CONTENTS

1. Process Description

i. Synthesis Section
ii. Decomposition Section
iii. Concentration and Prilling Section
iv. Recovery and Absorption Section

2. Start up operation
3. Start up preparation
4. Once Through Operation
5. Total Recycle
6. Start up of Prilling Section
7. Design Basis and Guarantees
8. Guaranteed Consumption of Raw materials and utilities
9. Raw material specifications at battery limit of Urea plant
i. Ammonia
ii. Carbon dioxide
10. Guaranteed quality of Urea prills
11. Liquid effluents discharge from Urea plant
12. Specifications of some important equipments
 PROCESS DESCRIPTION
UREA-III (PRODUCTION)

1.00 PROCESS DESCRIPTION:

The Namrup-III Urea plant has a production capacity of 900 MT/ day of prilled urea. The plant is laid
out in a single stream. It is based on PDIL’s Urea process Using anhydrous ammonia and Carbon
dioxide gas as raw materials.
For Convenience of presentation, the plant has been grouped into following sections: ---

i) Synthesis section.
ii) Decomposition Section,
iii) Concentration and prilling section.
iv) Recovery and absorption section.

1.01 SYNTHESIS SECTION:

This section consists of CO2 compressor, Ammonia charge pumps, carbamate charge pumps,
Ammonia preheater and urea Reactor.
Carbon-di-oxide gas is compressed to synthesis pressure 225 ata and fed to the reactor. The
compressor system consists of a steam turbine driven centrifugal Booster compressor, which will
boost up the pressure to 32 kg/cm2g and fed to first stage off reciprocating compressor. There are
two reciprocating motor driven compressors each of 60% capacity arranged in parallel. When the
plant is running at 30/40/50/60 percent load, only one reciprocating compressor will be in line
alongwith the CO2 Booster Compressor.
Liquid ammonia will be pumped through a plunger type, horizontal ammonia charge pump of uraca
make and fed to the urea Reactor after being preheated to temperature of 103 0C in two members
ammonia preheaters. Liquid ammonia is taken into a storage tank and then pumped by Ammonia
Booster pump to the suction of Ammonia charge pump.
Recycle carbamate is fed to the Reactor by means of horizontal, reciprocating carbamate charge
pumps of Uraca make. Three NOs of pumps will be running at the 100% load of the plant.
Urea Synthesis is carried out at 225 ata in Urea Reactor which is a multilayer construction with
12mm thick AISI 316(ELC) lining inside. The molar ratios of NH 3/CO2 and H2O/CO2 in the overall feed
to the Reactor are 3.7 and 0.62 respectively. The Reactor outlet temperature is 195 0C and
percentage of conversion of CO2 to urea is 63%. Reaction mixture of the Reactor outlet solution
contains about 32-33% Urea, balance being unconverted ammonia, carbamate, excess ammonia
and water. This flows to the decomposition section through a letdown valve located at the ground
floor. The reactor outlet line is from the top through inside the reactor and coming out at the bottom.
The letdown control valve will be on Auto control.

1.02 DECOMPOSITION SECTION.

Unconverted ammonia carbamate and excess ammonia of Urea reactor are recovered by three
stages of; the decomposition pressures being 74 ata, 18 ata and 4.5 ata. The solution temperature
Urea concentration (wt, %) at the end of these stages are 187 0C / 53%, 163oC / 65.33% and 142oC /
71.5% respectively. The first stage decomposition uses once through seam heater followed by a
flash separator, second stage make use of thermosyohon heater. Third stage decomposition is of
once through type. Oxygen concentration at 1000ppm is maintained in CO 2 stream entering the Urea
Reactor for continuous passivation of reactor liner. Additional passivation air is injected also in the
MP Decomposer through a passivation air compressor.
1.03 CONCENTRATION AND PRILLING:

The concentration of 71.5% Urea from third stage decomposer (HE-3) is done further in the vacuum
Section situated between 20M and 28M height of synthesis structure. 71.5% urea solution from SD-3
is pumped by 70% urea solution pump (PC-1) to two evaporators in series viz. stage vacuum
decom- decomposer(10HE-4a,b) and II nd stage vacuum decomposer (10HE-5) to be concentrated to
94.5%
And 99.6% urea solution respectively. Solution from vac. Separator (SD-4) to HE-5 is transferred by
Gravity. The 99.6% concentration solution is pumped by urea melt pump (PC-2) from 12.7 M to 79 M
at prilling tower top to a prilling machine from where prilling is done by a single spinning bucket. The
prilling machine consists of a bucket with up and down moving arrangement and the bucket rotates
At 150-450 r.p.m. as per the plant load. Urea melt is sprayed through 5468 holes on the periphery of
the bucket. There is a standby bucket for change over as per need.
The prills are falling on a concrete floor and scraped by rotary scraper rotating at 1.5 r.p.m. into the
prilling tower bottom conveyer ET-1. through a slit 450 mm wide, opening on the floor 1.5 M off set
from the tower centre. From ET-1 conveyer the oversize lumps are separated into a transit conveyer
ET-2 to be remelted in Urea Dissolving Tank SA-1 for reuse. The proper size Urea prills goes to
transit conveyers ET-3 and ET-4 for storing in silo or into ET-7 conveyer to Bagging Plant.
Prills are cooled in prilling tower while falling by natural draught air. Free fall height of prills is 65 M.

1.04 RECOVERY AND ABSORPTION SECTION:

Urea – III has four recovery and recycle stages.

i) First recycle carbamate at 74 ata and 1100C from H.P. first condenser and H.P. second
condenser.
ii) Second recycle carbamate at 18 ata and 720C from MP absorber C-2.
iii) Third recycle carbamate from L.P. absorber C-4 at 4.5 ata 420C.
iv) Recovered solution from stripper vapour condenser C-6 at 2.0 ata and 420C.

Vapours obtained from vacuum separators are condensed in the surface condenser of vacuum
section. Condensate is collected at vacuum condensate tank. The condensate containing 4%
ammonia and o.87% Urea is preheated to a temperature of 1100C and fed to the top of the upper
section of ammonia stripping column. The stripper is having 45 NOs of bubble cap trays in two
sections. Around 1% of ammonia is taken out and sent to hydrolyser after being preheated to a
temperature of 1840C. Urea hydrolysis ions carried out in hydrolyser at a pressure of 18 ata and
temperature 1950C.

1. H2NCONH2 + H2O ------------------- CO2 + 2NH3

The hydrolysed solution from hydrolyser after exchanging heat in hydrolyser feed preheater is
fed to the top of the lower section of the stripper. Necessary heat for stripping is provided through a
cattle type of reboiler heated by 6 ata steam. The solution from the reboler containing 150 ppm of
ammonia and 400 ppm of urea is sent to the effluent pit as waste water and this will be pumped to
500 m3 effluent pit and then to Air stripper for final disposal.
Vapours obtained from the ammonia stripper column and Urea hydrolyser are condensed in the
stripper vapour condenser with circulating carbamate solution at 2 ata pressure and 42 0 C. The
major portion of recovered carbamate solution is fed to the low pressure absorber while a part is fed
to the topmost plate of the upper section of the Ammonia Stripping Column as reflux.
The gases evolved in the third stage decomposition are first condensed partially in LP condenser
and then totally absorbed in LP absorber with the help of recovered carbamate solution recycled
from the previous stage. LP absorber is a packed column operating at a pressure of 4.5 ata and
bottom temperature at 420C.
 The gases from the second stage decomposer are absorbed in the MP absorber with the help of
third stage carbamate recycle solution. The packed section at the bottom serves as main absorption
section while the tray section at the top consisting six nos. of bubble cap trays constitute the
ammonia rectification zone. Condensation heat is removed with the help of circulating condensate
which is turning cooled by cooling water. The MP absorber operates at a pressure of 17.5 ata and
the temperature at the top and bottom are460C and 800C respectively. Hourly recovery of ammonia
is approximately 7.437 Tones. Ammonia condenser, ammonia sub cooler, liquid ammonia storage
tank, MP inert washing column equipments are involved in ammonia recovery process. Required
amount of nitrogen gas is added to carbon-di-oxide gas at the suction of CO 2 Booster compressor to
eliminate any danger of explosion at MP inert washing column vent.

The first stage carbamate condensation system consists of HP first condenser and HP second
condenser. The carbamate solution from MP absorber bottom is pumped to these condensers
through second stage carbamate recycle pump. The gases evolved in the first decomposition stage
of HP separator are mixed with a part of CO 2 bleed from the 1st stage discharge of reciprocating
CO2 Compressor are led to the HP 1st condenser where they are partly condensed on shell side
with the help of recycle carbamate solution. The heat of absorption is removed by generating about
28.2 Te / hr of 3.5 ata saturated steam at the tube side. The gas liquid mixture of HP 1 st condenser
is separated in upper portion the same and is led through separate pipes to HP 2 nd condenser where
almost full condensation of left over gases takes place on the tube side. The heat of condensation in
this case being removed by circulating condensate on the shell side. The inerts leaving the HP 2 nd
cond4enser are sent to MP Decomposer separator after being scrubbed with a part of second
recycle solution in the first stage inert washing column. The first stage condensation is maintained at
74 ata. The solution exit temperatures in case of HP 1st and 2nd condensers are 155 0C & 1100C
respectively. The solution from HP 2 nd condenser is pumped back to the Urea Reactor through
carbamate charge pumps.

