Plant Energy Index Report - July 2020

Day 31 Month 7 Year 2020

Ammonia Net Efficiency Index Ammonia Feed Index

Load limited 24.00
due to
38.00 Load limited
MMBTU/MeT Ammonia

Load variations mainly due to refrig machine high discharge pressure limitation caused by high CWS temperature Load reduction due Load limited due to Syn machine Load reduction due to Load variations due to refrig Encop-3D
Load reduction due due to refrig
to Encop-3A S/D vibrations and refrig machine Syn machine machine high discharge planned S/D
to Encop-3C tripping machine high
pressure limitation
high discharge pressure vibrations
discharge 23.00

MMBTU/MeT Ammonia
pressure

Possible erroneous treated Mari Production loss

Low load operation due
22.00 feed flow rate during FGE offloading
to ENCOP-3C shutdown due to K-451B
Load increase, availing margin in CO2 slip
33.00 Variations in CO2 slip Variations in CO2 slip

21.00
Higher feed index at higher
load due to increased CH4, CO
20.00 slip

28.00 30/6 1/7 2/7 3/7 4/7 5/7 6/7 7/7 8/7 9/7 10/7 11/7 12/7 13/7 14/7 15/7 16/7 17/7 18/7 19/7 20/7 21/7 22/7 23/7 24/7 25/7 26/7 27/7 28/7 29/7 30/7 31/7
AM-2 38.97 38.75 39.03 38.69 38.64 39.07 38.30 38.36 38.52 38.63 38.79 38.71 38.59 38.40 38.50 38.73 38.74 38.31 38.32 38.75 38.58 38.85 39.86 39.21 39.10 39.50 39.34 38.59 39.62 40.04 39.88 39.00 19.00
AM-3 34.37 33.94 33.77 33.70 33.82 33.87 33.85 33.85 34.12 33.93 33.94 34.02 33.86 33.79 33.79 33.91 34.17 33.62 33.86 33.90 34.05 34.04 33.87 33.92 34.02 33.85 33.83 33.80 33.85 33.92 34.34 34.18 30/6 1/7 2/7 3/7 4/7 5/7 6/7 7/7 8/7 9/7 10/7 11/7 12/7 13/7 14/7 15/7 16/7 17/7 18/7 19/7 20/7 21/7 22/7 23/7 24/7 25/7 26/7 27/7 28/7 29/7 30/7 31/7
PSI Best 28.12 28.12 28.12 28.12 28.12 28.12 28.12 28.12 28.12 28.12 28.12 28.12 28.12 28.12 28.12 28.12 28.12 28.12 28.12 28.12 28.12 28.12 28.12 28.12 28.12 28.12 28.12 28.12 28.12 28.12 28.12 28.12 AM-2 20.78 20.79 20.80 20.78 20.80 21.05 20.97 20.79 20.82 20.75 20.79 20.77 20.90 20.88 20.92 20.68 20.77 20.73 20.86 20.77 20.82 20.96 20.94 20.88 20.70 21.02 20.95 20.62 20.58 20.71 21.04 20.95
PSI Average 33.75 33.75 33.75 33.75 33.75 33.75 33.75 33.75 33.75 33.75 33.75 33.75 33.75 33.75 33.75 33.75 33.75 33.75 33.75 33.75 33.75 33.75 33.75 33.75 33.75 33.75 33.75 33.75 33.75 33.75 33.75 33.75 AM-3 21.65 21.36 21.32 21.17 21.25 21.30 21.16 21.23 21.50 21.25 21.25 21.30 21.18 21.13 21.18 21.25 21.39 21.05 21.20 21.22 21.33 21.29 21.21 21.23 21.30 21.26 21.25 21.22 21.24 21.29 21.54 21.31
AM-2 FEL 119 122 118 121 121 123 125 126 124 121 120 119 125 125 126 115 118 122 126 121 121 123 113 117 113 118 118 122 108 106 113 121 PSI Best 19.95 19.95 19.95 19.95 19.95 19.95 19.95 19.95 19.95 19.95 19.95 19.95 19.95 19.95 19.95 19.95 19.95 19.95 19.95 19.95 19.95 19.95 19.95 19.95 19.95 19.95 19.95 19.95 19.95 19.95 19.95 19.95
AM-3 FEL 102 102 102 102 102 103 103 103 102 102 102 102 102 103 103 102 102 101 102 102 102 102 102 102 102 102 102 102 102 102 102 102 PSI Average 21.94 21.94 21.94 21.94 21.94 21.94 21.94 21.94 21.94 21.94 21.94 21.94 21.94 21.94 21.94 21.94 21.94 21.94 21.94 21.94 21.94 21.94 21.94 21.94 21.94 21.94 21.94 21.94 21.94 21.94 21.94 21.94

Ammonia Fuel Index Net Other Energy Index (Ammonia)

