Operation Instruction for

TITLE Rev 00
Urea Plant

HURL-G-LD-U00-PRS-IOM-
DOC NO. Date 18-FEB-2019
000-0001

Revision History

Rev.0: Initial Issue

 Operation Instruction for
TITLE Rev 00
Urea Plant

HURL-G-LD-U00-PRS-IOM-
DOC NO. Date 18-FEB-2019
000-0001

OPERATION INSTRUCTION UREA PLANT

 Operation Instruction for
TITLE Rev 00
Urea Plant

HURL-G-LD-U00-PRS-IOM-
DOC NO. Date 18-FEB-2019
000-0001

CONTENTS

SECTION 1. INTRODUCTION
1.1 Preface
1.2 Operating Cautions
1.3 General Description of Urea (History)
1.4 Design Basis
1.5 Process Performance
1.6 Reference Drawing and Document List

SECTION 2. PROCESS AND OPERATING PRINCIPLES

2.1 General
2.2 Synthesis Section
2.3 Purification Section
2.4 Concentration & Prilling Section
2.5 Recovery Section
2.6 Process Condensate Treatment Section

SECTION 3. PROCESS FEATURE AND DESCRIPTION

3.1 Process Feature
3.2 Process Description
3.3 Equipment List

SECTION 4. PREPARATION FOR THE INITIAL START-UP

4.1 Line Check
4.2 Flushing
4.3 Unit Commissioning
4.4 Calibration for Radio Active Level Gauge and Density Meter
4.5 Water Run
4.6 Pre-commissioning for Prilling Section
4.7 Prilling Test

SECTION 5. START-UP
5.1 Introduction
5.2 Pre-Start-up Procedure
5.3 Normal Start-up Procedure

SECTION 6. NORMAL OPERATION

6.1 General
6.2 Increasing Plant Load
6.3 Routine Inspection and Operation
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SECTION 7. NORMAL SHUTDOWN

7.1 Introduction
7.2 Normal Shutdown
7.3 Normal Shutdown for Short Period

SECTION 8. EMERGENCY SHUTDOWN

8.1 General
8.2 General Emergency Procedure
8.3 Utility Failure
8.4 DCS Failure

SECTION 9. SAFETY
9.1 General
9.2 Fire Protection
9.3 Personnel Protective Equipment
9.4 Repair Work
9.5 Maintenance of Equipment and Housekeeping
9.6 Special Cautions in the Urea Plant
9.7 Occupational Safety Data

SECTION 10. ADDITIONAL INFORMATION

10.1 Special Caution for Operation
10.2 Start-up Procedures for Pumps and Turbines
10.3 Analysis

SECTION 11. EFFLUENT WATER TREATMENT SECTION

11.1 Process Feature and Description
11.2 Preparation for the Initial Start-up
11.3 Normal Start-up
11.4 Normal Operation
11.5 Normal Shut-down
11.6 Emergency Shut-down
 Operation Instruction for
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Urea Plant

HURL-G-LD-U00-PRS-IOM-
DOC NO. Date 18-FEB-2019
000-0001

SECTION 1 INTRODUCTION

1.1 Preface

1.2 Operating Cautions

1.3 General Description of Urea (History)

1.4 Design Basis

1.5 Process Performance

1.6 Reference Drawing and Document List

1.6.1 Process Flow Diagram and Material Balance Sheet

1.6.2 Plot Plan
1.6.3 P&I Flow Diagram and Utility Flow Diagram
1.6.4 Other Reference Drawing and Document

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SECTION 1. INTRODUCTION

1.1 Preface

These operation / Safety instructions are prepared for the assistance of operation of 3,850
MTPD Urea plant for Hindustan Urvarak and Rasayan Limited, Gorakhpur, in the State of Uttar
Pradesh, India.

Operation conditions described in this document is based on design capacity (3,850 MTPD) as
100% production capacity.

These instructions should be read, keeping the fact in mind that it is almost impossible for any
instructions to cover everything in all possible operating conditions. Therefore it is of great
importance that the operator should have a full understanding with functions, systems and
layout of the plant equipment to cope with each and every situation.

It should be also taken into consideration that the methods, data and operating conditions
described in these instructions may well have a necessity to be appropriately amended under
the abnormal operating conditions or emergency situations. Some figures and/or procedures
may be modified after actual operation if necessary.

Furthermore, without a written approval from Toyo Engineering Corporation Japan, any
information, such as process flow diagrams, P&I flow diagrams and so on shall not be copied or
reproduced in any manner, and they shall not be shown to any person non-concerned with this
project.

Operators should read this instruction along with other operation manuals and literatures of
special equipment, before they actually participate in operation or maintenance activities. This
is because one may not be complete without others.

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1.2 Operating Cautions

The following rules should be carefully followed, as neglect of these cautions may cause
serious damage to personnel and/or equipment. However, attention should be paid to that
operation of Urea plant.

(1) Always observe the start-up and the operating manual for pumps and compressors as
regards safety.

(2) Always make sure that steam is flowing through tracing and jacket for safety valves,
rupture diskette, etc.

(3) Never run a pump dry, keep suction strainer clean, and maintain proper liquid levels in the
vessels connected to the pump suction lines.

(4) Never stand directly facing any safety valves, sampling valves, etc.

(5) Do not permit water containing solid contaminants to enter the system, since they will
damage valves and pumps.

(6) Do not make a vacuum on equipment at any time, unless it is designed to with stand the
stresses set up under such conditions.

(7) Switch pumps regularly when spares are provided. This will help to assure the spare
pumps will be ready when needed.

(8) Operating equipment should be checked frequently for signs of leakage, overheating and
corrosion so that unsafe conditions upsets or injury to personnel or equipment breakage
are avoided. Unusual conditions should be reported immediately.

(9) Never disassemble piping and equipment without making sure that no ammonia or any
other harmful material is present.

(10) No hot work shall be allowed unless authorized by a work permit. All connections must be
properly sealed off to prevent leakage of any inflammable material.

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(11) Always flush out urea and carbamate solution lines with water or steam whenever flow is
interrupted.

(12) Before starting operations, check all safety devices to be sure it functions properly.

1.3 General Descriptions of Urea (History)

Urea was first synthesized by Woehler in 1828 who heated ammonium cyanate (NH 4 CNO) to
convert into urea (NH 2 CONH 2 ).
Previous to this, urea had been separated from urine and the experiment by Woehler showed
that organic material could be prepared from an "inorganic" chemical. This synthesis of urea in
1828 marked the beginning of synthesis of organic compound.

In 1870, Bassarow produced urea by dehydrating ammonium carbamate, which is the basis of
all current commercial processes. Urea was not produced commercially until 1920, when I.G.
Farben built a plant in Germany based on the ammonium carbamate process. Since then,
considerable ingenuity was used to overcome various process difficulties, such as corrosion
problems, recovery of off-gases, and improvement of economics.

Today, all commercial urea processes are based on the reaction of ammonia and carbon
dioxide to form ammonium carbamate with subsequent dehydration to urea. Ammonia and
carbon dioxide are usually available at the same site, since carbon dioxide is a by-product of
ammonia synthesis from hydrocarbons.

1.4 Design Basis

The Plant is designed based on the availability of raw materials and utilities with the
characteristics of Battery Limit conditions and the site conditions described in Process Design
Basis.

Doc.Name.
- Process Design Basis: HURL-G-ED-S00-PRS-INF-000-001

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1.5 Process Performance

The Plant is designed to have such performance characteristics regarding production capacity,
product quality, raw material and utility consumption on the average basis during the normal
operation described in the Process Design Basis (Doc. No. HURL-G-ED-S00-PRS-INF-000
-001) and Utility Balance Diagram (Doc. No. HURL-G-ED-U00-PRS-UBD-000-3A and 3B),
subject to such climatic conditions described in Process Design Basis fed to the Plant which
shall be constructed and operated in accordance with the technical specifications, documents,
drawings and supervisor's instruction provided with or given by Contractor.

1.6 Reference Drawing and Document List

1.6.1 Process Flow Diagram and Material Balance Sheet

- Process Flow Diagram and Material Balance Sheet (Normal Operation)

(HURL-G-ED-U00-PRS-PFD-000-2A~2Q)
- Utility Balance Diagram (Normal Operation)
(HURL-G-ED-U00-PRS-UBD-000-3A and 3B)

1.6.2 Plot Plan

- Plot Plan for Urea plant (HURL-G-ED-U00-PIP-PLT-000-0011)

1.6.3 P&I Flow Diagram and Utility Flow Diagram

- Piping & Instrument Flow Diagram (Legend) (HURL-G-ED-U00-PRS-PID-000-4A~04E)

- Piping & Instrument Flow Diagram (Process) (HURL-G-ED-U00-PRS-PID-000-5A~5W)
- Piping & Instrument Flow Diagram (Utility) (HURL-G-ED-U00-PRS-PID-000-13A~25C)

1.6.4 Other Reference Drawing and Document

- Interlock Narrative for Urea plant (HURL-G-LD-U00-PRS-INF-000-0007)

- Process Sketch and Data sheet for Equipment
- Data Sheet for Rotating Machine

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SECTION 2. PROCESS AND OPERATING PRINCIPLES

2.1 General

2.2 Synthesis Section

2.2.1 Reactor (U-DC101)

2.2.2 Stripper (U-DA101)
2.2.3 Carbamate Condenser (U-EA101)

2.3 Purification Section

2.3.1 HP Decomposer (U-DA201)

2.3.2 LP Decomposer (U-DA202)
2.3.3 Urea Hydrolysis and Biuret Formation

2.4 Concentration & Prilling Section

2.4.1 Vacuum Concentrator (U-FA202) and Heater of Vacuum

Concentrator (U-EA201)
2.4.2 Final Concentrator (U-EA202) and Final Separator (U-FA203)
2.4.3 Biuret Formation
2.4.4 Prilling Tower (U-IA301)

2.5 Recovery Section

2.5.1 LP Absorber (U-EA402)

2.5.2 HP Absorber System (U-EA401)
2.5.3 Principle of Vapor-Liquid Equilibrium in Recovery Section
2.5.4 Solidification Temperature

2.6 Process Condensate Treatment Section

2.6.1 Condensate from Concentration Section

2.6.2 Urea Hydrolyzer (U-DA502)

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SECTION 2. PROCESS AND OPERATING PRINCIPLES

2.1 General

The plant is designed to produce 3,850 MTPD of prilled urea with high-energy efficiency using
ACES 21® Process.

The Urea plant can be divided into seven sections, namely Ammonia and CO 2 Compression,
Synthesis, Purification, Concentration, Recovery, Process Condensate Treatment Sections
and Prilling Section. The relation between respective sections is illustrated as block flow
diagram of Fig. 2-1.

Fig.2-1 Block Flow Diagram of Urea Process

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2.2 Synthesis Section

2.2.1 Reactor (U-DC101)

Urea is produced by a highly exothermic reaction of NH 3 and CO 2 to form ammonium

carbamate (hereinafter referred to as carbamate) followed by slightly endothermic
dehydration of the carbamate to form urea. Chemical reaction taking place in Reactor
(U-DC101) is in following two stages:

(a) Carbamate formation

2NH 3 + CO 2 → NH 2 COONH 4 + 157.5 kJ

(b) Dehydration

NH 2 COONH 4 → NH 2 CONH 2 + H 2 O - 26.4 kJ

The reactions are reversible. The principal variables affecting the reaction are temperature,
pressure, feed composition and retention time.

In consideration of after mentioned conditions, operating temperature of 182°C, H 2 O/CO 2

molar ratio of 0.58, depending on operating mode, NH 3 /CO 2 molar ratio of 3.7 and
pressure of 155 kg/cm2G are selected for this plant and under these conditions CO 2
conversion is 63%.

CO 2 Conversion, NH 3 /CO 2 and H 2 O/CO 2 molar ratio are defined as

following formula.

CO 2 Conv. [%] = Urea [mol%] / (CO 2 + Urea) [mol%] x 100

NH 3 /CO 2 [mol/mol] = (Urea x 2 + NH 3 ) [mol%] / (CO 2 + Urea) [mol%]
H 2 O/CO 2 [mol/mol] = (H 2 O - Urea) [mol%] / (CO 2 + Urea) [mol%]

(1) Effect of the Purity of Raw Materials

(a) Liquid NH 3

So far as raw materials are concerned, liquid NH 3 does not differ much in quality in
any NH 3 synthesis process, and more than 99.9 wt% purity is expected. If the purity
cannot be maintained, the following unfavorable effects may happen:

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- Increase of the load for Ammonia Feed Pump (U-GA101).

- Decrease of CO 2 conversion in Reactor (U-DC101) due to increase of water

recycle.

(b) CO 2

As CO 2 fed to the Urea plant is by-product of ammonia synthesis, purity of CO 2 is

changeable according to the CO 2 removal/stripping process. CO 2 of low purity
causes the following unfavorable effects.

- Increase of the load for CO 2 Compressor (U-GB101) and its power consumption.

- Increase of inert gas rate, which results in lower CO 2 conversion in Reactor

(U-DC101), more steam consumption, and more NH 3 vent to atmosphere.

- More hydrogen leak in CO 2 , which results in overloading of Dehydrogen Column

(U-DC151) and finally forming explosive gas mixture in Synthesis Section.

(2) Effect of Pressure

The equilibrium pressure in Reactor (U-DC101) is naturally determined according to the

operating temperature and molar ratio of CO 2 to liquid NH 3 . When Reactor (U-DC101) is
operated below the equilibrium pressure, conversion of CO 2 to urea decreases
remarkably. However, even if Reactor (U-DC101) is operated higher than the equilibrium
pressure, conversion ratio would hardly increase in spite of the higher operating
pressure.

Equilibrium pressure at the equilibrium state of urea synthesis depends on NH 3 /CO 2

molar ratio, H 2 O/CO 2 molar ratio and temperature. Equilibrium pressure cannot be
easily expressed as a function of the above conditions. The effect of NH 3 /CO 2 molar
ratio and temperature on the equilibrium pressure is shown in Fig. 2-2.

On the other hand, the higher operation pressure decreases the stripping efficiency and
requires higher operation temperature in Stripper (U-DA101) to decompose unconverted
materials in the effluent from Reactor (U-DC101), resulting in increase of urea hydrolysis
and biuret formation due to high temperature.

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500
H2O/CO2 = 0.6
220oC

400
EQUILIBRIUM PRESSURE [kg/cm2G]

210oC
300

200oC
200

190oC

100 180oC

170oC

2 3 4 5

NH3/CO2 MOL RATIO [-]

Fig. 2-2 Effect of Excess NH 3 and Temperature on Equilibrium Pressure

(3) Effect of Temperature

The equilibrium conversion has its maximum value at a temperature, which lies between
190 and 195°C when NH 3 /CO 2 molar ratio is about 3.7. For instance, at condition of
NH 3 /CO 2 molar ratio being 3.7, CO 2 conversion ratio is as follows:

Temp. (°C) 170 180 190 200 210

CO 2 Conversion (%) 66.7 67.9 69.0 69.1 67.2

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Conversion mentioned above table is based on H 2 O/CO 2 molar ratio is 0.58.

As mentioned above rather higher operating temperature increases CO 2 conversion

ratio and these results in decreasing utilities consumption and the plant construction
cost.

However, on the other hand, high operating temperature of Reactor (U-DC101)

increases corrosion rate of its construction material, and also raises the equilibrium
pressure. Thus, the optimum temperature should be determined in consideration of
these factors.

The total heat balance around Reactor (U-DC101) is controlled by heat supply from
No.1, No.2 and No.3 Ammonia Preheater (U-EA102, U-EA106, U-EA103).

(4) Effect of Excess NH 3

The formation of urea is a reaction from one mole of CO 2 and two moles of NH 3 .
However, at this theoretical molar ratio, equilibrium CO 2 conversion to urea is quite low.
For instance, at 180°C, it reaches only 57% (no water is contained)

To increase the conversion ratio, it is required to feed excess NH 3 above the theoretical
amount.

Assuming temperature at 180°C without any water content, conversion ratio varies
according to NH 3 excess % as follows:

Excess NH 3 (%) 150 160 180 200 220

CO 2 Conversion (%) 71.2 73.3 76.8 79.6 82.1

As mentioned above, conversion ratio increases according to the excess amount of NH 3 .

Therefore, in order to increase conversion ratio, it is required to feed certain excess NH 3 .
However, on the contrary, it requires larger sized equipment for recovering the excess
NH 3 and higher synthesis pressure increase.

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(5) Effect of Water

Taking temperature at 180°C and excess NH 3 185%, the equilibrium conversion ratio
changes according to the molar ratio of water to carbon dioxide (H 2 O/CO 2 ) as follows:

H 2 O/CO 2 (molar ratio) 0.1 0.3 0.5 0.7 0.9

CO 2 conversion (%) 75.8 72.5 69.4 66.5 63.8

Effect of water is remarkable as shown above. Water fed into Reactor (U-DC101) is
contained in carbamate solution along with unconverted NH 3 and CO 2 .

Thus, to achieve high conversion ratio, it is required to increase concentration of CO 2

and NH 3 in recycle solution. On the other hand, solidifying temperature of the solution
rises. Therefore, as the concentration becomes higher, special attention should be paid
for design and operation taking possible clogging in piping, instrument and equipment
due to carbamate crystallization into consideration.

(6) Equilibrium Conversion to Urea

The effects of temperature, excess NH 3 molar ratio and H 2 O/CO 2 molar ratio on urea
synthesis are explained before. Equilibrium conversion to urea is also explained with
figure by Frejacques and our experimental data (Fig.2-3).

In commercial plants, the equilibrium conversion of CO 2 to urea is higher than that

shown by Frejacques. To confirm this, laboratory test was carried out using a batch
autoclave.

This test showed unexpectedly equilibrium conversion reached maximum value at a

certain temperature. Therefore, there exists an optimum operating temperature for
Reactor (U-DC101). The equilibrium conversion is higher than that by Frejacques by 5 ~
10% in the commercial temperature range as expected. Also, it is lower at a higher
temperature than that which gives the maximum conversion.

As shown in Fig. 2-3, the conversion falls steeply above 200°C. Also from Fig. 2-3, the
effect of H 2 O/CO 2 molar ratio on the conversion is almost linear. In this test, these
results were obtained by analyzing liquid phase only.

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Fig. 2-3 Effect of Temperature on Conversion Equilibrium

Fig.2-3 is made based on NH 3 /CO 2 molar ratio = 4.0.

Previous reports from batch type autoclave tests have shown that there is a maximum
conversion at a certain temperature, and the interpretation for this phenomenon was in

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relationship of temperature-loading density conversion that, at higher temperature, more

NH 3 and CO 2 transfer to the gas phase. Thus, the apparent conversion with respect to
the CO 2 charged has the maximum point even though conversion increases with
temperature.

Differing from conventional methods, the sampling was done directly from the liquid
phase and so that equilibrium conversion derived from these data is not affected by the
density.

There may be various theoretical interpretations for this maximum conversion. As the
first interpretations, there exists a dissociation phase wherein area is formed carbamate
as shown following equation.

K1
Carbamate (Sol'n) → 2NH 3 (Sol'n) + CO 2 (Sol'n) --- (1)

K2
Carbamate (Sol'n) → Urea (Sol'n) + H 2 O(Sol'n) --- (2)

So, the equilibrium conversion to urea depends on the balance between Equations (1)
and (2). If the dissociation equilibrium constant K1 varies more than K2, the overall
equilibrium constant K will be governed by K1 above a certain temperature. As a result,
there will appear a maximum conversion. Fig. 2-4 and 2-5 explain this. With this
assumption, considerable amounts of dissociated carbamate may exist at the exit
temperature of Reactor (U-DC101). This causes difficulty in explaining the heat balance
in Reactor (U-DC101).

It is also possible to assume that at a certain temperature, the sign of the reaction heat
for Equation (2) changes from minus to plus. In other words, the equilibrium conversion
reaches a maximum point where the heat of reaction for Equation (2) is zero.

Presently it cannot be concluded which is the correct interpretation, since satisfactory

testing methods are still difficult to establish.

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KOverall K1
EQUILIBRIUM CONSTANT

K2

K2 Controlling Zone K1 Controlling Zone

TEMPERATURE
Fig. 2-4 Temperature vs. Equilibrium Constant
CONVERSION EQUILIBRIUM

TMAX
TEMPERATURE
Fig. 2-5 Temperature vs. Conversion Equilibrium

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(7) Effect of Retention Time

We have mentioned about the effect of temperature on the synthesis reaction. The
volume of Reactor (U-DC101) or retention time is also determined by synthesis
temperature and pressure. In other words, at the lower temperature and pressure, the
longer retention time is required. When the operating pressure is too close to the
equilibrium pressure, the quantity of gas left in Reactor (U-DC101) increases, which
decreases process efficiency.

To minimize the retention time, the installation of baffle plates in Reactor (U-DC101) is
effective at the lower operation pressure by avoiding back mixing of the synthesis
solution. Fig. 2-6 shows a typical approach to equilibrium profile in Reactor (U-DC101).
ACES® 21 Process selects retention time in reactor for 20 minutes.

100

184oC
APPROACH FACTOR [%]

90

183oC
80

181oC

70

60

50

REACTOR REACTOR
BOTTOM TOP

Fig. 2-6 Typical Approach to Equilibrium Profile in Reactor

Approach Factor [%] = Actual Conversion / Equilibrium Conversion x 100

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2.2.2 Stripper (U-DA101)

Stripper (U-DA101) separates excess NH 3 and decomposes unconverted ammonium

carbamate from the urea synthesis solution by steam heating and CO 2 stripping under the
substantially same operation pressure as that of Reactor (U-DC101). The decomposition
reaction of ammonium carbamate is expressed by the following equation:

NH 2 COONH 4 (Ammonium Carbamate) → CO 2 + 2NH 3

During the decomposition and stripping process in Stripper (U-DA101), urea hydrolysis
reaction becomes an important factor, which determines the efficiency of urea synthesis.
The urea hydrolysis reaction is expressed by the following equation:

NH 2 CONH 2 (Urea) + H 2 O → CO 2 + 2NH 3

Since the hydrolysis consumes urea, which is the desired product, conditions are to be
closely controlled to minimize loss of product. The hydrolysis is favored by high
temperature, low pressure and long residence time. Stripper (U-DA101) is designed and
operation conditions are therefore carefully selected to minimize the hydrolysis in order to
maintain high yield of urea.

Biuret formation is another factor to be considered for Stripper (U-DA101) design and
operation. At low partial pressure of NH 3 and temperature above 110°C, urea converts to
form NH 3 and biuret as shown by the overall reaction below.

2HN 2 COHN 2 (Urea)→ NH 2 CONHCONH 2 (Biuret) + NH 3

The reaction is reversible. The principal variables affecting the reaction are temperature,
NH 3 concentration and residence time.

The rate at which biuret is produced in molten urea, and in concentrated urea solution, with
low NH 3 concentration, is very rapid. But in the synthesis step, an excess of NH 3 helps to
keep the biuret content low.

Low biuret content not exceeding 1.0 wt% is recommended for fertilizer grade urea. This is
particularly important in case of foliar applications of fertilizer where high biuret content can
cause crop damage. By judicious design and process control of the processing steps, the
biuret content in prilled urea product from Prilling Section in this plant is kept under 0.8
wt%.

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Influential factors on Stripper (U-DA101) performance are mainly operation pressure,

steam pressure and composition of urea synthesis solution.

(1) Effect of Operating Pressure

The high operation pressure results in the higher residual NH 3 content in Stripper
(U-DA101) effluent.

The effect of pressure is shown in Fig. 2-7.

15

160 kg/cm2G
14 155 kg/cm2G
RESIDUAL NH3 [wt%]

13

12

11 150 kg/cm2G

Operation Range
10
16 17 18 19 20 21 22 23
STEAM PRESSURE [kg/cm2G]

Fig. 2-7 Effect of Pressure on Stripper

(2) Effect of Steam Pressure

The steam pressure in Stripper (U-DA101) shell can be adjusted in the range of 18 – 20
kg/cm2G depending on the loading to Stripper (U-DA101) to maintain good stripping
efficiency (The effect of steam pressure is shown in Fig. 2-7), simultaneously avoiding
excessive urea hydrolysis and biuret formation in Stripper (U-DA101).

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In this plant, the pressure of extracted steam from Turbine for CO 2 Compressor
(U-GT101) limits the steam pressure for Stripper (U-DA101) at around 21 kg/cm2G
maximum. The steam pressure can be adjusted, monitoring residual NH 3 and CO 2
content in Stripper (U-DA101) effluent solution.

Lower steam pressure reduces heat supply to tube side, lowering stripping efficiency. If
heat supply is insufficient, excessive amount of NH 3 and CO 2 remains in the Stripper
(U-DA101) effluent as carbamate, so that the loading of Recovery Section increases. As
the result, more water is needed in Recovery Section to absorb the excessive unreacted
material as ammonium carbamate solution. Since water restrains CO 2 conversion to
urea in Reactor (U-DC101), unreacted material in urea synthesis solution should be
separated in Stripper (U-DA101) as much as possible. The lower limit of the steam
pressure is determined by the capacity of downstream Purification and Recovery
Sections.

In addition, the steam generation rate in Carbamate Condenser (U-EA101) decreases

due to insufficient stripping rate, resulting in some increase of steam consumption in
Urea plant.

The steam pressure of Stripper (U-DA101) shell is selected through optimization

between urea hydrolysis rate and concentration of residual NH 3 . If the steam pressure is
controlled at the optimum level, the NH 3 content in Stripper (U-DA101) effluent will be 12
- 13% by weight under normal operating condition.

(3) Effect of Composition of Urea Synthesis Solution

The stripping efficiency is affected by the composition of urea synthesis solution. The
high yield synthesis solution, i.e. high CO 2 converted solution, promotes high stripping
efficiency, resulting in the less steam demand in Urea plant. Therefore, optimum control
of NH 3 /CO 2 molar ratio, H 2 O/CO 2 molar ratio and temperature in Reactor (U-DC101) is
important to attain high stripping efficiency in Stripper (U-DA101).

(4) Temperature of Solution Leaving Stripper

The temperature of the solution-leaving Stripper (U-DA101) depends on various factors

but it is expected to be between 170°C and 180°C in normal operation. The higher
temperature indicates that stripping efficiency is not high and high residual NH 3 is
contained in the solution-leaving Stripper (U-DA101).

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(5) Level in Stripper (U-DA101)

Generally speaking, liquid level in the bottom of Stripper (U-DA101) should be kept as
low as possible. Higher liquid level increases the retention time of the urea solution in the
bottom, resulting in increase of urea hydrolysis and biuret formation.

If the liquid level is too low, the possible breakthrough of CO 2 gas to downstream
Purification and Recovery Sections may happen, resulting in rapid pressure increase in
Purification and Recovery Sections.

2.2.3 Carbamate Condenser (U-EA101)

The overhead gaseous mixture from Stripper (U-DA101) is introduced to the bottom of
Carbamate Condenser (U-EA101), where the gaseous mixture is condensed and
absorbed into the absorbent solution to form carbamate and subsequently urea is formed
by dehydration of the carbamate in the shell side.

The heat formed in Carbamate Condenser (U-EA101) by carbamate formation and NH 3

condensation is utilized to generate low-pressure steam in the tube side. The operation
pressure is substantially same as urea synthesis pressure.

The pressure of steam generated in tube side of Carbamate Condenser (U-EA101) is so

adjusted that the top temperature (solution temperature leaving Carbamate Condenser
(U-EA101)) becomes around 180 °C. The pressure of the generated steam is expected to
be 5 kg/cm2G at 100% load normal operation.

Carbamate Condenser (U-EA101) is so operated that N/C ratio of 2.9, which gives
minimum vapor pressure on the urea synthesis solution. Fig. 2-8 shows vapor pressure of
urea synthesis solution vs. N/C ratio in Carbamate Condenser (U-EA101).

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180
VAPOR PRESSURE [kg/cm2G]

Temp. 180oC
170 H/C 0.65

160
Designed NH3/CO2 value is 2.9.
Operation range is around 2.9 - 3.0.
150

140

130
2.2 2.4 2.6 2.8 3.0 3.2 3.4 3.6
NH3/CO2 [mol/mol]
Fig. 2-8 Vapor Pressure vs. N/C Ratio in Carbamate Condenser

In Carbamate Condenser (U-EA101), sufficient residence time (about 20 min) in shell side
allows urea synthesis reaction following the carbamate formation reaction. Fig.2-9 shows a
typical profile of approach to equilibrium conversion (%) in Carbamate Condenser
(U-EA101).

90
80
184oC
70
APPROACH FACTOR [%]

60
182oC
50 176oC
40

30

20

10
0
CONDENSER CONDENSER
BOTTOM TOP

Fig. 2-9 Typical Approach to Equilibrium Profile in Carbamate Condenser

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2.3 Purification Section

The products of the synthesis reaction consist of urea, biuret, ammonium carbamate, water
and excess NH 3 . Subsequent processing is required to separate urea from reaction products.
In general, the processing proceeds in the following manner: Ammonium carbamate, excess
NH 3 and some water are removed by application of heat at reduced pressure levels.
Ammonium carbamate is decomposed to NH 3 and CO 2 gases.

NH 2 COONH 4 (Ammonium carbamate) → CO 2 + 2NH 3

Decomposition is usually achieved at temperatures from 120°C to 165°C. Decreasing pressure

favors decomposition, as does increasing temperature.

During decomposition, hydrolysis of urea becomes an important factor. Hydrolysis proceeds as

indicated by the following reaction:

NH 2 CONH 2 (Urea) + H 2 O → CO 2 + 2NH 3

Since hydrolysis consumes urea, which is the desired product, conditions are to be closely
controlled to minimize loss of product. Hydrolysis is favored by high temperature, low pressure
and long residence time. Purification equipment and conditions of operation are therefore
carefully selected to minimize these effects to achieve high yield of urea. Biuret formation is
another factor to be considered both in purification and finishing processes. At low partial
pressure of NH 3 and temperature above 90°C, urea converts to form NH 3 and biuret as in the
overall reaction below.

2NH 2 CONH 2 (Urea) → NH 2 CONHCONH 2 (Biuret) + NH 3

The reaction is reversible, and the principal variables affecting the reaction are temperature,
NH 3 concentration and residence time.

The rate at which biuret is produced in molten urea, and in concentrated urea solution, with low
NH 3 concentration, is very rapid. But in the synthesis step, an excess of NH 3 helps to keep the
biuret content low.

Two decomposition steps, at 16.5 kg/cm2G and at 2.6 kg/cm2G are applied to remove
ammonium carbamate and excess NH 3 from urea solution, before being fed to Concentration

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Section. The concentration of the urea solution at the outlet of HP Decomposer (U-DA201) is
60.1 wt%, the outlet of LP Decomposer (U-DA202) is 64.6 wt% and the outlet of Flash
Separator (U-FA205) is about 70 wt%.

Every decomposition step has its corresponding absorber(s) in Recovery Section, and the
respective pressure is controlled in Recovery Section. The two pressure levels are carefully
selected in order to maximize heat recovery and thus to minimize overall steam requirement
without losing operability. The effect of operating condition changes is explained hereinafter.

2.3.1 HP Decomposer (U-DA201)

In HP Decomposer (U-DA201), NH 3 and CO 2 gases formed by decomposing ammonium

carbamate and evaporating excess NH 3 are separated. Heat to decompose ammonium
carbamate and evaporates excess NH 3 is supplied by condensation of steam.

The effects of pressure and temperature on the liquid composition are as follows:

(1) Effect of Pressure

At HP Decomposer (U-DA201), the amount of NH 3 and CO 2 in the effluent should be as

little as possible to reduce the loading on the downstream equipment and to simplify
those systems. In case that the amount of NH 3 and CO 2 in liquid increases, equilibrium
temperature at LP Absorber (U-EA402) decreases and more water should be fed to the
Recovery Section, which results in lowering CO 2 conversion. In this viewpoint, lower
operating pressure of HD Decomposer is favorable, however certain minimum pressure
also exists to condense NH 3 and CO 2 in shell side of HP Absorber (U-EA401) after
sufficient heat recovery to evaporate water in Heater of Vacuum Concentrator
(U-EA201). Optimum operating pressure at 16.5 kg/cm2G is selected considering the
above-mentioned factors.

(2) Effect of Temperature

Generally speaking, high temperature is favored for decomposition of carbamate.

However, as high temperature accelerates corrosion, biuret formation and urea
hydrolysis, optimum-operating temperature should be selected. The operating
temperature of HP Decomposer (U-DA201) is controlled at 152 °C at the bottom outlet.

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2.3.2 LP Decomposer (U-DA202)

The effects of pressure and temperature on the liquid composition are as follows:

(1) Effect of Pressure

In order to remove NH 3 and CO 2 from the solution in LP Decomposer (U-DA202) as

much as possible, it should be operated at as low pressure as possible.

However optimum operating pressure of LP Decomposer (U-DA202) should be selected

considering the operation of LP Absorber (U-EA402) and the fact that the solution is
more influenced by hydrolysis than in HP Decomposer (U-DA201) because the quantity
of NH 3 and CO 2 is far less in LP Decomposer (U-DA202). The operation pressure is thus
selected at 2.6 kg/cm2G.

(2) Effect of Temperature

Operating temperature is to be determined to minimize residual NH 3 in the effluent but

considering the effect on urea hydrolysis and biuret formation also. LP Decomposer
(U-DA202) is operated at 138 °C at heater outlet of LP Decomposer (U-DA202) middle
section.

(3) Effect of CO 2 Stripping

The use of CO 2 stripping in LP Decomposer (U-DA202) has following advantages:

1) Efficient and complete separation of residual NH 3 and CO 2 from the urea solution
without further heating.

2) Reduced demand of absorbent water for the absorber and condenser as CO 2 fed
for stripping in LP Decomposer (U-DA202) reacts with NH 3 to form ammonium
carbamate / carbonate in LP Absorber (U-EA402), which lowers the vapor pressure
of NH 3 .

3) Resultant low water content in the recycle carbamate solution to Reactor

(U-DC101).

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2.3.3 Urea Hydrolysis and Biuret Formation

Hydrolysis rate at typical operating conditions of HP Decomposer (U-DA201) and LP

Decomposer (U-DA202) are shown in Fig. 2-10 & Fig. 2-11.

4
For HP Decomposer
<Pressure : 16 Kg/cm2>
3.5
HYDROLYSIS RATE [%] (INLET UREA BASE)

2.5

1.5

0.5

0
0 5 10 15
RESIDENCE TIME [min]
Fig. 2-10 Hydrolysis Rate (HP Decomposer)

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3
For LP Decomposer
<Pressure : 2 Kg/cm2>
2.5
HYDROLYSIS RATE [%] (INLET UREA BASE)

1.5

0.5

0
0 2 4 6 8
RESIDENCE TIME [min]
Fig. 2-11 Hydrolysis Rate (LP Decomposer)

As well explained, reaction rate of biuret formation is promoted with temperature and
residence time but decreases with pressure.

Equipment in Purification Section and operating conditions are carefully selected

considering those effects on biuret formation and urea hydrolysis reactions.

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2.4 Concentration & Prilling Section

The urea solution from the previous Purification Section is concentrated to 99.7 wt% urea
solution and then send to Prilling Section.

At first, the urea solution is concentrated up to 96 wt% (including free NH 3 and biuret) in
Vacuum Concentrator (U-FA202) by utilizing condensation and absorption heat of the top gas
from the HP Decomposer (U-DA201). Finally, the urea concentration is increased to 99.7 wt%
in Final Concentrator (U-EA202) and Final Separator (U-FA203) as molten urea to be fed to
Prilling Tower (U-IA301).

The molten urea is distributed into Prilling Tower (U-IA301) by Prilling Basket (U-FJ302).

2.4.1 Vacuum Concentrator (U-FA202) and Heater of Vacuum Concentrator (U-EA201)

This stage consists of Heater of Vacuum Concentrator (U-EA201) and Vacuum

Concentrator (U-FA202).

Operating pressure and temperature shall be carefully selected so that operating condition
will lead urea concentration more than 96 wt%. The normal operating range of the pressure
is 210 - 290 mmHgA and the normal operating range of the temperature is 130 - 136°C.

If the pressure in Vacuum Concentrator (U-FA202) rises to over 290 mmHgA and/or the
temperature falls to less than 130 ºC, water evaporation is disturbed resulting in insufficient
concentration of urea, i.e. less than 96 wt% leading to overload of the Final Separator
(U-FA203).

Lower operating pressure promotes water evaporation resulting in higher concentration of

urea.

Higher temperature leads higher concentration of urea, however excessively high

temperature increases the biuret content and may result in off-spec product.

Fig. 2-12 shows the vapor pressure of aqueous urea solution.

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Fig. 2-12 Vapor Pressure of Aqueous Urea

2.4.2 Final Concentrator (U-EA202) and Final Separator (U-FA203)

This stage consists of Final Concentrator (U-EA202) and Final Separator (U-FA203).

Its operating pressure must be below 30 mmHgA. If it is higher than 30 mmHgA, water
evaporation will be insufficient and the melt will have high moisture content.

The normal operating range of the temperature is 138 ~ 140°C. If the temperature is too
low, the crystallization of urea will occur (solidification point: 133°C) and cause the
chocking trouble of the molten urea line. If the temperature is too high, the increase of the
biuret content will be too great.

In order to minimize the total biuret increase in the vacuum evaporation unit, the optimum
operating condition especially for the first stage (U-EA201 and U-FA202) should be
searched in actual operation.

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2.4.3 Biuret Formation

Biuret formation not only in Final Concentrator (U-EA202) but also downstream of Final
Concentrator (U-FA203) should be considered. The effects of pressure and temperature
are already stated.

In addition, there is another important factor namely, residence time. For instance,
relationship between biuret formation rate and residence time under atmospheric pressure
and temperature are shown in Fig. 2-13. Biuret formation is greatly affected by residence
time. In this plant, the system is designed to achieve the biuret formation minimum and the
plant should be operated so as to keep the residence time as short as possible.

Fig. 2-13 Relation Between Temp. and Time on Rate of Formation for Biuret in Molten Urea
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2.4.4 Prilling Tower (U-IA301)

The molten urea fed to Prilling Tower (U-IA301) is sprayed as urea droplets by Prilling
Basket (U-FJ302A,B). The urea droplets are cooled and solidified by contacting the air
rising through Prilling Tower (U-IA301), which is driven by natural draft force. The prills are
collected by Scraper (U-JJ301). Urea Lump Screen (U-FD301) separates oversize prills
from the product at the bottom of Prilling Tower (U-IA301). These oversize prills are
dissolved in Dissolving Tank (U-FA302). The urea prills thus produced are sent to outside
of Battery Limit after weighed by Belt Scale (U-JW301).

2.5 Recovery Section

The basic differences between various urea processes, relate to the method of handling of the
unreacted NH 3 and CO 2 gases from the decomposers. It is not practical to compress the NH 3
and CO 2 gas mixture and return them to Reactor (U-DC101), because compression causes a
recombination of NH 3 and CO 2 to solid ammonium carbamate, clogging the compressor. The
methods for recycling the unreacted gases can be classified into two types:

- Separate and Recycle as Gas

- Recycle in Solution, or Slurry

In ACES 21® Process, the solution recycle process is used. The NH 3 -CO 2 mixture gases from
decomposers are absorbed in water and carbamate solution in the respective absorbers, and
recycled back to Carbamate Condenser (U-EA101) and Reactor (U-DC101).

2.5.1 LP Absorber (U-EA402)

Operating conditions are decided by the condition that NH 3 and CO 2 gas from LP
Decomposer (U-DA202) is completely absorbed by the solution from upper part of
Washing Column (U-DA401).

Judging from the effects of temperature and pressure, solubility of NH 3 and CO 2 increases,
and the pressure increases. CO 2 gas is introduced to increase the absorption capacity,
because CO 2 reacts with NH 3 to form ammonium carbamate/carbonate, which lowers the
partial vapor pressure of NH 3 . As a consequence of this CO 2 injection, low water content in
the recycle carbamate solution to Reactor (U-DC101) can be achieved.

The temperature should be kept lower than equilibrium temperature and the optimum
temperature 45 °C is selected considering solidification temperature and the allowance to

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meet fluctuation of operation.

2.5.2 HP Absorber System (U-EA401)

The high pressure absorber system consists of HP Absorber (U-EA401) and Washing
Column (U-DA401).

NH 3 and CO 2 gas from HP Decomposer (U-DA201) is absorbed in shell side of Heater of

Vacuum Concentrator (U-EA201) and then blow into HP Absorber (U-EA401). Around 70
wt% of mixed gas is absorbed in Heater of Vacuum Concentrator Evaporator (U-EA201)
and HP Absorber (U-EA401). The rest of NH 3 and CO 2 are absorbed in bottom part of
Washing Column (U-DA401).

The operating pressure of HP Absorber system is decided to 15.0 kg/cm2G at the top of
Washing Colum (U-DA401) considering the operating pressure of HP Decomposer
(U-DA201). The operating temperature of HP Absorber (U-EA401) is 106 °C. The outlet
gas from HP Absorber (U-EA401) is fed to Washing Column (U-DA401). Washing Column
(U-DA401) consists of bottom cooling part and two packing beds. In the bottom cooling part,
NH 3 and CO 2 gas is absorbed in the solution coming from the packing bed of Washing
Column (U-DA401). The operating temperature of bottom part is 70 ºC.

NH 3 and CO 2 gas are absorbed sequentially in two packing beds in Washing Column
(U-DA401) by LP Absorber (U-EA402) solution and process condensate from Process
Condensate Tank (U-FA501) respectively.

2.5.3 Principle of Vapor-Liquid Equilibrium in Recovery Section

Each pure liquid has a peculiar vapor pressure based on its temperature. The vapor
pressure of a solution will be changed depending on its temperature and composition. The
vapor pressure of Urea-Ammonia-Carbamate-Water system handled in the Urea plant is
shown as follows:

Pt = pNH 3 + pCO 2 + pH 2 O + pUrea

Where:
Pt : Total Pressure
p : Partial Pressure

Each partial pressure varies depending on the composition of the solution even at the

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same temperature. In general, the total pressure can be reduced by increasing water
content in the solution or lowering the temperature.

In the absorbers, when the pressure of the gas phase is higher than the vapor pressure of
the solution having a certain composition, absorption will take place and the composition of
the solution tends to move to a composition having a vapor pressure equal to the pressure
of the gas phase.

The ultimate stage of this condition is equilibrium, therefore, the equilibrium pressure is
decreased by lowering temperature. However, it should be noticed that there is a minimum
operable temperature due to solidification point of the solution.

Vapor-liquid equilibrium diagrams of the system NH 3 -CO 2 -H 2 O in the wide range

(concerning Recovery Section) is attached hereinafter. Refer to Fig. 2-16 - 2-18.

40

Pressure : 0.6 kg/cm2A

35
20oC
30 25oC

30oC
25 35oC
NH3 [wt%]

40oC
45oC
20 50oC
55oC
60oC
15

10

0
5 10 15 20 25 30
CO2 [wt%]

Fig. 2-16 NH 3 -CO 2 -H 2 O Vapor-Liquid Equilibrium (Pressure 0.6 kg/cm2A)

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45 Pressure : 1.5 kg/cm2A

40
35oC
35 40oC
45oC
NH3 [wt%]

30 50oC
55oC
25

20

15

10

0
5 10 15 20 25 30 35 40
CO2 [wt%]
Fig. 2-17 NH 3 -CO 2 -H 2 O Vapor-Liquid Equilibrium (Pressure 1.5 kg/cm2A)

45 90oC
95oC
40 100oC
105oC
35

30 Pressure : 16 kg/cm2A
NH3 [wt%]

25

20

15

10

0
5 10 15 20 25 30 35 40

CO2 [wt%]
Fig. 2-18 NH 3 -CO 2 -H 2 O Vapor-Liquid Equilibrium (Pressure 16 kg/cm2A)
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2.5.4 Solidification Temperature

The solution in absorbers is a mixed solution of NH 3 , carbamate and water.

At the designed temperature, the soluble amount of carbamate has a limit, therefore, when
carbamate concentration is increased too much at the temperature, solid carbamate will be
deposited at a certain concentration.

Solidification of carbamate and urea causes such critical troubles in plant operation,
especially in the Recovery Section as pumping failure and plugging.

Therefore, a proper amount of solvent should be fed into absorber so that the solidification
temperature is being kept always lower than the operating temperature.

This is one of the reasons why the CO 2 concentration in the solution of each absorber
should be checked periodically by field analysis.

Refer to Fig. 2-19.

NH4HCO3
NH4CO2NH2

NH3/CO2 (wt%)

Fig. 2-19 Salting-out Temperature and Equilibrium Pressure of NH 3 -CO 2 Solution

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2.6 Process Condensate Treatment Section

This plant is designed to minimize the pollution problems as possible. Every component that
has possibilities of pollution problem is completely recovered to the process. Major pollutants
from Urea plant are NH 3 and urea. If those pollutants are caught and recycled back to the
process, drainage can be reduced with additional merits that the raw material consumption,
especially NH 3 consumption per ton of product urea will be improved at the expense of slight
increase of utilities consumption.

Based on the above idea, the following pollution control systems have incorporated into this
plant.

In the urea synthesis, one mole of water is formed with one mole of urea. This by-product water
is separated in Concentration Section and used as absorbent in Recovery Section.

Major part of the water evaporated in Concentration Section entrains very small amount of urea
mist, NH 3 and CO 2 . This water vapor is condensed in the surface condensers, and the
condensate is used partly as the absorbent in Recovery Section and the remaining is treated in
this Process Condensate Treatment Section.

2.6.1 Condensate from Concentration Section

The NH 3 contained in process condensate is stripped by steam heating and the contained
small amount of urea is decomposed by hydrolysis.

The treated condensate from the lowest stage of upper part of Process Condensate
Stripper (U-DA501) is further treated in Urea Hydrolyzer (U-DA502) and lower part of
Process Condensate Stripper (U-DA501) to make clean effluent free of NH 3 and urea.

The overhead gas from Process Condensate Stripper (U-DA501) is sent to LP

Decomposer (U-DA202) for recovery of NH 3 and CO 2 and also as heat source of
decomposition in it. The heating steam flow rate for Process Condensate Stripper
(U-DA501) is controlled in order to satisfy the operating condition of LP Decomposer
(U-DA202).

2.6.2 Urea Hydrolyzer (U-DA502)

The solution from the lowest stage of upper part of Process Condensate Stripper
(U-DA501) which contains about 1.1 wt% urea is sent to Urea Hydrolyzer (U-DA502)

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through Preheater for Urea Hydrolyzer (U-EA505) to hydrolyze urea into NH 3 and CO 2 by
the following reaction.

