will revert to a total recirculation condition and reduction in speed due to loss of
fresh feed leading to a reduction in extraCtion flow. The compressor train may
even trip on overspeed if the governor and anti-surge valves do not react in
time.
If the emergency is such that the synthesis loop must be isolated from C-21 03,
then follow the procedures stated for loss of the C-21 03.
If the stopping of feed gas to R-21 06 is due to high carbon oxides causing a
c. temperature "run-away" (temperatures in the vessel exceeding design

maximums), the vessel should immediately be depressured through the
manual vent, V1 011-2" at the vessel top and then purged with nitrogen injected
in R-21 06 outlet line through N1 007-1.5". This will decrease the amount of gas
remaining in the vessel for reaCtion and the high temperatures are less harmful
to the vessel at lower pressure.
Depressuring the methanator can make the carbon oxide

related problem worse IF the inlet trip valves to the
methanator leak through. This can allow high carbon oxide
containing gases to enter the vessel at greater quantities
as it is depressured. Check to be sure that the valves are
closed
The methanator must be cooled to below its normal operating temperature

before it can be put back in service. Flowing nitrogen up thorough the catalyst
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bed to the vent at top the vessel will aid in cooling and will remove the carbon
oxides from the catalyst bed.
Another effective method to cool the methanator is to open V1 011-2" vent and
then back flow synthesis gas from D-21 04. This provides a large reservoir of
carbon oxide free gas at a good flow rate and will effectively cool the catalyst.
c) Corrections to equipment upstream of the Methanator, to return the system to

normal carbon oxides should be rnade. Check temperatures, CO 2 Absorber
level, stripping and aMDEA solution purity. Check CO content of LT Shift
converter effluent.
c d) The Refrigeration and Synthesis Gas Compressors may have to be shut down
to aid the steam supply situation.
e) Once the Methanator tern perature is below that which it was before the
emergency and the carbon oxides content of the feed stream is on
specification, the Methanator may slowly be returned to normal operation. Use
the procedure similar to that used for normal start-up. Slowly return the
synthesis gas loop to normal, first using some recycling while attempting to
re-establish converter temperatures.
Feed rates that may have been reduced when the emergency developed,
should be slowly returned to norrnal. Return the synthesis and refrigeration
system to norrnal. Product flow to battery limits may be started.
9.5 LOSS OF FEED GAS
c
A sudden and complete feed gas failure will cause a loss of feed gas to the primary reformer
and fuel gas to the furnace bumers. However, more than likely the fuel gas flow will fall
gradually so that the loss of feed gas will be the first event to take place. When the feed gas
pressure falls low enough, the pressure alarm PAL-1187 will sound a warning to alert
personnel. A continued decrease in the gas flow will trigger PSLL-1191 which on a 2 out of
3 voting system will actuate interlock ESD-2102 and FSLL-1201 which will actuate ESD-
1201
See Section 11.3 for a detailed description of the actions of ESD-21 02 and ESD-
1201
No rnatter what the cause of loss of feed to the reformer, of prime importance is
the protection of the catalysts, compressors and the primary reformer. The
primary reformer temperatures will rise rapidly on loss of gas feed and prompt
action must be given to reducing the furnace firing to prevent overheating of the
catalyst tubes possibly to the extent of manually operating HS-1250 which will
actuate Interlock ESD-2111 and trip all the arch burners.
Note that even if the operator takes the correct actions by reducing the arch burner


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firing to minimum, the firing rate will still be too high for continued operation with
steam only through the radiant tubes. The trip of the arch bumers is therefore
required to avoid severe overheating of the radiant and convection coils upon loss
of feed.
Manually actuating feed gas shutdown switch HS-1202 has the same effect as
Steam to Carbon Ratio interlock ESD-1203 described in section 9.6. Feed Gas
Compressor shutdown interlock ESD-2102 also has the same effect as ESD-1201,
except that it does not switch control of vent valve PV-1169 to the control of
PIC-1169.
HV-1 006 will close isolating air to the secondary reformer and the air compressor
c C-21 01 will be reduced to minimum govemor speed with associated actions to

secure the machine.
Feed Gas Compressor C-21 02 will shutdown.
FV-1001 and HV-1010 will close to isolate feed gas to the primary reformer
The analysers on the primary reformer outlet and at the exit of E-21 02 will be
isolated
Closes FV-1022 and isolates recycle hydrogen from C-2103
It will also be necessary to protect the mixed feed and process air coils in the
furnace convection section by continuing MP steam flow through the primary
reformer tubes to sweep all hydrocarbons out to avoid possibility of a coke laydown
on the catalyst. Note however that if a preset lower radiant coil outlet temperature
is sensed together with confirmation that the arch burner fuel gas is isolated, then
the MP steam flow to the mixed feed coil will automatically be reduced to 40% of
c normal. To avoid cooling the radiant tubes too quickly and also to conserve MP
steam supply, the operator should further adjust the steam flow (importing as
o
necessary from Offsites), to target for a cool-down rate of 100 to 150 C/hr.
Check the emergency steam flow to the steam/air heater coils on FI-1044 to
prevent excess consumption. Other actions to be taken following loss of feed gas
are:
• Open the vent ahead of the HT Shift converter to discontinue any process flow
to downstream equipment.
• Block-in the synthesis loop and refrigeration system and shut down the
Synthesis Gas and Refrigeration compressors to aid the steam balance of the
plant. If necessary, shut down the process Air Compressor.
• Close HV-1034 and XV-1211 at the Methanator inletto prevent leakage into


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the Methanator.
• Maintain gas pressure on the Absorber to facilitate the regeneration of the

aMDEA solution and continue as long as possible then shut down the
circulating pumps. Make sure that the Stripper is vented by leaving open PV-
11 04A1B when the pressure drops to zero to prevent pulling a vacuum on the
column as it cools.
• Start steam to the bottom of the HT Shift and nitrogen to the Methanator to
purge these vessels and then block in under nitrogen pressure.
• The LT Shift converter should be blocked in, purged with nitrogen to the vent
C' and held under a slight nitrogen pressure until ready to restart.
• Anticipated duration of the failure will determine whether further shutdown of

the unit is imminent or whether present conditions should be held for a restart
as soon as the gas feed supply is restored.
• When the gas feed has been restored, the unit will have to be started in the
same manner as described in Section 6.0. of this manual. Start-up will be an
orderly and smooth move to normal operations.
9.6 LOSS OF STEAM TO CARBON RATIO
Should it not be possible to maintain the steam to carbon ratio, then interlock 21-ESD-
1203 will come into operation, which will protect the unit in the same way as 21-ESD-
1201 (section 9.5)
See section 11.3 for a detailed description of the actions of ESD-1203
c 9.7 LOSS OF PROCESS AIR
a) If loss of process air is due to C-21 01 compressor failure, the item of prime
importance is to verify that the offsite standby instrument air compressor has
taken over the supply of instrument air.
b) Loss of process air immediately terminates ammonia production due to loss of the
nitrogen portion of the hydrogen/nitrogen mixture. Process gas should be vented
ahead of the Methanator, closing the inlet blockvalve HV-1034 and XV-1211 using
HS-1011 push button in the control room.
c) Bypass and isolate the LT Shift converter
d) Steam production from E-2101 will decrease and after the above has been
accomplished, some steps will have to be taken to keep the steam system in
balance.


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e) With process air lost, the motor operated valve HV-1006 in the discharge line will
close. Automatic controls are provided to accomplish this but the operator should
double check to ensure that these controls have functioned properly to prevent hot
gases from back flowing to the air compressor.
f) The loss of air to the secondary reformer will open HV-1021 thereby admitting a
large amount of steam to the secondary reformer. Check the H-2101 steam/air
preheat coil outlet temperature and if possible reduce this flow in order to aid the
steam balance.
g) Reduce gas feed rate and try to maintain temperatures in the Secondary Reformer
c as high as possible without exceeding the normal operating temperatures set for the
Primary Reformer.
h) Hydrogen for desulphurisation will be provided from D-21 03 CO 2 Absorber

Overhead Drum.
i) Shut down the Synthesis Gas and Refrigeration Compressors.
j) Once air injection is resumed and the Secondary Reformer has been refired,
and the gas venting ahead of the Methanator is on specification, operations
will proceed to put the Methanator in service and take steps to initiate
ammonia production.
CAUTION: Even if air is restored immediately, the steps outlined above must be
taken. When air is reintroduced to the Secondary Reformer, the procedure should
be the same as for a normal start-up, i.e. the air must be added slowly, using the
2" bypass around the motor valve HV-1006 initially. Too rapid an introduction of air
will result in excessively high temperatures in the catalyst beds, with consequent
c 9.8
damage to the catalyst.
LOSS OF BOILER FEEDWATER TO STEAM DRUM D-21 01
a) Should this emergency occur and it is impossible to immediately re-establish the

boiler feed water flow to the drum, the action to be taken must be positive and
immediate. Loss of boiler feed water will mean loss of steam production and a
complete shutdown of the unit.
b) Loss of B.FW. will result in a lowllow level in the steam drum and cause LOW/low
level switch LSLL-1223A1B/C (2 out of 3) to actuate Interlock ESD-1223. This
interlock is described in Section 11.3.14. but the basic actions are as follows:
• Auxiliary Boiler & Arch bumers will be tripped.
• Control valve FV-1 001 and HV-1010 in the Natural Gas supply line will close and
automatically discontinue feed gas flow to the unit. It will also close FV-1022

c JOB NO. 5777

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control valve in the Hydrogen supply line from the Synthesis Gas Compressor.
Close the block valve in the feed line to prevent seepage of gas feed into the
primary reformer.
• Loss of Feed Gas will automatically trip valve HV-1 006 shut on C-2101 Air
Compressor discharge, open the interstage and discharge vents and reduce the
turbine speed to minimum governor .MP Steam to the air coil will immediately
trip wide open but the flow should immediately be manually adjusted to about 10
Te/hr using HIC-1021.
• Note that 15 seconds after the Arch burners are extinguished, InterlockESD-
1223 will reduce the process steam flow to the Primary Reformer by resetting
c FRC-1 002 to 40% rate, relative to normal. After a further 4 minutes (240
seconds), It will then stop the flow COMPLETELY by automatically closing valve
XV-1032 oli the MP Steam supply line to the Mixed Feed Coil. Import steam
from Offsites as required and establish a flow of MP Steam to the reformer tubes
as quickly as possible .. Approximately 25 tons/hr of steam is required for about
30 minutes to cool the reformer tubes and the operator should target for a cool-
down rate between 100-150oC/hr
Shut down synthesis gas compressor.

Shut down the refrigeration compressor.
Shut down the process air compressor.
• Isolate the LT Shift converter. Open the HT Shift converter inlet vent to
atmosphere and slowly depressurise the reform section Isolate the Methanator
and synthesis loop.
• Isolate gas inlet the C02 Absorber and maintain gas pressure on the Absorber.
Continue aMDEA circulation for as long as possible with available Absorber
c •
pressure to regenerate solution using E-2111 reboiler .Import steam from Offsites.
Shut down all remaining equipment except the cooling water pumps and
instrument air system. Use the offsite instrument air for instrument air supply.
Switch to motor driven equipment in critical services.
Stop aMDEA solution pumps P-21 07 & P-21 08 (after solution regeneration)
Stop ammonia product pump P-2113 & P-2124.
Stop the condensate pump P-2112 as the level in the surface condenser
drops.
Sweep through the reform section with Nitrogen as far as the HT shift inlet.
Establish positive Nitrogen pressure on all catalyst beds. Line up for
Nitrogen circulation for cool down or restart as required.
• Failure of the boiler feed water pumps or mechanical failure of the steam
generating system, such as tube rupture, will mean an immediate crash shutdown
c ,
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of the plant. All sources of heat to the steam generating system must be stopped
to prevent "drying up" of the remaining water in the system. Steam system
blowdown must be stopped. Serious damage will result if the system is
allowed to run dry.
9.9 LOSS OF PROCESS STEAM
a) In the event of the loss of process steam for any reason, gas feed and process air
must be cut out immediately. Simultaneously with this action, the fires must be cut
out of the primary reformer.
c b) Instrumentation and safety devices are provided to stop the flow of gas feed to the
reformer upon loss of process steam. If any of the safety devices are defeated, loss
of process steam will cause an almost immediate· coking of the reformer catalyst.
The extent of coking may be such that a complete replacement of the catalyst will be
necessary.
c) Loss of process steam coupled with the loss of gas feed will cause serious
overheating of the reformer tubes. Firing of the reformer furnace must be stopped if
the steam flow cannot be re-established. Fuel will shut off automatically but must be
checked immediately. Approxirnately 25 tons/hr of steam is required for about 30
rninutes to cool the reformer tubes and the operator should target for a cool-down
rate between 100-150oC/hr. The first 4-5 minutes could be supplied from
depressurising the ammonia plant stearn systern, but then it rnust come from
Offsites.
d) With the instrumentation functioning properly, the gas feed control valve will close
upon loss of process steam. The operator should immediately close the isolation
valve in the feed line to prevent any seepage of gas into the reformer.
c e) If necessary, the pressure on the desulphuriser section should be lowered and gas
feed to the desulphuriser stopped if there is any evidence of seepage through the
valves.
f) As described under loss of gas feed, the refrigeration and synthesis gas
compressors must be shut down and catalyst protected in all vessels. Import steam
should be used as necessary for purging the reformer.
9.10 HIGH H.P. STEAM SUPERHEAT TEMPERATURES
The operator will be alerted to high HP Steam superheat temperatures by High

Temperature Alarm TAH-1005. Should the temperature continue to increase then
High temperature switch TSHH-1088, TSHH-1218,TSHH-1219(2 OUT OF 3) will trip
the superheat burners and start an 8 minute timer. If the temperature does not
decrease below a preset level within the 8 rninutes, then the entire reforrner will trip.
The furnace will also immediately trip if a preset rnaximum temperature is reached.
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9.11 LOSS OF FIRING ON PRIMARY REFORMER/AUXILIARY BOILER
a) This emergency can be due to loss of fuel or loss of draft fan. Loss of fuel to the
Primary Reformer/Auxiliary Boiler will result in loss of steam production and a
complete shutdown of the ammonia plant.
b) Stop gas feed and air to the reformer section, stop gas feed to the desulphuriser
section. Verify that the offsite standby instrument air compressor is supplying
instrument air to the ammonia plant.
c) All compressors and steam users are shut down. Steam is required to sweep out
c the primary and secondary reformers and the HT Shift converter (so steam usage
must be conserved as much as possible) then replaced by nitrogen before
condensing temperatures are reached. The LT Shift converter and Methanator
should be purged with nitrogen and left under slight nitrogen pressure. Import
steam will be required.
9.12 LOSS OF STEAM PRESSURE
a) Partial loss of steam pressure can result from some operational problems. The
whole unit should be checked to see where the fault lies.
b) If a high pressure relief valve should open and not reseat, the entire plant may have
to be shut down as the plant is closely associated with steam production.
c) Conditions may arise in the unit during serious operational upsets or as a result of
emergencies, which could conceivably create a demand for steam generation
beyond the capacity of the eqUipment provided. In order to protect the steam
generating equipment against serious damage, the steam consumption should
never exceed the capacity that is available or that can be generated at that particular
c emergency condition.
d) In several of the "emergencies, which may occur, the synthesis gas is vented,
resulting in a loss of ammonia production. Loss of heat recovery in the synthesis
loop as ammonia production ceases, creates a large deficiency in the unit steam
balance due to the loss of boiler feedwater preheat and steam generation in the E-
2123A1B (The normal vaporization rate is 30%). No attempt should ever be made to
recover this loss beyond the normal steam generating capacity of the unit and the
package boiler. Instead, every effort should be made to conserve the steam being
produced by using less where possible.
e) It should always be kept in mind that any attempt to use more steam than can be
generated in the unit could result in an initial level swell in 0-2101, due to rapidly
reducing HP steam pressure, followed then by a low level in the steam drum 0-2101
tripping the front end of the unit.
f) The importance of maintaining the steam balance within safe limits during upsets or
other emergencies cannot be overemphasized. There is a steam generation unit in


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the offsites. The ammonia unit can be supplemented with offsites MP steam by
increasing the firing rate of the boiler.
9.13 INSTRUMENT AIR FAILURE
a) The likelihood of a general instrument air failure is normally remote since the
source of the instrument air is the C-2101 process air supply. However, air failure
at individual instruments is more frequently encountered and it is important to know
what will happen in the event of a failure.
b) In the case of total air failure, the plant will shut down. Valve actions on failure
c have been arranged to move to the safe position, nevertheless, the shutdown will
be somewhat disorderly.
c) Study of engineering flow sheets will show the fail positions of the various control
valves involved and operations must be as dictated by conditions existing after the
failure.
d) Primary consideration must be given to sweeping hydrocarbon vapours from the

reformer furnace tubes.
e) The philosophy with regard to valve action when the air fails is that the valve will
move in the direction of the greatest safety. When consistent with this basic
premise, the valve will move toward a shutdown position.
f) Thus, for example, air failure will close the gas to the primary reformer but the
process steam valve will fail open, because it is advantageous to keep a flow of
steam moving over the reforming catalyst.
c/
g) The action of some other valves is necessarily a compromise. For example, the
steam drum level controller will fail open. It is obviously undesirable to overflow the
steam drum but the '1ail open" alternative is chosen because (a) the operator will
have more time to catch the level and (b) serious damage will affect less
equipment by a too-high level than by loss of level.
h) As was pointed out, the C-2101 compressor furnisheS instrument air under normal
conditions. The standby instrument air compressor located offsite will
automatically be activated in the event of loss of this source of air, so an
instrument air failure is remote. Nonetheless, it is very necessary that the
operating personnel familiarise themselves with the control valve action (open or
close) on air failure.
i) The operators concern will be to take normal control of the level in the boiler drum
as this item is of prime importance and the level controlled until such time as
instrument air supply is re-established.
j) Steam is used to sweep out hydrocarbons from the primary reformer tubes and is

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vented upstream of the HT Shift converter.
k) Steps for the plant operators to take on instrument air failure after 0-2101 steam
drum and steam system are under control are:
• Discontinue feed to desulphuriser section.
• Shut down synthesis gas and refrigeration compressors to conserve steam that
may be needed elsewhere.
• Cut back the primary reformer process steam flow (block-in the controller and
regulate on bypass) to conserve steam, sweep the catalyst tubes free of
C~ gases, using import steam if available.
• Bypass the LT Shift converter and if indications point to an interruption of

prolonged duration, the LT Shift converter should be purged free of process
gas with nitrogen and a strong positive pressure of nitrogen maintained within
pending resumption of operation.
I) When the instrument air supply is re-established the first concern should be to
resume firing the auxiliary boiler section of the fumace in order to produce steam to
enable resumption as detailed in Section 6.0. of this manual. Catalysts are already
in a reduced state and the plant will be brought back into full production in a short
time.
9.14 ELECTRIC POWER FAILURE
Normal electrical power supply to the ammonia plant is from the Offsites Power House.
In the event of a total power house failure, an emergency source of power is provided
c via an emergency board fed from the national grid with a capacity of around 2MW
which automatically supplies enough power to enable continued operation of the
following items on the Ammonia Unit:
• C-21 01/02/05 & C-21 03 Standby Lube oil pump motors.

