DFL CHEMICAL ENGINEERING TRAINEES REPORT

NFL VIJAIPUR INDIA

WEEK: THIRTEEN (15TH – 20TH of April, 2019)

PLANT SESSION: UREA I

GROUP: ONE (S1)

GROUP MEMBERS: Yunus, Muhammad Halil

Ismail, Usman
Umar, Munir Mohammad
Gaiya, Zechariah Abba
Yakubu, Abdullahi
Shehu, Baffa Jakada
Abubakar, Kabir Isah
Baba, Muhammad Bello

GENERAL OVERVIEW OF CONDUCTED ACTIVITIES

➢ Participation and observations during activation (reduction) of ammonia line II low

temperature shift conversion LTSC catalyst using hydrogen diluted with nitrogen as start-
up kicks off
➢ Identifying the major pumps in the high pressure HP and medium pressure MP loops,
function and location in field
➢ Further studies on the Operation and Constructional Features of a Urea Reactor
➢ Study and apparent observation of the HP loop Valves, function and location in field
➢ Study, examination and comprehension of Medium Pressure (MP) Section
➢ Brainstorming and group discussion of the entire HP loop by team members
➢ Conclusion and challenges

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1.0 Activation (reduction) of ammonia line II low temperature shift conversion LTSC
catalyst using hydrogen diluted with nitrogen

The reduction process is carried out in an isolation loop using hydrogen H 2 diluted with nitrogen
N2 gas at 180-200°C for 93 hours after a temperature of 165°C is attained using an electric
heater, the heating rate is carried out at 30°C per hour.

LTS catalyst consists of CuO (Active catalyst), ZnO (catalyst promoter) and Al2O3 (Stabilizer),
but only CuO is reduced at the above given condition. The mixture of N2 and H2 are transferred
using a blower to the electric heater.

The reaction equation: CuO (s) +H2 (g) = Cu (s) + H2O (l) (1)

G/G Exchanger CWR

Heater Heat Exchanger
CWS
LT Shift Converter

G/G Exchanger Hydrogen

Nitrogen Blower
Separator
Hydrogen

Nitrogen

Drain

Figure 1: Process flow diagram for the reduction process is shown below

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As seen in the above flow diagram, the N2 and H2 from header are mixed and pass through a
blower with a makeup H2 which is fed through the shell of the gas-gas heat exchanger for pre-
heating using the outlet gas from the LTS before its finally heated to a temperature of 193°C by
the electric heater and sent to the LTS for the reduction process through the top of the reactor.
Exit gas from the bottom is saturated with water vapor, it passes through the tube gas-gas heat
exchanger for cooling by the incoming feed and for further cooling by water condenser before
entering a separator where the water and is separated and drained while the rich gas is recycled
back reduction.

2.0 Major pumps in the High pressure HP and Medium pressure MP loop

The urea plant has many liquid feeds in and out of different equipment ranging from liquid
ammonia, carbamate solution, carbonate solution to urea solution and condensates. All these
solutions require different pumps at one juncture or the other to be pumped to their respective
points of entry purposely for delivering high head (as in the case of a reciprocating pumps) or
delivering high volume (as it is in the case of a centrifugal pumps). There are many such pumps
of different significance in the urea plant. Major pumps we have studied and sighted at the plant
are as explained below.

2.1 P-1 A/B/C: The reactor feed pump

The P-1 pump in an important reciprocating pump among others at the NFL urea plant. It is the
liquid ammonia feed pump to the reactor R-1 through carbamate ejector EJ-1. This is after been
boosted by the ammonia booster pump P-5 A/B. The pump is driven by an electrical motor and it
has a design pressure specification of 416Kg/cm2g. While in operations, the P-1 pump has a
suction of about 23Kg/cm2g and a discharge of about 240Kg/cm2g. The P-1 pump is coded as P-
1A, P-1B and P-1C. The P-1C is always in operation and it has a low capacity of 25m3/hr with
no torque converter. The rate in the other pumps P-1A and P-1B is controlled with the use of a
torque converter.

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2.2 P-2 A/B: High pressure carbonate solution pump.

Its function is to pump carbonate from column C-1 to carbamate condenser E-5. The liquid is
sucked from the bottom of C-1 and sent to E-5 via mixer ME-1. The pump is a centrifugal high
speed type with a differential pressure of 138Kg/cm2g in normal operating conditions. The
temperature of the pumped liquid must be controlled to prevent crystallization.

2.3 P-3 A/B: Medium pressure carbonate solution pump.

This pump functions to pump carbonate from the carbonate solution tank, V-3 to medium
pressure condenser E-7. The liquid is sucked from the bottom of V-3 at a temperature of 40oC.
The pump is electric motor driven fitted with a mechanical seal and is made up of AISI-316. The
design temperature and pressure of the pump are 100oC and 16kg/cm2g respectively.

2.4 P-5 A/B: Ammonia booster pump

This pump sends ammonia to the suction of P-1A/B/C which feeds the reactor and also to the
medium pressure absorber C-1 as reflux. It is equipped with mechanical seal flushed with
ammonia. The pump is of the single stage type driven by electric motor. It has been designed for
a differential pressure of 6Kg/cm2g.

2.5 P-7A/B: Ammonia Solution Pump

This pump basically functions to pump ammonia solution from E-31 to C-1 to clean the trays. It
is electric motor driven with a design differential pressure of 6kg/cm2g. It has a suction
temperature ranging from 30oC to 60oC fitted with a mechanical seal and flushed with a process
fluid.