NH 2 CONH 2 + H 2 O → 2NH 3 + CO 2

As mentioned already, this reaction is promoted by high temperature and long residence
time.

The optimum operating conditions of Urea Hydrolyzer (U-DA502) are selected in

considerations of our experimental results.

In this plant, operating conditions of Urea Hydrolyzer (U-DA502) are 210 °C, 23.0 kg/cm2G
at the bottom and residence time of 50 minutes respectively in order to remove the urea
less than 1 wt ppm.

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SECTION 3. PROCESS FEATURE AND DESCRIPTION

3.1 Process Feature

3.1.1 Specific Feature of ACES 21® Synthesis Loop

3.1.2 Lowest Energy Consumption Process
3.1.3 Plant Reliability and Operability
3.1.4 Complete Pollution Control
3.1.5 Advanced Duplex Stainless Steel DP28WTM

3.2 Process Description

3.3 Equipment List

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SECTION 3. PROCESS FEATURE AND DESCRIPTION

3.1 Process Feature

There is a long history behind the development of urea process technology. Broadly speaking
there have been two main routes to urea production, namely, the "solution recycle" and
"stripping" technologies. TOYO have been committed to the development of urea technology
for over 50 years and have introduced process such as Total Recycle A, B, C, C-improved, D,
and ACES Process. TOYO’s basic philosophies of development of urea technology have been
based on easy operability, high on-stream factor, less maintenance and low energy
consumption. Energy saving has been attained by maintaining high NH 3 /CO 2 molar ratio in
Reactor (U-DC101) and thus obtaining a high once through CO 2 conversion.

ACES 21® process is the latest one of the solution recycle and stripping technologies. The main
feature of this process is the application of original CO 2 stripping technology while maintaining
the basic advantages of the TOYO solution recycle processes such as high once-through CO 2
conversion and heat recovery at low temperature levels. In addition, the Reactor (U-DC101),
which is the largest and heaviest vessel in the Urea Plant and normally installed at a height of
20 ~ 22 meters in CO 2 stripping technology, is installed at ground level.

By this improvement, ACES 21® achieves not only low civil and erection costs, but also better
operability.

TOYO process offers further advantages such as

High Product Quality

No Explosion Problem

Less Effluent (No Pollution)

Above advantages will be discussed in detail in the later sections.

The ACES 21® process also provides an efficient means of revamping a conventional solution
recycle process plant. For example, TOYO's Total Recycle C-Improved Process plant can be
revamped - capacity can be increased to 150 % of original nameplate and a saving of 30 % can
be achieved in specific energy consumption per metric ton of product simply by adding a
Carbamate Condenser (U-EA101), Stripper (U-DA101) and HP Carbamate Ejector (U-EE101)

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to the Synthesis Section and utilizing the full volume of the existing Reactor (U-DC101)
installed at ground level. The existing NH 3 pump discharge pressure is high enough to drive the
solution and gas circulation in the Synthesis Loop by HP Carbamate Ejector (U-EE101). Since
HP vessels are not installed at elevated levels and the existing Reactor (U-DC101) is fully
re-utilized, investment costs are greatly reduced compared to applying conventional stripping
technologies.

3.1.1 Specific Feature of ACES 21® Synthesis Loop

(1) Combination of High One-pass CO 2 Conversion and Efficient CO 2 Stripping

Only a way to minimize the energy required for decomposition and separation of
unconverted materials is to combine the CO 2 stripping process with the high
once-through CO 2 conversion which is the main feature of the Solution Recycle
Process.

High one-pass CO 2 conversion achieved by NH 3 /CO 2 molar ratio of 3.7 in Reactor

(U-DC101) and 2.9 in Carbamate Condenser (U-EA101) has been the basic feature of
the TOYO Urea processes.

Reactor (U-DC101) and Carbamate Condenser (U-EA101) are operated under,

Pressure 155 kg/cm2G

Temperature for Reactor 182 °C
Temperature for Carbamate Condenser 180 °C
NH 3 /CO 2 molar ratio in Reactor 3.7 mol/mol
NH 3 /CO 2 molar ratio in Carbamate Condenser 2.9 mol/mol

Fig. 3-1 shows correlation among NH 3 /CO 2 molar ratio, equilibrium pressure and
equilibrium CO 2 conversion rate under fixed H 2 O/CO 2 molar ratio at 0.58.

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Fig. 3-1 Optimizing N/C Ratio in Carbamate Condenser (U-EA101) and Reactor (U-DC101)

Equilibrium vapor pressure reaches its lowest level at around a NH 3 /CO 2 molar ratio of 3,
this is in Carbamate Condenser (U-EA101). The Reactor (U-DC101) NH 3 /CO 2 molar
ratio should be as high as possible to maximize CO 2 conversion as far as its operating
pressure has appropriate excess pressure to that of equilibrium.

NH 3 /CO 2 molar ratio of 2.9 in Carbamate Condenser (U-EA101) reduces vapor

pressure, resulting in minimum vapor loss from Carbamate Condenser (U-EA101).

A higher NH 3 /CO 2 molar ratio in Reactor (U-DC101) than in Carbamate Condenser

(U-EA101) increases the CO 2 conversion, reducing the heat required for decomposition
of carbamate in Stripper (U-DA101). Since different levels of NH 3 /CO 2 molar ratio are
employed for Carbamate Condenser (U-EA101) and Reactor (U-DC101), the urea
synthesis reaction takes place in two stages as shown in Fig. 3-2.

Initially it was believed that CO 2 stripping of the synthesis solution having high NH 3 /CO 2
molar ratio was not very efficient. This is overcome by TOYO's proprietary design of
Stripper (U-DA101), where unconverted materials can be efficiently stripped out from

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high NH 3 /CO 2 molar ratio solution with CO 2 . The liquid from Reactor (U-DC101) is
evenly distributed to the falling film heater by means of a feed distributor. In order to
ensure a uniform falling film in the heater tubes, swirl tubes are provided on top of the
heating tubes. The swirl tubes play an important role in the uniform distribution of the
liquid and ensure a uniform formation of falling film in the heater tubes.

Fig. 3-2 Conversion vs. Residence Time

(2) Vertical Submerged Carbamate Condenser (U-EA101)

The Vertical Submerged Carbamate Condenser (VSCC) functions to:

(a) Condense NH 3 and CO 2 gas from the Stripper (U-DA101) to form ammonium
carbamate in the shell side;
(b) Synthesize urea by dehydration of ammonium carbamate in the shell side;
(c) Remove the reaction heat of ammonium carbamate formation by generating 5.0
kg/cm2G steam in boiler tubes

Advantages of the vertical submerged configuration of Carbamate Condenser

(U-EA101) are summarized as follows:

▅ High gas velocity, appropriate gas holds up and sufficient liquid depth in the
bubble column promote mass and heat transfer, resulting in 30% reduction of heat

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transfer area from original ACES carbamate condensers;

▅ The appropriate number of baffle plates distribute gas bubbles in the column
effectively without pressure loss;
▅ Vertical design inevitably requires smaller plot area.

Configuration of VSCC

Fig. 3-3 illustrates the configuration and the fluid flow pattern in VSCC. VSCC is
categorized into a kind of bubble column reactor with cooling tubes. VSCC consists of
the condensation-reaction part in the main cylindrical shell and the scrubbing part at
top. The condensation-reaction part has a tube bundle and baffle plates. A down flow
pipe connects the scrubbing part and the condensation-reaction part so as to feed
carbamate solution from the scrubbing part to the bottom chamber of the VSCC by
gravity. Mixed gas from the Stripper (U-DA101) is introduced and distributed into the
bottom compartment as small gas bubbles via a gas sparger. Carbamate solution is
also introduced to the bottom compartment from the scrubbing part via the down-pipe
as absorbent. From the bottom to the top of the condensation-reaction part, the mixed
gas bubbles rise through the bundle of boiler tubes and partially condense, contacting
with urea-carbamate solution. The condensation (carbamate formation) heat is
removed by the boiler tubes in which saturated boiler water is circulated by a
circulation pump. The shell side volume is sufficient to promote dehydration of
ammonium carbamate to form urea.

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GAS OUT

CARB. SOLUTION IN PACKED BED

SCRUBBING
GAS Flow PART
DOWN PIPE FROM SCRUBBING PART
LIQ. Flow
TO CONDENSATION & REACTION PART

U-TUBE BUNDLE
DOWN PIPE FOR
REACTION PRODUCT

CONDENSATION
& BAFFLE PLATES
REACTION
PART

UREA SYNTHESIS
NH3+CO2 GAS IN
SOLUTION OUT

LIQ. NH3 IN

BFW IN BFW + STEAM OUT

Fig. 3-3 Configuration of VSCC

Fig. 3-4 shows a result of a computational fluid dynamic (CFD) analysis for gas
bubbles and solution in a compartment of VSCC. The rising bubbles in the central tube
bundle area agitates the urea-carbamate solution to circulate between the space
among bristled boiler tubes and the surrounding open annular space near the interior
wall, giving high mass transfer between the gas bubbles and the absorbent
urea-carbamate solution and high heat transfer between the carbamate solution and
the boiler tubes.

The bubbles enter the compartment from holes provided among the tube holes on the
lower baffle plate, then rise in the space among the bristled tubes and finally gather
beneath the upper baffle plate to be re-distributed evenly as the form of small bubbles
while passing through holes on the baffle plate. Urea-carbamate solution enters a
compartment from an opening provided on each baffle plate, then circulates by being
agitated by the rising bubbles and exits to the next compartment through the next
opening provided on the next baffle plate. Such carbamate formation - heat removal -

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urea formation process cycle taking place in a compartment between two baffle plates
repeats compartment-by-compartment from bottom to top, achieving high CO 2
conversion to urea at the exit of VSCC and efficient heat recovery in VSCC. The
urea-carbamate solution leaving the top compartment on the top baffle plate is
extracted through a down-pipe to be fed to the HP Carbamate Ejector (U-EE101).

Fig. 3-4 CFD Analysis in VSCC

Mixed gas containing uncondensed ammonia and CO 2 entrained by inert is

introduced to the scrubbing part where the most of NH 3 and CO 2 is absorbed
adiabatically into carbamate solution recycled from the downstream middle pressure
section while contacting counter-currently in a packed bed. The mixed gas which is
rich with inert after scrubbing is sent to middle pressure section for further treatment.

Corrosion Prevention

A small amount of liquid ammonia is fed into a small chamber at the bottom in order to
dilute the corrosive carbamate solution. The dilution with ammonia reduces corrosion
rate drastically in the bottom chamber, in particular tube to tubesheet weld joint part
which is essential for safe operation and for prolonging the equipment lifetime. This
corrosion prevention technology has been patented by TOYO in major countries and
areas worldwide.

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Maintainability

Sufficient annular space for inspection and maintenance in the shell side is available
between the tube bundle and the interior wall of the shell so that inspection and
maintenance personnel can work and walk through. Tube thickness is precisely
measured for full length of all the tubes from tube side by eddy current technique.

As described in the previous sections, advantages of the ACES 21® process over
conventional processes are summarized below:

■ Less HP piping and construction materials owing to lower elevation layout, fewer
HP vessels and simplified Synthesis Loop;
■ Easier erection using commonly available construction equipment and
techniques owing to low elevation layout and fewer and smaller HP vessels;
■ Easier operation supported by forced circulation by HP Ejector, low elevation
layout and fewer HP equipment ;
■ Easier maintenance owing to low elevation layout and fewer HP equipment ;
■ Smaller sized HP vessels by combining the VSCC and high efficiency Reactor ;
■ Less energy consumption owing to optimized synthesis conditions and
proprietarily designed VSCC, Reactor and Stripper.

3.1.2 Lowest Energy Consumption Process

Energy efficiency of the ACES 21® Process is attained by the following facts.

(1) Minimum Net Steam Consumption

- High NH 3 /CO 2 molar ratio of 3.7 in Reactor (U-DA101) and 2.9 in Carbamate
Condenser (U-EA101) and Reaction temperature of 182 °C result in high
one-pass CO 2 conversion of 63% which reduces the steam requirement of
Stripper (U-DA101) to remove unconverted material.

- Vertical submerged type Carbamate Condenser (U-EA101) allows 5.0 kg/cm2G

steam generation.

(2) Maximum Heat Recovery

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- Heat recovery from condensation of Stripper (U-DA101) gas to generate 5.0

kg/cm2G steam.

- Utilization of condensation heat of HP Decomposer (U-DA201) top gas in Heater

of Vacuum Concentrator (U-EA201) to evaporate water from the urea solution at
Concentration Section.

- Utilization of sensible heat of steam condensate for heating in No.1 Ammonia

Preheater (U-EA102).

- Utilization of sensible and latent heat of the overhead gas of Process Condensate
Stripper (U-DA501) in LP Decomposer (U-DA202).

Fig. 3-5 shows overall heat recovery scheme incorporated in the ACES 21® Process.

SML STEAM

Fig. 3-5 Heat Integration Scheme in ACES 21® Process

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By combining the well-proven energy saving technologies mentioned above, the

ACES 21® Process has the lowest overall energy consumption for process use.

Among the proven processes today, the ACES 21® Process has established the
minimum steam import and net steam consumption.

3.1.3 Plant Reliability and Operability

(1) High On-stream Factor

Emergency shutdown results in a large production loss that should be prevented as

far as possible. However sometimes due to maintenance trouble and lack of raw
materials and utilities, the plant has unavoidably been forced to be shut down. But the
production loss can be minimized by a quick restart of the plant that is a very specific
feature of the ACES 21® Process.

When the plant has to be shut down for unforeseen reasons, the urea solution can be
blocked in the Synthesis Loop for periods of 48 hours. The high NH 3 /CO 2 molar ratio
results in low corrosiveness of the solution and the low solidification temperature and
thus enables the solution to be blocked in the Synthesis Loop. This feature enables
quick restart of the plant and thus minimizes production loss.

(2) Less Corrosion

In the Synthesis Loop, Stripper (U-DA101) is operated under most corrosive condition.

During the development of the ACES and ACES 21® process, TOYO was able to
identify the best corrosion-proof materials with Know-How suitable for the process
through its many experiences from actual plants and intensive research works.

TOYO is the pioneer in applying duplex stainless steels to Urea Plants. TOYO has
applied 25Cr-5Ni-2Mo to HP Decomposer (U-DA201) and Carbamate Feed Pump
(U-GA102) since 1970s, and then 25Cr-7Ni-3Mo to Stripper (U-DA101) since 1980s.
The biggest advantage of duplex stainless steel is the excellent passivation property
in urea-carbamate solution, which enhances reliability of equipment and enables to
reduce the passivation air. Considering further improvement potential of duplex
stainless steel, TOYO and Nippon Steel & Sumitomo Metal Corporation (NSSMC)
(former Sumitomo Metal Ind., Ltd. (SMI)) have jointly developed new duplex stainless

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steel DP28WTM for Urea Plant as the best matching Urea Plant material getting all the
feedbacks from long experience by TOYO and NSSMC.
Thus, it was decided to apply this duplex stainless steel material for Stripper
(U-DA102), which has been giving very satisfactory performance.

The amount of passivation air required for duplex stainless steel is the least. This
feature gives the advantage to Stripper (U-DA101) tubes where the oxygen content is
the least in the Synthesis Loop. In addition, these materials neither corrode nor erode
even when the tubes go dry due to mal-distribution of the liquid at very low plant load.

At each scheduled annual shutdown of the ACES Urea Plants since commissioning,
the conditions of the materials have been inspected in detail by TOYO's metallurgists.
The inspection result has confirmed that the materials used for the service showed
satisfactory corrosion resistance.

(3) Operation Flexibility

High NH 3 /CO 2 molar ratio results in not only high one-pass CO 2 conversion, less
corrosive characteristic but also higher operation flexibility of the Urea Plant. Even if
the NH 3 /CO 2 molar ratio changes a little, it does not affect Reactor (U-DC101)
operating conditions and gives rare chance of the plant upset.

The incorporation of High Pressure Decomposition and High Pressure Absorption

step, which are operated at 16.5 kg/cm2G, enables easier and more flexible operation
of the Synthesis Loop and stable operation of downstream low-pressure system. That
is, any change of composition in Stripper (U-DA101) outlet solution, especially
increase of residual NH 3 content, can be absorbed by HP Decomposer (U-DA201)
and HP Absorber (U-EA401) system.

As specially designed swirl tubes are installed at the heater tubes of Stripper
(U-DA101), distribution of the solution and formation of proper thin falling film can be
firmly attained even at low operation load. Thus, in Stripper (U-DA101), high stripping
efficiency is maintained in the wider range of plant load.

The duplex stainless steel applied to Stripper (U-DA101) tubes helps to attain the
stable operation in the wide range of the designed capacity because the dry condition
of the tubes surface does not promote corrosion problem.

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(4) Less Maintenance

Application of carefully selected suitable materials for the equipment and machines in
the Synthesis Section can realize less maintenance of the Urea Plant. DP28WTM
stainless steel applied for Carbamate Condenser (U-EA101) are suitable at relatively
low corrosive characteristic of high NH 3 /CO 2 molar ratio synthesis solution. DP28WTM
stainless steel for Stripper (U-DA101) has superior anti-corrosion characteristic in less
oxygen environment and is well proven.

3.1.4 Complete Pollution Control

Major pollutants from the Urea Plant are NH 3 and urea. If those pollutants are caught and
recycled back to the process in an efficient manner, the emission of pollutants into the
atmosphere and drainage can be reduced simultaneously. The raw material consumption,
especially NH 3 consumption, will be improved at the expense of slight increase in utilities
consumption.

Based on the above idea, TOYO has developed various pollution abatement technologies,
incorporated them into the commercial plants and met with good results.

(1) Emission Control

At normal operation, top gas from Washing Column (U-DA401) is major emission gas
in where NH 3 will accompany with inert gas. The quantity of NH 3 with inert gases is
low since the required quantity of passivation air is less owing to application of Duplex
Stainless Steel to Stripper (U-DA101).

(2) Effluent Control

The water vapor, which is separated at the Concentration Section and contains a
small amount of NH 3 and urea, is condensed in Surface Condensers.

A part of the condensate is utilized as absorbent for the Recovery Section. The rest is
fed into Process Condensate Stripper (U-DA501) where the NH 3 and CO 2 gas are
stripped out. The separated gas is sent to LP Decomposer (U-DA202) for recovery of
NH 3 , CO 2 and heat.

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After separation of NH 3 in upper part of Process Condensate Stripper (U-DA501), the

process condensate is introduced into Urea Hydrolyzer (U-DA502). In Urea
Hydrolyzer (U-DA502), urea is hydrolyzed into NH 3 and CO 2 , which are stripped out in
lower part of Process Condensate Stripper (U-DA501). Low-pressure steam is utilized
for Process Condensate Stripper (U-DA501).

The purified process condensate containing less than 1 ppm of urea and 5 ppm of NH 3
respectively can be used as the make-up water for boiler feed water.

3.1.5 Advanced Duplex Stainless Steel DP28W TM

TOYO is the pioneer in applying duplex stainless steels to Urea Plants. TOYO has applied
25Cr-5Ni-2Mo to High Pressure Decomposer and HP Carbamate Pump since 1970s, and
then 25Cr-7Ni-3Mo to HP Stripper since 1980s. The biggest advantage of duplex stainless
steel is the excellent passivation property in urea-carbamate solution, which enhances
reliability of equipment and enables to reduce the passivation air. In the meantime, duplex
stainless steel has some weakness in corrosion resistance in heat affected zone (HAZ),
which shows up in the long-term operation. Therefore, chemical composition, forming
process and heat treatment etc. should be well designed for duplex stainless steel.
Considering further improvement potential of duplex stainless steel, TOYO and NSSMC
have jointly developed new duplex stainless steel DP28W TM for Urea Plant as the best
matching Urea Plant material getting all the feedbacks from long experience by TOYO and
NSSMC.

(1) Why Duplex?

The essential factors for the construction material in a Urea Plant are corrosion
resistance, mechanical property, weldability and cost as shown in Fig.3-6. The biggest
advantage of duplex stainless steel is that all essential factors are highly balanced.
DP28WTM is a duplex stainless steel, which has been further improved and developed
especially for Urea Plants by refining those factors.

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Titanium
Less passivation air 316L-UG
required 25Cr-22Ni-2Mo
Duplex SS
Weldability Resistance to SCC

Lower Cost Resistance to Erosion

Higher Strength

Fig. 3-6 Essential factors for Urea Plant material

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(2) Features of DP28WTM

Chemical composition:
DP28WTM shows excellent corrosion resistance not only in base metal but in the HAZ.
Range of chemical composition in comparison with DP12, which is existing duplex
stainless steel, is shown in Table 3-1. The features of chemical composition are
summarized below:

 Corrosion resistance of base metal

- addition of Cr, W
- α/γ balance
 Corrosion resistance of welded metal
- addition of Ni
- optimization of Mo and W
 Elimination of σ – phase
- addition of W instead of Mo

Table 3-1 Chemical Composition

Mechanical properties:
Mechanical properties of DP28WTM in comparison to other stainless steels are shown
in Table 3-2. DP28WTM has high mechanical strength compared to austenitic stainless
steels and conventional duplex stainless steels DP12. It provides great advantage for
mechanical design of equipment.

Table 3-2 Typical Mechanical Properties

Tensile Strength Yield Strength Elongation Hardness
(MPa) (MPa) (%) (Hv)
DP28W 934 647 42 281
DP12 822 610 42 251
25Cr-22Ni-2Mo 676 352 50 173
316L 518 234 52 144

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Under the favor of high mechanical strength of DP28WTM, thickness of parts can be
minimized. In case that DP28WTM is used for Carbamate Condenser (U-EA101) tube,
thickness can be reduced by 30%. Reduction of tube thickness reduces the number of
tubes because of the improved heat transfer. Then bundle size and shell diameter can
be minimized as well.

Corrosion resistance:
DP28WTM shows excellent corrosion resistance, which provides 10-20% lower
corrosion rate than S31260 (DP12) as shown in Fig.3-7.

1.50
3 times higher than S31260
Equivalent corrosion Rate

1.00

0.50

0.00
DP28W S31260(DP12) 316L-UG

Fig. 3-7 Result of immersion test in commercial plant

Passivation property:
The passivation property, which is discussed by how little the passivation air is
required or how quick the material is passivated, represents the resistance to active
corrosion. Comparison between active corrosion and intergranular corrosion is
described in Fig.3-8. Once active corrosion occurs, the corrosion rate is extremely
high. Accordingly, it should be primarily avoided. The material which has poor
passivation property requires large amounts of passivation air to prevent active
corrosion.

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Fig. 3-8 Active Corrosion and Intergranular Corrosion

To evaluate the passivation property of the material, corrosion potential is monitored

after releasing the potential from active region using electrochemical measurement
apparatus in urea-carbamate solution with various passivation air conditions. The
passivation property of each material is evaluated by the profile of electric potential.
The test result obtained under the condition with very little passivation air (1/3 of
normal requirement) is shown in Fig.3-9. Even in very severe conditions, under which
type 304 and 316L cannot be passivated, DP28WTM quickly recovers its potential from
active region to passive region.

0.2

-0.2 PASSIVE
Potential (V vs. Pt)

-0.4 ACTIVE

-0.6
S31050(25Cr-22Ni-2Mo)
-0.8 304
S31260(DP12)
-1
DP28W
316L
-1.2
0 10 20 30 40 50
Time (min.)

Fig. 3-9 Passivation property in urea-carbamate solution

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(3) Advantages of DP28WTM Throughout Plant Lifecycle

Advantages to apply DP28WTM through plant life are summarized as follows;

 High corrosion resistance

- Prolong life of equipment
- Enhance reliability of pressure parts
- Minimize accelerated corrosion in weld

 Excellent passivation property

- Quick passivation
- Good and safe operation

 High mechanical strength

- Reduce thickness of pressure parts
- Save equipment size and weight

Excellent advantages prove that DP28WTM is one of the best matching materials for
Urea Plants, providing great benefits to Urea Plant owners.

3.2 Process Description

Refer to Doc. HURL-G-LD-U00-PRS-INF-000-0001, “Process Description for Urea Plant”

3.3 Equipment List

Refer to Doc. HURL-G-LD-U00-PRS-EQL-000-0001, “Urea Equipment List”.

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SECTION 4. PREPARATION FOR THE INITIAL START-UP

4.1 Line Check

4.2 Flushing

4.3 Unit Commissioning

4.3.1 Introduction
4.3.2 Electrical Equipment
4.3.3 Cooling Water
4.3.4 Instrument Air and Plant Air
4.3.5 Steam
4.3.6 Vessel and Exchanger Inspection
4.3.7 Flushing of Lines and Equipment
4.3.8 Hydrostatic Test for Synthesis Loop
4.3.9 Tightness Test
4.3.10 Instrument Test
4.3.11 Run-in Operation

4.4 Calibration for Radio Active Level Gauge and Density Meter

4.4.1 Calibration of LT101 (Carbamate Condenser (U-EA101) Top)

4.4.2 Calibration of AT101 (Density Meter for Carbamate Condenser
(U-EA101) Outlet Solution)
4.4.3 Calibration of LT102 (Stripper (U-DA101) Bottom)

4.5 Water Run

4.5.1 Introduction
4.5.2 Water Run of Concentration Section
4.5.3 Water Run of Surface Condenser and Process Condensate
Treatment Section
4.5.4 Water Run of Synthesis Loop, Purification and Recovery Sections
4.5.5 Water Run for Dissolving Tank System

4.6 Pre-commissioning for Prilling Section

4.6.1 Prilling Tower (U-IA301)

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4.7 Prilling Test

4.7.1 General
4.7.2 Dissolving of Urea
4.7.3 Initial Water Charge
4.7.4 Dissolution of Urea
4.7.5 Concentration of Urea Solution
4.7.6 Prilling Test

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SECTION 4. PREPARATION FOR THE INITIAL START-UP

4.1 Line Check

(1) Purpose

In general, the line check is carried out from two viewpoints. One is checking the
piping in a viewpoint of design whether operation will be done without trouble. The
other is checking the nonworking parts and miss works whether the test and flushing
will be done without interference.

The former, of course, has been checked at office before construction when the piping
drawings were drawn. However, this check is carried out at the field as double check
to find out the wrong piping which could not be disclosed on the drawings.

(2) Procedure

It is desirable to check the lines by using the most newly issued P&I Flow Diagrams.
And use the piping drawing as reference. Considering subsequent operation, it is
better to check from utilities piping to process piping in order. Though there are many
check items, typical examples are shown in Table 4-1. The problems should be
immediately fed back because reworks will be finished before the subsequent
hydrotest and flushing. Therefore, on this line check, it is preferable to lay stress on
the checking about No. (a) to (h) of items (1) in Table 4-1.

The importance of the line check lies not only in the checking on the outward
appearance whether the works have been done in accordance with the drawings but
also in the checking of the piping materials, gasket materials, etc. The follow-up for the
elimination of the problems should be rechecked before the test and flushing.

(3) Timing of Line Check

Choosing the chance of line check is difficult. Rechecks are necessary for unworked
parts when the line check has been carried out too early. The checking too late is
difficult because the marking on piping material will have been faded and the stains
have appeared and the gaskets completely fixed. Perform the line check prior to the
hydrotest and flushing.

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Table 4-1 Line Check List

Check the following items.

(1) Before Test and Flushing

(a) "Note" written on P&I Flow Diagram.

(b) Flow direction and type (check, globe and angle, etc.) of valves.
(c) Existence of drain valves and vent valves.
(d) Installed location of instruments, flow direction of control valves and orifices.
(e) Operability of valves.
(f) Incomplete work.

(2) Before Start-up

(a) Existence of steam tracing.

(b) Existence of insulation.
(c) Inclining of impulse line for instruments.
(d) Flow direction of orifice and control valves.
(e) Installation of piping supports at the prescribed location.
(f) Removing of temporary supports.
(g) Removing of pre-set pin for springs and setting of scales to c (cold) point.
(h) Providing place for piping movement by heat expansion.
(i) Installation of spectacle according to the rule (open or shut).

(3) After Start-up

(a) Movement of piping expansion.

(b) Scale location of support for springs (h point is right).
(c) Vibration of piping, valves, etc.

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4.2 Flushing

(1) General

(a) Intent

The intent of this specification is to define the cleaning and flushing requirements
applicable to the pipelines at site.

(2) Scope

1) This specification covers the general requirements for cleaning and flushing of
pipelines after construction.

2) The cleaning of internal of pipe shall be done by a method selected from

following items considering kind of fluid, pipe material and internal wall
condition.

- Cleaning by water or air

- Flushing or cleaning by steam
- Cleaning by oil
- Other method defined specially

(3) Treatments of Piping Components

(a) Treatment of piping materials

The cap attached to new piping materials (such as pipe, valve and other parts)
shall not be removed till fabrication.

(b) Treatment of shop prefabricated pipe

Around welding bead at inside wall of prefabricated pipe shall be cleaned with
grinder, chisel or wire brush, and air blow of it is to be carried out as much as
possible. After inspecting it, cloth tape or vinyl or cork cap is attached at the end of
prefabricated pipe. Attached caps shall not be removed till installation.

(c) Treatment of field fabricated pipes

After the fabrication of pipe, sufficient treatment shall be done for welding beads
at inside wall of pipes, and especially, dropping of melting metal or chips shall be

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removed completely. When the field fabricated partially completed piping have a
long period until installation more than about a week, the piping shall be attached
to above mentioned end-protection materials as much as possible. However, it is
better that field fabricated piping shall be installed immediately after partially
completed and cleaning finished.

(d) Treatment of instrument equipment

1) As a rule, before the cleaning and flushing of pipe lines, instrument,

equipment shall be removed and treated as follows:

- Remove the control valve, flow meter or orifice etc. and install the spool pipe
or spool piece there.

- Remove thermometer or pressure gauge and isolate by block valve or plug it.

- Safety valve shall be isolated by blind plate.

2) When cleaning and flushing will be done with check valve installed on pipeline,
inner parts shall be removed during the flushing and cleaning.

(4) Cleaning Methods

(a) Water Flushing

In general, water flushing shall be applied where service fluid of pipeline is liquid.
If this method is not adequate, other method shall be adopted. Water flushing
shall be done as follows:

1) Water for cleaning is pure water, steam, condensate, or industrial water.

2) After cleaning, the pipeline shall be drained completely.

3) The number of cleaning times is shown as follows:

- Partial cleaning : two times and over

- Whole cleaning : one time and over

Frequency of cleaning shall be decided by each condition.

4) Cleaning shall be done by pressurized water or by the water filled in the pipe
with a rush.

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5) Partial cleaning shall be applied to the pipe fabricated partially. Whole

cleaning shall be applied to the pipeline installed between equipment. When
partial cleaning is done, internal treatment shall be done sufficiently with
flexible grinder, chisel, tube cleaner and other suitable methods as required.

6) If cleaning by water is not adequate, it shall be cleaned by compressed air.

7) Inspection of cleaning shall be made by checking draining water.

(b) Air Blowing

In general, air blowing shall be applied where service fluid is gas. If this method is
not adequate, other method shall be adopted. Air blowing by air shall be done as
follows:

1) Air blowing shall be done by blowing compressed air or by the air blown in
pipe. Compressed air shall be oil free.

2) The number of times of air blowing is shown as follows:

- Partial air blowing : two times and over

- Whole air blowing : one time and over

Frequency of flushing shall depend on the condition of media used.

3) Partial air blowing shall be done by compressed air before piping is installed
on equipment. Whole air blowing shall be done to each pipeline after it is
installed on the equipment.

(c) Steam Blowing

Steam blowing shall be applied for only steam lines, and target plates should be
used for inlet line of steam turbine.

1) The procedure of steam blowing

- Warm up steam line with minimum steam flow.

- 1st : Steam blow for 2 hours
- 2nd : Steam stop for 2 hours (Cooling Down)

Steam blowing shall be carried out repeating the above procedure.

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2) The number of times of Steam blowing is shown as follows:

- For steam turbine inlet line: 10 times and over

The flushing result is judged by target plate.

- For steam line of main header or line to heat exchanger: 2 times and over

3) Install the provided orifices at the specified lines after steam blowing is
completed.

If steam blowing is applied instead of air blowing, the thermal

expansion of pipeline must be considered.

Drain valves of steam line shall be opened and traps shall be

isolated by block valves during the blowing.

Operation of main valve of steam line shall be carried out with

careful control and step by step. If the valve is opened in a breath,
water hammering will happen.

Blowing procedure described in this section is typical one.

Procedure can be modified in accordance with Contractor’s
standard or experience.

4.3 Unit Commissioning

4.3.1 Introduction

This commissioning is very important step to perform the water run and initial start-up
smoothly. Because during the fabrication of the vessels or the piping, there is a possibility
of foreign materials such as hammer, wrench, clothes and glove, etc., entering the
vessels or the piping. These materials cause blocking of vessels, exchangers, rotating
equipment and instruments. Finally, the pump will be damaged seriously in operation. So,
this commissioning should be carried out carefully and thoroughly.

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4.3.2 Electrical Equipment

Commissioning of the electrical equipment will be performed in accordance with the plant
practice by qualified electrical personnel.
4.3.3 Cooling Water

The cooling water system should be cleaned, tightness tested, and commissioned as
early as possible during the period of preparation for initial start-up.

(1) Install temporary by pass lines for coolers (line size more than 6 inch dia.)

Remove cooling water inlet/outlet valve of coolers and connection

inlet/outlet line with temporary bypass line.

(2) Instrument equipment (flow meter, control valve etc.) shall be removed and install
spool piece.

(3) Consider a location where the water is flushed because of huge amount of water.

(4) Flushing the line as following steps.

Step 1
I. Fill up Cooling Water basin with treated water and operate cooling water
pump to blow off the main supply and return lines through temporary by
pass lines.
II. Repeat above (1) until the system become clean.

Step 2
I. Restore all temporary lines and spools and for each cooler, spools for
instrument, etc.
II. Start cooling water circulation through each cooler except small cooler
(line size below 3")
III. Stop cooling water circulation when water becomes dirty and drain it out.

Step 3
I. Make up the cooling water system by clean treated water and start
cooling water circulation through the all coolers.
II. Continue make up and blow down the cooling water until water
becomes clean.

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Detail requirement shall follow vendor criteria.

Step 4
Chemical dosing. After flushing, proceed to passivation according to
chemical supplier’s instruction.

4.3.4 Instrument Air and Plant Air

In order to avoid damaging instruments or regulators, inspect that all air-actuated control
valves etc., are closed off prior to commissioning the instrument air and plant air system.

(1) Remove the blind or valve installed at the end of the instrument air line and plant air
line.

(2) Flush the lines with instrument air until the lines become clean.

The air must be free from dust, moisture and oil.

(3) Put back the blind and valve to the former position.

(4) Dry the instrument air line by the instrument air.

Special attention should be paid to the instrument air capacity.

(5) Install the provided orifices at the specified lines after the flushing is completed.

(6) The system should then be pressurized, and a check should be made throughout
the units for air leaks.

4.3.5 Steam

The steam lines should be flushed from the high pressure side. Care must be taken in
admitting steam to the system because the lines may be initially cold and a large amount
of steam will be condensed in the lines. If this condensate is pushed through the lines at
high speed by more incoming steam, "water hammer" will occur. Water hammer can
cause line distortion and, if severe enough, may even rupture the steam lines.
To prevent the water hammer in steam system, warm up all lines gradually. After that,
receive steam to the system as follows:

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(1) Open all bypass valves of steam traps and drain valves to drain of the condensate in
the pipeline.

(2) Open slowly the bypass valve (1~2 inch dia.) of main header steam valve to
introduce steam for warming up.

Before receiving of steam, confirm enough amount of steam is

available.

(3) Close gradually the bypass valves of the steam traps and drain valves after the
condensate completely drain out from the line.

(4) Open gradually main steam valve to pressurize pipeline to normal condition and
close bypass valve of main steam valve.

(5) Adjust and set the operating condition for each controller to normal operation.

4.3.6 Vessel and Exchanger Inspection

Inside of each vessel and exchanger should be thoroughly checked visually.

4.3.7 Flushing of Lines and Equipment

(1) All towers should be manually flushed away. Before the flushing, open the manhole
of each tower and remove big foreign materials by hands.

(2) All lines should be flushed with water or air, preferably steam condensate, or boiler
feed water containing less than 30 wt ppm of chloride ion.

(3) The spray nozzles (in First Surface Condenser (U-EA501), Surface Condenser for
Final Separator (U-EA503), Flash Gas Condenser (U-EA506), etc.) should NOT be
installed before line flushing.

(4) The lines connected to the towers should be flushed away from the towers.

(5) The lines connected to the drums (equipped with crinkle wire mesh or other
internals): The lines should be flushed away from the drums. In instances where
flushing away from these drums is not practical, the nozzles should be blinded at

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the drums. The lines should be disconnected as close to the drums as possible,
and flushed.

(6) The lines connected to the drums (not equipped with crinkle wire mesh or other
internals): The lines may be flushed into the drums.

(7) The lines connected to the exchangers should be treated individually and flushed
by the most practicable method. The lines should not normally be flushed into the
exchangers; however, should this be necessary, the exchangers must be flushed
and cleaned after the line flushing is completed.

(8) The lube and seal oil systems for the machines should be cleaned.

(9) All control valves should be "dropped out" or "rolling" prior to line flushing.

(10) All drums should be cleaned manually. Drums flushed into during line cleaning
should be manually cleaned after the line flushing is completed.

(11) Any equipment flushed into during line cleaning should be opened and cleaned
manually.

(12) All block valves or other valves not "dropped out" or "rolled" prior to line flushing
should be checked for seating after line flushing, and "dropped out" and cleaned if
necessary.

(13) All blinds should be removed during or immediately after flushing.

(14) All control valves and orifice plates should be installed after line flushing.

(15) When draining water from the equipment after flushing, recheck to ensure that all
vessel vents are open to avoid pulling a vacuum on the equipment.

When there is any possibility to have the hot medium such as hot
water or steam etc. in the tube side, heat the shell side first in
anytime. Because it will cause severe damage of the vessel on
account of the differential temperature.

Flushing procedure described in this section (4.3.3 ~ 4.3.7) is

typical one. Procedure can be modified in accordance with
Contractor’s standard or experience.

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4.3.8 Hydrostatic Test of Synthesis Loop

It is required to carry out the hydrostatic test of synthesis loop to confirm the soundness
of piping and welding in accordance with applicable code and standard.
Equipment and piping part will be tested together since the piping and equipment is
directly welded.

4.3.8.1 Scope

This procedure applies to hydrostatic test for equipment and lines in ACES 21® Synthesis
Loop as listed in Table 4-2.

4.3.8.2 Preparation

(a) Measuring and Control Instrument

1) Following instruments shall be used for the testing.

- PI101, PI105, PG101 and PG110

2) Pressurizing and depressurizing curve of PI101 and PI105 should be

recorded in DCS during the testing.

3) Only pressure gauges that have been calibrated against a standard master
gauge shall be used.

Table 4-2 List of Equipment and Lines for Hydrostatic Test

U-DC101 (Reactor), U-DA101 (Stripper) and U-EA101 (Carbamate

Vessels
Condenser)
Lines U-DC101 to U-DA101 14US 21040 M1J2

HV105 to U-DA101 6CO2 21660 M1J1

FV105 to U-DC101 4CO2 21640 M1J1

U-DA101 to XV102 10US 21080 M1J2

U-DA101 to U-EA101 14MG 21050 M1J2

U-EA101 to PV101 6MG 21210 M1J2

U-EA101 to HV106 14US 21160 M1J2

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FV106 to U-EA101 1.1/2NHL 21830 M1J1

FV104 to U-EA101 6AC 24140 M1J1

HV106 to U-EE101 14US 21170 M1J2

FV101 to U-EE101 8NHL 21020 N1J1

U-EE101 to U-DC101 12US 21030 M1J2

Drain line from U-DA101 3/4DR 21661 M1J2

SHC line for PG101, PT101 1/2SHC 29083 M1J1

SHC line for PG110, PT105 1/2SHC 29062 M1J1

Transfer Line from U-EA101 1US 21831 M1J1

Transfer Line from U-EA101 4US 21051 M1J1

Transfer Line from U-DC101 1US 21031 M1J1

Transfer Line from U-DC101 4US 21641 M1J1

(b) Preparation for Testing

1) As the purpose of this test is to confirm the system can withstand the
specified pressure, the test may be done after all insulation works except
site welding point is completed.

2) The water to be used for the hydrostatic and leak test shall be
demineralized water or steam condensate (Chloride Concentration: less
than 30 wt ppm).

3) Following utilities and equipment shall be prepared for the test and be
confirmed ready for use:

- SL Steam
- Demineralized Water (DM)
- Instrument Air (IA) or Plant Air (PA)
- Electric Power
- U-GA104 (Low Pressure Flooding Pump)
- U-GA105 (High Pressure Flooding Pump)
- PI105 (CO2 Inlet to Stripper (U-DA101))
- PG110 (CO2 Inlet to Stripper (U-DA101))

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- PI101 (NH3 inlet to Carbamate Condenser (U-EA101))

- PG101 (NH3 inlet to Carbamate Condenser (U-EA101))

4) As preparatory work, the following shall be done.

- The following control valves and safety valves should be removed.

FV101, FV104, FV105, FV106, HV105, PV101, XV102,

SV101A,B,C and D

- Blind stub, specified in Piping Material Specification, shall be provided at

the following points:

FV101, FV104, FV105, FV106,

HV105, PV101, XV102,
SV101A,B,C and D

!
CAUTION
Blind stud of DMF type shall be prepared before hydrostatic test.

- Remove the spool piece of HV103 upstream (line no. 6MG 21250 M1J2)
so that the gas can be vented there for the testing.
- Set the valve positions as shown in Fig. 4.1.

(c) Test Pressure and Pressurizing Operation

1) The hydrostatic test pressure shall be 245 kg/cm2G at PG110, which must
NOT be exceeded at any point in the system.

2) Vent the air from Carbamate Condenser (U-EA101) top by opening

upstream isolation valve of HV103 and from 3/4” vent nozzle of Reactor
(U-DC101) top to eliminate possible air pockets while the vessel is being
filled by water.

3) The pressure shall be raised up to the test pressure as following manner.

3) - (a) The pressurizing rate shall be less than 30 kg/cm2 per hour.

3) - (b) Pressure shall be checked at the following pressure with PG110,

PI105, PG101 and PI101 and confirm the condition is stable at 50,

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100, 150, 200 and 245 kg/cm2G.

Refer to Fig.4-2 for pressurizing and depressurizing speed for the test.
4) The hydrostatic test pressure (245 kg/cm2G) shall be held for at least 30
minutes.

5) After the test, Synthesis Loop shall be depressurized carefully and the
water shall be drained out so that no stagnated water remains inside.

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Fig. 4-1 Schematic for Hydrostatic Test

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Note : - When draining, don't make a vacuum pressure

in ACES 21 Loop.
HF-P (U-GA105) - After depressurizing to ATM, breath air by opening
kg/cm2G SV101A,B,C,D blind
LF-P 245 kg/cm2G
240
(U-GA104) Medium : Water ( Chloride : Less than 30 ppm )
30 min. Pressurizing/Depressurizing Speed : 30 kg/cm2/hr
200 kg/cm2G
200

30 min.
160
150 kg/cm2G
Pressurizing
(30 kg/cm2G/hr) 30 min. Depressurizing
120 (30 kg/cm2G/hr)
100 kg/cm2G

80 30 min.

50 kg/cm2G
40
30 min.

30 min.

2 4 6 8 10 12 14 16 18 20 22
HOURS
Fig. 4-2 Schematic for Hydrostatic Test

(d) Acceptance of Hydrostatic Test Result

1) No detectable variation in test pressure and visible leaks are accepted.

2) Leaks of blind cover or flanged joints that are used for the purpose of
testing only and that are not parts of the finish vessel are acceptable
provided they do not interfere with the examination.

4.3.8.3 Procedure

(a) Make sure that utilities are ready and available such as steam, electric
power, demineralized water, plant air and instrument air.

(b) Make sure that all valve positions are correct.

(c) Make sure that instruments work well.

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(d) Start Low Pressure Flooding Pump (U-GA104) to feed water into Synthesis
Loop through the line (1SMLC 29360 BSA2) to Stripper (U-DA101). After
start feeding, the level of Steam Condensate Tank (U-FA103) should be
frequently checked to ensure the sufficient amount for water filling.

(e) The remaining air in the Synthesis Loop should be completely vented
during the water filling.

(f) Build up pressure in the Synthesis Loop with water and keep the pressure
at 25 kg/cm2G by Low Pressure Flooding Pump (U-GA104).

(g) Check the leakage from all manholes, flanges, drain valve and isolation
valves.

(h) When the pressure is raised up to 25 kg/cm2G, close the low pressure
water feed valve to Synthesis Loop and stop Low Pressure Flooding
Pump (U-GA104). Close manual angle drain valve and remove spool
piece in the line (1DR 21644 B1L0 and 1.1/2SML 27971 BSA2I).

(i) Start High Pressure Flooding Pump (U-GA105) and inject the high
pressure water to Synthesis Loop through the lines (1/2SHC 29083 M1J1,
1/2SHC 29062 M1J1) to pressurize the system.

(j) Pressurize Synthesis Loop keeping pressurizing rate 30 kg/cm2 per hour.

(k) Raise the Synthesis Loop pressure gradually up to around 245 kg/cm2G.

(l) When the Synthesis Loop pressure reaches 245 kg/cm2G, close the high
pressure water feed valves and stop High Pressure Flooding Pump
(U-GA105).

(m) Check the leakage from all manholes, flanges, drain valves and isolation
valves.

(n) Maintain the Synthesis Loop pressure at 245 kg/cm2G at least 30 minutes.

(o) After the hydrostatic test is completed, decrease the pressure and drain
water as following steps to avoid vacuum condition in Synthesis Loop.

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Depressurizing

(p) Step 1 :
Open crack the isolation valve for HV103 and adjust the depressurizing
rate. High Pressure Flooding Pump (U-GA105) can be operated to keep
maximum depressurizing rate (30 kg/cm2/ hour), if necessary.

(q) Step 2 :
When the pressure is decreased to atmospheric, remove the blind for
PV101.

Drain

(r) Step 3 :
- Open isolation valve of HV103 fully.
- Remove the blinds for SV3101A,B,C,D and drain the water through the
nozzle of SV101A,B,C,D.
- Wait until stop of drain from SV101A,B,C,D and confirm it visually.
- Open the manhole at top of Carbamate Condenser (U-EA101) (Nozzle
No. 1B).

