DAWOOD HERCULES CHEMICALS LIMITED

CANAL WATER SYSTEM

PURPOSE
Purpose of canal water system is to provide raw water for water treatment plant. Advantage of canal
water over tubewell water is that use of this water results in saving of local and imported water
conditioning chemicals. This is due to the fact that quality of canal water is better than tubewell water as
it has lesser dissolved salts and solids.
Water from canal enters in the first pit and then enters two 18 R.C.C. pipes through two gate valves.
Then it passes through the 2nd, 3rd and 4th pit and ultimately into the settling tank. Screens are fitted at
moga inlet and in the 3rd pit to separate debris and floating material. .
All particles heavier than water possess a tendency to settle due to influence of gravity. The specific
gravity of suspended particles is one of the main factors governing the rate of settling.
The main purpose of settling is to effect clarification of water by permitting settling of suspended matter
and consequent reduction in turbidity. Settling is of value chiefly in the removal of course particles
which settle rapidly and which can be more economically removed. A secondary result is removal of
bacteria. Percentage of bacteria removal generally closely parallels turbidity removal.
Residence time (2-4 hours) is provided in the settling tank for the suspended solids to settle down in the
bottom and cleaner water (Max. turbidity = 40) is pumped to Raw Water Filters.
For very small particles, which has very poor settling rate, alum as coagulant is added at moga. It is
thought that precipitation of alum produces finely divided precipitates of hydrous oxide which are
positively charged. Neutralization of the positive charges by negative ions such as sulfate and chloride
in the water causes coalescence of the fine particles, thus forming gelatinous vapours precipitate of large
volume.
Al2 (SO4)3 + 3 Ca (HCO3)2

2 Al (OH)3 + 3CaSO4 + 6 CO2

Al2 (SO4)3 + 3 Na2CO3 + 3H2O

2 Al (OH)3 + 3Na2SO4 + 3 CO2

Al2 (SO4)3 + 3 Ca (OH)2

2 Al (OH)3 + 3CaSO4

1-7% Alum is added in a controlled quantity through P-436 A/B at Moga. Polyelectrolyte is fed to the
3rd pit to enhance the settling rate in addition to alum. Poly electrolytes are high molecular weight water
soluble polymers that contain groups capable of undergoing electrolytic dissociation to give a highly
charged large molecular weight ion. Poly electrolyte is fed in controlled amount through P - 441. A
slurry pump is used intermittently for the removal of slurry from the tank. P-434 A/B/C pumps this
water to the filtration unit F-403 B, C, D.
EQUIPMENT:
I.

MP-434 A/B/C (Canal Water Pumps)

PUMP SPECIFICATION:
Make:
R.P.M:

K.S.B
1450

Flow:
Head:
H.P.:
Type:

1100 G.P.M.
266 ft.
91.37
7-stages vertical centrifugal

MOTOR SPECIFICATIONS:

Make:
Voltage:
Amps: H.P.:
R.P.M.:
Cycles/Sec :
Make:
Voltage:
Amps: H.P.:
R.P.M.:
Cycles/See:

II. MP-435

SIEMENS (MP-434 A/B)

380
140
100
1470
50
U.S. Electrical Motors (MP-434 C)
380
149
100
1470
50

MOTOR SPECIFICATIONS:

Make:
Voltage:
H.P.:
R.P.M.:
Cycles/See:

Westinghouse, USA
380
20
1470
50

Pump is single stage ordinary impeller with long shaft centrifugal type.

III. MP-436 A/B (Alum Injection Pumps)

MOTOR SPECIFICATIONS:

Make:
Voltage:
H.P.:
R.P.M.:
Cycles/See:
Time Rating:

General Electric Company

240/460
1/2
1725
60
Continuous

PUMP SPECIFICATIONS:
Make:
Type:
Capacity:
Pressure:

Milton Roy Co U.S.A.

Controlled Volume Pump. (Single stage Reciprocating Diaphragm type)
70 G.P.H. or 1.17 GPM
100 #

IV. ALUM PREPARATION TANK:

Capacity:
Height:

3300 gallons
108"

Width:
Material:

96"
Mild steel/rubber lined Tank is fitted with an agitator.

V. ALUM FEED TANK:

Capacity:
Height:
Width:
Material:

600 Approx. gallons

60"
54"
Mild steel/rubber lined Tank is fitted with an agitator.

VI. SETTLING TANK:

Total capacity
Effective Depth
Length X Width
Residence Time for water
Material

:
:
:
:
:

2000 g.p.m.
12', Max depth = 17'
73' X 40'
2 hours
R.C.C.

START UP PROCEDURES:

I. ALUM BATCH PREPARATION:

Add 100 Kg. of alum for every 10" of water added in the preparation tank.
Start Agitator after water is added up to the required level.
Add required quantity of alum.
After all the alum is dissolved take sample and check concentration. It should be 1 - 7 percent.

II. P-436 A/B (Alum Pump)

Open all the valves between pump suction and tank out let.
Open discharge valve.
Set pump stroke at minimum.
Check that alum solution level in the tank is O.K.
Check oil in the pump.
Start alum pump.
Check that flow actually has established.
Increase alum pump stroke as required.

III. P-435 (Slurry Pump)

Open inlet valve.
Open about 1/2 turn discharge valve.
Start pump.
Open discharge valve.
Check that flow has actually established, Otherwise stop pump and check the cause.

IV.

P-434 A/B/C (Canal Water Pumps)

Check that level in the settling tank is about 2" - 3" over the skimmer.
Check oil level in the bearings of the motor.
Check water for the glands. Add some if required to wet the glands properly.
Close discharge valve.
Open a little the valve for open drain.
Start P-434.
Check pressure on PI.
Open the drain valve.
Remember MINIMUM discharge pressure for the Pumps is 125 #.
Let the pump run for sometime until turbidity at pump out let is normal. Get a sample checked
from laboratory.
Close drain valve and open discharge valve of the pump simultaneously.
If the pump is to run after long time or after maintenance, get its amps checked. MAXIMUM
Amps = 140.

NORMAL OPERATION AND ALUM DOSING INSTRUCTIONS:

Proper alum dosing is required for good flocculation and efficient removal/separation of suspended
solids from canal water in the settling tank.
To avoid carryover of suspended solids with canal water, it is required that water level in settling tank
should be ONLY 2" - 4" high over the skimmer edge. Canal water should over flow the weir, located
under the skimmer into the suction chamber of P-434 A/B/C.
With the increase in the turbidity at inlet/outlet of settling tank, alum dose may be increased. Max.
turbidity at the outlet of P-434 = 40. If the turbidity continues to increase even after increase of alum
injection, then the canal water flow to Raw Water Filters should be reduced or stopped.
Sulphate at inlet of Moga and at outlet of P-434 should be analysed by the laboratory and the difference
in sulphate ions should not be more than 10 ppm.
Alum dosing rate should be controlled so that sulphates and turbidity limits are not exceeded.
SHUT DOWN PROCEDURES:

I. P-436 A/B (Alum Pump)

"STOP" button is pushed to stop this pump.
Close suction valve.
Close discharge valve.
Depending upon if both the pumps are to be stopped, close out let valve of feed tank.

II. P-434 A/B/C (Canal Water Pumps)

10

Close discharge valve of pump in operation. (Keep the discharge valve slightly open).
Stop P-434 by push botton.
Close completely the discharge valve.
Check water level in settling tank whenever a pump is put out of operation and regulated the
level by controlling the moga gates etc.
6.

EMERGENCY PROCEDURES:

I.

ELECTRIC FAILURE: In case of electric

failure all pumps will trip.
Canal water operator should inform U.S.E. immediately. Moga gate should be closed when
level in settling tank starts increasing.
Operator should close discharge valves of P-434 and P-436 alongwith the inlet and outlet valves
of P-435 if this is in operation.

II. CHANGE IN SETTLING TANK LEVEL:

Sudden change in settling tank level should be investigated immediately. This could be either
due to failure of P-434 or due to change in moga level. In both cases inform U.S.E. and act
according to the laid down procedures i.e.

In case of P-434 failure, close moga gate and close discharge valve of P-434. Stop alum
injection (only when all three pumps fail). I one pump fails, try to start third pump and
keep a watch on settling tank level.

If moga level has decreased, inform U.S .E. and increase discharge pressure of P-434.

In case of gradual decrease in settling tank level, check screens and if required clean
them.

SAFETY PROCEDURES:
Alum, on contact with skin, will cause irritation. If it happens, wash affected area thoroughly with
water. Avoid contact of alum solution with eyes. Alum is harmful to eyes. Use chemical splash goggles
and gloves while handling alum.

11

COOLING WATER SYSTEM

Purpose
The cooling Water System provides the Ammonia Unit, Urea Unit, Utility Unit, and Offsite users with a
common, continuous, closed loop supply of 90F (maximum) cooling water as heat sink.
Process General
The special process coolant pumps, p-4 11 A, B & C, take suction from the cooling tower basin, located
below the cooling tower, and pump cooling water to two separate supply headers. One header supplies
the Ammonia Plant exclusively. The second header supplies cooling water to the Utility Plant, the Urea
Plant, and all offsite users. The design circulating rates are as follows:
Ammonia Plant
Urea Plant
Utility Plant & Offsite Users
TOTAL

28,000 gpm
20,000 gpm
15,000 gpm
63,000 gpm

Spent cooling water is returned to the Cooling Tower, CT-401, via two separate headers. A 30" header
returns the Ammonia Plant cooling water to the south end of the cooling tower at a maximum
temperature of 120 oF A 36" header returns cooling water from the other users to the north end of the
cooling tower at a temperature of about 112 oF. Both return headers extend across the entire length at the
bottom of the tower, with each header manifold to feed each of the seven cells. Ambient air is drawn in
through the sides of the tower by fans located at the top of each cell. This dry air stream continuously
removes water vapor from the tower, effecting evaporative cooling of the water passing down through
the tower. The moist air is discharged from the top of the tower, and the cooled water falls into the
cooling tower basin, where it is redistributed through the cooling water system.
The design evaporation and draft losses from the cooling tower amount to approximately 1600 gpm.
The total design make-up required is about 2000 gpm.
DESCRIPTION OF FACILITIES
Cooling Tower, CT-401
This unit is a Head Wrightson induced draft, crossflow, Model 67D- 1-6711 cooling tower. The unit has
a rated capacity of 75,000 gpm, and a duty of 750 MM BTU/hr with a design wet bulb temperature of
82 oF and a return cooling water temperature of 110 oF. The tower consists of seven cells, each 36 feet
long by 48 feet wide. The overall length is 217 feet. The height of the distribution headers above the
basin curb is 41`-4".
Fans in three of the seven cells have 150 HP motor drive, while the four remaining cells have 175 HP
motor drives.
Special Process coolant Pumps, P-411 A, B, & C
These three pumps are Machine Fabriek Stork Company Model HGT 100-90/70 horizontal centrifugal
pumps. Each is rated for 39,000 gpm at a discharge pressure of 80 psig. The pumps operate at 735 rpm.
Materials of construction are carbon steel for casing and impeller, 11-13% chrome steel for shaft sleeve
and 11-15% chrome steel for the shaft.

12

P-4 11 A & C are each driven by a 21 90HP, 5000 rpm Elliott steam turbine. the inlet steam is at a
pressure of 600 psig and a temperature of 710 oF. Exhaust pressure is 60 psig. The water rate at design
horse-power is 23.5 lb./hp-hr.
P-41 1B is driven by a Siemens 2500 HP, 3000 volt, 3 phase, 50 hertz, totally enclosed fan-cooled
induction motor.
Process Coolant Chlorinator, CH-401
Cooling towers are efficient air washers so that contamination of water with bacteria and algae is
unavoidable. The silt and heat and sunlight in cooling tower provide ideal conditions for the growth of
micro-organism.
Three main groups of organism, which cause fouling, are algae, fungi and bacteria.
Chlorine is the most widely employed agent for control of microbiological deposits. Fischer porter
chlorinator feeds Cl2.
This unit, manufactured by Fischer Porter, consists of a 15 KW electrically heated evaporator, model
71V1008: 15KW, and a 70C4500 series cabinet mounted chlorinator. Chlorinator capacity is 8000
lb/day of gaseous chlorine. The components are constructed from corrosion resistant materials mounted
in a polyester impregnated fibreglass cabinet.
Liquid chlorine is fed from two (2) 1000-pound storage cylinders to the evaporator, where the liquid is
vaporized. Chlorine vapour enters the cooling water system through the chlorine Ejector, EJ-402. The
evaporation rate may be manually set in the range of 400 to 8000 lb/day. (See Fischer-Porter Operating
Manual in Design Data Section of this manual). Free chlorine of 0.8-1.2 is achieved at the end of
chlorination.
Inhibitor Chemical Feed Pumps, P-404 A & B
These pumps are Proportioneer Model 1731-30-9817 Simplex Propsuperb. Each pump has a manually
adjustable capacity (with pump shut down) of 0 to 100.0 gallons per hour against a maximum discharge
pressure of 100 psig. An internal relief valve set at 50 psig is provided with the pump. The pumps are
constructed with ductile iron cylinders, Hypalon diaphragms, and type 316 stainless steel check valves.
Each pump driver is a 1/2 HP, 220 volt, 1 phase, 50 hertz, T.E.F.C. motor.
Inhibitor Process Vessel, TK-409
This tank is a vertical cylindrical carbon steel vessel, with a hinged cover and a dished bottom. The tank
has a capacity of 1000 gallons (72 inch I.D. x 72 inch straight side x 5/16 inch thick shell). A pump
mounting platform, and anti-swirl baffles are provided with the tank. An agitator driven by a 1 HP, 220
volt, 1 phase, 50 hertz, explosion proof motor, is also provided with the tank.
Note: This inhibitor is not used these days.
Acid Feed Pump P-517 and Day Tank TK-507
H2 SO4 is added in mixing trough ME-402 to control pH of the cooling water in the range of 6.4 - 6.8.
This helps preventing dissolved salts from precipitating out, at high temperature, by increasing their
solubility. Moreover in above mentioned pH range protective layer of Zn- chromate keeps intact. Acid is
pumped from day tank TK-507 to ME-402 through acid feed pump P-517

13

Cooling Tower Mix Trough, ME-402

The mix trough is a rectangular fiber glass box, 20 inches wide, by 12 inches deep, extending along the
suction pit of P-41 1 A,B,C, with an open top. The trough has vertical baffles spaced at two feet
intervals from the make-up inlet end of the trough. The baffles provide sufficient residence time to mix
the chemical solutions with the make-up water added to the trough.
Cooling Water Slip Stream Filter, F-403 A
A small stream from cooling water supply header is passed through a slip stream filter and then fed to
cooling tower basin to maintain the suspended solids with in limit. Maximum inlet turbidity is 20 ppm
while maximum turbidity at the outlet is 10 ppm. Construction detail is provided under heading of
utility filters (F-403 B, C, D.)
Special Cooling Tower Sump Pump, P-418
This pump is located in a small sump in the cooling tower pump pit. Its purpose is to prevent large
quantities of water from collecting in the pump pit. See flow diagram 40-R-2 1, frame 11 for its
location.
The pump is a Gould`s model 3171 1 1/4 * 1 1/2-8 vertical centrifugal pump. It has a rated capacity of
40 gpm at a differential head of 35 feet. The driver is a 1 1/2 HP, 1500 rpm, 380 volt, 3 phase, 50 hertz,
T.E.F.C. motor.
Chromate Feed System
Chromate batch of 22-25 % concentration is prepared in TK-426. 200 kg ZnO and 850 kg SodiumChromate is dissolved in water. H2SO4 is added to bring pH 1-1.4.
This solution is transferred to day tank TK-410 from where it is feed to ME-402 with pump P-407 to
maintain 18-22 ppm chromate in cooling water.
Blow Down and Chromate Removal
A small portion of cooling water return is with drawn as blow down (to maintain the dissolved salts
concentration, especially chlorides (80-100 ppm), within limit) and passed through electrochemical
cells. ME-503 A-E
Electrolysis principle is used in cell for producing ferrous ions which react with hexavalent chromium,
present in cooling water passing through the cell and converts them into trivalent form. This trivalent
chromium is in precipitated form and can be removed by settling.
Cooling water enters the cells from bottom and overflows through 32 electrodes into drain line in into
the pit from where it is pumped by P-530 A/B to the settling pond. Electro chemical cell is designed
such that electric current is supplied to end electrodes only. Current passes through water by conduction.
One side of electrodes act as cathode while other side act as anode. Deposition of hydroxyl ions in the
form of chromic hydroxide on cathode occurs. A gelatinous film of hydroxide of iron and chromium
deposits on cathode which hinders the current flow and decreases the efficiency. For maintaining
optimum efficiency, chemical cleaning with 10 % H2SO4 once a day is done.
Following reactions occur:
At Anode:
At Cathode:
Fluid:

Fe = Fe +2 + 2 e2H2O + 2e- = H2 + 2 OH3 Fe+2 + CrO4 + 4 H2O = 3Fe + Cr+3 + 8 OH-

14

Material and Equipment

A.