• Instrument distribution.
• Emergency lighting.
• Fire Alarm System
9.15 COOLING WATER FAILURE
a) This emergency may be a mechanical failure of the pumps in service. In this case,
the spare pump must be placed in service as soon as possible and the unit
throughput may need to be reduced so that normal cooling can be achieved. Loss
or reduction of cooling water will result in the rapid loss of vacuum in the following
condensers E-2140, E-4133 Immediately effecting the process will be the inability
to condense ammonia vapor from C-21 05-J in E-2127. Slightly later, but not the
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least important, is the inability to cool lube oil to the compressors, turbines, fans
and pumps taking effect. Process exchangers, and compressor Interstage cooling
will also be affected as the water cooling water system warms up due to lack of
circulation.
b) A total and complete cooling water loss will force a complete shutdown until the
cooling water system can be returned to normal.
c) The synthesis gas loop and refrigeration systems will be isolated and blocked in.
Maintain gas pressure on the absorber with nitrogen to continue circulation of the
aMDEA solution for regeneration.
c d) The LT Shift converter and Methanator are blocked in and held under nitrogen
pressure until ready to restart. The unit can remain in this condition until cooling
water is restored.The longer the plant is without cooling water, the more caution
must be exercised in restarting flows. Severe damage can be done to equipment
by thermal shock caused by sudden cobling.
9.16 FAILURE OF WATER TREATMENT SYSTEM
a) Demineralised water tanks TK-6204 A & B store a sufficient amount of emergency

water supply (approximately 20 hours) so the unit does not have to be shut down if
water treatment problems cannot be immediately rectified, such as an outside
problem of short-time duration i.e. power failure.
b) If a condensate polisher has to be taken off line, it can be bypassed for a number of
hours without problems, providing boiler blowdown is increased.
c) The boiler feed water treatment plant failure will cause the level in V-21 01 to fall
c causing low alarm LAL-1030 to wam the operator.
d)· In any event, reduction in throughput will lengthen available supplies and may avoid
a complete shutdown if the failure is prolonged.
9.17 FAILURE OF AMDEA CIRCULATION
a) Loss of aMDEA circulation will result in a shut down of the back end of the plant if
not rectified immediately. A low flow alarm is provided on the main stream of
solution retuming to the absorber and on the semi-lean solution refluxing on the
stripper. Should the cause of the low flow not be rectified then extra low flow
switches will actuate the Methanator shutdown interlock 21-ESD-21 06. This
interlock will close the Methanator inlet valves HV-1034 and XV-1211. The vent
valve PV-1005 upstream of the Methanator will open as the pressure rises.
b) Gas must be backed out of the absorber and vented at PV-1032 down stream of
the HT shift.to prevent boil off of the solution in E-21 05.Steam to E-2111 must also

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be shut off until circulation can be re-established. Close the Absorber inlet valve.
c) The Methanator upstream pressure controller PIC-1005 should be set down to a

lower pressure than that eXisting in the Methanator to ensure no leakage of CO2
into the Methanator and the operator should watch the Methanator temperatures
closely.
d) The CO2 supply to the Urea unit will stop.
e) C-21 03 and C-21 05 will go on kickback and may have to be shut down if steam is
tight.
c f) Hydrogen must be supplied for the desulphuriser section from the outlet of
D-2102 ..
g) Change pump seal flushes to BFW
9.18 FAILURE OF REFORMER INDUCED DRAFT FAN
Failure of the ID Fan will result in the Primary Reformer and Auxiliary Boiler radiant
sections pressure going "positive" as draft is completely lost and the following
general sequence of shutdown action must be undertaken.
The increase in pressure will be sensed by various pressure switches which will
actuate interlock ESD-2111 and automatically shut-down the Auxiliary Boiler, Arch
and Superheat burners A klaxon and rotating light located on the Primary Reformer
firing platform will also be actuated to warn operators to speedily evacuate the area.
Aux and arch FD Fans to slow to minimum governor speed.
c To ensure that all burners are extinguished the operator should use emergency
shutdown switches HS-1252, HS-1255 & HS-1046 which also close the valves on
the fuel gas supply lines to the Auxiliary Boiler, Arch and Superheater burners.
With the loss of firing in the front end of the unit, the operator must quickly push the
following buttons as HP, MP & LP steam production will be completely lost.
• HS-1203 to shut down the Synthesis Gas Compressor and block in the synthesis
loop. HIC-1028 should be used to adjust the large steam let-down valve.
• HS-1205 to shut down the Refrigeration Compressor
• HS-1253 to shut down the Methanator.
• HS-1 004 to shut down and by-pass the LTS Converter. Vent the process gas at
PIC-1005.
• HS-1202 to shut down the air to the Secondary Reformer and to route C-21 01 Air


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Compressor discharge to vent. It also routes steam to the steam-air coil which
must be regulated to a minimum using HIC-1 021. HS-1202 also shuts off the feed
gas to the Primary Reformer by shutting HV-1 01 0 & FV.1 001.
• HS-1201 and HS-1202 to shut down the Air and Feed Gas Compressors. (Ensure
that feed gas valve HV-1010 is closed and the upstream line is blocked off and
depressured if the shutdown is expected to be prolongued.)
The following manual moves by the operator will be required and are set out in order
of importance:-
• Reduce HP steam letdown via HIC-1028 and PIC-1013NB and allow the steam
c drum pressure to fall towards the MS steam header pressure or to some

intermediate level compatible with automatic level control on 0-2101. The drum
will have to be switched from 3-element level control to straight level control and
care taken not to flood the steam drum.
• The C02 Removal system must be blocked-in to maintain a pressure on the CO2
Absorber and all coolers in the system stopped. Ensure that flush water is
available as flushing medium to pumps.
• Close the LTS Converter outlet valve and bypass valve MOV-1009. Vent down
the front end at V-1 007 to minimum pressure to optimize low steam flow for
maximum velocity through the primary reformer tubes to sweep out any
hydrocarbons.
• Adjust steam flow to maximum as import steam becomes available from offsites .
Turn HP steam to vent when temperature/pressure is at 280°C/20 barg or when
import steam is available. Ensure that the desuperheaters at the steam letdown
stations are satisfactory. (Do not fill steam headers with water). When there is no
c more residual heat to support HP steam superheat it must be turned out of the
MP steam header.
• Start flow of nitrogen to the hydrogenator and desulphurisers and sweep out
hydrocarbons as described in the normal shutdown procedure.
• When satisfied that all hydrocarbons have been swept from the Primary Reformer
tubes, establish and maintain a flow of nitrogen through the reformers to eliminate
air entry.
If the emergency is of short duration and the 1.0 fan can be speedily restarted, the
shutdown may be contained and the fires quickly relit in the Auxiliary Boiler first,
superheat burners next for prompt steam superheat, and then in the Primary Reformer
arch. The unit should be brought quickly back on stream as all catalyst beds should
have retained sufficient heat to support reaction. If this is not the case, the unit should
be swept of all process gas and be left under nitrogen pressure.


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9.19 LOSS OF C-2112 ARCH BURNER FD FAN
Loss of the Arch burner FD fan will result in shut down of the Arch burners via FSL-1181
and interlock 21-ESD-2111 .
The fuel gas trip valves should be immediately backed up by manual isolation of fuel
gas to all burners.
Loss of Arch firing will require immediate plant shut down. The primary concern
is to protect the Primary Reformer tubes from too rapid cooling by taking out the
feed gas as soon as possible.
The following actions are required:
c Operate:
loop. HIC-1 028 should be used to adjust the large steam let-down valve.
• HS-1253 to shut down the Methanator.
• HS-1 004 to shut down and by-pass the LTS Converter. Vent the process gas at
PIC-1005.
• HS-1202 to shut down the air to the Secondary Reformer and to route C-21 01 Air
Compressor discharge to vent. It also routes steam to the steam-air coil which must
be regulated to a minimum using HIC-1021. HS-1202 also shuts off the feed gas to
. the Primary Reformer by shutting HV-1 01 0 & FV.1001.
c • HS-1201 and HS-1202A to shut down the Air and Feed Gas Compressors. (Ensure
that feed gas valve HV-1 01 0 is closed and the upstream line is blocked off and
depressured if the shutdown is expected to be prolongued.)
The steam flow to the Primary reformer should be controlled to regulate the reformer
tube exit temperatures which, dependent upon how quickly the above actions have
been carried out, will rise rapidly as the feed gas is taken out, due to the residual heat
in the furnace, and then begin to fall rapidly. Reduce stearn flow to about 20 tlhr when
the tube exit temperatures have turned and take steam out completely as the
temperatures begin to fall.
9.20 LOSS OF C-2111 AUX BOILER FD FAN
Loss of the Auxiliary boiler FD fan will result in shut down of the Aux boiler burners
via FSL-1177 and Interlock 21-ESD-2112. The fuel gas trip valves should be
immediately backed up by manual isolation of fuel gas to all burners.


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The resultant loss of steam production will result in a complete plant shut down
unless the boiler can be' restarted immediately.
If the boiler cannot be immediately restarted the following actions should be taken:
Operate:
loop. HIC-1028 should be used to adjust the large steam let-down valve.
c •
•
HS-1253 to shut down the Methanator.
HS-1 004 to shut down and by-pass the LTS Converter. Vent the process gas at
PIC-1005.
• HS-1202 to shut down the air to the Secondary Reformer and to route C-2101 Air
Compressor discharge to vent. It also routes steam to the steam-air coil which
must be regulated to a minimum using HIC-1021. HS-1202 also shuts off the feed
gas to the Primary Reformer by shutting HV-1 01 0 & FV.1 001.
• HS-1201 and HS-1202A to shut down the Air and Feed Gas Compressors.
(Ensure that feed gas valve HV-1 01 0 is closed and the upstream line is blocked off
and depressured if the shutdown is expected to be prolongued.)
The following manual moves by the operator will be required and are set out in order
of importance:-
Reduce HP steam letdown via HIC-1028 and PIC-1013 and allow the steam drum
c pressure to fall towards the MP steam header pressure or to some intermediate

level compatible with automatic level control on 0-2101. The drum will have to be
switched from 3-element level control to straight level control and care taken not to
flood the steam drum.
9.21 LOSS OF HYDROGEN TO THE DESULPHURISER SECTION
a) Loss of normal syn gas from the synthesis loop occurs if the Syn Gas Compressor
has to be shut down or trips. In order to desulphurise natural gas the flow of
hydrogen must be restarted as soon as possible so the primary reformer
catalyst is not pOisoned.
b) If the syn. gas compressor can be restarted after a short time, the supply of
hydrogen from the syn loop may be used to keep the desulphuriser on line. If the
shutdown is to be prolonged, hydrogen supply should be switched to 0-2103
outlet.


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9.22 LOSS OF PURGE GAS OR EXCESS SYN GAS TO H-21 01 FUEL GAS
a) The loss or low flow of Purge gas or excess syn. gas being routed to H-21 01 fuel
gas supply will cause an increase in the calorific value of the fuel gas being supplied
to the arch burners and will cause an increase in the Prirnary Reforrner tube outlet
ternperature. InterlockESD-1031 described in Section 11.3 Of this manual is
therefore provided to protect the Primary Reformer from overfiring due to changes in
the calorific value of the fuel gas.
b) Low flow alarms located on each of the purge gas and excess syn gas supply lines
to the fuel gas to alert the operator to the need to reduce the arch burner firing.
Should the purge gas flow reach a Low/low situation then switch FALL-1184 will
(' actuate Interlock ESD-1031 which will automatically close block valve XV-1031 On
the Purge Gas and XV-1030 on the Syn Gas connections to the fuel gas. At the
same time it will reset PIC-1 002 pressure controller on the fuel gas supply line to the
arch burners to 25% of its normal value, but a manual adjustment and reduction of
the arch burner firing will still be necessary
Note that Interlock ESD-1031 will also be actuated by 2 out of 3 Low/low pressure
switches located on the fuel gas supply lines to each row of Arch burners and set at
0.2 barg when firing on mixed fuel gases.
9.23 GENERAL EMERGENCIES
In addition to the primary actions previously outlined for specific emergencies, it is well
to keep in mind the following:
Any of the emergency actions taken will result in a drastic change in the heat balance of
the unit. In the synthesis section, refrigeration loads drop to virtually zero. Level
c controllers to the chillers will usually have to be blocked in to prevent high levels
resulting from leakage through the control valves.
Level controllers on the high pressure separators may have to be blocked in to prevent
loss of liquid followed by synthesis gas leakage into downstream equipment. This in
turn may cause pressure build-ups that must be vented to prevent the lifting of one or
more relief valves.
• Steam generating eqUipment is particularly sensitive to sudden load changes. Boiler

feedwater level may bounce and cause wide variation in stearn production. Level
controllers may have to be reset, or even put on manual control until conditions have
stabilised.
• Preheat coils in the convection section of the primary reformer must have an
adequate flow through them at all times to avoid overheating. A change in the flow
rate of any of these streams, or a change in the firing conditions of the furnace itself,
should be immediately followed by a check of the preheat temperatures.


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9.24 PRECAUTIONS TO BE OBSERVED TO PROTECT STEAM GENERATING

EQUIPMENT
a) Conditions may arise in the unit during serious operational upsets or as a result of
emergencies just described, which could conceivably create a demand for steam
generation beyond the capacity of the equipment provided. In order to protect the
steam generating equipment against serious damage, the steam consumption
should never exceed the capacity that is available or that can be generated at the
particular emergency condition.
b) In several of the emergencies which may occur, the synthesis gas is vented and
c ammonia production ceases. Loss of ammonia heat recovery in the E-2123 item
results, creating a large deficiency in the unit steam balance. No attempt should be
. made to recover this loss beyond the normal steam generating capacity of the
auxiliary boiler. Instead, every effort should be made to conserve the steam being
produced by using less where possible, to compensate. Should any condition arise
whereby heat recovery from the ammonia converter is lost temporarily, loss of
production would eliminate the need for refrigeration and the C-21 05 compressor
should be shut down to keep the steam consumption in balance.
c) The importance of maintaining the steam balance within safe limits during
upsets or other emergencies cannot be over emphasised.
9.25 GENERAL PRECAUTIONS
a) Sudden venting, because of some emergency, may produce flow rates that exceed
the capacity of the vent system. If this occurs, as evidenced by a back pressure
increase, it will be necessary to reduce the unit throughput until normal flows can be
re-established.
C~ b) Follow all precautions and keep air out of the various catalyst vessels at all times
during any shutdown, unless entry is anticipated and then only after proper steps
are taken to oxidise the catalyst.
c) During emergencies when venting takes place, attention must be paid to those
vessels, especially 0-2109, in which ammonia collects. Sufficient pressure must be
maintained at all times on these vessels to prevent auto-refrigeration.

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M.W. Kellogg Limited Operating Manual
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10 SAFETY
10.1 INTRODUCTION
A major chemical or petrochemical process plant consists of a complex series of
systems which are linked in a specific format to produce the desired end product.
The Operating Manuals define the procedures for achieving the required production in
a safe and efficient manner and to ensure the plant remains at maximum efficiency it
must be maintained. The safety systems incorporated in its design must therefore be
inspected and tested to ensure they will remain fully operational and will continue to
c provide the protection they were designed to give in conformance with regulations and
codes of practice.
To ensure maintenance and other personnel are not exposed to unnecessary or

unacceptable risk during such operations, it is essential that they are carefully planned
and conform to strict safety procedures. This section is only a brief discussion on
Safety and reference should be made to the SAFETY MANUAL which contains more
detailed information on the hazards which will be encountered in operating and
maintaining the plant together with the systems by which these hazards will be
controlled.
Any work on an operational plant other than normal process operations, must be
carried out under a PERMIT TO WORK system. In addition to recommended Permit
procedures, the Safety Manual contains advice on protective clothing, breathing
apparatus and other items required to provide protection during operation and
maintenance activities; together with the activities necessary to provide the physical
protection required to enable a Permit to Work to be issued. This is essential to
ensure that Operations are aware of the work proposed and that which is in progress,
and will maintain the conditions specified by the issue of the Permit to Work.
L The Permit preparation is linked to the work order specifying the work and the
planning system which co-ordinates the work to enable the necessary preparations to
be completed prior to the issue of the Permit to Work document. A Permit to Work is
essential as it provides the catalyst by which information, concerning the state of the
equiprnent to be handed over, the hazards rernaining and the precautions necessary,
is communicated to the maintenance team. At the same time the maintenance team
will inform the operations of any hazards their intended work may introduce which is
especially important where their work involves Hot Work, Entry to a Confined Space,
Excavation, etc. This will identify and ensure any further precautions necessary are
put into place and any additional certificates obtained to allow the issue of the Permit
To Work.
10.2 FIRE/EXPLOSION HAZARDS
Due to the flammability of many of the chemicals in the ammonia plant, great care
should be exercised in the opening up of vessels to ensure the atmosphere is not in,
or will not enter, during the opening process, the flammable range of the constituents


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[NB. aMDEA Solution Tank].
Some of the systems contain substances in the pyrophoric state.
Opening a vessel may allow a flammable gas to migrate and mix with air to form a
flammable mixture which could contact an ignition source nearby.
Analysis of the atmosphere should be carried out before opening manways etc. for
inspection and again whenever entry is contemplated.
Analysis for the constituent flammables will have to be carried out. [A valid
flammability test using an explosimeter cannot be performed without> 19% oxygen
c present] ego hydrogen in the aMDEA Tank.
From this an assessment of the procedures necessary for safe working should be
completed which should include the following preparations:
1) Review Site Safety Regulations for compliance with Company and Local
Authorities requirements. Amend where required.
2) Check and ensure that the following is correct for Fire Prevention:
• Fire equipment in place and operational
• Fire points clearly signed and free from obstruction
• Fire exits clearly marked, with evacuation routes clear of obstruction
• Emergency and Evacuation Plans updated to take into account the
"operational" aspect of the site
• Fire and Exercise drills performed
3) Check and ensure that the following is correct for on-plant permanent Safety
Equipment (Safety Showers etc.)
c • Units/equipment in place and operational

• Units/equipment location clearly indicated
• Units/equipment in compliance with Local First Aid Regulations
10.2.1 Plant Signs
• Ensure necessary signs are in place to indicate Hazards, Requirements,

Regulations etc.
10.2.2 Consumables (Permits, Testing materials etc.)
• Ensure an adequate supply of consumables is available

• Ensure personnel are aware of availability and use of consumables
10.2.3 Notifications
• Notification to local Hospitals/First Aid Centres regarding nature of possible

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accidents from inventoried chemicals, and treatment requirements.

• Set up Information/Notification/Reporting system for intemal Company reports and
extemal Regulatory Authority Reports.
10.3 SAFETY SYSTEMS
An important part of the Loss Prevention Programme of any chemical plant are the
systems provided to protect major items of equipment and systems from damage and
ameliorate the consequences of excursions outside the normal operating parameters
laid down for the plant.
c These include relief valves and rupture discs as the ultimate system pressure relief if the
alarms and trips provided are unable to contain a major pressure or temperature
excursion. Such systems must be maintained properly and regularly so that should an
emergency arise, they will operate as designed. A summary of relief valves is included
as section 10.9. of this manual.
10.3.1 Pressure Relief Valves

Pressure relief valves require maintenance at specified times, some of which will be
achieved during a tumaround whilst others may receive attention whilst the plant is
in operation. It is essential that such systems are always maintained in a condition
which will provide protection and are not isolated from the system they protect
unless a suitable altemative is in operation. Changeover systems should be locked
in position to prevent them being compromised by unauthorised interference.The
maintenance will include overhaul and bench testing to ensure they will relieve at the
required pressure or in the case of a steam relief system, may necessitate on-line
setting by a qualified person.
Where Block Valves are fitted on the inlet and discharge lines of unspared Relief
c/ Valves or, in the case of Relief Valves discharging to atmosphere to the inlet lines
only, these valves must be locked open during plant operation.
It is the responsibility of the Plant Management to ensure that a strictly

observed administration system is in place which will ensure that this
condition
10.3.2 Rupture Discs
Rupture discs do not require maintenance as such, but must be replaced when they
operate to protect the system or, as happens occasionally, fail prematurely. It is
essential they are installed using correct materials and ratings and in the correct
operational direction.
10.3.3 Alarms & Trips
Alarms & trips are the essential first-line protection for operating systems. These
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require testing/checking on a regular basis against a laid-down procedure to confirm

settings are correct and the system will operate as designed. "On-line" tests should be
designed to ensure as much of the system as possible is tested without interfering with
plant operation. During tumaround/shutdown periods, systems can be tested in their
entirety to confirm efficient operation.
10.3.4 The Firewater System
The Firewater System is provided to enable immediate steps to be taken to control

and contain fires, gas escapes or other unplanned events should they unfortunately
occur. It is essential that these systems are maintained in good operating condition at
c all times. Pumps should be regularly test run and any faults found rectified as quickly
as possible to prevent the unit being exposed to unnecessary risks. Major
maintenance on the fire water system must be tied in with times when the plant
inventory is minima·1 and the risk can be met by altemative arrangements.
Such times will not coincide with the periods of shutting down and starting up linked to
a tumaround. Preparations should be made in good time to ensure the system will
function effectively during periods of cold or inclement weather. 'Winterisation" should
be completed before the expected cold weather to ensure lagging is in place and in
good condition and that those sections which require draining, can be effectively
drained to prevent freezing.
The complex is provided with a grid pattem firewater loop system which encompasses
the Ammonia Unit, Urea Unit and Utility & Offsite areas. The system is provided with
block valves to isolate sections of the firemain for maintenance without affecting the
rest of the firemain system. For frost protection the fire main is buried below the frost
line.
Hydrants are located adjacent to the roads approximately every 46 meters throughout
c the complex and are isolated by buried valves fitted with an extended spindle and fitted
with a bleed hole for self draining to prevent freezing. Each hydrant has two 21-2"
instantaneous hose connections and are fitted with stop valves.
Firewater monitors are provided at strategic locations around the Ammonia

Unit. The range of these monitors covers the area inside the battery limits of
the unit.
The firewater is fresh water from the raw water reservoir which has been clarified in
the raw water treatment plant. A supply of firewater is stored in an atmospheric·
storage tank TK-6205 which provides 1500 m3 storage capacity. A bypass is provided
around the raw water treatment plant to permit direct filling of the firewater storage
tanks. The firemain pressure is kept pressurised to 9 barg by a jockey pump P-621 0
which takes suction from TK-6206. The jockey pump is normally running at all times
and will recycle via the recirculation check valve if there is no requirement for
water.The main firewater pumps P-6209A1B are electric motor driven pumps of 300
M3/hr capacity each actuated automatically by low pressure in the firemain. The
standby pump P-6219C is diesel engine driven with a capacity of 600 M3/hr The


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CLASS
firewater pumps are designed to provide a minimum pressure of 12 barg at the

· furthest hydrant in the loop. The firewater pumps can also be started from the control
room.
10.4 PERSONAL SAFETY ASPECTS
All personnel involved in operation and maintenance activities require personal

protection equipment corresponding to the hazards to which they are exposed. To this
end, a full review of all hazards from chemicals and process media must be undertaken
to ensure that the issued personal protection equipment is adequate. Information for
special requirements will be indicated from "Control of Substances Hazardous to Health
c Regulations" (COSHH for UKlEEC), and the Material Safety Data Sheets (MSDS's).
10.5 NOISE
A hazard to personnel which can always be present during pre-commissioning and

commissioning activities is a high noise level. This is because the normal noise
prevention facilities incorporated in the process plant are not yet in service. All possible
noise emission activities, such as line blowing, should be highlighted and steps,such as
the fabrication and installation of temporary silencers, to reduce the noise levels during
these activities should be undertaken.
EEC regulations require that hearing protection be provided where noise levels are
above 85dB and it is a mandatory action to wear ear protection when the noise level
reaches 90dB. All "noisy" activities should be monitored and noise levels recorded and
retained on file. All personnel must be issued with ear protection and counselled as to
the usage of same.
c~
10.6 VESSEL ENTRY
With the introduction of water, gas and chemicals to the plant equipment, all activities
,especially entry into confined spaces (Vessel entry etc.) must be brought under a
rigorous, documented control. The recommended control procedures are described in
detail in the Safety Manual and include:
• Vessel Entry Permits to be used

• Positive isolation of vessel to be used
• Tests and analysis of atmosphere inside the vessel to be entered
• Provision of effective rescue plans and procedures
• Prevention of unauthorised entry
Personnel will be given familiarisation and training courses in the application of safety
equipment to be used during vessel entry, such as; gas detectorslanalysers, harnesses,
breathing apparatus, resuscitators etc. Training and familiarisation courses will also be
given in First Aid methods that could be required.
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10.7 ENVIRONMENTAL ASPECTS
This aspect of Safety Awareness and Safety Precautions during the operation and
maintenance activities can be separated into two main categories:
Category I is the environment to which personnel are exposed during operating and
maintenance activities.
c Category" is the hazard (pollution) to which the environment could be exposed by

operating and maintenance activities.
·10.7.1 Category I - Exposure of Personnel
Under the EEC "Control of Substances Hazardous to Health Regulations", an

assessment of all chemicals and/or hazardous substances on the site must be
conducted and recorded. This assessment covers;
• Type of substance and amount on site

• Where and when each substance is used or occurs in the process
• Likely exposure of personnel to the substance concerned
• Methods of controlling/eliminating risk of exposure to the substance concerned
• Measurement of levels of exposure/pollution for each substance concerned
• Information available/given to personnel (MSDS's) for each substance concerned
• Medical Examinations/Records (where necessary) of personnel
10.7.2 Category II - Pollution of the Environment
c Facilities to minimise/eliminate pollution of the environment by accidental or controlled

emissions during start-up and normal operation of a plant are incorporated within the
process operation either by specific items of equipment or by specific operating
procedures. However, this cannot be the case during pre-commissioning and/or
commissioning, as the equipment item or system may not have been placed in service
or may not be available for use. This is of particular importance during the
flushing/blowing clean of systems and the chemical cleaning of equipment and/or
systems. To minimise/eliminate environmental pollution all of the pre-commissioning
and commissioning activities must be reviewed and special equipment and/or
procedures introduced to safely control the following:
• Disposal of Waste (Toxic/Non-toxic)

• Discharge to Water Courses
• EmissionsiVents to atmosphere
Where draining of vessels, taanks etc is required for maintenance, Urea or Ammonia
rich solutions must not be drained to oily water sewer or to grade. A suitable portable

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CLASS
pump should be connected to a convenient low point drain and the contents pumped
to a disposable tanker or container.
Local restrictions and regulations must be checked with the client and any of the
above-mentioned types of discharge must be documented and recorded for the
Safety/Quality assurance file.
10.S HAZARDOUS CHEMICALS
The handling of chemicals is an intrinsic part of the operation and maintenance
c
activities. Personnel must be trained and become familiar with the safe handling of
these chemicals, and also in the hazards involved plus remedial actions to be taken
In the event of spillage and/or'exposure to the chemical substance. Volume 2 of the

Safety Manual contains the MATERIAL SAFETY DATA SHEETS which give detailed
information for all raw materials, products and chemical used and produced on a
chemical plant. THESE DATA SHEETS SHOULD BE CAREFULLY STUDIED and
familiarisation and Training sessions should be undertaken with all personnel prior to
any actual chemical handling. These sessions must be recorded and documented in
the site Safety File as well as in the individual employee file.
The following is a general outline of the more common gases and chemicals
encountered on an Ammonia Unit together with a brief first aid procedure should an
employee become exposed to one of them.
10.S.1 Natural Gas
Natural gas is used as a feedstock and a fuel for the furnaces and boilers. The main
constituent is methane which is extremely flammable. The liquefied gas is very cold
c and may cause frostbite. It is non-toxic but at high concentrations acts as a simple
asphyxiant reducing the oxygen content by dilution such that life cannot be supported.
At low concentrations its odour is undetectable when pure but above 5000ppm has a
sweet oil type odour.
It can be detected using a flammable gas monitor but where entry to a vessel is
proposed the level of oxygen should be checked to confirm it is sufficient to support
normal respiration.
The auto-ignition temperature is 53SoC. It forms explosive mixtures with air. Explosive
limits in air 5 -15% by volume (a concentration of 10% is especially explosive). Natural
gas fires should be extinguished by isolating the fuel supply to avoid vapour cloud
reignition or an explosion. Steelwork on which a flame may be impinging should be
kept cool by water sprays.
First Aid: Remove casualty to Fresh Air. Keep lying down. Give oxygen.
Commence resuscitation if breathing stops. Obtain medical assistance.
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10.8.2 Nitrogen
Nitrogen forms 78% of the air we breathe and therefore does not have a reaction on
the body in gaseous form but will cause freeze burns in the liquid form. It acts as a
simple asphyxiant. If atmospheric oxygen falls from its normal 20.5% to 18% mental
sluggishness will begin to show. At lower levels unconsciousness will rapidly occur.
Breathing of 100% nitrogen for a couple of minutes will cause anoxia and permanent
brain damage and may prove fatal.
Nitrogen should only be released to atmosphere (when purging etc.) in a well

ventilated area and not inside buildings or confined space. It does not support
combustion.
('
10.8.3 Carbon Monoxide
Carbon Monoxide is a colourless, practically odourless gas, slightly soluble in water.

Gas air mixtures are explosive and it is highly flammable buming with a violet flame.
Lower flammable limit 12.5%. The UK Occupational Exposure Standard (OES), Time
Weighted Average (TWA) 8 hours in 50 ppm. Short Terrn Exposure Limit (10
minutes) 300 ppm.
Carbon monoxide combines with haemoglobin in the blood to form

carboxy- haemoglobin, preferentially to oxy-haernoglobin. Continued exposure allows
it to build up in the bloodstream preventing oxygen transfer across the lung tissue and
at high concentrations leads to asphxiation. It has a high toxicity with possible
systemic effects.
c It is important to remember the cumulative effect because working for several hours in
concentrations which have no immediate toxicity may tend to impair the sense of
proportion or of danger. Individuals vary in response but the following are typical
reactions:
QQm CO In Air Effect on Working Person
50 O.E.S. (TWA 8 hrs).
200 Headaches after 2 hrs.
Headaches and nausea.

400
Possible collapse after 10 minutes.
1200 Palpitation after 10 minutes

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2000 Unconciousness after 10 minutes.
Headaches and dizziness in 1 to 2 minutes

6400
Unconciousness and possibly fatal after 10 minutes.
10.8.4 Carbon Dioxide
A colourless odourless gas at ambient temperature. Can also exist as a solid or

c~ liquid. The gas is non-flammable - used in fire extinguishers. It is an asphyxiant: UK
Occupational Exposure Standard (TWA) 8 hrs - 5,000 ppm. STEL (10 min) 15,000
ppm.
Gaseous carbon dioxide is slightly toxic having an effect on the respiratory and
cardiovascular system. Increased concentrations in the blood causes the rate of
respiration to increase. At 2-5% concentration in air breathing becomes deeper with a
slight feeling of choking. At 5-10% breathing becomes laboured and judgement may
be impaired. Above 10% unconsciousness and eventually death will follow more
quickly as the concentration rises.
First Aid: Remove to Fresh Air. Keep lying down. Give oxygen. Commence
resuscitation if breathing stops. Obtain medical assistance.
10.8.5 Hydrogen
It is a colourless gas which is lighter than air. It reacts vigourously with oxidising
c agents. It is a highly flammable gas. Auto-ignition temperature 560°C. Explosive

limits in air 4.1 - 74.2% by volume. Because it is lighter than air it disperses readily but
can collect under roofs or ceilings. It presents a serious explosion risk because of the
wide explosive limits and may be ignited by catalytiC substances below its ignition
temperature to as low as ambient temperatures. Buming hydrogen should be
extinguished by isolating the supply. No attempt should be made to extinguish it in any
other way because of the danger of re-ignition or explosion. If possible steelwork in
contact with, the flame should be kept cool with water sprays.
Occupation Exposure Standard - Simple asphyxiant.
First Aid: Remove to Fresh Air. Keep lying down. Give oxygen. Commence
resuscitation if breathing stops. Obtain medical assistance.
10.8.6 Ammonia
Ammonia is a colourless liquid or gas with a characteristic pungent odour which

provides ample warning of its presence. Odour threshold 5-20ppm. It forms flammable mixtures

+ M.W. Kellogg Limited .Operating Manual
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with air in the range 16-27% by volume. A lower explosive limit of 15% can be
obtained in ammonia/oxygen/nitrogen mixtures. The presence of oil or other
flammables enhances the risk. It is advisable to isolate the supply to extinguish a fire
as a continuous escape presents an explosion hazard. Water sprays should be used
to cool fire exposed containers but care should be taken as water reacts violently with
liquid ammonia. Fog nozzles are useful to disperse and absorb ammonia vapour.
Ammonia is a highly irritant and corrosive material. Exposure to the gas causes
irritation and stinging sensation especially if the skin is moist, blistering may also occur.
It irritates the eyes causi!lg watering, swelling of the eyelids and conjunctivitis.
High concentrations and splashes may cause temporary blindness and severe eye
damage. Impaired or complete loss of vision may result if the eye are not thoroughly
C~ irrigated with clean water immediately. Medical attention must be obtained from a
doctor or preferably an eye specialist.
Inhalation causes irritation of the nose and throat initially which may be followed by
coughing, laryngitis and bronchitis. High concentrations affect the whole respiratory
tract causing severe injury to the mucous membrane and lung tissue with possible fatal
results.
UK Occupational Exposure Standard TWA 8 hrs - 25ppm STEL 1Om ins - 35ppm.
The following describes typical reactions to exposure:
!!!!m Ammonia In Air Effect on Working Person
40 A few individuals will suffer eye irritation.
Noticeable irritation of eyes & nasal passages after a
c 100
400
few minutes eXDosure.
Severe irritation of the throat, nasal passages and
upper respiratory tract. -,.'
Severe eye irritation. Effect not permanent if
700
eXDosure less than 30 minutes. ,
Serious coughing, bronchial spasms.

1700
Less than 30 minutes eXDosure mavbe fatal.
Serious oedema, strangulation, asphyxia.
5000
Fatal almost immediately. minutes.
Liquid ammonia in contact with the skin will produce severe chemical bums and the
freezing effect due to rapid evaporation from the skin surface can cause frost bite.
Caution: Evaporating liquid or expanding gas can cause rapid cooling. Mild steel
etc. in contact with such conditions loses its ductility and at temperatures below _20 0
becomes subject to brittle fracture if struck. Non stressed relieved welds are liable to

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fracture if subject to immediate cold thermal shock.
10.8.7 Oxygen Scavenger(such as Nalco 72100)
10.8.7.1 Nalco 72100
Safety And Handling:

Read the Material Safety Data Sheet before using this product. NALCO 72100 may
cause irritation to skin and eyes. Avoid contact with skin, eyes, and clothing. Do not
take internally. In accordance with good industrial practice, handle with care and
avoid unnecessary contact.
c 10.8.8 Condensate Conditioner (Morpholine or alternative such as Nalco 72310)
10.8.8.1 Morpholine
Morpholine is a clear colourless liquid with an amine type odour and is soluble in
water.
The vapour is flammable and will move to an ignition source and flash back.
L.E.L. = 1.8% v/v U.E.L. = 11 % v/v

It is an irritant vapour and is poisonous by inhalation (inc. ingestion) and absorption
via undamaged skin. The effect is cumulative.
The chemical is handled using Butyl gloves, PVC splash suit and a full cannister
mask in open atmosphere. [Self contained breathing apparatus is needed for
confined space entry or in the fire situation).
c P.E.L. (skin) 8 hrTWA 20 ppm: 70 mg/m3

15 min STEL (skin) 30 ppm 105 mg/m3
Spillages of concentrate should be contained and adsorbed onto vermiculite or

granulated clay or treated with Sodium or Calcium Carbonate (powder) for
recovery into drums and disposal by manufacturer's recommended route.
Small spillages of dilute material should be contained and heavily diluted before
transfer to drain.
For further information see the Material Safety Data Sheet in Volume 2 of the
safety manual.
10.8.8.2 Nalco 72310
Safety And Handling: Read carefully the label and Material Safety Data Sheet for
complete handling information before using this product.

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10.8.9 Steam & Condensate
The hazards are from the high temperatures and pressures in these areas due to
contact with steelwork at high temperature causing thermal burns or leaks from the
plant causing scalds.
Beware - superheated stearn is not visible to the naked eye, until it cools slightly and
condenses and can cause severe burns at some distance away from a leak
dependent on pressure.
c 10.8.10 Catalysts
The ammonia plant uses a variety of catalysts some of which present problems
when handling them. The following information is relevant.
Note: Pyrophoric Catalysts are catalysts which react on exposure to air

generating heat.
10.8.10.1 LT Shift and Ammonia Synthesis Catalysts
These are pyrophoric when in their reduced state and as the charge for bed one of
the Ammonia Synthesis unit is normally supplied pre-reduced and any bed will be
in the reduced state when unloading after being on line for a turnaround etc. these
catalysts need special handling procedures. They are normally handled under an
inert (nitrogen) atmosphere until they can be returned to service or can be cooled
down and treated ready for disposal.
The procedures entail work in nitrogen atmospheres and under nitrogen
c blanketing. Great care must be exercised to ensure personnel are properly

equipped with air fed breathing apparatus to enable them to work in the oxygen
deficient atmospheres which will occur within and in close proximity to the vessels
under purge.
Sufficient nitrogen purge must be maintained to sweep out any oxygen from the air
exhaled by the work crew whilst working to release the catalyst bed carrier (see
also entry procedures section 9).
10.8.10.2 HT Shift, Methanator, Cobalt/Molybdenum Catalysts
These catalysts have the potential to generate heat on exposure to the air by some
oxidation of the catalyst.
10.8.10.3 Cobalt Molybdenum, Zinc Oxide Catalysts
These catalysts can generate heat due to oxidation of adsorbed carbon.