2.00 START UP OPERATION.

The plant is initially started up in once through operation and after about four hours total recycle is to
be taken in line. During once through process the first cycle (74 ata stage) is kept bypassed and
only MP and LP section is in line. The recycled solution from MP absorber instead of going to HP
condensers in 1st cycle goes to the start up solution tank (10 SR-4).

During total recycle, second cycle solution which was earlier taken to a storage tank will be recycled
to the first cycle viz. to HE-6 & HE-7. Start up solution stored in SR-4 will be reused in the system as
and when the conditions permit.

2.01 START UP PREPARATION:

1. Cooling water header is to be charged.

2. Steam header is to be charged.
3. Condensate level is to be taken in all steam Desuper Heater, MP absorber, LP absorber,
stripper vapour condenser and Ammonia stripping column.
4. It is to be ensured that all the feed lines to Reactor are clear and reactor outlet line to SD-
2 / HE-2, SD-3 / HE-3 upto SR-3 are clear.
5. Operation of Let down valve (PRC-13) should be checked.
6. Reactor is to be filled up with condensate and to be pressurized upto 80 ata.

2.02 ONCE THROUGH OPERATION:

1. Following vessels are to be lined up :

Reactor outlet to SD-2 / HE-2, SD-3 / HE-3, SR-3.
 2. CO2 Compressor will be started and to be vented from the final discharge of the
reciprocating Compressor. Passivation air is to be added in CO 2 feed line for maintaining
desired concentration.
3. Ammonia Booster pump (PC-15) and Ammonia Charge pump PA-1 are to be started for
giving feed to Reactor after preheating ammonia in HE-10 & HE-11.
4. Let down valve (PRC-13) is to be operated on manual.
5. After giving 10 minutes of ammonia feed, CO2 feed is to be introduced to Reactor.
6. Reactor outlet solution will go to SD-2 / HE-2, SD-3 / HE-3, solution from SD-3 will go to
70% urea solution pump PC-1 and to surge tank. The solution from surge tank will be
pumped back to SD-3 by pump PC-16.
7. Gases from SD-3 will be absorbed in LP absorber C-4 after partially condensed in LP
partial condenser (HE-9). When level in C-4 increases it will be diverted to MP absorber
C-2 by pump PC-7.
8. When level in C-2 increases it will be transferred to start up solution tank SR-4 by
Running PC-4 pump instead of sending to HE-6. Thus recycle carbamate solution will go
on collecting in start up solution tank (SR-4) during once through start up.
9. Passivation Air Compressor is to be started and air is to be injected to bottom of SD-2.
10. When pressure in C-2 rises above that of C-3 ammonia vapour should be sent to MP
inert washing column C-3 via ammonia storage tank SR-1 through the purge line.
Ammonia recovery from C-2 goes to ammonia condenser (HE-8), ammonia sub cooler
(HE-27) and to ammonia storage tank.

2.03 TOTAL RECYCLE:

1. When solution concentration in PC-4 discharge attains around 50% (by wt.) it is to be
diverted to HP 1st condenser (HE-6) to fill up HE-6, HE-7 upto 20% level to change over
to total recycle.
2. Following change over switches are to be operated CH-2, CH-3 and CH-4 in order to
interlock LRCA-14(V) with LRCA-14(RC); LRCA-33(V) with LRCA-33(RC); LRCA-32(V)
with LRCA-32(RC).
3. Gas line valve should be kept open for pressure equalization between HE-6 and HE-7.
4. Reactor outlet line HE-1/ SD-1, SD-2 to be kept clear.
5. When Reactor outlet temperature attains 185 0C the isolation valves towards HE-1/SD-1
are to be opened and the isolation valves towards SD-2 are to be closed.
6. Inert vent line for HP inert washing column C-1 should be crack open by PRCA-39 and
gradually pressure is to be maintained at 74 ata.
7. Pump PC-14 is to be run for removing heat of condensation in HE-7. Condensate in HE-
6 tube will be heated up gradually and steam will be generated.
8. When pressure and temperature in HP Decomposer is 74 ata and 187 0C and
temperature in HE-6 and HE-7 are 155 0C and 1100C, Cabamate charge pumps may be
started. Initially two carbamate pumps should be run on shared load. Prior to start up,
the pumps should be heated up with hot condensate and suction/discharge lines should
be kept clear.
9. When plant load is around 65% some CO 2 may be sent to HE-6 as per material balance.
After addition of CO2 more generation of steam will occur.

2.04 START UP OF PRILLING SECTION:

1. When the concentration of Urea Solution in Sd-3 outlet attains above 60% (by wt.)
Prilling section should be started.
2. Solution from PC-1 discharge should be sent to 1st vacuum decomposer HE-4 instead
. of Urea surge tank SR-3.
3. As soon as the level in SD-4 increases pump PC-2 should be run and the solution will be
sent to SR-3 through SV-5 (VI) by passing the prilling bucket for further concentration.
 4. Vacuum in SD-4 and SD-5 to be maintained at 0.35 ata and 0.04 ata and temperature
at 1330C/1400C respectively.
5. Prilling bucket should be heated and line towards bucket should be kept clear.
6. To be ensured that prilling tower bottom conveyers system and scraper are working and
interlocks are put in line. Belt weigher should be put in line.
7. When the solution concentration in SD-5 is around 99% prilling bucket is to be taken in
line. Solutions recycle line towards SR-3 to be washed immediately.
3.00 DESIGN BASIS AND GUARANTEES:

3.01 The plant is designed to produce 1167 Te/day of uncoated prilled urea in single stream.
3.02 Anticipated consumption of raw material and utilities are as follows:---

Qnty. / Te of Urea

I) Liquid ammonia (as 100%). 580 kg.

ii) Carbon-di-oxide (as 100%) 760kg.

iii) Steam at 45 ata and 3600C for process 1300 kg.

Including CO2 Centrifugal Booster Compressor
With hydrolyser cum stripper.

iv) Process water for cooling water make up. 6 M3

v) Electricity. 90 KWH

vi) Anticipated total export condensate

per tonne of Urea produced. 10.89 kg.

3.03 GURANTED CONSUPTION OF

RAW MATERIAL AND UTILITY:
Qnty/Te of Urea

i) Ammonia (as 100%). 590 kg.

ii) Carbon-di-oxide 770 kg.

iii) Steam at 45 ata, 3600C for process

Including Centrifugal Booster Compressor
With hydrolyser cum stripper.

iv) Process water for cooling water make up 7 M3

v) Electric Power. 98 KWH

* Excluding Elect. Power requirement for bagging, materihandling, airconditioning,

intermittent power for machinery and cooling towers.

3.04 The above guarantees are based on the raw materials of the following specifications at
the battery limit of urea plant.

LIQUID AMMONIA:

Ammonia content. : 99.8% by wt. (min).

 Moisture Content. : 0.2% BY WT. (max).

Oil content. : 15 ppm.

Pressure. : 27 kg/cm2 abs. (min).

Temperature : 0-250C.
CARBON-DI-OXIDE:

CO2 Purity. : 98.5% by vol.

Temperature. : 450C

Humidity. : Saturated with water vapour

At 450C.

3.05 GUARANTEED QUALITY OF UREA PRILLS:

I) Total N2 on dry basis : 46% by wt. (min).

ii) Moisture. : 0.5% by wt. (max.).

iii) Biuret : 1.0 by wt. (max).

iv) Size of product. : 98% between 0.8 to 2.8mm

5% below 0.8mm.

3.06 Expected figures for effluents discharge from urea plant are as follows:

a) Liquid effluents:
.
Ammonia : 15o ppm by wt. (nor).

Urea : 400 ppm by wt. (nor).

CO2 : 1000 ppm by wt. (nor).

Quantity (Continuous) : 21,263 kg/hr. (nor).

Temperature : 50-600C.

b) Urea dust from prilling tower. : 200 Mg/NM3 of air (max).

4.00 RAW MATERIALS AND UTILITIES:

1. AMMONIA:

This comes to urea plant at 27 kg/cm2 abs. and 250C from Ammonia Plant.
2. CARBON-DI-OXIDE:
CO2 is supplied at 1.04 ata pressure and 400C temperature from carbon dioxide gas
holder located in the Ammonia plant.
3. STEAM:
Superheated steam is supplied to urea plant at45 ata pressure and 3600C from Service
Boiler of steam Generation plant and Waste Heat Boiler of Captive Power Unit. This
steam is used in an Extraction cum condensing turbine to run CO2 centrifugal
 compressor. Steam at 24 ata pressure and 3030C is made available as extraction steam
to be consumed in various section of urea plant. 24 ata steam is desuperheated in
different desuperheaters where condensate is sprayed to steam to produce 22 ata, 20
ata and 6 ata saturated steam. These are used in hydrolyser, H.P. decomposer, M.P.
decomposer, L.P. Decomposer & 1st vacuum decomposer. Besides this, 3.5 ata
saturated steam is generated in H.P. carbamate condenser. Low pr. Steam is used in
some heat exchangers, jackets and tracing line as heating steam.