Electro Chemical Cell

Cell treating capacity 200 GPM flow of cooling water containing 15-20 ppm chromate.
Cell is rubber lined internally and externally, wall thickness of rubber lining = 3/16

15

B. Electrodes
Material:
Size Electrode:
Size of End Electrodes:
Total area of contact:

M.S. Plates
48 X 11.75 X 3/32 30 Nos.
56 X 11.75 X 3/32 2 Nos.
125 ft2

C. Rectifier

16

D.C. Power supply is adjustable

Input Voltage:
Three Phase, 380 V, 50 HZ.
Input Current:
0-25 Amp.
Output Current:
0 40 Amp.
Rectifier Unit contains:On-off switch.
Voltage and Amp. Meters.
Potentiometer for increasing or decreasing output current.

D. Acid Tank
M.S. Tank rubber lined internally.
Dimensions:
Dia:
42
Height:60 Capacity: 375
Gallons.

E. Acid Circulation Pump

17

Material of construction:
Discharge Pressure:
Capacity:
Drive:
H.P/Voltage:
RPM:

Alloy No.20
40 PSIG. 30
GPM. TEFC
Motor
3/3 80 Volt
3000

F. Piping & Valves

For Acid Circulation: For
C.W. Inlet To Cell:

PVC Pipe and Valve-1-1/2

M.S. Pipe rubber lined.
Two diaphram valves polypropylene lined-4

PVC Pipe and M.S. Globe Valve,

For Cooling Water Discharge:
Rubber Lined-6
from Cell:
RAW WATER AND FILTERED WATER SYSTEMS
Purpose
The raw water system furnishes water for all uses on the Dawood Hercules Plant site. The
filtered water system distributes filtered raw water to the cooling tower, Water Treatment
Unit and plant water header.
Source of Water
Five wells P-406 A-E and canal water pumps P-434 A,B,C located on plant property are
the source of raw water for the entire complex.
Process General
The nominal plant demand for water is
Cooling Water for Makeup:
Water Treatment Unit Feed:
Potable Water Feed:
Plant Water Users:
TOTAL:

2100 gpm
700 gpm
300 gpm
300 gpm
3400 gpm

To meet this demand four of the five Filter Feed Pumps (P-406 A-E) and/or P-434 are
used. One pump is a spare. Water pumped from the wells passes through the Utility
Filters, F-403 B, C & D, in which suspended solids are removed and the turbidity is
reduced to below five NTU.
The filter effluent passes to the Filtered Water Process Vessel, TK, 407, which serves as a
reservoir of filtered water for the following uses: demineralise unit, fire-water, plant water
users and cooling water make-up
The special Utility Pumps, P-410 A & B take suction from TK-407 and pump filtered
water through the plant water header to the Hypo chlorinator, the Water Treating Unit,
and to the miscellaneous plant water users.
DESCRIPTION OF FACILITIES

18

Filter Feed Pumps - P-406 A, B, C, D & E

Each is a KSB pump co., Model No. B12D-7 stage vertical centrifugal pump rated for
1200 gpm at discharge pressure of 85 psig at the well top. The pump operates at 1450
revolutions per minute. Pump materials are cast iron and carbon steel with the exception
of the shaft and shaft sleeve, which are 13% chromium stainless steel. Each pump has a
Newman (U.K.) 100 HP, 1500 rpm, 380 volt, 3 phase, 50 hertz, T.E.F.C. motor. In
addition to the motor driver, P-406D has a 125 HP diesel engine driver with gear. P-406 E
has 80 HP motor and capacity of 900 gpm. In addition it can be started with electric
generator.
Filtered Water Process Vessel, TK-407
TK-407 is a vertical cylindrical vessel, 59`-0 21/32" diameter by 44`-3 15/32" straight
side. It has a cone roof and is designed for atmospheric pressure at 1 50 oF. This vessel has
a capacity of 900,000 gallons, of which 245,000 gallons is a firewater reservoir. The
usable plant water capacity is equivalent to approximately a 3 1/2 hour supply at 3000
gpm.

19

Utility Filters, F-403 B, C, D,

The Neptune Microfloc filter system consists of three horizontal, multicell, sand filters. Each unit is 96"
in diameter and has an overall length of 28`-6". They are designed for a maximum working pressure of
100 psig at 150oF. All filters have a nominal 1500 gpm filtering capacity.
Materials for the shell and internal supports are carbon steel. Internal piping is carbon steel and PVC.
The purpose of raw water filters F-403 B,C & D is to filter the raw water (coming from P-406
A,B,C,D,E or P-434 A,B,C) to remove the suspended impurities. The filtered water, for the entire
Complex, will contain less than 5 ppm of suspended solids.
The filter system is explained by the sketch below.
Special Utility Pumps, P-410 A & B
P-4 10 A&B are Gould`s Model 3405 6*8-1 2G cast iron, horizontal centrifugal pumps, each rated for
1600 gpm at a differential head of 176 feet. The pumps operate at 2900 rpm. P-4 1 0A is driven by a
direct connected 150 HP, 380 volt, 3 phase, 50 hertz, T.E.F.C. motor. P-4 1 0B is driven by an Elliott
steam turbine, rated for 136 brake horsepower at 2950 rpm with a water rate of 41.6 lb/hphr. Inlet steam pressure is 600 psig. Exhaust steam pressure is 60 psig.

20

THE POTABLE WATER SYSTEM

PURPOSE
The purpose of potable water system is to provide filtered safe drinking water to the plant, maintenance,
administration, housing and other similar areas of the complex. The drinking water is produced from
sand filtered raw water by treating this with hypochlorite. The unit sketched below essentially consists
of a hypochlorinator CH 401 & potable water process vessel TK-4 14.
MATERIALS & EQUIPMENT
Hypochlorinator CH-402
Manufacturer:
Type:
Note:

Wallace Tiernan
A-429 Automatic water operated.
This unit includes a 55 gal polyethylene drum and a hydraulic in-line feed
pump.

Potable Water Process Vessel TK-414

21

Type:
Dimentions:
Designe Pressure:
Operating Pressure:
Capacity:

Horizontal cylindrical dished head carbon steel tank.

I.D.= 9` & T.P. length = 21`
75 psig 50 psig
10,000 gallons

System as a whole.
Source of water:
Capacity:

Plant water header at 80 psig.

300 gpm.

22

FIRE WATER SYSTEM

1. Purpose
The Fire Water System is designed to provide 1500 gpm of filtered raw water at a pressure of
100 psig to any hydrant or monitor. The looped fire water main extends to all areas in the plant,
including the housing area. The Administration Building, the Cafeteria, Change House, Security
Building, Product Storage Building and the Catalysts and Spare Parts Storage Building are each
provided with an internal fire protection system, which is fed from the fire water loop.

2. Firewater Source
Firewater is obtained from the Filtered Water Process Vessel, TK-407, by the Special Fire Loop
Pumps, P-501 A&B.

3. Process General
a.

All process water oulet nozzles on TK-407 are located about twelve feet from the tank
botton. This ensures a minimum twelve feet depth of filtered water or approximately
245,000 gallons; for the firewater reservoir.

b.

The firewater pumps are designed to start automatically when fire water line pressure
decreases to 135 psig. When firewater is not used, the pressure in the firewater loop is
maintained bay special jockey pump P-528. If a demand for firewater develops, as a
result of opening a hydrant or monitor, pressure in the firewater loop decreases. When
pressure falls to 135 psig, P-501 A starts. If conditions are such that the pressure falls
further to 120 psig P-501 B will start.

DESCRIPTION OF FACILITIES
1.

Special Fire Loop Pumps, P-501 A&B

These are each a Fairbanks Morse and Co., Model No. KP-98228, horizontal
centrifugal pump designed to discharge 1500 gpm at 150 pounds per square inch. They
operate at 1750 rpm. The pumps meet National Fire Protection Association
requirements.
P-501 A&B each have a Cummings Model NHRS-61 F diesel engine driver, designed to
start manually or automatically. Once started, they must be manually shut off. Each
engine driver has a 550 gallon fuel tank. (Refer to Fairbanks, Morse Operating Manual
in the Design Data Section of this Manual).
The firewater loop is designed so each hydrant overlaps the coverage of the two
adjacent hydrants. Hydrant spacing varies from 200 feet in hazardous areas to three
hundred feet maximum. Each hydrant has 150 feet of hose.
Monitors, Model CJ-2- 1/2", are provided in the Ammonia and Urea Plants and in the
Utility Steam Boiler Plant. The effective range of these monitors at 100 psig nozzle
pressure is as follows:

a.
b.
c.

Straight Stream - 155 feet

Narrow Fog - 70 feet
Wide Fog - 50 feet

23

Periodic tests of the firewater pumps are required to check the operability of the
automatic starting controls and the pumps. Both pumps should be tested weekly by
opening a hydrant and allowing the pumps to start.
The Catalyst and Spare Parts Storage Building and the empty bag storage section of the
Urea Product Storage Building have wet pipe fused head sprinkler systems. The cooling
tower is provided with a dry pilot deluge sprinkler system. The Administration
Building, the Change House, the Cafeteria, and the Security Building have interior hose
stations with not more than 75 feet of hose per station.

24

WATER TREATMENT SECTION

INTRODUCTION
The demineralisation section consists of three strong acid cation exchangers, a degassifier; three weak
base anion exchangers, three strong base anion exchangers and two mixed bed polishers respectively
arranged in series. Two condensate polishers are also included in this section, located at NH3 unit to
polish the condensate of 1500 psig steam system.
The demineralisation process reduces essentially all of the total dissolved solids to 0.1 ppm or less.
Silica is reduced to 0.005 ppm and iron is reduced to zero ppm. This water is supplied to the 1500 psig
steam-generating unit in ammonia unit. In case of 600 psig boilers, the treated water is not subjected to
the mixed bed polishing operation. This water contains a maximum of 6 ppm dissolved solids and 0.05ppm silica. The system is illustrated in the sketch on next page.
PURPOSE

25

The high quality of feed water (almost nil silica content) is required for the high-pressure steam
generation because at these high-pressure silica is dissolved in the steam and acts much like a gas. As
steam generation pressures increase above 400 psig, the tendency for silica to be selectively carried into
the steam increases in amounts proportionate to the amount of silica in the feed water. Silica in the
steam deposit in turbines as the steam pressure drops through the turbine and results in a reduction of
turbine efficiency which would result in costly shutdowns, also forms glassy scales on heat transfer
surfaces and reduces effective heat transfer rate.

1. Cation Units
a.

Description and Principles of Operation

The previously filtered water to be treated is supplied from TK-407 through P-410 A, B
and passes into a manifold, entering each vessel at the top, passing down flow through
the resin beds. The vessels operate flooded so the incoming water displaces the
contained water downward through the beds. (451 -UA- 1, UA-2 & UA-3). These
vessels have a size of 10' X 8' - 6" side shell and are of carbon steel lined internally
with 3/6" rubber sheeting. Each unit contains 400 cubic feet of exchange IRC-124
material, for a bed depth of 4.5 ft. The normal flow of water per unit through the
exchangers is 233.3 gallons per minute and the maximum capacity is 700 gallons per
minute. As the water flows downward through the beds of the cation exchangers, the
metallic cations are taken from the water and retained by the bed exchange material. In
doing so, an equivalent amount of hydrogen ions are exchanged to the anion radicals.
When regenerated, acid used removes the accumulated metallic cations and restores the
hydrogen to the exchanger.
(RSO3 )2 Ca + 2H2 CO3

Examples:

Ca (HCO3)2 + + 2RSO3H Mg (HCO3)2 +

2RSO3H Na HCO3 + RSO3 H NaCl +
RSO3 H

(RSO3)2 Mg + 2H2CO3
RSO3Na + H2CO3
RSO3 Na + HCl

Na2 SO4 + 2RSO3 H

2RSO3 Na + H2 SO4

RSO3 H is strong acid cation exchange resin

The flow rates through the exchangers in normal operation are indicated on the flow
indicators installed at the inlet to each of the exchangers and rates will respond to the
demand for water as required by level control in the Degassifier tank 452-U via a level
controller whose control valve is located at the outlet of the cations. A pressure
controller in the raw filtered water inlet line to cations maintains a constant pressure
through the exchanger train.

2. The Degassifier
A degassifier tank and tower are provided for the removal of carbon dioxide. When the raw
filtered water is passed thru the hydrogen cation exchangers, the cations are removed and
retained by the ion exchange material. The equivalent hydrogen ions given in exchange for the
cations unite with the bicarbonate radical to form carbon dioxide and water. Although carbon
dioxide can be removed in a strongly basic anion exchanger, (which is the subsequent

26

demineralisation step), it is less costly to remove large amounts of carbon dioxide by

mechanical means, rather than chemically.
The water effluent from the cation exchangers enters the top of the tower and flow by gravity
over the Rasching rings to the tank at the bottom. The flow of air from the blower is upward
through the tower to help liberate the carbon dioxide from the water.
The level controller on the storage tank controls the inlet flow to the degassifier. The signal
from this controller, throttles a stainless steel control valve, located approximately 3 feet above
grade on the outlet line from the cation exchangers. Water from the degassifier tank is pumped
by degassifier booster pumps 452-UJ2 (or UJ2A) into the three primary Anion Exchangers. A
pressure controller is provided to maintain a constant pressure on the inlet header. The control
valve for this control is installed on a 2-inch line from the booster pump discharge, which
releases back into degassifier storage tank.

3.

Anion Units
The purpose of primary anion is to remove chloride and sulphate, from degassifier effluent
water. These vessels have a size of 8'-6" X 5'-6" and are of carbon steel, lined internally with
3/16" rubber sheeting. Each unit contains 165 ft3 of A-378 weak base resin upto a depth of 36".
Primary Anion R3NHOH + HCl
2R3NHOH + H2SO4

R3NHCl + H2O

(R3NH)2 SO4 + 2H2O

27

Secondary Anion
R4 NOH + H2CO3
R4NOH + H2SiO3

R4NHCO3 + H2O
R4NHSiO3 + H2O

28

The secondary anions remove silica and bicarbonates from the degassifier effluent water. Silica
is removed effectively to 0.05 ppm and dissolved mineral content to 6 ppm. This procedure is
generally similar to the regeneration of the cation exchangers, except that caustic is the
regeneration medium.
This is not quite low enough to meet the specification of 0.005 ppm, required for the 1500 psig
generation facilities. However, the purity of the treated water from these exchangers does meet
the specification required for the 600 psig generating systems and the quantity required (about
250 gallons per minute) is taken on flow control and sent to the 600 psig generating facility via
a resin trap (455-U-2). The balance of the effluent from the secondary anion exchangers passes
into the mixed bed make-up polishing unit from which the effluent purity will be within the
limits desired for the 1500 psig generating system in the ammonia unit.
These vessels have a size of 9'-6' X 5'-6" and are of carbon steel, lined internally with 3/16"
rubber sheeting. Each unit contains 188 ft3 of IRA-402 weak base resin upto a depth of 36".

29

4. Mixed Bed Make up Polishers

a.

Description and Principles of Operation

The mixed bed-polishing Unit, as the name implies, is an exchanger in which the strong
Cation and Anion resins are combined in a mixed mass. It is employed for final
polishing of the make up water charged to 101 F feed water drum for high pressure
steam generation for which, as already mentioned, extremely pure water is required.
The water passing downward through the bed contacts a long series of strong acid
cation and strong base anion resins and results in a more nearly complete deionisation
than in a series of Cation and Anion exchanger beds.
There is always some leakage of cations in a cation exchanger and this results in
leakage of alkalinity (sodium hydroxide from sodium leakage) from the anion
exchangers. In the mixed bed, cation and anion exchange take place almost
simultaneously, which results, in effect, in a single irreversible reaction that goes very
close to completion to produce water of almost theoretical chemical purity.
The mixed bed polishers are two 5' X 7' carbon steel vessels, with stainless steel
internals lined with 3/16" rubber sheeting.
The exchange material in each of these units consists of 35 cubic feet of A 101 D 3
(strong acid) and 35 cubic feet of C-2 10 (strong base) resin. The normal flow per unit is
200 gpm and 400 gpm maximum. The flow per square foot of bed is 10 gpm (normal)
and 20 gpm maximum. The total flow between regeneration is 2,016,000 gallons.
Water from the mixed bed polishers is sent to the 157-F demineralized water storage
tank on level control of LC-20 via the resin trap 455-U-1.

