Professional Documents
Culture Documents
PREFACE 3
INTRODUCTION 5-
12
AMMONIA PLANT 64 -
75
UREA PLANT 76 -
84
PROJECT STUDY 91 -
98
1
ANKUSH SHARMA
INTRODUCTION
NFL Schedule - A & Mini Ratna Category 2004-2005. - I
Company, is a market leader in the fertilizer Industry in
India
With 17.0% share in Urea production during 2004-2005.
2
NFL was incorporated on 23rd
August, 1974 with two
manufacturing Units at Bathinda
and Panipat. Subsequently, on the
reorganization of Fertilizer group of
Companies in 1978, the Nangal
Unit of Fertilizer Corporation of
India came under the NFL fold. The
Company expanded its installed
capacity in 1984 by installing and NFL Corporate office: Noida
commissioning of its Vijaipur gas
based Plant in Madhya Pradesh.
3
Three of the Units are strategically located in the high
consumption areas of Punjab and Haryana. The Company has
an installed capacity of 35.49 lakh MTs of Nitrogenous
Fertilizers and has recorded an annual sales turnover
of Rs.3,474 crores during 2004-05. The Company’s strength
lies in its sizeable presence, professional marketing and strong
distribution network nationwide.
Kisan Urea and Kisan Khad NFL’s popular brands are sold
over a large marketing territory spanning the length and
breadth of the country. The Company also manufactures and
markets Biofertilizers and a wide range of industrial products
like Methanol, Nitric Acid, Sulfur, Liquid Oxygen, Liquid
Nitrogen etc. The Company has developed Neem coated Urea
which on demonstration has improved the crop yield by 4-5%.
The Company is focusing its thrust to widen the marketing
operations of Neem coated Urea.
4
percentage of sale outside ECA was raised to 50% in Rabi
2003-04, The same portion prevails for 2004-05 and Kharif
2005.
5
Fuel based plant as per consumption point of view since Punjab
is mainly agriculture based state.
" Feed in " at Bathinda was achieved on 7th Dec. 1984
and from this project ammonia was successfully produced on
28th May 1979 and urea on 2nd June 1979.NFL was
incorporated on 23rd August 1974 in order to implement this
project contract were entered into with M/s " TOYO
ENGINEERING CORPORATION " a well known Japanese Engg.
Company and Engg. India Ltd (EIL), a public sector and Engg.
Organization .This contract becomes effective on September
26, 1974 with a guaranteed “Feed in” on the Bathinda
Fertilizers project to implement within 36 months from the zero
date.
Due to the power requirements and some other
factors, later on it was planned to set up its own power house
known as Captive Power Plant (CPP) with 2 turbo generators of
15 MW each.
National Fertilizers Limited (N.F.L.) is the largest
manufacturer of nitrogenous fertilizers in the Northern India. It
is presently operating four large fertilizers plants, two of which
are located at Nangal and Bathinda in the Punjab State, one at
Panipat in Haryana and one at Guna in M.P. While plants at
Nangal, Bathinda and Panipat are fuel-oil based, the one at
Guna is gas-oil based. The overall installed capacity of NFL
plants is 10.42 lakh MT per annum.
6
Strategically Located - Urea Plants
7
Leading Producer of Nitrogenous Fertilizers in the Country.
PRODUCTS OF NFL
8
National Fertilizers is producing “Kisan Urea, Kisan
Khad and Ankur” on commercial scale. NFL is also marketing
number of Industrial products produced as By-Products during
the formation of “Kisan Urea, Kisan Khad and Ankur”in its plant
itself.
FERTILIZERS PRODUCTS
Kisan Urea:
Kisan Khad:
9
Fuel Oil /LHLS 850 MT / Day
Coal 1680 MT / Day
Water 13 MGD
Power 28 MW
PROJECT ’s BENEFITS
10
Steam Generation plant is mainly installed for production
of steam and then distributed to various parts of the plant.
Here this section of plant installed in National Fertilizers
Limited, Bathinda unit produces and supplies steam at 100 Kg /
cm2 pressure and nearly 480°C temperature to Ammonia Plant.
In today’s world steam has gained importance in Industries. It
may be used for power processes and heating purposes as
well.
BENEFITS OF STEAM
NFL , Bathinda is using steam for two purposes ; first and the
main reason is for running prime mover and other reason is to
exchange heat in the processes taking place their.
There are three boilers capable of producing steam at
the rate of 150 Tonnes/hr installed in CPP which were supplied
and erected b BHEL. Generally two boilers are enough to meet
the requirements but third boiler is simultaneously running
because if steam load consumption increases then the third
boiler play its part in order to avoid any faulty condition.