(s) Step 4 :
- Open blind flange of vent nozzle at top of Reactor (U-DC101) (Nozzle No.
8) and drain water through the vent nozzle.
- Wait until stop of drain from the vent nozzle of Reactor (U-DC101) and
confirm it visually.

(t) Step 5 :
Open two drain valves of Carbamate Condenser (U-EA101) shell side
(Nozzle No.31A and B) and drain the water in Carbamate Condenser
(U-EA101) completely.

Do not use liquid transfer line (4US 21051 M1J1) to drain the water
to avoid vacuum condition by rapid pressure decrease.

(u) Step 6 :
Open drain valve of Stripper (U-DA101) (Nozzle No. 76) and drain the
water in Stripper (U-DA101) completely.

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Do not use liquid transfer line (4US 21641 M1J1) to drain the water
to avoid vacuum condition by rapid pressure decrease.

(v) Step 7 :
Open drain valve (3/4DR 21032 A1L0, 3/4DR 21642 A1L0) and drain the
water in Reactor (U-DC101) completely.

Do not drain the water in Reactor (U-DC101) prior to Carbamate

Condenser (U-EA101) and Stripper (U-DA101).

Draining Step can be regarded as a substitute for Flushing Step of

the Synthesis Loop.

Drain in Synthesis Loop shall be proceeded as per this manual to

avoid vacuum condition in the system. Vacuum condition will
!
CAUTION
cause the damage of the lining for Synthesis Equipment (Reactor
(U-DC101), Stripper (U-DA101) and Carbamate Condenser
(U-EA101)).

Drain water in Carbamate Condenser (U-EA101) and Stripper

!
CAUTION
(U-DA101) before draining water in Reactor (U-DC101) to prevent
from making vacuum at top of Reactor (U-DC101).

4.3.9 Tightness Test

4.3.9.1 General

All piping and field fabricated vessels should be hydraulic pressure tested in
accordance with the applicable codes. This is done by Contractor before equipment is
handed over to the owner. The hydraulic pressure test should not be confused with the
tightness test, which is a recommendable step of the initial start-up procedure. The
tightness test is carried out to check the tightness of all piping and vessels when
cleaning and restatement works are completed and all equipment is reassembled.

(1) Water, air, inert gas and/or CO2 gas are used to pressurize the vessels and the
piping.

Please confirm the neighboring systems are NOT under internal

works in the systems when nitrogen / CO2 gas are introduced.

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(2) When the tightness test is carried out with gas, the leaks must be found by
applying soapy water to all connections. Leaks can be found quickly if the flanges
are taped with paper masking tape before the unit is pressurized.

(3) During the test, the vessels and associated piping should be kept at a pressure
equal to 1.0 times of the normal operation pressure. Any equipment or flange
leakage can then be observed visually and repaired or retightened.

The water used for the tightness test should be drained out with
the pressurized air to avoid pulling a vacuum on the equipment.

(4) Exchangers should be tightness tested on both the shell and the tube sides.
Exchangers low point drains should be used to detect leaks.

The water used for the tightness test should be drained out with
the pressurized air to avoid pulling a vacuum on the equipment.

(5) All control valves and orifice plates should be installed prior to the tightness test.

(6) The low pressure equipment should be tested first and their vents or drains then
opened so that the low pressure equipment will not be over pressurized while, the
high pressure equipment is tested.

Tightness Test Procedure described in this section is typical one.

Procedure can be modified in accordance with Contractor’s
standard or experience.

4.3.9.2 Vacuum Test for Concentration Section

This Test is applied to separate part in Concentration Section.

(1) Preparation

Fill up water to following vessel and piping.

- Urea Solution Tank (U-FA01) at 30% level.

- Seal leg between U-FA202 and U-FA203.
- Suction and discharge pipe of Urea Solution Pump (U-GA201) and Molten Urea

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Pump (U-GA204).
- Process Condensate Tank (U-FA501) at 50% level.

(2) Line up

Open the following valves fully.

- PV203 and association valves.

- PV206 and association valves.

(3) Start Process Condensate Pump (U-GA501) and establish circulation operation to
First Surface Condenser (U-EA501) and Final Absorber (U-DA503).
(a) Adjust FI503 at higher than minimum flow rate of Process Condensate Pump
(U-GA501).

(b) Open process condensate injection valve to First Surface Condenser

(U-EA501) and Flash Gas Condenser (U-EA506) at 2~3 turn.

(4) Start LP Absorbent Pump (U-GA503) and establish circulation operation to

Surface Condenser for Final Separator (U-EA503).

Isolation valve of minimum flow line to be open fully.

(5) Open cooling water isolation valve (in/out) of First Surface Condenser (U-EA501),
Second Surface Condenser (U-EA502), Surface Condenser for Final Separator
(U-EA503), Flash Gas Condenser (U-EA506), Final Absorber Cooler (U-EA507)
and Final Surface Condenser (U-EA509).

(6) Stick the masking tape onto all flanges whole connected system (for leak check).

(7) Establish vacuum by the following steps.

(a) Start Third Ejector (U-EE503), Second Ejector (U-EE502) and First Ejector
(U-EE501) in stepwise.

(b) Close PV203 gradually, watching the vacuum.

(c) Confirm that the vacuum can reach about 0.34 kg/cm2A (250 mmHgA).

(d) Start Ejector for Final Separator (U-EE201) and watch the vacuum of PIC206.

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(e) Close PV206 gradually to increase the vacuum.

(f) Confirm that the vacuum can reach about 0.034 kg/cm2A (25 mmHgA) by
PIC206.

If the vacuum of the above figure cannot be established, all the

flanges and connection are to be retightened.

Pay attention that boiling point of water is 27~28°C at 25 mmHgA.

4.3.10 Instrument Test

Before and/or during the process activation test, the following tests should be done to
confirm that all the instruments work well.

This instrument test and repairing is very important. Negligence of

the test may cause serious damage to the equipment and the
machine and/or injury to personnel.

These tests should be done under the instruction of the qualified instrument personnel.

- Controller and Control Valve Test

- Emergency Valve Test
- Alarm Test and Lamp Indication on DCS
- Trip Test
- Interlock System Test

4.3.10.1 Controller and Control Valve Test

(1) Confirm that proper air pressure is supplied to pneumatic lines.

(2) Set the controller on manual and close the related valve in the Control Room, and
then make sure at field that the control valve is closed completely.

(3) Set the valve positions at 0%, 25%, 50%, 75% and 100% manually in the Control
Room and check the opening ratios of the control valve at the field.

(4) Repeat above mentioned (2) and (3) procedures several times for each controller
and control valve and check the movement of stems.

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(5) Confirm that the function of each control valve for the air to open type or the air to
close type.

(6) These tests should be done with a close contact between the Control Room and
the field using a walkie-talkie.

4.3.10.2 Emergency Valve Test

The following tests shall be done on FV101, FV104, FV105, FV106,

!
CAUTION
HV105, HV106, LV102 and PV153 respectively.

(1) Make sure that instrument air is supplied properly to the above control valves.

(2) Open the control valves from the Control Room.

(3) Close the control valves from the Control Room. On the other hand, measure the
required time to close the control valves at the field. (Stroke speed for all
emergency valves is five second except PV153 and UV151/152. Stroke speed for
PV153 is one second. Stroke speed for UV151/152 shall be referred to anti-surge
controller vendor’s instruction.)

4.3.10.3 Alarm Test and Lamp Indication on DCS

During the run-in operation for rotating machines and the water operation etc., attention
should be paid to the alarms and running indications on display to confirm their function
one by one.

4.3.11 Run-in Operation

As for rotating machines, it is necessary to operate the machines with no load first and
to increase the load little by little before the machines are used at the design conditions.
This procedure is called "Run-in".

The purposes of the run-in operation are for run-in of bearings and checking of
vibration, abnormal noise, hot spot, etc.

The run-in operation for large machines and special ones such as CO2 Compressor
(U-GB101), etc. should be carried out in accordance with the vendor's instructions.
Before starting run-in operation, confirm that utilities are available such as steam,
cooling water and demineralized water.

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4.3.11.1 CO2 Compressor (U-GB101)

Regarding the detail of the run-in operation, refer to the vendor's Instruction.

Before the run-in operation, the whole systems are completely flushed such as the
CO2 gas, cooling water, and lube oil systems with respective mediums.

The run-in operation of the compressor should be carried out with air first and then
CO2 gas. During the run-in operation, the CO2 gas lines are also flushed away with
blowing air and CO2 gas.

There are two types of the run-in operation such as trial run with air, and Initial start-up
under gas load.

(1) Trial Run with Air

At this step, the compressor can be pressurized up to the admissible maximum

value, which is also evident from the steam consumption of the compressor drive.
During increasing of the pressure, carefully watch and monitor the machine, the
piping and the apparatus.
Air will be introduced from the manhole of 1st Stage Suction Separator (U-FA111)
(See Fig.4-3 as typical picture).

Fig. 4-3 Air Sucking from Manhole (Typical Picture)

(2) Initial Start-up Under Gas Load

The manner of the operation is completely same as the normal operation start-up,
and accordingly refer to the vendor's instruction.

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4.3.11.2 Ammonia Feed Pump (U-GA101)

The run-in operation of Ammonia Feed Pump (U-GA101) has to be carried out using
liquid ammonia instead of water because of the big difference of specific gravity of
these fluids.

The water operation of water of Ammonia Feed Pump (U-GA101)

!
CAUTION
results in over pressure of the discharge, because the pump is
designed to have the required head with liquid ammonia, which
has 0.584 of specific gravity.

(1) Condensate and/or boiler feed water will be utilized instead of actual fluids for
running in this pump.

(2) Fill Ammonia Reservoir (U-FA104) with water up to 50~70 % level and pressurize
the system to approx. 7 kg/cm2G.

(3) Make sure the valve position of Ammonia Feed Section.

(4) Confirm that the following items are done properly.

- Temporary Strainers are installed on the suction line of the pumps.

- Proper amount of cooled condensate is admitted for the sealing.

- Proper amount of cooling water is admitted to the oil coolers and Ammonia Bypass
Cooler (U-EA104).

(5) Start Ammonia Boost-up Pump (U-GA103) to circulate to Ammonia Reservoir

(U-FA104) through Ammonia Feed Pump (U-GA101) and NH3 bypass line via
FV131.

(6) Start Ammonia Feed Pump (U-GA101) to maintain the circulation flow with higher
than U-GA101 minimum flow rate on FIC131.

As for start-up of Ammonia Feed Pump (U-GA101), refer to the

vendor’s instruction.

“U-GA101 minimum flow” is defined as U-GA101 pump minimum flow

rate + flow rate for balance line.

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(7) The following items are to be checked during this period:

- Emulsion due to water mixing and lower level for lube oil.
- The temperature of the mechanical seals.
- The leakage from the mechanical seals.
- Lubricating conditions for the bearings.
- Abnormal noise, vibration and hot spots.

(8) During the run-in operation, some amount of water is added into Ammonia
Reservoir (U-FA104) to maintain the water temperature at around 40 °C with
continuous draining from the system.

4.3.11.3 Carbamate Feed Pump (U-GA102)

(1) Condensate and/or boiler feed water will be used instead of actual fluids for
running in this pump.

(2) Fill HP Absorber (U-EA401) with water up to 50 ~ 70% level and pressurize to
about 15 kg/cm2G with the nitrogen gas.

(3) Confirm that the following items are properly done.

- Temporary strainers are installed on the suction line of the pump.

- Proper amount of cooled condensate is admitted for the sealing.
- Proper amount of cooling water is admitted to the oil coolers.
- Tempered Water is in service condition.

(4) Start Carbamate Boost-up Pump (U-GA401) to circulate water to HP Absorber

(U-EA401) through Carbamate Feed Pump (U-GA102) and FV108.

(5) Start Carbamate Feed Pump (U-GA102) to maintain the circulation with more
flow rate than the U-GA102 minimum flow on FIC108.

As for start-up of Carbamate Feed Pump (U-GA102), refer to the

vendor's instruction.

“U-GA102 minimum flow” is defined as U-GA102 pump minimum flow

rate + flow rate for balance line.

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(6) The following items are to be checked during this period:

- Emulsion due to water mixing and lower level for lube oil.
- The temperature of the mechanical seals.
- The leakage from the mechanical seals.
- Lubricating conditions for the bearings.
- Abnormal noise, vibration, and hot spots.

(7) During the run-in operation, the temperature of HP Absorber (U-EA401) is

controlled at around 40°C by TIC402.

4.3.11.4 Other Centrifugal Pumps

Prior to starting up a unit, all centrifugal pumping equipment should be thoroughly

checked and run-in properly (after system is hydrostatically tested) as indicated in the
following outline.

(1) Confirm that necessary steam piping connections have been made to the casing
jackets and quench glands.

(2) Check installation of the temporary strainers in pump suction lines. To minimize
damage to the pumps during run-in with water, the strainers should be
temporarily lined with 40 mesh screen.

(3) Make sure that all utilities are available for run-in of pumps. See that necessary
pressure gauges and any special instrumentation are working in order.

(4) It is extremely important that the proper type of viscosity oil and the proper grade
of grease are used to lubricate the equipment. Refer to manufacturer's
instructions and lubricant list for this information.

(5) Fill liquid in the casing and vent air.

(6) See that the driver rotates the pump in the correct direction as indicated by the
arrow on the pump casing. Rotate pump by hand to see if everything is clear
before starting.

(7) If pump is to be run-in on a liquid that has a higher specific gravity than design,
special care must be taken to avoid motor overload. Throttle discharge and

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watch ammeter closely.

(8) After the lines and vessels have been flushed out with water, the pumps must be
run-in on water. Couple up and align the pump; then check availability of water
and start water flow through pump.

(9) Start the pump.

(10) Keep the operation for one hour.

(11) Check the temperature and sound of bearing and motor, discharge pressure,
ampere and vibration (If available).

(12) Stop the pump after the confirmation of normal condition during run-in operation.
Remove the temporary strainer on the suction line of the pump and re-install it
after cleaning the mesh.

4.3.11.5 Blowers

(1) Confirm that the direction of the motor rotation before connecting the coupling.
The direction of the motor rotation should be matched with the direction arrow on
the blower.

(2) Mark the damper blade direction on the axis before connecting suction duct. The
mark is useful to know the actual damper angle without opening indication of
damper adjustment devices.

(3) Connect the blower with the driver and make sure that they both run freely.

(4) Check that the bearings are lubricated with proper lubricant.

(5) Open the drain valve installed at the bottom of the casing.

(6) Make sure that damper installed on the discharge line is closed completely.

(7) Start the blower.

(8) If there is no trouble, open the damper gradually.

!
CAUTION
Be careful about the over loading of the motor.

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(9) Keep the operation for several hours.

(10) Check the amperage of the motor.

The blower should be operated below the design condition during

the run-in operation, because there is possibility to have the
overload on the motor on account of sucking the air of lower
temperature.

4.3.11.6 Belt Conveyors

(1) Fill the gearbox in the geared motor with proper lube oil up to the middle of the
sight glass.

(2) Confirm that all the idlers and bearings for the pulley are greased properly.

(3) Start the belt conveyor and continue the operation for a few hours.

(4) Be careful about the following items:

- Abrasion of the belt conveyor

- Slipping of the belt conveyor
- Abnormal high temperature of the bearings

(5) In Case of Belt Scale (U-JW301), performance shall be confirmed using “test
chain for check weight” during run-in operation.

Fig.4-3 Calibration of Belt Scale Using Test Chain

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4.3.11.7 Ejectors

Take care not to choke the nozzles of the ejectors by dust when steam lines are
cleaned.

4.3.11.8 Agitators

(1) Fill liquid in the vessel.

Do NOT operate any agitator without filling with liquid.

(2) Confirm that the bearings are lubricated properly.

(3) Start the agitator and continue the operation for a few hours watching the
amperage and noise.

4.3.11.9 Prilling Basket and Scraper

Refer to the Vendor’s Instruction Manual

4.3.11.10 Other Rotating Machines

The run-in operation of other rotating machines should be carried out in accordance
with the manufacturer's manuals.

Unit Commissioning Procedure described in this section is typical

one. Procedure can be modified in accordance with Contractor’s
standard or experience.

4.4 Calibration for Radio Active Level Gauge and Density Meter

!
CAUTION
Radioactive level gauges and density gauge shall be initially handled,
installed and powered on under supervision of the vendor supervisor.

4.4.1 Calibration of LT101 (Carbamate Condenser (U-EA101) Top)

(1) Prepare a wooden float tied with a rope. Mark scale on the rope every 100 mm.

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Float size to be smaller than nozzle #33A,B,C,D (SV101A,B,C,D) inner

diameter.

Rope length to be longer than 6 m.

(2) Connect transparent tube to Carbamate Condenser (U-EA101) bottom drain valve and
lead the other end to the top of Carbamate Condenser (U-EA101) (see Fig. 4-4).

(3) Make sure that SV101A,B,C,D have been removed from Carbamate Condenser
(U-EA101) top.

(4) Open Carbamate Condenser (U-EA101) top (scrubbing part) hand hole (nozzle #3A)
and manhole (nozzle #1B) on scrubbing part.

After LT101 calibration, the manhole for scrubbing part can be kept
opened for loading pall rings, if necessary.

(5) Fill Carbamate Condenser (U-EA101) until above the maximum level. Check the water
level from nozzle #33A,B,C,D with float and with the transparent tube.

If the calibration is done at the hydrostatic test of Synthesis Loop, the

remaining water used for hydrostatic test can be reused.

Chloride content in the water shall be less than 30 wt ppm.

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Open M/H
or
Open H/H

Maintain Water Level

Transparent Tube

U - EA101

U - DA101

Fig. 4-4 Transparent Tube Set-up for Level Calibration

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(6) Adjust the water level at the following point (check water level with the wooden float as
shown in Fig. 4-5) and record the indication of LT101 at DCS and field (Level span and
calibration point will be finalized based on vendor information) :

100% (1000 mm) = 1350 mm below from #33 nozzle top face
75% (750 mm) = 1600 mm below from #33 nozzle top face
50% (500 mm) = 1850 mm below from #33 nozzle top face
25% (250 mm) = 2100 mm below from #33 nozzle top face
0% (0 mm) = 2350 mm below from #33 nozzle top face

Density difference between water (1000 kg/m3) + air (0 kg/m3) system

and the design condition (liquid density = 1024 kg/m3, gas density =
153 kg/m3) shall be taken into consideration for the calibration work.
The compensation method shall be instructed by the vendor.

Actual water level can be also checked by the transparent tube.

(7) Calibrate LT101 based on the actual measurement result.

(8) Repeat the above (6) and (7) if required.

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Fig. 4-5 Calibration for LT101 (Carbamate Condenser)

4.4.2 Calibration of AT101 (Density Meter for Carbamate Condenser (U-EA101) Outlet Solution)

(1) Adjust AT101 indication at 1.0 when 14US 21160 M1J2 (urea solution line from
U-EA101 to U-EE101) is filled with water.

The adjustment and calibration work shall be done by the vendor

supervisor.

(2) Drain the water in Carbamate Condenser (U-EA101) (If necessary).

(a) After the calibration work for LT101 and AT101 is completed (In case that

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calibration and water distribution test is done separately), drain water in

Carbamate Condenser (U-EA101) and associated piping slowly until empty.

Do not make inside of Carbamate Condenser (U-EA101) vacuum

!
CAUTION
condition during draining. Confirm that nozzle #33A,B,C,D
Carbamate Condenser (U-EA101) top man hole are opened and
HV103 and its isolation valve are fully opened.

Drain water in Carbamate Condenser (U-EA101) before draining

!
CAUTION
water in Reactor (U-DC101) to prevent from making vacuum at top of
Reactor (U-DC101).

4.4.3 Calibration of LT102 (Stripper (U-DA101) Bottom)

(1) Connect transparent tube to the bottom drain valve. Fill the bottom boot of Stripper
(U-DA101) with water up to maximum level (See Fig. 4-6).

(2) Close the bottom manhole of Stripper (U-DA101).

(3) Adjust the water level at the following point (check water level with the transparent
tube as shown in Fig. 4-6) and record the indication of LT102 at DCS and field (Level
span and calibration point will be finalized based on vendor information) :

100% (1000 mm) = 1659 mm above from bottom face of man hole
75% (750 mm) = 1409 mm above from bottom face of man hole
50% (500 mm) = 1159 mm above from bottom face of man hole
25% (250 mm) = 909 mm above from bottom face of man hole
0% (0 mm) = 659 mm above from bottom face of man hole

Density difference between water (1000 kg/m3) + air ( 0 kg/m3) system

and the design condition (liquid density = 1087 kg/m3, gas density =
263 kg/m3) shall be taken into consideration for the calibration work.
The compensation method shall be instructed by the vendor.

(4) Calibrate LT102 based on the actual measurement.

(5) Repeat the above (3) and (4) if required.

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(6) After the calibration work for LT102 is completed, drain water in Stripper (U-DA101)
bottom boot until empty.

Fig. 4-6 Calibration for LT102 (Stripper)

4.5 Water Run

4.5.1 Introduction

Following the flushing, tightness test, run-in operation of rotating machines, etc. the plant
activation should be done by the water run for the following purposes.

- Final cleaning of the system

- Acquirement of the operating techniques
- Adjustment and checking of the instruments

From the viewpoint of start-up procedure, the water run is carried out individually for the
following sections and systems.

- Concentration Section

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- Process Condensate Treatment Section

- Synthesis Loop, Purification and Recovery Sections
- Dissolving Tank System

Following general preparations should be carried out.

(1) Make sure that all utilities are available, such as steam, electric power, cooling water,
demineralized water, plant air, instrument air, nitrogen and so on.

(2) Make sure that all valves for draining, sampling and venting are closed otherwise
noted.

(3) Make sure that all instruments are ready and all control valves are set on the start- up
positions.

(4) Make sure that all block valves for control valves are opened.

(5) Make sure that all temporary strainers are installed properly (40 mesh wire net).
During the water run, two pumps for one item (Normal use + Stand-by) are to be
changed for cleaning. Strainers should be cleaned as often as possible.

4.5.2 Water Run of Concentration Section

4.5.2.1 Preparation

(1) Follow the item (1) through (5) of Para. 4.5.1.

(2) Fill the following vessels with steam condensate.

(a) Urea Solution Tank (U-FA201) including piping and Urea Solution Pump
(U-GA201).

- 50% on LI203
- 50% on LI204

(b) Bottom of Final Separator (U-FA203) including piping and Molten Urea Feed
Pump (U-GA204).

- 100% on LIC207A

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(3) Pass the cooling water to all surface condensers (First Surface Condenser
(U-EA501), Second Surface Condenser (U-EA502), Flash Gas Condenser
(U-EA506), Surface Condenser for Final Separator (U-EA503) and Final Surface
Condenser (U-EA509)).

(4) Cut the steam to steam jacket of line and casing jacket of Urea Solution Pump
(U-GA201) and Molten Urea Pump (U-GA204) to avoid cavitation of the pump.

4.5.2.2 Start-up

(1) Start Urea Solution Pump (U-GA201), and feed the water from Urea Solution Tank
(U-FA201) to Final Separator (U-FA203) through Vacuum Concentrator (U-FA201).

(2) When LIC207A (level of Final Separator (U-FA203)) goes up more than 100%, start
Molten Urea Pump (U-GA204), and send the water to Urea Solution Tank (U-FA201)
via HV301.

The circulation loop is completed as follows:

U-EA201 & U-FA202 U-EA202 & U-FA203 U-GA204

U-GA201 U-FA201 HV301

(3) Establish the vacuum of Vacuum Concentrator (U-FA202) and Final Separator
(U-FA203) by following the items (1) through (7) of Para. 4.3.9.2.

(4) Continue the operation for sufficiently long to check the following items and to clean
the pipe work.

(a) Temperature and sound of bearing and motor for Urea Solution Pump (U-GA201)
and Molten Urea Pump (U-GA204).

(b) Ampere of these rotating machines (If available).

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(c) Instrument.

(d) Vibration (If available).

The liquid densities will not be same as specified to the instrument

manufactures because the plant is operated with water. Therefore,
these instruments will not give accurate readings. However, since the
purpose of Water Run is confirmation of the above item of (a) – (d),
such minor deviation could be allowed.

(5) After checking is completed, shutdown and drain out the water in all equipment.

(6) Remove all temporary strainers.

4.5.3 Water Run of Surface Condenser and Process Condensate Treatment Section

4.5.3.1 Preparation

(1) Follow the item (1) through (5) Para. 4.5.1.

(2) Check the following valves are opened.

- Gas vent valve (8MG 25392 A1K0) on the line from Process Condensate Stripper
(U-DA501) to LP Decomposer (U-DA202).
- Block valve of minimum flow line for Urea Hydrolyzer Feed Pump (U-GA502) and
LP Absorbent Pump (U-GA503).
- PV501 at Process Condensate Stripper (U-DA501) overhead

(3) Check the following valves are closed.

- Gas feed line from Process Condensate Stripper (U-DA501) to LP Decomposer

(U-DA202).

(4) Fill up Process Condensate Tank (U-FA501) with steam condensate to normal level.

- 50% on LI501A and LI506

(5) Pass the cooling water to all surface condensers (First Surface Condenser

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(U-EA501), Second Surface Condenser (U-EA502), Flash Gas Condenser

(U-EA506), Surface Condenser for Final Separator (U-EA503)) and Final Absorber
Cooler (U-EA507).

4.5.3.2 Start-up

(1) Start Process Condensate Pump (U-GA501) and circulate the water as follows at 96
t/h on FI503 (Higher than minimum flow rate of Process Condensate Pump
(U-GA501)).

U-EA501 & U-EA506 U-DA503 U-EA507

U-FA501 U-GA501

(2) Fill the bottom of Process Condensate Stripper (U-DA501) up to 50% of LIC503 with
steam condensate from Process Condensate Pump (U-GA501) via FV504 .

(3) Start Process Condensate Return Pump (U-GA505), and circulate water as follows:

U-FA501 U-GA501 U-EA504 Top of U-DA501

Mid.of U-DA501

U-EA508 U-GA505 U-EA504 Bot.of U-DA501

Keep the level of Process Condensate Tank (U-FA501) by feeding

steam condensate.

Keep LV502 closed, not to introduce condensate to Urea Hydrolyzer

(U-DA502).

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LIC502 indicates 100%, as condensate overflows chimney tray of the

middle of Process Condensate Stripper (U-DA501) and falls down to
the lower part of Process Condensate Stripper (U-DA501).

(4) Start steam injection into the bottom of the Process Condensate Stripper (U-DA501)
at a rate of approx. 8 t/h by FIC505.

(5) Mixed gas from top of Process Condensate Stripper (U-DA501) vent to
Vent Stack (14RV 24444 A1K0).

(6) Start pressurizing and warming up to Process Condensate Stripper (U-DA501) by

gradually closing PV501 up to 3.0 kg/cm2G. Then put PIC501 on auto.

(7) Start Process Condensate Return Pump (U-GA505), and open LV503 to keep the
level of the bottom of Process Condensate Stripper (U-DA501) at 50%, and put it on
auto.

(8) Circulate water as following pathway.

U-FA501 U-GA501 U-EA504 Top of U-DA501

Mid.of U-DA501
U-EA508

U-GA502

U-GA505
U-EA505

U-EA504 Btm.ofU-DA501 U-EA505 U-DA502

(9) Start LP Absorbent Pump (U-GA503) and circulate condensate to Surface

Condenser for Final Separator (U-EA503) through minimum flow line (RO502)

(10) Open PV502 to warm up to Urea Hydrolyzer (U-DA502).

(11) Gradually increase the condensate feed rate from Process Condensate Pump
(U-GA501) to Process Condensate Stripper (U-DA501) up to 35 - 45 t/h by FIC504.

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Increase steam injection rate on FIC505 so as to keep PV501 opened.

The level of Process Condensate Tank (U-FA501) is kept by making

up water from Steam Condensate Tank (U-FA103) via U-GA106.

(12) Start Urea Hydrolyzer Feed Pump (U-GA502) and circulate the water through
RO501.

(13) Gradually open LV502 and start feeding the condensate to Urea Hydrolyzer
(U-DA502).

Pay attention to sudden flow rate through LV-502 due to higher

!
CAUTION
differential pressure of LV-502. Keep crack open LV-502 firstly and
gradually increase opening after stabilization of flow rate.

(14) After confirming drain from drain valve of Preheater for Urea Hydrolyzer (U-EA505),
feed the steam gradually to the larger compartment of Urea Hydrolyzer (U-DA502)
by FV508 and pressurize Urea Hydrolyzer (U-DA502) up to 23.0 kg/cm2G by
gradually closing PV502, and put it on auto.

!
CAUTION
Take care of the water hammering in Urea Hydrolyzer (U-DA502).

Do not open FV508 quickly and do not start feeding steam on the
condition that larger compartment is in full liquid to avoid water
!
CAUTION
hammering. Start feeding steam just after liquid level in the large
compartment of Urea Hydrolyzer (U-DA502) reaches steam sparger
(Nozzle 13).

Never feed steam to the larger compartment of Urea Hydrolyzer

!
CAUTION
(U-DA502) (FV508), before water coming out from drain valve at inlet
of Urea Hydrolyzer (U-DA502).

The isolation and bypass valves for FV508 and FV509 shall be closed
when Process Condensate Treatment Section is not operated to
!
CAUTION
avoid feeding steam into empty Urea Hydrolyzer (U-DA502). Provide
CAUTION sign adjacent to the manual valve.

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(15) After the top level (LIC504) of Urea Hydrolyzer (U-DA502) appears, open LV504 to
keep the level at 50%, and put it on auto.

(16) Start feeding steam to the smaller compartment of Urea Hydrolyzer (U-DA502) by
FV509.

Never feed the steam to the smaller compartment of Urea Hydrolyzer

!
CAUTION
(U-DA502) (FV-509), before level (LIC504) in Urea Hydrolyzer
(U-DA502) appears.

The isolation and bypass valves for FV508 and FV509 shall be closed
when Process Condensate Treatment Section is not operated to
!
CAUTION
avoid feeding steam into empty Urea Hydrolyzer (U-DA502). Provide
CAUTION sign adjacent to the manual valve.

(17) Stabilize the condition of Process Condensate Stripper (U-DA501) and Urea
Hydrolyzer (U-DA502).

DO NOT increase the flow rate of FIC504 rapidly. Rapid increase of

process condensate feed to Process Condensate Stripper (U-DA501)
!
CAUTION
leads low feed temperature condition. It may cause vapor
condensation in U-DA501, and result in water hammering. In case
process condensate feed increases, pay attention to low alarm of
TI506 (inlet feed temperature of U-DA501).

(18) Continue the operation for sufficiently long to check the following items and to clean
the pipe work.

(a) Temperature and sound of bearing and motor for Process Condensate Pump
(U-GA501), LP Absorbent Pump (U-GA503), Urea Hydrolyzer Feed Pump
(U-GA502) and Process Condensate Return Pump (U-GA505).

(b) Ampere of these rotating machines (If available).

(c) Instrument.

(d) Vibration (If available).

The liquid densities will not be same as specified to the instrument

manufacturers because the plant is operated with water. Therefore,
these instruments will not give accurate readings. However, since the

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purpose of Water Run is confirmation of the above item of (a) – (d),

such minor deviation could be allowed.

(19) After checking is completed, shutdown and drain out the water in all equipment.

(20) Remove all temporary strainers.

4.5.4 Water Run of Synthesis Loop, Purification and Recovery Sections

4.5.4.1 Preparation

(1) Follow the items (1) through (5) of Para. 4.5.1.

(2) Make sure that all drain valves and vent valves on the process lines are closed.

(3) Make sure that the gas inlet valve to Separator for HP Absorbent (U-FA208) is
opened.

(4) Receive demineralized water into Steam Condensate Tank (U-FA103) and Ammonia
Reservoir (U-FA104).

Make Ammonia Reservoir (U-FA104) full liquid condition to maintain

the water run for at least 3 hours.

(5) Fill the following vessels with water through Steam Condensate Tank (U-FA103).

- Separator for HP Absorbent (U-FA208) (Up to 50%)

- HP Absorber (U-EA401) (Up to 50%)
- Washing Column (U-DA401) (Up to 50%)
- LP Absorber (U-EA402) (Up to 50%)
- Carbonate Solution Tank (U-FA401) (Up to 50%)
- Process Condensate Tank (U-FA501) (Up to 50%)

(6) Make sure that all instruments are ready and all control valves are set on the start-up
positions. The water run positions of the control valves are shown in Table 4-3.

(7) Make sure that Nitrogen and/or Plant Air are available for pressure control of
Ammonia Reservoir (U-FA104) and Synthesis Section.

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CO2 gas can be used as the pressure source for Synthesis Section
instead of Nitrogen or Plant Air, in case that CO2 gas from Ammonia
Plant is available and CO2 Compressor (U-GB101) is ready for
operation.

Table 4-3 Water Run Positions of Control Valves

Item No. Service Position Setting Value

FV101 NH3 to HP Carbamate Ejector (U-EE101) M/C

FV104 Carbamate Solution to Carbamate Condenser M/C

(U-EA101)

FV105 CO2 Feed to Reactor (U-DC101) M/C

FV106 NH3 Seal to Carbamate Condenser (U-EA101) M/C

FV108 Carbamate Feed Pump (U-GA102) Recycle Line M/O

FV131 Ammonia Feed Pump (U-GA101) Recycle Line M/O

FV202 CO2 Gas to LP Decomposer (U-DA202) M/C

FV401 Carbamate Solution to Washing Column (U-DA401) M/C

FV406 Carbamate Boost-up Pump (U-GA401) Recycle Line M/O

FV506 Process Condensate to Washing Column (U-DA401) M/C

HV103 Carbamate Condenser (U-EA101) Top Vent O

HV105 CO2 Feed to Stripper (U-DA101) C

HV106 Urea Solution to HP Carbamate Ejector (U-EE101) C

HV108 LP Steam Flash Drum (U-FA105) Make-up C

HV401 Washing Column (U-DA401) C.W Outlet C

HV402 LP Absorber (U-EA402) C.W Outlet C

LV102 Urea Solution from Stripper (U-DA101) Bottom M/C

LV103 Steam Drum (U-FA102) Make-up A 50%

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Table 4-3 Water Run Positions of Control Valves

Item No. Service Position Setting Value

LV201 Urea Solution from HP Decomposer (U-DA201) M/C
Bottom

LV202 Urea Solution from LP Decomposer (U-DA202) M/C

Bottom

LV209 Separator for HP Absorbent (U-FA208) to HP M/C

Absorber (U-EA401)

LV403 Washing Column (U-DA401) to LP Absorber M/C

(U-EA402)

LV405 Washing Column (U-DA401) to HP Absorber A 50%

(U-EA401)

PV101 Carbamate Condenser (U-EA101) Top Gas M/C

PV106 SML Steam to Steam Saturation Drum (U-FA101) M/C

PV107 Motive NH3 to HP Carbamate Ejector (U-EE101) M/O 70%

PV153 CO2 Compressor (U-GB101) 4th Stage Vent M/O

PV202 SL Steam to HP Decomposer (U- DA201) M/C

PV205 SL Steam to LP Decomposer (U-DA202) M/C

PV209 Mixed Gas from Carbamate Condenser (U-EA101) to M/O

Separator for HP Absorbent (U-FA208)

PV401 Washing Column (U-DA401) Top Vent M/C

PV402 LP Absorber (U-EA402) Top Vent M/C

PV131 A Ammonia Reservoir (U-FA104) (HP Nitrogen) M/C

PV131 B Ammonia Reservoir (U-FA104) (Venting) M/C

TV402 Tempered Water Return from HP Absorber M/C

(U-EA401) to Tempered Water Cooler (U-EA403)

Notes M/O = Manual Open M/C = Manual Close

O = Open C = Close A = Automatic

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4.5.4.2 Start-up

Concerning the scheme of the water run, refer to Fig. 4-7.

(1) Build up the pressure in Synthesis Loop with Plant Air or Nitrogen utilizing hose
station and keep the pressure at 5-7 kg/cm2G.

Pressure of Synthesis Loop can be controlled by PV101 and HV103.

In case CO2 gas is used for the pressurizing, the pressure of

Synthesis Loop shall be selected, for example 30 kg/cm2G,
considering CO2 Compressor (U-GB101) performance, Ejector
performance and availability of motive flow by Ammonia Feed Pump
(U-GA101) and/or Ammonia Boost-up Pump (U-GA103).

(2) Pressurize Ammonia Reservoir (U-FA104) by nitrogen and control the pressure at
10 kg/cm2G.

(3) Pressurize HP system including HP Decomposer (U-DA201), Separator for HP

Absorbent (U-FA208) and HP Absorber (U-EA401) by nitrogen and control the
pressure at around 3 kg/cm2G by PV401.

(4) Maintain pressure of low pressure system including LP Decomposer (U-DA202)

and LP Absorber (U-EA402) at atmospheric pressure, around 0 kg/cm2G, to keep a
sufficient differential pressure between HP recovery system and LP recovery
system.

(5) Start Carbamate Boost-up Pump (U-GA401) and circulate water via FV108.

Following interlocks shall be bypassed before starting of Carbamate

Feed Pump (U-GA102).
- FV104 shut to U-GA102 stop
- FALL 108AB,BB

Refer to the Vendor’s Instruction for start-up of the pumps.

If discharge pressure of Carbamate Boost-up Pump (U-GA401) is

enough to send the water to Carbamate Condenser (U-EA101),
Carbamate Feed Pump (U-GA102) may not be operated.

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Before start-up of Carbamate Feed Pump (U-GA102), completely vent

the remained air in the suction line of Carbamate Feed Pump
(U-GA102) and pump casing to prevent cavitation.

After start-up, suction pressure of the pump should be frequently

checked to ensure the sufficient pressure for operation.

Keep suction flow rate (FIC108) more than U-GA102 minimum flow
rate.

(6) When the discharge pressure of Carbamate Feed Pump (U-GA102) raises above
Reactor (U-DC101) pressure, feed water into Carbamate Condenser (U-EA101)
through FV104.

Adjust manual valve at discharge of Carbamate Feed Pump

(U-GA102) and downstream of FV104 to maintain the opening of
FV104 at more than 4-5%.

Start LP Absorbent Pump (U-GA503), Carbonate Solution Pump

(U-GA403), and HP Absorbent Pump (U-GA402) to keep a proper level
for each absorber.

Feed water into LP Absorber (U-EA402) to help keeping the level,

through FI402.

Water from Steam Condensate Tank (U-FA103) can be used to

maintain the level in Process Condensate Tank (U-FA501), LP
Absorber (U-EA402), Washing Column (U-DA401) and HP Absorber
(U-EA401).

Flow rate of feed water to Carbamate Condenser (U-EA101) is around

22 t/h. (Refer to Fig. 4-7.)

(7) Start Ammonia Boost-up Pump (U-GA103).

Watch discharge pressure of Ammonia Boost-up Pump (U-GA103)

!
CAUTION
and control the pressure below 32 kg/cm2G that is design pressure of
LP casing of Ammonia Feed Pump (U-GA101) and is set pressure of

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SV134. The discharge pressure of Ammonia Boost-up Pump

(U-GA103) should become higher than normal operation because of
specific gravity difference between water and liquid ammonia.

DO NOT start Ammonia Feed Pump (U-GA101). Discharge pressure

!
CAUTION
of Ammonia Feed Pump (U-GA101) will exceed the design pressure
of piping due to difference of specific gravity (density) between water
and liquid ammonia.

(8) When a level appears in Carbamate Condenser (U-EA101), open HV106 to feed
the water to Reactor (U-DC101).

(9) Open FV101 to feed the motive water to Reactor (U-DC101) via HP Carbamate
Ejector (U-EE101). Control motive water pressure by PV107.

This action should be taken as soon as after starting filling-up of

Reactor (U-DC101) with water from Carbamate Condenser (U-EA101).

(10) Maintain the Carbamate Condenser (U-EA101) level.

(11) Adjust the operating conditions referring to Fig. 4-7.

(12) Confirm that all instruments, pumps, etc. are working normally.

The liquid densities are not same as specified to the instrument

manufactures because the plant is operated with water. Therefore,
these instruments will inaccurate readings slightly. However, since
the purpose of Water Run is confirmation of the functionality of
instruments, such minor deviation could be allowed.

(13) Check the level readings on the instruments and their actual levels at the field.

The indicated level may be a little different as compared with the

normal operation because of the density difference between water
and actual liquid.

(14) Switch the pumps to spares and clean the temporary strainers as often as possible.

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(15) 2 hours after starting water feed to Reactor (U-DC101), stop water run and drain out
the remained water in vessel completely.

Use pressuized air or nitorgen gas to drain water used for water run
to avoid generating vacuum condition inside vessels.

Drain water in Carbamate Condenser (U-EA101) before draining

water in Reactor (U-DC101) to prevent from making vacuum at top of
Reactor (U-DC101). Refer to Section 4.3.8.4 Drain.

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Fig. 4-7 Water Run

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4.5.5 Water Run for Dissolving Tank System

4.5.5.1 Preparation

(1) Follow the item (1) through (5) Para. 4.5.1.

(2) Clean inside of Dissolving Tank (U-FA302)

(3) Fill Dissolving Tank (U-FA302) with steam condensate until the proper level
(50-80%).

4.5.5.2 Start-up

(1) Start Dissolving Tank Pump (U-GA302) and circulate steam condensate.

Take care the opening of the circulation valve.

(2) Start Agitator for Dissolving Tank (U-GD302).

Confirm the liquid level of Dissolving Tank (U-FA302) is higher than the
required minimum level of Agitator for Dissolving Tank (U-GD302)
before starting Agitator for Dissolving Tank (U-GD302).

(3) Continue the operation for sufficiently long to check following items and to clean the
pipe work.

a) Temperature and sound of bearing and motor for Dissolving Tank Pump
(U-GA302) and Agitator for Dissolving Tank (U-GD302).
b) Ampere of these rotating machines (If available)
c) Instrument
d) Vibration (If available)

The liquid densities will not be same as specified to the instrument

manufacturers because the plant is operated with water. Therefore,
these instruments will not give accurate readings. However, since the
purpose of Water Run is confirmation of the functionality of
instruments, such minor deviation could be allowed.

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(4) After checking is completed, shut down and drain out the water in all equipment.

(5) Remove all temporary strainers.

4.6 Pre-commissioning for Prilling Section

4.6.1 Prilling Tower (U-IA301)

(1) Check Prilling Basket (U-FJ302A,B) based on the Vendor’s operating instruction.

(2) Check the clogging of Prilling Basket (U-FJ302A,B) and clean it, if necessary.

(3) Check Scraper (U-JJ301) based on the Vendor’s operating instruction.

(4) Check Urea Lump Separator Screen (U-FD301) is clean.

(5) Check Conveyor system if belt is decline or abnormal sound is detected etc.

4.7 Prilling Test

4.7.1 General

Prilling Test prior to the initial start-up of the Urea Unit has following purpose.

- Commissioning of Concentration and Prilling Section

- Training for Operators
- Flushing of Equipment and Piping with the Urea Solution

Prilling test and its preparation work consist of 3 steps.

- Dissolution of Urea
- Concentration of Urea Solution
- Prilling Test

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4.7.2 Dissolving of Urea

520 ton of prilled urea is dissolved into water to 60 wt% urea solution.

Urea: 520 ton (60%)

Water: 350 ton (40%)
---------------------
870 ton

Therefore 350 ton water is initially charged to the system.

4.7.3 Initial Water Charge

(1) All temporary strainers should be installed at each pump suction properly before the
water charge.

(2) Install a temporary bar screen or grating at manhole of Dissolving Tank (U-FA302).

(3) Install a temporary line from Urea Solution Pump (U-GA201) discharge (6US 22160
A1I0) to Dissolving Tank (U-FA302).

(4) Introduce 350 ton steam condensate to Urea Solution Tank (U-FA201) via Steam
Condensate Tank (U-FA103).

Keep the valves open on 12 inch equalization line (12US 22003 A1I0)
for Urea Solution Tank (U-FA201).

(5) Start Urea Solution Pump (U-GA201) and transfer the water in Urea Solution Tank
(U-FA201) to Dissolving Tank (U-FA302) through the temporary line.

Open continuously the 4 inch valve on return line to Urea Solution

Tank (U-FA201) (4US 22118 A1I0) to keep the minimum flow for Urea
Solution Pump (U-GA201).

(6) Start Dissolving Tank Pump (U-GA302) to circulate the water to Urea Solution Tank
(U-FA201).

(7) Stabilize the above (5 and 6) circulation.

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4.7.4 Dissolution of Urea

(1) Activate the steam trace on the urea solution return line to Urea Solution Tank
(U-FA201).

(2) Activate the steam for the heater in Urea Solution Tank (U-FA201).

(3) Activate the steam for Heater of Vacuum Concentrator (U-EA201).

(4) Activate the steam for the heater in Dissolving Tank (U-FA302).

(5) Raise the temperature of circulation water up to 80°C.

Thus, the circulation loop is completed as follows:

WATER
350 Ton

U-FA201 U-EA201 U-EA202

U-FA202 U-FA203

U-GA201 U-GA204

UREA 520 Ton

U-FA302 U-GA302
Temporary Line

(6) Feed the prilled urea to Dissolving Tank (U-FA302) through its manhole (where
temporary bar screen or a grating has been installed).

Total 520 ton prilled urea is dissolved in about 14 days, therefore, 35 -

40 ton per day prilled urea is fed to Dissolving Tank (U-FA302).

Keep the temperature of urea solution at 70 ~ 80°C.

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Close the manhole of Dissolving Tank (U-FA302), after dissolution of

520 ton prilled urea to get 60 wt% urea solution.

It is advisable to close steam valves of Dissolving Tank (U-FA302) if

urea solution is to be kept for a long storage.

4.7.5 Concentration of Urea Solution

60 wt% urea solution is concentrated up to 70 ~ 75 wt% under the vacuum condition in

Vacuum Concentrator (U-FA202).

(1) Open the feed valve (FV203) of Vacuum Concentrator (U-FA202) to transfer the urea
solution from Urea Solution Tank (U-FA201) to Vacuum Concentrator (U-FA202).

(2) Stop Dissolving Tank Pump (U-GA302) and circulating the urea solution to Urea
Solution Tank (U-FA201).

Flush the urea solution return line by SL Steam.

(3) Supply the urea solution through Heater of Vacuum Concentrator (U-EA201) to
Vacuum Concentrator (U-FA202) at the rate of approx. 145 t/h adjusted by FV203.

The bottom outlet urea solution of Vacuum Concentrator (U-FA202)

flows into Final Separator (U-FA203) through Final Concentrator
(U-EA202) by gravity.

