Ammonia-V Plant Page: 1 of 9

Process Safety Management Manual Issue/Rev No.JUN-2013/0

Process Equipment Design Standard Dept: Mechanical

1.0 Purpose: To aid the operating and maintenance staff for carrying out safe process
actions for preventing or minimizing the unsafe process conditions which may lead to
potential hazard during the plant operations.

2.0 Scope: All the sections of plant.

Sr. Equipmen Description Discharg Capacit RPM Motor Make

No t Code e Head y Rating
. (M) (M3/Hr)
1 P-301 A BENFIELD 273 1174 2980 STEAM PUMP-M/S SHIN
CIRCULATION TURBINE NIPPON CO.
PUMP JAPAN,TURBINE-
M/S DRESSER
RAND
2 P-301 B BENFIELD 273 1174 2980 1325 KW M/S SHIN
CIRCULATION NIPPON CO.
PUMP
3 P-302 A BENFIELD 24 1140 973
CIRCULATION COUPLE
PUMP D WITH M/S SHIN
P-301 A NIPPON CO
4 P- 302 B BENFIELD 24 973 COUPLE M/S SHIN
CIRCULATION 1140 D WITH NIPPON CO
PUMP P-301 B
5 P-303 A/B CONDENSATE 52 52.3 12.5 KW M/S PROTOS
PUMP ENGINEERING
O.H.REGENERATO
R
6 P-304 BENFIELD 15 25 2.6 KW M/S KISHORE
SOLUTION DRAIN PUMPS
PUMP
7 P-305 BENFIELD FILTER 25.6 110 13.3 KW M/S PROTOS
PUMP ENGINEERING
8 P-306 BENFIELD MAKE 25.6 110 1470 14.6 KW M/S PROTOS
UP PUMP ENGINEERING
9 P-307 BENFIELD 9.1 ATA 25 L/Hr 0.5 HP M/S SHAPO
ANTIFOAM PUMP TOOLS
10 P-309 A/B CONDENSATE 10.53 1440 7.5 HP M/S KSB PUNE
PUMP
11 P-312 A/B LUBE OIL PUMP 6.7 7.5 3.3 KW M/S SHIMODIU
JAPAN
12 P-313 A/B SEAL WATER 7.5 15 HP M/S KISHORE
PUMP PUMPS
13 P-421 A/B CONDENSATE 6.0 71.08 1450 75 HP M/S KSB
PUMP FOR PAC KG/CM2
14 P-422 A/B LUBE OIL PUMP 1700 1450 75 HP M/S ALLWEILER
FOR PAC L/Min PUMPS
15 P-423 5.0 330 2900 7.2 HP M/S SAM
EMERGENCY OIL KG/CM2 L/Min
PUMP
16 P-431 A/B CONDENSATE 101 M 41 1460 22 KW M/S R0TOS
PUMP FOR NSGC P0MPE
17 P-432 A/B LUBE OIL PUMP 127.6 M 1593 2950 75 KW M/S FINDER
FOR NSGC L/Hr
18 P-433 EMERGENCY OIL 2.5 BAR G 116 L/Hr 2900 2.5 KW M/S ALLWEILER
PUMP
19 P-441 A/B CONDENSATE 109 M 36.6 1450 23.43 HP M/S KSB
PUMP FOR ARC
20 P-442 A/B LUBE OIL PUMP 11. 0 1700 1450 55.8 HP M/S ALLWEILER
FOR ARC KG/CM2 L/Min PUMPS
21 P-443 EMERGENCY OIL 5.0 140 3000 3.1 HP M/S SAM
PUMP KG/CM2 L/Min
22 P-444 A/B SEAL OIL PUMP 26 92 1450 6.3 HP M/S ALLWEILER
KG/CM2 L/Min PUMPS
23 P-501 A/B AMMONIA 425 M 70 2980 104 KW M/S KSB
TRANSFFER PUMP
24 P-619 A/B CONDENSATE 109 M 21.0 1450 10 HP M/S KSB
PUMP FOR CO2
25 P-620 A/B LUBE OIL PUMP 11.0 1700 1450 75 HP M/S ALLWEILER
FOR CO2 KG/CM2 L/Min PUMPS
26 P-621 EMERGENCY OIL 5.0 275 2900 7.5 HP M/S SAM
PUMP KG/CM2 L/Min
27 P-701 A/C BOILER FEED 1467 M 186 2980 1250 KW MN/S KSB
WATER PUMP
28 P-701 B BOILER FEED 1467 M 186 2980 STEAM PUMP-M/S KSB,
WATER PUMP TURBINE TURBINE- M/S
DRESSER RAND
29 P-703 A/B CONDENSATE 50.5 M 50 2931 15 HP M/S KSB
RECOVERY PUMP
30 P-704 A/B HYDRAZIN DOSING 8.1 50 L/Hr 100 0.25HP M/S
PUMP KG/CM2 SHAPOTOOLS
31 P-705 PHOSPHATE 129 ATA 50L/Hr 100 1.7 HP M/S
A/B/C DOSING PUMP SHAPOTOOLS
32 P-801 BTO COOLING WATER 40 M 3500 741 620 KW M/S JHONSTON
I PUMP PUMPS
33 P-801 A COOLING WATER 46.2 1750 988 350 KW M/S WPIL
PUMP(HALF MWC
CAPACITY)
34 P-801 N EMERGENCY 40 M 65 2910 15KW M/S BPCL
COOLING WATER
PUMP
35 P-902 A/B DM WATER PUMP 70 M 192 2975 56 KW M/S AKAY
INDUSTRIES
 36 P-903 BACK WASH PUMP 15 M 170 1485 15 KW M/S AKAY
INDUSTRIES
37 P-907 A/B DM WATER PUMP 30 M 150 2900 30 HP M/S BEST &
CROMPTION
38 P-802 CAUSTIC DOSING 12.5 M 20 2900 2.2 KW M/S AKAY
PUMP
39 P-807 V WASTE WATER 50 MLC 300 1480 63 kw M/S
PUMP S.U.MOTORS
40 P-807 WASTE WATER 33 200 1470 30 KW
(NEW) PUMP M/S KSB
P-502 INDUSTRIAL 2910 M/S CHEMFLO
41 WATER PUMP
42 P-503 N/S EFFLUENT PUMP M/S S.U.
MOTORS
43 P-503 H EFFLUENT PUMP 8.0 M 50 2935 M/S CHEMFLO
44 P-321 A/B CONDENSATE 35M 8 2850 2.2 KW M/S SULZER
BOOSTER PUMP
45 P-322 A/B PROCESS 189 M 42 2940 37 KW M/S SULZER
CONDENSATE
PUMP
46 P-320 A/B CONDENSATE 474 M 14 2940 55 KW M/S SULZER
PUMP
47 P-314 A/B CHILLED WATER 53 M 240 1450 45 KW M/S BEACON
PUMP WEIR
48 ---- CONDENSATE 25 MWC 7.0 1430 3.7 KW M/S MATHER &
TRANSFER PUMP PLATTE
M.U. CHILLER UNIT

