A study on steam piping in ammonia

plant at nfcl

Presented
by

S.V.R.KUMARI G.V.V.R SRINIVAS

J.JHANSI ARUNA Neerukonda.NANI

Under The Guidance Of

Dr. D. S. V. PRASAD. Ph.D

Professor

Page 1
 ABSTRACT

This mini project work program has been under taken to investigate the
requirement of steam pipe lines in ammonia plant at “ NAGARJUNA
FERTILIZERS AND CHEMICALS LIMITED (NFCL) KAKINADA”. And to
study about the types of steams ,valves used in pipe lines , welding procedure of
pipe lines , working of steam pipe lines.

By following this process we can prevent leakages and damage of steam pipe lines
and also we can reduce corrosion by insulation process

Page 2
 INTRODUCTION

Nagarjuna fertilizers and chemicals Limited operates a large modern Ammonia urea
complex compromising two streams of ammonia and urea each.
The manufacturing facilities are located at Kakinada in the state of A.P. It is the first
gas based fertilizer complex in South India .

In NFCL the manufacturing urea for this the main raw material is liquid ammonia
by steam .Air from atmosphere comes in contact with the process gas from primary
reformer.

This plant had gone a major revamping in September 2009.The capacities are
enhanced to ammonia 2325 tones .

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 NFCL PROFILE

 NAGARJUNA GROUP

 PROJECT PROFILE

 RAW MATERIAL

 OBJECTIVES OF NFCL

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 A STUDY ON STEAM PIPING IN
AMMONIA PLANT AT NFCL

In ammonia plant they are using three types of steams

Very high pressure steam(K.S) Pr:103kg / cm2 Temp:500ºc
High pressure steam (H.S) Pr: 37kg/cm2 Temp :370ºc
Low pressure steam(L.S) Pr: 3.5kg/cm2 Temp :145ºc

Generally the steam is produced in power plant in boilers, auxiliary boilers, waste heat
boilers (heat recovery steam generation units, HSRG) The piping for the steam is
according to the SNAMPROGRETTI‘s ITALY Specifications. Each line is designated
with specific number designating various features

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 Very High Pressure Steam:(KS)

In Ammonia Plant -1 approximately 240 t of KS is consumed. In this 20 t is imported

from Power plant and rest 220 t is produced in Ammonia plant itself by using primary
reformer’s waste heat. In emergencies KS is also let down to HS.

Ex. 14”-11-K.S1100-88D-I.
It indicates
14”-size of pipe.
11-plant unit code
K.S – service of the pipe.
1100 -location.
88D- spec for pipe.
I –insulated..

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Page 7
Various piping components and specifications:

piping components Specifications

Pipe Line 10"
Valve 2"VS01
Orifice
Pressure Indicator(PI) PI 003

Temperature Indicator (TI) TI 003

Control Valve HSV 003
By Pass Valve 2”VD04
Flow Transformer FT 003
Pressure Transformer 006
Temperature Indicator 006
Reducer 14”*10”
Pipe Line 14”-11-KS1100-88D-I

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Non return valve

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 Pressure Design Of Piping Components
The required thickness of straight section of pipe shall be determined by
equation Tm=t + c
The minimum thickness T for pipe selected, considering, manufacture minus
tolerance than tm. Shall be not less than tm. The following nomenclatur is used in
equations for pressure design of straight pipe.

The thickness on steel pipes determined by the following formulas

tm= (8/7)*(PD/2Se+P)+c
8/7= (from I.B.R)
Where,
Tm=minimum wall thickness,
P=working pressure (max)
S=allowable stress
D=out side diameter of pipe
E=efficiency factory, 1 for seamless and erul pipes
C= corrosion allowance, 1mm. Page 10
 Pipe Sizes & Thickness Available Are:

NPS code(in) OD(mm) Thickness(mm) Commercial

1/2” 21.3 3.22 Sch 160

1” 33.4 4.41 Sch 160

1-1/2” 48.3 5.87 Sch 160

2” 60.3 7.04 Sch 160

Rating:
2500 LB RJ
(ringjoint gasket)

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 Composition of K.S Pipe Material & Manufacture:
ASTM A 335 GRADE P22 SMLS +60637(I.B.R)
P22:

UNS Designation K 21590

Carbon 0.05-0.15

Manganese 0.30-0.60

Phosphorus Max 0.025

Max 0.025

Silicon 0.05 Max

Chromium 1.90-2.60

Molybdenum 0.87-1.13

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 Insulation
Insulation is also followed according to snamprogetti’s specifications. The various letters
indicate the various types of insulations.
A=internally treated and externally coated line
B=line with externally coating only
E=electric traced line
F=cold insulated line (+5ºc to -273ºc)
I=hot insulated line (temp +6ºc and above)
N=non painted and non insulated line
S=internally treated and externally painted line
T=hot fluid traced line
V=line with external painting only
W=jacketed line
Each insulation is to be carried out according to their respective specification.
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Ball Valve

