Failure of LP Flash Drum Packing Bed Support

The QAFCO-3 ammonia plant was tripped due to power failure. During start-up of CO2 removal
section, semilean solution pump tripped on low flow. Both semilean and stripper feed pumps strainer
found choked with 2” CS pall ring packing. LP flash drum bottom manhole opened subsequently and
found around 50 m3 (1766 ft3) of packing in sump area. Packed bed inspected and two bottom plates
of packed bed support found lifted from shell support ring towards upside direction by vertical force.
Packing from LP flash bottom sump unloaded and reloaded back in the column. Bottom packing bed
support repaired and production resumed after 9 days shutdown. The paper describes the root cause
of packed bed failure, bed support repairs and post repairs experience.

Geoff Blewett
Qatar Fertiliser Company, QATAR

Umesh R Desai
Qatar Fertiliser Company, QATAR

Introduction
Rich amine solution is regenerated in a two

Q atar Fertilizer Company S.A.Q. (QAFCO)

is located in Mesaieed, Qatar and operates
six ammonia and five urea production
stage flash drum and a stripper.

The CO2-enriched solution from the bottom of

trains. Sixth urea train is under construction.
The ammonia-3 plant is designed for 1500
MTPD (1653 STPD) based on natural gas steam
reforming technology. The plant is designed and
supplied by Uhde. The plant was commissioned
in January 1997.
CO2 product is removed from the process gas by
BASF's OASE process (See Figure 1). The
solution used is an aqueous amine solution with
an activator, contains around 40% MDEA and
balance water (by weight). The OASE process is
characterized by both a physical and a chemical
scrubbing system. CO2 removal system consists
of a two-stage absorber, a CO2 stripper, a HP
flash drum and a LP flash drum.
Process gas from low temperature shift
conversion is treated in CO2 removal section.
Process gas enters at bottom of CO2 absorber
and amine solution enters from top in two stages
i.e. lean solution and semilean solution. To
prevent loss of solution & activator by
entrainment in process gas, top of absorber
column is provided with BFW washing trays.
the absorber at 3350 kPag (486 psig) is fed to
HP-Flash Vessel via hydraulic turbine, where it
is expanded to approx. 560 kPag (81 psig).
During this process, mainly the dissolved inert
gases (H2, N2, CH4 and CO) are liberated along-
with some CO2. These inert gases are then fed
into the fuel gas system of primary reformer or
can be burnt in flare.
The flashed OASE solution from HP flash
vessel is expanded to approx. 25 kPag (3.6 psig)
into LP-flash vessel. In LP-Flash Vessel, the
OASE solution is heated with countercurrent
overhead gas (CO2)/steam from the stripper to
release CO2 from the solution.
Semilean solution from bottom of the LP-Flash
vessel splits into two streams. A part of semi-
lean stream, i.e. approx. 14%, is fed by means of
stripper feed pumps via lean/semi-lean solution
heat exchanger to the top of the stripper.
Balance (86%) of solution is fed to the middle
of the absorber by means of semi-lean solution
pump. This absorbs a major amount of CO2 in
the absorber.