18.00 6.00
5.00
17.00 4.00

MMBTU/MeT Ammonia
MMBTU/MeT Ammonia

16.00 3.00
2.00
15.00 1.00
14.00 0.00
-1.00
13.00 -2.00
12.00 -3.00
-4.00
11.00 -5.00
10.00 -6.00 30/6 1/7 2/7 3/7 4/7 5/7 6/7 7/7 8/7 9/7 10/7 11/7 12/7 13/7 14/7 15/7 16/7 17/7 18/7 19/7 20/7 21/7 22/7 23/7 24/7 25/7 26/7 27/7 28/7 29/7 30/7 31/7
30/6 1/7 2/7 3/7 4/7 5/7 6/7 7/7 8/7 9/7 10/7 11/7 12/7 13/7 14/7 15/7 16/7 17/7 18/7 19/7 20/7 21/7 22/7 23/7 24/7 25/7 26/7 27/7 28/7 29/7 30/7 31/7
AM-2 13.04 12.93 13.06 12.94 12.95 13.10 12.96 12.88 12.95 12.98 12.99 12.98 12.93 12.91 12.92 13.18 13.25 13.00 13.01 13.07 13.02 13.11 13.43 13.21 13.31 13.34 13.27 12.96 13.62 13.79 13.60 13.20 AM-2 5.16 5.03 5.17 4.97 4.88 4.92 4.38 4.70 4.76 4.90 5.01 4.96 4.76 4.61 4.66 4.86 4.72 4.58 4.44 4.91 4.74 4.78 5.49 5.12 5.10 5.14 5.12 5.00 5.42 5.54 5.25 4.85
AM-3 11.48 11.31 11.29 11.30 11.40 11.40 11.40 11.38 11.29 11.37 11.45 11.45 11.35 11.34 11.41 11.38 11.49 11.27 11.32 11.32 11.46 11.49 11.48 11.49 11.44 11.47 11.42 11.45 11.51 11.51 11.64 11.52 AM-3 1.24 1.26 1.17 1.23 1.17 1.17 1.29 1.24 1.32 1.31 1.24 1.27 1.34 1.32 1.19 1.28 1.29 1.31 1.34 1.36 1.26 1.26 1.19 1.21 1.27 1.13 1.16 1.12 1.10 1.12 1.16 1.35
PSI Best 3.33 3.33 3.33 3.33 3.33 3.33 3.33 3.33 3.33 3.33 3.33 3.33 3.33 3.33 3.33 3.33 3.33 3.33 3.33 3.33 3.33 3.33 3.33 3.33 3.33 3.33 3.33 3.33 3.33 3.33 3.33 3.33 PSI Best -5.15 -5.15 -5.15 -5.15 -5.15 -5.15 -5.15 -5.15 -5.15 -5.15 -5.15 -5.15 -5.15 -5.15 -5.15 -5.15 -5.15 -5.15 -5.15 -5.15 -5.15 -5.15 -5.15 -5.15 -5.15 -5.15 -5.15 -5.15 -5.15 -5.15 -5.15 -5.15
PSI Average 10.83 10.83 10.83 10.83 10.83 10.83 10.83 10.83 10.83 10.83 10.83 10.83 10.83 10.83 10.83 10.83 10.83 10.83 10.83 10.83 10.83 10.83 10.83 10.83 10.83 10.83 10.83 10.83 10.83 10.83 10.83 10.83 PSI Average 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00

Urea Power Index Urea Steam Index

Urea-2 load reduction
200.00 due to planned C-2E 2.00
S/D
180.00 Urea-2 load reduction
due to Am-2 FEL
160.00 reduction Urea-1 start-up and

MeT Steam/MeT Urea

Urea-2 load varation as per Am-2 load variation Urea-2 load increase
140.00
KWh/MeT Urea

120.00 Urea-1 S/D due to GT-

601 S/D

100.00 Urea-1 S/D due to HPD

level transmitter 1.00
leakage
80.00 Low load due to CDR shutdown

60.00
40.00
20.00
0.00 30/6 1/7 2/7 3/7 4/7 5/7 6/7 7/7 8/7 9/7 10/7 11/7 12/7 13/7 14/7 15/7 16/7 17/7 18/7 19/7 20/7 21/7 22/7 23/7 24/7 25/7 26/7 27/7 28/7 29/7 30/7 31/7 0.00 30/6 1/7 2/7 3/7 4/7 5/7 6/7 7/7 8/7 9/7 10/7 11/7 12/7 13/7 14/7 15/7 16/7 17/7 18/7 19/7 20/7 21/7 22/7 23/7 24/7 25/7 26/7 27/7 28/7 29/7 30/7 31/7
Plant1- Urea 127.33 124.43 127.66 123.68 124.58 126.81 118.82 119.52 121.01 124.76 125.03 127.16 120.26 119.88 117.67 128.47 126.15 121.17 117.98 121.33 121.84 121.10 132.23 145.12 172.78 171.74 170.91 125.46 124.70 128.31 128.07 125.10 Plant1-Urea 1.50 1.56 1.56 1.25 1.30 1.33 1.23 1.57 1.56 1.59 1.59 1.61 1.50 1.52 1.48 1.44 1.61 1.50 1.39 1.26 1.27 1.25 1.41 1.44 1.39 1.40 1.39 1.45 0.97 1.00 0.97 0.96
Plant2-Urea 45.36 45.02 45.23 44.96 44.93 44.55 44.03 44.30 44.31 44.09 44.14 43.59 45.19 44.11 44.67 45.14 45.61 43.60 43.32 42.73 42.20 42.27 42.00 43.22 44.79 44.86 43.64 42.57 42.66 42.74 51.91 42.69 Plant2-Urea 0.98 0.98 0.98 0.97 0.97 0.97 0.95 0.95 0.94 0.95 0.95 0.96 0.95 0.93 0.96 0.97 0.98 0.97 0.96 0.95 0.91 0.92 0.92 0.96 1.00 1.00 0.92 0.94 0.94 0.95 1.15 0.94
PSI Best 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 PSI Best 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
PSI Average 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 PSI Average 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

