buku pintar

TINDAKAN PERBAIKAN : ITEM No PRESS / TEMP P'TER/VESSEL/CATALIST

102-B Duty : 5,5 mm Start Up Heater For Ammonia * Kembalikan vaccum 101-JTC ke normal dengan menghentikan penyi - Kcal / sec Converter raman dan menambah / menaikkan tekanan steam header untuk 103-D P : 39,7 Kg Secondary Reformer 101-JTC dari 8 Kg ke 10 Kg bertahap. T +/- : 250 / 19 deg C.* Penyesuaian Rate Gas terhadap hilangnya udara dan steam hingga 104-D1 P : 39,7 Kg High Temperatur Shift Converter Rate Gas 80 %. T +/- : 450 / 19 deg C.* Shut Down kan HRU dan ARU, stop pompa 140-J dan 141-J. 104-D2 P : 39,7 Kg Low Temperatur Shift Converter* Mengoptimalkan Import Steam (pengaturan steam system secara me T +/- : 288 / 19 deg C. nyeluruh SH dan SM. Pengaturan Steam Balance Reforming system 105-D P : 188,0 Kg Ammonia Synthesis Converter dan menormalkan back press, pengaturan vent PC-1005 dan PC-1004. T +/- : 538 / 19 deg C.* Menormalkan temp coil udara dan kondisi 101-J hingga supply udara 106-D P : 36,2 Kg Methanator proses normal. T +/- : 454 / 19 deg C.* Start kembali 103-J hingga normal, start Synt Loop dengan menya- 107-D P : 39,7 Kg Primary Reformer Effluent lakan burner 102-B. T +/- : 838 / 19 deg Transfer Line* Jam 20.30 Ammonia sudah dapat diproduksi kembali. 108-D P : 52,7 Kg Cobalt Molybdenum /

T +/- : 427 / 0 deg Zinc Oxide Quard VesselANEKA TROUBLE P-IB 109-DA P : 112,0 Kg Molucular Sieve Drier

DCS HILANG POWER T +/- : 350 / 0 deg C.

109-DB P : 112,0 Kg Molucular Sieve DrierBILA POWER KE DCS HILANG KARENA UPS TROUBLE : T +/- : 350 / 0 deg C.1. DCS CRT tidak ada tampilan dan semua output controller dari DCS 201-D P : 15,8 Kg Iron Sponge Desulfuzation menjadi : 0 mA. T +/- : 150 / 19 deg Vessel

2. Semua control valve akan sesuai dengan specifikasi : ITEM No PRESS / TEMP COOLING WATER a. Warna merah akan terbuka al : FV-1002, HV-1021, HV-1028 dll. b. Warna kuning akan tertutup penuh al : PV-4001, HV-1262, 101-JTC P S/T : 1,75 / 10,5 Kg Surface Condenser for PV-1014, PV-1013, PV-1017. 101-JT & 102-JT3. Compressor 101-J, 102-J, 103-J, 105-J Gov akan ke minimum Speed 103-JTC P S/T : 1,75 / 10,5 Kg Surface Condenser for4. BFW Pump 104-J Governoor minimum Speed. 103-JT & 105-JT5. FD Fan dan ID Fan menjadi Maximum Speed. 107-C P Hot/C : 9,5 / 10,5 KgCarbon Dioxide Stripper 6. Seluruh Burner BBA; BBU; BBS akan mati. Quench Cooler130 91

ITEM No PRESS / TEMP EXCHANGER / REBOILER1-101-BJ2T ( ID FAN ) TRIP. 105-C

P S/T : 10,5 / 39,7 Kg Carbon Dioxide Stripper Process Gas Reboiler

*Beritahu Kabag Shift, Urea dan Utility. 109-CP Hot/C : 2,5 / 7 Kg Lean Solution /

LP BFW ExchangerTINDAKAN : 111-C

P S/T : 10,5 / 39,7 Kg Carbon Dioxide Stripper Ejector1. Stop pembakaran di Reformer 101-B, 101-BU, 101-B CCB/Field. Steam Generator * Tutup bv Fuel header dekat LTS. Field 113-C P S/T : 10,5 / 39,7 Kg Carbon Dioxide Stripper * Tutup LP Purge, Tail Gas, Gas Ex SO trap. Field Condensate Reboiler2. Stop 101-BJ1T ( FD Fan ). CCB/Field. 114-C

P S/T : 36,2 / 36,2 Kg Methanator Feed /3. Cabut Udara ke 103-D, Stop 101-J. Effluent Exchanger Atur : PC-1013, HV-1028, TC-1020, Import SM, level 101-F, 120-C

P S/T : 188 / 188 Kg Ammonia Unitized Chiller

4. Rate Gas kurang lebih 50%, Vent G.B out 108-D, 102-J 121-C P S/T : 188 / 188 Kg Ammonia Converter Feed / lihat Steam balance, Import Synt Gas, Cabut G.B ke 101-B. Effluent Exchanger5. Vent SM out HTS ( MOV-1018 ). CCB/Field. 122-C P S/T : 188 / 188 Kg Ammonia Converter Interchanger LTS B/P, tutup bv out nya.6. Main Benfield usahakan sirkulasi pompa 1/1, tutup bv 129-C

P S/T : 16,5 / 112 Kg Synhesis Gas Compressor inlet 101-E, de-press line d/s bv LTS, Inter Stage Chiller masukkan SLL ke 105-C. 132-C

P S/T : 7,4 / 10,5 Kg Carbon Dioxide Stripper Quench /7. 1-150-E Shut Down kan. LP BFW Exchanger8. S/D kan Synt Loop, HRU dan ARU. 140-C P S/T : 46,4 / 18.6 Kg Ammonia Stripper Reboiler9. S/D kan 103-J, atur SH ke SM ( PC-1013 / HV-1029 ).10. S/D kan 106-D ( Methanator ). 141-C

P S/T : 18,6 / 18.6 Kg Ammonia Stripper /11. FT. tetap sirkulasi, target rate lebih kurang 30%. Effluent Exchanger

188-CP S/T : 47,1 / 48 Kg Condensate Stripper Feed /

Effluent Exchanger

201-C P S/T : 15,8 / 15,8 Kg Feed Gas Pretreatment /Effluent Exchanger

128 93

T S/T : 121 / 65 0C

T S/T : 121 / 65 0C

T Hot/C : 132 /132 0C

T S/T : 200 / 200 0C

T Hot/C : 150 /100 0C

T S/T : 200 / 200 0C

T S/T : 150 / 200 0C

T S/T : 485 / 485 0C

SM ke Coil Udara ( BC-4 ) lebihkurang 585 0C. T S/T : 65 / 65 0C

T S/T : 300 / 300 0C.

T S/T : 450 / 535 0C.

T S/T : 50 / 100 0C

T S/T : 100 / 100 0C

T S/T : 425 / 250 0C.

T S/T : 250 / 180 0C.12. 105-J injeksi NH3 hot via 5101-J/JA atau Import NH3 Hot, Start 5103-L, tutup XV-1150. T S/T : 300 / 300 0C.

T S/T : 140 / 150 0C.

ITEM No PRESS / TEMP COOLING WATER PENGAMATAN PLANT :115-C P S/T : 36,2 / 10,5 Kg Methanator Effluent Cooler

* Jalankan Turning Gear : 103-J, 101-J. LO,SO trap.116-C P S/T : 112 / 10,5 Kg Synthesis Gas Compressor * Tutup Cock valve burner.

Inter Cooler * 105-D ( Mov-1001, 1002, FC-1077 = FC ).124-C

P S/T : 188 / 17,6 Kg Ammonia Converter * Tutup bv suction 103-JLP ( 104-F ).Effluent Cooler * HRU, ARU, LV-1163 bv FC. Cold Box Deriming.

127-C P S/T : 17,6 / 12,3 Kg Refrigerant Condenser * 101-F, Steam System.* Steam ke ID Fan, FD Fan, 103-J, 101-J = FC.

128-C P S/T : 16,0 / 10,5 Kg Refrigerant Compressor * Vaccum ke 101-JTC.3rd Stage Inter Cooler ANEKA TROUBLE P-IB

130-C P S/T : 62,2 / 10,5 Kg Synthesis Gas Compressor KEHILANGAN VACCUM DI 101-JTC1st Stage Cooler Tanggal 10 September 1999; jam 15,45

133-CP S/T : 15,8 / 10,5 Kg Feed Gas Compressor Kick Back

Akibat tindakan penyiraman untuk menurunkan temperatur CW salah134-C P S/T : 188 / 17,6 Kg Synthesis Gas Compressor arah, vaccum di 101-JTC turun kearah positif dari 60 mm HG VAC

Kick Back Cooler ke 290 mmHg VAC.142-C P S/T : 18.6 / 13,1 Kg Ammonia Stripper

Effluent Cooler Dampak terhadap Operasi Pabrik Ammonia IB :167-C P S/T : 16,0 / 10,5 Kg Refrigerant Compressor * Terganggunya supply DM ke 101-F ( 104-JT/speed turun akibat

2nd Stage Inter Cooler Exhaust press turun ).172-C2 P S/T : 52,7 / 10,5 Kg Start Up Cooler * Terganggunya supply Udara ke proses dari FCAL-1003

( 101-J Speed turun akibat Exhaust press turun ).174-C Stripper Condensate Cooler * Turunnya produk steam akibat menurunnya Udara proses dan

bertambahnya pemakaian Steam.202-C P S/T : 15,8 / 11,1 Kg Pretreatment Feed Gas Cooler * Naiknya temp 106-D Methanator melebihi temp normal akibat

204-CP Hot/C : 7,5 / 10,5 KgPretreatment Stripper tinggi ) dan back press terganggu.

OVHD Cooler * 103-J trip akibat terjadinya condensasi yang besar dari 106-D 205-C P S/T : 28,1 / 18,7 Kg Pretreatment Lean ke 104-F ( high level trip ) bekerja, Synt Loop Shut Down.

Solution Cooler * Kehilangan reaksi di 105-D akibat komposisi gas terhadap udara yang terganggu.

92 * Kemampuan 105-J menurun, Press Storage naik. 129

ITEM No REMARK PREHEATER / CATALISTA. PRIMARY REFORMER CONVENTION SECTION * Non Aktifkan 1-150-E.

101-BBSDuty / Burner Super Heater Burner * B/P LTS, buka MOV-1009 dan tutup MOV-1008, tutup bv outlet 1,26 mm Kcal / H LTS.

101-BC3Duty : HP Steam Superheater * S/D Synt Loop; HRU dan ARU.10,47 mm Kcal/H * Import Synt Gas untuk press up 1-101-E.

101-BC4Duty : Cold Process Air Preheater * Pertahankan sirkulasi Benfield ( 60 % Rate ).3,20 mm Kcal /H

101-BC5 Duty : Feed Gas Preheater4,66 mm Kcal / H

101-BC6Duty : Fuel Gas Preheater RINCIAN DARI SHUT DOWN SYNT LOOP; HRU DAN ARU :0,7 mm Kcal / H * total kick back 103-J, buka kick back FIC-301;303 dan 304.

101-BJ2Cap Max / Normal Induced Draft Fan. Centrifugal : * Turunkan speed ke minimum Governoor via PC-301 ( bila 103-J tidak

Speed Max/Nor : 900 / 648 rpm dalam kondisi Trip ).101-BU Duty / Burner Auxiliary Boiler * Vent Gas di PIC-1004 (back press 29 Kg), atur let down SH ke SM.

12,1 mm Kcal / H * Tutup MOV-1001 dan MOV-1002.* Tutup bv U/S LV-1013.

B. PRIMARY REFORMER * Tutup HCV-1044 dan buka lebar HCV-1046.101-B Primary Reformer * Masukkan Hot Ammonia ke 1-109-F via 5101-J/JA.

101-BC1 Duty : Hot Process Air Preheater SHUT DOWN HRU DAN ARU :42,2 mm Kcal / H

101-BC2 Duty : Mixed Feed Preheater * Buka vent Gas PC-1033, tutup bv Gas yang ke fuel 1-101-B.20,45 mm Kcal / H * Buka bv b/p 103-E dan 104-E (tutup bv inletnya), dan isolir LV nya.

101-BJ2T Output Max / Normal ID Fan Turbine Driver * Tutup Gas Ke Cold Box via TV-709.826 / 315 KW Speed Max/Min : 900 / 648 rpm * Tutup V-701 ( Inlet DA-101-A/B ).

* Deriming Cold Box ( buka V-714 aktifkan TCAL-0718 ).C. SECONDARY REFORMER

103-D Secondary Reformer

107-D P : 39,7 Kg Primary Reformer EffluentT +/- : 839 / 19 deg Transfer Line

94 127

ITEM No PRESS / TEMP DRUM

T S/T : 150 / 100 0C

T S/T : 200 / 100 0C

T S/T : 110 / 100 0C

T S/T : 150 / 100 0C

T S/T : 150 / 150 0C.

T S/T : 150 / 100 0C.

T S/T : 180 / 100 0C

T S/T : 150 / 100 0C

T S/T : 200 / 100 0C.

T S/T : 128 / 128 0C.

T S/T : 420 / 100 0C.

T S/T : 120 / 100 0C. terganggu supply steam untuk HTS dan LTS ( CO dan CO2 leak

T Hot/C : 130 /130 0C

T S/T : 200 / 100 0C.

TINDAKAN DIATAS SAMA JIKA 101-BJ1T DAN 101-BJ2T TRIP

251293/176236 Nm3/H

* Stop H2 produk ke 103-J dengan menutup V-704, vent do PIC-0711.

* Non aktifkan 1-150-E. 102-F1P : 36,2 Kg Raw Gas Separator

* By pass LTS (buka MOV-1009 dan tutup MOV-1008). T +/- : 150 / 19 deg C. Tutup bv Outlet LTS. 102-F2

P : 36,2 Kg Carbon Dioxide Absorber * Shut Down Synthesa Loop; ARU dan HRU. T +/- : 150 / 19 deg OVHD KO Drum* Pertahankan sirkulasi Benfield dengan tekanan yang ada. 104-F P : 35,2 Kg Synthesis Gas Compressor

Import Synthesa Gas. T +/- : 150 / 19 deg Suction Drum105-F1 P : 62,2 Kg Synthesis Gas Compressor

1-103-J TRIP : T +/- : 150 / 19 deg 1st Inter Stage Separator* Informasikan ke Kabag Shift, Urea dan Utility bahwa 103-J Trip : 105-F2 P : 112,0 Kg Synthesis Gas Compressor* Cut Rate Gas ke 80 %, vent Gas di PC-1004 (Back Press = 29 Kg) T +/- : 150 / 0 deg C2nd Inter Stage Separator* S/D Synt Loop; HRU dan ARU. 106-F P : 18,8 Kg Ammonia Separator* Atur Let Down Steam System HV-1029 ke PC-1013. T +/- : 150 / -25 deg C* Import Synt Gas untuk 108-D dan press up 1-101-E. 107-F P : 19,7 Kg Ammonia Let Down Drum* Jalankan turning Gear (jika penyebab S/D bukan dari Lube Oil). T +/- : 150 / -25 deg C

109-F P : 17,6 Kg Cobalt Molybdenum /1-105-J TRIP : T +/- : 150 / -18 deg Zinc Oxide Quard Vessel* Non Aktifkan XV-1150 bila SP-025 tidak Trip. 114-F P : 0 Kg Benfield Solution Storage Tank* Start MY COM 5103-L bila Tie-In tidak memungkinkan. T +/- : 150 / 19 deg C.* Shut Down kan Syn Loop; HRU dan ARU. 115-F P : 0 Kg Benfield Solution Sump* Import Synt Gas. T +/- : 123 / 19 deg C.

118-F P : 15,3 Kg Benfield Carbon FilterT +/- : 123 / 19 deg C.

* Stop semua penyalaan burner-burner di Reformer system 132-F P : 5,3 Kg Semi Lean Solutiopn Flash Tank (tutup header fuel dekat LTS). T +/- : 150 / 19 deg C.* Import Steam via HV-1262. 133-F P : 36,2 Kg Carbon Dioxide Stripper

T +/- : 150 / 19 deg Feed Flash Drum* Total kick back 101-J; 102-J; 103-J (bila mungkin) bila tdk matikan. 144-F P : 15,8 Kg Feed Gas Knock Out Drum* Atur temperatur Coil Udara via TV-1312. T +/- : 150 / 19 deg C.* Atur Speed 1-101-BJ1T dan 1-101-BJ2T. 157-F

P : 5,3 Kg Low Pressure Condensate* S/D 106-D via HS-1253 (tutup vent PC-1005 utk mempertahan - T +/- : 320 / 19 deg KO Drum kan tekanan Gas di 101-E).126 95

ITEM No REMARK PUMP/COMP/RV/S TURB 5. Setelah 30 menit kemudian PACKAGE BOILER dapat di-

102-JType : Centrifugal Feed Gas Compressor

Start Kembali. P S/D : 13,74/44,67 K6. Metode Start / Stop ini bisa dilakukan bila kenaikan Speed : 12400 r/m.

temperatur terlalu cepat.102-JT

Type : Condensate Steam Turbine Driver for 102-J7. Atur level Steam Drum secara manual melalui LV-3402 Speed : 12400 r/m.

bila tidak mampu dapat diatur melalui bv by-pass LV-3402 Output : 1770 KW8. Bila kondisi minimum firing sudah stabil, maka naikkan

103-JType : Centrifugal. Synthesis Gas Compressor.

firing rate sbb : P S/D : 98,88/179,31Kga. Robah posisi COMBUSTION AIR CONTROL PIC-3440 Speed : 10535 r/m. dari posisi MAN --> AUTO pada saat fuel flow control

103-JLPType : Centrifugal. LP Case Synth Gas Compressor

PIC-3422 akan berubah dari MNLK --> MAN. P S/D : 32,59/99,85 Kb. Robah posisi PIC-3422 dari MAN --> AUTO. Speed : 10535 r/m.c. Naikkan firing rate secara perlahan-lahan dengan me-

103-JTType : Extr / Cond Steam Turbine Driver for 103-J

nambah output dari BOILER MASTER PIC-3408 sampai Speed : 10535 r/m.Output : 14326 KW

9. Apabila kondisi Steam Product sudah normal, maka masuk 104-J/JA HP BFW Pumpskan ke system dengan membuka bv isolasi header SM se-

105-JType : Centrifugal. Amm Refrigerant Compressor

cara perlahan-lahan dan di imbangi dengan penutupan P S/D : 1,04 / 15,23 KPIC-3408 ( Blow Off Valve ) secara bertahap dengan Speed : 10200 r/m.memperhatikan tekanan PIA-3408 display monitor di

105-JTType : Condensate. Steam Turbine Driver for 105-J

panel. Speed : 10200 r/m.10. Atur injeksi Phospate dan sesuaikan dengan batasan Output : 4670 KW

batasan yang di izinkan. 107-JA Semi Lean Solution Pump.Differential : 286,5 M Power : 9,23 KW

107-JBSemi Lean Solution Pump.

Differential : 286,5 M Power : 7,26 KW

107-JCSemi Lean Solution Pump.

Differential : 286,5 M Power : 7,26 KW

108-J/JA Lean Solution Pumps.Differential : 310,9 M Power Normal/Rated :18/38,7 KW

124 97

ITEM No PRESS / TEMP DRUM

200-F P : 15,8 Kg Natural Gas Knock Out Drum AMMONIA PLANT

1-104-J/JA TRIP (bila tdk ada kesempatan untuk jalankan yg S/B) :

* Cut Rate ke 40 %, vent gas di MOV-1018 dan V-1000.

Cap : 29009 Nm3 / H

Cap : 609828 Nm3 / H

Cap : 164714 Nm3 / H

tercapai tekanan + 43 Kg / Cm2 dan temp SM + 390 0C. Des Flow : 235,5 m3/H

Cap : 1357850 Nm3 / H

Des Flow : 580,0 m3/H




200-F T +/- : 19 deg C. EMERGENCY SHUT DOWN201-F P : 5,3 Kg Pretreatment Lean Solution

T +/- : 150 / 19 deg Flash Tank

202-FP : 15,8 Kg Pretreatment Absorber Beberapa tindakan pertama yang harus dilakukan bila terjadiT +/- : 150 / 19 deg OVHD KO Drum 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-BJ2TITEM No REMARK 101-J AIR COMPRESSOR

101-J Type : Centrifugal Air Compressor ; Speed :7300 r/m 1-101-J TRIP :P S/D : 0,99 / 38,9 K

101-JC1Duty : 1,93 mm Kcal/ 1st Integral Inter CoolerS/T dP : 5,2 / 10,5 Kg S (max/min) : 150 / 5 deg C

T (max/min) : 150 / 5 deg C

101-JC2Duty : 1,36 mm Kcal/ 2nd Integral Inter CoolerS/T dP : 5,2 / 10,5 Kg S (max/min) : 150 / 5 deg C * Atur Let Down Steam (Steam System secara keseluruhan).


101-JC2Duty : 1,23 mm Kcal/ 3rd Integral Inter CoolerS/T dP : 5,2 / 10,5 Kg S (max/min) : 150 / 5 deg C


101-JCADuty : 1,73 mm Kcal/ Air Compr 2nd Stage Inter CoolerS/T dP : 11,2 / 10,5 KgS (max/min) : 240 / 5 deg C

T (max/min) : 240 / 5 deg C * Pertahankan sirkulasi Benfield dengan tekanan Gas yang ada

101-JC2Duty : 0,758 mm Kcal/HAir Compr 3rd Stage Inter Cooler (Import Synthesa Gas).

S/T dP : 18 / 10,5 Kg S (max/min) : 150 / 5 deg CT (max/min) : 150 / 5 deg C 1-102-J TRIP :

101-JTType : Extr / Cond Steam Turbine Driver for 101-J * Informasikan ke Kabag Shift, Urea dan Utility bahwa 102-J Trip :

Speed : 7300 r/m ;Output : 9040 KW * Cut Rate Gas menuju 40 %, buka vent V-1000 untuk vent Gas dan101-L Air Filter

101-LJType : Turbo Air Filter Bleed Fan * Atur temperatur Riser dan temperatur Coil Udara.

* Atur Reforming System dan Steam System.RV-101-J Relief Valve Discharge 3rd 101-J * Shut Down kan 106-D (Methanator) via HS-1253.

Setting pop : 43,9 Kg 12596

ITEM No REMARK PUMP/COMP/RV/S TURB

111-JBenfield Transfer Pump 6. Tekan Tombol START.

Differential : 280 M Power Nor/Rated : 6,69/7,00 KW System pembakaran akan mengikuti Squence yang diatur

112-J/JAProc Cond Pumps for 103-JTC oleh BURNER MANAGEMENT system :

Differential : 280 M Power Nor/Rated : 6,69 / 7.0 KW a. Proses PRE PURGE akan berlangsung selama 200 detik.

113-J/JA Warm Amm Product Pumps b. Proses penyalaan Pilot BURNER yang ditandai dengan Differential : 118 M Power Nor/Rated : 32,25/32,6 KW membukanya valve GAS ke BURNER sebanyak 2 EA dan

114-J/JA Proc Cond Pumps for 101-JTC menutupnya vent Pilot ( dapat dilihat pada monitorDifferential : 105,8 M Power : 28 KW Area 3 ).

115-JBenfield Sump Pump c. Proses Penyalaan BURNER ditandai dgn membukanya

Differential : 25,6 M Power : 4 KW valve Gas ke BURNER ( MAXON valve ) sebanyak 2 EA

116-J/JA dan menutupnya vent valve.

Differential : 30,5 M Power Nor/Rated : 42,84/43,5 KW d. Di lapangan bv by-pass relief valve pada saat proses

120-J Ammonia Injection Pumps penyalaan BURNER harus terbuka + 2 sampai 4 ulirDifferential : 30,5 M Power : 3,6 KW untuk mengatur tekanan GAS pada saat MAXON

121-J/JAP C Pumps for 102-F1 to 150-E membuka.

Differential : 84,2 M Power Nor/Rated : 34,58/35,1 KW e. Bila start BOILER berhasil BURNER akan menyala

124-J/JACold Ammonia Product Pumps maka Pilot valve akan menutup kembali dan MAXON

Differential : 86,6 M Power Nor/Rated : 22,50/23,8 KW valve tetap terbuka.

125-J/JAAmmonia Product Mixing Pumps

Differential : 228,3 M Power Nor/Rated : 12,13/12,7 KW IV. Kondisi pada posisi MINIMUM FIRING

140-J/JA LP Ammonia Scrubber Pumps 1. Perhatikan kenaikan temperatur Superheater TI-3406Differential : 76,5 M Power : 1,11 KW

141-J/JAHP Ammonia Scrubber Pumps 2. Bila kenaikan temperatur terlalu cepat, maka tambah

Differential : 18,40 M Power : 18,83 KW pembukaan PIC-3408 steam vent ( Blow Off Valve ).

201-J/JAPretreatment Circulating Pumps disesuaikan dengan kebutuhan.

Differential : 140,2 M Power Nor/Rated : 92,5/99,6 KW 3.

202-J/JA Pret'ment OVHD Quench Pumps dengan cara menambah pembukaan PIC-3408 Differential : 27,43 M Power Nor/Rated : 2,92/3,00 KW ( Blow Off Valve ).

RV-105-J Relief Valve disch 4th stage 105-J 4.Setting Pop : 17,6 Kg

RV-128-C Relief Valve Line CW Outlet 128-C PACKAGE BOILER ( distop ).Setting Pop : 10,5 Kg 123

98

6. Siapkan supply Gas Alam / Full sbb :a. Tutup PCV 3420 dengan mengatur setting control

Cap : 52596 Nm3/H * Imformasikan ke Kabag Shift dan Urea / Utility bahwa 101-J Trip* 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).

* 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.

MOV-1018 untuk vent Steam, back press = 7 Kg/Cm2G.

Cap : 7000 m3/H ;Output :3,7 KW4" 300# X 6" 150#

Des Flow : 44 m3/H

Des Flow : 44 m3/H



Des Flow : 7,8 m3/H

Des Flow : 411,5 m3/HCO2 Stripper Quench Pumps


Des Flow : 125 m3/H


Des Flow : 8,5 m3/H

Des Flow : 1,0 m3/Hkecepatan kenaikan temperatur maximum 55 0C per Jam.


Des Flow : 137,9 m3/HJaga temperatur TI-3406 tidak melebihi > 400 0C diatur


6" 600# X 10" 150# Bila temperatur TI-3406 > 4300C atau temperatur FlueGas mendekati maximum 900 0F atau 482 0C maka matikan

3/4" 150# X 1" 150#

sampai output = 0.b. Buka block valve isolasi ( Upsream PCV 3420 ).c. Naikkan perlahan-lahan setting PCV 3420 sampai men-

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 DCS1. 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 hilang berarti masih ada yang harus diperbaiki. Baik itudi lapangan maupun di Controlnya ( yang alarm tersebut ).

2. Buka blow off valve PIC-4308 secara manual + 25 %.3. Level Control Steam Drum LC-3402 posisi manual.4. Posisi Boiler Control ( Area 12 atau Control display 2B )

pada saat Start Up sbb :a. Boiler Master ( PIC-3408-M ) 10 % MANb. FD FAN Control ( FIC-3441 ) 42 % MANc. Comb Air Control ( FIC-3440 ) 5 % MANd. Fuel Flow Control ( FIC-3422 ) 10 % MAN

5. Bila semua Protection system telah terpengaruh, makaBOILER akan Permisive Start. ( POST Purge akan ber-langsung selama 200 detik setelah protection Alarm nyahilang ) dapat dilihat pada monitor display pada Area 2atau Graphic display 1A.

12299

- 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.

SYNCHRONIZINGAuto :- 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

capai tekanan 70 psi / 5.5 Kg / Cm2.

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 BOILER1. 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 DILAPANGAN1. 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 ).

121100

GAS & COOLING WATER

- Aktifkan gas Scrubber 33-5001-F dan gas Heater 33-5001-C

- 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

119102

PROSEDUR ( SOP ) START / STOP GTGPersiapan Start Up :

Temperatur NG Outlet 33-5001-C = 50 0C

Control Package :- Breaker supply Power dari TR 510 ON- Incoming Power TB 480 Volt AC ON- Incoming Power TB 125 Volt DC ON- 125 Volt DC Panel Board ON- 3 PH 4W PNLBD Main ON- 110 Volt Distant Panel ON- 120 Volt Distant Panel ON- Battery Charger ON- Aux Hydraulic Pump 88 HQ AUTO - General bearing Evacuator Pump 88 BQ AUTO / RUNNING- LO Tank Immersion Heater 23 QT OFF- Aux LO Pump 88 QA AUTO / RUNNING- Ratchet Opearsi 88 HR- Cooling Air Fan access & Turbine AUTO / RUNNING Compartment 88 BT-1- Access Compartment Heater 23 HA OFF- Turbine Compartment Heater 23 HT OFF- Stand by Lighting OFF- Emergency LO Pump 88 QE ON / STOP- CO2 Fire Extinguisher Stand by- Semua Protection System dapat bekerja dengan baik.

118103

POSISI VALVE UNTUKPERSIAPAN START UP WHB

1. VALVE-VALVE DRAIN :NAMA VALVE DRAIN POSISI VALVE

Drain Header Economiser ( 4 EA ) CloseDrain Down Commer ( 1 EA ) CloseDrain Evaporator CloseDrain Header Super Heater OpenDrain Header SM Open

2. VALVE VENTING :NAMA VALVE VENTING POSISI VALVE

Vent Header Economiser CloseVent Header Economiser Outlet CloseVent Header Saturated Steam OpenVent Header SM Outlet Open

116105

3. VALVE INSTRUMENTASI :

ITEM 34- NAMA VALVE POSISIVALVE

PI-001 BV isolasi BFW press transmitter OpenPG-002 BV isolasi press gauge Open

FRC-003 BV isolasi BFW flowmeter OpenAR-42/44 BV isolasi BFW Analiser OpenAR-40/41 BV isolasi Drum Water Analiser OpenFI-006 BV isolasi Continuous Blow Down OpenLG-011 BV isolasi level glass Steam Drum OpenLG-009 BV isolasi level glass Steam Drum OpenLSLL-10 BV isolasi level switch Steam Drum OpenLT012/013 BV isolasi level transmitter Steam Drum OpenPI-014 BV isolasi press transmitter Steam Drum OpenPG-015 BV isolasi press gauge Steam Drum OpenPG-019 BV isolasi press gauge Header SM OpenPRC-022 BV isolasi press tranmitter Header SM OpenPRC-021 BV isolasi flowmeter SM Product OpenFIR-023 BV isolasi flowmeter Spray Water Open

117104

--

-segera naikkan PY-022 Gas 25 % s/d 30 %, supaya nyala

3. MINIMUM FIRING BOILER-

mengatur kenaikan gas dan pembukaan vent HC-028 ( mengikuti kurva start up ).

-

sampai AUTO.-

4. PERSIAPAN ON LINE.-

-

-agar tidak hummering ).

boiler yang lainnya ( Package Boiler ).

115106

2. HEATING UPBOILER

UTILITY PLANTA.PERSIAPAN DILAPANGAN ( FIELD ).-

Beritahu operator lapangan WHB & GTG untuk mengecek

Tekan BURNER ON.BURNER START SEQUENCE / OPERATION menyala berkedip + 9 kali.FLAME DETECTOR bergerak kekanan ( indikasi nyala ),

api agak jelas ( flame detector tidak FAULT ).

Atur kenaikan pressure dan temperatur dengan

Atur spray Desuperheater sampai auto untuk mengaturtemperatur SM TC-018 + 388 0C dan atur BFW ZI-004

Tutup valve-valve vent ( Economizer, Steam Drum,Superheater dan Desuperheater ) dan atur Continuousblow down, aktifkan Flash Drum ( 34-5005-F ).

Setelah tercapai Pressure + 43 Kg/Cm2 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

Buka block valve SM outlet header pelan-pelan.Atur pressure dengan mengurangi HC-028 dan PC-3471 ( vent steam header ) atau turunkan beban

Buka Boiler Damper secara bertahap menuju 35 % open,

bukaan Damper dilapangan . Pertahankan tekanan steam

31 - WATER TREATMENT- & DEMIN PLANT

menit ) menuju 50 %, 75 % dan 100 % dengan tetap32 - COOLING TOWER

Super heater ( TI-017 ).33 - ELECTRIC POWER GENERATION SYS

34 - WASTE HEAT BOILER- Tutup vent steam drum yg masih terbuka bila tekan & PAKAGE BOILER

- 35 - PLANT AIRkan Let Down Valve dan Pilot Burner Valve. & INSTRUMENT AIR

-kemudian PSL-111 dibuka ( gunanya untuk menghin- 41 - GAS METERINGdari LGP = Low Gas Pressure ).

42 - RIVER WATER INTAKEB. PERSIAPAN DI CONTROL ROOM

- 45 - WASTE WATER TREATMENT-

baiki dahulu hingga tidak ada lagi yang alarm ).----

114 start ). 107

RIVER WATER INTAKE 31 - 5008 - C CAUSTIC SOLUTION COOLER31 - 5008 - F CAUSTIC DISSOLVING TANK

42 - 5201 RIVER WATER INTAKE PLAT FORM 31 - 5008 - J/JA CATION ACID PUMPS42 - 5201 - J/JA RIVER WATER PUMP 31 - 5009 - F REGENERANT CAUSTIC TANK

31 - 5009 - J/JA CAUSTIC DISSOLVI'G CIRCULATI'G PUMP31 - 5201 - F FILTER WATER STORAGE TANK

AMMONIA UTILITY UNIT 31 - 5202 - F OVER FLOW FIT31 - 5203 - F SLUDGE PIT

43 - 5101 - C AMMONIA HEATER 31 - 5204 - F CLEAR WELL43 - 5101 - F AMMONIA STORAGE TANK 31 - 5204 - J/JA FILTER WATER TRANFER PUMP43 - 5101 - J/JA AMMONIA TRANFER PUMP 31 - 5205 - FA/FB SLUDGE POND43 - 5102 - C AMMONIA VAPORIZED 31 - 5205 - J/JA COOLING WATER MAKE UP PUMP43 - 5102 - J/JA AMMONIA LOADING PUMP 31 - 5205 - UA ~ UD CARBON FILTER43 - 5102- F STEAM CONDENSATE POT 31 - 5206 - F BACK WASH RECOVERY PIT43 - 5103 - L AMMONIA PACKAGE 31 - 5210 - J/JA PORTABLE WATER PUMP

REFRIGERATION UNIT

COOLING TOWERWASTE WATER TREATMENT

32 - 5000 - J/JA CONDENSATE PUMPS45 - 5402 - F NETRALIZATION POND 32 - 5204 - LA/B/C SIDE FILTER45 - 5402 - J/JA WASTE WATER EFFLUENT PUMP 32 - 5204 - U BAR SCREEN45 - 5403 - C AMMONIA STRIPPER FEED HEATER 32 - 5204 - U COOLING TOWER 45 - 5403 - E AMMONIA STRIPPER 32 - 5204 - UF COOLING TOWER BASIN45 - 5403 - J/JA AMMONIA FEED PUMP 32 - 5204 - UJA ~ UJI INDUCE FAN45 - 5404 - F COLLECTION POND 32 - 5209 - JA/B/C AMMONIA / UTILITY CIRCULATING PUMP45 - 5407 - F EQUALIZATION POND 32 - 5209 - JTC SURFACE CONDENSER

32 - 5209 - JTCC INTER/AFTER COOLER32 - 5601 - JA/B UREA CIRCULATING C W PUMP

112 109

WATER TREATMENT PROSEDUR START UP WHB ( COLD START )

31 - 1001 - U CLARIFIER31 - 1002 - J AGITATOR CLARIFIER31 - 1003 - J RAKE FOR CLARIFIER 1. Persiapan Start Up :

drum sekitar 2 Kg / Cm2G dengan mengatur bukaan Vent Valve HC-028 + 40 %.Naikkan bukaan Boiler Damper perlahan-lahan ( + 15

memperhatikan tekanan Steam Drum & temperatur

a. Kenaikan temperatur TI-017 dijaga + 50 0C/jam.b. Bila kenaikan tekanan dan temperatur terlalu cepat, atur bukaan Start Up valve HC-028.

an Steam Drum sudah mencapai sekitar + 2 Kg/Cm2GBuka Butterfly Valve gas header 28 Kg/Cm2, aktif-

PSL-111 ditutup, setelah PIA-117 > 0,10 Kg/Cm2 baru

PY-022 gas posisi Manual, ZI-108 dibuka 25 % ( OP ). Reset Alarm di panel ( jika masih ada yang nyala, per-

READY FOR PURGING menyala.Tekan PURGING ON.PURGING SEQUENCE / FINISHER menyala.BURNER READY FOR OPERATION menyala ( siap

31 - 2001 - UA ~ UF SAND FILTER -31 - 3002 - JA/B/C CLARIFIER WATER TRANSFER PUMP pompa BFW sudah normal operasi.31 - 3003 - J/JA BACK WASH RECOVERY PUMP -31 - 3004 - J BACK WASH WATER EFFLUENT PUMP31 - 3005 - J/JA ALUM INJECTION PUMP -31 - 3006 - JA/B/C CAUSTIC INJECTION PUMP ( BFW dari 34-5003-J/JA ).31 - 4001 - F/FA ALUM TANK -31 - 4003 - J/JA AGITATOR ALUM TANK31 - 4005 - F CAUSTIC TANK Konstan.31 - 5001 - F DEMINERALZATION STORAGE - Instrumentasi dalam keadaan bagus ( ready ), baik 31 - 5001 - J/JA DEMIN WATER PUMPS Interlock system maupun control systemnya dengan 31 - 5001 - U DEMINETRALIZATION UNIT syarat proteksi untuk start up tidak ada yang alarm.31 - 5002 - J/JA ANION CAUSTIC PUMPS - Temperatur Flue Gas inlet WHB telah memenuhi 31 - 5003 - F SULPHURIC ACID REGENERANT TANK untuk purging WHB ( dibawah 350 0C )31 - 5003 - J/JA MIXER BED ACID PUMPS - Posisi valve dan damper didasarkan pada " Posisi31 - 5004 - J/JA MIXER BED CAUSTIC PUMPS valve persiapan Start Up " dengan perubahan 31 - 5004 - UA/B/C CATION EXCHANGER perubahan sebagai berikut :31 - 5005 - C WATER HEATER a. Drain valve superheater dan SM heater dibuka.31 - 5005 - UA/B/C ANION EXCHANGER b. Vent valve saturated heater & SM header dibuka.31 - 5006 - UA/B MIXER BED EXCHANGER c. Start up valve dibuka sekitar 20 %.31 - 5006 - UN MIXER BED BLOWER d. Block valve header limit SM WHB ditutup.31 - 5007 - F DEGASSER WATER SUMP31 - 5007 - U DEGASSER31 - 5007 - UJ/UJA DEGASSER BLOWER108 113

CHEMICALS INJECTION WASTE HEAT BOILER & PACKAGE BOILER

32 - 5202 - L CHLORINATOR32 - 5205 - LF ASAM SULFAT INJECTION TANK 34 - 5002 - U DEARATOR32 - 5205 - LJ/LJA ASAM SULFAT INJECTION PUMP 34 - 5003 - J/JA BFW PUMP32 - 5206 - LF INHIBITOR TANK 34 - 5003 - U WHB - STEAM DRUM, ECONOMICER, 32 - 5206 - LJ/LJA INHIBITOR INJECTION PUMP EVAPORATOR DLL.32 - 5207 - LJ DISPERSANT INJECTION PUMP 34 - 5005 - F BLOW DOWN FLASH DRUM ( WHB )32 - 5210 - LF DISPERSANT TANK 34 - 5006 - J GAS TURBINE GENERATOR

34 - 5007 - L HYDRAZINE INJECTION TANKELECTRIC POWER GENERATION 34 - 5007 - LJ/LJA HYDRAZINE INJECTION PUMP

34 - 5008 - L PHOSPHATE INJECTION TANK ( WHB )33 - 5001 - C GAS HEATER 34 - 5008 - LJ/LJA PHOSPHATE INJECTION PUMP33 - 5001 - F GAS SCRUBBER 34 - 5010 - L AMMONIA INJECTION TANK33 - 5001 - L AIR DRYER FOR GTG 34 - 5010 - LJ/LJA AMMONIA INJECTION PUMP33 - 5006 - J GAS TURBINE GENERATOR 34 - 5011 - L DESUPERHEATER33 - 5007 - J EMERGENCY DIESEL GENERATOR 34 - 6007 - F BLOW DOWN FLASH DRUM ( PB )33 - 5010 - J COOLING WATER BOOSTER PUMP 34 - 6007 - U PB STEAM DRUM

( GEN SET ) 34 - 6007 - UJT F D FAN34 - 6008 - L PHOSPHATE INJECTION TANK ( PB )

SUBSTATIONPLANT AIR & INSTRUMENT AIR

TR - 5006/MCC -5006 CRANKING MOTOR UNIT SUB-STATIONTR - 5006A/TR - 5006B LOAD DISTRIBUTION CENTER 35 - 5004 - J STAND BY AIR COMPRESSOR

( 150 KVA AUX POWER TRANSFORMER ) 35 - 5006 - F INSTRUMENT AIR RECEIVER35 - 5006 - L INSTRUMENT AIR DRYER

GAS METERING STATION

41 - 5103 - F KNOCK OUT DRUM

110 111

BFW sudah siap memenuhi persyaratan operasi dan

Steam Drum telah diisi sampai diatas level minimum( LC-013 ) + 30 % diposisi Manual.Pompa BFW benar benar telah siap operasi

Gas Turbine Generator ( GTG ) telah beroperasidiatas beban minimum dan temperatur Flue Gas nya

Start 1-105-J30. Buka kembali TTV : AMMONIA PLANT a) 500 rpm 60 menit (termasuk trip test). b) 1500 rpm 40 menit. c) 2500 rpm 10 menit. AMMONIA SYMBOL d) 7000 rpm 10 menit. e) 8670 rpm (MGS) --> TTV terbuka lebar

(lampu start OK padam). Catatan :* Hati-hati critical speed : 1 B : PREHEATER - LP Case --> 3600 rpm. 2 C : EXHANGER - HP Case --> 4400 rpm. 3 D : VESSEL / CATALIST - Turbine --> 5100 rpm. 4 E : VESSEL ( TOWER ) * Catat vibrasi pada setiap point. 5 F : DRUM31. Latching FV-501 s/d FV-504 (di lapangan). 6 J : PUMP / COMPRESSOR - Atur kick back FV-501 s/d FV-504 (bila TTV sudah wide open 7 K : BUILDING tetapi speed tidak mau ke MGS, adjust kick back tersebut. 8 L : FILTER / TANK32. 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. UNIT DESCRIPTION34. 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. 1 FEED TREATING37. Pindahkan control speed dengan PC-1009 dengan cara : 2 REFORMING - PC-1009 = 0 %. 3 SHIFT CONVERTER - Tekan "Proses speed control" di EG Panel (lampu nyala). 4 CO2 REMOVAL * Catatan : - Speed < 1000 rpm seluruh drain terbuka. 5 METHANATOR - 1000 rpm < speed < 8670 rpm (MGS) 6 AMMONIA SYNTHESIS

seluruh drain terbuka 50 %. 7 REFRIGERATION & NH3 STORAGE - Speed > 8670 rpm (MGS) seluruh drain tertutup. 8 STEAM SYSTEM & BFW PREP

9 PURGE GAS RECOVERY UNIT

40 1

Start 1-105-J ITEM CLASS C: EXCHANGER

ke casing (setelah yakin tutup kembali). 103-JTC SURFACE CONDENSER 6. Heating up line : 103-JTCC INTER / AFTER COOLER 1-103-JTC a) Line up SM steam sampai ke bv header. 105-C CO2 STRIPPER PROCESS GAS REBOILER - BV & bv by pass : tertutup penuh. 106-C L T S EFFLUENT / L P - BFW EXCHANGER - BV drain u/s bv header = terbuka. 107-C CO2 STRIPPER QUENCH COOLER b) Line up SLL sampai ke bv header ASV (Addmission Stop Valve). 109-C LEAN SOLUTION / L P B F W EXCHANGER - BV ditutup 111-C CO2 STRIPPER EJECTOR STEAM GENERATOR - BV drain u/s bv header ditutup. 113-C CO2 STRIPPER CONDENSATE REBOILER 7. Jalankan turning gear 1-105-J & aktifkan oil system ke turning 114-C METHANATOR FEED / EFFLUENT EXCHANGER gear, lalu masukkan gear motor dan tekan PB on untuk menjalan 115-C METHANATOR EFFLUENT COOLER kan turning gear. 116-C SYNTHESA GAS COMPRESSOR / INTER COOLER 8. Aktifkan gland condenser dan SP-100 (ejector dibawah exhaust). 120-C AMMONIA UNTIZED CHILLER

120-CF1 1ST STAGE REFRIGERANT FLASH DRUM10. Vacuum up (-500 mmHg). 120-CF2 2ND STAGE REFRIGERANT FLASH DRUM11. Heating up 1-105-J 120-CF3 3RD STAGE REFRIGERANT FLASH DRUM a) Line up SM s/d ke TTV. 120-CF4 4TH STAGE REFRIGERANT FLASH DRUM - Drain 3/4" u/s TTV. buka lebar. 121-C AMM CONVERTER FEED / EFF EXCHANGER - Vent 1" u/s TTV. buka lebar. 122-C AMMONIA CONVERTER INTER CHANGER - Drain chamber TTV 3/4" buka lebar. 123-C1 AMM CONVERTER EFF / STEAM GENERATION NO 1 - Buka kecil bv b/p bv header SM ke 1-105-J (1"). 123-C2 AMM CONVERTER EFF / STEAM GENERATION NO 2 b) SLL line up s/d ESV. 124-C AMMONIA CONVERTER EFFLUENT COOLER - Drain 3/4" u/s buka lebar. 127 -C REFRIGERANT CONDENSER - Drain chamber ASV tutup penuh. 128-C REFRIGERANT COMP 3RD STAGE INTERCOOLER - Buka kecil bv header ASV. 129-C SYNT GAS COMPRESSOR INTER STAGE CHILLER

130-C SYNT GAS COMPRESSOR 1ST STAGE COOLER (3.0 ~ 3.5 kg/cm2) dengan : 131-C L T S EFFLUENT / B F W EXCHANGER

132-C CO2 STRIPPER QUENH / L P B F W EXCHANGER133-C FEED GAS COMPRESSOR KICK BACK COOLER

hingga tekanan, 1-120-CF sama dengan casing compressor. 134-C SYNT GAS COMPRESSOR KICK BACK COOLER13. Jika point 12 "ok" buka lebar bv u/s ASV. 140-C AMMONIA STRIPPER REBOILER38 3

5. Drain casing & line NH3 sesaat untuk mengecek oli yang masuk

9. Aktifkan sealing steam ( 0.2 kg/cm2 ).

12. Pelan-pelan naikkan tekanan casing ke 4.2 kg/cm2.

- 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

Start 1-105-JAMMONIA PLANT PROCESS EQUIPMENT

15. Stop turning gear, tutup oil suplly ke turning gear (inlet/outlet) ITEM CLASS B : FURNACES / FIRED HEATERS start turbine.

16. On kan power electronic gover noor Woodward 509 (CCB).101-B PRIMARY REFORMER 17. Tekan HS-1205 --> lampu nyala (CCB).101-BBA ARCH BURNERS 18. Tekan reset (EG Panel)--> CCB.101-BBS SUPERHEATER BURNER 19. Tekan reset di lapangan 101-BC1 HOT PROCESS AIR PREHEATER (lampu permisive start "OK" nyala di lokal panel).101-BC2 MIXED FEED AIR PREHEATER Lampu start ok di EG Panel nyala.101-BC3 H P STEAM SUPERHEATER 20. Latching electric trip --> di lapangan.101-BC4 COLD PROCESS AIR PREHEATER 21. Tarik reset mechanical trip (warna putih --> di lapangan).101-BC5 FEED GAS PREHEATER 22. Angkat reset TTV ke posisi normal --> lapangan.101-BC6 FUEL GAS PREHEATER 23. Buka valve ramp (EG Panel) ke 100 % --> lampu nyala.101-BJ1 FORCED DRAFT FAN 24. Tekan start up (EG Panel).101-BJ2 INDUCED DRAFT FAN - Speed ref --> Governoor (EG Panel).101-BJ2T INDUCED DRAFT FAN TURBINE DRIVE - ACV membuka --> 100 % (EG Panel).101-BJIT FORCED DRAFT FAN TURBINE DRIVE 25. Tekan governoor start di lapangan maka :101-BL COMBUSTION AIR PREHETER a) Indikasi governoor ke minimum governoor --> CCB (EG Panel).101-BU AUXILIARY BOILER b) Posisi governoor bergerak ke 50 % --> lapangan.102-B START UP HEATER FOR AMMONIA CONVERTER 26. Yakinkan :

a) Admission valve ramp. 100 % EG Panel.ITEM CLASS C : EXCHANGER b) Admission Demand 0 % EG Panel.

c) PC-1009 0 % EG Panel.101-C SECONDARY REFORMER WASTE HEAT BOILER d) PC-1005 100 % EG Panel.101-JCA AIR COMPRESSOR 2ND COOLER 27. Perlahan-lahan buka TTV, tahan speed 500 rpm selama 60 menit.101-JCB AIR COMPRESSOR 3RD COOLER 28. Lakukan trip test (bila diperlukan).101-JTC SURFACE CONDENSER a) Tekan HS-1205 (CCB).101-JTCC INTER / AFTER CONDENSER 1-101-JTC b) Tekan emergency stop (lapangan).102-C H P STEAM SUPERHEATER 29. Jika point 28 ok ulangi point 17 s/d 26.103-C1 H T S EFFLUENT WASTE HEAT BOILER NO 1103-C2 H T S EFFLUENT WASTE HEAT BOILER NO 22 39

ITEM CLASS C: EXCHANGER Start 1-105-JPROSEDUR OPERASI BAKU P - IB

141-C AMMONIA STRIPPER FEED START UP 1 - 105 - J142-C AMMONIA STRIPPER EFFLUENT COOLER143-C SEAL FLUSH WATER COOLER 1. Persiapan dan yakinkan dilapangan :167-C REF COMP 2ND STAGE INTER COOLER * CW ke 1-128-C terbuka172-C1 START UP HEATER * CW ke 1-167-C terbuka172-C2 START UP COOLER * CW ke 1-127-C terbuka173-C MOLUCULAR SIEVE REGENERATION HEATER174-C STRIPPER CONDENSATE COOLER * 1-109-F isi level dgn ammonia, level ammonia, level 80 % ~ 90 %,188-C CONDENSATE STRIPPER FEED / EFF EXCHANGER201-C FEED GAS PRETREATMENT / EFF EXCHANGER * Semua kick back dibuka lebar dan posisi manual.202-C PRETREATMENT FEED GAS COOLER * Vapour ammonia dari 5101-F ditutup (XV-1150 & SP-025).203-C PRET'MENT CO2 STRIPPER STEAM REBOILER204-C PRETREATMENT STRIPPER OVHD COOLER205-C PRETREATMENT LEAN SOLUTION COOLER * PC-1009 output = 0 % (manual).

* PC-5001 output = 100 % (manual).ITEM CLASS D : REACTORS 2. Line up lube oil system untuk oil system 1-105-J/JT.

103-D SECONDARY REFORMER 1-102-JLF2A/B; JLF3.104-D1 HIGH TEMPERATUR SHIFT CONVERTER b) Supply LO ke 1-105-J/JT (L.O.C digabung dengan LO 1-102-J), 104-D2 LOW TEMPERATUR SHIFT CONVERTER sewaktu menggantikan LO/CO pelan-pelan sekali, karena akan105-D AMMONIA SYNTHESIS CONVERTER mempengaruhi LO/CO 1-102-J.106-D METHANATOR c) Aktifkan seal oil trap dan HP Case.107-D PRIMARY REFORMER EFFLUENT TRANSFER LINE108-D COBALT - MOLYBDENUM / ZINC OXIDE GUARD 109-DA MOLUCULAR SIEVE DRIER A 4. Line up seal oil system untuk 1-105-J.109-DB MOLUCULAR SIEVE DRIER B - Supply S.O ke 1-105-J HP & LP case dengan mengatur FIC-511 201-D IRON SPONGE DESULFULRIZATION VESSEL

V-508 setelah penuh tutup kembali bv V-508 (level 450 %), dilanjut kan isi 1-105-JLF4 (Cost Down Tank) sampai level normal (lampu

4 37

Start 1-103-J ITEM CLASS E : TOWERS

14. Jika temp TI-551 = 250 0C, buka lebar bv SM inlet turbine.

* Refrigerant dipurge N2 sampai O2 content < 0.5 %.

jaga tekanan PCAL-1109 = 12 kg/cm2

* 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.

a) Sebelumnya mech sudah mengisi N2 ke Bledder dari

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).

perlahan lahan ke 7.6 m3/H isi 1-105-JLF1 dengan membuka bv

alarm LALL-514 mati), tekanan casing dijaga maximum 2 kg/cm2.