3.0 Operation and Constructional Features of a Urea Reactor

The reactor is used for the synthesis of urea from the reaction of CO2 and NH3 inside the reactor.
In an approach to convert reactants to useful products, modifications on the reactor is necessary
for improved yield, process parameters and proper mixing of the reactants.

The reactor is a 40m high coil layered vessel with a diameter of 2.04m. The reactor’ shell is
Carbon Steel (CS) made of SPV 46Q and MY 56 type. The reactor liners have a thickness of
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7mm each and are of SS 316 L (mod) types which are cladded to the CS shell with longitudinal
and circumferential seems.

A weep hole monitoring system has been provided for the detection of leakages in the welds of
liners. The system is a set of microprocessor based scanners which have been specifically
designed to resistance inputs to monitor reactor leakages. There is a total of 95 weep holes in
both reactors used in NFL Urea line I.

The conversion of Carbamate into urea is a relatively slow reaction and requires heat. Because of
the equilibrium reaction, the reaction of CO2 and NH3 is preferably done in a plug flow type of
reactor for a higher fractional approach to equilibrium (FAE). Installing a number of continuous
stirred tank reactors in series can approach plug flow. Thus the urea reactor is divided into a
number of compartments, mostly separated with sieve trays, and each compartment acts as a
continuous stirred tank reactor. As a result, plug flow is approached in such a cascade type
reactor.

To obtain a continuous stirred tank reactor, stirrers should be applied. However, the urea reactors
are not equipped with mechanical stirrers. The driving force for mixing the liquid in the
compartments of the reactor is the gas phase. The urea reactors are a so-called high-pressure
bubble column. By adding the gas phase through the center of a compartment via carefully
designed holes, a Torus circulation exists and thus the required mixing of the liquid in such a
compartment is obtained.

There is a total of 15 high efficiency trays (HET) in the reactor. The material of construction of
the HETs are an SS of 2RE69 type. The trays are normally perpendicular to the vertical axis of
the reactor, and equally spaced along the axis to the full height of the reactor. The trays are very
often perforated, i.e. having holes variously arranged and possibly of different shapes and/or
sizes. There is a total of 3846 holes on the trays. In order to make the Split Flow Loop as
efficient as possible, the HET serves to:

1. Improve the redistribution of unreacted carbon dioxide inside the liquid phase rich in free
ammonia and maximize the hold time of the light (faster) phase.

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2. Reduce the back mixing phenomenon due to density increase of carbamate and urea solution
from bottom to reactor top.

3. Reduce channeling which has a negative effect on the solution residence time.

Figure 2: Urea reactor

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 BOTTOM HEAD CIRC. SEAM SHELL LONG. SEAM

Figure 3: Longitudinal and circumferential seaming of the reactor liner

4.0 HP loop Valves, function and location in field

HP loop is the heart of urea plant where Urea synthesis and high pressure recovery at 159 ata
takes place. HP loop Valves function and location in field was well explained in details and seen
practically in the field. There are 8 safety valves in the HP synthesis loop which are: HV-1, HV-
2, HV-3, HV-4, HV-5, HV-6, HV-7 and HV-8.

HV-1 is a pneumatic valve for Co2(g) feed near R-1

HV-2 is a pneumatic valve located before EJ1 and on MV-1 liquid line

HV-3 is a butterfly valve with special allowance for liquid flow when fully closed. The design is
for safety of the reactor R-1 in case of pressure built up at the outlet of reactor. It is located in
between R-1 and E-1.

HV-4 is the reactor R-1 drain valve or E-5 drain. During plant operation it is fully closed.

HV-5 is a motorized valve/pneumatic valve used for quick isolation. It is located on E-1 outlet to
MV-2. It's fully open during normal operation.

HV-6 is found at the P-2 discharge line near E-5, regulating the flow of carbamate from C-1 into
E-5.

HV-7 is P-1 discharge before PV-12 near R-1 and it’s used for quick isolation.

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HV-8 is a motorized valve for quick isolation located at the discharge of C02 compressor line
before HV-1.

5.0 Medium Pressure (MP) Section

The medium pressure (MP) section of the Urea plant operates at an approximate pressure of
18kg/cm2g, in this section the Urea solution is increased from 45% in the HP section to about
62%, most of the excess Ammonia present in the Urea solution and all the unconverted CO2 are
removed from this section. The MP loop has the following major equipment:

1. Medium Pressure Decomposer (MV2, E2 & ME2)

2. Medium Pressure Condenser (E7)
3. Medium Pressure Absorber (C1)
4. Ammonia Receiver Tank (V1)
5. Inert Washing Column (C3 & E11)

from C3

Vapor to Preconcentrator

Ammonical water
Vapor from Preconcentrator
Inert to CPP
from C3 CWR
MV2

NH3 V1 E9A C3 LW

Solution from E1 E9B

Vapor NH3 + Inerts E11

C1 CWS
E7
C5

Cond.
To V3 Vapor NH3 Liquid NH3

E2 Carbamate to P2
V1
CWR CWS
Ammonical Water Pump P7A/B

MS

Vapor from MV1 ME2 NH3 to P1

NH3 from B/L
NH3 Booster Pump P5A/B
Solution to LP Decomposer
Fig 4: medium pressure (MP) section of the Urea plant

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5.1 Medium Pressure (MP) Decomposer

The MP decomposer is a three-in-one combo vessel with a separator (MV2), a heat exchanger
(E2) and a solution holder (ME2). Its main function is to decompose more carbamate into vapor
NH3 and CO2, there by concentration the urea solution, the pressure of the vessel is maintained at
18kg/cm2g, the top temperature is around 150OC bottom temperature is around 160OC for
efficient decomposition and to prevent water present in the solution from forming vapor and
leaving the solution.

