EVALUATION OF REVAMP MODIFICATION

REVAMP JOBS CARRIED OUT IN.

(A) PHOSGENE PLANT
(B) TDI PLANT
1. SECTION 61
2. SECTION 63
3. SECTION 66
4. SECTION 67
5. SECTION 71

COOLING WATER CIRCUIT MODIFICATION AS

PER CEAB STUDY REPORT FOR 150% PHOSGENE
PLANT LOAD
OBSERVATIONS:
(1) COOLING WATER FLOW IN R-5121 A/B & R-5131
A/B HAS BEEN INCREASED FROM 25 M3/Hr & 9 M3/Hr
TO 32 M3/Hr. & 11 M3/Hr. RESPECTIVELY
(2) COOLING WATER CIRCUIT TEMP. REMAIN 68 deg.C
MINIMUM WITH FULL OPENING OF E-5203 BOTH
CONTROL VALVE.
NOW CIRCUIT TEMP. REMAIN 65 deg.C WITH
70% OPENING OF E-5203 ONE VALVE AT 105% PLANT
LOAD.

TO ACHIEVE REACTOR SEPARATOR (S-6112)

DESIGN TOP PESSURE(2.0 BARG.)
(1) S-6112 TO E-6121 VAPOR LINE SIZE INCREASED
FROM 6 TO 8.
(2) E-6121 TO S-6122 VAPOR LINE SIZE INCREASED
FROM 4 TO 6
(3) S-6122 TO C-6651 VAPOR LINE INCREASED FROM
4 TO 6.
(4) E-6121 LIQUID ODCB OUT LET LINE SIZE
INCREASED FROM 1.5 TO 2.
(5) FT-6144 OF 6 PROVIDED.

OBSERVATION:
BEFORE MODIFICATION S-6112 TOP PRESSURE WAS
REMAIN 2.5 barg. AT 100% PLANT LOAD. IT WAS ONE
OF THE MAIN LOAD GOVERNING PARAMETER.
NOW TOP PRESSURE AT 100% PLAT LOAD IS
1.95 TO 2 barg.
ALSO WE CAN REGULATE S-6112 TOP PRESSURE BY
CHANGING C-6651 TOP PRESSURE. AT 110% PLANT
LOAD C-6651TOP PRESS.WAS 1.8 barg. S-6112 TOP
PRESS. WAS 2.4 barg.

TO ACHIEVE DESIGN P-6113 LOOP FLOW (900 M3/Hr.)

(1) P-6113 SUCTION & DISCHARGE LINE SUPPORT

STRENGTHENING DONE TO ELIMINATE EXCESSIVE
VIBRATION AT DESIGN FLOW.
(2) P-6113 DISCHARGE ORIFICE SIZE CHANGED
FROM 5.75 TO 6.25.

OBSERVATIONS
P-6113 DISCHARGE FT-6165 IS NOT INDICATING
AFTER SHUT DOWN.
P-6113 Amp. INCREASED FROM 235 TO 250 amp.
FROM PUMP CHARACTERISTIC CURVE IT IS 920
M3/HR.

P 6302 TO C 7101 LINE LC 6333 REPLACED WITH NEW

OF HIGHER C.V
FT 6334 REPLACED WITH HIGHER SIZE (3).

TO COMPENSATE HEAT OF COMPRESSION OF B6612

E 6614 SHELL SIDE PROVISION OF CHILLED WATER

CIRCULATION GIVEN.
OBSERVATION:
S 6613 TEMPERATURE REMAINS 63C AT 110%
PLANT LOAD AND HIGHER COMPRESSION RATIO,
WHICH WAS 78C AT 100%PLANT LOAD.

TO REDUCE PRESSURE DROP OF S 6613 OUTLET LINE

S 6613 OUTLET TO C 6651 LINE SIZE CHANGED

FROM 4 TO 6.
OBSERVATION:
B 6612 DISCHARGE PRESSURE REMAINS 1.8
BARG. WHICH WAS 2.1 BARG. AT SUCTION
PRESSURE OF 10 MBARG.