34. Aktifkan FC-1808. - Buat output FC-1808 : 0 %. 101-E CARBON DIOXIDE ABSORBER - Tekan proses extraction Deman dengan FC-1808, perhatikan 102-E CO2 STRIPPER steam system imbangi dengan PC-1013. 103-E L P AMMO NIA SCRUBBER35. Pindahkan control speed ke PC-0301. 104-E H P AMMONIA SCRUBBER - Buat PC-0301 output : 0 %. 105-E AMMONIA STRIPPER - Tekan proses speed control di EG Panel. 150-E PROCESS CONDENSATE STRIPPER36. Atur disch pressure sesuai kebutuhan proses dengan : 201-E PRETREATMENT CARBON DIOXIDE ABSORBER - Atur speed control PC-0301 202-E PRETREATMENT CO2 STRIPPER - Atur kickl back FV-0301, 0303, 0304. - Catatan : ITEM CLASS F : DRUMS / TANKS - Speed < 1000 rpm, seluruh drain terbuka lebar. - 1000 rpm < speed < 9025 rpm seluruh drain 101-F STEAM DRUM terbuka 50 % 102-F1 RAW GAS SEPARATOR - Speed > 9025 rpm seluruh drain ditutup. 102-F2 CO2 ABSORBER OVHD K O DRUM

104-F SYNTHESA GAS COMPRESSOR SUCTION FILTER105-F1 SYNT GAS COMP 1ST INTER STAGE SEPARATOR105-F2 SYMT GAS 2ND INTER STAGE SEPARATOR106-F AMMONIA SEPARATOR107-F AMMONIA LET DOWN DRUM109-F REFRIGERANT RECEIVER114-F BENFIELD SOLUTION STORAGE TANK115-F BENFIELD SOLUTION SUMP118-F BENFIELD CARBON FILTER132-F SEMI LEAN SOLUTION FLASH TANK133-F CO2 STRIPPER FEED FLASH DRUM144-F FEED GAS KNOCK OUT DRUM156-F STEAM BLOW DOWN DRUM157-F LOW PRESSURE CONDENSATE KNOCK OUT DRUM200-F NATURAL GAS KNOCK OUT DRUM201-F PRETREATMENT LEAN SOLUTION FLASH TANK

36 5

Start 1-103-J ITEM CLASS J : ROTATING EQUIPMENT DRIVE112-J CONDENSATE PUMP 1-103-JTC ELECTR

6. Line up seal oil sytem. 112-JA CONDENSATE PUMP A 1-103-JTC - Isi seal oil OHT case&seal oil OHT HP case hingga kondisi norm 112-JAT TURBINE DRIVE FOR 1-112-JA STEAM - Aktifkan seal oil ke LP & HP case. 113-J WARM AMMONIA PRODUCT PUMP ELECTR - Stand by kan seal oil turbine pada posisi auto. 113-JA WARM AMMONIA PRODUCT PUMP A ELECTR 7. Drain out casing comperssor dan line syn gas. 114-J CONDENSATE PUMP 1-101-JTC ELECTR 8. Aktifkan sealing steam dan gland condensor 1-105-JT, aktifkan 114-JA CONDENSATE PUMP A 1-101-JTC SP - 100 dan putar Turning Gear 1- 105-JT setiap 30 menit. 114-JAT TURBINE DRIVE FOR 1-114-JA STEAM 9. Heating up 115-J BENFIELD SUMP PUMP ELECTR - Line up SH hingga bv header. 116-J QUENCH CO2 STRIPPER PUMP ELECTR - Line SM hingga bv extraction. 116-JA QUENCH CO2 STRIPPER PUMP A ELECTR - Buka bv drain line extraction up stream check valve sampai 120-J AMMONIA INJECTION PUMP ELECTR tidak ada condensate, lalau tutup kembali. 121-J PROCESS CONDENSATE PUMP ELECTR10. Aktifkan CO ke turning gear, jalankan turning gear. 121-JA PROCESS CONDENSATE PUMP A ELECTR11. Aktifkan Gland Condensor. 124-J COLD AMMONIA PRODUCT PUMP ELECTR

124-JA COLD AMMONIA PRODUCT PUMP A ELECTR13. Vacuum up 250 ~ 300 mm Hg. 124-JAT TURBINE DRIVE FOR 1-124-JA A STEAM14. Heating up. 125-J MIXER AMMONIA PRODUCT PUMP ELECTR

125-JA MIXER AMMONIA PRODUCT PUMP A ELECTR - Line SM hingga ke check valve extraction. 140-J L P AMMONIA SCRUBBER PUMP JM ELECTR15. Perlahan naikkan tekanan casing hingga sama dengan tekanan 140-JA L P AMMONIA SCRUBBER PUMP JMA ELECTR PV-1004 melalui bv by pass suct compressor jika sudah tercapai 141-J H P AMMONIA SCRUBBER PUMP JM ELECTR buka bv suct compressor dan tutup b/p nya. 141-JA H P AMMONIA SCRUBBER PUMP JMA ELECTR16. Buka lebar bv extraction dan tutup by passnya. 201-J PRETREATMENT CIRCULATION PUMP17. Buka lebar u/s bv header SH dan tutup by pass nya, ( sebelum 201-JT TURBINE DRIVE FOR 1-201-J STEAM membuka bv header ). Tutup dulu bv drain pemanasan untuk me - 201-JA PRETREATMENT CIRCULATION PUMP A nyamakan tekanan, supaya bv header tidak macet, setelah bv 201-JAT TURBINE DRIVE FOR 201-JA STEAM header terbuka lebar buka kembali drain pemanasannya). 201-JM PRETREATMENT CIRCULATING PUMP ELECTR18. Matikan turning gear dan tutup CO untuk turning gear. 202-J QUENCH OVER HEAD PUMP ELECTR19. ON kan power untuk Electrical Governoor Woodward 509 --> CCB 202-JA QUENCH OVER HEAD PUMP A ELECTR20. Tekan HS-1203 dan reset di CCB --> EG Panel. 203-J PRETREA'T BENFIELD TRANSFER PUMP ELECTR34 204-J PRETREATMENT BENFIELD SUMP PUMP ELECTR 7

ITEM CLASS F: DRUMS / TANKS Start 1-103-J21. Tekan reset (dilapangan) --> lampu start "OK" menyala.

5. Press up casing compressor dengan dengan N2 hingga 0.5 kg/cm2.

12. Aktifkan sealing steam (P = 0.1 kg/cm2).

- Line SH hingga TTV (> 450 0C).

202-F PRETREATMENT ABSORBER OVHD SEPARATOR 22. Latching electrical trip TTV --> dilapangan.203-F PRET'MENT BENFIELD SOLUTION STORAGE TANK 23. Tarik reset mechanical trip (warna putih) --> dilapangan.204-F PRETREATMENT BENFIELD SOLUTION SUMP 24. Angkat reset TTV dengan mendorongnya keatas --> dilapangan.205-F PRETREATMENT BENFIELD CARBON FILTER ( setelah lampu start "OK" di EG Panel menyala).

25. Tekan tombol start (di EG 509 Panel).ITEM CLASS J : ROTATING EQUIPMENT DRIVE 26. Buka extr valve ramp ke 100% --> lampu menyala (di EG Panel).

27. Tekan Governoor start (dilapangan) maka :101-J AIR COMPRESSOR - Indikasi Actuator Governoor bergerak ke minimum Governoor.101-JT STEAM TURBINE DRIVE FOR 1-101-J STEAM - Posisi Governoor left < 88.9 mm.102-J FEED GAS COMPRESSOR 28. Naikkan vacuum ke - 500 mmHg.102-JT STEAM TURBINE DRIVE FOR 1-102-J STEAM 29. Perlahan buka TTV sehingga running dengan speed 500 rpm.103-J SYNTHESIS GAS COMPRESSOR 30. Lakukan test trip pada speed 500 rpm.103-JT STEAM TURBINE FOR 1-103-J STEAM - Tekan HS-1203 --> CCB atau,104-J H P B F W PUMP - Emergency stop --> dilapangan.104-JT STEAM TURBINE DRIVE FOR 1-104-J STEAM 31. Jika ad 30 OK start kembali,ulangi prosedur 20s/d29, tahan speed 104-JA H P B F W PUMP A - 500 rpm 60 menit (termasuk point 30).104-JAT STEAM TURBINE DRIVE FOR 1-104-JA STEAM - 1100 rpm 40 menit.105-J AMMONIA REFRIGERANT COMPRESSOR - 1500 rpm 10 menit.105-JT STEAM TURBINE FOR 1-105-J STEAM - 2500 rpm 10 menit.107-JA SEMI LEAN SOLUTION PUMP A - 7000 rpm 5 menit.107-JAHT HIDROLIC TURBINE DRIVE FOR 1-107-JA BENFIELD - 9025 rpm (MGS) TTV terbuka lebar.107-JB SEMI LEAN SOLUTION PUMP B - Catatan :*Hati-hati Critical Speed :107-JBT STEAM TURBINE FOR 1-107-JB STEAM - LP Case --> 3645 rpm.107-JC SEMI LEAN SOLUTION PUMP C - HP Case --> 4405 rpm.107-JCT STEAM TURBINE FOR 1-107-JC STEAM - Turbine --> 4050 rpm.108-J LEAN SOLUTION PUMP - Catat vibrasi pada setiap step.108-JT STEAM TURBINE FOR 1-108-J STEAM 32. Latching FV-301, FV-303 & FV- 304 (biarkan terbuka lebar) dan 108-JA LEAN SOLUTION PUMP A switch dari lokal ke CCB (kondisi di lokal 0 % dan di CCB 0 %).108-JAT STEAM TURBINE FOR 1-108-JA STEAM 33. Turunkan extraction valve ramp : 0 % (lampu 0 % nyala).108-JM LEAN SOLUTION PUMP ELECTR111-J BENFIELD SOLUTION TRANFER PUMP ELECTR 6 35

ITEM CLASS L : SPECIAL EQUIPMENT Start 1-103-JOPERASI BAKU AMMONIA P - IB

101-L AIR FILTER START UP 1 - 103 - J103-L HYDROGEN RECOVERY UNIT104-L BENFIELD SOLUTION FILTER 1. Siap dan yakinkan dilapangan106-L HYDRAZINE INJECTION SYSTEM a,. CW ke 1-116-C terbuka.107-L AMMONIA INJECTION SYSTEM b. CW ke 1-130-C terbuka.108-L PHOSPHATE INJECTION SYSTEM109-L BENFIELD ANTI FOAM INJECTION SYSTEM110-L BENFIELD SOLUTIOM MIXER e. FV-301, FV-303, FV-304 terbuka lebar.111-L 103-J DISCHARGE SEAL OIL SEPARATOR f. MOV-1001 & by pass tertutup rapat.115-L BENFIELD SUMP FILTER g. MOV-1002 tertutup rapat.132-L1 FLASH TANK EJECTOR NO1 h. HV-1028 tertutup (posisi latch).132-L2 FLASH TANK EJECTOR NO2 I. HC-1029 output 0 % (unlatch).132-L3 FLASH TANK EJECTOR NO3 j. SP-020 terbuka lebar.132-L4 FLASH TANK EJECTOR NO4 k. SP-022 tertutup rapat.201-L PRETREATMENT BENFIELD SOLUTION FILTER l. 1-103-JTC aktif.202-L1 FLASH TANK EJECTOR NO 1 m. Siapkan moluculer sieve drier pada posisi yang tepat, tidak 202-L2 FLASH TANK EJECTOR NO 2 menjadi masalah step nomer berapapun.202-L3 FLASH TANK EJECTOR NO 3 - Yakinkan dilapangan seluruh line 1-109-DA/DB --> Ok.202-L4 FLASH TANK EJECTOR NO 4 - Yakinkan di CCB / lapangan semua MOV, XV dan PV pada 203-L PRETREATMENT CO2 STRIPPER posisi yang benar sesuai dengan step yang ada.204-L SODA ASH SOLUTION INJECTION SYSTEM - Jaga HS-1012 pada posisi stop.206-L PRETREATMENT BENFIELD SOLUTION MIXER n. PC-0301 output 0%207-L MASS SPECTROMETER o. FC-1808 output 0%

2. Supply udara ke pedestal seal. ITEM CLASS U : UTILITY EQUIPMENT 3. Line up oil system.

4. Start lube oil motor dan aktifkan LO ke 1-103-J/JT. 101-U DEAERATOR - Isi Accumular dan rundown tank sesuai dgn level yg ditentukan.102-U CONDENSATE POLISHER - 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.

8 33

Start 1-102-JMCC - 51 POWER SUPPLY DARI UTILITY IB

c. Kandungan O2 dicasing Comperssor < 0.5 %. d. Kandungan CO + CO2 gas outlet 1-106-D<10 ppm (CO2 < 0.5 ppm).

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. ITEM TAG NO. POWER DESCRIPTION15. Jika tekanan casing = PCAH-1071 buka lebar bv suction 1-102-J, No. KW dan buka lebar bv down stream FV- 201. 1. 112-JM 55 103-JTC Condensate Pump.16. Hidupkan power untuk electronic Gov 1-102-J di CCB marshalling. 2. 113-JM 75 Warm Ammonia Product pump.17. Tekan PB I (start up) --> start lampu "OK". 3. 116-JM 5518. Tekan reset di lokal panel. 4. 202-JM 4 Pretreatment Over Head Quench19. Tekan PBL I ( start up ) speed akan naik ke 1860 rpm tahan 5. 121-JM 75 Process Condensate Pump.

6. 204-JM 0.4 Soda Ash Solution Injection P ( catat dan monitor Vibrasi ). 7. 109-JM 0.55 Benfield Anti Foam Injection Sys20. Lakukan trip test dengan : 8. 125-JM 22 Ammonia Product Mixing Pump. - HS-1202 (CCB). 9. 140-JM 2.2 LP Ammonia Scrubber Pump. - Emergency stop (lapangan). 10. LCP-01 11 Local Panel For Air Blower 102-U 21. Bila point 20 "OK" start kembali, ulangi point 17 s/d 19. (102-UJ1M).22. Tekan PBL 2 (idle/rated) speed akan naik ke min gov 10540 rpm. 11. 141-JM 15 HP Ammonia Scrubber Pump. (catat dan monitor Vibrasi). 12. 100-OCM 30 Over Head Crane Comp Building.23. Pindahkan manual speed control ke process speed control 13. 109-LLM 0.4 Anti Foam Mixer Injection Syst (PC-1010 output : 0%) --> EG Panel. 14. 108-LLM 0.4 Phospate Mixer Injection System. - Drain casing turbine di tutup (2ea). 15. 108-LJM 0.55 Phospate Injection Pump. - Drain emergency stop valve ditutup. 16. 104-JLAM 3.7 LO Pump 104-JA24. FV-201 output local panel dibuat 0% di CCB 0% latchuing FV-201 17. 203-LJM 0.4 Pretreatment Benfield Transfer P25. Switch control local panel FV-201 ke CCB, output local panel 18. 107-LJM 0.4 Ammonia Injection Pump. dibuat 100 %. 19. 106-LJM 0.4 Hydrazine Injection Pump.26. On line kan 1-102-J buka bv disharge pelan-pelan. 20. 105-JJM 1.5 Turning Gear 105-J.27. Atur tekanan gas proses sesuai kebutuhan dengan : 21. 101-JLM 30 LO Pump 101-J. - Speed 1-102-J (PC-1010). 22. 105-JLM 75 LO & SO Pump 102-J / 105-J. - Kick back FV-201. 23. 107-JLBM 1.5 LO Pump 107-JB.* CRITICAL SPEED : 24. 125-JLM 0.4 Mechanical Pump Seal Pump.

Turbine 6200 rpm. 25. 101-JJM 1.5 Turning Gear 101-J.Compressor 4600 rpm. 26. 101-LLM 3.7 Air Filter Bleed Fan 101-J.

32 9

Start 1-101-J ITEM TAG NO. POWER DESCRIPTION35. Latching HV-1028 , stand by kan HC-1028 =60% buka bv u/s dan No. KW d/s HV-1028. 19. 124-JM 55 Cold Ammonia Product Pump.

20. 125-JAM 22 Ammonia Product Mixing Pump.Catatan : 21. 125-JLAM 0.4 Mechanical Pump Seal System. a. Speed < 1000 rpm semua drain terbuka lebar. 22. 140-JAM 2.2 LP Ammonia Scrubber Pump. b. Speed 1000 <speed 6205 r semua drain terbuka 50 %. 23. 141-JAM 15 HP Ammonia Scrubber Pump. c. Speed >6205 rpm semua drain tertutup. 24. 202-JAM 4 Pretreatment Over Head Quench.

25. 203-JM 3.7 Pre'atment Benfield Injection P26. 203-LJAM 0.4 Pre'atment Anti Foam Injection P27. 203-LLM 0.4 Pretreatment Anti Foam Mixer.28. 204-JM 2.2 Pretreatment Benfield Sump P29. 204-LJAM 0.4 Soda Ash Solution Injection P30. 204-LLM 0.4 Soda Ash Solution Mixer Inject P31. 206-LLM 7.5 Pre'atment Benfield Sump Mixer32. LCC-02 11 102-UJ2M33. LP-53 40 Floor Light34. LP-53A 24 Floor Light35. SRP-54 24 Space Heater Foundation 5101-F36. WO 3 & 4 66.51 Welding Outlet.

TAMBAHAN :

30 11

ITEM TAG NO. POWER DESCRIPTION Start 1-102-JNo. KW PROSEDUR OPERASI BAKU AMMONIA P - IB27. LP-51 40 Floor Light. START UP 1 - 102 - J28. LP-52 24 Lighting Comp. Building.

CO2 Stripper Quench Pump.

selama 50 menit (heating up) Atur seal steam tekanan 0.2 kg/cm2

29. RP-51 12 Receptacle 1. Siapkan / yakinkan dilapangan :30. WO 1 & 2 66.51 Welding Outlet. * 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.

MCC - 52 POWER SUPPLY DARI UTILITY P - IV * BV suction 1-102-J -tertutup rapat. * BV by pass 1-102-J -terbuka lebar.

ITEM TAG NO. POWER DESCRIPTION 2. Aktifkan 1-101-JTC.No. KW 3. Line Up Lube oil system.1. 101-BJ1LM 5.5 LO Pump 101-BJ1T 4. Start motor lube oil supply, lube oil ke 1-102-J / JT.2. 101-BJ2LM 5.5 LO Pump 101-BJ2T. 5. Line up seal oil system dan aktifkan oil trap.3. 103-JLM 45 LO Pump 103-J4. 103-JLM 55 SO Pump 103-J 7. Aktifkan seal oil ke 102-J buka bv u/s & d/s FC-512 control posisi 5. 104-JLM 3.7 LO Pump 104-J.6. 106-LJAM 0.4 Hydrazine Injection Pump. 8. Isi seal oil over head tank buka bv V-403, b/p LV-203 ditutup, 7. 107-JLCM 1.5 LO Pump 107-JC aktifkan LV-203. Apabila level sudah arah naik di S/G, naikkan 8. 107-LJAM 0.4 Ammonia Injection Pump. setting LT-203 ( 1-102-JLF2 ) pelan-pelan searah kenaikan level 9. 108-LJAM 0.55 Phospate Injection Pump. ke 50 % setting ( 85 % S/G ).10. 109-LJAM 0.55 Benfield Anti Foam Injection P Perhatikan LV-203 apabila sudah sudah ngontrol tutup bv V-203.11. 110-LLM 7.5 Benfield Solution Mixer. 9. Stand by kan lube oil turbine pada posisi auto.12. 111-JM 11 Benfield Solutiopn Transfer Pump 10. Heating up line SM hingga u/s emerg stop valve (ESV) dengan 13. 113-JM 75 Warm Ammonia Product Pump. crack openbv by pass (BV SM inlet 1-102-J).14. 114-JM 15 101-JTC Condensate Pump. 11. Aktifkan Gland Condenser.15. 115-JM 5.5 Benfield Solution Sump Pump. 12. Vacum Up (buka butt valve & drain casing ke 1-101-JTC ada 3 ea).16. 116-JAM 55 13. Heating up sampai dengan ESV.17. 120-JM 7.5 Ammonia Injection Pump (S/Up). - a. Buka lebar bv SM inlet turbin dan tutup b/p.18. 121-JAM 75 Process Condensate Pump. - b. Buka lebar bv drain d/s ESV.

10 - c. Buka ESV (dengan meriset turbine trip). 31

ITEM SPECIAL PIPING Start 1-101-J28. Jika point 27 “ok” start kembali, ulangi prosedure 17 s/d 23 lalu

SP-003 Needle V u/s FI-1101, H2 gas supply to P gas inlet 104-D2 buka kembali TTV ( start running ).SP-004 Rupture Disc at CW line outlet tube side 115-C a) 500rpm 10 menit ( melanjutkan point 27 ).SP-005 Rupture Disc at CW line outlet tube side 130-C b) 1000 rpm 40 menitSP-006 Rupture Disc at by pass HCV-1044, line S G inlet 105-D c) 1500 rpm 10 menit SP-008 Rupture Disc at CO2 product line, top outlet 102-E d) 2200 rpm 5 menit.SP-009A Relief Valve at CO2 product line, top outlet 102-E e) 4700 rpm 5 menit.SP-009B Relief Valve at CO2 product line, top outlet 102-E f) 6205 rpm 5 menit. TTV terbuka lebar.SP-009C Relief Valve at CO2 product line, top outlet 102-E Catatan : Hati-hati dengan critical speed.SP-009D Relief Valve at CO2 product line, top outlet 102-E a) LPC Compressor 2660 rpmSP-009E Relief Valve at CO2 product line, top outlet 102-E b) HPC Compressor 3930 rpmSP-010A Angle blowdown valve at Flutter level 106-F c) Turbine 3400 rpmSP-010B Angle blowdown valve at Flutter level 106-F d) Catat dan perhatikan kondisi vibrasi ( CCB & lapangan).SP-012 Rupture Disc at CW line outlet tube side 116-C 29. Tutup extraction valve ramp hingga 0 % ( lampunya nyala ).SP-013 Rupture Disc at CW line outlet tube side 124-C 30. Aktifkan PC-1012.SP-015 Drain Separator SLC from 111-C to header SLC 132-L1~4 a) Output PC-1012 = 0%.SP-016 Rupture Disc at CO2 product line, top outlet 202-E b) Tekan process extraction control ( EG panel ) --> lampu nyala.SP-017 Relief Valve at CO2 product line, top outlet 202-E c) Buka PC –1012 --> perhatikan steam system imbangi dengan SP-018 Rupture Disc at CW line outlet tube side 134-C menutup PC-1013.SP-020 Solonoid control valve, signal from 103-J --> Back flow 31. Latching HV-0101 (outputnya 0 % atau valvenya terbuka lebar ), SP-022 Solonoid control valve, signal from 103-J --> SG to 103-J tutup perlahan-lahan hingga rapat, bila perlu naikkan speed 101-JSP-023 Strainer for seal line 201-J/JA 32. Pindahkan control speed ke FCAL – 1003 dengan:SP-024 Strainer for seal line 108-J/JA a) Buat output FCAL-1003 =0%, extraction valve ramp --> 0% SP-025 Check Control valve, NHV from 5101-F to 1st suct 105-J lampu 0% nyala.SP-100 Ejector, exhaust turbine 103-JT to 103-JTC b) Tekan process speed control di EG panel ( lampu nyala )SP-101 Spool between 101-L and Suction line 101-J 33. Latching FV-102 ( output local panel dan CCB =0% ), speed dinaikSP-102 Silencer vent FV-101, 1st stage discharge line 101-J kan ke 7000 rpm.SP-104 Rupture Disc at CW line outlet tube side 172-C2 34. Atur tekanan discharge sesuai dengan kebutuhan proses dengan : SP-111 Silencer vent FV-1104, located at CO2 line top out 102-E a) Atur speed control 1-101-J ( FCAL-1003 )SP-132 Silencer header vent locate at top of CO2 stripper 102-E b) FV-102 ( vent discharge 1-101-J ).SP-133 Silencer header vent located above Compressor Shelter12 29

Start 1-101-J ITEM SPECIAL PIPING11. Aktifkan gland condencer dan sealing steam, buka but val exhaust 12. Vacum up ( -250 ~ -300 mmHG). SP-134 Silencer header vent located above Steam Drum 13. Heating up 1-101-JT . Structure 101-F

SP-138 Desuperheater S L L line, outlet PV-1816

* Casing Comp 1-102-J sudah dipurging dengan N2 (O2 < 0.5 %).

6. Press up casing hingga 0.5 kg / cm2 dengan N2.

auto, naikkan setting FIC-512 pelan2 menuju normal (3.2 m3/h)

CO2 Stripper Quench Pump.

a) Line SH hingga TTV ( T> 450 0C ), buka bv by pass steam SH

header bertahap. SP-139 Desuperheater S M line, oulet PV-1813 b) Line SM hingga check valve dan buka drain u/s check valve SP-140 Vent to atmosfier, located at S M line top out 101-U extractionke 101-JTC, apabila tekanan steam extraction > SP-141 Angle blowdown valve BFW line out 101-F to 156-F tekanan SLL, tutup drain tersebut dan aktipkan Steam trap. SP-142 Angle blowdown valve BFW line out 101-F to 156-F14. Sebelum nembuka bv header tutup dahulu drain pemanasan untuk SP-143A Angle blowdown valve BFW line out 101-F to 156-F menaikkan tekanan d/s bv sehingga sama dgn tek u/s, buka SP-143B Angle blowdown valve BFW line out 101-F to 156-F lebar bv steam SH ( untuk menghindari macetnya bv header ). SP-143C Angle blowdown valve BFW line out 101-F to 156-F15. Stop turning gear dan control oil ke turning gear . SP-143D Angle blowdown valve BFW line out 101-F to 156-F16. On kan power untuk electronic governor 509 di CCB . SP-143E Angle blowdown valve BFW line out 101-F to 156-F17. Reset di CCB ( EG panel). SP-143F Angle blowdown valve BFW line out 101-F to 156-F18. Reset di lapangan --> permisive start ok nyala (di lapangan ). SP-143G Angle blowdown valve BFW line out 101-F to 156-F19. Latching electric trip TTV--> di lapangan ( XV-1001) SP-146A Automatic Recirculation CV, located at disch line 104-J20. Tarik resetmechanical trip ( warna putih ) --> di lapangan. SP-146B Automatic Recirculation CV, located at disch line 104-JA21. Angkat reset TTV ke posisi normal --> di lapangan. SP-148 Relief Valve, located at discharge line 114-J/JA Bila lampu condition OK sudah nyala ( EG panel). SP-153 Silencer venting PV-1817 S L L ( Steam Low Low ) line22. Tekan start up di CCB --> Speed Ref akan menuju MGS & ECV SP-154 Silencer venting PV-1814 S M ( Steam Middle ) line akan membuka. SP-170 Desuperheater S M ( Steam Middle )23. Buka extraction ramp ke 100%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 ). AMMONIA PLANT VENTING SYSTEMTekananTemperatur ITEM SIZE POSITION LOSSSumber : 1-101-F (Steam Drum).Pemakaian : 1-101-JT, 1-103-JT, 1-173-C, PIC-1799 6 INCH 1-202-E LINE TOP OUT ( F.T ) CO2

Let Down ke SM, 172-C1 (Waktu Start Up) PIC-1071 * 4 INCH 1-144-F LINE TOP OUT ( F.T ) CO2V-1003 * 1,5 INCH 1-102-J OUT, 1-108-D TOP INLET CO2

MEDIUM PRESSURE STEAM ( SM ). V-1000 4 INCH 1-108-D LINE BOTTOM OUT CO2Tekanan V-1005 12 INCH 1-102 C OUT, 1-104-D1 INLET CO2Temperatur MOV-1018 10 INCH 1-104-D1 OUT, 1-104-D2 INLET CO2Sumber : Extraction Steam 1-101-JT dan 1-103-JT. V-1007 * 10 INCH 1-104-D2 LINE BOTTOM OUT CO2

: Let Down dari SH --> SM (Waktu Start Up) V-1008 10 INCH 1-102-F1 TOP OUT, 1-101-E IN CO2: Import dari Utility (Waktu Start Up). PIC-1104 12 INCH 1-102-E LINE TOP OUT CO2

Pemakaian : Penggerak turbin.: Steam and Air Coil PIC-1005 12 INCH 1-102-F2 TOP OUT, 1-106-D IN P. GAS: 1-103-L Heater PIC-1004 8 INCH 1-104-F TOP OUT, 1-103-J INLET P. GAS: 1-140-C: Let Down ke SLL. FIC-1077 3 INCH 1-120-C CHIL OUT, 1-103-J 4th IN S. GAS

V-1017 * 4 INCH 1-121-C S.SIDE OUT, 1-124-C IN S. GASLOW PRESSURE STEAM ( SLL )TekananTemperatur KETERANGANSumber : Exhaust Turbine.

: Blow Down Drum 1-156-F. ITEM * Jarang dipakai.: KO Drum 1-157-F.: Leakage Steam V-1000 1. Disebut Vent inlet bila 1-108- D belum aktif, 1-108-D : Let Down dari SM --> SLL. di by-pass melalui b.v 6".

Pemakaian : Admission Steam 1-105-JT. 2. Disebut Vent outlet bila 1-108-D sudah aktif.: 1-101-U Stripping:1-123-C V-1007 Jarang dipakai. : Ejector 1-101-JTC dan 1-103-JTC. Dipakainya hanya waktu Reduksi Katalis.: Gland Condenser

26 : Export ke UOA 15

ITEM HYDROGEN RECOVERY UNIT SERVICES Start 1-101-J

F-D103 WATER KNOCK OUT DRUM PROSEDUR OPERASI BAKU AMMONIA P - IBD-A101A ABSORBER A START 1 - 101- JD-A101B ABSORBER BC-E102 REGENERATION GAS HEATER 1. Yakinkan di lapangan :

: 123 kg/cm2g: 510 0C.

: 42.2 kg/cm2g.: 375 0C.

: 3.5 kg/cm2g.: 219 0C.

F-D101 H2 SEPARATOR CW ke 1-101-JCA terbukaF-D102 BLOW DOWN DRUM CW ke 1-101-JCB terbukaC-E102A FEED / PRODUCT HEAT EXCHANGER A CW ke 1-101-JC1 terbukaC-E102B FEED / PRODUCT HEAT EXCHANGER B CW ke 1-101-JC2 terbuka

CW ke 1-101-JC3 terbuka 2. Yakinkan di CCB dan di lapangan

ITEM AMMONIA RECOVERY UNIT a) FV-0102 terbuka lebar (TV-1312 : posisi b/p) b) HV-0101 terbuka lebar (BP-1006 : By-Pass)

103-E L P AMMONIA SCRUBBER c) MOV-1006 & BV by pass tertutup104-E H P AMMONIA SCRUBBER d) FV-1065 tertutup ( udara ke utilitas )105-E AMMONIA STRIPPER 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. 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.

14 27

1-101-JT : STEAM TURBINE PROCESS AIR COMPRESSOR a. By-pass 1-108-D.

Type : Extraction & Condensing TurbineMotive Steam : 123,00 Kg/Cm2G c. Regenerasi Benfield system untuk feed treatment. Extraction Steam : 42,20 Kg/Cm2G d. Drain larutan Benfield ke tangki.Steam Comsumtion : 109.120 Ton/HrSteam Extr product : 97.920 Ton/Hr 24. Stop steam MS ke Primary Reformer.Steam exhaust product : : 10.200 Ton/Hr 25. Matikan Arch burner secara bertahap.Speed : 7300 RPM 26. Stop gas di Battery Limit.

101-JTC : Surface Condenser101-JTCC : Inter/After Condense 1-101-JTC b. Stop 1-101-BU.114-J/JA : Condensate Pump c. Persiapan Hydrostatis test BFW & HP System.

1-101-J : PROCESS AIR COMPRESSOR d. Pelaksanaan Hydrostatis test BFW & HP System.Type : Centrifugal e. Matikan BFW pump (1-104-J).Stage : 3 ( 1 - 2 ) Stage at LP & HP CaseCapacity : 52596 NM3/Hr 28. Stop ID dan FD fan.Pressure Suction/Dicharge : 0,99 / 38,95 Kg/Cm2ATemperatur Suction/Discharge : 35 C / 183 C PERHATIAN KHUSUS SELAMA SHUT DOWN :

101-LJ : Air Filter Bleed Fan101-L : Air Filter 1. Molucular Sieve Dryer 1-109-DA akan diganti pada TA ini, usaha101-JC1 : 1st Integral Intercooler kan sebelum shut down sudah dalam keadaan te-regenerasi.101-JC2 : 2nd Integral Intercooler 2. Flash Drum (120-CF) akan dilakukan pemeriksaan internal part, 101-JC3 : 3rd Integral Intercooler matikan 1-105-J setelah level minimum dan lakukan pengamanan101-JCA : Air Compressor 2nd Stage Intercooler secepatnya.101-JCB : Air Compressor 3rd Stage Intercooler 3. Pekerjaan kritis selama TA adalah penggantian CAP, usahakanFV-101 : Venting discharge 1st Stage proses cooling down dapur dapat dilaksanakan secepat mungkin.FV-1065 : Flow Process Air to Instrument Air/P.A 4. Tube 1-127-C, 1-128-C dan 1-124-C diduga bocor, lakukan peng-PIC-1791 : Press Process Air to Instrument Air/P.A amanan khusus saat shut down.FV-102 : Venting discharge 3rd StageSP-102 : Silencer venting FV-101 & FV-102MOV-1006 : Emergency Control Valve disch 3rd StageFIC-1003 : Control Governoor 1-101-JT

16 HIC-1021 : MP Steam inject for Emergency Shut Down 25

Note : FV-1065 & PIC-1791 One Control ValvePROSEDUR SHUT DOWN NORMAL AMMONIA P - IB from 1st discharge.

: 3rd discharge to 1-101-BC4 --> 1-101-BC2 1. Start My Comp (5103-L), atau tie-in vapour dengan pabrik lain. --> 1-103-D. 2. Shut down Hydrogen Recovery Unit (HRU). : HIC-1021, Steam injectie for safety coil 3. Shut down Ammonia Recovery Unit (ARU). line because air to coil lossed (1-102-J trip) 4. Switch Synthesis Gas dari P-IV (tie-in) untuk 1-108-D.

b. By-pass CO2 Removal Feed Treating (201-E).

23. Turunkan temperatur riser dari 760 0C ke 380 0C.

a. Turunkan tekanan HS ke 45 kg/cm2g.

27. Pendinginan dapur hingga temperatur 35 0C.

5. Cut rate gas ke 80 %. LUBE OIL SYSTEM 1-101-JT 6. Shut down loop dan vent gas di PC-1004. 101-JLF1 : Oil Reservoir a. Stop Synthesis gas Compressor 1-103-J. 101-JLJ : Oil Pump J b. Penggosongan Refrigerant System / pump out. 101-JLJA : Oil Pump JA c. Stop Refrigerant Compressor (105-J) bila level sudah minimum 101-JLJAT : Steam Turbine 101-JA, Back P T. MS -> SLL

101-JLCA : Lube Oil Cooler A 8. Stop udara ke Utility Plant. 101-JLCB : Lube Oil Cooler B

101-JLLA : Lube Oil Filter A101-JLLB : Lube Oil Filter B

11. Shut down Methanator (1-106-D) dan vent di PC-1005. 101-JLF2A : Lube Oil Accumulator A12. By pass Low Temperatur Shift Converter (LTS). 101-JLF2B : Lube Oil Accumulator B

101-JLF3 : Control Oil Accumulator 101-JLF4 : Run Down Tank

a. Regenerasi Benfield System, FC < 0,20 PV-134 : Regulator Valve, setting Press : 7,5 K b. Sirkulasi cooling down larutan benfield. PV-135 : C.O --> L. O setting Press : 2,0 K c. Drain larutan Benfield ke tangki. 15. Cut rate gas ke 40 %. 1-102-JT : STEAM TURBINE FEED GAS COMPRESSOR16. Stop udara ke Secondary Reformer.17. Stop Air Comperssor (1-101-J). Type : Condensing Type

Motive Steam : 42,2 Kg/Cm2G19. Cut rate gas ke 25 %. Steam Consumtion : 9,123 Ton/Hr20. Stop gas ke Primary Reformer. Steam Exhaust product ( 101-JT + 102-JT + 104-JT/JAT ) 21. Stop Feed Gas Compressor (1-102-J). : 25,175 Ton/Hr22. Start Oksidasi katalis Primary dan Secondary Reformer hingga Sealing Steam : PV-257 SLL = 3,5 Kg/Cm2G non condensible gas = nil. Speed : 12400 RPM

24 17

1-103-JT : STEAM TURBINE FOR SYNTH GAS COMPRESSORPROSEDUR OPERASI BAKU AMMONIA P - IB

START UP AMMONIA P - IB Type : Extraction & Condensi'g TurbineMotive Steam : 123,0 Kg/Cm2G

Prosedur : Extraction Steam : 42,2 Kg/Cm2G 1. Firing awal memakai fuel gas dari gas yang ke 144-F (gas bersih). Steam Consumtion : 107,293 Ton/Hr

Steam Exhaust Product : 71,782 Ton/HrSpeed : 10535 RPM

103-JTC :Surface Condenser - Masukkan steam proses ke 1-101-B, buka seluruh drain riser, 103-JTCC : Inter/After Condenser 1-103-JTC 1-101-C/1-103-C. 112-J/JA : Condensate Pump - Buka vent V-1005. 103-J : SYNTHESIS GAS COMPRESSOR

Type : Centrifugal - Masukkan steam sparger ke 1-104-D1 (H.T.S). Stage : 4 (2 - 2) Stage at LP & HP Case

Capasity LP Case : 164714 NM3/Hr vent gas di V-1000 out 1-108-D --> Start heating up 1-108-D. Pressure Suction/Discharge : 32,59/ 99,85 Kg/Cm2A - Rate gas 20 % ~ 25 %. Temperatur Suction/Discharge : 37 C / 115 C

Capasity HP Case : 609823 NM3/Hr HS sudah di let down ke MS). Pressure Suction/Discharge : 98,88 / 179,31 Kg/Cm2A

Temperatur Suction/Discharge : 4,4 C / 42,3 C104-F : Synthesis Gas Compressor Suction Drum130-C : Synt Gas Compressor 1st Stage Cooler

6. Heating up 1-102-JT --> Start 1-102-JT. 105-F1 : Synt Gas Comp 1st Interstage Separator (lihat detail prosedur Start 1-102-J). 116-C : Synt Gas Compressor Inter Cooler

129-C : Synt Gas Compressor Interstage Chiller105-F2 : Synt Gas Interstage Separator

drain 1-101-C, drain 1-103-C. 109-DA : Molucular Sieve Drier A109-DB : Molucular Sieve Drier B111-L : 1-103-J Discharge Seal Oil Separator

10. Heating up 1-101-JT --> Start 1-101-JT. FIC-301 : Kick Back from 105-F2 to line 1st suction (lihat prosedur Start 1-102-J). MOV-1017 : Control Valve Inlet 109-DA11. Naikkan rate gas 40 % --> 50 %. XY-1164 : C V Regeneration outlet 109-DA to 114-C22 19

1-102-J : FEED GAS COMPRESSORType : Centrifugal 12. Masukkan udara ke 1-103-D.Stage : 1 Stage 13. Naikkan rate gas 50 % --> 60 %.Capacity : 29009 NM3/HrPressure Suction/Discharge : 13,74 / 44,67 Kg/Cm2A 1-107-JHT (lihat prosedur Start Gas masuk ke 1-101-E).Temperatur Suction/Discharge 37,8 C / 156 C 15. Heating up LTS --> aktifkan 1-150-E.

133-C : Feed Gas Compressor Kick Back Cooler (lihat prosedur detail Start Up 1-105-E).FV-201 : Kick Back Flow Control Valve 16. Heating up 1-105-JT --> Start 1-105-JT.

7. Stop CO2 tie-in setelah Urea Plant Shut down.

9. Cut rate gas ke 70 %, vent PV-1004 dan b/p = 30 kg/cm2g.10. Shut down 150-E dan drain condensate ke sewer, b/p = 26 kg/cm2.

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.

18. Turunkan tekanan HS ke 56 kg/cm2g .

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 ke coil udara, temperatur coil < 600 0C.

- Temperatur flue gas inlet 1-101 BC5 (TI-1445 > 350 0C) start

3. Naikkan tekanan steam HS > 45 Kg/cm2 (6 ~ 10 kg/cm2), steam

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

7. Bila temperatur riser 760 0C, masukkan gas ke 101-B, jaga temp tetap 760 0C dengan menambah Firing, tutup semua drain riser,

8. Naikkan rate gas ke 40 % bertahap, back press + 10 kg/cm 2g. 9. Naikkan tekanan HS steam menuju ke 123 kg/cm2g.

14. Masukkan gas ke Absorber, back press + 22 kg/cm 0 g --> jalankan

(lihat prosedur detail Start Up 1-105-JT).LUBE OIL SYSTEM 1-102-JT :

102-JLF1 : Oil Reservoir 18. Heating up 1-103-JT --> Start 1-103-JT.102-JLJ : Oil Pump J (lihat prosedur detail Start Up 1-103-JT).102-JLJA : Oil Pump JA 19. Aktifkan squence 1-109-D --> Regeneration.102-JLJAT : Steam Turb 102-JLJA, Back P T, MS -> SLL 20. Press up --> Heating up 1-105-D.102-JLCA : Lube Oil Cooler A (lihat prosedur detail Start Up 1-105-D).102-JLCB : Lube Oil Cooler B102-JLLA : Lube Oil Filter A102-JLLB : Lube Oil Filter B102-JLF2A : Control Oil & Lube Oil Accumulator A102-JLF2B : Control Oil & Lube Oil Accumulator B102-JLF3 : Control Oil & Lube Oil Accumulator 102-JLF2 : Lube Oil Run Down Tank102-JLF4 : Over Head Tank102-JLF5 : Degassing Tank102-JLL2A : Seal Oil Trap outboard Compressor102-JLL2B : Seal Oil Trap inboard CompressorPV-543 : Regulator Control Valve, setting 18,5 Kg/CmPV-544 : CV CO for 102-J & 105-J, setting 7,5 Kg/CPV-545 : CV LO for 102-J & 105-J, setting 2,0 Kg/CFV-511 : F V Seal Oil for 105-J, setting 7,6 M3/HrFV-512 : F V Seal Oil for 102-J, setting 3,2 M3/Hr

18 23

MOV-1015 : Control Valve outlet 109-DA 103-JLL2A : Filter OilPV-1047 : Control Valve Depress 109-DA. 103-JLL2B : FilterOilMOV-1160 : Gas Inlet regen 109-DA LV-340 : Regulator Seal OilMOV-1013 : Gas inlet109-DB. LV-341 : C V Seal Oil Supply LPCXY-1165 : Control valve gas out Ex regen 109-DB. LV-344 : C V Seal Oil Supply HPCMOV-1016 : Gas outlet 109-DB 103-JLF4 : L P Seal Oil Head Tank PV-1048 : Control Valve Depress 109-DB. 103-JLF5 : H P Seal Oil Head TankPV-1049 : Gas untuk press up 109-DA/DB. 103-JLL3A : L P Seal Oil Trap 173-C : Molucular Sieve Regeneration Heater 103-JLL3B : L P Seal Oil Trap 157-F : Low Pressure Condensate K. O. Drum 103-JLL3C : H P Seal Oil Head TankTV-1030A : Line gas untuk cooling A & B. 103-JLL3D : H P Seal Oil Head TankTV-1030B : Line gas untuk heating (heater) A/B. 103-JLF2 : AccumulatorFI-1046 : Flow regen, Cooling /heating.FIC-303 : Kick Back to 3rd suction from 4th dichargeFIC-304 : Kick Back to 4th suction from 4th discharge 1-105-JT : STEAM TURBINE FOR REFRIGERANT COMPRESSORMOV-1002 : Ctrl to 4th suct from 120-C out tube ChillerMOV-1001 : 4th dicharge line Type : Admission & Condensing turbineHIC-1279 : 4th dicharge venting Motive Steam : 42,2134-C : Synt Gas Compressor kick back Cooler Admission Steam : 3,5

Steam Consumtion SH : 14,570 T/H.LUBE OIL SYSTEM 1-103-J : SLL : 15,680 T/H.

103-JLF1 : Oil Reservoir Steam Exhaust Product : 30,250 T/H.103-JLJ1 : Oil Pump J1 Speed : 10200 Rpm.103-JLJ1A : Oil Pump J1A ( turbine ) 103-JTC : Surface Condenser.103-JLCA : Oil Cooler A 103-JTCC : Inter/After Condenser 1-103-JTC.103-JLCB : Oil Cooler B 112-J/JA : Condensate Pump.103-JLF3 : L O Run Down Tank 105-J : REFRIGERANT COMPRESSOR103-JLL1A : Oil Filter A Type : Centrifugal.103-JLL1B : Oil Filtre B Stage 4 ( 2 - 2 ) Stage at LP & HP Case.PCV-324 : C O --> L O : 2 K ( Oil Inst d/s PCV-324 ) Capasitas103-JLJ2 : Seal Oil Pump J2 Pressure Suction/Discharge103-JLJ2A : Seal Oil Pump J2A ( turbine )

20 21

Start Up Synthesis Loop10. Bila temperatur katalis 1-105-D inlet bed # 1 (TI-1379 ~ 1382)

nya temperatur outlet bed # 1 (TI-1387 ~ 1384) melampaui temp

BUKU 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

17.CheckCO/CO2 out 1-101-E < 1 % --> Heating up 106-D --> aktifkan.

Kg/Cm2G.Kg/Cm2G.

: 1357850 Nm3/H.: 1,04 / 15,23 Kg/Cm2G.

mencapai + 260 0C sudah mulai terjadi reaksi, terlihat dgn naik-

350 0C mulai tambah pembukaan HCV-1044. Buka secara bertahap

sambil memperhatikan flow FI-1257 dan FI-1105.

PINTAR 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 -

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

DISALIN Tutup rapat HCV-1045 bila temperatur gas outlet 1-102-B sudah DAN lebih rendah dari temp inlet bed # 1 105-D (TI-1396 < TI-1379).

DISUSUN KEMBALIOLEH (lihat prosedur steaming 1-123-C).

ZAINAL ABIDIN # 710683

46

Start Up Synthesis Loop ITEM No PRESS / TEMP STEAM132-C P S/T : 7,4 / 10,5 Kg

MOV-1001, kemudian buka lebar MOV-1001 dantutup by pass nya. LP BFW Exchanger156-F P : 6,3 Kg Steam Blow Down Drum

T +/- : 180 / 19 deg C. temp inlet bed # 2 lanjutkan membuka MOV-1002 secara bertahap 157-F P : 5,3 Kg Low Pressure Condensate sampai terbuka lebar. Sambil menambah load syn loop dengan T +/- : 320 / 19 degKO Drum mengatur speed dan kick back 1-103-J. 172-C1 P S/T : 140.6 / 36.2 KgStart Up Heater. 6. Adjust vent purge FC-1077. 7. Adjust kick back 103-J (FIC-301, FIC-303, FIC-304) secara manual 173-C P S/T : 112 / 140.6 Kg Molucular Sieve Regeneration 8. Adjust speed 1-103-J --> masukkan fresh gas sampai PC-1004 Heater tertutup. 174-C P Hot/C : 10,5 /10,5 K Stripper Condensate Cooler 9. Bila 1-106-F sudah ada kenaikkan level aktifkan LC-1013 bv u/s di trottle. 203-C P S/T : 5,3 / 2,9 kg

Steam Reboiler

ITEM No PRESS / TEMP EXCHANGER menurunkan temperatur gas inlet 1-105-D, temperatur gas inlet 101-E P : 36.2 Kg Carbon Dioxide Absorber

T +/- : 150 / 19 deg C atur temperatur inlet bed # 1 dgn membuka HC-1025, perhatikan 102-E P : 1,78 Kg Carbon Dioxide Stripper tekanan SH, dan fuel ke aux boiler (101-BU). T +/- : 150 / 19 deg C12. Auto kan kick back FIC-301, FIC-303, FIC-304. 103-E P : 12,5 Kg LP Ammonia Scrubber

T +/- : 150 / 19 deg C104-E P : 18,8 Kg HP Ammonia Scrubber

T +/- : 150 / 19 deg C105-E P : 17,6 Kg Ammonia Stripper

T +/- : 224 / 19 deg C.

150-E P : 46,4 Kg Process Condensate StripperT +/- : 398 / 19 deg C.

201-E P : 15,8 Kg Pretreatment Carbon DioxideT +/- : 150 / 19 deg Absorber

202-E P : 1,76 Kg Pretreatment Carbon Dioxide48 T +/- : 150 / 19 deg Stripper 89

Start Up Synthesis Loop - 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.

bila masih terpasang.

3. Buka bv by pass MOV-1001, naikkan tekanan syn loop menuju

4. Perhatikan temperatur Skin/metal shell 105-D TI-1395A-Y, bila

tahap naikkan tekanan syn loop sampai + 105 kg/cm2 g.

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.

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,

4. Press up Syn Loop sampai > 90 kg/cm2g melalui by pass CO2 Stripper Quench / T S/T : 100 / 130 0C.

5. Bukaan MOV-1002 + 2 %, perhatikan temp bed katalis 105-D bila sudah ada reaksi (kenaikan temp) di bed # 1>3200C (TI-1379), atau

T S/T : 360 / 360 0C.

T S/T : 350 / 360 0C.

T Hot/C : 100 /100 0CPretreatment CO2 Stripper

10. Apabila product NH3 mulai banyak, tutup injeksi NH3 ke 1-109-F. T S/T : 270 / 180 0C.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

(TI-1373) di jaga > 215 0C. Bila HCV-1046 sudah tertutup rapat,

13. Jaga FC-1020 + 75 T/H, Manual = 40 % TI-1370 > 200 0C dan TI-1371 > 190 0C.

- Lepaskan conector / selang N2 untuk purging / blanket,

2. Atur dan naikkan tekanan discharge 1-103-J sampai > 90m kg/cm2.

21 kg/cm2 g dengan laju kenaikan maksimum 2 kg/cm2 g per menit.

dgn menambah bukaan by pass MOV-1001 dan pengaturan 1-103-J. - Jaga kondisi tersebut hingga temperatur shell 105-D TI-1395A-Y

5. Lakukan leak test / check explosive semua flange dan perbaiki bila ada kebocoran.

discharge 1-103-J buka lebar MOV-1001 dan tutup by pass nya. 7. Lakukan leak test / check explosive.

dengan cara membuka MOV-1002 dan mengurangi pembukaan

back dan speed 1-103-JT. 9. Nyalakan burner 1-102-B. (sebelum melakukan purging dengan SLL minimal 15 menit).

Naikkan terus sampai temperatur katalis 1-105-D mencapai

45

ITEM No PRESS / TEMP FILTER / TANK Start Up Synthesis Loop

101-L Air Filter 15. Bila HCV-1046 sudah tertutup rapat, atur temperatur inlet bed # 1 dengan membuka HC-1025.

101-LJ Type : Turbo Air Filter Bleed Fan Catatan :output :3,7 KW - 4 P

103-L Hydrogen Recovery Unit - Flow gas ke 102-B, FI-1257 min 3.1 div

104-L P : 49,0 Kg Benfield Solution Filter - Batasan tekanan PI-1905 dan temp 102-B TI-1396 (lihat curva).T +/- : 150 / 5 deg C. - Temperatur metal skin / shell 105-D, TI-1395 A-Y max 282 0C.

110-L Benfield Solution Mixer

111-L P : 188,0 Kg 103-J Discharge Seal Oil T +/- : 150 / 5 deg C. Separator B. Start Up 1-105-D tanpa start up Heater 1-102-B

115-L P : 6,5 Kg Benfield Sump FilterT +/- : 123 / 19 deg C.

132-L1;L2;L3;L4 Flash Tank Ejector 1. Line Up. - Stand by kan FC-1077 --> posisi tertutup.

201-L P : 33,7 Kg Pretreatment Benfield - Stand by kan FC-1108.T +/- : 123 / 5 deg Solution Filter - Stand by kan PV-1033, 1-104-E di by pass.

202-L1;L2;L3;L4 Flash Tank Ejector - Stand by kan PV-1032, 1-103-E di by pass. - BV V-1017 --> tertutup.

203-L Anti Foam Injection Packed - Buka lebar HCV-1044, HCV-1046 --> terbuka lebar. - HCV-1045, HC-1025 --> tertutup.

204-L Soda Ash Solution Injection - MOV-1001, MOV-1002 --> tertutup.System - 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.

injeksi ammonia dari 1-5101-F --> ke 1-109- F.

regenerasi aktif.90 47

Start Up Synthesis LoopPROSEDUR OPERASI BAKU AMMONIA P - IB DAFTAR ISISTART UP SYNTHESIS LOOP

* Yang dimaksud dengan start up syn loop adalah mengaktifkan / AMMONIA PLANT heating up Ammonia Converter 1-105-D, hingga memproduksi Ammonia. ( Katalis Amm Converter 105-D sudah tereduksi ) Halaman

Ammonia Symbol 1 A. Heating up 1-105-D dengan start up heater 1-102-B. Unit Description 1 B. Heating up 1-105-D tanpa start up heater 1-102-B.

Process Equipment 2

temperatur < 30 0C lakukan warming up. - Buka vent V-1017,jaga tekanan sys loop PI-1905 mantap 21 kg/cm2

rata-rata 30 0C.

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

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).

HCV-1044 + 10 %. terbuka, dan membuka FC-1077 (OP + 30 %). Jaga tekanan syn loop mantap > 90 kg/cm2g, dgn mengatur kick

Atur kenaikan temp gas outlet 102-B TI-1396, 40 0C~60 0C / jam

3500C ~ 3700C.

Cap : 7000 m3 / H - Temperatur flue gas 1-102-B, TI-1397 maximum 834 0C.

(setting trip FSLL-1257 = 39000 Nm3/H)

Cap : 32 m3 / H - Beda temp skin/shell 105-D antara top dan bottom max 75 0C. - Kenaikkan tekanan syn loop maximum 2.0 kg/cm2g per jam.

(Bila temperatur bed katalis 1-105-D rata-rata 200 0C).

2. 1-105-J jalan. Refrigerant system, level & tekanan normal,

3. 1-103-J jalan. PC-301 Op = + 20 % man, 129-C aktif, 109-D

MCC - 51 Power Supply dari Utilitas P-IB 9 - Rate gas = 85 % (minimum), vent di PC-1004. MCC - 52 Power Supply dari Utilitas P - IV 10

Special Piping 12 - Syn gas compressor 1-103-JT sudah di start, total kick back. Hydrogen dan Ammonia Recovery Unit 14 - Molucular Sieve Dryer 1-109-D sudah beroperasi normal. Ammonia Plant Venting System 15 - Compressor 105-J sudah di start dan refrigerant system sudah 1-101-JT : Steam Turbine Process Air Compressor 16 aktif. Flash Drum 1-120-CF1 ~ 4 normal level, sirkulasi ammonia 1-102- JT : Steam Turbine Feed Gas Compressor 17 storage <----> storage. 1-103- JT : Steam Turbine for Synt Gas Compressor 19 - MOV-1001 dan MOV-1002 masih tertutup. 1-105 - JT : Steam Turbine for Refrig Compressor 21 - Siapkan log sheet khusus heating up 1-105-D. Prosedur Operasi baku Ammonia P - IB, S/U NH3 - IB 22

Prosedur Shut Down normal Ammonia P - IB 24PELAKSANAAN Prosedur Operasi baku Ammonia P - IB, Start 101-J 27 A. Heating Up 1-105-D dengan start up heater 1-102-B. Prosedur Operasi baku Ammonia P - IB, Start 102-J 31 1. Line Up. Prosedur Operasi baku Ammonia P - IB, Start 103-J 33 - Stand by kan FV-1077, FC-1077 posisi closed (manual). Prosedur Operasi baku Ammonia P - IB, Start 105-J 37

Prosedur Operasi baku Ammonia P - IB, Loading NH3 41Prosedur Operasi baku Ammonia P - IB, S/U Synt Loop 44

di by pass. Prosedur Operasi baku Ammonia IB, S/U 105-J tanpa 10 47Prosedur Operasi baku Ammonia P - IB, Gas -->101-E 49

di by pass line down stream PV-1032A ke Fuel system tertutup. Item Instrument 52 - BV vent V-1017 tertutup. - Buka lebar HCV-1044, HCV-1045, HCV-1046. 44 I

Loading Ammonia - Lihat temperatur dari TG didekat V3, jika terasa lambat dalam EMERGENCY SHUT DOWN Halaman Cooling down valve-valve tersebut bisa ditambah. 1 - 101- J Trip 125

1 - 102- J Trip 1251 - 103 - J Trip 126

5. CARA MENGAKTIFKAN ALF 1 - 105 - J Trip 126 - Yakinkan level minyak hydroulic ALF (level diatas 60 %). 1 - 104 - J Trip 126 - Buka pintu panel. Rincian dari S/D Synt Loop; HRU dan ARU 127 - Switch control power "ON" --> Alarm berbunyi. 1-101-BJ2T Trip 128 - Reset ERC Alarm --> Alarm bunyi mati. - Reset Pre Alarm --> Alarm bunyi mati. ANEKA TROUBLE P- IB - Reset Power --> Lampu indikasi akan nyala (hijau). Kehilangan Vacuum di 1-101-JTC 129 - Putar posisi ke posisi Manoeuvre (penggerak). DCS kehilangan Power 130 - Lepas kunci gerakkan ke bawah. - ALF dapat dioperasikan dari panel. GADO - GADO DARI P - IB - Jika ada Pre Alarm sewaktu Manoeuvre (digerakkan) kembali ke - UREA P - IB 132 sebelum Manoeuvre dan Reset Pre Alarm. AMMONIA P - IB 137 - Sambungkan flange (jangan lupa pasang gasket) dan posisikan UTILITAS - IB 143 pengaturan ke "frewheel" dari Control Panel (pindahkan dari posisi P P U 146 Manouvre ke posisi Free Wheel).

RINCIAN START UP AMMONIA PLANT 147 6. CARA LOADING AMONIAK SHUT DOWN AMMONIA PLANT 151 - Sambungan flange ALF ke kapal sudah terpasang. - Cooling down s/d bv 10" pakai selang, cooling down line sampai UTILITY STEAM PRODUCT 153 berkeringat / icing. - Buka bv 10" (product valve) melalui panel. GAMBAR - Buka bv V6 menuju ke terbuka lebar, tutup bv V5. DIAGRAM ALIR DISTRIBUSI GAS PUSRI P-IB 154 - Jalankan pompa 5201-J dengan posisi total kick back. - Tambah bukaan bv by pass discharge bertahap, perhatikan tekanan SHIFT SUPERVISOR - GAWEAN DAN PERLU TAU.

1-101-J Trip 155 - Apabila masih kurang flow tersebut, kurangi Min flow, jika masih 1-102-J Trip; 1-103-J Trip. 156 kurang tambah bukaan V3. 1-104-J Trip; 1-105-J trip; 1-124-J Trip. 15742 iii

Loading Ammoniahalaman

Instrument 74 - Untuk penambahan/pengurangan diatur dari bv V3 Ammonia DCS Schematic 87 ( bisa juga dari discharge pompa ).Process Design Basis Ammonia P-IB 88

7. SETELAH SELESAI LOADINGGAMBAR : - Buka lebar bv min flow pompa 5201-JM --> matikan pompa, tutup Feed Treatment Section - CO2 Pretreatment section 99 discharge dan tutup kembali bv min flow, buka line cooling down.Feed Gas Compressor Section - Process Air Section 100 - Tutup product valve (10") dari panel.Reforming / Shift Conversion Section 101 - Pindahkan ke posisi Manoeuvre.CO2 Removal Section 102 - Lepas flange ALF dari kapal.Methanator & Synthesis Section 103 - Pindahkan kunci, gerakkan keatas.

- Persiapan :

- Analisa gas outlet Methanator, CO/CO2 < 5 ppm, H2/N2 = 2.8~3.0

- Stand by kan PV-1108 (107-F), PC-1108 SP = 15 kg/cm2 g (auto). - Stand by kan PV-1033, PC-1033 SP = 85 kg/cm2 (auto) 104-E

- Stand by kan PV-1032B, PC-1032 SP = 10 kg/cm2 g (auto) 103-E

- Jika temperatur + -17 0C loading ke kapal bisa dimulai.

disch (PSLL-4323 : 5.8 kg/cm2g) dan bertahap tutup bv by pass.

- Tunggu + 1 jam, jika rate cukup maka loading dimantapkan.

NH3 Refrigerant Section 104 - Gerakkan ARM ke posisi tegak lurus bebas, ubah ke posisi kunci Purge Gas Recovery Unit 105 Automatic.Demin Water & BFW Section 106 - Matikan Power.

- Pengosongan line. V1 tetap terbuka, V3 dibuka kecil, UTILTY PLANT

PC-4320 dibuka diatur disesuaikan dengan tekanan storage 5101-F Unit Description 107 apabila tekanan 5101-F masih naik jalan kan My Com (5103-L).Water Treatment 108 - Apabila selesai pengosongan tutup kembali valve tersebut dan Cooling Tower 109 matikan My Com (4103-L).Chemical Injection 110Electric Power Generator - Sub Station 110W H B - P B - P A & I A - Gas Metering 111River Water Intake 112Ammonia - Utility Unit 112Waste Water Treatment 112Prosedur Start Up W H B 113Prosedur Start Up G T G 118Prosedur Start Up P B 121

ii 43

Loading AmmoniaHalaman PROSEDUR OPERASI BAKU AMMONIA P - IB

1-101-BJ2T ( ID FAN ) Trip; 1-107-J Trip. 158 LOADING AMMONIA1-106-D METHANATOR Trip 159

1. POMPA LOADINGSTEAM CONSUMTION FOR P-IB 161 - Pastikan level oil pada batas normal.

- Putar shaft pompa pakai tangan.UREA PLANT - Pastikan bv discharge & bv by pass discharge tertutup rapat.

- Pastikan pompa dalam posisi Cooling Down.PROCESS EQUIPMENT LISTSUPERHEATER; TOWER & REACTOR; HEAT EXCHANGER 163 - BV suction terbuka lebar.EJECTOR; TANK & SEPARATOR 164 - BV minimum flow terbuka lebar.CHAMBER; CYCLONE; STRAINER & FILTER 165DISTRIBUTOR & SPRAY NOZZLE 166 2. LINE UP

- BV VI (diatas York Pusri II) terbuka.AUXILIARY EQUIPMENT LIST - BV V2 & V4 (tie-in loading Pusri III) tertutup.COMPRESSOR & BLOWER; CENTRIFUGE; TURBINE 167 - V-4310 terbuka.GB101; GT101; GA101A/B; GT102A/B AUX EQUIPMENT 168 - BV by pass FQR-4301 tertutup.GA102A/B; GT103A/B; EA104; INSTRUMENT

AGITATOR; PRILLING TOWER & PIT 169 loading aktif (bv u/s FQR-4301 terbuka).HOIST & ELEVATOR; CONVEYOR & SCALE; CRANE 170

3. DERMAGA

- BV V6 (tertutup). - BV V10 (10") tertutup.

4. COOLING TOWER - Buka BV V1 terlebih dahulu, yakinkan V2 & V4 tertutup.

iiii 41

V5 dibuka + 5 ulir.

- Methanol di pompa + 70 % (di pot Methanol).

- Yakinkan RV-4302 (pop pada 8.2 kg/cm2) pada line ammonia

- BV V3 (terbuka kecil sekali + 1/4 ulir). - BV V5 (terbuka + 1/2 ulir).

- Buka BV V3 + 1 ulir. - Buka BV V5 + 4 ulir. - Buka BV by pass discharge + 1 ulir.

ATURAN PEMAKAIAN STEAM 42 KG/CM2SEJAK 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.

Masuk gas ke Absorber 1 - 101 - EPROCESS DESIGN BASIS AMMONIA P - IB PROSEDUR OPERASI BAKU AMMONIA P - IB

MASUK GAS KE ABSORBER 1 - 101 - EITEM No PRESS / TEMP STEAM I. PERSIAPAN.

101-B Superheat ( Primary Reformer ) 1. Rate gas 50 % ~ 60 % vent MOV-1018 back press PI-1814 =

101-C P S/T : 39,7 / 144,1 KgSecondary Reformer W.H.B

101-FP : 140,6 Kg Steam DrumT +/- : 350 / 19 deg 3. Atur level LCA-1042, LCA-1004 dan LCAL-1017 pada 50 % dan

101-JTCP S/T : 1,76 / 10,5 Kg Surface Condenser for yakinkan sight glassnya sesuai dengan level.

101-JT & 102-JT

101-UP : 3,5 Kg DearatorT +/- : 150 / 19 deg temperatur sebelum gas masuk ke 1-101-E.

102-C P S/T : 39,7 / 140,6 KgH P Steam Superheater 5. Buka make up Demin ke 1-107-C (bv 2") untuk top 102-E, boleh ditutup bila LCAL-1040 telah kontinyu terjadi level.

102-UP : 14,79 Kg Mixed Bed Condensate Polisher 6. Kontinyu isi Demin ke 111-C via line 1" ke d/s LV-1020 dan jaga

level 1-111-C normal.103-C1

P S/T : 39.7 / 161.7 KgHTS Effluent WHB. 7. Stand by kan PV-1040 pada 5 ~ 10 % open, buka vent motive steam (3") u/s ejector.

103-C2 P S/T : 39.7 / 161.7 KgHTS Effluent WHB. 9. But valve motive steam ejector : L1, L2, L3 dan L4 posisi tertutup.106-C P S/T : 10,5 / 39,7 Kg LTS Effluent / LP BFW Exchanger 10. Buka lebar drain 2" dan aktifkan trapnya pada down stream

ejector SLC-1009-24 ", tidak diperbolehkan dikurangi sebelum

109-CP Hot/C : 2,8 / 7 Kg Lean Solution / LP BFW Exhanger 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 123-C1

P S/T : 188 / 181.7 Kg Amm Conv Eff/Steam Generation FV-1050. 12. Buka drain MOV-1009 untuk membuang condensate dan tutup

123-C2 P S/T : 188 / 181.7 Kg Amm Conv Eff/Steam Generation lagi setelah kering. 13. Buka kecil drain-drain valve dari d/s MOV-1009 sampai ke102-F1

131-CP S/T : 39,7 / 161.7 KgLTS Effluent / BFW Exchanger 14. Drip sump 1-115-F stand by kosong.

88 49

INSTRUMENTS Masuk gas ke Absorber 1 - 101 - EITEM NO REMARK LOCATIONTIC-1005 HP header temperature SUPERHEATER 8. Aktifkan LC-1020 bila tekanan suction sudah lebih tinggi dariTIC-1006 CO2 produksi (top outlet stripper 1-102-E STRIPPERTIC-1010 inlet 1-104-D1 HTS 9. Aktifkan FC-1050 bila level top 1-102-E (LCAL-1040) sudah TIC-1012 inlet 1-106-D ABS OVHD & METH'TOR normal = 30 % dan tutup jumper line CB-1579 2" dari1-105-C TIC-1020 desuperheater HP to MP LETDOWN HP TO MP ke 1-113-C.TIC-1021 BFW to letdown SLL HEADER 10. Aktifkan FC-1806, tutup make up demin ke 1-107-C dan jaga TIC-1030 outlet 1-173-C DRIERS level dari top 1-102-E LCAL-1040 = 30 %, tutup make up demin TIC-1305 bypass 1-101-BC5 FEED GAS COMP ke 1-111-C.TIC-1311 by-pass 1-101-BC4 AIR COMPRESSORTIC-1414 1-105-E top outlet 1-105-E * Catatan :TIC-1769 outlet top stripper FEED TREATING 1. Jangan masukkan gas ke 1-101-E bila temperatur TIC-1796 ammonia to urea NH3 REF FLASH DRUMTIC-1825 BFW to export / import MP HEADER 2. Jangan ditutup drain 2" d/s ejector bila belum ter -TIC-4301 NH3 STORAGE bentuk level di LCAL-1040, sisakan 1 ulir tetap terbuka.TIC-4318 NH3 to Urea NH3 STORAGE 3. Bila level 1-111-C terlanjur kosong, atur flow motive TIC-718 SLL inlet 1-F-D104 HRU steam tidak naik secara mendadak.XI-4301 43-5101-J speed NH3 STORAGEXI-4302 43-5101-JA speed NH3 STORAGEXY-1264 HRU to fuel system 1-104-E

86 51

21 ~ 22 kg/cm2 g. 2. Sirkulasi Lean dan Semi lean sudah stabil FCAL-1014=140 m3/H

T S/T : 482 / 566 0C dan FCAL-1005 = 800 m3/H (satu pompa). PC-1005 = 21 ~ 22 kg/cm2g.

T S/T : 121 / 65 0C 4. Temp sirkulasi benfield TI-1407 > 100 0C dan TIAL-1354 > 80 0C, bila masih lebih rendah gunakan V-1008 untuk menaikkan

T S/T : 482 / 566 0C

T : 50 0C.

T S/T : 470 / 360 0C. 8. Set tekanan PC-1104 = 0,75 kg/cm2g auto control.

T S/T : 470 / 360 0C.

T S/T : 200 / 200 0C

T Hot/C : 150 /150 0C

T S/T : 482 / 343 0C.

T S/T : 482 / 343 0C.

T S/T : 280 / 280 0C. 15. TC-1101 di atur 185 0C. 16. S/C ratio inlet 1-101-B < 4.0 (FY-1201).

7. Atur temp CO2 outlet 102-E TC-1006 = 38 0C dengan FC-1016.

PC-1040 (+ 4,5 kg/cm2g).

sirkulasi rendah (harus > 100 0C).

Masuk gas ke Absorber 1 - 101 - EII. HEATING UP / PRESSURE UP 1. Tutup SLL ke 1-105-C dan atur demin ke 1-109-C utk mengatur 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.

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

ejector dgn membuka butterfly valve L4, L3, L2, L1 secara bertahap

5. Lanjutkan pindah vent dari MOV-1018 ke PC-1005 hingga MOV-1018 tertutup.

naikkan tekanan 1-102-E secara bertahap ke tekanan normal operasi, PC-1104 jangan sampai menutup rapat, agar tetap ada

50 88 87

ITEMS INSTRUMENT INSTRUMENTSITEM NO REMARK LOCATION

200-F 201-E 202-E 201-F 202-F 144-FTI-1761 outlet bottom absorber PRET CO2 REMOVALTI-1773 outlet flash drum PRET CO2 REMOVAL

LAL-1152 LAL-1154 FAL-1066 LAL-1157 LAH-1153 LAH-1002 TI-1774 lean solution temperature PRET CO2 REMOVALLAH-1154 PAL-1799 LALL-1158 LAL-1002 TI-1781 outlet 1-172-C1/C2 ABS OVHD & METH'TORPDAH-1798 PAH-1799 LAHH-1002 TI-1783 middle 1-108-D FEED GAS COMPTAL-1761 PDAH-1802 PAH-1071 TI-1785 catalist tube temperature 1-101-B TUBEFAL-1070 LAL-1155 TI-1786 catalist tube temperature 1-101-B TUBE

LAL-1156 TI-1787 second ref temperature middle SEC REF & WH EXCHTI-1792 discharge 2nd stage 1-103-J LP CASE

102-J/JA 108-D IN PG to FUEL to REF. 101-J/JT TI-1797 1-104-E top outlet 1-104-E1st REF ARCHBR FLUE G TI-1799 1-103-E liquid inlet 1-103-E

TAH-0200 TAH-1305 FAL-1001 LAH-1151 PAH-1023 TAH-0100 TI-1801 temperature from 1-140- C 1-105-EVAH-0200 FAL-1002 PAL-1120 TAH-1330 VAH-0100 TI-1802 1-103-E top outlet 1-103-EVAHH-0200 FALL-1201 PALL-1220 TAH-1328 VAHH-0100 TI-1806 stm to CW pump turbine MP HEADERXAH-0200 FFAL-1201 PAH-1121 PAHH-1060XAHH-0100 TI-1810 air to auxiliary boiler HP HEADERXAHH-0200 FFALL-1201PAHH-1221 PAH-1057 XAHH-0100 TI-701 inlet HRU HRUCA-1200 TAL-1313 PAH-1058 PDAH-0101 TI-703 outlet 1-D-A101A;B HRU, 1-D-A101TAH-1306 PAH-1059 TAH-1300 TI-704 outlet 1-D-A101A;B HRU, 1-D-A101

AAL-1010A TI-705 inlet 1-D-A101A;B HRU, 1-D-A101AAL-1011A TI-706 inlet 1-D-A101A;B HRU, 1-D-A101

TI-708 fuel gas product HRU, 1-D-A101SEC. HTS WATER

150-E 102-F1 LTSTI-709A out 1-D-A101A;B / in 1-C-E101A HRU

REC. IN JACKT TI-710 temp between C-E101A & C-E10 HRU,COLD BOXTAL-1314 TAH-1339 FAH-1151 PDAH-1069 LAL-1003 TAL-1011 TI-711 1-F-D101 top outlet HRU,COLD BOXTAH-1314 TAL-1339 LAL-1051 PDAHH-1069LALL-1205 TAH-1011 TI-712 temp between C-E101A & C-E10 HRU,COLD BOXTAH-1312 LAL-1052 FAL-1019 LAH-1003 TAH-1350 TI-713 HRU product HRU,COLD BOXTAH-1052 LAL1053 LAL-1025 TI-714 1-F-D101 bottom outlet HRUTAH-1787 LAL-1054 LAH-1025 TI-715 temp between C-E101A & C-E10 HRU,COLD BOXTAH-1053 LAL-1055 AHH-1017 TI-717 fuel gas product HRU,COLD BOXTAH-1034 TIC-1004 1-102-C outlet SUPERHEATER52 85

INSTRUMENTS ITEMS INSTRUMENT

4. Bila temp TI-1407 < 100 0C & TIAL-1354 < 80 0C gunakan

tekanan PC-1040 + 4,5 kg/cm2g mulai masukan motive steam ke

3. Atur tekanan motive steam PC-1040 = 4,5 kg/cm2g dan jaga mantap. 4. Jalankan 1-116-J bila tekanan suction > 5 kg/cm2g ( bila tekanan turun < 2,8 kg/cm2g. Matikan 1-116-J ).

6. Bila sudah ada produksi CO2 bukaan PC-1104 mulai bertambah,

aliran CO2 ke top 1-102-E.

ITEM NO REMARK LOCATIONTI-1387 1-105-D catalist bed temp # 2A 1-105-D, BED # 2A 101-E 102-E 132-F 107-J 115-F 106-DTI-1388 1-105-D catalist bed temp # 2A 1-105-D, BED # 2A 104-L 111-C 133-F 115-LTI-1389 1-105-D catalist bed temp # 2A 1-105-D, BED # 2A PDAH-1042PDAH-1043LAL-1017 TAH-8101 LAL-1119 TAH-1012TI-1390 1-105-D catalist bed temp # 2A 1-105-D, BED # 2A LAL-1004 LAL-1040 LAH-1017 PAL-8101 LAH-1119 TAH-1355TI-1391 1-105-D catalyst bed temp # 2B 1-105-D, BED # 2B LAH-1004 LAL-1041 LALL-1106 LAH-1162 PDAH-1115 TAH-1357TI-1392 1-105-D catalyst bed temp # 2B 1-105-D, BED # 2B FAL-1005 LAL-1042 LALL-1103 PALL-8103 TAH-1358TI-1393 1-105-D catalyst bed temp # 2B 1-105-D, BED # 2B FALL-1205 LAH-1042 LAL-1020 TAH-8102 TAH-1361TI-1394 1-105-D catalyst bed temp # 2B 1-105-D, BED # 2B FAL-1014 PAL-1104 LAH-1020 PAL-8102 TAH-1362TI-1396 Synth gas outlet 1-102-B START UP HEATER FALL-1214 PAH-1104 PALL-8104 TAHH-1200TI-1397 Fuel to start-up heater START UP HEATER TAL-1354 FAL-1016 TAL-1200TI-1398 1-120-CF4 bottom out 1-105-J SAH-1207 PDAH-1102 TAL-1355TI-1399 1-120-CF3 bottom out 1-105-J TAL-1203TI-1400 1-120-CF2 bottom out 1-105-JTI-1402 1-109-F bottom out PROD TO UREA STO'GE 104-F 103-J 105-F1 105-F2 111-L 106-FTI-1403 Ammonia out 1-107-F NH3 PRODUCTTI-1404 1-120-CF1 bottom out 1-105-J LAL-1008 VAH-0300 LAH-0303 LAH-0306 LAH-0317 LAL-1218TI-1405 Temp condensate outlet 1-150-E 1-150-E LAH-1008 XAH-0300 LAL-0303 LAL-0306 LAH-1218TI-1409 Inlet flash drum. LEAN&S LEAN TO ABS PAH-1004 TAH-0340 LAHH-0303LAHH-0306 LAHH-1218TI-1410 Semilean sol'n (outlet flash drumLEAN&S LEAN TO ABS LAHH-1008 TAH-1792TI-1411 BFW outlet 1-103-C BFW FROM 1-104-J TAH-1367TI-1412 BFW outlet 1-131-C BFW FROM 1-104-J TAL-1366TI-1416 1-105-E bottom outlet 1-105-E XAHH-0300TI-1418 Outlet 1-101-BC6 1-101-B FLUE GAS VAHH-0300TI-1420 1-111-C outlet LTS & W.H RECOVERY TAH-1364TI-1421 1-105-C / 1-113-C outlet. 1-101-E & FEEDTI-1550 HP steam outlet drum AUXILIARY BOILERTI-1554 MP header temp output desuperhLETDOWN HP TO MPTI-1555 Outlet desuperheater SLL HEADERTI-1556 1-104-J discharge DEARATORTI-1558 Demin to dearator. COND TO 1-102-U84 53

INSTRUMENTS ITEMS INSTRUMENTITEM NO REMARK LOCATIONTI-1316 catalist tube temperature 1-101-B TUBE

104-J/JAFUEL to FUEL to SM LP 102-U

TI-1317 catalist tube temperature 1-101-B TUBE 101-BBS BU/BBS STEAM STEAM CA-0808TI-1318 catalist tube temperature 1-101-B TUBE CA-1004A PALL-1240 LAH-1150 PAL-1013 PAH-1016 AHH-1018TI-1319 catalist tube temperature 1-101-B TUBE CA-1004B PAHH-1241 PAH-1001 TAH-1020 PAL-1016TI-1320 catalist tube temperature 1-101-B TUBE FAL-1106 PAL-1140 PAL-1001 PAL-1014 PAH-1017TI-1321 inlet 1-101-BC1 1-101-B FLUE GAS PAH-1141 PAH-1014 PAH-1017TI-1322 inlet 1-101-BC1 1-101-B FLUE GAS PAL-1145 TAH-1555TI-1323 inlet 1-101-BC1 1-101-B FLUE GAS PAH-1146TI-1324 inlet 1-101-BC1 1-101-B FLUE GASTI-1325 inlet 1-101-BC1 1-101-B FLUE GAS

101-JTC 103-JTC 103-E 104-E 105-ETI-1326 inlet 1-101-BC2 AIR COMPRESSORTI-1327 outlet 1-101-BC1 1-101-B FLUE GAS LAL-0601 LAL-0602 PDAH-1055PDAH-1056 LAL-1027TI-1331 outlet 1-101-BC3 AIR COMPRESSOR LAH-0601 LAH-0602 PDAL-1055PDAL-1056 LAH-1027TI-1334 outlet secondary reformer REFORMER FEED LHH-0601 LAHH-0602 LAH-1026 LAH-1163TI-1335 1-101-C outlet main line SEC REF & WH EXCH PAH-0608 PAH-0616 LAL-1026 LAL-1163TI-1337 1-102-C outlet bypass SUPERHEATERTI-1338 1-102-C outlet SUPERHEATER HRU HRU HRU NH3 NH3TI-1339 inlet 1-104-D1 SUPERHEATER DA-101 COLDBOX REGEN PROD STORGTI-1340 1-101-C outlet bypass SEC REF & WH EXCH TAH-0701 LAH-0702 TAL-0718 FAL-1061 PAL-4310TI-1341 1-104-D1 catalyst bed HTS LAH-0701 LAL-0702 TAH-0707 PAH-4310TI-1342 1-104-D1 catalyst bed HTS PDAH-0705 TAH-0711 TAL-0707 PAL-4311TI-1343 1-104-D1 catalyst bed HTS PDAH-0706 PAH-0719 PDAH-0707 PAH-4311TI-1344 1-104-D1 catalyst bed HTS TAH-0709B PAL-0718 PDAH-0708 LAL-4308TI-1346 1-104-D2 catalyst bed LTS PDAH-0709 TAL-0713 TAL-0702 LAH-4308TI-1347 1-104-D2 catalyst bed LTS FAL-0701A TAL-0717 TAH-0702 LAL-4307TI-1348 1-104-D2 catalyst bed LTS FALL-0701B TALL-0716 PAH-0720A LAH-4307TI-1349 1-104-D2 catalyst bed LTS TAH-0709A PAL-713 PAH-0720B TAL-4318TI-1351 1-131-C outlet LTS & W.H RECOVERY CA-4300TI-1352 1-106-C outlet temperature. 1-101-E & FEEDTI-1353 outlet absorber ABS OVHD & METH'TOR82 55

ITEMS INSTRUMENT INSTRUMENTSITEM NO REMARK LOCATION

102-B 109-D 157-F 107-E 109-F 120-CFTI-1354 1-101-E outlet 1-101-E & FEEDTI-1355 inlet 1-106-D ABS OVHD & METH'TOR

FALL-1257 KA-1001 LAH-1166 PAHH-1070 LAL-1015 LAL-1021 TI-1357 1-106-D catalist bed METHANATORTAH-1396 PAH-1108 LAH-1015 LAH-1021 TI-1358 1-106-D catalist bed METHANATORTAH-1397 LAL-1022 TI-1359 1-106-D catalist bed METHANATORPAL-1150 LAH-1022 TI-1360 1-106-D catalist bed METHANATORPAH-1151 LAL-1023 TI-1361 1-106-D catalist bed METHANATOR

LAH-1023 TI-1362 1-106-D catalist bed METHANATORLAL-1024 TI-1363 inlet 1-104-F temperature METHANATORPAH-1009 TI-1364 discharge 1st stage 1-103-J LP CASEPAL-1009 TI-1365 suction 2nd stage 1-103-J LP CASE

TI-1366 suction 4th stage 1-103-J HP CASE

105-J/JA STEAM SH FUEL to FD 101-U TI-1367 discharge 4th stage 1-103-J HP CASEDRUM STEAM 101-BU FAN TI-1369 outlet 1-121-C SYNTHESIS LOOP

TAH-0500 LAH-1029 PAH-1018 PAL-1135 XA-1206 LAH-1124 TI-1370 BFW outlet 1-123-C BFW FROM 1-104-JVAH-0500 LAL-1028 PAL-1018 PAH-1136 PAL-1855 LAL-1125 TI-1371 inlet 1-121-C SYNTHESIS LOOPVAHH-0500 LALL-1223 TAH-1005 PALL-1235 PALL-1856 LAL-1030 TI-1373 outlet 1-121-C 103-J DISCH TO LOOPXAH-0500 TAH-1336 PAHH-1236 TI-1374 outlet 1-105-D 1-105-D, BED # 2BXAHH-0500 TAL-1336 PAH-1131 TI-1375 1-105-D catalist bed temp # 2A 1-105-D, BED # 2ACA-1005 PAL-1130 TI-1376 1-105-D catalist bed temp # 2A 1-105-D, BED # 2ALALL-0512 PALL1130 TI-1377 1-105-D catalist bed temp # 2A 1-105-D, BED # 2ALALL-0513 PAHH-1231 TI-1378 1-105-D catalist bed temp # 2A 1-105-D, BED # 2ATAH-1401 TI-1379 1-105-D catalist bed temp # 1 1-105-D, BED # 1