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 In the stripper, the semi-lean solution is stripped
with countercurrent steam generated in reboiler.
In this manner, most of the CO2 is removed
from the solution. The regenerated lean OASE
solution leaves the stripper bottom, cooled in
lean/rich solution heat exchanger followed by
solution cooler and fed to the top of the absorber
by lean solution pump.
The CO2 & steam vapors from the top of the
stripper are fed into the bottom of the LP-Flash
vessel where vapors are used for heating up the
rich OASE solution, resulting in a better
performance of the low pressure flash. To
prevent loss of solution & activator by
entrainment with saturated CO2 gas, top of LP
flash column is provided with washing trays
using condensate recovered from CO2 product
or DM water during start-up.
The saturated CO2 product from LP flash drum
top after cooling in cooler and condensate
separation exported to urea plant.
LP flash drum is a packed bed column with bed
height of 6.0 meter (19.7 ft) and total packing
volume of around 137 m3 (4873 ft3). Top 1
meter (3.3 ft) of packing is provided with 2” SS
pall rings and bottom 5 meter (16.4 ft) of bed
provided with 2” CS pall rings. The vessel is
situated on top of the HP flash drum. LP flash
drum sump solution outlet elevation is approx.
18 meter (59 ft) and packed bed support is
approx. 29 meters (95 ft) above the ground
level. Solution outlet 28” line (approx. 10 meter
long - 32.8 ft) divides into two branches; one
10” supplying solution to stripper feed pump
(approx. 35 meter long -114.8 ft) and another
24” supplying solution to semilean solution
pump (approx. 21 meter long – 69 ft).
The incident
On August 28, 2011 at 00:34 hrs, plant tripped
due to 11kv power supply failure. After
confirmation of power availability, plant start-
up was delayed due to reformer FD fan suction
AMMONIA TECHNICAL MANUAL
2012
damper sticky operation. The front end up to
High Temperature shift converter started on
August 28, 2011.
CO2 removal section was prepared for start-up
and solution circulation was established on
August 29, 2011. LP flash drum level was
showing 99% (normal 35-40%) and stripper
level was showing 99% (normal 75-80%). CO2
production was lined up at 11:50 hrs. After
lining up of CO2 product, LP flash drum level
(95-99%), stripper DP, LP flash drum DP, CO2
header pressure was fluctuating. Semilean
solution pumps suction pressure was also
fluctuating between 280 kPag (40.6 psig) to 330
kPag (47.8 psig). CO2 header pressure was set at
31.6 kPag (4.6 psig).
At 14:25 hrs, set point of CO2 header pressure
reduced to 26.6 kPag (3.8 psig). At 14:38 hrs,
semilean solution flow dropped below trip
setting (<900 m3/hr – 3963 USGPM) and
semilean pump tripped. Stripper feed pump flow
also reduced substantially to 75 m3/hr (330
USGPM). Both lean and stripper feed pumps
stopped. Solution strength was measured and
found drastically reduced to around 17.4% from
38.7% of normal MDEA. Level in the LP flash
and stripper reduced by solution draining to slop
tank. OASE solution circulation again started
with lean solution pump and stripper feed pump
at 19:29 hrs with less flow.
At 19:35 hrs, attempts were made to restart
semilean pumps but each attempt resulted in
pump tripping due to low flow. Sharp reduction
in suction pressure observed from 250 kPag
(36.2 psig) to 47 kPag (6.8 psig) just after the
pump start. Solution circulation stopped again.
It was decided to open the suction strainers of
pumps.
Preliminary Inspection:
Both semilean and stripper feed pumps suction
strainers were opened. Strainers of semilean and
stripper feed pumps were found fully chocked
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25 AMMONIA TECHNICAL MANUAL
 with 2” pall ring packing. This has confirmed
disturbance in the packed bed of LP flash drum
or stripper. Both stripper and LP flash vessels
opened to inspect the bed condition. Summary
of observations follows:
 50 m3 (1766 ft3) of CS pall rings found in LP
flash drum bottom sump (See Figure 2).
 LP flash drum two bottom support plates of
packing support grid found opened / lifted
from the shell support ring near stripper
steam inlet nozzle (N8) (See Figure 3).
Packing at bed support opening plugged due
to packed bed height. Some clearances
observed in the support grid segments.
 Top liquid distributor gallery plates found
de-shaped (bent) and cracked near the bolts
towards same side of damaged bed support
due to vertically upward force of vapors.
 Top liquid distributor riser screens found
damaged and packings found on top of the
distributor gallery. (See Figure 4)
 Some pall rings also found in stripper vapor
inlet nozzle to LP flash drum bottom.
 Semilean solution Pumps and stripper feed
pumps suction lines from LP flash drum
sump found chocked with packing. See
Figure 5 for LP flash drum outlet suction
piping layout.
 Stripper top & bottom man-ways opened
and no abnormalities found in vessel.
 HP Flash Drum also inspected from both top
and bottom man ways. No abnormalities
found in the vessel.