FUELS USED :
11
Coal : To obtain steam of desired Temperature and
pressure, coal is burned to give major source of heat.
Initially coal is stored at Coal Handling plant brought from coal
sites. It is this section of plant where coal is crushed by
crushers in order to make small pieces of coal, then after
crushing it the coal pieces rare passed through heavy
electromagnet where iron is separated from coal if present.
Coal is then sent to Bunkers from where it goes to Grinding
mill. Grinding mill is grinding coal into powder form.
Conveyor Belts are being used in the whole plant for
transportation of Coal. The powder form of coal is sent to the
Boilers through pump as pump sucks the coal from grinding
mills and throws it into the boiler for combustion.
12
formation takes place. In the beginning coal is burnt with fuel
oil in order to get desired temperature.
FIRING SYSTEM :
C + O2 ▬► CO2 + Heat
13
purpose Raw Water is physically and chemically treated and
finally supplied to Steam Generation Plant from Ammonia
plant. This water is called Boiler Feed water which is further
heated to 240º C by the flue Gases and taken to Steam Drum.
Steam Drum Acts as storage tank and also separates water
from the steam at 315º C and 106 kg/cm2 pressure water then
enters the Ring Header formed at on the bottom of outside the
furnace and rises by gravity through water wall tubes on the all
the four sides ,taken heat from furnace and enters steam drum
as a mixture of steam and water.
14
The chief pollutants generated in SGP are ASH and SULPHUR –
DI-OXIDE. Their separation and disposal are discussed in brief.
ASH:
FLY ASH:
ELECTRO-STATIC PRECIPITATORS:
15
SULPHUR-DI-OXIDE:
MAIN EQUIPMENT
ECONOMIZER
SUPER-HEATER
16
The main function of the super-heater is to superheat the
steam. Super heater is located at the outlet of the furnace.
OPERATION
Before lighting off the unit, open wide inlet and outlet
header drains, vents links drains and main steam line drains.
Close all the drains prior to lighting off when the headers and
links appear free of water drain that senses as a starting drain
header drain and is kept open after the unit is on line.
DE SUPER-HEATER
DRUM
17
National Fertilizers Limited has set a Captive Power Plant
(CPP) at their complex at BATHINDA, to ensure availability of
stable, uninterrupted power and stream to the Ammonia and
Urea plant. This will minimize the tripping of the Fertilizer Plant
due to transit voltage dips and power cuts.
18
It was thought to install a captive power plant in which
electric power for our requirement shall be generated in a
COAL FIRED BOILER. The benefits envisaged were:
BOILER
19
utilization of heat of the gases and venting these gases at a
safe height. Main differences between the two boilers are:
DESCRIPTION
20
coal supply system.
primary air system.
seal air system.
Make MEIDEN
Degree of protection IP 55
No of poles 4
Frequency 50Hz
RPM 1475
Power factor 0.89
Insulation class F
Rated power 195kW
Type of construction IEC-34
Normal temp rise limit 700C
21
bearings and seals. This system should be in service before
being placed in operation.
Make MEIDEN
Degree of protection IP 55
Insulation class F
No of poles 4
Voltage 3300V
Frequency 50Hz
Current 98A
Power factor 0.89
Type of construction IEC-34
Power rating 445kW
Connection Y
0
Temp. risk limit normal 70 C
22
RPM 1430
The pulverized coal from the BTM is fed to the boilers with the
help of primary air fans. The coal is burnt in the boiler to
generate steam to move the turbines. The forced and induced
draft fans are used to assist in the combustion of fuel and
steam production. These two major types of fans supporting
the units operation.
Make MEIDEN
Rating Continuous
Insulation class F
Rated power 320kW
Voltage 3300V
Power factor 0.85
Current 71A
RPM 980
Poles 6
Connection Y
Make MEIDEN
Rating continuous
Insulation class F
Rated power 295kW
23
Voltage 3300V
Power factor 0.83
Current 67.5A
RPM 735
Poles 8
Connection Y
POWER GENERATION:
TURBINE:
24
steam and heat difference that is on condition of steam at the
main steam valve and the pressure at the turbine outlet or
condenser pressure. The turbine is connected to the generator
through speed reducing gears.
