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Engo report

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Report on CO2 Stripper

Report on CO2 Stripper

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  • 1. 2011 CO2 STRIPPER (T-1101) Problems, Solutions & Suggestions Report contains stripper history in detail and advanced technologies introduced for stripper tubing. Style of report is absolutely different from traditional styles as it gives an excellent & immediate review of stripper. SYED ETIZAZ HASSAN U.E.T LAHORE 8/25/2011
  • 2. [T-1101] [INTERNSHIP 2011]APPROVALSSUPERVISOR(Mr. Abdul Hakim )MENTOR(Mr. Azhar Rasool)GL(Mr. Qamar Jaleel) ENGRO FERTILIZERS Page 2
  • 3. [T-1101] [INTERNSHIP 2011]CONTENTS x CO2 STRIPPER x HISTORY OF CO2 STRIPPER(TURN AROUNDS) x T/A 2009 ,AN EXAMPLE x CURRENT ISSUES x SOLUTIONS SUGGESTED I. TUBES II. TUBESHEETS III. DISTRIBUTION TRAY IV. SWIRLS GASKETS V. x T/A 2012 x PREVENTIVE MEASURES x MY SUGGESTIONS WHAT I HAVE LEARNT????? What I DID FOR ALL OF IT???? THINGS IMPRESSED ME HERE @ ENGRO ENGRO FERTILIZERS Page 3
  • 4. [T-1101] [INTERNSHIP 2011]T-1101 in ACES • A ADVANCE • C COST • E ENERGY • S SAVINGT-1101 Installation(October-1998) ENGRO FERTILIZERS Page 4
  • 5. [T-1101] [INTERNSHIP 2011]ENGRO FERTILIZERS Page 5
  • 6. [T-1101] [INTERNSHIP 2011]CO2 STRIPPER (UREA STRIPPER T-1101) Stripper in ACES synthesis loop consists of tray part and stripping part with vertical tubes. The solution from Reactor is fed to tray part contacting with mixed gas from stripping part. NH3 and CO2 molar ratio is reduced from 4.0 to 3.0 at tray part to achieve suitable composition for CO2 stripping. Solution from side down comer of tray part enters on distribution plate. At the distribution plate, solution is distributed on tube sheet through holes of distribution plate equally with keeping liquid level around 100-200mm on the distribution plate. On the tube sheet, the solution makes liquid level higher than swirl’s holes by 60-70mm. And the solution enters to swirls’ holes tangentially to make uniform thin falling film on the internal surface of tube. CO2 gas introduced at the bottom of tubes as stripping medium contacts with the solution in the tubes under the falling film condition. The solution is heated from tube outside by 20kg/cm2g steam during contacting with CO2 gas. Carbamate is decomposed and NH3 is removed and separated from the solution by CO2 gas under the high-pressure condition. Finally, NH3 content in the solution from the bottom of Stripper is reduced to 13-14%. ENGRO FERTILIZERS Page 6
  • 7. [T-1101] [INTERNSHIP 2011]T-1101 Design by Toyo EngineeringSHELL SIDE  Operating Temperature 417°F(214 °C)  Design Temperature 464°F(240 °C)  Operating Pressure 284 psig  Design Pressure 355 psigTUBE SIDE  Operating Temperature 356°F/374°F(179/190°C)  Design Temperature 428°F(220 °C)  Operating Pressure 2490 psig  Design Pressure 2613 psig ENGRO FERTILIZERS Page 7
  • 8. [T-1101] [INTERNSHIP 2011]METALLURGYOuter Shell CS Tube DP-12Internal Lining DP-12 Sieve Tray DP-12Distribution Tray DP-12 Swirl DP-12, SUS-329, J4L, DP28WStay Rod DP-12 Gasket Tombo 9007-SC & Comp GraphIMPORTANT DATAInternal diameter top 2600 mm Length top 3060 mmInternal diameter middle 2500 mm Length after tubes 1000 mmTube Length 5963 mm Length bottom 900 mmNo. of Tubes 3100 diameter of Tube 31.8 mmThickness of tube 2.9 mm Weep Holes 69Number of Trays 3 No. of holes per tray 4508Lining thickness 6mm Corrosion allowance 1.5 mm (tube)Weight of shell 197000 kg ENGRO FERTILIZERS Page 8