Plant 1 & 2 Energy Index (HHV based) Comments:

Enven & Base Ammonia Plant Index:
1. Energy Index calculations are based on Plant Surveys International (PSI) guidelines & benchmark lines are drawn based on 42 ammonia plants located in 16 countries
2. GTs and boilers' efficiency is fixed at 40 and 90% respectively for Ammonia plant
Urea-1 start-up
3. ENCOPs' and GTs fuel along with steam credits of HRSGs' are part of plant index
36.00 4. Condensate debit and credit has been incorporated for both Ammonia plants
MMBTU/MeT Urea

Enven & Base Urea Plant Index:

1. Am-3 commulative production loss due to high CO2 slip is ~411 MeT, equivalent to 0.2 MMBTU/MeT Ammonia
31.00 2. Treated Mari fuel from FGE remained offline from 9th July. Variations in fuel index are due to low production due to CO2 slip
3. Ammonia loss of ~25-30 MeT due to K-451 on 30th July
4. PT-3 louver fell down on 30th July resulting in load reduction down to 80%, ~700 MeT Urea production loss
PT-3 louver fell down resulting in low load. 5. Am-2 experienced multiple load variations due to refrig machine high discharge pressure limitation caused primarily by unavailability of CT-2 Cell # 6. Benchmarking with 132% FEL that has been demonstrated
E-01 temperature issue on load increase
26.00 continuously, this has caused a loss of ~2000 MeT potential plant production in July.
6. Other than this, load reduction due to Syn machine high vibrations issue was also experienced. This load reduction amounts to a loss of ~600 MeT potential Ammonia production.
7. On 15th July Am-2 load reduced due to Encop-3A S/D, potential Ammonia loss of ~170 MeT
8. On 16th July Encop-3C tripped causing Am-2 FEL limitation at 117% (on average), potential production loss of ~150 MeT Ammonia
21.00 30/6 1/7 2/7 3/7 4/7 5/7 6/7 7/7 8/7 9/7 10/7 11/7 12/7 13/7 14/7 15/7 16/7 17/7 18/7 19/7 20/7 21/7 22/7 23/7 24/7 25/7 26/7 27/7 28/7 29/7 30/7 31/7 9. Am-2 load remained limited due to Encop-3D planned S/D on 28th,29th July (107% on average), potential production loss of ~500 MeT Ammonia
Plant 1-Unadjusted 30.73 30.82 30.87 30.51 30.76 31.56 30.04 30.30 30.42 30.66 30.67 30.98 30.21 30.11 29.78 30.48 30.37 30.02 29.80 30.07 29.83 30.20 30.21 33.71 44.71 45.90 45.92 36.18 31.82 32.24 33.69 34.29 10. Urea-1 S/D on 23rd July due to GT-601 S/D
Plant 2 Unadjusted 23.73 23.22 23.21 23.20 23.40 23.26 22.97 23.20 23.30 22.87 23.02 23.21 23.31 22.74 22.99 23.13 23.28 22.75 22.79 22.66 22.82 22.90 22.69 23.02 23.68 23.71 23.55 22.63 22.80 22.83 27.71 22.89 11. Urea-1start-up initiated on 27th July but shutdown again due to leakage from HPD level transmitter
Plant-1 Adjusted 29.89 29.98 30.25 29.91 30.01 30.31 29.71 29.65 29.82 30.00 30.08 30.10 29.80 29.73 29.66 30.21 30.14 29.67 29.61 30.03 29.85 30.05 29.81 29.81 31.81 31.99 32.11 34.59 30.87 30.37 31.11 30.46
Plant-2 Adjusted 23.89 23.51 23.50 23.39 23.53 23.66 23.60 23.69 23.79 23.63 23.67 23.68 23.54 23.50 23.58 23.59 23.72 23.32 23.61 23.59 23.79 23.75 23.68 23.67 23.60 23.58 23.69 23.58 23.73 23.77 24.43 23.77