DESCRIPTION :-
25
Critical speed 3200-3600 RPM
GENERATORS
DESCRIPTION:-
SYNCHRONOUS GENERATOR:
Make Jeumont-Schneider--France
Degree of protection IP 54
Type of excitation Brush less
Insulation class Stator F
26
Rotor F
Temp. Rise Stator 70 0K
Rotor 70 0K
Maximum Inlet temp. Air 50 0C
Water 36 0C
Altitude 236 m
Duty Continue
Generator weight 44000 kg
Output 18750 KVA
Connection star-delta
Voltage 11000 V
Current 984 A
Frequency 50 Hz
Phases 3
Speed 3000 rpm
Permissible over speed 3600 rpm
Time 2 minute
Power factor 0.8
Excitation voltage 163 V
Excitation current 580 A
Moment of inertia (wr2) 5684 kgm2
STATOR
a) STATOR BODY
27
b) STATOR CORE
The stator has a three phase, double layer short chorded bar
type windings having two parallel paths. Each coil side consists
of glass insulated solid and hollow conductors with cooling
water passing through the latter. The elementary conductors
are transposed in the slot portion of winding to minimize eddy
losses.
An adequate protector is provided to avoid corona and other
surface discharges in the slots the coil sides are firmly held in
position by fibrous slot wedges, which are mechanically strong
and have high dielectric properties.
ROTOR
a) ROTOR BODY
The rotor is of cylindrical type, the shaft and the body being
in one piece and formed from chromium, nickel, molybdenum
and vanadium steel. Prior to machining, a series of
comprehensive ultrasonic examination and other tests are
carried out on rotor body and shaft position to ensure that
there is not any internal defect. The rotor with all the details
assembled is subjected to 20% over speeding for two minutes
ensuring mechanical strength.
28
b) ROTOR WINDINGS
c) ROTOR SHAFT
29
SOLE PLATES
BEARINGS
Two end shield sleeve bearings with forced oil lubrication are
provided. These bearing reduce the friction coming in the way
of rotation of the rotor. The oil is continuously circulated to
dissipate the heat generated due to the working of bearings.
EXCITER
DESCRIPTION
ROTATING ARMATURE
The laminations cut in one piece, insulated after the slots, are
shrunk on arm that has to be keyed on the shaft. The armature
winding is installed in open slots, secured in position and
connected to a rotating bridge rectifier.
STATOR
30
RECTIFIER BRIDGE
The UPS has its own internal voltage and frequency regulator
circuits which ensure that its output is maintained within close
tolerances independent of voltage and frequency variations on
the mains power lines.
31
By rectifying the input A.C. power to D.C. power and then
converting it back to A.C., any electrical noise present on the
input mains supply line is effectively isolated from the UPS
output, therefore the critical load sees only clean power.
Power blackout protection: -
If the mains power fails, the UPS continues to power the critical
load from its battery source, leaving the load immune from
power disturbances.
32
mains power failure, the rectifier becomes inoperative and the
inverter is powered solely from the battery.
Critical load power is maintained under these conditions until
the battery is fully discharged, whereupon the UPS shuts down.
The end of battery discharge is assumed when the battery
voltage falls to 320V DC.
The period for which the load can be maintained following a
mains power failure is known as the system’s ‘Autonomy Time’
and is independent upon both the battery A/Hr capacity and
the applied percentage load.
MAINTAINANCE
BYPASS ISOLATOR MAINTAINANCE BYPASS LINE
º º
UPS
MAINS º STATIC OUTPUT
º º RECTIFIER INVERTER º º º
SUPPLY
SUPPLY INPUT SWITCH OUTPUT
ISOLATOR º ISOLATOR
BATTERY
ISOLATOR
º
BATTERY
33
A second manually controlled, ‘maintenance bypass’ supply
is also incorporated into the UPS design. Its purpose is to
enable the critical load to be powered from the mains (bypass)
supply while the UPS is shut down for maintenance or
troubleshooting.
The two modules can be used in parallel using a common
battery or separate battery for each module. In ammonia plant
the modules are used in parallel using a common battery. This
is shown in figure .
For connecting the two modules in parallel the following
thing should be taken care of:-
Generation
Transmission
Distribution
34
Utilization
GENERATOR
Differential
Over current (inverse, voltage controlled)
Rotor earth fault
Field failure (protection against asynchronous operation)
Stator earth fault
Instantaneous over voltage
Negative phase sequence (Unbalanced loading)
Overload (sustained overloading of machine)
Reverse power (protection against protection)
Under power
POWER TRANSFORMER
Differential
Overload IDMTL
Restricted earth fault (Winding protection)
Backup earth fault
Buchholz
Temperature (oil & Winding)
35
Backup earth fault
Buchholz
Differential
TRANSMISSION LINE
Over current
Phase imbalance
Earth fault
Thermal overload (sustained)
Locked rotor
Under voltage
Fuse
Thermal overload
Thermal overload
Backup protection as M.C.B (miniature circuit breaker)
Fuse protection
36
OUTGOING L.T FEEDERS AT 415V P.C.C (POWER
CONTROL CENTRE)
37
IDMTL Over current with high set instantaneous protection
Differential protection inter tripping
MW LOAD LIMIT
38
The steam dictates the maximum continuous MW ratings
generator capability of the boiler and the horsepower rating of
the turbine, rather than the rating of the generator. The
alternator in theory is capable of generating output of MW’s
that is the same figure as the MVA rating. provided that the
stator current is in phase with the voltage i.e. at unity power
factor.
