1.

1 PREFACE

This operating manual is prepared as the guidline for Operating Urea at NFL, Panipat unit.
The operating instructions should be read, keeping in view that it is almost impossible for
any instruction to cover every thing in all possible operating conditions.
Therefore, it is of great importance that the Operator should have a full understanding
with functions, systems and layout of Plant equipment to cope up with each and every
sitution.
It should be also taken into conalderation that methods, data and operating conditions
described in this instruction may well have a necessity to be appropriately amended under
abnormal operating conditions or emergency situation.

1.2 GENERAL DESCRIPTION OF UREA

Urea was first synthesised by Wohler in 1828 heating ammonium cyanate (NH4CNO).
Previously Urea was separated from urine and experiment by by Wohler showed that an
inorganic compound like ammonium cyante. This synthesis of urea in 1828 marked the
beginning of synthesis of organic compounds.
In 1870 Bassarao produced urea by dehydrating ammonium carbamate which is the basic
of all commercial production of urea today. In 1920 I.O. Farben first produced urea
commercially in a plant in Germany based in ammonium carbamate process. Since then
considerable modifications have been done to overcome various process difficulties such
as carrosion problems, recovery of off-gases, improvement of economics and energy
conservation.
Today, all commercial urea processes are based in synthesis of Ammonia and carbon di-
oxide with subsequent dehydration of carbamate to Urea, Ammonia and carbon-dioxide
are usually available on same site, since carbon dioxide is a by product at ammonia
synthesia from hydrocarbons.
1.3 DESIGN BASIS OF UREA PLANT:
CLINATIC CONDITIONS
a) Air temperature
Max. dry bulb temp. 46.40C
Min. dry bulb temp. -20C
Design dry bulb temp.390C
Design wet bulb temp. 280C

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b) Air humidity
Max. relative humidity 81% at 31oC
c) Baromatric pressure 971 milibar
d) Rainfall Max. 50 mm/Hr
RAW MATERIAL AND UTILITIES
a) Liquid Ammonia
Ammonia 99.9% by wt.min
Noisture 0.1% by wt.max.
Press. 18 kg/Cm 2g
Temp. 110C
b) Cassous Carbon dioxide
CO2 (dry basis) 98% by volume min.
Thert gas (dry basis) 2% by volume max.
Total sunphur 1.0 ppm by vol.
as H2S max.
Press. 0.1 kg/cm2G
Temp. 320C
c) High pressure Steam
Press. 40 kg/cm2G
Temp. 3700C
d) Cooling Water in circulation
Main Part (CT-2) CT-3 (CY part)
Press (received) 5.0 kg/cm2G 3.0 kg/cm
Temp. (received) 330C 330C
Press. (returned) 3.0kg/cm2G Atm.
Temp. (returned) 420C 420C
e) Normal electric power
Type A.C.3 Phase, 3 wire
Voltage 11 kv
Voltage fluctuation within 1.5% of 11kv
Frequency 50 Hz

Frequency fluctuation within 1.5% of 50 HZ

f) Emergency power
Type A.C.3 Phase 4 wire
Voltage 415 V/240 V
Frequency 50 Hz
g) Instrument Air
Dust Nil
Oil Nil
Dew point -150C at 7 kg/cm2G
Press. 7 Kg/cm2 G
Temp. Min. 00C
Max. 450C
1.4 PLANT PERFORMANCE
a) PRODUCTION CAPACITY
The plant is guaranteed to have a production capacity of 1550 MT of uncoated prilled urea per
stream day of 24 hours.
b) PRODUCT QUALITY
The product urea is guaranteed to have the following average quality on condition that plant runs
on full capacity.
Nitrogen 46.3% by wt.min
Moisture 0.3% by wt, Max.
Biuret 0.35% by wt. max.
Prill size (S-20 Tyler 95% by wt.min Mesh)
c) DEGIGN CONSUMPTION OF RAW MATERIALS AND UTILITIES
On condition that plant runs on full capacity, following are the consumption figures of raw
materials and utilities.
Liquid ammonis (100% NH3 basis) 0.58 MT/ten of Urea
Carbon dioxide (100% CO2 basis) 0.76 MT/ -do-
*1 Steam (39.7 kg/cm2C, 3700C) 1.45 MT/ -do-
Cooling Water in circulation 1.45 MT/ -do-
*2 Electric Power 86.4 KWH/ -do-
Note: *1 Including steam tracing but excluding space heating.
*2 Excluding requirement for electrical lighting you and cooling tower pumps
and cooling pumps and fans etc.
DESIRED CONSUPTION FIGRURES
The following are the desired consumption figrures for raw materials and utilities on 100% plant load:
Liquid Ammonia 0.575 MT/MT of urea
Carbon dioxide 0.725 -do-
*1 Steam (39.7 kg/cm2G 1.15 -do-
370 0co
Cooling water in 1.33 -do-
circulation
Condensate return 0.69 -do-
*2 Electric Power 74.00 -do-
1.5 OPERATING CAUTIONS
The following rules should be carefully followed as neglect of these may result in damage to
personnel/and or equipment. However, attention should be paid to that these rules may not cover all the
necessary iteme for safe operation of urea Plant.
1. Always observe start-up and safe operating precations for pumps and compressure as regular safelly.
2. Always ensure that steam is flowing through jacket tracing of sagety valve etc.
3. Never run a pump dry. Always keep suction strainer clean and maintain sufficient level in the
equipment concarned to pump suction.
4. Never stand directly racing safety valves, rupture disc, sight glass sampling valves etc.
5. Isolation valves of safety valves are in open conditions.
6. Do not allow water containing solid contaminants in system as otherwise they will damage valves &
pumps.
7. Do not pull vaccum on equipment unless it is design to withstand such a stress set up under such
conditions.
8. Switch pump regularly when spares are available. This will ensure that spares will be ready when
needed.
9. Operating equipments should be checked frequently for any leakage, overheating, corrosion
etc. so that corrective measures may be taken before these result in any serious damage to
personnal and or equipment. Unusual conditions should be reported immediately.
10. Never disassemble any equipment or piping unless it is sure that no harmful subatanes such
as ammonia etc. is present and it is depressurised.
11. Without a work permit (Class-I) no hor work should be allowed. All conditions should be
properly kept to seal off leakage of any inflamable material.
12. Always flush with water and or steam whenever flow of urea solution or carbamate solution
is interrupted.
13. Before starting operation check as to wheater all the safety equipments are functioning
properly.
14. Never allow water containing more than 50 ppm or chlorine ion to come in cantact of
stainless steel either ‘
inside or outside equipment.
15. Check that all the bleed valves are in open condition.
SECTION II- PROCESS DESCRIPTION
2.1 GENERAL
The Plant is designed to produce 511500 MT of urea per annum @ 1550 MT/day based on 330
on steam days in a single stream using total recycle ‘ C’Improved process. The process is
characterised by easy operation coat and high product quality. The urea plant can be divided into
four sections, namely Synthesis, Decomposition, Recovery and Crystalization & Prilling Section.
2.2 SYNTHESIS SECTION
Synthesis of urea incolves two steps. First gaseous CO2 reacts with ammonia to form an
intermediate product-Ammonia Carbamate. This reaction is highly exothermic and completes
immediately. Second step invalves dehydration of ammonium carbamateo urea and is
endothermic reaction. On the overall synthesis of urea is exothermic in nature.
2NH3 + CO2 NH 2COONH4 + 37.64 K. Cal.
(L) (g)
NH 2 COONH 4 NH 2 CONH 2 + H 2O - 6.32 K Cal.
The reactions are reveraible. The principal variables affecting the reaction rate are
temparature, pressure, feed composition and reaction time.
The converation of ammonium carbamate to urea takes place in lquid phase only, so high
pressure is required. High temparature and pressure inoreases the reaction rate. The
conversion to urea is decreased by the pressure of water 2000C, 250 Kg/cm2g pressure
and NH 3, CO2 moleratle of 3:7:1 by this process.
Urea synthesis is achived in a vertical vassel called Reactor, which has sufficient volume
to allow synthesis reaction to approach equilibrum conditions closely. Conversion of
about 72% on CO2 basis is achived in the reactor.
Residence time in Reactor is 25 minutes at design through put. Due to corrosive nature of
reactants and reaction products, anti-corroalive linings are provided inside the reactor
which is titanium in this case. To some extent, the reactants are also corrosive to titenium
but an addition of small amount of oxygen tends to possivate titanium so that a
satisfactory service lire is obtained. High temparature leads to high corrosion in reactor
and Since the overall reactor of ammounts and carbondiaxide is exothermic, care must be
taken to control the temperature in Urea synthesis reactor. In case of this plant it is
achived by combination of following factors.
1. Excess of Ammonia to Reactor
2. Recycle solution rate to Reactor
3. Preheat temperature of ammonia to reactor
2.3 DECOMPOSITION SECTION
The reaction product from reactor consists or Urea, ammonium carbamats, water and
excess ammonia. Subsequent processing is required to separate Urea from these products.
In general, the processing is none by application of heat at redused pressure levels to
remove carbamate exoess ammonia and water. Carbamate is decomposed to ammonia and
carbon dioxide gases.
NH 2COOMH 4 = 2 NH2 + CO2
Decomposition takes place at temparatures 1200C to 165OC depending on pressure.
During decompasition, hydrolysis of urea also takes place to make ammonia and carbon
dioxide.
NH 2CONH2 + H2O = 2NH3 + CO2
Since hydrolysis consume urea which is a desired product so steps must be taken to
control this reaction. Hydrolysis is favoured by high temprature low pressure and long
residence time.
Decomposition equipment and conditions of operations are therefore carefully selected to
avoid these factors to maintain high yield of urea.
Biuret formation is another factor in decomposition and finishing stages since at
temparature above 200C and low pressures, urea converte to form
2NH2CONH 2 NH2CoNHCONH 2 + NH 3
(Urea) (Bluret)
The reactions are reversible and is favoured by high temprature, low pressure and an
atmosphere having less ammounts. These conditions are existing in finishing stages and
so bluret formation rate is rapid there. Whereas in the synthesis loop, the axocess
ammonia and high pressure keeps the bluret content low.
Low bluret content to the extent of 1.0% is recommended for fartiliser grade. This is
partioniarly important in case of foliar spray of fertilizers, where high bluret aontent of
fertilizer may damage the crop. By careful design and process control of processing steps
the bluret content is kept less then 0.35% by wt. in this plant.
Three decomposition steps, from 17.5 kg/cm2G to 2.5 kg/cm2 to atmospheric pressure
are used to remove carbamate and excess ammonia completely from urea solution before
it flows to crystallizar.
Some amount of air is blown at the bottom of gas separate to atrip the residual amount if
any in the solution. The concentration of urea solution entering in Crystallizar is about
74% by wt.
2.4 RECOVERY SECTION
The basic difference between various urea processes lies in the method of handling
unreacted amonia and carbon diaoxide from decomposers. It is not practical to compress
NH3-CO2 mixture and return to reactor as compression causes recombination of
ammonia and carbon dioxide to form solid carbonate and result is clogging in compressor.
The methods for recycling these gases may be classified into two steps.
1. Separate and recycle as gases.
2. Recycle in solution or slurry form.
In this process, the solution recycle process is used. The NH3=CO2 gas mixture from
decompressor is absorbed in water and urea solution and recycle to reactor.
The excess ammonia is purified in High Pressure Abaorbef and recycle to reactor through
Ammonia Condensers, Recovery Ammonia Reservoir, Ammonia feed pumps and Amm.
preheaters.
2.5 CRYSTALLIZATION & PRILLING SECTION
The urea water solution leaving gas separator is vaccum concentrated and crystallised in
Crystallizer and urea crystals are separated by centrifuge. To use efficiently the heat of
crystallization and to evaporate water at low temperature vaccum crystallization is used.
Crystals containig 2% moisture are removed from mother liquor in centrifuge and then dri
ed to 0.3% moisture by hot air. To keep bluret content at about 0.1% in crystal urea, a
certain amount of mother liquor containing almost all of bluret originally present, is
recycle to the recovery section as an absorbant liquid for CO2 is finally sent back to
reactor, where the bluret is converted to urea in pressure of NH2 according to following
reaction.
NH 2 CONHCONH2 + NH 3 = 2 NH 2 CONH2
Dry crystalls are conveyed are conveyed to the top of prilling tower passing through
fluidizing dryer. These crystals are metled in a specially designed steam heated melter.
The molten urea then flow through distributors and is formed into droplets and solidified
in that shape, by cooling air in prilling tower. In order to minimise bluret content the
prilling section is designed to keep residence time of molten urea to minimum.
It is also desirable to keep moisture content of prills to less than 0.2 to 0.3% by wt. in
order to produce hard prills. In this plant crystals are dried before being melted. The
prilled urea coming from bottom of tower is screened to remove oversize and is stored in
a bulk storage, called silo.
2.6 EEFECT OF PROCESS VARIABLESS IN UREA REACTOR
INTRODUCTION
Urea is produced by the highly exothermic reaction of ammonia and carbondioxide to
form ammonium carbamate with slightly endothermic dehydration of ammonium
carbamate to form urea.
2NH3 (1) + CO2 (g) NH 2 CO 2 NH 4 (_) 37.64 K. cal.
(Amm. Carbamate)
NH 2 CCOMH4 NH 2 CONH 2 + H2O (+) 6.32 K.cal.
(Urea)
Overall reaction is exothermic. First reaction is instantaneous and goes to completion.
Second reaction is slow and progresses slowly through the reactor and determines
equilibrum conversion of urea in the reactor.
Although overall reaction is exothermic and lower temprature will increase equilibrum
conversion but for higher rate constant temparature has to be kept 185-200 oC.
There are several process variables in Urea Plant which effect conversion/yield of urea,
energy consumption and recovery cost of unconverted carbamate. All these process
variables are dependent on each other, and for best result these have to be optimised.
These process variables are:
1. Operating pressure of urea reactor.
2. Operating temparature in Urea reactor.
3. NH3/CO2 mole ratio.
4. H 2O/CO2 mole ratio.
All these variables and their impact on plant operation is given below:
1. REACTOR PRESSURE
As seen from the reaction (1) & (2) equillibrim conversion increases with reactor pressure.
Equilibrim pressure is fixed by the conditions such as temperature mole ration of
ammonia to CO2 and H2O to CO2. Change in equilibrium pressure due to excess
ammonia and temprature, when the total ration of H2O to CO2 is sure is given by
P = E a + b +1 * 10(c/T+d)
t
when P = Equilibrium Pressure
E = Excess Ammonia ratio
T= Absolute temparature
abod ara: Conversion Coefficients
Figure (1) gives equilibrium pressure as a function of temp. and NH3/CO2 mole ratio.
When mole ratio of H2O to CO2 is not zero, it may be considered that the value of
equillibrium press, is possibly smaller than that in case of H20/CO2 is zero.Objective is
to achieve maximum conversion in the reactor to reduce recycle. load. 10%
decrease in conversion increase recycle load by 50%. Merits & demirites of
operating at high pressure are as under:
ADVA NTAGES
i) High equilibrium conversion in reactor.
ii) Less recycle of carbamate.
DISADVANTAGES
i) Severe service conditions of ammonia and carbamate pumps.
ii) Motor power is required for feeding ammonia. CO2 and carbamate to reactor.
iii) For every high pressure centrifugal compressor are not available especially for
medium capacity plants.
2. TEMPERA TURE
The temperature increases conversion of urea in the reactor upto 200°C and
then decreases rapidly. Equilibrium constant in the urea reactor is
governed by following reactions:
Carbamate (soln) K1............ 2 NH3(soln)+ CO2(soln)
Carbamate (soln) K2............ Urea(soln)+H2O(soln)
Eqiulibrium conversion to urea depends on the balance between equation(1) and
(2) (see figure 2)
If the dissociation equilibrium constant K1 varies more than K2 the equilibrium
constant K will be governed by K1 above a certain temperature as a result there
appears a maximum conversion as given in figure-3. At temperature higher than
the point where the maximum conversion is achieved carbamate instead of
hydrolysing into urea starts decomposing into ammonia and CO2. Hence the
operating temperature has to be optimised. Figure-4 gives the effect of
temperature and H2O/CO2 ratio on equilibrium conversion. Normal operating
temperature chosen for max. Conversion in urea reactor are between 185-300°C
(see figure-4)/ depending upon reactor pressure.Operating at high temperature
increases the corrosion rate if reactor liner and hence special liner is required for
high temperature operation.
3. NH3/CO2 MOLE RATIO
A high NH3/CO2 mole ration results in high conversion of CO2 in urea hence
reactor effluent will contain less unconverted CO2. This results in low heat
demand in decomposition section because less ammonium carbamate needs to
decomposed and vaporized. This is more than off set as higher NH3/CO2 results
in excess NH3 for which of evaporation is rather higher. Excess feed to reactor
thus increases energy cost in recovery section. A higher NH3/CO2 mole ratio
requires a higher reactor pressure for same equilibrium conversion (see fig.1).
Hence ammonia CO2 ratio has to be optimised. It varies from 2.8 to 4.0
depending upon the process design. Advantages and disadvantages of operating
at higher ammonia/CO2 mole ratio are:
ADVA NTAGES
1. Higher equilibrium conversion.
2. Less recycle solution due to higher conversion.
3. Less water in recycle.
4. Less corrosion.
5. Less biuret formation in reactor.
DISADVANTAGES
1. Poerating press. has to be kept higher.
2. More heat required in recovery section as heat of vaporisition of excess
ammonia is very high, which increases energy consumption in recovery section.
4. H2O/CO2 MOLE RA TIO
Decrease of H2O CO2 mole ratio increases conversion on the reactor(figure-4).
Hence it is better to have as less water recycle to reactor as possible. Since
unconverted carbamate is recycled back to reactor as solution, water recycle
cannot be avoided totally efforts are made for minimum H2O/CO2 in reactor.
Couter current flow in decomposers reduces water recycle. H2O/CO2 recycle
depends upon plant design. Normal value of H2O/CO2 designed are 0.4-0.6.
Modern plants use HP decomposition with either NH4 or CO2 stripping to reduce
water recycle to the reactor.
SECTION III- LIST OF EQUIPMENT & THEIR SPECIFICA TIONS
3.1 LIST OF UREA PLANT EQUIPMENTS
a) SYNTHESIS SECTION
U-DA 101 : Methanol Absorber
U-DC 101 : Urea synthesis reactor
U-ES 101 : No. 1 Liq. NH3 preheater
U-EA 102 : No. 2 Liq. NH3 preheater
U-EA 103 : Condensate cooler
U-EA 104 : Surface condenser for U-GB
101 T
U-FA 101 : Steam condensate tank
U-FA 102 : Flash drum
U0GA 101 A-D : Liquid ammonia feed pump
U-GA B102 A-B : Recycle solution feed pump
U-GA 103 A-B : High pressure flooding pump
U-GA 104 : Low pressure flooding pump
U-GA 105 A-B : Steam condensate pump
U-GB 101 : CO2 Booster compressor
U-GB 102 : CO2 compresser
U-GT 101 : Steam turbine for U-GB 101
U-GT 102 A-B : Steam turbine for U-GA 102
A,B
U-JC 101 : Hoist for reactor
U-JE 101 : Crane for Machinery room
U-JE 102 A,B : Crane for pumps
b) DECOMPOSITION & CRYSTALLIZA TION SECTION
U-DA 201 : High pressure decomposer
U-DA 202 : Low pressure decomposer
U-DA 203 : Gas separator
U-EA 201 : Reboiler for U-DA 201
U-EA 202 : Reboiler for U-DA 202
U-EA 203 : Heat exchange for U-DA 202
U-EE 201 : Vaccum generator
(Barometric condenser)
U-FA 201 : Cryatallization
U-FA 202 : Hot water tank
U-FA 203 : mOTHER LIQUOR TANK
U-GA 201 A,B : Circulation pump for crystallization
U-GA 202 A,B : Slurry food pump
U-GA 203 A,B : Mother liquor pump
U-GA 204 A,B : Hot water pump
U-GA 205 A,B : Urea solution pump
U-GB 201 : Air compressure
U-GF 201 A-E : Centrifuge
U-JC 201 : Hoist for centrifuge
c) PRILLING SECTION
U-EA 301 : Melter
U-EC 301 : Air heater for dryer
U-FA 301 : Head tank
U-FA 302 : Dissolving tank for stainer
U-FA 303 : Washing tank for stainer
U-FA 304 : Cleaner for distributor
U-FA 305 : C.F.D. Wash tank
U-FC 301 : Cyclone
U-FD 301 : Stainer
U-FD 302 : Filter cooler
U-FD 303 : Trommel
U-FD 304 : Dust Separates
U-FD 305 : Fliter for prilling tower
U-FF 301 : Fluidzing Dryer
U-BA 301 A,B : Water pump for prilling tower
U-GA 302 A,B : Circulation pump for Prl. tower
U-GA 303 A : Dissolving tank pump
U-GA 304 : Wash Tank pump
U-GB 301 : Forced fan for dryer
U-GB 302 : Induced fan for dryer
U-GB 303 : Blower for fluidizing cooler
U-GB 304 A-D : Induced fan for prill. tower
U-IA 301 : Prilling tower
U-JC 301 : Elevator for operator
U-JD 301 A,B : Screw Conveyor to melter
U-JD 302 : Weighing Conveyor
U-JD 303 : Belt conveyor to trammel
U-PF 301 A,L : Distributor
U-PF 302 : Dust chamber
U-PF 303 : Spray nozzle for
U-FD 305
d) RECOVERY SECTION
U-DA 401 : High pressure absorber
U-DA 402 : Off gas absorber
U-EA 401 : High pressure absorber
cooler
U-EA 402 : Low pressure absorber
U-EA 403 : Purge ammonia condenser
U-EA 404 A-E : Ammonia condenser
U-EA 405 1-4 : Ammonia Recovery reservoir
U-EA 406 : Off gas condenser
U-EA 407 : Off gas final cooler
U-EA 408 : Cooler for U-DA 402
U-FA 401 : Recovery ammonia reservoir
U-FA 402 A,B : Ammonium carbamate
soln. tank
U-FA 403 : Off gas absorber tank
U-FA 404 : Gas releaser
U-GA 404 A-B : Low pressure absorbent pump
U-GA 402 A-B : High pressure absorbent pump
U-GA 403 A-B : Recycle solution booster pump
U-GA 404 A-B : Ammonia boost up pump
U-GA 405 A-B : Aqua Ammonia pump
U-GA 406 A-B : Water pump
U-GA 407 A-B : Ammonia carbonate Soln. pump
U-GA 408 A-B : Off gas absorbent pump
U-GA 409 A-B Circulation pump for U-DA 402
U-GB 401 : Off gas recycle blower
SPECIFICATIONS OF EQUIPMENTS
SPECIFICATION OF PUMPS
Specification Pump No.
GA 101 102 103 104 105 201 202
Service Liq. NH Carb. Steam Condensate Urea slurry
Pumpino Temp°C 30 100 60
Sp. Gravoty 0.59 1.15 1 1 1 1.2
Vap. Press kg/cm²G 12 0.3 0.1
Viscosity (cp) 0.22 0.4 2.0
Capicity M³h normal 48.3 0.2 30 79 1086 237
Design 53.2 81 0.23 285
Minimum 35 20