Page 14
 WELDING SPECIFICATIONS

CONTENTS:
SCOPE AND FIELD OF APPLICATION:
This specification provides the requirements for chromium molybdenum steel
piping
PREPARATION FOR WELDING:
EDGE PREPARATION:
HOT ADJUSTMENT:
Temperature range from 700 to 950.all pieces having under gone hot adjustment
shall be subjected to PWHT.

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WELDING PROCEDURE QUALIFICATIONS:
The welding procedure shall be previously qualified according to the
requirements of ASME.
PREHEATING:
It is required for any type of welding , including the welding of yokes,
tack welding, and the welding of permanent of temporary support.
ROOT PASS:
For but joint without back welding and for branch connections, the
root pass shall be performed with the welding process and the filler metal.
PWHT TREATMENTS:
The heating rate, measured at 100c intervals, shall not be higher than
200c/hr and difference measured by the various thermo couples shall never be higher
than 50c

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 HIGH PRESSURE STEAM (HS)

The HS lies in temperature of 370°c & a pressure of 37 kg/m^2. The Steam of this

network is coming from plant B.L &is utilized in Hydrolyzer 01-R—102. HS, there is no

import as HS is generated or extracted from DSTK 431/432 in Ammonia -1.(aprx.217 t).

•At ARC (AMMONIA REFRIGERATION COMPRESSOR) DSTK 451 IS 38tonnesper

hour.

•At PAC (PROCESS AIR COMPRESSOR) DSTK 421 is 28 tonnes per hour.

•Reformer is 101 tones.

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 H.S Pipe Line Specifications
Pipe line: 24”-11-HS-1100-65A-I
We already know about 24, 11, HS, 1100, 65A, I
In detail about 65A SPEC:
Service: Steam condensate; Medium pressure steam (I.B.R) pipe size& thickness
available are as follows:

Pipe class 65A

Pipe Material SMLS-ASTM A 335

GR.P1
Design pressure 44.00kg/cm^2

Design temperature 420°c=788°F

Allowable stress 13.60 KSI =956Kg/cm^2

Corrosion allowance 1.27

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Composition:
Pipe Line Material & Manufacture:
ASTM A 335 GRADE P1 SMLS +60637
P1:
UNS Designation K 11522

Carbon 0.10-0.20

Manganese 0.30-0.80
Phosphorus Max 0.025

Max 0.025

Silicon 0.10-0.50
Chromium --

Molybdenum 0.44-0.65

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 LOW PRESSURE STEAM

 The LS lie in temperature of 145°c and a pressure of 3.5kg/cm^2.

 In LS there is no import and 15 tones of steam is produced.

 Consumptions are 5 tones from GV section and 2 tones from deheater .

The export is 6 tones per hr.
From back pressure turbine - DSTP 710 A/B
DSTK 201/202
DSTK301/302

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Page 21
GATE VALVE

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LS pipe line specification:
pipe line 26”-11-LS-1100-11H-I

LS pipe material and manufacture:

ASTM A 106 GRADE B SMLS+60636

Properties :
Tensile strength minimum
Yield strength minimum

Top ups:

Tapings:

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Chemical composition:

Carbon maximum A - 0.30

Manganese - 0.29-1.06
Phosphorous maximum - -0.035
Sulphur maximum - 0.035
Silicon maximum - 0.10
Chrome maximum B - 0.40
Copper maximum B - 0.4
Molybdenum maximum - 0.15
Nickel maximum B - 0.4
Vanadium maximum B - 0.08

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How to charge LS pipe line:

 once MS header is charged. we can proceed with charging of LS header.

Turbine condenser vacuum system LS isolation values are closed.

Open all the utility points.

LS vent values PV-39 is open full by PIC-39on manual. open the isolated values.

Confirm P-110 is running and HW header is charged.

Now the LS header is ready for heating and charging.

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 Conclusion:

 It is an esteemed privilege to do mini project in one of the reputed industry

in south India (NAGARGUNA FERTILIZERS AND CHEMICALS LIMITED).

 By this project we got an over view of steam piping network i.e. selection of
valves, pipes & thickness, welding spec and how the mechanical equipment
is being used.

 By this process we can prevent leakages and damage of steam pipe lines
and hence we can reduce corrosion by insulation process.

Page 26
QUERY’S

Page 27
Thank Q

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