Reformer BM project for analysis of performance.

Analysis for failure

1. 10 Step Benchmarking Process STEP-1 Decide What to Bench mark Purchasing STEP-2 STEP-3 STEP-4 STEP-5 STEP-6 STEP-7 STEP-8 STEP-9 STEP-10 Identify whom to Bench mark Collect Data Analyze Performance Gap Project Future Performance Gaps Communicate Findings Revise performance goals Develop Action Plans Implement & Monitor Recycle the process Document the process and develop a project Determine who employs superior work practices Observe superior practices first hand . Analyze current performance gaps. Project industry trends and determine how to achieve a performance edge Communicate findings to all levels and gain commitment Convert your findings into operational Statements that describe what you’re committed to improving Create specific action steps, measurements, Assignments and timetables for implementing benchmark practices Implement the plan and monitor progress Stay current with industry changes by continually benchmarking and updating work practices.

2. Benchmarking Project Selection Matrix Title of Project FILTER 1 Impact on Business / Location Obj FILTER 2 Potential savings / intangible benefit FILTER 3 Impact on Stake-holder FILTER 4 Scope of improve- ment FILTER 5 Current Problem faced by dept. FILTER 6 Solution of the problem known Go / No Go Reliability Improvement of Primary reformer High Reduction of Sp. Energy consumption. ( Feed + Fuel Energy) High Efficiency of Primary Reformer. High Yes 17.5% Burners closed/ Throttle, Leading to increase Burner tip pressure No GO

3. Objective of Project Quality / Reliability Reliability Timelines Efficiency Cycle Time Business Case : Reliability improvement of Primary reformer. Opportunity : Primary reformer is critical and high energy consuming equipment in plant. Presently 17.5% burner are either closed or throttle. This increase burner tip pressure. This increase burner tip pressure further deteriorate reformer performance like poor flame pattern, increase Reformer tube skin temperature, Wall and burner plate temperature. High reformer heat duty. Linkage of the project with the parameter : No of closed and Throttle burner Burner Tip Pressure. Reformer Heat duty

4. Performance Measures Performance Measure Unit of Measure Definition No of closed and Throttle burner % Nos of burner closed or throttle with respect to total nos of burner. Burner Tip pressure Kg/cm2 02PC23. Fuel header pressure. Reformer Heat duty Gcal 150.0 Reformer DP Kg/cm2 3.55

5. Performance (Before benchmarking) Performance Measure Unit of Measure YFI Performance BM partner’s performance Gap for YFIL No of closed and Throttle burner % 17.5 3% CFCL 18 Burner were closed on 6 th row. High Burner Tip Pressure Kg/cm2 2.0 0.9 to 1.0 Kg/cm2 High Reformer Heat duty Gcal 150 Reformer DP Kg/cm2 3.55 Note : These are current year performance average value taken.

6. Expected benefit / advantages Performance Measure Unit of Measure YFI expected Performance (after benchmarking) No of closed and Throttle burner % < 2 % Burner Tip Pressure Kg/cm2 1.3 to 1.4 Kg/cm2 Reformer Heat duty G Cal No change Reformer DP Kg/cm2 3.55 ( No change) Expected benefit / advantages : To be shown in measurable form , preferably in rupees ( otherwise %, nos. etc)

7. Processes linked to Project Name of Process : Ammonia Production Process Start Point : Fuel gas inlet to Primary reformer End Point : Flue gas exhaust outlet. Scope: Primary reformer

8. Process Map & Flowchart

9. Problem Areas Sl.No Sub Process Problem areas 1 Combustion of fuel gas with the help of Combustion air. High Burner Tip Pressure High burner plate and tube skin temperature Maintenance difficulty to repair leaking CA bellow in running plant. 2 Reforming Process High CH4 Slip at design reformer outlet temperature. High Differential Pressure across reformer tube. High Reformer Heat duty to maintain CH4 Slip 3 Waste Heat recovery Section High Stack temperature

10. Key Problem Areas Presently in Ammonia plant primary reformer approximately 80 burner are either closed or throttle because of High Burner plate temperature Bad flame temperature. High Tube Skin Temperature High flue gas exhaust temperature. This reduce the reformer efficiency. Increase Burner tip pressure Increase Reformer Heat duty.

11. Output from the process Customer(s) Customer requirement Flue Gases and hot process feed gas from the WHS coils Internal Lower Flue gas stack temperature. High Process gas temperature at lower gas input as fuel. Input in the Process Supplier(s) Process Requirement Fuel gas for combustion Feed gas for reforming process Internal Efficient Reforming process to meet design output of feed gas composition in reformer feed gas exit. Document Process Details

12. Whom to Benchmark List of potential partners Source Potential partner 1. Subject experts 2. Library Publications Internet etc. 3. Consultants/ Benchmarking Association 4. Any other

13. Selection of BM Partner Matrix for Selection & Prioritisation of Benchmarking Partners Criteria for comparison and identification 1 = Not true, 5 = True Size of the company Likeliness for openness Best Practice likeliness Recognitions – FAI, IMC, CII, Deming etc Comparability : vintage, technology, automation etc Accessibility Performance Culture Weightage 5% 15% 20% 15% 10% 10% 15% 10% Sl.No Company Wt. Avg. points 1 IFFCO Aonle 33 4 4 4 3 5 4 5 4 2 CFCL Kota 33 4 4 4 4 5 4 4 4 3 IGFCL 32 4 4 4 4 4 4 4 4

14. Analysis for Reforming Section 14

15. Reformer Heat load Vs Feed NG 15 Conclusion : Reformer Heat load increasing as per plant load. NG FEED Kg/ Hrs Heat load Gcal / Hrs

16. Reformer Heat load Vs Fuel 16 Conclusion : Reformer Heat load increasing as per fuel. Fuel Nm3/ Hrs Heat load Gcal / Hrs

17. Total Fuel Vs Fuel header Pressure 17 Fuel header Pressure Kg/cm2s Fuel Nm3/ Hrs Conclusion : Fuel header pressure ( Burner tip Pressure direct linked with flow of fuel flow.)