Pressure (kg/cm²G) Discharge

260 260 400 2.4
Suction 21.5 24 0 Atm. Atm. Atm. Atm.
Shut off 22.5
Head MLC 214 60 8 20
NPSH Avoid (M) 15 3 4.5
Required 9 14 2.8
Efficiency % 89 66 66 73.8
R.P.M. 178 6450 161 2900 2930 970 1450
BHP KW 34.2

Direction of Rotation
Motor CW CW
Make Uraca Ebara Mastsu KSB Toris KSB
DRA-HPM HIMA .
Lube Oil T.O. T.O. S.S. S.S. T.O. S.S.
11 17 317 317 17 317
Motor KW 450 5.6 55 37
H.P. 50 50 75 50
Voltage 3.3 KV 415 415 415 415 415
Amp. 95 10.9 62 97 65
R.P.M. 1485 1440 2950 2940 980 1470

__________________________________________________________________
Specification Pump No.
GA203 204 205 301 302 303 401 402
Service M.L. H.W. Urea Water Urea Urea Carb. Carb.
Soln. Soln. .
Pump Temp.°C 60 40 45
Sp. Gravity 1.2 1.18 1.0 1.15 1.1 1.0 1.15
Vap Pressure
Kg/cm²G 0.1 0.1 1.4
Viscocity (CP) 15 1.1 1.0
Capicity M3/h
Normal 145 374 102 16 618 10 8 25.1
Design 174 680 30
Minimum 175 .
Pressure (kg/cm²G)
Discharge 4.5 20
Suction 0.1 2.2
Shut off .
Head MLC 25 32 13 70 40 10 40 155
NPSH Avoid
(M) 755 4 3
Required 3.7 2.7
Efficiency % 68 76 72.5 43 78.2 47 37 23.2
R.P.M. 1470 1470 2440 2900 1480 1400 2860 2900
BHP on KW 58 HP 9.65 HP 63.2

Direction of facing motor

Make KSB KSB KSB KSB DENGY KSB KSB DENGY
YOSHA YOSHA
Lube oil SS SS SS SS SS SS
317 317 317 317 T-11 317 317 T-11
Motor KW 55 125 1.5 3.7 45
H.P. 50 75 7.5 1550 170 2 5 60
Voltage 415 415 415 415 415 415 415 415
Amp. 64 95 10.7 21 210 3.4 70 75
RPM 1470 1470 1450 2900 1485 1400 2860 2950

.
Specification Pump No.
GA 403 404 405 406 407 408 409
Service Carb. Liq.nh3 Aq. NH3 NH3 Carba-
Mate Solution
Pump Temp.°C 100 30 37 45
Sp. Gravity 1.15 0.59 0.72 1.0 1.0 1
Vap. Pressure
KG/CM²G 16 12 11.5 0.15
Viscocity (CP) 1 0.22 0.2 1
Capicity M³/h
Normal 81 184 6 15 10 5.5 112
Design 89 202 7.2 135
Minimum 10 25 2 10
Pressure (kg/cm²G)
Discharge 20 22.5 18.5 2
Suction 17 16.6 16 0
Shut off 91 M 110M 36.5 24
Head MLC 70 102 35 350 10 20 20
NPSH Avoid (M) 3.5 15 5 3
Required 3.0 2.9 1.5 2.7
Efficiency % 71 76 35.6 47 27.5 61.3
R.P.M. 2900 2900 2900 2950 1400 1400 1450
BHP on KW 27.6 43.6 1.6 12

Directo of facing motor

__________________________________________________________________
Make Dengy Osha KSB KSB KSB KSB KSB KSB
Lube oil T-11 SS SS SS SS SS SS
317 317 317 317 317 317
Motor KW 37 55 3.7 45 1.5 2.2 15
H.P. 50 75 5.0 60 2 3.0 20
Voltage 415 415 415 415 415 415 415
Amp. 62 93 7.0 75 3.4 4.6 20
R.P.M. 2950 2965 2860 2950 1400 1420 1460
__________________________________________________________________

(15)
LIQUID AMMONIA FEED PUMP (GA 101 A-D)
1. INTRODUCTION
Liquid ammonia feed pumps feeds Ammonia to Rector (DC-101). Liquid ammonia from
reservoir (FA-401) is pumpted by GA-404 A/B to the suction of liquid ammonia feed
pump.
2. SPECIFICATION
2.1 Liquid ammonia 99.9 wt/mm viscocity 0.22 CP
H2O 0.10 % wt/max
Oil
2.2 Pump Specification
2.2.1 MANUFACTURER TYPES UREA HORIZONTAL
Capicity 48.3m³/hr. 2m³/hr (max desgn)
Suction pressure 21.5 kg/cm²G
Discharge pressure 260.0 kg/cm²G
Differential pressure 238.5 kg/cm²G
N.P.S.H. available 15.0 M
N.P.S.H. minimum 9.0 M
Speed 178 rpm
Efficiency 89 %
Plungers Three
Valve Type Plate
2.2.2 MOTOR MANUFACTURER CROMPTON GRENVAS
Rated output 450 KW
No. of poles 4
R.P.M. 1480
Phase Three
Cycle 50Hz
Volts 3300 V
Gear Ratio 83 %
2.2.3 LUBE OIL PUMP TYPE GEAR PUMP
Capicity 2.4 m³/hr
Discharge pressure 6-8 kg/cm²G
Motor 2.2 KW
R.P.M. 1400
2.2.4 LUBE OIL COOLER SHELLSIDE
Heat duty 4900 K.cal.hr
Surface area 0.8 m²
2.2.5 TUBE SIDE COOLING WATER
Temperature 55°C
Pressure 5.0 kg/cm²
2.2.6 LUBE OIL FILTER & LOWRESERVOIR
Design pressure 10 kg/cm²G
(16)

Filter size 63
 Pressure Drop (DP) 0.7-4.0 kg/cm²
Capacity 300 litre
Internal coating Rasin Paint
2.2.7 HIGH PRESSURE
LUBRICANTION (SEAL OIL) TYPE
Capacity 0.06 m³/hr
Discharge pressure 25.0 kg/cm²G
Speed 360 rpm
Driven type E-motor
415 V, 50HZ, 0.75 KW
2.2.8 MATERIAL OF CONSTRUCTION
Cylinder 0.2.2
Cylinder liner WM 10
Plunger CK 35
Colmony 6 coated
VALUE PLATE & SEAT
Gland packing Braided Tekcon Asbestes
Crank shaft 42 Cr MO4 Heat Treated
Connecting rod GGG 60
2.2.9 LUBE OIL PUMP
Casing Cast iron
Internals Nitriding steel cast
Handling steel
2.2.10 LUBE OIL COOLER
Shell ST 35
Channel GG 22
Tube ST 35
Filter Cast Iron
Reservoir Carbon steel
Lube oil cooler Cooling water
Gear box oil cooler Cooling water
3. DESCRIPTION
The pump is horizontal reciprocating type supplied by M/s. URACA . The pump has
three plungers with plate type suction and discharge valve.
The pump is driven by electric motor of 1480 rpm. The power is transmitted to the
pump by gear box which reduces the speed to 178 rpm.
The gear box oil is cooled by cooling water coil. Bearings in the pump crank case are
lubricated by forced lubrication.

(17)

Lube oil system consists of a gear type oil pump, two stage reversible filters, pressure
switches, thermostat, safety valve and lube oil cooler.
 For overload protextion of crank shaft,proximity limit switch and an emplifier are
provided.
The proximity limit switch is incorporated in the cover of power and frame. If due to
cover load, the deflection of crank shaft is too strong the control device cuts out the motor
of driving pump.
To avoid ammonia leakage from plunger shafts, packing is provided in the stuffing
box. Also seal oil system is provided amd [ressure should be maintained 2 KG/cm² higher
than that of suction.
The packing are also cooled by liquid my ammonia as coolant
4. PREPARATION FOR START UP
4.1 Check oil level and oil quality in crank case, reduction gear box and high pressure
seal oil lubricator tank.
4.2 Commission oil cooler
4.2.1 Lube oil cooler
4.2.2 Reduction gear box cooler
NOTE: If oil temperature is less then 20°C do not charge cooling water.
4.3 Rotate the oil pump by hand and check for free rotation.
4.4 Start lube oil pump and high pressure seal oil pump as per S.O.P.
NOTE: pressure 5.7 kg/cm²G
Low pressure alarm (PA 1201) 4.0 kg/cm²G
Trip pressure (PA 1201) 2.5 kg/cm²G
Trip Temperature (XA 1201) 60°C kg/cm²G
4.5 Start the high pressure lubritator as per SOP and set oil flow max position in
The scale.
4.6 Check all valves of GA-101 A-D in closed position.
4.7 Confirm GA-404 A/B running normal in circulation back to FA-401,
Otherwise start GA-404 A-B as per procedure.
5. Charging of ammonia from GA-404 A/B through GA-101 A-D to FA-401
5.1 Open both by-pass valves of GA-101 A-D two valves.
5.2 Crack open the main purge valve to removed the locked air.
5.3 Confirm the purge valve on suction line is closed.
5.4 Open main suction valve of GA-101 A-D slowly and closed the purge
valve.
5.5 See that the pump is full of liquid ammonis by opening purge valve and
Release vapour.
5.6 Open all isolation valves for instruments and safety valves.
5.7 Open main discharge valves for the pump and maintain circulation
Through FCV 102 to FA 401.
5.8 Rotate the pump by hand to confirm the pump turns smoothly.
5.9 Interlock by pass switch (No. BS 16) of EMV-102 is closed.
(18)
RECYCLE SOLUTION PUMP (U-GA 102 A-B)
A. PUMP SPECIFICATION (GA-102)
Manufacturar Ebara Mfg. Co. Ltd.
Type Centrifugal type
Capacity 81m³/hr
Minimum flow 35m³/hr
Pump speed 6450 rpm(100%)
Discharge pressure 260 kg/cm²G
Suction pressure 24 kg/cm²G
Required NPSH 14m aqua at 65m³/hr
Stuffing box Mechanical seal (Ext.)
Sealing water Steam condensate 61t/m
P=3.0 kg/cm²
Handed solution Urea carbamate soln.
Temperature 100°C
SP.GR. 1.15
Lube oil:
Pressure 0.8-1.0 kg/cm²G
Capacity ( oil P) 110 1/M
Capacity (Aux. oil-P) 110 1/M
Setting point of SV 3.0kg/cm²G
Setting point of PCV 1.2kg/cm²G
Outlet temp. of oil cooler 45°C
B. TURBINE SPECIFICATION (GA-102 T)
Manufacturer Ebara Mfg.Co.Ltd.
Type Back pressure
Power 966 KW
Turbine speed 6450 rpm (100%)
Governor Woodward type. PGD SAE-40
Governor range 5875 rpm-6773 rpm
(85% to 105%)
Trip speed 7450 rpm (110%)
Suction steam pr. 40kg/cm²G
(21)
Suction steam temperature 370°C
(Max.47.5kg/cm²G 410°C)
Discharge steam pr. 12kg/cm²G
Discharge steam temperature 275°C
Lube oil T.O.11
C. SAFETY
Oil pressure low 0.5kg/cm²G Alarm
Aux.Oil p start
(19)
Oil pressure extra low 0.3kg/cm²G Trip
Oil temperature high 60°C Alarm
Oil level low 300mm
Emv-103 shut Trip
FIA-105 low 35m³/H
Sealing water pump stop Trip
Differential pressure of 2.5kg/cm² Alarm
sealing water low
Temp. (Balance line) high 120°C Trip
Pressure (Balance line) high 30kg/cm²G Trip
Both booster pump Trip
(GA-403) stop
Suction press low 20kg/cm²G Alarm
Suction press. Extra low 18kg/cm²G Trip
CO2 BOOSTER (UGB-101)
1.0 INTRODUCTION
The CO2 booster compressors supplied by BHEL multi-stage tupe horizontly split
consists of static group live casing diapharams. Bearing and seals and dynamic group
shafter impellers. The turbine rotor connected to the compressor at the end of the L.P.
casing. The Governor block is arranged on the bearing box of higher pressure side of
Turbine and a geared motor drive turning device is provided. The CO2 Booster
compressor supplies at design condition 25256 NM³/ht. of dry CO2 at a discharge
pressure of 34kg/cm³ Abs. to the reciprocating high pressure compressor GB-102.
2.0 COMPRESSOR SPECIFICATION (3 STAGES)

2.1 Compressor type 2 MCL 805 MCL 455

2.2 Gas handled Carbon dioxide
2.3 Capacity (dry) (kg/Hr.) 48982
(dry) NM³/hr. 25,256
2.4 Suction conditions Pressure kg/cm² abs.
(3 stages) 1.02, 2.76, 11.25
Temp.°C 32.0, 40.0, 41.0
Molecular wt. 43.44
CP/CV (k1) 1.20, 1.27, 1.28
Inlet volume M³/Hr. 28410, 10297, 2466.5
Compresstrility (ZI) 0.99 0.95 0.92
2.5 Discharge Conditions (s stages)
Pressure kg/cm² abs. 2.88 12.1 34.0
Temperature °C 128.0 191.0 155.0
CP/CV 1.25 1.22 1.26
Compressibility Z2 1.0 .093 0.94
Total BHP KW 4730
(20)
Speed rpm 7930
Max.Cont.Speed rpm (MCS) 8463
 Rotational Director CW viewed from turbine

3.0 CONSTRUCTION FEATURE OF COMPRESSOR

3.01 Stage I & II (I casing) 3rd (II casing)
2 MCL 805 MCL 455
3.02 Casing split Horizontal Horizontal
3.3 No. of impeller(3 stages) 2 3 5
3.4 Impeller dia 630mm 630 630 420/410
(3 stages)
3.5 Impeller Tip M/s. 8060
3.6 Critical speed – 1 st
3700-5100
nd
-2 above 120% of MCS
3.7 Max. allowable for pr 15
3.8 Suction Nozzle Size 24" 14" 14"
Rating 300LB 300LB 300LB\
3.9 Discharge Nozzle Size 16" 12" 10"
3.10 Type of Radial bearing Sleev babit lined
3.11 Type Thrust bearing Double kings bury
3.12 Type of Seal Labyrinth
3.13 Material casing (I & II) Caste Steel Carbon Steel
Impeller SS SS
Diapharagm Cast Iron SS
Shaft SS SS
Labyrinth Alloy Steel
4.0 TURBINE SPECIFICATIONS
4.1 Driven Equipment : Compressor
4.2 Type : Condensing And Extraction EK 800.2
4.3 No. of stages 1 + 7(H.P.)+11 (L.P.)
Turbine Compressor Norm
4.4 Turbine Ratio Output 5792.0 KW (MCS) 4730 KW
4.5 Speed rpm 8463 (MCS) 7930 ()
4.6 Steam rate 53300 kg/hr. (MCS) 48000 kg.hr.
4.7 Extraction flow 34,140 kg/hr
4.8 Max.continuous speed 8463 rpm
4.9 Trip speed 9309
4.10 Speed range 6045-8463
(75% to 105%)
4.11 Specified initial steam pr. 39.8kg/cm²G
4.12 Extraction pr 13.0 kg/cm²G
4.13 Extraction Pr.Temp.range 105-15kg/cm²G
(21)
4.14 Temp.in let steam 370°C
4.15 Cooling water to condenser 33°C
4.16 Exhaust hood Press. 0.9kg/cm²g Temp. 65°C
4.17 Wheel chamber press. 21.0 kg/cm²g (32.2 kg/cm²g Max.)
OPERATING DATA FOR GB-102
1. General:
This operating data is for UGB-102 (CO2 reciprocating Compressor) At a suction press.
Of 29.5 kg/cm²G, the capacity of measure is 2626. NM³/hr. in normal operation. Its
capacity can be varied by suction press. With the help of by-pass (2-1). This compressor
is manufactured by KOBE STEEL LTD. Under the license agreement with COOPER-
BESSEMBER (U.S.A.).
SIMPLIFED DIAGRAM GB-102
2. SPECIFICATION
2.1 Compressor 1 Unit
2.2 Service co Compressor of CO2
2.3 Equipment No. UGB-102
2.4 Design data and operating condition
GAS COMPOSITIONS:
CO2 97.77 vol. %
Air 024 vol. %
Inert 1.99 vol. %
CP/CV 1.895
Mol.wt. 43.46
R.H. 81.1 at 31.4°C
Barometric pressure 971 milibar
2.5 OPERATING CONDITION
Capacity 2626. M³/hr.
s t
Suction pressure (1 ) 29.5 kg/cm²G
(24)