  • 9. [T-1101] [INTERNSHIP 2011]HISTORY of T-1101TURN AROUNDS’ SCHEDULE1 TURN AROUND 2000(MARCH)2 TURN AROUND 2001(APRIL)3 TURN AROUND 2002(OCTOBER 15)4 TURN AROUND 2004(MARCH-APRIL)5 TURN AROUND 2005(APRIL)6 FORCED OUTAGE 2006(OCTOBER)7 TURN AROUND 2009(MARCH) ENGRO FERTILIZERS Page 9
  • 10. [T-1101] [INTERNSHIP 2011]T/A 2000  10 % swirls were swinging & loose  Uneven liquid level on distribution plate  Seal weld leakage testing ENGRO FERTILIZERS Page 10
  • 11. [T-1101] [INTERNSHIP 2011]T/A 2001  High bottom temperaturev  100% ECT  Short circulation of liquid from bottom tray  Bottom tray sagging  ‘o’ rings damaged  All the swirls were swinging  Stay rods damagedT/A 2002  Swirls inspection  33% ECT  IPRL arrange adequate inventory of stay rods  IPRL plan repair /replacement of swirls based on TOYO analysis  Steam side PSV flange gasket replacement  Distribution holes on the distribution plate had been enlarged  Sample point valves relocation required ENGRO FERTILIZERS Page 11
  • 12. [T-1101] [INTERNSHIP 2011]T/A 2004  Lube oil filters Replacement  Swirls holes diameter increased from 2.8 mm to 3.1 mm  60 % ECT  Gaskets and swirl "o" rings damaged  Stay rod damaged  Bare wire for welding (Pak American)  Bottom temp raised to 192 deg C  Ammonia concentration raised to 21.19 %(NH3 rec. system overloaded )and NH3 vapors increased to 50%  Distribution holes on the distribution plate have been enlarged ENGRO FERTILIZERS Page 12
  • 13. [T-1101] [INTERNSHIP 2011]T/A 2005  Tube and tube sheet seal welds leakage  ‘o’ rings damaged  Gaskets of steam inlet and outlet valves damagedFORCED OUTAGE 2006  Tubes leakage was detected  Tube sheet inspection  Swirls hole diameter increment  Swirl guards damaged  2.8 % ECT ENGRO FERTILIZERS Page 13
  • 14. [T-1101] [INTERNSHIP 2011]T/A 2009  Thermo well corroded  Swirls destroyed  Vessel liner inspection required  Gaskets for manhole to be replaced  Swirls o rings damaged  Soft gaskets for swirls  Washers for stay rod  Seal welds damaged  Distribution plate hole diameter increased 129%  Chest side bleeder valve is leak thru  Condensate outlet sample point valve glands repacking required  Steam inlet sample point valve glanding required ENGRO FERTILIZERS Page 14
  • 15. [T-1101] [INTERNSHIP 2011] OUTCOME OF T/AsT/A 2009 AN EXAMPLE Efficiency BEFORE & AFTER t/a 2009 ENGRO FERTILIZERS Page 15
  • 16. [T-1101] [INTERNSHIP 2011] SWIRLS REPLACEMENT350300250200 New 2009150 Old 2005-200610050 0 Segment Segment Segment Segment Segment Segment Segment Segment Segment Segment #1 #2 #3 #4 #5 #6 #7 #8 #9 # 10 ENGRO FERTILIZERS Page 16
  • 17. [T-1101] [INTERNSHIP 2011]DISTRIBUTION PLATE HOLE DIMENSIONS ENGRO FERTILIZERS Page 17
  • 18. [T-1101] [INTERNSHIP 2011] CURRENT ISSUESISSUES FORESEEN (HISTORY BASED)  High bottom temperature  Swirls hole diameter increment  Swirl/stay rod gasket & o ring damaged  Swirls’ guard damage  Tubes leakage( CS lines corrosion)  Swirls, tubes and shell corrosion  Spurger holes diameter increment  Carbamate condenses on the level transmitters  Vortex breaker corroded  Sieve trays gasket leakage ENGRO FERTILIZERS Page 18
  • 19. [T-1101] [INTERNSHIP 2011]ALARMING ISSUES  Stripper efficiency dropped 2 %(02 /02/2011)  Decreasing tube thickness (TOYO report in 2006)  Distribution plate holes diameter increment  Weep holes  Seal welds leakages  Carbamate leakage at bottom may way  Corrosion & erosion ENGRO FERTILIZERS Page 19
  • 20. [T-1101] [INTERNSHIP 2011] SOLUTIONS SUGGESTEDTUBES  Proper adjustment of swirls  High pressure & temperature (non chloride)steam cleaning  Welding at lower temperature  ECT of 100% tubes  Tubes plugging ENGRO FERTILIZERS Page 20