(4) Open FV203 to transfer the urea solution from Urea Solution Tank (U-FA201) to
Vacuum Concentrator (U-FA202) when the level in Vacuum Concentrator (U-FA202) is
decreased.

(5) When the LIC207A (Level of Final Separator) goes up more than 100%, start Molten
Urea Pump (U-GA204) and send the urea solution to Urea Solution Tank (U-FA201)
via. three-way valve (HV301).

Thus, the circulation loop is completed as follows:

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HV301 LV207
U-IA301 U-GA204

U-FA201 U-FA203
FV203
U-GA201 U-EA201 U-FA202 U-EA202

(6) Prepare the vacuum generation system.

(a) Pass the cooling water to surface condensers.

(b) Fill Process Condensate Tank (U-FA501) with steam condensate.

(c) Start Process Condensate Pump (U-GA501) and make sure circulation
operation.

(d) Start LP Absorbent Pump (U-GA503) and open isolation valve of RO502.

(7) Start the vacuum concentration system and raise the vacuum gradually by PV203 and
PV206 on manual.

(8) Increase the outlet temperature of Heater of Vacuum Concentrator (U-EA201) to

100°C (TI209).

(9) When the vacuum level reaches to 250 mmHgA at PIC203, put PIC203 on auto.

(10) Concentrate the urea solution from 60 wt% to 70 wt%. The operation condition varies
as follows:

Concentration of urea solution : 60 → 70 wt%

Temperature of urea solution : 80 → 85°C
Pressure of system : 250 → 250 mmHgA
Density of urea solution : 1.135 → 1.165 g/cm3

When the level of Vacuum Concentrator (U-FA202) decreases by the

evaporation of water, make up 60 wt% urea solution from Urea
Solution Tank (U-FA201) to Vacuum Concentrator (U-FA202).

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4.7.6 Prilling Test

70 wt% urea solution in Vacuum Concentrator (U-FA202) is fed to Prilling Tower through
Final Concentrator (U-EA202) and Final Separator (U-FA203) to get prilled urea.

4.7.6.1 Start up of the Concentration and Prilling Section

70 wt% Urea Solution in Vacuum Concentrator (U-FA202) is concentrated up to more

than 99 wt% as molten Urea by Final Separator (U-FA203) under vacuum condition in
concentration section.

The molten Urea is sent to Prilling Section to get prilled urea. As for the start-up of the
concentration and Prilling Section, refer to para.5.2.11.

4.7.6.2 Prilling Test

1) Prilling Test is carried out 40% or more operating load, until minimum level of Urea
Solution Tank (U-FA201) and Vacuum Concentrator (U-FA202).

2) The following items shall be checked during this period.

- Distribution of Urea Droplets formed by Prilling Basket (U-FJ302A,B) in Prilling

Tower.

- Urea Product Condition (Temperature, size, form etc.)

4.7.6.3 After Prilling Test

1) Restoration of the temporary line or strainer.

2) Final Separator and Prilling Tower Section are washed or flushed by steam
condensate or steam completely. If the plant is planned to be start-up for 1 week or
less, keep the remaining of urea solution on Final Separator (U-FA203) by diluted to
60 wt% of Urea adding steam condensate.

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SECTION 5. START-UP

5.1 Introduction

5.2 Pre-Start-up Procedure

5.2.1 Passivation Run

5.2.2 Preparation and Receiving of Liquid NH3
5.2.3 Leak Test for Synthesis Loop
5.2.4 Preparation for Synthesis Section
5.2.5 Preparation for Purification and Recovery Sections
5.2.6 Preparation for Concentration Section
5.2.7 Preparation for Prilling Section
5.2.8 Start-up of Process Condensate Treatment Section
5.2.9 Heating up Synthesis Loop and Purification Section
5.2.10 Start-up of Synthesis Loop, Purification and Recovery Sections
5.2.11 Start-up of Concentration and Prilling Sections
5.2.12 Introducing SL steam to Turbine for CO2 Compressor (U-GT101)

5.3 Normal Start-up Procedure

5.3.1 Preparation
5.3.2 Start-up of Synthesis Loop, Purification and Recovery Sections
5.3.3 Purification and Recovery Sections on Service
5.3.4 Start-up of Concentration and Prilling Sections
5.3.5 Introducing SL steam to Turbine for CO2 Compressor (U-GT101)

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SECTION 5. START-UP
5.1 Introduction

In general, there are two kinds of start-up for urea production.

- Start-up with an empty Synthesis Loop

- Start-up with a solution in Synthesis Loop

The initial start, start-up after annual shutdown and or start after long time shutdown (more than
three days) are former case. This is called as "Pre-Start-up".

The start after short time shutdown (less than three days) is latter case. In the latter case,
Synthesis Loop is filled with solution under certain pressure and temperature. This is called as
"Normal Start-up".

5.2 Pre-Start-up Procedure

When the pre-commissioning work for Pre-Start-up such as unit commissioning, water
distribution test and water-run of Synthesis Loop, Concentration, Purification, Process
Condensate Treatment and Recovery Sections are completed sufficiently, start urea
production safely as following step.

Refer to Fig. 5-1 for the Pre-Start-up Schedule.

Steps: 1. Preparation for NH3 Receiving.

2. Pressurizing Synthesis Loop and Leak Test.

3. Preparation for Recovery Section.

4. Start-up of Process Condensate Treatment Section.

5. Heating up Synthesis Loop and Purification Section.

6. Start-up of Synthesis Loop, Purification and Recovery Sections.

7. Start-up of Concentration and Prilling Sections.

In order to prevent the loss of production and raw materials, following steps are highly
recommendable:

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Make sure that NH3 and CO2 are being produced in sufficient amounts with required qualities.

In case of start-up after annual shutdown or drained from Reactor (U-DC101), the solution in
Carbonate Solution Tank (U-FA401) and Urea Solution Tank (U-FA201) can be used
instead of demineralized water or steam condensate.

(1) As for the finishing section, pumps and conveyors should be kept running at least six
hours prior to service, to check the operation, to dry the equipment and to make sure
readiness for start-up.

(2) Make sure that all instruments work well (Do not forget to check controllability of some
control valves which are not used during normal operation, e.g. LV104B : located at
U-EA102 No.1 Ammonia Preheater Shell Side Inlet) and control valves are set on the
start-up positions. See "Start-up Positions of the Control Valve" in Table 5-1.

(3) Make sure that all utilities are ready and available such as steam, electric power, cooling
water, demineralized water, instrument air and nitrogen.

(4) Make sure that all drain, sample and vent valves on process lines are closed.

(5) Make sure that all isolation valves of control valves are opened.

(6) Make sure that all isolation valves of safety valves and rupture disks are opened.

(7) The recycle NH3 inlet valves of Ammonia Reservoir (U-FA104) are opened.

(8) Receive demineralized water and/or condensate into Steam Condensate Tank
(U-FA103) and activate condensate return lines.

(9) Fill the following vessels with water from Steam Condensate Tank (U-FA103) or
Carbonate Solution Tank (U-FA401). (Refer to 5.2.5)

(a) HP Absorber (U-EA401) → up to 50 ~ 60%

(b) LP Absorber (U-EA402) → up to 40 ~ 50%

(10)Fill steam condensate or demineralized water into Tempered Water Expansion Tank
(U-FA402) for initial make up, and pressurize tempered water system with nitrogen up to
2 kg/cm2G through PV736A.

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(11)Start Tempered Water Pump (U-GA405) to pass tempered water through HP Absorber
(U-EA401), adjust flow rate at 429 t/h manually and put FIC404 on auto.

(12)Put on nitrogen gas into the high pressure system and the low pressure system to purge
all remaining air from the highest vent of the system to atmosphere. If there is not
enough amount of nitrogen gas for air purge from the system, the above procedure can
be eliminated but an explosive gas may exist in the system during start-up operation, so
attention should be paid to prevent explosion.

Tempered water circulation line shall be fully filled by steam condensate.

Close PV736B to avoid overflow during filling up.

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Table 5-1 Start-up Positions of the Control Valve

Item No. Service Position Setting Value

FV101 NH3 to HP Carbamate Ejector (U-EE101) M/C

FV104 Carbamate Solution to Carbamate Condenser M/C

(U-EA101)

FV105 CO2 Feed to Reactor (U-DC101) M/C

FV106 NH3 Seal to Carbamate Condenser (U-EA101) M/C

FV108 Carbamate Feed Pump (U-GA102) Recycle Line M/O

FV109 Blow-down from Steam Drum (U-FA102) M/C

FV131 Ammonia Feed Pump (U-GA101) Recycle Line M/O

FV156 Passivation Air to CO2 Compressor (U-GB101) M/C

FV202 CO2 Gas to LP Decomposer (U-DA202) M/C

FV203 Heater of Vacuum Concentrator (U-EA201) M/C

FV204 Absorbent from No.2 HP Absorbent Pump M/C

(U-GA404)

FV209 Absorbent from HP Absorbent Circulation Pump M/C

(U-GA202)

FV401 Carbamate Solution to Washing Column M/C

(U-DA401)

FV404 Tempered Water Bypass for Tempered Water A

Cooler (U-EA403)

FV406 Carbamate Boost-up Pump (U-GA401) Recycle M/C

Line

FV504 Process Condensate to Preheater for Process M/C

Condensate Stripper (U-EA504)

FV505 SL Steam to Process Condensate Stripper M/C

(U-DA501) Bottom
FV506 Process Condensate to Washing Column M/C
(U-DA401)

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Table 5-1 Start-up Positions of the Control Valve

Item No. Service Position Setting Value

FV508 SM Steam to Urea Hydrolyzer (U-DA502) Tray M/C
Section

FV509 SM Steam to Urea Hydrolyzer (U-DA502) M/C

Stripping Section

FV705 Return Condensate Pump (U-GA107) to Turbine A

Condenser (U-EA105)

HV103 Carbamate Condenser (U-EA101) Top Vent O

HV105 CO2 Feed to Stripper (U-DA101) C

HV106 Urea Solution to HP Carbamate Ejector C

(U-EE101)

HV108 LP Steam Flash Drum (U-FA105) Make-up C

HV301 Molten Urea to Prilling Device A to C

HV302 Process Condensate to Molten Urea Line C

HV303 LP Steam to Molten Urea Line C

HV401 Washing Column (U-DA401) C.W Outlet C

HV402 LP Absorber (U-EA402) C.W Outlet C

HV403 HP Absorbent Pump (U-GA402) Minimum Flow C

HV501 Flash Gas Condenser (U-EA506) Gas Outlet C

HV715 Process Condensate to Vent Stack C

LV102 Urea Solution from Stripper (U-DA101) Bottom M/C

LV103 Steam Drum (U-FA102) Make-up A 50%

LV104A No.1 Ammonia Preheater (U-EA102) Steam M/C

Condensate Out

LV104B Steam Condensate at No. 1 Ammonia Preheater M/C

(U-EA102) Bypass

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Table 5-1 Start-up Positions of the Control Valve

Item No. Service Position Setting Value

LV106 Steam Condensate from Steam Saturation Drum M/C
(U-FA101) to Steam Flash Drum for HP
Decomposer (U-FA106)

LV107 Steam Condensate from Steam Flash Drum for M/C

HP Decomposer (U-FA106) to Steam Drum
(U-FA102)

LV131 NH3 to Ammonia Reservoir (U-FA104) M/C

LV151 Condensate from 1st Stage Suction Separator A 50%

for CO2 Compressor (U-FA111)

LV153 Condensate from 2nd Stage Suction Separator A 50%

for CO2 Compressor (U-FA112)

LV155 Condensate from 3rd Stage Suction Separator A 50%

for CO2 Compressor (U-FA113)

LV157 Condensate from 4th Stage Suction Separator A 50%

for CO2 Compressor (U-FA114)

LV201 Urea Solution from HP Decomposer (U-DA201) M/C

Bottom

LV202 Urea Solution from LP Decomposer (U-DA202) M/C

Bottom

LV206 Condensate from Condensate Pot for Vacuum A 50%

Concentrator (U-FA207)

LV207 Urea Solution from Molten Urea Pump M/C

(U-GA204) to Prilling Tower (U-IA301)

LV208 Steam Condensate from Condensate Pot for HP A 50%

Decomposer (U-FA206)

LV209 Separator for HP Absorbent (U-FA208) to HP A 50%

Absorber (U-EA401)

LV303 Dissolving Tank Pump (U-GA302) Discharge M/C

LV403 Washing Column (U-DA401) to LP Absorber M/C

(U-EA402)

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Table 5-1 Start-up Positions of the Control Valve

Item No. Service Position Setting Value

LV405 Washing Column (U-DA401) to HP Absorber A 50%

(U-EA401)

LV502 Process Condensate Stripper (U-DA501) Middle M/C

LV503 Process Condensate Stripper (U-DA501) Bottom M/C

LV504 Preheater for Urea Hydrolyzer (U-EA505) to M/C

Process Condensate Stripper (U-DA501)

LV701 Steam Condensate to Sealing Water Tank A 50%

(U-FA121)

LV702 Return Steam Condensate from Steam A 50%

Condensate Pump (U-GA106)

LV704 Return Condensate Pump (U-GA107) Discharge A 50%

Line

LV711A Steam Condensate to Tempered Water A 50%

Expansion Tank (U-FA402)

LV711B Tempered Water from Tempered Water A 50%

Expansion Tank (U-FA402)

PV101 Carbamate Condenser (U-EA101) Top Gas M/C

PV106 SML Steam to Steam Saturation Drum M/C

(U-FA101)

PV107 Motive NH3 to HP Carbamate Ejector (U-EE101) M/O 70%

PV111 SL Steam to No.3 Ammonia Preheater M/C

(U-EA103)

PV113A SML Steam to Steam Flash Drum for HP M/C

Decomposer (U-FA106)

PV113B Steam from Steam Flash Drum for HP M/C

Decomposer (U-FA106) to SL Steam Header

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Table 5-1 Start-up Positions of the Control Valve

Item No. Service Position Setting Value

PV114 LLP Steam to No.2 Ammonia Preheater (EA106) M/C

PV121 High Pressure Flooding Pump (U-GA105) M/O

Discharge

PV131A HP Nitrogen to Ammonia Reservoir (U-FA104) M/C

PV131B Vent Gas from Ammonia Reservoir (U-FA104) M/C

PV153 CO2 Compressor (U-GB101) 4th Stage Vent M/O

PV202 SL Steam to HP Decomposer (U-DA201) M/C

PV203 Vacuum Controller of Vacuum Concentrator M/O

(U-FA202)

PV205 SL Steam to LP Decomposer (U-DA202) M/C

PV206 Vacuum Controller of Final Separator (U-FA203) M/O

PV207 LP Steam to Heater of Vacuum Concentrator M/C

(U-EA201)

PV208 LP Steam to Final Concentrator (U-EA202) M/C

PV209 Mixed Gas from Carbamate Condenser M/O

(U-EA101) to HP Absorber (U-EA401)

PV301 Steam Jacket for Molten Urea Line A 2.8 kg/cm2G

PV401 Washing Column (U-DA401) Top Vent M/O

PV402 LP Absorber (U-EA402) Top Vent M/O

PV501 Process Condensate Stripper (U-DA501) Top M/C

PV502 Urea Hydrolyzer (U-DA502) Top M/C

PV706 Sealing Water Pump (U-GA121) to Sealing A 28 kg/cm2G

Water Cooler (U-EA121)

PV711 Cooling Water Bypass (CO2 Compressor A 3 kg/cm2G

(U-GB101))

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Table 5-1 Start-up Positions of the Control Valve

Item No. Service Position Setting Value

PV712 Cooling Water Bypass (Process Line) A 3 kg/cm2G

PV722 SM Steam Letdown to SML Steam M/C

PV723 SML Steam Header Vent A 21.5 kg/cm2G

PV724 SML Steam Letdown to SL Steam M/C

PV725 Turbine for CO2 Compressor (U-GT101) M/C

Admission Steam

PV726 SL Steam Vent A 6.0 kg/cm2G

PV727 SL Steam Letdown to SLL Steam M/C

PV731 IP Steam from Ammonia Plant M/C

PV734 HP Nitrogen Bypass A 21 kg/cm2G

PV735 SLL Steam Vent M/C

PV736B Nitrogen to Tempered Water Expansion Tank A 2.0 kg/cm2G

(U-FA402)

PV736B Nitrogen from Tempered Water Expansion Tank A 2.0 kg/cm2G

(U-FA402)

TV162 Cooling Water Outlet from 3rd Stage Intercooler M/O

for CO2 Compressor (U-EA113)

TV402 Tempered Water to Tempered water cooler M/O

(U-EA403)

TV702 Steam Condensate to Desuperheater (BH702) M/C

AV501 Treated Process Condensate (3-way valve) to A to B 30.0 µs/cm

B.L.

AV701 Steam Condensate Return (3-way valve) to B.L. A to B 30.0 µs/cm

AV702 Turbine Condensate Return (3-way valve) to B.L. A to B 30.0 µs/cm

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Table 5-1 Start-up Positions of the Control Valve

Item No. Service Position Setting Value

UV151 CO2 Compressor (U-GB101) LP Casing M/O
Anti-Surge Valve

UV152 CO2 Compressor (U-GB101) HP Casing M/O

Anti-Surge Valve

Note M/O = Manual Open M/C = Manual Close

O = Open C = Close
A = Automatic

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5.2.1 Passivation Run

In urea process, equipment, instruments and pipe lines exposed to corrosive

urea-carbamate environment must be in passivated condition to avoid excessive
corrosion. In normal operating condition, continuously supplied passivation air maintains
passivated (oxidized) film on the interior surface of equipment, instruments and pipe
lines.

“Passivation run” is essentially required to form the passivated film on equipment,

instruments and pipe lines for the following occasions:

(1) Before initial start-up of the plant

(2) Before start-up after replacing or adding new equipment

(3) Before start-up after repairing and/or replacing internal parts of equipment, instruments
or piping.

5.2.1.1 HP Decomposer (U-DA201)

(1) Make sure that all the valves are set on correct positions (refer to Fig. 5-2).

(2) Make sure that utilities (steam, instrument air, plant air, etc) are in service
condition.

(3) Introduce the plant air first and then introduce SML (20 kg/cm2G) steam to the
system (refer to Fig. 5-2).

Open the drain valve fully and open the plant air isolation valve by
two turns.

(4) Maintain the temperature (TI201) of HP Decomposer (U-DA201) at higher than

130 ºC for a minimum of 4 hours.

Maintain system pressure about 3 kg/cm2G by LV201.

(5) Stop feeding of SML (20 kg/cm2G) steam to system.

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(6) Drain out steam condensate inside the system.

Before and during draining, pressurize the system by supplying the

plant air continuously to prevent vacuum in the system.

(7) Stop feeding plant air to system.

5.2.1.2 Synthesis Loop

(1) Make sure that all the valves are set on correct positions (refer to Fig. 5-3).

(2) Make sure that utilities are in service condition.

(3) Make sure that all steam tracings and all steam jackets for control valves and
safety valves in Synthesis Loop are on service.

(4) Make sure that steam jacket for Carbamate Condenser (U-EA101) top part is
activated.

(5) Introduce plant air to the system by opening the isolation valve by two turns.

(6) Fill hot steam condensate to Steam Saturation Drum (U-FA101) up to normal level
by Low Pressure Flooding Pump (U-GA104). When LIC106 comes to 50%, put it
on auto.

(7) Introduce steam from PV722 and PV106 to Steam Saturation Drum (U-FA101).

PV722 and PV106 shall be opened little by little by manual to prevent

!
CAUTION
water hammering in Steam Saturation Drum (U-FA101).
Temperature indicator TI116 is a guideline for injection rate of steam.

(8) Introduce steam to SL steam by opening PV724 little by little.

(9) Feed hot steam condensate to Steam Drum (U-FA102) from Steam Saturation
Drum (U-FA101) via Flash Drum for HP Decomposer (U-FA106) and make level.

LV106 shall be opened little by little by manual to prevent water

!
CAUTION
hammering in Flash Drum for HP Decomposer (U-FA106).

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!
CAUTION
LV107 shall be opened little by little by manual to prevent water
hammering in Steam Drum (U-FA102).

(10) Start Steam Condensate Circulation Pump (U-GA109) to circulate steam

condensate through Carbamate Condenser (U-EA101).

Steam Drum (U-FA102) should be filled with steam condensate up to

90% level prior to starting Steam Condensate Circulation Pump
(U-GA109) to maintain sufficient level after tube side and associated
piping are filled with steam condensate.

(11) Pressurize Steam Drum (U-FA102) by SL (5 kg/cm2G) steam by PIC724.

(12) Introduce SML (20 kg/cm2G) steam to the system (refer to Fig. 5-3). At first open
the valve for SML (20 kg/cm2G) about 1/4 turn, taking care of quick rise of
temperature.

(13) Increase SML (20 kg/cm2G) feed rate after Reactor (U-DC101) is completely
heated up.

- During heating up, considerable amount of steam condensate may accumulate

in the bottom of Reactor (U-DC101), Stripper (U-DA101) and Carbamate
Condenser (U-EA101).

- Drain steam condensate from Synthesis Loop via drain lines.

Temperature difference between the lining and the shell shall not
!
CAUTION
exceed 50 ºC.

Heating up speed of the equipment in Synthesis Loop shall not

!
CAUTION
exceed 30 ºC/h. Temperature profile shall be monitored with
following temperature indicators:

Top position Bottom position

Item

Reactor (U-DC101) TI101 TI103

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Stripper (U-DA101) TI111 TI113

Carbamate Condenser (U-EA101) TI106 TI108

(14) Maintain the temperature at each point at more than 130 ºC for a minimum of 4
Hours.

Maintain system pressure about 3 kg/cm2G by HV103.

(15) Stop feeding SML (20 kg/cm2G) steam.

(16) Drain out steam condensate in the system.

!
CAUTION
Before and during draining, pressurize the system by supplying the
plant air continuously to prevent vacuum in the system.

(17) Stop feeding plant air.

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5.2.2 Preparation and Receiving of Liquid NH3

(1) Preparation

(a) Make sure that liquid NH3 is available in sufficient quality and quantity.

(b) Make sure that all isolation valves and spectacle blinds on NH3 import lines are
open.

(c) Build up pressure in Ammonia Reservoir (U-FA104) up to 15 kg/cm2G with

nitrogen gas.

PV131 manual operation.

(2) Receive liquid NH3 into Ammonia Reservoir (U-FA104) by following manner:

(a) Gradually open the level control valve (LV131) on manual to receive liquid
NH3 after the NH3 inlet valve to Ammonia Reservoir (U-FA104) and the
bypass valve for the flow meter (FI132) are opened.

In case turbine meter type is applied, FIQ132 shall be replaced with

spool piece temporary during initial make up to prevent fouling it
with catalyst powder etc. in liquid ammonia.

(b) Control U-FA104 pressure to 18 kg/cm2G by PV131 manually

(3) Switch the level control (LIC131) on auto, when the level comes to 50%.

(4) Switch the pressure control (PIC131) on auto, and maintain U-FA104 pressure at 18
kg/cm2G

If the temperature of liquid NH3 is 30 ~ 38°C, the vapor pressure of

liquid NH3 is 11 ~ 14 kg/cm2A.

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5.2.3 Leak Test for Synthesis Loop

This step is required just before raw material feed into the plant in case of initial start-up
and after maintenance shutdown of Synthesis Section.

All systems should be ready for operation.

The Synthesis Loop has 5 manholes and so many numbers of flanges. Once it happens to
leak strongly from those flanges after feeding NH3 and carbamate solution to the system,
all materials in Synthesis Loop should be drained out to Carbonate Solution Tank
(U-FA401). Therefore, this step is quite important prior to start-up of Synthesis Loop.

Refer to Fig. 5-4, regarding the pressure profile of this stage.

(1) Start CO2 Compressor (U-GB101) and keep venting CO2 to atmosphere through
PV153.

Regarding the detail, refer to the vendor’s instruction.

(2) Pressurize Synthesis Loop up to 50 kg/cm2G by CO2 gas.

(a) Open (1.1/2") bypass valve of the (8”) isolation valve on CO2 Compressor
(U-GB101) discharge line (8CO 21620 F1A2).

(b) Open (3/4") drain valve connected to the check valve at upstream of HV105 and
purge the CO2 gas in the compressor discharge line till the temperature of the
purged CO2 gas becomes around 40 ºC.

(c) Close the above mentioned (3/4") drain valve.

(d) Gradually open HV105 (CO2 feed to Stripper (U-DA101)) on manual and feed
CO2 gas to Synthesis Loop, while watching FI151 (CO2 gas intake from BL) and
FI155 (CO2 to Stripper & Reactor).

(e) Maintain the pressurizing speed of Synthesis Loop less than 30 kg/cm2/h by
HV105 and/or HV103 (vent from Carbamate Condenser (U-EA101) top).

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Adjust the CO2 intake rate (FI151) to CO2 Compressor (U-GB101) at

around 24,200 Nm3/h (40% of normal) by PV153.

(3) After pressurizing Synthesis Loop to 50 kg/cm2G, gradually close HV105 and HV103
fully.

Confirm that PIC153 is controlling compressor discharge pressure

and maintaining the CO2 intake rate (FI151) to CO2 Compressor
(U-GB101) at around 24,200 Nm3/h.

(4) Check leaks at 50 kg/cm2G by soap water.

(5) Pressurize Synthesis Loop up to 100 kg/cm2G by opening HV105 gradually.

(a) Crack open HV103 to continue CO2 purge.

(b) Gradually open the (8”) isolation valve on CO2 Compressor (U-GB101)
discharge line (8CO 21620 F1A2) and close it's (1.1/2") bypass valve.

Pay attention to FV105 and HV105 opening when changing over from
(1.1/2”) bypass to (8”) main valve to avoid sudden increase of CO2
flow to Synthesis Loop.

(6) Open (3/4") drain valve connected to the check valve at upstream of FV105, and purge
the CO2 gas in Reactor (U-DC101) inlet line (4CO 21630 M1J1) for 5 minutes.

(7) Open FV105 gradually to feed CO2 to Reactor (U-DC101).

Maintain pressurizing speed of Synthesis Loop less than 30 kg/cm2/h.

(8) After pressurizing Synthesis Loop to 100 kg/cm2G, gradually close HV105, FV105 and
HV103 fully.

Confirm that PIC153 is controlling compressor discharge pressure

and maintaining the CO2 intake rate (FI151) to CO2 Compressor
(U-GB101) at around 24,200 Nm3/h.

(9) Check leaks at 100 kg/cm2G by soap water.

(10) Pressurize Synthesis Loop up to 155 kg/cm2G by opening HV105 and FV105
gradually.

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Maintain the pressurizing speed of Synthesis Loop less than 30

kg/cm2/h by adjusting HV105 and/or FV105.

Maintain the CO2 intake rate (FI151) to CO2 Compressor (U-GB101) at

around 24,200 Nm3/h.

(11) After the pressure of Synthesis Loop is raised up to 155 kg/cm2G, close HV105, FV105
and isolation valve on (8") CO2 line to maintain the pressure at 155 kg/cm2G.

(12) Check the leakage from all manholes and flanges by soap water, and retighten the
bolts and nuts, if necessary.

(13) After leak test, depressurize Synthesis Loop to atmospheric pressure for starting up
the Synthesis Loop.

Keep the depressurizing speed less than 10 kg/cm2/h.

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 P S
CO 2 S
K P C
Carbamate Solution
P C
NH 3
TITLE

S
DOC NO.

Legend

2
S : Start

( kg/ c m G)
K : Kick Back
P : Preparation Load up
C : Circulation Leak Test at 155 kg/cm 2 G
150
000-0001

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Urea Plant

Depressurizing
100 10 kg/cm 2 /h
Operation Instruction for

HURL-G-LD-U00-PRS-IOM-

Leak Test 50 & 100 kg/cm 2 G

Rev

Date

50 Heating up & Pressurizing Heating up NH3 Feed

30℃/h, 30 kg/cm 2 /h 130℃
Carbamate Sol. Feed
00

0
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38
18-FEB-2019

(Hour)
Fig. 5-4 PRESSURE PROFILE DURING START-UP OF SYNTHESIS
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5.2.4 Preparation for Synthesis Section

(1) Open the following isolation valve.

- Isolation valve of HV103

- Isolation valve of FV101
- Isolation valve of FV106
- Isolation valve of FV109
- Isolation valve of PV101
- Isolation valve of PV106
- Isolation valve of LV102

(2) Confirm the interlock system before start-up as follows.

- Signal to PV153 open Bypassed

- FV101 shut Normal
- FV104 shut Normal
- FV105 shut Normal
- FV106 shut Normal
- HV105 shut Normal
- HV106 shut Normal
- LV102 shut Normal
- PV111 shut Normal
- FV104 shut to U-GA102 Stop Bypassed
- HV105 shut to U-GA101/U-GA102 Stop Bypassed
- FV101 shut to U-GA101 Stop Bypassed
- FIC108 Low Low to U-GA102 Stop Bypassed
- FIC131 Low Low to U-GA101 Stop Bypassed

5.2.5 Preparation for Purification and Recovery Sections

Preparation for Purification Section shall be performed within the leak test operation step
of Synthesis Loop.

(1) Check the following isolation valves are opened.

- Isolation valve of LV201

- Isolation valve of LV202
- Isolation valve of PV401
- Isolation valve of PV402

(2) Close the gas inlet valve from HP Decomposer (U-DA201) to Separator for HP

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Absorbent (U-FA208).

(3) Flush urea solution line by SML steam for 2 hours by the same procedure of
passivation run (Refer to 5.2.1).

(a) Open LV201 and LV202.

(b) Open PV202 and PV205. Introduce SL steam to shell side of HP Decomposer
(U-DA201) and LP Decomposer (U-DA202). Adjust the steam pressure at around
4.0 kg/cm2G.

(c) Flush from LV102 outlet lines to HP Decomposer (U-DA201), LP Decomposer

(U-DA202) and Flash Separator (U-FA205).

(4) Pass cooling water to Washing Column (U-DA401) and LP Absorber (U-EA402).

(5) Receive demineralized water and/or steam condensate into Steam Condensate Tank
(U-FA103).

(6) Start Tempered Water Pump (U-GA405) and pass tempered water through HP
Absorber (U-EA401).

(7) Put on nitrogen gas into the high pressure system and the low pressure system to
purge all the remaining air to atmosphere.

(8) Build up pressure in Separator for HP Absorbent (U-FA208), HP Absorber (U-EA401)

and Washing Column (U-DA401) up to 15.0 kg/cm2G with nitrogen and put PIC401 on
auto.

(9) Build up pressure in LP Decomposer (U-DA202) and LP Absorber (U-EA402) up to 1.5

kg/cm2G with CO2 gas using FV202 (or N2 gas) and put PIC402 on auto.

(10) Confirm the level of HP Absorber (U-EA401), bottom part of Washing Column
(U-DA401) and LP Absorber (U-EA402). If required, fill up HP Absorber (U-EA401),
Washing Column (U-DA401) and LP Absorber (U-EA402) with carbonate solution from
Carbonate Solution Tank (U-FA401) or steam condensate from Steam Condensate
Tank (U-FA103).

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(a) Fill LP Absorber (U-EA402) with carbonate solution from Carbonate Solution
Tank (U-FA401) up to 50 ~ 60% of LIC402.

(b) Fill the bottom part of Washing Column (U-DA401) with carbonate solution from
LP Absorber (U-EA402) via HP Absorbent Pump (U-GA402).

(c) Start No.2 HP Absorbent Pump (U-GA404) when the level in bottom part of
Washing Column (U-DA401), becomes sufficient. Open the manual valve on
the circulation line to Washing Column (U-DA401) to keep minimum flow.

(d) Fill HP Absorber (U-EA401) with carbonate solution from Washing Column
(U-DA401) by No.2 Absorbent Pump (U-GA404) and LIC405.

(11) Start HP Absorbent Pump (U-GA402) and make circulation flow through LP Absorber
(U-EA402).

(12) Confirm the level of Separator for HP Absorbent (U-FA208). If required, fill up
Separator for HP Absorbent (U-FA208) with steam condensate from Steam
Condensate Tank (U-FA103). Start HP Absorbent Circulation Pump (U-GA202) and
make circulation flow through Separator for HP Absorbent (U-FA208).

(13) Regarding start-up of Carbamate Feed Pump (U-GA102), refer to 5.2.10 (11).

5.2.6 Preparation for Concentration Section

(1) Flush the following process lines with SL steam or steam condensate to confirm the
lines are not plugged.

- Urea Solution Pump (U-GA201) suction and discharge line

- Molten Urea Pump (U-GA204) suction and discharge line

(2) Close all drain, vent and sampling valves.

(3) Activate all steam tracing and steam jackets except the steam jacket of Molten Urea
Pump (U-GA204) to avoid pump cavitation.

(4) Make sure that all block valves for control valves are opened.

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(5) Make sure that all relevant instruments are ready and control valves are set on start-up
positions.

(6) Fill the suction line and casing of Urea Solution Pump (U-GA201) and Molten Urea
Pump (U-GA204) with steam condensate to prevent clogging.

(7) Crack open the steam inlet valve (PV207) to Heater of Vacuum Concentrator
(U-EA201) for warming up.

(8) Purge the inert gases in shell side of Heater of Vacuum Concentrator (U-EA201) by
opening vent valves, and then close them.

(9) Flush PIC203 detecting point with steam and inject instrument air at 0.16 Nm3/h
through FI205.

(10) Crack open the steam inlet valve (PV208) to Final Concentrator (U-EA202) for
warming up.

(11) Purge the inert gases in shell side of Final Concentrator (U-EA202) by opening vent
valves, and then close them.

(12) Flush PIC206 detecting point with steam and inject instrument air at 0.16 Nm3/h
through FI208.

5.2.7 Preparation for Prilling Section

5.2.7.1 Preparation for Prilling Tower

(1) Fill the following vessels with potable water up to normal liquid level.

- Water Tank (U-FA305)

(2) Make sure that the following items are filled with dilute urea solution up to the normal
liquid level. At initial start-up, fill them with demineralized water and/or steam
condensate.

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- Dissolving Tank (U-FA302)

(3) Start the following conveyors for drying at least six hours prior to their start-up.

- Belt Scale (U-JW301)

- Conveyor ways to Bulk storage or Bagging Facility

(4) Start the following rotating machines at least one hour prior to their start-up.

- Agitator for Dissolving Tank (U-GD302)

- Scraper (U-JJ301)

(5) Flush and heat up the line from HV301 to Prilling Basket (U-FJ302) through with SL
steam.

(6) Flush the urea solution return line from HV301 to Urea Solution Tank (U-FA201) with
SL steam and confirm no clogging inside the line.

(7) Set PIC301 at 2.8 kg/cm2G and activate the steam jacket for molten urea lines.

After start-up, set point of PIC301 can be reduced to 2.1-2.2 kg/cm2G

to minimize biuret formation.

(8) Activate all steam trace for molten urea lines

5.2.8 Start-up of Process Condensate Treatment Section

Follow (1) through (5) of Para. 4.5.3.1 and (1) through (17) of Para. 4.5.3.2.

5.2.9 Heating up Synthesis Loop and Purification Section

In order to save the time for start-up, it is possible to heat up Synthesis Loop using steam
heaters such as Stripper (U-DA101) and Carbamate Condenser (U-EA101) after "Leak
Test of Synthesis Section."

(1) Preparation of Steam Receiving.

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(a) Fill hot steam condensate to Steam Saturation Drum (U-FA101) up to normal
level by Low Pressure Flooding Pump (U-GA104).

(b) Introduce SML steam from PV722 and PV106 to Steam Saturation Drum
(U-FA101).

PV722 and PV106 shall be opened little by little by manual to prevent

!
CAUTION
water hammering in Steam Saturation Drum (U-FA101).
Temperature indicator TI116 is a guideline for injection rate of steam.

(c) Increase Steam Saturation Drum (U-FA101) pressure gradually by

PIC106.When PIC106 comes up to 10 kg/cm2G, put PIC106 on auto and heat
up the shell side of Stripper (U-DA101).

(d) Letdown SML steam to U-FA106, and control PIC113 at 8 kg/cm2G

(e) Introduce the steam to SL steam header by opening PV724 little by little. Adjust
the pressure at 5 kg/cm2G, and then put PIC724 on auto.

(f) Fill steam condensate to Flash Drum for HP Decomposer (U-FA106) up to

normal level by Steam Condensate Pump (U-GA106). When LIC107 comes to
normal level, put it on auto.

(g) Feed hot steam condensate to Steam Drum (U-FA102) from LP Steam Flash
Drum (U-FA105) via LV103 and make level.

LV103 shall be opened little by little by manual to prevent water

!
CAUTION
hammering in Steam Drum (U-FA102).

(h) Start Steam Condensate Circulation Pump (U-GA109) to circulate steam

condensate through Carbamate Condenser (U-EA101).

Steam Drum (U-FA102) should be filled with steam condensate up to

90% level prior to starting Steam Condensate Circulation Pump
(U-GA109) to maintain sufficient level after tube side and associated
piping are filled with steam condensate.

(i) Put all steam tracing and jacketing on service. (Except jacket of Carbamate

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Condenser (U-EA101) top crack open)

(2) Heating up Synthesis Loop and Purification Section.

Heating up speed of Synthesis Loop shall not exceed 30 ºC/h by

adjusting steam injection rate to Synthesis Section.

(a) Inject SML steam to Synthesis Loop.

Refer to 5.2.1.2 (same as Passivation Run Procedure).

(b) Heating up for HP Decomposer (U-DA201)

1. Make sure that all the valves are set on correct positions (Refer to Fig. 5-5).

2. Open PV202. Introduce SL steam to shell side of HP Decomposer (U-DA201).

Adjust the steam pressure at around 4.0 kg/cm2G.

3. Introduce SML (20 kg/cm2G) steam to the system.

If the steam condensate is accumulated in the bottom of HP

Decomposer (DA201), open LV201 and push out to downstream. In
case that pressure at U-DA201 is not enough to push out steam
condensate, open drain valve at upstream of LV201.

4. When the temperature (TI201) of HP Decomposer (U-DA201) is 130 oC, stop

feeding SML steam.

5. Drain out steam condensate inside the system.

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Fig. 5-5 HEATING-UP for HP DECOMPOSER (U-DA201)

(c) Heating-up for LP Decomposer (U-DA202)

1. Make sure that all the valves are set on correct positions (Refer to Fig. 5-6).

2. Open PV205. Introduce SL steam to shell side of LP Decomposer (U-DA202).

Adjust the steam pressure at around 4.0 kg/cm2G.

3. Introduce SL (5 kg/cm2G) steam to the system.

If the steam condensate is accumulated in the bottom of LP

Decomposer (U-DA202), open drain valve at the bottom of U-DA202.

4. When the temperature (TI203) of LP Decomposer (U-DA202) is 120 oC, stop

feeding SL steam.

5. Drain out steam condensate inside the system.

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Fig. 5-6 HEATING-UP for LP DECOMPOSER (U-DA202)

(d) Open the SML steam flushing valve for PV101 (Carbamate Condenser
(U-EA101) top) down-stream.

(e) Check the lines and vessels for Purification Section are clear and heated by
steam.

Downstream Downstream
LV102 DA201 LV201 DA202

(f) Make pressure (PIC101) around 3 kg/cm2G by adjusting HV103 and PV101
after temperature in Reactor (U-DC101), Stripper (U-DA101), and Carbamate
Condenser (U-EA101) become 100 ºC.

(g) When all the temperatures in Reactor (U-DC101), Stripper (U-DA101), and
Carbamate Condenser (U-EA101) become higher than 130 ºC, Synthesis Loop

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is just ready for Start Up.

(h) Pressurize PIC106 up to 10 ~ 15 kg/cm2G.

(i) Open vent valve (3/4”) at the shell side of Stripper (U-DA101) for 10 minutes.
(Air Release)

5.2.10 Start-up of Synthesis Loop, Purification and Recovery Sections

After succeeding to heating up, proceed the following steps.

(1) Make sure that the feed lines of liquid NH3, CO2 and carbamate solution and purge
lines of HV103 (Carbamate Condenser (U-EA101) top vent) and PV101 are clear,
wash by High Pressure Flooding Pump (U-GA105) or flush by steam, if necessary.

(2) Make sure that CO2 Compressor (U-GB101) is running under the condition of
discharge pressure 100 kg/cm2G (PIC153) and CO2 intake rate at 24,200 Nm3/h
(FI151).

(3) Fill steam condensate in the following points:

(a) Carbamate Condenser (U-EA101) to HP Carbamate Ejector (U-EE101) with

High Pressure Flooding Pump (U-GA105).

(b) Seal NH3 line from FV106 (Seal NH3) to Carbamate Condenser (U-EA101) with
High Pressure Flooding Pump (U-GA105).

(c) Carbamate Condenser (U-EA101) bottom with Low Pressure Flooding Pump
(U-GA104) through solution transfer line.

Confirm the line and Carbamate Condenser (U-EA101) bottom are

filled with steam condensate by checking TI108 (bottom temperature
of Carbamate Condenser (U-EA101)).

(d) FV101 (NH3 feed to HP Carbamate Ejector (U-EE101)) to Reactor (U-DC101)

via HP Carbamate Ejector (U-EE101) with High Pressure Flooding Pump
(U-GA105), and FV105 (CO2 feed to Reactor (U-DC101)) to Reactor (U-DC101)
with Low Pressure Flooding Pump (U-GA104).

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Confirm the bottom of Reactor (U-DC101) and its feed lines are filled
with steam condensate by checking TI103.

(e) Stripper (U-DA101) bottom with Low Pressure Flooding Pump (U-GA104).

(f) Detecting line for PT101, 102, 105 and 107 for each point with High Pressure
Flooding Pump (U-GA105).

(g) Transfer line in Synthesis Section with High Pressure Flooding Pump
(U-GA105).

(4) Crack open the steam valve and put SLL steam on outlet of SV101A,B,C,D.

(5) Open HV103 fully. And crack open the steam valve and put SLL steam on
downstream of HV103.

(6) After confirming TI163 (outlet temperature from Dehydrogen Column (U-DC151))
becomes higher than 150 ºC, inject passivation air to the CO2 gas by FIC156 and
switch FIC156 on auto.

(a) Injection rate of the passivation air should be 5,000 ppm as O2 in CO2 gas at exit
of Dehydrogen Column (U-DC151), therefore, the air flow rate is set at 830
Nm3/h at the CO2 intake rate (FI151) of 24,200 Nm3/h.

(b) Confirm O2 content at outlet of Dehydrogen Column (U-DC151) is 4,000 - 5,000

ppm by AI151 and H2 content is nil (less than 100ppm) by AI152.

(c) Check outlet temperature of Dehydrogen Column (U-DC151) is normal by

TI163.

(7) Introduce CO2 gas to Stripper (U-DA101) by (1.1/2") bypass valve of (8”) isolation
valve on CO2 Compressor (U-GB101) discharge line (8CO 21620 F1A2) at the flow
rate around 3,500 Nm3/h (FI155).

The purpose of this CO2 gas introducing is to establish CO2 gas flow
from Stripper (U-DA101) to Carbamate Condenser (U-EA101) prior to
carbamate and NH3 feeding.

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(a) Open (1.1/2") bypass valve of (8”) isolation valve on CO2 Compressor
(U-GB101) discharge line (8CO 21620 F1A2).

(b) Open (3/4") drain valve connected to the check valve at upstream of HV105,
and purge the CO2 gas in the compressor discharge line till the temperature of
the purged CO2 gas becomes around 40 ºC.

(c) Close the above mentioned (3/4") drain valve.

(d) Gradually open HV105 on manual and feed CO2 gas at 3,500 Nm3/h to
Synthesis Loop, while watching FI151 and FI155.

(e) Maintain the pressurizing speed of Synthesis Loop less than 30 kg/cm2/h by
HV105 and/or HV103.

(8) Introduce CO2 gas to Reactor (U-DC101) up to 1,750 Nm3/h (FIC105).

(a) Open (3/4") drain valve connected to the check valve at upstream of FV105, and
purge the CO2 gas in Reactor (U-DC101) inlet line for five minutes.

(b) Close the above mentioned (3/4") drain valve.

(c) Gradually open FV105 on manual and feed CO2 gas to Reactor (U-DC101)
1,750 Nm3/h while watching FI155 and FIC105.

Indication of FI155 will be 5,250 Nm3/h (= 3,500 Nm3/h + 1,750 Nm3/h).

Adjust the CO2 intake rate to CO2 Compressor (U-GB101) at around

24,200 Nm3/h (FIQ151) by PV153.

(9) Confirm HV103 opening and keep the opening at 5-10%.

Do not close HV103 fully to prevent inert gas accumulation at the top
!
CAUTION
of Carbamate Condenser (U-EA101).
(e) Maintain the pressurizing speed of Synthesis Loop less than 30
kg/cm2/h by HV105 and/or HV103.

(10) Start carbamate solution feed to Synthesis Loop as follows:

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Start Carbamate Feed Pump (U-GA102), at least 10 minutes before

solution is injected to Carbamate Condenser (U-EA101).

(a) Start Low Pressure Flooding Pump (U-GA104).

(b) Start Carbamate Boost-up Pump (U-GA401) to circulate the solution to HP

Absorber (U-EA401) via Carbamate Feed Pump (U-GA102) and FV108.
Usually this circulation can be continued during short period of shutdown.

Before start-up of Carbamate Boost-up Pump (U-GA401), fill up the

suction line and discharge line to FV104 of Carbamate Feed Pump
(U-GA102) with water by Low Pressure Flooding Pump (U-GA104)
and completely vent the remained air in the suction line of pump and
pump casing to prevent cavitation.

Before start-up of Carbamate Boost-up Pump (U-GA401), confirm

that the pressure of HP Absorber (U-EA401) is maintained at 15
kg/cm2G by nitrogen.

(c) Close FV104 (carbamate solution feed to Carbamate Condenser (U-EA101))

fully and open FV108 at 85 ~ 90% on manual. This operation establishes
solution flow from HP Absorber (U-EA401) to Carbamate Feed Pump
(U-GA102).

(d) Start Carbamate Feed Pump (U-GA102).

Before start-up of Carbamate Feed Pump (U-GA102), inject water to

the suction line of Carbamate Feed Pump (U-GA102) for washing the
system of Carbamate Feed Pump (U-GA102).

Refer to vendor's Instruction.

(e) Keep circulation through HP Absorber (U-EA401).

Keep suction flow rate (FIC108) more than U-GA102 minimum flow
rate.
“U-GA102 minimum flow” is defined as U-GA102 pump minimum flow
rate + flow rate for balance line.

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(f) Switch the Interlock bypass switch for “FIC108 Low Low to U-GA102 Stop” to “Not
Bypassed” from “Bypassed”.