TI-1380 1-105-D catalist bed temp # 1 1-105-D, BED # 1TI-1381 1-105-D catalist bed temp # 1 1-105-D, BED # 1TI-1382 1-105-D catalist bed temp # 1 1-105-D, BED # 1TI-1383 1-105-D catalist bed temp # 1 1-105-D, BED # 1TI-1384 1-105-D catalist bed temp # 1 1-105-D, BED # 1TI-1385 1-105-D catalist bed temp # 1 1-105-D, BED # 1TI-1386 1-105-D catalist bed temp # 1 1-105-D, BED # 1

54 83

ITEMS INSTRUMENT INSTRUMENTSITEM NO REMARK LOCATIONPIC-1031 steam to dearator. DEARATOR

1202 REFORMER FEED PIC-1032 1-103-E top outlet 1-103-EFIC-1003 discharge of 3rd stage PIC-1033 1-104-E top outlet 1-104-EHS-1006 discharge of 3rd stage PIC-1034 1-105-E top outlet 1-105-EHIC-1021 Steam to air coil. PIC-1071 NG vent upstream 1-102-J FEED GAS COMPFIC-1001 NG to 1-101-BC2 PIC-1104 CO2 product (top outlet stripper) 1-102-E STRIPPERTI-1334 outlet secondary reformer PIC-1108 1-107-F pressure ( top outlet ) NH3 PRODUCTHS-1010 NG to 1-101-BC2 PIC-1791 air to utility AIR COMPRESSORFI-1044A Steam to air coil. PIC-1799 outlet top stripper FEED TREATINGFIC-1002 Steam to 1-101-BC2 PIC-1833 semilean sol'n from 1-107-JC LEAN&S LEAN TO ABS

PIC-1852 fuel to start-up heater START UP HEATER1201 AIR COMPRESSOR PIC-1855 air to auxiliary boiler HP HEADER

PIC-1791 air to utility PIC-3011-104-F out press; speed of 1-103-J. 1-104-F SUC DRUMFIC-1065 air to utility PIC-4001 naturalgas supply, inlet B / L FEED TREATINGPI-109 discharge of 3rd stage. PIC-4320 NH3 for loading system NH3 STORAGETI-1326 inlet 1-101-BC2 PIC-5001 1-105-JT extraction control. SLL HEADERFIC-102 discharge of 3rd stage. PIC-701 outlet 1-F-D103 HRUTI-1331 outlet 1-101-BC3 PIC-710 inlet 1-C-E101A HRU,COLD BOXTIC-1311 by-pass 1-101-BC4 PIC-710 inlet 1-C-E101 HRUTI-1312 air to 1-103-D PIC-711 HRU product HRU

TI-1011 process gas out 1-103-C1 / C2 LTS1207 1-101-B FIRING CONTROL TI-1024 steam gas to catalist tube STM TO CARBON RATIO

PIC-1002 fuel to arch burner TI-1029 natural gas suffly, inlet B/L NG FEED & CO2 PRODHIC-1035 inlet arch burner " A " bank. TI-1041 inlet 1-109-DA DRIERSHIC-1036 inlet arch burner " B " bank. TI-1043 inlet 1-109-DB DRIERSHIC-1037 inlet arch burner " C " bank. TI-1052 secondary ref temperature top SEC REF & WH EXCHHIC-1038 inlet arch burner " D " bank. TI-1053 second ref temperature bottom SEC REF & WH EXCHPIC-1019 radiant box pressure TI-1312 air to 1-103-D AIR COMPRESSORHIC-1259 inlet arch burner " E " bank. TI-1314 outlet primary reformer. 101-B FIRING CONTROLTI-1314 outlet primary reformer. TI-1315 catalist tube temperature 1-101-B TUBE56 81

INSTRUMENTS ITEMS INSTRUMENTITEM NO REMARK LOCATIONPI-1064 inlet arch burner FUEL TO ARCH BURNER

PI-109 discharge of 3rd stage. AIR COMPRESSOR 1205 1-101-B TUBEPI-1814 process gas outlet 1-103-C1/C2 HTS TI-1315 catalist tube temperaturePI-1838 inlet arch burner FUEL TO ARCH BURNER TI-1316 catalist tube temperaturePI-309 1-111-L outlet 1-103-J HP CASE TI-1317 catalist tube temperaturePI-4310 NH3 storage NH3 STORAGE TI-1318 catalist tube temperaturePI-4311 NH3 storage NH3 STORAGE TI-1319 catalist tube temperaturePI-608 1-101-JTC COND TO 1-102-U TI-1320 catalist tube temperaturePI-616 1-103-JTC COND TO 1-102-U TI-1785 catalist tube temperaturePI-713 1-F-D101 bottom outlet HRU TI-1786 catalist tube temperaturePI-714 fuel gas product HRU, 1-D-A101PIC-1001 fuel to aux boiler / superheater AUXILIARY BOILER 1206 1-101-B FLUE GASPIC-1002 fuel to arch burner 101-B FIRING CONTROL TI-1321 inlet 1-101-BC1PIC-1004 inlet 1-103-J 1-104-F SUC DRUM TI-1322 inlet 1-101-BC1PIC-1005 1-114-C upstream vent ABS OVHD & METH'TOR TI-1323 inlet 1-101-BC1PIC-1009 1st stage suction NH3 REF FLASH DRUM TI-1324 inlet 1-101-BC1PIC-1010 outlet 1-108-D FEED GAS COMP TI-1325 inlet 1-101-BC1PIC-1012 1-103-JT governoor control HP HEADER TI-1327 outlet 1-101-BC1PIC-1012 1-103-JT governoor control LETDOWN HP TO MP TI-1418 outlet 1-101-BC6PIC-1013 letdown HP to MP, press MP headLETDOWN HP TO MP AI-101-DA Flue gas O2PIC-1014MP steam to vent ( MP steam press )MP HEADERPIC-1016 LP pressure header SLL HEADER 1801 CONDENSATE TO 1-102-UPIC-1017 LP to vent SLL HEADER LIC-601 1-101-JTCPIC-1018 HP header pressure AUXILIARY BOILER PI-608 1-101-JTCPIC-1018 HP Header pressure HP HEADER LIC-602 1-103-JTCPIC-1019 radiant box pressure 101-B FIRING CONTROL PI-616 1-103-JTCPIC-1023 auxiliary boiler draft AUXILIARY BOILER FIC-1087 make up demin water.PIC-1023 auxiliary boiler draft HP HEADER AI-1018 condensate to condensate polister.PIC-1028 warm ammonia product to urea NH3 REF FLASH DRUM TI-1558 demin to dearator.PIC-1030 fuel to auxiliary boiler AUXILIARY BOILER CA-808 common alarm for 1-102-U80 57

INSTRUMENTS ITEMS INSTRUMENTITEM NO REMARK LOCATIONLAL-1054 1-101-C water jacket level WATER JACKETLAL-1055 1-102-C water jacket level WATER JACKET 1809 SLL HEADERLI-1001A steam drum level STEAM DRUM LEVEL PIC-1016 LP pressure headerLI-1001B steam drum level STEAM DRUM LEVEL PIC-1017 LP to ventLI-1017 level flash drum LEAN&S LEAN TO ABS PIC-5001 1-105-JT extraction control.LI-1041 liq level in the stripper (mid part)1-102-E STRIPPER FI-1092 LP to CW pump turbine.LI-1155 liq level in stripper ( upper part ) PRET CO2 REMOVAL FIC-1884 LP to 1-105-JLI-1157 flush drum level PRET CO2 REMOVAL TI-1555 outlet desuperheaterLI-4307 NH3 storage NH3 STORAGE LIC-1129 1-156-F levelLI-4308 NH3 storage NH3 STORAGE TIC-1021 BFW to letdownLIC-1001 steam drum level STEAM DRUM LEVELLIC-1002 level 1-144-F FEED GAS COMP 1303 LTS & W.H RECOVERYLIC-1003 1-102-F1 level 1-101-E & FEED HS-1009 MOV bypass 1-104-D2LIC-1004 absorber liquid level. 1-101-E & FEED TI-1351 1-131-C outletLIC-1008 1-104-F liquid level 1-104-F SUC DRUM TI-1420 1-111-C outletLIC-1012 1-107-F liguid level NH3 PRODUCT FIC-1050 lean sol'n to 1-113-C reboiler.LIC-1013 1-106-F liguid level NH3 PRODUCT FIC-1040 steam to ejectorLIC-1015 1-109-F liquid level NH3 REF FLASH DRUM FI-1049 condensate to 1-111-CLIC-1020 1-111-C liquid level. LTS & W.H RECOVERY LIC-1020 1-111-C liquid level.LIC-1021 1-120-CF4 bottom out NH3 REF FLASH DRUMLIC-1022 1-120-CF3 bottom out NH3 REF FLASH DRUMLIC-1023 1-120-CF2 bottom out NH3 REF FLASH DRUM 1401 1-101-E & FEEDLIC-1024 1-120-CF1 bottom out NH3 REF FLASH DRUM PDI-1042 absorber's bed differential press.LIC-1025 1-150-E liquid level 1-150-E LIC-1004 absorber liquid level.LIC-1026 1-103-E liquid level 1-103-E FIC-1014 lean sol'n to top of absorberLIC-1027 1-105-E liquid level 1-105-E FIC-1005 semi lean sol'n to mid. Part of absorberLIC-1030 dearator level DEARATOR TI-1421 1-105-C / 1-113-C outlet.LIC-1040 liq level in the stripper ( top part 1-102-E STRIPPER TI-1352 1-106-C outlet temperature.LIC-1042 liq level in the stripper (bott part 1-102-E STRIPPER LIC-1003 1-102-F1 levelLIC-1101 STEAM DRUM LEVEL TI-1354 1-101-E outlet78 59

ITEMS INSTRUMENT INSTRUMENTSITEM NO REMARK LOCATIONLIC-1129 1-156-F level SLL HEADER

1802 DEARATOR LIC-1132 1-102-F2 liquid level ABS OVHD & METH'TOR

TI-1556 1-104-J discharge LIC-1154 level absorber FEED TREATINGPIC-1031 steam to dearator. LIC-1156 liq level in stripper ( bottom part FEED TREATINGLIC-1030 dearator level LIC-1162 1-133-F liquid level LEAN&S LEAN TO ABSAI-1007 outlet dearator. LIC-1163 1-104-E liquid Level 1-104-EAI-1008 outlet dearator. LIC-1166 level 1-157-F DRIERS

LIC-303 1-105-F1 liquid level 1-103-J LP CASELIC-305 1-105-F1 liquid level 1-103-J LP CASELIC-4301 43-5102-F Liquid level NH3 STORAGELIC-601 1-101-JTC COND TO 1-102-U

1803 BFW FROM 1-104-J LIC-602 1-103-JTC COND TO 1-102-UFIC-1020 BFW to 1-123-C LIC-702 level 1-F-D101 HRU,COLD BOXFIC-1043 BFW to 1-101-C emergency LY-1012C select switch NH3 PRODUCTTI-1370 BFW outlet 1-123-C PDI-1042 absorber's bed differential press. 1-101-E & FEEDTI-1412 BFW outlet 1-131-C PDI-1054 1-105-D differential pressure SYNTHESIS LOOPTI-1411 BFW outlet 1-103-C PDI-1055 1-103-E different pressure 1-103-ECA-1004-A speed 1-104-J PDI-1056 1-104-E differential pressure 1-104-ECA-1004-B speed 1-104-J PDI-1069 1-150-E differential pressure 1-150-E

PDI-1102 1-104-L different pressure LEAN&S LEAN TO ABSPDI-1798 differential pressure absorber PRET CO2 REMOVAL

1804 STEAM DRUM LEVEL PDI-1802 stripper differential pressure PRET CO2 REMOVALLIC-1001 steam drum level PDIC-1022 combustion air control SUPERHEATERFIC-1006 1-104-J dicharge PDIC-705 fuel gas product HRUFI-1033 HP steam outlet drum PI-1028 fuel to arch burner FUEL TO ARCH BURNERHS-1101 selector LI-1001A or LI-1001B PI-1036 steam drum pressure AUXILIARY BOILERLI-1001A steam drum level PI-1053 steam gas to catalist tube STM TO CARBON RATIOLI-1001B steam drum level PI-1061 inlet arch burner FUEL TO ARCH BURNERHS-1102 selector flow vs level. PI-1062 inlet arch burner FUEL TO ARCH BURNERLIC-1101 PI-1063 inlet arch burner FUEL TO ARCH BURNER58 79

ITEMS INSTRUMENT INSTRUMENTSITEM NO REMARK LOCATIONHIC-1026 by-pass 1-121-C 1-103-J DISCH TO LOOP

1402 LEAN & SEMI LEAN TO ABS, RICH RETURN HIC-1028 letdown HP to MP LETDOWN HP TO MPLI-1017 level flash drum HIC-1029 letdown HP to MP LETDOWN HP TO MPTI-1410 semilean sol'n ( outlet flash drum ). HIC-1032 speed of 1-120-J PROD TO UREA STO'GEFI-1051 semilean sol'n to middle part of absorber. HIC-1035 inlet arch burner " A " bank. 101-B FIRING CONTROLFI-1052 semilean sol'n from 1-107-JB HIC-1036 inlet arch burner " B " bank. 101-B FIRING CONTROLPIC-1833 semilean sol'n from 1-107-JC HIC-1037 inlet arch burner " C " bank. 101-B FIRING CONTROLLIC-1162 1-133-F liquid level HIC-1038 inlet arch burner " D " bank. 101-B FIRING CONTROLTI-1409 inlet flash drum. HIC-1050 fuel to start-up heater START UP HEATERPDI-1102 1-104-L different pressure HIC-1259 inlet arch burner " E " bank. 101-B FIRING CONTROL

HIC-1262 export / import steam MP HEADER1403 1-102-E STRIPPER HS-1001 outlet 1-111-L, MOV-1001 1-103-J HP CASE

LI-1041 liquid level in the stripper ( mid part ) HS-1002 suction 4th stage, MOV-1002 1-103-J HP CASEFIC-1017 liquid from top to bottom part of stripper HS-1004 emergency s/d 1-104-D2 LTSLIC-1042 liquid level in the stripper ( bott. part ) HS-1006 discharge of 3rd stage REFORMER FEEDPIC-1104 CO2 product ( top outlet stripper ) HS-1008 MOV inlet 1-104-D2 LTSLIC-1040 liquid level in the stripper ( top part ) HS-1009 MOV bypass 1-104-D2 LTS & W.H RECOVERYFIC-1016 reflux flow HS-1010 NG to 1-101-BC2 REFORMER FEEDTIC-1006 CO2 produksi ( top outlet stripper ) HS-1011 MOV-inlet 1-106-D ABS OVHD & METHFIC-1806 condensate ( reflux ) excess HS-1018 MOV to vent d/s 1-104-D2 HTS

HS-1024 cold / hot product selection PROD TO UREA STO'GE1404 ABSORBER OVHD & METHANATOR HS-1027A 1-141-J/JA start 1-104-E

TI-1353 outlet absorber HS-1027B 1-140-J/JA start 1-103-ELIC-1132 1-102-F2 liquid level HS-1101 selector LI-1001A or LI-1001B STEAM DRUM LEVELFIC-1073 process gas outlet 1-102-F2 to fuel HS-1102 selector flow vs level. STEAM DRUM LEVELPIC-1005 1-114-C upstream vent HS-704 fuel gas product HRUTIC-1012 inlet 1-106-D HS-706 fuel gas product HRUHS-1011 MOV-inlet 1-106-D LAL-1051 1-103-D water jacket level WATER JACKETTI-1355 inlet 1-106-D LAL-1052 1-103-D water jacket level WATER JACKETTI-1781 outlet 1-172-C1/C2 LAL-1053 1-107-D water jacket level WATER JACKET60 77

INSTRUMENTS ITEMS INSTRUMENTITEM NO REMARK LOCATIONFIC-1043 BFW to 1-101-C emergency BFW FROM 104-JFIC-1050 lean sol'n to 1-113-C reboiler. LTS & W.H RECOVERY 1904 HRU, 1-D-A101FIC-1064 1-103-E liquid inlet 1-103-E TI-703 outlet 1-D-A101A;B

FIC-1065 air to utility AIR COMPRESSOR TI-704 outlet 1-D-A101A;BFIC-1066 reflux flow FEED TREATING TI-705 inlet 1-D-A101A;BFIC-1068 steam to ejector FEED TREATING TI-706 inlet 1-D-A101A;BFIC-1070 lean solution flow FEED TREATING FI-702 gas to regeneration / inlet 1-C-E102FIC-1073 process gas out 1-102-F2 to fuel ABS OVHD & METH'TOR TI-708 fuel gas productFIC-1077 synthesis gas to purge SYNTHESIS LOOP FI-706 fuel gas productFIC-1078 1-107-F to 1-120-CF3 NH3 PRODUCT PI-714 fuel gas productFIC-1079 1-107-F to 1-120-CF2 NH3 PRODUCTFIC-1087 make up demin water. COND TO 1-102-U 1905 HRUFIC-1088 steam to reboiler PRET CO2 REMOVAL TI-701 inlet HRUFIC-1278 air to auxiliary boiler HP HEADER PIC-701 outlet 1-F-D103FIC-1806 condensate ( reflux ) excess 1-102-E STRIPPER TI-709A outlet 1-D-A101A;B / inlet 1-C-E101AFIC-1808 1-103-JT extraction line HP HEADER FI-704 steam to 1-C-E101AFIC-1884 LP to 1-105-J SLL HEADER FI-701A inlet 1-C-E101AFIC-201 1-102-J disharge FEED GAS COMP FI-703 HRU productFIC-301 Kick back to 1st stage 1-103-J LP CASE PIC-711 HRU productFIC-303 kick back to 3rd stage 1-103-J HP CASEFIC-304 kick back to 4th stage 1-103-J HP CASEFIC-501 1st stage suction 1-105-J 1906 HRU,COLD BOXFIC-502 2nd stage discharge 1-105-J TI-717 fuel gas productFIC-503 3rd stage discharge 1-105-J TI-713 HRU productFIC-504 4th stage discharge 1-105-J TI-715 temperature between 1-C-E101A & 1-C-E101BFQI-1042 natural gas suffly, inlet B/L NG FEED & CO2 PROD TI-710 temperature between 1-C-E101A & 1-C-E101BFQI-1060 warm ammonia product to urea PROD TO UREA STO'GE TI-712 temperature between 1-C-E101A & 1-C-E101BFQI-1061cold ammonia product to storage PROD TO UREA STO'GE LIC-702 level 1-F-D101HIC-1021 Steam to air coil. REFORMER FEED TI-711 1-F-D101 top outletHIC-1025 synt gas to 1-105-D diff quench SYNTHESIS LOOP PIC-710 inlet 1-C-E101A76 61

INSTRUMENTS ITEMS INSTRUMENTITEM NO REMARK LOCATIONAI-1007 outlet dearator. DEARATORAI-1008 outlet dearator. DEARATOR 1502 1-104-F SUCTION DRUMAI-101 IA flue gas O2 AUXILIARY BOILER PIC-301 1-104-F outlet pressure; speed of 1-103-J.AI-1014 outlet 1-109-D DRIERS PIC-1004 inlet 1-103-JAI-1017 conductivity of process cond 1-150-E LIC-1008 1-104-F liquid levelAI-1018 cond to condensate polister. COND TO 1-102-UAI-101-DA Flue gas O2 1-101-B FLUE GASCA-1004-A speed 1-104-J BFW FROM 1-104-JCA-1004-B speed 1-104-J BFW FROM 1-104-JCA-808 common alarm for 1-102-U COND TO 1-102-UFALL-1257 flow to 1-102-B START UP HEATERFI-1027 steam to 1-140-C 1-105-E 1601 1-103-J LP CASEFI-1031 fuel to superheater burner SUPERHEATER FIC-301 Kick back to 1st stageFI-1033 HP steam outlet drum STEAM DRUM LEVEL TI-1364 discharge 1st stageFI-1042 natural gas suffly, inlet B/L NG FEED & CO2 PROD TI-1365 suction 2nd stageFI-1044A Steam to air coil. REFORMER FEED TI-1792 discharge 2nd stageFI-1046 syn gas to 1-173-C DRIERS LIC-303 1-105-F1 liquid levelFI-1047 total fuel from 1-200-F START UP HEATER LIC-305 1-105-F1 liquid levelFI-1049 condensate to 1-111-C LTS&W.H RECOVERYFI-1051 semilean sol'n to middle part of LEAN&S LEAN TO ABSFI-1052 semilean sol'n from 1-107-JB LEAN&S LEAN TO ABSFI-1059 discharge 4th stage 1-103-J HP CASE 1602 DRIERSFI-1060 warm ammonia product to urea PROD TO UREA STO'GE TI-1041 inlet 1-109-DAFI-1061 cold ammonia product to storagePROD TO UREA STO'GE TI-1043 inlet 1-109-DBFI-1062 condensate outlet 1-180-C 1-150-E FI-1075 purge gas to 1-173-CFI-1063 1-103-E top outlet 1-103-E TIC-1030 outlet 1-173-CFI-1075 purge gas to 1-173-C DRIERS FI-1046 syn gas to 1-173-CFI-1081 1-104-E liquid inlet 1-104-E LIC-1166 level 1-157-FFI-1089 stm to CW pump turbine MP HEADER AI-1014 outlet 1-109-DFI-1091B export / import steam MP HEADER74 63

ITEMS INSTRUMENT INSTRUMENTSITEM NO REMARK LOCATIONFI-1092 LP to CW pump turbine. SLL HEADER

1606 1-105-D, BED # 2A FI-1093 fuel to start-up heater START UP HEATERTI-1375 1-105-D catalist bed temperature # 2A FI-1094 condensate from 1-112-J WATER JACKETTI-1376 1-105-D catalist bed temperature # 2A FI-1095 CO2 product (top outlet stripper) NG FEED & CO2 PROD

TI-1377 1-105-D catalist bed temperature # 2A FI-1152 export / import steam MP HEADERTI-1378 1-105-D catalist bed temperature # 2A FI-1201 natural gas to catalyst tube STM TO CARBON RATIOTI-1387 1-105-D catalist bed temperature # 2A FI-1202 steam gas to catalist tube STM TO CARBON RATIOTI-1388 1-105-D catalist bed temperature # 2A FI-1280 CO2 product to header NG FEED & CO2 PRODTI-1389 1-105-D catalist bed temperature # 2A FI-4301 NH3 to Urea NH3 STORAGETI-1390 1-105-D catalist bed temperature # 2A FI-701A inlet 1-C-E101A HRU

FI-702 gas to regeneration / inlet 1-C-E HRU, 1-D-A1011607 1-105-D, BED # 1 FI-703 HRU product HRU

TI-1379 1-105-D catalist bed temperature # 1 FI-704 steam to 1-C-E101A HRUTI-1380 1-105-D catalist bed temperature # 1 FI-706 fuel gas product HRU, 1-D-A101TI-1381 1-105-D catalist bed temperature # 1 FIA-1151 demin to water jacket WATER JACKETTI-1382 1-105-D catalist bed temperature # 1 FIC-1001 NG to 1-101-BC2 REFORMER FEEDTI-1383 1-105-D catalist bed temperature # 1 FIC-1002 Steam to 1-101-BC2 REFORMER FEEDTI-1384 1-105-D catalist bed temperature # 1 FIC-1003 discharge of 3rd stage REFORMER FEEDTI-1385 1-105-D catalist bed temperature # 1 FIC-1005semi lean sol'n to mid part of abs 1-101-E & FEEDTI-1386 1-105-D catalist bed temperature # 1 FIC-1006 1-104-J dicharge STEAM DRUM LEVEL

FIC-1014 lean sol'n to top of absorber 1-101-E & FEED1501 METHANATOR FIC-1016 reflux flow 102-E STRIPPER

TI-1357 1-106-D catalist bed FIC-1017 liq from top to bott part of stripp 102-E STRIPPERTI-1358 1-106-D catalist bed FIC-1019 steam to 1-150-E 1-150-ETI-1359 1-106-D catalist bed FIC-102 discharge of 3rd stage. AIR COMPRESSORTI-1360 1-106-D catalist bed FIC-1020 BFW to 1-123-C BFW FROM 104-JTI-1361 1-106-D catalist bed FIC-1022 synthesis gas to Natural Gas FEED GAS COMPTI-1362 1-106-D catalist bed FIC-10271-104-E gas inlet ( purge gas to HRU )1-104-ETI-1363 inlet 1-104-F temperature FIC-1030 fuel to auxiliary boiler AUXILIARY BOILER

FIC-1040 steam to ejector LTS & W.H RECOVERY62 75

ITEMS INSTRUMENT ITEMS INSTRUMENT

1603 1-103-J HP CASE 1704 1-105-JFIC-303 kick back to 3rd stage FIC-501 1st stage suctionTI-1366 suction 4th stage FIC-502 2nd stage dischargeFIC-304 kick back to 4th stage FIC-503 3rd stage dischargeHS-1002 suction 4th stage, MOV-1002 FIC-504 4th stage discharge PI-309 1-111-L outlet TI-1398 1-120-CF4 bottom outTI-1367 discharge 4th stage TI-1399 1-120-CF3 bottom outFI-1059 discharge 4th stage TI-1400 1-120-CF2 bottom outHS-1001 outlet 1-111-L, MOV-1001 TI-1404 1-120-CF1 bottom out

1608 1-105-D, BED # 2B 1209 1-150-ETI-1374 outlet 1-105-D LIC-1025 1-150-E liquid levelTI-1391 1-105-D catalyst bed temperature # 2B PDI-1069 1-150-E differential pressureTI-1392 1-105-D catalyst bed temperature # 2B FIC-1019 steam to 1-150-ETI-1393 1-105-D catalyst bed temperature # 2B TI-1405 temperatur condensate outlet 1-150-ETI-1394 1-105-D catalyst bed temperature # 2B FI-1062 condensate outlet 1-180-C

AI-1017 conductivity of process condensate

1102 PRETREATMENT CO2 REMOVALTI-1761 outlet bottom absorberPDI-1798 differential pressure absorberLI-1155 liquid level in stripper ( upper part )FIC-1088 steam to reboilerLI-1157 flush drum levelTI-1773 outlet flash drumTI-1774 lean solution temperaturePDI-1802 stripper differential pressure64 73


1701 NH3 PRODUCT 1907 HRULIC-1013 1-106-F liguid level PIC-710 inlet 1-C-E101LIC-1012 1-107-F liguid level TIC-718 SLL inlet 1-F-D104PIC-1108 1-107-F pressure ( top outlet ) PI-713 1-F-D101 bottom outlet

TI-1403 ammonia out 1-107-F TI-714 1-F-D101 bottom outletFIC-1078 1-107-F to 1-120-CF3 PDIC-705 fuel gas productFIC-1079 1-107-F to 1-120-CF2 HS-704 fuel gas productLY-1012C select switch HS-706 fuel gas product

1702 NH3 REFRIGERATION FLASH DRUM 1201 WATER JACKETPIC-1009 1st stage suction FI-1094 condensate from 1-112-JLIC-1015 1-109-F liquid level FIA-1151 demin to water jacketPIC-1028 warm ammonia product to urea LAL-1051 1-103-D water jacket levelLIC-1021 1-120-CF4 bottom out LAL-1052 1-103-D water jacket levelLIC-1022 1-120-CF3 bottom out LAL-1053 1-107-D water jacket levelLIC-1023 1-120-CF2 bottom out LAL-1054 1-101-C water jacket levelLIC-1024 1-120-CF1 bottom out LAL-1055 1-102-C water jacket levelTIC-1796 ammonia to urea

1703 PRODUCT TO UREA STORAGE 1203 STEAM TO CARBON RATIOTI-1402 1-109-F bottom out FI-1201 natural gas to catalyst tubeFI-1060 warm ammonia product to urea FI-1202 steam gas to catalist tubeFQI-1060 warm ammonia product to urea PI-1053 steam gas to catalist tubeHIC-1032 speed of 1-120-J TI-1024 steam gas to catalist tubeFI-1061 cold ammonia product to storageFQI-1061 cold ammonia product to storage 1604 1-103-J DISCHARGE TO LOOPHS-1024 cold / hot product selection HIC-1026 by-pass 1-121-C

TI-1373 outlet 1-121-C72 65


1903 1-105-E 1805 AUXILIARY BOILERPIC-1034 1-105-E top outlet PIC-1001 fuel to auxiliary boiler / superheaterTIC-1414 1-105-E top outlet TI-1550 HP steam outlet drumFI-1027 steam to 1-140-C PI-1036 steam drum pressureTI-1801 temperature from 1-140- C FIC-1030 fuel to auxiliary boiler LIC-1027 1-105-E liquid level PIC-1030 fuel to auxiliary boiler TI-1416 1-105-E bottom outlet PIC-1018 HP header pressure

PIC-1023 auxiliary boiler draftAI-101 IA flue gas O2

1806 HP HEADER SUPERHEATERPIC-1012 1-103-JT governoor control TIC-1004 1-102-C outletFIC-1808 1-103-JT extraction line TIC-1005 HP header temperaturePIC-1018 HP Header pressure PDIC-1022 combustion air controlPIC-1023 auxiliary boiler draft FI-1031 fuel to superheater burnerFIC-1278 air to auxiliary boiler TI-1338 1-102-C outletPIC-1855 air to auxiliary boiler TI-1337 1-102-C outlet bypassTI-1810 air to auxiliary boiler TI-1339 inlet 1-104-D1

1807 LETDOWN HP TO MP 1207 SECONDARY REF & WH EXCHANGERPIC-1012 1-103-JT governoor control TI-1052 secondary ref temperature topHIC-1028 letdown HP to MP TI-1053 secondary ref temperature bottomHIC-1029 letdown HP to MP TI-1787 secondary ref temperature middleTIC-1020 desuperheater HP to MP TI-1335 1-101-C outlet main linePIC-1013 letdown HP to MP, pressure MP header TI-1340 1-101-C outlet bypassTI-1554 MP header temperature output desuperheater

70 67


1605 SYNTHESIS LOOP 1808 MP HEADERFIC-1077 synthesis gas to purge PIC-1014 MP steam to vent ( MP steam pressure )TI-1371 inlet 1-121-C FI-1089 stm to CW pump turbineHIC-1025 synthesis gas to 1-105-D differential quench TI-1806 stm to CW pump turbinePDI-1054 1-105-D differential pressure FI-1091B export / import steam

TI-1369 outlet 1-121-C FI-1152 export / import steamHIC-1262 export / import steam

NG FEED & CO2 PROD TIC-1825 BFW to export / importFI-1042 natural gas suffly, inlet B/LFQI-1042 natural gas suffly, inlet B/LTI-1029 natural gas suffly, inlet B/L 1101 FEED TREATINGFI-1280 CO2 product to header PIC-4001 naturalgas supply, inlet B / LFI-1095 CO2 product ( top outlet stripper ) LIC-1154 level absorber

FIC-1066 reflux flowNH3 STORAGE TIC-1769 outlet top stripper

LIC-4301 43-5102-F Liquid level PIC-1799 outlet top stripperTIC-4301 LIC-1156 liquid level in stripper ( bottom part )TIC-4318 NH3 to Urea FIC-1068 steam to ejectorXI-4301 43-5101-J speed FIC-1070 lean solution flow

XI-4302 43-5101-JA speedFI-4301 NH3 to Urea 1103 FEED GAS COMPRESSOR

LIC-1002 level 1-144-FNH3 STORAGE FIC-201 1-102-J disharge

LI-4307 NH3 storage PIC-1071 NG vent upstream 1-102-JLI-4308 NH3 storage TIC-1305 bypass 1-101-BC5PI-4311 NH3 storage FIC-1022 synthesis gas to Natural Gas PI-4310 NH3 storage PIC-1010 outlet 1-108-DPIC-4320 NH3 for loading system TI-1783 middle 1-108-D

66 71


1301 HTS 1208 FUEL TO ARCH BURNERTI-1341 1-104-D1 catalyst bed PI-1028 fuel to arch burnerTI-1342 1-104-D1 catalyst bed PI-1061 inlet arch burnerTI-1343 1-104-D1 catalyst bed PI-1062 inlet arch burnerTI-1344 1-104-D1 catalyst bed PI-1063 inlet arch burnerPI-1814 process gas outlet 1-103-C1/C2 PI-1064 inlet arch burnerHS-1018 MOV to vent d/s 1-104-D2 PI-1838 inlet arch burnerTIC-1010 inlet 1-104-D1

1302 LTS 1901 1-103-ETI-1011 process gas outlet 1-103-C1 / C2 PIC-1032 1-103-E top outletHS-1008 MOV inlet 1-104-D2 TI-1802 1-103-E top outletTI-1346 1-104-D2 catalyst bed PDI-1055 1-103-E different pressureTI-1347 1-104-D2 catalyst bed LIC-1026 1-103-E liquid levelTI-1348 1-104-D2 catalyst bed FIC-1064 1-103-E liquid inletTI-1349 1-104-D2 catalyst bed TI-1799 1-103-E liquid inletHS-1004 emergency s/d 1-104-D2 FI-1063 1-103-E top outlet

HS-1027B 1-140-J/JA start

1609 START UP HEATER 1902 1-104-EFI-1047 total fuel from 1-200-F PIC-1033 1-104-E top outletFI-1093 fuel to start-up heater TI-1797 1-104-E top outletPIC-1852 fuel to start-up heater PDI-1056 1-104-E differential pressureHIC-1050 fuel to start-up heater LIC-1163 1-104-E liquid LevelTI-1397 fuel to start-up heater FI-1081 1-104-E liquid inletFALL-1257 flow to 1-102-B HS-1027A 1-141-J/JA startTI-1396 synth gas outlet 1-102-B FIC-1027 1-104-E gas inlet ( purge gas to HRU )

XY-1264 HRU to fuel system68 69

HOIST & ELEVATOR TINDAKAN PENGAMANANA. FIELD :

2-JC101 HOIST FOR REACTOR * Tutup bv Gas Battery Limit ( d/s PV-4001 )2-JC201 HOIST FOR CENTRIFUGE * Hand Jack Close FV-1002 hingga tinggal 15 ~ 20 %.2-JC301 ELEVATOR FOR OPERATOR * Hand Jack Close HV-1021 hingga tinggal 5 ~ 10 %.2-JC302 HOIST FOR MELTER * Hand Jack Close HV-1028.2-JC303 HOIST FOR PRILLING TOWER * Atur level 101-F dengan mengatur speed 104-J.

* Atur bv disharge, perhatikan LI-1001 C/D dekat 104-J/JA.CONVEYOR & SCALE * Buka bv b/p HV-1262.

2-JD301A, B SCREW CONVEYOR TO MELTER * Stop semua pompa Benfield 108-J, 107-J, 201-J.2-JD302 BELT CONVEYER TO TROMMOL S * S/D Synloop, stop pompa 113-J, 124-J.2-JF301 BELT SCALE * Amankan semua Compresor

* Amankan ARU; HRU stop 140-J / 141-J.CRANE

B. CONTROL ROOM :2-JE101 CRANE FOR 2-GB101 * 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 GT - 102 : STEAM TURBINE AMMONIA FEED PUMP

2-GB101-EA1A,B OIL COOLER Type : Condensing Turbine2-GB101-FA1 OIL RESERVOIR Motive Steam : 42.0 Kg / Cm2G2-GB101-FA2 LUBE OIL HEAD TANK Steam Consumtion : 3.31 T/H2-GB101-FA3 CONTROL OIL ACCUMULATOR Steam Exhaust Product :2-GB101-FD1A,B OIL FILTER Speed Normal : 6500 RPM.2-GB101-GA1A,B OIL PUMP Speed Minimum Governoor : 4800 RPM.2-GB101-GB1 INDUCED FAN FOR OIL RESERV

GA - 101 : AMMONIA FEED PUMP.2-GT101 AUXILIARY EQUIPMENT

Type : Centrifugal.2-GT101-EA1 GLAND CONDENSER UNIT Capasity : 69 T/H2-GT101-FA1 OIL ACCCUMULATOR Pressure Suction / Discharge : 25.03 Kg / 181.03 Kg.2-GT101-FA2 DRAIN POT Temperatur Suction / Discharge2-GT101-GD1 TURNING GEAR

GT - 103 : STEAM TURBINE RECYCLE SOLUTION 2-GA101A, B AUXILIARY EQUIPMENT FEED PUMP.

Type : Condensing Turbine2-GA101A, B -EA1 OIL COOLER Motive Steam : 42.0 Kg / Cm2G2-GA101A, B -FA1 LUBE OIL RESERVOIR Steam Consumtion : 3.44 T/H.2-GA101A, B -FD1A,B OIL FILTER Steam Exhaust Product :2-GA101A, B -GA1A,B OIL PUMP Speed Normal : 5500 RPM.

Speed Minimum Governoor : 3800 RPM.2-GT102A, B AUXILIARY EQUIPMENT

GA - 102 : RECYCLE SOLUTION FEED PUMP.2-GT102A, B-FA1 DRAIN POT

Type : Centrifugal.Capasity : 75 T/HPressure Suction / Discharge : 25.03 Kg / 186.03 Kg.Temperatur Suction / Discharge

168 133

* Atur speed ID Fan + 600 rpm dengan men throttle bv steam inlet.

: 30 0C /

: 110 0C /

GADO - GADO DARI P - IB 2-GA102A, B AUXILIARY EQUIPMENT

2-GA102A, B -EA1 OIL COOLER2-GA102A, B -FA1 LUBE OIL RESERVOIR

UREA P - IB : 2-GA102A, B -FD1A,B OIL FILTER2-GA102A, B -GA1A,B OIL PUMP

2-GT103A, B AUXILIARY EQUIPMENT

Type : Extraction & Condensing Turbine 2-GT103A, B-FA1 DRAIN POTMotive SteamExtraction Steam TURBINE CONDENSER (2-EA-104) AUX EQUIPMENTSteam Consumtion : 61.07 T/HSteam Extraction Product : 37.01 T/H 2-EA104-EE1 STARTING EJECTORSteam Exhaust Product : 24.16 T/H 2-EA104-EE2 EJECTOR CONDENSERSpeed Normal : 7620 RPM.Speed Minimum Governoor : 6477 RPM. INSTRUMENT AUXILIARY EQUIPMENT

EA- 104 : Surface CondenserEE-102 : Ejector Condenser 2-FA106 GAS RELEASERGA-107 A/B : Condensate Pump

AGITATOR

Type : Centrifugal 2-GD201 AGITATOR FOR 2-FA202Stage : 2 (2 - 2 ) Stage at LP & HP Case. 2-GD301 AGITATOR FOR 2-EA301Capasity : 28.486 Nm3 / Hr. 2-GD302 AGITATOR FOR 2-FA302Pressure Suction / Discharge : 0.6 Kg / Cm2 G / 180 Kg / Cm2G. 2-GD303 AGITATOR FOR 2-FA303Temperatur Suction / Discharge

RPM 1500 ; kebutuhan Steam : 1.6 T/H PRILLING TOWER & PITExtraction Aktif; butuh Steam : 12 T/HRPM 7250; butuh Steam : 12 T/H IA-301 PRIILING TOWERMin Gov; butuh Steam : 25 T/H IH-501 DRAIN RECOVERY PIT

132 169

C W ke Urea : 2-GA401 CARBAMATE BOOST UP PUMP A & BFlow : 5883 / 6960 T/H 2-GA402 H. P. ABSORBENT PUMP A & BTekanan in / out : 4.0 Kg / 2.0 Kg. 2-GA403 CARBAMATE SOLUTION PUMP A & BTemperatur in / out 2-GA501 PROCESS CONDENSATE PUMP A & B Fouling Factor 2-GA502 UREA HYDROLYZER FEEED PUMP A & B

2-GA503 DRAIN RECOVERY PUMP A & BS M ke Urea : 2-GA 504 GLAND SEAL CIRCULATING PUMP A & B

Flow : 68 T/HFlow Actual : 84 T/H AUXILIARY EQUIPMENT LISTRatio : 0.944 T / T. Urea.

Steam Condensate dari Urea : COMPRESSOR DAN BLOWER80 % dari Steam Consumtion : 59.48 T/HActual + Demin Make Up Cond . : 105 T/H 2-GB101 CO2 COMPRESSOR

2-GB301 FORCED FAN FOR DRYERKonsumsi bahan baku Urea / Metrik Ton Urea : 2-GB302 INDUCED FAN FOR DRYER

NH3 ( 100 % NH3 ) : 0.568 m TON 2-GB303 BLOWER FOR FLUIDING COOLERCO2 ( 100 % CO2 ) : 0.745 m TON 2-GB304 INDUCED FAN FOR PRILLING TOWER A ~ FENERGY LISTRIK : 30 KWH

CENTRIFUGE: 0.99 m TON

2-GF201 CENTRIFUGE A ~ FExhaust PRILLING TOWER :

NH3 Constant TURBINEUREA DustDesign 2-GT101 STEAM TURBINE FOR 2-GB101

2-GT102 STEAM TURBINE FOR 2-GA101RATIO : 2-GT103 STEAM TURBINE FOR 2-GA102

H2O / CO2 : 0.46 mol / mol. 2-GT104 STEAM TURBINE FOR 2-GA104NH3 / CO2 : 4.0 mol / mol. 2-GT105 STEAM TURBINE FOR 2-GA105Conversi CO2

134 167

GT-101 : STEAM TURBINE COMPRESSOR CO2

: 42.0 Kg/Cm2G; 399 0C.: 22.0 Kg/Cm2G; 335 0C.

GB-101 : COMPRESSOR CO2

: 38 0C / 115 0C

: 32 0C / 41.9 0C.: 0.0002 M2Hr 0C / K.Cal.

C W Sirkulasi ( d T 10.1 0C ) : 88 m3

STEAM ( 42 Kg; 399 0C )

: max 50 mg / Nm3

: max 50 mg / Nm3

: NH3 = 29 mg / Nm3 UREA : 30 mg / Nm3

: + 70 %.

DISTRIBUTOR & SPRAY NOZZLE Performance Guarantee : 1725 Ton / Day.

2-FJ301 ACOUSTIC GRANULAR A ~ J Kualitas Urea :2-FJ302 SPRAY NOZZLE FOR PACKED BED Nitrogen : 46.2 % berat maximum.2-FJ303 SPRAY NOZZLE FOR DEMISTER H2O : 0.3 % berat maximum2-FJ304 SPRAY NOZZLE FOR 2-GB302 Biuret : 0.5 % berat maximum2-FJ501 SPRAY NOZZLE FOR 2-EA501 Fe : 1.0 ppm berat maximum

NH3 Free : 150 ppm berat maximum.PUMP Ash : 15 ppm berat maximum.

2-GA101 AMMONIA FEED PUMP A & B Prill Size :2-GA102 CARBAMATE FEED PUMP A & B 100 % lolos pada ayakan mesh no. 062-GA103 AMMONIA BOOST UP PUMP A & B 95 % lolos pada ayakan mesh no.182-GA104 LOW PRESSURE FLOADING PUMP 2 % lolos pada ayakan mesh no. 252-GA105 HIGH PRESSURE FLOADING PUMP2-GA106 STEAM CONDENSATE PUMP A & B2-GA107 RETURN CONDENSATE PUMP A & B Kebutuhan bahan baku pada Rate CO2 : 100 %2-GA108 WATER INJECTION PUMP A & B NH3 : 40.7 ~ 45 MT / Hr2-GA121 SEALING WATER PUMP A & B CO2 : 52.9 ~ 56 MT / Hr2-GA201 UREA SOLUTIOPN PUMP A & B STEAM : 69.4 ~ 76 MT / Hr2-GA202 CIRCULATING PUMP FOR CRYSTALLIZER LISTRIK : 2030 ~ 2200 KW2-GA203 SLURRY FEED PUMP A & B CW SIRKULASI : 5927 ~ 6570 MT / Hr2-GA204 MOTHER LIQUOR PUMP A & B INST AIR : 200 ~ 220 NM3 / Hr2-GA205 HOT WATER PUMP A & B PLANT AIR : 670 ~ 700 NM3 / Hr2-GA206 L. P . ABSORBENT PUMP A & B EMERGENCY POWER : 140 KW2-GA301 WATER PUMP FOR PRIILNG TOWER A & B DEMIN WATER : 2.0 MT / Hr2-GA302 CIRC PUMP FOR DUST RECOVERY A & B PROSES CONDENSATE : 7 ~ 27 MT / Hr2-GA303 No. 1 DISOLVING TANK PUMP A & B2-GA304 No. 2 DISOLVING TANK PUMP 2-GA305 PORTABLE WATER PUMP A & B

166 135

2-EA301 MELTER AMMONIA P - IB :2-EA401A HIGH PRESSURE ABSORBER A2-EA401B HIGH PRESSURE ABSORBER B Tie - In NH3 :2-EA402 LOW PRESSURE ABSORBER Cold NH3 : P-IB --> P-II > Bisa 2-EA501 1st SURFACE CONDENSER Hot NH3 : P-IV --> P-III2-EA502 2nd SURFACE CONDENSER2-EA504 PREHEATER FOR 2-DA501 Cold NH3 : P-IB --> P-II > Tidak bisa2-EA505 PREHEATER FOR 2-DA502 Cold NH3 : P-IV --> P-III2-EA506 FLASH GAS CONDENSER2-EA507 REBOILER FOR 2-DA501 Cold NH3 : P-IB --> P-IV > Bisa 2-EA508 GLAND SEAL CIRCULATION COOLER Hot NH3 : P-IB --> P-IV2-EC301 AIR HEATER FOR DRYER2-EC302 AIR HEATER FOR FLUIDIZING COOLER * Bila 5101-J / 5102-J Running; maka Cold NH3 dari P-II,

P-III & P-IV tidak bisa masuk ke NH3 Storage IB, karenaEJECTOR line min flow 5101-J & 5102-J bergabung dengan line tsb.

2-EE101 STARTING EJECTOR FOR EA-104 NH3 STORAGE LEVEL :2-EE102 EJECTOR CONDENDER FOR EA-104 : 342 Ton.2-EE501 FIRST EJECTOR FOR EA-501 (S.L). : 230 Ton.2-EE502 SECOND EJECTOR FOR EA-502 (S.M.L). : 230 Ton.

: 230 Ton.TANK & SEPARATOR NH3 STORAGE LEVEL Maximum :

Level Maximum P-IB : 24 Meter.2-FA102 SATURATION DRUM Level Maximum P-II : 13 Meter2-FA103 STAEM DRUM Level Maximum P-II : 13 Meter2-FA104 STAEM CONDENSATE TANK Level Maximum P-IV : 13 Meter2-FA105 AMMONIA RESERVOIR2-FA111 1st STAGE SUCTION SEPARATOR2-FA112 2nd STAGE SUCTION SEPARATOR level NH3 STO 5.5 M.2-FA113 3rd STAGE SUCTION SEPARATOR2-FA114 4th STAGE SUCTION SEPARATOR level 3 Meter.

164 137

Mutu Bahan Baku :NH3 Cair ( Komposisi ). 2-FA121 SEALING WATER TANK

Temperatur Product : 42 0C.

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

5101-J ( Hot Transfer Pump ) ; baru bisa running pada

5102-J ( Cold - Loading Pump ); Stop pada minimum

NH3 : 99.5 % berat minimum 2-FA201 UREA SOLUTION TANKH2O : 0.5 % berat minimum 2-FA202 CRYSTALLIZEROil : 0.5 ppm berat max 2-FA203 MOTHER LIQUOR TANKInsoluble Gas : Nill 2-FA204 HOT WATER TANKTekanan : 18.0 ~ 20,0 Kg / Cm2 2-FA205 UREA SOLUTION SEPARATORTemperatur 2-FA301 HEAD TANK

CO2 Gas ( Komposisi ). 2-FA302 No.1 SOLUTION TANKCO2 : 98.0 % berat minimum 2-FA303 No.2 SOLUTION TANKTotal Sulphur : 1.0 ppm vol maximum 2-FA304 STRAINER WASHING TANKH2O : Saturation 2-FA305 WATER TANKTekanan : 0.6 Kg / Cm2 g min 2-FA306 POT FOR 2-EA-301Temperatur 2-FA401 CARBONATE SOLUTION TANK

Steam : 2-FA501 PROCESS CONDENSATE TANKTek / TempFouling Factor CHAMBER; CYCLONE; STRAINER & FILTER

K CalDemin Water : 2-FC301 CYCLONE

Si O2 terlarut : 0.05 ppm max 2-FC302 DUST CHAMBERTotal padatan : 0.5 ppm max 2-FD202 PRETHICKENER A ~ E

Cooling Water : 2-FD301 STRAINERTek / Temp in / out 2-FD302 FLUIDING COOLERFouling Factor 2-FD303 TROMMOL SCREEN

K Cal 2-FD304 PACKED BED FOR DUST RECOVERYProcess Condensate : 2-FD305 DEMISTER FOR PRILLING TOWER

Kandungan Urea : < 5 ppm. 2-FF301 FLUIDIZING DRYERKandungan NH3 : < 5 ppm. 2-FG101 CO2 VENT SILENCER

Nitrogen Kualitas : 2-FG103 No.1 STEAM VENT SILENCER: 10 ppm max 2-FG104 No.2 STEAM VENT SILENCER

O2 : 300 pppm maxTemperatur : Ambient.

136 165

FLOW SYNT GAS ( FCAL-1001 ) UREA PLANT= Rate X 28

FLOW UDARA ( FCAL-1003 ) PROCESS EQUIPMENT LIST= Rate X 50

DESUPERHEATER

2-BH101 DESUPERHEATER.

Bila temp naik : NH3 lolos ke Purge Gas. TOWER & REAKTORBila temp turun : Aliran gas Refrigerant berkurang.

2-DA101 STRIPPER2-DA102 SCRUBBER

Segera Blow Down dan Injeksikan Demin Water. 2-DA201 HIGH PRESSURE DECOMPOSER2-DA202 LOW PRESSURE DECOMPOSER

Temp TI-0709 ( Out Molucular Sieve Dryer ). 2-DA401 WASHING COLUMNNor Operasi 2-DA501 PROCESS CONDENSATE STRIPPERHi- Alarm 2-DA502 UREA HYDROLIZERTrip 2-DA503 FINAL ABSORBER

2-DC101 REACTORFiring Awal Primary Reformer7 Burner pada posisi tertentu HEAT EXCHANGERHead Carrier : N2Kenaikan temp max 2-EA101 No.1 CARBAMATE CONDENSERKenaikan temp Norm 2-EA102 No.2 CARBAMATE CONDENSER

2-EA103 AMMONIA PREHEATERSTEAM 2-EA104 TURBINE CONDENSER

2-EA105 AMMONIA BY PASS COOLERSM ke Coil Udara & Bottom HTS. 2-EA111 1st STAGE INTER COOLER FOR GB-101

2-EA112 2nd STAGE INTER COOLER FOR GB-1012-EA113 3rd STAGE INTER COOLER FOR GB-101

138 2-EA121 SEALING WATER COOLER 163

AMMONIA PLANTSteam Consumtion = 123.0 Kg. From 1-101-F

karena tekanan Steam akan mengarah naik.

: 30 0C

: 38 0C.

: 42.0 Kg / Cm2/399 0C: 0.0001 M2Hr 0C/

: 4.0 Kg; 32 0C / 42 0C: 0.0002 M2Hr 0C/

NO x

Ratio H2 / N2 dimonitor pada inlet 105-J

Temp Normal 127-C = 36 0C.

Bila Conductivity di 174-C tinggi,

: 45 0C: 55 0C: 65 0 C

: 80 0C / Hr: 60 0C / Hr

Masuk pada temp 400 0C, vent di V-1005;

Bila UREA P-IB trip; segera hubungi P-II, III & IV

ITEM 1- DESCRIPTION CONSUMTION T/H Dan siap-siap untuk mengirim Hot NH3 ke P-II, III & IV.101-JT S T for Process Air Compressor 109.12 SH / V103-JT S T for Synth Gas Compressor 107,293 SH / V REVANADASISteam Consumtion = 42.2 Kg. Saat Revanadasi BF system ( Main BF / Feed T )ITEM 1- DESCRIPTION CONSUMTION T/H102-JT S T for Feed Gas Compressor 9,123 SM / V 0.7 % ~ 1.0 % ( Norm : 0.7 % ).104-JT S T for H.P BFW J Pump 5,688 SM / V104-JAT S T for H.P BFW JA Pump *5688 SM / V SYNT LOOP105-JT S T for Refrigerant Compressor 14,570 SM / V Kalau Start Loop pada kondisi temp 105-D masih panas

*15680 SLL / V107-JBT S T for Semi Lean Pump 12.7 SM / B.P107-JCT S T for Semi Lean Pump 12.7 SM / B.P Menaikkan Rate Gas108-JT S T for Lean J Pump 2,858 SM / B.P Habiskan dulu vent PIC-1004 ( vent menutup habis )108-JAT S T for Lean JA Pump *2858 SM / B.P112-JAT S T for 103-JTC Condens A Pump *0.35 SM / B.P Stop vent V-1005 in HTS.114-JAT S T for 101-JTC Condens A Pump *0.137 SM / B.P124-JAT S T for Cold Amm Product A Pum *0.323 SM / B.P201-JT S T for Pretreatment Circ J Pump 0.994 SM / B.P201-JAT S T for Pretreatment Circ JA Pum *0.994 SM / B.PFIC-1002 Steam for Arch Burner Prim Refo 94,245 SH AIR COIL 3,746 SH Bersamaan Reduksi Katalist HTS dengan Steam :173-C Steam for Molucular Sieve - Kemudian masukkan gas ke 101-B

Regeneration Heater 1,500 SH - Naikkan Rate101-BJ2 I D Fan 1-101-B 4,971 SM / B.P - Masukkan Udara. Dst nya.101-BJ1 F D Fan 1-101-B 3,728 SM / B.P101-JLJAT Lube Oil Pump 1-101-J total SM / B.P Menentukan Rate GAS102-JLJAT Lube Oil Pump 1-102-J pemakaian : GAS + STEAM + UDARA RATE 103-JLJ1AT Lube Oil Pump 1-103-J steam = 27,600 Nm95 T 50 T = 100 %103-JLJ2AT Seal Oil Pump 1-103-J 1.864 T/H 26,500 Nm90 T 40 T = 95 %162 * = Stand by 139

4. REFORMING dan STEAM SYSTEM. 11-11-'98 16.07 101-BJIT ( FD Fan Trip ).- Turunkan Rate Gas ke 40 %, vent di Force TTV XV-6101 ( Y-I ). MOV-1018. 10.09 101-BJIT Start Lagi.- Atur PIC-1018 = 123 Kg/Cm2. Naikkan 17.25 Inst; Jumper XAHA-6101 Force X-I untuk 6101. beban Aux Boiler.

26-11-'98 22.58 105-J Trip.START UP 105-D Penyebab : Vibrasi axial XVHH-0500.

Ikut terganggu 102-J (Trip). Accumulator tdk bekerja baikTindakan Pengaman :- Gas vent di V-1000.- HRU; 106-D Shut Down; b/p LTS.- Tutup segera tie-in CO2.

6. Venting Loop ( SV ) --> V-1017. - Import Syn Gas dari P-IV unmtuk 108-D.7. H2O max 1000 ppm ( out 105-D ) --> P = 110 Kg/Cm2 - Urea Plant Shut Down Total. ( CO2 habis ).

00.07 Start 102-J. Rate Gas 15 %.01.00 Masukkan Gas ke 101-B.

REDUKSI CATALIST 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.

HEATING UP SHELL 105-DCatatan :

PHILOSOPIE : - Gas di vent di MOV-1018 sebelum masuk 101-E.- Utk menaikkan temp metal shell side kebatas yg aman - Setelah masuk ke 101-E. Tutup MOV-1018, pindahkan sebelum tek dapat dinaikkan ke tek opr agar tidak terjadi vent ke PC-1005 (sebelum masuk ke 106-D, Methanator)Thermal Stress. - Setelah masuk ke 106-D, keluar. Gas vent di PC-1004

(persiapan start 103-J).tek dapat dinaikkan lebih besar dari pada 35 Kg/Cm2. - Start Up Loop : P Disch 103-J = 90 K.

- Press Up Loop berangsur-angsur, dengan menutup sirkulasi 103-J.

160 141

Naik atau turunkan Rate Gas STEAM CONSUMTION FOR P - IBBila akan naik atau turunkan rate Gas, Informasikan pada Supervisor P-II. UTILITY PLANT

Konsentrasi V2O5 ( Vanadium ), minimum :

( > 300 0C ), + 45 menit kemudian bisa produk NH3.

- Firing Target ( 101-B ) dengan N2 CarierYaitu temp Flow Gas sampai dengan + 350 0C.Kemudian N2 ganti dengan Steam, Vent di MOV-1018 sampai tempRiser = 760 0C.

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.

8. In.out 105-D nax 200 0C.9. By pass 123-C1C2 hingga temperatur Gas = 325 0C.

Fe + H2 ---> Fe + H2O + QFe2O3 + 3H2 ---> 2Fe + 3H2O + Q

- Utk 105-D telah ditetapkan max temp 320C, sebelum

Steam Consumtion = 42.2 Kg.FI-1152 Flow SM ( 42 K ).Indikasi Import SM dari Utility ke Ammonia Plant IB ITEM DESCRIPTION CONSUM T/H

Schematic 1804. 31-5001-JT S T for Demin Water Transfer Pu 3,35531-5204-JT S T for Filter Water Transfer Pum 2,483

O2 Content 31-5205-JT S T for C. T Make Up Water Pump 6,522Out 108-D = < 0.5 %. 32-5209-JTA S T for Amm/Util CW Circ A Pump 7,818

32-5209-JTB S T for Amm/Util CW Circ B Pump 7,818FCAH-1065 sp = 1400 Nm3/Hr. 32-5601-JAT S T for CW Circ A Pump for Urea 7,250

32-5601-JBT S T for CW Circ B Pump for Urea *7250RE - REDUKSI NH3 CONVERTER ( 1-105-D ). 34-5003-JT S T for BFW Pump to Dearator WHB 8,631Temp Bed I : 34-6007-JT S T for FD Fan Packed Boiler 8,541

UREA PLANTSteam Consumtion = 42.2 Kg.

Temp Bed I / 2 X / 2 B ITEM 2- DESCRIPTION CONSUM T/HGT101 S T for 2-GB101, Comp CO2 61.07 GT102A S T for 2-GA101A, NH3 Feed Pump A 3.31

Atur temp bed dengan HCV-1045, bila mengarah naik. GT102B S T for 2-GA101B, NH3 Feed Pump B *3.31 GT103A S T for 2-GA-102A, Carbamate Feed Pump A 3.44

100 ppm ------ Re-reduksi OK. GT103B S T for 2-GA-102B, Carbamate Feed Pump B *3.44 GT-104 S T for 2-GA-104, Steam Condensate Pump 0.24

1-106-D METHANATOR GT-105 S T for 2-GA-105, High Pressure floading P 0.3

140 161

DERIMING COLD BOX 106-D METHANATOR TRIP :Tujuan : - Menghilangkan H2O dan NH3 yang lolos, karena akan Penyebab :* Kegagalan HTS dan LTS.

menyebabkan kebuntuan. Sehingga menyebabkan Indi - TAHH - 1220; TAHH - 1201; TAHH - 1202; kasi temperatur di Cold Box naik ( TI-711 ).

Prosedur : - 1. Dengan memakai N2 via ( V-707 by-pass TV-709 ). * Dari flow larutan Benfield.- 2. Dgn memakai gas kering via ( V-710 ) dgn aliran sbb : FSLL-1205 ( Trip = 850 M3/jam )

V-707 ( V-708 ) --> kebagian hangat 1-C-E101 FSLL - 1214 ( Trip = 110 M3/jam ).--> 1-FD-101 --> V-714 --> Cold flare sampai Akibat : XV-1211 menutup.mencapai temperatur = MOV-1011 Menutup.

Terhentinya aliran synt gas ke Methanator danSEQUENCE ADSORBER A/B venting di PIC-1005.1. B Heating Up --> Check Temperatur. Tindakan : 1. HRU dan ARU2. B Cooling Down --> Check Temperatur. - HRU Shut Down.3. Valve Change --> Adsorber B Repress. - ARU dipertahankan sirkulasi, atur FIC-1027 4. Adsorber A & B Parallel --> valve change.5. A Depress 2. LOOP dan REFRIGERANT6. A Heating Up --> Check Temperatur. - Shut Down LOOP, tutup MOV-1001 dan 7. A Cooling Down --> Check Temperatur. Mov-1002.8. Valve Change --> Adsorber A Repress. - Tutup FIC-1077.9. Adsorber A & B Parallel --> valve change. - Tutup LIC-1013.10. Adsorber B Depress. - Stop 103-J.

- Tutup PIC-1004.MOLUKUL SIEVE ( 109-DA & DB ). - 105-J total Kick Back.Autimatic Regeneration Sequence. Catatan : Jika trip Methanator disebabkan kegagalanAdsortion ( A ) : 12 jam. sirkulasi Benfield, maka S/D dilanjutkan sbb:Depressurizing ( DP ) : 46 menit . DP Rate = 2.1 Kg/menit 3. PURIFIKASI.

= 3.5 Kg/menit (max). - Shut Down 150-E.Regeneration ( R ) - Cabut gas ke 101-E, vent gas di MOV-1018.Cooling ( C ) PIC-1014 = 21 Kg/Cm2.Stand By ( S ) ; 3 jam 14 menit. - Bila sirkulasi Benfield harus di Stop, lakukanTotal : 24 jam. Regenerasi terlebih dahulu.

142 159

101-BJ2T ( ID FAN ) TRIP : UTILITY IB :* Imformasikan melalui HT. ELECTRIC

AMMONIA dan UREA IB Shut Down total. BUS BAR GE ( 13.8 KV; 50 Hz; 2000 A ) ke :* Matikan semua Burner ( BBA; BBU; BBS ) SG-51A : Incoming Feeder.

30 0C s/d 250 0C ---> + 50 0C / Hr.250 0C s/d 300 0C ---> + 20 0C / Hr.300 0 C s/d 350 0C ---> + 10 0C / Hr.350 0C s/d 400 0C ---> + 5 0C / Hr.

---> 512 0C ( max 520 0C, TI-1386 )Skin temp Reactor 282 0C ( max ).d temp Top & Bottom < 75 0C.

Jika temp Bed I : 410 0C, Analisa air harus lebih kecil dari

- Temp out ( operasi normal ) = 347 0C.- High Temp Alarm = 399 0C.- Temp Maximum Katalis Methanator = 426 0C.- Temp Maximum Metal Methanator = 454 0C.

TAHH - 1203 Setting 4200C

agar TI-1001 = 199 0C.

: 6 jam H/U = 50C/menit.: 2 jam CD : 15 0C/menit.

* Tutup bv Fuel Gas header dekat LTS. SG-51B : ke TR 510 ( 480 V ) EMERGENCY UTILITY.* Secepatnya stop 101-BJ1T ( FD FAN ) --> Emerg Stop. SG-51C : Ke TR-51 ( 480 V ) Ammonia Plant.* Shut Down kan 102-J, 103-J, Synt Loop, 106-D, 150-E, : ke TR-53 ( 2.4 KV ) ID FAN Cooling Tower

HRU, ARU. No. 1; 3; 5; 7; 9.Cabut gas ke 101-B. SG-51D : ke TR-24 ( 1500 KVA ) Pusri II.

* Vent gas di V-1000, dan SM di MOV-1018. SG-51E : ke 5209-JM ( 1575 KW ) CW PUMP.* Cabut Udara ke 103-D, dan Stop 101-J. SG-51F : ke TR-58 ( 2.4 KV ) UREA IB.

Cut Rate Gas ke 30 %. : ke TR-511 ( 480 V ) UREA IB.FT dan MBF, tetap running sirkulasi Benfield. SG-51G : ke TR # ML1 ( 2.4 KV ) Melamine & Area K P1Tutup LP Purge, Tail Gas, Gas Ex SO trap. : ke TR # ML2 ( 480 V ) Melamine.Import Steam dari Utility. SG-51H : ke TR-59 ( 2.4 KV ) Pompa Sungai.

* 105-J injeksi NH3 hot dari 5101-J/JA atau import SG-51I : ke TR-55 ( 480 V ) Water Treatment.* NH3 Hot. Sirkulasikan. : ke TR-56 ( 480 V ) Urea Handling.* Start MY-COM 5103-L, tutup XV-1150. : ke TR-57 ( 480 V ) Urea Loading.* : ke TR-512 ( 2.4 KV ) NH3 Storage.

: TR-506 ( 3 KV ) Cranking Motor GTG.107-J TRIP ( SEMI LEAN PUMP ): SALAH SATU SG-51J : ( 52 S ) ke Syncronizing Bus.

SG-51-K : ke TR-43 ( P-III ) belum terconnect.Informasikan melalui HT, 107-J TRIP. SG-51L : ke Perumahan.Produksi CO2 turun.106-D Methanator, di by-pass. POWER TIE- IN dari 4006-J ( HITACHI-IV )103-J total kick back, bila kondisi tak teratasi dalam 1. Ke TR-54 ( 2.4 KV ) ID FAN Cooling Tower No.

waktu yang lama. Harus Shut Down Loop. 2; 4; 6; 8 ( TR-53 ---> TR-54 ).Vent gas di PC-1005. 2. Ke TR-52 ( 480 V ) Ammonia Plant ( TR-51 ---> TR-52 ).UREA : Ikuti perkembangan, melihat tekanan CO2. * point 1 dan 2 satu line.

3. 4006-J --> N.O <--- Feeder Line SG-51I ( DS 5852 ).158 143

KEBUTUHAN GAS ALAM 102-J TRIP : Packed Boiler = 5.0 mm BTU/day

* Informasikan melalui HT, bahwa 102-J Trip. G T G = 4.0 mm BTU/dayAMMONIA dan UREA IB Shut Down Total. W H B = 3.0 mm BTU/day

* Shut Downkan 106-D; Synt Loop; HRU dan ARU. Firing PRIM REF = 5.0 mm BTU/day* Cut Rate Gas ke 40 %. NH3 Start Up

Gas, vent di V-1000; Steam di Vent MOV-1018. for Example :Back Press = 8 Kg. Jam Tambah G Pakai Gas Rate Gas

* 105-J; pertahankan total Kick Back 23/02/'98 - - 15.0 mm Shut DownNon Aktifkan 150-E. 24/02/'98 15,00 5.0 mm 20.0 mm Start UpB/p LTS, buka MOV-1009 dan tutup MOV-1008, 23,00 10.0 mm 30.0 mm 30%

tutup b/p outlet LTS. 25/02/98 09,00 8.0 mm 38.0 mm 50%* Import Synt Gas untuk press up 101-E 15,00 2.0 mm 40.0 mm 60%

Pertahankan Sirkulasi Benfield (60 % rate ). 21,00 8.0 mm 48.0 mm 70%* Import Steam dari Utility. 26/02/98 10,00 6.0 mm 54.0 mm 85%* 27/02/98 20,00 7.0 mm 61.0 mm 96%

TINDAKAN YANG SAMA DGN 102-J TRIP, JUGA Natural GasBERLAKU JIKA101-BJ1T DAN 101-BJ2T TRIP Tekanan Natural Gas dari Pertamina = 450 p( 31.64 Kg )

di Let Down ke 28 Kg/Cm2G103-J TRIP :* Informasikan melalui HT. Natural Gas ke G T G

103-J Trip. Shut Down LOOP, 28 Kg/Cm2G ---> 15 Kg/Cm2G* Shut Down Synt Loop, HRU dan ARU. Chamber = 8.4 Kg/Cm2G* Cut Rate Gas ke 80 %. Vent gas di PC-1004 Temp

back press = 29 Kg. Flow = 8383 / 8719 Kg/Hr* Import Synt Gas untuk 108-D dan press up 101-E.

105-J, total Kick back. Natural Gas ke W H B* Naikkan beban Aux Boiler . Import SM. 28 Kg/Cm2G ---> 3 Kg/Cm2G ---> * 0.25 Kg/Cm2G ( Via 5 burner ).

Flow = 2696 / 5484 Kg/Hr156 145

104-J/JA TRIP: ( yang stand by tidak bisa Running ).5007-J EMERGENCY GENERATOR ( GENSET ) * Informasikan melalui HT, 104-J Trip. Amm S/D total.Supply ke : 104-J Trip. Ammonia IB Shut Down Total.

MCC-510 : Emergency utk UTILITAS. Stop semua penyalaan burner di Reformer System.MCC-513 : Emergency utk NH3. * Import Steam dari Utility.MCC-510 : Emergency utk UREA. * Cut Rate Gas ke 40 %. Vent gas di V-1000 dan MOV-1018

UREA : Shut Down Total.


= 55 0C

UREA : Ikuti perkembangan, dgn melihat tekanan CO2.Rate CO2 + 70 %.

MCC-515 : Emergency utk UOA. * 101-J; 102-J; 105-J ( bila Steam memungkinkan ),bila tidak segera matikan.

Opening PV-3471 ( Vent 42 K Steam ) * 103-J stop.10% = 7.8 T/H 60% = 43.4 T/H 106-D Shut Down via HS-1253 ( tutup vent PC-1005 utk20% = 10.67 T/H 70% = 61.6 T/H mempertahankan tekanan Gas di 101-E).30% = 15.15 T/H 80% = 87.5 T/H *40% = 21.52 T/H 90% 124.2 T/H50% = 30.56 T/H 100% 136.4 T/H 105-J TRIP :

Akibat : Tek di120-CF1~4 naik, karena pendingin hilangLISTRIK KE PERUMAHAN Peroduksi NH3 Liquid terhenti.

Perumahan Lama dari Area K P-I, *Sumber Power dari P-II * Shut Down kan 103-J, Synt Loop, HRU, ARU.

Perumahan KELLOG dari P-II * Potong Rate Gas ke 85 %.Perumahan Baru/ Gollan dari * MY-COM 5103-L start, bila tie-in tidak memungkinkan.

FEEDER B / SG-51L P-IB * Naikkan beban Aux Boiler 101-BUImport Synt Gas.

AIR KE PERUMAHAN Non aktifkan XY-1150 bila SP-025 tidak Trip.Tekanan air ke perumahan diatur dari bv pada line TIE-IN Vent Gas di PC-1004

cabang disch pompa 31-5210-J/JA. Switch sumber H2 utk 108-D, dari tie-in P-II, P-III, P-IV.* UREA : Ikuti perkembangan. Melihat tekanan CO2.

Pengaturan Beban LISTRIK Catatan : Tek NH3 STO PI 4010 dan PI 4311Pada 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 ).

144 157

G T G SUPERVISOR : GAWEAN DAN PERLU TAUCooling Water ke G T G = 261 m3/HrBila Hitachi P-II; P-III; P-IV akan test, cabut beberapa filter 101-J TRIP :

suction ( min 10 ea ). Supaya bila terjadi kejut- Akibat : - Terhentinya supply PA/IA. an beban naik, yang disebabkan oleh hitachi - Terhentinya udara proses ke 103-D.yang ditest, trip. Tdk terjadi Low flow Suction - CO yang masuk ke HTS dan LTS bertambah.

- Hilangnya reaksi Exothermis di top 103-D.Udara dari 101-J NH3 *. Informasikan melalui HT, bahwa 101-J Trip.

Flow udara dari 101-J ke UOA = AMM dan UREA IB Shut Down Total.1552 Nm3/Hr Tek = *

Distribusi : IA dari UOA = 1127 NM3/Hr. * - Shut Down : Loop; HRU; ARU; Cold Box; 106-D; 150-E.* - 102-J & 105-J ditahan (jangan dimatikan) bila Steam ada

DEMIN Tapi bila Steam krisis, matikan 105-J.Membuka/menutup Demin UOA ke P-IV Catatan : 105-J ditahan, Karena bila di Stop, perlu peng-

akan mempengaruhi tekanan osongan / Drain. Yang akan menyebabkan DEMIN ke AMM IB. ( Hati-hati ) terjadinya Polusi.

102-J; masih dirunningkan, dengan harapan P. P. U : untuk segera Start Up kembali.

Belt 5853 ---> BS IV, P IB Utk Urea P IB & P IV * - Cut Rate Gas ke 50 %, Belt 4852 ---> BSIII, P IV -----> Gudang. - Vent Gas di MOV-1018, back press = 18 Kg.

- Non aktifkan 1-150-E.Belt 5854-V ----> P IB - By pass LTS (buka MOV-1009, tutup MOV-1008) tutupBelt 2852-V ----> P III bv outlet.

* - Segera tutup bv Tie-in CO2 ke Plant lain, agar tidak mengganggu, dengan hilangnya Produksi CO2.

P III : 2852 - V -------- - Emerg Line / Belt. * - Export NH3; bila ada teruskan atau stop, lihat kondisi.- Bin. - Pertahanakan Hot Sirkulasi di MBF & FT.- Gudang P III * - Import Synthesa Gas.- 2853-V. *

P IV - Kurangi pemakaian udara ke bearing GB-302 ( UREA ).P IB : ( 5854-V ) * - Import Udara dari CENTAX P-III, atau dari 101-J1 P-III/IV.

146 * - Check pemakaian Gas Alam. 155

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.


Informasikan melalui HT, 105-J Trip. Shut Down LOOP.

- 103-J, harus dimatikan.

- UREA : Shut Down total ( CO2 habis ).

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-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

Rate Gas = 20 %.16.20 Buka steam Sparger HTS, FI-1103 = 4.5 div; V-1005 = WO

- Stop N2 Carrier ke 101-B, ganti dgn SM ( Proses )35 T/H via FV-1002.

155 - Masukkan steam ---> Air coil ---> 103-D ---> vent V-1005.154 147

- Purge dengan N2 ---> V - 1005. HARI ke IV :- Stop sirkulasi MBF, stop 108 - J. 00.30 Bertahap tutup V-1008, masukkan gas ke 101-E, Vent di- B/p 201 - E sirkulasi. Regenerasi. PC-1005. - Shut Down 105 - J. - Bertahap aktifkan steam ( motive ) ke 132-L1; L2; L3; L4

tutup vent motive steam.KONDISI NORMAL OPERASI - Kirim CO2 ke UREA Plant.

FEED TREATING 08.35 Heating Up LTS lewat 172-C, vent di V-1007.Rate Gas 100% PC - 4001 sp = - Buka MOV-1008.

Kons Benfield 25 ~ 30 % 09.45 Total vent di PC-1005, tutup MOV-1018.FC - 1022 = 09.47 Tutup MOV-1009, aktifkan LTS.FC - 1070 = 11.30 Rate Gas 50 % ~ 55 %.204 - L NaOH = 0.5 %, SG = 1,004 12.40 Rate Gas 55 % ~ 60 %.

FCAL - 101 sp = - LTS On line.Max temp tube katali PURIFICATION 13.00 Start 107-JAT

FC - 1005 15.00 Press Up 106-DREFORMING FC - 1004 16.00 Heating Up 106-D lewat 172-CRatio FY - 1201 >= 3.5 Eq K2CO3 16.20 Kirim CO2 ke Existing Plant.FY - 1062 TC - 1012 17.00 Start 112-JM Tkb.FY - 1044A 102 - E top, kontinyu injeksi DM. 17.50 Rate Gas 60 % ~ 65 %.

18.15 102-UB On line ( Conductivity = 0,26 ).TC - 1010 BFW / STEAM 18.30 106-D On line, total vent di PCAH-1004.TI - 1314 PC - 1018 123.0 Kg 19.20 Start 5101-JA Tkb.CH4 OUT 101 - B <= 12.2 150 - E Aktif, sc -->102 - U, 20.26 Kirim Warm NH3 ---> Urea IB.( dari 5101-JA )TC - 1011 conduct <= 25 m H HARI ke V :TC - 1012 pH >= 8.0 00.05 Heating Up 103-JPC - 1010 sp 41.0 Kg. FC - 1006 max 250 T/H 07.25 Rate Gas 65 % ~ 70 %.

08.10 Rate Gas 70 % ~ 75 %.SYNTHESAV LOOP 08.38 Rate Gas 75 % ~ 80 %.

- Refrigerant System, level & Press 120 CF1~CF4 Normal. 09.50 Rate Gas 80 % ~ 85%.ARU normal Operasi. - Start Press Up 150 - E.HRU : H2 Prod - loop --> Tail gas + Reg Gas --> Fuel. - PC drain ke Sewer.

152 HCV - 1046 : Full Closed. 149

18.00 Heating Up 102-J. AMMONIA- Vacuum Up 101-JTC

18.25 Pindahkan vent Steam Proses dari V-1005 ---> MOV-1018

- Stop Steam Sparger HTS. Guarantee Prod = 56.25 T/H = 1350 T/Day Ammonia.- Back Press = 3.4 Kg.

19.15 Aktifkan 201-D ( tutup by-pass ), injeksikan NaOH. FCAH - 1065 sp = 1400 Nm3/Hr.

Firing 101-BBA : 10 EA ( 60 0C / Hr ).

Start. Vent gas di V-1000 inlet 108-D ( TI-1445 >= 385 0C ).

( bila temp fuel gas 380 0C ).

899 0c.

TC - 1312 sp = 595 0C/auto 600 0C

Bila temp tube katalis 101-B >= 895 0C, segera kurangi penyalaan burner yg berdekatan, sehingga temp < 890 0C.

bila temperatur inlet HTS > 180 0C.

- 204-LJ di aktifkan.19.30 Aktifkan 201-E, aktifkan UCON. 104-J Test ARCV20.10 Pindahkan vent Gas dari V-1000 in ---> outlet 108-D, Speed Up, sebelumnya speed 5125 rpm, FC-1006= 235 T/H

108-D aktif. sesudah speed 5200 rpm, FC-1006 =250 T/H20.15 Start 102-J. Panel : Speed Actual 5300 rpm max.20.50 Rate Gas 20 % ---> 30 % Speed ref 5400 rpm.21.25 On line kan 102-J. ARCV W . OHARI ke III Turunkan flow ke 243 T/H, coba tutup ARCV00.15 Masukkan gas ke 101-B. bila flow mantap, tidak ada perubahan .02.00 Heating Up 107-D. Artinya ARCV tidak leak, buka kembali ARCV.

- Bertahap nyalakan semua Burner 101-B. UTILITY03.00 Vent V-1000 out 108-D closed, gas masuk ke 101-B. PRODUCT STEAM 04.10 Start 101-J.07.45 Start 107-J. pada beban Gas Turbin Generator 5.93 ~ 22.63 MW.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. 5005-F ( Blow Down Flash Drum ).13.30 Buka by-pass MOV-1009, pemanasan / pemekatan MB. Let Down valve dari line SM-3010-4"-(DI)

- Stop SLL ke 105-C, buka by-pass MOV-1009 - 102-F1. Exhaust Turbine.14.10 Inching MOV-1009, V-1008 open 3/4 ulir. Supply utk : Dearator; IA Drayer, NH3 Stripping dll.18.50 Press Up 101-E, buka V-1008 kemudian PIC-1005 dan

MOV-1018.23.00 Start 121-JA. Supply utk : NH3 Heater & Water Heater.148 153

10.00 Aktifkan 150 - E. 09.10 Switch supply H2 ke 108 - D dari P- IV ke 103-J ( LPC ).10.15 Pindahkan vent dari PCAH - 1004 ke PC-1005. 09.20 Start sirkulasi 141 - JA dan 140 - J ( ARU ) on line kan- Kirim PC dari 150 - E ---> 102- U ( 15 mm Hos ). 103 - E & 104 - E10.30 Start 103-J 10.20 Masukkan vapor NH3 Storage ke 105 - J.11.15 Heat Up 105-J. 10.30 Tutup by-pass 103 - E dan 104 - E.12.35 Aktifkan HV-1029. 11.35 Tutup vent 105 - E, masukkan vapor NH3 ke 127 - C14.30 Start 105-J. ( NH3 = 98 % ).17.15 Switch jacket water 107-D; 103 - D; 101 - C dari DM ---> SC 12.40 Masukkan LP Purge 103 - E ke Fuel System.18.25 Start Regen 109-D. 13.25 Press Up Absorber ( I - D - A101 ).21.00 Start 124-JM. - HRU regen to regen.21.20 Persiapan Start Loop System. 14.25 Start Mol Sieve Abs I - D - A101 ( HRU ).

MOV-1001 / 1002 : W. O Setelah regen step 10 ( NH3 di 104-E = 73,4 ppm ).HCV - 1044 : 10 %.HCV - 1045 : W. OHCV - 1025 / 1026 : F. C SHUT DOWN AMMONIA PLANT

- Mulai adjust FV-301 / 302, press Up loop ke 90 Kg. - Cut Rate Gas ke 80 %.- Adjust sirkulasi FV-304 ( tutup u/s SP - 006 sampai - Shut Down kan HRU & ARU.

FV - 1257 naik ). - Shut Down Loop, stop tie-in CO2 ke Existing Plant.22.05 Start Firing 102 - B, Start Synt Loop. - Stop 103-J, non aktifkan 150 - E.22.25 Tutup bv SL di BL. - Cut rate Gas ke 60 %.HARI ke VI : - Shut Down kan 106 - D & LTS.02.50 Start produksi liq NH3 di 106 - F. - Vent Gas di MOV-1018.- Aktifkan LC - 1013. - Cut rate Gas ke 50 % --> 40 %.03.10 Stop injeksi NH3 di 109 - F. - Stop udara ke 103 - D03.45 Start 113 - J, kirim Hot NH3 ke Urea IB. - 101 - E ( MBF ) Shut Downkan.04.15 HCV - 1044 arah buka lebar, HV - 1045 arah close. - Stop 101 - J.04.25 Matikan semua burner di 102 - B. - Stop Gas ke 101 - B.05.40 PCAH - 1004 full close, HCV - 1046 = 40 % Open. - Vent Gas di V - 1000 ( Rate Gas pada posisi min = 30 % ).

bertahap arah close. - Stop 102 - J.07.25 Heating Up line SH 173 - C. -08.20 Full close HCV - 1046. -150 151

W H B = 90 T/H ( 42.2 Kg, 399 0C ).

P B : 120 T/H 9 42.2 Kg, 399 0C ).

S L L ( 3.5 Kg, 220 0C ) dari :

S L L ( 3.5 Kg, 220 0C ) dari 4301-L (Desuperheater).

Cooling Down 101 - B, 60 0C / HrStop SM ke 101-B bila temperatur Riser =< 300 0C.

buku pintar

Documents