(2 nd) 91.5 kg/cm²G

st
Suction temp. (1 ) 42°C
(2 nd) 50°C
st
Discharge temp./press (1 ) 133°C 92.5 kg/cm²g
nd
(2 ) 115°C 260 kg/cm²g
st
Compressibility (1 ) 0.870/0.830
(2n d) 0.483/0.622
Shaft power 1960 + 4% KW
Motor power 2200 KW
CAPICITY CONTROL
100% - 50% By suction pressure GB-101

(22)
50% - 0% 2-1 by pass GB-102 also through purge valve.
2.6
Compressor type JM-3 horizantal opposed type.
Coupling method Electric motor directly coupled.
Rotation Clock wise view from driven side
Driven Synchronous motor.
2.7 Cylinder specification 1st 2 nd
Cylinder dia mm 254.0 144.2
Storoke mm 355.6 355.6
No. of cylinder 2 1
Single/Double Double Double
Liner Type Dry Dry
Design pressure kg/cm²G 110 226
Hydrulic test kg/cm²G 105 430
Air Test pressure kg/cm²G 121 375
Stoke volume m³/mm 22.92 360
Clearance % 19.4 23.5
Volume efficiency 65 78.2
Piston rod dia mm 76.2 76.2
Piston speed M/sec. 3.95 3.95
Revolution rpm. 333 333
No. of discharge valve 2x 2 4
No. of suction valve 2x2 4
Piston rod packing Full floating tupe
Safety valve setting kg/cm²G 102 6
3. UTILITY
3.1 ELECRICITY
Main motor 1960 KW oil 11000 V, 3 Phase 50 HZ synchronous motor
Pump motor 2.2 KW for 415 V phase 50 HZ Lube oil motor.
Turning motor 2.2 KW DC 110V for relay & trip.
3.2 COOLING WATER
For gas cooler 310m³/hr. Inlet pressure 405 kg/cm²G
For cylinder jacket 30 m³/hr. Outlet pressure 4.0 kg/cm²G
For oil cooler 7.5m³/hr. Inlet temperature 35º C
Rod packing 2.0 m³/hr. Outlet temperature 41º C
For rod packing cold condensate 3.0 kg/cm² temp.50º
C

3.3 INSTRUMENT AIR

Instrument air 7kg/cm²G
Lubricating oil Frame oil 560 litres
oil 440 litres
(23)
4. SAFETY DEVICE
4.1 LUBE OIL SYSTEM
i) Starting condition lube oil pressure 1.7 kg/cm²G
ii) Low Lube oil Pressure (Alarm) 1.4 kg/cm²G
iii) Low lube oil pressure (Trip) 1.0 kg/cm²G
iv) Lube oil outlet temp. (High alarm) 70°C
4.2 GAS SYSTEM
i) 1st stage discharge gas temp. (high alarm) + 10°C
ii) 2 nd stage discharge gas temp. (high alarm) + 10°C
iii) 1 st stage suction pressure high alarm 32 kg/cm²G
iv) 1s t stage suction pressure low alarm 20 kg/cm²G
v) 1 st stage suction pressure very low Trip 18 kg/cm²G
4.3 LIMIT SWITCH
Turning gear off Starting condition
EMV-101 close Compressor trip
Suction Separator High alarm
2 nd stage suction gas temp. Control at 50°C(TIC 1025)
5. GAS COOLER
Type U Type
Cooling area M³ 109.7
Gas Volume 26260 NM³/hr.
Gas inlet temp. 133°C
Gas outlet temp. 50°C
Water inlet temp. 35°C
Water outlet temp. 41°C
6. LUBRICATING SYSTEM
6.1 Motor driven oil pump gear type
Capacity 1381/mm
Suction pressure 0.3 kg/cm²G
Discharge pressure 2.0-3.5 kg/cm²G
Safety valve setting 3.5-5 kg/cm²G
6.2 OIL COOLER
Oil capacity 1381/mm
Oil inlet temp. 60°C
Oil outlet temp. 53.5°C
Water inlet temp. 35°C
Water outlet temp. 38°
6.3 OIL FILTER
Cassing- Material One set
Type F.G.
Mesh size Notch wire

(24)

Allowable pressure drop 40 (micron) 0.25kg/cm²G

6.4 FORCE FEED LIBRICATION
Tank capacity 160 Liter
Type Shaft driven
7. MAIN MOTOR TYPE
Quantity One No. synchronous
Output 2200 KW
Electric source 11000 V, 50 HZ
Synchronous speed 333 rpm.
Driving method Direct coupled
8. TURNING DEVICE
Purpose Turning
Type Indication geared
Output 2.2 KW
Electric source 415 V, 50HZ
Speed 1500-50 rpm.
Driving method Directly coupled
Key For hand operation.
SPECIFICATION OF CENTRIFUGES (UGF-201 H-E)
1. Capacity 12.9 Te/hr
Design 16.0 Te/hr
2. Slurry capacity 43.0 Te/hr
Design 53.3 Te/hr
3. Water content of 2% wt.
4. Washing water & steam 5% wt.
5. Slurry Con. 30% wt.
Urea Con. 70% wt.
6. Temperature 60°C
7. Mother Liquo P=1.19 P.Crystal=1.33
8. Grain Size=More than 35 mesh 40%
35-60 mesh 50%
Less than 60 mesh 10%
9. Outlet 0.2%
10. Motors 60KW, 7.5KWx2, 3.5kw
SPECIFICATION OF DRYER
1. Capacity 78 TE/hr.
2. Dia 3900 mm. Height 4100mm
3. Moisture content Inlet 205%
Outlet 0.3%
4. Crystal Size min. 0.40 mm
Max. 0.60 mm
(25)
5. Heat of Crystallization 57.8 K. cal/kg
6. Crystal air inlet temp. 120°C
 Exit temp. 65°C
7. Hot air inlet temperature 120°C
Exit temperature 65°C
8. a) Specific Heat 0.41 K. Cal/kg (°C).
b) Actual Density 1340 kg/m³
c) Apparent Density 750 Kg/m³
d) Molting point 130°C
9. Rake 2 RPM
10. Perforated plate Thickness : 2mm
Holes dia : 2mm
11. Dimensions 3900 x (3600 + 1500) mm
12. Cam Revolution (Damper) 6.5 rpm.
13. All materials SUS 304
SPECIFICATION OF AIR HEATER FOR DRYER UEC-301
Design Conditions Shell Tube Side

1. Fluid circulated Air Steam Steam condensate

2. Flow kg/hr. 89200 1630 54700
3. Latent head ------- 506.8 --------------
4. Temp. in °C (-) 2 143 100.2
Out °C 120 143 67.5
5. Operating Pressure 150 mmH2O 3.0 3.0
6. Alloeable Pr. Drop kg/cm² 0.01 0.50 0.50
7. Fouling Resistance ----- 0.0002 0.0002
m²/hr. ºC K Cal
8. Heat Transfer area m² ----- 799 2097
9. Heat Transfer rate 89220 x 0.24x 1630x506.8 54700x1.0x
K.cal,hr. (120+2)=2612000 =826000 (100.2-67.5) =
1789000
10. Design Pressure 300mm H2=0.03K 7.0K 7.0K
11. Corrosion allowance 3 3 3
SPECIFICATIONS OF SCREW CONVEYORS
1. Material handling Urea Crystal
2. Type Helical Flight
3. Length 8250mm
4. Capacity Max. 39 Te/hr. 32.3 Te/hr.
5. Screw dia 500 mm
6. Pitch 450 mm
7. RPM 60
8. Motors 7.5 kw/5.5kw
(26)
9. Material SUS-304
SPECIFICATIONS PF DUST SEPARATOR
Top ID 2670mm
Upto guide Vane 2700mm
Total height 3500mm
Outlet 270 ID
SPECIFICATIONS OF DISTRIBUTOR
I.D. 500mm
Holes 1941, dia = 0.60mm, Pitch =9.5
Hand Holes dia 250
Holes dia. Tolerance 0.6 = 0.002
Nozzle plate Thickness 4mm
Feed to Distributor 2½mm
SPECIFICATIONS OF TROMMEL
Length 2500mm
ID-I 934mm
ID-II 1200mm
Wire mesh SS-304 105

SPECIFICATION OF TOWERS
Specifications DC-101 DA-201 High DA-202
DA-203 DA-401
Press Decomposer L.P.D.
G.S. H.A.
1. Pressure operating/Design K 250/260 17.5/25 2.3/3.5
Atm./1.0 17/20
2.TEMP. " ºc 200/210 151-165/180 130/150
92/120 50/85
3. Corrosion allowance mm/year 8-4, M-3 T-2 1.0 1.0
1.0 T=1.0. B=2.0
4. Hydraulic Test Press. 390 --- 90
1.50 ----
5. Capacity 105 --- 19-73
25.50 ----
6. Meterial Shell lining K Ten 62M --- SA-240,
SA-240. ----
Ti Gr.316
Gr.304
Also trays

(27)
7. Dimensions ID (mm) Ht(M) 2100 3300/2100
1784 2800/2200
 34.1 14.162
93 22.3
8. Insulation (mm) ---- ---- 75
75 100
9. Wt. erection (M.T.) ---- 37.7 8.85
9.45 ----
10. Packed bed ht./Packing Top sealing Falling film type 4,5 4 Sieve
trays 3” x102RR S.S.E-2/B-3
Sieve trays 1087 tubes 2”RR bed
bed SS-304 7000/2:RR
Packed Ht. 5 bubble cap
= 3.0M (186x5) Pitch
150

START UP AND SHUT DOWN CHEKS OF UREA PLANT & ITS EQUIPMENTS
1. Important checks before start-up
A handy check list is very important for start up /shut down of plant. One may not
always remember all the points and there is likelyhood of some slip. If we have a
complete check list, this will eliminate such possibility. Listed below are important
checks to be made ,mentioned section wise.
a) CO2 BOOSTER COMPRESSOR
i) Inter lock checking : This is important to ensure the safety of burbine &
compressor in case of any emergency
ii) Governor stroke : To ensure proper functioning of governor valves
checking
(simulation check)
iii) Lubrication system : Check auto start of stand by pump, tank level, oil
temp. pressure drop across the filter, N2 pressure
in the accumulators.
iv) Vacuum system : Check hot wall pump auto start up, desired
vacuum is reached, positive steem pressure at
turbine exhaust gland and CW to surface
condenser is open.
v) Valves position : Check suc. Valve, 2-1 by pass valve, anti surge
valve, inter coolers CW valves, SVs isolation
valves are open. Compressor and inter coolers
drains are open.
vi) Check inlet steam line is warmed up to 350º C turning gear is running &
turbine drains are open.

(28)
vii) CO2 analysis : Check CO2 purity, to be more than 98% H2S
Content should be less then 1 ppm & CH3 OH
 Should be less than 1000 ppm.
b) CO2 RECIPROCATING COMPRESSOR
i) Inter-lock checking : To ensure safety of compressor & synchronous
motor.
ii) Lubricant system : Check crank case & tank levels, oil temp.
differential pressure across filtr.
iii) Valves position : Check suc. Valve, 2-1 by pass valve are open
& disch valve & vent valve are close.
iv) Check cold condensed flow for cooling of piston packing (rod packing)

v) Process conditions : Check suction pressure about 25kg/cm²g turning

is done & gear is in off position.

vi) Force feed lubricator : Check oil flow to all points and breathe out. Air
form all points.
c) RECYCLE CARBAMATE PUMP
i) Interlock checking : To ensure of turbine & pump
ii) Lubricant system : Check auto start of oil pumps tank level, oil
temp. across filter.
iii) Seal water system : Check differential pressure of seat water.
iv) Check, turbine is warmed up & its drains are open.
v) Valve position : Check suction, balance line, discharge, LCV-
401 & its isolation valves are open.
vi) Check its booster pump is running to ensure sufficient NPSH.
vii) Breathe out air from suction. Balance line, discharge line vents.
d) LIQ AMM. FEED PUMP
i) Interlock checking : To ensure safety of motor & the pump.
ii) Lubricant system : Check crankcase level, seal oil tank &
box oil level, lube oil temp. & pressure,
seal oil pressure.
iii) Check its booster pump is running to ensure sufficient NPSH.
iv) Valve position : Check suction, both by pass valve are open.
Disch. Valve and all drains are close. FCV-
102 & its IV are open.
v) Cheak manual barring is done, to ensure that pumpis not jammed & motor
does not trip on overload when started.
e) DECOMPOSITION & RECOVERY SECTION
Cheak all valves for lining HD to LD, LD to GS, HD to HAC, their steam
Valves, all control valves, isolation valves are open. Two or more
condenser are in line. All condensers, purge amm. Condenser, amm.
(29)
reservoir & recovery absorbers, LA, HAC& other coolers/condensers are
open.
f) CRYSTALLIZATION & PRILLING SECTION
Cheak proper vaccum in the concentrator, slurry concentration (82 %)
& crystal density (35 %). Cheak smooth running of centrifuges, number of strokes of the
basket (58/min). Cheak ll machineries of prilling secti are running. Cheak system valve
for melter, melter otuleu urea valve & water for dust separators are poen. Head tank
strainers are clean & mesh is not damaged. All distributors are clean.
IV OPERATING CONDITIONS
4.1 Synthesis Section
In this section urea is synthesized in urea reactor under high temperature and pressure
from carbon dioxide and ammonia and recycle cabbamate solution. The temp. pressure is
the reactor and mole ration of ammonia to carbon dioxide are so choosen as to achieve
the max. conversion of carbon dioxide with minimum cost.
Carbon dioxide is compressed by CO2 booster compressor (UGB-101) to
29.5kg/cm² and further to 250kg/cm² compressor (UGB-102) and is sent to reactor (UDC-
101). Since about 1000 ppm of methanol is present in feed carbon dioxide, methanol is
absorbed by cooled condensate in methanol absorber (UDA 101) before being sent to
CO2 compressor. Flow rate of condensate is controlled by FTC-104 and the bottom liquid
is sent to effluent
Treatment plant through LICA-102. Air of the order of 2500 ppm is already injected in
CO2 feed line to UGB-101 through FCV-103 for the passivation of reactor liner. The
CO2 rate to the reactor is controlled with reference to CO2 flow recorder (FRS-101).
Make-up ammonia from ammonia plant is fed through LCV-407 to recovery ammonia
reservoir (FA-401) where it meets the recovered ammonia from ammonia condensers
(UEA-404 A-E) and purge ammonia condenser (UEA-403). Liquid ammonia is pumped
by booster pump (UGA-403) to suction of ammonia feed pump (UGA-101) at a pressure
of 22 kg/cm² which feeds to reactor through ammonia preheaters (UEA-101 ,102) and
excess ammonia returns to Ammonia reservoir (UFA-401) through FCV-102.
Normally 3 ammonia feed pumps are required for 100% load. In preheaters, ammonia is
preheated by hot water from hot water tank (UFA-202) in UEA-101 preheater. This hot
water picks up heat from High Pressure Absorber cooler (EA-401). In the second
preheater (UEA-102) it is heated to 82º C by steam condensate from flash drum (UFA-102)
in order to supply additional heat to maintain synthesis temperature of 200°C inside the
reactor.
The recycle carbonate solution from high pressure absorber cooler is pumped by
carbonate booster pump to one of the centrifugal recycle feed pump (UGA-102) to urea
reactor.
The flow rate of CO2 is measured by FRS-101-1 at the suction of CO2 booster
compressor Ammonia feed rate to reactor is measured by FCA-102 at the ammonia to
CO2. The flow rate of carbonate is regulated by LCV-401 which maintains level in UEA-
401.
(30)
Ammonia booster pump UGA-404 is required to provide NPSH to ammonia feed pump
and also to fee ammonia from reservoir to high pressure absorber UDA-401. Similarly
carbonate boost up pump is required to provide suction head for recycle solution pump
suction line to high pressure absorber cooler through a recycle loop in order to prevent
any solidification of carbonate solution.

The pressure inside the reactor is controlled by PVC-101 at 250 kg/cm²G and temperature
is controlled at 200ºC by preheating liquid ammonia in preheaters & NH3/CO2 molar
ratio. The temperature of ammonia at No. 2 preheater outlet is controlled at 82º C by HCV
-101.
The lower temperature inside reactor decreases the conversion of carbonate to urea which
results in increase of carbonate solution. This increase of carbonate makes if necessary to
have more decomposition and absorption in the recovery section which will further
decrease the conversion.
On the other hand, high temperature in the reactor (200º C) will increase the corrosion rate
of titanium lining. Moreover the equilibrium pressure may exceed the actual pressure in
the rector which will result in lowering of conversion of carbonate to urea.

