KAFCO UTILITY PLANT OPERATION

 Power Generation
 Steam Generation System
 Natural Gas Metering & Distribution
 Raw Water Treatment
 Cooling Water System
 Demineralization
 Plant Air & Instrument Air
 Inert Gas Generation
 Storage & Ancillary
 Deep Tube Wells
 Waste Water Treatment

Power Generation Unit

Steam Generation System

Description of Steam System:

In Utility plant there are three different kinds of pressure level of steam like, High Pressure (HP),
Medium Pressure (MP) and Low Pressure (LP), whose conditions are shown in the table.

Steam Conditions
Steam Level Pressure - Present Temperature Pressure ( Previous) Temperature -
(Kg/cm2G) (Present) OC (Kg/cm2G) (Previous) OC
HP 100 510 109/110 513
MP 38 385 38 385
LP 4.5 220 4.5 220

HP Steam Header:

HP steam generated in the No. 1 and No. 2 Boilers is supplied only to the Steam Turbine for Power
Generator (3-EG-101 and 3-EG-102). According to the demand some HP steam to be letdown to the
MP steam header through the letdown system. During normal operation, the pressure of the HP steam
header is controlled by the Automatic Combustion Control (ACC) system of both the Boilers at 100
kg/cm2G. HP steam header is controlled by the controller 3 –PIC- 201 and 3- PIC- 202, where 3-PIC
201 is the Boiler master controller and 3-PIC-202 is the let down controller.

If the pressure of the HP steam header exceeds the set point of 3-PIC-202, HP steam is letdown to the
MP steam header through 3-PV-202 to keep the pressure.
If the HP steam header pressure is decreasing down the set point of 3-PIC-201 i.e., 100 kg/cm 2G, then
pressure control will be done automatically by this controller.

Now the new set point of 3 –PIC-201 is 100 kg/cm2G, previously it was 109 kg/cm2G and new set
point of 3-PIC-202 is 102.5 kg/cm2G, previously it was 111.5 kg/cm2G.

MP Steam Header:

MP steam is produced as extraction steam from the Steam Turbine for 3 – EG- 101 and 3-EG-102, and
supplied to different users.

During normal operation, the pressure of the MP steam header is controlled by the governor valves of
the Steam Turbines for 3 – EG- 101 and 3-EG-102, and the controller 3-PIC-203. MP steam pressure
is maintained at 38 kg/cm2G.

If the pressure of the MP steam header exceeds the set point of 3-PIC-203 i.e. 38 kg/cm 2G, then two
actions will execute automatically:
i. HP steam letdown will decrease by 3-PV203 and
ii. Extraction steam from STG will decrease

If the pressure of the MP steam header is extremely high and exceeds the set point of MP vent
controller 3-PIC-204 i.e. 40.5 kg/cm2G, then 3-PV-204 is actuated automatically to maintain the
pressure of the MP steam header by venting of excess MP steam to the atmosphere.

If the MP steam header pressure is decreasing down the set point of 3-PIC-203 i.e. 38 kg/cm 2G, then
pressure control will be done by two actions automatically:
i. 3-PV-203 starts to control the MP steam header by increasing letdown
ii. Extraction steam from STG will increase

LP Steam Header:

In normal operation, LP steam is produced as exhaust steam from different Steam Turbines (Utility
Cooling Water Pump, FDF Boiler No.2 and BFW Pump) and CBD flashing, and supplied to different
users. Some amount of steam also is produced as extraction steam from the Steam Turbine of Process
Air Compressor (1-TS-402).

During normal operation, LP steam header is controlled by the controller 3-PIC-206. LP steam
pressure is maintained at 4.2 kg/cm2G.

If the pressure of the LP steam header is extremely high and exceeds the set point of LP vent
controller 3-PIC-207 i.e. 4.5 kg/cm2G, then 3-PV-207 is actuated automatically to maintain the
pressure of the LP steam header by venting of excess LP steam to the atmosphere.
If the LP steam header pressure is decreasing down the set point of 3-PIC-206 i.e., 4.2 kg/cm 2G, then
pressure control will be done by opening or increasing letdown automatically, and by opening of
extraction control valve of 1-TS-402.

DCS Operation at Normal and Emergency Plant Condition:

Actually at normal plant condition, constant monitoring is the activity.

Actual activities start in case of start up, shutdown and emergency situation. All these cases prompt
action and sincere monitoring is necessary.

Natural Gas Metering & Distribution

Natural Gas Specification:

Component Mole % (dry basis) Design Limit
CH4 94.191 93 – 97
C 2 H6 3.619 2–3
C 3 H8 0.772 0–1
i C4H10 0.217 0 – 0.5
n C4H10 0.103 0 – 0.5
i C5H12 0.036 0 – 0.1
n C5H12 0.019 0 – 0.1
i C6H14 None 0 – 0.05
C7 + None 0 – 0.2
CO2 0.392 0–2
Ar 0.068 ---
N2 0.583 0–5
Olefins & Aromatics None None
Total Sulfur as H2S None 0 – 10 vol ppm.
100.00

Condensates (liq. HC) : 0.3 (max) l/ 1000 Nm3.

Water Vapor : 3 (max) kg/ 1000 Nm3.

LHV (Lower Heating Value) : 8887.2 Kcal/ Nm3.

Supply pressure/ temperature : Min. 8.2 kg/cm2G
Nor. 8.4 ,, / Ambient
Max. 8.6 ,, / 490 C.

NG to Canteen : Pressure 0.6 kg/cm2G.

Odorant 30 vol. Ppm of Tetra Hydro Thiophene.
Design Flow Rate : 76,057 Nm3/ Hr.
At 100% load NG required = 62112 Nm 3/ Hr
To Boiler : 20191 Nm3/ Hr.
To Ammonia Plant : 55902 ,,
To Flare System : 1526 ,,
To DFEG : 1046 ,,
To Canteen : 16.6 ,,

Major Equipments:
NG K. O. Drum Odorant Dosing Drum
Type : Cylindrical, Vertical Cylindrical, Vertical with shell flange
Size : 1900 mmID * 2500 mmH 14'' * 665 mmH
Material : Carbon Steel 304 SS.

Preparation for start up:

Prior to start up the following shall be checked and confirmed.
 LP N2 is available.
 All instruments, sequences and loops have been inspected and tested.
 Pipelines have been tested and blown with air.
 Drums have been cleaned internally.
 PSV have been tested.
 Fire fighting equipment have been already provided/ installed and tested properly.

Start up:
 Nitrogen purge: The natural gas metering and distribution system must be purged with N 2
gas before filling NG.
 Pressurize the system to 3 – 7 kg/ cm 2G. with LP nitrogen and depressurize by blowing
off at the drain valves or vent valves at higher ends. Repeat the process until O 2 content
decrease to 2 vol % or less.
 Open the block valve at the battery limit fully and introduce the NG to the system.

Shut down:
 Close the battery block valve on natural gas feed line.
 Close all the block valves on NG header and isolate the system.
 Purge the system with nitrogen.

Draw-off of Condensate in Natural Gas.

Liquid condensate, if present in NG K.O. Drum (3-S-301) may flash at the draw off valve to
stick opened with ice. Two valves are provided for safe removal.
 Operation of valves must be gradually to limit generation of static electricity.
  Open fully the first valve.
 Gradually open the second valve to partial open. Never open fully.
 Close the second valve after finishing drawing.
 Close the first valve.

Safety Instruction:
Tetra Hydro Thiophene is not toxic. However, breathing of this vapor is not favorable.
Molecular wt. : 88.17 [(CH2)4S]
Explosion limit (with air) : 9.5~16 vol %
Flash point : 180 C
Boiling point : 118 ~1210 C

NG contains CH4 as the lightest component which , explosion limit (with air) : 5.3 ~ 14 vol %
& Ignition Temp. : 5350C.
Caution shall be made no naked flame or sparking element exist adjacent to the system at any
time.

NG Calculation:
Nm3 – Volume at 00C & 1 atm. Pressure.
SCF - Volume at 150C / 600F & 1 atm. Pressure.
Absolute Temp. = 2730K / 4600R.
1 m = 3.2808 ft, & 1 m3 = 35.31467 c.ft.
35.31467 * ( 460  60) 0 R
1 Nm3 = SCF
( 460  32) 0 R

= 37.32445 * 10-6 MMSCF.

NG Price:
KAFCO Purchase NG from GOB in terms of - $ / MSCF (1000 c.ft).

& Price = 1.5 + (Urea Price - 180) * 0.015 $. But not less than 1$.
RAW WATER TREATMENT UNIT

INTRODUCTION:
Raw water from Raw Water Intake Pumps (4-P-101~107) is introduced into the Clarifiers (3-
S-401 A/B) for Coagulation, Flocculation & Sedimentation of suspended solids and Iron.
Finally the clarified water passed through the Sand Filters (3-F-401 A~H) to obtain clean fresh
water. Treated water is used for the following purposes:
 Service Water
 Drinking Water
 Cooling Water
 Fire Water
 Demineralized Water

Water Quality:
Raw Water Treated Water
Turbidity (FTU) : 35 Suspended solid – 1.0 ppm(max).
Conductivity (s/ cm) : 220
pH : 6.9 6.5~8.5
Total Alkalinity (as CaCo3, ppm) : 120
Total Hardness ( ,, ) : 70
Calcium Hardness ( ,, ) : 35
Chloride (ppm) : 30 (max) 30 (max)
Sulphate : 20 60 (max)
Nitrate : 0.05
Nitrite : 0.015
Ionic Silica : 60 (max)
Colloidal Silica : 3 (max) 1 (max)
Free CO2 : 35
Manganese (as Mn) : 2 (max) 0.05 (max)
Iron (as Fe) : 10 (max) 0.3 (max)
Ammonia (as NH4) : 0.01
Permanganate value(as KmnO4) : 6
Clarifiers (3-S-401 A/B):
Flow rate Design : 970.1 m3/ hr.
Normal : 645.2 m3/ hr.

Type : Slurry blanket type

Dimension : 21.6 m x 24.7 m x6.8 mD x 2 ponds.
Upward velocity : 39 mm/ min, at design flow rate.
Retention time at design : Approx. 2.5 hours, at design flow rate.

PREPARATION FOR START UP:

Prior to start up of the system the following items shall be checked and confirmed:
 Electrical Power is available.
 Instrument Air is available and ensures that all the valves are working properly according
to logic.
 All the Chemical dosing pumps and Chlorinators are in good condition.
 Chemicals are available for dosing.
 Raw water is available according to demand.
 Clarifier inlet valve is closed and outlet valve opened.
 Confirm that the filter media are cleaned and packed properly.
 Before start-up, filter backwash shall be carried out.
 Clarifier Sludge Pit and Backwash Waste Basin are clean and empty.

INITIAL STARTUP:
 Start Lift Pumps with a minimum flow of 250 m 3/hr. and fill Clarifiers & Sand Filters and
Filtered Water basin with raw water.
 Fill water in the filters from the bottom of drums to release air in the drum.
 Start Filtered Water Pump (3P411A or B) and commission 3LIC402 at 50% on automatic.
 Start chemical injection pumps at the dosage determined by the “Jar-test” and adjust the
caustic solution injection rate within the optimum range.
 Check the state of slurry blanket layers in the clarifiers, the clarified water quality and the
filtered water quality. It may take days to establish the good slurry blanket layer.
 Carry out the blow down of the clarifiers manually from the local control panel when
sludge is accumulated considerably in sludge thickener compartments of the clarifiers.
 Carry out the filter regeneration from the local control panel by selecting switch of desired
filter to AUTO position and push the start button.
 When filtered water quality reaches the specified one, increase the raw water flow rate to
the clarifiers gradually up to desired flow.
 Start Backwash Waste Water Pump (3P412A or B) and start Clarifier Sludge Pump (3P405
A or B). Select switches at a local control station to AUTO position for automatic level
control of the basins.

 When the quality is stable, set the blow down cycle time of the clarifiers and the filter
regeneration cycle time from local control panel and operate automatically.

CHEMICAL INJECTION:
Chlorine(Cl2):
Purposes:
 To Oxidize the dissolved Fe and precipitate it by flocculation and
2Fe(HCO3)2 + Cl2 + 2H2O 2Fe(OH)3 + 4 CO2 + 2 HCl.
Dissolve precipitate
2 Fe : Cl2 = 2 * 55.85 : 35.42 * 2 = 1 : 0.64.
  To sterilize the water.
 To regenerate Mn Sand (in sand filter) oxidize by Mn2+.
Mn2+ + MnO2.H2O + H2O 2MnO2.MnO.H2O + 2H+
Mn Coating Oxidized Sand

MnO2.MnO.H2O + Cl2 + H2O 2MnO2.H2O + 2H+ + 2Cl-

i.e. Mn2+ : Cl2 = 54.94 : 35.45 * 2 = 1 : 1.29
 To sterilize organic matter (1 permanganese value) : 0.67 gm Cl2

Chlorine flow rate is adjusted so that residual chlorine at the outlet of clarifier is maintained
approx. 0.5~1.0 ppm.

Caustic Solution (NaOH):

To keep raw water pH in a desirable range for efficient solid removal by
coagulation/flocculation.
40% Caustic solution of sp.gr. 1.42 dosed in mixing Joan such that pH of clarified water is
maintained 7.0 or as decided by the ‘Jar Test’.
pH = log [Alk] – log [CO2] + 6.3………………………..(i)
For pH = 6.9 [Alk] = 120 (ppm as CaCO3) & [CO2] = 30 (ppm as CaCO3)
Changing rates of [Alk] & [CO2] by 1 ppm injection of chemicals are as follows:
Chemicals [Alk] [CO2]
Alum -0.45 ppm +0.40 ppm
Caustic soda +1.25 ppm -1.10 ppm
i.e. pH = log (120-0.45X+1.25Y) – log(30+0.40X-1.10Y) + 6.3….(ii)
where X: Dosage of Alum (ppm)
Y: Dosage of Caustic soda (ppm)
For pH = 7.0, X = 20……….> Y = 11.7~12 (ave. dosage)
& X = 40……….> Y = 19 (max. dosage)

Pmg Qm3 1gm 1ml 1hr 1gm 1000lit

Dosing Rate = * * * * * *
lit hr 0.4 gm 1.42 gm 60 min 1000mg 1m3
=PQ * 0.02934 ml/ min.
=PQ * 0.02934*.12 litre / 2 hrs.

where P is the ppm dosed and Q is the water flow rate.

Alum Solution (Al2SO4.18H2O):

To coagulate suspended solids.
Al2(SO4)3 + 3Ca(HCO3)2 2Al(OH)3 + 3CaSO4 + 6CO2
 Micro flocs

Micro flocs of Al(OH)3 attract the fine suspended solids and grow to large particles.
10% solution of Alum is prepared during normal operation and concentration of Alum is
maintained 20~40 ppm.

Pmg Qm 3 1gm 1ml 1Hr 1gm 1000mg

Dosing rate = * * * * * *
lit Hr 0.1gm 1.05 gm 60 min 1000 mg 1m3

= PQ * 0.15873 ml / min.
where P is the ppm dosed and Q is the water flow rate.

Tank volume = 6379.39 litre/ 1000 mmH

PQ0.15873ml 1000mmH 1lit 120 min

Dosing rate = * * *
min 6379.39lit 1000ml 2hrs

= PQ * 0.0029856 mmH / 2 Hrs.

Coagulant Aid (Polymer):

Coagulant aid is injected together with alum for promoting coagulation of suspended solids.
0.10 wt% Coagulant aid is prepared and stroke of the pump adjusted such that dosage is
maintained at .08 to 0.1 ppm.

Pmg Qm3 1gm ml 1hr 1gm 1000lit

Dosing Rate = * * * * * *
lit hr 0.001gm 1gm 60 min 1000mg 1m3

=PQ * 16.6667 ml/ min.

= PQ * 16.6667 * 0.12 litre/ hr.

where P is the ppm dosed and Q is the water flow rate.

Raw water mixed with chemicals flows through mixing section with-
 Velocity : 0.18 m/sec.
 Retention time : 15 min. at design flow rate.

SHUT DOWN:

1. Stop the feeding of raw water by stopping lift pumps & closing the Clarifier inlet valve.
2. Stop chemical feeding by stopping the chemical dosing pumps.
3. Stop the sludge discharge by turning the select switch of the clarifier blow down valves
on the local control panel to OFF.
SAND FILTER:

Eight Sand Filters are provided to remove manganese (Mn) and fine suspended solids (micro-
flocks) remaining in the effluent from the clarifiers. Silica sand, half of which is coated by
manganese oxide (MnO2), is packed in the filters as filtration media.

Flowing down through the filter media, fine suspended solids in water are caught by sieving,
adhesion, sedimentation, etc. and are retained in the voids of the filtration media. Filtered
water flowing out from the bottom of the filter is sent to Filtered Water Basin (3CP411) by
gravity flow.

Sand Filters:
Flow rate, Design : 969.6 m3/hr (121.2 m3/hr x 8 units)
Normal : 644.7 m3/hr (80.6 m3/hr x 8 units)
Type : Gravity type
Filtration area : 26.4 m2 x 8 = 211.2 m2
Filtration velocity : 3.1 m/hr at normal flow rate
m/hr at regeneration of one unit.
4.6 m/hr at design flow rate.
Filter media : 300 mm Processed Manganese sand Size : 0.6 mm
300 ,, Silica Sand ,, 0.6 ,,
75 ,, Gravel ,, 2~5 ,,
50 ,, ,, ,, 5~10 ,,
50 ,, ,, ,, 10~15 ,,
75 ,, ,, ,, 15~25 ,,
150 ,, ,, ,, 25~40 ,,

REGENERATION OF THE SAND FILTER:

The filters are regenerated one by one automatically by PLC in the local control panel.
However, if the head loss of the filter increases considerably (annunciated by 3LAH401A~H)
before the specified time is passed, the filter should be regenerated manually from the local
control panel.

Filter regeneration shall be carried out by the following conditions:

Flow rate
Backwash : 0.68 m3/min/m2
Surface wash : 0.1 m3/min/m2
Frequency : 1 time/day per each filter.
Washing time : 25 min

Steps of Regeneration:

1. Water drain:
The water in the filter is drained out until the water level of the filter reaches the inlet
nozzle level.
Valves open 3XV415 A~H, 3XV417 A~H.
 This step takes 5 min.

2. Surface wash:
The backwash water is sprayed to the surface of filter media from the distribution nozzles.
This is for breaking and dispersing the hardened solids accumulated on the surface of filter
media.
Valves open 3XV414 A~H, 3XV418 A~H and 3XV415 A~H remain open.
This step takes 4 min.

3. Backwash:
The backwash water is passed upward through the filter media bed so as to expand the
volume of the filter media to 120 ~ 130% of the initial volume.
First stage: Backwash inlet water valve open and discharge to clarifier sludge pit.
Valves open 3XV413 A~H, and 3XV414 A~H, 3XV415 A~H, 3XV418 A~H remain open.
This stage takes 2 min.
Second stage: Backwash waste water discharge to Backwash waste basin
Valve open 3XV417 A~H and 3XV413 A~H, 3XV414 A~H, 3XV415 remain open.
This step takes 2 min.
Third Stage: Surface water inlet valve close.
Valve 3XV413 A~H, 3XV415 A~H, 3XV417 A~H remain open.
This stage takes 2 min.

4. Rinsing :
Clarified water is passed through the filter media bed downwards to rinse the filter media
until the outlet water quality is stabilized.
Valve open 3XV411 A~H, 3XV416 A~H, and 3XV417 A~H valve remain open.
This step takes 10 min.
After completing rinsing 3XV416 A~H, 3XV417 A~H close and Filtered water outlet
valve 3XV412 A~H open and Sand Filter goes to service.
Cooling Water System

5.1 INTRODUCTION:
There are two types of cooling water pumps in cooling tower, one is Main Cooling Water
Pumps and other is Utility Cooling Water Pumps. The supply and return temperature of the
water is 330C and 430C respectively as per design.
For users in Ammonia/Urea plants cooling water is supplied by Main Cooling Water Pumps
(3P501A/B/C) driven by motor. Out of three, two of them are in service and one is on standby
in normal operation. Total about 24000 m3/h water is circulated by the Main Cooling Water
Pumps and the supply pressure is normally near 3.9 kg/cm 2G. When the supply pressure falls
below 3.4 kg/cm2G, the standby pump starts automatically.

Main Cooling Water Pumps: (3P501A/B/C)

Quantity : 3 (2+1 Spare)
Type : Cetrifugal
Capacity : 12300 m3/h
Head : 35 m
Driver motor voltage : 6.6 kv
Driver power : 1460 kw

For critical users in Ammonia/Urea plants, users in utility plants and ancillary installations,
cooling water is supplied by Utility Cooling Water Pumps (3P502A/B). 3P502a is driven by
steam turbine (3TS502), and 3P502B by motor. In normal operation, 3P502A is operated,
while the motor driven pump is on standby. Total 4053 m 3/h water is supplied by Utility
Cooling Water Pump and supply pressure is 3.8 kg/cm 2G normally. When the supply pressure
falls below 3.4 kg/cm2G, the standby 3P502B starts automatically.

Utility Cooling Water Pumps (3P502A/B)

Quantity : 2 (1+1 spare)
Type : Cetrifugal
Capacity : 4053 m3/h
Head :35 m
Driver : Steam Turbine (3TS502) for A
(583 kw x 4500 rpm)
Motor for B (550 kw)

5.2 MAIN OR UTILITY (MOTOR DRIVEN) COOLING WATER PUMPS:

5.3.1 PREPARATION FOR START UP:

Prior to start up of the system, the following items shall be checked and confirmed
1. Electrical power is available.
2. Instrument system is OK and logics are properly functioning.
3. Filter water is available
4. Cooling water inlet and outlet valve in different heat exchangers are properly open.
5. Pump outlet valves are closed and inlet valves open.
6. The cooling water Basin is filled up.
7. Chemical dosing is going on and chemical dosing pump are OK.
8. Side stream filter is ready.
9. Priming ejector is running with service water and priming of pumps is complete.
 10. Cooling water return header valve is open as well as inlet of individual cells.

5.3.2 START-UP:
1. Make confirm that the priming is complete by watching full water in sight glass in the
priming line and no air bubbling from the outlet of the priming ejector discharge in the
cooling tower basin.
2. Start the Main cooling water pump by pressing the start button.
3. After confirming the discharge pressure to come up, open discharge valve. The
discharge valve should be opened gradually. Open the discharge valve fully, if
discharge pressure fall below 4.0 kg/cm2G stop opening the valve to prevent
unexpected overload.

5.3.3 NORMAL OPERATION:

Check the following items during normal operation:
1. Check the sound and vibration of the motor.
2. Check the driving end and non driving end gland water supply and monitor the
temperature of the both end.
3. Check the Lube oil level.
4. Check the discharge pressure of the pump.

5.3.4 SHUT DOWN:

1. Close the discharge valve gradually.
2. Press the push button to stop the pump.

6. TURBINE DRIVEN UTILITY COOLING WATER PUMP (3P502A):

6.1 PREPARATION FOR START-UP:

Prior to start up of the system, the following items shall be checked and confirmed:
1. Electrical power supply is available.
2. Instrument air supply is normal and all instruments work properly.
3. Cooling water supply to lube oil cooler is normal.
4. Lube oil level is normal.
5. Cooling water basin level is normal.
6. Pump suction valve is open and discharge valve is open 5%.
7. MP steam is available.
8. Reset 3HS015 from DCS panel.
9. Check the priming of the pump is OK.

6.2 START-UP:
1. Start the auxiliary lube oil pump manually pushing local start button. This will ensure
the lube oil pressure more than 1.7 kg/cm2G.
2. Open all the drain valves, TTV (Turbine Trip Valve) and open the MP steam inlet block
bypass valve slowly for warm up the turbine.
3. Watch the temperature of LP steam outlet 3TI504 and the condensate through the drain
valve. If no more condensate out through the drain and temperature of 3TI504 raises to
nearly 220, then it will ensure that the warm up of the turbine is complete.
4. Slowly open the steam bypass valve fully, this will increase the rpm of the turbine
slowly and at the same time open the LP steam outlet valve. Close all the drain valves.
 5. Now open the main MP steam inlet block valve slowly and fully, this will increase the
rpm near 2800.
6. Now close the bypass inlet steam valve.
7. Increase the rpm by rotating governor rpm control device through screw driver. Set the
rpm to near 4500 watching the discharge pressure.
8. Now open the discharge valve slowly and observe the header pressure which should be
above 3.7 kg/cm2G.
9. Observe that the main lube oil pump is started and put the lube oil pump to AUTO.
Check whether lube oil pressure is OK.

6.3 NORMAL OPERATION:

During normal operation the following items should be checked and monitor.
1. Lube oil pressure and temperature
2. Driving and non driving end temperature should below 1300C.
3. Check the rpm and discharge pressure.
4. Check the lube oil level.
5. Check the vibration and abnormal sound.
6. Check the steam or lube oil leakage.

6.4 SHUT DOWN:

1. Rotate the rpm control device of governor to decrease the rpm.
2. Slowly close the discharge valve.
3. When the rpm decrease to near 3000 start closing the MP steam block valve.
4. After full closing the steam block valve, close the TTV.
5. Open all the drain valves.
6. Check that the auxiliary lube oil pump is started automatically, if not start it manually.

4. COOLING TOWER FANS:

4.1 INTRODUCTION:
Cooling Tower (3CT501) consists of 10 cells, and each cell is equipped with 132 kw induced
draft fan. ID fans create vacuum during operation, drive the air to flow through the Cooling
Tower, promote the evaporation of water and cool down water.