Actions Planned:
An emergency meeting was called to decide
further course of actions. It was decided
 To unload LP flash drum sump area 50 m3
(1766 ft3) packing.
 To erect scaffolding for close visual
inspection of LP flash drum packed bed
support.
 To repair bed support grid from bottom of
the bed. Repair procedure to be finalized
after close visual inspection.
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2012
 To remove damaged packing from bottom
sump 50 m3 (1766 ft3). To reload remaining
packing and new 9 m3 (318 ft3) available SS
pall ring packing to LP flash drum top.
 To repair top distributor riser screens and
de-shaped plates of feed flash gallery.
 To remove packing from LP flash drum
outlet 28” line, semi-lean pump 24” suction
line and stripper feed pump 10” suction line
by filling and draining of water or by water
hydro-jet/fire water jet in pipes. If no
success in above two methods then by
cutting the pipelines at appropriate locations
for ease of removal of packing. Vacuuming
was not considered for packing removal
based on previous unloading experience
without any success, long pipes and higher
elevation of LP flash drum.
Jobs Performed:
 After lining up of contract, bottom 50 m3
(1766 ft3) of packing unloaded manually in
24 hours from LP flash drum sump.
 Scaffolding erected at LP flash drum bottom
for closed visual inspection and to finalize
the repaired procedure. It was observed that
2nd and 3rd packed bed support plates got
lifted by approx. 8” from the shell support
ring due to vertical upward force.
Adjustment of lifted plates back into
position was not easy task (safety concern)
due to packing weight on the support bed. It
was decided to repair lifted plates in position
by covering the bed openings. Accordingly,
the opening in the two lifted plates was
closed by welding perforated sheet box in
sections using SS316L (See Figure 6). It was
planned to do permanent repairs during
planned inspection shutdown after 6 months.
 LP flash drum packed bed bottom support
plates secured with additional reinforcement
by tacking support from main beam to shell
support ring.
 No entry permitted at LP flash drum top to
avoid any vibration and further loss of
packing from the packed bed until
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 completion of sump area packing unloading
& repair of packing bed support lifted plates.
 Top liquid distributor riser screens and de-
shaped liquid gallery plates opened and
repaired in workshop.
 Damaged packing removed from LP flash
vessel sump unloaded packing and rest
approx. 41 m3 (1448 ft3) of the packing
reloaded in the packed bed top.
 New 9 m3 (318 ft3) 2” SS pall ring packing
loaded above 2” CS pall rings. Top SS bed
height was now 400 mm (1.3 ft) against
original design of 1000 mm (3.3 ft).
 Stripper feed pump suction isolation valves
spool dropped for ease of removal of
packing.
 Semilean solution suction strainers kept
opened and secured with plastic and wooden
sheet to prevent any debris towards the
pump.
 Packing removal tried from LP flash drum
bottom nozzle by hydroject and fire water
jet without any success. In order to save
time, LP flash drum bottom solution outlet
line was cut at 3 locations. One at T-joint of
both pumps suction, one at 24” semilean
pump suction line and one at 10” stripper
feed pump suction line.
 Packing unloaded after cutting the pipeline
manually and by using hydrojet water from
opened pipe access.
 Boroscopic inspection done from
appropriate locations for both 24” and 10”
pipeline to ensure that pipes were free of
packing. However, entire length of the 10”
line could not be inspected using this
method.
Problem Analysis:
 After plant trip on August 28, 2011 process
gas BFW wash water valve to CO2 absorber
and LP flash drum condensate return valve
were not isolated. DM water make-up
continued in the LP flash drum during
shutdown period of 24 hours. This increased
the level in the columns during start-up.
AMMONIA TECHNICAL MANUAL
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 Lean, semilean and stripper feed pumps of
CO2 recovery section started and OASE
solution circulation established on August
29. Column levels were around 70% in
absorber, 74% in HP flash vessel (normal
55-60%), 95-99% in LP flash vessel (normal
35-40%) and 100% in the stripper (normal
75-90%). Column levels were not adjusted
after establishing the OASE circulation.
 09:32 hrs to 11:00 hrs: solution heating was
completed, process gas introduced to
absorber and CO2 product to header / urea
plant lined up.
 Semilean solution pump suction pressure
was higher and between 310-320 kPag (45-
46.4 psig). During normal operation, semi-
lean pump suction pressure remains around
230 kPag (33.3 psig). Higher suction
pressure indicates the solution level was up
to 1 to 2 meter (3.3 to 6.5 ft) into the packed
bed. This is around 1.6 to 2.6 meter (5.2 to
8.5 ft) above the steam inlet nozzle from the
stripper.
 LP flash drum was provided with only one
level indicator (not controller). Level in LP
flash vessel was fluctuating between 95-