TO REDUCE PRESSURE DROP AT C6651 OUTLET LINE

C 6651 TOP NOZZLE CHANGED FROM 3 TO 4 AND

LINE SIZE CHANGED FROM 3 TO 6.
FT 6675 SIZE CHANGED FROM 1 TO 3.
E 6654 INLET/OUTLET NOZZLES CHANGED FROM
2 TO 4.

TO OVERCOME CAVITATION PROBLEM OF P6656

C 6651 TO P 6656 LINE SIZE CHANGED FROM 3 TO

4 WITH FULL BORE PLUG VALVE OF 4.
OBSERVATION:
P 6656 IS RUNNING NORMAL WITH 9.2 BARG.
DISCHARGE PRESSURE AND 10 M/HR OF FLOW.

HCL SECTION PRESSURIZATION PROBLEM

NEW HCL ABSORBTION SYSTEM OF 60% CAPACITY

IN PARALLEL WITH EXISTING.
OBSERVATION:
NEW ABSORPTION SYSTEM RUNNING NORMAL
w.r.t HCl CONCENTRATION.
SYSTEM PRESSURE REMAIN 0.4 BARG AT 110%
PLANT LOAD.

TO REDUCE E 6711 OUTLET HCL PRODUCT TEMP.

GRAPHITE COOLER PROVIDED AT E 6711 OUTLET

HCL LINE.
OBSERVATION:
HCL PRODUCT TEMPERATURE REDUCED FROM
60C TO 42C AT 110% PLANT LOAD.

JOB CARRIED OUT.

REFLUX FLOW LCV-7198 AND ODCB WITHDRAW
TCV-7147 HIGHER CV VALVE PROVIDED.
OBSERVATION:
AT PRESENT LCV-7198 OPENING REDUCED
FROM 100% TO 65%.

Revamp related pending job list

.SECTION 61:
E 6121 LOW PRESSURE DROP EXCHANGER
REQUIRED.
SECTION 62:
AT 115% PLANT LOAD WE ARE NOT HAVING ANY
PROBLEM OF RESIDENCE TIME IN S 6201. AS PER
CEAB REPORT S 6201 IS OKAY FOR REVAMP LOAD.

SECTION 63:
HIGHER CAPACITY FILTER F-6307 HAS BEEN
ORDERDED.
6303 CIRCULATION FLOW INCREASED FROM 56
TO 65 M/HR FOR BETTER STRIPPING.
OBSERVATION:
NO SIGNIFICANT IMPROVEMENT IN STRIPPING
WAS OBSERVED.

SECTION 71:
P 7112 AND P 7107 OF HIGH HEAD AND FLOW
ORDER GIVEN.(OCT01)
LCV 7105 OF HIGHER SIZE TO BE INSTALLED.
E 7109 ODCB-ODCB COOLER PROCUREMENT.
C 7101 WILL HANDLE MAX. LOAD UP TO 140%.

SECTION 66:
OPERATION OF C 6651 AT GREATER THAN 115% IS
DOUBT
FULL.(AS
PER
REPORT
OF
DR.
S.R.BHUTADA).

LIMITATION BEYOND 110% PLANT LOAD.

(1) P-3503 A/B, MTD FEED TO M-5407 PRIMARY MIXTEE.

HIGHER HEAD/CAPACITY PUMP HAS BEEN
ORDERDED.
(2) P-5408 A/B MTD-ODCB FLOW TO M-6101
SECONDARY MIX-TEE.
HIGHER HEAD/CAPACITY PUMP HAS BEEN
ORDERDED.
(3) C-6651 16TH PLATE TEMPARATUE MAY REMAIN
GRATER THAN +2C.

(4) P-6656 DISCHARGE AND P-6652 CIRCULATION

LOW FLOW
(5) AT HIGH ODCB INPUT RATE ( > 10 M/HR) INTO C6651, CHILLED ODCB TEMP. MAY INCREASE.