Ammonia Storage & Handling

AMMONIA – I
SANJAY JAIN

1
 Introduction
Three methods of storage of Liquid Ammonia are currently used, the choice
primarily depending on the quantity to be stored, economy and end use.

Storage at ambient temperature and equivalent pressure in cylindrical vessels.

This method is used when relatively small quantities (2.5 – 150 T) are to be
stored.

Storage under pressure in spherical vessels. These can be constructed at sites

to hold several thousand tons of ammonia. However, very large spheres are
uncommon and most vessels are in the range of 500 to 3000 tons. Refrigeration
equipment may be used to lower the temperature of the ammonia and in such
cases the vessels operate at lower temperature than ambient. This type of
storage is often referred to as semi-pressure or semi-refrigerated.

Storage at atmospheric pressure. Ammonia can be stored at atmospheric

Pressure by reducing the temperature to –330 C. In this condition it may be
contained in cylindrical flat bottomed tanks, since the pressure, the tank must
withstand, is only imposed by the head of liquid. In practice, a slight positive
pressure is maintained to simplify the operation of refrigeration system. This
method of storage is generally adopted when quantities in excess of 3000 tons
are involved. Many tanks have been built in the 20000 – 35000 tons range with
few in excess of 35000 tons. 2
 Atmospheric storage tanks:

Cylindrical flat bottom tanks, used for large storage of ammonia in fully
refrigerated condition, may be divided into three basic types.

Single walled tank: This comprises of flat bottom tank with a dome roof
designed to withstand the stated conditions. Tanks of this type will have
external surfaces insulated to minimize heat gain from the surroundings.

Double wall tank: The outer tank is not designed to contain any escape of
liquid from the inner tank, its function being only to support and protect
the insulation. The simplest form comprises an inner tank which is
surrounded by an outer tank, from the roof which is suspended an
insulated deck designed to fit loosely with in the shell of inner tank.

Double integrity tank: This tank consists of double wall construction with
both tanks designed so that in the event of failure of inner shell the
ammonia will be contained by the outer shell. The inner tank is open
topped and the insulation be applied to the exterior of the outer tank .
The inter-space between the tanks will contain only cold ammonia vapor.
A suspended deck type insulation arrangement may be used as an
alternative to insulate the roof.

3
Process Description

Liquid ammonia is received from the ammonia plant

temp. of -330C. When ammonia is being transferred
to the storage tanks, flash vapors are generated.

In normal operation, vapor blower K-7001 is always

running to remove ammonia vapors generated due to
ingress of heat to the storage tank & are sent to
GP-II (Ammonia refrigeration compressor system)
for condensation & liquid ammonia production; and
only at the time when vapor blower (K-7001) is in
maintenance/break down or in the event of build up
of excessive pressure, these vapors taken to the
refrigeration system (K-2001 A/B) for liquefaction
and sent back to the storage tanks
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 From Tanks

PV 7001
PDIC 7001
PG
PG

Ammonia Vapor
from tank PV7002 Ammonia Vapor
to Amm-2
Ammonia Blower K-7001

5
 Ammonia Storage 6

Flare header
Flare
HV 502 A HV 502B
Ammonia Vapor

PIC 512

T
T 2001
2001 B
B
T 2001 A

EMV 506

EMV 507

Liquid Ammonia P-2001A P-2001B P-2001C

From A-1
Loading/Unloadin
HV 501
g arm

Liquid Ammonia
From A-2

HIC 7001 Ammonia to

PV 512 Urea
 Flare and drain system

For disposal of vent ammonia vapor from ammonia tank and

equipment safety valves (except safety valve on ammonia tank,
which shall be vented directly to atmosphere), flare system is
provided.

Drain system is provided to drain the vessels for any

maintenance. The liquid from drain lines from static equipments
are sent to vent drum where evaporated vapor ammonia from the
top is released to flare header.

The system consists of vent drum, flare stack, NG supply etc.