4. STEAM CONDENSATE:
Condensate is required in urea plant as washing fluid as well as sealing / flushing /
injecting fluid for pumps. All steam condensate from heat exchangers and steam traps
are collected in condensate tank after cooling it to 75 0C and then condensate is fed to
the wash pump. The surplus condensate will be exported to steam Generation plant.
Small amount of cold condensate is consumed in absorbers.
5. D.M.WATER:
DM water to urea plant is supplied at 7 ata and 40 0C from DM water plant. It will be
required when condensate is not available, make up to the condensate tank. During
initial start up of the plant for running all wash pumps and filling up of vessels etc.
6. WASH WATER:

Wash water is required for urea plant for washing and cleaning the process lines at
different pressure stages. There are five types of wash water available in this plant.

i) H.P.W. (H) at 300 kg/cm2g, for washing Reactor feed lines.

ii) H.P.W. (L) at 100 kg/cm2g, for first cycle washing which is operated
at 76 ata.
iii) M.P.W. at 43 kg/cm2g, for MP cycle washing.
iv) Condensate at 13 kg/cm2g, for process condensate cooler, 6 ata
steam desuperheaters etc.
v) L.P.W. at 8 kg/cm2g, for low pressure stage washing.
7. COOLING WATER:
Cooling water at 4.5 kg/cm2g and 330C is supplied to battery limit of the plant from urea
cooling tower. Cooling Tower is having four pumps, (Three running and one standby)
each having a capacity of 3500 m3/hr.Cooling water is used in different heat
exchangers, condenser, inter coolers of CO2 compressors and lube oil coolers of
pumps/compressor etc.
8. PROCESS WATER:
Process water is supplied at 7ata pressure and ambient temperature to the battery limit
of the plant. It is to be used for flushing of lines, equipments etc. for precommissioning
stage and cooling water make up.
9. INSTRUMENT AIR:
Instrument air is supplied to battery limit of the plant at 7ata and 40 0C for the use of
various instruments and suction line of CO2 Booster Compressor as passivation air.
10. SERVICE AIR:
Service air is supplied at about 8 ata pressure and 40 0C for the use of pneumatic tools
and cleaning purposes in different floors.
11. NITROGEN:
Nitrogen is required for purging of various lines and equipments during start up and
shutdown. Also it is injected in the suction line of CO 2 Compressor to prevent the
formation of explosive mixtures. It is supplied at 7 ata and ambient temperature.
12. PASSIVATION AIR:
Passivation air for MP Decomposer / Separator and Urea Hydrolyser is supplied by a
passivation air compressor and also from the process air compressor of Ammonia
plant, in case of non availability of passivation air compressor.
13. ELECTRICITY:
 Electricity of urea plant is supplied at different voltage for running plant machinery as
given below:
i) 11000 volts, 3 phase, 50 cycles, for Co2 charge compressor.
ii) 3300 volts, 3 phases, 50 cycles for ammonia charge pumps, carbamate
charge pumps, Recovered solution circulation pump and condensate
circulation pump for H.P. second condenser. 1st stage circulation & recycle
pump.
iii) 415 volts, 3 phase, 50 cycles and 240 volts, 1 phase 50 cycles for other
machineries.

5.00 CO2 COMPRESSOR:

CO2 compression is done in Urea-III combindly by centrifugal and reciprocating

compressors. One centrifugal compressor is in series with two reciprocating
compressor, when the plant load is above 60%. In the Initial start up the centrifugal
compressor will be in series with one reciprocating compressor.
The centrifugal Booster Compressor does CO2 compression from 1.02 kg/cm2g to 32
kg/cm2g and this gas is further compressed to 240 kg/cm2 by two stage reciprocating
compressor (CO2 charge compressor). CO2 gas from the final stage of CO2 charge
compressor is fed to the final stage at 135 0C without cooling. About 13% of CO2 (4901
kg/hr) is taken from the first discharge of CO 2 charge compressor for bleeding. It is the
1st stage HP condenser, HE-6.

5.01 CO2 BOOSTER COMPRESSOR:

i) Type -- Centrifugal, Turbine driven.

ii) No of stage -- Four.
iii) Suction/Discharge pressure -- 1.02 / 32 kg/cm2
iv) Suction / Discharge temperature -- 400 / 400C
v) No of unit will be in line – One.
At all plant load.

5.02 TURBINE FOR CO2 BOOSTER COMPRESSOR:

I) Type --- Extraction cum condensing turbine.

ii) No of stage --- Two
iii) Inlet steam to turbine --- 63.05 Te / hr at 45 ata and 3600C.
iv) Extraction steam from the exit of
1st stage of the turbine. --- 49.84 Te / hr at 24 ata 303.50C.
v) Normal speed --- 7500 RPM.
vi) Speed Range --- 6885 -- 8545 RPM.
vii) Speed to be avoided --- 2100 -- 5500 RPM.

The turbine will trip at

a) 9356 RPM
b) Inlet steam pressure --- 43.4 kg/cm2
c) Extraction steam pressure
Low : 23.76 kg / cm2
High: 25.83 kg / cm2

Turbine speed will be controlled by Governor.

5.03 CO2 CHARGE COMPRESSURE:

I) Type --- Reciprocating, balance opposed.

 ii) No of stages --- Two
iii) Suction Discharge pressure --- 30 kg / cm2 / 240 kg cm2
iv) Suction / Discharge temp. --- 400c / 1350C.
v) No of unit will be in line --- Two
Above 60% plant load.

6.00 AMMONIA AND AMMONIUM CARBAMATE PUMP:

In Namrup-III Urea plant approximately 31 Te / hr of ammonia and 88 Te / hr of

ammonia carbamate solution is fed to the reactor. Ammonia from storage tank is first
pumped by ammonia booster pump to the suction of the ammonia charge pump. The
ammonia charge pumps raise the pressure of ammonia from 18 ata to 225 ata and fed
to the reactor after preheating in two nos. of preheaters heated by 3.5 ata steam and
hot condensate.
Carbamate solution obtained from H.P. Second Condenser HE-7 at 74 ata is
pressurized by carbamate charge pump to 225 ata and fed to the reactor. Three
carbamate pumps are to be used for 100% load of the plant. All the ammonia and
carbamate charge pumps are Motor driven triplex plunger, horizontal and uraca make.
Ammonia and carbamate charge pumps are having pneumatic speed variator by which
ammonia and carbamate flow to Reactor can be controlled. In carbamate charge pump
washing arrangement exists in both suction and discharge lines. Besides oil sealing, low
pressure and high pressure condensate flushing is provided to the stuffing box of the
plungers.

6.01 AMMONIA CHARGE PUMP:

I) Type --- Horizontal, Reciprocating, Triplex plunger pump

ii) Capacity --- 14M3 / hr (min).

54M3 / hr (nor).

68M3 / hr (max).
iii) Suction Temp. --- 400C

iv) Suction Pressure --- 21 kg / cm2 (nor).

v) Disch. Pressure --- 240 kg / cm2 (max).

vi) RPM --- (min) 20 / (nor) 80 / (max) 110.

vii) Motor rating --- 640 KW.

Pump will trip at

i) Low suction pressure --- 15.3 kg / cm2

ii) High Disch. Pressure --- 244 kg / cm2

iii) Low lube oil pressure --- 3 kg / cm2

 iv) Lube oil pump DIsch. High temp. --- 650C

v) Over speed

vI) Gear box oil high tempr. ---- 1000C

6.02 CARBAMATE CHARGE PUMP:

i) Type --- Horizontal, Reciprocating, triplex

ii) Capacity --- 8m3 / hr (min)

--- 40m3 (max)

iii) Suction pressure --- 74 ata

iv) Suction temperature --- 1100C

v) Max. disch. Pressure --- 240 kg / cm2

vi) pump RPM --- 14 (min) / 64 (nor) / 76 (max).

vii Motor Rating --- 320 KW.

Pump will trip at

i) Lube oil disch. Pr.low --- 3 kg / cm2

ii) lube oil pump disch. --- 650C .

tempr. High.
iii) Gear box oil tempr. --- 1000C
High.
iv) Over speed

v) Discharge high pr.

vi) Crank shaft over load deflection high.

7.0 SIDE STREAM FILTRATION SCHEME:

The circulating Cooling water collects dust, rust, mud etc. and also because of chemical
dosing for maintaining quality of the same, there are solid products of reaction which
tend to increase the turbidity of cooling water. This is determined to heat transfer
capacity and so heavy purge or blow down of cooling water is required to be
maintained. This result on heavy make up water consumption and loss of costly
chemicals.
To overcome this problem a portion of water is circulated by passing through pressure
filters using gravel and sand as filtering media to remove the suspended impurities. For
this purpose eleven nos. of pressure filters are provided, out of which seven nos. are
used for ammonia cooling tower and four nos. are used for urea cooling tower.
A portion of cooling water ( about 2% ) from the discharge header of cooling water
pumps enter into the filter to remove the suspended particles from the top and passing
through the filtering media leaves at the bottom. When the pressure drop across the
 particular filter exceeds the predetermined value, the forward flow of cooling water is
stopped. Then the filter is to be given a backward wash with cooling water, i.e. the water
entering from the bottom leaving at the top for about 10 to 15 minutes Alongwith air so
that the filter is cleared of the solids and the filter is ready for filtration. The back washed
water will be drained to Chromate Section.

