Ammonia Plant Sops
Ammonia Plant Sops
Ammonia Plant Sops
T-1002 T-1003
Note:
1. If the pump change over motor to turbine, turbine startup procedure should be followed
once turbine reaches required RPM, change over motor to turbine.
8. FURNACE OIL LINE UP TO D.A.P
1. Furnace oil will be lined up as per requirement to DAP.
2. Normally P1003 C is used for pumping Furnace oil to DAP.
3. Open the suction valve of the pump P1003 C and prime the pump.
4. Open spillback valve.
5. Close the discharge valve.
6. Start the pump.
7. Close spill back valve to get required pressure.
8. Once required pressure is attained slowly open the discharge valve to DAP .
9. Adjust the pressure using spill back.
10. Check the Amps, vibration and discharge pressure.
11. Inform to control room.
PRTREATMENT
3. Ensure that the gun to be used is cleaned, fitted with specified spud and gasket.
5. Rest trip 8 in panel and locally also reset ESDV bring naphtha till burner end.
9. Call safety person and check explosive mixture inside furnace and get clearance (While checking
atomizing steam to be isolated).
10. Wear suit with helmet and gloves before lighting. Ensure all the PPE's are wore.
11. Light LPG torch keeping it away from the cylinder staying upwind.
13. Light burner by opening fuel naphtha valve slowly standing behind the pillar.
15. If the burner doesn’t light. Purge the system for 5 minutes to complete purging.
Knock out drum naphtha should be transferred to raw naphtha tank through V207.
Present condition:
Changeover procedure:
COIL
IN
NT
OUT
OUT
VENT
COIL
A/M COIL
SWITCH
OUT
IN
IN
5.SM1 (two strainers in series) STRAINER CHANGE OVER
1. Inform to control room.
2. Inhibit trip 1A.
3. Check which strainers are online?
4. Crack open vent valve prime the stand by strainers by slowly opening the upstream isovalve.
5. Slowly open the downstream isovalve of standby strainers by watching the pressure.
6. Now both the strainers are online.
7. Slowly close the downstream isovalve watching pressure isovalve of strainers which is yet to
handover to maintenance then close upstream isovalve.
8. Drain the naphtha; depressurize the strainers by crack opening vent valve.
9. Check the permit and handover to maintenance.
10. Check the loading of strainers.
11. After the maintenance, open upstream isovalve of strainers and prime it and check for leakage.
12. Inform to control room.
NOTE: Check which are the burner number s for syngas/LPG gas supply before lighting.
CO CONVERSION AND CO2 REMOVAL
1.LT HEAT UP
SPADE
INLET VALVE VENT
V 254 HEATING CIRCUIT
DRAIN DRAIN
SPADE
TI 269 V 254
SPADE
STEAM TI 263 HICV 269
DRAIN
OUTLET VALVE
LT BYPASS
BYPASS VENT
K 1101
SPADE PCV 261
FROM V 257
V-254 Heating up procedure:
Depressurize LT converter, which is under +ve N2 pressure,
After depressurizing N2bleed to be kept open
Keep H-258 drain open, De-spade the following flanges,
a. H-258 inlet flange (near K-1101 i.e. CO2 compressor)
b. H-258 outlet 3wayvalve flange,
c. V-254 outlet to PIC-257 iso-valve u/s flange spectacle-blind to open position
Inhibit(override) Trip- 9,to avoid HICV-269 closing
Close LT bypass vent iso-valve
Open PRC-257(midstream vent) and depressurize the blocked pressure in the line,
Keep PRC-257 set pressure 2kg/cm2
Seal water
To V-301
1. Ensure there is sufficient oil level in the pump that has to be started.
2. If pump is in standby condition from a long time, it is better to get the bearing oil flushed.
3. Ensure there is sufficient flow of bearing cooling water.
4. Ensure the seal water flow is there to the pump and also that the suction isolation valve is
full open.
5. Check locally whether the motor is in energized condition or not. If not, get it energized.
6. Prime the pump by crack opening the casing vent valve.
7. Contact control room operator to inhibit the Benfield solution low flow trip for safety and
ask clearance from MPSS to start the pump.
8. Once the clearance is got, start P-301B and check the discharge pressure.
9. If the discharge pressure is normal, start opening its discharge isolation valve and parallel
close the discharge isolation valve of P-301A in the same speed.
10. Once the discharge isolation valve of P-301B is open and P-301A is closed, contact
control room officer to ensure if sufficient flow is there.
11. If the flow is normal, STOP P-301A.
Note:
Whether the pump is getting enough suction to deliver the discharge flow can be observed
by the motor Amps. Once it is getting the suction, its current draw starts to increase.
