ear Shankar

Please be advised with the following:-

1- KNPC dont consider the APH tripping state as transit phase , also please note
that high flue gas outlet temperature is occurring after long time gap from start-up.
Full flue gas is diverted to APH within very short time from forced draft to balanced
draft mode and high temperature trip is occurring after about 16 to 24 hours of
diverting full flue gas through APH. Air flow is always being maintained through APH
during forced draft operation. If flue gas temperature remains within design value
then only long period Data can be collected and load can be increased.Could you
please advise the load of the furnace/ air preheater during the period between the
diverting of the fluegases to the APH and the high temperature trip. Is this a constant
load or a slightly increasing load? Could you please advise the trend of the fluegas
temperature during the 16 to 24 hours period. (temperature rise versus time).

KNPC Response: Date 12 Nov 2012:

We have indicated the load of furnaces earlier with all Data provided. It was normal
operating load of unit. We intend to run the unit at little higher load as all other
equipment were tested for their performance for a little higher load. Moreover please
note that APH was operating at much lower than design load of APH all the time.
Expecting a further modification of unit capacity in future, the APH was designed at little
higher load of unit. The duration of APH operation always remained very short and
throughout this period the temp. kept on increasing. However metal temps were
showing erratic (sometimes high but suddenly low). Temp trend print out from DCS and
the sequence of event are as below.

ID Fan was started at 17:33 hrs, 06/09/2012; plant load at that time was 64%.
Plant Load reached 96% at 00:15 hrs, 08/09/2012 i.e. 31 hrs after ID fan was started.
Plant load stayed at 96% upto 10:50 hrs, 09/09/2012 i.e for 35 hours.
Plant Load was subsequently increased (gradually) to 109% till 15:04 hrs, 09/09/2012 when the ID
fan stopped (or tripped).
Flue gas Temp trend is shown below (the dashed trend line gives you the plant load):




2- With respect to LHT request to increase the maximum allowed temperature for
ID fan to 270 degree C (trip set point of ID fan ) temporarily to carry out the
performance test , and the same has been taken up with MAA refinery and we shall
revert back to you at the earliest.This is very important to make a collection of long
period data at increased (design) load possible. Please provide to allow us to
establish a measurement program

KNPC Response : Date 12 Nov 2012
We will keep the raised trip setting of temp as long as LHT desire.


3- Further to our earlier explanation on oxygen level in flue gas, we have no
objection to increase the oxygen level as per your advice during test run in your
presence. Our purpose is not to increase the oxygen, but to make sure, that there is
no after burning. From the data submitted it was not clear to us how much oxygen
was present at which location.This can be discussed during a the visit.
KNPC Response: Date 12 Nov 2012

Noted

4- Further provide us details of proposed measurement procedure for
measurements and tentative program of Lummus engineer visit. We understand they
will be having their own instruments/means to take additional measurements
(differential pressure & temperature etc.) proposed in your mail. While we are
prepared to visit KNPC for measurements, we are confused by this remark.
Our Mr.Herberghs visited your site with our own instrument, but was advised, that it
was not allowed to take measurements. He was informed, that KNPC could do
measurements with their explosion proof instrument, based on our instructions.
When we give the location and type of measurements, can KNPC than do
measurements on the running heater in our presence?

KNPC Response: Date 12 Nov 2012:

KNPC never stopped Mr Herberghs to use his instrument to take reading rather we were
surprised how the instrument made for checking the dp of heat exchangers tube can be
used for APH. We repeatedly asked him to show it to us. We will take all readings with
our existing instruments and make sure Data are correct. If you want any special/extra
Data then you have to take the measurement yourself or advise to us in advance so that
we can explore the possibilities.


We will change all field pressure gauges with calibrated gauges in mean
time. Noted. Please confirm when done.

5- We look for an early action in this regard.


Waleed A/Rahman A. Al-Awadhi
Sr. Engineer Project Coordination G-IV PD-II




From: shankar3@qualitynet.net [mailto:shankar3@qualitynet.net]
Sent: Monday, October 15, 2012 10:10 PM
To: Waleed A/Rahman A. Al-Awadhi; Ahmed Makhlouf M. Ali
Subject: Fw: 62591 KNPC MAA APH - LHT-AOC- L120 - APH measurements

Please find enclosed response from Lummus, which is self explanatory.

Best Regards
C.M. Shankar
Sent from my BlackBerry smartphone from Zain Kuwait



From: Paul van den Brink <pvandenBrink@cbi.com>
Date: Mon, 15 Oct 2012 20:43:38 +0200
To: C.M.Shankar<alomer@qualitynet.net>
Cc: 62591 MAA APH<62591_MAA_APH@cbi.com>; <shankar3@qualitynet.net>; Henny
Oudenhoven<HOudenhoven@cbi.com>; 62591 MAA APH<62591_MAA_APH@cbi.com>
Subject: 62591 KNPC MAA APH - LHT-AOC- L120 - APH measurements



Dear Shankar

From the e-mail submitted by KNPC, we understand now, that all the data submitted by KNPC until
now are for a transit phase and do not represent a steady state situation we originally assumed. This
may explain why we could not match the in- and outlet tempertures at the air side and flue gas side.
However, for an investigation and analysis of the situation it is essential that data are measured for a
steady state operation of the APH system. This could be possible, by operating the APH system at
partial load or by changing the trip setting of the ID fan.

From your answer we learned, that partial load is not possible, because fluegases are conducted
100% or 0 % to the system. We therefore propose to change the trip setting for the ID fan to 270 C.
For your information we were informed by the fan manufacturer CBI, that the fan has a mechanical
design temperature of 300 C. Refer CBI's message below.

When KNPC confirms that this is acceptable, we would like to prepare a measurement procedure for
measurements during the steady state operation (with air bypass 100% closed).
This measurement procedure will include e.g. local delta P measurements across the APH (air and
fluegas side), temperature measurements (air and fluegas at in and outlet), oxygen measurement at
inlet of the fan. Again, it is only possible to evaluate the APH operation when these measurements
are done when the APH is in steady state operation.

Please advise if and when this will be possible.

Best Regards

Paul van den Brink Project Manager
Office: + 31 70 373 3085
Fax: + 31 70 373 3030
cell: + 31 6 343 85 980
pvandenBrink@cbi.com
Lummus Technology
Lummus Technology Heat Transfer BV
Oostduinlaan 75
2596 JJ The Hague
The Netherlands
www.CBI.com/lummus-technology