8.00 CHROMATE REMOVAL SECTION:

Filter backwash water and blow down water containing chromate is first collected in
collection tank of chromate removal section. The water is pumped by effluent transfer
pump to the reaction tank. Sulphuric acid and sodium Metabisulphite solution is added
to the reaction tank. From reaction tank water flows to Neutralization tank by gravity.
The water is then treated with lime solution before final disposal to the settling pond.

*******************
***********
*****
**
 START-UP OPERATION

1.0.0 It is presumed that Reactor, H.P., L.P., and Stripper Hydrolyser section have been purged with
N2 and the following N2 pressure i.e. 6 kg / cm2g, 6 kg / cm2g, 6 kg / cm2g, 2 kg / cm2g and 1 kg /
cm2 have been maintained in respective stages.
1.1.0 Charge treated cooling water in the header and establishes circulation in the cooling water
circuit. Run the number of pumps as may be required to maintain the normal header pressure
and look for the normal operating amperage of the motor. Isolate the exchangers where cold
C.W. can create problem e.g. HE-8, HE-27, HE-12a, b, HE-20, HE-9, HE-14 oil coolers of
pumps, CO2 compressor, jackets of compressor etc.
1.2.0 Keep start-up solution Tank (10SR-4), Third Separator (10SD-3) and Urea Surge Tank (10SR-
3) practically empty.
1.3.0 Fill condensate Tank (10SR-2), with water upto overflow level. Start Condensate Export pump
(10PC-11,11r) in closed circulation with the tank. Charge condensate header and LPW header
at normal operating pressure. Keep return line to tank open. Keep D.M. water valve to tank also
open but condensate export line valve closed. Maintain condensate header pressure at 13 kg /
cm2 and LPW pressure 8 kg / cm2 (by PIC-21).
Fill up HE-20, PA-3 circuit with D.M. water (PA-3 need not to be run). Set PIC-104(V) to 6 kg /
cm2g to supply flushing / quenching water required for different pumps.
Fill up SR-9 through LIC-11(V) and condensate circuit of HE-7, HE-12a, and b without running
PC-14 pump. Vent air from highest point. Fill up all steam desuperheaters HE-23, HE-21, HE-22
and HE-31 with D.M. water from condensate header upto 50% level and set level controllers to
50% and keep condensate outlet valves closed. Fill up SD-11 and HE-6 condensate circuit upto
30% of LRCA-10 by using HIC-2 (V). Keep V-829 and V835 closed. Keep PRCA-34 (V), and V-
1502 wide open but V-685 closed.
Fill up all seal pots, seal legs, and vent stack seal with D.M. water. Fill up PC-17, HE-13 and
He-14 circuit from SR-9 with D.M. water and PC-17 pump can be run for circulation.
1.4.0 Fill up Stripper (10C-5) bottom with LPW available from different sources. Maintain 20% level in
stripper bottom as indicated by LICA-47. LPW can be taken through V-1428, V-1427 connected
to vapour outlet line of Stripper (10-5) or PC-13suctionwash point. Hydrolyser (HE-29) can be
kept empty and by-passed by using valve V-214 (80-CS-94-10.26). LPW will come from top
section to bottom section develop level at bottom. Waste Water Pump discharge can be kept
isolated for time being. Fill up Stripper Condenser (10C-6) upto 30% of LIAE-41 through LPW
line in PC-12-C-6-HE-17 loop.
1.5.0 Fill up C-4 bottom with D.M. water / condensate upto a level of 30% as indicated by LRCA-32.
Condensate can be fed through 25-C-95-25.6 coming from HE-20. Start PC-7,7r and maintain a
closed circulation across the column keeping PC-6,6r idle. When level rises above 30% stop
water injection to C-4 column.
1.6.0 Similarly fill up C-3 upto a level of 30% of LIAE-35 by pushing LPW through 25-C-93-40.6 from
the discharge of PA-3 pump. Establish circulation in C-3 column by running pump PC-8 through
HE-16.
 Introduce water in C-3 column plates through FIC-25 and V-296 from discharge line of PC-8
maintaining the level in C-3. Build up level in C-2 column upto 30% of LRCA-33 with this water
and also MPW from PA-4. Now C-2-PC-5 circuit is filled up and circulation can be established
by running PC-5 keeping PC-4 pump idle. As soon as level rises above 30% cut-off all input
water to C-2 column.
1.7.0 Charge steam in steam network as per the instruction mentioned in 8.02 Para. Adjust all
condensate traps. Charge steam in jackets. Safety valve, control valves, Ammonia vaporizer
etc.

1.8.0 Now Reactor has to be filled with D.M. water. For this hot water or condensate would have been
preferable. There is a DN25 size hose connection in carbamate suction header for filling up the
Reactor through Carbamate Charge pumps. Keeps PRC-13(V) closed and upstream sample
valve (V-1523) has to be kept open to vent out N 2 from the reactor. During filling, steam tracing /
jackets should be taken in line. Introduce steam (6 ata) in to the reactor through the hose
connection (V-1568) and record temperature rise in the reactor. Heating rate should be kept
below 200C / hr. Stop steam introduction when temperature of water has attained 80 0C. Reactor
is filled up when water comes out of sample point. Close sample valve and continue
pressurization with HPW injection pump upto 80 ata through line in ammonia inlet to
Reactor.
2.0.0 PRESSURIZATION OF MP LOOP:
It is presumed that liquid ammonia is available at the B.L. at sufficient pressure.Charge liquid
NH3 in the header going to SR-1 through Ammonia Filter (FI-1) upto V-238, V-239, and keep V-
281.V-241, V-263, V-264 and V-236 closed. Take LRCA-37 on manual. Crack open V-238 to
allow liquid ammonia flow in SR-1.Check rise of level and gradually build up 60% level in SR-1.
Close LRCA-37(V). Observe pressure in PRC-80 and set it at 12 ata on AUTO.
2.1.0 Inject some cold condensate to top of M.P. Inert Wash Column (C-3) through V-961. For this ,
Process Condensate Pump (10PA-3,3r) may have to be run. Maintain C-3 level by diverting the
formed aqua ammonia to M.P. Absorber (C-2) through FIC-25(V) and V-296 maintaining
circulation by 10PC-8.
2.2.0 Prime up and start Ammonia Booster Pump PC-15 to maintain closed ammonia circulation
across SR-1. This will also charge the line upto Ammonia Charge Pump (10PA-1) and reflux line
to C-2. If pressure in SR-1 does not rise, open jacket steam in the recirculation line to keep the
extent necessary.
2.3.0 Inject small quantity of liq. Ammonia reflux to C-2 through FIC-22(V). Open valves V-223, V-224
in the vapour balancing line to build up back pressure in SD-2 if required. Thereafter close these
two valves. Check that 10C-1 is isolated from SD-2 and SD-SD-2 vapour line to C-2 and SD-3
vapour line to HE-9 and C-4 clear.
2.4.0 Pressure in C-2 & SD-2 should be kept lower than that of SR-1 & C-3 till reactor effluents come
in SD-2. Steam in HE-2 should not be kept on to avoid high pressure build-up in C-2. Cooling
Water in HE-14 and HE-8 need not be put now. Put as such cold condensate as necessary in
C-3 and Establish solution circulation in C-3 with PC-8 to absorb completely all ammonia
vapours. Maintain solution feed to C-2 as dilute and as cold as possible at this stage. C-3 outlet
solution should contain at least 70% water.
2.5.0 ONCE THROUGH OPERATION:

When pressure in the reactor has upto 80 ata stop HPW(H) wash pump PA-2,2r. Make sure
that that there is no blockage in the Urea solution from R-1 to SD-2 to HE-2 SD-3 outlet line
circuit.
2.6.0 Start CO2 Compressor as per vendor’s instructions and vent about 11000 kg / hr of CO 2 gas
(corresponding to 30% plant load) from final discharge of reciprocating compressor and keep
the discharge pressure at least 20 kg / cm 2 higher then the reactor pressure. Inject passivation
air in CO2 line to maintain oxygen concentration 0.05% - 0.1% by volume and inject dilution
nitrogen in sufficient quantity to meet the following requirements.

O2 / 5% by volume
 ---------------------------- =
Total Inerts

Prime up Ammonia Charge Pump PA-1 with NH3 by proper purging and venting the vapours.

2.7.0 Make sure about the operation of let down valve which is taken on manual control. Start Ammonia
Charge Pump as per vendor’s instructions and gradually raise RPM to send about 12650 kg / hr liquid
ammonia to reactor.
2.8.0 Charge steam to Second Ammonia Preheater (HE-11) to preheat NH3 upto around 500C.
2.9.0 Put LRCA-37 in auto operation at 40% setting. Observe temperature rise in Reactor bottom and
ammonia flow rate may be kept constant. Operate let down valve manually to maintain 80 ata
pressures in reactor.
2.10.0 Check CO2 line to reactor with HPW injection. After 10 minutes of Ammonia feed to reactor stop venting
of CO2 by closing the vent valve and simultaneously opening the inlet CO 2 valves towards reactor thus
sending about 11000 kg / hr. of CO 2.Reactor temperature will start rising at a higher rate. Act carefully
on PRC-13(V) to maintain the following temperature-pressure relationship.
2.11.0 Reactor pressures, ata 90 100 130 150 170 190 210 225 (PRC-13).