P-301A handing over for mechanical maintenance:
1. Once the maintenance job is over, line up bearing cooling water to the pump bearings.
2. Close all the casing/line vents and drains.
3. Check the bearing oil levels and make up if required.
4. Crack open seal water inlet line to the pump, prime the pump and pressurize up to 2.5-3.0
Kg/cm2.
5. Isolate the seal water and check for leaks if any.
6. If no leaks are found, slowly open the suction isolation valve and also charge seal water
to the pump.
7. Once the seal water and suction are normalized, prime the pump once again and get the
motor kept energized.
P-302A CHANGEOVER TO P-302B:
1. Discharge isolation valve is Motorized and during changeover first the discharge ROV
of P302A should be closed slowly.
2. Once the ROV of A pump is around 40% closed, Start B pump and start opening its
discharge ROV.
3. Once the discharge ROV of B pump is full open and that of A pump is full closed,
contact control room and stop A pump.
Note:
If during simultaneous operation of ROV’s the semi lean flow drops, stop the
closing of A pump ROV and open it back if required. And once the B pump ROV
opens further, A pump ROV can be closed.
A. Preliminary Checks
The following preliminary checks have to be carried before starting K401.
1. Ensure that ESDV 2424 is shut and its isovalves are open.
2. Ensure that the isovalve in the line connecting the 1st barrel seal oil traps to common
header shall be fully closed and upstream vent is open by 2 turns.
3. Ensure that the Seal gas to V404 inlet and V404 outlet to K401 suction is closed.
4. ESDV 2424 bypass isovalve shall be kept 50% open.
5. Ensure that all isovalves of LG and level switch are open and all drains shall be kept
closed.
6. With the above conditions satisfied, the Seal Gas System is ready to receive Seal vent
gases from the Compressor as soon as compressor is started.
B. Lining up the system
1. Keep the drain valve of level switch open.
2. Crack open V404 inlet isovalve slowly to pressurise V404. Purge through the drain
valves.
3. Observe the pressure in V404 and open the inlet valve fully once the pressure is steady.
Slowly close the vent valve to pressurise the system to a pressure 2 kg/cm2 higher than
K401 suction pressure.
4. Pressurising to be done slowly, the filter element may collapse if sudden pressurising is
done.
5. Once pressurising is complete, V404 to K401 suction isovalve is to be opened, with
simultaneous closing of ESDV 2424 bypass valve.
6. Open the isovalve in the line connecting the 1st barrel seal oil traps to common header
fully and upstream vent is fully shut.
7. Observe the levels in all seal oil traps and ensure that they are steady.
8. Observe the Differential pressure in the gauge provided on V404.
C. Operation during normal running
1. Observe the DP of V404. If DP goes above 1.5 kg/cm2, the filter should be isolated and
replaced.
2. If V404 high level alarm appears (LAH 404 on DCS) or high level is observed in the
level gauge, oil may be drained to tank.
3. Levels in the Seal Oil Traps of all three barrels to be observed regularly.
P-501A to P501B
1. Inform to control room.
2. Check oil level, pressure gauges standby pump (B).
3. Ensure standby pump is energized. (B)
4. Check suction isovalve of standby pump and prime the pump. (B)
5. Start the standby pump. (B)
6. Once pressure developed open the discharge isovalve of P-501B.
7. Slowly close the discharge isovalve of P-501A.
8. Check the flow.
9. Inform to control room.
P-502A to P-502B
1. Inform to control room.
2. Check oil level, pressure gauges
3. Ensure standby pump is energized. (B)
4. Check suction isovalve of standby pump open position and prime the pump.
5. Start the standby pump (B).
6. Once pressure developed open the discharge isovalve of P-502B.
7. Slowly close the discharge isovalve of P-502A.
8. Check the flow.
9. Inform to control room.
P-503A to P-503B
1. Inform to control room.
2. Check oil level, pressure gauges
3. Ensure standby pump is energized. (B)
4. Check suction isovalve of standby pump and prime the pump.
5. Start the standby pump.
6. Once pressure developed open the discharge isovalve of P-503B.
7. Slowly close the discharge isovalve of P-503A.
8. Check the flow.
9. Inform to control room.
P-504A to P-504B
TRANFER ISOLATION
1. Close steam valve.
2. Open Heat exchanger drain and remove all condensate.
3. Ask IAT de- pressurizing towards which side If it is towards V554 side keep ball
valve and PCV bypass open If it is towards IAT close ball valve and PCV bypass.
4. Keep glycol circulation for 15 min. after that stop the pump close discharge
valve
5. Close glycol make up valve.
6. Inform to control room transfer isolated.
LY 403A is in Auto.
LY 403B is in manually closed, u/s & d/s iso-valves are closed.
LIC 403 in Auto.
Procedure: