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TINDAKAN PERBAIKAN :

* Kembalikan vaccum 101-JTC ke normal dengan menghentikan penyi raman dan menambah / menaikkan tekanan steam header untuk 101-JTC dari 8 Kg ke 10 Kg bertahap. * Penyesuaian Rate Gas terhadap hilangnya udara dan steam hingga Rate Gas 80 %. * Shut Down kan HRU dan ARU, stop pompa 140-J dan 141-J. * Mengoptimalkan Import Steam (pengaturan steam system secara me nyeluruh SH dan SM. Pengaturan Steam Balance Reforming system dan menormalkan back press, pengaturan vent PC-1005 dan PC-1004. * Menormalkan temp coil udara dan kondisi 101-J hingga supply udara proses normal. * Start kembali 103-J hingga normal, start Synt Loop dengan menyalakan burner 102-B. * Jam 20.30 Ammonia sudah dapat diproduksi kembali.

ITEM No 102-B 103-D 104-D1 104-D2 105-D 106-D 107-D 108-D 109-DA 109-DB 201-D ITEM No 101-JTC 103-JTC 107-C

DCS HILANG POWER

ANEKA TROUBLE P-IB

BILA POWER KE DCS HILANG KARENA UPS TROUBLE : 1. DCS CRT tidak ada tampilan dan semua output controller dari DCS menjadi : 0 mA. 2. Semua control valve akan sesuai dengan specifikasi : a. Warna merah akan terbuka al : FV-1002, HV-1021, HV-1028 dll. b. Warna kuning akan tertutup penuh al : PV-4001, HV-1262, PV-1014, PV-1013, PV-1017. 3. Compressor 101-J, 102-J, 103-J, 105-J Gov akan ke minimum Speed 4. BFW Pump 104-J Governoor minimum Speed. 5. FD Fan dan ID Fan menjadi Maximum Speed. 6. Seluruh Burner BBA; BBU; BBS akan mati. 130

PRESS / TEMP P'TER/VESSEL/CATALIST Duty : 5,5 mm Start Up Heater For Ammonia Kcal / sec Converter P : 39,7 Kg Secondary Reformer T +/- : 250 / 19 deg C. P : 39,7 Kg High Temperatur Shift Converter T +/- : 450 / 19 deg C. P : 39,7 Kg Low Temperatur Shift Converter T +/- : 288 / 19 deg C. P : 188,0 Kg Ammonia Synthesis Converter T +/- : 538 / 19 deg C. P : 36,2 Kg Methanator T +/- : 454 / 19 deg C. P : 39,7 Kg Primary Reformer Effluent T +/- : 838 / 19 deg C. Transfer Line P : 52,7 Kg Cobalt Molybdenum / T +/: 427 / 0 deg C.Zinc Oxide Quard Vessel P : 112,0 Kg Molucular Sieve Drier T +/: 350 / 0 deg C. P : 112,0 Kg Molucular Sieve Drier T +/: 350 / 0 deg C. P : 15,8 Kg Iron Sponge Desulfuzation T +/- : 150 / 19 deg C.Vessel PRESS / TEMP P S/T : 1,75 / 10,5 Kg T S/T : 121 / 65 0C P S/T : 1,75 / 10,5 Kg T S/T : 121 / 65 0C P Hot/C : 9,5 / 10,5 Kg T Hot/C : 132 /132 0C COOLING WATER Surface Condenser for 101-JT & 102-JT Surface Condenser for 103-JT & 105-JT Carbon Dioxide Stripper Quench Cooler

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ITEM No 1-101-BJ2T ( ID FAN ) TRIP. *Beritahu Kabag Shift, Urea dan Utility. TINDAKAN : 1. Stop pembakaran di Reformer 101-B, 101-BU, 101-BBS. * Tutup bv Fuel header dekat LTS. * Tutup LP Purge, Tail Gas, Gas Ex SO trap. 2. Stop 101-BJ1T ( FD Fan ). 3. Cabut Udara ke 103-D, Stop 101-J.
Atur : PC-1013, HV-1028, TC-1020, Import SM, level 101-F,

105-C 109-C CCB/Field. Field Field CCB/Field. 111-C 113-C 114-C 120-C 121-C CCB/Field. 122-C 129-C 132-C 140-C 141-C 188-C 201-C

SM ke Coil Udara ( BC-4 ) lebihkurang 585 0C. 4. Rate Gas kurang lebih 50%, Vent G.B out 108-D, 102-J
lihat Steam balance, Import Synt Gas, Cabut G.B ke 101-B.

5. Vent SM out HTS ( MOV-1018 ). LTS B/P, tutup bv out nya. 6. Main Benfield usahakan sirkulasi pompa 1/1, tutup bv inlet 101-E, de-press line d/s bv LTS, masukkan SLL ke 105-C. 7. 1-150-E Shut Down kan. 8. S/D kan Synt Loop, HRU dan ARU. 9. S/D kan 103-J, atur SH ke SM ( PC-1013 / HV-1029 ). 10. S/D kan 106-D ( Methanator ). 11. FT. tetap sirkulasi, target rate lebih kurang 30%. 12. 105-J injeksi NH3 hot via 5101-J/JA atau Import NH3 Hot, Start 5103-L, tutup XV-1150.

PRESS / TEMP P S/T : 10,5 / 39,7 Kg 0 T S/T : 200 / 200 C P Hot/C : 2,5 / 7 Kg T Hot/C : 150 /100 0C P S/T : 10,5 / 39,7 Kg T S/T : 200 / 200 0C P S/T : 10,5 / 39,7 Kg T S/T : 150 / 200 0C P S/T : 36,2 / 36,2 Kg T S/T : 485 / 485 0C P S/T : 188 / 188 Kg T S/T : 65 / 65 0C P S/T : 188 / 188 Kg T S/T : 300 / 300 0C. P S/T : 188 / 188 Kg T S/T : 450 / 535 0C. P S/T : 16,5 / 112 Kg T S/T : 50 / 100 0C P S/T : 7,4 / 10,5 Kg T S/T : 100 / 100 0C P S/T : 46,4 / 18.6 Kg T S/T : 425 / 250 0C. P S/T : 18,6 / 18.6 Kg T S/T : 250 / 180 0C. P S/T : 47,1 / 48 Kg T S/T : 300 / 300 0C. P S/T : 15,8 / 15,8 Kg T S/T : 140 / 150 0C.

EXCHANGER / REBOILER Carbon Dioxide Stripper Process Gas Reboiler Lean Solution / LP BFW Exchanger Carbon Dioxide Stripper Ejector Steam Generator Carbon Dioxide Stripper Condensate Reboiler Methanator Feed / Effluent Exchanger Ammonia Unitized Chiller Ammonia Converter Feed / Effluent Exchanger Ammonia Converter Interchanger Synhesis Gas Compressor Inter Stage Chiller Carbon Dioxide Stripper Quench / LP BFW Exchanger Ammonia Stripper Reboiler Ammonia Stripper / Effluent Exchanger Condensate Stripper Feed / Effluent Exchanger Feed Gas Pretreatment / Effluent Exchanger

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ITEM No 115-C

PRESS / TEMP COOLING WATER P S/T : 36,2 / 10,5 Kg Methanator Effluent Cooler 0 T S/T : 150 / 100 C

PENGAMATAN PLANT :
* Jalankan Turning Gear : 103-J, 101-J. LO,SO trap.

116-C 124-C 127-C 128-C 130-C 133-C 134-C 142-C 167-C 172-C2 174-C 202-C 204-C 205-C 92

P S/T : 112 / 10,5 Kg T S/T : 200 / 100 0C P S/T : 188 / 17,6 Kg T S/T : 110 / 100 0C P S/T : 17,6 / 12,3 Kg 0 T S/T : 150 / 100 C P S/T : 16,0 / 10,5 Kg T S/T : 150 / 150 0C. P S/T : 62,2 / 10,5 Kg T S/T : 150 / 100 0C. P S/T : 15,8 / 10,5 Kg T S/T : 180 / 100 0C P S/T : 188 / 17,6 Kg T S/T : 150 / 100 0C P S/T : 18.6 / 13,1 Kg T S/T : 200 / 100 0C. P S/T : 16,0 / 10,5 Kg T S/T : 128 / 128 0C. P S/T : 52,7 / 10,5 Kg T S/T : 420 / 100 0C.

Synthesis Gas Compressor Inter Cooler Ammonia Converter Effluent Cooler Refrigerant Condenser Refrigerant Compressor 3rd Stage Inter Cooler Synthesis Gas Compressor 1st Stage Cooler Feed Gas Compressor Kick Back Synthesis Gas Compressor Kick Back Cooler Ammonia Stripper Effluent Cooler Refrigerant Compressor 2nd Stage Inter Cooler Start Up Cooler Stripper Condensate Cooler

* * * * * * *

Tutup Cock valve burner. 105-D ( Mov-1001, 1002, FC-1077 = FC ). Tutup bv suction 103-JLP ( 104-F ). HRU, ARU, LV-1163 bv FC. Cold Box Deriming. 101-F, Steam System. Steam ke ID Fan, FD Fan, 103-J, 101-J = FC. Vaccum ke 101-JTC.

KEHILANGAN VACCUM DI 101-JTC Tanggal 10 September 1999; jam 15,45

ANEKA TROUBLE P-IB

Akibat tindakan penyiraman untuk menurunkan temperatur CW salah arah, vaccum di 101-JTC turun kearah positif dari 60 mm HG VAC ke 290 mmHg VAC. Dampak terhadap Operasi Pabrik Ammonia IB : * Terganggunya supply DM ke 101-F ( 104-JT/speed turun akibat Exhaust press turun ). * Terganggunya supply Udara ke proses dari FCAL-1003 ( 101-J Speed turun akibat Exhaust press turun ). * Turunnya produk steam akibat menurunnya Udara proses dan bertambahnya pemakaian Steam. * Naiknya temp 106-D Methanator melebihi temp normal akibat terganggu supply steam untuk HTS dan LTS ( CO dan CO2 leak tinggi ) dan back press terganggu. * 103-J trip akibat terjadinya condensasi yang besar dari 106-D ke 104-F ( high level trip ) bekerja, Synt Loop Shut Down. * Kehilangan reaksi di 105-D akibat komposisi gas terhadap udara yang terganggu. * Kemampuan 105-J menurun, Press Storage naik. 129

P S/T : 15,8 / 11,1 Kg T S/T : 120 / 100 0C. P Hot/C : 7,5 / 10,5 Kg T Hot/C : 130 /130 0C P S/T : 28,1 / 18,7 Kg T S/T : 200 / 100 0C.

Pretreatment Feed Gas Cooler Pretreatment Stripper OVHD Cooler Pretreatment Lean Solution Cooler

ITEM No REMARK PREHEATER / CATALIST A. PRIMARY REFORMER CONVENTION SECTION Duty / Burner Super Heater Burner 101-BBS 1,26 mm Kcal / H Duty : HP Steam Superheater 101-BC3 10,47 mm Kcal/H Duty : Cold Process Air Preheater 101-BC4 3,20 mm Kcal /H Duty : Feed Gas Preheater 101-BC5 4,66 mm Kcal / H Duty : Fuel Gas Preheater 101-BC6 0,7 mm Kcal / H Cap Max / Normal Induced Draft Fan. Centrifugal : 101-BJ2 251293/176236 Nm3/H Speed Max/Nor : 900 / 648 rpm Duty / Burner Auxiliary Boiler 101-BU 12,1 mm Kcal / H B. PRIMARY REFORMER 101-B 101-BC1 Duty : 42,2 mm Kcal / H 101-BC2 Duty : 20,45 mm Kcal / H 101-BJ2T Output Max / Normal 826 / 315 KW C. SECONDARY REFORMER 103-D 107-D 94 P T +/Secondary Reformer : 39,7 Kg Primary Reformer Effluent : 839 / 19 deg CTransfer Line

* Non Aktifkan 1-150-E. * B/P LTS, buka MOV-1009 dan tutup MOV-1008, tutup bv outlet LTS. * S/D Synt Loop; HRU dan ARU. * Import Synt Gas untuk press up 1-101-E. * Pertahankan sirkulasi Benfield ( 60 % Rate ). TINDAKAN DIATAS SAMA JIKA 101-BJ1T DAN 101-BJ2T TRIP RINCIAN DARI SHUT DOWN SYNT LOOP; HRU DAN ARU : * total kick back 103-J, buka kick back FIC-301;303 dan 304. * Turunkan speed ke minimum Governoor via PC-301 ( bila 103-J tidak dalam kondisi Trip ). * Vent Gas di PIC-1004 (back press 29 Kg), atur let down SH ke SM. * Tutup MOV-1001 dan MOV-1002. * Tutup bv U/S LV-1013. * Tutup HCV-1044 dan buka lebar HCV-1046. * Masukkan Hot Ammonia ke 1-109-F via 5101-J/JA. SHUT DOWN HRU DAN ARU : * Stop H2 produk ke 103-J dengan menutup V-704, vent do PIC-0711. * Buka vent Gas PC-1033, tutup bv Gas yang ke fuel 1-101-B. * Buka bv b/p 103-E dan 104-E (tutup bv inletnya), dan isolir LV nya. * Tutup Gas Ke Cold Box via TV-709. * Tutup V-701 ( Inlet DA-101-A/B ). * Deriming Cold Box ( buka V-714 aktifkan TCAL-0718 ).

Primary Reformer Hot Process Air Preheater Mixed Feed Preheater ID Fan Turbine Driver Speed Max/Min : 900 / 648 rpm

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ITEM No * Non aktifkan 1-150-E. * By pass LTS (buka MOV-1009 dan tutup MOV-1008). Tutup bv Outlet LTS. * Shut Down Synthesa Loop; ARU dan HRU. * Pertahankan sirkulasi Benfield dengan tekanan yang ada. Import Synthesa Gas. 102-F1 102-F2 104-F

PRESS / TEMP DRUM P : 36,2 Kg Raw Gas Separator T +/- : 150 / 19 deg C. P : 36,2 Kg Carbon Dioxide Absorber T +/- : 150 / 19 deg C.OVHD KO Drum P : 35,2 Kg Synthesis Gas Compressor T +/- : 150 / 19 deg C.Suction Drum

1-103-J TRIP : * Informasikan ke Kabag Shift, Urea dan Utility bahwa 103-J Trip : * Cut Rate Gas ke 80 %, vent Gas di PC-1004 (Back Press = 29 Kg) * S/D Synt Loop; HRU dan ARU. * Atur Let Down Steam System HV-1029 ke PC-1013. * Import Synt Gas untuk 108-D dan press up 1-101-E. * Jalankan turning Gear (jika penyebab S/D bukan dari Lube Oil). 1-105-J TRIP : * Non Aktifkan XV-1150 bila SP-025 tidak Trip. * Start MY COM 5103-L bila Tie-In tidak memungkinkan. * Shut Down kan Syn Loop; HRU dan ARU. * Import Synt Gas. 1-104-J/JA TRIP (bila tdk ada kesempatan untuk jalankan yg S/B) : * Stop semua penyalaan burner-burner di Reformer system (tutup header fuel dekat LTS). * Import Steam via HV-1262. * Cut Rate ke 40 % , vent gas di MOV-1018 dan V-1000. * Total kick back 101-J; 102-J; 103-J (bila mungkin) bila tdk matikan. * Atur temperatur Coil Udara via TV-1312. * Atur Speed 1-101-BJ1T dan 1-101-BJ2T. * S/D 106-D via HS-1253 (tutup vent PC-1005 utk mempertahan kan tekanan Gas di 101-E). 126

105-F1 105-F2 106-F 107-F 109-F 114-F 115-F 118-F 132-F 133-F 144-F 157-F

P : 62,2 Kg Synthesis Gas Compressor T +/- : 150 / 19 deg C.1st Inter Stage Separator P : 112,0 Kg Synthesis Gas Compressor T +/- : 150 / 0 deg C. 2nd Inter Stage Separator P : 18,8 Kg Ammonia Separator T +/- : 150 / -25 deg C P : 19,7 Kg Ammonia Let Down Drum T +/- : 150 / -25 deg C P : 17,6 Kg Cobalt Molybdenum / T +/- : 150 / -18 deg C. Zinc Oxide Quard Vessel P : 0 Kg Benfield Solution Storage Tank T +/- : 150 / 19 deg C. P : 0 Kg Benfield Solution Sump T +/- : 123 / 19 deg C. P : 15,3 Kg Benfield Carbon Filter T +/- : 123 / 19 deg C. P : 5,3 Kg Semi Lean Solutiopn Flash Tank T +/- : 150 / 19 deg C. P : 36,2 Kg Carbon Dioxide Stripper T +/- : 150 / 19 deg C.Feed Flash Drum P : 15,8 Kg Feed Gas Knock Out Drum T +/- : 150 / 19 deg C. P : 5,3 Kg Low Pressure Condensate T +/- : 320 / 19 deg C. KO Drum 95

5. Setelah 30 menit kemudian PACKAGE BOILER dapat diStart Kembali. 6. Metode Start / Stop ini bisa dilakukan bila kenaikan temperatur terlalu cepat. 7. Atur level Steam Drum secara manual melalui LV-3402 bila tidak mampu dapat diatur melalui bv by-pass LV-3402 8. Bila kondisi minimum firing sudah stabil, maka naikkan firing rate sbb : a. Robah posisi COMBUSTION AIR CONTROL PIC-3440 dari posisi MAN --> AUTO pada saat fuel flow control PIC-3422 akan berubah dari MNLK --> MAN. b. Robah posisi PIC-3422 dari MAN --> AUTO. c. Naikkan firing rate secara perlahan-lahan dengan menambah output dari BOILER MASTER PIC-3408 sampai tercapai tekanan + 43 Kg / Cm2 dan temp SM + 390 0C. 9. Apabila kondisi Steam Product sudah normal, maka masuk kan ke system dengan membuka bv isolasi header SM secara perlahan-lahan dan di imbangi dengan penutupan PIC-3408 ( Blow Off Valve ) secara bertahap dengan memperhatikan tekanan PIA-3408 display monitor di panel. 10. Atur injeksi Phospate dan sesuaikan dengan batasan batasan yang di izinkan.

REMARK PUMP/COMP/RV/S TURB Type : Centrifugal Feed Gas Compressor 3 102-J P S/D : 13,74/44,67 Kg Cap : 29009 Nm / H Speed : 12400 r/m. Type : Condensate Steam Turbine Driver for 102-J Speed : 12400 r/m. 102-JT Output : 1770 KW Type : Centrifugal. Synthesis Gas Compressor. 3 103-J P S/D : 98,88/179,31Kg Cap : 609828 Nm / H Speed : 10535 r/m. Type : Centrifugal. LP Case Synth Gas Compressor 3 103-JLP P S/D : 32,59/99,85 KgCap : 164714 Nm / H Speed : 10535 r/m. Type : Extr / Cond Steam Turbine Driver for 103-J Speed : 10535 r/m. 103-JT Output : 14326 KW 3 104-J/JA Des Flow : 235,5 m /H HP BFW Pumps Type : Centrifugal. Amm Refrigerant Compressor 3 105-J P S/D : 1,04 / 15,23 Kg Cap : 1357850 Nm / H Speed : 10200 r/m. Type : Condensate. Steam Turbine Driver for 105-J Speed : 10200 r/m. 105-JT Output : 4670 KW 3 Des Flow : 580,0 m /H Semi Lean Solution Pump. 107-JA Differential : 286,5 M Power : 9,23 KW Des Flow : 770,6 m3/H Semi Lean Solution Pump. 107-JB Differential : 286,5 M Power : 7,26 KW Des Flow : 770,6 m3/H Semi Lean Solution Pump. 107-JC Differential : 286,5 M Power : 7,26 KW Des Flow : 183,9 m3/H Lean Solution Pumps. 108-J/JA Differential : 310,9 M Power Normal/Rated :18/38,7 KW 97

ITEM No

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ITEM No 200-F 201-F 202-F ITEM No 101-J

PRESS / TEMP DRUM P : 15,8 Kg Natural Gas Knock Out Drum T +/: 19 deg C. P : 5,3 Kg Pretreatment Lean Solution T +/- : 150 / 19 deg C.Flash Tank P : 15,8 Kg Pretreatment Absorber T +/- : 150 / 19 deg C.OVHD KO Drum REMARK Type : Centrifugal P S/D : 0,99 / 38,9 K 101-J AIR COMPRESSOR Air Compressor ; Speed :7300 r/m Cap : 52596 Nm3/H

AMMONIA PLANT

EMERGENCY SHUT DOWN

Beberapa tindakan pertama yang harus dilakukan bila terjadi Emergency Shut Down dari peralatan seperti : 1-101-J; 1-102-J; 1-103-J; 1-105-J; 1-104-J; 1-101-BJ1T; 1-101-BJ2T 1-101-J TRIP : * Imformasikan ke Kabag Shift dan Urea / Utility bahwa 101-J Trip

Duty : 1,93 mm Kcal/H 1st Integral Inter Cooler 101-JC1 S/T dP : 5,2 / 10,5 Kg S (max/min) : 150 / 5 deg C T (max/min) : 150 / 5 deg C Duty : 1,36 mm Kcal/H 2nd Integral Inter Cooler 101-JC2 S/T dP : 5,2 / 10,5 Kg S (max/min) : 150 / 5 deg C T (max/min) : 150 / 5 deg C Duty : 1,23 mm Kcal/H 3rd Integral Inter Cooler 101-JC2 S/T dP : 5,2 / 10,5 Kg S (max/min) : 150 / 5 deg C T (max/min) : 150 / 5 deg C Duty : 1,73 mm Kcal/H Air Compr 2nd Stage Inter Cooler 101-JCA S/T dP : 11,2 / 10,5 Kg S (max/min) : 240 / 5 deg C T (max/min) : 240 / 5 deg C Duty : 0,758 mm Kcal/H Air Compr 3rd Stage Inter Cooler 101-JC2 S/T dP : 18 / 10,5 Kg S (max/min) : 150 / 5 deg C T (max/min) : 150 / 5 deg C Type : Extr / Cond Steam Turbine Driver for 101-J 101-JT Speed : 7300 r/m ;Output : 9040 KW 101-L Air Filter Type : Turbo Air Filter Bleed Fan 101-LJ Cap : 7000 m3/H ;Output :3,7 KW 4" 300# X 6" 150# Relief Valve Discharge 3rd 101-J RV-101-J Setting pop : 43,9 Kg

* Cut Rate Gas menuju Rate 50 % , vent Gas di MOV-1018, back press = 18 Kg/Cm2G. * Import SM via HV-1262. * Atur temp Coil Udara via TV-1312 (Check Trip System TV 1312). * Atur Let Down Steam (Steam System secara keseluruhan). * Shut Down kan Methanator via HS-1253. * Non Aktifkan 1-150-E. * By pass LTS (buka MOV-1009; tutup MOV-1008) tutup bv outlet. * Atur Riser + 750 0C (matikan beberapa Burner). * Pertahankan S/G Ratio tetap diatas 3,5. * Shut Down Loop; HRU; ARU dan Cold Box. * Pertahankan sirkulasi Benfield dengan tekanan Gas yang ada (Import Synthesa Gas). 1-102-J TRIP : * Informasikan ke Kabag Shift, Urea dan Utility bahwa 102-J Trip : * Cut Rate Gas menuju 40 %, buka vent V-1000 untuk vent Gas dan MOV-1018 untuk vent Steam, back press = 7 Kg/Cm2G. * Atur temperatur Riser dan temperatur Coil Udara. * Atur Reforming System dan Steam System. * Shut Down kan 106-D (Methanator) via HS-1253. 125

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ITEM No 111-J 112-J/JA 113-J/JA 114-J/JA 115-J 116-J/JA 120-J 121-J/JA 124-J/JA 125-J/JA 140-J/JA 141-J/JA 201-J/JA 202-J/JA RV-105-J RV-128-C

REMARK Des Flow : 44 m3/H Differential : 280 M Des Flow : 44 m3/H Differential : 280 M Des Flow : 95,3 m3/H Differential : 118 M Des Flow : 27,2 m3/H Differential : 105,8 M Des Flow : 7,8 m3/H Differential : 25,6 M Des Flow : 411,5 m3/H Differential : 30,5 M Des Flow : 411,5 m3/H Differential : 30,5 M Des Flow : 125 m3/H Differential : 84,2 M Des Flow : 92,1 m3/H Differential : 86,6 M Des Flow : 8,5 m3/H Differential : 228,3 M Des Flow : 1,0 m3/H Differential : 76,5 M Des Flow : 1,38 m3/H Differential : 18,40 M Des Flow : 137,9 m3/H Differential : 140,2 M Des Flow : 18,6 m3/H Differential : 27,43 M 6" 600# X 10" 150# Setting Pop : 17,6 Kg 3/4" 150# X 1" 150# Setting Pop : 10,5 Kg

PUMP/COMP/RV/S TURB Benfield Transfer Pump Power Nor/Rated : 6,69/7,00 KW Proc Cond Pumps for 103-JTC Power Nor/Rated : 6,69 / 7.0 KW Warm Amm Product Pumps Power Nor/Rated : 32,25/32,6 KW Proc Cond Pumps for 101-JTC Power : 28 KW Benfield Sump Pump Power : 4 KW CO2 Stripper Quench Pumps Power Nor/Rated : 42,84/43,5 KW Ammonia Injection Pumps Power : 3,6 KW P C Pumps for 102-F1 to 150-E Power Nor/Rated : 34,58/35,1 KW Cold Ammonia Product Pumps Power Nor/Rated : 22,50/23,8 KW Ammonia Product Mixing Pumps Power Nor/Rated : 12,13/12,7 KW LP Ammonia Scrubber Pumps Power : 1,11 KW HP Ammonia Scrubber Pumps Power : 18,83 KW Pretreatment Circulating Pumps Power Nor/Rated : 92,5/99,6 KW Pret'ment OVHD Quench Pumps Power Nor/Rated : 2,92/3,00 KW Relief Valve disch 4th stage 105-J Relief Valve Line CW Outlet 128-C

6. Tekan Tombol START. System pembakaran akan mengikuti Squence yang diatur oleh BURNER MANAGEMENT system : a. Proses PRE PURGE akan berlangsung selama 200 detik. b. Proses penyalaan Pilot BURNER yang ditandai dengan membukanya valve GAS ke BURNER sebanyak 2 EA dan menutupnya vent Pilot ( dapat dilihat pada monitor Area 3 ). c. Proses Penyalaan BURNER ditandai dgn membukanya valve Gas ke BURNER ( MAXON valve ) sebanyak 2 EA dan menutupnya vent valve. d. Di lapangan bv by-pass relief valve pada saat proses penyalaan BURNER harus terbuka + 2 sampai 4 ulir untuk mengatur tekanan GAS pada saat MAXON membuka. e. Bila start BOILER berhasil BURNER akan menyala maka Pilot valve akan menutup kembali dan MAXON valve tetap terbuka. IV. Kondisi pada posisi MINIMUM FIRING 1. Perhatikan kenaikan temperatur Superheater TI-3406 kecepatan kenaikan temperatur maximum 55 0C per Jam. 2. Bila kenaikan temperatur terlalu cepat, maka tambah pembukaan PIC-3408 steam vent ( Blow Off Valve ). disesuaikan dengan kebutuhan. 0 3. Jaga temperatur TI-3406 tidak melebihi > 400 C diatur dengan cara menambah pembukaan PIC-3408 ( Blow Off Valve ). 0 4. Bila temperatur TI-3406 > 430 C atau temperatur Flue Gas mendekati maximum 900 0F atau 482 0C maka matikan PACKAGE BOILER ( distop ). 123

98

6. Siapkan supply Gas Alam / Full sbb : a. Tutup PCV 3420 dengan mengatur setting control sampai output = 0. b. Buka block valve isolasi ( Upsream PCV 3420 ). c. Naikkan perlahan-lahan setting PCV 3420 sampai mencapai tekanan 70 psi / 5.5 Kg / Cm2. d. Atur tekanan Gas dengan membuka sedikit block valve vent ( by pass Relief Valve ). e. Aktifkan valve valve Gas ke line Pilot dan Main Burner. III. PERSIAPAN DI PANEL DCS 1. BMS Alarm Display ( Graphic Display 4A atau Area 5 yakinkan tidak ada alarm lagi. Bila masih ada indikasi alarm, coba di reset. Setelah direset alarm nya tidak

2. 3. 4.

5.

hilang berarti masih ada yang harus diperbaiki. Baik itu di lapangan maupun di Controlnya ( yang alarm tersebut ). Buka blow off valve PIC-4308 secara manual + 25 %. Level Control Steam Drum LC-3402 posisi manual. Posisi Boiler Control ( Area 12 atau Control display 2B ) pada saat Start Up sbb : a. Boiler Master ( PIC-3408-M ) 10 % MAN b. FD FAN Control ( FIC-3441 ) 42 % MAN c. Comb Air Control ( FIC-3440 ) 5 % MAN d. Fuel Flow Control ( FIC-3422 ) 10 % MAN Bila semua Protection system telah terpengaruh, maka BOILER akan Permisive Start. ( POST Purge akan berlangsung selama 200 detik setelah protection Alarm nya hilang ) dapat dilihat pada monitor display pada Area 2 atau Graphic display 1A.

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- Accelary Speed 50 % 14 HA muncul pada speed 60 % Jaw Clutch Disenganged dan Starting Motor Stop. - Menuju full speed, IGV akan membuka posisi Auto. - 14 HS muncul speed 5100 rpm ( Full Speed no Load ). - Tekan Droop dan Execute. SYNCHRONIZING Auto : - Tempatkan selector Switch ( 43.S ) pada posisi Auto. - Tekan ON pada Auto Synch dan Execute. - Jarum Synchroncope akan berputar searah jarum jam. Kalau putarannya cepat atau terbalik, atur dengan menggunakan raise atau Lower Governoor sampai putaran jarum Synchroncope pelan searah jarum jam. - Atur tegangan dengan menggunakan Raise atau Lower ( 90.R4 ) Regulator. - Close kan Generator Breaker 52.G bila jarum Synchroscope 1 detik sebelum jam 12. - Atur load GTG dengan raise Governoor. NB : Minimum beban lebih besar 2 MW. NORMAL SHUT DOWN - Turunkan beban sampai nol ( Lower Governoor ) Generator Breaker ( 52.G ) open. - GTG operasi no Load. - Tekan stop pada master control selector switch dan execute. - Tutup valve inlet gas to GCV. - Periksa ratchet system dan 88.QA running ( Operasi Ratchet ) sebaiknya selama 48 jam ). - GTG Cool Down. 120

101

EMERGENCY SHUT DOWN - Tekan tombol Emergency Shut Down dapat juga dilakukan dengan manual pada gauge cabinet Assembly atau manual trip dibawah mekanis trip. - Tutup valve inlet to GCV. - Periksa ratchet system dan 88.QA running ( GTG Cool Down ).

SOP START PACKAGE BOILER UTILITY P - IB


I. PERSIAPAN SECARA UMUM START PACKAGE BOILER 1. Yakinkan bahwa Natural Gas, BFW, Steam cukup tersedia. 2. Periksa kembali / cek semua peralatan Instrumentasi, apakah dapat bekerja dengan baik. 3. Periksa kembali kondisi FD Fan 34-6007-UJT.

Bila sudah OK jalankan Aux Pump secara auto. 4. Yakinkan bahwa P BOILER siap untuk di Operasikan. II. PERSIAPAN DILAPANGAN 1. Buka block valve drain super heater ( 2 EA ). 2. Buka block valve vent super heater ( 2EA ). 3. Isi STEAM DRUM secara perlahan-lahan dengan BFW sampai level mencapai 25 % di Sight Glass. 4. Jalankan FD FAN 6007 UJT sampai normal speed + 4450 rpm. 5. Yakinkan FY3441 pada posisi II ( Remote Control ).

121

100

GAS & COOLING WATER - Aktifkan gas Scrubber 33-5001-F dan gas Heater 33-5001-C Temperatur NG Outlet 33-5001-C = 50 0C - Aktifkan CWS / CWR dari Utilitas P-IB. Kalau belum ada dari P-IB, aktifkan CWS / CWR line tie-in dari P-IV. START UP GTG - ON kan Power Control Mark IV. - Tekan Normal Switch pada Key Pad CRT, akan ditampilkan : Status File : Off Cool Down. Select Field : Select Off. Control Field : Control Start Up - Tekan Auto Switch pada Operation Selection. Led nyala dan adanya suara Beef, lalu tekan Execute. - Tekan Start pada Master Control Selector, lalu tekan Execute. - Rotor akan berputar oleh Starting motor dan Jaw Clutch Engaged 14 HR muncul ( 20 % ) Speed. - Speed naik sampai 14 HM muncul ( 40 % Speed ). Speed konstan sampai timer L2TV habis FSR akan memberikan harga ke GCV pada batas Firing. FSR akan atur harga Warm Up CRT akan menampilkan : Title Field : Start Up Status Status Field : Warming Up. Select Field : Warming Up. Control Field : Control Start Up. Masage Field : Flame 2 ; 3

119

102

PROSEDUR ( SOP ) START / STOP GTG


Persiapan Start Up : Control Package : - Breaker supply Power dari TR 510 - Incoming Power TB 480 Volt AC - Incoming Power TB 125 Volt DC - 125 Volt DC Panel Board - 3 PH 4W PNLBD Main - 110 Volt Distant Panel - 120 Volt Distant Panel - Battery Charger - Aux Hydraulic Pump 88 HQ - General bearing Evacuator Pump 88 BQ - LO Tank Immersion Heater 23 QT - Aux LO Pump 88 QA - Ratchet Opearsi 88 HR - Cooling Air Fan access & Turbine Compartment 88 BT-1 - Access Compartment Heater 23 HA

ON ON ON ON ON ON ON ON AUTO AUTO / RUNNING OFF AUTO / RUNNING AUTO / RUNNING OFF

Turbine Compartment Heater 23 HT Stand by Lighting Emergency LO Pump 88 QE CO2 Fire Extinguisher Stand by Semua Protection System dapat bekerja dengan baik.

OFF OFF ON / STOP

118

103

POSISI VALVE UNTUK

PERSIAPAN START UP WHB


1. VALVE-VALVE DRAIN : NAMA VALVE DRAIN Drain Header Economiser ( 4 EA ) Drain Down Commer ( 1 EA ) Drain Evaporator Drain Header Super Heater Drain Header SM 2. VALVE VENTING : NAMA VALVE VENTING Vent Header Economiser Vent Header Economiser Outlet Vent Header Saturated Steam Vent Header SM Outlet POSISI VALVE Close Close Open Open POSISI VALVE Close Close Close Open Open

116

105

3. VALVE INSTRUMENTASI : ITEM 34PI-001 PG-002 FRC-003 AR-42/44 AR-40/41 FI-006 LG-011 LG-009 LSLL-10 LT012/013 PI-014 PG-015 PG-019 PRC-022 PRC-021 FIR-023 BV BV BV BV BV BV BV BV BV BV BV BV BV BV BV BV

NAMA VALVE
isolasi BFW press transmitter isolasi press gauge isolasi BFW flowmeter isolasi BFW Analiser isolasi Drum Water Analiser isolasi Continuous Blow Down isolasi level glass Steam Drum isolasi level glass Steam Drum isolasi level switch Steam Drum isolasi level transmitter Steam Drum isolasi press transmitter Steam Drum isolasi press gauge Steam Drum isolasi press gauge Header SM isolasi press tranmitter Header SM isolasi flowmeter SM Product isolasi flowmeter Spray Water

POSISI VALVE Open Open Open Open Open Open Open Open Open Open Open Open Open Open Open Open

117

104

- Tekan BURNER ON. - BURNER START SEQUENCE / OPERATION menyala berkedip + 9 kali. - FLAME DETECTOR bergerak kekanan ( indikasi nyala ), segera naikkan PY-022 Gas 25 % s/d 30 %, supaya nyala api agak jelas ( flame detector tidak FAULT ). 3. MINIMUM FIRING BOILER - Atur kenaikan pressure dan temperatur dengan mengatur kenaikan gas dan pembukaan vent HC-028 ( mengikuti kurva start up ). - Atur spray Desuperheater sampai auto untuk mengatur temperatur SM TC-018 + 388 0C dan atur BFW ZI-004 sampai AUTO. - Tutup valve-valve vent ( Economizer, Steam Drum, Superheater dan Desuperheater ) dan atur Continuous blow down, aktifkan Flash Drum ( 34-5005-F ). 4. PERSIAPAN ON LINE. 2 - Setelah tercapai Pressure + 43 Kg/Cm dan temperatur + 380 0C dengan bukaan vent HC-028 + 60 %. - Buka ZSH-027 ( non return valve ) dan block valve SM outlet tetap tertutup. - Buka by pass SM Header + 30 s/d 45 menit ( heating up agar tidak hummering ). Buka block valve SM outlet header pelan-pelan. Atur pressure dengan mengurangi HC-028 dan PC-3471 ( vent steam header ) atau turunkan beban boiler yang lainnya ( Package Boiler ).

115

106

2. HEATING UPBOILER A.PERSIAPAN DILAPANGAN ( FIELD ). - Buka Boiler Damper secara bertahap menuju 35 % open, Beritahu operator lapangan WHB & GTG untuk mengecek bukaan Damper dilapangan . Pertahankan tekanan steam drum sekitar 2 Kg / Cm2G dengan mengatur bukaan Vent Valve HC-028 + 40 %. - Naikkan bukaan Boiler Damper perlahan-lahan ( + 15 menit ) menuju 50 %, 75 % dan 100 % dengan tetap memperhatikan tekanan Steam Drum & temperatur Super heater ( TI-017 ). a. Kenaikan temperatur TI-017 dijaga + 50 0C/jam. b. Bila kenaikan tekanan dan temperatur terlalu cepat, atur bukaan Start Up valve HC-028. - Tutup vent steam drum yg masih terbuka bila tekan an Steam Drum sudah mencapai sekitar + 2 Kg/Cm2G 2 - Buka Butterfly Valve gas header 28 Kg/Cm , aktifkan Let Down Valve dan Pilot Burner Valve. 2 - PSL-111 ditutup, setelah PIA-117 > 0,10 Kg/Cm baru kemudian PSL-111 dibuka ( gunanya untuk menghindari LGP = Low Gas Pressure ). B. PERSIAPAN DI CONTROL ROOM - PY-022 gas posisi Manual, ZI-108 dibuka 25 % ( OP ). - Reset Alarm di panel ( jika masih ada yang nyala, perbaiki dahulu hingga tidak ada lagi yang alarm ). - READY FOR PURGING menyala. - Tekan PURGING ON. - PURGING SEQUENCE / FINISHER menyala.

UTILITY PLANT
31 WATER TREATMENT & DEMIN PLANT COOLING TOWER ELECTRIC POWER GENERATION SYS WASTE HEAT BOILER & PAKAGE BOILER PLANT AIR & INSTRUMENT AIR GAS METERING RIVER WATER INTAKE WASTE WATER TREATMENT

32 33 34 -

35 -

41 42 45 -

114

- BURNER READY FOR OPERATION menyala ( siap start ).

107

RIVER WATER INTAKE 42 - 5201 42 - 5201 - J/JA RIVER WATER INTAKE PLAT FORM RIVER WATER PUMP

AMMONIA UTILITY UNIT 43 43 43 43 43 43 43 5101 - C 5101 - F 5101 - J/JA 5102 - C 5102 - J/JA 5102- F 5103 - L AMMONIA HEATER AMMONIA STORAGE TANK AMMONIA TRANFER PUMP AMMONIA VAPORIZED AMMONIA LOADING PUMP STEAM CONDENSATE POT AMMONIA PACKAGE REFRIGERATION UNIT

31 31 31 31 31 31 31 31 31 31 31 31 31 31 31

5008 - C 5008 - F 5008 - J/JA 5009 - F 5009 - J/JA 5201 - F 5202 - F 5203 - F 5204 - F 5204 - J/JA 5205 - FA/FB 5205 - J/JA 5205 - UA ~ UD 5206 - F 5210 - J/JA

CAUSTIC SOLUTION COOLER CAUSTIC DISSOLVING TANK CATION ACID PUMPS REGENERANT CAUSTIC TANK CAUSTIC DISSOLVI'G CIRCULATI'G PUMP FILTER WATER STORAGE TANK OVER FLOW FIT SLUDGE PIT CLEAR WELL FILTER WATER TRANFER PUMP SLUDGE POND COOLING WATER MAKE UP PUMP CARBON FILTER BACK WASH RECOVERY PIT PORTABLE WATER PUMP

WASTE WATER TREATMENT 45 45 45 45 45 45 45 5402 5402 5403 5403 5403 5404 5407 F J/JA C E J/JA F F NETRALIZATION POND WASTE WATER EFFLUENT PUMP AMMONIA STRIPPER FEED HEATER AMMONIA STRIPPER AMMONIA FEED PUMP COLLECTION POND EQUALIZATION POND

COOLING TOWER 32 32 32 32 32 32 32 32 32 32 5000 - J/JA CONDENSATE PUMPS 5204 - LA/B/C SIDE FILTER 5204 - U BAR SCREEN 5204 - U COOLING TOWER 5204 - UF COOLING TOWER BASIN 5204 - UJA ~ UJIINDUCE FAN 5209 - JA/B/C AMMONIA / UTILITY CIRCULATING PUMP 5209 - JTC SURFACE CONDENSER 5209 - JTCC INTER/AFTER COOLER 5601 - JA/B UREA CIRCULATING C W PUMP

112

109

WATER TREATMENT
31 31 31 31 31 31 31 31 31 31 31 31 31 31 31 31 31 31 31 31 31 31 31 31 31 31 31 1001 - U 1002 - J 1003 - J 2001 - UA ~ UF 3002 - JA/B/C 3003 - J/JA 3004 - J 3005 - J/JA 3006 - JA/B/C 4001 - F/FA 4003 - J/JA 4005 - F 5001 - F 5001 - J/JA 5001 - U 5002 - J/JA 5003 - F 5003 - J/JA 5004 - J/JA 5004 - UA/B/C 5005 - C 5005 - UA/B/C 5006 - UA/B 5006 - UN 5007 - F 5007 - U 5007 - UJ/UJA CLARIFIER AGITATOR CLARIFIER RAKE FOR CLARIFIER SAND FILTER CLARIFIER WATER TRANSFER PUMP BACK WASH RECOVERY PUMP BACK WASH WATER EFFLUENT PUMP ALUM INJECTION PUMP CAUSTIC INJECTION PUMP ALUM TANK AGITATOR ALUM TANK CAUSTIC TANK DEMINERALZATION STORAGE DEMIN WATER PUMPS DEMINETRALIZATION UNIT ANION CAUSTIC PUMPS SULPHURIC ACID REGENERANT TANK MIXER BED ACID PUMPS MIXER BED CAUSTIC PUMPS CATION EXCHANGER WATER HEATER ANION EXCHANGER MIXER BED EXCHANGER MIXER BED BLOWER DEGASSER WATER SUMP DEGASSER DEGASSER BLOWER

PROSEDUR START UP WHB

( COLD START )

1. Persiapan Start Up : - BFW sudah siap memenuhi persyaratan operasi dan pompa BFW sudah normal operasi. - Steam Drum telah diisi sampai diatas level minimum ( LC-013 ) + 30 % diposisi Manual. - Pompa BFW benar benar telah siap operasi ( BFW dari 34-5003-J/JA ). - Gas Turbine Generator ( GTG ) telah beroperasi diatas beban minimum dan temperatur Flue Gas nya Konstan. - Instrumentasi dalam keadaan bagus ( ready ), baik Interlock system maupun control systemnya dengan syarat proteksi untuk start up tidak ada yang alarm. - Temperatur Flue Gas inlet WHB telah memenuhi untuk purging WHB ( dibawah 350 0C ) - Posisi valve dan damper didasarkan pada " Posisi valve persiapan Start Up " dengan perubahan perubahan sebagai berikut : a. Drain valve superheater dan SM heater dibuka. b. Vent valve saturated heater & SM header dibuka. c. Start up valve dibuka sekitar 20 %. d. Block valve header limit SM WHB ditutup.

108

113

CHEMICALS INJECTION 32 32 32 32 32 32 32 5202 - L 5205 - LF 5205 - LJ/LJA 5206 - LF 5206 - LJ/LJA 5207 - LJ 5210 - LF CHLORINATOR ASAM SULFAT INJECTION TANK ASAM SULFAT INJECTION PUMP INHIBITOR TANK INHIBITOR INJECTION PUMP DISPERSANT INJECTION PUMP DISPERSANT TANK

WASTE HEAT BOILER & PACKAGE BOILER

34 - 5002 - U 34 - 5003 - J/JA 34 - 5003 - U 34 34 34 34 34 34 34 34 34 34 34 34 34 5005 - F 5006 - J 5007 - L 5007 - LJ/LJA 5008 - L 5008 - LJ/LJA 5010 - L 5010 - LJ/LJA 5011 - L 6007 - F 6007 - U 6007 - UJT 6008 - L

ELECTRIC POWER GENERATION 33 33 33 33 33 33 5001 - C 5001 - F 5001 - L 5006 - J 5007 - J 5010 - J GAS HEATER GAS SCRUBBER AIR DRYER FOR GTG GAS TURBINE GENERATOR EMERGENCY DIESEL GENERATOR COOLING WATER BOOSTER PUMP ( GEN SET )

SUBSTATION TR - 5006/MCC -5006 CRANKING MOTOR UNIT SUB-STATION TR - 5006A/TR - 5006B LOAD DISTRIBUTION CENTER ( 150 KVA AUX POWER TRANSFORMER )

DEARATOR BFW PUMP WHB - STEAM DRUM, ECONOMICER, EVAPORATOR DLL. BLOW DOWN FLASH DRUM ( WHB ) GAS TURBINE GENERATOR HYDRAZINE INJECTION TANK HYDRAZINE INJECTION PUMP PHOSPHATE INJECTION TANK ( WHB ) PHOSPHATE INJECTION PUMP AMMONIA INJECTION TANK AMMONIA INJECTION PUMP DESUPERHEATER BLOW DOWN FLASH DRUM ( PB ) PB STEAM DRUM F D FAN PHOSPHATE INJECTION TANK ( PB )

PLANT AIR & INSTRUMENT AIR 35 - 5004 - J 35 - 5006 - F 35 - 5006 - L STAND BY AIR COMPRESSOR INSTRUMENT AIR RECEIVER INSTRUMENT AIR DRYER

GAS METERING STATION 41 - 5103 - F 110 KNOCK OUT DRUM 111

30. Buka kembali TTV : a) 500 rpm b) 1500 rpm c) 2500 rpm d) 7000 rpm e) 8670 rpm

Start 1-105-J

60 menit (termasuk trip test). 40 menit. 10 menit. 10 menit. (MGS) --> TTV terbuka lebar (lampu start OK padam). Catatan :* Hati-hati critical speed : - LP Case --> 3600 rpm. - HP Case --> 4400 rpm. - Turbine --> 5100 rpm. * Catat vibrasi pada setiap point. 31. Latching FV-501 s/d FV-504 (di lapangan). - Atur kick back FV-501 s/d FV-504 (bila TTV sudah wide open tetapi speed tidak mau ke MGS, adjust kick back tersebut. 32. Tutup admission valve ramp ke 0 % (lampu nyala). 33. Perlahan buka lebar ACV (di lapangan) & setelah terbuka lebar kembalikan ke posisi netral, dan buka lebar bv u/s nya. 34. Buka admission demand dgn PC-5001, perhatikan tekanan SLL. 35. Tekan proses admission control --> lampu indikasi nyala. 36. Atur admission demand dengan PC-5001, perhatikan tekanan SLL. 37. Pindahkan control speed dengan PC-1009 dengan cara : - PC-1009 = 0 %. - Tekan "Proses speed control" di EG Panel (lampu nyala). * Catatan : - Speed < 1000 rpm seluruh drain terbuka. - 1000 rpm < speed < 8670 rpm (MGS) seluruh drain terbuka 50 %. - Speed > 8670 rpm (MGS) seluruh drain tertutup.

AMMONIA PLANT
AMMONIA SYMBOL
1 2 3 4 5 6 7 8 B : PREHEATER C : EXHANGER D : VESSEL / CATALIST E : VESSEL ( TOWER ) F : DRUM J : PUMP / COMPRESSOR K : BUILDING L : FILTER / TANK

UNIT DESCRIPTION
1 2 3 4 5 6 7 8 9 FEED TREATING REFORMING SHIFT CONVERTER CO2 REMOVAL METHANATOR AMMONIA SYNTHESIS REFRIGERATION & NH3 STORAGE STEAM SYSTEM & BFW PREP PURGE GAS RECOVERY UNIT

40

Start 1-105-J
5. Drain casing & line NH3 sesaat untuk mengecek oli yang masuk ke casing (setelah yakin tutup kembali). 6. Heating up line : a) Line up SM steam sampai ke bv header. - BV & bv by pass : tertutup penuh. - BV drain u/s bv header = terbuka. b) Line up SLL sampai ke bv header ASV (Addmission Stop Valve). - BV ditutup - BV drain u/s bv header ditutup. 7. Jalankan turning gear 1-105-J & aktifkan oil system ke turning gear, lalu masukkan gear motor dan tekan PB on untuk menjalan kan turning gear. 8. Aktifkan gland condenser dan SP-100 (ejector dibawah exhaust). 9. Aktifkan sealing steam ( 0.2 kg/cm2 ). 10. Vacuum up (-500 mmHg). 11. Heating up 1-105-J a) Line up SM s/d ke TTV. - Drain 3/4" u/s TTV. buka lebar. - Vent 1" u/s TTV. buka lebar. - Drain chamber TTV 3/4" buka lebar. - Buka kecil bv b/p bv header SM ke 1-105-J (1"). b) SLL line up s/d ESV. - Drain 3/4" u/s buka lebar. - Drain chamber ASV tutup penuh. - Buka kecil bv header ASV. 12. Pelan-pelan naikkan tekanan casing ke 4.2 kg/cm2. (3.0 ~ 3.5 kg/cm2) dengan : - Buka line uap dari 107-F ke 109-F, jaga PCAL-1108 = 5.0 kg - Kirim uap NH3 ke 1-120-CF1 s/d CF4 melalui let down valve hingga tekanan, 1-120-CF sama dengan casing compressor. 13. Jika point 12 "ok" buka lebar bv u/s ASV. 38

ITEM 103-JTC 103-JTCC 105-C 106-C 107-C 109-C 111-C 113-C 114-C 115-C 116-C 120-C 120-CF1 120-CF2 120-CF3 120-CF4 121-C 122-C 123-C1 123-C2 124-C 127 -C 128-C 129-C 130-C 131-C 132-C 133-C 134-C 140-C

CLASS C: EXCHANGER SURFACE CONDENSER INTER / AFTER COOLER 1-103-JTC CO2 STRIPPER PROCESS GAS REBOILER L T S EFFLUENT / L P - BFW EXCHANGER CO2 STRIPPER QUENCH COOLER LEAN SOLUTION / L P B F W EXCHANGER CO2 STRIPPER EJECTOR STEAM GENERATOR CO2 STRIPPER CONDENSATE REBOILER METHANATOR FEED / EFFLUENT EXCHANGER METHANATOR EFFLUENT COOLER SYNTHESA GAS COMPRESSOR / INTER COOLER AMMONIA UNTIZED CHILLER 1ST STAGE REFRIGERANT FLASH DRUM 2ND STAGE REFRIGERANT FLASH DRUM 3RD STAGE REFRIGERANT FLASH DRUM 4TH STAGE REFRIGERANT FLASH DRUM AMM CONVERTER FEED / EFF EXCHANGER AMMONIA CONVERTER INTER CHANGER AMM CONVERTER EFF / STEAM GENERATION NO 1 AMM CONVERTER EFF / STEAM GENERATION NO 2 AMMONIA CONVERTER EFFLUENT COOLER REFRIGERANT CONDENSER REFRIGERANT COMP 3RD STAGE INTERCOOLER SYNT GAS COMPRESSOR INTER STAGE CHILLER SYNT GAS COMPRESSOR 1ST STAGE COOLER L T S EFFLUENT / B F W EXCHANGER CO2 STRIPPER QUENH / L P B F W EXCHANGER FEED GAS COMPRESSOR KICK BACK COOLER SYNT GAS COMPRESSOR KICK BACK COOLER AMMONIA STRIPPER REBOILER

AMMONIA PLANT PROCESS EQUIPMENT

14. Jika temp TI-551 = 250 0C, buka lebar bv SM inlet turbine. 15. Stop turning gear, tutup oil suplly ke turning gear (inlet/outlet)

Start 1-105-J

ITEM 101-B 101-BBA 101-BBS 101-BC1 101-BC2 101-BC3 101-BC4 101-BC5 101-BC6 101-BJ1 101-BJ2 101-BJ2T 101-BJIT 101-BL 101-BU 102-B ITEM 101-C 101-JCA 101-JCB 101-JTC 101-JTCC 102-C 103-C1 103-C2 2

CLASS B : FURNACES / FIRED HEATERS PRIMARY REFORMER ARCH BURNERS SUPERHEATER BURNER HOT PROCESS AIR PREHEATER MIXED FEED AIR PREHEATER H P STEAM SUPERHEATER COLD PROCESS AIR PREHEATER FEED GAS PREHEATER FUEL GAS PREHEATER FORCED DRAFT FAN INDUCED DRAFT FAN INDUCED DRAFT FAN TURBINE DRIVE FORCED DRAFT FAN TURBINE DRIVE COMBUSTION AIR PREHETER AUXILIARY BOILER START UP HEATER FOR AMMONIA CONVERTER CLASS C : EXCHANGER SECONDARY REFORMER WASTE HEAT BOILER AIR COMPRESSOR 2ND COOLER AIR COMPRESSOR 3RD COOLER SURFACE CONDENSER INTER / AFTER CONDENSER 1-101-JTC H P STEAM SUPERHEATER H T S EFFLUENT WASTE HEAT BOILER NO 1 H T S EFFLUENT WASTE HEAT BOILER NO 2

start turbine. 16. On kan power electronic gover noor Woodward 509 (CCB). 17. Tekan HS-1205 --> lampu nyala (CCB). 18. Tekan reset (EG Panel)--> CCB. 19. Tekan reset di lapangan (lampu permisive start "OK" nyala di lokal panel). Lampu start ok di EG Panel nyala. 20. Latching electric trip --> di lapangan. 21. Tarik reset mechanical trip (warna putih --> di lapangan). 22. Angkat reset TTV ke posisi normal --> lapangan. 23. Buka valve ramp (EG Panel) ke 100 % --> lampu nyala. 24. Tekan start up (EG Panel). - Speed ref --> Governoor (EG Panel). - ACV membuka --> 100 % (EG Panel). 25. Tekan governoor start di lapangan maka : a) Indikasi governoor ke minimum governoor --> CCB (EG Panel). b) Posisi governoor bergerak ke 50 % --> lapangan. 26. Yakinkan : a) Admission valve ramp. 100 % EG Panel. b) Admission Demand 0 % EG Panel. c) PC-1009 0 % EG Panel. d) PC-1005 100 % EG Panel. 27. Perlahan-lahan buka TTV, tahan speed 500 rpm selama 60 menit. 28. Lakukan trip test (bila diperlukan). a) Tekan HS-1205 (CCB). b) Tekan emergency stop (lapangan). 29. Jika point 28 ok ulangi point 17 s/d 26.

39

ITEM 141-C 142-C 143-C 167-C 172-C1 172-C2 173-C 174-C 188-C 201-C 202-C 203-C 204-C 205-C ITEM 103-D 104-D1 104-D2 105-D 106-D 107-D 108-D 109-DA 109-DB 201-D

CLASS C: EXCHANGER AMMONIA STRIPPER FEED AMMONIA STRIPPER EFFLUENT COOLER SEAL FLUSH WATER COOLER REF COMP 2ND STAGE INTER COOLER START UP HEATER START UP COOLER MOLUCULAR SIEVE REGENERATION HEATER STRIPPER CONDENSATE COOLER CONDENSATE STRIPPER FEED / EFF EXCHANGER FEED GAS PRETREATMENT / EFF EXCHANGER PRETREATMENT FEED GAS COOLER PRET'MENT CO2 STRIPPER STEAM REBOILER PRETREATMENT STRIPPER OVHD COOLER PRETREATMENT LEAN SOLUTION COOLER CLASS D : REACTORS SECONDARY REFORMER HIGH TEMPERATUR SHIFT CONVERTER LOW TEMPERATUR SHIFT CONVERTER AMMONIA SYNTHESIS CONVERTER METHANATOR PRIMARY REFORMER EFFLUENT TRANSFER LINE COBALT - MOLYBDENUM / ZINC OXIDE GUARD MOLUCULAR SIEVE DRIER A MOLUCULAR SIEVE DRIER B IRON SPONGE DESULFULRIZATION VESSEL

PROSEDUR OPERASI BAKU P - IB START UP 1 - 105 - J

Start 1-105-J

1. Persiapan dan yakinkan dilapangan : * CW ke 1-128-C terbuka * CW ke 1-167-C terbuka * CW ke 1-127-C terbuka * Refrigerant dipurge N2 sampai O2 content < 0.5 %. * 1-109-F isi level dgn ammonia, level ammonia, level 80 % ~ 90 %, jaga tekanan PCAL-1109 = 12 kg/cm2 * Semua kick back dibuka lebar dan posisi manual. * Vapour ammonia dari 5101-F ditutup (XV-1150 & SP-025). * Isi level NH3 di 1-120-CF 1 s/d CF 4, 1-129-C. Isi dgn min level * Supply N2 / Udara untuk oil slinger turbine. * PC-1009 output = 0 % (manual). * PC-5001 output = 100 % (manual). 2. Line up lube oil system untuk oil system 1-105-J/JT. a) Sebelumnya mech sudah mengisi N2 ke Bledder dari 1-102-JLF2A/B; JLF3. b) Supply LO ke 1-105-J/JT (L.O.C digabung dengan LO 1-102-J), sewaktu menggantikan LO/CO pelan-pelan sekali, karena akan mempengaruhi LO/CO 1-102-J. c) Aktifkan seal oil trap dan HP Case. 3. Purging 1-105-J dan refrigerant system dgn NH3 sampai N2 habis. - Press up casing dengan NH3 > 0.5 kg/cm2 (PG-511 disch HP). 4. Line up seal oil system untuk 1-105-J. - Supply S.O ke 1-105-J HP & LP case dengan mengatur FIC-511 perlahan lahan ke 7.6 m3/H isi 1-105-JLF1 dengan membuka bv V-508 setelah penuh tutup kembali bv V-508 (level 450 %), dilanjut kan isi 1-105-JLF4 (Cost Down Tank) sampai level normal (lampu alarm LALL-514 mati), tekanan casing dijaga maximum 2 kg/cm 2. 37

34. Aktifkan FC-1808. - Buat output FC-1808 : 0 %. - Tekan proses extraction Deman dengan FC-1808, perhatikan steam system imbangi dengan PC-1013. 35. Pindahkan control speed ke PC-0301. - Buat PC-0301 output : 0 %.

Start 1-103-J

ITEM 101-E 102-E 103-E 104-E 105-E

CLASS E : TOWERS CARBON DIOXIDE ABSORBER CO2 STRIPPER L P AMMO NIA SCRUBBER H P AMMONIA SCRUBBER AMMONIA STRIPPER

- Tekan proses speed control di EG Panel. 36. Atur disch pressure sesuai kebutuhan proses dengan : - Atur speed control PC-0301 - Atur kickl back FV-0301, 0303, 0304. - Catatan : - Speed < 1000 rpm, seluruh drain terbuka lebar. - 1000 rpm < speed < 9025 rpm seluruh drain terbuka 50 % - Speed > 9025 rpm seluruh drain ditutup.

150-E 201-E 202-E ITEM 101-F 102-F1 102-F2 104-F 105-F1 105-F2 106-F 107-F 109-F 114-F 115-F 118-F 132-F 133-F 144-F 156-F 157-F 200-F 201-F

PROCESS CONDENSATE STRIPPER PRETREATMENT CARBON DIOXIDE ABSORBER PRETREATMENT CO2 STRIPPER CLASS F : DRUMS / TANKS STEAM DRUM RAW GAS SEPARATOR CO2 ABSORBER OVHD K O DRUM SYNTHESA GAS COMPRESSOR SUCTION FILTER SYNT GAS COMP 1ST INTER STAGE SEPARATOR SYMT GAS 2ND INTER STAGE SEPARATOR AMMONIA SEPARATOR AMMONIA LET DOWN DRUM REFRIGERANT RECEIVER BENFIELD SOLUTION STORAGE TANK BENFIELD SOLUTION SUMP BENFIELD CARBON FILTER SEMI LEAN SOLUTION FLASH TANK CO2 STRIPPER FEED FLASH DRUM FEED GAS KNOCK OUT DRUM STEAM BLOW DOWN DRUM LOW PRESSURE CONDENSATE KNOCK OUT DRUM NATURAL GAS KNOCK OUT DRUM PRETREATMENT LEAN SOLUTION FLASH TANK

36

5. Press up casing compressor dengan dengan N2 hingga 0.5 kg/cm2. 6. Line up seal oil sytem. - Isi seal oil OHT case&seal oil OHT HP case hingga kondisi norm - Aktifkan seal oil ke LP & HP case. - Stand by kan seal oil turbine pada posisi auto. 7. Drain out casing comperssor dan line syn gas. 8. Aktifkan sealing steam dan gland condensor 1-105-JT, aktifkan SP - 100 dan putar Turning Gear 1- 105-JT setiap 30 menit. 9. Heating up - Line up SH hingga bv header. - Line SM hingga bv extraction. - Buka bv drain line extraction up stream check valve sampai tidak ada condensate, lalau tutup kembali. 10. Aktifkan CO ke turning gear, jalankan turning gear. 11. Aktifkan Gland Condensor. 12. Aktifkan sealing steam (P = 0.1 kg/cm2). 13. Vacuum up 250 ~ 300 mm Hg. 14. Heating up. - Line SH hingga TTV (> 450 0C). - Line SM hingga ke check valve extraction. 15. Perlahan naikkan tekanan casing hingga sama dengan tekanan PV-1004 melalui bv by pass suct compressor jika sudah tercapai buka bv suct compressor dan tutup b/p nya. 16. Buka lebar bv extraction dan tutup by passnya. 17. Buka lebar u/s bv header SH dan tutup by pass nya, ( sebelum membuka bv header ). Tutup dulu bv drain pemanasan untuk me nyamakan tekanan, supaya bv header tidak macet, setelah bv header terbuka lebar buka kembali drain pemanasannya). 18. Matikan turning gear dan tutup CO untuk turning gear. 19. ON kan power untuk Electrical Governoor Woodward 509 --> CCB 20. Tekan HS-1203 dan reset di CCB --> EG Panel. 34

Start 1-103-J

ITEM 112-J 112-JA 112-JAT 113-J 113-JA 114-J 114-JA 114-JAT 115-J 116-J 116-JA 120-J 121-J 121-JA 124-J 124-JA 124-JAT 125-J 125-JA 140-J 140-JA 141-J 141-JA 201-J 201-JT 201-JA 201-JAT 201-JM 202-J 202-JA 203-J 204-J

CLASS J : ROTATING EQUIPMENT CONDENSATE PUMP 1-103-JTC CONDENSATE PUMP A 1-103-JTC TURBINE DRIVE FOR 1-112-JA WARM AMMONIA PRODUCT PUMP WARM AMMONIA PRODUCT PUMP A CONDENSATE PUMP 1-101-JTC CONDENSATE PUMP A 1-101-JTC TURBINE DRIVE FOR 1-114-JA BENFIELD SUMP PUMP QUENCH CO2 STRIPPER PUMP QUENCH CO2 STRIPPER PUMP A AMMONIA INJECTION PUMP PROCESS CONDENSATE PUMP PROCESS CONDENSATE PUMP A COLD AMMONIA PRODUCT PUMP COLD AMMONIA PRODUCT PUMP A TURBINE DRIVE FOR 1-124-JA A MIXER AMMONIA PRODUCT PUMP MIXER AMMONIA PRODUCT PUMP A L P AMMONIA SCRUBBER PUMP JM L P AMMONIA SCRUBBER PUMP JMA H P AMMONIA SCRUBBER PUMP JM H P AMMONIA SCRUBBER PUMP JMA PRETREATMENT CIRCULATION PUMP TURBINE DRIVE FOR 1-201-J PRETREATMENT CIRCULATION PUMP A TURBINE DRIVE FOR 201-JA PRETREATMENT CIRCULATING PUMP QUENCH OVER HEAD PUMP QUENCH OVER HEAD PUMP A PRETREA'T BENFIELD TRANSFER PUMP PRETREATMENT BENFIELD SUMP PUMP

DRIVE ELECTR STEAM ELECTR ELECTR ELECTR STEAM ELECTR ELECTR ELECTR ELECTR ELECTR ELECTR ELECTR ELECTR STEAM ELECTR ELECTR ELECTR ELECTR ELECTR ELECTR STEAM STEAM ELECTR ELECTR ELECTR ELECTR ELECTR

ITEM 202-F 203-F 204-F 205-F ITEM 101-J 101-JT

CLASS F: DRUMS / TANKS PRETREATMENT ABSORBER OVHD SEPARATOR PRET'MENT BENFIELD SOLUTION STORAGE TANK PRETREATMENT BENFIELD SOLUTION SUMP PRETREATMENT BENFIELD CARBON FILTER CLASS J : ROTATING EQUIPMENT AIR COMPRESSOR STEAM TURBINE DRIVE FOR 1-101-J DRIVE

STEAM

21. Tekan reset (dilapangan) --> lampu start "OK" menyala. 22. Latching electrical trip TTV --> dilapangan. 23. Tarik reset mechanical trip (warna putih) --> dilapangan. 24. Angkat reset TTV dengan mendorongnya keatas --> dilapangan. ( setelah lampu start "OK" di EG Panel menyala). 25. Tekan tombol start (di EG 509 Panel). 26. Buka extr valve ramp ke 100% --> lampu menyala (di EG Panel). 27. Tekan Governoor start (dilapangan) maka : - Indikasi Actuator Governoor bergerak ke minimum Governoor. - Posisi Governoor left < 88.9 mm.

Start 1-103-J

102-J 102-JT 103-J 103-JT 104-J 104-JT 104-JA 104-JAT 105-J 105-JT 107-JA 107-JAHT 107-JB 107-JBT 107-JC 107-JCT 108-J 108-JT 108-JA 108-JAT 108-JM 111-J

FEED GAS COMPRESSOR STEAM TURBINE DRIVE FOR 1-102-J SYNTHESIS GAS COMPRESSOR STEAM TURBINE FOR 1-103-J H P B F W PUMP STEAM TURBINE DRIVE FOR 1-104-J H P B F W PUMP A STEAM TURBINE DRIVE FOR 1-104-JA AMMONIA REFRIGERANT COMPRESSOR STEAM TURBINE FOR 1-105-J SEMI LEAN SOLUTION PUMP A HIDROLIC TURBINE DRIVE FOR 1-107-JA SEMI LEAN SOLUTION PUMP B STEAM TURBINE FOR 1-107-JB SEMI LEAN SOLUTION PUMP C STEAM TURBINE FOR 1-107-JC LEAN SOLUTION PUMP STEAM TURBINE FOR 1-108-J LEAN SOLUTION PUMP A STEAM TURBINE FOR 1-108-JA LEAN SOLUTION PUMP BENFIELD SOLUTION TRANFER PUMP

STEAM STEAM STEAM STEAM STEAM BENFIELD STEAM STEAM STEAM STEAM ELECTR ELECTR

28. Naikkan vacuum ke - 500 mmHg. 29. Perlahan buka TTV sehingga running dengan speed 500 rpm. 30. Lakukan test trip pada speed 500 rpm. - Tekan HS-1203 --> CCB atau, - Emergency stop --> dilapangan. 31. Jika ad 30 OK start kembali,ulangi prosedur 20s/d29, tahan speed - 500 rpm 60 menit (termasuk point 30). - 1100 rpm 40 menit. - 1500 rpm 10 menit. - 2500 rpm 10 menit. - 7000 rpm 5 menit. - 9025 rpm (MGS) TTV terbuka lebar. - Catatan :*Hati-hati Critical Speed : - LP Case --> 3645 rpm. - HP Case --> 4405 rpm. - Turbine --> 4050 rpm. - Catat vibrasi pada setiap step. 32. Latching FV-301, FV-303 & FV- 304 (biarkan terbuka lebar) dan switch dari lokal ke CCB (kondisi di lokal 0 % dan di CCB 0 %). 33. Turunkan extraction valve ramp : 0 % (lampu 0 % nyala). 6 35

ITEM 101-L 103-L 104-L 106-L 107-L 108-L 109-L 110-L 111-L 115-L 132-L1 132-L2 132-L3 132-L4 201-L 202-L1 202-L2 202-L3 202-L4 203-L 204-L 206-L 207-L ITEM 101-U 102-U

CLASS L : SPECIAL EQUIPMENT AIR FILTER HYDROGEN RECOVERY UNIT BENFIELD SOLUTION FILTER HYDRAZINE INJECTION SYSTEM AMMONIA INJECTION SYSTEM PHOSPHATE INJECTION SYSTEM BENFIELD ANTI FOAM INJECTION SYSTEM BENFIELD SOLUTIOM MIXER 103-J DISCHARGE SEAL OIL SEPARATOR BENFIELD SUMP FILTER FLASH TANK EJECTOR NO1 FLASH TANK EJECTOR NO2 FLASH TANK EJECTOR NO3 FLASH TANK EJECTOR NO4 PRETREATMENT BENFIELD SOLUTION FILTER FLASH TANK EJECTOR NO 1 FLASH TANK EJECTOR NO 2 FLASH TANK EJECTOR NO 3 FLASH TANK EJECTOR NO 4 PRETREATMENT CO2 STRIPPER SODA ASH SOLUTION INJECTION SYSTEM PRETREATMENT BENFIELD SOLUTION MIXER MASS SPECTROMETER CLASS U : UTILITY EQUIPMENT DEAERATOR CONDENSATE POLISHER

OPERASI BAKU AMMONIA P - IB START UP 1 - 103 - J

Start 1-103-J

1. Siap dan yakinkan dilapangan a,. CW ke 1-116-C terbuka. b. CW ke 1-130-C terbuka. c. Kandungan O2 dicasing Comperssor < 0.5 %. d. Kandungan CO + CO2 gas outlet 1-106-D<10 ppm (CO2 < 0.5 ppm). e. FV-301, FV-303, FV-304 terbuka lebar. f. MOV-1001 & by pass tertutup rapat. g. MOV-1002 tertutup rapat. h. HV-1028 tertutup (posisi latch). I. HC-1029 output 0 % (unlatch). j. SP-020 terbuka lebar. k. SP-022 tertutup rapat. l. 1-103-JTC aktif. m. Siapkan moluculer sieve drier pada posisi yang tepat, tidak menjadi masalah step nomer berapapun. - Yakinkan dilapangan seluruh line 1-109-DA/DB --> Ok. - Yakinkan di CCB / lapangan semua MOV, XV dan PV pada posisi yang benar sesuai dengan step yang ada. - Jaga HS-1012 pada posisi stop. n. PC-0301 output 0% o. FC-1808 output 0% 2. Supply udara ke pedestal seal. 3. Line up oil system. 4. Start lube oil motor dan aktifkan LO ke 1-103-J/JT. - Isi Accumular dan rundown tank sesuai dgn level yg ditentukan. - Stand by kan LO turbine pada posisi auto. - Isikan rundown tank melalui b/p valve (b/p VF-076) sampai lampu Permissive start nyala, lalu tutup b/p (VF-076) valve tersebut. 33

14. Jika SM inlet turbine (TG-253) > 340 0C, perlahan-lahan naikkan tekanan casing ke 14.1 kg/cm2 = PCAH-1071 ( dengan crack open bv suction 1-102-J ) --> hingga terbuka lebar. 15. Jika tekanan casing = PCAH-1071 buka lebar bv suction 1-102-J, dan buka lebar bv down stream FV- 201. 16. Hidupkan power untuk electronic Gov 1-102-J di CCB marshalling. 17. Tekan PB I (start up) --> start lampu "OK". 18. Tekan reset di lokal panel. 19. Tekan PBL I ( start up ) speed akan naik ke 1860 rpm tahan selama 50 menit (heating up) Atur seal steam tekanan 0.2 kg/cm 2 ( catat dan monitor Vibrasi ). 20. Lakukan trip test dengan : - HS-1202 (CCB). - Emergency stop (lapangan).

Start 1-102-J

MCC - 51 POWER SUPPLY DARI UTILITY IB ITEM No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. TAG NO. 112-JM 113-JM 116-JM 202-JM 121-JM 204-JM 109-JM 125-JM 140-JM LCP-01 POWER KW 55 75 55 4 75 0.4 0.55 22 2.2 11 DESCRIPTION 103-JTC Condensate Pump. Warm Ammonia Product pump. CO2 Stripper Quench Pump. Pretreatment Over Head Quench Process Condensate Pump. Soda Ash Solution Injection P Benfield Anti Foam Injection Sys Ammonia Product Mixing Pump. LP Ammonia Scrubber Pump. Local Panel For Air Blower 102-U

21. Bila point 20 "OK" start kembali, ulangi point 17 s/d 19. 22. Tekan PBL 2 (idle/rated) speed akan naik ke min gov 10540 rpm. (catat dan monitor Vibrasi). 23. Pindahkan manual speed control ke process speed control (PC-1010 output : 0%) --> EG Panel. - Drain casing turbine di tutup (2ea). - Drain emergency stop valve ditutup. 24. FV-201 output local panel dibuat 0% di CCB 0% latchuing FV-201 25. Switch control local panel FV-201 ke CCB, output local panel dibuat 100 %. 26. On line kan 1-102-J buka bv disharge pelan-pelan. 27. Atur tekanan gas proses sesuai kebutuhan dengan : - Speed 1-102-J (PC-1010). - Kick back FV-201. * CRITICAL SPEED : Turbine 6200 rpm. Compressor 4600 rpm. 32

11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26.

141-JM 100-OCM 109-LLM 108-LLM 108-LJM 104-JLAM 203-LJM 107-LJM 106-LJM 105-JJM 101-JLM 105-JLM 107-JLBM 125-JLM 101-JJM 101-LLM

15 30 0.4 0.4 0.55 3.7 0.4 0.4 0.4 1.5 30 75 1.5 0.4 1.5 3.7

(102-UJ1M). HP Ammonia Scrubber Pump. Over Head Crane Comp Building. Anti Foam Mixer Injection Syst Phospate Mixer Injection System. Phospate Injection Pump. LO Pump 104-JA Pretreatment Benfield Transfer P Ammonia Injection Pump. Hydrazine Injection Pump. Turning Gear 105-J. LO Pump 101-J. LO & SO Pump 102-J / 105-J. LO Pump 107-JB. Mechanical Pump Seal Pump. Turning Gear 101-J. Air Filter Bleed Fan 101-J. 9

35. Latching HV-1028 , stand by kan HC-1028 =60% buka bv u/s dan d/s HV-1028. Catatan : a. Speed < 1000 rpm semua drain terbuka lebar. b. Speed 1000 <speed 6205 rpm semua drain terbuka 50 %. c. Speed >6205 rpm semua drain tertutup.

Start 1-101-J

ITEM No. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36.

TAG NO. 124-JM 125-JAM 125-JLAM 140-JAM 141-JAM 202-JAM 203-JM 203-LJAM 203-LLM 204-JM 204-LJAM 204-LLM 206-LLM LCC-02 LP-53 LP-53A SRP-54 WO 3 & 4

POWER KW 55 22 0.4 2.2 15 4 3.7 0.4 0.4 2.2 0.4 0.4 7.5 11 40 24 24 66.51

DESCRIPTION Cold Ammonia Product Pump. Ammonia Product Mixing Pump. Mechanical Pump Seal System. LP Ammonia Scrubber Pump. HP Ammonia Scrubber Pump. Pretreatment Over Head Quench. Pre'atment Benfield Injection P Pre'atment Anti Foam Injection P Pretreatment Anti Foam Mixer. Pretreatment Benfield Sump P Soda Ash Solution Injection P Soda Ash Solution Mixer Inject P Pre'atment Benfield Sump Mixer 102-UJ2M Floor Light Floor Light Space Heater Foundation 5101-F Welding Outlet.

TAMBAHAN :

30

11

ITEM No. 27. 28. 29. 30.

TAG NO. LP-51 LP-52 RP-51 WO 1 & 2

POWER KW 40 24 12 66.51

DESCRIPTION Floor Light. Lighting Comp. Building. Receptacle Welding Outlet.

PROSEDUR OPERASI BAKU AMMONIA P - IB START UP 1 - 102 - J

Start 1-102-J

MCC - 52 POWER SUPPLY DARI UTILITY P - IV

ITEM No. 1. 2. 3. 4. 5.

POWER KW 101-BJ1LM 5.5 101-BJ2LM 5.5 103-JLM 45 103-JLM 55 104-JLM 3.7

TAG NO.

DESCRIPTION LO Pump 101-BJ1T LO Pump 101-BJ2T. LO Pump 103-J SO Pump 103-J LO Pump 104-J.

1. Siapkan / yakinkan dilapangan : * CW ke 1-133-C & 1-174-C -terbuka. * FV-0201 -terbuka lebar. * BV down stream FV-0201 -tertutup rapat. * BV discharge 1-102-J -tertutup rapat. * BV suction 1-102-J -tertutup rapat. * BV by pass 1-102-J -terbuka lebar. * Casing Comp 1-102-J sudah dipurging dengan N2 (O2 < 0.5 %). 2. Aktifkan 1-101-JTC. 3. Line Up Lube oil system. 4. Start motor lube oil supply, lube oil ke 1-102-J / JT. 5. Line up seal oil system dan aktifkan oil trap. 6. Press up casing hingga 0.5 kg / cm2 dengan N2. 7. Aktifkan seal oil ke 102-J buka bv u/s & d/s FC-512 control posisi 2 3 auto, naikkan setting FIC-512 pelan menuju normal (3.2 m /h)

10

6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.

106-LJAM 107-JLCM 107-LJAM 108-LJAM 109-LJAM 110-LLM 111-JM 113-JM 114-JM 115-JM 116-JAM 120-JM 121-JAM

0.4 1.5 0.4 0.55 0.55 7.5 11 75 15 5.5 55 7.5 75

Hydrazine Injection Pump. LO Pump 107-JC Ammonia Injection Pump. Phospate Injection Pump. Benfield Anti Foam Injection P Benfield Solution Mixer. Benfield Solutiopn Transfer Pump Warm Ammonia Product Pump. 101-JTC Condensate Pump. Benfield Solution Sump Pump. CO2 Stripper Quench Pump. Ammonia Injection Pump (S/Up). Process Condensate Pump.

8. Isi seal oil over head tank buka bv V-403, b/p LV-203 ditutup, aktifkan LV-203. Apabila level sudah arah naik di S/G, naikkan setting LT-203 ( 1-102-JLF2 ) pelan-pelan searah kenaikan level ke 50 % setting ( 85 % S/G ). Perhatikan LV-203 apabila sudah sudah ngontrol tutup bv V-203. 9. Stand by kan lube oil turbine pada posisi auto. 10. Heating up line SM hingga u/s emerg stop valve (ESV) dengan crack openbv by pass (BV SM inlet 1-102-J). 11. Aktifkan Gland Condenser. 12. Vacum Up (buka butt valve & drain casing ke 1-101-JTC ada 3 ea). 13. Heating up sampai dengan ESV. - a. Buka lebar bv SM inlet turbin dan tutup b/p. - b. Buka lebar bv drain d/s ESV. - c. Buka ESV (dengan meriset turbine trip). 31

ITEM SP-003 SP-004 SP-005 SP-006 SP-008 SP-009A SP-009B SP-009C SP-009D SP-009E SP-010A SP-010B SP-012 SP-013 SP-015 SP-016 SP-017 SP-018 SP-020 SP-022 SP-023 SP-024 SP-025 SP-100 SP-101 SP-102 SP-104 SP-111 SP-132 SP-133 12

SPECIAL PIPING Needle V u/s FI-1101, H2 gas supply to P gas inlet 104-D2 Rupture Disc at CW line outlet tube side 115-C Rupture Disc at CW line outlet tube side 130-C Rupture Disc at by pass HCV-1044, line S G inlet 105-D Rupture Disc at CO2 product line, top outlet 102-E Relief Valve at CO2 product line, top outlet 102-E Relief Valve at CO2 product line, top outlet 102-E Relief Valve at CO2 product line, top outlet 102-E Relief Valve at CO2 product line, top outlet 102-E Relief Valve at CO2 product line, top outlet 102-E Angle blowdown valve at Flutter level 106-F Angle blowdown valve at Flutter level 106-F Rupture Disc at CW line outlet tube side 116-C Rupture Disc at CW line outlet tube side 124-C Drain Separator SLC from 111-C to header SLC 132-L1~4 Rupture Disc at CO2 product line, top outlet 202-E Relief Valve at CO2 product line, top outlet 202-E Rupture Disc at CW line outlet tube side 134-C Solonoid control valve, signal from 103-J --> Back flow Solonoid control valve, signal from 103-J --> SG to 103-J Strainer for seal line 201-J/JA Strainer for seal line 108-J/JA Check Control valve, NHV from 5101-F to 1st suct 105-J Ejector, exhaust turbine 103-JT to 103-JTC Spool between 101-L and Suction line 101-J Silencer vent FV-101, 1st stage discharge line 101-J Rupture Disc at CW line outlet tube side 172-C2 Silencer vent FV-1104, located at CO2 line top out 102-E Silencer header vent locate at top of CO2 stripper 102-E Silencer header vent located above Compressor Shelter

28. Jika point 27 ok start kembali, ulangi prosedure 17 s/d 23 lalu buka kembali TTV ( start running ). a) 500rpm 10 menit ( melanjutkan point 27 ). b) 1000 rpm 40 menit c) 1500 rpm 10 menit d) 2200 rpm 5 menit. e) 4700 rpm 5 menit. f) 6205 rpm 5 menit. TTV terbuka lebar. Catatan : Hati-hati dengan critical speed. a) LPC Compressor 2660 rpm b) HPC Compressor 3930 rpm c) Turbine 3400 rpm d) Catat dan perhatikan kondisi vibrasi ( CCB & lapangan). 29. Tutup extraction valve ramp hingga 0 % ( lampunya nyala ). 30. Aktifkan PC-1012. a) Output PC-1012 = 0%. b) Tekan process extraction control ( EG panel ) --> lampu nyala. c) Buka PC 1012 --> perhatikan steam system imbangi dengan menutup PC-1013. 31. Latching HV-0101 (outputnya 0 % atau valvenya terbuka lebar ), tutup perlahan-lahan hingga rapat, bila perlu naikkan speed 101-J 32. Pindahkan control speed ke FCAL 1003 dengan: a) Buat output FCAL-1003 =0%, extraction valve ramp --> 0% lampu 0% nyala. b) Tekan process speed control di EG panel ( lampu nyala ) 33. Latching FV-102 ( output local panel dan CCB =0% ), speed dinaik kan ke 7000 rpm. 34. Atur tekanan discharge sesuai dengan kebutuhan proses dengan : a) Atur speed control 1-101-J ( FCAL-1003 ) b) FV-102 ( vent discharge 1-101-J ).

Start 1-101-J

29

11. Aktifkan gland condencer dan sealing steam, buka but val exhaust 12. Vacum up ( -250 ~ -300 mmHG). 13. Heating up 1-101-JT . a) Line SH hingga TTV ( T> 450 0C ), buka bv by pass steam SH header bertahap. b) Line SM hingga check valve dan buka drain u/s check valve extractionke 101-JTC, apabila tekanan steam extraction > tekanan SLL, tutup drain tersebut dan aktipkan Steam trap. 14. Sebelum nembuka bv header tutup dahulu drain pemanasan untuk menaikkan tekanan d/s bv sehingga sama dgn tek u/s, buka lebar bv steam SH ( untuk menghindari macetnya bv header ). 15. Stop turning gear dan control oil ke turning gear . 16. On kan power untuk electronic governor 509 di CCB . 17. Reset di CCB ( EG panel). 18. Reset di lapangan --> permisive start ok nyala (di lapangan ). 19. Latching electric trip TTV--> di lapangan ( XV-1001) 20. Tarik resetmechanical trip ( warna putih ) --> di lapangan. 21. Angkat reset TTV ke posisi normal --> di lapangan. Bila lampu condition OK sudah nyala ( EG panel). 22. Tekan start up di CCB --> Speed Ref akan menuju MGS & ECV akan membuka. 23. Buka extraction ramp ke 100%

Start 1-101-J

ITEM SP-134 SP-138 SP-139 SP-140 SP-141 SP-142 SP-143A SP-143B SP-143C SP-143D SP-143E SP-143F SP-143G SP-146A SP-146B SP-148 SP-153 SP-154 SP-170

SPECIAL PIPING Silencer header vent located above Steam Drum Structure 101-F Desuperheater S L L line, outlet PV-1816 Desuperheater S M line, oulet PV-1813 Vent to atmosfier, located at S M line top out 101-U Angle blowdown valve BFW line out 101-F to 156-F Angle blowdown valve BFW line out 101-F to 156-F Angle blowdown valve BFW line out 101-F to 156-F Angle blowdown valve BFW line out 101-F to 156-F Angle blowdown valve BFW line out 101-F to 156-F Angle blowdown valve BFW line out 101-F to 156-F Angle blowdown valve BFW line out 101-F to 156-F Angle blowdown valve BFW line out 101-F to 156-F Angle blowdown valve BFW line out 101-F to 156-F Automatic Recirculation CV, located at disch line 104-J Automatic Recirculation CV, located at disch line 104-JA Relief Valve, located at discharge line 114-J/JA Silencer venting PV-1817 S L L ( Steam Low Low ) line Silencer venting PV-1814 S M ( Steam Middle ) line Desuperheater S M ( Steam Middle )

24. Tekan governor valve start ( lapangan ). a) Indikasi actuator governor bergerak ke min gov = 6300 rpm b) Posisi governor life < 88,9 mm=71%. c) Ikat ZS-151. 25. Vacuum up ke 500mmHG. 26. Perlahan buka TTV ( start running) speed ke 500 rpm selama 60 menit ( heating up ). 27. Lakukan trip test dengan : a) Tekan HS-1201 ( CCB) atau b) Emergency stop ( lapangan).

28

13

HIGH PRESSURE STEAM ( SH ). Tekanan : 123 kg/cm2g Temperatur : 510 0C. Sumber : 1-101-F (Steam Drum). Pemakaian : 1-101-JT, 1-103-JT, 1-173-C, Let Down ke SM, 172-C1 (Waktu Start Up) MEDIUM PRESSURE STEAM ( SM ). Tekanan : 42.2 kg/cm2g. Temperatur : 375 0C. Sumber : Extraction Steam 1-101-JT dan 1-103-JT. : Let Down dari SH --> SM (Waktu Start Up) : Import dari Utility (Waktu Start Up). Pemakaian : Penggerak turbin. : Steam and Air Coil : 1-103-L Heater : 1-140-C : Let Down ke SLL. LOW PRESSURE STEAM ( SLL ) Tekanan : 3.5 kg/cm2g. Temperatur : 219 0C. Sumber : Exhaust Turbine. : Blow Down Drum 1-156-F. : KO Drum 1-157-F. : Leakage Steam : Let Down dari SM --> SLL. Pemakaian : Admission Steam 1-105-JT. : 1-101-U Stripping :1-123-C : Ejector 1-101-JTC dan 1-103-JTC. : Gland Condenser 26 : Export ke UOA

AMMONIA PLANT VENTING SYSTEM ITEM PIC-1799 PIC-1071 * V-1003 * V-1000 V-1005 MOV-1018 V-1007 * V-1008 PIC-1104 PIC-1005 PIC-1004 FIC-1077 V-1017 * SIZE 6 INCH 4 INCH 1,5 INCH 4 INCH 12 INCH 10 INCH 10 INCH 10 INCH 12 INCH 12 INCH 8 INCH 3 INCH 4 INCH POSITION 1-202-E LINE TOP OUT ( F.T ) 1-144-F LINE TOP OUT ( F.T ) 1-102-J OUT, 1-108-D TOP INLET 1-108-D LINE BOTTOM OUT 1-102 C OUT, 1-104-D1 INLET 1-104-D1 OUT, 1-104-D2 INLET 1-104-D2 LINE BOTTOM OUT 1-102-F1 TOP OUT, 1-101-E IN 1-102-E LINE TOP OUT LOSS CO2 CO2 CO2 CO2 CO2 CO2 CO2 CO2 CO2

1-102-F2 TOP OUT, 1-106-D IN P. GAS 1-104-F TOP OUT, 1-103-J INLET P. GAS 1-120-C CHIL OUT, 1-103-J 4th INS. GAS 1-121-C S.SIDE OUT, 1-124-C IN S. GAS

KETERANGAN ITEM * V-1000 Jarang dipakai. 1. Disebut Vent inlet bila 1-108- D belum aktif, 1-108-D di by-pass melalui b.v 6". 2. Disebut Vent outlet bila 1-108-D sudah aktif. Jarang dipakai. Dipakainya hanya waktu Reduksi Katalis. 15

V-1007

ITEM F-D103 D-A101A D-A101B C-E102 F-D101 F-D102 C-E102A C-E102B

HYDROGEN RECOVERY UNIT SERVICES WATER KNOCK OUT DRUM ABSORBER A ABSORBER B REGENERATION GAS HEATER H2 SEPARATOR BLOW DOWN DRUM FEED / PRODUCT HEAT EXCHANGER A FEED / PRODUCT HEAT EXCHANGER B

Start 1-101-J
PROSEDUR OPERASI BAKU AMMONIA P - IB START 1 - 101- J 1. Yakinkan di lapangan : CW ke 1-101-JCA terbuka CW ke 1-101-JCB terbuka CW ke 1-101-JC1 terbuka CW ke 1-101-JC2 terbuka CW ke 1-101-JC3 terbuka 2. Yakinkan di CCB dan di lapangan a) FV-0102 terbuka lebar (TV-1312 : posisi b/p) b) HV-0101 terbuka lebar (BP-1006 : By-Pass) c) MOV-1006 & BV by pass tertutup d) FV-1065 tertutup ( udara ke utilitas ) e) ECV terbuka lebar f) FCAL-1003 output 0 % ( manual ) g) PC-1012 output 0 % ( manual ) h) HV-1028 output 0 % ( manual ) i) HV-1029 output 0 % ( manual ) j) BV- u/s & d/s HV-1028 tertutup ( lapangan ) 3. Aktifkan 1-101 JTC. 4. Supply udara ke pedestal seal. 5. Line up lube oil. 6. Jalan kan motor lube oil , aktifkan lube oil ke 1-101- J/JT. 7. Stand bykan lube oil turbine pada posisi auto.

ITEM 103-E 104-E 105-E

AMMONIA RECOVERY UNIT L P AMMONIA SCRUBBER H P AMMONIA SCRUBBER AMMONIA STRIPPER

14

8. Drain casing compressor dan buka drain u/s MOV-1006. 9. Heating up line 1-101-JT. a) Line SH hingga u/s bv header. b) Line SM hingga bv extraction. 10. Aktifkan control oil ke turning gear , aktifkan turning gear.

27

1-101-JT : STEAM TURBINE PROCESS AIR COMPRESSOR Type : Extraction & Condensing Turbine Motive Steam : 123,00 Kg/Cm2G Extraction Steam : 42,20 Kg/Cm2G Steam Comsumtion : 109.120 Ton/Hr Steam Extr product : 97.920 Ton/Hr Steam exhaust product : : 10.200 Ton/Hr Speed : 7300 RPM 101-JTC : Surface Condenser 101-JTCC : Inter/After Condenser1-101-JTC 1-101-JTC 114-J/JA : Condensate Pump 1-101-J : PROCESS AIR COMPRESSOR Type : Centrifugal Stage : 3 ( 1 - 2 ) Stage at LP & HP Case Capacity : 52596 NM3/Hr Pressure Suction/Dicharge : 0,99 / 38,95 Kg/Cm2A Temperatur Suction/Discharge : 35 C / 183 C 101-LJ : Air Filter Bleed Fan 101-L : Air Filter 101-JC1 : 1st Integral Intercooler 101-JC2 : 2nd Integral Intercooler 101-JC3 : 3rd Integral Intercooler 101-JCA : Air Compressor 2nd Stage Intercooler 101-JCB : Air Compressor 3rd Stage Intercooler FV-101 : Venting discharge 1st Stage FV-1065 : Flow Process Air to Instrument Air/P.A PIC-1791 : Press Process Air to Instrument Air/P.A FV-102 : Venting discharge 3rd Stage SP-102 : Silencer venting FV-101 & FV-102 MOV-1006 : Emergency Control Valve disch 3rd Stage FIC-1003 : Control Governoor 1-101-JT 16 HIC-1021 : MP Steam inject for Emergency Shut Down

a. By-pass 1-108-D. b. By-pass CO2 Removal Feed Treating (201-E). c. Regenerasi Benfield system untuk feed treatment. d. Drain larutan Benfield ke tangki. 23. Turunkan temperatur riser dari 760 0C ke 380 0C. 24. Stop steam MS ke Primary Reformer. 25. Matikan Arch burner secara bertahap. 26. Stop gas di Battery Limit. a. Turunkan tekanan HS ke 45 kg/cm2g. b. Stop 1-101-BU. c. Persiapan Hydrostatis test BFW & HP System. d. Pelaksanaan Hydrostatis test BFW & HP System. e. Matikan BFW pump (1-104-J). 27. Pendinginan dapur hingga temperatur 35 0C. 28. Stop ID dan FD fan. PERHATIAN KHUSUS SELAMA SHUT DOWN : 1. Molucular Sieve Dryer 1-109-DA akan diganti pada TA ini, usaha kan sebelum shut down sudah dalam keadaan te-regenerasi. 2. Flash Drum (120-CF) akan dilakukan pemeriksaan internal part, matikan 1-105-J setelah level minimum dan lakukan pengamanan secepatnya. 3. Pekerjaan kritis selama TA adalah penggantian CAP, usahakan proses cooling down dapur dapat dilaksanakan secepat mungkin. 4. Tube 1-127-C, 1-128-C dan 1-124-C diduga bocor, lakukan pengamanan khusus saat shut down.

25

PROSEDUR SHUT DOWN NORMAL AMMONIA P - IB 1. Start My Comp (5103-L), atau tie-in vapour dengan pabrik lain. 2. Shut down Hydrogen Recovery Unit (HRU). 3. Shut down Ammonia Recovery Unit (ARU). 4. Switch Synthesis Gas dari P-IV (tie-in) untuk 1-108-D. 5. Cut rate gas ke 80 %. 6. Shut down loop dan vent gas di PC-1004. a. Stop Synthesis gas Compressor 1-103-J. b. Penggosongan Refrigerant System / pump out. c. Stop Refrigerant Compressor (105-J) bila level sudah minimum 7. Stop CO2 tie-in setelah Urea Plant Shut down. 8. Stop udara ke Utility Plant. 9. Cut rate gas ke 70 %, vent PV-1004 dan b/p = 30 kg/cm 2g. 10. Shut down 150-E dan drain condensate ke sewer, b/p = 26 kg/cm 2. 11. Shut down Methanator (1-106-D) dan vent di PC-1005. 12. By pass Low Temperatur Shift Converter (LTS). 13. Cut rate gas ke 50 % dan b/p = 24 kg/cm2g. 14. Stop gas ke CO2 Absorber (101-E) dan vent gas di MOV-1018. a. Regenerasi Benfield System, FC < 0,20 b. Sirkulasi cooling down larutan benfield. c. Drain larutan Benfield ke tangki. 15. Cut rate gas ke 40 %. 16. Stop udara ke Secondary Reformer. 17. Stop Air Comperssor (1-101-J). 18. Turunkan tekanan HS ke 56 kg/cm2g . 19. Cut rate gas ke 25 %. 20. Stop gas ke Primary Reformer. 21. Stop Feed Gas Compressor (1-102-J). 22. Start Oksidasi katalis Primary dan Secondary Reformer hingga

Note

: FV-1065 & PIC-1791 One Control Valve from 1st discharge. : 3rd discharge to 1-101-BC4 --> 1-101-BC2 --> 1-103-D. : HIC-1021, Steam injectie for safety coil line because air to coil lossed (1-102-J trip)

LUBE OIL SYSTEM 1-101-JT 101-JLF1 : Oil Reservoir 101-JLJ : Oil Pump J 101-JLJA : Oil Pump JA 101-JLJAT : Steam Turbine 101-JA, Back P T. MS -> SLL 101-JLCA : Lube Oil Cooler A 101-JLCB : Lube Oil Cooler B 101-JLLA : Lube Oil Filter A 101-JLLB : Lube Oil Filter B 101-JLF2A : Lube Oil Accumulator A 101-JLF2B : Lube Oil Accumulator B 101-JLF3 : Control Oil Accumulator 101-JLF4 : Run Down Tank PV-134 : Regulator Valve, setting Press : 7,5 K PV-135 : C.O --> L. O setting Press : 2,0 K 1-102-JT : STEAM TURBINE FEED GAS COMPRESSOR Type : Condensing Type Motive Steam : 42,2 Kg/Cm2G Steam Consumtion : 9,123 Ton/Hr Steam Exhaust product ( 101-JT + 102-JT + 104-JT/JAT ) : 25,175 Ton/Hr Sealing Steam : PV-257 SLL = 3,5 Kg/Cm2G

non condensible gas = nil.

24

Speed

: 12400

RPM

17

PROSEDUR OPERASI BAKU AMMONIA P - IB START UP AMMONIA P - IB Prosedur : 1. Firing awal memakai fuel gas dari gas yang ke 144-F (gas bersih). 2. Naikkan temp flue gas menuju ke > 350 0C, kenaikan temperatur 60 0C/jam (TI-1321 s/d TI-1335). - Stop N2 ke 1-102-B. - Masukkan steam proses ke 1-101-B, buka seluruh drain riser, 1-101-C/1-103-C. - Buka vent V-1005. - Masukkan steam ke coil udara, temperatur coil < 600 0C. - Masukkan steam sparger ke 1-104-D1 (H.T.S). - Temperatur flue gas inlet 1-101 BC5 (TI-1445 > 350 0C) start vent gas di V-1000 out 1-108-D --> Start heating up 1-108-D. - Rate gas 20 % ~ 25 %. 3. Naikkan tekanan steam HS > 45 Kg/cm2 (6 ~ 10 kg/cm2), steam HS sudah di let down ke MS). 4. Temp inlet HTS TC-1010 > 170 0C, pindahkan vent steam proses dari V-1005 ke MOV-1018, stop sparger di HTS, back press +7 k 5. Switch fuel gas dari 144-F ke fuel out 200-F bila TI-1418 >115 0C 6. Heating up 1-102-JT --> Start 1-102-JT. (lihat detail prosedur Start 1-102-J). 7. Bila temperatur riser 760 0C, masukkan gas ke 101-B, jaga temp tetap 760 0C dengan menambah Firing, tutup semua drain riser, drain 1-101-C, drain 1-103-C. 8. Naikkan rate gas ke 40 % bertahap, back press + 10 kg/cm 2g. 9. Naikkan tekanan HS steam menuju ke 123 kg/cm2g. 10. Heating up 1-101-JT --> Start 1-101-JT. (lihat prosedur Start 1-102-J). 11. Naikkan rate gas 40 % --> 50 %. 22

1-103-JT : STEAM TURBINE FOR SYNTH GAS COMPRESSOR Type : Extraction & Condensi'g Turbine Motive Steam : 123,0 Kg/Cm2G Extraction Steam : 42,2 Kg/Cm2G Steam Consumtion : 107,293 Ton/Hr Steam Exhaust Product : 71,782 Ton/Hr Speed : 10535 RPM 103-JTC :Surface Condenser 103-JTCC : Inter/After Condenser 1-103-JTC 112-J/JA : Condensate Pump 103-J : SYNTHESIS GAS COMPRESSOR Type : Centrifugal Stage : 4 (2 - 2) Stage at LP & HP Case Capasity LP Case : 164714 NM3/Hr Pressure Suction/Discharge : 32,59/ 99,85 Kg/Cm2A Temperatur Suction/Discharge : 37 C / 115 C Capasity HP Case : 609823 NM3/Hr Pressure Suction/Discharge : 98,88 / 179,31 Kg/Cm2A Temperatur Suction/Discharge : 4,4 C / 42,3 C 104-F : Synthesis Gas Compressor Suction Drum 130-C : Synt Gas Compressor 1st Stage Cooler 105-F1 : Synt Gas Comp 1st Interstage Separator 116-C : Synt Gas Compressor Inter Cooler 129-C : Synt Gas Compressor Interstage Chiller 105-F2 : Synt Gas Interstage Separator 109-DA : Molucular Sieve Drier A 109-DB : Molucular Sieve Drier B 111-L : 1-103-J Discharge Seal Oil Separator FIC-301 : Kick Back from 105-F2 to line 1st suction MOV-1017 : Control Valve Inlet 109-DA XY-1164 : C V Regeneration outlet 109-DA to 114-C 19

1-102-J : FEED GAS COMPRESSOR Type : Centrifugal Stage : 1 Stage Capacity : 29009 NM3/Hr Pressure Suction/Discharge : 13,74 / 44,67 Kg/Cm2A Temperatur Suction/Discharge 37,8 C / 156 C 133-C : Feed Gas Compressor Kick Back Cooler FV-201 : Kick Back Flow Control Valve LUBE OIL SYSTEM 1-102-JT : 102-JLF1 : Oil Reservoir 102-JLJ : Oil Pump J 102-JLJA : Oil Pump JA 102-JLJAT : Steam Turb 102-JLJA, Back P T, MS -> SLL 102-JLCA : Lube Oil Cooler A 102-JLCB : Lube Oil Cooler B 102-JLLA : Lube Oil Filter A 102-JLLB : Lube Oil Filter B 102-JLF2A : Control Oil & Lube Oil Accumulator A 102-JLF2B : Control Oil & Lube Oil Accumulator B 102-JLF3 : Control Oil & Lube Oil Accumulator 102-JLF2 : Lube Oil Run Down Tank 102-JLF4 : Over Head Tank 102-JLF5 : Degassing Tank 102-JLL2A : Seal Oil Trap outboard Compressor 102-JLL2B : Seal Oil Trap inboard Compressor PV-543 : Regulator Control Valve, setting 18,5 Kg/Cm PV-544 : CV CO for 102-J & 105-J, setting 7,5 Kg/C PV-545 : CV LO for 102-J & 105-J, setting 2,0 Kg/C FV-511 : F V Seal Oil for 105-J, setting 7,6 M3/Hr FV-512 : F V Seal Oil for 102-J, setting 3,2 M3/Hr 18

12. Masukkan udara ke 1-103-D. 13. Naikkan rate gas 50 % --> 60 %. 14. Masukkan gas ke Absorber, back press + 22 kg/cm 0 g --> jalankan 1-107-JHT (lihat prosedur Start Gas masuk ke 1-101-E). 15. Heating up LTS --> aktifkan 1-150-E. (lihat prosedur detail Start Up 1-105-E). 16. Heating up 1-105-JT --> Start 1-105-JT. (lihat prosedur detail Start Up 1-105-JT). 17.CheckCO/CO2 out 1-101-E < 1 % --> Heating up 106-D --> aktifkan. 18. Heating up 1-103-JT --> Start 1-103-JT. (lihat prosedur detail Start Up 1-103-JT). 19. Aktifkan squence 1-109-D --> Regeneration. 20. Press up --> Heating up 1-105-D. (lihat prosedur detail Start Up 1-105-D).

23

MOV-1015 PV-1047 MOV-1160 MOV-1013 XY-1165 MOV-1016 PV-1048 PV-1049 173-C 157-F TV-1030A TV-1030B FI-1046 FIC-303 FIC-304 MOV-1002 MOV-1001 HIC-1279 134-C

: Control Valve outlet 109-DA : Control Valve Depress 109-DA. : Gas Inlet regen 109-DA : Gas inlet109-DB. : Control valve gas out Ex regen 109-DB. : Gas outlet 109-DB : Control Valve Depress 109-DB. : Gas untuk press up 109-DA/DB. : Molucular Sieve Regeneration Heater : Low Pressure Condensate K. O. Drum : Line gas untuk cooling A & B. : Line gas untuk heating (heater) A/B. : Flow regen, Cooling /heating. : Kick Back to 3rd suction from 4th dicharge : Kick Back to 4th suction from 4th discharge : Ctrl to 4th suct from 120-C out tube Chiller : 4th dicharge line : 4th dicharge venting : Synt Gas Compressor kick back Cooler

103-JLL2A : Filter Oil 103-JLL2B : FilterOil LV-340 : Regulator Seal Oil LV-341 : C V Seal Oil Supply LPC LV-344 : C V Seal Oil Supply HPC 103-JLF4 : L P Seal Oil Head Tank 103-JLF5 : H P Seal Oil Head Tank 103-JLL3A : L P Seal Oil Trap 103-JLL3B : L P Seal Oil Trap 103-JLL3C : H P Seal Oil Head Tank 103-JLL3D : H P Seal Oil Head Tank 103-JLF2 : Accumulator

1-105-JT : STEAM TURBINE FOR REFRIGERANT COMPRESSOR Type Motive Steam Admission Steam Steam Consumtion : Admission & Condensing turbine : 42,2 Kg/Cm2G. : 3,5 Kg/Cm2G. SH : 14,570 T/H. SLL : 15,680 T/H. Steam Exhaust Product : 30,250 T/H. Speed : 10200 Rpm. 103-JTC : Surface Condenser. 103-JTCC : Inter/After Condenser 1-103-JTC. 112-J/JA : Condensate Pump. 105-J : REFRIGERANT COMPRESSOR Type : Centrifugal. Stage 4 ( 2 - 2 ) Stage at LP & HP Case. Capasitas : 1357850 Nm3/H. Pressure Suction/Discharge : 1,04 / 15,23 Kg/Cm2G. 21

LUBE OIL SYSTEM 1-103-J : 103-JLF1 : Oil Reservoir 103-JLJ1 : Oil Pump J1 103-JLJ1A : Oil Pump J1A ( turbine ) 103-JLCA : Oil Cooler A 103-JLCB : Oil Cooler B 103-JLF3 : L O Run Down Tank 103-JLL1A : Oil Filter A 103-JLL1B : Oil Filtre B PCV-324 : C O --> L O : 2 K ( Oil Inst d/s PCV-324 ) 103-JLJ2 : Seal Oil Pump J2 103-JLJ2A : Seal Oil Pump J2A ( turbine ) 20

10. Bila temperatur katalis 1-105-D inlet bed # 1 (TI-1379 ~ 1382) mencapai + 260 0C sudah mulai terjadi reaksi, terlihat dgn naiknya temperatur outlet bed # 1 (TI-1387 ~ 1384) melampaui temp inlet bed # 1. Perhatikan level 106-F (LC-1013), bila level mengarah naik, aktifkan LV-1013. Stop make up ammonia ke 1-109-F, bila produksi ammonia di 1-106-F sudah kontinyu. 11. Bila temp inlet bed # 1 1-105-D (TI-1379 ~ 1382) sudah mencapai 350 0C mulai tambah pembukaan HCV-1044. Buka secara bertahap sambil memperhatikan flow FI-1257 dan FI-1105. Jaga agar flow gas ke 102-B, FI-1257 tidak turun, atur dgn me nambah bukaan MOV-1002 serta kick back dan speed 103-JT, ber tahap naikkan tekanan syn loop sampai + 105 kg/cm2 g. 12. Lanjutkan membuka HCV-1044 dan MOV-1002 secara bertahap sampai terbuka lebar, sambil memperhatikan temperatur bed katalis 1-105-D, jangan sampai turun. Tambah load dan tekanan syn loop , dgn mengatur beban 103-J. 13. Bila semua bed katalis 1-105-J sudah ada reaksi dan temperatur outlet bed # 1, 2A, 2B sudah lebih dari 420 0C, atau temp inlet bed #1 (TI-1379) sudah > 360 0C, stop / matikan burner 1-102-B. Tutup rapat HCV-1045 bila temperatur gas outlet 1-102-B sudah lebih rendah dari temp inlet bed # 1 105-D (TI-1396 < TI-1379). 14. Bila temp gas outlet 105-D TI-1374 > 430 0C dan temperatur gas inlet TI-1373 > 220 0C mulai tutup HCV-1046 secara bertahap utk menurunkan temperatur gas inlet 1-105-D = 215 0C ~ 220 0C, (lihat prosedur steaming 1-123-C).

Start Up Synthesis Loop

BUKU

PINTAR
DISALIN DAN DISUSUN KEMBALI
OLEH
ZAINAL ABIDIN # 710683

46

4. Press up Syn Loop sampai > 90 kg/cm2g melalui by pass MOV-1001, kemudian buka lebar MOV-1001 dantutup by pass nya. 5. Bukaan MOV-1002 + 2 %, perhatikan temp bed katalis 105-D bila sudah ada reaksi (kenaikan temp) di bed # 1>3200C (TI-1379), atau temp inlet bed # 2 lanjutkan membuka MOV-1002 secara bertahap sampai terbuka lebar. Sambil menambah load syn loop dengan mengatur speed dan kick back 1-103-J. 6. Adjust vent purge FC-1077. 7. Adjust kick back 103-J (FIC-301, FIC-303, FIC-304) secara manual 8. Adjust speed 1-103-J --> masukkan fresh gas sampai PC-1004 tertutup. 9. Bila 1-106-F sudah ada kenaikkan level aktifkan LC-1013 bv u/s di trottle. 10. Apabila product NH3 mulai banyak, tutup injeksi NH3 ke 1-109-F. 11. Bila temperatur gas outlet 105-D, TI-1374 > 430 0C dan temp gas inlet TI-1373 > 220 0C mulai tutup HCV-1046 secara bertahap utk menurunkan temperatur gas inlet 1-105-D, temperatur gas inlet (TI-1373) di jaga > 215 0C. Bila HCV-1046 sudah tertutup rapat, atur temperatur inlet bed # 1 dgn membuka HC-1025, perhatikan tekanan SH, dan fuel ke aux boiler (101-BU). 12. Auto kan kick back FIC-301, FIC-303, FIC-304. 13. Jaga FC-1020 + 75 T/H, Manual = 40 % TI-1370 > 200 0C dan TI-1371 > 190 0C.

Start Up Synthesis Loop

PRESS / TEMP STEAM ITEM No P S/T : 7,4 / 10,5 Kg CO2 Stripper Quench / 132-C 0 T S/T : 100 / 130 C. LP BFW Exchanger P : 6,3 Kg Steam Blow Down Drum 156-F T +/- : 180 / 19 deg C. P : 5,3 Kg Low Pressure Condensate 157-F T +/: 320 / 19 deg C. KO Drum P S/T : 140.6 / 36.2 Kg Start Up Heater. 172-C1 T S/T : 360 / 360 0C. P S/T : 112 / 140.6 Kg Molucular Sieve Regeneration 173-C T S/T : 350 / 360 0C. Heater P Hot/C : 10,5 /10,5 Kg Stripper Condensate Cooler 174-C T Hot/C : 100 /100 0C P S/T : 5,3 / 2,9 kg Pretreatment CO2 Stripper 203-C T S/T : 270 / 180 0C. Steam Reboiler ITEM No 101-E 102-E 103-E 104-E 105-E 150-E 201-E PRESS / TEMP EXCHANGER P : 36.2 Kg Carbon Dioxide Absorber T +/- : 150 / 19 deg C P : 1,78 Kg Carbon Dioxide Stripper T +/- : 150 / 19 deg C P : 12,5 Kg LP Ammonia Scrubber T +/- : 150 / 19 deg C P : 18,8 Kg HP Ammonia Scrubber T +/- : 150 / 19 deg C P : 17,6 Kg Ammonia Stripper T +/- : 224 / 19 deg C. P : 46,4 Kg Process Condensate Stripper T +/- : 398 / 19 deg C. P : 15,8 Kg Pretreatment Carbon Dioxide T +/- : 150 / 19 deg C.Absorber P : 1,76 Kg Pretreatment Carbon Dioxide T +/- : 150 / 19 deg C.Stripper

48

202-E

89

HC-1025 dan HC-1026 tertutup. Aktifkan rupture disc SP-006 (bila belum aktif). Stand by kan LV-1013 (106-F) bv up stream nya biarkan tertutup. Lepaskan conector / selang N2 untuk purging / blanket, bila masih terpasang. 2. Atur dan naikkan tekanan discharge 1-103-J sampai > 90m kg/cm2. 3. Buka bv by pass MOV-1001, naikkan tekanan syn loop menuju 21 kg/cm2 g dengan laju kenaikan maksimum 2 kg/cm2 g per menit. 4. Perhatikan temperatur Skin/metal shell 105-D TI-1395A-Y, bila temperatur < 30 0C lakukan warming up. - Buka vent V-1017,jaga tekanan sys loop PI-1905 mantap 21 kg/cm 2 dgn menambah bukaan by pass MOV-1001 dan pengaturan 1-103-J. - Jaga kondisi tersebut hingga temperatur shell 105-D TI-1395A-Y rata-rata 30 0C. 5. Lakukan leak test / check explosive semua flange dan perbaiki bila ada kebocoran. 6. Bila temp shell 105-D rata-rata 30 0C, tutup V-1017. Naikkan tekanan syn loop 100 kg/cm2g per jam hingga sama dgn tekanan discharge 1-103-J buka lebar MOV-1001 dan tutup by pass nya. 7. Lakukan leak test / check explosive. 8. Atur : - flow ke 1-105-D + 45000 Nm3/H (FI-1105 + 0.7 div). - flow ke 1-102-B + 45000 Nm3/H (FI-1257 + 3.5 div). dengan cara membuka MOV-1002 dan mengurangi pembukaan HCV-1044 + 10 %. terbuka, dan membuka FC-1077 (OP + 30 %). Jaga tekanan syn loop mantap > 90 kg/cm2g, dgn mengatur kick back dan speed 1-103-JT. 9. Nyalakan burner 1-102-B. (sebelum melakukan purging dengan SLL minimal 15 menit). Atur kenaikan temp gas outlet 102-B TI-1396, 40 0C~60 0C / jam Naikkan terus sampai temperatur katalis 1-105-D mencapai 3500C ~ 3700C. 45

Start Up Synthesis Loop

ITEM No 101-L 101-LJ 103-L 104-L 110-L 111-L

PRESS / TEMP

FILTER / TANK Air Filter Air Filter Bleed Fan output :3,7 KW - 4 P Hydrogen Recovery Unit

Type : Turbo Cap : 7000 m3 / H

P : 49,0 Kg Benfield Solution Filter T +/- : 150 / 5 deg C. Cap : 32 m3 / H Benfield Solution Mixer P T +/P T +/-

: 188,0 Kg 103-J Discharge Seal Oil : 150 / 5 deg C. Separator : 6,5 Kg Benfield Sump Filter 115-L : 123 / 19 deg C. Flash Tank Ejector 132-L1;L2;L3;L4 201-L : 33,7 Kg Pretreatment Benfield : 123 / 5 deg C.Solution Filter Flash Tank Ejector 202-L1;L2;L3;L4 Anti Foam Injection Packed Soda Ash Solution Injection System P T +/-

15. Bila HCV-1046 sudah tertutup rapat, atur temperatur inlet bed # 1 dengan membuka HC-1025. Catatan : - Temperatur flue gas 1-102-B, TI-1397 maximum 834 0C. - Flow gas ke 102-B, FI-1257 min 3.1 div (setting trip FSLL-1257 = 39000 Nm3/H) - Batasan tekanan PI-1905 dan temp 102-B TI-1396 (lihat curva). - Temperatur metal skin / shell 105-D, TI-1395 A-Y max 282 0C. - Beda temp skin/shell 105-D antara top dan bottom max 75 0C. - Kenaikkan tekanan syn loop maximum 2.0 kg/cm2g per jam. B. Start Up 1-105-D tanpa start up Heater 1-102-B (Bila temperatur bed katalis 1-105-D rata-rata 200 0C). 1. Line Up. - Stand by kan FC-1077 --> posisi tertutup. - Stand by kan FC-1108. - Stand by kan PV-1033, 1-104-E di by pass. - Stand by kan PV-1032, 1-103-E di by pass. - BV V-1017 --> tertutup. - Buka lebar HCV-1044, HCV-1046 --> terbuka lebar. - HCV-1045, HC-1025 --> tertutup. - MOV-1001, MOV-1002 --> tertutup. - Aktifkan SP-006 (bila belum di aktifkan). - LV-1013 (1-106-F), stand by. - Minta analisa gas outlet Methanator (1=106-D). - Steam Drum (1-101-F) control 1 element. 2. 1-105-J jalan. Refrigerant system, level & tekanan normal, injeksi ammonia dari 1-5101-F --> ke 1-109- F. 3. 1-103-J jalan. PC-301 Op = + 20 % man, 129-C aktif, 109-D regenerasi aktif.

Start Up Synthesis Loop

203-L 204-L

90

47

PROSEDUR OPERASI BAKU AMMONIA P - IB START UP SYNTHESIS LOOP

Start Up Synthesis Loop

DAFTAR ISI
AMMONIA PLANT Ammonia Symbol Unit Description Process Equipment MCC - 51 Power Supply dari Utilitas P-IB MCC - 52 Power Supply dari Utilitas P - IV Special Piping Hydrogen dan Ammonia Recovery Unit Ammonia Plant Venting System 1-101-JT : Steam Turbine Process Air Compressor 1-102- JT : Steam Turbine Feed Gas Compressor 1-103- JT : Steam Turbine for Synt Gas Compressor 1-105 - JT : Steam Turbine for Refrig Compressor Prosedur Operasi baku Ammonia P - IB, S/U NH3 - IB Prosedur Shut Down normal Ammonia P - IB Prosedur Operasi baku Ammonia P - IB, Start 101-J Prosedur Operasi baku Ammonia P - IB, Start 102-J Prosedur Operasi baku Ammonia P - IB, Start 103-J Prosedur Operasi baku Ammonia P - IB, Start 105-J Prosedur Operasi baku Ammonia P - IB, Loading NH3 Prosedur Operasi baku Ammonia P - IB, S/U Synt Loop Prosedur Operasi baku Ammonia IB, S/U 105-J tanpa 102-B Prosedur Operasi baku Ammonia P - IB, Gas -->101-E Item Instrument Halaman 1 1 2 9 10 12 14 15 16 17 19 21 22 24 27 31 33 37 41 44 47 49 52 I

* Yang dimaksud dengan start up syn loop adalah mengaktifkan / heating up Ammonia Converter 1-105-D, hingga memproduksi Ammonia. ( Katalis Amm Converter 105-D sudah tereduksi ) A. Heating up 1-105-D dengan start up heater 1-102-B. B. Heating up 1-105-D tanpa start up heater 1-102-B. - Persiapan : - Rate gas = 85 % (minimum), vent di PC-1004. - Analisa gas outlet Methanator, CO/CO2 < 5 ppm, H2/N2 = 2.8~3.0 - Syn gas compressor 1-103-JT sudah di start, total kick back. - Molucular Sieve Dryer 1-109-D sudah beroperasi normal. - Compressor 105-J sudah di start dan refrigerant system sudah aktif. Flash Drum 1-120-CF1 ~ 4 normal level, sirkulasi ammonia storage <----> storage. - MOV-1001 dan MOV-1002 masih tertutup. - Siapkan log sheet khusus heating up 1-105-D. PELAKSANAAN A. Heating Up 1-105-D dengan start up heater 1-102-B. 1. Line Up. - Stand by kan FV-1077, FC-1077 posisi closed (manual). - Stand by kan PV-1108 (107-F), PC-1108 SP = 15 kg/cm 2 g (auto). - Stand by kan PV-1033, PC-1033 SP = 85 kg/cm 2 (auto) 104-E di by pass. - Stand by kan PV-1032B, PC-1032 SP = 10 kg/cm 2 g (auto) 103-E di by pass line down stream PV-1032A ke Fuel system tertutup. - BV vent V-1017 tertutup. - Buka lebar HCV-1044, HCV-1045, HCV-1046. 44

- Lihat temperatur dari TG didekat V3, jika terasa lambat dalam Cooling down valve-valve tersebut bisa ditambah. 0 - Jika temperatur + -17 C loading ke kapal bisa dimulai.

Loading Ammonia

EMERGENCY SHUT DOWN 1 - 101- J Trip 1 - 102- J Trip

Halaman 125 125

5. CARA MENGAKTIFKAN ALF - Yakinkan level minyak hydroulic ALF (level diatas 60 %). - Buka pintu panel. - Switch control power "ON" --> Alarm berbunyi. - Reset ERC Alarm --> Alarm bunyi mati. - Reset Pre Alarm --> Alarm bunyi mati. - Reset Power --> Lampu indikasi akan nyala (hijau). - Putar posisi ke posisi Manoeuvre (penggerak). - Lepas kunci gerakkan ke bawah. - ALF dapat dioperasikan dari panel. - Jika ada Pre Alarm sewaktu Manoeuvre (digerakkan) kembali ke sebelum Manoeuvre dan Reset Pre Alarm. - Sambungkan flange (jangan lupa pasang gasket) dan posisikan pengaturan ke "frewheel" dari Control Panel (pindahkan dari posisi Manouvre ke posisi Free Wheel). 6. CARA LOADING AMONIAK - Sambungan flange ALF ke kapal sudah terpasang. - Cooling down s/d bv 10" pakai selang, cooling down line sampai berkeringat / icing. - Buka bv 10" (product valve) melalui panel. - Buka bv V6 menuju ke terbuka lebar, tutup bv V5. - Jalankan pompa 5201-J dengan posisi total kick back. - Tambah bukaan bv by pass discharge bertahap, perhatikan tekanan disch (PSLL-4323 : 5.8 kg/cm2g) dan bertahap tutup bv by pass. - Apabila masih kurang flow tersebut, kurangi Min flow, jika masih kurang tambah bukaan V3. 42

1 - 103 - J Trip 1 - 105 - J Trip 1 - 104 - J Trip Rincian dari S/D Synt Loop; HRU dan ARU 1-101-BJ2T Trip ANEKA TROUBLE P- IB Kehilangan Vacuum di 1-101-JTC DCS kehilangan Power GADO - GADO DARI P - IB UREA P - IB AMMONIA P - IB UTILITAS - IB PPU RINCIAN START UP AMMONIA PLANT SHUT DOWN AMMONIA PLANT UTILITY STEAM PRODUCT GAMBAR DIAGRAM ALIR DISTRIBUSI GAS PUSRI P-IB SHIFT SUPERVISOR - GAWEAN DAN PERLU TAU. 1-101-J Trip 1-102-J Trip; 1-103-J Trip. 1-104-J Trip; 1-105-J trip; 1-124-J Trip.

126 126 126 127 128

129 130

132 137 143 146 147 151 153

154

155 156 157 iii

Instrument Ammonia DCS Schematic

Process Design Basis Ammonia P-IB


GAMBAR : Feed Treatment Section - CO2 Pretreatment section Feed Gas Compressor Section - Process Air Section Reforming / Shift Conversion Section CO2 Removal Section Methanator & Synthesis Section NH3 Refrigerant Section Purge Gas Recovery Unit Demin Water & BFW Section UTILTY PLANT

halaman 74 87 88

- Tunggu + 1 jam, jika rate cukup maka loading dimantapkan. - Untuk penambahan/pengurangan diatur dari bv V3 ( bisa juga dari discharge pompa ).

Loading Ammonia

99 100 101 102 103 104 105 106

Unit Description

Water Treatment Cooling Tower Chemical Injection Electric Power Generator - Sub Station W H B - P B - P A & I A - Gas Metering River Water Intake Ammonia - Utility Unit Waste Water Treatment Prosedur Start Up W H B Prosedur Start Up G T G Prosedur Start Up P B

107 108 109 110 110 111 112 112 112 113 118 121

7. SETELAH SELESAI LOADING - Buka lebar bv min flow pompa 5201-JM --> matikan pompa, tutup discharge dan tutup kembali bv min flow, buka line cooling down. - Tutup product valve (10") dari panel. - Pindahkan ke posisi Manoeuvre. - Lepas flange ALF dari kapal. - Pindahkan kunci, gerakkan keatas. - Gerakkan ARM ke posisi tegak lurus bebas, ubah ke posisi kunci Automatic. - Matikan Power. - Pengosongan line. V1 tetap terbuka, V3 dibuka kecil, V5 dibuka + 5 ulir. PC-4320 dibuka diatur disesuaikan dengan tekanan storage 5101-F apabila tekanan 5101-F masih naik jalan kan My Com (5103-L). - Apabila selesai pengosongan tutup kembali valve tersebut dan matikan My Com (4103-L).

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1-101-BJ2T ( ID FAN ) Trip; 1-107-J Trip. 1-106-D METHANATOR Trip STEAM CONSUMTION FOR P-IB UREA PLANT

Halaman 158 159 161

PROSEDUR OPERASI BAKU AMMONIA P - IB LOADING AMMONIA

Loading Ammonia

1. POMPA LOADING - Pastikan level oil pada batas normal. - Putar shaft pompa pakai tangan. - Pastikan bv discharge & bv by pass discharge tertutup rapat.

PROCESS EQUIPMENT LIST SUPERHEATER; TOWER & REACTOR; HEAT EXCHANGER EJECTOR; TANK & SEPARATOR CHAMBER; CYCLONE; STRAINER & FILTER DISTRIBUTOR & SPRAY NOZZLE AUXILIARY EQUIPMENT LIST COMPRESSOR & BLOWER; CENTRIFUGE; TURBINE GB101; GT101; GA101A/B; GT102A/B AUX EQUIPMENT

163 164

Pastikan pompa dalam posisi Cooling Down. Methanol di pompa + 70 % (di pot Methanol). BV suction terbuka lebar. BV minimum flow terbuka lebar.

165
166

167 168 169 170

GA102A/B; GT103A/B; EA104; INSTRUMENT

AGITATOR; PRILLING TOWER & PIT HOIST & ELEVATOR; CONVEYOR & SCALE; CRANE

2. LINE UP - BV VI (diatas York Pusri II) terbuka. - BV V2 & V4 (tie-in loading Pusri III) tertutup. - V-4310 terbuka. - BV by pass FQR-4301 tertutup. - Yakinkan RV-4302 (pop pada 8.2 kg/cm2) pada line ammonia loading aktif (bv u/s FQR-4301 terbuka). 3. DERMAGA - BV V3 (terbuka kecil sekali + 1/4 ulir). - BV V5 (terbuka + 1/2 ulir). - BV V6 (tertutup). - BV V10 (10") tertutup. 4. COOLING TOWER - Buka BV V1 terlebih dahulu, yakinkan V2 & V4 tertutup. - Buka BV V3 + 1 ulir. - Buka BV V5 + 4 ulir. - Buka BV by pass discharge + 1 ulir.

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Start Up Synthesis Loop

Start Up Synthesis Loop

ATURAN PEMAKAIAN STEAM 42 KG/CM2 SEJAK 08 JUNI 2001 1. Bila PB-IB Trip, Urea III atau Urea IV potong 1 compressor CO2 secara bergantian : - tanggal ganjil Urea III - tanggal genap Urea IV Pabrik Urea yang lainnya rate CO2 menyesuaikan. Semua Boiler yang masih jalan dinaikkan bebannya, kebeban maksimum. 2. Bila salah satu Boiler di Utilitas ada yang trip ( kecuali PB-IB ), semua pabrik Urea cut rate ke 90 %, bila tekanan steam masih tidak dpt naik maka Urea III atau Urea IV potong 1 compressor CO2 secara bergantian : - tanggal ganjil Urea III - tanggal genap Urea IV 3. Apabila pada saat butir 1 atau 2 tiba-tiba ada Boiler trip lagi, rate CO2 Urea-III & IV @ 50%. Bila tekanan MS masih kurang, maka pabrik Urea yang boiler nya baru trip SHUT DOWN total. Berlaku juga bila WHB trip yang disebabkan oleh GTG trip, pabrik Urea tetap normal operasi ( tidak ada yang ter Shedding ). Kondisi operasi dari seluruh boiler di Utility normal operasi dan dapat dioperasikan dengan aman, sampai beban maksimum yang dapat diijinkan yaitu : WHB-II, III, IV, IB = 80, 80, 80, 75 ton/jam. PB-II, III, IV, IB = 90, 80, 80, 100 ton/jam.

PROCESS DESIGN BASIS AMMONIA P - IB


ITEM No 101-B 101-C PRESS / TEMP STEAM Superheat ( Primary Reformer )

P S/T : 39,7 / 144,1 Kg Secondary Reformer W.H.B T S/T : 482 / 566 0C P : 140,6 Kg Steam Drum 101-F T +/- : 350 / 19 deg C P S/T : 1,76 / 10,5 Kg Surface Condenser for 101-JTC T S/T : 121 / 65 0C 101-JT & 102-JT P : 3,5 Kg Dearator 101-U T +/- : 150 / 19 deg C P S/T : 39,7 / 140,6 Kg H P Steam Superheater 102-C T S/T : 482 / 566 0C P : 14,79 Kg Mixed Bed Condensate Polisher 102-U T : 50 0C. P S/T : 39.7 / 161.7 Kg HTS Effluent WHB. 103-C1 T S/T : 470 / 360 0C. P S/T : 39.7 / 161.7 Kg HTS Effluent WHB. 103-C2 T S/T : 470 / 360 0C. 106-C 109-C 123-C1 123-C2 131-C 88 P S/T : 10,5 / 39,7 Kg T S/T : 200 / 200 0C P Hot/C : 2,8 / 7 Kg T Hot/C : 150 /150 0C P S/T : 188 / 181.7 Kg T S/T : 482 / 343 0C. P S/T : 188 / 181.7 Kg T S/T : 482 / 343 0C. P S/T : 39,7 / 161.7 Kg T S/T : 280 / 280 0C. LTS Effluent / LP BFW Exchanger Lean Solution / LP BFW Exhanger Amm Conv Eff/Steam Generation Amm Conv Eff/Steam Generation LTS Effluent / BFW Exchanger

PROSEDUR OPERASI BAKU AMMONIA P - IB MASUK GAS KE ABSORBER 1 - 101 - E I. PERSIAPAN. 1. Rate gas 50 % ~ 60 % vent MOV-1018 back press PI-1814 = 21 ~ 22 kg/cm2 g. 2. Sirkulasi Lean dan Semi lean sudah stabil FCAL-1014=140 m 3/H dan FCAL-1005 = 800 m3/H (satu pompa). PC-1005 = 21 ~ 22 kg/cm2g. 3. Atur level LCA-1042, LCA-1004 dan LCAL-1017 pada 50 % dan yakinkan sight glassnya sesuai dengan level. 4. Temp sirkulasi benfield TI-1407 > 100 0C dan TIAL-1354 > 80 0C, bila masih lebih rendah gunakan V-1008 untuk menaikkan temperatur sebelum gas masuk ke 1-101-E. 5. Buka make up Demin ke 1-107-C (bv 2") untuk top 102-E, boleh ditutup bila LCAL-1040 telah kontinyu terjadi level. 6. Kontinyu isi Demin ke 111-C via line 1" ke d/s LV-1020 dan jaga level 1-111-C normal. 7. Stand by kan PV-1040 pada 5 ~ 10 % open, buka vent motive steam (3") u/s ejector. 8. Set tekanan PC-1104 = 0,75 kg/cm2g auto control. 9. But valve motive steam ejector : L1, L2, L3 dan L4 posisi tertutup. 10. Buka lebar drain 2" dan aktifkan trapnya pada down stream ejector SLC-1009-24 ", tidak diperbolehkan dikurangi sebelum mendapat level di 111-C tanpa injeksi. (drain trap dekat 1-109-C). 11. Buka jumper line CB-1579 2" dari 1-105-C ke 1-111-C dan tutup FV-1050. 12. Buka drain MOV-1009 untuk membuang condensate dan tutup lagi setelah kering. 13. Buka kecil drain-drain valve dari d/s MOV-1009 sampai ke102-F1 14. Drip sump 1-115-F stand by kosong. 15. TC-1101 di atur 185 0C. 49 16. S/C ratio inlet 1-101-B < 4.0 (FY-1201).

Masuk gas ke Absorber 1 - 101 - E

ITEM NO TIC-1005 TIC-1006 TIC-1010 TIC-1012 TIC-1020 TIC-1021 TIC-1030 TIC-1305 TIC-1311 TIC-1414 TIC-1769 TIC-1796 TIC-1825 TIC-4301 TIC-4318 TIC-718 XI-4301 XI-4302 XY-1264

INSTRUMENTS REMARK HP header temperature CO2 produksi (top outlet stripper) inlet 1-104-D1 inlet 1-106-D desuperheater HP to MP BFW to letdown outlet 1-173-C bypass 1-101-BC5 by-pass 1-101-BC4 1-105-E top outlet outlet top stripper ammonia to urea BFW to export / import NH3 to Urea SLL inlet 1-F-D104 43-5101-J speed 43-5101-JA speed HRU to fuel system

LOCATION SUPERHEATER 1-102-E STRIPPER HTS


ABS OVHD & METH'TOR

LETDOWN HP TO MP SLL HEADER DRIERS FEED GAS COMP AIR COMPRESSOR 1-105-E FEED TREATING
NH3 REF FLASH DRUM

7. Atur temp CO2 outlet 102-E TC-1006 = 38 0C dengan FC-1016. 8. Aktifkan LC-1020 bila tekanan suction sudah lebih tinggi dari PC-1040 (+ 4,5 kg/cm2g). 9. Aktifkan FC-1050 bila level top 1-102-E (LCAL-1040) sudah normal = 30 % dan tutup jumper line CB-1579 2" dari1-105-C ke 1-113-C. 10. Aktifkan FC-1806, tutup make up demin ke 1-107-C dan jaga level dari top 1-102-E LCAL-1040 = 30 %, tutup make up demin ke 1-111-C. * Catatan : 1. Jangan masukkan gas ke 1-101-E bila temperatur sirkulasi rendah (harus > 100 0C). 2. Jangan ditutup drain 2" d/s ejector bila belum ter bentuk level di LCAL-1040, sisakan 1 ulir tetap terbuka. 3. Bila level 1-111-C terlanjur kosong, atur flow motive steam tidak naik secara mendadak.

Masuk gas ke Absorber 1 - 101 - E

MP HEADER NH3 STORAGE NH3 STORAGE HRU NH3 STORAGE NH3 STORAGE 1-104-E

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51

II. HEATING UP / PRESSURE UP 1. Tutup SLL ke 1-105-C dan atur demin ke 1-109-C utk mengatur

Masuk gas ke Absorber 1 - 101 - E

temperatur suction 1-108-J. 2. Press Up 1-102-F1 via by pass MOV-1009. 3. Bila tekanan di 1-102-F1 (PG-1816) sudah sama dengan tekanan inlet LTS (PI-1814), buka lebar MOV-1009 perlaha-lahan. 4. Bila temp TI-1407 < 100 0C & TIAL-1354 < 80 0C gunakan V-1008 untuk memanaskannya. 5. Press up Absorber 1-101-E dengan membuka by pass bv inlet. 6. Bila tekanan 1-102-F1 (PG-1816) sudah sama dengan tekanan absorber PC-1005 maka buka lebar bv inlet absorber 1-101-E dan tutup by pass nya. III. PROSEDUR 1. Mulai alirkan gas ke absorber 1-101-E secara perlahan dan ber tahap dengan membuka PC-1005 dan menutup MOV-1018 dgn menjaga tekanan outlet HTS (PI-1814) mantap. Kurangi V-1008, bertahap. 2. Bila motive steam sudah mulai berproduksi biarkan ter-vent di vent 3" u/s ejector, setelah drain 2" pada SLC-1009 24" kering dan tekanan PC-1040 + 4,5 kg/cm2g mulai masukan motive steam ke
ejector dgn membuka butterfly valve L4, L3, L2, L1 secara bertahap 3. Atur tekanan motive steam PC-1040 = 4,5 kg/cm2g dan jaga mantap.

4. Jalankan 1-116-J bila tekanan suction > 5 kg/cm 2g ( bila tekanan turun < 2,8 kg/cm2g. Matikan 1-116-J ). 5. Lanjutkan pindah vent dari MOV-1018 ke PC-1005 hingga MOV-1018 tertutup. 6. Bila sudah ada produksi CO2 bukaan PC-1104 mulai bertambah, naikkan tekanan 1-102-E secara bertahap ke tekanan normal operasi, PC-1104 jangan sampai menutup rapat, agar tetap ada aliran CO2 ke top 1-102-E.

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87

ITEMS INSTRUMENT 200-F LAL-1152 201-E 202-E 201-F 202-F 144-F

LAL-1154 FAL-1066 LAL-1157 LAH-1153 LAH-1002 LAH-1154 PAL-1799 LALL-1158 LAL-1002 PDAH-1798 PAH-1799 LAHH-1002 TAL-1761 PDAH-1802 PAH-1071 FAL-1070 LAL-1155 LAL-1156 FUEL to REF. 101-J/JT ARCHBR FLUE G LAH-1151 PAH-1023 TAH-0100 PAL-1120 TAH-1330 VAH-0100 PALL-1220 TAH-1328 VAHH-0100 PAH-1121 PAHH-1060 XAHH-0100 FFALL-1201 PAHH-1221 PAH-1057 XAHH-0100 TAL-1313 PAH-1058 PDAH-0101 PAH-1059 TAH-1300
AAL-1010A AAL-1011A

PG to 1st REF TAH-0200 TAH-1305 FAL-1001 VAH-0200 FAL-1002 VAHH-0200 FALL-1201 XAH-0200 FFAL-1201 102-J/JA 108-D IN
XAHH-0200

CA-1200 TAH-1306

SEC. HTS WATER REC. IN JACKT TAL-1314 TAH-1339 FAH-1151 TAH-1314 TAL-1339 LAL-1051 TAH-1312 LAL-1052 TAH-1052 LAL1053 TAH-1787 LAL-1054 TAH-1053 LAL-1055 TAH-1034 52

150-E

102-F1

LTS

TAL-1011 PDAHH-1069 LALL-1205 TAH-1011 FAL-1019 LAH-1003 TAH-1350 LAL-1025 LAH-1025 AHH-1017

PDAH-1069 LAL-1003

ITEM NO TI-1761 TI-1773 TI-1774 TI-1781 TI-1783 TI-1785 TI-1786 TI-1787 TI-1792 TI-1797 TI-1799 TI-1801 TI-1802 TI-1806 TI-1810 TI-701 TI-703 TI-704 TI-705 TI-706 TI-708 TI-709A TI-710 TI-711 TI-712 TI-713 TI-714 TI-715 TI-717 TIC-1004

INSTRUMENTS REMARK outlet bottom absorber outlet flash drum lean solution temperature outlet 1-172-C1/C2 middle 1-108-D catalist tube temperature catalist tube temperature second ref temperature middle discharge 2nd stage 1-104-E top outlet 1-103-E liquid inlet temperature from 1-140- C 1-103-E top outlet stm to CW pump turbine air to auxiliary boiler inlet HRU outlet 1-D-A101A;B outlet 1-D-A101A;B inlet 1-D-A101A;B inlet 1-D-A101A;B fuel gas product out 1-D-A101A;B / in 1-C-E101A temp between C-E101A & C-E101B 1-F-D101 top outlet temp between C-E101A & C-E101B HRU product 1-F-D101 bottom outlet temp between C-E101A & C-E101B fuel gas product 1-102-C outlet

LOCATION PRET CO2 REMOVAL PRET CO2 REMOVAL PRET CO2 REMOVAL
ABS OVHD & METH'TOR

FEED GAS COMP 1-101-B TUBE 1-101-B TUBE SEC REF & WH EXCH 1-103-J LP CASE 1-104-E 1-103-E 1-105-E 1-103-E MP HEADER HP HEADER HRU HRU, 1-D-A101 HRU, 1-D-A101 HRU, 1-D-A101 HRU, 1-D-A101 HRU, 1-D-A101 HRU HRU,COLD BOX HRU,COLD BOX HRU,COLD BOX HRU,COLD BOX HRU HRU,COLD BOX HRU,COLD BOX SUPERHEATER 85

ITEM NO TI-1387 TI-1388 TI-1389 TI-1390 TI-1391

INSTRUMENTS REMARK 1-105-D catalist bed temp # 2A 1-105-D catalist bed temp # 2A 1-105-D catalist bed temp # 2A 1-105-D catalist bed temp # 2A 1-105-D catalyst bed temp # 2B

LOCATION 1-105-D, BED # 2A 1-105-D, BED # 2A 1-105-D, BED # 2A 1-105-D, BED # 2A 1-105-D, BED # 2B

ITEMS INSTRUMENT 102-E 132-F 107-J 115-F 106-D 104-L 111-C 133-F 115-L PDAH-1042PDAH-1043 LAL-1017 TAH-8101 LAL-1119 TAH-1012 LAL-1004 LAL-1040 LAH-1017 PAL-8101 LAH-1119 TAH-1355 LAH-1004 LAL-1041 LALL-1106 LAH-1162 PDAH-1115 TAH-1357 101-E

TI-1392 TI-1393 TI-1394 TI-1396 TI-1397 TI-1398 TI-1399 TI-1400 TI-1402 TI-1403 TI-1404 TI-1405 TI-1409 TI-1410 TI-1411 TI-1412 TI-1416 TI-1418 TI-1420 TI-1421 TI-1550 TI-1554 TI-1555 TI-1556 TI-1558 84

1-105-D catalyst bed temp # 2B 1-105-D, BED # 2B 1-105-D catalyst bed temp # 2B 1-105-D, BED # 2B 1-105-D catalyst bed temp # 2B 1-105-D, BED # 2B Synth gas outlet 1-102-B START UP HEATER Fuel to start-up heater START UP HEATER 1-120-CF4 bottom out 1-105-J 1-120-CF3 bottom out 1-105-J 1-120-CF2 bottom out 1-105-J 1-109-F bottom out PROD TO UREA STO'GE Ammonia out 1-107-F NH3 PRODUCT 1-120-CF1 bottom out 1-105-J Temp condensate outlet 1-150-E 1-150-E Inlet flash drum. LEAN&S LEAN TO ABS Semilean sol'n (outlet flash drum) LEAN&S LEAN TO ABS BFW outlet 1-103-C BFW FROM 1-104-J BFW outlet 1-131-C BFW FROM 1-104-J 1-105-E bottom outlet 1-105-E Outlet 1-101-BC6 1-101-B FLUE GAS 1-111-C outlet LTS & W.H RECOVERY 1-105-C / 1-113-C outlet. 1-101-E & FEED HP steam outlet drum AUXILIARY BOILER MP header temp output desuperheater LETDOWN HP TO MP Outlet desuperheater SLL HEADER 1-104-J discharge DEARATOR Demin to dearator. COND TO 1-102-U

FAL-1005 FALL-1205 FAL-1014 FALL-1214 TAL-1354 SAH-1207

LAL-1042 LALL-1103 PALL-8103 LAH-1042 LAL-1020 TAH-8102 PAL-1104 LAH-1020 PAL-8102 PAH-1104 PALL-8104 FAL-1016
PDAH-1102

TAH-1358 TAH-1361 TAH-1362


TAHH-1200

TAL-1200 TAL-1355 TAL-1203 111-L 106-F

104-F

103-J

105-F1

105-F2

LAL-1008 VAH-0300 LAH-0303 LAH-0306 LAH-0317 LAL-1218 LAH-1008 XAH-0300 LAL-0303 LAL-0306 LAH-1218 PAH-1004 TAH-0340 LAHH-0303LAHH-0306 LAHH-1218 LAHH-1008 TAH-1792 TAH-1367 TAL-1366
XAHH-0300 VAHH-0300

TAH-1364

53

ITEM NO TI-1316 TI-1317 TI-1318 TI-1319 TI-1320 TI-1321 TI-1322 TI-1323 TI-1324 TI-1325 TI-1326 TI-1327 TI-1331 TI-1334 TI-1335 TI-1337 TI-1338 TI-1339 TI-1340 TI-1341 TI-1342 TI-1343 TI-1344 TI-1346 TI-1347 TI-1348 TI-1349 TI-1351 TI-1352 TI-1353 82

INSTRUMENTS REMARK catalist tube temperature catalist tube temperature catalist tube temperature catalist tube temperature catalist tube temperature inlet 1-101-BC1 inlet 1-101-BC1 inlet 1-101-BC1 inlet 1-101-BC1 inlet 1-101-BC1 inlet 1-101-BC2 outlet 1-101-BC1 outlet 1-101-BC3 outlet secondary reformer 1-101-C outlet main line 1-102-C outlet bypass 1-102-C outlet inlet 1-104-D1 1-101-C outlet bypass 1-104-D1 catalyst bed 1-104-D1 catalyst bed 1-104-D1 catalyst bed 1-104-D1 catalyst bed 1-104-D2 catalyst bed 1-104-D2 catalyst bed 1-104-D2 catalyst bed 1-104-D2 catalyst bed 1-131-C outlet 1-106-C outlet temperature. outlet absorber

LTS & W.H RECOVERY

LOCATION 1-101-B TUBE 1-101-B TUBE 1-101-B TUBE 1-101-B TUBE 1-101-B TUBE 1-101-B FLUE GAS 1-101-B FLUE GAS 1-101-B FLUE GAS 1-101-B FLUE GAS 1-101-B FLUE GAS AIR COMPRESSOR 1-101-B FLUE GAS AIR COMPRESSOR REFORMER FEED SEC REF & WH EXCH SUPERHEATER SUPERHEATER SUPERHEATER SEC REF & WH EXCH HTS HTS HTS HTS LTS LTS LTS LTS 1-101-E & FEED

ITEMS INSTRUMENT FUEL to FUEL to 101-BBS BU/BBS CA-1004A PALL-1240 LAH-1150 CA-1004B PAHH-1241 PAH-1001 FAL-1106 PAL-1140 PAL-1001 PAH-1141 PAL-1145 PAH-1146 104-J/JA 101-JTC LAL-0601 LAH-0601 LHH-0601 PAH-0608 103-JTC 103-E SM STEAM PAL-1013 TAH-1020 PAL-1014 PAH-1014 LP 102-U STEAM CA-0808 PAH-1016 AHH-1018 PAL-1016 PAH-1017 PAH-1017 TAH-1555

104-E

105-E

LAL-0602 PDAH-1055PDAH-1056 LAL-1027 LAH-0602 PDAL-1055 PDAL-1056 LAH-1027 LAHH-0602LAH-1026 LAH-1163 PAH-0616 LAL-1026 LAL-1163 NH3 STORG PAL-4310 PAH-4310 PAL-4311 PAH-4311 LAL-4308 LAH-4308 LAL-4307 LAH-4307 TAL-4318 CA-4300

HRU HRU HRU NH3 DA-101 COLDBOX REGEN PROD TAH-0701 LAH-0702 TAL-0718 FAL-1061 LAH-0701 LAL-0702 TAH-0707 PDAH-0705 TAH-0711 TAL-0707 PDAH-0706 PAH-0719 PDAH-0707 TAH-0709B PAL-0718 PDAH-0708 PDAH-0709 TAL-0713 TAL-0702 FAL-0701A TAL-0717 TAH-0702 FALL-0701B TALL-0716 PAH-0720A TAH-0709A PAL-713 PAH-0720B

ABS OVHD & METH'TOR

55

ITEMS INSTRUMENT 102-B 109-D 157-F 107-E 109-F 120-CF

FALL-1257 KA-1001 TAH-1396 TAH-1397 PAL-1150 PAH-1151

LAH-1166 PAHH-1070 LAL-1015 LAL-1021 PAH-1108 LAH-1015 LAH-1021 LAL-1022 LAH-1022 LAL-1023 LAH-1023 LAL-1024

ITEM NO TI-1354 TI-1355 TI-1357 TI-1358 TI-1359 TI-1360 TI-1361 TI-1362 TI-1363

INSTRUMENTS REMARK 1-101-E outlet inlet 1-106-D 1-106-D catalist bed 1-106-D catalist bed 1-106-D catalist bed 1-106-D catalist bed 1-106-D catalist bed 1-106-D catalist bed inlet 1-104-F temperature

ABS OVHD & METH'TOR

LOCATION 1-101-E & FEED METHANATOR METHANATOR METHANATOR METHANATOR METHANATOR METHANATOR METHANATOR

PAH-1009 PAL-1009 STEAM SH FUEL to FD 101-U DRUM STEAM 101-BU FAN TAH-0500 LAH-1029 PAH-1018 PAL-1135 XA-1206 LAH-1124 VAH-0500 LAL-1028 PAL-1018 PAH-1136 PAL-1855 LAL-1125 VAHH-0500 LALL-1223 TAH-1005 PALL-1235 PALL-1856 LAL-1030 XAH-0500 TAH-1336 PAHH-1236 XAHH-0500 TAL-1336 PAH-1131 CA-1005 PAL-1130 LALL-0512 PALL1130 LALL-0513 PAHH-1231 TAH-1401 105-J/JA

54

TI-1364 TI-1365 TI-1366 TI-1367 TI-1369 TI-1370 TI-1371 TI-1373 TI-1374 TI-1375 TI-1376 TI-1377 TI-1378 TI-1379 TI-1380 TI-1381 TI-1382 TI-1383 TI-1384 TI-1385 TI-1386

discharge 1st stage suction 2nd stage suction 4th stage discharge 4th stage outlet 1-121-C BFW outlet 1-123-C inlet 1-121-C outlet 1-121-C outlet 1-105-D 1-105-D catalist bed temp 1-105-D catalist bed temp 1-105-D catalist bed temp 1-105-D catalist bed temp 1-105-D catalist bed temp 1-105-D catalist bed temp 1-105-D catalist bed temp 1-105-D catalist bed temp 1-105-D catalist bed temp 1-105-D catalist bed temp 1-105-D catalist bed temp 1-105-D catalist bed temp

1-103-J LP CASE 1-103-J LP CASE 1-103-J HP CASE 1-103-J HP CASE SYNTHESIS LOOP BFW FROM 1-104-J SYNTHESIS LOOP
103-J DISCH TO LOOP

# 2A # 2A # 2A # 2A #1 #1 #1 #1 #1 #1 #1 #1

1-105-D, BED # 2B 1-105-D, BED # 2A 1-105-D, BED # 2A 1-105-D, BED # 2A 1-105-D, BED # 2A 1-105-D, BED # 1 1-105-D, BED # 1 1-105-D, BED # 1 1-105-D, BED # 1 1-105-D, BED # 1 1-105-D, BED # 1 1-105-D, BED # 1 1-105-D, BED # 1

83

ITEMS INSTRUMENT

1202 FIC-1003 HS-1006 HIC-1021 FIC-1001 TI-1334 HS-1010 FI-1044A FIC-1002 1201 PIC-1791 FIC-1065 PI-109 TI-1326 FIC-102 TI-1331 TIC-1311 TI-1312 1207 PIC-1002 HIC-1035 HIC-1036 HIC-1037 HIC-1038 PIC-1019 HIC-1259 TI-1314 56

REFORMER FEED discharge of 3rd stage discharge of 3rd stage Steam to air coil. NG to 1-101-BC2 outlet secondary reformer NG to 1-101-BC2 Steam to air coil. Steam to 1-101-BC2 AIR COMPRESSOR air to utility air to utility discharge of 3rd stage. inlet 1-101-BC2 discharge of 3rd stage. outlet 1-101-BC3 by-pass 1-101-BC4 air to 1-103-D 1-101-B FIRING CONTROL fuel to arch burner inlet arch burner " A " bank. inlet arch burner " B " bank. inlet arch burner " C " bank. inlet arch burner " D " bank. radiant box pressure inlet arch burner " E " bank. outlet primary reformer.

ITEM NO PIC-1031 PIC-1032 PIC-1033 PIC-1034 PIC-1071 PIC-1104 PIC-1108 PIC-1791 PIC-1799 PIC-1833 PIC-1852 PIC-1855 1-104-F PIC-301 out PIC-4001 PIC-4320 PIC-5001 PIC-701 PIC-710 PIC-710 PIC-711 TI-1011 TI-1024 TI-1029 TI-1041 TI-1043 TI-1052 TI-1053 TI-1312 TI-1314 TI-1315

INSTRUMENTS REMARK steam to dearator. 1-103-E top outlet 1-104-E top outlet 1-105-E top outlet NG vent upstream 1-102-J CO2 product (top outlet stripper) 1-107-F pressure ( top outlet ) air to utility outlet top stripper semilean sol'n from 1-107-JC fuel to start-up heater air to auxiliary boiler press; speed of 1-103-J. naturalgas supply, inlet B / L NH3 for loading system 1-105-JT extraction control. outlet 1-F-D103 inlet 1-C-E101A inlet 1-C-E101 HRU product process gas out 1-103-C1 / C2 steam gas to catalist tube natural gas suffly, inlet B/L inlet 1-109-DA inlet 1-109-DB secondary ref temperature top second ref temperature bottom air to 1-103-D outlet primary reformer. catalist tube temperature

LOCATION DEARATOR 1-103-E 1-104-E 1-105-E FEED GAS COMP 1-102-E STRIPPER NH3 PRODUCT AIR COMPRESSOR FEED TREATING
LEAN&S LEAN TO ABS

STM TO CARBON RATIO NG FEED & CO2 PROD

START UP HEATER HP HEADER 1-104-F SUC DRUM FEED TREATING NH3 STORAGE SLL HEADER HRU HRU,COLD BOX HRU HRU LTS

DRIERS DRIERS SEC REF & WH EXCH SEC REF & WH EXCH AIR COMPRESSOR
101-B FIRING CONTROL

1-101-B TUBE

81

ITEM NO PI-1064 PI-109 PI-1814 PI-1838 PI-309 PI-4310 PI-4311 PI-608 PI-616 PI-713 PI-714 PIC-1001 PIC-1002

INSTRUMENTS REMARK inlet arch burner discharge of 3rd stage. process gas outlet 1-103-C1/C2 inlet arch burner 1-111-L outlet NH3 storage NH3 storage 1-101-JTC 1-103-JTC 1-F-D101 bottom outlet fuel gas product fuel to aux boiler / superheater fuel to arch burner

LOCATION
FUEL TO ARCH BURNER

ITEMS INSTRUMENT

AIR COMPRESSOR HTS

FUEL TO ARCH BURNER

1-103-J HP CASE NH3 STORAGE NH3 STORAGE COND TO 1-102-U COND TO 1-102-U HRU HRU, 1-D-A101 AUXILIARY BOILER
101-B FIRING CONTROL

1205 TI-1315 TI-1316 TI-1317 TI-1318 TI-1319 TI-1320 TI-1785 TI-1786 1206 TI-1321

1-101-B TUBE catalist tube temperature catalist tube temperature catalist tube temperature catalist tube temperature catalist tube temperature catalist tube temperature catalist tube temperature catalist tube temperature 1-101-B FLUE GAS inlet 1-101-BC1

PIC-1004 inlet 1-103-J 1-104-F SUC DRUM PIC-1005 1-114-C upstream vent ABS OVHD & METH'TOR PIC-1009 1st stage suction NH3 REF FLASH DRUM PIC-1010 outlet 1-108-D FEED GAS COMP PIC-1012 1-103-JT governoor control HP HEADER PIC-1012 1-103-JT governoor control LETDOWN HP TO MP PIC-1013 letdown HP to MP, press MP header LETDOWN HP TO MP PIC-1014 MP steam to vent ( MP steam press )MP HEADER PIC-1016 LP pressure header SLL HEADER PIC-1017 LP to vent SLL HEADER PIC-1018 HP header pressure AUXILIARY BOILER PIC-1018 HP Header pressure HP HEADER PIC-1019 radiant box pressure 101-B FIRING CONTROL PIC-1023 auxiliary boiler draft AUXILIARY BOILER PIC-1023 auxiliary boiler draft HP HEADER PIC-1028 warm ammonia product to urea NH3 REF FLASH DRUM PIC-1030 fuel to auxiliary boiler AUXILIARY BOILER 80

TI-1322 TI-1323 TI-1324 TI-1325 TI-1327 TI-1418 AI-101-DA 1801 LIC-601 PI-608 LIC-602 PI-616 FIC-1087 AI-1018 TI-1558 CA-808

inlet 1-101-BC1 inlet 1-101-BC1 inlet 1-101-BC1 inlet 1-101-BC1 outlet 1-101-BC1 outlet 1-101-BC6 Flue gas O2 CONDENSATE TO 1-102-U 1-101-JTC 1-101-JTC 1-103-JTC 1-103-JTC make up demin water. condensate to condensate polister. demin to dearator. common alarm for 1-102-U

57

ITEM NO LAL-1054 LAL-1055 LI-1001A LI-1001B LI-1017 LI-1041 LI-1155 LI-1157 LI-4307 LI-4308 LIC-1001 LIC-1002 LIC-1003 LIC-1004 LIC-1008 LIC-1012 LIC-1013 LIC-1015 LIC-1020 LIC-1021 LIC-1022 LIC-1023 LIC-1024 LIC-1025 LIC-1026 LIC-1027 LIC-1030 LIC-1040 LIC-1042 LIC-1101 78

INSTRUMENTS REMARK 1-101-C water jacket level 1-102-C water jacket level steam drum level steam drum level level flash drum liq level in the stripper (mid part) liq level in stripper ( upper part ) flush drum level NH3 storage NH3 storage steam drum level level 1-144-F 1-102-F1 level absorber liquid level. 1-104-F liquid level 1-107-F liguid level 1-106-F liguid level 1-109-F liquid level 1-111-C liquid level. 1-120-CF4 bottom out 1-120-CF3 bottom out 1-120-CF2 bottom out 1-120-CF1 bottom out 1-150-E liquid level 1-103-E liquid level 1-105-E liquid level dearator level liq level in the stripper ( top part ) liq level in the stripper (bott part)

LOCATION WATER JACKET WATER JACKET STEAM DRUM LEVEL STEAM DRUM LEVEL
LEAN&S LEAN TO ABS

ITEMS INSTRUMENT

1-102-E STRIPPER PRET CO2 REMOVAL PRET CO2 REMOVAL NH3 STORAGE NH3 STORAGE STEAM DRUM LEVEL FEED GAS COMP 1-101-E & FEED 1-101-E & FEED 1-104-F SUC DRUM NH3 PRODUCT NH3 PRODUCT
NH3 REF FLASH DRUM LTS & W.H RECOVERY NH3 REF FLASH DRUM NH3 REF FLASH DRUM NH3 REF FLASH DRUM NH3 REF FLASH DRUM

1809 PIC-1016 PIC-1017 PIC-5001 FI-1092 FIC-1884 TI-1555 LIC-1129 TIC-1021 1303 HS-1009 TI-1351 TI-1420 FIC-1050 FIC-1040 FI-1049 LIC-1020

SLL HEADER LP pressure header LP to vent 1-105-JT extraction control. LP to CW pump turbine. LP to 1-105-J outlet desuperheater 1-156-F level BFW to letdown LTS & W.H RECOVERY MOV bypass 1-104-D2 1-131-C outlet 1-111-C outlet lean sol'n to 1-113-C reboiler. steam to ejector condensate to 1-111-C 1-111-C liquid level.

1-150-E 1-103-E 1-105-E DEARATOR 1-102-E STRIPPER 1-102-E STRIPPER STEAM DRUM LEVEL

1401 PDI-1042 LIC-1004 FIC-1014 FIC-1005 TI-1421 TI-1352 LIC-1003 TI-1354

1-101-E & FEED absorber's bed differential press. absorber liquid level. lean sol'n to top of absorber semi lean sol'n to mid. Part of absorber 1-105-C / 1-113-C outlet. 1-106-C outlet temperature. 1-102-F1 level 1-101-E outlet

59

ITEMS INSTRUMENT

1802 TI-1556 PIC-1031 LIC-1030 AI-1007 AI-1008

DEARATOR 1-104-J discharge steam to dearator. dearator level outlet dearator. outlet dearator.

1803 FIC-1020 FIC-1043 TI-1370 TI-1412 TI-1411

BFW FROM 1-104-J BFW to 1-123-C BFW to 1-101-C emergency BFW outlet 1-123-C BFW outlet 1-131-C BFW outlet 1-103-C

ITEM NO LIC-1129 LIC-1132 LIC-1154 LIC-1156 LIC-1162 LIC-1163 LIC-1166 LIC-303 LIC-305 LIC-4301 LIC-601 LIC-602 LIC-702 LY-1012C PDI-1042 PDI-1054 PDI-1055

INSTRUMENTS REMARK 1-156-F level 1-102-F2 liquid level level absorber liq level in stripper ( bottom part ) 1-133-F liquid level 1-104-E liquid Level level 1-157-F 1-105-F1 liquid level 1-105-F1 liquid level 43-5102-F Liquid level 1-101-JTC 1-103-JTC level 1-F-D101 select switch absorber's bed differential press. 1-105-D differential pressure 1-103-E different pressure

ABS OVHD & METH'TOR

LOCATION SLL HEADER

FEED TREATING FEED TREATING


LEAN&S LEAN TO ABS

1-104-E DRIERS 1-103-J LP CASE 1-103-J LP CASE NH3 STORAGE COND TO 1-102-U COND TO 1-102-U HRU,COLD BOX NH3 PRODUCT 1-101-E & FEED SYNTHESIS LOOP 1-103-E

CA-1004-A CA-1004-B

speed 1-104-J speed 1-104-J

1804 LIC-1001 FIC-1006 FI-1033 HS-1101 LI-1001A LI-1001B HS-1102 LIC-1101 58

STEAM DRUM LEVEL steam drum level 1-104-J dicharge HP steam outlet drum selector LI-1001A or LI-1001B steam drum level steam drum level selector flow vs level.

PDI-1056 PDI-1069 PDI-1102 PDI-1798 PDI-1802 PDIC-1022 PDIC-705 PI-1028 PI-1036 PI-1053 PI-1061 PI-1062 PI-1063

1-104-E differential pressure 1-150-E differential pressure 1-104-L different pressure differential pressure absorber stripper differential pressure combustion air control fuel gas product fuel to arch burner steam drum pressure steam gas to catalist tube inlet arch burner inlet arch burner inlet arch burner

1-104-E 1-150-E
LEAN&S LEAN TO ABS

PRET CO2 REMOVAL PRET CO2 REMOVAL SUPERHEATER HRU


FUEL TO ARCH BURNER AUXILIARY BOILER STM TO CARBON RATIO FUEL TO ARCH BURNER FUEL TO ARCH BURNER FUEL TO ARCH BURNER

79

ITEMS INSTRUMENT

1402 LI-1017 TI-1410 FI-1051 FI-1052 PIC-1833 LIC-1162 TI-1409 PDI-1102 1403 LI-1041 FIC-1017 LIC-1042 PIC-1104 LIC-1040 FIC-1016 TIC-1006 FIC-1806 1404 TI-1353 LIC-1132 FIC-1073 PIC-1005 TIC-1012 HS-1011 TI-1355 TI-1781 60

LEAN & SEMI LEAN TO ABS, RICH RETURN level flash drum semilean sol'n ( outlet flash drum ). semilean sol'n to middle part of absorber. semilean sol'n from 1-107-JB semilean sol'n from 1-107-JC 1-133-F liquid level inlet flash drum. 1-104-L different pressure 1-102-E STRIPPER liquid level in the stripper ( mid part ) liquid from top to bottom part of stripper liquid level in the stripper ( bott. part ) CO2 product ( top outlet stripper ) liquid level in the stripper ( top part ) reflux flow CO2 produksi ( top outlet stripper ) condensate ( reflux ) excess ABSORBER OVHD & METHANATOR outlet absorber 1-102-F2 liquid level process gas outlet 1-102-F2 to fuel 1-114-C upstream vent inlet 1-106-D MOV-inlet 1-106-D inlet 1-106-D outlet 1-172-C1/C2

ITEM NO HIC-1026 HIC-1028 HIC-1029 HIC-1032 HIC-1035 HIC-1036 HIC-1037 HIC-1038 HIC-1050 HIC-1259 HIC-1262 HS-1001 HS-1002 HS-1004 HS-1006 HS-1008 HS-1009 HS-1010 HS-1011 HS-1018 HS-1024 HS-1027A HS-1027B HS-1101 HS-1102 HS-704 HS-706 LAL-1051 LAL-1052 LAL-1053

INSTRUMENTS REMARK by-pass 1-121-C letdown HP to MP letdown HP to MP speed of 1-120-J inlet arch burner " A " bank. inlet arch burner " B " bank. inlet arch burner " C " bank. inlet arch burner " D " bank. fuel to start-up heater inlet arch burner " E " bank. export / import steam outlet 1-111-L, MOV-1001 suction 4th stage, MOV-1002 emergency s/d 1-104-D2 discharge of 3rd stage MOV inlet 1-104-D2 MOV bypass 1-104-D2 NG to 1-101-BC2 MOV-inlet 1-106-D MOV to vent d/s 1-104-D2 cold / hot product selection 1-141-J/JA start 1-140-J/JA start selector LI-1001A or LI-1001B selector flow vs level. fuel gas product fuel gas product 1-103-D water jacket level 1-103-D water jacket level 1-107-D water jacket level

LOCATION
1-103-J DISCH TO LOOP

LETDOWN HP TO MP LETDOWN HP TO MP

PROD TO UREA STO'GE 101-B FIRING CONTROL 101-B FIRING CONTROL 101-B FIRING CONTROL 101-B FIRING CONTROL

START UP HEATER
101-B FIRING CONTROL

MP HEADER 1-103-J HP CASE 1-103-J HP CASE LTS REFORMER FEED LTS


LTS & W.H RECOVERY

REFORMER FEED ABS OVHD & METH HTS


PROD TO UREA STO'GE

1-104-E 1-103-E STEAM DRUM LEVEL STEAM DRUM LEVEL HRU HRU WATER JACKET WATER JACKET WATER JACKET 77

ITEM NO FIC-1043 FIC-1050 FIC-1064 FIC-1065 FIC-1066 FIC-1068 FIC-1070 FIC-1073 FIC-1077 FIC-1078 FIC-1079 FIC-1087 FIC-1088 FIC-1278 FIC-1806 FIC-1808 FIC-1884 FIC-201 FIC-301 FIC-303 FIC-304

INSTRUMENTS REMARK BFW to 1-101-C emergency lean sol'n to 1-113-C reboiler. 1-103-E liquid inlet air to utility reflux flow steam to ejector lean solution flow process gas out 1-102-F2 to fuel synthesis gas to purge 1-107-F to 1-120-CF3 1-107-F to 1-120-CF2 make up demin water. steam to reboiler air to auxiliary boiler condensate ( reflux ) excess 1-103-JT extraction line LP to 1-105-J 1-102-J disharge Kick back to 1st stage kick back to 3rd stage kick back to 4th stage

LTS & W.H RECOVERY

LOCATION BFW FROM 104-J

ITEMS INSTRUMENT

1-103-E AIR COMPRESSOR FEED TREATING FEED TREATING FEED TREATING


ABS OVHD & METH'TOR

SYNTHESIS LOOP NH3 PRODUCT NH3 PRODUCT COND TO 1-102-U PRET CO2 REMOVAL HP HEADER 1-102-E STRIPPER HP HEADER SLL HEADER FEED GAS COMP 1-103-J LP CASE 1-103-J HP CASE 1-103-J HP CASE

1904 TI-703 TI-704 TI-705 TI-706 FI-702 TI-708 FI-706 PI-714 1905 TI-701 PIC-701 TI-709A FI-704 FI-701A FI-703 PIC-711

HRU, 1-D-A101 outlet 1-D-A101A;B outlet 1-D-A101A;B inlet 1-D-A101A;B inlet 1-D-A101A;B gas to regeneration / inlet 1-C-E102 fuel gas product fuel gas product fuel gas product HRU inlet HRU outlet 1-F-D103 outlet 1-D-A101A;B / inlet 1-C-E101A steam to 1-C-E101A inlet 1-C-E101A HRU product HRU product

FIC-501 1st stage suction FIC-502 2nd stage discharge FIC-503 3rd stage discharge FIC-504 4th stage discharge FQI-1042 natural gas suffly, inlet B/L FQI-1060 warm ammonia product to urea FQI-1061 cold ammonia product to storage HIC-1021 Steam to air coil. HIC-1025 synt gas to 1-105-D diff quench 76

1-105-J 1-105-J 1-105-J 1-105-J


NG FEED & CO2 PROD PROD TO UREA STO'GE PROD TO UREA STO'GE

REFORMER FEED SYNTHESIS LOOP

1906 TI-717 TI-713 TI-715 TI-710 TI-712 LIC-702 TI-711 PIC-710

HRU,COLD BOX fuel gas product HRU product temperature between 1-C-E101A & 1-C-E101B temperature between 1-C-E101A & 1-C-E101B temperature between 1-C-E101A & 1-C-E101B level 1-F-D101 1-F-D101 top outlet inlet 1-C-E101A

61

INSTRUMENTS REMARK LOCATION outlet dearator. DEARATOR outlet dearator. DEARATOR flue gas O2 AUXILIARY BOILER outlet 1-109-D DRIERS conductivity of process cond 1-150-E cond to condensate polister. COND TO 1-102-U Flue gas O2 1-101-B FLUE GAS CA-1004-A speed 1-104-J BFW FROM 1-104-J CA-1004-B speed 1-104-J BFW FROM 1-104-J CA-808 common alarm for 1-102-U COND TO 1-102-U FALL-1257 flow to 1-102-B START UP HEATER FI-1027 steam to 1-140-C 1-105-E FI-1031 fuel to superheater burner SUPERHEATER FI-1033 HP steam outlet drum STEAM DRUM LEVEL FI-1042 natural gas suffly, inlet B/L NG FEED & CO2 PROD FI-1044A Steam to air coil. REFORMER FEED FI-1046 syn gas to 1-173-C DRIERS FI-1047 total fuel from 1-200-F START UP HEATER FI-1049 condensate to 1-111-C LTS&W.H RECOVERY FI-1051 semilean sol'n to middle part of abs LEAN&S LEAN TO ABS FI-1052 semilean sol'n from 1-107-JB LEAN&S LEAN TO ABS FI-1059 discharge 4th stage 1-103-J HP CASE FI-1060 warm ammonia product to urea PROD TO UREA STO'GE FI-1061 cold ammonia product to storage PROD TO UREA STO'GE FI-1062 condensate outlet 1-180-C 1-150-E FI-1063 1-103-E top outlet 1-103-E FI-1075 purge gas to 1-173-C DRIERS FI-1081 1-104-E liquid inlet 1-104-E FI-1089 stm to CW pump turbine MP HEADER FI-1091B export / import steam MP HEADER 74 ITEM NO AI-1007 AI-1008 AI-101 IA AI-1014 AI-1017 AI-1018 AI-101-DA

ITEMS INSTRUMENT

1502 PIC-301 PIC-1004 LIC-1008

1-104-F SUCTION DRUM 1-104-F outlet pressure; speed of 1-103-J. inlet 1-103-J 1-104-F liquid level

1601 FIC-301 TI-1364 TI-1365 TI-1792 LIC-303 LIC-305

1-103-J LP CASE Kick back to 1st stage discharge 1st stage suction 2nd stage discharge 2nd stage 1-105-F1 liquid level 1-105-F1 liquid level

1602 TI-1041 TI-1043 FI-1075 TIC-1030 FI-1046 LIC-1166 AI-1014

DRIERS inlet 1-109-DA inlet 1-109-DB purge gas to 1-173-C outlet 1-173-C syn gas to 1-173-C level 1-157-F outlet 1-109-D 63

ITEMS INSTRUMENT

1606 TI-1375 TI-1376 TI-1377 TI-1378 TI-1387 TI-1388 TI-1389 TI-1390 1607 TI-1379 TI-1380 TI-1381 TI-1382 TI-1383 TI-1384 TI-1385 TI-1386 1501 TI-1357 TI-1358 TI-1359

1-105-D, BED # 2A 1-105-D catalist bed temperature # 2A 1-105-D catalist bed temperature # 2A 1-105-D catalist bed temperature # 2A 1-105-D catalist bed temperature # 2A 1-105-D catalist bed temperature # 2A 1-105-D catalist bed temperature # 2A 1-105-D catalist bed temperature # 2A 1-105-D catalist bed temperature # 2A 1-105-D, BED # 1 1-105-D catalist bed temperature # 1 1-105-D catalist bed temperature # 1 1-105-D catalist bed temperature # 1 1-105-D catalist bed temperature # 1 1-105-D catalist bed temperature # 1 1-105-D catalist bed temperature # 1 1-105-D catalist bed temperature # 1 1-105-D catalist bed temperature # 1 METHANATOR 1-106-D catalist bed 1-106-D catalist bed 1-106-D catalist bed

INSTRUMENTS ITEM NO REMARK LOCATION FI-1092 LP to CW pump turbine. SLL HEADER FI-1093 fuel to start-up heater START UP HEATER FI-1094 condensate from 1-112-J WATER JACKET FI-1095 CO2 product (top outlet stripper) NG FEED & CO2 PROD FI-1152 export / import steam MP HEADER FI-1201 natural gas to catalyst tube STM TO CARBON RATIO FI-1202 steam gas to catalist tube STM TO CARBON RATIO FI-1280 CO2 product to header NG FEED & CO2 PROD FI-4301 NH3 to Urea NH3 STORAGE FI-701A inlet 1-C-E101A HRU FI-702 gas to regeneration / inlet 1-C-E102HRU, 1-D-A101 FI-703 HRU product HRU FI-704 steam to 1-C-E101A HRU FI-706 fuel gas product HRU, 1-D-A101 FIA-1151 demin to water jacket WATER JACKET FIC-1001 NG to 1-101-BC2 REFORMER FEED FIC-1002 Steam to 1-101-BC2 REFORMER FEED FIC-1003 discharge of 3rd stage REFORMER FEED FIC-1005 semi lean sol'n to mid part of abs 1-101-E & FEED FIC-1006 1-104-J dicharge STEAM DRUM LEVEL FIC-1014 lean sol'n to top of absorber 1-101-E & FEED FIC-1016 reflux flow 102-E STRIPPER FIC-1017 liq from top to bott part of stripper 102-E STRIPPER FIC-1019 steam to 1-150-E 1-150-E FIC-102 discharge of 3rd stage. AIR COMPRESSOR

TI-1360 TI-1361 TI-1362 TI-1363 62

1-106-D catalist bed 1-106-D catalist bed 1-106-D catalist bed inlet 1-104-F temperature

FIC-1020 BFW to 1-123-C BFW FROM 104-J FIC-1022 synthesis gas to Natural Gas FEED GAS COMP FIC-1027 1-104-E gas inlet ( purge gas to HRU ) 1-104-E FIC-1030 fuel to auxiliary boiler AUXILIARY BOILER FIC-1040 steam to ejector LTS & W.H RECOVERY 75

ITEMS INSTRUMENT

ITEMS INSTRUMENT

1603 FIC-303 TI-1366 FIC-304 HS-1002 PI-309 TI-1367 FI-1059 HS-1001 1608 TI-1374 TI-1391 TI-1392 TI-1393 TI-1394

1-103-J HP CASE kick back to 3rd stage suction 4th stage kick back to 4th stage suction 4th stage, MOV-1002 1-111-L outlet discharge 4th stage discharge 4th stage outlet 1-111-L, MOV-1001 1-105-D, BED # 2B outlet 1-105-D 1-105-D catalyst bed temperature # 2B 1-105-D catalyst bed temperature # 2B 1-105-D catalyst bed temperature # 2B 1-105-D catalyst bed temperature # 2B

1704 FIC-501 FIC-502 FIC-503 FIC-504 TI-1398 TI-1399 TI-1400 TI-1404 1209 LIC-1025 PDI-1069 FIC-1019 TI-1405 FI-1062 AI-1017

1-105-J 1st stage suction 2nd stage discharge 3rd stage discharge 4th stage discharge 1-120-CF4 bottom out 1-120-CF3 bottom out 1-120-CF2 bottom out 1-120-CF1 bottom out 1-150-E 1-150-E liquid level 1-150-E differential pressure steam to 1-150-E temperatur condensate outlet 1-150-E condensate outlet 1-180-C conductivity of process condensate

1102 TI-1761 PDI-1798 LI-1155 FIC-1088 LI-1157 TI-1773 TI-1774 PDI-1802 64

PRETREATMENT CO2 REMOVAL outlet bottom absorber differential pressure absorber liquid level in stripper ( upper part ) steam to reboiler flush drum level outlet flash drum lean solution temperature stripper differential pressure

73

ITEMS INSTRUMENT

ITEMS INSTRUMENT

1701 LIC-1013 LIC-1012 PIC-1108 TI-1403 FIC-1078 FIC-1079 LY-1012C

NH3 PRODUCT 1-106-F liguid level 1-107-F liguid level 1-107-F pressure ( top outlet ) ammonia out 1-107-F 1-107-F to 1-120-CF3 1-107-F to 1-120-CF2 select switch