Reactor top tempr., 0C 90 100 120 140 160 180 190 195 (TR-3.1).
2.12.0 PRC-13(V) should be meticulously opened manually to discharge urea carbamate solution towards SD-
2 / HE-2-SD-3 / HE-3-PC1.PC-1 discharge is to be connected to SR-3 or drain till urea solution
becomes amply concentrated for further processing. Maintain SD-3 level at least 30%.
2.13.0 Slowly charge 12 at and 6 ata steam in HE-2 and HE-3 and control MP stage pressure at 12 ata by
PRC-80(V). Use HIC-7(V) or C-4 top to maintain a pressure of 2 ata in L.P. stage. Cooling water in He-
9 is to be carefully opened at this stage to maintain a positive pressure in L.P. system. It will be
necessary to open HIC-7(V) and PRC-80(V) occasionally to let out uncondensed gases. Maintain liquid
ammonia reflux in C-2.
2.14.0 Check the themosyphonic solution circulation in SD-2 / HE-2.
2.15.0 Steam-condensate from HE-22 should be manually drained for sometime before it is diverted towards
HE-23.
2.16.0 When vapour from SD-3 from SD-3 gets absorbed in C-4, level (LRCA-32) will rise. Keep LRCA-32(V)
closed on manual and set LRCA-32 and LRCA-33 at 50%. Open scrubbing water to C-4top. Arrange
changeover switches CH-4, CH-3, and CH-2 in such away that LRCA-32(V) controls LRCA-33(V), and
LRCA-33(RC) controls LRCA-14(V). As level in C-4 rises above 50%, start PC-7 pump to divert solution
to C-2 through LRCA-33(V). When C-2 level reaches 50% of LRCA-33 start pump PC-4 to send its
discharge to SR-4 instead of HE-6 by operating valves V-186 and V-193. Recycle carbamate solution
goes on collecting in SR-4.
2.17.0 Start Passivation Air Compressor and build up pressure higher than that of SD-2. Open passivation air
at minimum flow to SD-2 bottom.
2.18.0 Maintain level control in SD-2 with LRCA-16 set at 50% on auto and observe level rise in SD-3 which
was initially almost empty. When level in SD-3 rises more than 50% in LICA-27 take LICA-27(V) on
manual and start PC-1 pump as per vendor’s instructions sending the discharge towards SR-3
bypassing HE-4. Check level rise in SR-3.
2.19.0 Increase liq. Ammonia reflux in C-4 column and open C.W. in HE-27 and HE-14. When pressure in C-2
column starts rising above that of C-3, (check from PIC-76 and PRC-80). Open valve V-280, V-281, V-
282 so that uncondensed vapours from HE-8, HE-27 can go to SR-1 and gas flow from SD-2-C-2-SR-
1-C-3 is established.
2.20.0 Gradually raise temperature of SD-2 outlet solution around 1450C by acting on TRC-26(V) and
temperature of SD-3 outlet solution upto 1200C by acting on TRC-44(V).
2.21.0 When reactor top temperature shoots up rapidly it is to be controlled by reducing steam to Ammonia
Preheater (HE-11) or reducing CO2 feed and vice versa. In no case the temperature at any point of
reactor should go beyond 1950C.
2.22.0 Stabilize the operation of C-2 column such that vapours from SD-2 are mostly absorbed in its packed
section. To prevent CO2 or water vapour escape from the tray section, C-2 top temperature is to be
kept below 300C at 12 ata pressure. This can be done by increasing liquid ammonia reflux or by
 injection of aqua ammonia in the trays. If still top temperature starts rising it may be necessary to
reduce steam in HE-2 and increase colder solution circulation rate in C-2 column for higher absorption.
Observe each tray temperature and check carbamate concentration at bottom. Bottom tempr. Should
be kept around 600C.Initially there may not be any ammonia condensation and till such time valve V-
240, V-241 should not be opened. The vapours should be sent to C-3 via SR-1 through the purge lines
to maintain pressure in C-2 column. Carryover of CO 2 from C-2 top which be indicated by rise in tray
tempr. Should be always avoided. Performance of M.P. absorber (C-2) is to be critically controlled.
3.0.0 TOTAL RECYCLE OPERATION:
When water concentration of PC-4 discharge solution reaches around 50% (wt.) and reactor outlet
tempr. Attains 1600C, start diverting PC-4 solution to HE-6 instead of SR-4 to fill HE-6, HE-7 upto 20%
of LRCA-14 as a preparation for changeover to total recycles. Restore the position of changeover
switches CH-2, CH-3 and CH-4 in order to interlock LRCA-14(V) with LRCA-14(RC), LRCA-33(V) with
LRCA-33(RC) and LRCA-32(V) with LRCA-32(RC). Keep gas line valves open for pressure
equalization between HE-6 and HE-7 Keep ready 20 ata desuperheater (HE-21) and first decomposer
(HE-1). Fill HE-21 with condensate LICA-20(V) and drain for some time locally maintaining 50% level till
pressure is built up. Later on it can be diverted to HE-23. When reactor top tempr. reaches 185 0C
change over to total recycle should be done. For this, first open valves V-002, V-003, V-004, and V-005
and then close V-006 and V-007. Check that SD-1 outlet line towards SD-2 is free and set LICA-7 at
50%. Set LRCA-14 and LRCA-15 at 50% on auto. Keep inert vent line from C-1 (PRCA-39(V 2) ) crack
open for some time and increase gradually set point of PRCA-39(V 1) to 74 ata corresponding to
temperature rise. Send solution from PC-4 to C-1 top through FRC-10(V) at around 1500 kg / hr. Make
sure that PRCA-39(V1) line to SD-2 kept free by water injection from time to time.
3.1.0 Starts pump PC-14 for removing of carbamate condensation heat in HE-7. The condensate in HE-6
tubes will gradually get heated up. Vent generated steam through PRCA-34 (V) keeping V-685 closed.
Gradually raise set point of PRCA-34 to 3.6 ata. Observe pressure rise in SD-11 from PI-35 & PI-34.1.
Lineup condensate from HE-23 with steam drum SD-11 and maintain level in SD-11 by LRCA-10 set at
40%. Excess condensate from SD-11 should now be routed through Ammonia Preheaters to
condensate storage tank SR-2 by operating the relevant valves.
3.2.0 Change gradually and carefully steam in HE-21 by means of PIC-50(V) and TRC-16(V) to raise 20 ata
steam for HE-1. Set PIC-50 at 20 ata and open TRC-16(V) to heat up HE-21. Raise TRC-16 set point
gradually to 1870C and take it on auto to raise first pressure upto max. 74 ata. Check that 20 ata steam
temperature does not go above 2120C. It is to be seen that solution temperature in HE-6 should attain
1550C at bottom when C-1 pressure attains 74 ata.
3.3.0 As steam production in SD-11 rises and PRCA-34 indicates 3.5 ata, open V-685 to admit steam in 3.5
ata headers. Check flow of steam in FR-9 and stop steam flow to Condenser (HE-25) by HIC-1(V), if
required.
3.4.0 When level of HE-7 reaches 50% of LRCA-15 makes arrangement for the startup of Carbamate pumps.
Prior to startup, the machine shall remain heated up with hot condensate and its suction and discharge
lines are to be kept clear.
3.5.0 Starts two Carbamate pumps as per vendor’s instruction at shared and maintain the level of HE-7. As
carbamate is recycled to reactor, increase CO 2 flow from 11000 kg / hr. to 13600 kg / hr. and increase
preheat of Ammonia to maintain reactor temperature, which may tend to fall. Increase little ammonia
flow, if required.
3.6.0 Check top and bottom temperature of HE-6 by TR-3.5 and TR-3.7. Check analysis of C-1 outlet gases
for Ammonia, CO2, O2, and H2. Analysis reactor outlet solution and maintained levels of HE-6 and HE-7.
3.7.0 Increase setting of MP stage pressure controller PRC-80 gradually to 18 ata.Close all water injection in
circulation pump suction / discharge if any limit scrubbing water to C-3 and C-4. Act on HIC-7(V) to
maintained 4.5 ata pressure in L.P. absorber.
In PDIL process some condensate would continuously be given in C-3 and C-4 top for
scrubbing the gases before venting, but all water entry should be limited minimum to maintain water
balance of the system. Any upset of water balance will be reflected by increase of levels in absorber /
condensate.
3.8.0 Increase gradually setting to TRC-26 (on SD-2) to 163 0C and TRC-44 (SD-3) to 1400C. Keep Reactor
pressure between 210-220 ata. Check the RPM or carbamate flow to reactor.
3.9.0 Check functioning of C-2 column, recovered ammonia concentration / flow and also thermosyphon
circulation of urea solution in HE-2, HE-3.
3.10.0 Whenever the concentration of urea in SD-3 outlet comes above 60% (by wt.), line up prilling section.
At the same time, if every thing goes normal, increase the plant load gradually to 50%. Increase
delivery of carbamate pumps keeping reactor mole ratios as specified. Increase ammonia preheater
outlet temperature, as required. Start prilling with lowest rpm of bucket, only when melt tempr. attains
minimum 1350C. Check the quality of prills formed. Refer chapter 10.00 for Prilling Section start-up.
3.11.0 Set TRC-22 of HE-7 to 1100C and TRC-29 to 650C. Control level of steam drum. Check steam flow
rate. Changeover the pump if strainers are chocked. Increase ammonia reflux in C-2.
3.12.0 Gradually raise reactor pressure to 225 ata and if required, send CO 2 to HE-6 as per material balance
at this load. Before that analyse HE-6 carbamate outlet Solution. After CO 2 addition, more steam
generation would occur. It is better to introduce CO2 when reactor load is at least 65%.
3.13.0 Increase CO2 Compressor load to 65% and also Ammonia pump RPM accordingly alongwith
Carbamate pump RPM when level rises in HE-7. Increase bucket speed for prilling at this load and
increase reflux in C-2.
3.14.0 Start PC-9 to send vacuum condensate from SR-5 to C-6 directly through HIC-9(V). Start PC-13 when
level of C-6 rises above 50% and send solution to C-4 through LRCA-32(V) for supplying water for
absorption.
3.15.0 Take Stripper and Hydrolyzer section in line as per instruction given in chapter 11.00. Set PIC-118 on
C-6 at 2 ata and use HIC-8 vent valve on C-5 top if required to maintain pressure. Set PRC-119 on
Hydrolyzer at 18 ata.
3.16.0 The load of the plant can be thereafter gradually increased in steps to 100% maintaining design Mole
Ratio of NH3 :CO2 and H2O :CO2 in the reactor. Increase speed of Ammonia and carbamate pumps and
prill bucket accordingly. Increase reflux in C-2. Check that all level, pressure and temperature
controllers are working perfectly on auto. Increase C.W. and steam flows to process vessels as
required. Increase CO2 feed to HE-6 and all analyses for reactor conversion, stage wise concentration,
carbamate recovery, biuret in prills.
3.17.0 Note the consumption figures of raw materials, utilities and product rate to check up specific
consumption.