The reaction mixture containing urea, water, carbonate & excess ammonia is in liquid
phase under reactor pressure and temperature conditions. They are flashed through PCV-
101 into high pressure decomposer (UDA-201) which result in the flash vaporization of
most of excess liquid ammonia and carbon dioxide. The sensible heat of reactants is
utilized in this vaporization. The temperature of urea, water, excess ammonia and
carbonate entering the UDA-201 is 126º .
4.2 DECOMPOSITION SECTION
The gas liquid mixture from reactor flows into high pressure decomposer (UDA-201) low
pressure decomposer (UDA-202) and gas separatoe (UDA-203) where excess ammonia
and uncoverted carbonate are removed in the form of gaseous ammonia and carbonate
are removed in the form of gaseous ammonia and carbon dioxide from liquid stream of
urea and water.
Overhead gases from these decomposers are arsorbed and or condensed in their
respective absorbers in recovery section, namely high ressure absorber cooler (UEA-401).
High pressure absorber (UDA-401), low pressure absorber (UEA-402), and the off gas
recovery system containing off gas condenser (UEA-406),off gas absorber (UDA-402)
off gas final cooler (UEA-407) and cooler for off gas absorber (UEA-408).
High pressure decomposer consists of two parts the upper part contains 4 Nos. sieve
plates and the lower part is falling film heater. The mixture from reactor at about 126°C
enters the upper part where that flashed gases are separated and liquid falls down the
sieve plats where it comes in contact with high temp. gas from reboiler for UDA-201
(UEA-201) and falling film heater. The sensible heat of gas and heat of condensation of
water vapour is utilized in further evaporation of excess ammonia and decomposition of
carbonate. This way the evaporation of water is minimized and this results in lower steam
consumption and lower wather content in the recycle carbonate solution. The same
process takes place in upper part of UDA-202 also.
In reboiler for UDA-201 (UEA-201) the liquid is heated to about 151°C by TCV-201
with medium pressure steam (SM, 12 kg/cm²G) and most of excess ammonia and
carbonate are released as gases.
Then the solution is further heated to 165°C in falling film heater of UDA-201 by TCV-
202 and level is controlled by LCV-201.
The falling film type of heater is utilized to minimize residence time and ther by reducing
the biuret formation and hydrolysis of urea.
The pressure of this system is controlled at 17.5 kg/cm²G by PCV-405 on top of recovery
absorber (EA-405) through purge ammonia condenser (EA-403), ammonia condensers
(EA-404) and high pressure absorber (DA-401). Anti corrosion air is injected to bottom
of the reboiler (EA-201) and in the middle of high pressure decomposer at a rate of 2500
ppm each.
The overhead gases from (UDA-201) go to high pressure absorber cooler (UEA-401) and
liquid flows to the top section of UDA-202 through LCV-201 after it has been cooled
down in heat exchanger for UDA-202 (UEA-203).
Additional flashing of the solution takes place in upper part of UDA-202 (where solution
from off gas absorber is also fed) when the pressure falls down from 1705 kg/cm²G . Low
pressure decomposer has 4 Nos. of sieve trays and packed bed. The process taking place
on sieve trays is similar to that taking place in UDA-201.
In the packed bed remaining amount of ammonia is stripped off by means of a stripping
action caused by CO2 gas fed from the discharge of UGB-101. The solution in UDA-202
is heated in UEA-203 with solution from UDA-201 and by SU steam (7 kg/ cm²G) in
reboiler for UDA-202(UEA-202).The temperature is controlled at 130º C by TIC-203 and
level by LIC-202.
The overhead gases from UDA-202 go to low pressure absorber UEA-402. The pressure
is controlled at 202 kg/cm²G by PICA-402. Temperature of UEA-402 is maintained by
controlling the cooling water with the help of HC-401. Most of the excess ammonia and
carbonate is separated from the solution which flows to gas seprator(UDA-203).
Gas separator has two parts, upper part is operating at 106º C and 0.3 kg/cm²G and lower
part having a packed sectiom is operating at 92º C and atmospheric pressure.
The remaining small amounts of ammonia and CO2 are removed by reduction in pressure
and the sensible heat of solution is enough to vaporize these gases. The pressure in upper
part is controlled by PIC-203 and leval is maintained by overflow through U-seal.
In the lower part, air containing small amount of ammonia and CO2 is fed from off gas
absorber by off gas blower (UGB-401) to remove the remaining small amount of
ammonia and CO2 present in solution. Off gases from lower and upper parts are mixed
and fed to off gas condenser (UEA-406). The urea solution concentrated to extent of 70-
75% is fed crystallizer section through LIC-203. The temperature of urea solution is
controlled at 92º C by TIC-204 by means of low pressure steam (SL. 305 kg/cm²G)
obtained from flash drum (UFA-102) and steam let down valve (PCV-504)
4.3 RECOVERY SECTION.
The gases from UDA-203 enter the off gas condenser (UEA-406) where part of the gases
are cooled down to 61°C by cooling water. The uncondensed gases then go to off gas
absorber (UDA-402) and condensed gases are collected in off gas absorbent tank (UFA-
403). This solution is sent to off gas absorber top a long with some make up steam
condensate after they are further cooled down to 36°C in off gas final cooler (UFA-407)
and act as absorbent in upper packed bed of UDA-402.
Off gas absorber consists of two packed columns. In the lower columns, uncondensed
gases from UEA-406 are fed where they are absorbed and condensed by recycle solution
which is cooled down in cooler for off gas absorber (UEA-408). The residual gases for
lower column then rise up the upper packed bed where they are further absorbed and
condensed completely by absorbent from UFA-403 after cooled down in UEA-407 . The
level in UEA-403 is controlled by LIC-403.
The air from top of gas absorber (DA-402) is blown to gas separator (DA-203) by UGB-
401 after the fresh air is added at the suction and pressure is controlled at discharge by
PIC-404. The level is controlled by LICA-404 feeding a portion of the solution to low
pressure decomposer (UDA-202) and a constant flow amount of solution is sent to (EA-
402) as absorbent by FIC-404 with the help of UGA-401 pump. The gases from DA-202
are completely condensed in EA-402 bubbling through the sprayer pipe beneath the liquid
surface.
The mother liquor recycled from M.D. tank (UFA-203) for biuret removal steam
condensate and diluted carbonate solution from off gas absorber through. FIC-404 are
utilized as absorbent in low pressure absorber. The amount of mother liquor is controlled
by FIC-204. The pressure is controlled by PICA-402 and temperature by HC-401 which
regulates the CW flow to keep the temperature at 40°C.
Control of pressure at 2.2 kg/cm²G in low pressure absorber is very important as low
pressure will cause problems in transfer of solution from UDA-402 to UDA-203 and
higher pressure will lead to insufficient decomposition inside UDA-202 thus requiring
more decomposition in UDA-203.
The recycle solution from EA-102 is pumped by means of high pressure absorbent pump
(UGA-402)to the packed section of high pressure absorber (UDA-401) through mixing
cooler (double tube cooler) where it meets with fresh liquid ammonia which acts as a
cooling medium in absorber. The level in UEA-402 is controlled by LCV-402 which
controls addition of condensate. The concentration of CO2 should be analysed in the
solution for about 16% by wt.
In EA-401 and DA-401 all the carbon dioxide from UDA-201 is absorbed by low
concentrated carbonate solution from UEA-402 and aqua ammonia from UEA-405. This
absorption is achieved in following 3 steps:
a) Initially the gas from UDA-201 is bubbled through sparge pipe in UEA-401 where
65% of gas is absorbed.
b) Then the remaining 35% gas go to the UEA-401 and this is scrubbed by a mixture of
liquid ammonia and weak carbonate solution from UEA-402 (this mixture is made in the
mixing cooler and heat of reaction is absorbed by cooling water) in the packed section of
UDA-401.
c) Finally the ammonia gas from the packed column is scrubbed with weak ammonia
aqua solution is 5 Nos. of bubble caps tray section of UDA-401 where any residual
carbon dioxide is removed completely. The top temperature of UDA-401 is controlled at
50°C and this control is very much important to avoid any –break through of CO2. This
temperature is controlled by evaporating liquid ammonia on bubble cap trays by the use
of ammonia as a reflux through FCV-403. The temperature of packed section of UDA-
401 is controlled at 60°C by evaporation of liquid ammonia added to recycle carbonate
solution at mixing cooler through FCV-402.
The temperature of UEA-401 is controlled at 100º C by circulating cooling water, urea
slurry and hot water from hot water tank UFA-202.
The heat of reaction of carbonate is absorbed by urea slurry and hot water circulation as
mentioned above. This heat is utilized in evaporating water from urea water slurry in
crystallizer and also in perheating liquid ammonia in preheater UEA-101. The level in
UEA-401 is controlled by LCV-401 and concentration of CO2 in carbonate solution is
controlled at around 30 –35% by regulating amount of weak carbonate solution.
The ammonia gas from UDA0401 flows to ammonia condensers (UEA-404) and purge
ammonia condenser (UEA-403) for condensation and collected in recovery ammonia
reservoir (UFA-401). The gas from UDA-401 corresponds to the sum of excess ammonia
sent to reactor and the liquidammonia feed to high pressure absorber UDA-401.
The non-condensables, mostly the inert gases present in CO2 and air injected to urea
reactor and UDA-201 for minimizing corrosion are withdrawn from UEA-404 and flow
to UEA-405 (ammonia recovery absorber) via purge ammonia condenser (UEA-403)
Recovery ammonia absorber (UEA-405) consists of 4 Nos. horizontal absorbers in series.
The inert gases along with ammonia, pass to the bottom most of these absorbers through a
sparge pipe and are absorbed in aquas ammonia. The heat of solution is removed by
cooling water flowing in the tube side. Uncondensed gases pass overhead to the next
absorber where a similar counter current washing process take place. This way the
overhead gases from second absorber pass to next and then to the final absorber. The
pressure of the whole decomposition and recovery system (high pressure side) is
controlled at abour 16.5 kg/cm²G by PCV-405 which is installed at the outlet vapour line
of top most absorber. The gas vented from here goes to off gas absorber UDA-402 for
further recovery of ammonia.
Cold condensate from condensate tank UFA-101 through condensate cooler (UEA-406).
This condensate after dissolving in the ammonia absorber comes down to 3 rd absorber by
an overflow pipe and from 3 rd to 2 nd absorber after dissolving ammonia in 3 rd absorber
and so on and ultimately flows down to bottom absorber. The aquous ammonia thus
forned is withdrawn from bottom absorber and is fed to UDA-401 by a-qua ammonia
pump (UGA-405). The level in bottom absorber is controlled by LCV-408. The
temperature in all the absorbers is controlled at 35º
C approx. by cooling water flow in all
the absorbers.
4.4 CRYSTALLISATION AND PRILLING SECTION
The urea solution from gas separator UDA-203 is pumped to the lower part of crystallizer.
The crystallizer consists of two parts –lower part is crystallizer fitted with a close
clearance frame type agitator and operating under atmospheric pressure. The upper part is
consentrator operating under vaccum of 75 mm HG abs with the help of a 2 stage ejactor
having a barometric condenser.
In the upper part which is operating at 60º
C, the urea solution gets consentrated and then
falls down through a downcomer pipe to the crystallizer where crystals are allowed to
grow up when they come in contact of super saturated urea solution. The heat required to
ecaporate water in concentrator comes from sensible heat of urea solution from UDA-401.
The crystallizer is operating at 60º
C and atoms. pressure should be operated so the urea
slurry contains 30 –35% by wt. of urea crystals.

The level and pressure in concentrator is controlled by LRA-205 and PCV-204

respectively. The level in crystallizer is controlled by the vaccum in concentrator and
indicated by LRA-206. Circulation pumps for crystallizer
UGA-201 A , B are provided to circulate slurry. Water vapours from concentrator are
condensed in barometric condensers and condensate and cooling water come down to a
pump and from there it is sent to cooling tower III by water pumps CGA-302 A/B.
A hot water jacket is provided for crystallizer concentrator walls and for piping to prevent
urea crystals build up on piping and vessels surface. This hot water is circulated by hot
water pumps UGA-201 A/B from hot water tank UFA-202 through high pressure
absorber cooler UEA-401 , ammonia preheater No. 1 (UEA-101) and crystallizer section.
The urea slurry is pumps by slurry feed pumps UGA-202 A/B to 5 Nos. centrifuges (GF-
201) and a portion of slurry is circulated back to the crystallizer to prevent choking in the
system.
All five centrifuges have been provided to obtain 100% production. The feed rate to
centrifuge is controlled manually by HCV-201 A-E by remote control after seeing the
level in the crystallizer and ammeter (EI-201 E) of each centrifuge on the panel.
In the centrifuge crystals are separated from mother liquor. These crystals contain about 2.
5% moisture and are discharged to Fluidizing dryer (FF-301).
The separated mother liquor flows down to mother liquor tank UFA-203 where steam coil
s are provided to prevent crystallization. This mother liquor is pumped by UGA-203 to
discharge line of UGA-201 and also under flow control by FCV-204 to low pressure
absorber UEA-402 as absorbent to prevent biuret accumulation in crystallizer. The level
discharge line of UGA-203 going to crystallizer.
In fluidizing dryer (UFF-301) urea is dried to 0.1-0.3% water content by hot air. Air is
heated in air heater UEC-301 using steam condensate and low pressure steam (SL 3.5
kg/cm²G). Inlet air temp. is controlled in between 110°C to 120°C otherwise urea will get
melted in the dryer (Urea M.P.132.6°C)
The dried urea is conveyed to top of prilling tower by a pneumatic pipe and more than
99.8% urea is collected in cyclone (UFC-301). The collected crystals are fed to melter by
screw conveyors (UJD-301)
On the other hand, air from cyclone is sent to dust separator (FD-304) through ID fan
(UGB-302). In dust separator air is scrubbed by water spray and then clean air is
exhausted to atmosphere.
In melter (UEA-301), crystals are melted by SU steam (7 kg/cm²G). Molten urea then
falls down to head tank (FA-301) through strainer for distributor (UFD-301).
To keep biuret content at a minimum the plant is designed and operated in such a way so
as to keep molten urea temperature just above its M.P.P. (133°C) and also to keep
residence time as short as possible. The temperature in melter is controlled by PCV-301.
Molten urea from head tank is equally distributed through 12 Nos. (11+1) distributors (PF
-301 A-L) in prilling tower where it is cooled and solidified in process. Normally 11 Nos.
of distributed are sufficient for 100% production.
As the molten urea falls down the tower, it is prilled and cooled by up coming air which
is blown from blower UGB-303 and sucked secondarily at the bottom of the tower.
The urea dust collecting system is provided to minimize air pollution by tower effluent.
Dust chamber (PF-302) is provided to reduce the velocity of the effluent air & to settle
fine urea particles. Spray nozzles and strainers are also provided for scrubbing. Then the
air is exhausted to atmosphere by ID fan prilling tower (UGB-304) after the water mist
from scrubbing section is eliminated by filters.
Circulation pump for prilling tower (UGA-302) is installed to circulate urea solution from
pump to the spray nozzles and to dust separator. The concentration of urea solution is
kept at between 10-20% by regulating the amount of make up (FA-302) to maintain the
solution level in sump.
The prilling urea collected at the bottom of tower overflows in the trammel where product
size material is separated from oversize. Product size material is sent bagging plant or silo
through a weigh scale (WIS-301).
The oversize is collected and dissolved in dissolving tank and solution is pumped by
UGA-303 to U.T. ammonium carbonate solution tank(UFA-402) or crystallizer (FA-201)
or gas separator (UDA-203). This solution from U.T. is recovery section.
SECTION IV STANDARD OPERATING PROCEDURE
5.1 Normal start-up of the plant
The normal start-up of the plant i.e. from the circulation run is discussed here.
Circulation run is done in the following situation:
a) Reactor is full of the urea/carbonate solution.
b) All the vessels in decomposition section are drained out.
c) All the vessels in recovery section are full of solution.
d) Crystallizer is full of solution and circulation being done under reduced
vaccum.
e) Machines in prilling section are operating after washing.
5.1.1 Preparation for Start-up
Carryout the following checkings:
a) Clearance for all the electrical equipments.
b) Cooling water systems- Minimum of two pumps and three fans of CT-II
system and one pump and one fan of CT-III system are running.
c) Instrument Air-Sufficient pressure in available.
d) Steam tracings- Steam tracings of the lines and safey valve and level troll
jackets steam lines are in service and their steam traps are functioning
 properly.
e) 40 K.N2 header is charged.
f) Isolation valves of safety valves are in open position.
g) Breathers valves provided in flushing lines are in open position.
h) All the alarms and warning lamps in control Room are in working order.
i) Interlock checking of various machines done.
j) Checking of all the lines for any choking.
5.1.2 Start-up Machines
Starting of big machines such ad CO2 Booster, CO2 Compressor ammonia pumps,
carbamate pumps, Air Compressor and centrifuges is to be done as per the instructions of
the supplier/manufacturer. For starting other centrifuges machines the general precaution
for starting any such machine should be taken.
1. Start CO2 Booster compressor and pressurise it to 25 kg/cm²G after the final cooler
through its vent (HC-1054). Transfer the control of compressor to control Room.
2. Take Methanol Absorber (V-DA-101) in line by supplying cold condensate with UGA-
406 pump through FIC-104 and when the level appears in LIC-102 put it on auto and
maintain a level around 50%.
3. Start CO2 compressor and transfer the venting of Co2 gas from HC 1054 to this
compressor vent. Pressurise the gas to 210kg/cm²G.
4. Start ammonia booster pump (UGA-404) and circulate ammonia through 3 Nos. of HP
ammonia pumps (UGA-101). Start one HP ammonia pump and pressurize it to 210
kg/cm²G through the by-pass valve. Open the isolation valve of FCV-102 and also the
control valve. Open discharge valve of pump and slowly close the by pass valve. Further
pressurize the ammonia pump discharge header by closing FCV-102 to 210 kg/cm²G.
5. Start High pressure flooding pump (UGA-103) and pressurize to 210 kg/cm²G. Flush
EMV-103 and 102 valves one by one. Give injection in EMV-101 and check for anu
choking. Continue this injection till the CO2 feed in is done and UGB-102 vent valve is
closed.
6. Check that carbamate booster pump (UGA-103) is running. Start HP carbamate pump
(UGA-102) and pressurize it to 10-15 kg/cm²G more than reactor pressure.
5.1.3 Preparation of synthesis, Recovery, Crystallisation & Prilling Section
1. Check the Reactor outlet line to gas Separator and flush these lines with
steam/condensate.
2. Set all the controller on manual position.
3. Pressure High pressure decomposer (UDA-201) and low pressure decomposer (UDA-
202) to 15.0 kg/cm²G and 20 kg/cm²G with the help of Nitrogen.
4. Crack open all the temperature control valve of all the heaters and warm then up. Keep
their condensate pot drains on open position.
5. Flush the tapping or PRC-101 sensing line (keeping reactor high pressure trip (BL-1)
by passed with Hp flooding pump. Open PCV-101 slightly and see of the reactor pressure
decreases which will indicate that reactor outlet line is clear. If not then flush the reactor
block valve with HPP pump.
6. Check the temperature of hot water (TI-602-28) and maintain it at 80°C by opening
steam in it. Check hot water circulation and male sure that it reaches to the jacket of
concertrator of UFA-201.
7. Commissioning of crystallization section
a) Open PRC-204 on manual.
b) Close isolation valves of HCV-201 A & E and open HCV-201 A to E to 40% valve.
c) Open the dampers of drain Separator bos.
d) Commission centrifuges. For that warm the centrifuges by check opening of SL valves.
Start all the L.O. pumps and adjust the Lube oil temperature to 50°C and start centrifuges
in unloaded condition. Adjust the pusher strokes to 60 per minutes.
8. Preheat melter (EA-301) with PTC-301 on automatic control giving tube side steam
pressure at 2kg/cm²G. Put LIC-302 on automatic control.