99%. Level was not showing higher than
99% due to calibration error.
 Physical location of LP flash drum level
transmitter LP taping is very near to steam
inlet nozzle from stripper i.e. at a
circumferential distance of 2.5 meter (8.2 ft)
and 0.25 meter (0.8 ft) below nozzle
elevation. Lower indication (95-98%) of
level was due to turbulence effect of steam
entering in LP flash vessel high level.
 At 12:46 hrs semilean solution flow was
further increased from 2100 (9246 USGPM)
to 2400 m3/hr (10567 USGPM). LP flash
drum level came down to 87% due to
sudden withdrawal of liquid from LP flash
drum and pump suction pressure reduced to
around 280 kPag (40.6 psig). Reduction in
pump suction pressure reconfirming the
level in LP flash drum into the packed bed.
 Semilean solution flow is a closed
circulation of solution between absorber, HP
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 flash and LP flash vessel. After increasing
the semilean solution flow rate at 12:46 hrs
to 2400 m3/hr, absorber and HP flash drum
level was maintained at set-points by level
controllers. But LP Flash drum level again
increased between 12:55 hrs to 14:24 hrs i.e.
Semilean solution pump suction pressure
increased from 280 kPag (40.6 psig) to 330
kPag (46.4 psig).
 Due to increase in LP flash vessel level
above steam inlet nozzle, overhead steam
from stripper condensed in LP flash drum
bottom and CO2 product vent opening
reduced to zero between 13:30 hrs to 14:24
hrs.
 Pump suction pressure of 330 kPag (47.8
psig) indicated that packing bed filled with
solution up to 3.0 meter (9.8 ft) (approx. 3.6
meter – 11.8 ft above the steam inlet nozzle
from the stripper).
 At 14:25 hrs, CO2 header pressure came
down to 30 kPag (4.4 psig). Set point of CO2
header pressure reduced from 31.6 kPag (4.6
psig) to 26.6 kPag (3.9 psig). CO2 vent
opened immediately and vapors started
escaping through minimum resistance path
in LP flash drum very near to steam inlet
nozzle. The vapor slugged (developed
vertically upward force) through the liquid
lifted two trays off from their support. The
slugging of vapors through the liquid had
also bent upward liquid gallery trays and
displaced liquid distributor riser screens.
Due to damage of vapor riser screens, pieces
of packing from bed were blown out and
found on top of liquid distributor and
gallery.
 Due to high level in LP flash drum and high
downward liquid flow, packing started
coming out from bed opening and escaped
in semilean and stripper feed pumps suction
lines. Immediately pump suction pressure
started reducing from 330 kPag (47.9 psig)
to less than 50 kPag (7.3 psig) at 1435 hrs.
Pump discharge flow also reduced
accordingly from 2434 m3/hr (10716
2011
2012
USGPM) to less than 900 m3/hr (3963
USGPM).
 Semi-lean pump tripped due to low flow
caused by low suction pressure. Stripper
feed pump flow also came down. This
indicates restriction / blockage in the suction
line of both the pumps.
 In summary, packing bed support failed due
to lining up of stripper vapors in LP flash
drum having a high liquid level i.e. level
higher than vapor inlet nozzle.
Post Repairs Experience:
After completion of all repair jobs as listed in
jobs performed, LP flash drum was boxed up on
September 4, 2011 at 18:30 hrs. On September
5, 2011 solution circulation was established and
CO2 product lined up to Urea plant. Ammonia
production was lined up on September 6, 2011
at 10:24 hrs. It was noticed that stripper feed
pump suction pressure came down to 50 kPag
(7.3 psig) (instead of normal 250 kPag – 36.2
psig) and flow restricted to 250 m3/hr (1100
USGPM) against normal flow of 380 m3/hr
(1673 USGPM). Suction strainer of both the
pumps were opened one by one and packing
again found in strainers. Even after removal of
packing from strainer suction pressure improved
to 100 kPag (14.5 psig). However, suction
pressure of semilean solution pump remained
normal at around 230 kPag (33.3 psig). This was
confirmed that 10” stripper feed pump suction
line was still left with some packing. Location
of chocked packing was confirmed in pipe
through X-ray. It was identified that packing
from stripper feed pump common suction line
near the pumps (approx. 10 meter -32.8 ft) were
not removed (See Figure 6).
The following was done to remove the packing
from line.
 Frequent changeover of the stripper feed
pump was done to increase sudden flow
through pipe, but after some attempts,
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 packing stopped coming out in strainers as
badly chocked in pipe & elbows.
 Packing removal was tried with light
wooden hammering on the chocked pipe
locations to release the chocking with flow
of solution. This started release of chocked
packing but became stuck in the pump
suction isolation valve seat and valve started
passing badly. Due to this pump changeover
for suction strainer cleaning was not
possible.
Plant production was reduced by 14% compared
to load prior to packed bed failure incident due
to reduction in lean solution flow. To avoid
production loss, hot bypass was made on suction