4.00 START-UP AND STABILIZATION OF VACUUM CONDENSATION SECTION:

When once through operation is going on and processed Reactor effluents are finally collected in SD-
3 / SR-3, preparation should be undertake to start Vacuum Concentration Section.
4.1.0 Open 6 at and 3.5 ata steam to all steam tracings, jackets of vacuum section, including solution recycle
lines to SR-3. Adjust SV-5(V1) towards Bucket. Ensure that steam valves V-699 and V-702 are open.
Maintain traps in line to avoid steam hammering in condensate lines.
4.2.0 Ensure that C.W. remains charged in all vacuum condensers and release all entrapped air from highest
points. Ensure C.W. flow as per material balance through FIC-67, FI-64, and FIC-41. For this requisite
number of C.W. pumps may be taken in line to maintain pressure and flow.
4.3.0 Fill up tubes of HE-4, HE-5 with LPW overflow in SD-4 and SD-5. LPW valves are available at suction
of PC-2, bottom of HE-5 and HE-4. Thereafter cut off LPW in HE-4 by closing V-030 and also to HE-5
and PC-2. This should be done during initial filling-up of vessels.
4.4.0 Open valve V-033 between SD-4 and HE-5. Keep Urea Melt Pump PC-2 ready with LICA-65(V) closed
on manual control. Keep the lines filled up with LPW upto pump discharge valve which is kept closed.
4.5.0 Open LPW to fill up seals in vacuum Condensate Tank (SR-5) and SL-5.
4.6.0 Open air intake valves HIC-11(V) and HIC-13(V) alongwith bypass valves on gas outlet line from SD-4
and SD-5.
4.7.0 Charge 3.5 ata steam to Vac. Ejectors as per manual of M/S. KOERTING starting from last stage and
try to establish a vacuum of 0.7 ata (read on PRA-145) in SD-5 by acting on HIC-13(V) and its bypass
valve. Maintain pressure in SD-4 0.31 ata higher than that of SD-5 of initiate natural flow of solution
between SD-4 and SD-5. Wash the line which is isolated.
4.8.0 When a conc. above 60% (by wt.) of urea solution is achieved in SD-3, throttle recycle valve V-032 and
open V-030 to send urea solution towards HE-4, SD-4 and gradually close V-032.
4.9.0 Observe level rise through sight glass in SD-4 and SD-5. there should be very little level or no level in
SD-4 . Throttle V-033, if required.
4.10.0 As soon as level of urea solution in SD-5 reaches 50% of LICA-65, start pump PC-2 as per vendor’s
instruction, after opening LICA-65(V) on manual. This solution will now flow up through SV-5(V1) and
 be diverted towards SR-3 tank bypassing prilling bucket for further concentration. Ensure that
condensate injection valves are closed.
4.11.0 Charge steam to Vac. Decomposer HE-4b, HE-5 through TRC -56 (V) and TRC-57 (V) on manual. If
required, HE-4a with HIC-10(V) can also be taken in line.
4.12.0 Heat both Vac. Decomposer and maintain Vacuum in SD-4 and SD-5 to concentrate urea solution as
far as possible and store the solution in SR-3. An indicative chart of Temperature pressure
concentration is given below for reference.
4.13.0 Temp. in SD-5 Vac. In SD-5 Conc. In SD-5

1000C 0.6 ata 70% urea

1100C 0.46 ata 88% urea

1200C 0.32 ata 94.5% urea

1300C 0.18 ata 98.2% urea

1400C 0.04 ata 99.7% urea

4.14.0 In any case a constant pressure difference of about 0.31 ata is to be maintained between SD-5 and
SD-4.
4.15.0 When desired urea concentration of 70-75% is available in SD-3 exit, maintain design vacuum and
temperature in SD-4 and Sd-5 to obtain desired concentration of urea melt in SD-5. For this act on HIC-
10(V), TRC-56(V), TRC-57(V).HIC-11(V) and HIC-13(V), is setting finally TRC-56 at 133 0C and TRC-57
at 1400C on auto, and corresponding vacuum in SD-4 as 0.35 ata and in SD-5 as 0.04 ata.
4.16.0 Heat up the Prilling Bucket and the line. Put it in position after inspection and having proper flexible
connection. Ensure that the line towards Bucket is clear.
4.17.0 Ensure that Prilling Tower Bottom Conveyer system and Scraper are working and interlocks are put in
operation. Belt Weigher should be put in line.
4.18.0 Check temperature of urea melt in SD-5 which should be around 135-140 0C. Check urea melt
concentration from SD-5 by crystallization point method. When it reaches 99.0% at least, stop recycle
to SR-3, and divert it towards Prilling Bucket, by acting on SV-5(V 1). Start Prilling Bucket motor at
lowest rpm. Immediately wash the recycle line SR-3 with condensate, and keep the steam on.
4.19.0 Check physically urea melt flow in Bucket, prill quality, solution overflow or any other abnormality. In
case of any abnormality divert the melt again towards SR-3 and wash the used line. Take care that
Water should not fall inside the Prilling Tower. For washing the Prilling Bucket it has to be lifted and a
cover plate is to be arranged to block the bucket entry hole.
4.20.0 Regulate rotation of the Bucket in case of overflow, less flow or bad prill quality. An ammeter is
available in the Central Control Panel to check its loading and performance. Lumps will be diverted
towards Urea Dissolving Tank (SA-1) by 13.0 ET-2 conveyors. Solution from SA-1 tank can be
gradually fed to SR-3 tank for further processing.
4.21.0 When plant load is raised or lowered, speed of prilling bucket has to be changed accordingly.

5.0.0 START-UP OF AMMONIA STRIPPER- HYDROLYZER SECTION:

Vacuum condensate may contain around 1% urea, 3-4% ammonia and 0.7% CO 2. If this effluent is
disposed of as it is, it may pose pollution problem incurring ammonia and urea losses.
5.1.0 A stripper-Hydrolyser section has therefore been provided in this plant to render this normal effluent
practically free from ammonia and urea and also to recover them for reuse in the process. This section
can be operated when vacuum section is in line.
This unit consists of vacuum Condensate Tank (SR-5), Stripper Feed Pump (PC-9,9r), Stripper
(C-5), Stripper Reboiler (HE-19), Urea Hydrolyser (HE-29), Stripper Vapour Condenser (C-6),
Recovered Solution Circulation Cooler (HE-17), Hydroliser Feed Pump (PC-20, 20r), Waste Water
Pump (PC-25, 25r), Recovered solution Circulation Pump (10PC-12,12r), Recovered Solution Recycle
Pump (PC-13,13r), Hydrolyzer Feed Preheaters (HE-30a,b) , Stripper Feed Preheaters (HE-18a,b) and
 Waste Water Cooler (HE-32). Stripper uis operated at 2.5 ata pressure and Hydrolyser at 18 ata
pressure. The sequence for start-up is as follow:
5.2.0 Open cooling water to HE-17 and HE-32.
5.3.0 Energise the following control instrument :