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In both these cases providing that the catalyst beds are cooled to ambient
temperature using nitrogen before discharge the catalyst is unlikely to heat up.
However water hoses equipped with fog sprays should be available for use
particularly if Cobalt/Molybdenum or Methanator catalyst is to be stored in open
piles for a prolonged period.
10.8.10.4 Primary and Secondary Reformer Catalysts (Nickel)
These do not present a pyrophoric hazard providing that they have been steamed
as indicated in the normal shutdown procedures.
c 10.8.10.5 Nickel Catalysts (Primary and Secondary Reformers, Methanator)
Catalyst containing metallic nickel must not be exposed to atmospheres containing

Carbon monoxide at temperatures below 150°C. This is to prevent the formation of
NICKEL TETRACARBONYL Ni(CO). which is extremely toxic and flammable.
It is an almost odourless gas which is quite stable at low temperatures and would
present a high risk to maintenance operations in or immediately downstream of
units containing the nickel catalyst. The possibility of the formation of Nickel
Tetracarbonyl must always be considered particularly if the plant conditions have
forced a shutdown outside the normal operating parameters.
The Primary and Secondary Reformers will normally be purged clear of Carbon
Monoxide by the steam injection used during normal shutdown procedures. If not
they must be purged to remove residual CO.gas. The Methanator must always be
purged with nitrogen to remove the Carbon Monoxide contained in the process gas
before the catalyst is allowed to cool down.
c 10.9 RELIEF VALVES
RV Number P.& 1.0. Set Pressure Vents To:

barq
PSV-FG 1002A1B 64-0110 13.0 Front End Flare
PSV-C2101 62-0101 43.0 Air Compo Silencer !
PSV-C2102A 62-0104 51.5 Front End Flare

PSV-C2102B . 62-0104 54.1 Front End Flare
PSV-R2160 62-0105 51.5 Front End Flare
PSV-E2102A 62-0107 38.8 Front End Flare
PSV-E2102B 62-0107 40.7 Front End Flare
PSV-R2109 62-0108 38.8 Front End Flare
PSV-02102 62-0110 36.6 Front End Flare
PSV-T2101 62-0110 36.6 Front End Flare
PSV-E2172 62-0111 36.6 Atmosphere
PSV-02104 62-0112 34.0 NH3 Flare
PSV-02105 62-0113 73.0 Atmosphere
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RV Number P.& 1.0. Set Pressure Vents To:

barg
o
PSV-C2103 62-0114 154.0 NH Flare
PSV-02120 62-0117 16.5 NH3 Flare
PSV-02121 62-0117 16.5 NH3 Flare
PSV-02122 62-0117 16.5 NH3 Flare
PSV-02123 62-0117 16.5 NH3 Flare
PSV-C2105 62-0119 16.5 Atmosphere
PSV-02107 62-0120 18.0 NH3 Flare
PSV-E2175 62-0121 10.5 Oily Water Sewer
PSV-T2103 62-0128 13.0 NH3 Flare :
c PSV-T2104
PSV-FF1001
PSV-SC036
PSV-P2140AT
62-0129
63-0102
63-0103
63-0125
20.5·
43.8
6.9
5.2
NH3 Flare
To Qrade
Grade
Atmosphere
PSV-02101A 64-0101 137.9 Atmosphere
PSV-02101B 64-0101 142.0 Atmosphere
PSV-SC033 64-0101 6.9 Grade
PSV-H2101A 64-0102 132.5 Atmosphere
PSV-H2101B 64-0102 136.5 Atmosphere
PSV-MPS1001A 64-0103 47.1 Atmosphere
PSV-MPS1 001 B 64-0103 47.1 Atmosphere
PSV-MPS1 001 C 64-0103 47.1 Atmosphere
PSV-MPS1001D 64-0103 49.4 Atmosphere
PSV-MPS1 001 E 64-0103 49.4 Atmosphere
PSV-LPS1002 64-0104 7.1 Atmosphere
PSV-P2104TA 64-0107 7.1 Atmosphere
PSV-P2104TB 64-0107 7.4 Atmosphere
PSV-C2105TA 64-0107 47.1 Atmosphere
c PSV-C2105TB
PSV-C2103TB
PSV-C2103TA
64-0107
64-0107
64-0107
49.4
49.4
47.1
Atmosphere
Atmosphere
Atmosphere
PSV-P2141AT 63-0111 5.2 Atmosphere
PSV-V2101 64-0106 3.5 Atmosphere

PSV-E2140 64-0105 0.04 Atmosphere
PSV-C2110(T) 64-0107 7.1 Atmosphere
PSV-C2111m 64-0107 7.1 Atmosphere
PSV-P2120AlB 62-0119 124.1 Pump Suction
PSV-SG1030 62-0128 13.0 NH3 Flare
PSV-PG1040 62-0101 5.9 Atmosphere
PSV-AM1023 62-0119 32.5 NH3 Flare
PSV-AM1034 62-0120 24.5 NH3 Flare
PSV-FF1005 62-0123 49.4 To Qrade
PSV-C2112T 64-0107 7.1 Atmosphere
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CLASS
10.10SUMMARY OF RUPTURE DISCS
Disc No P.&I.D. Protects Burst Vents to:

Pressure
bam
SP-006 62-D116 E-2121 20.0 across SP-173
SP-008 62-D122 T-21 02 tower 3.5 Atmosphere
SP-011 62-D104 E-2133 tubes 7.6 Atmosphere
c SP-013
SP-014
SP-017
62-D115
62-D102
62-D109
E-2124 tubes
E-2173 tubes
E-21 06 shell
7.6
7.6
10.5
Atmosphere
Atmosphere
Atmosphere
I

SP-033 62-D113 E-2117 tubes HOLD Atomosohere
10.11 ALARM AND TRIP SETTING

See DWGS 850-B2001 and SMRY-0-2002


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11 INSTRUMENTATION
11.1 INTRODUCTION
Automatic control instruments and valves are provided to effectively regulate

temperatures, flows and levels at key pOints within the unit. The piping and
instrumentation diagrams show all the instrumentation for the unit. To assist in
understanding these drawings, reference should be made to the general notes and
instrument symbols on drawings 62-0001, -0002 & -0003.
c Most of the unit's instrumentation is conventional in construction and application.

Details regarding various instruments may be found in the Job Specification Book and
in the vendors' brochures.
The complex loop instrumentation is discussed under a separate heading in Section

11.2. These loops are more complex than the standard single element type and
should be studied carefully in conjunction with the P&I diagrams.
Instrumentation has been provided at various locations on the unit for the protection of
equipment by automatic shutdown upon development of undesirable alarm conditions.
This instrumentation is discussed. under 'Shutdown Devices'in section 11 .3.
Important Note
In the NORMAL operating mode all solenoids are ENERGISED and will
DE-ENERGISE to the TRIP position.
11.2 COMPLEX LOOP INSTRUMENTATION
C 11.2.1 0-2101 Steam Drum Level Control
In order to provide a maximum stability of the steam drum and to maintain a

preset boiler drum level, an integrated one-three element control system is
provided using steam flow, water flow and drum level measurements. The
system is switchable from one element to three element and vice-versa at
the operator's option using selection switch HS-1102. Irrespective of the
control mode chosen for start-up operation, once plant start-up has been
achieved, the steam drum level control system should be placed in the
three element mode for normal operation of the plant.
The one element system compares a signal indicative of drum level as

received from either level transmitter LT-1001A or LT-1001B using selector
switch HS-11 01, to a preset setpoint signal on L1C- 1101. Any deviation
between the signal and the preset point will result in L1C-11 01 taking
corrective action by transmitting a signal via HS-11 02 to adjust the speed of
the BFW pump turbine and position the control valve in the discharge of the


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motor driven pump as required.
The three element system compares the HP steam flow indication from
FI-1033 and the steam drum level indication from LlC-1001 in computing
relay FY-1033. The resultant signal resets boiler feed water controller
FRC-1006 and the FRC-1006 output signal is routed through HS-11 02 to
adjust the flow of the BFW in the same way as described above for the one
element system.
Both one and three element systems afford manual control. Outputs from
FRC-1006 arid LlC-1001 need not be balanced for transfer from one to
three element control; however, they should be balanced when transferring
c from three to one element control.
Should a low flow of BFWto the steam drum occur, then low flow switch
FSL-1106 will actuate InterlockESD-11 06 which will automatically start the
motor driven standby pump P-2104B.
In the event of an extra low level in the steam drum, Low low level switches
LSLL-1223A1B/C will actuate InterlocksESD-2112, ESD-1223 and ESD-2111.
11.2.2 HP Steam to MP Steam Letdown System.
11.2.2.1 HP Steam & MP Steam Pressure Control
The pressure in the HP Steam header is controlled by PRC-1018 which adjusts the
firing of the Auxiliary Boiler. The output signal from this controller acts upon the
leading air system of the Auxiliary Boiler to regulate the fuel gas and combustion
air supply to the burners.
c In providing the major driving force for the C-21 03 Synthesis Gas Compressor and
C-21 05 Refrigeration Compressor, their turbines are the only users of high
pressure steam and are also the major supplier of MP steam. It is apparent,
therefore, that controls must be provided to prevent a major steam system upset
from affecting synthesis gas compression and refrigeration control and vice versa.
Instrumentation is therefore provided to ensure corrective action during load
changes or periods of upset operates in the following manner to effect smooth
control of both these steam systems.
The MP steam system pressure is regulated by PRC-1012 which senses the

pressure in the MP header. In conjunction with PRC-1006 which serves D-21 04
Suction Drum Pressure, PRC-1012 is used to set the C-21 03 HP/LP turbine
governors. PRC-1 012 will regulate the amount of HP stearn letting down through
the turbine into the MP steam header to control the MP stearn header pressure;
and PRC-1006 will adjust the steam valves of the condensing stage to regulate the
compressor speed as necessary for the control of the pressure on the Compressor
Suction Drum D-21 04.

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The overall effect of the control system is to achieve minimum and gradual load
change on the C-21 03 HP turbine during steam variations with compensatory
changes being effected smoothly and simultaneously in the HP system through the
combined actions of the PRC-1 018, FRC-1177 and FIC-1030 control instruments
on the Auxiliary Boiler.
11.2.2.2 HP to MP Steam Letdown Station
A letdown sy1em from the HP to MP steam systems consisting of three parallel

control valves PV-1013B (8'), PV-1013A (3') and HV-1028 (10') is provided.
PV-1013A & PV-1013B respond to signals from PIC-1013 located on the MP
Steam header whilst HV-1028 may be positioned using one of three hand
C' controllers HIC-1075, HIC-1028 or HIC-1029.
In normal operation, the let-down valve HV-1028 is maintained'in a closed position

with the HP steam being let down through the C-21 03 and C-21 05 HP turbines.
During startup and at low loads on the compressors, HP steam "let-down" will be
via one of the PIC-1 013 control valves around C-21 03 and C-21 05, together with
the quantity being let down via C-21 03 HP turbine under control of PRC-1012 and
via C-21 05 HP turbine.
Under a condition where the Syn. Gas and/or Refrigeration compressors are not
running or trips, the let-down of HP steam will be via HV-1 028 positioned by an air
signal from HIC-1028, HIC-1029 or HIC-1075 plus PIC-1013 control valve
(PV-1 013A or PV-1 013B depending on flow quantity), to satisfy the MP steam
system. This is made possible by pressure signals from the compressor turbine
governor oil on which the snap-acting pneumatic controller is set to actuate on
falling pressure of the governor oil; i.e. on compressor failure, as soon as governor
oil pressure falls below a preset setting, its control signal will start to fall and
actuates the pneumatic trip valve.
C This will activate the trip system and de-energise solenoids HV-1028B, HV-1029B
or HV-1075B which causes valve HV-1028 to open to a position as preset by
HIC-1028, HIC-1029 or HIC-1075 (equivalent to the sum of the preset signals from
HIC-1028 and HIC-1029), thus bypassing the steam around the C-21 03 and/or
C-2105 turbines. The pneumatic trip valves must be manually reset once they
have been tripped after re-establishing normal governor oil pressure prior to the
restart of the compressors.
The solenoids at HV-1028 are arranged in series on a common air supply line to
. the control valve positioner and each has two positions: i) NORMAL (energised)
and ii) TRIPPED (de-energised).
In the NORMAL position the control valve is held shut by instrument air pressure
directed through the solenoid valves onto the positioner. The solenoid will be
energised and latched in position and no control of HV-1028 by HIC-1028,
HIC-1029 or HIC-1 075 is possible. There is a back-up source of air to the control
valve HV-1028 so that it fails safe on loss of the normal instrument air supply.
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In the TRIPPED positions the solenoid will be de-energised and unlatched with the
air supply blocked at the solenoid valve and the preset output signal from
HIC-1028, HIC-1029 or HIC-1075 will be routed through to valve HV-1028
positioner.
Note: In the event of either C-2103 andfor C-21 05 tripping, it is only possible to
route the preset signal from ONE HIC to the diaphragm. Since there is a larger
flow of HP steam let down through C-21 03 HP turbine than through C-2105,
solenoid HV-1028B associated with C-21 03 is therefore located nearer the control
valve than HV-1029B. Should both turbines trip, then solenoid HY-1075B (located
c
nearer the control valve than HV-1 028B & HV-1 029B), will be actuated and the
preset signal from HIC-1075 will then position valve HV-1028. It is essential that
when starting C-21 03 and C-21 05, that a careful note is made of the HIC output
corresponding to the amount of steam passing through each HP turbine and the
HIC positioned accordingly to ensure a steady switch over in the event of a
compressor trip. '. -
11 .2.3 Auxiliary Boiler Combustion Air & Fuel Gas Control
An Auxiliary Boiler combustion air and fuel control system is provided to ensure
corrective action during load changes or periods of upset. The control system will
operate in the following manner, for effecting smooth control of the HP steam
system and the Auxiliary Boiler combustion air and fuel controllers.
The systems function is to control the Auxiliary Boiler FD Fan Turbine driver speed
in response to steam system load changes which will require a change in
combustion air ffuel gas demand. When steam demand changes as sensed by
PRC-1 018 located in the HP steam header, an output signal passes to two select
relays FY-1177B and FY-1030C which are arranged as follows to act on the Turbine
c governor and the burner fuel pressure controller respectively.
Relay FY-1177B receives a signal from PRC-1018 (HP steam header pressure) and
also from FT-1030 (fuel gas flow to Auxiliary Boiler burners). This relay selects the
highest signal and passes a Signal to FRC-1177 to reposition the set point of this
instrument which changes the turbine governor speed setting in response to a
signal from FT-1177 (combustion air flow to Auxiliary Boiler.)
Relay FY-1030C also receives a signal from PRC-1018 (HP steam header pressure)
together with a signal from FT-1177 (combustion air flow to Auxiliary Boiler). This
relay selects the lowest of these two signals and passes a signal to FIC-1030 to
reposition the set paint on this instrument which is responding to a Signal from
FT-1030 (fuel gas flow to Auxiliary Boiler burners).
The signal from FIC-1030 passes to relay FY-1030B which also receives a signal
from PIC-1030 (fuel gas pressure to Auxiliary Boiler burners downstream of
FIC-1030 control valve). FY-1030B then selects the lowest of these two signals and
in response repositions FV-1030 thus adjusting the flow and/or pressure of fuel gas

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to the Auxiliary Boiler burners.
Net result of this control system ensures that the correct amount of combustion air is
available to the Auxiliary Boiler bumers at all times and specifically in timely
response to any steam production requirements. It should be noted that low flow of
combustion air switch, FSL-1177 is provided which, unless this switch is satisfied,
interlock ESO-2112 will prevent lighting-off the Auxiliary Boiler burners.
11.2.4 Auxiliary Boiler Light-off Sequence
a) With the 10 and FO fan running, set FRC-1177 to control the Auxiliary Boiler
c firebox draft and PIC-1 019 to control the main Reformer firebox draft. These
should be adjusted to satisfy the Combustion Air low flow air switch, FSL-1177
and2 out of 3 voting PT-1060 on the Auxiliary Boiler; the Arch high Pressure
switch PSH-1424 and the 10 Fan speed transmitter ST-1 011.
b) Check that all Pilot and main burner fuel gas cocks are closed, all burner air
register doors are OPEN, the fuel gas header depressured and the vent valves
closed. Then press HS-1236 'Purge/Checking Sequence Start' pushbutton
which will start the purge timer providing:
• The Auxiliary Boiler main fuel gas and pilot gas headers are confirmed
isolated, depressured and no burners lit
• The Auxiliary Boiler checking gas valves are confirmed closed.
• The Superheater pilot and main fuel gas headers are confirmed isolated and
depressured and no burners are lit.
• The 10 Fan is confirmed as running and there is a purging air flow into the
c Aux Boiler fire box and adequate draft in both the radiant box and Auxiliary
Boiler fire box.
c) The 'Purging' indicator XL-1236A will illuminate and the purge timer will run for
20 minutes at the end of which time the 'Purging Complete' indicator XL-1236B
will illuminate
d) To allow the checking procedure to progress, the downstream trip isolation

valves XV-1230-1/213/4 on the main gas supply and valves XV-1235-1/213/4 on
the pilot gas will be forced open, and the vent valve XV-1230C on the main gas
supply and valve XV-1235C on the pilot gas will be forced closed. This will allow
the pilot and main gas systems to be checked for tightness through to the burner
cock valves.
e) The solenoids on checking gas valves, XV-1231A1B/C and XV-1236A1B/C will be

energised allowing checking gas into the burner and pilot gas supply headers
and providing the checking permissive switches PSL-1137 on the pilot gas
header and PSL-1132 on the main fuel gas header are satisfied Le. the headers
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are pressured, the 'Checking' indicator XL-1236A will illuminate and the
checking timer will run start.
f) If the pressure in the headers fails to reach the pressure switches PSL-1132 &
PSL-1137 settings, then XZ-1236D 'Checking Failed' indicaiion will illuminate.
This will require a repeat of the previous steps following a check and closure of
any burner and pilot manual cock valves found open.
g) If the checking gas permissive switches PSL-1132 & PSL-1137 are satisfied and
continue to remainn so during the time-out period of the checking timer, then the
'OK to Open Pilot Fuel Gas Valves' indicator XL-1235, will illuminate.
c h) Press HS-1235, 'Open Pilot FG Valves' pushbutton to override the Pilot Fuel Gas
Header switches PSLL-1235 and PSHH-1236 for a timed period (the latch-up
timer). As long as Draft switch PSHH-1060 remains satisfied, the timed override
energises the pilot ignitors and allows latching of the solenoids on Pilot Fuel Gas
valves XV-1235A & C and XV-1235-1/2/3 & 4.
i) Establish correct Pilot Fuel Gas Header pressure, open a pilot burner cock and
at the same time press the corresponding Pilot Ignitor pushbutton
HS-1237A1B/C or D to light the pilot burner. Repeat for each pilot burner.
j) Providing PSLL-1235 and PSHH-1236 Pilot Fuel Gas Header switches remain
satisfied and the pilot flame rods indicate all pilots are lit, then XL-1230 'OK to
Open Main FG Valves' indication will illuminate.
k) Press HS-1230 to 'Open Main FG Valves' pushbutton to override PSLL-1230 and

PSHH-1231, main fuel gas header switches for a timed period (Main Latchup
timer). As long as PSHH-1060 Draft and LSLL-1223A1B/C (2 out of 3) Steam
Drum level switches remain satisfied and HS-1255, Manual SID switch in the
c main control room remains in the Normal (run) position, the timed override allows
manual latching of the solenoids on the Main Burner valve XV-1230A & vent
XV-1230C and the individual burner valves XV-1230-1/213 & 4.
I) After establishing correct header pressure push HS-123SAlB/C or D to open the

corresponding individual main fuel gas valve, then open the corresponding
manual burner cock to light the burner and repeat this operation for the
remaining burners.
m) In the event of an unsuccessful pilot light-off after a number of attempts or of an

unsuccessful first main burner light-off; shutdown the Auxiliary Boiler.
n) A repurge of the firebox is required if pilot burner or main burner flames have not
been established. After a main burner trip it can be re-lit by repeating steps k) &
I). After a pilot trip it can be relit by repeating steps h) & i) as long as the main
burners remain It.

c JOB NO. 5777

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CLASS
11 .2.4.1 Shutdowns:
• PSHH-1060 Auxiliary Firebox Draft (After a 3 second time delay).