9. Flush stainer (UFC-301) head tank (UFA-301) and few distributors with steam and
drain down to dust chambers.
10. Start water pump GA-301 and give make up about chanber.
11. Start dust chamber circulation pump GA-302 and put water to dust separator and
spray nozzles for U-FD-309.
12. Start ID fan (GB-302) and FD fans (GB-301) and open HC-302 to full. Adjust the
discharge damper of GB-301 to such that a negative pressure of -5 to -10 mm of H2O is
maintained in the dryer (EC-301) at PL-303. Put TICA-301 on automatic control at 120º C.
13. Start the following Mechanical Equipments
a) Screw converter for melter (JD-301 A/B)
b) Agitator for melter
c) Blower (GB-303) for fluidizing cooler
d) Viberators for cyclones.
e) Trommel (FD-303)
f) I.D. fans for prilling tower (UGB-304 Ato D)
g) Weighing conveyor
h) Agitator for dryer
i) UGA-201 & UGA-202 one pump each.
5.1.4 CIRCULATION RUN
a) Start GA-405 (Aqua NH3 Pump). Air compressor (GB-201) off gas blower (GB-
401) and GA-409 pump on circulation.
b) Open EMV-103 and for increase in flow through carbamate pump (indicated by
FLA-105) which indi-cates that carbamate line to reactor (DC-101) is clear.
c) If reactor pressure is less than 200kg/cm²G increase the pressure by increasing HP
carbamate pump (GA-102) speed.
d) Put anti-corrosive air to UDA-201 and UEA-201-2500 ppm as air to CO2 flow by
starting GB-201.

e) Add cold condensate to top of UEA-405 through FIC and to UFA-403 through FI
at the rate of 1.2 Tph.
 f) Start off gas absorbent pump (GA-408) and pump solution to the top of off gas
absorber through cooler EA-407. Put LIC-403 on auto.
g) When level in DA-402 starts increasing, Start GA-401 pump and transfer
carbonate solution to the top of the packed portion of Low Pressure Absorber EA-402
THROUGH fic-404. Keep LIC-404 closed on manual.
h) Star GA-402 pump and transfer carbonate solution to middle of high Pressure
Absorber (DA-401) through FIC-401 maintaining a flow of 7-10 tph.
i) Open PCV-101 slowly and let reactor solution flash to top of high pressure
decomposer. While increasing PCV-101 opening keep a watch on the flow
through UGA-102 pump, which will increase thereby causing a fall in its suction pressure
to trip value of 18.0kg/cm²G. So simultaneously close control valve on the by-pass line at
the discharge of the pump(LCV-401). This control valve helps in maintaining level in
high pressure absorber cooler (EA-401).
j) Increase the steam supply to High Pressure Decomposer (HPD) through TCV-201
and 202. These valves are to be opened very slowly as a sudden fall in the 12kg/cm²
steam header may take place which can trip the CO2 booster at low extraction pressure.
Try to maintain a temperature of 150°C at TIC-201 and 160-165º C at TRC-202.
When the level rises in condensates pots of the heaters, should be lined up to the flash
drum (FA-102).
When the level appears at the bottom of DA-201 indicated by LIC-201, transfer this soluti
on to low pressure decomposer.
(LPD) and put LCV-201 on auto.
Level in EA-401 is to be maintained at such a valve that it is visible in the second sigh
glass. This can be achieved by adjusting GA-102 speed and some adjustment in the flow
through FIC-401.
During this time a watch is to be kept on the temperature at the middle and top of DA-401.
These are to be maintained at 60º C and 48º C respectively by putting liquid ammonia at
the middle and top of H.P.A. tower through FIC-402 and FIC-403 respectively.
When level in ammonia absorber (EA-405) starts increasing divert the discharge of GA-
405 pump from circulation to top of DA-401 through LIC-408.
Maintain a pressure of 15kg/cm²G in the Ist stage with the help of LCV-405.
k) Increase the steam supply to the reboiler of Low Pressure Decomposer (DA-202)
and maintain temp. of 130º C at TIC-203. The level in EA-402 is to be maintained with
the help of week carbonate solution from DA-402 and by adding condensate from LCV-
402. When level appears at the bottom of DA-202, transfer this solution to DA-203 top
and put LCV-202 on auto.
l) Heat the solution by increasing the steam to 92º C at TIC-204.
Maintain make-up air (200m³/hr) at the suction of the gas blower (GB-401)
If the gas separator (DA-203) solution urea concentration is 60% & more the solution can
be taken in crystallizer it should be transferred by running Urea solution pump (GA-205).
Otherwise it should be pumped to urea storage tank (UT) FA-402 B,C. Put LCV-203 on
auto.
 m) When the level in EA-401 is maintained at the second sight glass, temperature at
TIC-201, TRC-202. TIC-203, TIC-204,pressure at PIC-450 are at their design valve. feed
is given.
n) When condensate level in flash drum appears, open the IV’ s of HC-101 and LCV-
101 and put LCV-101 on auto.
5.1.5 FEED IN
1.Feed ammonia into the reactor
- Ensure that NH3 pump discharge header pressure is 210kg/cm²G (maintained with the
help of FCV-102).
1 PRC-101 is on manual.
Open EMV-102
HP carbamate pump will flow have a tendency to fall and thereby trip the pump.
Hence after opening of EMV-102 the flow through carbamate pump is to be
maintained by controlling the opening of PCV-101.
Slowly preheat ammonia by opening HC-101 to avoid and undue thermal shock in
Ammonia preheater (EA-102), NH3 is preheated by hot water in preheater (EA-
101) when it pivks up heat in EA-401.
2. Open 1" by pass valve (½ turn) and pressurize the GB-102 discharge header upto
EMV-101. Wait for the discharge line to get pressurised 210kg/cm²G. Start CO2
injecion to urea reactor 10-15 minutes after injecting NH3 to reactor.
a) Reactor bottom temperature (TR-101-1) will start increasing.
b) Check the temperature at TI-502-2 which will start increasing indicating that
CO2 flow to reactor has started. Increase the ammonia supply to reactor by closing
FCV-102.
Since reactor pressure control valve is on manual whenever any additional
material is given into reactor the reactor pressure should be maintained by opening
PCV-101 otherwise HP carbamate pump may trip at low flow.
c) If the temperature indicated at TI-602-2 is not oncreasing, open the discharge
valve of GB-102.
CLOSE 1" BY PASS VALCE AFTER OPENING DISCHARGE VALVE
If still temperature is not increasing, close the vent valve a little.
Reactor bottom temperature wlii start increasing at a faster rate. Give ammonia
into the reactor to arrest this increasing tendency.
The temperature of the reactor liner and shell will also follow the bottom the
bottom temperature.
The temperature difference of reactor bottom and shell should be maintained
below 50°C.
When the reactor bottom temperature becomes ready for some times close vent
valve further. Bottom temperature will again rise. Give some more ammonia to
check the rise in bottom temperature. This process is to be repeated until the CO2
compressor vent valve is closed fully.

3. Stop HPF pump after the vent valve has been closed.
4. As more and more CO2 and NH3 are fed into the reactor increase steam supply
to different reboilers of decomposition section and try to maintain temperatures
around the design value.
When the reactor bottom temperature reaches 180°C increases reactor pressure
to 215kg/cm²G.
5. The concentration of CO2 in absorbers will tend to increase.
The CO2 concentration of 6 –7 litres of CO2 per 25 C.C. of solution is to be
maintained in EA-401 by increasing solution from EA-402.
6. DA-401 temperature are to be controlled by opening the I.V. of built in cooler
and increasing the reflux of cold NH3 to the middle and top position. The top
temperature has to be maintained below 50°C
7. Level in the absorber EA-401 is to be maintained by adjusting speed of HP
carbamate pump. Cross checking of level indicated by LIC-401 is to be done by
actual level indicated by sight glass. The level in EA-401 should be such that it is
visible in middle sight glass. The control of this level is very important because a
low level means less condensation/ absorption of decomposed gases. This will
overload the HPA(DA-401) the temperature of which will rise and hence some of
CO2 may slip to NH3 condenser. A high level will cause flooding of HPA and
carbamate carryover to NH3 condensers will take place. Both these conditions will
lead to formation of ammonium carbamate crystals in ammonia reservoir which
will choke
The NH3 booster pumps(GA-404) discharge strainer. Plant will be stopped in that
condition.
8. Control temperature of EA-401 by first closing HC-203 (Max. 90% closed) and
then by slowly increasing vacuum in crystallizer with the help of PRC-204. Check
that proper amount of Hot water circulation is also maintained.
9. Start CO2 feeding to UDA-202 and regulate the flow (FI-203)
10. Divert Urea solution to crystallizer when urea concentration is 60% by wt. in
UDA-202.
While pulling vacuum in crystallizers care is to be taken for the level in
crystallizer (LRA-206) which shouldn’ t fall below 48% otherwise urea slurry
circulation pump UGA-201 will loose suction.
11. Gradually the vacuum in crystallizer is increased to 95 mm of HG abs.
Concentration in crystallizer will increase. When sufficient level is available the
gas separator solution can be diverted to urea Tank (FA-402B) in increase
concentration in crystallizer at a faster rate.
12. When crystal density is 30-35% start feeding slurry to one of the centrifuges.
13. When the level in UFA-203 is high enough start UGA-203 and open LICA-
207 (ML tank) manually to feed ML back to crystallizer.
Put LICA-207 on auto.
 14. Dryer should be operated so as to maintain a slight vacuum at thr crystal inlet
by adjusting damper setting.
15. Melter is already preheated by this time and strainer (UFD-301) head tank and
few distributors are also warned up by this time.
16. Urea crystal will melt and this molten urea is to be diverted to dust chamber
unless temperature of 137°C is reached in head tank.
17. When level of molten urea appears in head tank, put distributors in line to
maintain level in head tank. Gradually close head tank drain.
18. Check the condition of fluidizing cooler and trammel (UFD-303) to maintain
such conditions that prilled flows smoothly.
19. Maintain proper make-up in dust chamber through FI-301 and start UGA-303
pump and transfer the solution to Gas separator. Oversize urea may also be
dissolved in it.
_________________ GA-102 A/B CHECK LIST___________________
Step Check Marks___
1. Lube Oil pump start
Oil tank level Head Tank over flow in each
Flow Check flow gauge
Filter outlet press
Auto Start Check Switch Position 1 or 3
2. Seal water Pump start Dis. Press 30 kg/cm²
P 3.0 kg/cm²
3. Cooling water Oil cooler Open
Gland Condenser Open
4. Valve Position Suc. Valve Open
Dis. Valve Open
By Pass valve Close
Balance valve Open
5. GA-403 Start PIA-103 22kg/cm²
6. Air Vent GA-403 Dis.
GA-403 Dis. Strainer
GA-102 Suc. Pipe
GA-102 Balance Pipe
7. By-Pass Switch BS-28 (Em V-103 Shut) On
Bs-27 or 33(Suc. Flow low) On
BS-23 or 29(Oil Trouble) Off
GA-403 (Trouble)
DS-5A (E-V 103 Defeat)
BS-25 or 31(Bal. Line Temp.) Off
BS-26 or 32(Balance Line Press) Off
8. Trip Test Trip Lever
GA-403 A/B Stop
PB-1 (Plant Manual Stop)
 9. Gland Ejector Start
10. Warm up the casing 200°C
11. Reset
SECTION VI ROUTINE CHECK DURING OPERATION

6.1 GENERAL

Any abnormality in plant condition should be reported immediately to shift incharge in

the control Room / concerned persons.
1. Check that all equipments are provided with the correct grade and quantity of
Lubricant.
2. Check that all utilities are operating satisfactorily.
3. Ensure that regular analysis are being performed and that quality of raw material is
acceptable.
4. Operating equipment should be checked frequently for the signs of leakage sight
glass and others.
5. All rotating machines should be checked for the vibration and noise.
Gland leakage and temperature.
Lubrication and metal temperature.
Pressure at suction and discharge
6. Optimise all operating conditions at the design valve.
7. All stand by pumps , stand by distributors , stand by strainers and transfer solution
lines to ammonium carbonate solution tank should be ready to be taken into service.
8. The solution in Ammonia Carbonate solution tank (FA-402 A/B) should be
recovered and these tanks must be empty during normal operation.
9. Check the workability of all instruments.
6.2 SYNTHESIS SECTION

6.2.1 Co2 Booster Compressor(GB 101) and CO2 Compressor(GB 102)

1. Make sure that intake gas quantity is sufficient and the flow control valve (FIC-1051)
is closed.
2. Make sure that oil pressure, oil temperature and oil flow etc. are normal.
3. Check the pressure and temperature of each stage.
4. Make sure there is nothing abnormal in moving parts and there is no abnormal
vibration in pipe racks.
5. Make sure no condensate is accumulated in each Separator.
6. Make sure that the quantity (FIC-103) of anti corrosion air sent to reactor (DC-101)
is sufficient.
7. Check the steam turbine system (GB-101 T)
Note: Refer to manufacturer’ s instructions.

6.2.2 Urea Synthesis Reactor (DC-101)

 1. The temperature in the reactor should be kept at 200°C by controlling preheating
temperature of Ammonia to the reactor and also the qty. of Ammonia to Reactor.
2. Inspect all the flange-joints and leaky holes for leakage which will be indicated by
the change in the colour of leakage monitoring system solution.
3. Smell of condensate from ammonia preheaters (EA-101 & 102) for the
Presence of ammonia.
4. Flush the tapping of PRCA-101.

6.2.3 LIQUID AMMONIA FEED PUMP (GA-101 A-D)

1. Check the flow rate to the Reactor by the flow meter (FRC-102).
2. Make sure there is nothing abnormal in the oil pressure oil temperature and oil
quality.
3. Check the gland packings for ammonia leakages and high temperature.
4. Make sure there is no abnormal vibration in the pipe rocks and no abnormal noise in
the moving parts.
5. Check the amperage of each main motor.
6. Check all NH3 pipe lines for leaks and each isolation valve tight shut off.

7. Check that all flow and temperature of cooling water to oil coolers O.K.

8. Check the suction and discharge pressure.

6.2.4 Recycle Solution Feed pumps (GA-102 A/B)

1. Check that the steam pressure of turbine is normal.

2. Check for any carbamate leakage and each isolation valve for tight shut off.

(67)
3. Check the pressure at the discharge and balance line and also the temperature of
balance line.
4. Check that the pressure of seal water is normal.
5. Check the oil quality and oil pressure.

6.3 DECOMPOSITION SECTION

GENERAL
1. In order to assure the action of safety valves, check the steam isolation valves for
jackets.

2. Make sure the actual level of the solution in each vessel by visual check.

-High Pressure and Low Pressure Decomposer(DA-201 ,201)

1. Check the temperature of the solution.
2. Check the actual level in the vessel.

3. Check the passivation air flow to DA-201

--Gas Saparator (DA-203)

1. Check the temperature, pressure and level in Vessel.

2. Make sure the concentration of the urea solution is kept around 72%.

6.4 RECOVERY SECTION

-High Pressure absorber and cooler (DA-401 & EA-401)

1. Check the concentration of CO2 in HPAC(EA-401). The content of CO2 should be

kept at 6-7 litres CO2 gas/25 c.c solution during the normal operation.

2. Check the actual level of High Pressure Absorber cooler frequently and flush the
level troll of LCV-401 once in a shift.

3. Check the temperature throughout the system and regulate to design conditions.
Note: Keep the temperature at the top of HPA (DA-401) below 50°C

4. Flush the mist return line from the top of high pressure absorber periodically by low
pressure flooding water.

5. Check the operation of Recycle solution boost up pump (GA-403).

(68)
-Low Pressure Absorber (EA-402)
1. Make sure the pressure in low pressure absorber is lept at 2.0 –2.2kg/cm²G. In case
the pressure rises above 2.2 kg/cm² purge the accumalated inert gas to atmosphere by PIC
-402.
2. Check the actual level of low pressure absorber.
3. Check the concentration of CO2 in the cooler.
Note: Maintain around 2.0 litres Co2 gas/25 c.c soluation.

--Ammonia condenser (EA-404) and purge ammonia condenser (EA-403).

1. Check the temperature of recovery ammonia from each condenser.
Ammonia Recovery Absorber (EA-405)
1. Check the actual level.

2. Check the pressure and opening of the pressure control valve (PIC-405).
3. Check the operation of water pump GA-406 and aqua ammonia pump (GA-405).
Recovery Ammonia Reservoir (FA-401)
1. Check the operability of the flow meter (FRS-407).

2. Inspect all equipment hancling ammonia for leaks,

3. Check the actual level and drair oil in every shift.

4. Check amperage of ammonia boost-up pump (GA-404).

Off Gas Recovery System
1. Check the pressure temperature and level.

2. Check the operation of off-gas recycle blower (GB-401)

Note: Especially observe the draining of the blower.

3. Check feeding condensate to off gas absorbent tank (FA-403).

4. Check the flow rate of air.

6.5 CRYSTALLIZATION AND PRILLING SECTION
--Crystallizer (FA-201)

1. Keep crystal density of the urea slurry at 30-35%.

2. Check that the levels in the upper and lower crystallizers are correctly
balanced.

(69)
3. Control the feed rate to centrifuges according tp level in crystallizer.
Note: Watch the amperage.
4. Wash the upper part of crystallizer with hot water (HC-202) from top of the vessel
every shoft.
5. Check the operation of PRC-204.
Note: Flush the tapping of PRCA-204 with hot water once in a shift.
6. Check the jacketing hot water return flow at the upper part of crystallizer.
7. Check the amperage of agitator for crystallizer.
Note: The amperage is proportional to crystal density.

8. Check the operation of circulation pumps for crystallizer (GA-201) and slurry feed
pump (GA-202) and mother liquor pump (GA-203).

9. Maintain the design purge of mother liquor to LPA (EA-402) through FIC-204.

Centrifuge (GF-201)
1. Check the oil pressure, temperature and level.

2. Wash out each centrifuge once per day.

3. Check for abnormal noises or viberation.

4. Inspect the vent pipes of the centrifuge.

5. Check the rinse water flow.

6. Check the number of pusher strokes. Normally 60 strokes per min.

7. Check the deposition of dust catchers and keep them clean.

8. Check the condition of centrifuge and if necessary wash it once per shift.

Fluidizing Dryer (FF-301)

1. Check that dryer pressure balance is maintained to give a slightly negative pressure
at the crystals inlet.
2. Check the inlet air temperature.

3. Wash the dust after cyclone with water 3-5 minutes every 8 hours.

4. Make sure that the flappers of cyclones are working properly.

(70)
5. Check the suction strainer of FD fan GB-301 and keep them clean.

6. Inspection of dust boxes of cyclone and clean any urea deposition.

7. Check the operation of cyclone/Dust Boxes viberators.

Malter (EA-301) and prilling equipment

1. The temperature of molten urea should be maintained at 137°C.

2. Check the amperage of melter agitator.

3. Check the strainer overflow pipe and strainers for blockage.

4. Check and maintain level in Head Tank (FA-301).

5. Check operation of each distributor. Change distributors as necessary to maintain

good prilling operation.
6. Distributors and strainers should be washed-out at proper intervals.

7. Control the urea concentration of the solution in dust chamber (PF-302) and
maintain proper make-up in dust chamber.

8. Check the working of ID fans (GB-304) for prilling tower.

9. Inspect the fluidized bed of fluidizing cooler (FD-302) and adjust the air flow evenly.

10. Check the amount of urea lump recovered from Trommel (FD_303) and fkuidizing
cooler. If too much check the condition of distributors.

11. Check the operation of spray nozzles(PF-302). Circulation pump for prilling
tower(GA-302) and its discharge strainer.

(71)
6.6 NORMAL OPERATION

The normal operating conditions of each instrument are ad follows:

Normal Condition in Full Load Operation

Tag. No. Indication Point Normal_____

1. Utility Section
PIA-501 SH 40.0kg/cm²G
FIS-501 SH 74.5 Ton/Hr.
PIC-502 SM(Vent) 12kg./cm²G
PIC-505 SM 12 -do-
PIC-503 SU 7 -do-
PIC-504 S.L. 4.0 –do-
PIC-507 CW 3.5-4.5 –do-
 PIA-506 IA 7.0 -do-
TIC-501 SM(D.S.H.) 200°C
LIC-501 Steam condensate Tank
FIS-510 CW 6616 Ton/Hr.
FIS-511 CW 1975 "
TI 602-31 CW 33°C
TI 602-32 CW(UEE-201) 33°C
-35 SH 370°C
-36 SH 200°C

2. Synthesis Section
FIC_104 6 Ton/Hr.

LICA-102 Methanol Absorber

FRS-101-1 CO2 Booster Suction CO2 24690 Nm³/Hr.
FIC-103 CO2 Booster Inlet I.Air 61.7 "
FIC-1051 CO2 Booster 25260 "
SI-1051 CO2 Booster Turbine 7930 rpm
PIC-1001 CO2 Booster Outlet 30965 kg./cm²abs
Recycle Sol’ n Feed 98.9 Ton/Hr.
Pump Suction
PRCA-101-1 Reactor 250 kg./cm²G
FRC-102 Reactor inlet liq NH3 85.5 Ton/Hr.

(72)
FC-101 No. 2 N.P. Outlet
Steam cond.
TR -101-1 Reactor bottom 195°C
-2 Reactor top 200°C
-3 Reactor inlet Liq. NH3 82.3°C
-4 Reactor lining 195°C
-5 Reactor shell 195°C
TR-602-1 CO2 Booster inlet CO2 20°C
-2 Reactor inlet CO2 140°C
TI-602-4 No. 1 NP-H outlet Liq. NH3 53.2°C
-30 No. 1 NP-H Outlet Hot water 73.8°C
LIC-101 Flush Drum
PIA-103 Recycle Sol’ n Feed 24 kg/cm²G
Pump Section
SI 1301 A,B Recycle Sol’ n Feed pump 6500 rpm.

