QUESTIONS [REVIEW BY ZHS]

DAY-ONE
1- 885# Steam balance?
Ans. FI-203=368KPPH FI-685=67KPPH TOTAL=435KPPH
Steam Consumption, FI-47A=255KPPH FI-48=46KPPH FR-295=109KPPH FI804=25KPPH
TOTAL=435KPPH
1- PRC-192 Pressur alarm?
Ans. PVLO=700# PVHI= NOT EXIST
1- TI-802 Group[885# steam to KT-2502]?
Ans. Group=235
1- How will you control 885# steam pressure in case of K-2502 tripping?
Ans. Open HIC-1105 to control 885# steam pressure,letdown increase about 110 KPPH, open 585#
steam in vents, decrease FEL to 90%.

1- PRC-1012 alarm pressure?

Ans. PVLO=130#
1- PRC-1012 , 150# Steam production?
Ans. 31KPPH at FR-2127B
1- PRC-3112 alarm pressure?
Ans. PVHI=50 #
PVLO= 30#
1- 585# Steam low pressure alarm and high pressure alarm?
Ans. PVLO=480# PVHI= Not exist
1- 40# steam balance?
Ans. 40# steam production.
ID Fans=16 KPPH From 150# steam=30KPPH FR-2008=09KPPH
KPPH
Total=61KPPH
Consumption= FR-1020=53KPPH FR-2118=6 KPPH

From D-2532=06

Uty points+spargers+40# steam turbines+TP-2508+TP-25208A+Vacuume ejectors=61KPPH

1- 40# Steam pressure decreasing effects and action steps?

Ans. 1- PIC-1053 pressure will decrease
2- Turbines RPM will increase if the governors are not controlling.
3- Low vacuume in E-2535/36/16
4- Governors hunting problem.
ACTION STEPS

First off all check the circuit and detect the cause and then open PRC-3112A or bypass
valve to restore the pressure.

DAY-TWO
1What will be your action steps if FRC-147/HIC-147 malfunction to full close and their bypass
valve is
Unoperatable?
Ans.Open E-2526A/B inlel vent to control loop pressure .If there is margin at FRC-1021 you may increase
flow at FRC-1021 otherwise open emergency vent.Later on rectify the FRC/HIC-147 problem.
1Can we change the Dynelco set point?
Ans.No we can not change the Dynelco set point because its contacts will loose which will trip the machine.
1Difference between K-2502 normal and emergency shutdown ?
Ans.NORMAL SHUTDOWN
Normal shutdown is a planned shutdown during which we gradually decrease the load on machines and
similarly control the other parameters like convertor temperatures,loop pressure,K-2502 suction pressure, D-2526
level,HP purges rate,885# steam pressure,purge header pressure, H/N ratio, D-2528 level and pressure, K-2503
RPM , suction pressure and K-2503 2nd suction temperatures.
While proceeding normal shutdown K-2502 speed decreasing rate is =40 RPM/Sec.
During critical speed this rate is =60RPM/Sec.

EMERGENCY SHUTDOWN
Emergency shutdown is proceeded when there is following conditions exist on the plant.
A]Heavy ammonia leakage
B]Fire
C] Heavy syn gas leakage.
D] Equipment failure etc.
1N2 Increasing causes at convertor inlet and its effects?
Ans. 1-Low ambient temperatures
2-High liquid ammonia in E-2542
3-Low load of backend
4- PRC-335 malfunction to close[ if open]

EFFECTS
1Loop pressure will increase

2Convertor temperatures will decrease

3K-2502 steam consumption will increase.

DAY-THREE
1How high thrust pad temperature security of IP case trips K-2502?
Ans. Its signal goes to VHCO-2502 which trips K-2502.
Alarm =275 F Trip =300 F
1What will be your action steps if D-2526 level decrease to zero?
Ans. Immediately ask the area operator to check the level in the GLG, If the level in the GLG is normal,put LRC366 on manual and calibrate LRC-366T.If however the actual level is zero ,close LRC-366 on manual and ask the
area operator to pinch its isolating valve.whenever there is some abnormality in the level, also confirm from its
level recorder LR-271.
D-2526 low level alarm=30% High level alarm=65%
1What is the group of LRC-366?
Ans. Group =227
1If MCC-2B trips how will you detect and what will be your action steps?
Ans.Backend breakers at MCC-2B
MOV-156/157 MP-2509 MP-2512 MP-2514 LT-K
MP-2512 will trip and its start indication will disappear from panalarm and MP-2512B will start on APS and its
start indication will appear at panalarm and control room emergency lights will turn off.

ACTION STEPS
1-Ask syn operator to check MP-2512B discharge pressure and vibration.
1If feed forward security actuates how will you detect and what will be your action steps?
Ans.PSL-2500 will actuate on ESD.
FRC-137/38/39/40 will full open
Rec.MOV will full close
Immediately ask the area operator to check control oil pressure on local pi to check whether it is actual or
transmitters malfunction.Rectify the problem and then put all the antisurges on manual and reset the
security,Rec.MOV will close and then load the machine by closing the antisurges on manual.[Group210-213]
1If D-2526 level rises to 70% what will be your action steps?
Ans.D-2526 high level alarm will sound at 65%.Immediately ask the area operator to check the level in the
GLG.Also check the level at LR-271.Put the valve on manual and control the level with close coordination of area
operator.Calibrate the transmitter later on.
1How many speed probes are installed at K-2502 in the field and how many indications are
provided in the control room?
Ans. 4

22-.How many radial and thrust probes are installed at K-2502?

Ans.RADIAL=16 THRUST=08

1How many total trips are at K-2502/03?

Ans.K-2502-03 total trips=12/11
1- K-2502 suction high and low pressures reasons and its effects on backend?
Ans.Suction high pressure may be due to the following reasons,
1-FRC-137 malfunction to open
2 Sudden decrease in K-2502 RPM
3-K-2502 suction high temperature

EFFECTS
1-K-2502 suction high pressure alarm will sound at 385# /395 #
2-K-2502 discharge pressure will increase
3-Convertor temperatures will increase
4-PRC-132 will open
5-Flows across the compressor will increase
K-2502 suction low pressure may be due to the following reasons,
1- PRC-132 malfunction to open
2- Any U/S vent open
3- Sudden increase in K-2502 RPM
4- Low pressure alarm will sound at TDC at 325#

EFFECTS
1234-

K-2502 discharge pressure will decrease

Convertor temperatures will decrease
LRC-366 opening will decrease
FRC-137 may open

1- K-2502 suction high temperature reasons and its effects on backend?

Ans.K-2502 suction high temperature may be due to following reasons,
1- HIC-1018 malfunction to close.
2- E-2515A high shell pressure
3- Oil in E-2515 liquid ammonia
4- High cooling water temperature
5- Low cooling water flow
EFFECTS
Load on K-2502 will increase which will increase rack opening of KT-2502 and ultimately steam
consumption will increase.High suction temperature alarm=120F. D-2523 level will also increase.
1Fromwhere you see the circuit fault indication of K-2502 vibration probes and its
gap voltage?
Ans.Circuit fault indication will appear at panalarm and gap voltage are checked from the bentley nevada
vibration monitoring system.
1What will you do if V-201 bad PV indication appears?
Ans.This indication will appear on TDC in case if it is on higher side as well as CIRCUIT FAULT
indication will also appear at panalarm.We will also see the vibration at V-202.
1Ans.Group #61 -68

From where you see the high vibration alarms indications.[Group Number]?