The heat exchanger part (E2) of the decomposer work exactly as the HP decomposer (E), it also
have ferule for tangential falling film flow of the solution down the wall of the tubes as the
solution flows from the top of the decomposer into the ferule, the vapor formed during the
stripping falls through the center of the tubes to the top of the decomposer through MV2. The
tubes are heated by medium pressure steam (MS) through the shell of the heat exchanger (E2).

The separator part (MV2) is equipped with pal ring packings arranged in a bed to prevent free
fall, provide more residence time and more contact area for the solution coming in to condense
the water vapor escaping with the vapor NH3 and CO2 going out through the top to allow
efficient stripping and ensure only vapor NH3, CO2 and inert leaves from the top.

The solution holder (MV2) serve as a temporary storage for the more concentrated urea solution
going to the low pressure (LP) section.

Condensation of water in the urea solution is important because low amount of water and too
high concentration of urea in this section can lead to Biuret formation and also corrosion of the
equipment.

5.2 Medium Pressure Condenser

The medium pressure condenser (E7) serves to condense the vapor (NH2 & CO2) after it is used
to preheat the urea solution going into the pre-concentrator in the vacuum section. The vapor
after leaving the top of MV2 is mixed with liquid carbamate (Ammonical water) to favor its
condensation in E7. In E7, the vapor passes through the shell while cooling water from E9A/B

9
passes through the tube to condense the vapor, the cooling water is circulated within E7 using
pump (P4A/B) while condensed vapor is sent to the medium pressure absorber (C1).

5.3 Medium Pressure Absorber

The medium pressure absorber (C1) is often called the heart of the urea plant because it is one of
the critical equipment in the plant. In the absorber all the CO2 present in vapor face are absorbed
by ammonical water from the Inert Washing Column and reflux liquid ammonia from the
Ammonia Receiver so that only pure vapor NH3 is allow to leave the top of the Absorber.

The top of the absorber is equipped with for bubble cap trays to provide surface area and
residence time for efficient and complete absorption of CO2.

Pure vapor NH3 leaving the top of C1 is condensed by cooling water in two heat exchangers
(E9A/B), C1 is maintained at 18kg/cm2g and the vapor ammonia is condensed by cooling water
because, NH3 at 18kg/cm2g and at cooling water temperature will begin to form liquid, both the
liquid and vapor ammonia from E9A/B is sent to the Ammonia Receiver.

The absorber operates at 18kg/cm2g and the top temperature is kept below 45OC, an increase in
the top temperature above 45OC indicated by thermocouple shows that there is CO2 carry over
from the top of C1 because formation of carbamate is exothermic. If CO2 is allowed to leave
with vapor NH3 at the top of C1 through E9A/B to V1, carbamate will be formed which as a
result clog the ammonia booster pump (P5A/B) and may result to tripping the plant operation. If
a temperature increase is noticed at the top of C1 more reflux liquid ammonia should be added to
arrest the situation. The CO2 vapor absorbed by the ammonical water and reflux NH3 forms
carbamate at the bottom of C1. The resulting solution is removed from the bottom and pumped
by the HP carbamate pump (P2A/B) to the HP carbamate Condenser (E5). The level of the
absorber needs to be maintained between 30-40% as too high level and too low level can trip the
plant.

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5.4 Ammonia Receiver

The ammonia receiver (V1) is where ammonia supplied to urea from the ammonia plant and all
recovered NH3 from the MP loop are received in V1. Ammonia from V1 is pumped through
P5A/B and P1A/B & C to the reactor R1.

The vessel is maintained at 18kg/cm2g to be able to receive all the NH3 coming in and below
40OC to reduce vaporization of NH3 in the vessel.

Vapor ammonia trying to leave with the inert at top of V1 through C5 is condensed by part of the
liquid NH3 from Battery Limit (B/L) coming through the top of C5. Residual vapor NH3 that
eventually escaped with the inert is sent to the inert washing column.

5.5 Ammonia (Inert) Washing Column

The inert washing column is also a combo vessel with a separator (C3) and a heat exchanger
(E11), its main function is to help condense and allow the vapor NH3 escaping with inert to be
absorbed. In the heat exchanger part, the vapor flows through the tubes and it is condensed by
cooling water flowing through the shell.

6.0 Brainstorming and group discussion of the entire HP loop

Team had a productive brainstorming and group discussion of the entire HP loop alongside some
Indian trainees who appreciated our fruitful discussion, teamwork and enthusiasm towards
learning.

7.0 Conclusion and challenges

Facilitators are becoming more generous in mentoring and sharing knowledge. Team continues
to maintain an inquisitive spirit towards learning as well as a positive attitude and drive in the
learning environment. However, the following challenges continue to impede our learning
process

• Lack of proper engagement by the technical staffs to learn more technical aspect
• Lack of task assignment to team members
• Language barrier
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 DFL CHEMICAL ENGINEERING TRAINEES REPORT

NFL VIJAIPUR INDIA

WEEK: THIRTEEN (15TH – 20TH of April, 2019)

PLANT SESSION: UREA II

GROUP: TWO (S2)

GROUP MEMBERS: Mohammed Adamu Ibrahim

Obidiagha Collins Uzochukwu
Okeke Ifeanyichukwu John
Nnadi Okechukwu Franklin
Akinboro Raymond Adebobajo
Ogunniyi Oluwaseun Timothy
Bashorun Adeola Khadijat
Ojo Iyanuoluwa Joshua

Activities of the Week

1. Start-up activities in Ammonia II plant

2. The group had a chat with Shri S.K Shangal on conclusion of our training in
Ammonia II.
3. The group also reported to Shri Ramjam Madhav (Dy. Mgr. Urea II Prod.) and
was divided into two (2) Shifts.
4. Preliminary study of Urea process manual & PFD to identify the major sections
and process steps involved in the production of Urea.