2.PGR PLANT ROTARY EQUIPMENTS DETAILS:-

Sr. No. Equipment Description Discharge Capacity RPM Motor Make

Code Head (M) (M3/Hr) Rating
1 P-101 A/B WATER 10.0 4.65 2900 9.46KW M/S KEPL
WASH PUMP
2 ------- CW BOOSTER M/S
PUMP CHEMFLO
3 P-301 A/B METHANE M/S
PUMP CRYOSTAR

SR.NO EQUIPMENT DESCRIPTION MAKE MODEL

. CODE
1 C-301 N2-LP M/S ATLAS COPCO MODEL-HRH7-1,CAPACITY-9378
COMPRESSOR NM3/Hr, INLET PR.-1.2 BAR, DIS.
 PR.-7.25 BAR, COMPRESSOR
RPM- 23476
2 C-302 N2 COMPRESSOR M/S BURCKHARDT TYPE-2D-200-2M, LABYRINTH
COMPRESSION PISTON COMPRESSOR, INLET
VOL.-484 M3/Hr, DIS. PR.-37.5
BAR, 238KW,492 REV/MIN
3 X-301/C-303 EXPANDER- M/S ATLAS COPCO TYPE-ETB125NS, RPM-36000,70
TURBINE KW, 950 M3/Hr
4 Y-001 A/B CHILLING UNIT M/S KPCL
COMPRESSOR

