1. INSTALLATION OF S-50 AMMONIA
CONVERTOR
Prem Baboo
Sr.Manager (Prod)
National fertilizers Ltd. India
S-50 AMMONIA SYNTHESIS CONVERTER (R-3502)
Supplier: M/s MANGIAROTTI SpA
Transporter (Kandla port to NFL Vijaipur) : M/s Reshamsingh & Co Pvt Ltd., Mumbai
2. Operating conditions
Inlet Gas
Temperature oC 372
Pressure Kg/cm2 183.2
Total flow Nm3/hr 615,133
Composition
H2 Vol% 50.50
N2 Vol% 16.84
Inerts, CH4 + Ar Vol% 13.50
NH3 Vol% 19.16
Outlet Gas
Temperature oC 417
Pressure Kg/cm2 182.7
Total flow Nm3/hr 596,242
Composition
H2 Vol% 47.35
N2 Vol% 15.78
Inerts, CH4 + Ar Vol% 13.93
NH3 Vol% 22.94
Catalyst
Type KM1
Size mm 1.5-3
Diameters, OD (effective)/ ID mm 2,896 / 760
Height (excl./incl. bottom cone m 20,100 / 21,200
Volume m3 125,4
Mechanical Data (Pressure Vessel)
Type Vessel with top manhole
Inner diameter mm 3,000
Inner length (T-T) mm 20,250
Normal operating pressure Kg/cm2 g 183.1
Design pressure Kg/cm2 g 245
Hydrogen partial pressure, design Kg/cm2 130
Temperature of Operating Design
Cover and cylinder part oC 372 430
Spherical bottom oC 372 430
Bottom forging oC 419 450
Bottom flange oC 419 450
Nozzle sizes
Main inlet inch 16
outlet inch 16
Installation of S-50 ammonia synthesis
converter along with waste heat boiler in
downstream of existing S-200 ammonia
synthesis converter is one of the major
scheme of Capacity Enhancement Project of
Ammonia-II plant.
Pre shutdown activity
3. The anchor bolts were position with the help of template during casting of top portion of
foundation of S-50 ammonia synthesis converter and the same was grouted with Shrinkom-
20 after completion of civil work and removal of template. Top surface of foundation was
prepared for placement of equipment.
First of all skirt were placed on foundation and leveled at elevation of 106.200 mtr. with the
help of MS plats and gaps between base plate of skirt and civil foundation was filled by
Shrinkom-20.
After placement of skirt, S-50 ammonia synthesis converter was placed and leveled /
centered on skirt with the help of Demag CC2800-1and CC2000 crane on 12.08.2011.
Erection plan submitted by M/s Sarens Heavy Lift India Pvt. Ltd., party engaged by piping &
equipment erection contractor (M/s Satnam Global Infraprojects Ltd., Delhi) for heavy
equipment erection alongwith cranes is enclosed.
After opening of top cover and outer screen panel covers, joint inspection was done by NFL /
HTAS to check any damage during transportation / erection and found Ok. Lot of rust as
4. scale was found on inside surface of reactor which was vacuum cleaned before catalyst
loading.
Catalyst was charged with the help of shower head from 31.01.2012 to 06.02.2012 by M/s
Amol Construction in presence of HTAS representative Mr. AsadRadfar. The approximate
density of catalyst achieved was 2.95 Kg/litre. During charging of catalyst, support
provided for centre screen and outer screen panels were removed which was provided by
the supplier to avoid any damage while transit.
After catalyst loading, outer screen panel cover boxed up and tack weld as instructed by
HTAS. Gland packing of stuffing box (centre screen and outer screen panel cover flange)
checked and found OK. Top cover and bottom cover were boxed up with the help of bolt
tightening device and lip seal welded with Inconel filler wire.
Insulation job of S-50 Ammonia synthesis converter (160.0 mm thick) and connecting pipe
line job done by M/s Kaefer Punj Lloyd Limited.
Shutdown Activity:
All the prefabricated pipelines were hydrotest at 367.5 Kg/cm2 before hookup with existing
header and S-50 converter. RT of the all weld joint done on half weld and UT at full weld joint
of pipe line. Stress reliving of alloy steel pipe weld joint (2.25Cr 1Mo steel) was done as per
ASME section and Hardness was achieved below 220 HB. Instrumentation, Electrical and
Structure job were taken care by respective department.