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Ammonia II Start up Activities

The group witnessed start up activities carried out in Ammonia II plant. These jobs are
usually carried out before the main start-up of the plant (Circulation of Feed) namely:

• Nitrogen gas Circulation for purging of systems

• Steam Circulation
• Cooling Water Circulation
• Reduction of Low Temperature Shift converter catalyst
• Flaring of gases
• Primary Reformer Burner lighting.

Introduction to Urea Process

Using the PFD and process manual, the group did line tracing of the entire Urea process
to identify the major equipment. We also had a tour round the plant.

The Urea Production process takes place through these main operations namely:

• Urea Synthesis and High Pressure Recovery

• Urea Purification and Low pressure Recovery
• Urea Concentration
• Urea Prilling and
• Waste Water Section.

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Figure 1: UREA PLANT PROCESS BLOCK DIAGRAM

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 Table 1: Sections in Urea and Major Equipment

Section Major Equipment

• CO2 Knock out Drum

• CO2 Compressor
Urea Synthesis and High • Carbamate Recycle ejector
Pressure Recovery • Urea Reactor
• Stripper
• Carbamate Condenser
• Carbamate Separator
• Carbamate Feed Pump
• Ammonia Feed and Booster Pumps

• Medium Pressure Pre-Decomposer

• Stripped Condensate Cooler
• Medium Pressure Decomposer
• Pre-Concentrator
Urea Purification and low- • Medium Pressure Condenser
pressure recovery • Medium Pressure Absorber
• Ammonia Condenser
• Inert Gas Washing tower
• Ammonia Receiver Tank
• Low Pressure Decomposer
• Low Pressure Condenser
• Carbonate Solution tank

• First Vacuum Concentrator

• Second Vacuum Concentrator
Urea Concentration • First Vacuum Separator
• Second Vacuum Separator

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 • Prilling Bucket
• Urea Melt Pump
Urea Prilling • Prilling Tower
• Rotary Scraper

• Waste water tank

• Drain Collecting tank
Waste Water Treatment • Buffer waste water tank
• Waste water Distillation tank
• Hydrolyzer
• Reflux Accumulator

Conclusion

For a successful shut down of a plant, a Checklist is first prepared. Also, the various factors affecting
plant operations are considered to note grey areas in the plant to carry out maintenance activities.

Figure 2: Group Picture with Ammonia II Chief Manager after Successful Completion of Training
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 DFL CHEMICAL ENGINEERING TRAINEES REPORT

NFL VIJAIPUR INDIA

WEEK: THIRTEEN (15TH – 20TH of April 2019)

PLANT SESSION: AMMONIA I

GROUP: THREE (S3)

GROUP MEMBERS: BILAU AbdulWaheed Ademola

LAOYE Kemi Omowunmi
AYINLA Habeeb Oladimeji
TIAMIYU AbdulGafar Olatunji
ALIYU Ibrahim Nagidi
AIMANOHI U. Ikhile
STEPHEN Alvin Mikin
JOHNSON Bright Benjamin

This is the summary of the activities carried out by Group 3 members on a daily basis at Urea 1
for the just concluded week.

Day 1: 15th April, 2019

The group reported to Ammonia Line 1 plant after concluding a week training in Captive Power
plant (CPP). Upon resumption of duty in the morning the team had a session with Mr S.K. Saha
where he made a brief general introduction of Ammonia line 1 from the commission till date. He
also explained the total production process of Ammonia which is divided into our main sections
namely;

• Hydrodesulphurization of Natural gas (feedstock)

• Reforming (Primary reformer with Steam and Secondary reformer with Air)
• Process gas purification:
• High temperature and Low temperature CO Converters
• Carbon dioxides removal (GV Section)
• Methanation

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Day 2: 16th April, 2019

The group embarked on daily study of the operation manual and PFD taking each section and
discussing together. The sections of the production process studied and discussed were:

HYDRODESULPHURIZATION

The natural gas feedstock contains up to 10ppm by volume of Sulphur which is poisonous to the
primary reformer catalyst and the shift converter catalyst, therefore the NG must be
desulphurized. The desulphurisation took place in two stages:

Hydrogenation: Conversion of organic sulphur to inorganic by passing a stream of recycled

Hydrogen gas from synthesis gas in the Hydrogenator, catalyst used is Ni-Mo.

H2S Absorption: The inorganic sulphur is then absorbed in two ZnO absorbers at 380 degree
Celsius and 37Kg/cm2.

Day 3: 17th April, 2019

REFORMING

The Hydrocarbon feed is completely desulphurized containing less than 0.1ppm of Sulphur. The
desulphurized hydrocarbon is first reformed into Hydrogen gas, carbon oxides and water in the
Primary reformer by mixing it with steam maintaining Steam to Carbon ratio of 3.3 which is first
preheated to 480 degree Celsius and is passed downwards through vertical tubes containing
catalyst (Nickel, Magnesium and Alumina). The Primary reformer is a fired heater where the
sensible heat and the heat of reaction are transferred by radiation from the walls of burners to the
catalyst tubes. It contains 288 tubes and 576burners. NG is uses s combustion fuel gas. The
outlet gas at about 770 degree Celsius leaving the primary reformer contains 13% of unreformed
methane which proceeds further into secondary reformer which air is introduced from the top to
mix with the process gas resulting in partial combustion. The exit gas from here contains 0.30%
of methane, 22.5mole% of N2 and 13mole m percent of CO, 7.3 mole % of CO2 at 990 degree
Celsius.

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Day 4: 18th April, 2019

GAS PURIFICATION SECTION

This is divided into three segments:

Shift Converters (CO Conversion)

In the gas purification section, the process gas leaving the reforming section contains 13vol%
CO which is converted into CO2 and H2 with steam in the process gas by means of shift
reaction. It passed through High, Medium, and Low Temperature Shift Converters. The reaction
is favoured by lower temperature and more water vapour therefore the process gas is cooled from
990 to 350 degree Celsius before going to the converters.

CO2 Removal (GV Section)

In this section, the CO2 is absorbed from the process gas by hot aqueous potassium carbonate
solution then sent to the methanator. The absorbed CO2 is sent to two regenerators to regenerate
the CO2 and sent to Urea plant for Urea production.

Day 5: 19th April, 2019

METHANATOR

The final part of the gas purification where the residual Carbon oxides are converted into
methane which acts like inert gas in the ammonia synthesis loop. The carbon oxides are very
poisonous to Ammonia synthesis catalyst therefore need to be converted. the methanation
reaction is the reverse of the reforming section therefore, low temperature, high pressure and low
steam content favour the reaction. The optimum temperature ranges from 280-400 degree
Celsius depending on the activity of the catalyst which is Nickel based.

Day 6: 20th April, 2019

AMMONIA SYNTHESIS

The purified synthesis gas is the compressed to about 220kg/cm2 and sent to the ammonia
synthesis loop where it is converted into ammonia.

Ammonia Refrigeration Loop and Storage were also discussed.

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 DFL CHEMICAL ENGINEERING TRAINEES REPORT

NFL VIJAIPUR INDIA

WEEK: THIRTEEN (15TH – 20TH of April 2019)

PLANT SESSION: AMMONIA II

GROUP: FOUR (S4)

GROUP MEMBERS: AKOR, ABRAHAM . E.

AGIDI, SEGUN .O.

USMAN BABATUNDE

AHMAD ISYAKU

UMUNNA, JUSTIN .O.

OLUMUYIWA, FEMI .D.

NAZIR, MOMOHJIMOH .O.

AKPORE, OGHENERUKEVWE .J.

TASK PERFORMED: START UP OF THE PLANT

Having taken clearance from maintenance departments (mechanical, electrical and

instrumentation), Ammonia-I and Urea-I, the startup of Urea-II plant commenced with the
following activities.

1. Sealing tests of all sections: The sealing test of the entire sections in the plant was carried out
to eliminate leaks, if any before charging process fluids. In this case, steam condensate at
ambient temperature was used. The steam was admitted from the lowest points and vent at the
highest points were opened and the pressure was slowly increased to the test value. All flanges
and connections were checked in order to identify leaks and eliminate them, and the constant
value of the pressure value after 4 hours shows that the test was successful and satisfactory (i.e.,
there was no pressure fall within this time frame).

2. Purging M.P and L.P Sections with Nitrogen(N2): This operation was carried out in order to
remove all the oxygen(O2) present to avoid any risk of explosive mixture formation during
ammonia charging. While admitting the nitrogen, the pressure controller was in automatic mode,
and when it comes out of the drain, the block valves were closed. It was ensured that the system

20
was depressurized to about positive pressure of 0.5kg/cm2 and the gas outlet was analyzed for the
presence of oxygen(O2) which was expected to be around 0.1% for effective purging.

3. Charging of Ammonia in M.P Section: The purposes of the operation were to have a make-up
of ammonia (raw material), pressurize the M.P section, test H.P ammonia pump and for
ammoniation. Ammonia preparation was carried out in V-3 for the preparation of L.P section to
receive process fluid and to ensure that the concentration ammonia in V-3 is 30%.

4. Plant heating prior feed cut-in: This operation helps in bringing the equipment which were
initially at ambient temperature to the best conditions to feed-in process fluids. It also helps to
avoid thermal stresses on the material and the possibility of crystallization of products in cold
piping and walls. The H.P section was heated up to the temperature of about 150-160OC before
the process fluids were introduced and the heating rate was at 30OC/hr.

5. The following conditions were met and ensured prior ammoniation

✓ CO2 compressor ready to be started with high pressure line heated up

✓ The compressor was put in running before ammoniation
✓ H.P pumps were prepared ready for the commencement of the operation
✓ H.P section heated up prior ammoniation
✓ M.P section was charged and pressurized with ammonia using ammonia booster pump, p-
5
✓ L.P section was charged with ammonia solution and M.P carbonate solution pump, p-3
kept running in circulation to carbonate receiver v-3 through M.P absorber.
✓ Vacuum Section was prepared ready to be taken in line
✓ Prilling system was ready to be started
✓ Waste water section was put in running condition.