i) PIC -118 on Stripper Vapour Condenser C-6, discharging to Stack and Stack
and set it on auto at 2.0 ata. Open isolation valve V-1489.
ii) PRC-119 on outlet vapour from Hydrolyser (HE-29) and HIC-8 0n vent line
from Stripper (C-5). Set PRC-119 on auto at 18 ata. Open isolation valves V-
221, V-222, V-1470.
iii) Level controller LICA-44 on upper part of C-5, level controller LICA-57 on the
Hydrolyser, LICA-47 on Reboiler HE-19, SV-4(V1) on C-6 solution outlet line.
Take all level controllers on manual. Set SV-4(V1) on auto at its upper set
point.
iv) PRC-45 on stripper feed line, FIC-50 on reflux line. Put them on manual for
the time being.
5.4.0 Take condensate from HE-20 to C-6 through V-1047 and start Circulation Pump PC-12 when sufficient
level comes up in C-6. Start PC-13 to send condensate to top of 10C-5 through reflux line 40-CS-
32.Keep bypass line from PC-13 discharge to C-6 open and line towards C-4 closed. When sufficient
level (LICA-44) is reached in the upper part, start Hydrolyser Feed Pump PC-20, 20r to feed
condensate to Hydrolyser through exchangers.
5.5.0 Now LPW can be sent through Stripper Feed Pump (PC-9) to Stripper top (10C-5) by operating FRC-
45(V).
5.6.0 The water flows from Hydrolyser to lower part of column C-5 and fills up Reboiler shell (HE-19).
5.7.0 When the level is formed in 10HE-19, start heating the Reboiler tube side with 6 ata steam by gradually
opening TRC-49(V). The waste Water Pump PC-25 may be started to deliver C-5 bottom condensate to
Effluent Pit.
5.8.0 When level is formed in 10HE-29 shell, take 22 ata Desuperheater (HE-31) in line. For this admits
condensate/ MPW to 10HE-31 through open either V-1342 or V-794. Send 24 ata steams to HE-31
through TRC-47(V) and vent the same through V-1519. When 22 ata pressures is reached, open V-189
in line. Heat up HE-29.
5.9.0 Raise the pressure in C-5 column and Hydrolyser (HE-29) gradually by acting on PRC-119, HIC-8 and
PIC-118.
5.10.0 Send passivation air through FI-51, FI-52, and FI-53 whenever necessary.
5.11.0 When vacuum condensate is available in SR-5, close LPW to PC-9 suction and run it with vacuum
condensate to feed 10C-5. Set LICA-44 and LICA-47 on AUTO position.
5.12.0 Gradually establish the conditions for normal operation by absorbing the vapours from C-5 and HE-29.
When desired concentration is achieved in C-6 column, sent the solution to L.P. Absorber (10C-4)
using LRCA-32(V).

6.0.0 SHUT-DOWN OPERATION:

6.1.0 Shut-down of Synthesis Section

Shut-down of the plant may be necessitated due to following occasions:

a) Short shut-down
b) Long shut-down
c) Emergency shut-down

Generally long shut downs are programmed or planned. For any shut-downs the principle is to cut off
the feed and to bring the whole plant under safe conditions so that re-start up is possible.

6.2.0 Actions for short shut-down:

 1. Reduce the feed to Reactor to 50% and all other flow proportionately. Cut off CO 2 feed to H.P.
Partial condenser.
2. Reduce steam to decomposers / preheater and cooling water to condensers.
3. Change over to once through and cut off the feed gradually. CO 2 feed should be cut off first, then
ammonia feed and then carbamate feed. These are to be done by stopping respective machineries
and as per guideline in respective manuals. CO 2 compressors may be continue to run venting CO 2
from the discharge of reciprocating compressor.

Ammonia pump should be cut off after 20 minutes of CO 2 feed cut off while carbamate charge pump
can continue running depending on the level of HE-6 and HE-7. Cut off steam to Ammonia
preheater (HE-11).
4. Keep wash water pumps available and wash all feed lines to the Reactor and CO 2 line to HE-6.
Dilute the solutions to some extent only in all stages including Reactor. Cut off passivation air.
Dilute the Reactor and bring down its temperature to around 120 0C. Reactor pressure can also be
brought down to 12 ata by setting PRC-13(V) generally.
5. Emptying, washing and purging of the equipments are not necessary. The Reactor can be kept
blocked for maximum period of 48 hours with dilution and lowering of pressure.
6. Keeps Ammonia Booster Pump running on recirculation with reflux in C-2. Maintain level of SR-1.
Keep all pressure control valves can be taken on manual.
7. Push water whenever pressure or temperature goes high in any condenser. Maintain level of
condensers. All other pumps can be kept running as required in case of short shut-down. Check
that temperature of HE-6 and HE-7 does not fall below 1000C.
8. Keep hydrolyser and stripping section running. Recover maximum quantity of urea by prilling from
SD-3 and SR-3 as long level permits.

6.3.0 Actions for long shut-down:

General procedure is to reduce the plant load i.e. the feed to the Reactor gradually to 35%, and finally
cut off the feeds, dilution of solution, draining to tanks or closed drains, washing the lines, purging with
nitrogen, cutting off steam and then cooling water. Keep wash water pumps available. Maintain level in
Condensate Tank. It will be necessary to reduce SR-1 level to accommodate recovered ammonia as such as
possible. Recover maximum amount of urea by prilling. Keeps Hydrolyser- Stripper section running as long as
prilling continues. Keep almost all drain and vent valves open after washing. First inform ammonia plant, steam
generation plant and electric substation before S / D. Steps to be taken are as follows:
1. Gradually reduce plant load to 50%. Keep the plant under this condition for at least one hour.
2. Changeover to Once-Through. By pass HE-6, HE-1, and SD-1 & HE-7. Cut off steam to HE-1 and
steam from SD-11. Cut off CO2 to partial condenser (HE-6).
3. Reduce the load further to 35% and all other material flows to minimum.
4. Stop CO2 feed to Reactor by tripping CO 2 charge Compressor first. Stop CO2 Booster Compressor
as per manual. Wash CO2 line to Reactor and CO2 line to HE-6.Wash also the lines to HE-1, SD-1.
Passivation air injections should also be stopped.
5. Stop steam and hot condensate flow to Ammonia Preheaters. Continue ammonia feed at minimum
RPM for 10 minutes. Then stop the pump, close its delivery. Wash ammonia line towards Reactor.
Keeps PC-15 running on bypass. Close make=up ammonia inlet valve to SR-1Continue ammonia
reflux in C-2 to arrest temperature rise.
6. Reduce Carbamate Pump speed to minimum. When HE-7 level comes down, inject wash water at
PA-5 suction. Reactor temp. and pr. Will fall and it will continue to discharge through letdown valve
to MP stage. Stop Carbamate Charge Pump and wash it thoroughly. Whenever level of C-2 rises,
drain it to SR-4. Also push some HPW from reactor outlet line towards Reactor. Heat up HE-2 and
HE-3 to decompose as much carbamate as possible. Take PRC-13(V) on manual and go on
releasing pressure in Reactor gradually at the rate of 20 kg / hr. Keeping HPW injection at the
bottom of Reactor through one of the feed line. Recover as much ammonia as possible in SR-1
from MP stage.
7. When SD-3 solution becomes quite dilute , divert urea solution from Prilling Bucket to SR-3 and
push LPW in PC-1 suction. Wash the Bucket and the connected lines. Stop the conveyors.
 8. Maintain temperature in Decomposer as required for once through operation so that excess
ammonia do not go to vacuum section. Be careful to avoid vacuum formation in LP stage or any
where. Take all level controllers on manual.
9. When no more ammonia recovery is possible, cut off steam to HE-2, HE-3. Cut off cooling water to
condensers and condensate to C-3 and C-4. Open vent valve HIC-7 of C-4. Depressurize the first
cycle equipment gradually and push HPW in HE-6, HE-7 through C-1 and drain to SR-4. Drain HE-
1 & SD-1 through LICA-7 after dilution.
10. Introduce wash water in C-2 trays and stop reflux whenever temperature is tolerable. Isolate SR-1
completely keeping PRC-80(V) connected and set at 18 ata. Close valve between condenser and
SR-1 when no more ammonia condensing. Wash C-2 overhead lines, ammonia condenser and
drain.
11. Open wash water to Vacuum Decomposers and Separators to wash them thoroughly keeping PC-2
running. Gradually reduce vacuum keeping differential pressure of 0.31 ata between two vacuum
stages. Cut off steam to ejector and Decomposers. Close with water.
12. Drain & wash all equipment thoroughly except C-3 and SR-1. Stop PC-15. Close suction and
discharge valves. Cut off aqua ammonia to C-2 column. Stop PC-4, PC-1.
13. Depressurize C-2 and HE-8 after isolating it from SR-1 tank. Since there is no vent from C-2, it is
advisable to depressurize C-2 by gradual absorption with wash water as far as possible. There after
introduce nitrogen after emptying the column.
14. Purge all the equipments except SR-1 & C-3 with nitrogen. Since there will be liquid ammonia in
SR-1 and C-3 these equipments can be kept isolated with PRC-80 set at 18 ata.
15. Bring all interlocks changeover switches for level controllers to once through position.
16. Depressurize the Reactor as such as possible through PRC-13(V) transferring the solution to SR-3
via SD-2, SD-3.
If S / D are prolonged, reactor contents require draining. Open the reactor bypass valve at outlet
and transfer as such as possible to lower stages by pressure differences. Thereafter drain the
contents to closed drain after proper dilution. The rate should be slow and sample point should be
kept open to prevent vacuum. If N2 is available, this can be connected to sample point to conduct
pressure draining for necessary. Keep Reactor under N2 blanket
17. Ammonia Stripper can be kept operating to distill off ammonia from ammonia cal solution collecting
In SR-5, SR-4 and venting vapours to atmosphere. Stop all circulation pumps and C.W. to
exchangers, isolate steam and maintain positive pressure with N 2 in all evacuated equipments.