18. Relation with Surplus 02FC33 with Burner tip pressure 18 After 2016 TR even though high surplus, burner tip pr was in the range of 1.6 to 1.7 max. Where as in 2018 even surplus is less but burner tip pressure is high. Surplus Nm3/ Hrs Fuel header Pressure Kg/cm2s

19. Gap analysis report Comparing with Bench Marking partner Reforming Section Comparing with ours best operating parameters in 2016. There is no operational issues in reforming section in tube side. Reformer tube side DP (02PDT-27) increasing trend is 0.05 Kg/cm2 per year. Catalyst loading was done in 2012 TR, That time DP was 3.11 kgcm2 where as on 31 Oct 19 DP is 3.55 Kg/cm2.

20. Analysis for Radiation and Convection Section 20

21. Gaps in Convection section S,no Description Data 1 Data 2 Date 3 Data4 Remark 3 Burner tip deposition Yes No Very less Very less 4 Analysis schedule for Presence of ammonia in common fuel line. No No Need base There is no fixed schedule for analysis. But even disturbance only C-03 diverted. 5 Presence of ammonia in off gas. Design is 0.03% v/v 0.04 to 0.07 % v/v 0.03 % v/v (oral information) <0.04 % v/v 6 Ammonia in C-03 gas 0.06 to 0.5 % v/v Not in line <1% (Mostly value is <0.5% <1% 7 C-03 Gas flow (Nm3/ Hrs ) 1850 Nm3 Not in line 1600 Nm3 1600 Nm3 21 There is an observation that Burner tip cleaning frequency increase when PGRU either running at low load or under deriming with same CO2 load 107.0 TPH, This is the clear indication that high amount of off gas of ammonia 0.07% going to reformer may causing chocking of burner tip.

22. Gaps in Convection section S,no Description Date 1 Data 2 Data 3 Data 4 Suggestion 8 Air cone and burner tip Burning Yes No Yes in old design Burner No in New design burner Yes May be discussed with Hamworthy with the problem and possible improvements. 9 Muffle Block burn out (Mono block Muffle block using) Yes Yes Yes 22 All plant have experience of Air cone and burner tip burning, This is an observation that when taking more surplus gas to reformer then due to presence of Hydrogen gas some pre-firing phenomena happened which causing Air cone burning. High pressure of surplus gas and more flow is one of the cause of high burner tip pressure. CFCL has done detail study of existing burner with Hamworthy, Hamworthy suggested them new design Burner FMPR after replacement there is no observation of Air cone burning. CFCL and IFFCO are not taking surplus gas because CFCL maximize ammonia production, and IFFCO have CDR unit.

23. Gaps in Convection section S,no Description YFIL IFFCO CFCL IGFCL Recommendation 10 Burner status closed/ Throttle 49+31=80 190+60=250 40 (Top row only) Layout of LS Steam header with multiple nozzle to be provide at each floor so that hot spot can be manage without creating hazard by steam hose. Proper arrangement help to open more number of burner which help to reduce burner tip pressure. 11 Hot spot in reformer Yes At the time of visit – No 23 LS Header LS Header For this Modification was already raised in MOC no 31/ 2017 , which was partially approved and under PE study

24. Burner closed status Vs Refectory Status 24 Conclusion : All wall towards Cooling water side has more hot spot, where as A and D wall has more hotspot toward plant side..

25. Burner closed status 25 Conclusion : C and D wall has almost hot spot in each row. A and B has maximum hot spot in 2,3,4 row,

26. Thermal imbalance 26 Temperature imbalance between the wall and tube are because of either burner throttle or bad flame. This thermal imbalance will reduce the reformer efficiency.

27. Tube wall temperature of A/B wall 27

28. Tube wall temperature of C/D wall 28

29. Catalyst performance report for reformer 03 Sept 19 29

30. Burner tip pressure Vs Burner closed 30 Initial condition when 49 Burner was closed and 31 Burner was throttle, Then for a short time open all throttle burner then burner tip pressure was down from 1.95 Kg/cm2 to 1.82 Kg/cm2 This indicate that burner throttling is the major cause of increasing burner tip pressure. After attending all hot spot we can be able to open all burner then at this plant load burner tip pressure will be around 1.5 Kg/cm2

31. Summary in chronological order

32. Analysis for WHR Section 32

33. Heat Recovery Section Heat Recovery Section No measure gaps. We already have practice for dry ice cleaning in TR. Other Benchmarking partner also have the same. During Dry ice cleaning CFCL using instrument air to ensure minimum air pressure > 5.0 Kg/cm2 We already taken action cleaning with additional air compressor to ensure air pressure >8.0 Kg/cm2 Exhaust temperature is high although as per our design condition 170 Degc, presently running 178 Degc. CFCL and IFFCO has lower exhaust temperature, CFCL has different operation philosophy using fuel NG heating coil. 33

34. Other Graph 34

35. Recommended Action Plan Sl.No . Gap Analysis Recommended Action Plan Benefit Target Date Responsibility Remark