3. Purification Section
 PIA 201 HD Top 17.5 kg./cm²G
TIC 201 HD Middle 151º C
TRC 202 HD Bottom 165º C
LICA 201 HD
LIC 204 HD Cond pot for U-EA-201
LIC 208 HD " U-DA-201
FI 201 Air to HD Bottom 61.7 Nm³/Hr.
FI 202 Air to HD Middle 61.7 "
PIA 202 LD Top 2.5 kg./cm²G
TIC 203 LD Middle 130°C
FI 203 CO2 to LD Bottom 1.085 Nm³/Hr.
LIC 209 LD Cond. Pot for U.EA-202
PIC 203 GS Top 0.3kg./cm²G
TIC 204 GS Lower 92º
C
LICA 203 GS Lower
TR 101-6 HD Inlet U Sol’n 124ºC
TI 601-1 LD Bottom 115ºC
TI 602-5 HD Top 124ºC
-6 HD Middle U.Sol’ n 151º
C
-7 HD Bottom U. Sol’ n 165ºC
-8 LD Inlet U.Sol’
n 145ºC

(73)
-9 LD Top 117ºC
-10 LD Middle 130ºC
-11 DA-203 Gas 106ºC
-12 GS Upper 106ºC
-13 GS Bottom U.Sol’n 92ºC

4. Crystallization section

PRCA-204 CY Top 75 mm Hg Abs

HC 202 HW to CY
HC 203 Slurry to HA-C
LRA 205 CT Top
LRA 206 CY Bottom
EI 202 CY Agitator Amp.
FI 205 HW to HAC
FI 207 Steam to U_EE 201 1500 kg./Hr.
EI 201-A-E Centrifuge Amp.
HC 201 A-E Centrifuge Inlet Siurry
FIC 204 ML to LA 10.3 Ton/Hr.
LICA 207 Mother Liq. Tank
TR 601-2 Cy. Inlet Slurry 65ºC
-3 Cy. Bottom Slurry 60ºC
TI -14 Mother Liq. Tank 60º
C

5. Prilling Section

TICA 301 Dryer Inlet Air 110º C

PIA 302 Air Heaer outlet 250 mm Aq
PI 303 Fluidizing Dryer 0
PI 304 Cyclone Inlet 150 mmAq.
PI 305 Cuclone outlet 250 mmAq.
HC 302 ID Fan Exit
PIC 301 Steam to Melter 5 kg./cm²G
LIC 302 Condensate Pot for U-EC 301
EI 301 Agitator for U-EA-301
LRA 301-1 Head Tank
FI 301 CW to Dust Chamber 15.8 m³/Hr.
TI 502-15 Fludizing Dryer 110º C
-16 Cuclone outlet 60-65º C
TRA 302 Head Tank 137º C
301 Product 64.6 Ton/Hr.

(74)
6. Recovery Section

PI 401 HA Top 17.0 kg./cm²G

LRCA 401 HA-C
FIC 402 Liq. NH3 to Mix cooler 17.3 Ton/Hr.
FIC 403 Liq. NH3 to HA Top 5.8
TRCA 401 HA-C 100°C
FIC 401 LA to HA Carbamate soln. 28.9Ton/hr.
PICA 402 LA 2.2kg/cm²G
PIC 402 LA vent valve Close
LICA 402 LA
LIC 403 O.G.A. Tank
FI 405 O.G.A. Tank
LICA 404 O.G.A.
PIC 404 OGA Blower outlet 0.1+0.05kg/cm²G
FIC 404 OGA to LA Carb.Sol’ n 254 Ton/hr.
FRS 407 Liq. NH3 to U-FA 401 36.8 Ton/hr.
LICA 407 Recovery Amm. Resorvior
FIC 408 S.C. to N.R.A 12.9 Ton/hr.
PICA 405 N.R.A. 16.0kg/cm²G
LICA 408 N.R.A.
TRA 601-4 HA Top 50°C
TRA 601-6 HA Middle 65°C
-8 LA solution 45°C
TI 602-17 HA middle mixed gas 85°C
-18 HA-C inlet slurry 60°C
-19 HA-C outlet slurry 65°C
-20 HA-C solution 100°C
-21 HA-C outlet hot water 80°C
-22 O.G.A. Tank 55.6°C
-23 O.G.A. Top 36°C
-24 O.G.A Bottom 45°C
-25 U-EA 401 Inlet Liq. NH3 11°C
-26 U-FA 401 outlet Liq. NH3 30°C
-27 U-EA 405 Bottom Aq. NH3 37°C
-29 Mix cooler exit 65°C
TG-402 AD NH3 comd. Outlet liq. NH3 42.5°C
LA OUTLET CO2 2.0-2.5 1/25cc
HA-C outlet CO2 5.0-6.0 1/25cc

(75)
SECTION VII SHUTDOWN
Switching over from production to circulation run.
1. Reduce the plant load to 50% of the design.
2. Stop mother liquor feed to UEA-402,30 minutes before stopping CO2
feed to reactor.
Flush the line with condensate and live steam. If necessary put hot
Watet to UEA-402.

3. Stop CO2 feed to reactor. For this:

a) Stop CO2 feed to UDA-202.
b) Give HPF injection to EMV-101 and CO2 line NRV.
c) Stop UGB-102 and cheak for indication of closing of EMV-101 in
C.R. Close its discharge valve.
d) Maintain CO2 flow through UGB-101 by opening its vent.
e) Keep flushing of CO2 inlet line to reactor at least 30mts. stopping
CO2 feed.
f) Keep running CO2 booster compressure.
 g) Maintain carbamate flow through reactor by adjusting reactor
pressure control valve (PCV-101) on manual.
H) Take all the precation for stopping comperssors as recommended by
Supplier.
4. Stop NH3 feed to reactor 10 minutes after stopping the CO2 feed. For
this:
a) Condensate and hot water to No. 2 and No.1 ammonia preheater
respectively, should be stopped before stopping ammonia feed.

b) Stop UGA-102 pump. EMV-102 automatically close.

c) Close the discharge valve and open by pass valve.

d) Close the block valve of FCV-102.

e) Again control the reactor pressure so that flow through GA-102 is

maintained, otherwise it may trip on low suction pressure.
5. Gradually decrease temperature in each decomposer on hour after stopping CO2 feed
to reactor:
a) UDA-201 130-135º C
b) UDA-202 110-115º C
c) UDA-203 90ºC

6. Reduce passivation air flow to UDA-201 to 37 NH3/hr. at both the points.

(76)
7. Dilute the solution in UEA-401 and EA-402.

a) Increase the condensate feed to off-gas absorbent tank UFA-403 through FI-405.
Close LIC-404 (in discharge line of UGA-401 to DA-202) on mainual.

b) Increase the condensate flow to EA-402 by LCV-402

c) CO2 concentration in UEA-402 lowers to 1.0 lit.of CO2 gas and in UEA-401 to 2.5
litres of CO2 as gas per 25 c.c of solution.

8. Switch the urea solution of UFA-402 B from gas separator when urea concentration
goes to less than 60%.

9. Stop the recovery solution feed to reactor when the CO2 concentration of solution in
UEA-401 has come down to 2.5 liter of gas per 25 ml. of solution. For this:

a) Gradually decrease the pressure setting of PRCA-101 to about 180 kg/cm²g.

b) Stop HP carbamate pump (GA-102) and check for closinf of EMV-103.

c) Close PRC-101 fully to maintain reactor pressure.

d) Open LCV-401 fully in manual.

e) Open the low pressure flooding line at the suction of UGA-403 and flush the lines
(Including the pump).

f) Open the low pressure flooding water valve at the up stream of non return valve (in
feed line to reactor and flush back to the disch. Valve of UGA-102 pump).

g) Close the discharge valve of UGA-102 and flush the LCV-401 line.

h) Flush the EMV-103

Stop GB-401
- Close TIC-201, TRC-202, TIC-203 and TIC-204.
- Close passivation air to DA-201 middle and reboiler and stop Air.
- Compressor (GB-201).
- Close FIC-402 and 403 on manual.
- Divert UGA-405 pump discharge back to UEA-405 and run it in
Circulation. Stop UGA-406 pump.

(77)
- Flush UGA-402 pump and its discharge line and close FIC-401 in
Manual.
- Give injection of low pressure flooding water to the middle and
reboiler of DA-201.
- When level appears in LICA put it on auto and let this dilute urea
solution go to UDA- 202 and from there to UDA-203. Solution
fromUDA-203 may be pumped to urea solution tank (UFA-402B)
This solution transfer and minimum of one hour.
- Close isolation valves of LICA-202. Open drain of UDA-203.

During fluching, if there is need maintain pressures of UDA-201 and 202

at 12.5 kg/cm²g and 2.0 kg/cm²g with the help of N2.

NORMAL SHUTDOWN OF CRYSTALLIZATION AND PRILLING SECTION

1. Keep the slurry feed to centrifuges as long as possible to bring down the level in
gradually.
2. When the level in crystallizer is getting down, decrease the vacuum setting gradually.
3. Stop the slurry feed to centrifuge when the level of slurry is sufficiently low. After the
block valves of HC-201 are closed, wash the centrifuge. Wash down the lines and stop
mother liquor pump (UGA-203).

4. Slowly cut one by one the distributors but keeping the level in head tank when the level
comes down sufficiently low in head tank cut the remaining distributors and line-up the
head tank to dust chamber through the drain line. Flush all the pipe lines, Head Tank,
strainers (UFD-301), distributors with steam and drain to dust chambers.
Close PIC-331 (Steam to melter) on manual and its block valve.

5. close TICA-301 for Air Hater (UEC-301) on manual.

6. Flush the slurry line going to UEA-401 with hot water and bring down the
concentration of crystallizer down to 60%. Decrease the vacuum in the upper part of
crystallizer and finally open PCV-204 fully.

7. Cleaning the dryer system. For this:

a) Open man-hole of the dryer and inject hot condensate to the pneumatic dust for about
one hour.

(78)
b) Pay Special attention to the ammeter of the ID fan for dryer (UGB-302) and if
necessary close the dampers to prevent overload.
c) The water from cyclones should be drained.
d) Check the inside of cyclones (UFC-301) and then stop the hot condensate.
e) Stop FD fan (UGB-301) and ID fan for dryer (G302) and wash perforated plats or
dryer with hot condensate and drain it to dissolving tank.

8. Finishing section machines are washed.

9. In order to save power in case the shut down is of more than 24 hrs. duration stop all
the machines except the following ones:

UGA-403, One L.O.Pump of Centrifuges, Lubrication pumps of UGB-101, 102, UGA-

101 & 102, 2 Nos.of UGB-304 turn bytrun UGA-201 & UGA-202 and Agitator for UFA-
201.
 (79)
VIII UREA PLANT PROBLEMS AND REMEDIAL MEASURES
.
S.No Problem Reasons Remedial
Action .
UGB-101

1. Drift in Hydraulic system i) Common problem with i) Periodic

Overhauling
Of CO2 Booster BHEL System
ii) Sludge or Vapor locking ii) Stroke
checking in all S/DS
in oil lines
iii) Distrubed spring tension iii) Effective
oil centrifuging
iv) Prevent
water/steam entry in oil
from
labrynths.
2. High wheel chamber press. Due to drift in hydraulic As given
in S.No. 1
System & unbalance opening
of steam valves.
3. Cooler leaks in E1, E2 i) Reaction of moisture with i) Coolers
are normally kept N2
CO2 and later corrosion when
available
ii) Cooling water quality

4. High Axial displacement Jamming of coupling with i) Proper oil

centrifuging
of HPC oil sludge in it.
ii) Prevent
condensate entry from
turbine
labyrinths

5. Oil leaks i) Common problem with all To be

attended in all available
BHEL machines.
Opportunities.
ii) Flanges are not matching.
6. Corrosion of comp. lines Water in suction from leaky Open
proper drains/remove drain
Coolers. Valve
before starting to ensure
Draining.

(80)
. S. No. Problem Reason Remedial
Action__________________
UGB-102

7. IInd stage suction pressure i) Gas by passing at valves or i) Valves

checking
High inter coolers.
ii) High Suction temp. ii) Cooler
cleaning, if tubes are
choked
with carbonaceous
material.
Suppliers for using other
grade of
oil.
Quality in cylinder liner IInd stage cyclinder liner has
Compressor to be attended for
of II stage become oval. Repair
of cylinder.

8. Vibration and crack in level i) Indenquate supports i)

Additional supporting
Troll. (2 nd stage separator of ii) Defective material of pipe ii) Change
of pipe with right
H.P. Comp.)
material.

9. Succion strainer choking Due to cooling while starting i) Steam

hose to be provided on
H.P.Comp.
strainers.
ii) Proper
steam tracing and

insulation provided.
10. Muck deposition in cylinder Cooling water quality Cooling
water treatment changed
C.W. jacket of HP pump over to
organophosphanate.
UGA-101 A-D

11. Vibrations in Ammonia pumps Inadequate supports

Supports strengthened

12. S. Valve of NH3 pumps passing Seats gets eroded/corroded Periodi

cal overhauling
13. High oil consumption in NH3 i) Worm out gland packing i)
Packing to be kept in good
Pump
condition.
ii) Oil flow not proper ii)
Adjustment of oil flow.

(81)
. S. No. Problem Reason Remedial
Action_________________
14. By pass and drain valves i) High Vibrations i)
Vibrations reduction by
Opening due to vibration
proper supports
ii) Yoke studs breaking ii) Yoke
studs of batter material
and
stronger studs can be

provided.
UGA-102 A/B
15. Corrosion in carbamate pump 02 deficient atmosphere i)
Continuos/prelodical washing to
GA-102 during S/D and presence
remove/dilute carbamate soln.
Of corrosive carbamate as Ist
valves pass generally.
Solution. ii) Passing
valves to be attended at
Ist
available opportunity.
16. Carbamate backing in CO2 line i) Defective NRV Check
NRV/EMV on CO2 line at
ii) EMV Passing least every
year and avoid passing
of these.
17. CO2 carryover with NH3 i) Lower rector press at as i) Maintain
proper operating
Compared to capacity
conditions.
ii) High H.P.Abs. Temp. and ii) Trip the
plant when the H.A. top
delaued S/D decision temp.
reaches 65º
C
iii) Malfunctioning of level iii)
Provided TRA for HA middle
troll of LA reducing liquid temp.
flow.
18. Emergency plant trip due to i) Defective flange gasket i) Use of
better than normal type
NH3 leaks. Of
gasket.
ii) NH3 valve in drain line ii) Reduce
vibrations by proper
remained open by mistake.
Supportin
 iii) High vibrations in Amm. iii) NH3
vent shifting to a safer
Header causing drain valve heights
is proposed
to open.

(82)
. S. No. Problem Reason Remedial
Action__________________
19. Pitting in reactor lining i) Mainly due to H2S slip with i) Stop
plant when H2S in CO2
CO2
increases beyond 1 ppm
20. Leakage in Recovery absorbers water quality i) Proper
water treatment.
ii) Leaky
tubes to be plugged at
the
earliest.
21. Leakage from Ammonia condensers -do-
-do-
22. CFD plate sagging mesh damage i) Falling of Lumps i)
Levelling and repairing of
And inadequate cooling of prills CPD
plates.
ii) Use of scrappers for ii)
Cutting of skirt.
Dis;ocating accumulated heap.
iii)
Provision of rubber on side

skirts to clean it regularly and

avoid lump formation.

23. Leaks in dust chamber Attack on concrete by Urea
Epoxy coating of dust chamber
24. Failure of GB-304 motor Ingrass of moisture and urea i) Spare
motor is to be kept ready
Dust into motor windings ii)
Regular overhauling being done
iii) Motor
sealing arrangements
 made
proper to avoid ingress of
urea.
iv) Dust
chamber filters provided
to
avoid entertainment.
25. Replacement of butterfly valves passing. Isolation i)
Replaced with gate valves
i) UGA-203 A,B suction not possible.
(steam jacket) on urea lines.
And discharge
ii) UGA-201 A-B suction and
discharge
iii) UGA-201 A-B Suction and
discharge.-201 A-B Suction and
discharge.

(83)
S. No. Problem Reason
Remedial Action_____________
25A. Ammonia condensers inlet Valves passing. Isolation I/V
provided in C.W. intet
and outlet not possible. Lines
of condensers so that
these
can be isolated in running
26. Fines in prills i) High air humadity and temp. i)
Regular distributor cleaning
ii) Regular cleaning of distributors ii) Avoid
free NH3 in melt.
Not done.
iii) Leavelling of distributors iii) Avoid
to high melt temp
iv) Check
leveling of distributors
v) To
reduce fines and oversize
Provision
of acoustic granulators
Is being
considered.
27. High urea dust losses i) Improper washing of chamber i) dust
chamber filters regularly
Filters & choking of nozzles & velar
nozzles at the earliest.
ii) Improper functioning of ii) Rectify
faulty cyclone dampers
cyclones dampers.
iii) Removal of filters iii) Provide
new filters.
iv) High dust chamber iv) Maintain
dust chamber
concentration
concentration (14-18%)
28. Vibration problem in i) density disturbed i) density maintain
35-40%
Centrifuges ii) Improper supports ii)
Additional supports are being
Provided.
29. Ammonia Recovery i) More vapor load to absorbers i) increase
of system pressure
Absorber level high ii) Pump not taking load ii) Jet
cleaning of condensers & abso-
-rbers.
iii) Cooling water temp.high iii) Running
of third CT-II pump.
iv) Cooling water low flow.
30. CO2 Booster compressor HP/LP valve opening less due i) Check
amplifier system for HP/LP
speed running low. To hydraulic system problem. Valve.
ii) Check
LP valve’
s actual opening

(84)
. S. No. Problem Reason Remedial
Action__________________

31. Dryer temp. indication Urea falling on plate due to i) Maintain

proper air flow.
Going out of order. Insufficient air flow and
thermocouple embedded in urea.

32. UGA-103 H.P. flooding Capacity is low. Slight leakage i) Spare

pump has been provided
Pump not coveloping from plunger glands making for
maintenance flexibility.
pressure pump ineffective.

33. Urea and carbamate backing Due to passing/not closing of NRV or

double block and bleed
in steam and condensate lines injection valves. Valves
being provided.

(85)
________________________COMPARISON OF VARIOUS UREA
PROCESSES____________________________
Sr. MTC-C MTC-D Chemicao Stamicarbon SNAM
progetti
No. Variable Improved Recycle CO2 stripping
NH3 stripping_
1. NH3/CO2 3.5:1 4:1 4:1 4:1 2.8:1
3.54:1
ratio
2. H2O/CO2 0.55 .054 - - -
-
ratio
3. Temp. º C 195 200 200 - 180
185
4. Pressure
 Kg./cm²G 220 250 250 220 140
150
5. Conversion 60% 72% 69% 70% 58-
60% 65-67%
6. Liner SS316L+O2 Ti Ti S.S SS316
+O2 SS316L+O2
7. Excess Amm. Only as Amm. AS liquid As Liquid As Liquid As
carbamate As Liquid
recycle carb. solution Ammonia Ammonia Ammonia
Ammonia
8. Decomposition I-70K, 195º C I-17.5k I-80k 30% I-20k II No. I-140k All
CO2 I-150k about
LP steam 165º C with unconverted steam reqd. fed to
stripper LP 90% carbamata
generated 20% FFH reboiler ammonia in this stage to stripper
LP decomposed in
CO2 fed to II2.5k/135º C and CO2 Ammonia steam
generated stripper LP steam
Decomposer 5% CO2 fed are separate from 2 nd II.3k
generated.
Strips II. 12k, to LD III.0.3 Rest of the stage sent to
Carbamate recycle
III 3.5k K/atm.92º C stage are NH3 condenser
to reactor by
The same
ejector. III 4.5K.
9. Conc. & Vac. Con. At Crystallization Same as Induces draft Vac. Con.
At Vac. Con. At 0.3/
Prilling a prilling by & Prilling by MTC-C prilling tower 0.4/0.3 at
a 0.03 ata. Prilling
Distributors. Distributors improved prilling
by bucket dust
No screaning CFD at PT. buckrt.
Recovery system

At PT.