6.4.0 Normal Shut-down of Vacuum Section:

Keeps Vacuum Section running sending urea melt to Bucket to obtain prills as long as there is sufficient
level and concentration in SD-3 and SR-3. Transfer all solution of SR-3 to Sd-3 for prilling.
6.4.1 Open LPW in PC-16 discharge line towards SD-5 bottom keeping PC-16 idle and PC-1, PC-2 running.
Actuate 3way valve SV-5(V1) to divert urea solution from Prilling Bucket towards recycle line to SR-3.
Stop Prillingh Bucket motor.
6.4.2 Thoroughly dilute and wash the system keeping PC-1, PC-2 pumps running. Lift the bucket. Open
flexible pipe and wash the lines outside, including Bucket.
6.4.3 Maintain a vacuum difference of about 0.31 ata between SD-4 and SD-5 for natural flow and gradually
reduce the vacuum in both vessels with the help of air valves.
6.4.4 Take TRC-56, TRC-57 on manual and gradually cut off steam in HE-4 and HE-5. Cut off 3.5 ata steam
with HIC-10(V). Take LRCA-27, LRCA-65 on manual.
6.4.5 When temperature has sufficiently come to zero by opening HIC-11 & HIC-13 valves.
6.4.6 Close steam to ejectors. Stop pumps PC-2 and then PC-1.
6.4.7 Close all LPW injections which were opened. Open the drain valves to evacuate the headers and
equipments. Drain from SR-3, SD-3, if required. Wash the vessels several times.
6.4.8 Stop steam to tracings, jackets and flushing, if prolonged shutdown is planned. Isolate steam from 6
ata, 3.5 ata header. Close condensate outlet isolation valves to prevent backflow.
6.4.9 Stop Conveyers. Scraper and engage personnel to keep the area clean.
6.5.0 Normal Shutdown of Stripper- Hydrolyser section:
6.5.1 Top Stripper Feed Pump (PC-9,9r). Close its Discharge valve.
6.5.2 Gradually reduce the reflux to Stripper (C-5). Simultaneously act on TIC-49(V) to keep the temperature
of C-5 bottom constant. When the column top temperature rises, close TIC-49(V) to cut off steam
supply to Reboiler HE-19. When level in Stripper top (LICA-44) comes down, stop Hydrolyser Feed
Pump PC-20.
6.5.3 When level in Hydrolyser (LICA-57(V) comes down, stop steam supply to Hydrolyser. Close LICA-57(V)
on manual.
6.5.4 Stop PC-13 and wash the inlet lines with LPW. Stop PC-25 when Reboiler level (LICA-47) comes
down. Stop PC-12 circulation pump.
6.5.5 Wash inlet and outlet lines of HE-29. Bring down the pressure in Hydrolyser and Stripper by acting on
PRC-119 and HIC-8. Avoid formation of vacuum.
6.5.6 Stop cooling water flow to HE-17 (FI-49).

6.6.0 EMERGENCY SHUT-DOWNS:

Emergency shut-down may be required under the following condition:-

6.6.1 Failures of major equipment, heavy leakages, failure of important machineries, failure of vital
instruments, process upsets, heavy clogging in pipe lines.
6.6.2 Dangerous situations like very high pressure and repeated blowing of safety valves, high temperature
in Reactor, fire, explosion, rupture with release of toxic substances.
6.6.3 Sudden failure of utilities or raw materials.
6.6.4 Miscellananeous.
The decision to shutdown the plant lies squarely on shift in charge or plant manager who should judge
the situation in its totality and when no alternatives are left should take prompt action.
Should trip occur for reasons given as in (1) and (2), wash the lines, dilute the stages to some
extent, eliminate the trip causes and bring the plant to safe shut-down condition as mentioned in short/
long shutdown.
6.7.0 Electrical Power Failure:

In such case, there will be alarm in C.C.P. all the electric motors and electric drive machine will stop
giving audiovisual alarms and trips indication in C.C.P. If it is momentary failure or voltage dip, restart
the pumps and machineries or their spares from local starters after resetting and electrical clearance. If
power failure continues for long time, the following steps should be taken:
6.7.1. Start condensate pump and wash pumps as emergency power.
6.7.2. Drain the 99.5% urea melt from PC-2 discharge header and wash the line.
6.7.3. Introduce wash water to first Vacuum Decomposer and other decomposers.
6.7.4. Introduce wash water to C-1 top, C-2 top (over the trays), PC-4 discharge line.
6.7.5. Inject wash water in Carbamate Charge Pump (PA-5a, b, c, r) suction and discharge lines.
6.7.6. Inject wash water to CO2 and ammonia lines to Reactor.
6.7.7. Cut off steam to Decomposer and preheate.
6.7.8. Close pump delivery valves after washing.
6.7.9. Open the topmost vent in C.W. circuit to avoid vacuum.
6.7.10. Take level control valves on manual and take measures to reduce pressure rise in all stages.
6.7.11. Till power is available, continues dilution in all the stages and drain whenever necessary.
6.7.12. Follow short shutdown/ long shutdown/ restart-up procedure as the case may be when normal power is
available.

6.8.0 Steam Failure:

In case failure, there will be no heating of decomposer, CO 2 Booster Compressor will stop, the plant
cannot be run if the failure continues for a long time. After CO 2 feed gets off, Ammonia Charge Pump is
to be run at minimum rpm some time. Stop Carbamate Charge Pump. Dilute and introduce wash water
in reactor feed lines, decomposer/ separators, C-1 column and drain excess solution to tanks/ Effluent
Pit. Continue reflux in C-2 by running PC-15 till necessary. As vacuum will be lost, divert urea solution
 to Surge Tank and proceed dilution in vacuum section. Stop / cut off C.W. whenever crystallization or
vacuum formation can be take place. Start normal shutdown procedure.
6.9.0 Cooling Water Failure:

In case cooling water fails momentarily, start more cooling water pumps to build up pressure. Lack of
cooling water in compressor intercoolers may trip the CO 2 compressor. Lack of cooling water in
coolers/condensers will cause pressure and temperature increase in all stages beyond limit and safety
valve may blow. Vacuum will also be lost and prilling will have to be suspended. Precautions to be
followed are:-
6.9.1 Open the topmost vent in cooling water circuit to avoid vacuum formation.
6.9.2 Isolate all rotating machines and stop them either locally or from panel to avoid damage.
6.9.3 Run wash water pumps and inject wash water wherever necessary, in C-2 column trays and
condensers to absorb as much vapours as possible in a bid to arrest pressure rise.
6.9.4 Stop CO2 Charge Compressor, Ammonia Charge Pump and Carbamate Charge Pump.
6.9.5 Take care of all pressure control valves in all stages; if required, open the vents to release
overpressure.
6.9.6 Reduce or cut off heating of decomposer, reboiler etc. Close steam to ejectors.
6.9.7 Proceed with normal shut-down procedure.

6.10.0 Instruments Air Failure:

In case of instruments air failure important control valves assume the safe position as indicated in
chapter 16. If the failure is for a very short period, then plant can be kept running sometime with the
stored air available from Instrument Air Receiver, otherwise a shutdown has to be taken.
6.10.1 In case of such emergency, the following actions have to be taken.
6.10.2 All instruments control valves have to be taken on manual.
6.10.3 Start the wash pumps for washing and dilution
6.10.4 Stop CO2 feed, ammonia feed and carbamate feed to reactor.
6.10.5 Start the operation of normal shutdown.

6.11.0 Raw Material Failure:

In case CO2 or Ammonia supply fails for a considerable time, emergency shutdown as detailed in case
of power failure have to be undertaken forthwith.

6.12.0 Forced shutdown of Vacuum section:

In case of electric power failure, PC-1, PC-2 and Prilling Bucket will stop. No C.W. will be available in
condensers. Take all controllers on manual e.g. TRC, LRC. Take plant cannot run to obtain prills and
shutdown is necessary. Run wash pumps on emergency power.
6.12.1 Cut off steam to vacuum decomposers, but steam in jackets and tracing etc. should continue. Open
LPW injections wherever possible and dilute all lines and vessels. Open condensate in recycle lines to
SR-3. Cover Bucket entry hole.
6.12.2 Air intake valves HIC-11(V) & HIC-13(V) should be opened.
6.12.3 Drain the solution from all drain points available.
6.12.4 In case of instruments air failure vacuum will break. Take all control instruments on manual. Use
isolation valves and take action manually. Shutdown will have to be taken if instrument air is not
available for more than say 15 minutes.

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