3. AMMONIA-V EQUIPMENT DESIGN DATA-

SR. EQUIPMENT DESCRIPTION SUPPLIER

NO. CODE
1 E-208 R.G.BOILER M/S STRUTHERS WELLS FRANCE
2 E-210 C.G.BOILER M/S STRUTHERS WELLS FRANCE
3 E-209 TRIM HEATER M/S ISGEC
4 E-211 BFW PREHEATER M/S NUOVO PIGNONE
5 E-212 N2 HEATER SU CIRCUIT
6 E-213 N2 COOLER SU CIRCUIT M/S BHPV
7 E-301 L.P.BOILER M/S ISGEC
8 E-302 RE BOILER M/S ISGEC
9 E-304 BFW PREHEATER M/S ISGEC
10 E-305 WATER COOLER O.H. M/S ISGEC
REGENERATOR
11 E-306 BFW PREHEATER O.H. M/S ISGEC
REGENERATOR
12 E-307 BFW PREHEATER M/S ISGEC
13 E-311 GAS-GAS EXCHANGER M/S ISGEC
14 E-312 FINAL GAS COOLER M/S
15 E-351 CONDENSATE COOLER M/S ISGEC
16 E-421 1ST STAGE COOLER K-421 M/S BHEL
17 E-423 2nd STAGE COOLER K-421 M/S BHEL
18 E-424 3RD STAGE COOLER K-421 M/S BHEL
19 E-442 GAS COOLER M/S BHEL
20 E-501 A/B BFW PREHEATER M/S NUOVO PIGNONE
21 E-502 HOT AMMONIA EXCHANGER
22 E-503 WATER COOLER M/S NUOVO PIGNONE
23 E-504 COLD EXCHANGER
24 E-505 1ST AMMONIA CHILLER
25 E-506 2ND AMMONIA CHILLER
26 E-507 PURGE GAS CHILLER
27 E-508 A LET DOWN GAS CHILLER M/S GRSE
28 E-509 A/B AMMONIA CONDENSER
29 E-510 PURGE GAS HEATER
30 E-511 AMMONIA AFTER COOLER M/S GRSE
31 E-628 1ST STAGE COOLER K-601 M/S BHEL
32 E-629 2ND STAGE COOLER K-601 M/S BHEL
33 E-630 3RD STAGE COOLER K-601 M/S BHPV
34 E-701 UREA CONDENSATE COOLER M/S BHPV
35 E-902 TURBINE CONDENSATE M/S BHPV
COOLER
36 V-201 STEAM DRUM M/S STRUTHERS WELLS,FRANCE
37 V-202 CONTINUOS BLOW DOWN M/S KANARA ENG. MUMBAI
VESSEL
38 V-203 INTERMITTENT BLOW DOWN M/S KANARA ENG. MUMBAI
VESSEL
39 V-204 SEPARATOR SU CIRCUIT M/S KANARA ENG. MUMBAI
40 V-205 FUEL GAS SEPARATOR M/S KANARA ENG. MUMBAI
41 V-207 START UP AMMONIA VESSEL
42 V-301 SEPARATOR O.H. M/S TRIVENI STRUCTURAL LTD.
REGENERATOR
43 V-302 SEPARATOR O.H. ABSORBER M/S TRIVENI STRUCTURAL LTD.
44 V-303 SEPARATOR OUTLET M/S ISGEC
REBOILER
45 V-304 SEPARATOR OUTLET BFW M/S ISGEC
PREHEATER
46 V-311 FINAL SEPARATOR
47 V-312 BENFIELD SOLUTION FLASH
VESSEL
48 V-313 DM WATER RECEIVER M/S ANUP ENGG.
49 V-501 AMMONIA SEPARATOR M/S BERGUM, ITALY
50 V-502 LET DOWN VESSEL M/S ISGEC
51 V-503 FLASH VESSEL M/S ISGEC
52 V-504 K.O. DRUM PURGE GAS M/S BERGUM,ITALY
53 V-505 K.O. DRUM LET DOWN GAS M/S ISGEC