6. Introduction of Ammonia (Ammoniation): The purpose was to reach the best conditions to
start the reactions inside the reactor. The ammoniation involved pressurizing the H.P loop with
ammonia vapour up to 90kg/cm2 and lasted for about 3 hours (i.e., at the rate of 3kg/cm2 per
hour) before the introduction of the feeds (CO2&NH3) to the reactor. The steps are as follows;

✓ The pressurization of the synthesis system was started by sending ammonia via
ammonia booster pump, p-5 to start up line, leaving opened the suction and delivery
valves of HP ammonia pump, p-1 and it vapourized in the jacket line. It was ensured
that the ammonia vapour temperature was over 140OC.
✓ When the H.P system reaches the value of booster pump delivery pressure, the H.P
ammonia pump p-1 was started in recycling to the ammonia receiver by opening the
relevant valves and the ammonia rate of feeding was adjusted to have gradual increase
in the pressure up to 90kg/cm2.

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 ✓ When the set value of pressure was reached(90kg/cm2) the ammonia feeding to the
startup line was stopped by closing the inlet valves and simultaneously stopped p-1and
followed by the closing of the steam jacket of startup line and washed with high
pressure water for few minutes.
✓ The speed of pressure increased on H.P section (PIC-7) was maintained at 30kg/cm2
per hour to arrive at 90kg/cm2

7. M.P and L.P section preparation: Ammonia has been fed into ammonia receiver and both
sections (M.P & LP) were pressurized with ammonia vapour at 15kg/cm2 and 3kg/cm2
respectively. MP carbonate solution pump P-3 was running with a week ammonia solution
accumulator via MP condenser and MP absorber. Small reflux flow into the MP absorber to
increase the ammonia content into this solution keeping the MP carbonate solution pump p-3
running in recycle. The ammonia reflux to M.P absorber(C-1) was stopped when the carbonate
solution accumulator analysis indicated an ammonia content of 35% by wt. Steam was fed into
shell sides of the M.P and L.P decomposers by opening the relevant control valves to about 10-
15% and the equipment were heated up by sending HW/LW at the inlet. The levels of the MP &
LP decomposer holders were kept and steam tracing was put in service in all the process lines.

8. The vacuum evaporation section was put in water recirculation to the urea solution tank via
vacuum concentrator/separator/urea solution pump P-8.

9. The process water treatment section was running through the distillation tower C-2.

10. Carbon dioxide compressor and passivation air system preparation: The carbon dioxide
compressor was started and loaded and it was stabilized by venting the carbon dioxide to the
atmosphere from final discharge vent in auto. The passivation air flow was opened and oxygen
analyzer was put in service.

11. The following action were performed for feed-in

✓ Condensate was sent to the reactor for 10 minutes

✓ Ammonia was fed for about 15minutes
✓ CO2 was fed to the reactor
✓ Carbamate was fed at reactor over flow
✓ Passivation air was kicked started
✓ Parameters stabilization commenced

Other operational activities that would ensure further stabilization of the plant process
parameters were put in place for the effective running of the plant.

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CHALLENGE: We were not carried along in the startup procedures hence, this report was a
product of our personal effort and development through group discussions.

23
 DFL MECHANICAL ENGINEERING TRAINEES REPORT

NFL VIJAIPUR INDIA

WEEK: THIRTEEN (15TH – 20TH of April 2019)

PLANT SESSION: UREA I, BAGGING, CPP, NDT, WORKSHOP

GROUP MEMBERS: UMAR ABDULLAHI

ONWUAJUESE CHIKA PRINCE
SALAKO BABATUNDE SAMSUDEEN
AKINGBADE BABATUNDE RICHARD
OHUE COLLINS
OGBEKENE YEROWO FAVOUR

There are six trainees, two in NDT, while the remaining are for Bagging Section, CPP, Urea I
and workshop.

The basic outline of the maintenance activities carried out are:

BAGGING

1- Maintenance of a sewing head, now 106,105,101,110,96

Parts changed include: 99,98parts, block shaft and lubrication pipes were cleaned.

2- DM water displacement pump leakage:

*Damaged carbon face of the stationary part of the mechanical seal.

*Bearing failure, bearing clearance was 0.4mm > maximum clearance allowed.

Mechanical seal and bearings were changed.

3- ET 28, Belt running off center was corrected. Maintenance also carried out on the
conveyor belt.
4- Urea solution pump, Damaged coupling hub. ---job still ongoing, part is been procured.
5- Weighing machine sprocket 5A: broken teeth and damaged pulley.
Both were changed.

6- Weighing machine conveyor belt damage.

Belt was changed.

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CAPTIVE POWER PLANT

1- Modification of the key way of a worm and wheel gearbox to fitting width and depth.
2- Tapping, keyway fabrication and assembling of a scrapper gearbox.
3- Lubrication and assembling of the pacifier gearbox.
4- Vibration test on the boiler feed water pump.
5- Getting the centerline of two mating gears in the worm and wheel gear box system.
6- Replacement of oil seals in the scrapper (Master) gearbox.
7- Modification of spacer between the hub and bearing of the worm and wheel gearbox to
precise length.
8- Working on the oil pump and oil filter in the gas turbine compartment.

CENTRAL WORKSHOP

1- Fabrication of a screw to be used in the bagging plant

Machine used: Lathe machine (NH22)

2- Fabrication of a labyrinth ring for MP9901A.

Location: CPP

Ring material: Aluminum

3- Machining of distorted electric motor shaft.

Capacity: 9.3kw

Reason: worn out key way

4- Enlargement of a key way of a half sprocket.