(g) Control the discharge pressure of Carbamate Feed Pump (U-GA102) at sufficient
level.

(h) Open discharge valve and FV104.

(i) Feed the solution through FV104 to Carbamate Condenser (U-EA101) at a rate of
about 56 t/h.

When the opening of FV104 becomes small due to large pressure

difference of FV104, adjust the manual valve at downstream of FV104.

Maintain FIC108 (suction flow controller for Carbamate Feed Pump

(U-GA102)) at more than U-GA102 minimum flow by FV108 on auto.
“U-GA102 minimum flow” is defined as U-GA102 pump minimum flow
rate + flow rate for balance line.

Do not close FV108 fully to avoid choking of circulation line to HP

Absorber (U-EA401). Maintain FV108 opening at least 5-10% during
normal operation.

(j) Switch the Interlock bypass switch for “FV104 shut signal to U-GA102 stop” to “Not
Bypassed”.

(11) Preparation of carbamate solution feed to Synthesis Loop.

Make up the lean carbamate solution to Recovery Section as follows after feeding
carbamate solution to Synthesis Section is started.

(a) Make lines from “Carbonate Solution Tank (U-FA401) to Carbonate Solution
Pump (U-GA403)” and “Carbonate Solution Pump (U-GA403) to LP Absorber
(U-EA402)”. Confirm all drain valves and vent valves are closed.

(b) Introduce the solution to Carbonate Solution Pump (U-GA403) and remove the
air in the suction piping.

(c) Start Carbonate Solution Pump (U-GA403) and feed solution from Carbonate

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Solution Tank (U-FA401) to LP Absorber (U-EA402).

(12) Feed liquid NH3 to Carbamate Condenser (U-EA101).

Start Ammonia Feed Pump (U-GA101), at least 10 minutes before NH3

is injected to Carbamate Condenser (U-EA101).

(a) Make sure that Ammonia Reservoir (U-FA104) level is sufficient and the
pressure is maintained at 18 kg/cm2G.

(b) Confirm the suction valves (XV131 and manual valve) for Ammonia Boost-up
Pump (U-GA103) are open.

(c) Make sure that FV101 (NH3 feed to HP Carbamate Ejector (U-EE101)) and
FV106 (NH3 feed to Carbamate Condenser (U-EA101)) are closed on manual.

(d) Start Ammonia Boost-up Pump (U-GA103) through Ammonia Feed Pump
(U-GA101) and FV131 circulation line to Ammonia Reservoir (U-FA104).

(e) Start Ammonia Feed Pump (U-GA101).

Before start-up of Ammonia Feed Pump (U-GA101) and injection of

NH3 to Carbamate Condenser (U-EA101), inform Ammonia Plant of
start-up situation.

Before start-up of Ammonia Feed Pump (U-GA101), completely vent

the remained air in the suction line of the pump and pump casing to
prevent cavitation.

(f) Switch the Interlock bypass switch for “Signal to PV153 Open” to “Not
Bypassed” from “Bypassed” after both U-GA101 and U-GA102 have started.

(g) Maintain the discharge pressure of Ammonia Feed Pump (U-GA101) at

190~200 kg/cm2G by FV131.

This NH3 feed is for the purpose of sealing Carbamate Condenser

(U-EA101) bottom part and control solution composition in
Carbamate Condenser (U-EA101) during filling up.

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Keep FIC131 (suction flow controller for Ammonia Feed Pump

(U-GA101)) at more than U-GA101 minimum flow by adjusting FV131
manually.
“U-GA101 minimum flow” is defined as U-GA101 pump minimum flow
rate + flow rate for balance line.

Adjust FV131 to maintain the discharge pressure.

(h) Switch the Interlock bypass switch for “FIC131 Low Low to U-GA101 Stop” to
“Not Bypassed” from “Bypassed”

(i) After confirming PIC101 (Synthesis Loop pressure) becomes higher than 30
kg/cm2G, open discharge valve for Ammonia Feed Pump (U-GA101).

Do not feed NH3 to Carbamate Condenser (U-EA101) before PIC101

!
CAUTION
becomes 30 kg/cm2G to prevent adiabatic flashing of liquid NH3
which causes rapid temperature decreasing and freezing.

(j) Open the isolation valve of FV106 little by little, then gradually feed NH3 to
Carbamate Condenser (U-EA101) by opening FV106 a little on manual to
prevent the rapid temperature increase of Carbamate Condenser (U-EA101)
bottom (TI108 for process, TI110 for lining, TI109 for shell).

The temperature increase speed in Carbamate Condenser (U-EA101)

!
CAUTION
bottom shall be less than 10 ºC/minute (TI108)

!
CAUTION
Temperature difference between the lining and the shell (TI110 and
TI109) shall be less than 50 ºC.

(k) Control NH3 feed rate at 11,300 kg/h by FIC106.

(13) Continue filling operation of Carbamate Condenser (U-EA101).

During filling operation, adjust Steam Drum (U-FA102) pressure by

PIC724 (5-6 kg/cm2G) to control Carbamate Condenser (U-EA101)
temperature (TI106 and TI107) around 150 ~ 170 ºC.

Maintain Steam Saturation Drum (U-FA101) pressure at 10 kg/cm2G.

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It takes about 2 hours until Carbamate Condenser (U-EA101) is filled

with urea-carbamate solution.

Control raw material feed to Synthesis Loop as follows during filling

operation:

- CO2 to Stripper = 3,500 Nm3/h by HV105

- CO2 to Reactor = 1,750 Nm3/h by FV105
- NH3 to Carbamate Condenser = 11,300 kg/h by FV106
- Carbamate Solution to Carbamate Condenser = 56 t/h by FV104

(14) Increase the speed of CO2 Compressor (U-GB101)

(a) Make sure that synthesis pressure reaches 40 kg/cm2G.

(b) Increase the speed of CO2 Compressor (U-GB101) and close PV153 on manual
gradually.

(c) Increase the discharge pressure up to 160 kg/cm2G and maintain this condition.

(15) Open isolation valve of PV101 (Top of Carbamate Condenser (U-EA101)) and open
PV209 (mixed gas to HP Absorber (U-EA401)) on manual fully when level of
Carbamate Condenser (U-EA101) reaches 5th baffle plate (check TI107). Then
open PV101 gradually about 10% opening on manual to pressurize HP
Decomposer (U-DA201). After the pressure of HP Decomposer (U-DA201)
becomes to the same pressure of HP Absorber (U-EA401), open the gas inlet valve
to Separator for HP Absorbent (U-FA208). After that, close HV103 fully.

(16) Start introducing absorbent to shell side of Heater of Vacuum Concentrator

(U-EA201) lower part (SPN202A via FV204 and SPN202B,C via FV209). FIC204 is
to be set at 25t/h (40% load). FIC209 is to be set at 137t/h.

(17) Put PIC209 on auto at 25 kg/cm2G.

Pay attention to pressure increase in Washing Column (U-DA401).

(18) When the level in Carbamate Condenser (U-EA101) appears and LI101 becomes
20%, open HV106 gradually up to 20% to introduce urea synthesis solution from
Carbamate Condenser (U-EA101) to Reactor (U-DC101) by gravity.

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Pay attention to LI101. Adjust the opening of HV106 to keep LI101 at

40 ~ 50%.

The level during filling up Carbamate Condenser (U-EA101) is

checked by the temperature profile by TI106 and TI107.

Confirm solution flows to HP Carbamate Ejector (U-EE101) by AI101

(N/C Ratio Meter).

Confirm that urea synthesis solution comes to Reactor (U-DC101)

bottom by TI103.

(19) Feed NH3 to Reactor (U-DC101) via HP Carbamate Ejector (U-EE3101).

This action should be taken as soon as possible after starting

filling-up of Reactor (U-DC101) with CO2 and carbamate solution.

(a) Make sure that Ammonia Feed Pump (U-GA101) discharge pressure is
maintained at sufficient level.

(b) Make sure that PIC107 is 70% opening position on manual.

(c) Open FV101 (NH3 feed to HP Carbamate Ejector (U-EE101)) gradually on

manual and start feeding NH3 to Reactor (U-DC101) via HP Carbamate Ejector
(U-EE101).

(d) Control LI101 at 40 ~ 50% by HV106.

If LI101 becomes less than 10%, reduce motive NH3 pressure by

FIC131. Even if the level cannot be recovered by only adjustment of
motive NH3 pressure, close HV106 fully and wait for the level
increase.

(e) Control discharge pressure of Ammonia Feed Pump (U-GA101) by FV131 on

manual.

When the discharge pressure becomes high, adjust the manual valve
at the discharge of Ammonia Feed Pump (U-GA101).

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The temperature increase speed in Reactor (U-DC101) bottom shall

!
CAUTION
be less than 10 ºC/minute (TI103).

Temperature difference between the lining and the shell (TI104 and
!
CAUTION
TI105) shall be less than 50 ºC.

(f) Increase FIC101 to 61 t/h on manual and keep discharge pressure of Ammonia
Feed Pump (U-GA101) by adjusting PIC107 on manual.

Maintain FIC131 at more than U-GA101 minimum flow by FV131 on

auto.
“U-GA101 minimum flow” is defined as U-GA101 pump minimum flow
rate + flow rate for balance line.

(g) Put FIC101 on auto at 61 t/h.

(h) Put FIC106 (NH3 feed to Carbamate Condenser (U-EA101)) on auto at 11,300
kg/h.

(i) Switch the Interlock bypass switch for “FV101 shut signal to U-GA101 stop” to
“Not Bypassed”.

(20) Put No.3 Ammonia Preheater (U-EA103) on service. Increase TIC118 (NH3 exit
temperature) slowly up to 138ºC by adjusting PIC111.

(21) Increase CO2 feed rate to Reactor (U-DC101) up to 21,400 Nm3/h (FIC105).

(a) Gradually open 8” isolation valve on CO2 Compressor (U-GB101) discharge line
(8CO 21620 F1A2) and close its 1.1/2” bypass valve.

(b) Pay attention to the opening of FV105 and HV105 to avoid sudden increase of
CO2 flow rate when changing over the 8” and 1.1/2” valves.

!
CAUTION
The temperature increase speed in Reactor (U-DC101) bottom shall
be less than 10 ºC/minute (TI103).

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!
CAUTION
Temperature difference between the lining and the shell (TI104 and
TI105) shall be less than 50 ºC.

(22) When 45 – 60 minutes passed since activating HP Carbamate Ejector (U-EE101),

prepare for overflowing from Reactor (U-DC101) to Stripper (U-DA101).

(a) Adjust PIC101 around 100 kg/cm2G on manual.

(b) Increase pressure of Steam Saturation Drum (U-FA101) to 15 kg/cm2G by

PIC106.

(23) Synthesis Solution Overflow from Reactor (U-DC101) to Stripper (U-DA101).

(a) It will take around 90 minutes since activating HP Carbamate Ejector (U-EE101)
till filling up of Reactor (U-DC101).

Overflowing from Reactor (U-DC101) to Stripper (U-DA101) can be

checked by the indication of TI101 (Reactor (U-DC101) top), TI111
(Stripper (U-DA101) top) and LIC102 (Stripper (U-DA01) bottom level).

(b) When the level (TI101) reaches to top of Reactor (U-DC101), decrease CO2
flow rate (FIC105) to Reactor (U-DC101) to 4,300 Nm3/h gradually and slowly.

(c) Simultaneously, increase CO2 flow rate to Stripper (U-DA101) gradually from
3,500 up to 19,300 Nm3/h.

!
CAUTION
Take care of synthesis pressure (PIC101) increase.

Indication of FI155 is 23,600 Nm3/h (= 19,300 Nm3/h + 4,300 Nm3/h).

(d) Switch the Interlock bypass switch for “HV105 shut signal to Ammonia Feed
Pump (U-GA101) / Carbamate Feed Pump (U-GA102) stop” to “Not Bypassed”.

(e) When the Stripper (U-DA101) level (LIC102) appears and comes up to 30-40%,
open LV102 gradually on manual and feed the solution to HP Decomposer

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(U-DA201).

Pay attention to the indication of LIC102. Since the level of LIC102 is

increased rapidly, carry out above procedure smartly.

(f) Put LIC102 on auto to keep the level around 40%.

Confirm valid range of LIC102 that was checked by LIC102 calibration

and keep the level within the range.

(g) Increase the steam pressure in Steam Saturation Drum (U-FA101) little by little
up to 18 kg/cm2G by changing PV106 opening manually and finally set PIC106
on auto.

As the falling film of solution is made in vertical tubes in Stripper

(U-DA101), steam consumption suddenly increases. The operation of
PIC106 shall be done carefully to prevent level fluctuation in Steam
Saturation Drum (U-FA101) due to the rapid increase of steam
condensation.

(h) When N/C ratio in Carbamate Condenser (U-EA101) becomes 2.9 ~ 3.0 (check
AT101), decrease NH3 flow (FIC106) to Carbamate Condenser (U-EA101) to
2,261 kg/h.

(i) Decrease NH3 flow (FIC101) to Reactor (U-DC101) to 34 t/h gradually while
checking AT101 (maintain N/C ratio at 2.9 ~ 3.0).

(j) Control LI101 at 40 ~ 50% by HV106.

Pay attention to the level (LI101) in Carbamate Condenser (U-EA101).

HP Carbamate Ejector (U-EE101) suction flow rate will be changed
due to change of motive NH3 flow rate.

(k) Maintain carbamate solution feed to Carbamate Condenser (U-EA101) at 56

t/h.

(l) Decrease the set pressure of PIC724 to 5.0 kg/cm2G, which is the generated
steam pressure in Steam Drum (U-FA102) to control the temperature (TI106) of
Carbamate Condenser (U-EA101) in the range of 165 ~ 175 ºC.

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(m) Control PV101 on manual to adjust the pressure at around 120 ~ 130 kg/cm2G
and PV401 opening less than 50%.

Control CO2, NH3 and carbamate solution feed rate to Synthesis Loop
constantly in accordance with the pressure increase.

(n) Put PIC101 on auto and control PIC101 at 120-130 kg/cm2G after synthesis
pressure stabilizes.

Keep always PV101 opening more than 5%.

If synthesis pressure cannot be stabilized on auto, control PIC101 on

manual.

(o) Confirm that PV153 (CO2 Compressor (U-GB101) 4th discharge) is closed fully.

(24) Increase Plant Load to 50%.

Load up ratio should be 10% maximum. A rapid load increase may

cause fluctuation of the system. If operators are not so familiar with
plant operation, especially initial start-up, gradual load increase is
highly recommended.

Refer to Table 6-1.

Load-up operation to 50% should be done in accordance with the

following order:
1) Increase NH3 to Reactor (U-DC101) from 40% to 50% rate.
2) Increase CO2 to Reactor (U-DC101) from 40% to 50% rate.
3) Increase CO2 to Stripper (U-DA101) from 40% to 50% rate.
4) Increase passivation air to CO2 Compressor (U-GB101) from 40%
to 50% rate.
5) Increase carbamate solution to Carbamate Condenser (U-EA101)
in accordance with level increase in HP Absorber (U-EA401).

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(a) Increase NH3 feed to Reactor (U-DC101) to 50 % load (23 t/h) by FIC101.

(b) Increase CO2 flow rate to Reactor (U-DC101) to 50% load (2,800 Nm3/h) by
FIC105 on auto.

(c) Open HV105 and increase CO2 gas flow rate to Stripper (U-DA101) at 50% load
(12,700 Nm3/h).

Indication of FI155 is 15,500 Nm3/h (= 12,700 Nm3/h + 2,800 Nm3/h).

(d) After the level (LIC401) of HP Absorber (U-EA401) is increased, adjust

carbamate solution feed rate to Carbamate Condenser (U-EA101) by FIC104
(approx. 37 t/h at 50% load).

Flow rate of FIC104 is adjusted in accordance with the level of

LIC401.

(e) After Carbamate Condenser (U-EA101) level (LI101) increases, increase

HV106 opening and increase urea-carbamate solution flow rate to Reactor
(U-DC101) through HP Carbamate Ejector (U-EE101).

(f) Maintain steam pressure in Steam Saturation Drum (U-FA101) at 18 kg/cm2G.

(g) Maintain 50% load until Prilling Section becomes in operation at stable
condition.

(25) Stabilize Synthesis Loop at 50%.

(a) Adjust the flow rate as shown below.

- CO2 intake (FIQ151) : approx. 16,500 Nm3/h

- CO2 to Reactor (FIC105) : approx. 2,800 Nm3/h on auto.
- CO2 to Stripper & Reactor (FI155) : approx. 15,500 Nm3/h
- Passivation Air (FIC156) : approx. 650 Nm3/h
- Carbamate solution (FIC104) : 37 t/h on manual
- Liquid NH3 (FIC101) : 23 t/h on auto
- Synthesis Pressure (PIC101) : 150 - 155 kg/cm2G on auto

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If LIC401 (Level of HP Absorber (U-EA401)) is increased too much,

transfer the solution in HP Absorber (U-EA401) to Carbonate Solution
Tank (U-FA401).

If LIC401 is decreased too much, make up the solution to HP

Absorber (U-EA401) to keep the normal level.

Adjust FIC156 to keep O2 content at 4,000-5,000ppm in accordance

with H2 content in CO2 gas.

(b) Introduce steam condensate to No.1 Ammonia Preheater (U-EA102) and make
it on service.

In case opening of LV104A is small due to insufficient quantity of

steam condensate, open manual valve on the circulation line from
discharge of Steam Condensate Make-up Pump (U-GA110) to LP
Steam Flash Drum (U-FA105) to keep minimum-flow of the pump.

(c) Control temperature of Reactor (U-DC101) top (TI101) to around 175-180 ºC by

adjusting NH3 temperature at No.2 Ammonia Preheater (U-EA103) outlet by
PIC111.

Reactor (U-DC101) top temperature will be changed about 30 - 40

minutes after NH3 temperature is adjusted.

Pay attention to LI101, because motive NH3 flow volume of HP

Carbamate Ejector (U-EE101) will be changed due to NH3
temperature.

(d) Adjust liquid NH3 feed by FIC101 to control NH3/CO2 molar ratio of Carbamate
Condenser (U-EA101) outlet solution (AI101 = approx. 2.9)

NH3 feed rate can be changed only slowly to avoid fluctuation of HP

Carbamate Ejector (U-EE101), which supplies pump head for
Synthesis Loop circulation.

Analyze the solution from Carbamate Condenser (U-EA101) exit

(sample point S-101) and Reactor exit (S-105) to check actual
NH3/CO2 molar ratio.

(e) Control motive NH3 pressure (PIC107) for HP Carbamate Ejector (U-EE101) at

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195 kg/cm2G.

(f) Check solution temperature of Stripper (U-DA101) bottom (TI113) around 170 ~
180 ºC. Adjust PIC106, if necessary.

The rate of set pressure change of PIC106 shall be less than 0.2
kg/cm2 per once to prevent fluctuation of heating which makes
Synthesis Loop unstable.

The temperature (TI113) of Stripper (U-DA101) bottom (TI113) is

expected to be around 170 ~ 180 ºC in case even falling film of the
solution is formed and CO2 stripping is performed properly.

Increase analysis frequency of NH3 and CO2 concentration in the

solution of Stripper (U-DA101) bottom outlet (S-104).

Adjust Pressure of Steam Saturation Drum (PIC106) around 13 ~

15kg/cm2 during low load operation according to the Stripper Bottom
condition (component).

(g) Control the pressure of Flash Drum for HP Decomposer (U-FA106) at 8kg/cm2G
by PIC113.

(h) Control the pressure of SL steam header at 5.0 ~ 5.5 kg/cm2G by PIC724
(let-down) and 5.5 ~ 6.0 kg/cm2G for PIC726 (vent).

(26) Purification and Recovery Section on Service.

When synthesis solution from Stripper (U-DA101) comes to Purification Section,
operate Purification Section as follows:

(a) When the level of HP Decomposer (U-DA201) bottom reaches 50%, open
LV201 (Level of HP Decomposer (U-DA201)) and adjust the level on manual.
Then put LIC201 on auto.

(b) Adjust the pressure as follows. Confirm not only DCS but also local gauges.

- PIC401 (Washing Column (U-DA401)) : 15.0 kg/cm2G

- PIC402 (LP Absorber (U-EA402)) : 2.4 kg/cm2G

(c) Check the following pressure.

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- PI201 (HP Decomposer (U-DA201)) : 16.5 kg/cm2G

- PI212 (LP Decomposer (U-DA202)) : 2.6 kg/cm2G

(d) Control the temperature of outlet solution from HP Decomposer (U-DA201) at

152 ºC by SL steam (TIC202).

(e) When the level of LP Decomposer (U-DA202) bottom reaches 50%, open
LV202 (Level of LP Decomposer (U-DA202)) and adjust the level on manual.
Then put LIC202 on auto.

(f) Control the temperature at middle of LP Decomposer (U-DA202) at 138 ºC by

SL steam (TIC205).

(g) Start feeding CO2 to LP Decomposer (U-DA202) by opening FV202 and adjust
the flow rate in accordance with the plant load.

(h) Gradually shift the heat source for LP Decomposer (U-DA202) from SL steam to
the mixed gas from Process Condensate Stripper (U-DA501). Adjust the steam
feed rate to Process Condensate Stripper (U-DA501) by FIC505 in order to
satisfy heat requirement of LP Decomposer (U-DA202).

Mixed gas sending to LP Decomposer (U-DA202) shall be done after

Recovery Section is stabilized.

(i) Open FV401 (LP Absorber (U-EA402) Outlet Flow Rate) and control the level of
LP Absorber (U-EA402). After stabilizing the level of LP Absorber (U-EA402),
put LIC402 on auto.

(j) Open FV506 and send process condensate to Washing Column (U-DA401).
Check the level of Process Condensate Tank (U-FA501 and U-GA503 side) by
LI505.

(k) When the level at the middle of Washing Column (U-DA401) appears, control
the level at 50% by LV403 and put it on auto.

(l) Regulate the temperature of the following absorbers by cooling water.

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- Washing Column (U-DA401) : 71 ºC

- LP Absorber (U-EA402) : 45 ºC

Cooling water is sent to 2nd header through LP Absorber (U-EA402).

On the other hand, 2nd header pressure is kept stable by PV712 which
regulates flow rate bypassing heat exchanger. Temperature in LP
Absorber shall be controlled with checking PIC712 and opening of
PV712.

(m) Regulate the temperature of HP Absorber (U-EA401) at 106 ºC by tempered

water flow rate to Tempered Water Cooler (U-EA403) (TIC402).

(n) Distribute the mixed gas from PV101 to HP Decomposer (U-DA201) by opening
manual valve downstream of FI201. Control PIC209 at 25 kg/cm2G to keep
sufficient pressure to feed the mixed gas.

80% of the total gas from PV101 is distributed to HP Absorber

(U-EA401) through PV209 and 20% is injected to the bottom of HP
Decomposer (U-DA201) by FI201.

5.2.11 Start-up of Concentration and Prilling Sections

(1) Concentration Section

(a) When the level of Urea Solution Tank (U-FA201) becomes normal level, start
Urea Solution Pump (U-GA201) to feed the solution to Heater of Vacuum
Concentrator (U-EA201) at the rate of approx. 119 T/h (50 % Load) by FV203
and put FIC203 on auto.

Pay attention to the level in Urea Solution Tank (U-FA201), LI203

(b) Absorbent feed to Heater of Vacuum Concentrator (U-EA201) shell side

(FIC204) is adjusted around 31 t/h (50 % load).

(c) When level (LIC207) in Final separator (U-FA203), increases more than 100%,
start Molten Urea Pump (U-GA204) and make circulation flow to Urea Solution
Tank (U-FA201) via three way valve HV301.

The circulation loop above is as follows.

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LV HV
207 301

U-EA202 U-FA203 U-GA204 U-IA301

(Open)

U-FA202

U-EA201 U-GA201 U-FA201

(d) Control the level in Final Separator (U-FA203) by LIC207 manually. Then put
LIC207 on auto after the level is stabilized.

(e) Increase the temperature and vacuum pressure in Vacuum Concentrator

(U-FA202) and Final Separator (U-FA203) to concentrate the urea solution.

1) Supply process condensate for washing the line as follows.

- FI206 : 1,500 kg/h

- FI211 : 3,500 kg/h

2) Start Second Ejector (U-EE502) and Third Ejector (U-EE503). Increase

gradually the vacuum pressure in Vacuum Concentrator (U-FA202) and
Final Separator (U-FA203) up to 0.54kg/cm2A (400 mmHgA) by closing
PV203.

In case sufficient gas from HP Decomposer (U-DA201) is not

available, the outlet temperature (TI209) of Heater of Vacuum
Concentrator (U-EA201) will not increase by increasing the flow rate
of absorbent. In such case, keep absorbent flow rate at constant
rate 31 t/h (50% load).

3) When concentration of urea solution in Final Separator (U-FA203)

comes up to 90 wt% of urea (temperature (TI212) becomes higher than
120 °C), open the steam condensate feed valve (HV302) to urea
solution return line from HV301 to Urea Solution Tank (U-FA201).

Concentration of return urea can be confirmed with temperature

TI213 indirectly. Adjust HV302 opening so that return urea solution
temperature TI213 becomes to around 105℃.

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4) Open PV207 & PV208 gradually and heat the urea solution by Heater of
Vacuum Concentrator (U-EA201) and Final Concentrator (U-EA202).

5) Start First Ejector (U-EE501) and increase gradually the vacuum

pressure in Final Separator (U-FA203) up to 0.42kg/cm2A (320 mmHgA)
by closing PV206.

6) Increase the outlet temperature of Heater of Vacuum Concentrator

(U-EA201) and Final Concentrator (U-EA202) by opening PV207 and
PV208 manually.

- TI209: 132 ~ 135°C (Outlet of U-EA201)

- TI211: 138 ~ 140°C (Outlet of U-EA202)

Do not make vacuum before outlet temperature from Final

!
CAUTION
Concentrator (U-EA202) increases to avoid solidification of urea
solution.

!
CAUTION
Keep above temperature always during proceeding following steps
to avoid solidification of urea solution.

7) Control HV501 and adjust PI503 (Pressure of Flash Gas Condenser

(U-EA506)) at 0.54 kg/cm2A (400 mmHgA).

8) Increase more vacuum pressure in Vacuum Concentrator (U-FA202)

and Final Concentrator (U-FA203) simultaneously by controlling PV203
and PV206.

Target : U-FA202 400 mmHg Abs. 250 mmHg Abs.

U-FA203 320 mmHg Abs. 70 mmHg Abs.

Do not make vacuum before outlet temperature from Heater of

!
CAUTION
Vacuum Concentrator (U-EA201) and Vacuum Concentrator
(U-FA202) increases to avoid solidification of urea solution.

9) Increase the bottom temperature of Final Separator (U-FA203) up to

145 °C (TI212) by PV208.

10) Confirm that PV206 has been almost closed, then start Ejector for Final
Separator (U-EE201) and make more vacuum up to 25 mmHgA.

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Refer to Fig. 5-7 (Vacuum Profile for Start-up of Vacuum

Evaporation Unit.)

11) Confirm the following items.

- FI206: 1,500 kg/h (Process cond. for washing the line)

- FI211: 3,500 kg/h (Process cond. for washing the line)
- FI205: 0.16 Nm3/h (Purge air to PT203)
- FI208: 0.16 Nm3/h (Purge air to PT206)

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1.03

2
0.54 kg/cm A (400mmHg)

0.5 U-FA202

U-FA203
OPERATION PRESS. (kg/cm 2 A)

2
0.43 kg/cm A
0.4 (320mmHg)

2
0.33 kg/cm A (250mmHg)

0.3

0.2

0.1 2
0.095 kg/cm A (70mmHg)

2
0.03 kg/cm A

(25mmHg)
0.0 STEP

Fig.
Fig. 5-7
5-7 VACUUM PROFILE FOR START UP OF VACUUM EVAPORATION UNIT

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(2) Prilling Section

(a) When the operating condition of Concentration Section has been stabilized as
follows, start Prilling Section.

- TI212: 145 °C
- PIC206: 0.033 kg/cm2A (25 mmHgA)
- AI201: 99.8%

(b) Confirm that the molten urea line from HV301 to Prilling Basket (U-FJ302A,B)
are flushed and heated continuously so that the line is not clogged.

(c) Close the steam flushing valve by HV303 to molten urea line and change over
the flow direction of HV301 from circulation line to Prilling Basket (U-FJ302A,B).

(d) Wash circulation line from HV301 to Urea Solution Tank (U-FA201) with
condensate by HV302.

(e) Decrease the temperature of TI212 to normal at 138°C and put PIC208 on auto.

(f) Start Prilling Basket (U-FJ302A,B):

Refer to the Vendor Instruction regarding the operation of Prilling

Basket (U-FJ302A,B).

(g) Close the steam flushing valve by HV303 to molten urea line and change over
the flow direction of HV301 from circulation line to Prilling Basket.

(h) Wash circulation line from HV301 to Urea Solution Tank (U-FA201) with
condensate by HV302.

(i) Confirm the prilled urea is smoothly sent to Urea Product Handling Facility via
Product Cooler.

(j) Adjust the rotating speed of Prilling Basket (U-FJ302A,B), if necessary.

(k) Activate the interlock system to automatic, when the transportation condition of
product becomes normal.

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After stabilization of the condition of whole section, confirm all

interlock system is not bypassed.

5.2.12 Introducing SL steam to Turbine for CO2 Compressor (U-GT101).

SL steam can be admitted to Turbine for CO2 Compressor (U-GT101) at 80% or higher
load and Urea Plant including steam system is operated stable.

Heat up SL steam line and drain steam condensate completely before

introducing SL steam to Turbine for CO2 Compressor (U-GT101).

(1) Introduce SL steam to Turbine for CO2 Compressor (U-GT101) as admission in

accordance with vendor manual.

(2) After stabilizing FI725 (admission flow rate) and SL steam header pressure, set
PIC725 at 5 kg/cm2G on auto.

(3) Change PIC724 set from 5 kg/cm2G to 4.5 kg/cm2G slowly.

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5.3 Normal Start-up Procedure

The plant is left under following condition after short time shut-down.

(1) Confirm synthesis pressure. Normally, hold-up pressure is 80-90 kg/cm2G. However, it
depends on the situation and duration of shut-down.

(2) Diluted carbamate solution remains in HP Absorber (U-EA401) and LP Absorber

(U-EA402).

(3) In Concentration Section and Prilling Section, machines are stopped. Vessels and
process lines are flushed with steam or water.

(4) In Process Condensate Treatment Section, steam injection and process condensate
feeding is stopped.

5.3.1 Preparation

(1) Process Condensate Treatment Section

(a) Operation steps are same as (1) through (6) of Para. 4.5.3.1 and (1) through
(17) of Para. 4.5.3.2.

(2) Synthesis Section

(a) Open the following isolation valve.

- Isolation valve of HV103

- Isolation valve of FV101
- Isolation valve of FV106
- Isolation valve of FV109
- Isolation valve of PV101
- Isolation valve of PV106
- Isolation valve of LV102

(b) Check the level (40-50%) and pressure (10 ~ 15 kg/cm2G) of Steam Saturation
Drum (U-FA101).

(c) Check the level (40-50%) and pressure (5.5 kg/cm2G) of Steam Drum (U-FA102).

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(d) Confirm that steam condensate is circulated through tube side of Carbamate
Condenser (U-EA101) by Steam Condensate Circulation Pump (U-GA109).

(e) Crack open the steam valve and put SL steam on downstream of SV101A,B,C,D
and HV103.

(f) Flush the following lines by High Pressure Flooding Pump (U-GA105).

- All feed lines after check valves

- Upstream and downstream of HV103
- Upstream and downstream of HV106
- Upstream of PV101
- Upstream of LV102
- Detecting line for PT101, PT102 and PT105.

(g) Flush the downstream piping of PV101 and LV102 by SML steam.

(h) Confirm the interlock condition before start-up as follows.

- Signal to PV153 open Bypassed

- FV101 shut Normal
- FV104 shut Normal
- FV105 shut Normal
- FV106 shut Normal
- FV202 shut Normal
- HV105 shut Normal
- HV106 shut Normal
- LV102 shut Normal
- LV104A shut Normal
- PV111 shut Normal
- FV104 shut to U-GA102 Stop Bypassed
- HV105 shut to U-GA3101 / U-GA102 Stop Bypassed
- FV101 shut to U-GA101 Stop Bypassed
- FIC108 Low Low to U-GA102 Stop Bypassed
- FIC131 Low Low to U-GA101 Stop Bypassed

(i) Check controllers for Synthesis Loop are at the correct positions.

(j) Make sure that CO2 Compressor (U-GB101) is running well with maintaining
around 160 kg/cm2G and venting CO2 gas through PV153 at a rate of
approximately 24,200 Nm3/h equivalent to 40% plant load.

(k) Make sure that liquid NH3 is circulating through Ammonia Feed Pump (U-GA101)

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and its bypass line. Refer to Para. 5.2.10 (13).

(l) Make sure that carbamate solution is circulating through Carbamate Feed Pump
(U-GA102) and its bypass line. Refer to Para. 5.2.10 (11).

(m) Make sure that steam headers are controlled as following conditions.

- SML Steam Header : Keep 21 kg/cm2G by PIC722 and PIC723

- SL steam Header : Keep 5.0 kg/cm2G by PIC724 and PIC726
- SLL steam Header : Keep 2.5 kg/cm2G by PIC727 and PIC735

(n) Adjust the pressure in Synthesis Loop.

1) Open HV103 and confirm the gas flow to atmosphere and close fully.

2) Open PV101 and confirm the gas flow to HP Decomposer (U-DA201).

3) Check the pressure in Synthesis Loop. Normally, hold-up pressure is

80~90 kg/cm2G. However, it depends on the situation and duration of
shut-down.

(3) NH3 Receiving

Operation steps are same as Para. 5.2.2.

(4) Purification and Recovery Sections

Operation steps are same as Para. 5.2.5.

Inert gas from Synthesis Loop can be utilized to pressurize Washing

Column (U-DA401), HP Absorber (U-EA401) instead of nitrogen.

If heating-up procedure is required, follow the operation steps described in Para.

5.2.9 (2) (b) and (c).

(5) Concentration Section

Concentration Section is flushed with steam or water, and is kept clean.

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5.3.2 Start-up of Synthesis Loop, Purification and Recovery Sections

Confirm the level (LI101) of Carbamate Condenser (U-EA101) is lower

than 20%. If LI101 is higher than 20%, following steps shall be
required.

- Open HV106 and send the solution in Carbamate Condenser

(U-EA101) to Stripper (U-DA101) via Reactor (U-DC101).
If the solution cannot be sent and the level of Carbamate Condenser
(U-EA101) is increased, close HV106 and transfer the solution to
Stripper (U-DA101) by liquid transfer line (1US 21831 M1J1 and 4US
21051 M1J1).

- Open LV102 gradually at 5% and send the solution at the bottom of

Stripper (U-DA101) to Purification Section. (Pay attention to the
pressure of Purification and Recovery Sections. (PI201 and
PIC401)).

- When LIC102 becomes lower than 10%, close LV102 fully.

(1) Make sure that CO2 and NH3 are being produced in sufficient amount with required
qualities.

(2) Make sure that each utility system is ready; steam, electric power, cooling water,
process water and instrument air.

(3) Make sure that all steam traces and jacket are on service.

(4) CO2 Injection to Stripper (U-DA101).

The purpose of this CO2 gas introducing is to prevent the reverse

flow of carbamate solution from Carbamate Condenser (U-EA101) to
Stripper (U-DA101) by establishing CO2 gas flow.

Introduce CO2 gas to Stripper (U-DA101) by (1.1/2") bypass valve of the (8”) isolation
valve on CO2 Compressor (U-GB101) discharge line. Flow rate is 3,500 Nm3/h (FI155).
Control the CO2 flow to Stripper (U-DA101) by bypass valve observing Stripper
(U-DA101) bottom temperature.

Refer to Para. 5.2.10 (8).

(5) Feed carbamate solution to Synthesis Loop.

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Operation steps are same as Para. 5.2.10 (11).

(6) Feed liquid NH3 to Carbamate Condenser (U-EA101).

Operation steps are same as Para. 5.2.10 (13). However, control NH3 feed rate at
2,261 kg/h by FIC106 (not 11,300 kg/h).

(7) When Synthesis Loop pressure start increasing, keep PV101 open at 2 ~ 3% and
control Synthesis Loop pressure on manual. Take care that PV401 should be closed.

(8) When the level (LI101) in Carbamate Condenser (U-EA101) becomes 20%, start
introducing urea solution to Reactor (U-DC101)

(a) Open HV106 gradually to 20%.

Pay attention to LI101. Adjust the opening of HV106 to keep LI101 at

40-50%.

(b) Confirm solution flow by AI101 (N/C ratio meter) because the indication will
change when the solution flows in.

(c) Confirm that solution comes to Reactor (U-DC101) bottom by TI103.

(9) Feed NH3 to Reactor (U-DC101) via HP Carbamate Ejector (U-EE101).

Operation steps are same as Para. 5.2.10 (19). However, control NH3 feed rate at 34
t/h by FIC101 (not 61 t/h). And put FIC106 (NH3 feed to Carbamate Condenser
(U-EA101)) on auto at 2,291 kg/h.

(10) Put No.3 Ammonia Preheater (U-EA103) on service. Increase TIC118 (NH3 exit
temperature) slowly up to 138 ºC by adjusting PIC111.

(11) Introduce CO2 feed rate to Reactor (U-DC101) up to 1,750 Nm3/h (FIC105).

Operation steps are same as Para. 5.2.10 (21).

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(12) Prepare for overflow from Reactor (U-DC101) to Stripper (U-DA3101).

(a) Adjust PIC101 around 100 kg/cm2G on manual.

(b) Increase pressure of Steam Saturation Drum (U-FA101) to 15 kg/cm2G by

PIC106.

(c) Gradually open 6” isolation valve on CO2 Compressor (U-GB101) discharge line
(8CO 21620 F1A2) and close its 1.1/2” bypass valve.

(d) Pay attention to the opening of FV105 and HV105 to avoid sudden increase of
CO2 flow rate when changing over the 8” and 1.1/2” valves.

(e) Start introducing absorbent solution to FV204 at 25 t/h (40% load) by U-GA404
after confirming that gas inlet valve to Separator for HP Decomposer (U-FA208)
is fully open.

(13) Increase CO2 flow rate to 4,300 Nm3/h by FIC105.

!
CAUTION
The temperature increase speed in Reactor (U-DC101) bottom shall
be less than 10 ºC/minute (TI103).

!
CAUTION
Temperature difference between the lining and the shell (TI104 and
TI105) shall be less than 50 ºC.

(14) Synthesis Solution Overflow from Reactor (U-DC101) to Stripper (U-DA101).

Overflowing from Reactor (U-DC101) to Stripper (U-DA101) can be

checked by the indication of TI101 (top of Reactor (U-DC101)), TI111
(Stripper (U-DA101) top) and LIC102 (Stripper (U-DA101) bottom
level).

(a) Increase CO2 flow rate to Stripper (U-DA101) gradually from 3,500 up to 19,300
Nm3/h.

!
CAUTION
Take care of synthesis pressure (PIC101) increase.

Indication of FI155 is 23,600 Nm3/h (=19,300 Nm3/h + 4,300 Nm3/h).

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(b) Switch the Interlock bypass switch for “HV105 shut signal to Ammonia Feed
Pump (U-GA101) / Carbamate Feed Pump (U-GA102) stop” to “Not Bypassed”.

(c) When the Stripper (U-DA101) level (LIC102) appears and comes up to
30~40%, open LV102 gradually on manual and feed the solution to HP
Decomposer (U-DA201).

Pay attention to the indication of LIC102. Since the level of LIC102 is

increased rapidly, carry out above procedure smartly.

(d) Put LIC102 on auto to keep the level around 40%.

Confirm valid range of LIC102 that was checked by LIC102 calibration

and keep the level within the range.

(e) Increase the steam pressure in Steam Saturation Drum (U-FA101) little by little
up to 18 kg/cm2G by changing PV106 opening manually and finally set PIC106
on auto.

As the falling film of solution is made in vertical tubes in Stripper

(U-DA101), steam consumption suddenly increases. The operation of
PIC106 has to be done carefully to prevent level fluctuation in Steam
Saturation Drum (U-FA101) due to the rapid increase of steam
condensation.

(f) Readjust LI101 at 40-50% by HV106.

(g) Maintain carbamate solution flow to Carbamate Condenser (U-EA101) at 56 t/h.

(h) Decrease the set pressure of PIC724 to 5.0 kg/cm2G, which is the generated
steam pressure in Steam Drum (U-FA102) to control the temperature (TI106) of
Carbamate Condenser (U-EA101) in the range of 165 ~ 175 ºC.

(i) Keep the pressure of Flash Drum for HP Decomposer (U-FA106) at 8 kg/cm2G
by PIC113.

(j) Control PV101 on manual to adjust the pressure at around 120 ~ 130 kg/cm2G
and PV401 opening less than 50%.

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Control CO2, NH3 and carbamate solution feed rate to Synthesis

Section constantly in accordance with the pressure increase.

(k) Put PIC101 on auto and control PIC3101 at 120 ~ 130 kg/cm2G after synthesis
pressure stabilizes.

Keep always PV101 opening more than 5%.

If synthesis pressure cannot be stabilized on auto, control PIC101 on

manual.

(l) Confirm that PV153 (CO2 Compressor (U-GB101) 4th discharge) is closed fully.

(15) Increase Plant Load to 50%.

Operation steps are same as Para. 5.2.10 (25).

(16) Stabilize Synthesis Loop at 50%.

Operation steps are same as Para. 5.2.10 (26).

5.3.3 Purification and Recovery Sections on Service

Operation steps are same as Para. 5.2.10 (27).

5.3.4 Start-up of Concentration and Prilling Sections

Operation steps are same as Para. 5.2.11.

5.3.5 Introducing SL steam to Turbine for CO2 Compressor (U-GT101)

Operation steps are same as Para. 5.2.12.

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SECTION 6. NORMAL OPERATION

6.1 General

6.1.1 Raw Materials and Utilities

6.1.2 Product

6.2 Increasing Plant Load

6.2.1 General

6.3 Routine Inspection and Operation

6.3.1 Synthesis Section

6.3.2 Purification Section
6.3.3 Recovery Section
6.3.4 Concentration Section
6.3.5 Prilling Equipment
6.3.6 Process Condensate Treatment Section and Surface Condenser
Section
6.3.7 Others

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SECTION 6. NORMAL OPERATION

6.1 General

The normal operating conditions should be followed to the design figure, and as many
controlling instruments should be operated on automatic as possible.

Note that minor changes in the settings of instruments may be necessary to maintain the
steady operation. The solution in Urea Solution Tank (U-FA201) and Carbonate Solution Tank
(U-FA401) should be recovered during normal operation.

6.1.1 Raw Materials and Utilities

(1) Make sure all raw materials and utilities are sufficient with required quantities and
qualities.

(2) Check their pressures and temperatures.

(3) Check their consumptions.

Following regular monitoring is recommended for cooling water.

Periodical analysis of cooling water detects tube leakage of coolers.
- Check the conductivity of cooling water by the on-line analyzer in
Utility & Offsite.
- Check any contamination material (ex. ammonia) by the laboratory
analysis.

6.1.2 Product

(1) Make sure urea product can be produced at the designed rate.

(2) Check the product qualities (expected) such as:

Characteristics Product qualities

Nitrogen (Dry Basis) 46.3 wt%

Moisture 0.3 wt%
Biuret 0.90 wt%

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Free Ammonia 130 ppm wt

Delta Iron 1 ppm wt
Product Size
+2.8 mm 5 wt% Max.
+1.4 to 2.8 mm 85 wt% Min
-1.0 mm 1.5 wt% Max.

6.2 Increasing Plant Load

6.2.1 General

The basic procedure for increasing load is as follows:

(1) Make sure the plant is operating under stable conditions.

(2) Gradually increase CO2 flow rate to the required value by regulating CO2 compressor
(U-GB101).

(3) Increase air flow rate according to CO2 flow rate by regulating FIC156.

(4) Gradually increase liquid NH3 flow rate according to the plant load by regulating FIC101.

(5) Gradually increase recovered solution flow rate according to the plant load by regulating
FIC104 and LIC401.

(6) Gradually increase steam pressure for Stripper (U-DA101) by regulating PIC106.

When increasing the steam pressure, adjust it carefully to maintain

steam flow rate equivalent to the plant load, because slight increase of
steam pressure causes much steam consumption.

(7) Maintain the temperature (TI106) in Carbamate Condenser (U-EA101) at 179 ~ 180 °C
by Steam Drum (U-FA102) pressure (PIC724, SL header).

(8) Maintain the bottom temperature (TI103) in Reactor (U-DC101) around 177 ~ 179°C to
maintain top temperature (TI101) at 181~182 oC.

(9) Increase the absorbent flow rate from Process Condensate Tank (U-FA501) to LP
Absorber (U-EA402) through top part of Washing Column (U-DA401) and from LP

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Absorber (U-EA402) to HP Absorber (U-EA401) through lower of Washing Column

(U-DA401) to maintain levels.

(10) Increase CO2 flow rate to LP Decomposer (U-DA202) by FIC202.

(11) Increase the urea solution flow rate to Concentration Section.

!
CAUTION
Increase the feed rate gradually by FIC203 to prevent fluctuation of the
operating condition for the Vacuum Evaporation Section.

(12) Adjust the flow rate of process condensate to Process Condensate Stripper (U-DA501)
by FIC504.

Plant load shall be increased with keeping the flow rate at each load as
shown in Table 6.1 with checking the levels in towers/vessels.

6.3 Routine Inspection and Operation

6.3.1 Synthesis Section

(1) General

(a) Check all steam tracing and jacket are on service.

(b) Inspect all flanged joints for leakage.

(c) Check AI111, AI112 and AI113 for Leak Detection System at CCR and Local.

Do not continue the plant operation in case that leakage is detected by

AI111, AI112 or AI113. If leak NH3 is detected, plant shall be shut-down
!
CAUTION
immediately and check/repair the leak point of stainless lining for high
pressure equipment.

Performance and accuracy of NH3 detector for Leak Detection System

!
CAUTION
(AI111, AI112 and AI113) shall be checked and confirmed by standard
gas during periodic intervals (minimum every three months). Standard
gas shall be purchased by Client periodically.

(d) Analyze the synthesis solution every eight hours. (S101, S104 and S105)

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(e) Check synthesis pressure (PG101 and PG110 at local).

(f) Check regularly the steam injection to SV101A,B,C,D, SV203 and HV103 outlet
lines so that there is no possibility of solidification and clogging on the line.