4.2 PREPARATION FOR START-UP:

1. Electrical power is available.
2. Instrument air is normal
3. Lube oil level is normal.
4. Cooling water is available.

4.3 START-UP:
1. Open the cell for cooling water supply.
2. Push the start button to start the fan.

4.4 NORMAL OPERATION:

During normal operation the following items should be checked
1. Check and monitor the vibration of the fan.
2. Check the lube oil level and fill if required.
3. Check for any leakage of lube oil.
4.5 SHUT DOWN:
1. Stop the fans by turning off the motor power through push button.
2. Close the cell if required.
Chemical dosing calculation
Corrosion Inhibitor:

Pmg Qm3 1gm ml 1000lit

Dosing Rate = * * * *
lit hr 0.1gm 1.05 gm 1m3

=P * (B + 20) * 9523.8095 lit/ hr


V= * (1560) 2 mm3/ mmH
4
=1911.345 ml/ mmH
P * (B + 20) * 0.00996555 mmH / 2 Hrs.

Dispersent:

Pmg Qm3 1gm ml 1hr 1gm 1000lit

Dosing Rate = * * * * * *
lit hr 0.001gm 1gm 60 min 1000mg 1m3

= P * (B + 20) * 0.096065 mmH / Hrs.

Demineralization & BFW

Plant Air & Instrument Air

Inert Gas Generation

CHEMICAL RECEIVING AND STORAGE

3.1 INTRODUCTION
Two chemicals are received and stored for utility plant. An unloading of chemical for
individual tank and stored for the supply to the user is carried out regularly

1. Sulfuric Acid system:

The sulfuric acid supply system is provided to supply sulfuric acid to all users in the
plant.
Sulfuric acid Storage Tank (6T101) is installed and has a capacity of 133 m 3 . The type
of tank is cone roof.
 Sulfuric Acid Pumps (6P101A/B), one operating and one standby, are provided near the
tank to unload sulfuric acid from a tank lorry to the tank and to distribute sulfuric acid
to the user.
The tank is located on paved floor with chemical coating in a dike and floor drain is
drawn off to the oily sewer collection system.
Sulfuric acid is very hygroscopic. It easily becomes diluted sulfuric acid solution by
absorbing water content in fresh air. Since diluted sulfuric acid solution is very
corrosive, therefore, the contact of sulfuric acid with fresh air in the tank shall be
avoided. Instrument air is continuously introduced in the tank for this purpose.
2. Caustic Soda system:
The caustic soda supply system is provided to supply caustic soda to all users in the
plant.
Caustic Soda Storage Tank (6T102) is installed and has a capacity of 240 m 3 . The type
of tank is cone roof.
Caustic Soda Pumps (6P102A/B), one operating and one standby, are provided near the
tank to unload caustic from a tank lorry to the tank and to distribute caustic soda to the
user.
The tank is located on paved floor in a dike and floor drain is drawn off to the oily
sewer collection system.
As 45% of caustic soda solution has a freezing point of 9 0C, steam heater is provided in
the tank and hot insulation for related pipeline.

Sulfuric Acid Storage Tank (6T101):

-Type : Cone Roof
-Capacity :133 m3
-Diameter and Height : 5000 mm x 7500 mm
-Material :Carbon Steel

. Caustic Soda Storage Tank (6T102):

-Type : Cone Roof
-Capacity : 240 m3
-Diameter and Height : 6700 mm x 7500 mm
-Material : Carbon Steel

3.2 UNLOADING:
Preparation for start-up of unloading:
1. Electrical power is available.
2. Pumps are ready to operate.
3. Instrument air is available.
4. Confirm that Pump suction valve open and discharge valve are close.

3.3 UNLOADING PROCEDURE:

1. Check inventory of each material in the respective tank by monitoring level
gauges locally, and request arrangement for lorry.
2. Place lorry in unloading position, and stop the engine.
3. Connect unloading hose to lorry.
4. Set and check the unloading line.
5. Slowly and fully open outlet valve of lorry.
6. Check that there is no leakage.
 7. Start unloading pump.
8. Slowly open pump discharge valve.
9. Continue the unloading operation until the lorry is empty.
10. Stop unloading pump.
11. Close pump discharge and suction valves and lorry outlet valve.
12. Drain out the material remaining in unloading hose, close the block valve
provided for the hose and install blind flange.
13. Disconnect unloading hose.

Deep Tube Wells

Waste Water Treatment