Initial ID: 95mm

Required ID: 95.05mm

5- Creation of a key way slot on a love joy coupling.

Model: L-095

Dimension: 25 X 6 X 3.5

*All dimensions in mm.

6- Fabrication of Yoke nut for 33FV59

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 Location: Ammonia II

Equipment: Gate valve (10" X 300mm)

NDT

1- RE-vibration readings on BFW multistage centrifugal pump at captive power plant.

Reason: condition monitoring after maintenance.

2- Vibration checks/readings on urea dust solution pump (Centrifugal) at Bagging section.

Reason: Excessive vibration cause by damage coupling connection both pump and motor.

3- Physical inspection and Die Penetrant Test (DPT) on welding point of Heat Exchanger
(second intercoolers E-3432 A/B) for synthesis gas/recirculating compressor at
compressor section of Ammonia II plant.
Reason: check for point cracks on welding point and tubes for plugging.

4- Tube thickness test on Heat Recovery Unit (HRU) burners chamber around the steam
drum of GTG-II at CPP.
Reason: leakage from tube at HRU.

5- Vibration checks on Excess condensate pump (centrifugal) at Ammonia II and Semi-lean

solution pump at Co2 removal and methanation section of Ammonia I.
Reason: Condition Monitoring.

6- Physical inspection and Vibration checks on mini Effluent treatment plant at boundary
wall.
Reason: conditions monitoring before maintenance.

UREA I

1- Overhauling of a two-stage centrifugal pump

Problem: Failure of pump as a result of contact between the impeller and inter-stage
casing.
2- Construction of washer to be used as parking between the impeller and the inter-stage
casing.
Blue matching technique was used to verify that the impeller is not in contact with the
inter-stage casing.
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3- Mechanical seal assembly
Assembling of centrifugal pump (21 MP 3B)
Leakage testing along the mechanical seal by sending water through the quenching water
line at suction pressure.
4- Alignment was done on pump (21 MP 3B) using dial gauge.
Impeller balancing at mechanical general workshop

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 DFL ELECTRICAL ENGINEERING TRAINEES REPORT

NFL VIJAIPUR INDIA

WEEK: THIRTEEN (15TH – 20TH of April 2019)

PLANT SESSION: AMMONIA I&II

GROUP MEMBERS: IDUH OBOKPARO LEWIS

SHAMSUDEEN SULAIMAN ABUBAKAR

ACTIVITIES CARRIED OUT WITHIN THE WEEK.

We participated in the ongoing three (3) weeks training on Load Management System (LMS)
and Programmable Logic Controllers (PLC) - delivered by Energy Ventures (A System
Integrator of Rockwell Automation) to NFL Electrical first line Supervisors/Engineers.

TOPICS LEARNT
1. Introduction to Load Management System.
2. How to Program Ladder Logic using RSlogix 5000 Programming Software for Allen
Bradley ControlLogix 5573 PLC.
3. Introduction to SCADA software (Factory Talkview Studio) used for LMS Human
Machine Interface.
4. Introduction to RS Linx Classic Software used for communication between PLC and
SCADA.
5. Components of PLC and Hardware wiring of LMS – Block diagram
Introduction to Load Management System (LMS).
NFL plant has a running load of average 32 MW. For this, at a time two gas turbine generators
run which have a capacity of 17.225 MW each. In case if any one of the GTG gets trip due to
any reason the total load comes on the other generator running in parallel. Due to sudden load
throw on the GTG it gets highly overloaded and then trips on under frequency which may cause
blackout condition. To prevent this blackout condition, we have LMS.
LMS has a load shedding program (interruption of electrical supply to reduce excessive load on
generator) which operates when

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 • A single generator is running and it is overloaded.
• Two generators running in parallel and both are overloaded.
• Two generators running in parallel and one generator get tripped.
LMS sheds the load according to the priorities decided (A total of eight priorities) keeping the
running healthy generator within its safe limits of operation. Below are the eight (8) priorities.

LOAD
PRIORITY MERGE FEEDERS TO BE TRIPPED THROUGH LMS
RELIEF
UREA-1 COOLING TOWER
P2 23.50 11.275
08 MP-01 C, NEW 08 MP-01 D [500 KW]
AMMONIA-1 COOLING TOWER
MP 1801 A
P3 25.30 12.575
(Only pulse command is generated to trip the motor. Hence after load shedding
motor is ready to run)
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 UREA-2 (31-STREAM)
P4 27.00 13.780
31 MP-01 A/B, 31 MP-02 A/ B, 31 MP-01 C (230 KW)
UREA-2 COOLING TOWER
NEW MP-4801 B MOTOR [1450 KW]
P5 27.70 CPP 15.230
HRU-1,2,3 FD FAN BLOCKING
(SGFM-101 , SGFM-201, MK-9901)
UREA-2 (41-STREAM)
P6 29.00 41 MP-01 A/B, 41 MP-02 A/ B, 31 MP-14 A/B 16.435
41 MP-01 C (230 KW)
UREA-2 COOLING TOWER
P7 30.50 MP-4801 C 17.935
MK-4801 A, MK-4801 B, MK-4801 D, MK-4801 E
A After P7 priority following additional load to be shedded :
If GTG-1 /2 tripped then PM-002 B
If GTG-3 tripped then MP-9901 A / B
P7 Extended IAC-1 , MP-1601 C
MP-1302 A/B, MP-1301 D, MP-1307 A, MP-1301 B and MP-1307 B,
MP-1301C & MP-1307 C

Practical topics learnt on Ladder Logic Programming using RSlogix 5000 Programming
Software for Allen Bradley ControlLogix PLC.
Ladder logic functions - such as input symbols (XIC & XIO), Output symbols (Output enable,
output latched, Output unlatched), OR gate, AND, NOR, NAND, XOR and XNOR gates, On
delay timer, Off delay Timer, Counter Up, Counter Down, Equal block, Greater than or equal to,
Less than or equal to, Limit block .etc.