5. Automation and Instrumentation

The instrumentation described below is generalized in presentation. The vendor of the water
treatment plant supplies all of the instruments.
A PLC system is provided for operating and regeneration of trains, mix beds and condensate
polishers.
A programmable logic controller (PLC) is a user-friendly computer that carries out control
functions of many types and levels of complexity.
A PLC consists of a processor (CPU), power supply, Input/output modules, programmer (usually
a PC) and chassis. PLC based control system was originally designed to replace relay logic
system and solid state hard wired logic control panels. Their advantages over relay logic system
are that they are easily programmed, highly reliable, flexible, relatively inexpensive, secure and
able to communicate with other plant computers. Two panels (Panel view 900 in CCR and panel
view 550 local) are provided for controlling and monitoring.
An automatic silica analyser is mounted at the local control panel. The analyser is capable of
detecting as little as 0.005 ppm of silica. The silica content is monitored in treated water to the
ammonia plant and discharge line from the anion exchangers.
Conductivity meters and a recorder are provided for monitoring conductivity at points downstream of
the three primary anion exchangers, three secondary anion exchangers and

30

outlets of the two make up mixed bed polishers and the condensate polishers (175-U 1 and 175U 2) associated with the ammonia plant steam system.
Pressure gauges are installed at suitable locations throughout the system. Three resin traps for
removing entrained resin particles are furnished. The locations of these traps are at the outlet of
the make up mixed bed polishers, outlet of the cation exchanger, anion exchangers and the
condensate mixed bed polishers.

6. Miscellaneous
Utilities are supplied to the Water Treatment section. These consist of 55 psig steam, plant and
instrument air and plant and cooling water. The chemicals used for regeneration, i.e. 50%
caustic and 98% sulphuric acid and 34% HCL are also made available in the building.
Overflows and drains from regenerant vessels as well as drains from block and bleed valves do
not enter the sewer connection but this material is disposed of to a neutralizing pit.

7. REGENERATION
a.

Cation Exchangers
Basically, regeneration involves four separate steps consisting of backwash,
introduction of regeneration chemicals, displacement and rinsing. It may be done
manually or automatically. It is expected that the flow per unit between regeneration
will approximate 336,000 gallons for cation exchangers (This quantity does not include
the amount used for regeneration). Although rates and time period are given in the
regeneration procedure which follows, they are approximated. The equipment vendors'
operating instruction will specify precise rates and time periods for the different
functions.
The backwashing is accomplished by diverting the inlet water from the top of the
exchanger bed to the bottom of the bed. The backwash water effluent from the top is
directed to the neutralization pit ME-504. As the water flows upward through the
exchanger, the bed is loosened and expanded to facilitate washing of the exchange
resin. If regeneration should prove to be ineffective, it is invariably the result of bed
fouling with suspended matter. Proper backwash procedures should be strictly adhered
to and are governed by backwash rate, temperature and the density of the ion
exchanger. Excessive backwash rate must not be used in order to prevent loss of resin by
carryover.
When the backwash is completed, the bed will settle back down and regeneration with
hydrochloric acid can be started.
The dilute acid is introduced directly above the bed of the cation (strong acid)
exchanger through the distributor and passes downwards through the bed. Ejector is
used for injecting the acid solution. Excess regenerate passes out at the bottom. As the
regenerant proceeds downwards through the beds, the cation radicals are removed from
the resin and replaced by hydrogen. The waste chemicals are drawn off at the bottom of
the exchanger and are directed to the neutralization pit ME-504.
The cation units require about 2.75 MT of hydrochloric acid ( oBe 5-6.5) for canal water
and 3.5 MT for tube well water, but this amount is approximated and will depend on
the impurities in the raw water. As already mentioned, the precise rates

31

will be specified in the operating instructions issued by the equipment vendor. The
injection period, most generally, is over in a 20 to 40 minutes period.
Following reactions occur during regeneration.
CaCl2 + 2RSO3H
MgCl2 + 2RSO3H
NaCl + RSO3H

(RSO3)2 Ca + 2HCl (RSO3)2

Mg + 2HCl RSO3 Na + HCl

b.

Anion Exchangers
The regeneration of an anion unit is normally done immediately after the completion of
the cation unit regeneration in a given train. The need for regeneration is indicated by
conductivity meters, which is provided for each anion exchanger outlet, or effluent water
analysis. Sample points are also provided in the vicinity of these meters so that samples
of the effluent can be analysed for silica, total dissolved solids and pH.
The regeneration steps are essentially the same as for the cation exchangers except that
caustic is injected instead of HCl. The backwash rate is somewhat less than that of the
cation exchanger. First caustic of 5-6.5 oBe is injected, through ejector, to secondary
anion and waste effluent is directed to neutralising pit ME-504. After injection to
secondary anion is completed, waste outlet of secondary anion is diverted to primary
anion caustic inlet and waste outlet of primary anion is sent to neutralising pit ME-504.
This step is secondary to primary caustic injection. The anion units require about 13" (8
for secondary anion and 5 for secondary to primary anion) of day tank of 50% caustic
soda for canal water and 17" (10 + 7 or 8 + 9 for secondary anion + secondary to
primary anion injection) of day tank of 5-6.5 o Be for tube well water. Following reactions
occur during regeneration.
In primary anion
R3NHCl + NaOH
(R3NH)2SO4 + 2Na OH

R3NHOH + Na Cl
2 R3NHOH + Na2SO4

In secondary anion
R4NHSiO3 + NaOH
R4NHCO3 + NaOH

R4NOH + NaHSiO3
R4NOH + Na HCO3

As already mentioned, the regeneration is mechanically and sequentially the same as the
cation exchanger regeneration and should be done in like manner provided the previously
mentioned exception and difference are incorporated. In the anion exchanger
regeneration, the caustic soda (NaOH) reacts with the resin to remove the anion radical
ions which forms a soluble salt with sodium (Na) and the hydroxide ion (OH) is retained
by the resin for the restoration of its exchange power. Completion of the rinse period with
degasified water will be indicated by the conductivity meter and by sample analysis.

32

REGENERATION SEQUENCE OF A TRAIN

S.No.

Operation & Sequence

1. Primary Anion backwash B/W inlet (5) & B/W.

outlet (6) valves open all other closed
2. Cation backwash B/W inlet (7) & B/W outlet
(8) valves open all other closed.
3. Cation Acid injection Acid inlet (11) & Rinse
outlet (12) valves open all other closed.
4. Cation acid displacement.
Valve position same as in step 3.
5. Cation Rinsing
Service inlet (1) & rinse outlet (12) Valves open
all other closed
6. Secondary Anion backwash
B/W inlet (17) & B/W outlet (18) valves. Open
all other closed.
7. Secondary Anion caustic injection. Caustic
inlet (19) & rinse outlet (21) valves & BCV-1
open all other closed.
8. Secondary to primary caustic injection
Caustic inlet (19) rinse outlet (21)
Caustic inlet (9) & rinse outlet (14)
Valves open all other closed.
9. Secondary to primary caustic displacement
valve position same as in step 8
10. Primary Anion final rinsing Service inlet (3) &
rinse outlet (14) valves open all other closed.
11. Secondary Anion final rinsing Service inlet (15)
& rinse outlet valve (21 will be open

Flow
Rate
GPM

Time
Canal
Min.

Time
Tubewell
Min.

80

20

90

290

90

30

Or till water is clear

90
45
60
90
50
50
Or till outlet oBe = nil
230

45

45

115

20

20

36

40

40

36

20

20

36

90

90

Till oBe at P.anion = nil

230
45
45
Till conductivity < 10
micro mhos/cm
230
45
45
Till conductivity is less
than 5 micro mhos/cm and
SiO2 < 0.05 ppm.

PRECAUTIONS FOR REGENERATION

1.

During backwash steps check that resin is not going out with water. If resin is going out
stop regeneration immediately.

33

2.

During acid & caustic injection be careful about leakage to trains in service. Analysis of
running trains should be performed continuously with 15 minutes interval. A sudden
increase of conductivity for anion and disturbance of FMA for cation are indications of
leakages. In such case isolate the affected train for rinsing.

3.

During caustic or acid injection, oBe of chemical being injected should be kept constant.
Also check oBe at outlet.

4.

While handling chemicals safety rules should be observed i.e. goggles, gloves, helmet,
rubber/safety boots & face shield is necessary.

5.

During rinsing steps check for resin going out. If resin comes out during rinsing, it
might be due to a broken outlet distributor of vessel.

6.

Before taking a stand-by train in service, rinse it and analyse it.

c.

Mixed Bed Make up Polishers

In order to regenerate the mixed bed unit, the cation and anion resins must be separated
into individual beds by hydraulic classification. This is possible because the density of
the anion resin is slightly less than the cation resin.
A suggested stepwise procedure for the regeneration of a mixed bed unit is listed below.
It is possible to do this manually or automatically. This procedure is not intended to
supersede the regeneration procedure recommended by the equipment vendors, which
must remain the final authority.

The resin is back washed, which classifies the cation and anion resins to form two separate Beds.
Excessive back wash rates can result in resin carry over to the waste stream sewer so care should be
taken to avoid such an occurrence. Upon completion of the backwash period, the resins are allowed to
settle and they form two separate beds with the anion resin on top. Looking into the lower sight glass at
the cation/anion interface can make confirmation of the effectiveness of the hydraulic classification.
Caustic of 5-6.5 oBe is injected on top of the anion resin bed. Ejectors are used to feed caustic solution
from caustic day tank. 4" of the day tank is injected for canal water and 27" for tubewell water.
CYCLE OF OPERATION CHART
S.No.
1.
2.
3.
4.
5.
6.
7.

Operation
Back wash B/W inlet (24) & B/W outlet (25) valves open all
other closed.
Caustic injection (oBe = 5 6.5) caustic inlet (26) rinse outlet
(27) valves open all other closed.
Caustic displacement valve position same as for step 2.
Acid injection (H2SO4) (oBe = 5 - 6.5) acid inlet (29) & rinse
outlet (27) valves open all other closed.
Acid displacement, valve position same as for step 4
First Rinse Service inlet (22) & rinse outlet (27) valves open
all other closed.
Blow down Rinse outlet (27) open and all other closed and
air valve 31 open.
34

Flow
GPM
60

Rate

17
4 of day tank
17
17

Time
Min.
45
30
50
30

3 of day tank
200

15

10

8. Air Mix Valve (32) &

(44) open
all other
Final
Rinsing

100 C.F.M.
200
Till conductivity < 1
micro mhos/cm

35

10
60

Caustic displacement is done for 50 minutes. Water passes through the same path as that of injection.
Zero oBe at outlet confirms complete displacement.
Acid injection is done with 4 of 5-6.5 oBe H2SO4 from day tank with ejectors. Acid's fed at the top of
the cation in resin. This is followed by acid displacement.
Upon completion of the regeneration, passing compressed air again mixes the bed. The mixing air must
be oil free and at a pressure of from 5 to 15 psig. The required air rate through resin bed is 8 CFM per
square foot of bed. The air mix is in the presence of water, which facilitates mixing without increasing
or swelling the bed. The air is vented via the top distributor during the mixing period. The effectiveness
of the mix is best determined by visually observing the mixed resin bed through the vessel sight glass.
The vessel can then be slowly filled through the normal water inlet and when full a fast rinse is
performed by passing a portion of the anion effluent water through the resin bed in the normal service
flow path and directing the outlet flow to the neutralizing pit ME-504. When the conductivity of the
water flowing to ME-504 is within normal range, the rinsing should be stopped and the unit can be
placed in normal service.

36

INERT GAS GENERATOR

THE NITROGEN GAS GENERATOR
The nitrogen generator 460-L is a packaged unit supplied by Gas Atmospheres and is housed in the
Water Treatment building. The equipment has been supplied by Gas Atmospheres, Inc. Briefly, the
system consists of (1) the inert gas generator in which the inert gas containing nitrogen and carbon
dioxide is produced from natural gas and the necessary air needed for combustion: (2) the gas
compressor which functions to take the gas produced from the generator and compresses it into a
receiver at a higher pressure and (3) an absorbing system for the removal of carbon dioxide and any
water vapour present, from the inert gas. A more detailed description of these systems are outlined
hereunder. The operating manual, drawings, etc. Which are supplied by the vendors of this packaged
item must be referred to in order to obtain a clearer understanding of the equipment described.

1. Generator Section
The inert gas generator is designed for producing 6000 SCFH of oil free nitrogen at a discharge
pressure of 100 psig. Natural gas and air are needed for combustion to produce the inert gas.
The air is delivered to the burner at a pressure from an air blower and its rate is measured by a
flow indicator. This air is drawn through a filter into the suction side of the blower which raises
the air pressure to that of the natural gas and constant pressure is maintained by a pilot loaded
relief regulator in the discharge line. The natural gas is supplied to the burner at the same
pressure as that of the air by the use of a proportioning regulator and a pressure control valve in
the gas line. The air and gas are mixed in a nozzle type burner and combustion takes place in a
partially refractory lined firing tube which is water cooled.
The products of combustion (nitrogen, carbon dioxide and water vapour) on leaving the
combustion chamber pass into an oxygen stripper. This vessel is packed with a highly active (G43) platinum catalyst that is used for converting excess oxygen with hydrogen, carbon
monoxide, natural gas, etc. to water. From the oxygen stripper the gas enters a cooler when the
water content is condensed. The gas next flows to a separator where entrained moisture is
removed via a trap. From the separator the moisture-free gas passes into a surge tank which
assures an adequate volume to satisfy the compressor suction. A pressure relief regulator is
provided at the Surge tank to protect the unit against excessive pressure build-up.
The natural (fuel) gas is supplied under pressure through a strainer, a pressure reducing
regulator, a safety shut-off valve and an orifice flow element for measuring the rate which is
read on a flow indicator. Pressure to the burner is maintained the same as that of the air by a
proportioning regulator, impulsed from the airline. In addition the fuel gas line is provided with
a hand valve for start up and a gas adjuster for analysis control. A branch line for pilot gas is
taken from the fuel line at a point between the inlet gas regulator and the safety shut-off valve.
Included in this line are a low gas pressure switch and a pilot gas solenoid shut off valve.

2. Compressor Section
The gas produced by the generator is compressed into a receiver at a higher-pressure level. The
compressor is a 9 X 7 (Type ESH) driven through a V-belt by a 50 HP electric motor. Control of
the compressor is by pneumatic unloader. The compressor takes suction from the surge tank and
discharges at a higher pressure to the CO2 absorbing system via a pulsation damper, cooler, a
separator and oil filter.

37

Surge tank suction pressure to the compressor is maintained by replenishing the low-pressure
volume through a "kickback" line, if necessary. The discharge gas taken from a point
downstream of the separator is reduced in pressure by two regulators installed on the
"kickback" line which will open should pressure on the surge tank fall below the prescribed
(pre-set) value. The surge tank is also provided with the compressor suction switch, which,
when actuated by a pre-set minimum pressure, will shut off the machine. The compressor inlet
filter is located inside the surge tank beneath top cover.
A backpressure controller located downstream of the CO 2 adsorbing system and the storage tank
holds the rated compressor discharge pressure at all times. Thus, the compressor capacity remains
the same regardless of the storage tank pressure. Pressure in the storage tank is held within the
desired limits by a differential pressure switch actuates the pneumatic unloader. When the high
set point is reached, and compression of the gas is stopped. As the storage tank pressure drops to
the low set point, the switch resets and compression is resumed.

3. CO2 Adsorber Section

The primary function of the molecular sieve absorber is to remove the carbon dioxide from the
inert gas. As a secondary function, the sieve material will also readily absorb water vapour,
actually giving the absorbers a two-fold purpose.
The adsorbing section consists of two chambers filled with molecular sieve, a large volume jet
vacuum pump and two smaller volume high vacuum booster pumps.
The inert gas containing carbon dioxide and water vapour enter the adsorber through a manual
shutoff valve. This inert stream enters the bottom of the adsorbing chamber and flows up
through the bed to exit at the top. This exit gas is known as the product gas, pure dry nitrogen. It
passes into the storage tank previously discussed for delivery to the field.
During its passage thought the molecular sieve bed, water vapour and carbon dioxide are
removed from the inert gas leaving only nitrogen gas. This chamber only adsorbs for a short
period of time and then must be reactivated.
The unit is a dry system employing two chambers filled with molecular sieve materials. A
vacuum system is employed for regeneration. As one chamber adsorbs, the other chamber is
automatically valved off and placed under vacuum. A branch line from the product stream
allows a metered amount of clean, dry product gas to sweep the carbon dioxide and water
vapour off the sieve and out thru the vacuum system, purging the regenerating chamber. After a
set time, the vacuum cycle times out and the chambers repressurize and are switched. Thus each
chamber is saturated and regenerated in turn with no break in the product flow.
This vacuum system employs the use of three pumps two to serve as roughing pumps for initial
evacuation and one serving as a booster pump to aid in attaining the very high vacuum required
to release the carbon dioxide and water vapour from the molecular sieve material. The released
carbon dioxide and water vapour are swept from the adsorbent bed by a slight pure product
purge flow to the vacuum system. After a set time, the vacuum booster pump stops and the
reactivated chamber is repressurize in preparation for the chamber switching.
The jet pump which serve as the roughing pump operate continuously while the booster pump is
operated by means of a vacuum switch set to start the booster when a prescribed vacuum is
attained.