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Flare Stack
Flare stack height is 30 M which is designed for ground level
radiation of maximum 1200 BTU/hr/ft2 and ground level
concentration of 25 ppm ammonia and 30 ppm maximum NO X
concentration. It consists of 2 pilot burners, one flare tip and
automatic flare front generation. Flare stack is also provided
with labyrinth seal, which prevents ingress of atmospheric air
into the flare line by reversing the fluid path. Water seal is
provided for labyrinth seal and riser pipe to drain any rain water
that may enter.
Natural gas is used as pilot gas.
Supply rate : 6 Nm 3/hr.
Auto ignition temperature of ammonia: 651 0C
Explosive range of ammonia: 16-25 %.
To minimize the hazard, a small amount of nitrogen or natural
gas is continuously purged to flare header.  
2 NH3 + 3/2 O2 ---- N2 + 3 H2 O
But there is some possibility for generating some undesirable
oxides of nitrogen.
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9
9
 T-2001

K-2001 A
First Stage

250 mmWC to 2.7 Kg/cm2 g

10
 T-2001

Flash Vessel
K-2001 First Stage

11
 T-2001

Flash Vessel K-2001 Second Stage

K-2001 First Stage

2.5 Kg/cm2 g to 16 kg/cm2 g.

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Condenser

13
Receiver

14
15
16
Flare

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 PIC 7002

Ammonia Vapor
from T-2001 A/B Ammonia Vapor to AMM-
PV 7002 II

1 2

K-7001
PIC 509
K-2001 A/B

CW

PV 509

E-2001 A E-2001 B
Condenser Condenser
CW CW

V-2001
V-2002
LIC 504
LIC 505 LIC 506 To Flare PIC 511
V-2001 Header
Flash
Receiver
Vessel B-2001

Saturator
KO
Drum

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19
Storage Tank T-2001 A/B
6 mm Thick Single Tap Welded
Dome Roof

250 Thick Fiber Glass

Deck Insulation

3.6 Thick
Suspended Deck

Outer Shell Stiffener

Poly Urethane Foam Shell

25000 ID outer shell Insulation 210 mm Thick
t hgi e Hll ehs r et u0 00091

23400 ID inner shell

t hgi e Hll eh Sr ennI 00081

l ev eL di uqi L x a M02571

Bottom Insulation 200

Foam Glass bricks and
25 mm thick Sand Layer

Foundation
20
Ground Level
 Storage Tank Specifications
1 Storage capacity 2 x 5000 Tons of liquid ammonia at -330C
temp.
2 Normal Op. pressure of tank + 350 mmWC

3 Range of operating pr. of tank +200 to +800 mmWC

4 Design pressure of tank + 1050 mmWC

5 Design vacuum of tank - 50 mmWC

6 Safety valve pr. setting + 1050 mmWC

7 Vacuum relief valve setting - 50 mmWC

8 I.D. / Height (inner shell) 23.4 M / 18.0 M

9 I.D. / Height (outer shell) 25.0 M / 19.0 M

10 Insulation Shell - PUF

Suspended Deck - Fibre Glass

Bottom - Foam Glass

These storage tanks are of double wall, double integrity design (steel cup in steel
tank) and outer tank shell is designed to contain entire liquid ammonia in the event
of failure / leakage in inner tank
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Ammonia Compressor
K-2001 A/B
Service: To compress vapor
ammonia from tank during
holding duty and unloading
from plant.

Ist stage: (design)

Suction : 0.96 Kg/cm2 A / -20 0C
Discharge : 4.8 Kg/cm2 A./ 106.5 0C
Capacity : 621 Kg/hr.
2nd stage: (design)
Suction : 4.6 Kg/cm2 A / 1.5 0C
Discharge : 20.66 Kg/cm2 A./ 121.68 0C
Capacity : 883 Kg/hr. 22
Intermediate Flash Vessel: (V-2002)
Service: To saturate the compressor
first stage discharge before
compression in second stage by
bubbling the vapors through liquid.
Liquid is taken from V-2003 and
returned to T-2001.