Practical topics learnt on SCADA software (Factory Talkview Studio) used for LMS
Human Machine Interface.
Topics learnt are Project creation in SCADA, How to create new display, what is Tag name,
what is HMI tag, Animation, Alarm, Communication between PLC and SCADA and Trend.

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Fig 1: Wiring of Input/Output panel of LMS.

31
 DFL INSTRUMENTATION ENGINEERING TRAINEES REPORT

NFL VIJAIPUR INDIA

WEEK: THIRTEEN (15TH – 20TH of April 2019)

PLANT SESSION: AMMONIA II (INSTRUMENTATION)

GROUP MEMBER: OGUN Nduka Clifford

The following stated below were done during the week In Ammonia II

DIFFERENTIAL PRESSURE TRANSMITTERS

It works on the principle of differential capacitance. Here, the sensing element is a taut metal
diaphragm located equidistant between two stationary metal surfaces, comprising three plates for
a complementary pair of capacitors. An electrically insulating fill fluid (usually a liquid silicone
compound) transfers motion from the isolating diaphragms to the sensing diaphragm, and also
doubles as an effective dielectric for the two capacitors:

32
Any difference of pressure across the cell causes the diaphragm to flex in the direction of least
pressure. The sensing diaphragm is a precision-manufactured spring element, meaning that its
displacement is a predictable function of applied force. The applied force in this case can only be
a function of differential pressure acting against the surface area of the diaphragm in accordance
with the standard force-pressure-area equation F = PA.

In this case, we have two forces caused by two fluid pressures working against each other, so our
force-pressure-area equation may be rewritten to describe resultant force as a function of
differential pressure (P1 − P2) and diaphragm area: F = (P1 − P2)A. Since diaphragm area is
constant, and force is predictably related to diaphragm displacement, all we need now in order to
infer differential pressure is to accurately measure displacement of the diaphragm.

The diaphragm’s secondary function as one plate of two capacitors provides a convenient
method for measuring displacement. Since capacitance between conductors is inversely
proportional to the distance separating them, capacitance on the low-pressure side will increase
while capacitance on the high-pressure side will decrease:

A capacitance detector circuit connected to this cell uses a high-frequency AC excitation signal
to measure the difference in capacitance between the two halves, translating that into a DC signal
which ultimately becomes the signal output by the instrument representing pressure.

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These pressure sensors are highly accurate, stable, and rugged. An interesting feature of this
design – using two isolating diaphragms to transfer process fluid pressure to a single sensing
diaphragm through an internal “fill fluid” – is that the solid frame bounds the motion of the two
isolating diaphragms such that neither one is able to force the sensing diaphragm past its elastic
limit.

As the illustration shows, the higher-pressure isolating diaphragm gets pushed toward the metal
frame, transferring its motion to the sensing diaphragm via the fill fluid. If too much pressure is
applied to that side, the isolating diaphragm will merely “flatten” against the solid frame of the
capsule and stop moving. This positively limits the isolating diaphragm’s motion so that it
cannot possibly exert any more force on the sensing diaphragm, even if additional process fluid
pressure is applied. This use of isolating diaphragms and fill fluid to transfer motion to the
sensing diaphragm, employed in other styles of differential pressure sensor as well, gives modern
differential pressure instruments excellent resistance to over-pressure damage.

It should be noted that the use of a liquid fill fluid is key to this overpressure-resistant design. In
order for the sensing diaphragm to accurately translate applied pressure into a proportional
capacitance, it must not contact the conductive metal frame surrounding it. In order for any
diaphragm to be protected against overpressure, however, it must contact a solid backstop to
limit further travel. Thus, the need for non-contact (capacitance) and for contact (overpressure
protection) are mutually exclusive, making it nearly impossible to perform both functions with a
single sensing diaphragm. Using fill fluid to transfer pressure from isolating diaphragms to the
sensing diaphragm allows us to separate the function of capacitive measurement (sensing
diaphragm) from the function of overpressure protection (isolation diaphragms) so that each
diaphragm may be optimized for a separate purpose.

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2. ROSEMOUNT MODEL 3051 DIFFERENTIAL PRESSURE TRANSMITTER: This is a
more modern realization of the differential capacitance pressure-sensing principle.

As is the case with all differential pressure devices, this instrument has two ports through which
fluid pressure may be applied to the sensor. The sensor, in turn, responds only to the difference
in pressure between the ports.

The differential capacitance sensor construction is more complex in this particular pressure
instrument, with the plane of the sensing diaphragm perpendicular to the plane of the two
isolating diaphragms. This “coplanar” design is more compact than the older style of sensor, and
more importantly it isolates the sensing diaphragm from flange bolt stress.

35
Note how the sensor assembly is not embedded in the solid metal frame. Instead, the sensor
assembly is relatively isolated from the frame, connected only by two capillary tubes joining it to
the isolating diaphragms. This way, stresses inside the metal frame imparted by flange bolts have
virtually no effect on the sensor.

36