(86)
Sr. MTC-C MTC-D Chemicao Stamicarbon SNAM
progetti
No. Variable Improved Recycle CO2 stripping
NH3 stripping_
9. Conc. & Vac. Con. At Crystallization Same as Induces draft Vac. Con.
At Vac. Con. At 0.3/
Prilling a prilling by & Prilling by MTC-C prilling tower 0.4/0.3 at
a 0.03 ata. Prilling
Distributors. Distributors improved prilling
by bucket dust
No screaning CFD at PT. buckrt.
Recovery system

At PT.
10. Con./Te of 0.575/0.76/ 0.58/0.76/1.24 0.58/0.76/ 0.58/.75/
0.57/0.755/ 0.57/0.74/
Urea, NH3 0.90/140 1024/86/120 0.70/81/79 0.8/170 1/125
1025/114/90
CO2/Steam
Power CW.
Te/Te/Te,
KWH/M³
11. Salient Power saving Power saving Heat of No steam LP
steam Given in nest page.
Features as 20% CO2 fed to LD PT absorption heating in
generated.
Is fed to first height is fed at 80K is 2n d decom- No
carbamated
Decon. CW due to CFD at used to -poser flash
pump is red.
Saving as NH3 bottom Biuret preheat separators as it
recycled
Condensers are is less in prod- Ammonia to before deco-
through ejector.
Not there. No -duct. Liner reactor. 5K -mposers
Condensate are
Risk of damaging is T1 hence steam is reduce water
hydrolysed. NH3
NH3 handling less corrosion generated. Recycke NH3 and
CO2 are
Equip. due to Water recycle Steam,Power from 2 nd stage
recovered &
CO2 carryover is less due to & CW cons- is compressed
recycled. Excess
LP steam genre- counter current -umption are to 20K and
Ammonia feed is less
-ation. Flow of liquid less than sent to NH3
thus reducing the size
& vapour. MTC-C condenser. Of
recovery MP(17K)
Improved has
been eliminated.
Process. Rest
Features are same
As
(87)
SECTION –IX EMERGENCY SHUT DOWN
9.1 General
Emergency condition in the Urea Plant are caused by:
1. Less of utilities such as loss of electrical power, steam or cooling water.
2. Mechanical failure of machines or equipment which could prevent normal
Operation.

In some instance these conditions can be tolerated for a very short time if it is abvious
that conditions will improve almost immediately to their normal conditions. However in
general the emergency shut down is taken immediately.

In some cases emergency conditions might not be so serious so as to take a complete

shut down but bypassing the malfunctioning equipment until repair work is carried out
the plant can be operated.

The following steps are to be taken:

1. Determine the cause and extent of emergency condition.
2. Decide how to cope up the emergency condition.
a) Handle the emergency as a localized condition without shutting down the
whole Plant.

b) Shut down the plant according to “

Normal Shut Down”procedure.

c) Shut down the plant according to “

Emergency Shut Down”procedure.

The general emergency procedure consist of following basic action:

1. Immediately cutting of all the feeds to Reactor.
2. Flush all the urea, Carbonate lines with steam and or condensats to avoid any
Choking in the system.
3. Avoid wastage of Urea and Ammonia to the extent possible.

9.2 Electric Power Failure

 Electric power failure is most critical and require an immediate plant shut down.
Note: The emergency power source is given to following machines:
-Higher Pressure Flooding Pump: UGA-103
-Low Pressure Flooding Pump: UGA-104
-Hot water pump: UGA-204
Oil pumps of steam turbines of UGB-101 and UGA-102A, B Emergency light.
Beraring motor of GB-101

(88)
9.2.1 Operation in the control Room
a) TIC-201, TRC-202 HP Decomposer.
TIC-203 LP Decomposer.
TIC-204 Gas Separator.
HC -101 No. II Liq. Amm. Preheater
Close these valves completely on manual.
b) PRC-101-1
After confirming that all the feeds to reactor are cut orr, ckose above valve
completely on manual.
c) TRC-301 Air heater for Dryer.
PIC-301 Melter.
Close these completely on manual.
d) FIC-103 Air flow to CO2 booster suction
Close the valve completely on manual.
9.2.2 Operation in the field.
a) Switch off the main motors of UGA-101 and UGB-102 at the ;oca; boxes.
b) Close the steam inlet and outlet valves of UGA-102T and UGB-101T. Start
barring of UGB-101.
c) Cut off steam and hot water to UEA-102 and UEA-101 and drain the remaining
condensate.
d) Start UGA-103 and flush all the three feed lines to reactor.
e) Close the isolation valve on CO2 feed line to UDA-202.
f) Depressurise CO2 compressor and CO2 booster compresser .
g) Close the discharge valve of Ammonia feed pumps and open the bypass valve.
h) Start UGA-104 to flush the following pumps and lines and dilute the carbonate
solution in recovery section. Recycle solution feed pump.
Discharge line of UGA-102
Circulationline from UGA-403 to UEA-401.
Absorbant feed line from UGA-402 to UDA-401.
Note: Since the quantity of condensate is not sufficient in UFA-101 so it should be used
effactivelly.
i) Close the block valve of PRCA-101
j) Stop anticorrosion air to UDA-201 and UGB-101.
k) If pressure rises in UDA-401 or UEA-402 then vent it. l) Start
UGA-204 to flush a following pumps and lines and to dilute the Urea
solution in crystallization section.
Slurry line to and from UEA-101 and UGF-201
Motber liquor lines from UEA-203.
m) Close steam valve of vacuum generator.
n) Flush out all molten Urea lines & distributors with steam.

(89)
o) Other procedures except as mentioned above should be same as “Normal Shut Down
Procedure”and are carried out once the normal power is received.

9.3 Steam and cooling water failures.

All the procedure should be same as “Electric Power Failure”except the mentioned
below.
1. Immediately stop the slurry feed to centrifuge (GF-201). Stop prilling and flush
the molten Urea lines with remaining steam.
2. Centrifuge and water pump for prolling tower UGA-301 should be stopped to
prevent over heat.
a) Circulation pump for srystallizer UGA-201.
b) Slurry feed pump UGA-202.

NOTE: Treated water Is available.

3. Urea solution in crystallizer is to be diluted to 55% concentration by addition of

Hot water.
4. Water flushing of the vessels and lines from UDA-201 to UDA-203 are to be
Flushed with LPF water.
5. Check that all steam injection valves are in closed position.

9.4 Instrument Air Failure.

All the procedures should be same except mentioned below:
1. Keep in mind the action of control valves in the event of instrument air failures.

Note: Refer the attached sheets,

2. Regulate the pressure in UEA-405 by means of bypass valve of PCV-405

3. All the controllers of FC type should be switched to manual and close position.

Note: When the instrument air recovers the opening of the valve is not suitable.

4. Pay a special attention to rotating machines in the Point of cavitation, surging and
overload.
 (90)
SECTION X CONTROL VALVES ON PANEL
__________________________________________________________________
Taq No. Controlled Variable Control Valve
FISA-501 Main steam to plant flow Orifice plate in Inlet header.
FISA-510 Cooling water flow from Pilot tube in 40”inlet header.
CT-II.
FISA-511 Cooling water flow from Pilot tube in 24”inlet header
CT-III
PIA-506 Pressure or Instrument header In instrument air inlet header.
LIC-501 Level control of UFA-101 In export condensate line,
CRCA-501 Conductivity recorder of export -do-
Condensate.
TIC-501 Temperature of saturated 12kg/ In condensate line to
cm² header. Desulperheater.
FIC-503 Flow control of condensate to In condensate line to CW pit.
CW pit.
PIC-502 Steam Pressure of 12kg/cm² Vent line of 12kg. header.
Header.
PIC-503 7kg./cm² steam pressure. Let down valve of SM-SU
Header.
PIC-504 4 kg./cm² Steam pressure. Let down valve of SU-SL
Header.
PIC-505 Let down valve of SH-SM
Reactor.
FIS-501 Flow Integrator of 40 kg/cm²
Steam inlet to Plant.
FISA-510 Flow Integrator of CW from CT-II

FISA-51 Flow Integrator of CW from CT-III

FIA-1051 Flow indicator of UGB-101 discharge

PI-1062 Pressure indicator of UGB-101 T

exhaust.
HC-1052 Hand control in.
SI-1051 Speed indicator of UGB-101T

PIC-1052 Pressure control of UGB-102 inlet.

PIA-103A,B Pressure indicator in UGA-102

Suction line.

(91)
__________________________________________________________________
Taq No. Controlled Variable Control Valve
FL-105A,B Flow indicator in UGA-102A,B -----------
UST-102A,B Speed indicator of UGA-102TA,B -----------
PIA-201 Pressure indicator of DA-201. -----------
PIA-202 Pressure indicator of DA-201. -----------
FICA-203 Air flow to suction line of UGB-101 Air line to UGB-101
Suction.
LICA-102 Level control of DA-101 Condensate outlet line
of DA-101
PRCA-101 Reactor Pressure Outlet line of DC-101.
LICA- 407 Level control of UFA-401 NH3 inlet line to FA-401
LICA-201 Level control of DA-201 Outlet line (liq. Of DA-
201).
FIC-104 Flow control of condensate of Condensate to DA-101.
UDA-101.
LIC-101 Level control of DA-1102 Condensate outlet line of
UFA-102.
FRS-101-1 CO2 inlet flow of UGB-101 --------------
HC-101 Hand control (Temperature) Condensate outlet line
Of HN3. of UEA-102
FRS-407 Liquid Ammonia inlet to UF-401
TIC-201 DA-201 top temperature. Steam line to UEA-201.
FRS-101-1 CO2 flow integrator.
FRS-407 NH3 flow to UFA-401 intergator.
FRC-202 Temperature control of DA-201 middle. Steam line to UDA-201.
PI- 401 Pressure indicator of EA-401.
LICA- 202 Level of DA-202 Outlet liquid line of
DA-201.
LIC-203 Level of DA-103 bottom. Discharge line of
GA-205.
LRC-401 Level of FA-401 Bypass line from
102 to EA-401.
LICA-402 Level control of EA-402. Condensate line to
EA-402.
LICA-408 Level control of EA-405. Discharge line of
405 to DA-401
LICA-404 Level control of DA-402. Discharge line of
401 to DA-202

(92)
_________________________________________________________________
Taq No. Controlled Variable Control Valve
TIC-203 Temperature control of solution in Steam line to DA-203
DA-202 (middle).
TIC-204 Temperature control of DA-203 Steam line to DA-203.
Lower portion
TRCA-401 EA-401 temperature Cooling water outlet line
(carbamate solution) from EA-401.
PICA-402 EA-402 pressure. Gas line of EA-402.
PICA-405 EA-405 pressure. In the vebt line of EA-405
LIC-403 FA- 403 level. Outlet line of GA-408
To EA-407.
PIC-203 DA-203 pressure (top.) Gas outlet line of DA-203
(top portion).
FIC-408 Condensate flow control Condensate line to EA-405.
To EA-405.
FIC-403 Liquid Ammonia flow to Liquid Ammonia line to
DA-401 DA-401 top.
FIC-402 Liquid Ammonia flow to Liquid Ammonia line to
DA-401 mixing cooler.
FIC-404 Flow control of carbamate GA-401 delivery line to
Solution to EA-402 EA-402.
HC-401 Hand control. In C.W. outlet line of EA-402
UEI-201A-E Amperage Meter for GF-201A-E.
UEI-201 Amperage meter of FA-201 agitator
PI-303 Pressure/Vacuum inside FF-301.
PI-304 Hot Air pressure up stream of FC-301
PI-305 Air pressure upstream of GB-302.
UHC-201A-E Urea inlet slurry to GF-201 A-E.
UHC-202 Hand control in condensate line to
FA-201.
TICA-301 Temperature control of air from Steam line to EC-301.
EC-301.
PIC-301 Steam pressure in the inlet steam
Line to EA-301.
LRA-301-1 Level in Head Tank.

(93)
__________________________________________________________________
Taq No. Controlled Variable Control Valve

TRA-302 Temperature recorder of moltan

Urea in EA-301.

U-LRA-206 Level reforder of Urea solution

In EA-201.

PRCA-204 Vacuum control of FA-201 Air line to vapour outlet

Line fromFA-201.

LICA-207 Level control of FA-203. Delivery line of GA-203.

FIC-204 Flow control of mother liquor. Delivery line of DA-203

Going EA-402.

WIS-301 Urea production (Integrator)

HC-302 Hand control. UGB-302 outlet line.

LIA- 302 Level indicator of UEA-301 Condensate outlet line

Condensate pot. (Local control From condensate pot.
Of level in condensate pot).

LIA-301B Head tank level alarm.

FIC-401 Carbamate solution flow control GA-402 discharge line.

To DA-401.

HC-203 Hand control. GA-201 Discharge line.

 (94)
VALVES ACTION ON INSTRUMENT AIR FAILURE

Item No Service Action .

FIC-104 Condensate line to UD-101 Close

LIC-102 UDA-101 Open
FIC-101 CO2 booster suction by pass Open
PIC-1052 UGB-101 Discharge To Governor
FCV-105 UGB-101 Discharge. Close
TIC-1025 UGB-102 cooler Open
EMV-101-3 CO2 Ammonia, & RC to UDC-101 Close
FIC-103 Air to UGB-101 Close
PRCA-101-1 UDC-101 Close
HC-101 UEA-102 condensate line Close
FRC-102 Ammonia kine to U-FA-401 Close
LIC-101 Flash Drum Close
TRC-202 UDA-201 heater. Close
TIC-201 UEA-201 Close
LICA-201 UDA-201 Close
LIC-204 UEA-201 condensate pot. Close
LIC-208 UDA-201 condensate pot Close
TIC-203 UEA-202 Close
LIC-202 UDA-202 Close
LIC-209 UEA-202 condensate pot. Close
PIC-203 Gas separator- upper Open
TIC-204 UDA-203 heater Close
LICA-203 UDA-203 lower part Close
FIC-402 Ammonia to UDA-401 middle Close
FIC-403 Ammonia to UDA-401 top. Open
LRCA-401 UEA-401 level Close
FIC-401 RC line from UEA-402 to UDA-401 Open
LICA-402 UEA-401 Level. Open
 (95)
Item No Service Action .

HC-401 U-EA-402 C.W. Close

PIC-402 CW line of UEA-401 Open
LIC-403 UFA-403 Close
PIC-404 UGB-401 discharge. Open
LIC-404 UDA-402 Close
LIC-407 UFA-401 Close
PICA-405 UEA-405 Close
LICA-408 UEA-405 level Close
PRCA-204 UFA-201 upper Open
FIC-204 Mother liquor line from UFA-203 to
UEA-402 Close
LICA-207 UFA-203 Level Close
HC-203 UFA-201 circulation line Open
HC-202 Hot water to UFA-201 upper Close
HC-201A-E UGB-201 inlet Close
TICA-301 Air heater Close
PIC-301 Steam to melter Close
LIC-302 UEA-301 condensate pot Close
 (96)
EMV-101,102 & 103 OPERATION PRCEDURE
( Refer to Motoyama Engg. Works Ltd. Letter)

Step. Key Point Remarks

AUTO HAND WHEEL.

1. Shut –open

- Adjust the key stem to cross connection

Position of stem.

- Put on cross-connection key.

- Godown the cylinder to bottom position

by handle.

- Close the air supply valve.

- Open the equalizing valve.

-Check the air pressure comes OK(G)

- Open the value by handle.

2. Open-Shut
- Adjust the key stem to cross connection
position of stem.

- Put on cross-connection key.

- Go up the cylinder to top position by handle.

- Close the air supply valve.

 - Open the equalizing valve.

- Check the air pressure comes OK (G)

- Shut the valve by handle.

Do not operate over shut and open position by handle.

(97)
Step. Key Point Remarks

HAND WHEEL - AUTO

1. In case of shut position

- Adjust the shut position by handle.

- Close the equalizing valve.

- Open the air supply valve.

- check the air pressurs of upper cylinder Set pressure 4.5

Comes 405 Kg/cm² . Kg./cm²

- Remove the cross connection key.

- Lift up the key stem to neutral position

By handle.

2. In case of open position:

- Adjust the open position by handle.

- Close the equalizing valve.

- Open the air supply valve.

- Check the air pressure of lower cylinder Set pressure 4.5

Comes 405 Kg/cm². Kg/cm²

- Remove the cross connection key.

- Lift up the key stem to natural position

by handle.
 (98)
SECTION XI SAFETY

CENERAL.
The purpose of these safety instructions are to prevent any possible accident
in Urea Plant and to minimize damage for employees and plant equipments. So operating
personal should always follow these safety instructions
Keeping in mind that “ SAFETY IS THE FIRST” .
These are intended to supplement, not supersede, any existing general safety
regulations which covers all units and reference should be made to the latter for all points
not mentioned below:

1. Smoking shall be allowed only in designated areas. Lighers and matches shall not be
carried within an operating plant handling inflammables.

2. All personnel must know the location and use of all fire hoses and hydrants, fire
blankets, gas maskets and respirators and other protective equipment such as hard hats,
rubber gloves.

3. Intoxicants of any kind shall not be allowed to bring into or use in the Plant. Anyone
under the influence pf intoxicants will not be allowed in the plant area.

4. Pass only the specified side walks in the plant unless necessary.
5. Do not walk undercranes, books or loads being hoisted.
6. Do not jump from platforms, ladders etc.

FIRE PROTECTION
GENERAL CAUTIONS:
1. Foam type extinguishers and water must not be used in fires around electrical
equipment, carbon dioxide or dry powder extinguishers may be used.

2. The carbon tetrachloride extinguishers which liberates poisonous fumes should not be
used.

3.Carbon dioxide , dry chemical or foam type extinguishers are suitable for oil fires.
4. Do not use light distillates such as gasoline or nahthe to clean machinery or for any
other cleaning purpose. Use kerosene or heavier oil instead.

5. Keep all areas free of waste papers, and trash, especially oily rage and clothes should
not be left in lockers or tool boxes.

(99)
6. Lighting fixtures and electrical equipment should be vapour prop.

Fire and explosive hazards in the Urea Plant, Ammonia is capable of forming flammable
and explosive mixtures with air within certain range (16-28% by volume).
Such concentrations are seldom encountered in practical handling, accordingly, the
relative fire ad explosion hazards are small.

The presence of oil or a mixture of Ammonia with other corbustible material will
increase the fire hazare, The explosive range of Ammonia is broadened by the following
factors:
i) Admixture of hydrogen or Oxygen replacing air.
ii) Highar cemperature and pressure.
PERSONAL PROTECTIVE EQUIPMENT
The use of personnel protective equipment is urged under many circumstances for
the protection of eyes, hands and other parts of body.
- Respirator Protection.

All gases other than air are harmful to human beings if inhaled in sufficient
concentration.
Toxic gases may be classified as either as phyxiating or irritating. As phyxiating
gases may cause death by replacing air in the lungs or by reacting with the Oxygen
carried in the blood. Irritating gases may cause injury or death not only by as phyxration
but also by burns both internal and external.
When the following gas masks are used the correct type should be selecter
depending upon the circumstances.
- Canistar type mask.
- Oxygen respirator.
- Fresh air mask.
The characteristics and best application of such gas maske should be acquainted by
all operators.
- Eyes Protection:
Safe goggles should e worn to protect eyes whenever the following cases are
there in the plant:
- When handling acid, caustic Ammonia or other danagerous material.
- When working where materials may splash.
- When working around open lines and/or disconnecting the lines.
- When striking a hammer to another object which may cause a chiptofly.
-When sampling under pressure or operating drain and vent valves.
OTHERS
- Suitable rubber or plastic coat, pants. Boots and hood shall be worn when working on
lines or equipment which contains hazardous materials.
- Gloves should be worn at all times while operating. They protect your hands from cuts.
Burns, chemical burns etc.
- It is recommended that helmet, safety shoes and wellfitting clothes shall be worn at all
times in the plant.
SPECIAL CAUTIONS IN THE UREA PLANT.
-Plugging in lines.
When plugging occurred in lines with solidified urea solution and/or Ammonia carbamate
solution, first try to dissolve it by flushing with steam or hot water.
If the plugging cannot be dissolved by this method dis-connect the flanges to separate
pipe lines into suitable pieces. Care must be taken for the remained pressure in the lines.
Then at first try again to dissolve plugging with steam or hot water.
If still impossible, heat the pipe with flame from the end of the pipe and melt off the
plugging.
Never heat the pipe from the middle otherwise the decomposed gas will be pressurized in
the pipe and hazardous break of pipe or splash of hot solution might be caused.
-Sampling
When taking sample of solution or gas from a pressurized equipment for example from
high pressure absorber cooler care must be taken not to face against the flow from the
sampling valve but stand in parallel to the flow direction. Safety goggles and glover
should always be worn for sampling.
FIRST AID IN THE UREA PLANT.
When a person has inhaled Ammonia and fainted away move the patient to an
uncontaminated atmosphere and kept him comfortably warm and quite.