Operating Pressure : 3.8 Kg/cm2 g

Operating temperature : 1.5 0C (max)
Design Pressure : 25 Kg/cm2 g
Design Temperature : - 34/60 0C
I.D. : 700 mm
Length : 2500 mm
Material of construction :LTCS.
Insulation : PUF

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 Ammonia Pumps P-2001 A/B/C

Service : To dispatch liquid ammonia to plant battery limits. The suction and
discharge headers of pumps are designed for a combine flow of 69 MT/hr.
The pumps can also transfer liquid ammonia from one tank to another tank
through plant ammonia unloading line.
The minimum flow to the pump suction is assured by minimum flow line. A
part of the discharge is sent to the tank via ARC (Auto Recirculation
Control) valve and minimum flow line when pump operates with discharge
valve closed condition.

Type : Vertical, Barrel, Multistage, centrifugal.

Capacity : 47 M3/hr. (32 tons/hr)
Minimum Continuous Flow: 10 M3/hr.
Discharge Pressure : 25.55 Kg/cm2 g
Efficiency : 56.4 %
Material (case/impeller) : LTCS
Motor (KW/rpm) : 75 / 2900
Insulation : PUF (cold)
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No. of stages : 10
Ammonia Blower K-7001

Capacity : 1719.6 Nm3/hr.

Inlet Volume Flow: 1654.43 Nm3/hr.
Temperature : -33 (min), -10 0 C (normal).
Pressure: 100 (suction)/ 1140 (discharge) mmWC g.
Differential Pr. : 1040 (rated) mmWC g.
Speed : 2940
Power : 9.8 KW.
MOC : case – LTCS, internals - SS
Impellers : 1,
Dia : 980 mm
Blades : 14
Driver : Induction Motor, 22 KW, 415 V, 50 Hz.

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 Safety
(1) Instrumentation of high reliability have been used viz. two
independent systems for the important measurements such as tank
pressure, level and temperature.
(2) Dependable alarms and interlock system for critical parameters.
(3) Flare system availability to take care of excess pressure build up by
venting & burning ammonia vapors manually or automatically through
HV-502 A/B.
(4) Reliable safety valves to take care of any build up of pressure in the
tank beyond a pressure of +1050 mmWC.
(5) Installation of Ammonia detectors( 7 nos.) at specific locations for
detection of amm. leak in storage area.
(6) Arrangement of water spray at tank top and water curtains around
compressors house, ammonia transfer pumps & B/L I/Vs to control the
leakage of ammonia at the source.

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PRESSURE / TEMP. AND LEVEL CONTROL FOR
AMMONIA STORAGE TANKS

1)      PRESSURE AND TEMPERATURE CONTROL

Under normal conditions, pressure control of vapour in the tanks

is achieved through the vapour blower, which discharges the
vapour into the suction of Amm-2 refrigeration compressor
system for compression & condensation of liquid ammonia. This
operation takes care of flash vapours generated during transfer
of ammonia to the storage tanks from ammonia plant & vapours
generated as boil off.

The Vapour blower K-7001 (having rated cap. of 1320 kg/hr) has
the capacity to handle the max. vapours generation, calculated
as 1307 kg/hr considering total ammonia production @ 150
T/hr of GP-I & II is transferred at -320C temperature when all
four streams of urea trips .
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In the event of build up of excessive pressure (above +750 mmWC) due to

(1) Failure of Vapour blower/refrigeration system or,

(2) higher rate of transfer of liquid ammonia from ammonia plant- I & II
resulting in higher generation of flash vapour or,

(3) Damage to insulation resulting in higher boil off,

Venting is done to flare stack through vent control valves HV-502 A & B
(Cap.595 kg/hr each) to bring the normal pressure in the tanks and to make the
conditions safe from any untoward release of ammonia vapors in the
atmosphere.
 
In addition to this, two nos. 12" x 16" safety relief valves (having relieving cap.
of 25,470 kg/hr & set pressure +1050 mmWC) and four nos. 8” vacuum relief
valves (suction cap. 3763 kg/hr) have been provided on each tank. The safety
valves are designed to release ammonia vapours that may get generated due to
any external fire around the tanks. While the vacuum valves protect the tank
from vacuum due to failure of safety interlocks or reliquification system.
These safety relief valves and vacuum relief valves are mounted on three-way
valves in such a way that even if one safety/vacuum relief valve is isolated for
maintenance the other valve remain lined up with tank. 29
2) TANK LEVEL CONTROL

If the level in storage tank is Very High, the level high alarm and
interlock I-103 will close the control valves PV-512 on the
wagon/truck unloading line and HV-501 & HV-7001 on the liquid
ammonia transfer line from plant – I & II. Similarly, in case of Very
Low level in the tank, the level low alarm and interlock I-104 A/B will
close the respective tank outlet valves (i.e. EMV-506 / 507).