(2) Reactor (U-DC101)

(a) Pressure is automatically controlled by PIC101 (pressure detection point is

located at seal NH3 inlet to Carbamate Condenser (U-EA101)). When changing
the setting point of pressure, degree of the change should be 1~2 kg/cm2G
maximum on auto.

!
CAUTION
Minimum opening of PV101 is 5 %. Keep PV101 opening more than 5 %
to avoid clogging of the line.

(b) Maintain the bottom temperature (TI103) at 178~180 °C to keep the top
temperature (TI101) at 181~182 °C by regulating No.3 Ammonia Preheater
(U-EA103) exit NH3 temperature (TIC118) by PIC111.

(c) Maintain NH3/CO2 molar ratio at 3.7 at exit of Reactor (U-DC101) by analyzing the
solution periodically. Control NH3/CO2 molar ratio by changing liquid NH3 feed rate
(FIC101) to Reactor (U-DC101) via HP Carbamate Ejector (U-EE101).

Check opening of FV105 periodically to avoid higher corrosion rate at

!
CAUTION
Stripper (U-DA101) bottom, because less CO2 feed to Stripper
(U-DA101) due to wide open of FV105 might cause higher temperature
at Stripper (U-DA101) bottom owing to less stripping efficiency.

(3) Stripper (U-DA101)

(a) Make sure whether the intake CO2 gas quantity is sufficient and stable by FI155A
(CO2 feed to Stripper (U-DA101) and Reactor (U-DC101)) and FIQ151 (CO2
intake from BL).

(b) Steam pressure is automatically controlled by PIC106 (Steam Saturation Drum

(U-FA101) pressure). Steam pressure is 16~20 kg/cm2G at 100% normal
operation depending on the operating mode according to the stripper bottom
component condition. Normal fluctuation of the solution feed rate caused by
regulating HV106 (Carbamate Condenser (U-EA101) to HP Carbamate Ejector

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(U-EE101)) can be absorbed without changing the set point of PIC106. Steam
consumption should be checked by FI717 in terms of the proportionality to the
plant load, and steam pressure is changed, if required.

If required, maintain SML steam header pressure by steam let-down

valve and control the pressure of U-FA101 by PV-106. In case it’s
!
CAUTION
unable to control the pressure of U-FA101, decrease the plant load in
order to avoid the process upset.

(c) Bottom temperature (TI113) is an important index of stripping efficiency. To check

the stripping efficiency, analyze NH3 and CO2 content in the bottom effluent
periodically. Normal bottom temperature is expected to be 170~180 °C depending
on the operating mode. The excessively high bottom temperature (> 185 °C)
indicates deterioration of the efficiency. If stripping efficiency deteriorates, steam
consumption (FI717) also decreases.

(d) Maintain the bottom liquid level at around 40% by LIC102. High liquid level
(>50 %) accelerates urea hydrolysis and biuret formation and too low liquid level
(< 30 %) may increase the risk of gas break-through to the downstream.

(e) Check actual level and pressure in Steam Saturation Drum (U-FA101) by local LG
and PG.

(f) Monitor conductivity of condensate in Steam Saturation Drum (U-FA101) with

AI102 to assure no leak from tube side to shell side.

Do not continue the plant operation in case that leakage is detected by

!
CAUTION
AI102. If high conductivity is detected, plant shall be shut-down
immediately and check/repair the leak point of Stripper (U-DA101).

(4) Carbamate Condenser (U-EA101)

(a) Maintain top temperature (TI106) at 179~180°C. Change SL steam header

pressure by PIC724 when required but must be adjusted very gradually.
Relationship between top temperature of Carbamate Condenser (U-EA101) and
SL header based on original design is as follows:

SL Header Pressure Top Temperature (TI106)

4.5 kg/cm2G 177°C
5 kg/cm2G 180°C
5.5 kg/cm2G 183°C

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If required, maintain SL steam header pressure by steam let-down

valve and control the pressure of U-FA102. In case it’s unable to
!
CAUTION
control the pressure of U-FA102, decrease the plant load in order to
avoid the process upset.

(b) Check actual level and pressure in Steam Drum (U-FA102) by local LG and PG.

(c) Maintain the liquid level in Carbamate Condenser (U-EA101) between 30% and
70% by HIC106. Do not operate HIC106 roughly or rapidly.

(d) Check PV101 opening. Wider opening is an indication of the following

phenomena:

- Gas flow increases due to insufficient absorption in the scrubbing part.

- (Partial) clogging of upstream or downstream of PV101. In such case, flush the

lines by High Pressure Flooding Pump (U-GA105).

PV101 opening shall be always more than 5% to avoid clogging of the line.

(e) Check and adjust the feed rate of carbamate solution by FIC104.

(f) Check discharge pressure (7~9 kg/cm2G) and motor amperage of Steam
Condensate Circulation Pump (U-GA109). Adjust circulation flow rate at 1400 ~
1820 t/h with FI110. Check the stand by pump is in auto position.

(g) Blow steam condensate in Steam Drum (U-FA102) from FIC109 at 1.6 ~ 1.7 t/h to
avoid chloride accumulation in the system. Check chloride content in the blow
down periodically.

If the chloride is accumulated, SCC (Stress Corrosion Cracking) may

!
CAUTION
be caused inside of Carbamate Condenser (U-EA101). Blow steam
condensate continuously.

(h) Monitor conductivity of blow down condensate with AI103 to assure no leak from
shell side to tube side.

Do not continue the plant operation in case that leakage is detected by

!
CAUTION
AI103. If high conductivity is detected, plant shall be shut-down
immediately and check/repair the leak point of Carbamate Condenser
(U-EA101).

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In case the conductivity rises and reaches to high alarm point, stop the
!
CAUTION
admission steam to Turbine for CO2 Compressor (U-GT101).

(i) Check and adjust the feed rate of seal NH3 by FIC106. If seal NH3 cannot be sent
to Carbamate Condenser (U-EA101) due to malfunction of FV106 or choking in
piping, check the cause and inject seal NH3 to Carbamate Condenser (U-EA101)
again as soon as possible.

Purpose of seal NH3 injection is to ensure reliability of internal bore

welding (IBW) from corrosion. Since seal NH3 injection is not primary
parameter in view of IBW protection in itself, operator could try to
resume seal NH3 injection during plant operation even in case of
FV-106 malfunction or choking in piping.

(j) In order to assure the action of safety valves, check the skin temperature of steam
jacket for SV-101A,B,C,D.

(5) CO2 Compressor (U-GB101)

(a) Make sure that the intake CO2 gas quantity and quality is sufficient and all kick–
back valves are fully closed (at 100% load).

(b) Make sure that oil pressure, oil temperature, oil flow and oil level in Run down
Tank etc. are normal and lube oil stand-by pump is in auto position.

(c) Check the pressure and temperature of each stage.

(d) Make sure that there is nothing abnormal in the moving parts and there is no
abnormal vibration in pipe lines.

(e) Make sure that the actual condensate level is normal by local LG and no
excessive accumulation in each separator.

(f) Make sure that temperature, level, and pressure of Turbine Condenser (U-EA105)
are in normal and standby pump of Return Condensate Pump (U-GA107) is in
auto position.

(g) Make sure that the flow rate (FIC156) of passivation air supplied to the second

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stage suction is normal.

The passivation air feed rate shall be adjusted so that O2 content at

Dehydrogen Column (U-DC151) exit is 4,000 ~ 5,000 ppm by AI151 and
in accordance with plant load as indicated in Table 6-1.

In case that the feed rate (FIC156) of passivation air cannot be

maintained due to some trouble, identify the cause and recover the
feed by FIC156 immediately.

Unless the feed rate of passivation air (FIC-156) can be recovered

!
CAUTION
within 10 minutes, shut down Synthesis Section immediately to avoid
excessive corrosion of synthesis equipment due to loss of passivated
film. If CO2 flow rate to Stripper (U-DA101) and/or Reactor (U-DC101) is
stopped due to malfunction of HV-105 and/or FV-105, follow the same
philosophy to prevent excessive corrosion.

(6) Dehydrogen Column (U-DC151)

(a) Make sure that O2 content at 4th discharge of CO2 Compressor (U-GB101) is
between 4,000 and 5,000 ppmv by AI151. Low O2 content can be caused by :

- Increase of H2 content at inlet of Dehydrogen Column (U-DC151).

- Decrease of passivation air feed rate.
- Workability of AI151.

(b) Make sure that H2 content at the exit is always below 100 ppmv by AI152. High H2
content can be caused by:

- Decrease of passivation air feed rate.

- Low temperature of CO2 gas at the inlet.
- Low activity of catalyst.
- Workability of AI152.

High H2 content causes to be within flammable range and hazardous condition.

(c) Make sure that inlet temperature is high enough (must be higher than 150°C) to
maintain high catalyst activity. Expected temperature at inlet of Dehydrogen
Colum (U-DC151) will be specified in CO2 Compressor (U-GB101) vendor’s
information as 2nd stage discharge temperature.

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(d) Temperature rise through the catalyst bed will be about 24 °C when H2 content in
CO2 is 0.5 vol. % (this is maximum as per Design Basis). Lower temperature at the
exit can be caused by:

- Low H2 content in CO2 gas from Ammonia Plant.

- Low O2 content at the inlet.
- Low temperature at the inlet.
- Low activity of catalyst due to poisoning.

Higher temperature at the exit can be caused by:

- High H2 content in CO2 gas from Ammonia Plant.

- High temperature at the inlet.

If the exit temperature exceeds the design temperature, stop the CO2
!
CAUTION
Compressor (U-GB101) to protect Dehydrogen Column (U-DC151) and
its associated system. Synthesis Loop is automatically shut down by
interlock.

(e) Make sure the pressure difference between inlet and outlet is less than 0.5
kg/cm2G by PDI160. High pressure difference can be caused by powdering of
catalyst.

(7) Ammonia Feed Pump (U-GA101)

(a) Check the suction pressure (24 kg/cm2G).

(b) Check that the minimum flow is kept at any time by FIC131.

Keep suction flow higher than minimum flow rate of U-GA101.

U-GA101 minimum flow shall be included the flow rate of balance line.

(c) Check the flow rate to Reactor (U-DC101) by FIC101.

(d) Check all NH3 pipelines for leakage.

(e) Check discharge pressure is at 200 kg/cm2G by PI104 and PG133.

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(f) At stable load operation, try to maintain pressure (PIC107) of motive NH3 to HP
Carbamate Ejector (U-EE101) as low as possible (around 195 kg/cm2G or less) as far
as level of Carbamate Condenser (U-EA101) is controllable.

(g) Make sure that pressure and flow of sealing water are normal.

(h) Make sure that temperature and pressure of lube oil are normal.

(8) Carbamate Feed Pump (U-GA102)

(a) Check the suction pressure (24 kg/cm2G).

(b) Check that the minimum flow is kept at any time by FIC108.

Keep suction flow higher than minimum flow rate of U-GA102.

U-GA102 minimum flow shall be included the flow rate of balance line.

(c) Check all carbamate solution pipelines for leakage.

(d) Check the discharge pressure around 161.5 kg/cm2G by PI109 and PG106.
Check also pressure difference from that of Synthesis Loop (PIC101).

(e) Check the opening of FV108 and maintain the opening at 5~10 % to prevent
clogging in the line.

(f) Make sure that the temperature (TI114) and pressure (PI110) of balance line are
normal.

(g) Make sure that pressure and flow of sealing water are normal.

(h) Make sure that temperature and pressure of lube oil are normal.

As for the standby pump and idle lines, fill the standby pump with
water to avoid plugging of carbamate in the pump, including the
re-circulation line due to carbamate solidification.

Conduct routine check in every shift for regular monitoring of Sealing

Water Tank (U-FA121) level by LG701.

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(9) High Pressure Flooding Pump (U-GA105)

(a) Check all of high pressure flooding line is not choked once a day by starting High
Pressure Flooding Pump (U-GA105).

(b) Confirm the passage of following high pressure flooding lines once per day.

- Line to PG111
- Line to PG112
- Line to PG113
- Line to PG115
- Line to PG126

(10) Ammonia Reservoir (U-FA104)

(a) Check the workability of flow meter (FIQ132)

(b) Make sure that there is no leakage of NH3 from the vessel or pipelines.

(c) Check the actual level from level gauge.

6.3.2 Purification Section

(1) General

(a) In order to assure the action of the safety valves, check the steam jacket supply
valves.

(b) Make sure of the solution actual level in each vessel by visual check by sight
glass.

(2) HP Decomposer (U-DA201) and LP Decomposer (U-DA202)

(a) Check the temperature of the solution.

(b) Check there is nothing abnormal in the level indicator, and check the actual level
in the vessel by sight glass.

(c) Check the steam condensate level in Condensate Pot for HP Decomposer
(U-FA206).

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In case of LV208 fails close, accumulated steam condensate in

Condensate Pot for HP Decomposer (U-FA206) overflows into SL
!
CAUTION
steam header and finally this steam condensate may be contaminated
in admission steam for Turbine for CO2 Compressor (U-GT101). If
LV208 fail close happened, control the level by bypass valve of LV208
or bypass drain valve provided at upstream of LV208.

(d) Check the condition of PV209 by FI201 through regular monitoring (Field patrol and
DCS monitoring).

Make sure that sufficient process gas (passivation air) coming from
synthesis section via PV209 is always supplied to HP Decomposer
!
CAUTION
(U-DA201) and Lower part of Heater of Vacuum Concentrator (U-EA201)
by checking FI201 according to the plant load.

If it’s unable to supply the sufficient process gas (passivation air) to HP

Decomposer (U-DA201) and lower part of Heater of Vacuum
!
CAUTION
Concentrator (U-EA201), it’s recommended to reduce the plant load
and shutdown the plant.

6.3.3 Recovery Section

(1) HP Absorber (U-EA401) and Washing Column (U-DA401)

(a) Check the concentration of CO2 in HP Absorber (U-EA401) from lab sampling.
The content of the CO2 should be kept at 38 ~ 42% during the normal operation.

(b) Check the actual level of the HP Absorber (U-EA401) and Washing Column
(U-DA401) frequently from sight glass.

(c) The temperatures of HP Absorber (U-EA401) and Washing Column (U-DA401)

are controlled by introduced flow rate of tempered water / cooling water by
adjusting TV402 and HV401 respectively enough to absorb decomposed gas
from Purification Section.

(d) The Carbamate Boost-up Pump (U-GA401) should be changed every month to be
ready to start in any time.

(e) Make sure that manual valve in the mixed gas line from HP Decomposer
(U-DA201) to Separator for HP Absorbent (U-FA208) is open.

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Manual valve is to be used only for start-up purpose and should be

kept open during normal operation.

(2) LP Absorber (U-EA402)

(a) Make sure the pressure in LP Absorber (U-EA402) is kept at 2.3 ~ 2.5 kg/cm2G.
Adjust the cooling water flow rate by HV402 so as to keep PV402 almost shut
position.

(b) Check the level of the solution is kept between sight glasses.

(c) Check the concentration of CO2 in LP Absorber (U-EA402) from lab sampling. The
content of the CO2 should be kept at 22 ~ 25% during the normal operation.

6.3.4 Concentration Section

(a) Maintain the pressure in Vacuum Concentrator (U-FA202) and Final Separator
(U-FA203) as follows:

- U-FA202 : 250 mmHgA by PIC203

- U-FA203 : 25 mmHgA or higher vacuum
(PV206 is fully closed)

Normally, PV206 is fully closed and the pressure of PIC206 is

maintained higher vacuum than 25mmHgA because the high vacuum
gives the high quality of prilled urea.

Check the flushing water and air to each pressure detector to prevent
choking.

- FI206 = 1500 kg/h

- FI211 = 3500 kg/h
- FI205 = 0.16 Nm3/h
- FI208 = 0.16 Nm3/h

(b) Maintain the temperature in U-FA202 at 132°C by PIC207 and in U-FA203 at

138°C by PIC208. It’s very important to control the temperature to prevent the
biuret formation under higher temperature and to prevent the choking trouble
under lower temperature. With controlling pressure and temperature at U-FA203,
monitor the concentration of urea by AI201.

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(c) Keep the normal liquid level in Vacuum Concentrator (U-FA202) by FIC203 and in
Final Separator (U-FA203) by LIC207.

(d) Check the steam condensate level in Condensate Pot for U-EA201 (U-FA207).

In case of LV206 fails close, accumulated steam condensate in

Condensate Pot for U-EA201 (U-FA207) overflows into SL header and
!
CAUTION
finally this steam condensate may be contaminated in admission
steam for U-GT101. If LV206 fail close happened, control the level by
bypass valve of LV206 or bypass drain valve provided at upstream of
LV206.

It is recommended that molten urea flushing is done to wash the

internal of Vacuum Concentrator (U-FA202) and Final Separator
(U-FA203) via 1.1/2US (3SL) 23212 B1I0J (ASA2J) one time a week for
removal of cyanuric acid deposit on the surface of the shell.

(e) Confirm the steam jacketing of valves and steam tracing for piping are active.

(f) Check the operation condition of Molten Urea Pump (U-GA204), no abnormal
vibration, sound, any leak from the seal and current value by ampere meter.

6.3.5 Prilling Equipment

(1) Make sure that the rotating speed and vibration frequency of Prilling Basket are properly set.

(2) Make sure that the molten urea return line from HV301 to Urea Solution Tank (U-FA201)
is not plugged.

Continuously feed a little steam to keep the line warm (TI213).

(3) Change and wash Prilling Basket (U-FJ302A,B) to maintain good prilling operation, if
required.

6.3.6 Process Condensate Treatment Section and Surface Condenser Section

(1) Vacuum Generation System

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(a) Check the pressure in each surface condenser.

(b) Check that the temperature of condensate from each condenser and regulate to
the design condition by cooling water.

(c) Check the operating condition of steam ejectors is normal.

(d) Check that the liquid level in Process Condensate Tank (U-FA501) is normal.

(e) Check the workability of Process Condensate Pump (U-GA501), LP Absorbent

Pump (U-GA503) and circulation flow rate of FI503.

(f) Check PG516 for spray nozzles for U-EA501 and SPN501, and PG517 for
spray nozzles for U-EA503 and SPN503 to confirm the spray pressure is
maintained.

(g) Check STR502 located on minimum flow line of LP Absorbent Pump (U-GA503)
periodically to prevent choking.

The flow rate from Process Condensate Pump (U-GA501) to Final

Absorber (U-DA503) should be maintained at a normal value
irrespective of plant turndown to ensure minimum flow requirement of
Process Condensate Pump (U-GA501).

(2) Process Condensate Stripper (U-DA501)

(a) Check the temperature at the top and the bottom of Process Condensate Stripper
(U-DA501) and regulate them to the design condition.

(b) Check the pressure at the top and the bottom of Process Condensate Stripper
(U-DA501).

(c) Make sure that there is nothing abnormal in the level indicator.

(d) Check the workability of PIC501.

(3) Urea Hydrolyzer (U-DA502)

(a) Check the temperature and pressure.

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(b) Check the workability of Urea Hydrolyzer Feed Pump (U-GA502)

(4) Final Absorber (U-DA503)

(a) Check the temperature (TI502) of Final Absorber (U-DA503) bottom.

If TI502 is much higher than the temperature of inlet absorbent, more

ammonia is coming to final absorber from upstream equipment. Check
the operating condition of the equipment.

6.3.7 Others

(1) Water Seals for Tanks

Check the water seal for top manhole part and overflow line of Tanks (Urea Solution
Tank (U-FA201), Carbonate Solution Tank (U-FA401) and Process Condensate Tank
(U-FA501) to avoid gaseous ammonia leakage.

(a) Make sure that drain valve of seal pot is closed.

(b) Control the overflow minimum by steam condensate supply valve, and check the
continuous over flow by visual check at open funnel.

!
CAUTION
Ensure continuous over flow from seal pot to avoid air ingress into
tanks.

(2) Water Seals for Vent System

Check the water seals for Vent System to avoid personnel exposure to gaseous
ammonia when safety valve pops.

(a) Make sure that drain valve of seal pot is closed.

(b) Control the overflow minimum by steam condensate supply valve, and check
continuous over flow from seal pot confirmed by sight glass of drain line.

!
CAUTION
Ensure continuous over flow from seal pot to avoid air ingress into
vent system.

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(3) Steam Tracing & Flushing Line of Safety Valve Outlet

Check the steam tracing and flushing line of safety valve outlet regularly so that there is
no possibility of urea or carbamate solidification inside piping.

(4) Steam Heating of Urea Solution Storage Tank

If urea solution is to be kept for long storage, close steam heating valve for Urea Solution
Tank (U-FA201), Dissolving Tank (U-FA302) and Carbonate Solution Tank (U-FA401) to
avoid releasing NH3 and CO2 due to slow decomposition of urea. However, in such case,
periodic check of urea solution (e.g. periodic sampling by laboratory) is required to
confirm no solidification in the storage tanks.

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 Hindustan Urvarak & Rasayan Limited - HURL Project
OPERATION INSTRUCTION FOR UREA PLANT
TOYO Work No. : BA120511 Project Doc. No. : HURL-G-LD-U00-PRS-IOM-000-0001 Rev. 0 18-FEB-2019

Table 6-1 The Flow Rate at each load

Tag No Service Unit Plant load (%)

110% 100% 90% 80% 70% 60% 50% 40%
FIC101 U-EA102 NH3 INLET t/h 97.6 88.5 79.4 70.4 61.3 52.2 43.1 34.0
FIC104 U-EA101 CARB. SOL'N INLET t/h 155.2 141.1 127.0 112.9 98.8 84.4 70.6 56.4
FIC105 CO2 FEED TO U-DC101 Nm3/h 11800 10720 9600 8600 7500 6400 5400 4300
FIC106 NH3 FEED TO U-EA101 kg/h 2487 2261 2261 2261 2261 2261 2261 2261
FIC108 CARB. SOL’N TO SYNTHESIS t/h 175 161 147 133 119 104 90 76
FIC131 NH3 FEED TO SYNTHESIS t/h 121 112 103 94 85 76 67 58
FI132 NH3 TO U-FA104 t/h 99.8 90.8 81.7 72.6 63.5 54.5 45.4 36.3
FI151 CO2 FEED Nm3/h 66400 60409 54400 48300 42300 36400 30200 24200
FI155 U-GB101 4TH DISCH. TO U-DA101 Nm3/h 65000 59053 53100 47200 41300 35500 29500 23600
FIC156 AIR TO U-GB101 (PASSIVATION) Nm3/h 2300 2087 1880 1670 1460 1250 1040 830
FIC202 U-DA201 BOTTOM INLET GAS Nm3/h 2980 2710 2440 2170 1900 1630 1360 1080
FIC203 U-EA201 UREA SOL’N INLET t/h 262 239 215 191 167 145 119 96
FIC204 CARB. SOL’N TO U-EA201 t/h 68.8 62.5 56.2 50.0 43.7 37.1 31.2 25.0
FIC209 CARB. SOL’N TO U-EA201 t/h 151 137 137 137 137 137 137 137
FIC401 U-DA401 LIQ. INLET t/h 73.0 66.3 59.6 53.0 46.4 39.3 33.1 26.5
FIC404 TEMPERED WATER CIRCULATION t/h 429 429 429 429 429 429 429 429
FIC406 U-GA401 CIRCULATION t/h 11.7 11.7 11.7 11.7 11.7 11.7 11.7 11.7
FIC504 FEED TO U-DA501 t/h 96.7 90.4 84.0 77.6 71.3 64.9 58.5 52.2
FIC505 SL STEAM TO U-DA501 t/h 21.5 20.1 18.7 17.2 15.8 14.4 13.0 11.6
FIC506 U-GA503A,B DISCH. t/h 19.8 17.8 15.8 13.9 11.9 10.0 8.1 6.1
FIC508 MP STEAM TO U-DA502 kg/h 5510 5169 4780 4390 4000 3615 3230 2840
FIC509 MP STEAM TO U-DA502 kg/h 735 689 637 586 534 482 430 379

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SECTION 7. NORMAL SHUTDOWN

7.1 Introduction

7.2 Normal Shutdown

7.2.1 Preparation for Shutdown

7.2.2 Stop the Feed to Synthesis Loop
7.2.3 Shutdown of Purification and Recovery Sections
7.2.4 Shutdown of Concentration and Urea Solution Feed
7.2.5 Shutdown of Process Condensate Treatment Section
7.2.6 Draining the Solution from Synthesis Loop
7.2.7 Purge the Gas in Synthesis Loop
7.2.8 Treating of Synthesis Loop for Inspection

7.3 Normal Shutdown for Short Period

7.3.1 Stop of Feed to Synthesis Loop

7.3.2 Purification and Recovery Sections
7.3.3 Concentration Section and Urea Solution Feed
7.3.4 Process Condensate Treatment Section

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SECTION 7. NORMAL SHUTDOWN

7.1 Introduction

Normal shutdown will be also divided into two cases, that is:

- Shutdown for long period (more than 48 hours)

- Shutdown for short period (48 hours or less)

In the former case (when the shutdown is planned to be more than 48 hours), all solution and
gas in Synthesis Loop shall be drained out to prevent corrosion.

After shutdown, all mixture in the Synthesis Loop is drain out to Urea Solution Tank (U-FA201)
and Carbonate Solution Tank (U-FA401) at first, then this solution will be reused as a recycle
solution when restart-up the Synthesis Loop.

Purification Section is drained and depressurized, then flushed by steam to prevent choking.
The remaining solution in Recovery Section is diluted and held in the system or drained if
necessary. Concentration Section is shutdown completely and is washed or flushed by steam
condensate or steam.

When the plant is planned to be shutdown for three days or less for repair works of rotating
machines, vessels, etc., Synthesis Loop is just shutdown and depressurized to 80~90 kg/cm2G,
keeping the solution in the system. Other sections will be shutdown with same manner as long
period shutdown.

Before the plant shutdown, make sure that Urea Solution Tank (U-FA201) and Carbonate
Solution Tank (U-FA401) are available to store the solution. Of course, it is necessary to
communicate with all related departments such as the Ammonia Plant, the electric section, the
boiler, etc.

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7.2 Normal Shutdown

If plant shutdown is planned, reduce the plant operation load to the minimum load before
shutdown.

7.2.1 Preparation for Shutdown

(1) Reduce the plant load to 50%.

(2) Confirm the system becomes stabilized.

(3) Confirm the following interlock system is shutdown condition.

- Signal to PV153 open Bypassed

- FV101 shut Normal
- FV104 shut Normal
- FV105 shut Normal
- FV106 shut Normal
- HV105 shut Normal
- HV106 shut Normal
- LV102 shut Normal
- PV111 shut Normal
- FV104 shut to U-GA102 Stop Bypassed
- HV105 shut to U-GA101/ U-GA102 Stop Bypassed
- FV101 shut to U-GA101 Stop Bypassed

7.2.2 Stop the Feed to Synthesis Loop

(1) Stop Ammonia Feeding

Ammonia feed rate to Reactor (U-DC101) via HP Carbamate Ejector (U-EE101) is

reduced by FV101. This action should be taken at the almost same time of (2) “Stop
Carbamate Solution Feeding” and (3) “Stop CO 2 Feeding”.

(a) Bypass the steam condensate to No.1 Ammonia Preheater (U-EA102) by LV104B
and stop SLL steam to No.2 Ammonia Preheater (U-EA106) and SL steam to
No.3 Ammonia Preheater (U-EA103) before NH 3 feed stop.

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If these heating media are not stopped before NH 3 feed is cut, PI104
!
CAUTION
will increase suddenly because of NH 3 expansion. Confirm valve
position of LV104A,B, PV111 and PV114.

(b) Put FIC131 on manual position.

Control PG133 and PI104 higher than PIC101 by FV131 manually.

Keep suction flow rate more than U-GA101 minimum flow.

!
CAUTION
“U-GA101 minimum flow” is defined as U-GA101 pump minimum flow
rate + flow rate for balance line.

(c) Stop NH 3 feed to Carbamate Condenser (U-EA101) by closing FV106 little by little
and close fully.

(d) Stop NH 3 feed to Reactor (U-DC101) by closing FV101 little by little and close
fully.

(e) Start High Pressure Flooding Pump (U-GA105) and inject flushing water from
FV106 to Carbamate Condenser (U-EA101) and continue flushing for 5 minutes.

(f) Inject flushing water from FV101 to Reactor (U-DC101) by High Pressure
Flooding Pump (U-GA105) and continue flushing for 10 minutes.

(g) LI101 start increasing due to flow rate decrease of motive NH 3 for HP Carbamate
Ejector (U-EE101).
According to the decrease of NH 3 flow rate to Reactor (U-DC101), reduce
carbamate solution feed to Carbamate Condenser (U-EA101). Refer to Para.
7.2.2.(2).

(h) Close the block valve for FV101 and FV106, and stop Ammonia Feed Pump
(U-GA101) in accordance with vendor's instruction.

(i) Stop Ammonia Boost-up Pump (U-GA103) and close FV131.

(j) Close discharge valve, suction valve and bypass valve for Ammonia Feed Pump
(U-GA101) and close isolation valve of FV131.

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(k) Check the level in Ammonia Reservoir (U-FA104). Close LV131 and isolation
valve at B.L.

(2) Stop Carbamate Solution Feeding

According to the decrease of NH 3 flow rate to Reactor (U-DC101), reduce carbamate

solution feed rate to Carbamate Condenser (U-EA101) by FV104. This action should
be taken at the almost same time of (1) “Stop Ammonia Feeding”.

(a) Close discharge valve of Carbamate Feed Pump (U-GA102) gradually and keep
suction flow rate more than minimum flow of Carbamate Feed Pump (U-GA102)
by FV108.

Keep suction flow rate more than U-GA102 minimum flow.

!
CAUTION
“U-GA102 minimum flow” is defined as U-GA102 pump minimum flow
rate + flow rate for balance line.

When LI101 start decreasing due to flow rate decrease of carbamate

!
CAUTION
solution, fully close HV106 immediately.

(b) Flush the line from Carbamate Feed Pump (U-GA102) to Carbamate Condenser
(U-EA101) through FV104 by High Pressure Flooding Pump (U-GA105).

It takes 30 minutes to replace carbamate solution in the line by High

Pressure Flooding Pump (U-GA105).

Do not flush the carbamate feed line into Carbamate Condenser

!
CAUTION
(U-EA101) by diluted solution longer than 30 minutes. This action may
form explosive gas because of absorption of NH 3 and CO 2 .

Do not flush the carbamate feed line into Carbamate Condenser

!
CAUTION
(U-EA101) if PV101 and HV103 are fully closed. This action may form
explosive gas because of absorption of NH 3 and CO 2 .

(c) Make circulation flow from Carbamate Boost-up Pump (U-GA401) to Carbamate
Feed Pump (U-GA102) and HP Absorber (U-EA401).

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(d) Dilute carbamate solution in HP Absorber (U-EA401) lower than CO 2

concentration, 17 wt%. Refer to Para. 7.2.3 (1) ~ (6).

(e) Stop Carbamate Feed Pump (U-GA102) in accordance with vendor's instruction.

(f) Stop Carbamate Boost-up Pump (U-GA401) and close FV108 and FV406.

(g) Flush the suction line, pump casing, balance line and return line by Low Pressure
Flooding Pump (U-GA104).

(h) Open each drain valve and confirm that water flows out.

(i) Close FV104 by manual and close its isolation valve.

(3) Stop CO 2 Feeding

According to decrease of NH 3 feed rate to Reactor (U-DC101), reduce CO 2 feed rate to

Stripper (U-DA101) by HV105 and to Reactor (U-DC101) by FV105. This action also
should be taken at almost same time of (1) ”Stop Ammonia Feeding”.

(a) Open PV153 on manual and close HV105 and FV105 fully with maintain 160
kg/cm2G pressure.

(b) Close 8” manual valve at CO 2 discharge line of CO 2 Compressor (U-GB101)

(c) Inject high pressure water by High Pressure Flooding Pump (U-GA105) to
Stripper (U-DA101) from downstream of HV105 and to Reactor (U-DC101) from
downstream of FV105 for CO 2 feed line for 10 minutes.

(d) Close the block valve for FV202 to stop CO 2 feeding to LP Decomposer
(U-DA202) and flush the line by SL steam.

(e) Stop passivation air feeding to CO 2 Compressor (U-GB101).

(f) Stop CO 2 Compressor (U-GB101), in accordance with vendor's instruction.

(g) When CO 2 Compressor (U-GB101) is stopped, close HV105 and FV105

completely by interlock system.

(h) Close water flushing valve for CO 2 feed line after flushing.

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(4) Flushing Pressure Detection Points

(a) PT101 and PT102 on seal NH 3 line to Carbamate Condenser (U-EA101) by High
Pressure Flooding Pump (U-GA105) for 5 minutes.

!
CAUTION
Bypass PT102 HH interlock.

(b) PT105 on CO 2 feed line to Stripper (U-DA101) by High Pressure Flooding Pump
(U-GA105) for 5 minutes.

(c) PT107 on NH 3 line to HP Carbamate Ejector (U-EE101) by High Pressure

Flooding Pump (U-GA105) for 5 minutes.

(5) Dilution of urea solution line from HV106 to HP Carbamate Ejector (U-EE101)

Dilute urea solution line at downstream of HV106 to HP Carbamate Ejector (U-EE101)

by High Pressure Flooding Pump (U-GA105) for 5 minutes.

(6) Reduce Heating in Stripper (U-DA101)

After closing HV105, reduce the steam pressure to 15 kg/cm2G by PIC106.

(7) Heating of Carbamate Condenser (U-EA101)

After stopping CO 2 feed to synthesis, set pressure of PIC724 at 5 kg/cm2G and continue
steam condensate circulation by Steam Condensate Circulation Pump (U-GA109) to
maintain temperature of synthesis solution in Carbamate Condenser (U-EA101) around
150 ºC.

(8) Purge Inert Gas in Synthesis Loop

(a) Inject flushing water to the suction line of PV101.

(b) Change PIC101 to manual and keep 5 ~ 20 % opening to purge gas from
Carbamate Condenser (U-EA101) to HP Absorber (U-EA401).

PIC101 to be maintained 120 kg/cm2G by adjusting PV101 opening.

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(c) Continue purging for about 30 minutes.

(9) Reduce Pressure in Synthesis Loop

(a) After stopping water injection to CO 2 feed line to Reactor (U-DC101) and Stripper
(U-DA101), open HV103 by 5 %.

(b) Close PV101 by manual.

(c) Flush PV101 upstream back to Carbamate Condenser (U-EA101) by High

Pressure Flooding Pump (U-GA105) for 2 minutes.

(d) Close isolation valve of PV101 and open PV101 and flush downstream of isolation
valve through PV101 by High Pressure Flooding Pump (U-GA105) for 2 minutes.

(e) Close PV101 and flush downstream of PV101 by SML steam.

(f) After LIC102 becomes 0 % and LV102 is closed completely, flush the solution line
from LV102 downstream to HP Decomposer (U-DA201) by SML steam.

(10) Dilution of overflow line from Carbamate Condenser (U-EA101) to HV106

Dilute urea solution line at upstream of HV106 by High Pressure Flooding Pump
(U-GA105) for 90 minutes.

(11) Dilute bottom chamber of Carbamate Condenser (U-EA101)

Dilute urea solution in the bottom chamber of Carbamate Condenser (U-EA101) from
seal NH 3 line by High Pressure Flooding Pump (U-GA105) for 90 minutes.

(12) Flushing check valve of control valve

Following check valves at upstream of control valve in Synthesis section are required to
conduct flushing:

- Check valve at upstream of FV105

- Check valve at upstream of HV105
- Check valve at upstream of FV101
- Check valve at upstream of FV106
- Check valve at upstream of FV104
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Flush each check valve at upstream of control valve in following manner:

- Confirm block valves (incl. bypass valve, if available) at upstream of check valve are
closed.
- Open drain valve at downstream of check valve
- Fill high pressure water in piping at upstream of check valve till water is coming out
from drain valve.
- Close drain valve.
- When High Pressure Flooding Pump (U-GA105) discharge pressure increases, open
control valve at 3 ~ 5% and continue flushing for 5 minutes. Confirm U-GA105
discharge pressure decreases.
- Stop water flushing and close water injection valve and control valve.

7.2.3 Shutdown of Purification and Recovery Sections

(1) When close the block valve for FV202, flush the line to LP Decomposer (U-DA202) by SL
steam.

(2) Vent the mixed gas from Process Condensate Treatment Section to atmosphere via
Vent Stack (14RV 24444 A1K0) and close the mixed gas inlet valve to LP Decomposer
(U-DA202).

(3) LV201 and LV202 are closed automatically when LV102 is closed. Open these control
valves manually and flush the urea solution line to Flash Separator (U-FA205) by SL
steam.

(4) Dilute the urea solution in small chamber of Urea Solution Tank (U-FA201) below 60 wt%
of urea concentration and flush the urea solution line of Urea Solution Pump (U-GA201)
by steam condensate.

(5) Dilution of the solution in HP Absorber (U-EA401) and LP Absorber (U-EA402).

(a) Inject steam condensate to HP Absorbent Pump (U-GA402) suction, and feed to
Washing Column (U-DA401) by FIC401.

(b) The solution in LP Absorber (U-EA402) is diluted automatically by injected water

to Washing Column (U-DA401) upper part by FIC506.

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(c) Increase condensate flow to LP Absorber (U-EA402) by local valve at FI402.

(d) Drain the solution of HP Absorber (U-EA401) to Carbonate Solution Tank

(U-FA401) to maintain the level in HP Absorber (U-EA401) through RO401.

(e) Confirm that the CO 2 concentration in LP Absorber (U-EA402) lowers to 10 wt%,

and in HP Absorber (U-EA401) lowers to 17 wt%.

(f) Check the pressure of Washing Column (U-DA401) and close PV401 by manual.

(6) Dilution of the solution in Separator for HP Absorbent (U-FA208).

(a) Inject steam condensate to Separator for HP Absorbent (U-FA208).

(b) Drain the solution of Separator for HP Absorbent (U-FA208) to Carbonate Solution
Tank (U-FA401) to maintain the level in Separator for HP Absorbent (U-FA208)
through RO202.

(c) Confirm that the CO2 concentration in Separator for HP Absorbent (U-FA208)
lowers to 17 wt%.

7.2.4 Shutdown of Concentration Section and Urea Solution Feed

(1) Preparation

(a) The urea solution from Urea Solution Tank (U-FA201) should be sent to
Concentration Section.

Adjust feed rate to the Concentration Section considering the heating

capacity in Heater of Vacuum Concentrator (U-EA201). If mixed gas is
not sufficient to concentrate the urea solution due to the lower load of
Purification Section, increase the steam heating instead in order to get
the required concentration at outlet of Heater of Vacuum Concentrator
(U-EA201).

(b) Keep molten urea feeding to Prilling Tower (U-IA301) as long as possible to
decrease the level in Urea Solution Tank (U-FA201).

(c) When the level in Urea Solution Tank (U-FA201) comes down to the minimum level,
decrease the flow rate of urea solution to Heater of Vacuum Concentrator
(U-EA201) to 65 T/h (60 % load) by FV203.

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(2) Open HV302 and feed the steam condensate to urea solution return line to confirm the
line has no clogging referring to TI213 indication.

(3) Stop molten urea feeding to Prilling Tower (U-IA301) by turning HV301 to change the
flow to Urea Solution Tank (U-FA201).

(4) Flush the line from HV301 to Prilling Basket (U-FJ302) by SL and stop the operation.

(5) Stop U-EE201 motive steam.

(6) Open PV203, PV206 & HV501 gradually. At the same time, inject vacuum break air
(STR-512 & 513) to the system.

(7) Confirm PIC203 & PIC206 become 760 mmHgA.

(8) Stop U-EE501 motive steam.

(9) Reconfirm PIC203 & PIC206 become 760 mmHgA.

(10) Stop U-EE502 motive steam.

(11) Stop U-EE503 motive steam.

(12) Put PIC207 and PIC208 on manual and decrease the temperature of urea solution by
closing PV207 and PV208 gradually. Finally, close PV207 and PV208 completely.

(13) Stop Urea Solution Pump (U-GA201) and Molten Urea Pump (U-GA204).

(14) Open steam condensate injection valve to the suction of Urea Solution Pump (U-GA201)
and close the pump suction valve.

(15) Flush following lines:

1. Discharge and suction line of Urea Solution Pump (U-GA201) and Molten Urea
Pump (U-GA204)
2. Urea solution line to HV301
3. Urea Solution from HV301 to Urea Solution Tank (U-FA201)

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(16) Stop the flushing of water to FI206 (Mix Gas outlet of U-FA203) and FI211 (Mix Gas
outlet of U-FA202).

(17) Stop the flushing of steam to Final Separator (U-FA203) top.

(18) Stop the purge of air to PT203 for U-FA202 and PT206 for U-FA203.

(19) Close HV302 after 5 minutes from stopping of Molten Urea Pump (U-GA204).

(20) Stop all rotating machines in the finishing section and wash the equipment, if necessary.

7.2.5 Shutdown of Process Condensate Treatment Section

(1) Confirm that Concentration Section has been stopped completely and check the level in
Process Condensate Tank (U-FA501).

(2) Close FV505 by manual to stop SL steam feeding to Process Condensate Stripper
(U-DA501). Close isolation valve of FIC505.

(3) Close FV508 and FV509 by manual to stop SM steam feeding to Urea Hydrolyzer
(U-DA502). Close isolation valve of FIC508.

(4) Close manually FV511 to stop process condensate feeding to Process Condensate
Stripper (U-DA501).

(5) When the level (LIC502) in the middle part of Process Condensate Stripper (U-DA501)
comes down, stop Urea Hydrolyzer Feed Pump (U-GA502).

(6) Reduce the pressure of Urea Hydrolyzer (U-DA502) by opening PV502 manually.

(7) Vent the mixed gas from Process Condensate Stripper (U-DA501) by PV501 manually.

(8) Close the isolation valve of FI503 (Process Condensate to U-DA503).

(9) Stop Process Condensate Pump (U-GA501).

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(10) When the liquid level (LIC503) in the bottom of Process Condensate Stripper (U-DA501)
comes down, stop Process Condensate Return Pump (U-GA505).

(11) Stop LP Absorbent Pump (U-GA503).

7.2.6 Draining the Solution from Synthesis Loop

When the hold-up time is expected beyond 48 hours, the solution in Synthesis Section shall
be transferred and drained out to Carbonate Solution Tank (U-FA401) to prevent the
corrosion.

Draining speed to be referred to Fig. 7-1.

When the water filled in vessels are drained, special attention should
!
CAUTION
be paid to avoid vacuum.

(1) Close the liquid outlet valve of Stripper (U-DA101) bottom (Isolation valve for LV102).

(2) Flush the drain lines from Synthesis Loop to Purification Section by SML steam or high
pressure water.

(3) Drain solution in Synthesis Loop from drain lines through LV102 manually in accordance
with the following order:

(a) Stop flushing for transfer line.

(b) Close the drain valve of transfer line.

(c) Drain the solution in Carbamate Condenser (U-EA101) through drain line at mixed
gas inlet line from Stripper (U-DA101) overhead and drain line at seal NH 3 line.

(d) Gradually open LV102 by manual and transfer the solution through LV102 to HP
Decomposer (U-DA201).

(e) Drain the solution in Reactor (U-DC101) through drain line at CO 2 gas line from the
downstream of FV105.

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(f) Drain the solution in HP Carbamate Ejector (U-EE101) through drain line at urea
solution outlet line from HP Carbamate Ejector (U-EE101).

Drain solution in Carbamate Condenser (U-EA101) before draining

!
CAUTION
solution in Reactor (U-DC101) to prevent from making vacuum at top of
Reactor (U-DC101).

(4) The level in HP Decomposer (U-DA201) is controlled by LIC201.

(5) The temperature of solution in HP Decomposer (U-DA201) and LP Decomposer

(U-DA202) is controlled at 110°C by TIC202 and TIC205.

(6) The urea solution from HP Decomposer (U-DA201) and LP Decomposer (U-DA202) is
fed to Urea Solution Tank (U-FA201).

(7) The off gas from HP Decomposer (U-DA201) and LP Decomposer (U-DA202) are
absorbed in HP Absorber (U-EA401) and LP Absorber (U-EA402) respectively.

Continue feeding absorbent to Heater of Vacuum Concentrator

(U-EA201) through FV204 and FV209. Otherwise plugging of shell side
of Heater of Vacuum Concentrator (U-EA201) might result due to
condensation and solidification of the gas from HP Decomposer
(U-DA201) by cooling of urea solution in tube side.

(8) Drain the diluted carbamate solution from HP Absorber (U-EA401) to Carbonate
Solution Tank (U-FA401) in accordance with the level through RO401.

(9) When the pressure in Synthesis Loop is decreased to around 60 - 70 kg/cm2G, close
LV102 on manual and the isolation valve (it will take several hours to drain the solution).

(10) Flush the line from LV102 downstream to HP Decomposer (U-DA201) by SML steam.

(11) Flush the line to LP Decomposer (U-DA202) by SL steam.

(12) Drain out the remaining solution and gas in HP Decomposer (U-DA201) and LP
Decomposer (U-DA202) by opening each drain valves on the solution draining line.

(13) Put the temperature control valves for HP Decomposer (U-DA201) and LP Decomposer
(U-DA202) (PV202 and PV205) on manual and keep it crack open.

(14) Flush HP Decomposer (U-DA201) and LP Decomposer (U-DA202) with steam and/or
water from Low Pressure Flooding Pump (U-GA104). Then the temperature control
valves and their isolation vales should be closed completely.
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Fig. 7-1 Pressure vs. Time for Draining Synthesis Solution

7.2.7 Purge the Gas in Synthesis Loop

Subsequent to draining, the gas held in Synthesis Loop is purged out and absorbed in
Recovery Section.

(1) Open PV101 on manual gradually, and purge the gas to HP Decomposer (U-DA201).

(2) The gas from HP Decomposer (U-DA201) is absorbed in HP Absorber (U-EA401) and
drain the solution from HP Absorber (U-EA401) to Carbonate Solution Tank (U-FA401)
by level increase through RO401.

(3) When the pressure in Synthesis Loop comes near to that of HP Decomposer (U-DA201),
drain the remaining solution to chemical sewer and vent the remaining gas.

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When the remaining solution is drained to chemical sewer, pay

!
CAUTION
attention to the rapid depressurizing in Synthesis Loop. Feed SML
steam (20 kg/cm2G) to Synthesis Loop to keep the pressure at certain
level, if necessary. Refer to below (7).

(4) After finishing gas purge, close PV101 on manual and isolation valve.