4. Instrumentation

38

The entire system and all of its controls are fully automatic and are supplied by the vendor. It is
important, therefore, that operating personnel familiarize themselves with the literature made
available by the vendors in order to understand fully the application and method of control of
the instruments which have been provided. Some of the more important controls and their
function are described hereunder:-

a. Fuel Gas pressure Control Valve

This is a general service regulator for reducing intermediate distribution pressures to the
desired outlet pressure.
This regulator is factory set during shop test to operate at the required pressure. To readjust this setting, remove the closing cap of the regulator and turn the adjusting screw
counter-clockwise to decrease outlet pressure and clockwise to increase outlet pressure.
This adjustment should be made while the regulator is showing gas.

b. Gas pressure Balance Valve (Proportionator)

The gas proportionator is air loaded from the combustion air apply. The balanced
regulator reduces incoming gas pressure to the pressure in the air line.
The upper diaphragm chamber is connected to the combustion supply while the lower
chamber senses the fuel gas pressure.
When the air blower is operating, the pressure in the upper chamber is increased. The
pressure differential across the main diaphragm moves the valve down allowing gas to
flow. The gas flow increases until the outlet pressure equals the pressure in the upper
diaphragm chamber.
For proper operation, the air load pressure should be equal to the gas pressure
downstream of the regulator. The upstream to downstream pressure drop should be in
the range of 4" WC to 8" WC. If the pressure drop is too low, the inlet gas pressure
should be raised slightly to increase the pressure drop. If it is too high, the inlet pressure
should be decreased slightly to reduce the drop.
For applications requiring turndown of the generator by reducing air-gas flows, the
loading air pressure may be reduced too far for proper control and allow less gas to
flow than is required to maintain product gas analysis. Where this occurs, a loader
assembly is used. This assembly provides a smoothly adjustable pressure makeup to the
proportionator.
This provides what is termed as a "false loading" of the proportionating regulator.
Regulator diaphragms should not be replaced in the field. If a failure occurs, replace
with a new or factory rebuilt regulator.

c. Diaphragm Trim Valve

This valve functions as a "trim" control for drift in generated gas analyses, brought
about primarily by fuel gas changes. The valve is impulsed pneumatically by a signal
from the analyser recorder controller. The analyser receives its sample of combusted
gases from the surge tank.
If the combusted gases drift toward "lean", a signal from the analyser recorder is
transmitted to the diaphragm of the motor valve causing the valve to travel to a more
open position, admitting additional fuel gas to the burner. The additional fuel gas
enriches the gas to air mixture ratio and brings the analyser back to the control set
39

point. The reverse action takes place if the combusted gas gets richer or past the control
point in the opposite direction. After all adjustments are completed the pointer on the
position indicator of the trim valve should be at mid-scale or half open when the
instrument reading is at the set point.
A gas limiting orifice valve is installed to operate in conjunction with the trim motor
valve. This gas orifice is mounted in the main fuel supply line between the bypass
piping. There is also a similar type orifice valve on the airline, just ahead of the nozzle
mix gas burner. These provide final adjustment is accomplished by turning the screws
located on the tops of these valves. Turning counter-clockwise increases the particular
flow. Caps conceal the adjusting screws, protecting the adjustment against tampering or
accidental change. Shut off valves for turning off the air or gas to the burner are
installed upstream of the orifice valves.

d.

Ultra Violet - flame Failure The flame failure apparatus on this unit
consists of two major items:
The first of these items is the flame detector which is mounted on the burner casting.
This unit detects the ultraviolet radiation that is present in the burner flame and
transmits energy to electronic control station.
The heat of the flame failure system is the electronic control, which is mounted in the
control panel. This is an automatic start "cut-off" type electronic combustion safeguard.
The control station completes a component check before each manual start following a
shutdown from pushbutton, flame failure line switch or power interruption. Absence of
flame or an external failure that simulated the absence of flame sill prevents the starting
of the unit.
Cut off of both the pilot or burner would occur is this were to happen during operation.
Abnormal conditions in the external flame detector circuit such as open circuits, short
circuits or leakage to ground, simulate the absence of flame. They will thus either
prevent a start or cause the entire system to shut down.
A warm up timer is incorporated in the control station and is energized when main
power is applied. The tube filament is therefore allowed to heat properly before the
starting relay can be energized.
There are few moving parts in the flame failure system subject to wear. Simple
preventative maintenance such as periodic inspection of ultra vision flame detector,
scheduled replacement of vacuum tubes annually and a check of the burner adjustment
and flame characteristics, may forestall unnecessary shutdowns.

e. Compressor Operation - (Constant Speed Control)

On generating systems that incorporate compressors with constant speed control, the
following items are incorporated in conjunction with compressor operation.
A suction pressure switch is provided in the upstream or suction side of the compressor. This is
a minimum pressure switch, which prevents the compressor from

40

operating unless the switch is tripped with pressure from the generator. This prevents a vacuum
being put on the generator and assures ample gas supply to the compressor.

A backpressure regulator is provided in the system discharge (downstream of the

adsorbers). Its purpose is to keep a constant discharge pressure on the system regardless
of receiver pressure.
A bypass system is provided in conjunction with the compressor and is installed in a
branch line which goes from the downstream or discharge side to the upstream or inlet
side of the compressor. Its function is to provide a momentary bypass of process gas
around the compressor when starting this phase of the system, or when the compressor
goes from the unloaded to the loaded condition.
A constant speed compressor control is provided. It consists of a mercoid pressure
switch and a three-way unloaded valve. When the receiver pressure reaches a
predetermined set point, the mercoid trips and actuates the solenoid, which will unload
the compressor. When the pressure in the receiver drops, the mercoid will reset, actuate
the solenoid-unloaded valve and reload the compressor.
For detailed information on the compressor, reference should be made to the bulletins
supplied by the manufacturer, Ingersoll-Band Corp.

f. Fuel Gas Safety Shutoff Valve

The safety shut off valve is a feature incorporated on all Gas Atmospheres, Inc.
Generators. The mechanism is opened manually and held open by a solenoid valve. The
solenoid in this valve is not actuated until a pilot is established and the electrical circuit
closed through the flame failure device. When actuated, operating the valve handle can
open this valve. This opens the valve and passes the gas the burner. If for any reason the
power to the solenoid is cut off, the valve will shut automatically and the handle swings
freely.
The valve cannot be reopened until power is restored to the solenoid. The valve
automatic closing cannot be prevented by tempering with the handle. A visual indicator
shows whether the valve is opened or closed.

g. Blower Relief Regulator

In order to maintain a constant pressure in the air line to the burner, the blower relief
regulator is pilot loaded to the top side of the main diaphragm housing through a pilot
load regulator. To increase or decrease the air pressure required in the air line to the
burner, loosen lock nut on the pilot load regulator and turn screw until the proper air
line pressure is attained. Tighten lock nut to keep setting from changing.
A secondary load line is installed from the air line to the underside of the main
diaphragm housing of the relief regulator to sense any change in pressure above the set
point. The main diaphragm causing the valve to stroke open and relieve the excess air
pressure senses this pressure builds up.

41

Note:
Do not make adjustments on the spring located in the top diaphragm cove housing to
obtain air line pressure required. All adjustments have to be made with the pilot loading
regulator A bleed spud located in the top cove of the blower relief regulator guards
against a pressure lockup on the top side of the diaphragm.

42

THE AIR COMPRESSORS & RECEIVER

PURPOSE:
The purpose of the air compressors (C-501 A/B) is to supply compressed air for all pneumatic
instruments (after drying), and air to all plant users. There are two air compressors.

1) C-501 A is steam turbine driven.

2) C-501 B is electric motor driven.
Each air compressor is for continuous operation. The compressors discharge air to instrument and plant
air process vessel. Sketches are shown
MATERIALS AND EQUIPMENT:

1.

Compressors:- The compressors are: Non lubricating type. They have wide rider rings of
"TAPE" fluorocarbon resin and require no lubrication.

43

Manufacturer
Stages
Model
Material of construction
Valve seats and stops
Piston Rods
Valve step plates, channel
Valve and spring
Piston ring and rod packing
First stage piston RPM
RPM (Max)
Discharge Pressure
Suction Pressure

=
Ingersoll-rand
=
Two with intercooling
= XLE-2NL-2
=
Cylinders, 2nd stage piston
=
Cast Iron
=
ALSI 1050
=
Stainless steel
=
Teflon
= Aluminium
=
585
=
750
=
106.6 psig
=
13.05 psia

2. Turbine C-501 A
Manufacturer
Type
RPM
H.P. Rating
Overspeed trip
Steam inlet press
Steam inlet Press Max.
Steam inlet temperature
Steam inlet Temp. Max.
Steam Exhaust Press

=
Terry
=
ZS-1
=
3240
=
188
= 3930 RPM
=
600 psig
=
750 psig
=
710 F
=
750 F
=
55 psig

44

3. Motor MC-501 B - Induction Motor

Manufacture
Type
H.P.

=
Allis-Chalmer
= AZ
=
200

45

Amperes
Volts 380 V, 3 phase, 50 cycles,
Totally enclosed fan cooled
Duty

=
296
class insulation B
=

continuous.

4. After cooler E-502A/B.

Manufacturer
Model
Type
cooling water
Outlet temperature
Design duty
No. of tubes
size
Baffles on shell side
Mat. of Construction
Max. Pressure = shell
Max. Temperature = shell

=
American Standard.
=
810 - cp
=
single shell, two tube cide
= 75 gpm
=
105 (max.)
=
185,000 BTU/Hr.
=
48
=
3/4" O.D.,14 BWG 120" long.
=
14baffles, 8" spacing.
=
carbon steel
=
150 psig Tube = 150
=
350 Tube = 350

5. Intercoolers E-501 A/B

Type
Cooling water required.
Duty Tubes

=
shell and tube
= 20 gpm
=
192,000 BTU/Hr.
=
30
5/8 O.D. 18 BWG, 21" long stainless steel.

46

4. Reduction Gear TK-501-A

Manufacturer
Model
Ratio
RPM in
RPM out
H.P. Rating
cil at 100

=
=
=
=
=
=
=

Western Gear Corp.

4111
5.54/1
3240
585
188
150 ssv

47

5. Air compressor exhauster driver F-501/A/B

48

Manufacturer
H.P.
Volts
Amperes
Time rating

=
=
=
=
=

General Electric.
1/2
220/380 v 3 phase, 50 cycles
2.5/1.45
Continuous.

=
=
=
=
=
=

Mippon kokan
96" I.D. x 21 -6% length
130 psig
150
248 - 98 psig
1197 M3 (10 min. supply of normal usage).

6. Process Vessel V-501

Manufacturer
Dimensions
Design Pressure
Design Temperature
Hydraulic Test Pressure
Capacity

49

50

PLANT & INSTRUMENT AIR SYSTEM

Purpose
The Plant and Instrument Air System provides dry compressed air for operation of all pneumatic
instruments in the Ammonia, Urea, and Utility Units and in Offsite areas, and provides a common
source for all other plant uses of plant air.
General
Each two-stage compressor, C-501 A or B is designed to compress air to 106.4 psig. The compressed air
discharges directly into after coolers, E-502 A or B, in which the air is cooled to a maximum
temperature of about 105 F. The air from the after coolers is combined in a common header and piped to
the Plant Air Receiver, V-501. The air flowing from V-501 splits into two streams: plant air and
instrument air. The instrument air is dried and cooled in the Instrument Air Dryer, DR-501, to a dew
point of ambient temperature 18 oF, at a maximum outlet temperature of 100 F. The plant air passes
from the receiver directly into its distribution header, bypassing the dryer.
A Pressure Control Valve, PV-5302, is located in the plant air header to protect the instrument air supply
in the event of an excess plant air demand. If the air receiver pressure decreases, PV-5302 will start
closing to reduce the use of plant air. If the pressure in the air receiver falls to 70 psig, PV-5302 will
close completely. An alarm sounds on the main control board if the pressure in V-501 falls below 80
psig.
Each compressor is furnished with a high level alarm in the intercooler moisture separator and a low
lube oil pressure shutdown.
DESCRIPTION OF FACILITIES

1. Air Compressors, C-501 A&B

Each unit is an Ingersoll-rand Model XLE-2NI,-2 air compressor with a rated capacity of 652
CFM at an inlet pressure of 13.05 psia at 100 F and a discharge pressure of 106.4 psig. The
compressors operate at 585 rpm. Materials of construction are cast iron for cylinders, 2nd stage
piston, valve stop plates, channels, and valve springs; stainless steel for valve stop plates,
channels, and valve springs; filled teflon for piston rings and rod packing; and aluminium for
the first stage piston.
C-501A is steam turbine driven. (See below). C-501B is driven by an Allis-Chalmers 200 hp,
600rpm, 380 volt, 3 phase, 50 hertz, T.E.F.C. motor.
Each compressor includes an internal shell and tube Intercooler, E-501 A&B, each with a duty
of 192,000 BTU/hr. at the rated capacity of the compressor. Twenty gpm of cooling water are
required to cool the air. Each intercooler contains 30 tubes, 5/8" O.D., 1 8BWG, by 21" length.
The air side has two baffles with a spacing of about 7". The tubes are constructed of stainless
steel.

2. Steam Turbine Drive for C-501A

This turbine is a Terry, Model ZS-1 furnished by ingersoll-Rand. It has a water rate of 42.
lbs/hp-hr at its real capacity of 188 HP with the following steam conditions:
a.

Inlet pressure 600 psig

51

b.
c.
3.

Inlet temperature 71 0f
Exhaust pressure 60 psig

Compressor After coolers, E-501 A&B

The after coolers are American Standard, Model 81 0-CP shell and tube type heat exchangers.
Each exchanger uses 75 gpm of cooling water to cool the air from one compressors to a
maximum 105 F. The design duty is 185,000 BTU/hr. The exchanger has two tube side passes and
a single pass on the shell side. Each exchanger has 48 tubes, 3/4" O.D., 14 BWG, by 120 inches
in length., The shell side has 14 baffles spaced at 8". The exchanger is constructed of carbon
steel.

4.

Instrument Air Drier, DR-501

The drier is a Burnett and Lewis 89 OV Automatic Humidryer Model "8/W". The unit is rated to
dry 500 SCFM air, with inlet conditions of 120 F temperature and 100% relative humidity, to a
dew point of -25F. A Burnett and Lewis model CDP 8/48 Water Cooled Precooler, E-503 A/B, is
furnished with the drier, and designed to reduce the air temperature from 120 @ 100 psig to 100
F. The precooler includes a complete entrainment type separator/oil mist prefilter with
automatic float type drainer.
Each of the four adsorbers in this unit are designed to operate for a minimum of sixteen hours.
Adsorber regeneration consists of the following operations:
Drying period
Heating period
Cooling period

6 hours
3 hours
3 hours

The Instrument Air drier A/B, C/D is also furnished with a VPF2/8 Desiccant Dust After filter,
F-502 A/B, designed to remove 99.6% of all solids larger than 5 micron from the 500 SCFM air
from DR-501.

5.

Plant Air Process Vessel, V-501

V-501 is a horizontal cylindrical dished head vessel, 96" I.D. by 21`-6" tangent to tangent
length. The vessel is designed for a pressure of 130 psig at a maximum temperature of 150 F. If
both air compressors fail, the receiver has capacity to supply instrument air for 10 minutes at
the design rate, during which the pressure in the vessel will decrease from 100 psig to 30 psig

THE INSTRUMENT AIR DRYER DR-501

Purpose:
The type PB purge regenerated Humidryer is designed for drying moderate flows of Compressed air to
supply pneumatic control instrument, valves and other air operated tools and equipment. The unit is fully
automatic.
MATERIALS AND EQUIPMENT:

52

The Humidryer absorption dryer contains solid granular desiccant which adsorbes water vapour at
normal temperatures and is then regenerated-to restore adsorption capacity by heating and purging with
a flow of air to release and disperse the moisture evolved. The cycle of adsorption and regeneration does
not change the mechanical and physical properties of desiccant, which does not wear out and is virtually
everlasting. Designed for continuous 24 hrs/day operation, the type PB regenerated Humidryer
incorporates dual absorber towers-one adsorber being regenerated and cooled while the other is in use.
The main components are:-

i) Automatic Humidryer (Four adsorber towers) DR-A/B, C/D

ii) Water Cooled Precooler, E-503 A/B
iii) Desieoant Dust after filter, F-502 A/B
DATA DR-501
Manufacturer Burnett and Lewis

53

Type
Model
Capacity
Working Pressure
Maximum Pressure
Inlet Temperature
Inlet Humidity (rel.)
Outlet Dew point
Heating medium
Heater Rating
Regeneration flow
Electricity power
KW
Pneumatic Control
Cooling Water

80 PB
B "/W"
500" S.C.F.M.
100/105 psig
150 psig
100 F 100%
ambient temperature 18 oF @ working press.
Steam
625 lbs/day max.
24 S.C.F.M.
120 V, 1ph, 50 cycles
1
Working pressure
70 psig, 90 F

Design Pressure and Temperature.