Level Measuring System:
 
Ø Inner Tank is provided with
- Servo type Float operated Level gauge
- Differential Pressure type Level transmitter

Ø Outer tank is provided with

- Differential Pressure type Level transmitter

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Pressure/Temperature Measuring/Monitoring System:
 Normally the pressure/temperature in storage tank is maintaining between 200
mmWC and 550 mmWC and -33o C. The tanks are provided with

Ø      Pressure transmitter: used for recording the pressure of the tank
Ø      Pressure switches: used for compressor loading and unloading
Ø      Interlocks: To trip compressor and pumps on very low tank pressure.
Ø      The tanks are provided with Pressure gauge on each tank top, a common PG
at tank bottom, one pressure indicating recorder for each tank and one pressure
indicating controller are provided in control panel. Two number of multipoint
temperature recorder are provided to record liquid ammonia temperature in
storage tank and re-liquification system.
Ø      Pressure relief valves and Vacuum relief valves (Three way valves): protects
the tank from over pressure and vacuum incase of failure of safety interlocks or
reliquification system. These are mounted on three way valves in such a way that
if one pressure or vacuum relief valve is isolated for maintenance the other valve
remains lined up with tank.
Ø      The tank pressure can be controlled by manual venting device HIC-502 A/B.
when the tank pressure is high, the operator can manually vent vapor ammonia to
flare stack H-2001.
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 Alarm/Interlock Logic System:

A. Storage Tanks
1. Level alarm:
• If the level in the storage tank is very high, the level high alarm
and interlock I-103 will close the control valves PV-512 on
wagon/truck unloading line and HV-501 in the liquid unloading line
from plant.

• In case of very low level in the tank, the level low alarm and
interlock I-104 close the respective tanks out let valves.
I-104 A closes EMV-506
I-104 B closes EMV-507
If both the tanks level Is very low then both EMV-506 and EMV-507
are closed and this leads to the tripping of all the ammonia pumps.
 
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2. Pressure alarm
          · If the pressure in the tank is very high (805
mmWC), the pressure high alarm interlock I-102 will close
the control valves HV-501, HV-503, PV-512 and opens the
tank vents HV-502 A/B. This will lead to the closing of
liquid/vapor inlets to the tank and venting of ammonia
vapor from tank to flare.
· In case of pressure falling very low (150 mmWC),
I-101 will stop the ammonia pumps P-2001 and stops the
compressor.

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Interlocks - Ammonia Pumps

I-101 stops the pump in case of very low pressure in tank.

I-105 stops the pump if both tank outlet valves are

in closed condition.
I-106 A will stop the pump P-2001 A in case of low
differential pressure across the pump
(25 Kg/cm2 g)
I-106 B will stop the pump P-2001B in case of low
differential pressure across the pump

I-106 C will stop the pump P-2001 C in case of low

differential pressure across the pump.

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Interlock - Ammonia compressor:
I-101 stops the compressor in case of very low
pressure in tank.
I-107 trips the compressor in case of high liquid level
in the ammonia saturator V-2001.
I-108 trips the compressor in case of high level in
the intermediate flash vessel V-2002.
I-109 trips the compressor in case of low cooling
water flow to the condenser E-2001 A/B.
I-111 A/B Trip respective Comp. K-2001 A/B if the First
stage suction pressure is low. (-400 mmWC)

I-112 A/B Trip respective Comp if first stage discharge

pr. Is high. (4.2 Kg/cm2 g)

I-113 A/B Trips respective Comp. K-2001 A/B if second

stage discharge pressure is High (20.56 kg/cm2 g)

I-117 A/B Trips the respective Comp. K-2001 A/B if the lube
oil pressure is very low. (0.35 Kg.cm2 g)
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