line (chocked location already identified
through X-ray). Hot taping was made just after
T-joint in 10” suction line and connected
downstream to standby stripper feed pump
suction isolation valve (See Figure 5 marked
with hot bypass solution line). After lining up of
bypass line, suction pressure improved to 250
kPag (36.2 psig) and normal flow established
through the pump. Ammonia production
improved by 13.3% due to increased lean
solution flow.
Semilean solution CO2 loading was observed
increased due to minor channeling after the
incident of LP flash drum bed failure. CO2 slip
from absorber increased accordingly and
ammonia production reduced by approx. 0.7%.
Long term repairs:
 As inspection shutdown was already
planned in March, 2012, it was planned to
replace complete LP flash drum packing
with 2” IMTP SS304 from 2” CS pall rings.
Bed support replacement also planned
during the shutdown window. Both LP flash
drum packing and bed support replaced
during inspection shutdown of March, 2012
as per plan. Packing was removed from 10”
pipe after cutting from two locations during
the shutdown.
AMMONIA TECHNICAL MANUAL
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 A packing holder/cage implementation is
also planned during annual shutdown of year
2015 around the bottom sump vortex
breaker of LP flash drum to arrest packing in
case of bed support failure.
Conclusion:
 Condensate / DM water recycle to LP flash
drum and CO2 absorber top BFW wash
water was not isolated after trip. This diluted
the solution and increased level in the CO2
removal system columns before the start-up.
 CO2 recovery system: solution heating by
reboiler was lined up before liquid level
adjustment in LP flash drum. Heating started
with high level in LP flash drum; level was
above the steam inlet nozzle from stripper.
This increased the backpressure in stripper
and increased reboiler temperature.
 High semilean pump suction pressure and
reboiler saturation temperature confirmed
the high level in LP flash drum.
 Lining up of stripper overhead vapors along-
with high level (liquid level in packed bed)
in the LP flash drum slugged stripper vapor
through liquid near the steam inlet line.
Vapor force (driving force) again increased
due to depressurization of the column
caused by reduction in CO2 header pressure.
This developed a high vertical force and
lifted packing bed support plates from shell
support ring.
 Due to high vertical force, upper distributor
gallery plate was damaged (found bent), gas
risers screen also damaged on the same side
of support bed lifting. Damaged screens and
blown out packing from bed were found on
top of liquid distributor gallery.
 Lack of packing holders at LP flash drum
bottom caused all pumps suction pipelines to
be chocked with packing rings.
Recommendations:
 Packings are vulnerable to damage during
start-up and shutdown operation. Base liquid
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 level rise above reboiler return or vapor feed
nozzle has been one of the most common
cause of packing failure. Bottom liquid level
needs to be watched closely during the start-
up.
 Keep liquid level in columns in operational
range during start-up / normal operation. If
high, reduce level in columns by draining (in
slop tank) during initial circulation and
before lining up of steam / gas stream in
packed bed columns to avoid vapor
slugging through liquid.
 If column operates with only one level
indicator, do not rely on transmitter when
level is above 95%. Observe other
parameters like pressure drop, column
temperatures, pumps suction pressure etc. to
understand abnormal operation.
 If applicable use pumps suction pressure as
reference and provide pump high suction
pressure alarm to avoid even faulty level
indication.
Figure 1: CO2 removal process
Figure 1: CO2 removal process
2011
2012
 In case of abnormal increase in DP of the
columns, cut-off vapors / gas streams
immediately to avoid internal damage.
 Avoid pressure fluctuations in packed bed
during start-up and particularly when liquid
level is high. Depressurization of the column
to be done with precaution to avoid damage
of bed support by sudden release of
excessive vapor flow through the bed.
 It is recommended to provide packing holder
in LP flash drum bottom surrounding vortex
breaker to avoid cutting and welding of
pipes in case of similar incident.
Acknowledgement:
Our sincere thanks go to Mr. Ali Jama, Qafco 5
& 6 Commissioning Manager, Mr. Richard de
La Bastide, Production Manager (Q1 to Q4) and
Mr. Iftikhar Turi, Overall Oncall Coordinator
for their guidance and support.
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30 AMMONIA TECHNICAL MANUAL
 Figure 2: Packing in LP flash drum Sump Area

Figure 3: LP flash drum damaged bed support plate

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 Figure 4: Top side liquid gallery damage

Figure 5: LP flash drum outlet piping

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 Figure 6: Packed bed Support Plate Repair

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