54 V-506 K.O. DRUM INERT VENT GAS M/S GRSE

55 V-507 K.O. DRUM, K-451 M/S ISGEC
56 V-508 K.O. DRUM K-441 1ST STAGE M/S ISGEC
57 V-509 K.O. DRUM, K-441 2ND STAGE M/S ISGEC
58 V-510 AMMONIA ACCUMULATOR M/S ISGEC
59 V-511 AMMONIA VENT DRUM M/S KANARA ENGG.
60 V-512 BFW FLASH VESSEL M/S M/S KANARA ENGG.
61 V-701 FEED WATER DEAERATOR M/S ION EXCHANGE
62 V-702 TURBINE CONDENSATE M/S ANUP ENGG.
RECOVERY VESSEL
63 V-703 CONDENSTAE FLASH DRUM M/S SIESTA STEEL
64 V-805 CAUSTIC TANK
65 V-351 CO2 FLASH VESSEL
66 V-901 A/B CONDENSATE CARBON
FILTER
67 V-352 AMMONIA WATER M/S KANARA ENGG.
SEPARATOR
68 T-301 BENFIELD SOLUTION M/S LLOYD STEEL
STORAGE TANK
69 T-302 BEN. SOL. PREPARATION
TANK
70 T-303 ANTIFOAM AGENT TANK
71 T-304 BEN. SOL. DRAIN TANK
72 T-701 HYDRAZINE DOSING TANK
73 T-702 PHOSPHATE DOSING TANK
74 T-803 CHLORINE ABSORPTION M/S VTV
SYSTEM
75 E-331 CONDENSATE FEED M/S GRASIM INDUSTRIES
EXCHANGER
76 E-330 A/B/C CONDENSATE FEED M/S PRECISION EQUIPMENTS
EXCHANGER

4.AMMONIA-V ROTARY EQUIPMENTS DESIGN DATA-

SR.NO EQUIPMEN DESCRIPTION MAKE MODEL

. T CODE
1. K-202 NITROGEN M/S TYPE-SINGLE STAGE RADIAL
BLOWER SIEMENS,DEMA COMPRESSOR WITH INTEGRAL GEAR,
G SUCTION FLOW-27238 KG/Hr, DIS. PR.-
5.423 BAR, DRIVE-MOTOR,MOTOR
SPEED-2985
2 K-421 PROCESS AIR M/S BHEL TYPE-CENTRIFUGAL, 2MCL805-
COMPRESSOR 4+2MCL456, INLET PR.-1.01 KG/CM2,
FINAL OUTLET PR.-36KG/CM2
3 K-431 SYNTHESIS M/S NUOVO TYPE- CENTRIFUGAL
GAS PIGNONE BCL458+BCL457/N+2BCL409/A
COMPRESSOR
4 K-441 AMMONIA M/S BHEL TYPE-
COMPRESSOR CENTRIFUGAL,MCL453+2MCL456,SUCTI
ON PR.-3.1 KG/CM2, FINAL DIS. PR.-20.2
KG/CM2
5 K-451 A/B AMMONIA M/S TYPE-RECIPROCATING,MODEL-1 BHB2T,
BOOSTER K.G.KHOSHLA CAPACITY-5020 M3/Hr,588 RPM
COMPRESSOR COMPRESSORS
6 K-601 CO2 M/S BHEL TYPE-
COMPRESSOR CENTRIFUGAL,2MCL527+BCL305/A+BCL-
205/A
7 K-452 AMMONIA M/S KPCL,PUNE TYPE-SCREW COMPRESSOR,OIL
BOOSTER FLOODED,MODEL-WIRVBTS 321/2.2/2.1,
COMPRESSOR INLET PR.-0.02 KG/CM2, OUTLET PR.-2.1
KG/CM2
8 K-801 CHLORINE M/S AIR RPM-1500, 7.5 KW, TYPE-MW
BLOWER CONDITIONING
CORPORATION
9 K-1001 A/B INSTRUMENT M/S K.G. TYPE-RECIPROCATING, SUCTION PR-
AIR KHOSHLA ATMOSPHERIC, DIS. PR-10
COMPRESSOR COMPRESSORS ATA,240KW,750 RPM ,CAPACITY-
1110NM3/Hr
10 K-301 STEAM M/S ATLAS MODEL NO.- SC-14,TYPE-CENTRIFUGAL
COMPRESSOR COPCO
10 TK-201 TURBINE FOR M/S ELLIOTT, TYPE-2 CVR.PG-D, RPM-5000,KW-350,
ID FAN USA INLET PR.- 30 ATA, EXHAUST PR.-5 ATA
 11 TP- TURBINE FOR M/S DRESSER
301/302/A BENFIELD RAND
PUMP
12 TK-421 TURBINE FOR M/S BHEL MODEL-K1101-2 CONDENSING NON-
PAC EXTRACTION TYPE, TYPE-HORIZONTAL
SPLIT,INLET PR.-38.6 KG/CM2,INLET
TEMP.-366° C,INJECTION PR.-5 KG/CM2,
10236 KW,6880 RPM
13 TK-431 TURBINE FOR M/S NUOVO TYPE- SAC1-6 ,15035 KW,10304 RPM,
SGC PIGNONE STEAM INLET PR.-99.6 KG/CM2, INLET
TEMP.-495° C,EXTRACTION PR-39.1
KG/CM2
14 TK-441 TURBINE FOR M/S BHEL MODEL- NK 25/36-3 CONDENSING NON-
ARC EXTRACTION TYPE, TYPE- HORIZONTAL
SPLIT, INLET PR.-39 KG/CM2, INLET
TEMP.-367° C,6193 KW, 11200 RPM
15 TK-601 TURBINE FOR M/S BHEL MODEL-HG 32/20-3 +, TYPE-
CO2 HORIZONTAL SPLIT,INLET PR.-101
COMPRESSOR KG/CM2, INLET TEMP.-480° C,6490 KW,
9510 RPM
16 T-701 TURBINE FOR M/S DRESSER MODEL-E70MVF, NO. OF STAGES-5
BFW PUMP/B RAND RATEAU, 1276 KW,5400RPM
17 TK-203 TURBINE FOR M/S COPPUS MODEL-RCHA 19,INLET PR.-37.2
FD FAN KG/CM2, INLET TEMP.-375°C,350 KW,
6000 RPM
18 HT-301 HYDRAULIC M/S SULZER TYPE-HST,DOUBLE SUCTION AXIAL SPLIT
TURBINE
19 K-203 PRIMARY M/S TYPE-80W/A-150 SWSI, VOLUME-
REFORMER FD BOLDROCCHI,IT 171214 M3/Hr, 1480 RPM, 318 KW, PR.-
FAN ALY 566 MM H2O
20 MK-220 SH FD FAN M/S TLT ENGG. TYPE-2668/410, V-4.26 M3/S, 1470 RPM,
A/B 23.5 KW
21 MK-221 SH ID FAN M/S TLT ENGG. TYPE-2118/484,V-6.38 M3/S, 1470 RPM,
A/B 18.2 KW