150 psig, 200 F 200 psig, 200 F
Absorber Towers Valves and piping
Steam Coil and Accessories
Pre-Cooler (Water side)
Pneumatic Control lubricant
Vesel Design Code
DATA E-503
Model
Air inlet temperature
Air Outlet temperature
Working pressure

100 psig, 150 F

Shell Tellus 23
A.S.M.E.

CDP 1/48
120 F 100
F
100
psig.

54

The precooler includes a complete entrainment type separator/oil mist prefilter with automatic float type
drainer.
DATA F-502

55

Model
Capacity
Performance

VPF 2/8
500 SCFM
99.6% of all solids larger than 5 microns.

56

FIRE WATER SYSTEM

1. Purpose
The Fire Water System is designed to provide 1500 gpm of filtered raw water at a pressure of
100 psig to any hydrant or monitor. The looped fire water main extends to all areas in the plant,
including the housing area. The Administration Building, the Cafeteria, Change House, Security
Building, Product Storage Building and the Catalysts and Spare Parts Storage Building are each
provided with an internal fire protection system which is fed from the fire water loop.

2. Firewater Source
Firewater is obtained from the Filtered Water Process Vessel, TK-407, by the Special Fire Loop
Pumps, P-501 A&B.

3. Process General
a.

All process water oulet nozzles on TK-407 are located about twelve feet from the tank
botton. This ensures a minimum twelve feet depth of filtered water or approximately
245,000 gallons; for the firewater reservoir.

b.

The firewater pumps are designed to start automatically when fire water line pressure
decreases to 135 psig. When firewater is not used, the pressure in the firewater loop is
maintained bay special jockey pump P-528. If a demand for firewater develops, as a
result of opening a hydrant or monitor, pressure in the firewater loop decreases. When
pressure falls to 135 psig, P-501 A starts. If conditions are such that the pressure falls
further to 120 psig P-501 B will start.

DESCRIPTION OF FACILITIES
1.

Special Fire Loop Pumps, P-501 A&B

These are each a Fairbanks Morse and Co., Model No. KP-98228, horizontal
centrifugal pump designed to discharge 1500 gpm at 150 pounds per square inch. They
operate at 1750 rpm. The pumps meet National Fire Protection Association
requirements.
P-501 A&B each have a Cummings Model NHRS-61 F diesel engine driver, designed to
start manually or automatically. Once started, they must be manually shut off. Each
engine driver has a 550 gallon fuel tank. (Refer to Fairbanks, Morse Operating Manual
in the Design Data Section of this Manual).
The firewater loop is designed so each hydrant overlaps the coverage of the two
adjacent hydrants. Hydrant spacing varies from 200 feet in hazardous areas to three
hundred feet maximum. Each hydrant has 150 feet of hose.
Monitors, Model CJ-2- 1/2", are provided in the Ammonia and Urea Plants and in the
Utility Steam Boiler Plant. The effective range of these monitors at 100 psig nozzle
pressure is as follows:

a.
b.
c.

Straight Stream - 155 feet

Narrow Fog - 70 feet
Wide Fog - 50 feet

57

Periodic tests of the firewater pumps are required to check the operability of the
automatic starting controls and the pumps. Both pumps should be tested weekly by
opening a hydrant and allowing the pumps to start.
The Catalyst and Spare Parts Storage Building and the empty bag storage section of the
Urea Product Storage Building have wet pipe fused head sprinkler systems. The cooling
tower is provided with a dry pilot deluge sprinkler system. The Administration
Building, the Change House, the Cafeteria, and the Security Building have interior hose
stations with not more than 75 feet of hose per station.

58

BOILER PLANT AND STEAM SYSTEM

PROCESS DESCRIPTION

1. Purpose
The boiler plant and steam system is designed to produce and distribute steam at three pressure
levels, 600 psig, 185 psig, and 55 psig, for use in the Urea and Utility Plants and Offsite areas.

2. Sources of Steam
a.

600 psig steam is produced in the two Process Steam Generators, B-401 A&B, in the
Utility Plant area.

b.

The primary source of 185 psig steam is extraction steam from the two
Turbogenerators, TG-401 A&B, located in the Utility Plant. 600 psig steam is pressure
reduced and desuperheated to provide a secondary source of 185 psig steam. The
letdown station, including PV-43 18, is located in the Utility Plant.

c.

The major portion of the 55 psig steam produced is exhaust from turbine drivers
throughout the Urea and Utility Plants. 55 psig steam is also produced by pressure
reducing and desuperheating 600 psig steam. This is accomplished at letdown station
PV-4317 in the Utility Plant.

3. Chemical Feed System

Feed to the Process Steam, Boilers, B-401 A & B, consists of chemically treated, mechanically
deaerated, preheated condensate from the deaerator. Oxygen in steam and condensate may
originate directly from the boiler feed water or may enter the various points in the condensate
system. When oxygen is present in the feed water entering the boiler, a portion will be flashed
and will leave the boiler with the steam. The remainder of the dissolved oxygen can attack the
boiler metal. While the point of attack will vary with the boiler design and feed water
distribution, oxygen pitting is usually concentrated adjacent to the water level in the feed water
drum.
The first and the foremost important step, in eleminating the corresive influence of dissolved
Oxygen, is mechanical deaeration of the boiler feed water. Efficient deaeration will reduce the
dissolved oxygen content of the boiler water to a very low value. It is advisable to follow
mechanical deaeration by chemical deaeration in order to remove the last traces of dissolved
oxygen. The chemical used in our case is Hydrazine. Hydrazine is a reducing agent which
removes dissolved oxygen in accordance with the following reaction.
N2 H4 + O2 = 2 H2 O + N2
Since the products of this reaction are water and nitrogen, no solids are added to boiler water.
The decomposition products of hydrazine are ammonia and nitrogen. The ammonia is alkaline
and, therefore, will not attack steel. On the other hand ammonia will neutralize carbon dioxide so
that corrosion due to CO2 will be reduced. Hydrazine is injected into the deaerator to chemically
remove any remaining dissolved oxygen in the feedwater. The hydrazine is prepared as an
aqueous solution in the hydrazine Mix Tank, TK-402. It is pumped to the injection point by the
Hydrazine Feed Pumps, P-403 A & B. The main components of the hydrazine injection system
are shown in diagram:-

59

Hydrazine Process Vessel, TK-402

The hydrazine tank is a carbon steel vertical vessel with a dished bottom and a flat hinged
cover. The tank has a capacity of 500 gallons (54" I.D. x 48" side x 1,4" shell).
Hydrazine Feed Pumps, P-403 A & B
These pumps are Propertioneer Model 1732-12-9816, Duplex Propsuperb controlled volume
pumps. They each have a manually adjustable capacity of O to 21.6 gph against a discharge
pressure of 950 psig. Materials of construction for the pump are 316 stainless steel cylinders,
Hypalon diaphragm, and 316 stainless steel check valves. The pump driver is a Reliance 1/3
HP, 220 volt, 1450 rpm, 1 phase, 50 hertz, explosion proof motor.
Phosphate Chemical Feed Pumps, P-414 A&B
To maintain a protective oxide film in the steam drum and to prevnet boiler scaling, sodium
phosphate solution is injected directly into the mud drum through an internal sparger.
Each pump is a Proportioneer, Model No. 1732-10-9816 Duplex Propsuperb controlled volume
pump, with adjustable capacity of 0.82 to 20.8 gph at a maximum discharge pressure of 1000
psig. The pumps may be adjusted manually-only when the pump is shut down. Pump cylinders
are constructed of ductile cast iron; the diaphragm is Hypalon and the check valves are 316
stainless steel. The pump driver is a Reliance 1/2 HP, 220v, 1 phase, 50 hertz explosion proof
motor.
Phosphate Solution Process Vessel, TK-403
This tank is a vertical carbon steel vessel with a dished bottom head and a flat hinged cover.
The tank capacity is 400 gallons (54" I.D. x 48" side). A 1/2 hp agitator are furnished with P - 414
A & B as part of the phosphate injection system.

4.

Process General
a.

Boiler and Auxiliary Systems

The Process Steam Generators, B-401 A&B are each designed to produce 250,000 lb/hr
of 600 psig steam when operating at "full firing" conditions. The expected normal
winter steam production is nearly 310,000 lb/hr of 600 lb/hr. See summer and winter
steam balances.
For normal steam rates, the Fuel for the gas fired boilers is a mixture of about 62% (by
weight) natural gas and 38% waste ammonia synthesis gas exported from the Ammonia
Plant. The design analysis of the boiler fuel is:
Component

Vol %

hydrogen
methane

31.1
55.1

60

ethane
propane
n-butane
carbon monoxide
carbon dioxide
oxygen
nitrogen
argon
Total

0.6
0.2
0.1
0.2
0.1
0.1
12.3
0.2
100.0

61

The fuel gas system is designed to preferentially burn the entire normal waste synthesis
gas stream. The natural gas consumption fluctuates with steam demand. If an excess
amount of waste synthesis gas is exported from the Ammonia Plant, the excess is
vented to atmosphere through pressure control valve, PV-43 19.
Air Preheater
Each boiler is equipped with a Ljungstrom type regenreative Air Preheater (E-410
A&B) to increase the boiler operating efficiency. See the Mitsubishi Operation Manual
for details of the Ljungstrom Air Heater.
b.

Steam System
The major portion of the 600 psig steam powers the Turbogenerators, TG-40 1 A & B.
The balance of the 600 psig steam supply is used in turbine drivers in the Utility and
Urea Plants, and at the letdown stations producing 185 psig and 55 psig steam.
Most of the 185 psig steam is used in the Urea Plant. Before entering the Urea Plant,
the entire extraction steam flow is desuperheated, at DS-403, to about 20 F above its
saturation temperature.
Other users of 185 psig steam include the Instrument Air Drier (DR-501), the air
removal system for the Surface Condensers (E-401 A&B), and two small back pressure
turbine drivers, TP 205 B and TP-405 B for the Urea Condensate Pump and the
Demineralized Solution Pump, respectively. Pressure Control Valve PV43 18 will
maintain pressure in the 185 psig steam system by "letting down" 600 psig steam.
Before entering the main 185 psig steam header, the letdown steam is desuperheated
with boiler feedwater in DS-40 1. The maximum production of 185 psig steam at this
reducing station is 14,000 lb/hr.
The low pressure steam system consists of two separate headers in the Utility and Urea
Plants. The main header collects the exhaust from the turbine drivers throughout the
Utility Plant and distributes the nominal 55 psig steam to Utility Plant, Urea Plant, and
Offsite users. The second low pressure steam header, operating at a nominal 50 psig,
transports the Ammonia Plant export steam to the Utility Plant. This export steam can
be used only at the Utility Deaerator (DA-401), the Steam Boiler Feedwater Heater (E403), and the Steam Jet Refrigeration Water Chiller (ME-403).
Export steam from NH3 unit is not used now.
The pressure in the main 55 psig header is maintained by reducing 600 psig seam, at
PV-43 17, followed by desuperheating at DS-402 with boiler feedwater. The normal
letdown rate is about 9400 lb/hr.

62

DESCRIPTION OF FACILITIES

1. Process Steam Boilers, B-401 A&B

The two boilers, Mitsubishi Model VU-60, are each designed to generate 250,000 lb/hr 600
psig, 710 F steam. (See Mitsubishi Operating Manual for Operating and Startup Procedures)

2. Utility Blowdown Process Vessel, V-417

Each boiler has one continuous blowdoen connection in the steam drum, and two intermittent
blowdown streams are piped to the Utility Blowdown Process Vessel, V-417. Here the
condensate flashes at near atmosphere pressure. The flashed steam is vented to atmosphere and
the remaining liquid is drained to an offsite ditch.
The blwodown drum is a vertical vessel,48" I.D. by 7'-6" T-T. The design conditions are 25 psig
at 250 F. Normal operating conditions are atmospheric pressure and 212 F. This vessel receives
intermittent and continuous blowdown streams from B-401 A, B and any overflow from the
Utility Deaerator, DA-40 1.

3. Auxiliary High Pressure Feedwater Pump, P-415

This unit is a Nuovo-Pignone model 1-1/2 - VMS-H 21 stage vertical centrifugal pump. The
pump operates at 2950 rpm with a rated capacity of 75 gpm at a differential heat of 1700 feet.
The pump is constructed of cast iron and carbon steel. The driver is a 60 hp, 3000 rpm, 380
volt, 3 phase, 50 hertz, T.E.F.C. motor.

4. Special Demineralized Solution Pumps, P405 A,B & C

These are Gould's model 3196 M 1-1/2 X 3-10 horizontal centrifugal pumps, each with a rated
capacity of 120 gpm at a differential head of 185 feet. The pumps are constructed of type 304
stainless steel.
P-405 A is driven by a 20 hp, 3000 rpm, 380 volt, 3 phase, 50 hertz, T.E.F.C. moteo. P-405 B is
driven by an Elliott steam turbine designed for 14 hp at 2900 rpm with a water rate of 97.8
lb/hp-hr at the design horsepower.

5. Demineralised Solution Process Vessel, TK-401

This vertical cylindrical vessel is 28' -2 9/16" I.D. X 28 - 2 9/16 " high with a cone roof. The
vessel is constructed of carbon steel with a 15.0 mil thick Carboline #368 lining. The storage
capacity is 3170 barrels, or approximately a two-day supply at the normal dearator make-up rate
of 50 gpm.

6. Fuel Gas Process Vessels, V-412 A&B

These are each a vertical cylindrical vessel, 24" I.D. X 4'-0" T-T length. Each is constructed of
carbon steel and is designed for 700 psig at 150 F. Each tank is provided with a gage glass and a
drain valve to empty any water, which collects in the vessel.

7. The Main Forced Draft Fan (TBL-401 A/B)

The purpose of the Forced Draft Fan is to Produce Draft in the boiler furnace. Boilers provided
with Mechanically Produced Draft do not require a stack so high or so expensive. As those
necessary for natural draft.

63

Forced Draft is secured by blowing air into a closed Boiler Furnace under pressure. The general
Practice in forced draft is to remove the product of combustion from the Boiler Furnace.
Forced Draft Fan also supplies the oxygen present in the air for the complete combustion of fuel
in the furnace. Air is one of the three elements required for the combustion. These three elements
are Fuel, Air & Source of Ignition.
The Main Components of Turbine driven main Forced Draft Fan are shown in the sketch. 8.
Auxiliary Forced Draft Fan (MBL-402 A/B)
Motor driven auxiliary forced draft fan is used only at the time of start up of the boiler or in case
of main forced draft fan fails due to some reason.
Main components of auxiliary forced draft fan are shown in the drawing:-

64

CONDENSATE RECOVERY AND FEED WATER SYSTEMS

PROCESS DESCRIPTION

1. Purpose
The Condensate Recovery System collects condensate and returns it to the feedwater system via
the Utility Deaerator. The feedwater is physically and chemically deaerated, further preheated in
the Steam Boiler Feedwater Heater, and distributed to the Process Steam Boilers and
miscellanceous users.

2. Feeds
Saturated condensate, subcooled condensate, and deionized make up water are mechanically
deaerated in the Utility Deaerator and chemically deaerated with hydrazine.

3. Process General
There are two condensate headers in both the Urea and Utility Plants, one in each plant for
subcooled condensate, another in each plant for saturated condensate.

a.

The saturated condensate in th Yrea Plant flows into the Urea Condensate Process
Vessel, TK-201, where it is mixed with Urea Plant subcooled condensate. The
subcooled condensate is then pumped from TK-201 to the Utility Plant, where it joins
subcooled condensate from the Surface Condensers, E-401 A&B. This entir sub-cooled
condensate stream is combined with deionized make up water immediately prior to
entering the deaerator. The sub-cooled water stream enters the deaerator through spray
valves. Steam is admitted to the eaerator and contacts the water droplets in the upper
portion of the deaerator, neating the water to the saturation temperature of about 228 F.
The steam strips dissolved carbon dioxide, oxygen and ammonia from the condensate.
These gases are vented to the atmosphere. The deaerated feed water is collected in the
storage section of the deaerator.

b.