(5) Open the steam flushing valve just after PV101 and flush the line to HP Decomposer
(U-DA201) and subsequent Purification Section.

(6) Open HV103 and the isolation valve fully.

(7) Flush all equipment and lines of Synthesis Loop with SML steam until NH 3 is purged out
completely.

(8) Check the CO 2 concentration in Separator for HP Absorbent (U-FA208), HP Absorber

(U-EA401) and LP Absorber (U-EA402). When the CO 2 concentration is diluted to lower
than 17wt% and 10 wt% respectively, stop the steam condensate feed to the suction of
Carbamate Boost-up Pump (U-GA401).

(9) Stop Carbamate Boost-up Pump (U-GA401).

7.2.8 Treating of Synthesis Loop for Inspection

When it is necessary to inspect the inside of Synthesis Loop, following steps are required for
safety:

(1) Flush all equipment and lines with steam and air supplied from the bottom of Reactor
(U-DC101).

(2) When steam flushing completed, stop the steam feeding. Then purge the system only
with air (from hose connection).

(3) When NH 3 smell is disappeared, stop air feed.

(4) Stop all steam tracing in Synthesis Loop.

(5) Open the manholes of Reactor (U-DC101) and Carbamate Condenser (U-EA101) at
least.

(6) Start Low Pressure Flooding Pump (U-GA104).

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(7) Feed the cold water (steam condensate or demineralized water) to Synthesis Loop by
FIC104. Feed water from open manholes to inside of Reactor (U-DC101) and
Carbamate Condenser (U-EA101) by using hose station if necessary.

(8) When Synthesis Loop is cooled down enough, stop the water feed.

(9) Stop Low Pressure Flooding Pump (U-GA104).

(10) Drain the water in Synthesis Loop completely.

(11) Open the manholes required for inspection.

(12) Before entering inside of equipment, check NH 3 smell and O 2 concentration.

7.3 Normal Shutdown for Short Period

When the shutdown duration is expected within 48 hours, all solution and gas in Synthesis
Loop are blocked in without any dilution. During the blocked in period, pay attention to the
followings:

- Temperature in Reactor (U-DC101) and Carbamate Condenser (U-EA101) should not

drop below 125°C.

- Open PV101 or HV103 around 1% for 30 minutes once per shift to avoid accumulation of
inert gas in top of Carbamate Condenser (U-EA101).

Keep the pressure of Steam Saturation Drum (U-FA101) at around 15 ~

!
CAUTION
18 kg/cm2G to prevent back flow of the solution from Carbamate
Condenser (U-EA101) to Stripper (U-DA101).

7.3.1 Stop of Feed to Synthesis Loop

Refer to Normal Shutdown (Para. 7.2.2-(1) ~ (3)).

7.3.2 Purification and Recovery Sections

Refer to Normal Shutdown (Para. 7.2.3-(1) ~ (6)).

7.3.3 Concentration Section and Urea Solution Feed

Refer to Normal Shutdown (Para. 7.2.4-(1) ~ (20)).

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7.3.4 Process Condensate Treatment Section

Refer to Normal Shutdown (Para. 7.2.5-(1) ~ (11)).

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SECTION 8. EMERGENCY SHUTDOWN

8.1 General

8.2 General Emergency Procedure

8.3 Utility Failure

8.3.1 Power Failure

8.3.2 Instrument Air Failure
8.3.3 Steam Failure
8.3.4 Cooling Water Failure

8.4 DCS Failure

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SECTION 8. EMERGENCY SHUTDOWN

8.1 General

Emergency conditions on the Urea Unit are caused by:

- Loss of raw material such as CO 2 and NH 3 .

- Loss of utility such as electric power, instrument air, cooling water and steam.
- Mechanical failure of equipment, which could disturb normal operations.

Some of these emergency conditions can be tolerated for a very short time, if proper
countermeasures are taken. In general, however, Emergency Shut Down Procedure should
be started immediately.

In some cases, the emergency condition might not be so serious as to shut down all
equipment, and the plant can be operated by bypassing the malfunctioning equipment until
repairs can be made. The following steps are to be taken in case of an emergency:

(1) Determine the extent of the emergency conditions.

(2) Decide how to cope with emergency.

(a) Handle the emergency as a localized condition without shutting down the rest of the
units.

(b) Shutdown the unit using normal procedure as described under shutdown for short
time.

(c) Shutdown the unit using Emergency Procedure.

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8.2 General Emergency Procedure

The general emergency shutdown procedure consists essentially of:

(1) Cut off the effluent from Synthesis Loop.

(2) Flush out the piping, which might become plugged with urea or carbamate.

(3) Try to minimize the amount of ammonia and urea vented.

8.3 Utility Failure

8.3.1 Power Failure

Loss of electricity is critical and requires immediate shutdown as follows:

The emergency power source is connected with following machines.

- Low Pressure Flooding Pump (U-GA104)

- High Pressure Flooding Pump (U-GA105)
- Steam Condensate Pump (U-GA106)
- Return Condensate Pump (U-GA107)
- Steam Condensate Circulation Pump (U-GA109)
- Steam Condensate Make-up Pump (U-GA110)
- Sealing Water Pump (U-GA121)
- Tempered Water Pump (U-GA405)
- Elevator for Prilling Tower (U-JC301)
- Lube Oil Pump for Ammonia Feed Pump
- Lube Oil Pump for Carbamate Feed Pump
- Turning Device for Turbine for CO 2 Compressor
- Lube Oil Pump for CO 2 Compressor

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(1) Control Room Operations

(a) PIC106: Steam Saturation Drum (U-FA101)

Reduce the set pressure of PIC106 to 18 kg/cm2G.

(b) PIC101: Carbamate Condenser (U-EA101)

After confirming that all the feeds to Synthesis Loop are stopped, put PIC101 on
manual, and close them completely.

LV102 closes by interlock in case raw material feeds to synthesis are

cut off.

(c) Immediately stop heating No.1, No.2 and No.3 Ammonia Preheaters (U-EA102,
U-EA106 and U-EA103) to avoid ammonia expansion.

Steam and steam condensate to No.1 Ammonia Preheater (U-EA102),

No.2 Ammonia Preheater (U-EA106) and No.3 Ammonia Preheater
(U-EA103) are cut off by interlock.

(d) Make sure the following condition by interlock system.

- HV301: Open (A to C)

(e) Open HV302 by manual to dilute urea solution recycled to Urea Solution Tank
(U-FA201).

(f) Close following control valves on manual:

- Steam Saturation Drum (U-FA101) : LV106

- HP Decomposer (U-DA201) : PV202
- LP Decomposer (U-DA202) : PV205
- CO 2 Gas to U-DA202 : FV202
- Heater of Vacuum Concentrator (U-EA201) : PV207
- Final Concentrator (U-EA202) : PV208
- Process Condensate to U-DA501 : FV504
- Process Condensate Stripper (U-DA501) : FV505

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- Urea Hydrolyzer (U-DA502) : FV508, FV509

(2) Out-side Operation

(a) Synthesis Loop

1) Confirm the isolation valve for HV103 is opened.

The isolation valve of HV103 must be kept open in normal operation.

2) Start following machines for Turbine for CO 2 Compressor (U-GT101) by

emergency power.

- Lube Oil Pump for CO 2 Compressor (U-GB101)

- Turning Device for Turbine for CO 2 Compressor (U-GT101)

3) Drain the remaining condensate in No.1, No.2 and No.3 Ammonia Preheater
(U-EA102, U-EA106 and U-EA103) through the drain valve.

4) Start High Pressure Flooding Pump (U-GA105) and wash following points one by
one:

- Both CO 2 feed lines to Reactor (U-DC101) and Stripper (U-DA101)

- Carbamate solution feed line to Carbamate Condenser (U-EA101)

- Both NH 3 feed lines to Carbamate Condenser (U-EA101) and HP Carbamate

Ejector (U-EE101)

- Upstream of LV102 and Upstream of PV101

- Overflow line from Carbamate Condenser (U-EA101) to Reactor (U-DC101)

- Bottom chamber of Carbamate Condenser (U-EA101)

Washing procedure shall be in accordance with that for normal shut

down (Para. 7.2.2).

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5) Close the discharge valve of CO 2 Compressor (U-GB101), Ammonia Feed

Pump (U-GA101) and Carbamate Feed Pump (U-GA102).

6) Start Low Pressure Flooding Pump (U-GA104).

a) Close the suction valve of Carbamate Feed Pump (U-GA102) and open the
flooding water valve and wash the lines and pump with water.

b) Wash the circulation line for Carbamate Boost-up Pump (U-GA401).

7) Flush and dilute the solution in downstream of LV102 to HP Decomposer

(U-DA201) by Low Pressure Flooding Pump (U-GA104).

8) Close the steam inlet valve of Turbine for CO 2 Compressor (U-GT101).

(b) Purification and Recovery Sections

1) Close the isolation valves on steam and steam condensate to HP Decomposer

(U-DA201).

2) Close the isolation valves on steam to LP Decomposer (U-DA202).

3) Watch the pressure in HP and LP Decomposer (U-DA201 and U-DA202)

carefully, and if there is any sign of sudden rise, vent the system through vent
valves.

4) Start Low Pressure Flooding Pump (U-GA104) and wash the absorbent or
carbamate solution lines from the flooding water connections.

5) Flush the process lines with steam where possible.

6) Dilute the solution in HP Absorber (U-EA401) and Separator for HP Decomposer

(U-FA208) to lower than 15 ~ 20 wt% in CO 2 concentration and solution in LP
Absorber (U-EA402) to lower than 10 ~ 15 wt% in CO 2 concentration.

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(c) Concentration, Prilling and Process Condensate Treatment Sections

1) Stop the steam to Ejectors and open PV203, PV206 and HV501 manually to
break the vacuum in Concentration Section.
Refer to 7.2.4 (5) ~ (12).

2) Close the isolation valve of PV207 and PV208.

3) Inject steam condensate to suction line of Urea Solution Pump (U-GA201) and
Molten Urea Pump (U-GA204) and wash the urea solution line to Final Separator
(U-FA203).

4) Drain the urea solution in Final Separator (U-FA203) from the drain line of Molten
Urea Pump (U-GA204).

5) Start Low Pressure Flooding Pump (U-GA104) and wash the molten urea line
from Molten Urea Pump (U-GA204) discharge to HV301 and drain to Urea
Solution Tank (U-FA201).

6) Inject steam from downstream of HV301 to Prilling Basket (U-FJ302) for flushing.

7) Start Steam Condensate Pump (U-GA106) and wash the top of Vacuum
Concentrator (U-FA202) and Final Separator (U-FA203).

8) Other steps are same as Normal Shutdown Procedure (Para. 7.2.3, 7.2.4 and
7.2.5).

8.3.2 Instrument Air Failure

In case of instrument air failure, the following steps should be taken:

(1) When the instrument air pressure come down abnormally, CO 2 Compressor (U-GB101),
Ammonia Feed Pump (U-GA101) and Carbamate Feed Pump (U-GA102) are stopped
by interlock.

(2) Block all feeds and effluents for Synthesis Loop, and hold the solution and gas in the
system.

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(3) Drain urea solution from HP Decomposer (U-DA201) and LP Decomposer (U-DA202) to
Carbonate Solution Tank (U-FA401).

(4) Regulate the pressure in HP Absorber (U-EA401) by manual control of PV401.

(5) For flushing the lines and dilution of the solution, follow the emergency shutdown
procedure for Power Failure described in para. 8.3.1 with the exception of above
procedure.

All controllers, which will be closed on instrument air failure, should be

switched to manual and set them at close position to prevent the valve
action when instrument air becomes available.

Special attention should be paid to the rotating machines regarding

such points as cavitation and overload.

Valve action of instrument air failure is shown in Table 8-1.

8.3.3 Steam Failure

In case of steam failure, Turbines, Stripper, Decomposers, Process Condensate Treatment

and Prilling operation are impossible to keep in operation and require immediately to follow
the shutdown procedure:

(1) The pressure of high pressure steam header come down abnormally, CO 2 Compressor
(U-GB101) shall be stopped manually by Push Button.

(2) Block all feeds and effluents for Synthesis Loop, and hold the solution and gas in the
system.

(3) Drain urea solution from HP Decomposer (U-DA201) and LP Decomposer (U-DA202) to
Carbonate Solution Tank (U-FA401).

(4) Stop urea solution feed to Concentration and Prilling Sections as soon as possible and
flush the urea solution lines with steam before losing steam pressure.

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(5) Flush the line that might be plugged by urea or carbamate as far as possible with steam,
if losing steam pressure flush with water.

(6) Follow the shutdown procedure for Power Failure described in para. 8.3.1 with
the exception of above procedure.

8.3.4 Cooling Water Failure

In case of cooling water failure, the Urea Unit is stopped automatically by interlock and
requires immediately to follow the shutdown procedure for Steam Failure described in
para.8.3.3.

8.4 DCS Failure

DCS is protected by lots of safety devices for its trouble. If DCS fails, confirm the cause of
trouble and instruct whether total shutdown or not as soon as possible. For DCS
troubleshooting, refer to DCS Operation Manual.

Table 8-1 The Valve Action upon Instrument Air Failure

Item No. Service Action

FV101 NH 3 to HP Carbamate Ejector (U-EE101) Close

FV104 Carbamate Solution to Carbamate Condenser Close

(U-EA101)

FV105 CO 2 Feed to Reactor (U-DC101) Close

FV106 Seal NH 3 to Carbamate Condenser (U-EA101) Close

FV108A,B Carbamate Feed Pump (U-GA102) Recycle Line Open

FV109 Blow-down from Steam Drum (U-FA102) Close

FV131A,B Ammonia Feed Pump (U-GA101) Recycle Line Open

FV156 Passivation Air to CO 2 Compressor (U-GB101) Close

FV202 CO 2 Gas to LP Decomposer (U-DA202) Close

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Table 8-1 The Valve Action upon Instrument Air Failure

Item No. Service Action

FV203 Urea Solution to Heater of Vacuum Concentrator Close
(U-EA201)

FV204 Absorbent from No.2 HP Absorbent Pump (U-GA404) Open

FV209 Absorbent from HP Absorbent Circulation Pump Open

(U-GA202)

FV401 Carbamate Solution to Washing Column (U-DA401) Open

FV404 Tempered Water Bypass for Tempered Water Cooler Close

(U-EA403)

FV406 Carbamate Boost-up Pump (U-GA401) Recycle Line Open

FV504 Process Condensate to Preheater for Process Close

Condensate Stripper (U-EA504)

FV505 SL Steam to Process Condensate Stripper (U-DA501) Close

Bottom

FV506 Process Condensate to Washing Column (U-DA401) Close

FV508 SM Steam to Urea Hydrolyzer (U-DA502) Tray Section Close

FV509 SM Steam to Urea Hydrolyzer (U-DA502) Stripping Close

Section

FV705 Return Condensate Pump (U-GA107) to Turbine Open

Condenser (U-EA105)

HV103 Carbamate Condenser (U-EA103) Top Vent Close

HV105 CO 2 Feed to Stripper (U-DA101) Close

HV106 Urea Solution to HP Carbamate Ejector (U-EE101) Close

HV108 LP Steam Flash Drum (U-FA105) Make-up Close

HV301 Molten Urea to Prilling Device Open

（A to C）

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Table 8-1 The Valve Action upon Instrument Air Failure

Item No. Service Action

HV302 Process Condensate to Molten Urea Line Open

HV303 LP Steam to Molten Urea Line Open

HV401 Washing Column (U-DA401) C.W. Outlet Open

HV402 LP Absorber (U-EA402) C.W. Outlet Open

HV403 HP Absorbent Pump (U-GA402) Minimum Flow Open

HV501 Flash Gas Condenser (U-EA506) Gas Outlet Close

LV102 Urea Solution from Stripper (U-DA101) Bottom Close

LV103 Steam Drum (U-FA102) Make-up Close

LV104A No.1 Ammonia Preheater (U-EA102) Steam Close

Condensate Out

LV104B Steam Condensate No.1 Ammonia Preheater Open

(U-EA102) Bypass

LV106 Steam condensate from Steam Saturation Drum Close

(U-FA101) to Steam Flash Drum for HP Decomposer
(U-FA106)

LV107 Steam Condensate from Steam Flash Drum for HP Close

Decomposer (U-FA106) to Steam Drum (U-FA102)

LV131 NH 3 to Ammonia Reservoir (U-FA104) Close

LV151 Condensate from 1st Stage Suction Separator for Close

CO 2 Compressor (U-FA111)

LV153 Condensate from 2nd Stage Suction Separator for Close

CO 2 Compressor (U-FA112)

LV155 Condensate from 3rd Stage Suction Separator for Close

CO 2 Compressor (U-FA113)

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Table 8-1 The Valve Action upon Instrument Air Failure

Item No. Service Action

LV157 Condensate from 4th Stage Suction Separator for Close
CO 2 Compressor (U-FA114)

LV201 Urea solution from HP Decomposer (U-DA201) Close

Bottom

LV202 Urea solution from LP Decomposer (U-DA202) Close

Bottom

LV206 Condensate from Condensate Pot for Heater of Close

Vacuum Concentrator (U-FA207)

LV207 Urea Solution from Molten Urea Pump (U-GA204) to Open

Prilling Tower (U-IA301)

LV208 Steam Condensate from Condensate Pot for HP Close

Decomposer (U-FA206)

LV209 Separator for HP Absorbent (U-FA208) to HP Close

Absorber (U-EA401)

LV303 Urea Solution from Dissolving Tank (U-FA302) Close

LV403 Washing Column (U-DA401) to LP Absorber Close

(U-EA402)

LV405 Washing Column (U-DA401) to HP Absorber Close

(U-EA401)

LV501 Process Condensate to No.3 Process Condensate Close

Tank (U-FA503)

LV502 Process Condensate Stripper (U-DA501) Middle Close

LV503 Process Condensate Stripper (U-DA501) Bottom Close

LV504 Preheater for Urea Hydrolyzer (U-EA505) to Process Close

Condensate Stripper (U-DA501)

LV701 Steam Condensate to Sealing Water Tank (U-FA121) Close

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Table 8-1 The Valve Action upon Instrument Air Failure

Item No. Service Action

LV702 Return Steam Condensate from Steam Condensate Close
Pump (U-GA106)

LV704 Return Condensate Pump (U-GA107) Discharge Line Close

LV711A Steam Condensate to Tempered Water Tank Close

(U-FA402)

LV711B Steam condensate from Tempered Water Tank Close

(U-FA402)

PV101 Carbamate Condenser (U-EA101) Top Gas Close

PV106 SML Steam to Steam Saturation Drum (U-FA101) Close

PV111 SL Steam to No.2 Ammonia Preheater (U-EA103) Close

PV113A SML Steam to Steam Flash Drum for HP Decomposer Close

(U-FA106)

PV113B SL Steam from Steam Flash Drum for HP Close

Decomposer (U-FA106) to SL Header

PV121 High Pressure Flooding Pump (U-GA105) Discharge Close

PV131A Vent Gas from Ammonia Reservoir (U-FA104) Close

PV131B Nitrogen to Ammonia Reservoir (U-FA104) Close

PV153 CO 2 Compressor (U-GB101) 4th Stage Vent F.L. Close

PV202 SL Steam to HP Decomposer (U-DA201) Close

PV203 Vacuum Controller of Vacuum Concentrator Open

(U-FA202)

PV205 SL Steam to LP Decomposer (U-DA202) Close

PV206 Vacuum Controller of Final Separator (U-FA203) Open

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Table 8-1 The Valve Action upon Instrument Air Failure

Item No. Service Action

PV207 LP Steam to Heater of Vacuum Concentrator Open
(U-EA201)

PV208 LP Steam to Final Concentrator (U-EA202) Open

PV209 Mixed Gas from Carbamate Condenser (U-EA101) to Open

HP Absorber (U-EA401)

PV301 Steam Jacket for Molten Urea Line Open

PV401 Washing Column (U-DA401) Top Vent Close

PV402 LP Absorber (U-EA402) Top Vent Close

PV501 Process Condensate Stripper (U-DA501) Top Close

PV502 Urea Hydrolyzer (U-DA502) Top Close

PV706 Sealing Water Pump (U-GA121) to Sealing Water Open

Cooler (U-EA121)

PV711 Cooling Water Bypass (CO 2 Compressor (U-GB101)) Close

PV712 Cooling Water Bypass (Process Line) Close

PV722 SM to SML Steam Let Down Close

PV723 SML Steam Vent Close

PV724 SML to SL Steam Let Down Close

PV725 Turbine for CO 2 Compressor (U-GT101) Admission Close

Steam

PV726 SL Steam Vent Close

PV727 SL Steam Let Down to SLL Steam Close

PV731 IP Steam Import to Turbine for CO2 Compressor Close

(U-GT101)

PV734 HP Nitrogen Bypass Open

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Table 8-1 The Valve Action upon Instrument Air Failure

Item No. Service Action

PV735 SLL Steam Vent Close

PV736A Nitrogen to Tempered Water Tank(U-FA402) Close

PV736B Tempered Water Tank (U-FA402) to ATM Close

TV162 Cooling Water Outlet from 3rd Stage Intercooler for F.L. Close
CO 2 Compressor (U-EA113)

TV402 Tempered Water to Tempered Water Cooler Open

(U-EA403)

TV702 BH701 Close

AV501 Treated Process Condensate to Battery Limit Open

(A to C)

AV701 Steam Condensate Return (3-way valve) to B.L. Open

(A to C)

AV702 Turbine Condensate Return (3-way valve) to B.L. Open

(A to C)

UV151 CO2 Compressor (U-GB101) LP Casing Anti-Surge Open

Valve

UV152 CO2 Compressor (U-GB101) HP Casing Anti-Surge Open

Valve

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SECTION 9. SAFETY

9.1 General

9.2 Fire Protection

9.2.1 General Cautions

9.2.2 Fire and Explosive Hazards in Urea Plant

9.3 Personnel Protective Equipment

9.3.1 Respiratory Protection

9.3.2 Eye Protection
9.3.3 Eye Washers
9.3.4 Others

9.4 Repair Work

9.4.1 General Cautions

9.4.2 Rotating Machines
9.4.3 Entering Vessels

9.5 Maintenance of Equipment and Housekeeping

9.6 Special Cautions in the Urea Plant

9.6.1 Plugging in Lines

9.6.2 Sampling

9.7 Occupational Safety Data

9.7.1 Anhydrous Ammonia

9.7.2 Carbon Dioxide
9.7.3 Urea

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SECTION 9. SAFETY

9.1 General

The purpose of these safety instructions is to prevent any possible accident in the Urea Plant
and to minimize damages for employees and plant equipment.

Operating personnel should always follow these safety instructions keeping in mind that,
"SAFETY IS FIRST".

These are intended to supplement, not supersede, any existing general safety regulations
which cover all units, and reference should be made to the latter for all points not mentioned
below.

(1) Smoking shall be allowed only in designated areas. Lighters and matches shall not be
carried within an operating plant handling inflammables.

(2) All personnel must know the location and use of all fire hoses and hydrants, fire blankets,
gas masks and respirators, and other protective equipment such as hard hats, rubber
gloves.

(3) Intoxicants of any kind shall not be allowed to brought into or be used in the plant. Anyone
under the influence of intoxicants should not be allowed in the plant area.

(4) Pass only on specified sidewalks in the plant unless otherwise necessary.

(5) Do not walk under cranes, booms or loads being hoisted.

(6) Do not jump from platforms, ladders, etc.

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9.2 Fire Protection

9.2.1 General Cautions

(1) Foam-type extinguishers and water must not be used in fires around electrical
equipment. Carbon dioxide or dry powder extinguishers may be used safely.

(2) Carbon tetrachloride extinguishers which liberate poisonous fumes should not be used.

(3) Carbon dioxide, dry chemical, of foam-type extinguishers are suitable for oil fires.

(4) Gas masks must be worn whenever poisonous fumes are encountered, such as
ammonia, hydrogen sulfide, or petroleum vapors.

(5) Do not use light distillates such as gasoline or naphtha to clean machinery or for any
other cleaning purpose. Use kerosene or heavier oil instead.

(6) Keep all areas free of waste paper and trash, especially oily rags and clothes should not
be left in lockers or tool boxes.

(7) Lighting fixtures and electrical equipment should be vapor-proof.

9.2.2 Fire and Explosive Hazards in Urea Plant

Ammonia is capable of forming flammable and explosive mixtures with air within a certain
range (16 to 25% by volume). Such concentrations are seldom encountered in practical
handling, accordingly, the relative fire and explosion hazards are small.

The presence of oil or a mixture of ammonia with other combustible materials, will increase
the fire hazard.

The explosive range of ammonia is broadened by the following factors as mentioned in Fig.
9-1 and Fig. 9-2.

- Admixture of hydrogen or oxygen replacing air

- Higher temperature and pressure

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NH3

H2 + N2 : H2 75vol%
N2 25vol%

Cal Atm
c ula
te d os
ph
eri
cP
res
s.
Explosion

AIR H2 + N2

Fig. 9-1 Explosion Range of Ammonia (Pressure : Atmospheric Pressure)

NH3

H2 + N2 : H2 75vol%
N2 25vol%

30
kg
/c
10 k m2
g/cm 2 G
G

Explosion

AIR H2 + N2

Fig. 9-2 Explosion Range of Ammonia (Pressure : 10 kg/cm2G and 30 kg/cm2G)\

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9.3 Personnel Protective Equipment

The use of personnel protective equipment is urged under many circumstances for the
protection of eyes, hands and other parts of the body.

9.3.1 Respiratory Protection

All gases, other than air, are harmful to human beings if inhaled in sufficient concentration.
Toxic gases may be classified as either asphyxiating or irritating. Asphyxiating gases may
cause death by replacing air in the lungs or by reacting with the oxygen carried in the blood.
Irritating gases may cause injury or death not only by asphyxiation, but also by burns both
internal and external. When the following gas masks are used, the correct type should be
selected depending on the circumstances.

- Oxygen respirator
- Canister type mask
- Fresh air mask

The characteristics and best application of such gas masks should be acquainted by all
operators.

9.3.2 Eye Protection

Safety goggles should be worn to protect eyes whenever the following cases occur in the
plant:

- When handling acid, caustic or other dangerous materials.

- When working where materials may splash.
- When working around open lines and/or disconnecting the lines.
- When striking a hammer to another object which may cause a chip to fly.
- When sampling under pressure, or operating drain and vent valves.

9.3.3 Eye Washers

Eye washers are recommended to provide but not limited to the following locations.

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No. Req'd
- Ground : 2 (near Ammonia Feed Pump (U-GA101) & Carbamate Feed Pump
(U-GA102) / near Ammonia Reservoir (U-FA104))
- Prilling Tower : 1 (in Prilling Basket Room)

9.3.4 Others

Suitable rubber or plastic coat, pants, boots, and hood shall be worn when working on lines
or equipment, which contain hazardous materials.

Gloves should be worn at all times while operating. They protect your hands from cuts,
chemical burns, etc.

It is recommended that helmet, safety shoes and well fitting clothing shall be worn at all times
in the plant.

9.4 Repair Work

9.4.1 General Cautions

(1) Mechanical work around an operating unit must be kept to a minimum, and the
minimum number of men should be employed.

(2) No mechanical work on the equipment is to be done without a properly authorized work
permit.

(3) No burning, welding, or other hot work shall be allowed in the area unless authorized by
a work permit.

(4) No personnel shall enter a vessel for any purpose whatsoever until it has been
adequately purged, blanked off as required and tested to insure freedom from noxious or
inflammable gases.

(5) Non-sparking tools must be used for making emergency repairs where ammonia,
hydrocarbon gases, hydrogen, or naphtha are present.

(6) Nothing should be carried in either hand when climbing up or down a vertical ladder, and

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objects shall not be carried in pockets, which might fall on someone below.

(7) When working overhead, make sure tools cannot fall on someone below. Tie them to a
line if necessary.

(8) Prevent injuries by using proper tools in proper manners.

(9) Never use a water hose as substitute for steam or air hose, and before using any hose,
inspect it for defects, cuts, loose clamps, improper fitting, etc.

9.4.2 Rotating Machines

(1) Driver motors should be de-energized by the main switch in the substation and a warning
tag signed by an authorized person shall be hung on the switch board.

(2) Remove guards only after the equipment has been shut down tagged and locked out of
service. Replace the guards as soon as repair work is completed.

(3) Only authorized persons shall be allowed to enter substations, transformer banks or
electrical control rooms.

9.4.3 Entering Vessels

(1) Vessels shall be washed and/or purged with inert gas and blown with air completely.

(2) All lines to the vessel shall either be disconnected or blinded. The blockade by only
isolation valves is trusted too much.

(3) Before entering, assurance of satisfactory atmosphere must be made.

(4) No one shall enter a vessel unless an attendant stays on the immediate outside at all
times to supply air if necessary. He must be in sight or communication with the men
inside.

(5) A safety belt and rope shall be used.

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9.5 Maintenance of Equipment and Housekeeping

(1) Fire extinguishers must be recharged or replaced immediately after use. All steam and
water hose equipment must be put back in place after use, and checked periodically.
Access to such equipment must not be obstructed.

(2) Personnel protective equipment must be kept in designated accessible places, which
are well identified at all times.

(3) Gas masks must have fresh cartridges installed after use.

(4) Tools, pieces of pipe, etc. should never left on platforms or railings of operation
equipment where they can be knocked off and injure someone below.

(5) Access to ladders and fire escapes must be kept clear. Waste material and refuse must
be put in proper locations where they will not cause a fire or will not be stumbled over.

(6) Liquid spills must be cleaned up immediately.

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9.6 Special Cautions in the Urea Plant

9.6.1 Plugging in Lines

When plugging occurs in lines with solidified urea solution and/or ammonium carbamate
solution, first try to dissolve it by flushing with steam or hot water. If the plugging cannot be
dissolved by this method, disconnect the flanges to separate pipe lines into suitable pieces.
Care must be taken for the remaining pressure in the lines. Then, at first, try again to
dissolve plugging with steam or hot water.

If still impossible, heat the pipe with flame from the end of the pipe, and melt off the
plugging.

Never heat the pipe from the middle, otherwise the decomposed gas will be pressurized in
the pipe and hazardous break of the pipe or splashing hot solution might be caused.

9.6.2 Sampling

When taking sample of solution or gas from a pressurized equipment, for example, from
the HP Absorber (U-EA401), care must be taken not to face against the flow from the
sampling valve, but stand in parallel to the flow direction. Safety goggles and gloves should
always be worn for sampling.

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9.7 Occupational Safety Data

The following materials are handled in Urea Plant under the high pressure and hot condition.

- Ammonia Liquid
- Ammonia Gas
- Carbon Dioxide Gas
- Ammonium Carbamate
- Urea Solution

Urea can be considered to be nontoxic. However, it is conceivable that some individuals might
have an allergic reaction with repeated contact with urea.

Occupational safety data for ammonia and carbon dioxide are prepared hereunder.
Ammonium carbamate can be handled as same manner as of ammonia.

For urea solution, which is not toxic, the caution and the first aid treatment is introduced here as
well.

9.7.1 Anhydrous Ammonia

9.7.1.1 Description

Colorless gas, extremely pungent odor, liquefied by compression, chemical name is

ammonia and common name is anhydrous ammonia.

9.7.1.2 Properties

(1) Physical and Chemical Properties

Formula Liquid Gas

Odor Pungent Pungent

Color Colorless Colorless

Density (kg/m3) 617

at 15°C

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Boiling point -33.35°C

Melting point -77.7°C

(Freezing point)

Light sensitivity No No

Explosive limits 16-25

(% by volume in air)

Corrosivity Corrosive to copper, same as copper alloys

Affinity for water Yes Yes

Autoignition 651°C
temperature

Vapor density 0.597

(air = 1) (0°C and 1 atm.)

(2) Vapor Pressure of Ammonia

Temperature Pressure

(Degrees F (oC)) (psia (kg/cm2A)) (psig (kg/cm2G))

0 (-18) 30.40 (2.13) 15.7 (1.10)
5 (-15) 34.27 (2.41) 19.6 (1.37)
10 (-12) 38.51 (2.71) 23.8 (1.68)
15 (-9) 43.14 (3.03) 28.4 (1.99)
20 (-7) 48.21 (3.39) 33.5 (2.35)
25 (-4) 53.78 (3.78) 39.0 (2.75)
30 (-1) 59.74 (4.20) 45.0 (3.17)
35 (2) 66.26 (4.66) 52.6 (3.63)
40 (4) 73.32 (5.16) 58.6 (4.13)
45 (7) 80.96 (5.69) 66.3 (4.66)
50 (10) 98.06 (6.89) 74.5 (5.86)
60 (16) 107.3 (7.56) 92.6 (6.51)
70 (21) 128.8 (9.06) 114.1 (8.02)
80 (27) 153.0 (10.7) 138.3 (9.67)
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90 (32) 180.6 (12.7) 165.9 (11.7)

100 (38) 211.9 (14.9) 197.2 (13.8)
110 (43) 249.0 (17.5) 232.3 (16.5)
120 (49) 285.4 (20.1) 271.7 (19.1)
130 (54) 330.3 (23.2) 315.6 (22.2)
140 (60) 379.1 (26.6) 364.4 (25.6)

9.7.1.3 Hazards and Control

(1) Physiological Effects of Gaseous and Liquid Ammonia

Since ammonia has a penetrating, intensely pungent, suffocating odor, and is strongly
irritating, there is little likelihood that one will remain dangerously long in an
atmosphere seriously contaminated with ammonia if one is conscious and able to
escape. However, serious injury may result if escape from the gas is impossible, or if
one is subjected to the action of liquid ammonia (anhydrous). Ammonia exerts mainly a
local corrosive action and is rarely absorbed into the blood stream. Its greatest danger
arises from the fact that it is frequently used in combination with other chemicals as a
familiar part of a process and is, therefore, not considered seriously as a hazardous
agent. That ammonia may cause severe injury if it is employed improperly should be
evident from the information given in the sections, which follow.

(a) Gaseous Ammonia

Ammonia gas in concentrations of 0.6 to 1% by volume is lethal within a few

minutes. Irritation of the eyes, respiratory tract, and throat results from
concentrations as low as 0.05 to 0.1%; a concentration of 0.2% produces
convulsive coughing and may be fatal after a short exposure, i.e., less than half an
hour. The maximum concentration tolerated by the skin for more than a few
seconds is 2.0% (i.e., when suitable respiratory protection is worn).

The following signs and symptoms result from exposure to gaseous ammonia:

Burning of the eyes, conjunctivitis, skin irritation; swelling of the eyelids and lips;
dry, red mouth and tongue; burning of the throat; coughing and, in more severe
cases of exposure, difficult breathing (due, in part, to a reflex laryngeal spasm);
tenacious, blood-stained sputum; signs and symptoms of pulmonary congestion
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(pulmonary edema); and ultimate death from suffocation (asphyxia), due primarily
to the congestion of all tissues of the respiratory tract.

Inadequately treated cases of severe exposure who have developed pulmonary

edema may occasionally contract a secondary bronchopneumonia, which may be
fatal.

(b) Liquid Ammonia

Anhydrous liquid ammonia produces severe burns on contact, due not only to its
caustic action but also the freezing effect produced by the rapid evaporation of
liquid ammonia. Also, if the liquid is carelessly handled so that gaseous.

(2) Fire and Explosive Hazards

Ammonia is capable of forming flammable and explosive mixtures with air within
certain limits (16 to 25% by volume). Such concentrations are seldom encountered in
practical handling and accordingly the relative fire and explosion hazards are small.

Lighting fixtures and electrical equipment should be vapor-proof. If portable electric

lights are necessary, they should be vapor-proof, grounded and consist of a single
piece of water-proof cable. They should be plugged in at a location free from ammonia
gas. Tanks, lines and equipment should be purged or washed free of ammonia before
welding by any means. Blank off lines, do not depend on shut-off valves.

The presence of oil or a mixture of ammonia with other combustible materials will
increase the fire hazard. The explosive range of ammonia is broadened by:

a. Admixture of oxygen replacing air.

b. Temperature and pressure higher than atmospheric.

Ammonia forms violently explosive compounds with metallic Hg. For this reason Hg
should not be used as a manometer liquid or in pressure gauges on ammonia
equipment. Ammonia reacts readily with chlorine and when chlorine is in excess, the
violently explosive compound NCl3 is formed.

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Ammonia is soluble in water. Hose streams are comparatively effective

in removing the gas from the atmosphere.

(3) Prevention of Injuries and the Control of Hazards:

(a) Ventilation

It is of primary importance that adequate ventilation be provided and maintained to

keep the concentration of ammonia gas below 100 ppm by volume in air. Higher
concentrations are dangerous for the unprotected worker. (See Table 9-1).

Although special ventilating systems will not found necessary in most processes,
rooms into which ammonia might escape should have ventilating ducts leading to
the outside, so that escaping gas will not contaminate adjoining areas or bar the
escape of persons who may be working in them.

(b) Periodic Inspections

There should be regular, stringent inspections of all equipment and procedures

employed in processes in which ammonia is manufactured, used, or transported,
to check the serviceability of equipment and safety devices and to evaluate
potential hazards.

(c) Physical Examination of Employees

Although most employees may be assigned with impunity to processes in which

ammonia is used, it is recommended that those with chronic lung disease e.g.,
tuberculosis, bronchitis, asthma, pollinosis, be excluded from such work.
Individuals who are known to be unusually sensitive to ammonia should also be
assigned work in which exposure to ammonia in any form is not possible. Special
periodic physical examinations are unnecessary.

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Table 9-1 Influence of Ammonia Gas for Unprotected Worker

------------------------------------------------------------------------------------------
Gaseous Effects on Exposure
Concentration Unprotected Period
(ppm) Worker
------------------------------------------------------------------------------------------
50 Least detectable Permissible
odor for 8 hour
working
exposure

100 No adverse effects

for average unprotected
worker
------------------------------------------------------------------------------------------
400 Causes irritation Ordinarily no
of throat serious results

Causes irritation following

of eyes infrequent
short
exposures
(less than 1 hr)
------------------------------------------------------------------------------------------
1720 Causes convulsive No exposure
coughing permissible
(may be fatal
after short
exposures,
less than 1/2
hr)
------------------------------------------------------------------------------------------
5000 to 10000 Causes respiratory No exposure
spasms strangulation, permissible
asphyxia (rapidly fatal)
------------------------------------------------------------------------------------------

(d) Conduct in an Emergency

When trapped in an atmosphere of ammonia and while seeking an escape to fresh

air, refrain from breathing for as long a time as possible. Should it become
necessary to breathe before respiratory equipment can be secured and adjusted,
take only short, shallow breaths.

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(4) Personal Protective Equipment

(a) General

No personal protective equipment is an adequate substitute for safe working

conditions and carefulness on the part of individual employees. Furthermore, if
personal protective equipment is to be used effectively, each worker must be fully
informed with respect to its proper employment and trained in its use.

(b) Respiratory Equipment

All respiratory equipment must be approved by the recognized code and standard
for the use to which it is to be put and must be used in strict compliance with the
instructions issued by the manufacturer.

Low Concentrations of Gas: Suitable respiratory protection is needed if even small

concentrations of ammonia are to be encountered.

For concentrations of ammonia gas not exceeding 3% and for relatively brief
exposure periods, an industrial gas mask with full face mask and green canister,
approved by the recognized code and standard, may be used, provided also that
there is no atmospheric oxygen deficiency and that adequate shin and mucous
membrane protection have provided.

Such respirators should be readily available at all points where such limited
exposures may occur. They are not suitable for emergency use, since in
emergency the actual ammonia concentration is unknown.

High Concentrations of Gas: Prolonged Exposure, Emergencies: Where the gas

concentration exceeds 3% or is unknown, as in most emergency situations, or
when exposure is prolonged, supplied-air respiratory equipment of appropriate
design with full face masks, together with protective clothing as indicated, must be
used by all persons entering the contaminated area. This is true also for
oxygen-deficient atmospheres such as those which exist frequently in storage
tanks, tank cars, pits, and sewers handling ammoniacal waste.

Such supplied-air respiratory equipment consists of approved type of:

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1) Hose masks with or without air pump, as may be required to maintain an

adequate air supply (hose inlet must be in a vapor-free atmosphere)

2) Air line masks with compressed air supply, equipped with a suitable filter and
a proper reducing valve or other device designed to effect delivery of piece
under optimum pressure.

Hose or air line masks are suitable for use only where conditions will
permit safe escape in case of failure of the air supply.

3) Self-contained breathing apparatus with proper reducing valve and filter,

containing an adequate supply of stored oxygen or air (such equipment
allows greater mobility but usually requires more training for its proper
employment).

Gas masks and other respirator protective equipment must be

inspected at regular intervals and should be cleaned and serviced after
!
CAUTION
each use. It is particularly important that canisters and oxygen
cylinders be replaced before they become exhausted.

(c) Rescue Harness

A safety belt and lifeline should be used in every case where the wearer of
respiratory equipment enters a confined, irrespirable atmosphere. A man should
be stationed outside the contaminated area to act in case of an emergency; this
attendant should also be provided with adequate protective equipment in case it
becomes necessary for him to enter the contaminated area.

(d) Eye, Skin and Mucous Membrane Protection

The following protective equipment should be used as required for protection of

the eyes, skin and mucous membranes:

1) Cotton shirt, trousers and underwear (cotton resists alkalis better than does
wool).

2) Rubber boots, gloves, apron, and coat (rubber is more resistant to alkali than is
leather).

3) Rubber or felt hat with broad brim.

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4) Safety goggles of an approved type.

For optimum protection the collar should be kept buttoned, glove gauntlets should be
tucked inside of sleeves and trouser legs should be left outside of boots. In areas of
high ammonia concentration, ammonia may condense on any body area subject to
perspiration even though appropriate protective clothing is worn. The severe
discomfort caused by such condensation may be minimized or prevented by the
application of protective oil to such body areas in addition to the wearing of protective
clothing.

!
CAUTION
Protective creams alone do not afford adequate protection.

9.7.1.4 First Aid and Medical Treatment

(1) General Principles

Speed in removing ammonia from contact with the patient and in moving the patient to
an uncontaminated atmosphere is of primary importance. In all cases of severe injury
call a physician at once giving him a complete, accurate account of the accident. Until
the physician arrives, and after having accomplished as thorough removal of the
ammonia as possible, keep the patient comfortably warm and quiet. Take such specific
actions as may be indicated.

(2) Specific Actions

(a) Inhalation

A worker who has been overcome by gaseous ammonia must be carried at once
into an uncontaminated atmosphere and effective artificial respiration initiated
immediately if breathing has ceased. A physician should be called at once. In order
to prevent the development of severe lung congestion (pulmonary edema), 100%
oxygen should be administered as soon as possible after a severe exposure.
Oxygen administration is most effective if expiration is made against a positive
pressure of 6 cm (about 2-3/8 inches) of water. This may be accomplished readily
by use of a rubber tube connected to the outlet valve of a snugly fitting facemask

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and inserted to a depth of not more than 6 cm below the surface of water in a
suitable container.

The pressure resisting exhalation should be adjusted to the patient's tolerance by

varying the depth of the end of the tube below the water's surface.

Oxygen inhalation must be continued as long as necessary to maintain the normal

color of the skin and mucous members. In cases of severe exposure, the patient
should breath 100% Oxygen under positive exhalation pressure for one-half hour
periods every hour for at least three hours. If there are no signs of lung congestion
at the end of this period, breathing is easy, and the color good, oxygen inhalation
may be discontinued. Throughout this time the patient should be kept comfortably
warm but not hot.

Stimulants will rarely be necessary where adequate oxygenation is maintained.

Any such drugs or shock treatment should be given only by the attending physician.
Never attempt to give anything by mouth to an unconscious patient.

(b) Contact with Skin and Mucous Membranes

All contaminated clothing should be removed at on once. The affected areas

should be washed thoroughly with large quantities of cool water. Under no
condition should salves or ointments be applied to skin or mucous membrane
burns during the 24-hour period following the injury. During this time the burns
should be covered with dressings kept wet continuously with a mild oxidizing
reducing solution, such as a saturated solution of sodium thiosulfate.

The patient should be kept comfortably warm. For persistent cases of skin irritation
or for serious burns of the skin or mucous membranes, a physician should be
consulted immediately.

(c) Contact with Eyes

Call a physician at once. Immediately begin irrigation of the eyes with copious
quantities of clean water. This may be accomplished by use of a bubbler drinking
fountain, a water hose, or by plunging the head into any convenient container of
water and repeatedly opening and closing the eyes.

Irrigate continuously for 15 minutes; repeat this procedure every 10 minutes for an
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hour, each time irrigating for a period of 5 minutes. If readily available, a 5% boric
acid solution may be used instead of water, but irrigation must not be delayed
while such a solution is sought. Prompt and thorough irrigation is of primary
importance.

Continuous cold boric acid compresses should be used for cases of severe injury,
in addition to irrigation. After the first 15 minutes period of irrigation is completed, it
is permissible as a first aid measure to instill two or three drops of an 0.5 percent
pontocaine solution or an equally effective aqueous topical anesthetic. No oils or
oily effective aqueous topical anesthetic. No oils or oily ointments should be
instilled unless ordered by the physician. Ulcers of the cornea should be treated by
an ophthalmologist.

Signs and symptoms of shock, such as pallor; coldness of the

!
CAUTION
extremities; weak, rapid or irregular pulse, or stupor, as well as
changes in the rate and depth of respiration, should be reported
immediately to the attending physician and treated only as directed by
him or her. Never attempt to give anything by mouth to an unconscious
patient!

9.7.1.5 Storage & Handling

(1) Hazards

(a) Corrosion-Anhydrous ammonia corrodes copper, copper alloys, aluminum alloys

and galvanized surfaces; therefore, special pipe, valves and other fittings are
required. Direct contact with mercury should be avoided.

(b) Avoid mechanical injury or overheating of storage tanks and cylinders. Store away
from steam pipes and heating devices in a fire resistive structure. If possible, avoid
direct rays sun of on pressure storage tanks or cylinders. (See table vapor
pressure of ammonia.) Cylinders should not be allowed to reach a temperature
exceeding 125 degrees F (52 ℃).

(2) Conditions of Storage

Anhydrous ammonia vaporizes at atmospheric temperature and pressure and for that
reason must be stored in gaslight containers under pressure or in adequate vapor
recovery systems at atmospheric conditions. Storage tanks should be painted a light

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(heat) reflecting color.

Each pressure storage tank (except cylinders) must be equipped with two relief valves
set at 250 psig pressure. The two relief valves should be mounted on a three-way hand
valve to provide means for repair of faulty valve, while protecting the tank. Vent pipes
from the valves should terminate downward. When conditions require upward
termination of vent pipes, suitable provision should be made to prevent water, ice or
snow from entering the vents.