1How will you unoptimize the backend so as to control TK-200 inventory at a

constant level?
Ans. 1- Inform Urea-1 and Urea-2 about load reduction.
2- Inform boiler operator and base plant about purge header pressure increase /fluctuation.
3Open steam in stripper and ammonia vents.
4Increase HP purges rate from 660 kscfh to 710 kscfh gradually and watch the
pressure at PRC-123. It should not open at this flow.Keep its set point at 88#.
5Similarly decrease K-2502 speed upto 9180 RPM slowly depending upon suction
pressure.Keep set point of PRC-132 at 380#.
6Control convertor temperatures by closing HIC-141 and by adjusting HIC142/143/144.Do not close HIC-144 to control bed temperatures because it will increase
convertor outlet temperatures.[TI-223/224]. Normally at 115% load the HIC,s opening will
be as follows,
HIC-141= 100%
HIC-142/143=44%
HIC-144=70%
7-Maintain H2/N2 ratio
8-Closly observe chillers levels and E-2524A/B levels.
9-Check K-2502 antisurges controllers deviation and interstage temperatures.
10-During load reduction closly observe the prism unit feed pressure.[PT-219].It should not decrease
below 2200#,because PSL-3297 will actuate at 2000#. If this pressure decrease upto 2200# then bypass
PSL-3297 security.
11-Check PIC-3296 opening from the field,if it goes upto 90%,ask syn operator to open D-2541 gas side
bypass valve to keep it at 70% opening.
12-Closly watch the D-2526 level,LRC-366 opening and TK-200 inventory.If TK-200 inventory rise rate
is high then proceed the following steps,
A] Keep PRC-132 set point at 375# and start gas venting at PRC-132. Also control the convertor
temperatures.
11-Unoptimize the prism unit so that minimum hydrogen is recovered from the prism unit to control
TK-200 constant.Keep the following parameters,
FRC-1021 =400 KSCFH
PIC-1030 =1650 #
PIC-1033 =1100 #
PIC-1028 =
1051#
PIC-1031
=
490#
FT-2571
= 160 KSCFH
FT-2573
=113 KSCFH
13- If still TK-200 is rising ,cut prism unit post treatment section.
14-Decrease K-2503 speed up to 7800 RPM.
Following are the ideal conditions at which TK-200 inventory is constant and PRC-132 and PRC-123
are full close.
FEL=115%
S/G Ratio=2.89
TI-114=1420F
AR-2 CH4= .88
AR-7 NH3=3.09
PT-174=384#
PDR-294=3.23
H2/N2 Ratio=3.09
HIC-141=100%
HIC-142/143=44%
HIC-144=68%
PT-176B=2550#
FRC-1021=400 KSCFH

PIC-1030=1650#
PIC-1033=1100#
PIC-1028=1051#
PIC-1031=490#
FT-2571=460 KSCFH
FT-2573= 113 KSCFH
PRC-123=FULL CLOSE
PRC-132= FULL CLOSE
K-2502/03 RPM=9180/7800
TI-206=978F
TI-223/224=744F
FT-300=48Met
FT-301=16Met
FT-302=32Met

DAY-FOUR
1Which are the controllers are on APM.If APM fails,what will be the indications and
what will be your action steps?
Ans. CONTROLLERS ON APM [FAIL SAFE CLOSE]
FRC-160 PRC-132 LIC-340 LRC-366 LRC-368 PDCV-3137 FRC-158 TRC-185 HIC-1018 LRC-1017
LRC-1018 LRC-359 LRC-373 LRC-374 LRC-375 FRC-155 LRC-362/363 LRC-367
APM failure indication will appear on TDC.[SYSTEM STATUS]
As LIC-340 and LRC-366 will close so it will actuate LSH-339 and LSH-352 which will trip K-2502.

REVIEW ON 14-08-04
1-What are the precautions for K-2503 normal stop?
Ans.Keep following parameters under close observation for normal shutdown of K-2503
AK-2503 suction pressure
BK-2503 2nd suction temperatures[TIC-370]
CD-2528 level
DPRC-152 Pressure
EK-2503 casing temperatures
FFlows across the compressor
2- D-2528 level minimum limit during shutdown?
Ans.Keep the level 10% if it is to be hand over for turnaround.Otherwise keep the level upto normal.
3-How RBV-2528 closing trips P-2509?
Ans. RBV-2528 limit switch trips P-2509 .
4-P-200 Circuit towards Urea-1/2 and Ammonia-2?

Ans.Drawing attached in the file.

5-How we can lineup P-200 directly with Urea-1 and Urea-2?
Ans. Drawing attached in the file.
6-Urea-1/2 drainage circuit into TK-200?
Ans. Drawing attached in the file.
7-How chillers levels are reduced with K-2503 during shutdown?
Ans.