  • 21. [T-1101] [INTERNSHIP 2011]TUBE SHEET  Arrangements for proper seal welding of tubes  Distribution plate laser leveling  Efficient grinding of seal weldsDISTRIBUTION PLATE  Proper adjustment of swirl guards and stay rods’ gaskets  Proper bolting with shell  Plugging  Change it(as in 2004)SIEVE TRAYS  Gasket replacement  Level maintenance ENGRO FERTILIZERS Page 21
  • 22. [T-1101] [INTERNSHIP 2011]SWIRLS  Installation procedure  ‘O’ rings replacement  2-passes seal welds  Gaskets for swirl guards  Proper adjustments for distribution plate leveling  Proper hole testing (specially for swirls of 2004-05)  Buy some new swirls (as swirls replaced in 2004-05 may destroyed)GASKETS  Gaskets at inlets & outlets  ‘O’ rings Teflon gaskets (tombo T #2090)  Black gasket (Tombo #9007-SC)  Soft gasket (Tombo T #9096)  Man way gaskets  Sieve trays gaskets ENGRO FERTILIZERS Page 22
  • 23. [T-1101] [INTERNSHIP 2011]T/A 2012 (CO2 STRIPPER) PLAN ENGRO FERTILIZERS Page 23
  • 24. [T-1101] [INTERNSHIP 2011]PREVENTIVE MEASURES  New swirls purchase  Tombo sheets for gaskets and o rings  Stay rods replacement required  Bare wire DP 3T  Prepare for 100 % ECT  Man holes gaskets replacement  Weep holes cleaning and lining judgment  Proper arrangement for seal welder & seal weld cutter  Proper testing of methyl red solution for weep hole testing  UT for shell lining  Distribution plate needed to be replaced ENGRO FERTILIZERS Page 24
  • 25. [T-1101] [INTERNSHIP 2011]MY SUGGESTIONS  Tubes replacement (FFC)  2RE69(Cr & Ni ) by Sand vick  Zr layering Omega Bond technology (ATI Wah Chang) (waiting for quotation)  Seal welding machine & grinder (Ar cooling)  Distributor plate plugging and boring more holes  Thermo vision of stripper lines  ECT report should be sent to TOYO  Experienced persons’ involvement in T/A s  A/C cooling during shutdown ENGRO FERTILIZERS Page 25
  • 26. [T-1101] [INTERNSHIP 2011] OTHER THAN MY PROJECTUREA II  C2E Shutdown  NH3 Line tracing  NH3 Reservoir (D-261)  NH3 Condensers (E-264)  MP 262 A/B  URACA’S Pumps(P 201’S)  ACES Tower visit (Thermo vision)  Prill Tower visitOVER ALL PLANT  GT startup @ URUT  Packing leak in ST @ enven  Piston repairing @ workshop  Visited skill shop ENGRO FERTILIZERS Page 26
  • 27. [T-1101] [INTERNSHIP 2011] Shut down @ urea ii (c2e)SHUT DOWN @ UREA II (C2E) ENGRO FERTILIZERS Page 27
  • 28. [T-1101] [INTERNSHIP 2011]SHUT DOWN @ UREA II (C2E) ENGRO FERTILIZERS Page 28
  • 29. [T-1101] [INTERNSHIP 2011]ENGRO FERTILIZERS Page 29
  • 30. [T-1101] [INTERNSHIP 2011]WHAT I HAVE LEARNT?????  Technical data handling  T/A planning  Equipment Order & purchase for T/A  Total maintenance procedure  Collaboration of Operation ,Process, Maintenance ,Inspection ,I& E and Safety section  Non-destructive techniques  Permit protocol  Seniority protocol  Crisis management  Rapid decision makingWhat I DID FOR ALL OF IT????  Spent most of the time in plant premises  Read all history files and job cards  Visited inspection, planning ,process ,projects  Met the technicians of FM  Coordinated with operators & board men in CCR  Met senior persons worked here before ENGRO FERTILIZERS Page 30
  • 31. [T-1101] [INTERNSHIP 2011] THINGS IMPRESSED ME HERE @ ENGRO Safety and importance of life Line of protocol Team work Qualified staff Well equipped offices Ethics & moral values Well mannered workers Seniority honor ENGRO FERTILIZERS Page 31

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