A drain should also be provided at the bottom of the vent pipe. They should be
arranged so that in case of a release through the safety devices, the escaping
ammonia will not enter working areas, collect under roofs, contact sources of ignition,
or endanger workmen. If housed in a building or protected by sun shades, ventilation
must be provided at the top of the structure. If natural ventilation is not sufficient, then
storage area should be equipped with suitable type of mechanical ventilation. All
lighting fixtures must be vapor proof type and all other electrical devices protected to
prevent sparks within the storage area. Store in a cool, dry place, away from other
chemicals which could react with ammonia should a leak occur.

Each ammonia storage tank should be electrically grounded for protection against
electric storms.

In case of multiple storage facilities, a plan should be prepared for readily and
definitely approaching all shutoff valves and valves used for isolating various parts of
the storage facilities. This is imperative, otherwise a serious leak under certain
weather conditions may completely blanket the storage area and make approach
impossible.

If gauge glasses are used, they should be provided with excess flow check valves. The
gauge glasses should not be longer than four feet and not more than two feet between
supports. They should be protected against breakage by gauge glass guards.

(3) Handling

(a) Leakage

Leaks of ammonia should be searched for with sulfur dioxide gas using a small

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cylinder of the compressed gas. Ammonia gas leaks can also be located by use of
a small bottle of concentrated hydrochloric acid.

9.7.2 Carbon Dioxide

9.7.2.1 Description

Colorless, faintly pungent gas; colorless liquid; white snow-like solid.

9.7.2.2 Properties

Formula CO2

Color Colorless

Odor Faintly pungent

Density Gas 1.977 g/l at 0°C Liquid 1.101 g/ml at -37°C

Solid 1.56 g/ml at -79°C

Corrosivity Carbonate solution is corrosive to carbon steel

M. W. 44.01

M. P. -56.6°C

B. P. -78.5°C

Light sensitivity No

9.7.2.3 Hazard and Control

Gaseous carbon dioxide is the regulator of the breathing function in the body. An increase in
the percentage of CO2 breathed results in an increased rate of breathing. High
concentrations, however, paralyze the respiratory center and cause asphyxiation and death.

Concentrations in some atmospheres are sufficient to cause symptoms in man, or even

unconsciousness and death.

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Carbon dioxide gas is a heavy vapor; therefore, it can collect in manholes, mine floors,
shipholds, wells, vats, etc. It does not tend to diffuse away readily.

High concentrations in such places can remain for considerable lengths of time. A CO2
percentage of 0.5 to 1 in normal air causes a slight and unnoticeable increase in the
ventilation by 50%, whereas 3% will increase it about 100%. 5% causes about 300%
increase in lung ventilation.

Breathing now becomes laborious and 10% can be endured only for a few minutes. 12 to
15% causes quick loss of consciousness. Death may take place after exposure of several
hours to 25%.

Liquid CO2 can exist only at low temperatures or at normal temperatures and high pressures.
Therefore, CO2 is extremely dangerous when confined. Containers of it should not be
dropped. Solid carbon dioxide is extremely cold; it can cause burns when in contact with any
part of the body. It is used as a refrigerant and is sometimes called "Dry Ice".

Intoxication from carbon dioxide causes excitement, headache, difficult respiration,

drowsiness, dizziness and muscular weakness. Following the initial excitement, high
concentrations may result in coma or even death. It can cause visual disturbances in high
concentrations.

9.7.2.4 First Aid

If a person is overcome by high concentrations of carbon dioxide vapor, he should

immediately be removed to fresh air. If breathing has stopped, institute artificial respiration,
and if necessary, give oxygen. Call a physician.

9.7.2.5 Storage and Handling

When carbon dioxide is stored as liquid or as gas under pressure, it should be kept in a cool
place. The containers should never be dropped. Personnel handling solid carbon dioxide
should have complete body protection from the freezing cold.

If there is any danger of CO2 collecting in an area where personnel must work, this area
should be tasted before they are allowed to enter. When personnel must enter such areas,
they should be protected by the use of positive pressure, or self-contained airline
respirators.
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Because of the high pressure under which it exists, liquid CO2 can cause container
fragments to fly as if from an explosion, if the containers are dropped and broken. Do not
store where they may be exposed to high temperatures.

9.7.3 Urea

9.7.3.1 Description

White, odorless crystalline solid with a cool, saline taste resembling that of sodium nitrate.

9.7.3.2 Properties

Melting Point 132.7°C

M.W. 60.06

Boiling Point Decomposes

Formula NH2CONH2

9.7.3.3 Hazardous

(1) Crystal and Prilled Urea

Urea is not normally considered a hazardous material. It does not burn, it is not caustic
and its dusts are non-toxic. In fact, it is used in treatment of certain illnesses and as a
cream conditioner for hand creams and deodorants.

(2) Urea Solution and Molten Urea

In the synthesis of urea, CO2 and ammonia are used and since these have their own
hazards, the Safety Practices pertaining to these substances shall be observed.

Burns by molten urea occur very often to naked hands and face. So the operator shall
wear protective equipment for eyes and for hands.

When skin is burn by molten urea, wash the part cleanly with water and apply
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ointments. When the burn is serious, medical treatment by a physician is required.

When urea solution splashes into eyes, wash and clean with water or 2% boric acid
solution at first and get medical treatment.

Whenever handling urea solution, molten urea especially, the protective equipment
such as rubber gloves, goggles, boots and rubber coat shall be worn by operators.

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SECTION 10. ADDITIONAL INFORMATION

10.1 Special Caution for Operation

10.1.1 Special Caution for High Pressure Vessels Lined with Stainless Steels
10.1.2 Special Caution for Stripper (U-DA101)
10.1.3 Special Caution for Vent Gas Line of Washing Column (U-DA401)
10.1.4 Special Caution for Carbamate Feed Pump (U-GA102)
10.1.5 Special Caution for Ammonia Feed Pump (U-GA101)
10.1.6 Solidification Temperature
10.1.7 Monitoring Conductivity of Steam Condensate
10.1.8 Corrosion Protection
10.1.9 On-line Leak Detection System for HP Equipment Lined with Anti-
corrosive Liner

10.2 Start-up Procedures for Pumps and Turbines

10.2.1 Procedure for Turbine Starting

10.2.2 Procedure for Pump Starting

10.3 Analysis

10.3.1 Analysis Instruction

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SECTION 10. ADDITIONAL INFORMATION

10.1 Special Caution for Operation

10.1.1 Special Caution for High Pressure Vessels Lined with Stainless Steels

Special attention should be paid to the operation of 25Cr duplex stainless steel lined
Reactor (U-DC101) and Carbamate Condenser (U-EA101), especially during the start-up
from the empty state. Because stainless steel has a bigger thermal expansion coefficient
than shell material of carbon steel.

Therefore, if the Reactor (U-DC101) and/or Carbamate Condenser (U-EA101) is heated

before the liner is pressed to the shell by inner pressure and/or liquid NH 3 is injected directly
into empty Reactor (U-DC101), evaporation of liquid NH 3 will cause the liner to shrink
resulting in an enlarged gap between the liner and the shell.

When pressure is put on such a liner, it will be cracked or broken. So, the following points
should be always kept in mind:

(1) Liquid NH 3 must not be injected into an empty Reactor (U-DC101) or Carbamate
Condenser (U-EA101).

(2) Pressurizing should proceed to temperature rising.

(3) The temperature difference between the shell and the lining should be kept smaller
than 50°C.

(4) Changes in temperature and pressure shall be accomplished as slowly as possible.

These cautions should be kept in mind also when the solution is drained from the
Reactor (U-DC101) and/or Carbamate Condenser (U-EA101).

If it is necessary to clean Reactor (U-DC101) and/or Carbamate Condenser (U-EA101),

the following procedures should be followed:

(5) After the gas in Reactor (U-DC101) is completely vented to atmosphere by HV103,
cool down the wall temperature to about 70°C naturally.

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(6) Fill water in it using the Low Pressure Flooding Pump (U-GA104). The stainless steel
liner shall not be cooled too quickly, therefore the washing shall be accomplished with
steam condensate.

(7) Drain the water after removal of the top cover to prevent a vacuum.

10.1.2 Special Caution for Stripper (U-DA101)

Prohibition of Stripper (U-DA101) fill-up operation with the synthesis solution. (To prevent
Stripper (U-DA101) from the deterioration of the performance).

To attain the expected performance of Stripper (U-DA101), it is necessary to uniformly

distribute the synthesis solution and CO 2 gas used as stripping agent into each tube. The
swirls are installed on the tubes to make thin film of the synthesis solution. The O-ring
gasket is installed between the swirl and tube to prevent from the leakage of synthesis
solution. And the swirls are fixed by the hold-down plates not to dismount during the
operation. (Refer to Engineering Drawing of Stripper (U-DA101))

However, it is difficult to fix all of the swirls by the hold-down plates completely from the
view point of the manufacturing tolerance.

The swirls do not loose at normal operation. However, the swirls become loose due to
flotation when Stripper (U-DA101) is operated under the filling up inside of Stripper (U-
DA101) with synthesis solution. Once the swirls are lost, the performance of Stripper (U-
DA101) become extremely worse and cannot be recovered during the operation. Then, it is
necessary to stop the Plant and to reinstall all of the swirls.

At normal operation, the liquid level is maintained around 40% by LV102 automatically. The
filling up inside of Stripper (U-DA101) with synthesis solution is caused by over range of
liquid level (LIC102) at Stripper (U-DA101) bottom.

When the liquid level exceeds the level of CO 2 feed pipe (more than 100% level), the
distribution of CO 2 gas into each tube become worse. As the result, the performance of
Stripper (U-DA101) becomes worse and NH 3 & CO 2 content in Stripper (U-DA101) outlet
solution increases. When the liquid level raises furthermore and Stripper (U-DA101) is
operated under filling up inside tubes and top channel, the swirls become easy to lose due
to flotation. Under the filling up condition, the swirls fixed incompletely by the hold-down

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plate move upside down by the flotation and the raising gas from inside tubes. As the result,
the seal of the O-ring gasket become loose and the synthesis solution leak through the O-
ring gasket.

Once the O-ring gasket is loosen, the seal cannot be recovered even after the liquid level
return to normal liquid and a large quantity of synthesis solution leak through the seal, thus
the synthesis solution is not distributed into the tube uniformly. As the result, the
performance of Stripper (U-DA101) becomes worse.

Most of the causes of the deterioration of Stripper (U-DA101) performance in experienced

Plants are operation as described above. Therefore, operator should pay attention to
maintain the liquid level within the level range and not to raise the level to over the range.

10.1.3 Special Caution for Vent Gas Line of Washing Column (U-DA401)

Nitrogen in CO 2 gas and Oxygen fed to CO 2 gas as anti-corrosion agent are vented from
Washing Column (U-DA401) to atmosphere through the vent gas line. However, hydrogen
in CO 2 gas is removed by Dehydrogen Column (U-DC151).

Although performance of Dehydrogen Column (U-DC151) is deteriorated and the vent gas
from Washing Column (U-DA401) is a flammable gas, the plants have no experience to
flame the vent gas because of the following operating conditions:

(1) Washing Column (U-DA401) is operated under wet condition, thus the vent gas is
wet.

(2) Static electricity as ignition source is eliminated by grounding.

(3) The gas is vented to atmosphere at safe location via Washing Column (U-DA401).

However, the vent gas from Washing Column (U-DA401) has a chance of flaming at vented
point by lightening. In this case, SL steam connected on the vent line should be purged into
the vent line to extinguish the fire.

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10.1.4 Special Caution for Carbamate Feed Pump (U-GA102)

Regarding the operation of Carbamate Feed Pump (U-GA102), special attention should be
paid to the following things such as the air removal from the casing, the minimum flow and
the specific gravity of the carbamate solution.

Hereinafter the important items are described individually.

(1) Air Removal from the Casing

The rotation speed of the Carbamate Feed Pump (U-GA102) is quite high, so there is a
big possibility to occur the cavitation in the casing if air remains in the casing. It will
result in serious damage to the pump on account of the cavitation.

Before the start-up of the pump, air in the suction line and the casing should be
completely removed.

(2) Minimum Flow

There is a minimum flow for Carbamate Feed Pump (U-GA102) at any speed, below
which the pump also has a gasification problem.

In any case of the operation, keep in mind on the U-GA102 minimum flow. When the
pump is operated under a low production rate or start-up, take care to operate the
pump at above the minimum flow using recycle line.

(3) Specific Gravity

The flow and discharge pressure of Carbamate Feed Pump (U-GA102) are very
influenced by the specific gravity of the solution in HP Absorber (U-EA401).

10.1.5 Special Caution for Ammonia Feed Pump (U-GA101)

Regarding the operation of Ammonia Feed Pump (U-GA101), special attention should be
paid to the following points such as the air removal from the casing and minimum flow for
the pump.

Hereinafter the important items are described individually.

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(1) Air Removal from the Casing

The rotation speed of Ammonia Feed Pump (U-GA101) is quite high, so there is a big
possibility to occur the cavitation in the casing if the casing has air and NH 3 gas. It will
result in serious damage to the pump on account of the cavitation.
Before the start-up of the pump, air in the suction line and the casing should be
completely removed.

Pay attention to the suction temperature and pressure of Ammonia Feed Pump (U-
GA101) to avoid a vaporization of liquid NH3. (Refer to vapor pressure of liquid NH3.)

(2) Minimum Flow

There is a minimum flow for Ammonia Feed Pump (U-GA101) at any speed, below
which the pump also has a gasification problem.

In any case of the operation, keep in mind on the U-GA101 minimum flow. When the
pump is operated under a low production rate or start-up, take care to operate the
pump at above the minimum flow using recycle line.

10.1.6 Solidification Temperature

The solution in absorbers is a mixed solution of urea, NH 3 , carbamate and water.

At the designed temperature, the soluble amounts of urea and carbamate are limited,
therefore, when carbamate concentration is increased too much at the same temperature,
solid carbamate will be deposited at a certain concentration.

Solidification of carbamate and urea causes critical troubles in plant operation, especially at
the Recovery Section such as pumping failure and plugging. Therefore, a proper amount of
solvent should be fed into absorbers so that the solidification temperature is always kept
lower than the operating temperature.
This is one of the reasons why the CO 2 concentration in the solution of each absorber
should be checked periodically.

Refer to Fig. 2-19 for solidification temperature.

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10.1.7 Monitoring Conductivity of Steam Condensate

Conductivity detectors are installed to measure continuously the conductivity of steam

condensate for monitoring the leakage of the process fluid to the steam condensate.
Conductivity detectors are installed on the steam condensate lines at the following
locations:

Tag. No. Location

- AI102 Steam Saturation Drum (U-FA101) outlet line.

- AI103 Steam Drum (U-FA102) outlet line.

- AI701 Steam Condensate Tank (U-FA103) outlet line.

- AI702 Turbine Condenser (U-EA105) outlet line.

(1) Make sure that the above conductivity detectors are indicating less than 10µs/cm as
normal.

(2) When the indication of the conductivity detector increases beyond the normal level,
investigate the possible cause as below.

- Back flow of process fluid to steam or steam condensate through steam or steam
condensate flushing line.

- Leakage of process fluid to steam condensate through heat exchanger.

- Malfunction of the conductivity detector.

(3) When the process fluid leaks through heat exchanger to the steam condensate, predict
which heat exchanger is leaking.

The steam condensate flow scheme in the Urea Plant is as follows:

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Steam
U-GT101
Turbine
Condensate
U-EA103 U-EA105

U-EA201 AI702
U-EA202
U-FA105
U-DA202

Steam U-DA201 U-EA102

Steam Make-up Steam

Condensate Condensate
U-FA101 U-FA102 U-FA103
(Stripper, U- (Carbamate
DA101) Condenser,
U-EA101)
AI102 AI103 AI701

Case-1 : Only AI701 indicates high conductivity.

→ The heat exchanger among the group illustrated above except

Carbamate Condenser (U-EA101), Stripper (U-DA101) and Turbine
Condenser (U-EA105) is predicted to be leaking.

Case-2 : AI701 & AI702 indicate high conductivity and AI102 & AI103 indicate normal.

→ The heat exchanger among the group illustrated above except

Carbamate Condenser (U-EA101) and Stripper (U-DA101) is
predicted to be leaking.

Case-3 : AI103 indicates high conductivity and AI102 indicates normal.

→ Carbamate Condenser (U-EA101) is predicted to be leaking.

Case-4 : AI102 indicates high conductivity.

→ Stripper (U-DA101) is predicted to be leaking.

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In the case that above conductivity detectors continuously indicate

high conductivity exceeding high alarm point of 30 µs/cm due to the
!
CAUTION heat exchanger leakage, immediately shutdown the plant and inspect
the heat exchanger.

10.1.8 Corrosion Protection

The high corrosive fluids, such as urea synthesis solution, carbamate solution, are handled
at the corrosive condition in Urea Plant. The construction materials are so selected as to
have suitable corrosion resistance under the operating conditions of each equipment.
Oxygen is injected as air to the Synthesis Section to passivate the material of equipment.
The air is injected at the intermediate stage of CO 2 Compressor (U-GB101) and sent to the
Synthesis Section with CO 2 gas. On the other hand, raw material and utility contain a very
small amount of undesirable components to cause corrosion.

In this section, the following special caution is described for corrosion protection at the plant
operation.

(a) Amount of Air Requirement for Passivation

(b) Maximum Operation Temperature of Stripper (U-DA101)
(c) Contamination of Chloride (Cl - )
(d) Contamination of Hydrogen Sulfide (H 2 S)

(1) Keep the amount of air requirement for passivation

Air is injected to the Synthesis Section to passivate the material of synthesis

equipment. The air is injected at the intermediate stage of CO 2 Compressor (U-
GB101) and send to the Synthesis Section with CO 2 gas. The amount of air
requirement for passivation is maintained by FV156 to keep 4,000 - 5,000 vol.ppm
as oxygen per the amount of CO 2 gas.

Fig.10-1 shows the relationship between oxygen content of Stripper (U-DA101) top
gas and the corrosion rate of each material. When the amount of oxygen decrease
less than 4,000 vol.ppm, the corrosion rate tends to increase.

If Stripper (U-DA101) is operated under the less oxygen quantity than the
requirement, the life of Stripper (U-DA101) tubes become short due to increase of
corrosion rate. Therefore, it is essential to maintain the air feed rate at the
requirement for passivation.

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The air for passivation is supplied from Ancillary Facility. In case that the air supply is
stopped due to some reason, the plant should not be operated more than 10 minutes
without air injection from the viewpoint of corrosion in Synthesis Section. The plant
should be stopped immediately.

Fig. 10-1 Corrosion Rate in Stripper (U-DA101)

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(2) Operation Temperature of Stripper (U-DA101)

In spite that the Stripper (U-DA101) tubes are heated by 20 kg/cm2G steam,
temperature in Stripper (U-DA101) bottom is normally around 170 ~ 180 ºC due to
cooling effect of CO 2 stripping in bottom region.

If the performance of Stripper (U-DA101) becomes deteriorated due to trouble of

internals condition (for example, loosened swirl tubes, clogged swirl holes, etc.),
Stripper (U-DA101) bottom temperature rises. Therefore, in other words, the
performance of Stripper (U-DA101) can be monitored by observing the bottom
temperature during normal operation.

If the performance (efficiency) of Stripper (U-DA101) becomes deteriorated, NH3

and CO 2 content of Stripper (U-DA101) outlet solution increases, resulting in
overloading in Purification and Recovery Sections.

The Urea Plant should not be operated anyhow if Stripper (U-DA101) bottom
temperature exceeds 195 ºC because the increased temperature accelerates the
corrosion rate higher than normally expected and finally may shorten the service life.

In such situation, Stripper (U-DA101) overhauling is highly recommended to identify

the cause of trouble and prepare the corrective actions to solve the problem or
eliminate the cause of the trouble.

(3) Contamination of Chloride (Cl－ )

Most equipment and pipes in Urea Plant are made of stainless steel (304 SS, 316
SS etc.), which cause stress corrosion cracking (SCC) by chloride in the fluid. It is
necessary to pay attention to the fluid handled in Urea Plant not to be contaminated
with chloride.

Fig.10-2 shows the relationship between the concentration of chloride and operation
temperature for risk of stress corrosion cracking (SCC).

The fluids possibly contaminated by chloride in the plant are introduced as below.
And also, if equipment and pipe contact with the materials and fluids other than
those introduced below, it should be confirmed that the materials and fluids are not
contaminated with chloride (Cl－ ).

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(a) Process Fluid

Liquid NH 3 and CO 2 as raw material for Urea Plant do not usually contain chloride
(Cl -).

In Recovery Section, process condensate or demineralized water (DM) is used as

absorbent. If those fluids are contaminated by chlorides, the process fluids are
also contaminated by chlorides. Therefore, chloride monitoring for process fluids
is also necessary.

(b) Steam

Usually steam does not include chloride. However, steam possibly includes a
very small quantity of chloride by entrainment of boiler water in boiler.

In case of high concentration of chloride in the boiler water (thus chloride content
in the steam is high), the tubes of Stripper (U-DA101) and Carbamate Condenser
(U-EA101) may cause SCC because of high operation temperature.

Therefore, it should be necessary to monitor the concentration of chloride in the

steam by periodical laboratory analysis during the plant operation.

The concentration of chloride in steam is usually less than 0.1 wt ppm.

(c) Steam Condensate

Chloride concentration of steam condensate must be same as that of steam

because steam condensate is formed as the result of condensation of steam.
Therefore, it is appropriate to analyze chlorides in steam condensate for the
purpose of monitoring the chloride contamination in steam.

(d) Circulating Boiler Water in Steam Drum

5 kg/cm2G steam is generated in Steam Drum (U-FA102) by utilizing the

condensation heat in Carbamate Condenser (U-EA101), where the chloride may
be concentrated. The concentration of chloride in circulating boiler water in Steam
Drum (U-FA102) shall not exceed 1 wt ppm.

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It is essentially required to monitor the concentration of chloride in

!
CAUTION
the circulating boiler water in Steam Drum (U-FA102) by periodical
laboratory analysis during normal operation.

(e) Polished Water

In Urea Plant, polished water is received into Steam Condensate Tank (U-FA103).
The polished water is used for the make-up water of equipment in Urea Plant
during the plant start-up and used for the flushing water at the plant shut-down,
when the steam condensate is not available or shortage in the tanks.

Although usually the concentration of chloride in the polished water is less than 1
wt ppm, the concentration depends on the operation condition of polished water
facility. Therefore, it is necessary to monitor the concentration of chloride in the
polished water periodically.

The polished water is used for the make-up water of Steam Drum (U-FA102)
during the plant start-up or normal operation.

As mentioned above, chloride is concentrated in Steam Drum (U-FA102) during

normal operation, so that the chloride content shall be checked periodically by
laboratory analysis.

Moreover, the process fluid has a chance of the contamination by chloride through
the polished water, since the steam condensate including the polished water is
used for the flushing water of Concentration Section and for the absorbent water
of Recovery Section instead of process condensate.

Therefore, the monitoring and controlling the concentration of chloride in the

polished water is important for the plant operation.

The demineralized/polished water is used for hydraulic test medium of the

equipment as well. If the demineralized/polished water contained high
concentrated chloride is used, SCC may occur due to the concentration of
chloride remained in the demineralized/polished water in the equipment after the
plant is started. The concentration of chloride in the demineralized /polished water
for hydraulic test medium does not exceed 30 wt ppm.

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(f) Process Condensate

The water vapor (including urea mist, NH 3 and CO 2 ) evaporated from urea
solution by heating in Concentration Section is condensed by Surface Condensers
(U-EA501, U-EA503, and U-EA506) to be process condensate. Urea, NH 3 and
CO 2 in process condensate are hydrolyzed and separated in Process Condensate
Treatment Section.

The process condensate after treatment (clean process condensate) is reused for
absorbent water in Recovery Section and for boiler feed water in utility facility.

Drain solution in Drain Recovery Pit (U-FA701) is treated with the process
condensate in Process Condensate Treatment Section. The condensate from the
pit has a chance to be contaminated with chloride by receiving the fluid from
outside into the pit. When the condensate contaminated by chloride is treated in
the Process Condensate Treatment Section with process condensate, the clean
process condensate is finally contaminated by chloride as well. The clean process
condensate fluid is used for absorbent water in Recovery Section, so that the
process fluid will be contaminated with chloride.

Therefore, it is necessary to pay attention to the mixing of contaminated fluid from

outside of the plant into the pit.

It is possible that the chloride contaminating in process fluid is concentrated at

dead space of equipment and SCC occurs at such parts. Especially, at the
location of equipment where the process fluid is repeatedly contacted and
evaporated, the chloride is concentrated and accumulated on the surface of such
location, which resulted in SCC.
Hence, it should be necessary to pay attention to the contamination of chloride in
process fluid.

(g) Cooling Water Contamination into Process Fluid

Cooling water may contaminate process fluid in case heat exchangers cooled by
cooling water have leaks in tubes or tube to tube sheet joint part, and process fluid
pressure is lower than cooling water pressure; for example, LP Absorber (U-
EA402), Surface Condensers in vacuum generation system, etc. For this reason,
it is required to monitor chloride in such process fluids periodically to avoid
corrosion troubles due to contamination by cooling water.
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Fig. 10-2 Risk of SCC due to Chloride

(4) Contamination of Hydrogen Sulfide (H 2 S)

CO 2 gas as raw material contains many kinds of impurity. Among them, Hydrogen
Sulfide (H 2 S) is corrosive fluid for equipment of Urea Plant and it should be necessary
to pay attention to the concentration of H 2 S in CO 2 gas.

In case that Ammonia Plant uses Steam Reforming Process, H 2 S contained in Natural
Gas as raw material of Ammonia Plant is removed by desulfurizer in Ammonia Plant
since sulfur is a poison for nickel steam reforming catalyst. H 2 S content in CO 2 gas
from NH 3 Plant is less than 1 mg/Nm3 and can be used for raw material of Urea Plant
without any treatment.
However, it is necessary to pay attention to the H 2 S content in CO 2 gas and to check
whether the H 2 S content satisfies the design figure.

10.1.9 On-line Leak Detection System for HP Equipment Lined with Anti-corrosive Liner

Stainless steel liner on carbon steel is applied for high pressure equipment of Synthesis
Section to protect the equipment from the corrosive solution. When a leakage occurs in

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the liner, the high pressure equipment shell made of carbon steel is rapidly corroded and
seriously damaged.

To detect the leakage of liner as early as possible, detection system is provided on each
high pressure equipment. Conventional detection system consists of weep hole,
transparent hose and methyl red solution bath (pH indicator). An improved method with
continuous purge gas circuit renders more quick and reliable leak detection (On-line
Leak Detection System).

The On-line Leak Detection System should have the following characteristics of:

- Accurate and reliable in detecting liner leakage.

- Quick response
- Easy identification of leakage location

The following explanations should be considered to assure the above requirement for the
system.

(1) Passageway Networks

Grooved passageway networks at outer surface of liner plates and carbon steel shell
equipped with vent holes shall be provided. Network of longitudinal and lateral
grooves shall be provided along the weld seams between liner plates, connecting to
at least two vent holes for one segment of liner plate so that the circulating purge
gas enters from one vent hole and the gas with leaking fluid, when occurred, flows
through the grooved passageways and exit from the other vent holes. Fig.10-3
shows the example illustration for passageway with tubing.

(2) Tubing

Stainless steel tubing shall be provided to connect all the vent holes and shall be
connected to the leak detector. The tubing shall be routed under the equipment
insulation to avoid plugging due to leaking fluid solidification or freezing after flashing.
However, connection points of vent pipe with tubing should be easily maintained,
therefore, for example, being covered with removable insulation. See Fig. 10-3 for
an example of tubing arrangement.

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Fig. 10-3 Example Illustration for Passageway with Tubing (TYPICAL)

(3) Response Time

The recommended response time by a detector is less than one hour, considering
the rapid corrosion rate of carbon steel and propagation of leaking urea and/or
carbamate which may form triuret or cyanuric acid when heated in between the liner
and the shell for certain duration, which are very difficult to remove.

The purge gas flow rate shall be determined considering the above response time
between leakage occurrence and the leakage detection and the volume of gap
between the liner and the carbon steel shell, passage way grooves and tubing.

(4) System Description and Operating Principle

Fig. 10-4 illustrates a typical example of On-line Leak Detection System. Nitrogen
gas is circulated in the loop by a gas circulator (air pump) of capacity-adjustable.

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A flow meter shall be provided to the gas inlet tubing to each segment of liner
plate(s) or group of liner plates so as to control and distribute the purge gas flow rate
appropriately. The purge gas flow rate shall be periodically confirmed by checking
the readings of the flow meters during normal operation.

Nitrogen gas is made up to the circuit by a control valve if the system pressure drops
as a result of leakage of the tubing system or trouble of the circulator.

NH 3 removal filter removes NH 3 which might contaminate the circulating gas from
outside of the system, so as to prevent mal-signaling of the NH 3 detector, as well as
preventing accumulation of NH 3 in the circuit in case process fluid really leaks out
from the liner.

A water sealed breather prevents excess system pressure which may cause bulging
of liner plates. The water seal depth shall be determined based on the maximum
allowable back pressure of the liner, especially during the internal pressure is as low
as atmospheric, which is to be specified by the vessel manufacturer.

NH 3 detector shall be capable for detecting NH 3 content of 0 to 75 ppm in the

circulating gas after cooled by a cooler. The reading and alarm signal from the NH 3
detector should be connected to central control room.

(5) Identification of Leaking Liner Location

In case a leakage occurs, location of the leaking liner plate can be identified by
opening the flushing connection and closing the block valve before the NH 3 detector
one by one, until NH 3 detection signal decreases or disappears. Gas sampling from
the flushing connection for NH 3 analysis helps identification of the location more
quickly and precisely.

(6) Flushing of Tubing and Passageways

When leakage happens and plant is shut-down, disconnect all tubing connections at
the inlet side of the Leak Detector (opposite side of flow meters, i.e. outlet from
vessels) and flush the tubing and passageways by low pressure steam from spare
nozzle, so that flashing steam is vented out through tubing and passageways to the
atmosphere. Steam flushing shall be continued until the vessel is depressurized and
become cold to purge the leakage product completely and avoid plugging of tubing
and passageways due to carbamate and/or urea crystal formation. After the steam

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flushing is completed, tubing and passageway shall be dried by instrument air or

nitrogen gas to prevent corrosion of carbon steel shell due to wet condensate and
freezing when ambient temperature is low.

Do not raise the pressure in the tubing and the back side of the liner
higher than the maximum allowable liner back pressure specified by
the vessel manufacturer. Use manometer and water sealed breather at
!
CAUTION
upstream of inlet vent hole and disconnect all tubing connections at
the inlet side of the Leak Detector when flushing by steam to avoid
liner plate bulging due to excess pressure.

Make sure that the inlet tubing connection to the Leak Detector is

!
CAUTION
open to the atmosphere before steam flushing to avoid contamination
of steam condensate into the Leak Detection System.

Do not continue the plant operation in case that leakage is detected

by AI111, AI112 or AI113. If leak NH 3 is detected, plant shall be shut-
!
CAUTION
down immediately and check/repair the leak point of stainless lining
for high pressure equipment.

Performance and accuracy of NH 3 detector for On-line Leak Detection

System (AI111, AI112 and AI113) shall be checked and confirmed by
!
CAUTION
standard gas during periodic intervals (minimum every three months).
Standard gas shall be purchased by Client periodically.

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LEAK DETECTION SYSTEM
FOR U-DA101

Fig. 10-4 Typical Flow Diagram of On-line Leak Detection System

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10.2 Start-up Procedures for Pumps and Turbines

Different types of pumps and turbines are installed in the plant and each equipment has
specific starting procedure. In this section, a general procedure is described to start pump
and turbine.

When actually starting pumps and turbines, operator must have a complete understanding of
the vendor's instruction for the pump and turbine and must follow the specified starting
procedure, and also, must be familiar with the piping surrounding the machine.

The following procedures are outline of operation.

10.2.1 Procedure for Turbine Starting

(1) Starting Preparations

(a) Check to ensure that there is nothing wrong with the interlock system,
instrument air, electric power, water treatment unit and steam system.

(b) Check to ensure that there is nothing wrong with the emergency shut-off
apparatus and over speed shut-off apparatus.

(c) Move manually the speed control valve rod and check to see if the speed control
valve moves smoothly. (Check operation of the emergency shut-off valve
manually.)

(d) Fill the bearings box with lubricating oil and supply cooling water to cooler and
check the oil pressure as well as water flow rate.

(e) Remove thoroughly drain collected in the steam pipes and steam valves.

(f) Check to ensure that the turbine rotates smoothly by turning and that all
instruments of the turbine and auxiliary pumps are ready in service.

(g) Open fully the drain valves of the steam filter and the bottom of the turbine
casing.

(h) Open slightly the steam valve for warm-up for a while. Avoid quick starting
except in an emergency. For quick starting, it is a prerequisite that drain has
been completely removed and that a turbine parts have been thoroughly
warmed up. During warm-up, rotate the turbine occasionally by hand to warm up
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all sections evenly.

(i) Confirm completion of preparation for pump side.

(2) Starting

(a) Fully open the exhaust valve, open steam trap bypass valve on the exhaust line
slightly.

(b) Slightly open the steam inlet valve and warm up the casing of the turbine. While
paying heed to the turbine speed and driven machine (pump) load, pull the
starting handle a little to feed steam into the turbine and start the rotation.

(c) If the turbine has started, check for anything wrong inside the turbine, using an
inspection rod to hear a rotation sound.

(d) Run the turbine at a low speed for a while for warming up.

(e) Pay attention to the temperature of each bearing and adjust the oil pressure
(Generally, 70 oC or below). If there is an overheated bearing, shutdown the
turbine immediately and investigate the cause. Probable causes are dust and
dirt in the bearing, shortage of cooling water flow, inadequate centering, etc.

(f) After making sure that drain has been removed completely, close all drain valves
and steam trap bypass valve.

(g) If there is no abnormal sound, gradually open the steam valve to increase the
speed. Under any operating condition, avoid opening the steam valve quickly
and increasing the speed radically.

(h) Increase load of turbine gradually.

(3) After Starting

(a) In order to check operation of the governor, change load of turbine at around the
specified speed and test its operational stability and smoothness.

(b) Fully open the steam valve after making certain that the governor is
commissioned, the speed is regulated, and the turbine is operated in satisfactory
condition.
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(c) After the turbine has reached normal operating speed, measure the vibration of
the main bearing housing part and others, the oil pressure and the bearing
temperature to make certain that there is nothing wrong.

10.2.2 Procedure for Pump Starting

(1) Starting Preparations

(a) Check for the turning direction.

(b) Feed oil to the pump bearings box and if necessary, feed oil to the oil tank as
well. If the pump is forced lubrication type, check to ensure that the oil pressure
is normal. (Generally, 0.5 to 1.5 kg/cm2G)

(c) Supply cooling water to cooler and check this flow by the sight glass or others.

(d) Fully open the suction valve and filter in service. Confirm discharge valve can be
opened smoothly and open it slightly.

(e) Open the pressure gauge socket or the air purge valve on the delivery piping or
pump casing and fill the pump will liquid.

(f) Open the valves of the min. flow bypass from delivery line and balancing pipe if
installed.

(g) Turn the pump shaft by hand to correct direction and check for troubles.
(Abnormal sound inside the pump, leaks from mechanical seals, etc.)

(h) Check to ensure that the oil ring is properly lubricating the bearing.
(If the pump is a motor driven one, drive once the pump, and shut it down
immediately.)

Check to ensure that the shaft smoothly rotates and slowly comes to a stop, and
that the oil ring is properly lubricating the bearings.

(2) Starting

(a) Starting for Centrifugal Pump

1) Before starting pump, confirm that some equipments and lines in the
downstream of pump discharge are prepared for liquid feeding.
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2) Start the pump. (If it is a motor-driven pump, set the switch to On. If it is a
turbine driven pump, open the steam valve.)

3) Check to ensure that the specified delivery pressure is available.

When the pump has reached a regular operating pressure, gradually

open the delivery valve.

If non-return valves (check valve) which are located on the pump

discharge have the bypass valves, open their bypass valves at normal
operating time to maintain the temperature of stand-by pump casing.

(b) Starting for Gear Pump and Reciprocating Pump

1) Open discharge valve fully and line up to user or return line.

2) Confirm the stroke adjuster, if any, is showing zero to reciprocating

pump.

3) Start the pump and check the abnormality.

4) Adjust the stroke to the required value for reciprocating pump.

(3) After Starting

After the pump has reached a regular operating condition, measure the vibration of the
main bearing housing part, the oil pressure and the bearing temperature to make sure
that there is nothing wrong.

10.3 Analysis

10.3.1 Analysis Instruction

Analytical Manual for Urea Plant (Doc. No. HURL-G-LD-U00-LAB-IOM-000-0001)

includes;
- Sample Poling List
- Analysis Method for each item

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SECTION 11. EFFLUENT WATER TREATMENT SECTION

11.1 Process Feature and Description

11.2 Preparation for the Initial Start-up

11.3 Normal Start-up

11.4 Normal Operation

11.5 Normal Shut-down

11.6 Emergency Shut-down

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SECTION 11. EFFLUENT WATER TREATMENT SECTION

11.1 Process Feature and Description

Normally, floor washing from process area will be collected in Effluent Water Pit (U-AP704)
and send it to OSBL for further treatment.
However, Effluent Water Treatment System is provided to treat floor washing from process
area to ensure ammonia and urea content in it within prescribed limits before sending it to
OSBL. For achievement of such requirement, steam stripping and Urea Hydrolyzer system
are provided.

Effluent system consists of following two towers:

(a) U-DA751: Stripper for Effluent Water
(b) U-DA752: Urea Hydrolyzer for Effluent Water

The floor washing from process area is once collected in Effluent Water Pit (U-AP704), and
the effluent is fed to Effluent Water Treatment System, Urea and ammonia content are
expected to be 1.0 wt% and 0.5 wt% as maximum respectively in the effluent. The effluent is
fed to Urea Hydrolyzer for Effluent Water (U-DA752) first via Effluent Water Pump
(U-GA704) and Effluent Water Feed Pump (U-GA751). The urea is hydrolyzed under the
condition of 210˚C and 23 kg/cm2G and hydrolyzed effluent is sent to Stripper for Effluent
Water (U-DA751) to strip off ammonia from the effluent. The stripped gas is blown off to
atmosphere from the top of Stripper for Effluent Water (U-DA751) operated under the
condition of 141˚C and 3 kg/cm2G. Treated water is sent to Final Effluent Sump in Utility
Facility at the level of 5 ppm wt of ammonia and 5 ppm wt of Urea.

It is noted that effluent water including ammonia and urea does not occur continuously for
the following reasons. Consequently, the effluent system will be operated intermittently.

Normally, ground surface of the main process area in Urea Plant is clean. Urea and
ammonia solution are spilled on the surface during an emergency case only, such as flange
leaks and etc.

1. Floor washing will be performed intermittently, especially during shut down

period.

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2. In case that it rains for a long period of time, the only initial rain water from the
beginning is defined as an effluent. The remaining rain water can be
discharged to outside without any treatment, as the ground surface is
considered as clean after washing by the initial rain water.

3. Process drain from Effluent Water Treatment System will be collected in the
Effluent Water Pit only.

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11.2 Preparation for the Initial Start-up

(1) Follow the item (1) through (5) Para.4.5.1

(2) Check the level in Effluent Water Pit (U-AP704)

(3) Start Effluent Water Pump (U-GA704) and Effluent Water Hydrolyser Feed Pump
(U-GA751).

(4) Fill the Urea Hydrolyser for Effluent Water (U-DA752) with Effluent Water from Effluent
Water Hydrolyser Feed Pump (U-GA751) via FV751.

Take care of the minimum flow (21 t/h) of effluent water hydrolyzer feed pump

!
CAUTION
(U-GA751). Make sure activation of cooling water jacket on minimum flow
return line to U-AP704 via RO751 to avoid heat accumulation.

(5) After confirming drain from drain valve of Second Preheater for Hydrolyzer (U-EA752),
feed the steam gradually to the larger compartment of Urea Hydrolyzer for Effluent
Water (U-DA752) by FV752 and pressurize Urea Hydrolyzer for Effluent Water
(U-DA752) up to 23 kg/cm2G by gradually closing PV752, and put it on auto.

Take care the water hammering in Urea Hydrolyzer for Effluent Water
!
CAUTION
(U-DA752). Don’t open FV752 quickly and do not start feeding steam on
the condition that larger compartment is in full liquid to avoid water
hammering. Start feeding steam just after liquid level in the large
compartment of Urea Hydrolyzer for Effluent Water (U-DA752) reaches
steam sparger.

Never feed steam to the larger compartment of Urea Hydrolyzer for Effluent
!
CAUTION
Water (U-DA752), before water coming out from drain valve at inlet of Urea
Hydrolyzer for Effluent Water (U-DA752).

(6) Start steam injection into the bottom of the Stripper for Effluent Water (U-DA751) at a
rate of approx. 2 t/h by FIC754.

(7) Start pressurizing and warming up of Stripper for Effluent Water (U-DA751) by
gradually closing PV751 up to 3 kg/cm2G. Then put PIC751 on auto.

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(8) After the top level (LIC752) of Urea Hydrolyzer for Effluent Water (U-DA752) appears,
open LV752 to keep the level at 50%, and put it on auto.

(9) Start feeding steam to the smaller compartment of Urea Hydrolyzer for Effluent Water
(U-DA752).

Never feed the steam to the smaller compartment Urea Hydrolyzer for
Effluent Water (U-DA752), before level (LIC752) in Urea Hydrolyzer for
!
CAUTION
Effluent Water (U-DA752) appears.

The manual gate valve on upstream of FT752 shall be closed when Effluent
Water Treatment Section is out of service to avoid feeding steam into empty
!
CAUTION
Urea Hydrolyzer for Effluent Water (U-DA752). Provide CAUTION sign
adjacent to the manual valve.

(10) Open LV751 to keep the level of the bottom of Stripper for Effluent Water (U-DA751) at
50%, and put it on auto.

(11) Circulate Effluent Water as follows:

U-AP704  U-GA704  U-GA751  U-EA751  U-EA752  U-DA752 
U-DA751  U-EA751  U-EA753  U-AP704

(12) Gradually increase the Effluent Water feed rate to Urea Hydrolyzer for Effluent Water
(U-DA752) up to 10 t/h by FIC751.

Increase steam injection rate on FIC754 so as to keep PV751 open.

(13) Stabilize the condition of Stripper for Effluent Water (U-DA751) and Urea Hydrolyzer for
Effluent Water (U-DA752).

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11.3 Normal Start-up

Follow (1) through (14) of 11.2

Table 11-1 Start-up Positions of the Control Valve

Item Service Position Setting

No. Value

FV751 Effluent Water to First Preheater for Hydrolyzer (U-EA751) M/C

FV752 SM Steam to Urea Hydrolyzer for Effluent Water (U-DA752) Tray M/C
Section

FV753 SM Steam to Urea Hydrolyzer for Effluent Water (U-DA752) Stripping M/C
Section

FV754 SL Steam to Stripper for Effluent Water (U-DA751) Bottom M/C

LV751 Stripper for Effluent Water (U-DA751) Bottom to Battery Limit M/C

LV752 Second Preheater for Hydrolyzer (U-EA752) to Stripper for Effluent M/C
Water (U-DA751)

PV751 Stripper for Effluent Water (U-DA751) Top M/C

PV752 Urea Hydrolyzer for Effluent Water (U-DA752) Top M/C

HV751 Effluent Water to Battery Limit Open

A to C

Note M/O = Manual Open M/C = Manual Close

O = Open C = Close
A = Automatic

The quality of effluent in Effluent Water Pit (U-AP704) shall be checked before
transferring of the effluent to the treatment section. In case Urea and/or
ammonia content is more than designed figure (1 wt%, 0.5wt% respectably),
dilution or low load operation shall be considered.

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11.4 Normal Operation

(1) Stripper for Effluent Water (U-DA751)

(a) Check the temperature at the top and the bottom of Stripper for Effluent Water
(U-DA751) and regulate them to the design condition.

(b) Check the pressure at the top and the bottom of Stripper for Effluent Water
(U-DA751).

(c) Make sure that there is nothing abnormal in the level indicator.

(d) Check the workability of PIC751.

(2) Urea Hydrolyzer for Effluent Water (U-DA752)

(a) Check the temperature and pressure.

(b) Check the workability of Effluent Water Feed Pump (U-GA751)

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11.5 Normal Shut-down

(1) Close FV754 by manual to stop SL steam feeding to Stripper for Effluent Water
(U-DA751). Close isolation valve at upstream of FV754.

(2) Close FV752 and FV753 by manual to stop SM steam feeding to Urea Hydrolyzer for
Effluent Water (U-DA752). Close isolation valve at upstream of FE752.

(3) Close FV751 by manual to stop Effluent Water feeding to Urea Hydrolyzer for Effluent
Water (U-DA752).

(4) First stop Effluent Water Feed Pump (U-GA751) and then stop Effluent Water Pump
(U-GA704).

(5) Reduce the pressure of Urea Hydrolyzer for Effluent Water (U-DA752) by opening
PV752 manually.

(6) Vent the mixed gas from Stripper for Effluent Water (U-DA751) by PV751 manually.

(7) When the liquid level (LIC751) in the bottom of Stripper for Effluent Water (U-DA751)
comes down, close LV751.

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11.6 Emergency Shut-down

All controllers, which will be closed on instrument air failure, should be

switched to manual and set them at close position to prevent the valve action
when instrument air becomes available.

Table 11-2 The Valve Action upon Instrument Air Failure

Item No. Service Action
FV751 Effluent Water Pump (U-GA751) discharge to First Close
Preheater for Hydrolyzer (U-EA751)

FV752 MP Steam to Urea Hydrolyzer for Effluent Water Close

(U-DA752)

FV753 MP Steam to Urea Hydrolyzer for Effluent Water Close

(U-DA752)

FV754 LP Steam to Stripper for Effluent Water (U-DA751) Close

LV751 Treated Water Cooler (U-EA753) to Battery Limit Close

LV752 Second Preheater for Hydrolyzer (U-EA752) to Close

Stripper for Effluent Water (U-DA751)

PV751 Stripper for Effluent Water (U-DA751) Vent Close

PV752 Effluent Water from Urea Hydrolyzer for Effluent Close

Water (U-DA752) to Stripper for Effluent Water
(U-DA751)

HV751 Effluent Water to Battery Limit Open

(A to C)

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