1907 PIC-710 TIC-718 PI-713 TI-714 PDIC-705 HS-704 HS-706

HRU inlet 1-C-E101 SLL inlet 1-F-D104 1-F-D101 bottom outlet 1-F-D101 bottom outlet fuel gas product fuel gas product fuel gas product

1702 PIC-1009 LIC-1015 PIC-1028 LIC-1021 LIC-1022 LIC-1023 LIC-1024 TIC-1796 1703 TI-1402 FI-1060 FQI-1060 HIC-1032 FI-1061 FQI-1061 HS-1024

NH3 REFRIGERATION FLASH DRUM 1st stage suction 1-109-F liquid level warm ammonia product to urea 1-120-CF4 bottom out 1-120-CF3 bottom out 1-120-CF2 bottom out 1-120-CF1 bottom out ammonia to urea PRODUCT TO UREA STORAGE 1-109-F bottom out warm ammonia product to urea warm ammonia product to urea speed of 1-120-J cold ammonia product to storage cold ammonia product to storage cold / hot product selection

1201 FI-1094 FIA-1151 LAL-1051 LAL-1052 LAL-1053 LAL-1054 LAL-1055

WATER JACKET condensate from 1-112-J demin to water jacket 1-103-D water jacket level 1-103-D water jacket level 1-107-D water jacket level 1-101-C water jacket level 1-102-C water jacket level

1203 FI-1201 FI-1202 PI-1053 TI-1024

STEAM TO CARBON RATIO natural gas to catalyst tube steam gas to catalist tube steam gas to catalist tube steam gas to catalist tube

1604 1-103-J DISCHARGE TO LOOP HIC-1026 by-pass 1-121-C

72

TI-1373

outlet 1-121-C

65

ITEMS INSTRUMENT

ITEMS INSTRUMENT

1903 PIC-1034 TIC-1414 FI-1027 TI-1801 LIC-1027 TI-1416

1-105-E 1-105-E top outlet 1-105-E top outlet steam to 1-140-C temperature from 1-140- C 1-105-E liquid level 1-105-E bottom outlet

1805 PIC-1001 TI-1550 PI-1036 FIC-1030 PIC-1030 PIC-1018 PIC-1023 AI-101 IA

AUXILIARY BOILER fuel to auxiliary boiler / superheater HP steam outlet drum steam drum pressure fuel to auxiliary boiler fuel to auxiliary boiler HP header pressure auxiliary boiler draft flue gas O2 SUPERHEATER 1-102-C outlet HP header temperature combustion air control fuel to superheater burner 1-102-C outlet 1-102-C outlet bypass inlet 1-104-D1

1806 PIC-1012 FIC-1808 PIC-1018 PIC-1023 FIC-1278 PIC-1855 TI-1810

HP HEADER 1-103-JT governoor control 1-103-JT extraction line HP Header pressure auxiliary boiler draft air to auxiliary boiler air to auxiliary boiler air to auxiliary boiler

TIC-1004 TIC-1005 PDIC-1022 FI-1031 TI-1338 TI-1337 TI-1339

1807 PIC-1012 HIC-1028 HIC-1029 TIC-1020 PIC-1013 TI-1554

LETDOWN HP TO MP 1-103-JT governoor control letdown HP to MP letdown HP to MP desuperheater HP to MP letdown HP to MP, pressure MP header MP header temperature output desuperheater

1207 TI-1052 TI-1053 TI-1787 TI-1335 TI-1340

SECONDARY REF & WH EXCHANGER secondary ref temperature top secondary ref temperature bottom secondary ref temperature middle 1-101-C outlet main line 1-101-C outlet bypass

70

67

ITEMS INSTRUMENT

ITEMS INSTRUMENT

1605 FIC-1077 TI-1371 HIC-1025 PDI-1054 TI-1369

SYNTHESIS LOOP synthesis gas to purge inlet 1-121-C synthesis gas to 1-105-D differential quench 1-105-D differential pressure outlet 1-121-C NG FEED & CO2 PROD natural gas suffly, inlet B/L natural gas suffly, inlet B/L natural gas suffly, inlet B/L CO2 product to header CO2 product ( top outlet stripper ) NH3 STORAGE 43-5102-F Liquid level NH3 to Urea 43-5101-J speed 43-5101-JA speed NH3 to Urea NH3 STORAGE NH3 storage NH3 storage NH3 storage NH3 storage NH3 for loading system

1808 PIC-1014 FI-1089 TI-1806 FI-1091B FI-1152 HIC-1262 TIC-1825

MP HEADER MP steam to vent ( MP steam pressure ) stm to CW pump turbine stm to CW pump turbine export / import steam export / import steam export / import steam BFW to export / import

FI-1042 FQI-1042 TI-1029 FI-1280 FI-1095

LIC-4301 TIC-4301 TIC-4318 XI-4301 XI-4302 FI-4301

1101 PIC-4001 LIC-1154 FIC-1066 TIC-1769 PIC-1799 LIC-1156 FIC-1068 FIC-1070 1103 LIC-1002 FIC-201 PIC-1071 TIC-1305 FIC-1022 PIC-1010 TI-1783

FEED TREATING naturalgas supply, inlet B / L level absorber reflux flow outlet top stripper outlet top stripper liquid level in stripper ( bottom part ) steam to ejector lean solution flow FEED GAS COMPRESSOR level 1-144-F 1-102-J disharge NG vent upstream 1-102-J bypass 1-101-BC5 synthesis gas to Natural Gas outlet 1-108-D middle 1-108-D 71

LI-4307 LI-4308 PI-4311 PI-4310 PIC-4320 66

ITEMS INSTRUMENT

ITEMS INSTRUMENT

1301 TI-1341 TI-1342 TI-1343 TI-1344 PI-1814 HS-1018 TIC-1010

HTS 1-104-D1 catalyst bed 1-104-D1 catalyst bed 1-104-D1 catalyst bed 1-104-D1 catalyst bed process gas outlet 1-103-C1/C2 MOV to vent d/s 1-104-D2 inlet 1-104-D1

1208 PI-1028 PI-1061 PI-1062 PI-1063 PI-1064 PI-1838

FUEL TO ARCH BURNER fuel to arch burner inlet arch burner inlet arch burner inlet arch burner inlet arch burner inlet arch burner

1302 TI-1011 HS-1008 TI-1346 TI-1347 TI-1348 TI-1349 HS-1004

LTS process gas outlet 1-103-C1 / C2 MOV inlet 1-104-D2 1-104-D2 catalyst bed 1-104-D2 catalyst bed 1-104-D2 catalyst bed 1-104-D2 catalyst bed emergency s/d 1-104-D2

1901 PIC-1032 TI-1802 PDI-1055 LIC-1026 FIC-1064 TI-1799 FI-1063 HS-1027B 1902 PIC-1033 TI-1797 PDI-1056 LIC-1163 FI-1081 HS-1027A FIC-1027 XY-1264

1-103-E 1-103-E top outlet 1-103-E top outlet 1-103-E different pressure 1-103-E liquid level 1-103-E liquid inlet 1-103-E liquid inlet 1-103-E top outlet 1-140-J/JA start 1-104-E 1-104-E top outlet 1-104-E top outlet 1-104-E differential pressure 1-104-E liquid Level 1-104-E liquid inlet 1-141-J/JA start 1-104-E gas inlet ( purge gas to HRU ) HRU to fuel system

1609 FI-1047 FI-1093 PIC-1852 HIC-1050 TI-1397 FALL-1257 TI-1396

START UP HEATER total fuel from 1-200-F fuel to start-up heater fuel to start-up heater fuel to start-up heater fuel to start-up heater flow to 1-102-B synth gas outlet 1-102-B 68

69

HOIST & ELEVATOR 2-JC101 2-JC201 2-JC301 2-JC302 2-JC303 CONVEYOR & SCALE 2-JD301A, B 2-JD302 2-JF301 CRANE 2-JE101 CRANE FOR 2-GB101 SCREW CONVEYOR TO MELTER BELT CONVEYER TO TROMMOL S BELT SCALE HOIST FOR REACTOR HOIST FOR CENTRIFUGE ELEVATOR FOR OPERATOR HOIST FOR MELTER HOIST FOR PRILLING TOWER

TINDAKAN PENGAMANAN A. FIELD : * Tutup bv Gas Battery Limit ( d/s PV-4001 ) * Hand Jack Close FV-1002 hingga tinggal 15 ~ 20 %. * Hand Jack Close HV-1021 hingga tinggal 5 ~ 10 %. * Hand Jack Close HV-1028. * Atur level 101-F dengan mengatur speed 104-J. * Atur bv disharge, perhatikan LI-1001 C/D dekat 104-J/JA. * Buka bv b/p HV-1262. * Atur speed ID Fan + 600 rpm dengan men throttle bv steam inlet. * Stop semua pompa Benfield 108-J, 107-J, 201-J. * S/D Synloop, stop pompa 113-J, 124-J. * Amankan semua Compresor * Amankan ARU; HRU stop 140-J / 141-J. B. CONTROL ROOM : * Matikan semua Comp via HS-1201, HS-1202, HS-1203, HS-1205. * Buka MOV-1018 untuk mengalirkan steam proses. * Tutup MOV-1008 dan matikan semua pompa benfield system.

170

131

2-GB101 AUXILIARY EQUIPMENT 2-GB101-EA1A,B 2-GB101-FA1 2-GB101-FA2 2-GB101-FA3 2-GB101-FD1A,B 2-GB101-GA1A,B 2-GB101-GB1 OIL COOLER OIL RESERVOIR LUBE OIL HEAD TANK CONTROL OIL ACCUMULATOR OIL FILTER OIL PUMP INDUCED FAN FOR OIL RESERV

GT - 102 : STEAM TURBINE AMMONIA FEED PUMP Type Motive Steam Steam Consumtion Steam Exhaust Product Speed Normal Speed Minimum Governoor : Condensing Turbine : 42.0 Kg / Cm2G : 3.31 T/H : : 6500 RPM. : 4800 RPM.

2-GT101 AUXILIARY EQUIPMENT 2-GT101-EA1 2-GT101-FA1 2-GT101-FA2 2-GT101-GD1 GLAND CONDENSER UNIT OIL ACCCUMULATOR DRAIN POT TURNING GEAR

GA - 101 : AMMONIA FEED PUMP. Type Capasity Pressure Suction / Discharge Temperatur Suction / Discharge : Centrifugal. : 69 T/H : 25.03 Kg / 181.03 Kg. : 30 0C /

2-GA101A, B AUXILIARY EQUIPMENT 2-GA101A, 2-GA101A, 2-GA101A, 2-GA101A, B B B B -EA1 -FA1 -FD1A,B -GA1A,B OIL COOLER LUBE OIL RESERVOIR OIL FILTER OIL PUMP

2-GT102A, B AUXILIARY EQUIPMENT 2-GT102A, B-FA1 DRAIN POT

GT - 103 : STEAM TURBINE RECYCLE SOLUTION FEED PUMP. Type : Condensing Turbine Motive Steam : 42.0 Kg / Cm2G Steam Consumtion : 3.44 T/H. Steam Exhaust Product : Speed Normal : 5500 RPM. Speed Minimum Governoor : 3800 RPM. GA - 102 : RECYCLE SOLUTION FEED PUMP. Type Capasity Pressure Suction / Discharge Temperatur Suction / Discharge : Centrifugal. : 75 T/H : 25.03 Kg / 186.03 Kg. : 110 0C /

168

133

GADO - GADO DARI P - IB

2-GA102A, B AUXILIARY EQUIPMENT

UREA P - IB :

2-GA102A, 2-GA102A, 2-GA102A, 2-GA102A,

B B B B

-EA1 -FA1 -FD1A,B -GA1A,B

OIL COOLER LUBE OIL RESERVOIR OIL FILTER OIL PUMP

GT-101 : STEAM TURBINE COMPRESSOR CO2 Type Motive Steam Extraction Steam Steam Consumtion Steam Extraction Product Steam Exhaust Product Speed Normal Speed Minimum Governoor EA- 104 EE-102 GA-107 A/B : Extraction & Condensing Turbine : 42.0 Kg/Cm2G; 399 0C. : 22.0 Kg/Cm2G; 335 0C. : 61.07 T/H : 37.01 T/H : 24.16 T/H : 7620 RPM. : 6477 RPM. : Surface Condenser : Ejector Condenser : Condensate Pump

2-GT103A, B AUXILIARY EQUIPMENT 2-GT103A, B-FA1 DRAIN POT

TURBINE CONDENSER (2-EA-104) AUX EQUIPMENT 2-EA104-EE1 2-EA104-EE2 STARTING EJECTOR EJECTOR CONDENSER

INSTRUMENT AUXILIARY EQUIPMENT 2-FA106 AGITATOR 2-GD201 2-GD301 2-GD302 2-GD303 PRILLING TOWER & PIT IA-301 IH-501 PRIILING TOWER DRAIN RECOVERY PIT AGITATOR AGITATOR AGITATOR AGITATOR FOR FOR FOR FOR 2-FA202 2-EA301 2-FA302 2-FA303 GAS RELEASER

GB-101 : COMPRESSOR CO2 Type : Centrifugal Stage : 2 (2 - 2 ) Stage at LP & HP Case. Capasity : 28.486 Nm3 / Hr. Pressure Suction / Discharge : 0.6 Kg / Cm2 G / 180 Kg / Cm2G. Temperatur Suction / Discharge : 38 0C / 115 0C RPM 1500 ; kebutuhan Steam : 1.6 T/H Extraction Aktif; butuh Steam : 12 T/H RPM 7250; butuh Steam : 12 T/H Min Gov; butuh Steam : 25 T/H 132

169

C W ke Urea : Flow Tekanan in / out Temperatur in / out Fouling Factor S M ke Urea : Flow Flow Actual Ratio

: 5883 / 6960 T/H : 4.0 Kg / 2.0 Kg. : 32 0C / 41.9 0C. : 0.0002 M2Hr 0C / K.Cal.

: 68 T/H : 84 T/H : 0.944 T / T. Urea.

2-GA401 2-GA402 2-GA403 2-GA501 2-GA502 2-GA503 2-GA 504

CARBAMATE BOOST UP PUMP A & B H. P. ABSORBENT PUMP A & B CARBAMATE SOLUTION PUMP A & B PROCESS CONDENSATE PUMP A & B UREA HYDROLYZER FEEED PUMP A & B DRAIN RECOVERY PUMP A & B GLAND SEAL CIRCULATING PUMP A & B

AUXILIARY EQUIPMENT LIST


COMPRESSOR DAN BLOWER 2-GB101 2-GB301 2-GB302 2-GB303 2-GB304 CENTRIFUGE 2-GF201 TURBINE 2-GT101 2-GT102 2-GT103 2-GT104 2-GT105 STEAM STEAM STEAM STEAM STEAM TURBINE FOR TURBINE FOR TURBINE FOR TURBINE FOR TURBINE FOR 2-GB101 2-GA101 2-GA102 2-GA104 2-GA105 167 CENTRIFUGE A ~ F CO2 COMPRESSOR FORCED FAN FOR DRYER INDUCED FAN FOR DRYER BLOWER FOR FLUIDING COOLER INDUCED FAN FOR PRILLING TOWER A ~ F

Steam Condensate dari Urea : 80 % dari Steam Consumtion Actual + Demin Make Up Cond . T

: 59.48 T/H : 105 T/H

Konsumsi bahan baku Urea / Metrik Ton Urea : NH3 ( 100 % NH3 ) : 0.568 m TON CO2 ( 100 % CO2 ) : 0.745 m TON ENERGY LISTRIK : 30 KWH C W Sirkulasi ( d T 10.1 0C ) : 88 m3 : 0.99 m TON STEAM ( 42 Kg; 399 0C ) Exhaust PRILLING TOWER : NH3 Constant UREA Dust Design : NH3 = 29 mg / Nm3 RATIO :

: max 50 mg / Nm3 : max 50 mg / Nm3 UREA : 30 mg / Nm3

134

H2O / CO2 NH3 / CO2 Conversi CO2

: 0.46 mol / mol. : 4.0 mol / mol. : + 70 %.

DISTRIBUTOR & SPRAY NOZZLE 2-FJ301 2-FJ302 2-FJ303 2-FJ304 ACOUSTIC GRANULAR A ~ J SPRAY NOZZLE FOR PACKED BED SPRAY NOZZLE FOR DEMISTER SPRAY NOZZLE FOR 2-GB302

Performance Guarantee Kualitas Urea : Nitrogen H2O Biuret

: 1725 Ton / Day.

: 46.2 % berat maximum. : 0.3 % berat maximum : 0.5 % berat maximum

2-FJ501 PUMP 2-GA101 2-GA102 2-GA103 2-GA104 2-GA105 2-GA106 2-GA107 2-GA108 2-GA121 2-GA201 2-GA202 2-GA203 2-GA204 2-GA205 2-GA206 2-GA301 2-GA302 2-GA303 2-GA304 2-GA305 166

SPRAY NOZZLE FOR 2-EA501

Fe NH3 Free Ash Prill Size :

: 1.0 ppm berat maximum : 150 ppm berat maximum. : 15 ppm berat maximum.

AMMONIA FEED PUMP A & B CARBAMATE FEED PUMP A & B AMMONIA BOOST UP PUMP A & B LOW PRESSURE FLOADING PUMP HIGH PRESSURE FLOADING PUMP STEAM CONDENSATE PUMP A & B RETURN CONDENSATE PUMP A & B WATER INJECTION PUMP A & B SEALING WATER PUMP A & B UREA SOLUTIOPN PUMP A & B CIRCULATING PUMP FOR CRYSTALLIZER SLURRY FEED PUMP A & B MOTHER LIQUOR PUMP A & B HOT WATER PUMP A & B L. P . ABSORBENT PUMP A & B WATER PUMP FOR PRIILNG TOWER A & B CIRC PUMP FOR DUST RECOVERY A & B No. 1 DISOLVING TANK PUMP A & B No. 2 DISOLVING TANK PUMP PORTABLE WATER PUMP A & B

100 % lolos pada ayakan mesh no. 06 95 % lolos pada ayakan mesh no.18 2 % lolos pada ayakan mesh no. 25 Temperatur Product : 42 0C.

Kebutuhan bahan baku pada Rate CO2 : 100 % NH3 : 40.7 ~ 45 MT / Hr CO2 : 52.9 ~ 56 MT / Hr STEAM : 69.4 ~ 76 MT / Hr LISTRIK : 2030 ~ 2200 KW CW SIRKULASI : 5927 ~ 6570 MT / Hr INST AIR : 200 ~ 220 NM3 / Hr PLANT AIR : 670 ~ 700 NM3 / Hr EMERGENCY POWER : 140 KW DEMIN WATER : 2.0 MT / Hr PROSES CONDENSATE : 7 ~ 27 MT / Hr

135

2-EA301 2-EA401A 2-EA401B 2-EA402 2-EA501 2-EA502 2-EA504 2-EA505 2-EA506 2-EA507 2-EA508 2-EC301 2-EC302 EJECTOR 2-EE101 2-EE102 2-EE501 2-EE502 TANK & SEPARATOR 2-FA102 2-FA103 2-FA104 2-FA105 2-FA111 2-FA112 2-FA113 2-FA114

MELTER HIGH PRESSURE ABSORBER A HIGH PRESSURE ABSORBER B LOW PRESSURE ABSORBER 1st SURFACE CONDENSER 2nd SURFACE CONDENSER PREHEATER FOR 2-DA501 PREHEATER FOR 2-DA502 FLASH GAS CONDENSER REBOILER FOR 2-DA501 GLAND SEAL CIRCULATION COOLER AIR HEATER FOR DRYER AIR HEATER FOR FLUIDIZING COOLER

AMMONIA P - IB : Tie - In NH3 : Cold NH3 : P-IB --> P-II Hot NH3 : P-IV --> P-III Cold NH3 Cold NH3 Cold NH3 Hot NH3 : P-IB --> P-II : P-IV --> P-III : P-IB --> P-IV : P-IB --> P-IV

> Bisa

> Tidak bisa

> Bisa

* Bila 5101-J / 5102-J Running; maka Cold NH3 dari P-II, P-III & P-IV tidak bisa masuk ke NH3 Storage IB, karena line min flow 5101-J & 5102-J bergabung dengan line tsb. NH3 STORAGE LEVEL : 1 M Level NH3 STO P-IB 1 M Level NH3 STO P-II 1 M Level NH3 STO P-III 1 M Level NH3 STO P-IV NH3 STORAGE LEVEL Maximum : Level Maximum P-IB Level Maximum P-II Level Maximum P-II Level Maximum P-IV

STARTING EJECTOR FOR EA-104 EJECTOR CONDENDER FOR EA-104 FIRST EJECTOR FOR EA-501 (S.L). SECOND EJECTOR FOR EA-502 (S.M.L).

: 342 : 230 : 230 : 230

Ton. Ton. Ton. Ton.

164

SATURATION DRUM STAEM DRUM STAEM CONDENSATE TANK AMMONIA RESERVOIR 1st STAGE SUCTION SEPARATOR 2nd STAGE SUCTION SEPARATOR 3rd STAGE SUCTION SEPARATOR 4th STAGE SUCTION SEPARATOR

: 24 Meter. : 13 Meter : 13 Meter : 13 Meter

5101-J ( Hot Transfer Pump ) ; baru bisa running pada level NH3 STO 5.5 M. 5102-J ( Cold - Loading Pump ); Stop pada minimum level 3 Meter.

137

Mutu Bahan Baku : NH3 Cair ( Komposisi ). NH3 H2O Oil Insoluble Gas Tekanan Temperatur CO2 Gas ( Komposisi ). CO2 Total Sulphur

: 99.5 % berat minimum : 0.5 % berat minimum : 0.5 ppm berat max : Nill : 18.0 ~ 20,0 Kg / Cm2 : 30 0C : 98.0 % berat minimum : 1.0 ppm vol maximum

2-FA121 2-FA201 2-FA202 2-FA203 2-FA204 2-FA205 2-FA301 2-FA302 2-FA303 2-FA304

SEALING WATER TANK UREA SOLUTION TANK CRYSTALLIZER MOTHER LIQUOR TANK HOT WATER TANK UREA SOLUTION SEPARATOR HEAD TANK No.1 SOLUTION TANK No.2 SOLUTION TANK STRAINER WASHING TANK

Steam :

H2O Tekanan Temperatur Tek / Temp Fouling Factor

: Saturation : 0.6 Kg / Cm2 g min : 38 0C. : 42.0 Kg / Cm2/399 0C : 0.0001 M2Hr 0C/ K Cal : 0.05 ppm max : 0.5 ppm max : 4.0 Kg; 32 0C / 42 0C : 0.0002 M2Hr 0C/ K Cal : < 5 ppm. : < 5 ppm. : 10 ppm max : 300 pppm max : Ambient.

2-FA305 2-FA306 2-FA401 2-FA501

WATER TANK POT FOR 2-EA-301 CARBONATE SOLUTION TANK PROCESS CONDENSATE TANK

CHAMBER; CYCLONE; STRAINER & FILTER 2-FC301 2-FC302 2-FD202 2-FD301 2-FD302 2-FD303 2-FD304 2-FD305 2-FF301 2-FG101 2-FG103 2-FG104 CYCLONE DUST CHAMBER PRETHICKENER A ~ E STRAINER FLUIDING COOLER TROMMOL SCREEN PACKED BED FOR DUST RECOVERY DEMISTER FOR PRILLING TOWER FLUIDIZING DRYER CO2 VENT SILENCER No.1 STEAM VENT SILENCER No.2 STEAM VENT SILENCER

Demin Water : Si O2 terlarut Total padatan Cooling Water : Tek / Temp in / out Fouling Factor Process Condensate : Kandungan Urea Kandungan NH3 Nitrogen Kualitas : NO x O2 Temperatur

136

165

FLOW SYNT GAS ( FCAL-1001 ) = Rate X 28 FLOW UDARA ( FCAL-1003 ) = Rate X 50 Ratio H2 / N2 dimonitor pada inlet 105-J Temp Normal 127-C = 36 0C. Bila temp naik : NH3 lolos ke Purge Gas. Bila temp turun : Aliran gas Refrigerant berkurang. Bila Conductivity di 174-C tinggi, Segera Blow Down dan Injeksikan Demin Water. Temp TI-0709 ( Out Molucular Sieve Dryer ). Nor Operasi : 45 0C Hi- Alarm : 55 0C Trip : 65 0 C Firing Awal Primary Reformer 7 Burner pada posisi tertentu Head Carrier : N2 Kenaikan temp max : 80 0C / Hr Kenaikan temp Norm : 60 0C / Hr STEAM Masuk pada temp 400 0C, vent di V-1005; SM ke Coil Udara & Bottom HTS.

UREA PLANT
PROCESS EQUIPMENT LIST DESUPERHEATER 2-BH101 TOWER & REAKTOR 2-DA101 2-DA102 2-DA201 2-DA202 2-DA401 2-DA501 2-DA502 2-DA503 2-DC101 HEAT EXCHANGER 2-EA101 2-EA102 2-EA103 2-EA104 2-EA105 2-EA111 2-EA112 2-EA113 2-EA121 No.1 CARBAMATE CONDENSER No.2 CARBAMATE CONDENSER AMMONIA PREHEATER TURBINE CONDENSER AMMONIA BY PASS COOLER 1st STAGE INTER COOLER FOR GB-101 2nd STAGE INTER COOLER FOR GB-101 3rd STAGE INTER COOLER FOR GB-101 163 SEALING WATER COOLER STRIPPER SCRUBBER HIGH PRESSURE DECOMPOSER LOW PRESSURE DECOMPOSER WASHING COLUMN PROCESS CONDENSATE STRIPPER UREA HYDROLIZER FINAL ABSORBER REACTOR DESUPERHEATER.

138

AMMONIA PLANT Steam Consumtion = 123.0 Kg. From 1-101-F DESCRIPTION ITEM 1101-JT S T for Process Air Compressor 103-JT S T for Synth Gas Compressor Steam Consumtion = 42.2 Kg. DESCRIPTION ITEM 1102-JT S T for Feed Gas Compressor 104-JT S T for H.P BFW J Pump 104-JAT S T for H.P BFW JA Pump 105-JT S T for Refrigerant Compressor 107-JBT 107-JCT S T for Semi Lean Pump S T for Semi Lean Pump CONSUMTION T/H 109.12 SH / V 107,293 SH / V CONSUMTION T/H 9,123 SM / V 5,688 SM / V *5688 SM / V 14,570 SM / V *15680 SLL / V 12.7 SM / B.P 12.7 SM / B.P

Bila UREA P-IB trip; segera hubungi P-II, III & IV karena tekanan Steam akan mengarah naik. Dan siap-siap untuk mengirim Hot NH3 ke P-II, III & IV. REVANADASI Saat Revanadasi BF system ( Main BF / Feed T ) Konsentrasi V2O5 ( Vanadium ), minimum : 0.7 % ~ 1.0 % ( Norm : 0.7 % ). SYNT LOOP Kalau Start Loop pada kondisi temp 105-D masih panas ( > 300 0C ), + 45 menit kemudian bisa produk NH3. Menaikkan Rate Gas

S T for Lean J Pump 2,858 SM / B.P S T for Lean JA Pump *2858 SM / B.P S T for 103-JTC Condens A Pump *0.35 SM / B.P S T for 101-JTC Condens A Pump *0.137 SM / B.P S T for Cold Amm Product A Pump *0.323 SM / B.P S T for Pretreatment Circ J Pump 0.994 SM / B.P S T for Pretreatment Circ JA Pump*0.994 SM / B.P Steam for Arch Burner Prim Refor 94,245 SH 3,746 SH Steam for Molucular Sieve Regeneration Heater 1,500 SH 101-BJ2 I D Fan 1-101-B 4,971 SM / B.P 101-BJ1 F D Fan 1-101-B 3,728 SM / B.P 101-JLJAT Lube Oil Pump 1-101-J total SM / B.P 102-JLJAT Lube Oil Pump 1-102-J pemakaian 103-JLJ1ATLube Oil Pump 1-103-J steam = 103-JLJ2ATSeal Oil Pump 1-103-J 1.864 T/H 162 * = Stand by

108-JT 108-JAT 112-JAT 114-JAT 124-JAT 201-JT 201-JAT FIC-1002 AIR COIL 173-C

Habiskan dulu vent PIC-1004 ( vent menutup habis ) Stop vent V-1005 in HTS. - Firing Target ( 101-B ) dengan N2 Carier Yaitu temp Flow Gas sampai dengan + 350 0C. Kemudian N2 ganti dengan Steam, Vent di MOV-1018 sampai tempRiser = 760 0C. Bersamaan Reduksi Katalist HTS dengan Steam : - Kemudian masukkan gas ke 101-B - Naikkan Rate - Masukkan Udara. Dst nya. Menentukan Rate GAS : GAS + STEAM + UDARA 27,600 Nm 95 T 50 T 26,500 Nm 90 T 40 T

RATE = 100 % = 95 % 139

4. REFORMING dan STEAM SYSTEM. - Turunkan Rate Gas ke 40 %, vent di MOV-1018. - Atur PIC-1018 = 123 Kg/Cm2. Naikkan beban Aux Boiler. START UP 105-D 1. DT Top & Bottom 105-D tidak boleh > 55 0C. 2. T max press shell inlet = 282 0C. 3. T in/out 102-B harus < 110 0C. 4. 102-B out dgn T 105-D out < 200 0C. 5. 102-B out dgn T Cat tertinggi < 175 0C. 6. Venting Loop ( SV ) --> V-1017. 7. H2O max 1000 ppm ( out 105-D ) --> P = 110 Kg/Cm2 8. In.out 105-D nax 200 0C. 9. By pass 123-C1C2 hingga temperatur Gas = 325 0C. REDUKSI CATALIST Fe + H2 ---> Fe + H2O + Q Fe2O3 + 3H2 ---> 2Fe + 3H2O + Q HEATING UP SHELL 105-D PHILOSOPIE : - Utk menaikkan temp metal shell side kebatas yg aman sebelum tek dapat dinaikkan ke tek opr agar tidak terjadi Thermal Stress. - Utk 105-D telah ditetapkan max temp 32 0C, sebelum tek dapat dinaikkan lebih besar dari pada 35 Kg/Cm2.