Saturated condensate from the Steam Boiler Feed water Heater and from traps
throughout the Utility Plant and Offsite areas is returned to the deaerator via a separate
header. The saturated condensater enters the deaerator through a three (3) inch nozzle in
the side of the heater section. The condensate flashes, with the steam passing to the
internal vent condenser, and with the liquied going directly to the storage section of the
deaerator.
Demineralized water passes direced from Water Treating Section to the Demineralized
Solution Process Vessel, TK-40 1, from which it is pumped, as required to the Utility
Deaerator by the Special Demineralized Solution Pumps, P-405 A, B & C.
Under normal operating conditions two of the three 50% capacity High Pressure
Feedwarer Pumps (P-402 A, B & C) take suction from the deaerator storage section and
pump feedwarer to the Steam Boiler Feedwater Heater (E-403). In E-403 the feedwater
is heated to about 280 F using 50 psig steam as the heating media. The feedwater is
passed from E-403 to the two Process Steam Boilers.

DESCRIPTION OF FACILITIES

65

1. Utility Deaerator, DA-401

The deaerator is a Chicago Heater Company design, consisting of a vertical heater section, 4'-6"
T-T and 108" I.D.; and a horizontal storage section, 120" I.D. X 32'-0" T-T. The unit has a
deaerating capacity of 440,000 lb/hr. of condensate return and make up. The storage sections
holds 114,000 lbs., or approximately 20 minutes supply of feedwater at the normal operating
rate.
The deaerator is constructed of carbon steel with the exception of the trays, vent condenser, and
spray valves which are all type 304 stainless steel.

2. High Pressure Feedwater Pump, P-402 A, B & C.

The purpose of the high pressure feed pumps P-402 A, B, C is to supply chemically treated,
mechanically deaerated feed water to the boilers for steam generation. The control of the pump
is by minimum flow valve.
The main components of the feed water pumps and its system are as shown in the sketch.
Each of the feed pumps is designed for 50% of the steam generating capacity of the boilers. The
pumps are each a Nuovo Pignone Model Y-3X9 WMSND-H/9 stg. horizontal centrifugal pump,
rated for 615 gpm at a differential head of 1950 feet. The pumps are constructed of 11-13%
chrome steel.
One pump, P-402 C is drivne by a Conti 500 horsepower, 3000 volt, 50 hertz, 3 phase, 3000
rpm, T.E.F.C. motor. The two other pumps are driven by Elliott steam turbines, each rated at
386 horsepower at 5000 rpm. Each of the steam turbines has one hand valve to allow more
efficient operation at the normal T pumping rate of about 350 gpm.

3. Steam Boiler Feed Heater, E-403

The purpose of bioler feed heater is to heat bvoiler feed water from 228 F to 275 F. Heating is
done by supplying steam from the 55 psig steam header. Steam is supplied on the shell side.
The shell has been protected by providing one rupture dise set at 75 psig. The main
Components of the heating system are as shown in the Sketch below:BOILER CONTROL SYSTEM
The controls for Steam Boilers B-401 A&B consist of three basic inter-related systems. These are: (1) a
fuel pressure control system; (2) a feedwater drum level control system and (3) a flame safegaurd
system. The function of each component in the three systems is described separately along with a
description of their interrelation with the other systems.
1.

Fuel Pressure Control System

This system consists of the following control components:

a.

PVC-4346 A field mounted pressure regulator set at 180 psig and used for the first stage
pressure reduction of natural gas.

b.

FE-46 15 A test orifice for measuring total flow of 180 psignatural gas to the boilers
and the Nitrogen Generator.

c.

PIC-43 15 A pressure controller mounted on the Utility Plant section 40-5 5 # letdown
of the control house panel. This controller is used as a second stage pressure
66

controller to regulate the natural gas pressure to the boilers. This controller should set to
maintain a pressure of about 40-5 5 psig in the natural gas line.

d.

PCV-4350 A field mounted pressure regulatro in the 150 psig natural gas line used as
the second stage pressure reduction for natural gas to the Nitrogen Generator. This
regulator is set at 27 psig.

e.

PIC-43 19 A pressure controller mounted on the Utility Plant section of the Control
House panel. This instrument controls the pressure of excess synthesis gas used for
mixing with fuel gas for boiler fuel. If the synthesis gas pressure continues to rise after
the maximum synthesis gas has been reached, the controller will automatically vent the
excess synthesis gas. This controller should be set to maintain a pressure of 40 psig in
the synthesis gas line.

f.

PIC-4308 A field mounted indicating pressure controller for regulating the pilot gas
pressure to the boiler burners. The regulater should be set for 5 psig.

g.

Pi-4304-1 A pressure indicator located on the Utility Section of the control house panel
indicating the steam pressure at the outlet from boiler B-40 1 A. This pressure is also
indicated on PI-4304-2 in the field near the transmitter and by PI-4304-3 on the boiler
burner control panel at the poilers.

h.

FIC-4304 A flow controller located on the Utility section of the control house panel.
This controller regulates the amount of fuel fed to the burners of Boiler B-40 1 A based
on steam demand.

i.

FIC-4527 An indicating controller located on the Utility section of the control house
panel. This controller regulates the flow of excess synthesis gas to boiler B-40 1 A. The
flow of synthesis gas, before correction for BTU content, is recorded on FR-4527 and
totalized on FQ-4527.

j.

The flow of natural gas is recorded on FR-4528 and totalized on FQ-4528.

k.

FIC-4503 A controller located on the Utility section of the control house panel. This
controller regulates the flow of combustion air to boiler B-40 1 A. The setting of the
controller normally is determined by the output of the stack oxygen controller AIC4002. Air flow is recorded on FR-4503 after being linearized by FY-4503-5. The air
flow system also includes a low oxygen alarm switch which actuates an annunciator
point on the boiler panel and the Boiler Trouble Annunciator in the control house.

l.

PI-4439-1 through 7-Draft gauges located on the local panel at the boilers.
PI-4439-1 and PI-4439-2 indicate forced draft fan suction pressure downstream of the
two fan inlet filters.
PI-4439-3 indicates the forced draft fan outlet pressure.
PI-4439-4 indicates the wind box pressure.
PI-4439-5 indicates the furnace pressure.
PI-4439-6 indicates the flue gas pressure upstream of the air preheater.
PI-4439-7 indicates the flue gas pressure downstream of the air preheater.

n. PDSL-4305 A differential pressure switch measuring differential pressure across the forced
draft fan outlet and the burner windbox. On low air flow, the signal from this switch
actuates an annunciator on the local boiler panel and the Boiler Trouble Alarm on the
control house panel.

67

o.

PI-4305-1 and PI-4305-2. These units indicate wind box pressure.

PI-4305-1 is located on the control house panel and
PI-4305-2 is located on the wind box.

p.

PI-4438-1 and PI-4438-2. These are direct connected pressure gauges connected to the
steam drum.
PI-4438-1 is located on the steam drum.
PI-4438-2 is located on the local boiler board at the bvoilers.

q.

The boiler is protected by three relief valves. PSV-49 16 and PSV-49 17 are located on
the boiler steam drum and PSV-49 15 is located on the superheater outlet header. These
relief valves are set at the following pressures.
PSV-4915 set at 665 psig.
PSV-4916 set at 710 psig.
PSV-4915 set at 725 psig.

r.

PSH-437 1 A direct connected pressure switch on the steam drum. This switch provides
the high steam pressure signal for burner shutdown. The switch is set at 760 psig.
Combustion air temperatures are indicated at several locations:

s.

TI-4264 gives a local indication of the inlet air temperature to the air preheater.

t.

TI-4225 Gives a local indication of the air temperature downstream of the air preheater
and upstream of the boiler.

u.

TI-4226 gives a local indication of the flue gas temperature on the outlet side of the air
preheater.

v.

The flue gas temperatures at the inlet and outlet of the air preheater are also indicated
on TI-2 102, located at the control house panel on points 29 (inlet) and 30 (outlet).

w.

2.

AIC-4002 An oxygen controller mounted on the Utility Plant section of the control
house panel. This controller measures the oxygen content of the flue gas from the boiler.
The oxygen measurement is recorded on AR-4002, located on the control house panel.
The controller also actuates high and low alarms on the annunciator on the control house
panel and on the boiler panel at the boilers.

Feed water Drum Level Control System

This system consists of the following components:
a. LIC-4707 A level controller mounted on the Utility Plant section of the control house penel.
This controller regulates the boiler water level in the boiler steam drum. The output of
the controller is used to adjust the set point of the boiler feedwater flow controller, FIC4506. The output of LIC-4707 is first modified by combining it with a signal
representing the linearized steam flow. The combined signal is used to adjust the set
point of the water jlwo controller.
c. FIC-4506 A flow controller mounted on the Utility Plant section of the control house panel.
This controller regulates the flow of boiler feed water to the steam drum. The flow of
boiler feedwater is recorded on FR-4506. The boiler water level in the steam drum is
recorded on LR-4707.

68

d.

LSH4707 & LSL-4707 Level alarms in LIC-4707. These are the primary or first stage
alarms for boiler feedwater level in the steam drum. The switches are used to actuate
annunciator points on the local boiler panel and the Boiler Trouble Alarm on the control
house panel.

e.

LG-4804 & LG-4805 Gauge glasses directly connected to water columns on the boiler
drum. LG-4805 is equipped with a light and mirrors to provide a direct reading of drum
level at grade adjacent to the boiler.

f.

LSLL-47 13-1 A probe type level alarm in the boiler water column containing LG4804. This alarm is connected in parallel with LSLL-47 13-2 so that EITHER one will
shut down the burners on low level. Both switches are set for the SAME level.

g.

LI-47 13 A direct connected level indicator located on the local boiler control panel.

h.

LSLL-4713-2 A low level alarm actuated by level on LI-4713. This alarm is connected
in parallel with LSLL-47 13-1 so that EITHER one will shutdown the burners on low
level. Both switches are set for the SAME level.
HS-4713-1 & 4713-2 Shutdown bypass push buttons. These buttons are pressed during
water column or level instrument blow down to prevent boiler shutdown. One of them
must be held in continuously during the entire blow down period. HS-4713-1 is located
adjacent to the water column and gauge glass. HS-4713-2 is located on the local boiler
board under the local boiler drum level indicator.

Flame Safeguard System

a.

Flame detectors - Each of the six burners on each boiler is scanned by two ultra-violet
flame detectors. Both units on each burner are aimed at the pilot flame but will also
detect the burner flame. The flame detectors on each burner are connected to the burner
control logic in such a way that if one of the two flame detectors on one burner loses
flame or faults only an alarm is sounded. If both flame detectors on one burner lose
flame or fault that burner is shut down. Loss of flame at all the burners will shut the
safety shut off valves in the fuel gas and pilot gas lines to that boiler.

b.

Burner controls - The burner controls located on the Boiler Panel at the boilers are
arranged to provide semi-automatic operation of each burner.
BV-4024-1 & 2 - A tauden safety shut-off valve with manual resent. This valve is the
main shut-off valve in the fuel gas supply line to each boiler. The valve must be opened
manually after trip or shut-down and will open only if all other safety interlocks have
been staisfied.

c.

d.

BV-4025-1 & 2 A tandem automatic vent valve. This valve automatically vents the line
between the main fuel safety shut-offvalve and the individual burner valves whenever
the safety shut off valve and ALL the burner valves are closed.

e.

BV-4004-1 thru 6 - Automatic burner fuel valves. These valves are operated
automatically by the burner logic. Each valve controls the fuel to one burner.

f.

BV-4032 An automatic shutt-off valve that controls the pilot gas to all the burners on
one boiler. This vlave is operated automatically by the burner control logic.

g.

BV-4033 An automatic vent vavle in the pilot gas supply line to all the burners on one
boiler. This valve vents the pilot gas line between the main automatic shut-off
69

valve and the individual pilot shut-off valve on each burner whenever ALL the shut off
valve are closed. This action is controlled by the burner control logic.

h.

BV-4004 thru 12 - Automatic pilot gas valves at each burner pilot. These valves are
operated automatically by the burner logic. Each vlave controls the gas to one pilot.

i.

PI-443 7 This pressure gauge indicates the fuel gas pressure in the header downstream
of the fuel gas sfety shut-off valve.

j.

TI-42 10-2 This thermometer indicates the fuel gas temperature in the header
downstream of the fuel gas safety shut-off valve.

k.

PI-4440-1, 3,5,7,9 &1 1 Pressure gauges indicating fuel gas pressure at each burner
downstream of the burner automatic shutoff valve.

l.

PI-4440-2,4,6,8,10 & 12 Pressure gauges indicating pilot gas prssure at each pilot
downstream of the automatic pilot shutoff valve.

m.

FCV/FI-45 14-1 thru 12 Instrument air purge air flow regulators and rotameters. These
units regulate and indicate the fow of purge air to the flame detctors. The air form each
regulator is connected to one flame detector sightig tube. The flow of air keeps the
sighting tube free of soot and other combustion products. The flow regulator does NOT
supply air to either the main burner or pilot burner.

70

CHILLED WATER SYSTEM

GENERAL DESCRIPTION
Steam Vacuum Refrigeration was first tried prior to 1901 by the Blanc and Parsons and had, of that
time, a very limited application in industry. This was due primarily to the inefficiency of the early Steam
Ejector, one of the main components of a Steam Vacuum Refrigeration Unit. The Graham
Manufacturing Co., Inc., through some thirty-five years of development has greatly improved in ejector
design and other construction details of this system and today offers industry one of the most reliable
and satisfactory methods of producing refrigeration.
The principle of operation behind the Steam Vacuum Refrigeration is not new and may be explained for
those not already familiar with it.
For each given pressure, water has a corresponding temperature of vaporization, or boiling point, where
it changes to water vapour if sufficient heat is available. Most common is the relationship of
atmospheric pressure, 14.7 PSIA and 212 oF, its boiling point. Under pressure, this vaporization is
elevated and under vacuum (sub atmospheric pressure), this temperature is lowered. For distance, at
114.7 PSIA, water will vaporize at 338 oF and at 0.815 PSIA, the temperature of vaporization for water
is 95 oF. Water, when at a temperature greater than the vaporization temperature of the pressure, the
water is submitted to, will vaporize until the remaining water, which has been giving up heat to
vaporization, is cooled to the vaporization temperature corresponding to the pressure present.
Applying this principle to produce refrigeration, if one was to produce a sub-atmospheric condition in a
tank, say 0.178 PSIA, and water at a temperature greater than 50 oF, which is the vaporization
temperature at 0.178 PSIA, was sprayed into the tank, the water would immediately start to vaporize.
Each pound of water that changes state would require approximately 1000 BTU`s of heat. This heat
would be supplied by the water and vaporization would continue until the remaining water was at 50 oF.
In this process about 1% of the entering water is evaporated for each 10 oF cooling. To continue to
produce refrigeration, one would have to circulate water through the tank and remove the water vapour
that resulted in producing this refrigeration. Approximately 11.3 lbs. per hour of water vapour must be
removed per ton of refrigeration.
To accomplish this, the Graham Manufacturing Co., Inc. makes these of four (4) basic parts: A Flash
Tank, Booster Ejectors, Main Condenser and Secondary Ejectors.
The vaporising or "flashing-off" of water vapour, takes place in the Flash Tank. This tank is carefully
proportioned for the volume of water handled and vapours evacuated and is equipped with special water
distributors. The low absolute pressure maintained in the flash tank of this unit is 0. 1781 PSIA, which
corresponds to the desired chilled water temperature of 50 oF.
As mentioned previously, the water vaporized must be removed if we are to continue to produce
refrigeration. The booster ejector compresses this low pressure vapour, which is constantly forming in
the flash tank, to the pressure level in the main condenser. The pressure in the main condenser is
considerably higher than the pressure in the flash tank, and here we may condense it along with the
motive steam used by the booster ejectors. This unit was designed for an absolute pressure of 3 inches of
mercury in the main condenser. This pressure is selected in accordance with the available quantity and
temperature of cooling water available.

71

To remove the low pressure water vapour from the flash tank, and compress or "boost" it to the pressure
level in the main condenser, the booster ejectors are designed to operate in the following manner:
Live steam is expanded through a steam nozzle, which is designed to create velocities at the exit of the
nozzle in the range of 2000 to 10000 ft. per second. These high velocity jets of steam entrain the low
pressure vapour from the flash tank and drive it through a converging, diverging tube, called a diffuser.
The velocity changes, which occur as the mixture of water vapour and live steam passes through the
diffuser, are such that the total effluent discharged is at the pressure level maintained in the main
condenser.
Since a low absolute pressure (high vacuum), is maintained through out the system, air leakage is
inevitable. To first obtain and then maintain the design main condenser pressure, secondary ejectors are
required. Once these secondary ejectors "pull" the system down to the design main condenser pressure,
they must continue to remove air leaking into the system so this pressure is maintained.
The secondary ejectors serving the main condenser are of the Graham two stages type with an intercondenser. The first stage takes suction from the main condenser and compresses the air and its
saturation component down to about 23" of vacuum (7" Hg. Abs.). The air and propelling steam from
the first stage is then discharged into the inter-condenser. The steam and the saturation component of the
air are condensed in the inter-condenser and the air is taken by the second stage and further compressed
from the inter-condenser vacuum to atmospheric pressure. The air and the propelling steam from the
second stage are then discharged to the atmosphere.
OPERATION
In starting or shutting down a Graham Steam Vacuum Refrigeration unit, the following procedures are
recommended.
In starting a unit, it should be realized that one must first obtain the design main condenser pressure
before the booster ejectors may be turned on to start producing refrigeration. In starting up a unit and in
continuous operation unless the design main condenser pressure is held the booster ejectors will not
function properly and the desired chilled water temperature will not be obtained.
To obtain the main condenser pressure follow these steps:

1.

