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Technical Audit of Existing Ammonia Plants

IP.com Disclosure Number: IPCOM000218864D
Publication Date: 2012-Jun-07
Document File: 20 page(s) / 1M

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Page 01 of 20

TECHNICAL AUDIT OF EXISTING AMMONIA PLANTS

BY

S. MADHAVAN and B. LANDRY

THE MOW. KELLOGG COMPANY

HOUSTON, U.S.A.

   PRESENTED AT THE 1987 AMMONIA SYMPOSIUM SAFETY INAMMONIA PLANTS AND RELATED FACILITIES

AMERICAN INSTITUTE OF CHEMICAL ENGINEERS MINNEAPOLIS, MINNESOTA

AUGUST 1987



Page 02 of 20

t

TABLE OF CONTENTS

Abstract

Introduction

Performance and Efficiency

Reliability/Availability

Life Extension of Existing Equipment

Safety and Hazard/Operability Considerations

Changes in Codes and Standards

PAGE 1

1

4 4

5 7

7

9

10


I.

I1

.

111.


IV.


VI.

. Up9rading of Meta1lurgy


VIII. Noise and Environmental Considerations


IX. Audit Plethodology

VI1


X. Conclusions

11

Bibliography

APPENDICES


I. Overview of remaining life assessment


11. Checklist for reviewing fire hazards

12

14

15



Page 03 of 20

ABSTRACT

As t h e technology matures, ammonia p l a n t s t h a t have been i n o p e r a t i o n f o r some l e n g t h of t i m e a r e good c a n d i d a t e s f o r improvement from v a r i o u s a s p e c t s . Performance and e f f i c i e n c y , l i f e e x t e n s i o n of e x i s t i n g equipment, changes i n codes and s t a n d a r d s , upgrading o f m e t a l l u r g y , r e l i a b i l i t y , s a f e t y c o n s i d e r a t i o n s , and noise/environmental c o n s i d e r a t i o n s a r e f a c t o r s on which a complete e n g i n e e r i n g a u d i t s h o u l d f o c u s . T h i s paper p r e s e n t s t h e j u s t i f i c a t i o n s and t h e methodology f o r conducting a comprehensive e n g i n e e r i n g a u d i t of a n e x i s t i n g ammonia p l a n t .

0



Page 04 of 20

TECHNICAL AUDIT OF EXISTING AMMONIA PLANTS

BY


S. MADBAVAN and B. LANDRY


I. INTRODUCTION

Ammonia p l a n t s d e s i s n e d and b u i l t some y e a r s ago nay n o t be a s e n e r g y - e f f i c i e n t a s t h e nodern E.lants, s i n c e t h e lower c o s t of f e e d and f u e l d i c t a t e u a i f f e r e n t economic d e s i s n d e c i s i o n s a t t h a t time. Moreover, t h e y were designed f o r d i f f e r e n t e n g i n e e r i n g and environmental s t a n d a r d s . A s some of t h e p l a n t s approach a 15-20 y e a r a y e , a n a d d i t i o n a l c o n s i d e r a t i o n i s t o extend t h e l i f e o f e x i s t i n g equiprrient by i n c o r p o r a t i n g a p p r o p r i a t e and c o s t - e f f e c t i v e

An e n g i n e e r i n g a u d i t o f o l d e r p l a n t s should f o c u s on the f o l l o w i n g as&lecLSz

0 rliodificati o n s .


1. Performance and e f f i c i e n c y


2. Reliability/availability


3 . L i f e e x t e n s i o n of e x i s t i n g equipmerit


4. S a f e t y and h a z a r d / o p e r a b i l i t y c o n s i d e r a t i o n s

5, Changes i n codes and s t a n d a r d s


6. Upgrar3ing o f metallurgy

/. Noise and environmental c o n s i d e r s t i o n s


The most common j u s t i f i c a t i o n f o r a p l a n t r e t r o f i t is e i t h e r improving t h e energy e f f i c i e n c y o r i n c r e a s i n g t h...