• Flame failure of all Auxiliary Boiler bumers.
11.2.4.2 Pilot Trips:
• PSLL-1235 Lowllow pressure on pilot fuel gas header

• PSHH-1236 High/high pressure on pilot fuel gas header.
c 11.2.4.3
•
Main Bumer Trips:
HS-1255 Manual shutdown (From control room)

• PSLL-1132 Lowllow pressure on pilot gas header
• PSLL-1230 Lowllow pressure on main fuel gas header.
• PSHH-1236 High/high pressure on pilot gas header
• PSHH-1231 High/high pressure on main fuel gas header.
• LSLL-1223A1B/C Lowllow level on steam drum ( 2 out of 3 after a 5
second time delay)
• TSHH-1088 High/high HP Steam Superheat Temperature. On
tripping Superheat burners an 8 minute timer is started. If temperature fails to
drop below 538°C after 8 minutes, then the Auxiliary Boiler will trip.
• BE-1005/6/7/8 Loss of an individual scanner will close the
corresponding individual gas valve but loss of all scanners will in addition close
. the main gas valve to all burners.
11.2.4.4 Permissives for Purging:
c •
•
•
SSL-1011
FSL-1177
PSHH-1060
ID Fan speed satisfied
Auxiliary firebox draft satisfied.
Auxiliary Boiler draft pressure not High/high
• PSH-1474 Arch draft pressure not high.
• PSLL-1235 Lowllow pressure on Aux. Boiler pilot fuel gas header.
• PSLL-1230 Lowllow pressure on Aux.Boiler main fuel gas header.
• PSLL-1475A1B/C Lowllow pressure on Arch main fuel gas header.
• PSLL-1245 Lowllow pressure on Superheater pilot fuel gas
header.
• PSLL-1240 Lowllow pressure on Superheater main fuel gas
header.
All valves to all burners (including the Arch & Superheater) are closed and vents
open. No flame is present.


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11.2.5 Arch Burner Light-off Sequence
a) Check the fuel gas header is depressured, all burner fuel gas cocks and vents
are closed and all burner air register doors are open. With the ID and FD Fan
running, set PIC-1 019 to control the Arch draft and FIC-11B1 to control the
combustion air and then press HS-1221 'Checking Sequence Start' pushbutton
and the Checking logic will latch-on providing:
• The rnain fuel gas valves are confirmed closed and the supply header to the
Arch burners is confirmed depressured.
c • Arch draft switch PSH-1474 is satisfied.
b) The checking gas solenoids will then be energised allowing checking gas into the
burner fuel gas supply header and providing the checking permissive switches
PSL-1161 thru PSL-1165 on the five supply headers are satisfied, i.e the
headers are pressured, the 'Checking' indicator XL-1221A will illuminate and the
checking timer will start.
c) If the Fuel Gas header does not hold pressure until the Checking timer times out,
the Fail Timer will illuminate XL-1221 B 'Checking Failed' indication. The reason
for the failed indication must be corrected and the sequence restarted.
d) If the PSL-1161, PSL-1162, PSL-1163, PSL-1164 and PSL-1165 Checking

Permissive remains satisfied, the Checking timer will tirne out, extinguish the
'Checking' indicator and iIIurninate XL-1220 'OK to Open FG Valves' indication.
e) Press HS-1220 'Open MainFG Valves' pushbutton to override PSL-1161 thru

PSL-1165 fuel gas header switches for a timed period (The Latchup timer). The
timed override will then allow manual latching of the solenoids on the fuel gas
c valves, XV-1220AlB/C providing:
• the manual shutdown buttons in the control room (HS-1252) and in the
Reformer penthouse (HS-1250) are in the run position.
• Low/low flow process gas switch FSLL-1184 is satisfied, i.e. flows norrnal:
• All High/high and Low/low pressure switches on the fuel gas supply lines are
satisfied, i.e. normal.
• The High/high and High/high/high temperature switches on the superheated

steam line are satisfied, i.e. pressures normal.
f) Open the fuel gas header vents to vent the nitrogen which will make light-off
easier and to establish a flow of fuel gas to enable pressure regulator PIC-1 002
to function and control the desired light-off pressure. The pressure to each row
of burners will be regulated by the corresponding HIC controller and the vents
should be closed after 3 to 4 burners in the row are lit.
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Manual shutdown switch in Penthouse

Manual shutdown switch in control room.
High/high Arch firebox draft (2 out of 3 after a 3
Low/low Steam Drum level (2 out of 3 after 5 sec.
High/high temperature on HP Steam will trip

Superheater burners and start 8 rninute timer. If
temperature fails to drop below 538°C after 8
minutes, then the arch burners will trip.
High/high/high temperature on HP Steam.
Manual shutdown of Feed to Reformer
Steam to Carbon ratio
Low/low Feed gas flow
Reformer Feed Steam Low Low Flow
Arch Burner fuel gas to burners

High Hugh Pressure (Natural Gas Service)

High Hugh Pressure (Mixed Gas Service)

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• PSLL-1477 AlBIC Arch Bumer fuel gas to burners

• PSLL-1478 AlBIC Arch Burner fuel gas to burners
• PSLL-1479 AlBIC Arch Burner fuel gas to burners
• PSLL-1475 NAiNB/NC Arch Burner fuel gas to burners
C • PSLL-1478 NAiNB/NC Arch Burner fuel gas to burners
11.2.5.2 Personnel Safety:
For personnel safety, actuation of Interlock ESD-2111 will in turn actuate interlock
ESD-1058 which will cause Air Horn PAH-.1058A to sound and Rotating Light
PAH-1 058B to light. These are both located in the Reformer penthouse. The
following will also actuate interlock ESD-1058
• • PSH-1057 High ID Fan suction pressure.

• • PSH-1058A1B/C High Arch firebox draft.(2 out of 3 voting)
11.2.6 Superheater Burner Light-off Sequence
c a) With the ID fan running, set PIC-1 019 to control the main Reformer firebox draft
and satisfy arch pressure switch PSH-1474.
b) Check all Pilot and main burner fuel gas cocks are closed, the fuel gas header
depressured and the vent valves closed and ensure all Superheater burner
registers are open. Then press HS-1246 'Checking Sequence Start' pushbutton
and the pressuring/checking timer will start providing:
• The main and pilot gas headers are confirmed isolated and depressured.
• The checking gas isolation and vent valves are confirmed closed.
c) To allow the checking procedure to progress, the downstream trip isolation

valves XV-1204-1 thro 10 on the main gas supply and valves XV-1245-1 thro
10 on the pilot gas will be forced open, and the vent valve XV-1240C on the
main gas supply and valve XV-1245C on the pilot gas will be forced closed. This
will allow the pilot and rnain gas systems to be checked for tightness through to
the burner cock valves.


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d) The solenoids on checking gas valves, XV-1241 AlBIC and XV-1246A1B/C will be
energised allowing checking gas into the burner and pilot gas supply headers
and providing the checking permissive switches PSL-1147 on the pilot gas
header and PSL-1142 on the main fuel gas header are satisfied i.e. the headers
are pressured, the 'Checking' indicator XL-1246A will illuminate and the
checking timer will run for 90 seconds.
e) If the pilot and main fuel gas headers do not hold pressure until the Checking
timer reaches its setting, the 'Checking Failed' indication XL-1246B will
illuminate. The reason for failed indication must be corrected and the sequence
restarted ..
c f) If the pilot and main fuel gas headers do hold pressure and PSL-1142 and
PSL-1147 Checking Permissive switches remain satisfied until the Checking
timer reaches its limit, then the 'Checking' indicator will extinguish and XL-1245
'OK to Open Pilot FG Valves' indicator will illuminate.
g) Press HS-1245, 'Open Pilot FG Valves' pushbutton to override the Pilot Fuel Gas
timer). As long as the arch draft pressure switch PSH-1474 remains satisfied,
the timed override allows latching of the solenoids on main Pilot Fuel Gas valve
XV-1245A, vent valve XV-1245C and individual pilot gas valves
XV-1245-1/213/4/5 & 6.
h) Establish proper Pilot Fuel Gas Header pressures and light a selected pilot by
pushing one of the pushbuttons HS-1242A1B/C/D/E or F to open the
corresponding individual pilot gas valve, and then opening the corresponding
pilot burner cocks and using an ignitor light the selected pilot. This action is
repeated for the remaining pilots.
c i) Providing PSLL-1245 and PSHH-1246 Pilot Fuel Gas Header switches remain
satisfied and the pilot flame rods indicate all pilots are lit, then XL-1240 'OK to
Open Main FG Valves' indication will illuminate.
j) Press HS-1240 'Open Main FG Valves' pushbutton to override PSLL-1240 and

PSHH-1241, main fuel gas header switches for a timed period (Main Latchup
timer). As long as PSH-1474 Draft switch remains satisfied and HS-1256,
Manual SID switch in the main control room remains in the Normal (run) position,
the timed override allows latching of the solenoids on the Main Burner valve
XV-1240A, vent valve XV-1240C and individual rnain burner valves
XV-1240-1/213/4/5 & 6.
k) Establish proper header pressures, press a selected burner light switch

HS-1244A1B/C/D/E or F to open the corresponding individual burner gas valve
and then opening the corresponding manual cock to fire the first burner. Further
burners rnay be then be lit as required.
I) In the event of an unsuccessful pilot light-off, to wait for two minutes before
(
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retrying. If the first main burner does not light (say 10 seconds), wait for five
minutes before retrying. This is to allow purging of unburnt fuel gas.
m) After a Main Burner trip the main burners can be re-lit by repeating steps i) and
D·
n) After a Pilot Trip the pilots can be re-lit by repeating steps f) and g) as long as
the main burners remain lit.
0) If all pilots and main burners should trip or if there is no flame in the fire box,
then the pilots must be established by repeating steps a) thru D.
C 11.2.6.1 Shutdowns:
• PSHH-1 059A1B/CHigh/high Arch firebox draft (2 out of 3 after a 3 second time

delay).
• Flame failure on all Superheater burners.
• Auxiliary Boiler trip.
11.2.6.2 Pilot Trips:
• PSLL-1245 Low/low pressure on pilot fuel gas header

• PSHH-1246 High/high pressure on pilot fuel gas header.
11.2.6.3 Main Burner Trips:
• HS-1256 Manual shutdown (From control room)

• PSLL-1240 Low/low pressure on main fuel gas header.
• PSHH-1241 High/high pressure on main fuel gas header.
c •
•
•
TSHH-1088
TSHHH-1218
Arch Burners trip.
High/high temperature of HP steam
High/high/high temperature of HP Steam.
11.2.7 Tunnel Burner Light off sequence
a) With the ID fan running, set PIC-1019 to control the main Reformer firebox draft
and satisfy arch pressure switch PSH-1474.
b) Check all main burner fuel gas cocks are closed, the fuel gas header
depressured and the vent valves closed and ensure all Tunnel burner registers
are open. Then press HS-1560 'Checking Sequence Start' pushbutton and the
pressuring/checking timer will start providing:
• The main gas headers are confirmed isolated and depressured.

• The checking gas isolation and vent valves are confirmed closed.
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c) The solenoids on checking gas valves, XV-1561, XV-1562 and XV-1563 will be
energised allowing checking gas into the burner gas supply headers and
providing the checking perrnissive switch PSL-1571 on the main fuel gas header
is satisfied i.e. the headers are pressured, the 'Checking' indicator XL-1560A will
illuminate and the checking timer will run for 90 seconds.
d) If the main fuel gas headers do not hold pressure until the Checking timer
reaches its setting, the 'Checking Failed' indication XL-560B will illuminate. The
reason for failed indication must be corrected and the sequence restarted ..
e) I(the main fuel gas headers do hold pressure and PSL-1568 Checking
c Permissive switches remain satisfied until the Checking timer reaches its limit,
then the 'Checking' indicator will extinguish and XL-1561 'OK to Open FG
Valves' indicator will illuminate.
f) Press HS-1561 'Open FG Valves' pushbutton to override PSLL-1571 and

PSHH-1570, main fuel gas header switches for a timed period (Main_Latch up
timer). As long as PSH-1474 Draft switch remains satisfied and HS-1256,
Manual SID switch in the main control room remains in the Normal (run) position,
the timed override allows latching of the solenoids on the Main Burner valve
XV-1564A1B, vent valve XV-1564C.
g) In the event of an unsuccessful main burner say within 10 seconds wait for five
minutes before retrying. This is to allow purging of unburnt fuel gas.
h) After a Main Burner trip the main burners can be re-lit by repeating steps i) and
j).
c'
c 11.2.8' Start-up Heater Light-off Sequence
a) Check all burner and pilot fuel gas cocks are closed, the fuel gas headers are
depressured and the vent valves closed. Start the steam purge. Then press
HS-1251 'Purge/Checking Sequence Start' pushbutton and the Purge/Checking
logic will latch-on providing:
• The burner fuel gas supply valves are closed and vented and the header is
confirmed depressured by PSLL-1250.
• The Startup Heater checking gas valves are confirmed closed.
• PSL-1198 is satisfied confirming there is a steam purge flow to the heater.
b) The purge timer will start and XL-1251 A 'Purging' indication is illuminated. When
the purge timer setting is reached, XL-1251A 'Purging' indication will extinguish
and XL-1251 B 'Purge Complete' will illuminate. At the same time, the solenoids
on checking gas valves, XV-1251A1B/C on the main gas supply and valves XV-

C' continuation sheet

CLASS
1263-AlB/C on the pilot gas are energised allowing checking gas into the fuel
gas supply headers and XL-1251C 'Checking' indication illuminates and the Fail
timer is started.
c) When the Checking Gas solenoids are energised, the fuel gas headers are
pressurised and when PSL-1152 and PSL-1155 Checking permissive switch is
satisfied, the Checking timer starts.
d) If the fuel gas headers do not hold pressure until the Checking timer reaches its
setting, the Fail timer will illuminate XL-12510 'Checking Failed' indication. The
start up heater is then re-purged. .
c e) If the fuel gas headers holds pressure as indicated by PSL-1152 and PSL-1155
Checking Permissive switch remaining satisfied until the Checking timer reaches
its setting, then XL-1250 'OK to Open FG Valves' willjlluminate. At the same
time, the Fail timer will be disabled and XL-1251 C 'Checking' indication will
extinguish.
f) Press HS-1250, 'Open Fuel Gas Valves' pushbutton to override the Fuel Gas
timer). As long as HS-1257 Manual shutdown switch in the control room
remains in Normal(run) position and FSLL-1257 Low/low Syn.Gas flow and
PSHH-1196 (High/high syn.gas pressure) shutdown switches remain satisfied;
the timed override allows latching of the solenoids on fuel gas valves
XV -1250AlB/C.
g) Establish proper fuel gas header pressures and providing the local panel still
indicates pilot flames present, manually light-off of the first bumer followed by the
others as required.
c h) An unsuccessful light-off, i.e. the inability to establish a stable fuel gas header
pressure, requires repeating steps a) thru g).
11.2.8.1 Shutdowns:
• HS-1257 Manual shutdown from control room.

• FSLL-1257 Low/low syn.gas flow (after 3 second delay).
• PSHH-1196 High/high excess syn.gas pressure.
• PSHH-1251 High/high pressure in fuel gas header.
• PSLL-1250 Low/low pressure in fuel gas header.
• Individual flame failure
11.2.8.2 Permissives for Purging:
• PSLL-1250 Low/low pressure on fuel gas header

• PSL-1198 Low pressure purging steam switch is satisfied.
• Bumer valves closed and vents open - No flame present.

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11.2.9 CO 2 Absorber (T-21 01) Level Control
During normal operation of the CO2 Absorber with hydraulic turbine P-2017A(H) in
service the major flow is through the hydraulic turbine set by HIC-1005. L1C-1004
controls the level in the bottom pan by controlling LCV-1004A and LCV-1004B on split
range.LCV-1004A operates from 0.2 - 0.6 bar and LV-1004B from 0.6-1.0 bar. The
hydraulic turbine load should be adjusted such that LCV-1004A has sufficient
throughput to modulate and control the absorber level. In the event of a hydraulic
turbine trip LCV-1004A1B have sufficient capacity to handle the total solution flow.
C 11.2.9.1 Low Level in the CO2 Absorber
A Low/low level in the CO2 Absorber will actuate low/low level alarm switch
LSLL-1204. This switch will trip solenoids LY -1 004B and HY -1005 thus closing
valves LV-1004A1B and HV-1005 and maintaining a liquid seal in the absorber and
preventing the overpressuring of the CO2 Stripper. This action will hold until the
Absorber inventory is re-establish ed, at which time the solenoids will be manually
reset and re-energised allowing return of the control valves to their former
positions.
11.2.9.2 P-2107A and Hydraulic Turbine Overspeed Trip
On shaft (or coupling) failure between the P-2107A(H) Hydraulic Turbine and the
pump, overspeed trip switch SSH-1207, will actuate interlock S-1207 which in turn
will sound the High Speed Alarm SAH-1207 and at the same time will denergise
the solenoid valve HY-1005A. This action will close valve HV-1005 at the
hydraulic turbine while the absorber level will still be maintained via LRC-1004
c sending its signal to the "A" and'B' valves.
When the overspeed trip condition has been corrected, LY -1 004A should be
manually reset, and the hydraulic turbine placed back in service with HIC-1066A
and HIC-1066B on rnanual slowly closing back on the flow via LV-1004B whist
opening control valve 'A'.
11.2.10 Instrumentation of the Compressor End of the Synthesis Gas Compressor
Synthesis gas flows into the Synthesis Gas Compressor Suction Drum 0-2104
from the Methanator. When the Syn Gas Compressor C-21 03 is started
(HV-1001 and HV-1031 closed, recycle valve HV-1030 wide open), the kickback
valves FIC-1 007 and FIC-1 008 will be wide open. As the compressor is brought
up in speed the flow through these two valves will increase to the point where the
controllers may be put on control. From this point on, the FIC-1 007 will take care
of the first case of the compressor when set to maintain a flow rate above the
surge point at the conditions existing. In the same manner FIC-1 008 will take
care of the 'make-up' wheels in the HP case. The flow rate through the 'recycle'

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wheel, which is much greater than the gas flow through FIC-1008, is determined
by manual setting of HIC-1 030 valve.
The HP/LP turbine governors are set by PRC-1 006 which serves D-21 04 Suction
Drum pressure and PRC- 1012 which serves the 42.5 bara steam header
pressure. Both of these signals are fed into the C-2103(T) control system and
adjust pistons within the control box assembly to adequately control the amount
of HP steam to the topping turbine to meet the MP steam pressure requirements
and the MP steam requirements of the LP turbine for control of D-21 04 suction
drum pressure. The LP turbine governor adds enough condensing turbine
power to that supplied to the topping turbine to adequately control the desired
c
suction drum pressure.
Hand-switch HS-1203, or a high/high level in D-21 04 (LSHH-1208), or a

high/high level in D-2105 (LSHH-121 0) will shut down the C-2103(T) turbines by
dumping the turbine governor oil. Loss of pressure on the governor oil system
will isolate the compressor from the synthesis loop by closing HV's 1001 and
1031 and will also open HV-1030.
A high/high level in D-2106 (LSHH-1218) will isolate the compressor from the
synthesis loop by closing HV-1001 and HV-1031 and all sections of the
compressor are protected against surge by the automatic opening of FV-1007,
FV-1008 and HV-1030.
NOTE: The restriction orifice RO-SG1009 around the check valve in the
suction line from D-21 05 Interstage Separator to C-21 03 2nd Stage allows all
cases to depressure to suction pressure.
11.3 INTERLOCKS & SHUTDOWN DEVICES
c 11.3.1 Shutdown 21-ESD-1203/1201 Low Steam/Carbon Ratio & Low Natural Gas Feed
Rate
P&ID's: 62D101, 105, 106 and 107
The shutdown logic is designed to protect the catalyst if the steam to carbon
ratio drops below the safe operating value or the natural gas feed flowrate
becomes too low.
ESD inputs for the steam pressure, temperature and flow are measured by the
following and are voted 2 out of 3:
21 PT1 053A1B/C
21TT1024A1B/C
21 FT1202A1B/C
ESD inputs for the feed gas pressure, temperature and flow is measured by


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the following and voted 2 out of 3.