Open the circulating water (canal water, tube well water or cooling water) valve to the main
condenser and inter-condenser. Since this is a condensing type arrangement in regard to the
ejectors, the condenser cooling water should always be turned on before steam is turned on the
booster ejectors or secondary ejectors.

2.

Open the steam supply valves to the secondary ejectors. Since the booster ejectors are designed
to discharge to the design pressure in the main condenser, until this pressure is obtained thru use
of the secondary ejectors, they will produce no refrigeration.

3.

When the design pressure is obtained in the main condenser, which in this case is 3" Hg.
Absolute, the steam may be turned on to the booster ejectors.

4.

Now that the unit is turned on, the return chilled water line may be opened to the flash tank.
Once this is opened the chilled water pump should be opened. It should be remembered, that the
return line must be opened before the chilled water pump is started.

5.

The make-up water connection to the liquid level controller on the flash tank should now be
turned on. When shutting down the unit, use the following procedure:

72

Shut off the make-up water connection to the liquid level controller on the flash tank.
Shut off the return water line to the flash tank.
Shut down the chilled water pump.
Shut off the steam to the booster ejectors.
Shut off the steam to the secondary ejectors.
Shut off the circulating water to the main and inter-condensers

TROUBLE-SUGGESTIONS FOR CORRECTING

1.

Insufficient water to the main condenser will overload the first stage of the air ejector and cause
the vacuum in the main condenser to drop. Similarly, insufficient water to the inter-condenser
will affect the second stage of the air ejector.

2.

Although the steam nozzles of the air ejector are protected by a steam strainer, dirt sometimes
plugs up the steam nozzles. A few system of piping should be cleaned out several times, and if
possible, the line should be broken as near as possible to the ejector and steam blown through
the line.
When ejector steam nozzles are plugged, they should be cleaned by means of a reamer with a
diameter correct for the nozzles. The proper size reamers are listed below.

Air Ejector
First Stage Nozzle----------------0.228"
Second Stage Nozzle---------------0.261"

3.

If the chilled water pump is not properly sealed at the pump packing gland, air will leak into the
pump and as a result, the pump capacity will be reduced or fail entirely.

4.

The chilled water pump must be vented to the flash tank. If this is not done the pump will
become air-bound and the pump capacity will be reduced or the pump will fail entirely.

5.

When the unit is installed a hydrostatic test should be applied to the unit to make sure that all
the gasketed joints are tight. Air leakage at these joints will very severely affect the capacity of
the unit. The pressure head must be considered when the unit is hydrostatically tested.

6.

Steam to the boosters and to the jets of the air ejector must be supplied at the design pressure. If
the steam pressure drops below the design pressure, the unit will cease to operate. Steam
applied to the unit above design pressure will not increase the efficiency of the unit and will
only result in the wasting of the steam.

DESIGN PRESSURE OF NOZZLES

Booster Nozzles --------------------45 psig @ 400 F
Air Ejector 1st stage ---------------45 psig @ 400 F
73

Air Ejector 2nd stage --------------45 psig @ 400 F

RECOMMENDED SPARE PARTS
Proper reamers for first and second stages of the air ejector.
Spare strainer basket for steam strainer of the air ejector.
One (1) spare nozzle for the first stage and one (1) spare nozzle for the second stage of the air ejector.
One (1) spare nozzle for the booster ejectors.
PERFORMANCE
Cold Booster
Refrigeration Effect - B.T.U. per Hour
Hot Booster
Chilled Water Circulated - Lbs. Per Hour
Chilled water temperature - oF
Return water temperature - oF
(Stacked Two Stage Flash Tank - 62 oF - 55 oF - 50 oF.)
Steam Pressure:
(a)
(b)

Steam Jet Boosters - psig

Air Ejectors - psig

944,400

675,600
135,000

50
62

45 psig @ 400 FTT

45 psig @ 400 FTT

Steam Consumption:
(a)
(b)

LBS/Hr.
LBS/Hr.

5300
250

Condenser Water Inlet Temperature - oF

Condenser Water Outlet Temperature - oF
Condenser Water Required - G.P.M.

09
113
653

* Top Flash Tank Absolute Pressure

Bottom Flash Tank Absolute Pressure

11.07 mm Hg.
9.21 mm Hg.

74

CANAL WATER SYSTEM

1. PURPOSE
Purpose of canal water system is to provide raw water for water treatment plant. Advantage of
canal water over tubewell water is that use of this water results in saving of local and imported
water conditioning chemicals. This is due to the fact that quality of canal water is better than
tubewell water as it has lesser dissolved salts and solids.
Water from canal enters in the first pit and then enter two 18 R.C.C. pipes through two gate
valves. Then it passes through the 2 nd, 3rd and 4th pit and ultimately into the settling tank. Screens
are fitted at moga inlet and in the 3rd pit to separate debris and floating material. .
All particles heavier than water possess a tendency to settle due to influence of gravity. The
specific gravity of suspended particles is one of the main factors governing the rate of settling.
The main purpose of settling is to effect clarification of water by permitting settling of
suspended matter and consequent reduction in turbidity. Settling is of value chiefly in the
removal of course particles which settle rapidly and which can be more economically removed.
A secondary result is removal of bacteria. Percentage of bacteria removal generally closely
parallels turbidity removal.
Residence time (2-4 hours) is provided in the settling tank for the suspended solids to settle
down in the bottom and cleaner water (Max. turbidity = 40) is pumped to Raw Water Filters.
For very small particles which has very poor settling rate alum as coagulant is added at moga. It
is thought that precipitation of alum produces finely divided precipitates of hydrous oxide which
are positively charged. Neutralization of the positive charges by negative ions such as sulfate and
chloride in the water causes coalescence of the fine particles, thus forming a gelationous pours
precipitate of large volume.
Al2 (SO4)3 + 3 Ca (HCO3)2 ---- 2 Al (OH)3 + 3CaSO4 + 6 CO2
Al2 (SO4)3 + 3 Na2CO3 + 3H2O ---- 2 Al (OH)3 + 3Na2SO4 + 3 CO2
Al2 (SO4)3 + 3 Ca (OH)2 ---- 2 Al (OH)3 + 3CaSO4
1-7 % Alum is added in a controlled quantity through P-436 A/B at Moga. Polyelectrolyte is fed
to the 3rd pit to enhance the settling rate in addition to alum. Poly electrolytes are high
molecular weight water soluble polymers that contain groups capable of undergoing electrolytic
dissociation to give a highly charged large molecular weight ion. Poly electrolyte is fed in
controlled amount through P-441. A slurry pump is used intermittently for the removal of slurry
from the tank. P-434 A/B/C pump this water to the filteration unit F-403 B,C,D.

2. EQUIPMENT:
I.

MP-434 A/B/C (Canal Water Pumps)

PUMP SPECIFICATION:
Make : K.S.B
R.P.M : 1450
Flow : 1100 G.P.M.

75

Head : 266 ft.

H.P. : 91.37
Type : 7-stages vertical centrifugal
MOTOR SPECIFICATIONS:
Make : SIEMENS (MP-434 A/B)
Voltage : 380
Amps : 140
H.P. : 100
R.P.M. : 1470
Cycles/See : 50
Make : U.S. Electrical Motors (MP-434 C)
Voltage : 380
Amps : 149
H.P. : 100
R.P.M. : 1470
Cycles/See : 50

II.

MP-435 MOTOR

SPECIFICATIONS:
Make : Westinghouse, USA
Voltage : 380
H.P. : 20
R.P.M. : 1470
Cycles/See : 50
Pump is single stage ordinary impeller with long shaft centrifugal type.

III. MP-436 A/B (Alum Injection Pumps)

MOTOR SPECIFICATIONS:
Make : General Electric Company
Voltage : 240/460
H.P. : 1/2
R.P.M. : 1725
Cycles/See : 60
Time Rating : Continuous
PUMP SPECIFICATIONS:
Make : Milton Roy Co U.S.A.
Type : Controlled Volume Pump. (Single stage Reciprocating
Diaphragm type)
Capacity : 70 G.P.H. or 1.17 GPM
Pressure : 100 #

IV. ALUM PREPARATION TANK:

Capacity : 3300 gallons
Height : 108"
76

Width : 96"
Material : Mild steel/rubber lined Tank is fitted with an agitator.

V. ALUM FEED TANK :

77

Capacity
Height
Width

:
:
:
Material agitator. :

600 Appx. gallons

60"
54"
Mild steel/rubber lined Tank is fitted with an

VI. SETTLING TANK:

Total capacity
Effective Depth
Length X Width
Residence Time for water
Material

:
:
:
:
:

2000 g.p.m.
12', Max depth = 17'
73' X 40'
2 hours
R.C.C.

78

3.

START UP PROCEDURES:

I.

ALUM BATCH PREPARATION:

Add 100 Kg. of alum for every 10" of water added in the preparation tank.
Start Agitator after water is added up to the required level.
Add required quantity of alum.
After all the alum is dissolved take sample and check concentration. It should be nearly
7 percent.

II.

P-436 A/B (Alum Pump)

Open all the vaves between pump suction and tank out let.
Open discharge valve.
Set pump stroke at minimum.
Check that alum solution level in the tank is O.K.
Check oil in the pump.
Start alum pump.
Check that flow actually has established.
Increase alum pump stroke as required.
III P-435 (Slurry Pump)
Open inlet valve.
Open about 1/2 turn discharge valve.

79

Start pump.
Open discharge valve.
Check that flwo has actually established, Otherwise stop pump and check the cause. IV
P-434 A/B/C (Canal Water Pumps)
Check that level in the settling tank is about 2" - 3" over the skimmer.
Check oil level in the bearings of the motor.
Check water for the glands. Add some if required to wet the glands properly.
Close discharge valve.
Open a little the valve for open drain.
Start P-434.
Check pressure on PI. Open the drain valve.
Remember MINIMUM discharge pressure for the Pumps is 125 #.
Let the pump run for sometime until turbidity at pump out let is normal. Get a sample
checked from laboratory.
Close drain valve and open discharge valve of the pump simaltaneously.
If the pump is to run after long time or after maintenance, get its amps checked.
MAXIMUM Amps = 140.
4.

NORMAL OPERATION AND ALUM DOSING INSTRUCTIONS:

Proper alum dosing is required for good flocculation and efficient removal/seperation of
suspended solids from canal water in the settling tank.
To avoid carryover of suspended solids with canal water, it is required that water level in
settling tank should be ONLY 2" - 4" high over the skimmer edge. Canal water should over
flow the weir, located under the skimmer into the suction chamber of P-434 A/B/C.
With the increase in the turbidity at inlet/outlet of settling tank, alum dose may be increased.
Max. turbidity at the outlet of P-434 = 40. If the turbidity continues to increase even after
increase of alum injection, then the canal water flow to Raw Water Filters should be reduced or
stopped.
Sulphate at inlet of settling tank and at outlet of P-434 should be analysed by the laboratory and
the difference in sulphate ions should not be more than 10 ppm.
Alum dosing rate should be controlled so that sulphates and turbidity limits are not exceeded.

80

5. SHUT DOWN PROCEDURES:

I.

P-436 A/B (Alum Pump)

"STOP" button is pushed to stop this pump.
Close suction valve.
Close discharge valve.
Depending upon if both the pumps are to be stopped, close out let valve of feed tank.

II.

P-434 A/B/C (Canal Water Pumps)

Close discharge valve of pump in operation. (Keep the discharge valve slightly open).
Stop P-434 by push botton.
Close completely the discharge valve.
Check water level in settling tank whenever a pump is put out of operation and
regulated the level by controlling the moga gates etc.

6. EMERGENCY PROCEDURES:
I.

ELECTRIC FAILURE:
In case of electric failure all pumps will trip.
Canal water operator should inform U.S.E. immediately. Moga gate should be closed
when level in settling tank starts increasing.
Operator should close discharge valves of P-434 and P-436 alongwith the inlet and
outlet valves of P-435 if this is in operation.

II.

CHANGE IN SETTLING TANK LEVEL:

Sudden change in settling tank level should be investigated immediately. This could be
either due to failure of P-434 or due to change in moga level. In both cases inform
U.S.E. and act according to the laid down procedures i.e.

a)

In case of P-434 failure, close moga gate and close discharge valve of P-434.
Stop alum injection (only when all three pumps fail). I one pump fails, try to
start third pump and keep a watch on settling tank level.

b)

If moga level has decreased, inform U.S.E. and increase discharge pressure of
P-434.

c)

In case of gradual decrease in settling tank level, check screens and if required
clean them.

7. SAFETY PROCEDURES:
81

Alum, on contact with skin, will cause irritation. If it happens, wash affected area throughly
with water. Avoid contact of alum solution with eyes. Alum is harmful to eyes. Use chemical
splash goggles and gloves while handling alum.

82

COOLING WATER SYSTEM

PROCESS DESCRIPTION
Purpose
The cooling Water System provides the Ammonia Unit, Urea Unit, Utility Unit, and Offsite
users with a common, continuous, closed loop supply of 90F (maximum) cooling water as heat
sink.
Process General
The special process coolant pumps, p-4 11 A, B & C, take suction from the cooling tower basin,
located below the cooling tower, and pump cooling water to two separate supply headers. One
header supplies the Ammonia Plant exclusively. The second header supplies cooling water to
the Utility Plant, the Urea Plant, and all offsite users. The design circulating rates are as follows:
Ammonia Plant
Urea Plant
Utility Plant & Offsite Users

28,000 gpm
20,000 gpm
15,000 gpm

TOTAL

63,000 gpm

Spent cooling water is returned to the Cooling Tower, CT-401, via two separate headers. A 30" header
returns the Ammonia Plant cooling water to the south end of the cooling tower at a maximum
temperature of 120 oF A 36" header returns cooling water from the other users to the north end of the
cooling tower at a temperature of about 1 12 oF. Both return headers extend across the entire length at the
bottom of the tower, with each header manifold to feed each of the seven cells. Ambient air is drawn in
through the sides of the tower by fans located at the top of each cell. This dry air stream continuously
removes water vapor from the tower, effecting evaporative cooling of the water passing down through
the tower. The moist air is discharged from the top of the tower, and the cooled water falls into the
cooling tower basin, where it is redistributed through the cooling water system.
The design evaporation and draft losses from the cooling tower amount to approximately 1600 gpm.
The total design make-up required is about 2000 gpm.
DESCRIPTION OF FACILITIES
Cooling tower, CT-401
This unit is a Head Wrightson induced draft, crossflow, Model 67D- 1-6711 cooling tower. The unit has
a rated capacity of 75,000 gpm, and a duty of 750 MM BTU/hr with a design wet bulb temperature of
82 oF and a return cooling water temperature of 110 oF. The tower consists of seven cells, each 36 feet
long by 48 feet wide. The overall length is 217 feet. The height of the distribution headers above the
basin curb is 41`-4".
Fans in three of the seven cells have 150 HP motor drive, while the four remaining cells have 175 HP
motor drives.
Special Process coolant Pumps, P-411 A, B, & C
These three pumps are Machinefabriek Stork Company Model HGT 100-90/70 horizontal centrifugal
pumps. Each is rated for 39,000 gpm at a discharge pressure of 80 psig. The pumps operate at 735