When he is suffocated give him artificial respiration of course, it is necessary to call a

physician first. When liquid Ammonia splashes into eyes, wash and clean up with water
or 2% baric acid solution thoroughly as soon as possible.
When skin is chemically burnt by liquid Ammonia immediately take off the clothes
contaminated with Ammonia , then was the effected area with large quantities of water
and wash again with 2% boric acid or saturated sodium thiosulphate solution.
When the patient can drink, give him large amount of ½% citric acid or lemon water.
When an ammonia solution is handled, such protective equipment as goggles and rubber
gloves shall be worn. Gas mask and rubber coal may also be required to wear in some
cases.
-Urea Solution.
Burn by molten Urea occur so often to naked hands and face. So the Operator shall wear
protective equipment for eyes and hands.
When skin is burnt by molten Urea, wash the part cleanly with water and apply ointments.
When the burn is serious, medical treatment by a Physician is required.
When Urea solution splashes into eyes, wash and clean up with water or 2% boric acid
solution at first and get medical treatment.
(1.) Specifications of GB-203 (Blower for Fludising Cooler)
Gas Composotion
- Air 100%
- Relative humidity at
Suction 81%
- Malecular Weight 29%
Capacity:
- 327620 NM3/hr. (Dry basis)
- 408540 NM3/hr. at suction
- Suction temparature : 31.404 (Dosign) Min -20C.
- Discharge pressure (Static) 150mm H2OG,
- Suction pressure (Static) -10mm H2OG,
- Di- ferential pressure: 160 mm H2O,
Materials:-
- Casing: 15226 (Carbon Steel)
- Impeller: 15226 (Carbon Steel),
- Shaft: 15226 (Carbon Steel),
Motors:-
Phuse: 3 RPM: 747
Cycle: 50 Weight: 7100 Kgs.
Volts: 3300 Ampers: 107
HP: 650 K.W. 480
PERFORMANCE:-
RPM: 740
BHP: 439 HP.
Weight of blower: 6220 Kva.
Sfficiency (Static): 60%
(2.) SPECIFICATIONS OF G.B-302 (Insuced fan from Dryer)
Gas Composition:
- Air: 100%
- Solid at Suction Urea dust contsined 1g.
- Relative humidity at suction: 26%
- Molecular Weight: 29 (Dry).
CAPACITY:
- 81450 NM3/hr. (dry base)
- 121700 NM3/hr. at Suction.
-Suction temparature 650C (Design) -2 0C minimum.
- Discharge pressure (Static). - 650 mm H20G.
- Suction pressure (Static): 700 mm H2O.
- Differentissl (Static):
Materials:
- Casing AISI 304 (A240 Type 304),
- Impeller AISI 304 (A204 Type 304),
- Shaft AISI 304 (AIS2 GR. F 304),
- Shaft Sleeve AISI 304 (AIS2 Gr. F504),
Performance:
RPM: 1450
BHP: 515 HP
Efficiency (Static): 64.5 %
Weight of the blower: 5250 Kgs.
Motor:
Phase: 3
Cycle: 50 Hz,
Volts: 3300
Ampere: 122
RPM: 1400
KW: 600
(3.) Specification of GB 301 (Foread fan for Dryer):
Gas Composition:
- Air: 100%
- Relative humicity at
Suction: 81%
- Molecular Weight: 29
Capacity:
-75180 NM3/hr. (Dry basis),
- 91150 NM3/hr. at suction,
- Suction temparature:31.40C (Design) -20C min.
- Discharge pressure (Static): 250mm H2OG,
- Suction pressure (Static): 8 mm H2OG,
- Differential pressure (Static): 250 mm H2OG,
Materials:
- Casing (Carbon Steel),
- Impeller ( Carbon Steel),
- Shaft (Carbon Steel),
Performance:
RPM: 985
BHP: 110 KW
Efficiency (Static): 81.5%
Motor:
Phase: 3
Volts: 415
HP: 150
KW: 110
Cycle: 50 Hz.
Ampere: 195
RPM: 990
(4.) Specification of GB 401 (Off Gas Recycle Blower).
Gas Composition:
- Air: 85.1%
- H2O: 5.6%
- NH3: 9.3%
- Relative humicity at
Suction: 100%
- Molecular Weight: 27.24%
- Specific weight
at Suction: 1.03
- Barometri Pr: 971 milli bar.
Capacity:
- 3010 NM3/hr,
- 3560 NM3/hr. at Suction,
- Suction temparature: 360C
- Discharge temparature: 900C
- Discharge pressure (Static): 5000 mmH 20G,
- Diserential pressure (Static): 5000 mmH 20G,
- Suction pressure (Static): 0 MM H2O
Materials:
- Casing SUS: 304
- Impeller SUS: 304
- Shaft SUS: 304
- Shaft Sleeve: SUS 304
Performance:
RPM: 2950
BHP: 80 KW
Efficiency (Static): 52%
(Adisbatic).
Motor:
Phase: 3
Volts: 415
HP: 156
KW: 100
Cycle: 50 Hz.
Ampere: 162
RPM: 2985
( 25CM2 grease to be injected after 1700 running hours),
(5.) Specification of GB 304 A D.
Capacity:
- 144670 NM3/hr. (Dry basis),
- 161940 NM 3/hr. ar Suction,
- Suction temparature Design: 350C,
- Discharge pressure (Static): 0 mm H2 OG,
- Suction pressure (Static): -50 mm H2OG,
- Differential pressure (Static): 50 mm H2OG,
Materials:
- Casing: AISI 304
- Impeller Aluminium alloy + AISI 304,
- Shaft AISI 304
OD 302 Weghing conveyor:
Operating condidtions:
Angle of repose: 25 degree,
Dry of wet: 0.2 % H2O,
Acid of alkali: Alkali (NH 3),
Quantity to be handled:
Maximum: 78 T./hr.
Normal: 64.6 Te/hr.
Minimum: 15.6 Te/hr.
Temparature: 40-500C,
Size: 1.5mm
Dansity (apparent): 750 Kg/M2
(6) Specification of GB 201 (Air Composser)
Description: Ist Stage 2nd Stage
Nos. of cylinders: 2 2
Stroke: 150mm 150mm
Displacement: 5.61M3/min. 1.60 M3/min.
Val. efficiency: 76% (overall)
Max. allowable cylinder pr, 7 Kg/cm2 35 Kg/cm2
Max. allowable cylinder temp. 200 0C 200 0C
Max. piston speed: 3m/Sec. 3m/Sec.
-Section relative humidity: 81%,
- Mo1, weight: 29
- Cp/Cv: 1.4
- Z at Suction 1.0
- Capacity: 204 M3/hr.
- Weight flow: 270.6 Kg/hr.
- Suction volume: 247.5 M3/hr.
- Suction Pressure: 0.99 Kg/cm2
- Discharge Pressure: 20.9 Kg/cm2
- Suction temparature: 31.4 0C
SUB-TANK
-Pressure: 19.9 KH/CM2
- SV Pressure: 22 Kg/cm2
- Temparature (Normal) 152 0C
(Alarm) 160 0C,
INTER COOLER:
 -Design Pressure: 7.0 Kg/cm2
- Pressure (Normal) 4.5 Kg/cm2
- Temparature: 600C
MOTOR:
-RPM: 980
-Volts: 415
- KW: 55
- Phase: 3
- Cycle: 50 Hz.
- HP: 75
After 3000 running hours, 35 CM3 grease is to be injected.
(7) Specifications of Heat Exchangers:
Sr. Description of Shell Side Tube Side Heat Nos. of
No. Equipment No. Temper- Temper- Duty Tubes
X100K X100K X100K
___ ___________ In Out In Out Cal/hr. ____
a) AMMONIA CONDENSERS 50 42.5 33 40 3.026 1614
(EA_404 A_E)
b) AMMONIA RECOVERY ASSORDER
- EA 405 (1/4, 2/4, 3/4, 4/4) 37 37 33 35 0.586 1000
- EA 405 (2/4) 37 37 33 35 0.241 406
- EA 405 (3/4) 37 37 33 35 0.160 275
- EA 405 (4/4) 37 37 33 43 0.045 76
c) OFF GAS CONDENSER (EA 406) 109.2 61 33 43 2.068 404
d) OFF GAS ABSORDER
FINAL COLER (EA 407) 55.6 36 33 34.5 0.0909 78
e) PURGE AMMONIA CONDENSER
(EA 403) 42.5 37 33 35 3.83 1690
f) LPA (EA-402) 50 50 35 40 7.252 2061
g) HPAC (EA-401) 100 100 60 60 - 1350
h) 70 80
35 50
h) CONDENSATE COOLER (EA-103) 60.5 40 33 35 0.727 257
i) No. 2 LIQUID AMMONIA
PRE HEATER (EA-101) 00 73.0 30 53.2 2.13 369
j) No. 2 LIQUID AMMONIA
PRE HEATER (EA-102) 151.1 100.2 53.2 83.2 2.84 299
k) REBOLDER FOR DA-201(EA 201) 183 183 151 151 16.44 1432
l) REBOLDER FOR DA- 202 (EA 202) 15 150 130 130 1.956 312
m) HEAT EXCHANGER FOR DA-202
(EA-203) 130 130 135 145 1.564 160
n) COOLER FOR DA-402 (EA-400) 45 36 33 34.5 1.011 1056
o) GB-101 E1 INTER COOLER: 35 40 131 40 1.104 1199
p) GB-101 E2 INTER COOLER: 196 41 35 40 1.857 856
q) GB-101 E3 INTER COOLER: 157 40 35 40 1.40 4653
r) INTERNAL HEATER FOR
DA-203 (DA203EA) 97 97 147 147 1.369 181
s) LO COOLER For GB-102E2 60 53.5 35 38 0.0227 116
t) INTER COOLER FOR GD-102E2
(EA-107) 133 60 35 41 1.8 228
u) GB 101 OILCOOLER GB-101
E4. 58.5 40 35 40 - 94x2
(8) Specifications of Urea Prills (As Per FCO & Ist)
A). Urea (4.6%N) Whils free felling:-
-Percentage of moisture 1.0 (maximum).
- Total Nitrogen % by weightion cry besis)
minimum 46.0C
- Blurst 1.5% by weight maximum.
- Particle size: 90% of the material shall pass through
2.0 mm is Slave and not less than 80%
by weight shall be ratained on imm is Slave.
9) Urea (Caoted-45%N) while free falling:
- Moistyre % by weight maximum 0.5,
- Total Nitrogen % by weight, content with cooling Minimum 45
- Bluret & by weight maximum 1.5
- Particle Size: 90% of the material shall pass
through 2.8mm is Slave and not
less than 80% by weight shall be
retained on 1mm is Slave.
EFFLUENT CONTROL IN UREA PLANT:
Urea is produced by the reaction of Ammonia and Carbondioxide along with the
equimolal quantity of water formation.
Liquid Effluent:
The water formed in the process as well as water added to the system must be
removed continously in Plant effiuant. Urea and Ammonia which are valuable
constituents are also present in this effluent water as a major toxic contaminates. Because
of the stringent pollution control regulations enforced by the Pollution Control Board,
liquid effluent emanating from the plant need adequate treatment before safe disposal. It
is required to control the effluent generation in the Urea Plant intself to save
Urea/Ammonia loos in effluent for sconomy reason as well as to reduce load in effluent
treatment plant. The major quantity of liquid plant for further Biological treatment for
reductions of Ammonia and Urea. Part of the effluent from reductions of Ammonia and
Urea. Part of the effluent from effluent pit is also sent to CT-3 pit as make up but the
concentration of Urea and Ammonia is not allowed more than 1.5% and 2000 ppm
respectively in CT-3 water. In the effluent Plant, treatment of this effluent is possible only
if concentration of Urea and Ammonia in the Chemical Sump is below 340 ppm and 520
ppm respectively. So Strict control of effluent generation is required.
The major quentity of effluent generated in the Plant is from Prilling Section.
Air passing through CFD picks up fine atomised undersized prillis and a scrubbin
system in used in the Dust chember through GA 302 A/B pump to remove urea dust in
exhoust gases. This is followed by from filters to arrest filter dust before the exhaust gas
emitted through GB 304/un.
The sources of liquid effluent in Prilling Section area;
i) DC make up to maintain level and concentration.
ii) Filter washed water.
In normal operation of the Plant around 15 Te/hr. make up water from CT-3 through CA-
301 is used in Dust Chamber.
10 tonnes/hr. are going out with gases and 5 tonnes/hr. being overflown to disolving tank
and reused in Crystallizer to maitain density. The quantity overflown from dust chamber
is also increased due to ingress of filter washed water in dust chamber during washing of
filters. Normally, washing of filters being done twicw in a shift. To control dust chamber
overflow it is required to reduce the make up dust chamber during washing of filters. If it
is not properly controlled dust chamber water started overflowing from dissolving tank.
Under no circumstances dissolving tank overflow is to be allowed sice it is wastage of
Urea along with water which is ultimately transferred to wffluent Plant through effluent
pump. As per design the cancentration of d/c overflow should be maintained between 15-
18% for better scrubbing. So by checked the analysis report of d/c overflow, adjustment
of make up in dust chamber is ressible.
A 150 M3 tank is installed and it is connected to CFD duct,. During washing of CFD,
the washed water to be collected in the tank and to be need in the process.
Chemical waste (Surface drain) going to effluent Treatment Plant for treatment should
not contain more than 340 ppm Urea and 520 Ammounts.
CASEOUS EFFLUENT
To per MINAS (Minimum National Standard) enforced by Central Pollution Control
Board Urea dust allowed in the air emanating from Prilling Tower top is 50mg/NM3.
ISOKINETIC sampling is done at regular intervals to monitor the Prilling Tower
emission rate. Polyurethene filters are need in the dust chamber to arrest the fine atomte
and Urea dust coming out from the CFD. However, some amount of Urea dust still
escapes through the filters which are generally of the order of 30-40 mg/Nm3 i.e. well
bellow the prescribed limit. Some amount of Urea dust is also amitted through wet
cyclones which is of the order of 20-25 mg/Nm3. Amount of Ammonia gas going through
PCV-405 is Kg/hr.

INTERLOCK DETAILS OF UREA PLANT

COMMON TRIPS HYPASS/OUT/DEFEAT
Sr. No. Function Setting Switches
1. Urea Plant Manual step
(PD-1).
2. 110 VDC failure
3. Instrument air failures
(Low Pressure) 4.5K BS-2
4. 11 KV Power failure BS-3
5. Synthesis Reactor high
Pressure 275K BS-1
CO2 DOOSTER GD-101 TRIPS
1. Cooling water flow low: DS-38 & CS-4
2. Suction Gas Pressure low: -0.30K BS-5
3. Exrtraction steam pr. high: 16.0K BS-6
4. Extraction steam pr. low: 9.5K BS-7
5. Exhaist hood pr. high -0.4K BS-30
6. LO Pressure low: 1.0K BS-8
7. Axial displacement high
(I casing) 28 mills BS-9
8. Axial displacement high
(II casing) 28 mills BS-10
9. Axial displacement high
(Turbine) 0.5mm BS-36
10. Suction valve not FULLY OPEN
11. PCV-103 CLOSE when GB-101
Trip (Air Flow) BS-39
CO2 COMPRESSOR GB-102 TRIPS.
1. Cooling water flow low. 80T/hr. BS-40 & CS-5
2. Lo Pressure low: 1.0K BS-11
3. Suction pressure low: 18K BS-12
4. EMV-101 Shut CS, DL-1, DL-LA BS-13
5. GA-102 or GA-101 TRIPS CS-3
CARBAMATE PUMP 102 TRIPS
PUMP A PUMP B
1. LO Pressure low 0.3K BS-23 BS-29
2. Seal water pump trip (Motor) BS-24 BS-30
3. Bypass temparature high 1200 BS-25 BS-31
4. Bypass pressure high 30K BS-26 BS-32
5. Suction low flow 10300kg/ BS-26 BS-32&
Hr. & CS-11 CS-11
6. Suction pressure low: 18K CS-11 CS-11
7. EMV-103 shut. BS-28 BS-28 &
&CS CS
8. GA-403 A/C TRIP BS-24 BS-30
9. Bypass valve Close BS-27 BS-33
AMMONIA PUMPS GA-101 ABCD
1. LO Pressure low A. 2.5K BS-14
B. 2.5K BS-17
C. 2.5K BS-19
D. 2.5K BS-21
2. SO Pump Stop. A. BS-15
B. BS-16
C. BS-20
D. BS-22
3. Crank Shaft overload A. BS-15
B. BS-18
C. BS-20
D. BS-22
4. EMV-102 Close BS-16
DI-2,2A,3,4,5 & 5A.
MATHANOL AUSORDER
1. GA-406 Stop FCV-104 CLOSE BS-34
AUTO START SYSTEM
1. GA 102A LO Pump 0.5K DS-6
Auto Start.
2. GA 102B LO Pump
Auto Start 0.5K DS-7
3. GB 101 LO Pump
Auto Start 6.5K DS-8
4. GB-101 Hot well pump
Auto Start 80% DS-9
START CONDITION SYTEM
A). Co2 BOOSTER GD-101.
1. Lo head tank lavel low: DS-43
2. Anti surge valve full open. DS-44
3. Vent valve full open. DS-45
4. Turning gear off: BS-46
B). CO2 CONPRESSOR GB-102.
1. Turning gear low: BS-47
2. LO Pressure normal: 1.7K BS-48
C). ATR COMPOSSER BG-201.
1. Lo Pressure low: BS-49
2. CW Flow low (Ist Stage) BS-50
3. CW Flow low (II Stage) BS-51
4. Loading start: BS-52
5. Unloading start: BS-53
D). OTHERS
GB-101
1. Seal Gas pressure high
steam valve to open: BS-54
2. Conductivity high control valve
GROA-501 to drain: BS-35
3. a. PJD-101 Trip
UJD-302 Trip
UJD-303 Trip
b. UJD-303 Trip
c. UJD-301 A/B trip
d. UGB-301 Trip
UGB-302 Trip
e. UGB-303 Trip
4. Ammonia Plant vant open CS-1
when booster trips.
5. GB-101 vent open when
GB-102 trips. CS-2
6. Antisurde valve full open
when GB-101 trips. CS-6
7. Crystalizer agitator starts when
its LO motor starts.
PUSH BUTTON SWITCHES
1. Urea Plant Manual Stop PD-1
2. GB-101 Reset PD-2
3. GA-102 A reset PD-3
4. GA-102 B reset PD-4
5. CRCA-501 High Conductivity reset PD-5
6. Manual stop reset PD-6
7. Bypass 1 amp Test PD-7
8. Running Lamp Test PD-8
NOTE 1
BS- Bypass Swithches
CS- Cut Switches
DS- Defeat Switches
PD- Push Bottons