21-PTc 1011A1B/C, 21-TT-1302A1B/C and 21-FT-1201A1B/C
This system is designed to monitor the reforming steam to gas ratio on a

weight basis.
The normal operating value is a molar ratio of 3.2mol H20/mol C to 1.
If the molar ratio reduces to a value of 3:1 an alarm FFAL1201 is activated

which alerts the operator to take corrective action.
If the ratio reduces further to a value of 2.5:1, a low low trip 21 FFSLL1201
c occurs and the interlock will be activated.
A delay timer of 5 second is applied to ensure short duration excursions do not

result in interlock activation.
Activation of the interlock will :
(1 ) Close 21 HV1 01 0 and 21 FV1 001 to isolate the feed to the Primary
Reformer
(2) Close 21XV1220A and B and open 21XV1220C to isolate the fuel gas to
the Arch burners
(3) Reduce C21 01 governor to minimum speed
(4) Open 21 HV1 023 C21 01 interstage vent
(5) Open 21 UV1 004 C21 01 discharge vent
(6) Close 21 HV1 006 C21 01 discharge valve
(7) Introduce steam to the air preheat coil via 21 HIC1 021
(8) Close 21 FV1 022 the hydrogen supply from C2103 to the feed gas
preheat coil
(9) Place controllers 21 FIC1 022 and 21 FRC1 001 in manual and output to
C 0%
(10) Route natural gas feed to vent under the control of 21 PIC1169
(11 ) Close 21AY1001A and B, primary and secondary reformer outlet
analyser isolation valves
21 HS1202 is provided as a manual shutdown switch.
Activation of 21 HS1202 will immediately perform the actions listed above with
no time delay.
21 HS1 059 serves as the manual reset switch.
21 HS1261 is provided as an override to the interlock to enable start-up of the

unit.
Low low natural gas feed flow to H2101 measured by voted 2003 inputs
21 FSLL1201A1B/C which will after a 5-second delay actuate the interlock.

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21 HS1048 is provided to override the interlock during start up to enable

operation of C2101 for catalyst dusting and nitrogen warm up purposes.
11.3.2 Shutdown 21-ESD-1202 Low Low Process Steam Flow
P&ID's: 62D1 01, 105, 106 and 107
The provision of the low low process steam flow interlock is designed to protect
the Primary Reformer tubes and catalyst from overheating when process .
· steam is flowing to the Reformer. It will also act as a back up to the low
C/
steam/carbon ratio shutdown interlock during normal operation.
The ESD inputs for steam flow, pressure and temperature are
21 FT1202A1B/C, 21 PT1 053A1B/C and 21 TT1 024A1B/C and are voted 2003.
The main purpose of the interlock is to shutdown the Primary Reformer if the
process steam flow falls below the value of 21 FSLL1202(2003 voted with 5 sec
delay). A low flow alarm 21 FAL 1002 is also provided to give advance warning
of a falling steam flow.
Interlocks ESD-1201 and ESD-1202 are interlocked and shutdown the Primary
Reformer in the same manner.
Activation of the interlock will:
(1 ) Close 21 HV1 01 0 and 21 FV1 001 isolate the feed gas to the Primary
Reformer
(2) Close 21XV1220A and B and open XV-1220C isolate the fuel gas to the
Arch Burners
C (3)
(4)
Reduce C2101 Governor to minimum speed
Open 21 HV1 023 C2101 interstage vent
(5) Open 21 UV1 004 C2101 discharge vent
(6) Close 21XV1027 C2101 discharge valve
(7) Introduce steam to the Air Preheat Coil via 21 HIC1 021
(8) Close 21 FV1 022 the hydrogen supply from C21 03 to the fed gas preheat
coil
(9) Place controllers 21 FIC1 022 and 21 FRC1 001 in manual and output to
0%"
(10) Route the natural gas feed to vent via 21 PIC1169
(11 ) Close 21AY1001A and B the Primary and Secondary Reformer outlet
analyser isolation valve
21 HS1260 is provided as a manual override to the interlock to enable start-up

of the unit.

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11.3.3 Shutdown 21-ESD-21 06 Methanator Emergency Vent
P&ID: 62D110, 111 and 123
It is important not to overheat the Methanator catalyst and vessel and

because a large quantity of heat is generated in the methanation reaction the
logic will provide a rapid & tight shutoff.
High temperature alarms from 21 TT1357 and 21 TT1362A are located at the
top and bottom of the Methanator catalyst bed respectively.
c Temperature transmitters 21TT1358 to 21TT1361 inclusive are symmetrically

located between temperature transmitters 21 TT1357 and 21 TT1362 which
also provide high alarms.
Shutdown transmitters 21 TT1200,21 TT1201 ,21 TT1202 and 21TT1203 are

located at the same locations and activate the logic.
Hand switch 21 HS1253 will shut down the Methanator.
Low lean aMDEA solution flow trip from 21 FT1205 and low semi-lean
aMDEA solution flow trip from 21 FT1217 will activate the logic after a time
delay of 20 sec.
Activation of the logic will close valves 21 HV1 034 and 21 XV1211 at the
Methanator inlet and close valve 21 PV1180 to prevent thermal shock.
The combination of 21XV1211 and 21HV1034 will provide a rapid and
c positive shutoff.
Closure of 21 HV1034 and 21XV1211 will cause the methanator inlet pressure
to increase above the set point of 21 PIC1 005 which will open in order to vent
the process gas and control the line pressure at this pOint.
The venting pressure controller 21 PIC1 005 set point should be at a pressure
slightly greater than the normal methanator inlet pressure in order to prevent
vent leakage during normal operation.
Hand controller 21 HIC1 034 in the CCR allows the operator to control
21 HV1 034 once solenoid 21 HY1 034B has been reset. The solenoid
21XY1211 must be manually relatched in order to reopen 21XV1211 after
the input becomes healthy and the control system is reset.
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11.3.4 Shutdown 21-ESD-21 02 Feed Gas Compressor
P&ID: 62D102 and 104
The Feed Gas Compressor Shutdown logic is activated by any of

the following:
(1) Shutdown hand switch 21 HS1202A located on the ESD matrix in the
CCR
c (2)
(3)
Shutdown hand switch 21 HS1202B located local to the compressor skid
High high trip voted 2003 from level transmitters 21 LT1212NB/C on the
Feed Gas KO Drum D2144
(4) . High high trip from pressure transmitters 21 PT1191NB/C (2003 voted) at
C2102 suction
(5) Low low trip from pressure transmitters 21 PT1191NB/C (2003 voted) at
C2102 suction
(6) Common shutdown alarm 21XA1202 from C2102
The activation of the logic by any of the above will shut down C2102 Feed
Gas Compressor and at the same time open the kickback valve 21 UV1 015.
The initiation of the logic described above will also cause the following
Effects:
C (1 ) C2101 interstage vent valve 21 HV1 023 and 4th stage vent valve
21 UV1 004 will both open
(2) C2101 discharge valve 21XV1027 will close
(3) Close 21 HV1 010 and 21 FV1 001 on the natural gas feed supply to the
Primary Reformer
(4) Introduce steam to the air preheat coil via 21 HIC1 021
(5) Close 21 FV1 022 supplying hydrogen rich gas from C-21 03 discharge
(6) Reduce C2101 govemor to minimum speed
(7) Isolate analysers on the Primary and Secondary Reformer outlet
lines(c1ose AV-1 001 NB)
(8) Close 21XV1220A and B and open 21XV1220C to isolate fuel gas to the
arch burners.
(9) Place controllers 21 FIC1 022 and 21 FRC1 001 in manual and output 0%.

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(10) Shutdown C2102 turbine.
11.3.5 Shutdown 21-ESD-21 01 Air Compressor
P&ID: 62D101
The Air Compressor shutdown logic will be activated by any of the following:
(1) Shutdown hand switch 21HS1201A located on the ESD matrix in CCR
(2) Shutdown hand switch 21 HS1201 B located adjacent to the compressor
(3) Common shutdown alarm 21 XA 1201 from the compressor Unit Control Panel
c (4) High high trip voted 2003 from

21 LT1957/1958/1960, 21 LT1952/1953/1956, 21LT1954/1955/1959
Activation of the logic by any of the above will:
(1) Shut down C21 01 turbine

(2) Close C2101 discharge valve 21 XV1 027
(3) Open the interstage vent valve 21 HV1 023
(4) Open 4th stage vent valve 21 UV1004
(5) Introduce steam to air preheat coil via 21 HIC1 021.
11.3.6 Shutdown 21-ESD-21 03 Synthesis Gas Compressor
P&ID: 62Dl13, 114, 115 and 120, 64D102
The Synthesis Gas Compressor Shutdown logic will be activated by any of the
following:
c (1) Shutdown handswitch 21 HS1203A located on the ESD matrix in CCR

(2) Shutdown handswitch 21 HS1203B located adjacent to the compressor
(3) High high level trip from 21 LT1208A1B/C(2003 voted) in D2104 Compressor
Suction Drum .
(4) High high level trip voted 2003 from 21LT1210AlB/C(2003 voted) in D2105
Compressor Interstage Suction Drum
(5) Common shutdown alarm 21 XA 1203 from the compressor
(6) High high level trip voted 2003 from 21 LT1218A1B/C in D21 06 secondary flash
separator (Note 2).
(7) Compressor on recycle hand switch 21 HS1 061 located on the ESD matrix in
CCR(Note 2)
Activation of the interlock by any of the above will:
(1) Shut down C21 03 Synthesis Gas Compressor

(2) Open 1st stage kickback valve 21 UV1 007
(3) Open 2nd/3rd stage kickback valve 21 UV1 008
(4) Open start-up/kickback valve 21 HV1 030 to the 3rd stage suction

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(5) Close 3rd stage suction valve 21 HVl 031

(6) Close 21 FVl 020 on the boiler feed water supply line to E2123
(7) Close C2103 discharge valve 21 HVl 001 located at Cooler E2124 shell outlet
valve
(8) Switch HP steam letdown valve 21 HVl 028 from the closed position to FCS
control using 21 HICl 075 if both C-21 03 and C-21 05 have tripped. Otherwise
21 HVl 028 is controlled by 21 HIC 1028.
(9) Closes purge gas valve 21-XV-l029.
Note 2: Isolates the synthesis loop and places syn. gas comp on recycle.
c
11.3.7 Shutdown 21-ESO-21 05 Refrigeration Compressor
P&IO: 620117,118,119 and 640102
The Refrigeration Compressor shutdown logic will be activated by any of the

following:
(1) Shutdown handswitch 21 HS1205A located on the ESO matrix in CCR

(2) Shutdown handswitch 21 HS1205B located adjacent to the compressor
(3) High high level trip voted 2003 from 21 LT1214A1B/C in 02123 the 4th stage
refrigerant flash drum
(4) High high level trip voted 2003 from 21 LT1215 AlBIC in 02122 the 3rd Stage
Refrigerant Flash Orum
(5) High high level trip voted 2003 from 21 LT1216 AlBIC in 02121 the 2nd Stage
(6) High high level trip voted 2003 from 21 LT1217 AlBIC in 02120 the 1st Stage
(7) Common shutdown alarm 21XA1205
c Activation of the interlock by any of the above will:
(1)
(2)
Shut down C2105 Refrigeration Compressor
Open 1st stage 21UV1012
(3) Open 2nd stage 21 UVl 011
(4) Open 3rd stage 21UV10l0
(5) Open 4th stage kickback valve 21 UVl 009
(6) Close 21 XVl 001 on the Ammonia return line from the storage tanks
(7) Switch HP steam letdown valve 21 HVl 028 from the closed position to FCS
control using 21 HIC1029. If both C-2103 and C-21 05 have tripped, switch HP
steam letdown valve 21 HVl 028 from closed position to FCS control using
21HIC1075.
High high level trip voted 2003 from 21 LT1214A1B/C on 02123 the 4th stage
refrigerant flash drurn will de-energise solenoid 21 LYl 015B to close 21 LVl 015 on
the letdown line 02109 to 02123.
If 21 LVl 015 fails to close (21 ZSCl 028) within a specific time period then valve

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group failure alarm 21 XA 1025 is initiated.
Valve position switches 21 ZS01 023/1 024/1 025/1 026 are the associated with
valves 21 UV1 009, 21 UV1 01 0, 21 UV1 011 and 21 UV1 026 and if any valve fails to
open an alarm valve group failure 21 XA 1025 will be initiated. The same will apply
for valve 21 XV1 001 using position switch 21 ZSC1 027.
11.3.8 Shutdown 21-ESD-2112 Auxiliary Boiler
P&ID: 62D106, 64D102 and 112
c The shutdown logic will be activated by the following:
High high pressure trip from 21 PT1 060AlB/C (2003 voted) (3 sec. delay) in the
Auxiliary Boiler firebox.
21 XS1 011 included fan tripped.
Loss of all pilot flames will be initiated by flame detectors 21 BE1 005 to 21 BE1 008.
High high pressure trip from 21 PT141 0 AlBIC (2003 voted) Aux. boiler FD fan disch:
(3 sec. delay)
Actuation of the interlock by any of th.e above will:
Shut down the Auxiliary Boiler burners as follows:
Close 21 XV1230A on the fuel gas supply line to the burners

Close individual burner block valves 21XV1230/1/2/3/4
Open vent 21XV1230C located on the main burner supply line and vent to
atmosphere
Close 21 XV1235A on the pilot gas supply line to the burners
Close the individual pilot supply valves 21XV1235/1/2/3/4
c Open vent 21 XV1235C located on the common pilot gas supply line to atmosphere
The interlock will be activated by the following temperature trips:
21TT1 088/1218/1219 (2003 voted) high high outletternperature of the Hot Steam
Superheater Coil will also start an 8-minute timer during which time if the
temperature has not dropped to 538.00 deg.C the auxiliary boiler and arch burners
will be tripped)
21 TT1218/1 088/1219(2003 voted) High High High outlet temperature of Hot Steam
Superheater outlet coil
Activation of any of the above will:
Close 21 XV1230A on the fuel gas supply line

Close 21 XV1230/1/2/3/4 individual burner isolation valves
Open 21 XV1230C fuel gas supply vent valve

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The pilot burners remain in service during the above actions.
A trip of the Auxiliary Boiler causes a shutdown of the Superheater main burners
Should a single sensor detect no pilot or main burner flame, then only the individual
gas supply valves to the pilot or main burner of that particular burner will close. Only
when ALL four sensors (4004) together detect total pilots flame loss will the
interlock operate as described above. If the induction fan stops then aux boiler FD
fan and radiant section FD will be tripped.
Low low pressure trip from 21 PT1235A1B/C and high high pressure trip from
21PT1236A1B/C are located on the pilot gas supply line to the burners. If any of
c these trips occur then 21 XV1235A on the pilot gas supply line and the individual pilot
supply valves 21 XV1235/1/213/4 will close
Open vent 21XV1235C located on the common supply line to atmosphere.
The loss of ALL pilot burner flames is sensed by 21 BS1 005 to 1008 which will
activate the interlock described above and shutdown the main burners.
Low low pressure trip frorn 21 PT1230AlB/C and high high pressure trip from
21 PT1231A1B/C are provided on the main fuel gas supply line to the burners.
In the event of either of these two trips, then the main burners will be tripped by
qlosing valve 21XV1230A on the main fuel gas supply line and closing individual
burner valves 21XV1230/1/2/3/4. The vent valve 21XV1230C located on the main
gas supply line will open and vent to atmosphere.
A shutdown hand switch 21 HS1255 located on the ESD matrix panel in the CCR will
activate the interlock to shutdown the rnain burners. The outputs will:
c~ Close the main supply valve 21 XV1230A

Close the individual burner supply valves 21 XV1230/1/213/4
Open the main fuel gas vent valve 21XV1230C, but the pilot burners remain
operational.
Three low low level trips 21 LT1223A1B/C (2003 voted with 5 sec delay) are provided
on the Steam Drurn D2101 and will trip to the Auxiliary Boiler burners. At this time
the pilot gas burners will remain operational.
11.3.9 Shutdown 21-ESD-2113 Superheater Burner
P&ID: 62D106, 64D102, 113 and 114
The following logic provides shutdown of the superheater burner system in the
following manner.
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Any of the following will activate shutdown logic to cause a complete shutdown of the
superheater burner system:
High high pressure trip from 21 PT1 059A1B/C in the Primary Reforrner firebox having
been voted on a 2003 basis with a 3 second delay.
When the logic is activated by the above a shutdown to the Superheater burners will
occur as follows:
c Close 21 XV1240A on the fuel gas supply line to the burners

Close individual rnain burner block valves 21 XV1245/1/2/3/4/5/6/7/8/9/1 0
Open vent valve 21 XV1240C located on the rna:in burner supply line to atmosphere.
Close 21XV1245A on the pilot gas supply line
Close individual pilot supply valves 21 XV1240/1/2/3/4/5/6/7/8/9/1 0
Open vent valve 21 XV1245C on the common pilot supply line
Low low pressure trip from 21 PT1245A1B/C (2003 voted) and high high pressure trip
from 21 PT1246A1B/C (2003 voted) are located on the gas supply line to the pilots.
If either of these trips activate the logic, then the pilot burners will be tripped by:
Close 21 XV1245A on the pilot gas supply line
Close individual pilot valves 21 XV1245/1/213/4/5/61718/9/1 0
Open vent valve 21 XV1245C located on the pilot supply line to atmosphere.
The loss of all the pilot burners will cause the main burners to trip.
c 21BE-1035 and 21BE-1037thro 1045, main burner flame detectors, will shutdown its
respective burner only.
21 BE-1036 and 21 BE-1046 thro 1054, pilot burner flame detectors, will shutdown its
respective burner only. However, failure of all the pilot burners will instigate a
shutdown of all the superheater main burners.
Low low pressure trip from 21 PT1240AlB/C (2003 voted) and high high pressure trip
from 21 PT1241 AlBIC (2003 voted) are provided on the main fuel gas supply line to the
burners. In the event of either trip occurring then:
Close 21 XV1240A on the main gas supply line to the bumers
Close individual burner valves 21XV1240/1/213/4/5/61718/9/1 0
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Open vent valve 21 XV1240C located on the main burner supply header to atmosphere
shutting down the superheater burners.
Loss of arch burners or an Auxiliary Boiler trip will cause a shutdown of the
Superheater main burners and leave the pilot burners in service.
A shutdown handswitch 21 HS1256 is located on the ESD Matrix located in the CCR,
which will shut down the superheater burners by:
Closing valves 21 XV1240A and 21 XV1240/1 /2/3/4/5/6/7/8/9/10
c Opening vent valve 21XV1240C and leaving the pilot burners operational
A high high temperature trip from 21 TT1 088/1218/1219 (2003 voted) is provided on the
HP steam line leaving the Superheater coils. If this trip occurs the logic will trip the
Superheater burners and start an 8-minute timer. If the temperature fails to fall below
538.00 degC within 8 minutes then the Auxiliary Boiler and Arch burners will be tripped.
The pilots will remain operational.
A high high high (HHH) temperature trip from 21 TT1 088/1218/1219 (2003 voted) is
provided on the Steam Superheater coil outlet which will trip the Superheater, Arch and
Auxiliary Boiler burners if the temperature reaches 555.00 degC.
11.3.10 Shutdown 21-ESD-2111 Arch Burner
P&ID: 62D106, 64D101, 106 and 111
The Primary Reformer Arch burner shutdown logic will shutdown the Arch Burners in
c the event of abnormal operating conditions which may affect the safe operation of
the unit.
Any of the following will activate the interlock and shutdown the Primary Reformer
H2101:
Manual shutdown hand switch 21 HS1250 located in H2101 local control room
Manual shutdown hand switch 21 HS1252 on the ESD matrix located in the CCR
High high pressure trip 21 PT1473A1B/C (2003 voted with 3 sec delay) radiant
section FD fan discharge.
High high pressure trip voted 2003 from 21 PT1 059A1B/C in the Primary Reformer
firebox
Low low steam to carbon ratio flow shutdown 21 FFSLL1201 derived as explained
previously
Low low trip from feed gas flow from 21 FSLL 1201A1B/C as explained previously.
Low low trip from steam flow from 21 FSLL 1202A1B/C as explained previously.
High high outlet temperature trip voted 2003 from 21TT1088, 21TT1218 and
21 TT1219 at the Hot Steam Superheater Coil after a delay of 8 minutes if the