11-11-'98

16.07 101-BJIT ( FD Fan Trip ). Force TTV XV-6101 ( Y-I ). 10.09 101-BJIT Start Lagi. 17.25 Inst; Jumper XAHA-6101 Force X-I untuk 6101.

26-11-'98 22.58 105-J Trip. Penyebab : Vibrasi axial XVHH-0500. Ikut terganggu 102-J (Trip). Accumulator tdk bekerja baik Tindakan Pengaman : - Gas vent di V-1000. - HRU; 106-D Shut Down; b/p LTS. - Tutup segera tie-in CO2. - Import Syn Gas dari P-IV unmtuk 108-D. - Urea Plant Shut Down Total. ( CO2 habis ). 00.07 Start 102-J. Rate Gas 15 %. 01.00 Masukkan Gas ke 101-B. 01.16 Switch V-1000 (out 108-D) ke MOV-1018 (inlet LTS). 01.18 Rate Gas 30 %. 02.20 Masukkan Udara ke 103-D via by-pass MOV-1006. 03.30 Masukkan gas ke 101-E. Catatan : - Gas di vent di MOV-1018 sebelum masuk 101-E. - Setelah masuk ke 101-E. Tutup MOV-1018, pindahkan vent ke PC-1005 (sebelum masuk ke 106-D, Methanator) - Setelah masuk ke 106-D, keluar. Gas vent di PC-1004 (persiapan start 103-J). - Start Up Loop : P Disch 103-J = 90 K. - Press Up Loop berangsur-angsur, dengan menutup sirkulasi 103-J. 141

160

Naik atau turunkan Rate Gas Bila akan naik atau turunkan rate Gas, Informasikan pada Supervisor P-II. FI-1152 Flow SM ( 42 K ). Indikasi Import SM dari Utility ke Ammonia Plant IB Schematic 1804. O2 Content Out 108-D = < 0.5 %. FCAH-1065 sp = 1400 Nm3/Hr.

STEAM CONSUMTION FOR P - IB


UTILITY PLANT Steam Consumtion = 42.2 Kg. ITEM 31-5001-JT 31-5204-JT 31-5205-JT 32-5209-JTA 32-5209-JTB 32-5601-JAT 32-5601-JBT 34-5003-JT 34-6007-JT DESCRIPTION CONSUM T/H S T for Demin Water Transfer Pump 3,355 S T for Filter Water Transfer Pump 2,483 S T for C. T Make Up Water Pump 6,522 S T for Amm/Util CW Circ A Pump 7,818 S T for Amm/Util CW Circ B Pump 7,818 S T for CW Circ A Pump for Urea 7,250 S T for CW Circ B Pump for Urea *7250 S T for BFW Pump to Dearator WHB 8,631 S T for FD Fan Packed Boiler 8,541

RE - REDUKSI NH3 CONVERTER ( 1-105-D ). Temp Bed I : 30 0C s/d 250 0C ---> + 50 0C / Hr. 250 0C s/d 300 0C ---> + 20 0C / Hr. 0 0 0 300 C s/d 350 C ---> + 10 C / Hr.

UREA PLANT

350 0C s/d 400 0C

---> +

5 0C / Hr.
0 0

Steam Consumtion = 42.2 Kg. ITEM 2GT101 GT102A GT102B GT103A GT103B GT-104 GT-105 DESCRIPTION CONSUM T/H T for 2-GB101, Comp CO2 61.07 T for 2-GA101A, NH3 Feed Pump A 3.31 T for 2-GA101B, NH3 Feed Pump B *3.31 T for 2-GA-102A, Carbamate Feed Pump A 3.44 T for 2-GA-102B, Carbamate Feed Pump B *3.44 T for 2-GA-104, Steam Condensate Pump 0.24 T for 2-GA-105, High Pressure floading Pump 0.3

Temp Bed I / 2 X / 2 B ---> 512 C ( max 520 C, TI-1386 ) Skin temp Reactor 282 0C ( max ). d temp Top & Bottom < 75 0C. Atur temp bed dengan HCV-1045, bila mengarah naik. Jika temp Bed I : 410 0C, Analisa air harus lebih kecil dari 100 ppm ------ Re-reduksi OK. 1-106-D METHANATOR - Temp out ( operasi normal ) = 347 0C. - High Temp Alarm = 399 0C. - Temp Maximum Katalis Methanator = 426 0C. - Temp Maximum Metal Methanator = 454 0C.

S S S S S S S

140

161

DERIMING COLD BOX - Menghilangkan H2O dan NH3 yang lolos, karena akan menyebabkan kebuntuan. Sehingga menyebabkan Indi kasi temperatur di Cold Box naik ( TI-711 ). Prosedur : - 1. Dengan memakai N2 via ( V-707 by-pass TV-709 ). - 2. Dgn memakai gas kering via ( V-710 ) dgn aliran sbb : V-707 ( V-708 ) --> kebagian hangat 1-C-E101 --> 1-FD-101 --> V-714 --> Cold flare sampai mencapai temperatur = Tujuan : SEQUENCE ADSORBER A/B 1. B Heating Up --> Check Temperatur. 2. B Cooling Down --> Check Temperatur. 3. Valve Change --> Adsorber B Repress. 4. Adsorber A & B Parallel --> valve change. 5. A Depress 6. A Heating Up --> Check Temperatur. 7. A Cooling Down --> Check Temperatur. 8. Valve Change --> Adsorber A Repress. 9. Adsorber A & B Parallel --> valve change. 10. Adsorber B Depress. MOLUKUL SIEVE ( 109-DA & DB ). Autimatic Regeneration Sequence. Adsortion ( A ) : 12 jam. Depressurizing ( DP ) : 46 menit . DP Rate = 2.1 Kg/menit = 3.5 Kg/menit (max). Regeneration ( R ) : 6 jam H/U = 50C/menit. Cooling ( C ) : 2 jam CD : 15 0C/menit. Stand By ( S ) ; 3 jam 14 menit. Total : 24 jam.

142

106-D METHANATOR TRIP : Penyebab : * Kegagalan HTS dan LTS. TAHH - 1220; TAHH - 1201; TAHH - 1202; TAHH - 1203 Setting 4200C * Dari flow larutan Benfield. FSLL-1205 ( Trip = 850 M3/jam ) FSLL - 1214 ( Trip = 110 M3/jam ). Akibat : XV-1211 menutup. MOV-1011 Menutup. Terhentinya aliran synt gas ke Methanator dan venting di PIC-1005. Tindakan : 1. HRU dan ARU - HRU Shut Down. - ARU dipertahankan sirkulasi, atur FIC-1027 agar TI-1001 = 199 0C. 2. LOOP dan REFRIGERANT - Shut Down LOOP, tutup MOV-1001 dan Mov-1002. - Tutup FIC-1077. - Tutup LIC-1013. - Stop 103-J. - Tutup PIC-1004. - 105-J total Kick Back. Catatan : Jika trip Methanator disebabkan kegagalan sirkulasi Benfield, maka S/D dilanjutkan sbb: 3. PURIFIKASI. - Shut Down 150-E. - Cabut gas ke 101-E, vent gas di MOV-1018. PIC-1014 = 21 Kg/Cm2. - Bila sirkulasi Benfield harus di Stop, lakukan Regenerasi terlebih dahulu. 159

101-BJ2T ( ID FAN ) TRIP : * Imformasikan melalui HT. AMMONIA dan UREA IB Shut Down total. * Matikan semua Burner ( BBA; BBU; BBS ) * Tutup bv Fuel Gas header dekat LTS. * Secepatnya stop 101-BJ1T ( FD FAN ) --> Emerg Stop. * Shut Down kan 102-J, 103-J, Synt Loop, 106-D, 150-E, HRU, ARU. Cabut gas ke 101-B. * Vent gas di V-1000, dan SM di MOV-1018. * Cabut Udara ke 103-D, dan Stop 101-J. Cut Rate Gas ke 30 %. FT dan MBF, tetap running sirkulasi Benfield. Tutup LP Purge, Tail Gas, Gas Ex SO trap. Import Steam dari Utility. * 105-J injeksi NH3 hot dari 5101-J/JA atau import * NH3 Hot. Sirkulasikan. * Start MY-COM 5103-L, tutup XV-1150. * UREA : Shut Down Total. 107-J TRIP ( SEMI LEAN PUMP ): SALAH SATU

UTILITY IB : ELECTRIC BUS BAR GE ( 13.8 KV; 50 Hz; 2000 A ) ke : SG-51A : Incoming Feeder. SG-51B : ke TR 510 ( 480 V ) EMERGENCY UTILITY. SG-51C : Ke TR-51 ( 480 V ) Ammonia Plant. : ke TR-53 ( 2.4 KV ) ID FAN Cooling Tower No. 1; 3; 5; 7; 9. SG-51D : ke TR-24 ( 1500 KVA ) Pusri II. SG-51E : ke 5209-JM ( 1575 KW ) CW PUMP. SG-51F : ke TR-58 ( 2.4 KV ) UREA IB. : ke TR-511 ( 480 V ) UREA IB. SG-51G : ke TR # ML1 ( 2.4 KV ) Melamine & Area K P1 : ke TR # ML2 ( 480 V ) Melamine. SG-51H : ke TR-59 ( 2.4 KV ) Pompa Sungai. SG-51I : ke TR-55 ( 480 V ) Water Treatment. : ke TR-56 ( 480 V ) Urea Handling. : ke TR-57 ( 480 V ) Urea Loading. : ke TR-512 ( 2.4 KV ) NH3 Storage. : TR-506 ( 3 KV ) Cranking Motor GTG. SG-51J : ( 52 S ) ke Syncronizing Bus. SG-51-K : ke TR-43 ( P-III ) belum terconnect.

Informasikan melalui HT, 107-J TRIP. Produksi CO2 turun. 106-D Methanator, di by-pass. 103-J total kick back, bila kondisi tak teratasi dalam waktu yang lama. Harus Shut Down Loop. Vent gas di PC-1005. UREA : Ikuti perkembangan, melihat tekanan CO2.

SG-51L

: ke Perumahan.

POWER TIE- IN dari 4006-J ( HITACHI-IV ) 1. Ke TR-54 ( 2.4 KV ) ID FAN Cooling Tower No. 2; 4; 6; 8 ( TR-53 ---> TR-54 ). 2. Ke TR-52 ( 480 V ) Ammonia Plant ( TR-51 ---> TR-52 ). * point 1 dan 2 satu line. 3. 4006-J --> N.O <--- Feeder Line SG-51I ( DS 5852 ). 143

158

102-J TRIP : * Informasikan melalui HT, bahwa 102-J Trip. AMMONIA dan UREA IB Shut Down Total. * Shut Downkan 106-D; Synt Loop; HRU dan ARU. * Cut Rate Gas ke 40 %. Gas, vent di V-1000; Steam di Vent MOV-1018. Back Press = 8 Kg. * 105-J; pertahankan total Kick Back Non Aktifkan 150-E. B/p LTS, buka MOV-1009 dan tutup MOV-1008, tutup b/p outlet LTS. * Import Synt Gas untuk press up 101-E Pertahankan Sirkulasi Benfield (60 % rate ). * Import Steam dari Utility. * UREA : Shut Down Total. TINDAKAN YANG SAMA DGN 102-J TRIP, JUGA BERLAKU JIKA101-BJ1T DAN 101-BJ2T TRIP 103-J TRIP : * Informasikan melalui HT. 103-J Trip. Shut Down LOOP, * Shut Down Synt Loop, HRU dan ARU. * Cut Rate Gas ke 80 %. Vent gas di PC-1004 back press = 29 Kg. * Import Synt Gas untuk 108-D dan press up 101-E. 105-J, total Kick back. * Naikkan beban Aux Boiler . Import SM. * UREA : Ikuti perkembangan, dgn melihat tekanan CO2. Rate CO2 + 70 %. 156

KEBUTUHAN GAS ALAM = 5.0 mm BTU/day Packed Boiler = 4.0 mm BTU/day G T G = 3.0 mm BTU/day W H B = 5.0 mm BTU/day Firing PRIM REF NH3 Start Up for Example : Jam Tambah G Pakai Gas 23/02/'98 15.0 mm 24/02/'98 15,00 5.0 mm 20.0 mm 23,00 10.0 mm 30.0 mm 25/02/98 09,00 8.0 mm 38.0 mm 15,00 2.0 mm 40.0 mm 21,00 8.0 mm 48.0 mm 26/02/98 10,00 6.0 mm 54.0 mm 27/02/98 20,00 7.0 mm 61.0 mm

Rate Gas Shut Down Start Up 30% 50% 60% 70% 85% 96%

Natural Gas Tekanan Natural Gas dari Pertamina = 450 psi ( 31.64 Kg ) di Let Down ke 28 Kg/Cm2G Natural Gas ke G T G 28 Kg/Cm2G ---> 15 Kg/Cm2G Chamber = 8.4 Kg/Cm2G Temp = 55 0C Flow = 8383 / 8719 Kg/Hr Natural Gas ke W H B 28 Kg/Cm2G ---> 3 Kg/Cm2G ---> 0.25 Kg/Cm2G ( Via 5 burner ). Flow = 2696 / 5484 Kg/Hr

145

5007-J EMERGENCY Supply ke : MCC-510 MCC-513 MCC-510 MCC-515

GENERATOR ( GENSET ) : Emergency utk UTILITAS. : Emergency utk NH3. : Emergency utk UREA. : Emergency utk UOA.

Opening PV-3471 ( Vent 42 K Steam ) 10% = 7.8 T/H 60% = 43.4 T/H 20% = 10.67 T/H 70% = 61.6 T/H 30% = 15.15 T/H 80% = 87.5 T/H 40% = 21.52 T/H 90%= 124.2 T/H 50% = 30.56 T/H 100%= 136.4 T/H LISTRIK KE PERUMAHAN Perumahan Lama dari Area K P-I, Sumber Power dari P-II Perumahan KELLOG dari P-II Perumahan Baru/ Gollan dari FEEDER B / SG-51L P-IB AIR KE PERUMAHAN Tekanan air ke perumahan diatur dari bv pada line TIE-IN cabang disch pompa 31-5210-J/JA. Pengaturan Beban LISTRIK

104-J/JA TRIP: ( yang stand by tidak bisa Running ). * Informasikan melalui HT, 104-J Trip. Amm S/D total. 104-J Trip. Ammonia IB Shut Down Total. Stop semua penyalaan burner di Reformer System. * Import Steam dari Utility. * Cut Rate Gas ke 40 %. Vent gas di V-1000 dan MOV-1018 * 101-J; 102-J; 105-J ( bila Steam memungkinkan ), bila tidak segera matikan. * 103-J stop. 106-D Shut Down via HS-1253 ( tutup vent PC-1005 utk mempertahankan tekanan Gas di 101-E). * UREA : Shut Down Total. 105-J TRIP : Akibat : * * * * *

Tek di120-CF1~4 naik, karena pendingin hilang Peroduksi NH3 Liquid terhenti. Informasikan melalui HT, 105-J Trip. Shut Down LOOP. Shut Down kan 103-J, Synt Loop, HRU, ARU. Potong Rate Gas ke 85 %. MY-COM 5103-L start, bila tie-in tidak memungkinkan. Naikkan beban Aux Boiler 101-BU Import Synt Gas. Non aktifkan XY-1150 bila SP-025 tidak Trip. Vent Gas di PC-1004 Switch sumber H2 utk 108-D, dari tie-in P-II, P-III, P-IV. UREA : Ikuti perkembangan. Melihat tekanan CO2. Catatan : Tek NH3 STO PI 4010 dan PI 4311

Pada saat pengaturan beban listrik ( tie-in ) perhatikan juga tekanan Steam.

124-J TRIP ( COLD AMM PRODUCT PUMP ) Secepatnya harus di Start kembali. Sebab bisa mematikan 105-J ( Liq NH3 ke 105-J ). 157

144

G T G Cooling Water ke G T G

= 261 m3/Hr

SUPERVISOR :

GAWEAN DAN PERLU TAU

Bila Hitachi P-II; P-III; P-IV akan test, cabut beberapa filter

suction ( min 10 ea ). Supaya bila terjadi kejutan beban naik, yang disebabkan oleh hitachi yang ditest, trip. Tdk terjadi Low flow Suction Udara dari 101-J NH3 Flow udara dari 101-J ke UOA = 1552 Nm3/Hr Tek = Distribusi : IA dari UOA = 1127 NM3/Hr. DEMIN

101-J TRIP : Akibat :

*. * * *

Membuka/menutup Demin UOA ke P-IV akan mempengaruhi tekanan DEMIN ke AMM IB. ( Hati-hati )

P. P. U :

Belt 5853 ---> BS IV, P IB Belt 4852 ---> BSIII, P IV Belt 5854-V ----> P IB Belt 2852-V ----> P III

Utk Urea P IB & P IV -----> Gudang.

* * * *

P III : 2852 - V --------> - Emerg Line / Belt. - Bin. - Gudang P III - 2853-V. P IV P IB : ( 5854-V )

146

* - Import Udara dari CENTAX P-III, atau dari 101-J1 P-III/IV. * - Check pemakaian Gas Alam. 155

- Terhentinya supply PA/IA. - Terhentinya udara proses ke 103-D. - CO yang masuk ke HTS dan LTS bertambah. - Hilangnya reaksi Exothermis di top 103-D. Informasikan melalui HT, bahwa 101-J Trip. AMM dan UREA IB Shut Down Total. - 103-J, harus dimatikan. - Shut Down : Loop; HRU; ARU; Cold Box; 106-D; 150-E. - 102-J & 105-J ditahan (jangan dimatikan) bila Steam ada Tapi bila Steam krisis, matikan 105-J. Catatan : 105-J ditahan, Karena bila di Stop, perlu pengosongan / Drain. Yang akan menyebabkan terjadinya Polusi. 102-J; masih dirunningkan, dengan harapan untuk segera Start Up kembali. - Cut Rate Gas ke 50 %, - Vent Gas di MOV-1018, back press = 18 Kg. - Non aktifkan 1-150-E. - By pass LTS (buka MOV-1009, tutup MOV-1008) tutup bv outlet. - Segera tutup bv Tie-in CO2 ke Plant lain, agar tidak mengganggu, dengan hilangnya Produksi CO2. - Export NH3; bila ada teruskan atau stop, lihat kondisi. - Pertahanakan Hot Sirkulasi di MBF & FT. - Import Synthesa Gas. - UREA : Shut Down total ( CO2 habis ). - Kurangi pemakaian udara ke bearing GB-302 ( UREA ).

START UP AMMONIA PLANT HARI pertama : 00.00 Energized S L L. 00.20 Energized S M. 02.10 -Heating Up 201-JT dan 108-JT. 02.30 Sirkulasi BF FT via 201-JA. 02.55 Sirkulasi BF Purification via 108-JA dan 107-JC ---> Hot Sirkulasi. HARI ke II: 23.30 Purge Dgn N2 line Fuel ke 101-BBA / BBU dan BBS ---> force di XY-1220; 1235; 1230. 03.30 Start 101-BJ2T ( FD FAN ). 07.00 Masukkan N2 ---> 101-B. ( HCV-1043 WO; V-1005 = 50 % ) 08.15 -Vacuum Up 101-JTC 114-J total Idle Speed. 09.00 Firing 101-BBA : 10 EA ( 60 0C / Hr ). Firing 101-BBU, 5 Pilot. Press Up STEAM DRUM. 10.00 -Firing Main Burner. 13.05 -Pindahkan vent SH dari top 101-F ke V-1019. 14.00 -Arch Burner 40 EA, Main Burner 5 EA. Masukkan Gas ---> 201-E, tutup by=passnya. 15.25 -Let Down SH ---> SM, via PIC-1013 ( SH = 48 Kg ). Close vent SH ( V-1019 ). 15.35 -Firing 11 Pilot Burner + 4 Main Burner. 16.07 - Start. Vent gas di V-1000 inlet 108-D ( TI-1445 >= 385 0C ). Rate Gas = 20 %. 16.20 -Buka steam Sparger HTS, FI-1103 = 4.5 div; V-1005 = WO ( bila temp fuel gas 380 0C ). - Stop N2 Carrier ke 101-B, ganti dgn SM ( Proses )

154

155

35 T/H via FV-1002. - Masukkan steam ---> Air coil ---> 103-D ---> vent V-1005. 147

Purge dengan N2 ---> V - 1005. Stop sirkulasi MBF, stop 108 - J. B/p 201 - E sirkulasi. Regenerasi. Shut Down 105 - J.

KONDISI NORMAL OPERASI Rate Gas =

FCAL - 101 sp = Max temp tube katalis= 899 0c.

FEED TREATING 100% PC - 4001 sp = Kons Benfield = 25 ~ 30 % FC - 1022 = FC - 1070 = 204 - L NaOH = 0.5 %, SG = 1,004 PURIFICATION FC - 1005 FC - 1004 Eq K2CO3 TC - 1012 102 - E top, kontinyu injeksi DM. BFW / STEAM PC - 1018 1 =23.0 Kg 150 - E Aktif, sc -->102 - U, conduct <= 25 m H pH >= 8.0 FC - 1006 max = 250 T/H

REFORMING Ratio FY - 1201 >= 3.5 FY - 1062 FY - 1044A TC - 1312 sp = 595 0C/auto 600 0C TC - 1010 TI - 1314 CH4 OUT 101 - B <= 12.28 % TC - 1011 TC - 1012 PC - 1010 sp =41.0 Kg.

SYNTHESAV LOOP - Refrigerant System, level & Press 120 CF1~CF4 Normal. ARU normal Operasi. HRU : H2 Prod - loop --> Tail gas + Reg Gas --> Fuel. 152 HCV - 1046 : Full Closed.

HARI ke IV : 00.30 Bertahap tutup V-1008, masukkan gas ke 101-E, Vent di PC-1005. - Bertahap aktifkan steam ( motive ) ke 132-L1; L2; L3; L4 tutup vent motive steam. - Kirim CO2 ke UREA Plant. 08.35 Heating Up LTS lewat 172-C, vent di V-1007. Buka MOV-1008. 09.45 Total vent di PC-1005, tutup MOV-1018. 09.47 Tutup MOV-1009, aktifkan LTS. 11.30 -Rate Gas 50 % ~ 55 %. 12.40 -Rate Gas 55 % ~ 60 %. LTS On line. 13.00 -Start 107-JAT 15.00 -Press Up 106-D 16.00 -Heating Up 106-D lewat 172-C 16.20 -Kirim CO2 ke Existing Plant. 17.00 -Start 112-JM Tkb. 17.50 -Rate Gas 60 % ~ 65 %. 18.15 -102-UB On line ( Conductivity = 0,26 ). 18.30 -106-D On line, total vent di PCAH-1004. 19.20 -Start 5101-JA Tkb. 20.26 Kirim Warm NH3 ---> Urea IB.( dari 5101-JA ) HARI ke V : 00.05 Heating Up 103-J 07.25 Rate Gas 65 % ~ 70 %. 08.10 -Rate Gas 70 % ~ 75 %. 08.38 Rate Gas 75 % ~ 80 %. 09.50 Rate Gas 80 % ~ 85%. - Start Press Up 150 - E. - PC drain ke Sewer. 149

18.00

-Heating Up 102-J. - Vacuum Up 101-JTC 18.25 -Pindahkan vent Steam Proses dari V-1005 ---> MOV-1018 bila temperatur inlet HTS > 180 0C. - Stop Steam Sparger HTS. - Back Press = 3.4 Kg. 19.15 -Aktifkan 201-D ( tutup by-pass ), injeksikan NaOH. - 204-LJ di aktifkan. 19.30 -Aktifkan 201-E, aktifkan UCON. 20.10 -Pindahkan vent Gas dari V-1000 in ---> outlet 108-D, 108-D aktif. 20.15 -Start 102-J. 20.50 Rate Gas 20 % ---> 30 % 21.25 -On line kan 102-J. HARI ke III 00.15 -Masukkan gas ke 101-B. 02.00 Heating Up 107-D. - Bertahap nyalakan semua Burner 101-B. 03.00 Vent V-1000 out 108-D closed, gas masuk ke 101-B. 04.10 -Start 101-J. 07.45 Start 107-J. 09.00 Rate Gas 30 % ---> 40 %. 10.15 -Load Up 40 % ---> 45 % ---> 50 %. 11.15 - Buka by-pas MOV-1006, masukkan udara ke 103-D. 12.25 -Buka MOV-1006, tutup by-pass. 103-D On Line. 13.30 -Buka by-pass MOV-1009, pemanasan / pemekatan MB. - Stop SLL ke 105-C, buka by-pass MOV-1009 - 102-F1. 14.10 -Inching MOV-1009, V-1008 open 3/4 ulir. 18.50 -Press Up 101-E, buka V-1008 kemudian PIC-1005 dan MOV-1018. 23.00 Start 121-JA. 148

AMMONIA Bila temp tube katalis 101-B >= 895 0C, segera kurangi penyalaan burner yg berdekatan, sehingga temp < 890 0C. Guarantee Prod = 56.25 T/H = 1350 T/Day Ammonia. FCAH - 1065 sp = 1400 Nm3/Hr.

104-J Test ARCV Speed Up, sebelumnya speed 5125 rpm, FC-1006= 235 T/H sesudah speed 5200 rpm, FC-1006 =250 T/H Panel : Speed Actual 5300 rpm max. Speed ref 5400 rpm. ARCV W.O Turunkan flow ke 243 T/H, coba tutup ARCV bila flow mantap, tidak ada perubahan . Artinya ARCV tidak leak, buka kembali ARCV. UTILITY PRODUCT STEAM W H B = 90 T/H ( 42.2 Kg, 399 0C ). pada beban Gas Turbin Generator 5.93 ~ 22.63 MW. P B : 120 T/H 9 42.2 Kg, 399 0C ). S L L ( 3.5 Kg, 220 0C ) dari : 5005-F ( Blow Down Flash Drum ). Let Down valve dari line SM-3010-4"-(DI) Exhaust Turbine. Supply utk : Dearator; IA Drayer, NH3 Stripping dll. S L L ( 3.5 Kg, 220 0C ) dari 4301-L (Desuperheater). Supply utk : NH3 Heater & Water Heater.

153

10.00 10.15 10.30 11.15 12.35 14.30 17.15 18.25 21.00 21.20

-Aktifkan 150 - E. -Pindahkan vent dari PCAH - 1004 ke PC-1005. Kirim PC dari 150 - E ---> 102- U ( 15 mm Hos ). -Start 103-J - Heat Up 105-J. -Aktifkan HV-1029. -Start 105-J. -Switch jacket water 107-D; 103 - D; 101 - C dari DM ---> SC -Start Regen 109-D. -Start 124-JM. -Persiapan Start Loop System. MOV-1001 / 1002 : W. O HCV - 1044 : 10 %. HCV - 1045 : W. O HCV - 1025 / 1026 : F. C - Mulai adjust FV-301 / 302, press Up loop ke 90 Kg. - Adjust sirkulasi FV-304 ( tutup u/s SP - 006 sampai FV - 1257 naik ). 22.05 Start Firing 102 - B, Start Synt Loop. 22.25 Tutup bv SL di BL. HARI ke VI : 02.50 Start produksi liq NH3 di 106 - F. Aktifkan LC - 1013. 03.10 -Stop injeksi NH3 di 109 - F. 03.45 Start 113 - J, kirim Hot NH3 ke Urea IB. 04.15 -HCV - 1044 arah buka lebar, HV - 1045 arah close. 04.25 Matikan semua burner di 102 - B. 05.40 PCAH - 1004 full close, HCV - 1046 = 40 % Open. bertahap arah close. 07.25 Heating Up line SH 173 - C. 08.20 Full close HCV - 1046. 150

09.10 09.20 10.20 10.30 11.35 12.40 13.25 14.25

-Switch supply H2 ke 108 - D dari P- IV ke 103-J ( LPC ). Start sirkulasi 141 - JA dan 140 - J ( ARU ) on line kan 103 - E & 104 - E -Masukkan vapor NH3 Storage ke 105 - J. -Tutup by-pass 103 - E dan 104 - E. -Tutup vent 105 - E, masukkan vapor NH3 ke 127 - C ( NH3 = 98 % ). -Masukkan LP Purge 103 - E ke Fuel System. -Press Up Absorber ( I - D - A101 ). HRU regen to regen. -Start Mol Sieve Abs I - D - A101 ( HRU ). Setelah regen step 10 ( NH3 di 104-E = 73,4 ppm ).

SHUT DOWN AMMONIA PLANT - Cut Rate Gas ke 80 %. - Shut Down kan HRU & ARU. - Shut Down Loop, stop tie-in CO2 ke Existing Plant. - Stop 103-J, non aktifkan 150 - E. - Cut rate Gas ke 60 %. - Shut Down kan 106 - D & LTS. - Vent Gas di MOV-1018. - Cut rate Gas ke 50 % --> 40 %. - Stop udara ke 103 - D - 101 - E ( MBF ) Shut Downkan. - Stop 101 - J. - Stop Gas ke 101 - B. - Vent Gas di V - 1000 ( Rate Gas pada posisi min = 30 % ). - Stop 102 - J. - Cooling Down 101 - B, 60 0C / Hr - Stop SM ke 101-B bila temperatur Riser =< 300 0C. 151

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