STEAM BALANCE ON DIFFERENT EMERGENCY SCENARIOS

1. TWO BFW PUMPS FAILURE

Water Balance
Total BFW Requirement 440 m3/h
One pump capacity 260 m3/h
MP-604 capacity 35 m3/h
Total available capacity with one pump 295 m3/h
Deficit 145 m3/h
B-602/603 + TK-101 +TK-421 + TK-431 + TK-441 will be manually tripped
(B-602 + B-603 trip)/ CO2 compressor 90 m3/h
trip
Back end + Air compressor trip 100 (50 + 50) m3/h
CBD isolation 10 m3/h
Total reduction 200 m3/h
Margin available 200 – 145 = 55 m3/h

2. GAS TURBINE GT-703 TRIPPING I-33C

Steam balance
B-603 tripping I-32C +30 Ton
TG-701A/B load increment of ~4.5 MW +20 Ton
Boilers load increment +50 Ton

3. PRIMARY REFORMER TRIPPING I-1

Steam balance
HS steam demand
Utilities HS steam load 40 Ton
Steam to E-201 process gas pre-heater 20 Ton
 Steam to E-202 air pre-heater 30 Ton
TK-201 (steam demand will be low) 8 Ton (normal steam flow = 14 Ton)
TK-421 HS steam flow on lock up 18 Ton
Urea HS steam demand for flushing 40 Ton
Small turbines HS steam consumption ~10 Ton
KS to HS steam let down +166 Ton
KS steam demand
TG-701A/B steam consumption 22 Ton
Overall boilers load 188 Ton (B-601/602/603: 79/79/30)
Note: TK-421 LS steam do not cut on I-15B, as its LS steam valve is on manual.

4. SYN COMPRESSOR TRIPPING I-16A

Steam balance
TK-431 condensing steam flow cut -50 Ton
V-201 production decrease due to E- +55 Ton
501A/B
TK-441 HS steam rejection -22 Ton
Boilers load reduction -17 Ton
Note: 22 Ton boilers load will be reduced by purge gas cut I-20. Natural gas flow
to boilers will almost remain same.
In case of syn compressor lock up (I-16B)
Steam balance
TK-431 condensing steam flow -50 Ton
minimization
V-201 production decrease due to E- +55 Ton
501A/B
TK-441 HS steam rejection -22 Ton
Boilers load reduction -17 Ton
Note:
  22 Ton boilers load will be reduced by purge gas cut I-20. Natural gas flow
to boilers will almost remain same.
 In case of I-16A HS steam will be produced by KS to HS letdown valves,
while in I-16B HS steam will be produced through TK-431 HS extraction &
KS to HS letdown valves.

5. AMMONIA COMPRESSOR TRIPPING I-17

Steam balance
TK-441 HS steam rejection -22 Ton
22 Ton HS steam to be managed through LS steam venting by steam letdown.

6. CO2 COMPRESSOR TRIPPING I-21

Steam balance
TK-101 KS steam rejection -95 Ton
Urea HS steam demand for flushing +40
Boiler load reduction requirement -55 Ton
Note:
 22 Ton boilers load will be reduced by purge gas cut I-20.
 No further boilers load can be reduced, since B-601/602 natural gas
remained on MLO at reduced boilers load.
~ 33 Ton steam to be managed by KS venting or B-603 load reduction or TG-
701A/B load increment or through LS steam venting by steam letdown

7. BENFIELD PUMP MP-301A TRIPPING I-10A

Steam balance
TP-301B HS steam demand +16 Ton
Boilers load increment +16 Ton
TP-301B LS steam extraction 16 Ton (LS steam will be vented)

8. ABSORBER TRIPPING, I-5

 I-5 leads to (I-16B + I-17 + I-21)
Steam balance
TK-431 condensing steam flow -50 Ton
minimization
V-201 production decrease due to E- +55 Ton
501A/B
TK-441 HS steam rejection -22 Ton
TK-101 KS steam rejection -95 Ton
Urea HS steam demand for flushing +40
Boilers load reduction requirement -72 Ton
Note:
 22 Ton boilers load will be reduced by purge gas cut I-20.
 No further boilers load can be reduced, since B-601/602 natural gas
remained on MLO at reduced boilers load.
~ 50 Ton steam to be managed by KS venting or B-603 load reduction or TG-
701A/B load increment or through LS steam venting by steam letdown
Note: Front end load will be reduced resulting in reduction of V-201 steam
production. Consequently excess KS steam will decrease, so does the steam
venting.

9. AIR COMPRESSOR TRIPPING I-15A

Steam balance
TK-421 LS steam rejection 16 Ton (LS steam will be vented)
TK-421 HS steam rejection -34 Ton
HS steam flow to E-202 coils +40 Ton
V-201 production decrease due to I-3 +55 Ton
Boilers load increment +61 Ton
I-16B and I-17 actuation if TK-421 do not start in 3 minutes
TK-441 HS steam rejection -22 Ton
TK-431 condensing steam flow -50 Ton
minimization
 V-201 production decrease due to E- +55 Ton
501A/B
Overall boilers load increment +44 Ton
In case of air compressor lock up (I-15B)
Steam balance
TK-421 HS steam rejection -16 Ton (TK-421 consuming 18 Ton HS)
HS steam flow to E-202 coils +40 Ton
V-201 production decrease due to I-3 +55 Ton
Boilers load increment +79 Ton
Note: TK-421 LS steam do not cut on I-15B, as its LS steam valve is on manual.
I-16B and I-17 actuation if TK-421 do not load in 3 minutes
TK-441 HS steam rejection -22 Ton
TK-431 condensing steam flow -50 Ton
minimization
V-201 production decrease due to E- +55 Ton
501A/B
Overall boilers load increment +62 Ton
Note: Higher boiler load in case of I-15B is due to TK-421 HS steam consumption
on lock up speed.

10. SECONDARY REFORMER TRIPPING I-3

Steam balance
HS steam flow to E-202 coils +40 Ton
V-201 production decrease due to I-3 +55 Ton
TK-421 HS steam rejection -16 Ton (TK-421 consuming 18 Ton HS)
Boilers load increment +79 Ton
Note: TK-421 LS steam do not cut on I-15B, as its LS steam valve is on manual.
I-16B and I-17 actuation if TK-421 do not load in 3 minutes
TK-441 HS steam rejection -22 Ton
 TK-431 condensing steam flow -50 Ton
minimization
V-201 production decrease due to E- +55 Ton
501A/B
Overall boilers load increment +62 Ton

11. POWER FAILURE I-34

Steam balance
Utilities steam load 40 Ton
Steam to E-201 process gas pre-heater 20 Ton
Steam to E-202 air pre-heater 20 Ton
TK-201 (steam demand will be low) 8 Ton (normal steam flow = 14 Ton)
TK-421 HS steam flow on lock up 18 Ton
Boilers load +106 Ton
In case TK-602 is in isolated condition, B-602 will trip. All steam load will be on B-
601.
TK-421 loading for instrument air supply provision
Steam margin to be created before its loading by minimizing E-201/E-202 steam
consumption and by stopping 01 cooling water turbine.
E-201 and E-202 steam flow 15 + 15 = 30 Ton (10 Ton reduction)
01 cooling water turbine stop 06 Ton
Reduced boiler load +90 Ton
TK-421 HS steam flow on loading +34 Ton (16 Ton steam flow increased)
TK-421 LS steam flow 14 Ton (through LS steam extraction
from TK-201, TK-601 and small turbines)
Boiler load after TK-421 loading +106 Ton