83

rpm. Materials of construction are carbon steel for casing and impeller, 11-13% chrome steel for shaft
sleeve and 11-15% chrome steel for the shaft.
P-4 11 A & C are each driven by a 21 90HP, 5000 rpm Elliott steam turbine. the inlet steam is at a
pressure of 600 psig and a temperature of 710 oF. Exhaust pressure is 60 psig. The water rate at design
horse-power is 23.5 lb./hp-hr.
P-41 1B is driven by a Siemens 2500 HP, 3000 volt, 3 phase, 50 hertz, totally enclosed fan-cooled
induction motor.
Process Coolant chlorinator, CH-401
Cooling towers are efficient air washers so that contamination of water with bacteria and algae is
unavoidable. The silt and heat and sunlight in cooling tower provide ideal conditions for the growth of
micro-organism.
Three main groups of organism which cause fouling are algae, fungi and bacteria.
Chlorine is the most widely employed agent for control of microbiological deposits. Cl 2 is fed by fischer
porter chlorinator.
This unit, manufactured by fischer Porter, consists of a 15 KW electrically heated evaporator, model
71V1008: 15KW, and a 70C4500 series cabinet mounted chlorinator. Chlorinator capacity is 8000
lb/day of gaseous chlorine. The components are constructed from corrosion resistant materials mounted
in a polyester impregnated fiberglass cabinet.
Liquid chlorine is fed from two (2) 1000 pound storage cylinders to the evaporator, where the liquid is
vaporized. Chlorine vapour enters the cooling water system through the chlorine Ejector, EJ-402. The
evaporation rate may be manually set in the range of 400 to 8000 lb/day. (See Fischer-Porter Operating
Manual in Design Data Section of this manual). A free chlorine of 0.8-1.2 is achieved at the end of
chlorination.
Inhibitor chemical Feed Pumps, P-404 A & B
These pumps are Proportioneer Model 1731-30-9817 Simplex Propsuperb. Each pump has a manually
adjustable capacity (with pump shut down) of 0 to 100.0 gallons per hour against a maximum discharge
pressure of 100 psig. An internal relief valve set at 50 psig is provided with the pump. The pumps are
constructed with ductile iron cylinders, Hypalon diaphragms, and type 316 stainless steel check valves.
Each pump driver is a 1/2 HP, 220 volt, 1 phase, 50 hertz, T.E.F.C. motor.
Inhibitor Process Vessel, TK-409
This tank is a vertical cylindrical carbon steel vessel, with a hinged cover and a dished bottom. The tank
has a capacity of 1000 gallons (72 inch I.D. x 72 inch straight side x 5/16 inch thick shell). A pump
mounting platform, and anti-swirl baffles are provided with the tank. An agitator driven by a 1 HP, 220
volt, 1 phase, 50 hertz, explosion proof motor, is also provided with the tank.
Note: This inhibitor is not used now a days. Acid
Feed pump P-517 and day tank TK-507
H2 SO4 is added in mixing trough ME-402 to control pH of the cooling water in the range of 6.4 - 6.8.
This helps preventing dissolved salts from precipitating out, at high temperature, by increasing their
solubility. Moreover in above mentioned pH range protective layer of Zn- chromate keeps intact. Acid is
pumped from day tank TK-507 to ME-402 through acid feed pump P-517
84

Cooling Tower Mix Trough, ME-402

The mix trough is a rectangular fiber glass box, 20 inches wide, by 12 inches deep, extending along the
suction pit of P-41 1 A,B,C, with an open top. The trough has vertical baffles spaced at two feet
intervals from the make-up inlet end of the trough. The baffles provide sufficient residence time to mix
the chemical solutions with the make-up water added to the trough.
Cooling water slip stream filter, F-403 A
A small stream from cooling water supply header is passed through a slip stream filter and then fed to
cooling tower basin to maintain the suspended solids with in limit. Maximum inlet turbidity is 20 ppm
while maximum turbidity at the outlet is 10 ppm. Construction detail is provided under heading of
utility filters (F-403 B, C, D. )
Special Cooling Tower Sump Pump, P-418
This pump is located in a small sump in the cooling tower pump pit. Its purpose is to prevent large
quantities of water from collecting in the pump pit. See flow diagram 40-R-2 1, frame 11 for its
location.
The pump is a Gould`s model 3171 1 1/4 * 1 1/2-8 vertical centrifugal pump. It has a rated capacity of
40 gpm at a differential head of 35 feet. The driver is a 1 1/2 HP, 1500 rpm, 380 volt, 3 phase, 50 hertz,
T.E.F.C. motor.
Chromate Feed System
Chromate batch of 22-25 % concentration is prepared in TK-426. 200 kg ZnO and 850 kg Na-Chromate
is dissolved in water. H2SO4 is added to bring pH 1-1.4.
This solution is transferred to day tank TK-410 from where it is feed to ME-402 with pump P-407 to
maintain 18-22 ppm chromate in cooling water.
Blow down and Chromate Removal
A small portion of cooling water return is with drawn as blow down (to maintain the dissolved salts
concentration, especially chlorides (80-100 ppm), within limit) and passed through electrochemical
cells. ME-503 A-E
Electrolysis principle is used in cell for producing ferrous ions which react with hexavalent chromium,
present in cooling water passing through the cell and converts them into trivalent form. This trivalent
chromium is in precipitated form and can be removed by settling.
Cooling water enters the cells from bottom and overflows through 32 electrodes into drain line in into
the pit from where it is pumped by P-530 A/B to the settling pond. Electro chemical cell is designed
such that electric current is supplied to end electrodes only. Current passes through water by conduction.
One side of electrodes act as cathode while other side act as anode. Deposition of hydroxyl ions in the
form of chromic hydroxide on cathode occurs. A gelatinous film of hydroxide of iron and chromium
deposits on cathode which hinders the current flow and decreases the efficiency. For maintaining
optimum efficiency, chemical cleaning with 10 % H2SO4 once a day is done.
Following reactions occur:
At Anode:
Fe -------Fe +2 + 2 eAt Cathode: 2H2O + 2e------------H2 + 2 OHFluid:
3 Fe+2 + CrO4 + 4 H2O -----------3Fe + Cr+3 + 8 OH-

85

Material and Equipment

a.

Electro chemical Cell

i.
ii.
b.

Cell treating capacity 200 GPM flow of cooling water containing 15-20 ppm
chromate.
Cell is rubber lined internally and externally, wall thickness of rubber lining =
3/16

Electrodes

Material:
Size Electrode:
Total area of contact:

M.S. Plates
48 X 11.75 X 3/32 30 Nos. Size of End Electrodes: 56 X 11.75 X 3/32 2
Nos.
125 ft2

86

c.

Rectifier
D.C. Power supply (adjustable).
Input voltage
Input current
Output current
=
Rectifier Unit contains:-

=
Three Phase, 380 V, 50 HZ.
=
0-25 Amp.
0 40 Amp.

87

On-off switch.
Voltage and Amp. Meters.
Potentiometer for increasing or decreasing output current.

d. Acid
i.
ii.

Tank
M.S. Tank rubber lined internally.
Dimensions.

iii.

e. Acid

Dia
Height

=
=

Capacity = 375 Gallons.

circulation Pump

88

42
60

Material of construction
Discharge Pressure.
Capacity.
Drive
H.P/Voltage
RPM
f.

=
=
=
=
=
=

Alloy No.20
40 PSIG.
30 GPM.
TEFC Motor.
3/3 80 Volt.
3000

=
=

PVC Pipe and Valve-1-1/2

M.S. Pipe rubber lined.
Two diaphram valves polypropylene
lined-4

Piping & Valves

For acid circulation
For C.W. Inlet to cell

89

For cooling water discharge

from cell

90

PVC Pipe and M.S. Globe Valve,

Rubber Lined-6

RAW WATER AND FILTERED WATER SYSTEMS

Purpose
The raw water system furnishes water for all uses on the Dawood Hercules Plant site. The
filtered water system distributes filtered raw water to the cooling tower, Water Treating Unit,
plant water header, and the potable water system.
Source of Water
Five wells P-406 A-E and canal water pumps P-434 A,B,C located on plant property are the
source of raw water for the entire complex.
Process General
The nominal plant demand for water is
cooling water for make-up
Water Treating Unit feed
Potable water feed
Plant water users

2100 gpm
700 gpm
300 gpm
300 gpm

TOTAL

3400 gpm

To meet this demand four of the five Filter Feed Pumps (P-406 A-D) each operate at about 1200 gpm
capacity. One pump is a spare. Water pumped from the wells passes through the Utility Filters, F-403 B,
C & D, in which suspended solids are removed and the turbidity is reduced to below five NTU.
The filter effluent passes to the Filtered Water Process Vessel, TK, 407, which serves as a reservoir of
filtered water for the following uses: demineralise unit, fire-water, potable water, plant water users, and
cooling water make-up
The special Utility Pumps, P-410 A & B take suction from TK-407 and pump filtered water through the
plant water header to the Hypo chlorinator, the Water Treating Unit, and to the miscellaneous plant
water users.
DESCRIPTION OF FACILITIES
Filter Feed Pumps - P-406 A, B, C, D & E
Each is a KSB pump co., Model No. B12D-7 stage vertical centrifugal pump rated for 1200 gpm at
discharge pressure of 85 psig at the well top. The pump operates at 1450 revolutions per minute. Pump
materials are cast iron and carbon steel with the exception of the shaft and shaft sleeve, which are 13%
chromium stainless steel. Each pump has a Newman (U.K.) 100 HP, 1500 rpm, 380 volt, 3 phase, 50
hertz, T.E.F.C. motor. In addition to the motor driver, P-406D has a 125 HP diesel engine driver with
gear. P-406 E has 80 HP motor and capacity of 900 gpm. In addition it can be started with electric
generator.
Filtered Water Process Vessel, TK-407
TK-407 is a vertical cylindrical vessel, 59`-0 21/32" diameter by 44`-3 15/32" straight side. It has a cone
roof and is designed for atmospheric pressure at 1 50 oF. This vessel has a capacity of 900,000

91

gallons, of which 245,000 gallons is a firewater reservoir. The usable plant water capacity is equivalent
to approximately a 3 1/2 hour supply at 3000 gpm.
Utility Filters, F-403 B, C, D,
The Neptune Microfloc filter system consists of three horizontal, multicell, sand filters. Each unit is 96"
in diameter and has an overall length of 28`-6". They are designed for a maximum working pressure of
100 psig at 150oF. All filters have a nominal 1500 gpm filtering capacity.
Materials for the shell and internal supports are carbon steel. Internal piping is carbon steel and PVC.
The purpose of raw water filters F-403 B,C & D is to filter the raw water (coming from P-406
A,B,C,D,E or P-434 A,B,C) to remove the suspended impurities. The filtered water, for the entire
Complex, will contain less than 5 ppm of suspended solids.
The filter system is explained by the sketch below.
Special Utility Pumps, P-410 A & B
P-4 10 A&B are Gould`s Model 3405 6*8-1 2G cast iron, horizontal centrifugal pumps, each rated for
1600 gpm at a differential head of 176 feet. The pumps operate at 2900 rpm. P-4 1 0A is driven by a
direct connected 150 HP, 380 volt, 3 phase, 50 hertz, T.E.F.C. motor. P-4 1 0B is driven by an Elliott
steam turbine, rated for 136 brake horsepower at 2950 rpm with a water rate of 41.6 lb/hphr. Inlet steam pressure is 600 psig. Exhaust steam pressure is 60 psig.

92

THE POTABLE WATER SYSTEM

PURPOSE
The purpose of potable water system is to provide filtered safe drinking water to the plant,
maintenance, administration, housing and other similar areas of the complex. The drinking
water is produced from sand filtered raw water by treating this with hypochlorite. The unit
sketched below essentially consists of a hypochlorinator CH 401 & potable water process vessel
TK-414.
MATERIALS & EQUIPMENT
Hypochlorinator CH-402
Manufacturer : Wallace Tiernan
Type
: A-429 Automatic water operated.
Note
: This unit includes a 55 gal polyethylene drum and a hydraulic in-line feed
pump.
Potable Water Process Vessel TK-414
Type
: Horizontal cylindrical dished head carbon steel tank.
I.D. 9`-0" & T.P. length 21`-o"
Designed Pressure 75 psig
Operating Pressure 50 psig
Capacity 10,000 gallons
System as a whole.
Source of water: Plant water header at 80 psig.
Capacity : 300 gpm.

93

ELECTRICITY GENERATING PLANT

PROCESS DISCUSSION
Purpose
The two main Electric Generators, G-40 1 A & B, provide electric power for the entire
Ammonia-Urea complex. Two diesel driven Auxiliary Generators, G-403 and G-4 10, provide
power during start -up and in emergency situations.
Process General Main
Generator Plant
Each main generator is driven by a steam turbine. Motive steam enters at 600 psig and 71 0f.
The turbines exhaust to 3" Hg absolute pressure, and have a substantial extraction steam flow at
the 185 psig pressure level. This extraction steam is used in the Urea plant.
Exhaust steam from each generator turbine driver is condensed at 115f in the water-cooled
surface condensers, E-4o1 A & B. Cooling water supply design temperature is 90f and the
design return temperature is 1 06f. The condenser vacuum is maintained by a two stage steam
jet ejector system with condensing after each stage.
The Condensate Pumps, P-401 A, B, C, D, two for each surface condenser, return the
condensate to the dearator thru the Surface Condensers jet ejector Inter- and After-condenser, E404 A&B, 405 A&B. Using condensate as the heat removal media in these units increases the
condensate return temperature from 115f to 1 22f. Surface Condenser hotwell water level
controls the return condensate flow rate at level control valve, LV-4710-1 (&2), in the discharge
line of the ejector after condensers.
Either of the two condensate pumps on each condenser may serve as the spare pump. The spare
pump will start automatically upon low pressure in the condensate return line.
Each generator is an Asgen manufactured unit operating at 1500 rpm. Each generator has a
brushless exciter, is air cooled, and has a rated output of 7500 KW of 10.5 kilovolt, 3 phase, 50
hertz, and electric power. The generator has a 0.8 leading power factor. The static exciter
requires 45 KW of 60-volt direct current.
The extraction turbine drivers, furnished by Franco Tosi, operate at 6000 rpm and drive the
main generator through a reduction gear furnished with the turbine. The turbine drivers have
complete sealing steam, lube oil, and control oil systems. The main lube oil pump on each
turbine is shaft driven and has one turbine driven and two motor driven spare pumps.
Surface Condenser, E-401 A & B
The condensers are F.B.M. design and manufacture. Each unit is a divided water box (channel)
type and is two pass on the tube side. The tubes are 3/4" O.D., 14 B.W.G., AND 19`-0" long.
The tube side is designed for 125 psig at 1 50oFand the shell is designed for full vacuum and 60
psig at 300oF. The entire exchanger is constructed of carbon steel.
E-401 A&B each have a rated duty of 78,000,000 Btu/hr. The design-condensing rate at 3" Hg
absolute is 82,000 lb/hr of turbine exhaust steam.

94

The Surface Condenser Air Removal Systems are also furnished by F.B.M. and consist of the
following equipment:

a.
b.
c.
d.
e.

1st Stage Ejectors, EJ-401 A, B, C, D

2nd Stage Ejectors, EJ-404 A, B, C, D
Inter condensers, E-404 A & B
After condensers, E-405 A & B
Hogging Ejector, EJ-403

Each system consists of a twin element, two-stage ejector system. In each system the exhaust
steam from the first stage ejectors discharges to the Inter condenser, E-404 A/B, while the
exhaust steam from the second stage ejectors discharges to the After condenser, E-405 A/B.
Motive steam for the ejector system is 185 psig, 510 oF extraction steam from the turbogenerators. Each ejector system is designed to maintain a suction pressure of 0.104
atmospheres, using 308 lb/hr of 185 psig steam. The ejectors are constructed of cast iron with
the exception of the ejector steam nozzles, which are stainless steel.
The Inter condensers and After condensers are constructed of carbon steel including the tubes.
The Inter condenser and the After condensers have 98, 15 mm O.D., 1 mm thick carbon steel
tubes. The Inter condenser tubes are 800 mm long and the After condenser tubes are 400 mm
long. Total design pressure drop through the tubes of E-404 A/B and E-405 A/B is 2 psi.
The Hogging Ejector, EJ-403 provides air removal from the Surface Condensers during start-up
of the Turbo generators. This ejector operates with 600 psig steam inlet and discharges to the
atmosphere. It is furnished by F.B.M., and is constructed of cast iron, with a stainless steel steam
nozzles.

4. Condensate Pumps, P-401 A, B, C & D

These four pumps are Nuovo Pignone Model 3" VCMS-L single stage, vertical
centrifugal pumps. Each pump operates at 2950 rpm and has a rated capacity of 180
gpm against a differential head of 121 feet. Materials of construction for the pumps are
cast iron and carbon steel. Each pump has a 10 hp, 380-volt, 3 phase, and 50 hertz,
T.E.F.C. motor.

5. Auxiliary Generators, G-403 and G-410

Each package generator unit includes the generator (G-403 is 400 KW, G-4 10 is 240
KW), diesel engine driver, fuel tank, complete lube oil system, jacket water cooling
system, blower fan and driver, governor and controls, all mounted on a common base
plate.
G-403 is a Wausan Viso onsin Diesel Electric Set Model No. 680 FDF4036FFP416W
as follows: 400 KW at 50 hertz, 3 phase, 415 volt, 4 wire.
G-410 is a FG-WILSON ENG. LTD. set model HC444E rated for 240 KW, 50 hertz,
330 KVA and 380/220 volts.
Both the auxiliary generation start on AUTO in case of tripping of both main
generators.

95