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temperature has not fallen below 538 degC, HHH trip voted 2003 from
21 TT1 088/1218/1219
High high pressure trip voted 2003 from 21 PT1475A1B/C in number one fuel gas
header when on mixed gases
Low low pressure trip voted 2003 from 21 PT1475D/EIF of number one fuel gas
header when on natural gas
High high pressure trip voted 2003 from 21 PT1475D/EIF in number one fuel gas
High high pressure trip voted 2003 from 21 PT1476A1B/C in number one fuel gas
Low low pressure trip voted 2003 from 21 PT1476D/EIF in number two fuel gas
c High high pressure trip voted 2003 from 21 PT1476D/EIF in number two fuel gas
High high pressure trip voted 2003 from 21 PT1477A1B/C in number three fuel gas
header when on mixed ·gases
Low low pressure trip voted 2003 from 21 PT1477D/EIF in number three fuel gas
High high pressure trip voted 2003 from 21 PT1477D/EIF in number three fuel gas
High high pressure trip voted 2003 from 21 PT1478A1B/C in number four fuel gas
Low low pressure trip voted 2003 from 21 PT1478D/EIF in number four fuel gas
High high pressure trip voted 2003 from 21 PT1478D/EIF in number four fuel gas
header when on natural gas.
High high pressure trip voted 2003 from 21 PT1479A1B/C in numberfive fuel gas
header when on mixed gas.
Low low pressure trip voted 2003 from 21 PT1479D/EIF in number five fuel gas
c High high pressure trip voted 2003 from 21 PT1479D/EIF in number five fuel gas
Low low level trip voted 2003 from 21 LT1223A1B/C (with 5 sec delay) on the steam
drum D2101
Low low trip 21 FSLL1184 generated by 21 FT1184 and 21 FSLL 1178 generated by
21 FT1178 will inhibit the the action of the above ESD pressure trip set paints
depending on whether the burners are operating on natural or rnixed gas.
Activation of the logic by any of the above conditions will:
• shut down all the arch burners in the Prirnary Reformer by closing valves
21 XV1220AlB on the fuel gas supply line
• open the vent valve 21 XV1220C between these valves
High suction pressure from 21 PT1 057 at the inlet Induced draft Fan, 21 PT1 058A1B/C
high pressure prirnary reformer firebox and 21 PT1 059A1B/C high high pressure
prirnary reformer will operate audible alarm 21 PAH1058A and visual indication


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CLASS
21PAH1058B.
11.3.11 Shutdown 21-ESO-2114 Tunnel Burner
P&ID: 64-D115
The shutdown logic will be activated by the following:

Manual shutdown hand switch 21 HS1562 located on the ESD matrix in the CCR.
High High fuel gas pressure from 21 PT1570AlB/C (2003 voted)
Low Low fuel gas pressure from 21 PT1569A1B/C (2003 voted)
Loss of arch burners
c High High primary reformer firebox pressure from 21 PT1 059A1B/C (2003 voted) with a
3 sec delay.
Activation of the logic will

Close fuel gas valves 21 XV1564 and 21 XV1565
Open vent valve 21 XV1566.
11.3.12 Shutdown 21-ESO-2116 Startup Heater
P&ID: 62D116, 640114
The start-up heater logic provides the shutdown for the start-up heater in the event
of abnormal operation.
Any of the following will activate the logic to shutdown the burners on the Start-up
Heater H2102:
Manual shutdown hand switch 21 HS1257 located on the ESD matrix in the CCR
Low low flow trip from 21 FT1257(3 sec delay) of synthesis gas to the start-up heater
c High high pressure trip from 21 PT1196 of synthesis gas to start-up heater (Note 1)
High high pressure trip from 21 PSHH1251 of fuel gas to burners
Low low pressure trip from 21 PSLL1250 of fuel gas to burners
Loss of an individual burners by flame detectors 21BE1020 to 21BE1023 .. ,.:'
Activation of the logic will shutdown the heater burners by:
• Closing the fuel gas supply valves 21 XV1250AlB

• Opening the vent valve 21XV1250C
To permit lighting of the start-up heater the low low pressure trip from 21 PSLL1250
on the fuel gas supply line and the low low pressure trip from 21 PT1198A1B/C on the
purging steam supply line must be healthy and the system logic reset.
Note 1: 21 PSHH1196 is a permissive to light the burners and operate the heater at
a pressure below the normal operating pressure of the synthesis loop. The trip
setting is to be confirmed from the start-up heater H-2102 data sheets.

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C JOB NO. PAGE: 294 OF 312
5777 SPEC. TYPE:
CLASS
11.3.13 Shutdown 21-ESD-1 031 Fuel Gas High Calorific Value
P&ID: 62D105, 64D110 and 111
The logic provides protection for the Primary Reformer Furnace from overfiring due
to changes in the calorific value of the fuel gas supply to the Arch burners and tunnel
burners.
The logic will be activated by:
Low low flow trip from 21 FT1184 for purge gas make up to the fuel gas.
c Low low flow trip from 21 FT1278 for excess syn gas
Low low pressure trip voted 2003 from 21 PT1475A1B/C or 21 PT1476A1B/C or

21 PT1477AlBIC or 21 PT1478A1B/C or 21 PT1479A1B/C located on the fuel gas
supply line to each row of arch bumers.
When the logic is activated it will:

• Close block valve 21 XVi 031 on the purge gas
• Close 21 XV1 030 on the synthesis gas connection to the fuel gas
• Reduce the set point of 21 PIC1 002 to 25% of the process measurement range
If after 3 minutes of 21 FT1184 and 21 FT 1178 low low trip and the natural gas fuel
high pressure trips continuing to be active, the logic will provide outputs to isolate the
fuel gas to the Arch burners and open the fuel gas vent valve.
Note 1 Mixed gas consists of either natural gas plus purge gas or natural gas plus
excess syn. gas
c Note 2 Logic enables mixed gas pressure trips when flow of purge gas or excess
syn gas is above low low flow trip value. Natural gas settings are inhibited
Note 3 Logic enables natural gas pressure trips when purge gas and excess syn
gas low low flow trips have been activated for more than 3 minutes. Mixed
gas settings are inhibited.
11.3.14 Shutdown 21-ESD-1223 Steam Drum Low Level
P&ID: 62D101, 105, 106, 107 and 121, 64D101, 110 and 112
This shutdown logic is intended to protect the steam generating equipment from the
consequences of a low low level. This will protect the tubesheet of the waste heat
boiler E2101 as well as auxiliary boiler
The logiC will shutdown the auxiliary boiler and Arch burners on low low level trip
from 21 LT1223A1B/C when voted 2003 (5 sec delay). The choice of level transmitter
shall be reviewed during detail design in order the appropriate type (eg., Hydrastep)
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is chosen for steam drum service.
The logic will provide the following shutdowns:
Close 21 HV1 01 0
Close 21 FV1 001
Activate digital output to the vendor logic in the Air Compressor Turbine C21 01 T to
place it on minimum speed
Close Air Compressor discharge valve 21 XV1 027 HV-1006
Open interstage vent valve 21 HV1 023
Open discharge vent valve 21 UV1 004
Open 21 HV1 021 to and switch to control via FCS controller 21 HIC1 021
c~ Close valve 21 FV1 022 on the H2 makeup line from C2103 to Feed Gas preheat coil.
Switch vent valve 21 PV1169 on natural gas feed line upstream of the reformer from
closed being under FCS control by 21 PIC1169
Isolate the analysers located on the Primary and Secondary Reformer outlets
Place controllers 21 FIC1 022 and 21 FRC1 001 in manual and output to 0%.
When the Arch burners are tripped a 15-second timer will start. At this time the set
point of 21 FRC1 002 will be reduced to 40% of design flowrate.
If during the 15 second time delay, the Primary Reformer outlet temperature falls
from the normal operating point of 812 degC to 775 degC as detected by 21 TT1314,
then the setpoint of 21 FRC1 002 will be reduced to 40% of design flowrate.
After a 4-minute delay the logic will provide an output to close valve 21 XV1 032 on
the MP steam supply line to the Mixed Feed Coil.
11.3.15 Interlock 21-ESD-1106 Boiler Feed Water Low Flow
P&ID: 64D106
c Low boiler feed water flow interlock from 21 FT11 06 in the line to the steam drum from
the duty pump P2104A (turbine driven) will activate the logic in i5fde/to: ;;.
• start the auxiliary lubrication oil pump system providing the oil pressure and level
trips & alarms in the vendor lubrication oil system are healthy
• autostart the standby pump P2104B (Motor driven)
11.3.16 Shutdown 21-ESD-1 003 Raw Gas Separator Low Level
P&ID: 62-D110
Low low level trip from 21 LT1205 on the raw gas separator D21 02 will activate the
logic which will:
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• Close 21 LV1 003A on the condensate feed line from D21 02 to T2150 the
Process Condensate Stripper
• Close 21 LV1003B on the condensate disposal line from D2102 to drain
11.3.17 Shutdown 21-ESD-1 069 Process Condensate Stripper High Differential

Pressure
P&ID: 62D121
c High high differential pressure trip from 21 PDT1069 across T-2150 the Process
Condensate Stripper will provide the following shutdown:
• Close 21 FV1 019 on the tower overhead line

• Close 21 LV1 003A on the condensate feed line from D-21 02
11.3.1S Interlocks For Auto Start Of Pumps By FCS
• P& ID:62-D110, Interlock 21-1-1003

High High level 21-LAHH-1003 in raw gas separator D-21 02 will autostart standby
process condensate pump P-2121 AlB.
• P&ID:62-D122, Interlock 21-1-1016

Low Low C02 stripper quench flow 21-FALL-1016 will autostart standby C02
stripper quench pump P-2116A1B.
c
• P&ID:62-D123, Interlock 21-1-1 017
Low Low semi-lean amine flow 21-FALL-1 017 will autostart standby semi-lean
solution pump P-210SAlB.
• P&ID:62-D126,lnterlock 21-1-6704
High level 21-LAH-6704 in aMDEA solution sump will start aMDEA sump pump P-
2115 and low level 21-LAL-6704 will stop it.
• P&ID:62-D110, Interlock 21-1-1005

Low Low lean amine flow 21-FALL-1005 will autostart standby lean solution pump
P-2107A1B provided level 21-LALL-1 043 in C02 stripper T-21 02 is satisfied.
11.4 ANALYSERS
There are several analysers throughout the entire process unit. These instruments do
not control the process, however, they do analyse and record results to provide the
operations with the desired information to aid in the operation of the unit. The
recorded results on these analysers (along with temperature, pressure and flow rates)
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may be studied to observe long range trends of the equipment operation.
The operation of the analysers is not usually an "operator" responsibility, and should
be placed in service by a qualified analyser technician. The information regarding
these special instruments can be found in the Job Specification Books. If more
information is desired, manufacturers manuals have been provided for installation,
calibration and operation of these instruments. It is essential for satisfactory operation
of the analysers that these instructions are followed.
In some cases, an analyser is arranged to serve two streams. A qualified analyser

technician should instruct the operating personnel in making a proper switch from one
c
stream to the other when desired. If one of the analysers is suspected of giving faulty
results a technician should be called to have it checked and back in service as soon
as possible.
The importance of these analysers to satisfactory operation of the unit cannot be

over-emphasised as they provide operations with "instant" information as to process
conditions. However, it maybe necessary to confirm the more critical results by
laboratory analysis.
12 EQUIPMENT LIST
Refer to DWG-PROJ-PD-001
13 LABORATORY ANALYSIS
13.1 INTRODUCTION
c A separate Laboratory Manual (2 Volumes) of laboratory ,test procedures and

methods of analysis has been prepared for the Kermanshah Ammonia I Urea
Complex and is designed to assist Laboratory personnel in the analytical methods
and procedures for the 1200 MTPD Ammonia Plant and the 2000 MTPD Urea Plant.
It should be understood that the methods and procedures included therein have been
compiled from the various annotated sources and are not necessarily exclusive.
For safe and efficient plant operation, a laboratory has to develop a reputation for
excellence in quality so that any deviation in a plant parameter is detected and corrected
without product loss or unsafe operation.
To develop such a reputation for quality, the following are necessary:

continuation sheet
(,
CLASS

c
results a technician should be called to have it checked and back in service as soon
as possible.

12 EQUIPMENT LIST
13.1 INTRODUCTION
c A separate Laboratory Manual (2 Volumes) of laboratory test procedures and

methods of analysis has been prepared for the Kermanshah Ammonia / Urea


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PAGE: 297 OF 312
CLASS

c results a technician should be called to have it checked and back in service as soon
as possible.

12 EQUIPMENT LIST
13.1 INTRODUCTION
(' A separate Laboratory Manual (2 Volumes) of laboratory test procedures and

methods of analysis has been prepared for the Kermanshah Ammonia / Urea

$ M.W. Kellogg Limited Operating Manual
c
~-.
continuation sheet
CLASS
a) Precision and accuracy of results by use of a method applicable to range being

measured.
b) Sampling by correct procedure at the agreed time.
c) Analysis within the agreed time schedule.
d) Provision of results to all interested parties by fastest route.
e) Supervision of all procedures by qualified staff.
c f) In event of absence of sample or slippage in analysis high priority to be given in

communication to operations personnel.
g) Strict calibration routines for analysers and eqUipment, Le.:
• Use of high quality calibration standards.

• Use of calibration routines as per attached frequency list (Section 13.3)
• Use of check samples and/or standard procedures.
NOTE: Reference should be made to the Safety Manual which contains

guidelines for General Laboratory Safety
13.2 GENERAL LIST OF TARGET VALUES FOR CONTROL TESTS FOR AMMONIA
PLANT AND ASSCOIATED SAMPLE AND ANALYSER POINTS
TAG No. SAMPLE COMPONENTS DETERMINED

c 001 Natural Gas Feed VOLUME%
62-0102 CH4 96.85
C2H6 1.23
C3H a 0.216
iC4 H,o 0.054
nC4 H,o 0.085
iC5H'2 0.041
nC5 H'2 0.042
C6 and Heavier 0.15
I
CO2 0.242
N2 1.09
Organic Sulphur 20ppmv
Inorganic Sulphur 20 ppmv
H2O 150 ppmv
Calorific Value 11,615 kcallkg
c -
(LHV)
- -
8645.7
_.-
kcallNm3
_. -

CLASS

002 Oxygen 2.0%
Flue Gas Ex Reformer Radiant Box
62-D102
003 Auxiliary Boiler Oxygen 2.0%
62-D106 Flue Gas
004,005, Primary Reformer Flue Gas Between Oxygen 2.0%

006 Each Row of Tubes
007
62-D106
c 008
62-D106
Primary Reformer
Effluent
CH4 12.12%
0.65%
N2
H2 67.82%
CO 9.48%
CO2 9.93%
Ar 0.004%
011 CO2 Absorber

62-D110 (Middle Section)
aMDEA concentration
012 CO 2 Absorber
62-D110 (Bottoms)
013 CO2 Absorber Overheads VOLUME%

62-D110 To Methanator CH 4 0.46%
N2 24.32%
H2 74.46%
c Ar
CO
CO2
0.29%
0.37%
0.1%
014 Methanator Effluent CH 4 0.94%

62-D112 N2 24.69%
H2 74.07%
Ar 0.30%
CO/CO2 < 5 ppmv
AR-1041 NH3 Converter Inlet CH4 6.06%

to 1045 N2 ·22.27%
62-D115 H2 67.03%
Ar 1.94%
NH3 2.69%
CH4 6.83%
015 N2 18.75%
NH3 Converter Effluent
62-D115 56.48%
c H2
Ar 2.19%
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NHs 15.75%
016 Start-up Heater Flue Gas Oxygen 2.0%

62-0116
017 Warm NHs Product H2O 0.1% (wt max)

62-0119 Oil Content 5 ppmw (max)
c 018
62-0120
Ammonia
(0-2107 TO 0-2123)
H2O
019 Stripped Condensate to Offsites NHs 5 ppmv

62-0121 Conductivity <10 (JS/cm
020 CO 2Product N2 0.09%

62-0122 H2 0.51%
CO2 99.4%
021 CO 2 Stripper
62-0122 (Middle Section)
022A& B CO2 Stripper

62-0122 (Bottom Section)
aMOEA Density
023A& B Lean Solution
62- (To Absorber) Total Amine
01221127
c AR-1061-
65
Purge Gas to T21 03 CH4 7.86%
21.65%
N2
62-0115 H2 65.23%
Ar 2.52%
NHs 2.74%
027 Purge Gas Scrubber Overheads NHs 0.10%

62-0128
028 Secondary Reformer Effluent CH 4 0.43%

OIAG N2 22.56%
30103-1 H2 56.34%
CO 13.10%
CO2 7.30%
Ar 0.27%
c
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029A HTS Converter Effluent CH4 0.39%

OIAG N2 20.63%
30103-2 H2 60.08%
CO 3.43%
CO2 15.23%
Ar 0.25%
029B LTS Converter Effluent CH4 0.38%

OIAG N2 20.00%
c= 30103-2 H2
CO
CO2
61.28%
0.30%
17.79%
Ar 0.24%
029C LTS Converter Inlet Same As HTS Converter Effluent

OIAG
30103-2
030A Hydrogenator Effluent H2S 40 ppmv

OIAG
30103-3
030B Oesulphuriser Effluent CH4 93.12%

OIAG N2 2.01%
30103-3 H2 2.88%
Ar 0.01%
CO2 0.23%
( C2 + 1.8%
TOTAL SULPHUR <0.1 ppmv
031 Surface Condenser Condensate Conductivity 10llS/cm

OIAG Oxygen 20 ppb
30103-4
032 Mixed Feed to Reformer Steam to Gas 3.2: 1 Ratio

OIAG
30103-5
c
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033 Steam Orum Water Silica <0.8 ppm

64-0101 Phosphate 5-10 ppm
Chloride <2.5 ppm
Sulphate/
Nitrate <2.5 ppm
Ph 9.5 - 9.8
Conductivity IIS/cm
Iron 0.02 ppm
TOS < 50 ppm
C~·
AI-1015 Oemin Water to Oeaerator Conductivity <0.25I1S/cm
64-0106
034 B.F.w EX Oxygen <7 ppb

62-0106 Oeaerator Iron <0.01 ppm
Ph 8.8- 9.2
Residual
Oxygen scavenger *******
Conductivity <0.35 IIS/cm
AR-1023 B.F.W EX Conductivity <0.35I1S/cm

62-0115 E2123NB .
035 Cold Ammonia to Storage H2O 0.1%wt (max)

62-0120 Oil 5 ppmw (max)
c 036
OIAG
HPSteam Silica
Conductivity
< 20 ppb
<0.35I1S/cm
30103-7 Sodium <10 ppb
Chloride <6 ppb
Sulphate <6 ppb
PH 8.8 - 9.2
Total Organic
Carbon <100 ppb
037 Flue Gas From Reformer Stack Oxygen 2.0%