5. COOLING TOWER DETAILS:-

NO. OF CELLS - 7 NOS.

MAKE- M/S PAHARPUR COOLING TOWERS PVT. LTD

MODEL:-6715-4-07

SERIES-CLASS 600 DF

TYPE-CROSS/COUNTER CURRENT INDUCED DRAFT

FAN-28’

FAN RPM-136
HOT WATER DESIGN FLOW RATE- 24000 M3/Hr

TEMP. DIFFERENCE-10°C

6. AMMONIA-V STATIC EQUIPMENT DESIGN DATA-

SR. EQUIPMENT DESCRIPTION MAKE

NO. CODE
1 R-102 HDS REACTOR M/S VTV
2 R-201 SECONDARY REFORMER M/S TERNI ,ITALY
3 R-202 HT SHIFT CONVERTER M/S BHPV
4 R-203 LT SHIFT CONVERTER M/S BHPV
5 R-311 METHANATOR M/S VTV
6 R-502 AMMONIA CONVERTER M/S L&T, HALDOR
TOPSOE,DENMARK
7 C-301 BENFIELD REGENERATOR M/S VTV
8 C-302 BENFIELD ABSORBER M/S VTV
9 F-501 START UP HEATER M/S BHPV
10 F-202 AUX. STEAM SUPERHEATER M/S BHPV
11 F-201 PRIMARY REFORMER M/S L&T
12 F-103 ASSOCIATED GAS PREHEATER M/S BHPV
13 C-331 CONDENSATE STRIPPER M/S GRASIM INDUSTRIES

7. PGR PLANT EQUIPMENT DESIGN DATA--

SR. EQUIPMENT DESCRIPTION MAKE

NO. CODE
1 E-204 TAIL GAS COOLER M/S LINDE
2 T-101 WATER WAS COLUMN M/S LINDE
3 T-102 REGENERATION COLUMN M/S LINDE
4 E-103 REBOILER M/S LINDE
5 D-201 WATER SEPARATOR M/S LINDE
6 D-501 BLOW DOWN VESSEL M/S LINDE
7 E-201 REGEN. GAS HEATER M/S LINDE
8 A-201 A/B ADSORBER M/S LINDE
9 E-305 1/2 BOOSTER COMPRESSOR AFTER COOLER M/S LINDE
10 Y-001 D1/D2 AMMONIA RECEIVER M/S KPCL
11 D-401 N2 TANK M/S LINDE
12 D-402 N2 TANK M/S LINDE