62-0131
038 aMOEA Solution Sump TK-2115 H2 Nil
62-0126 Vapour Space O2 20%
Entry Purposes Only
-
c
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CLASS
13.3 GENERAL LIST OF CONTROL TESTS FOR AMMONIA PLANT
COMPONENTS MANUAL
TAG NO SAMPLE FREQUENCY
DETERMINED TEST REF.
001 Natural Gas Feed a) Complete Analysis a) 1.7.3 a) Daily
b) Total Sulphur b) 1.1.3 b) Daily
c) Lower Heating value (By calculaijon from a) c) Daily
002 Flue Gas ex Reforme a) CO & C02 a) 1.5 a) On request
c [62-0106] Radiant box b) Oxygen

c) Oxygen
b) Analyser AR-1010A
c) 1.5
b) Continuously
c) On request
d) Combustibles d) Analyser AR-1 01 OB d) Continuously
a) On request
003 Auxiliary Boiler a) CO & C02 a) 1.5
b) Continuously
162-0105] Flue Gas b) Oxygen b) Analyser AR-1011A
c) On request
c) Oxygen c) 1.5
d) Continuously
d) Combusijbles d) Analyser AR-1011B
004.005 Flue Gas in Reformer a) Carbon Monoxide a) 1.5 a) Daily

006,007 Radiant Box between b) Carbon Dioxide b) 1.5 b) Daily
162-0106] each row of tubes c) Oxygen c) 1.5 d) Daily
008 Primary Reformer a)CH, a) Analyser AR-1001A a) Continuously

[62-0106] Effluent b) N2/H2/CO/C02/CH, b) 1.7.5 b) 1 per Shift
c 011
[62-0110]
012
C02 Absorber
(Middle section)
C02 Absorber Bottom
On request
On request
[62-0110]
013 C02 Absorber O'hds. a) Complete analysis a) 1.7.5 a) 1 per Shift
[62-0110] to Methanator
014 Methanator Effluent a) Carbon Oxides a) Analyser AR-1 002 a) Continuously
[62-0112] b) N2/H2/CH, b) Analyser AR-1031/213 b) Continuously
c) Complete analysis c) 1.7.5 c) 1 per Shift
d) Carbon Oxides d) 1.7.5 d) 1 per Shift
AR-1041-1045 NH3 Converter a) H2.N2 & CH, a) Analyser AR-1041/213 a) Continuously

[62-0115] Inlet b)Ar&NH, b) Analyser AR-1044/5 b) Continuously
c) Complete Analysis c) 1.7.5.C) On request
015 NH3 Converter a) Water Content a) 2.1.2 a) During

[62-0115] Effluent [To E2123A] Reduction
c
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~
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CLASS
COMPONENTS MANUAl
015 NH3 Converter a) Ammonia a) Analyser AR-1055 a) Continuously
[62-0115J Effluent b) Complete Analysis b) 1.7.5 b) 1 per Shift
c) Ammonia c) 2.2.1 c) 1 per Shift
016 Startup Heater a) Carbon Monoxide a) 1.5 a) [Periodically

[62-0116J Flue Gas b) Carbon Oioxide b) 1.5 b) when in
c) Oxygen c) 1.5 c) S9lVice]
c 017
[62-0119J
Warm NHs Product a) H20
b) Oil content
a) 2,3.1A or B
b) 2.3.2A or B
a) 1 per Shift
b) Oaily
018 Ammonia a) H2O a) 2.3.1A or B a) On request

[62-0120J (0-2107 to 0-2123)
019 Stripped Condensate a) NHs content a) 5.2.1/5.2.2 a) 1 per Shift

[62-0121J to Ollsites b) Conductivity b) Analyser AI-1017 b) Continuous
c) Conductivity c) 5.3.6 c) 1 per Shift
d) pH d) 5.3.12 d) 1 per Shift
020 C02 Product a) Totallnerts a) 4.7/4.8/4.9 a) Each shift

[62-0122J b) N2/H2ICH"CO/A b) 1.7.5 b) On request
021 C02 Stripper On request

[62-0122J (LP Hash seclion)
023AorB lean Solution a) aMOEA Oensity a) 3.1 a)1 per Shift

[62-01221127] [To AbsorberJ b) Total Amines b)3.2 b)1 per week
c) aMOEA and Activator c) 4.0 c) 1 Month
c AR-1 061-1 065 Purge Gas

content
a)H2IN2 & CH, a) Analyser AR-1061/213 a} Continuous
(62-0115) to T2103 b)Ar&NHs b) Analyser AR-1064/5 b) Continuous
c) Full Analysis c) 1.7.5 c) Oaily
027 Purge Gas Scrubber a) Ammonia a) 2.2.3 a) 1 per Shift

[62-0128J Overheads
028 Secondary Reformer a)CH, a) Analyser AI-1001 B a) Continuously
[DiAG 30103-1J Effluent b) N2/H2/CO/C02/CH, b) 1.7.5 b) 1 per Shift
029A HTS Converter a) N2/H2/CO/C02/CH, a) 1.7.5 a) 1 per Shift

[OIAG 30103-2J Effluent
029B LTS Converter a) CO a) Analyser AR-1022B a) Continuously

[OIAG 30103-2J Effluent b) N2/H2/CO/C02/CH, b) 1.7.5 b) 1 per Shift
029C LTS Converter a) CO a) Analyser AR-1022A a) Continuously

[OIAG 30103-2J Inlet b) N2/H2/CO/C02/CH, b) 1.7.5. b) 1 per Shift
c 030A
[OIAG 30103-3J
Hydrogenator
Effluent
a) Sulphur a) 1.1.3 a) Oaily
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JOB NO. 5777 SPEC. TYPE: PAGE: W5 OF 312
CLASS
DOC NO. PROJ-PM-008 REVISION: e.
COMPONENTS MANUAL
030B Desulphuriser a) Complete Analysis a) 1.7.3 a) Daily
[DIAG 3D103-3J Effluent b) Total Sulphur b) 1.1.3 b) Daily
031 Surface Condenser a) Conductivity a) Analyser AI-1018 a) Continuously

!
[DIAG 3D103-4J Condensate b) Conductivity b) 5.3.6 b) 1 per Shift
c) Oxygen c) 5.3.5 c) 1 per Shift
d) Iron d) 5.3.9 d) 1 per Shift
c 032
[DIAG 3D103-5J
033 Steam Drum Water
Mixed Feed to Refonner
a) Silica
a) Steam to Gas Ratio
a) 5.3.13
a) 1.4
a) 1 per Shift
[64-D101J b) Phosphate b) 5.3.11 b) 1 per Shift
c) Free Hydroxide c) 5.3.1 c) 1 per Shift
d) Chloride d) 5.3.3A,B or C d) 1 per Shift
e) Suspended Solids e) 5.2.7 e) Daily
I) Total Dissolved Solids I) 5.2.7 I) 1 per Shift
Note: * Dependent on g) Sulfate/Nitrate'[NoteJ g) 5.3.10/5.3.16 g) 1 per Shift
acid being used on h) pH h) 5.3.12 h) 1 per Shift
Oemin. Plant i) Conductivity i) Analyser AI-1890 i) Continuously
j) Iron j) 5.3.9 j) 1 per Shift
AI-1015 Oemin. Water to a) Conductivity a) Analyser AI-1015 a) Continuous

[64-D106J Deaerator b) Conductivity b) 5.3.6 b) 1 per Shift
034 B.F. W. ex Deaerator a) Oxygen a) 5.3.5 a) 1 per Shift
C~ [64-D106J b) Iron b) 5.3.9 b) 1 per Shift

c) pH c) Analyser AI-1007 c) Continuously
d) pH d) 5.3.12 d) 1 per Shift
e) Residual Oxygen e) 5.3.8 e) 1 per Shift
Scavenger I) 5.3.6 I) 1 per Shift
I) Conductivity
AR-1023 B.F.W. ex E-2123A1B a) Conductivity a) Analyser AR-1023 a) Continuously

[62-D115J b) Conductivity b) 5.3.6 b) 1 per Shift
035 Cold Ammonia a)H,O a) 2.3JA or B a) 1 per Shift

[62-D120J to Storage b) Oil content b) 2.3.2A or B b) Daily
036 H.PSteam a) Silica a) 5.3.13 a) 1 per Shift

[DIAG 3D103-7] b) Conductivity b) 5.3.6 b) 1 per Shift
c) Sodium c) 5.3.15 c) 1 per Shift
d) Chloride d) 5.3.3A,B or C d) 1 per Shift
e) Sulfate e) 5.3.10 e) 1 per Day
( I) pH I) 5.3.12 I) 1 per Shift
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1(; continuation sheet
CLASS
COMPONENTS MANUAL
037 Flue Gas from a) Oxygen a) Analyser AR·1021A a) Continuous
[62·D131] Reformer Stack b) Combustibles b) Analyser AR·1021B b) Continuous
c) Oxygen c) 1.5 c) Daily
aMDEA Solution
038 a) Hydrogen a) 1.5 Only for Vessel Entry
Sump TK-2115
62·D126 Vapour Space b) Oxygen b) 1.5
C~ 13.4 CALIBRATION ROUT[NES
Method Frequency
PH Meters Daily
Conductivity Meters Daily
Chromatography Methods Twice Weekly
Water Tests Oxygen Scavenger Weekly and

after new
Phosphate Soluble Reagents
C Silica "
Ammonia by Ness[er "
Chloride "
Acid and base titrations "

Titrations
Iron "
Copper "
Wastewater Methods Month[y
c
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PAGE: 307 OF 312
CLASS
aMDEA Methods Weekly
Urea Methods Weekly
Reagent Water (Demin) Conductivity Daily

Ammonia
Chloride
Silica "
14 DRAWINGS
C" 14.1 PLOT PLAN

Refer to DWG-010-E002
14.2 PFDS & MATERIAL BALANCE TABLES

Refer to the following drawings
Dwg.060-D101 Feed Gas System
Dwg.060-D102 Ammonia Storage System
Dwg.060-D004 Air/Gas Compression & LTS Reduction Circuits

Dwg.060-D005 Desulphurisation, Reforming & Shift Conversion
Dwg.060-D006 CO 2 Removal (aMDEA®)
Dwg.060-D007 Methanation and Ammonia Synthesis
Dwg.060-D008 Refrigeration(warm product case)
Dwg.060-D009 Refrigeration( cold product case)
c
14.3 STEAM AND COOLING WATER BALANCES
Refer to the drawings below
Dwg.061-B001 Steam Balance (Warm Product Case)

Dwg .061-B002 Steam Balance (Cold Product Case)
Dwg.061-B003 Steam Balance C-21 01 Start Up
Dwg.061-B004 Steam Balance C-21 01 Restart
Dwg.061-B005 Steam Balance C-21 03 Start Up
Dwg.061-B006 Steam Balance C-21 03 Restart
Dwg.061-B007 Steam Balance Emergency Shut Down
Dwg.061-B008 Cooling Water Balance (Warm Product Case)


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PAGE: 308 OF 312
CLASS
14.4 PIPING AND INSTRUMENTATION DIAGRAMS

Refer to DWGS 62-D001 to D009,
62-D101 to D132,
63-D101 to D115 and D117 to D126,
64-D101 to D119.
14.5 HAZARDOUS AREA CLASSIFICATION

Refer to DWG-704-E21 001
c 14.6 INSTRUMENT LOGIC DIAGRAMS

Refer to DWG 81-A2003
14.7 INSTRUMENT INDEX. ALARM & SHUTDOWN SCHEDULE
Refer to DWGs 850-B2001 and SMRY-0-2002

continuation sheet
(' JOB NO. 5777 SPEC. TYPE: PAGE: 309 OF 312
CLASS
APPENDIX I
CORRECTION OF ORIFICE, AVERAGING PITOTTUBE

AND VENTURI FLOWMETERS
If the actual flow conditions through the meter are different from design, which
they usually are, then the indicated flow will have to be corrected. Liquid flow
meters are not greatly affected by deviations from design conditions. However,
C' gas flow meters are significantly affected by moderate changes in composition,
pressure and molecular weight.
The flowmeter reading is to be multiplied by the flow correction factor to obtain the actual
flowrate.
A. VAPOUR FLOW METER CORRECTION FACTOR
Actual volume flow Nm3/h= C x indicated volume flow (Nm3/h).
C' C =
..
(PaxTdx MW d / PdxTaxMW a ) .
.. 05
Where,
P = Pressure bara (barg + Atmospheric pressure)
T = Temperature, OK (oC + 273)
MW = Molecular Weight
Subscript a = Actual
Subscript d = Design
• Invert Molecular Weights for flowmeters indicating weight flow.
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c~
CLASS
Example:
Natural gas is measured in Nm3/h at Ta =20°C and Pa = 14.0 bara The actual molectJlar
weight calculated from gas analysis is 17.5.
Design conditions for the flow meter are Td = 24°C, Pd = 14.41 bara and MW d = 16.5.
Therefore, the correction factor is:-
C = (14.0 x 297 x 16.5/14.41 x 293 x 17.5) 0.5 = 0.9285
C' B LIQUID FLOW METER CORRECTION FACTOR
Actual mass flow (kg/hr) = C x indicated mass flow (kg/h)
C = (Dd / Da) 0.5
D = Liquid Density (kg/m3)
Subscript a = Actual
Subscript d = Design
Example:
Boiler feed water flow rate is measured at a temperature of 38°C.

Design temperature for the meter is 44°C.
C·''
j Density @ 44°C = 990.6 kglm3
Density @ 38°C = 992.8 kglm3
C = (992.8/990.6) 0.5 = 1.00111
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c= JOB NO. 5777 SPEC. TYPE:
CLASS
PAGE: 311 OF 312
APPENDIX II
LOWER HEATING VALUE (LHV) CALCULATIONS
A. LHV FOR NATURAL GAS
The lower heating value for natural gas will be calculated as shown in the following
( j
". example,
based on the design composition of natural gas.
KCAUK
Component Fraction MW KG KCAL
G
CH4 0.9685 16.04 15.53 11946 185578.00

C2H6 0.0123 30.07 0.37 11342 4194.96
C3H8 0.0022 44.09 0.10 11072 1054.44
i-C4H10 0.0005 58.12 0.03 10885 341.62
n-C4H10 0.0009 58.12 0.05 10919 539.42
i-C5H12 0.0004 72.15 0.03 10806 319.66
n-C5H12 0.0004 72.15 0.03 10833 328.27
C6H14+ 0.0015 86.18 0.13 10772 . 1392.501
CO2 0.0024 44.01 0.11
C~ N2 0.0109 28.01 0.31
Totals 1.00 16.68 193748.87
LHVKCAUKG 11615
jMW 16.68
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+M,W, Kellogg Limited Operating Manual
continuation sheet
c~
CLASS
APPENDIX III
DENSITY OF LIQUID AMMONIA
Temperature IDensity
of °c Ib/ft3(11 MTlm 3121
c: -40
-35
-30
-40
-37.2
-34.4
43.07
42.86
·42.64
0.6899
0.6866
0.6831
-25 -31.7 . 42.43 0.6796
-20 -28.9 42.21 0.6762
-15 -26.1 42.00 0.6728
-10 -23.3 41.79 0.6694
-5 -20.6 41.56 0.6658
,
0 -17.8 41.34 0.6622
5 -15 41.12 0.6587
10 -12.2 40.88 0.6549
15 -9.4 40.65 0.6512
20 -6.7 40.42 0.6475
25 -3.9 40.19 0.6438
30 -1.1 39.95 . 0.6400
35 1.7 39.71 0.6362
40 4.4 39.48 0.6324
45 7.2 39.25 0.6287
( /
';
50 10 39.00 0.6247
55 12.8 38.74 0.6206
60 15.6 38.51 0.6168
65 18.3 38.26 0.6128
70 21.1 37.99 0.6086
75 23.9 37.74 0.6045
80 26.7 37.48 0.6004
85 29.4 37.22 0.5961
90 32.2 36.94 0.5917
95 35 36.67 0.5874
3
1. Reference: US Department of Commerce, Bureau of Standards No. 142, (ft I1b).
2. MT/m3 = Metric tones per cubic meter.
('
'---,
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01-Operating Manual For 1200 MTPD Ammonia Plant PDF

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M.w. Kellogg Limited ....--.....

EST/JOB NO. 5777 CLASS

Operating Manual for 1200 MTPD Ammonia Plant

4 6/07/05 Client Approved PCS MH CM

Revised Pages in Revision 5

Page Number(s) Change

2.1 DUTY OF UNIT 13

2.2 FEED CHARACTERISTICS 13

2.5 BATTERY LIMIT CONDITIONS [OPERATING TEMP. & PRESSURE] 16

2.6 DESIGN FEATURES 17

c 2.6.8 Synthesis Loop Section ....................................................................................... 19

P:IS777kermanshahISharedl- After OVOsIManualsIPROJ-PM-008-RS -NH3 Operating Manual.doc

2.6.9 Refrigeration Section ........................................................................................... 19

3 DESCRIPTION OF UNIT CONTROL 34

3.1 UNIT CONTROL 34

4 UTILITY I CHEMICAL REQUIREMENTS 111

c 4.1 UTILITY GENERATING CAPACITIES 111

P:15777kermanshahISharedl- After DVDsIManualsIPROJ·PM-008-R5 -NH3 Operating Manual.doc

4.2 STEAM REQUIREMENTS 111

4.5 REFORMER COOLING WATER JACKETS 123

4.6 RAW WATER TREATMENT (OSBL) 124

4.7 SERVICE & POTABLE WATER (OSBL) 124

4.8 FLARE SYSTEM 124

4.9 AIR REQUIREMENTS 125

c 4.11 FUEL GAS

4.13 ELECTRICAL REQUIREMENTS 130

4.14 CATALYST SPECIFICATIONS 131

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c JOB NO. 5777 SPEC. TYPE:

4.14.7 Catalyst Specification for Methanator R-21 06 .................................................... 132

PREPARATION FOR INITIAL STARTUP 137

5.1 INTRODUCTION 137

5.2 PRELIMINARY STARTUP PROCEDURES 138

6 INITIAL START-UP PROCEDURE 158

6.1 INTRODUCTION 158

6.2 Instrument calibration 160

6.3 Surge system checking 160

6.4 test run of the machines 161

6.5 PRELIMINARY START-UP PROCEDURES 161

C 6.6 INITIAL UNIT START-UP PROCEDURE 163

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6.6.1 Commission DeaeratorV-2101 .......................................................................... 163

c 7 NORMAL OPERATION 208

7.1 INTRODUCTION 208

7.2 START-UP WITH ACTIVATED CATALYSTS 208

7.4 OPERATION AT 60% DESIGN CONDITIONS 212

7.5 WARM [37.5°C] AMMONIA PRODUCTION 212

7.6 COLD [-35°C] AMMONIA PRODUCTION 213

7.7 UREA PLANT OPERATION WITH AMMONIA PLANT SYNTHESIS SECTION

C~ 8 SHUTDOWN PROCEDURE 217

8.1 NORMAL SHUTDOWN PROCEDURES 217

9 EMERGENCY SHUTDOWN PROCEDURES 232

9.1 INTRODUCTION 232

P:IS777kermanshahISharedl- After DVDslManualsIPROJ-PM-OOB-RS -NH3 Operating Manual.doc

9.3 LOW TEMPERATURE SHIFT CONVERTER 233

9.4 METHANATOR 234

9.5 LOSS OF FEED GAS 235

9.6 LOSS OF STEAM TO CARBON RATIO 237

9.7 LOSS OF PROCESS AIR 237

9.8 LOSS OF BOILER FEEDWATER TO STEAM DRUM 0-2101 238

C 9.9 LOSS OF PROCESS STEAM 240

9.10 HIGH H.P. STEAM SUPERHEAT TEMPERATURES 240

9.11 LOSS OF FIRING ON PRIMARY REFORMER/AUXILIARY BOILER 241