But generating the true power (MW’s) the alternator has also
to be capable of supplying reactive power (MVAR’s) and
therefore the alternator is designed to operate at a lagging
power factor (typically at 0.85 lag). This mean that when
maximum stator current is flowing the rated MVA output is
being achieved but as the MW output is equal to the MVA * p.f,
then only 85% of the MVA output is MW’s and therefore less
steam and smaller turbines are provided to rotation of the
turbo generator.
39
A reduction in the field current, without any change in
steam entering, will have same result. The breaking of the
magnetic coupling with the subsequent loss of machine
stability cannot normally be altered and therefore the
alternator must be operated with sufficient rotor current to
ensure that the magnetically coupling is enough.
MOTORING ACTION
FREQUENCY VARIATION
OVERLOADING
40
Under abnormal conditions, the generator can be overloaded
for short duration. So the generator must not be made to run
beyond the overloading time limit.
Supply the oil to the generator bearing and shaft seals and
make sure that the quality, temperature and flow are normal.
Fill the generator with inert medium of desired purity and bring
it up to rated pressure.
Set the different pressure and thrust oil regulator to maintain
the desired pressure automatically.
41
Charge the stator winding with distillate of desired quality
and ensure normal pressure, flow and temperature.
Supply to generator air coolers of desired quality and ensure
normal pressure, flow temperature.
The generator circuit breakers should be open.
The generator field breakers should be open.
Select the mode of excitation (auto or manual).
RUNNING UP
2. SWITCHING IN OF EXITATION
SYNCHRONIZATION
42
Effective values of both voltages are same.
Both the voltages are in phase.
Frequencies of both the voltages are same.
LOADING
WINDING TEMPERATURE
BEARING TEMPERATURE
OVERLOAD
43
NEGATIVE SEQUENCE
LOSS OF EXITATION
REVERSE POWER
44
When the input to the turbine is stopped the generator
continuous to rotate as a synchronous motor taking power
from the bus bars. It then rotates as a synchronous motor and
the turbine acts as a load. Power taken by the generator under
such condition is very low being about 2% for the turbo
generator and 10% for the engine driven set.
UNDER POWER
UNDER VOLTAGE
For under voltage we have signal relay only TTG 7123 used
for this purpose with a setting of 0.8Vm. 3 seconds. This relay
is two-phase time-delayed relay. Relay gets supply from
11/1.73KV/110/1.73P.T.
OVER VOLTAGE
UNDER/OVER FREQUENCY
45
aging of insulation. Over frequency cause high speed which is
responsible for over voltage, which will ultimately damage the
machine insulation. We have relay HD4 7020 to check this
situation.
Only turbine will trip by this relay.
Intentional time lag is provided in the reverse power protection
so that the protection does not operate during system
disturbance and power swing WTGA 7131 is active reverse
power relay for 3-wire, 3-phase unbalanced/balanced network.
TRANSFORMER
TECHNICAL DATA:-
LV- 31.5/25MVA
46
Frequency 50 Hz
Rated KV HV – 132KV
LV – 11KV
SV – 11KV
Connections Star/Star/Delta
Rated Amperes HV - 137 94A
LV – 1655.28
SV – 318.18A
Oil temperature rise 500C
Winding temperature rise 550C
(c) CORE
47
special attachment to connect top and bottom end plates for
lifting the core with windings four number of lifting legs are
provided.
(d) WINDINGS
(f) TANK
48
suitable for 5A, 250V AC or D.C. oil alarm temperature is 800C
and tripping temperature is 900C.
49
INCIPIENT FAULTS : - Short circuited core lamination,
broken down core bolt insulation, local overheating of windings
etc.
(i) CONSERVATOR
50
The oil seal ensures that the gel absorbs moisture only
when the transformer is breathing. When the breather is first
installed the crystals have a blue color and after a period of
operation, the color of the crystals gradually changes to pink,
this indicates that the silica gel is becoming saturated and
loosing its absorbent properties when all the silica gel gets pink
color then it should be changed or reactivated. Silica gel can
be reactivated by heating the gel at a temperature of 1500C to
2000C for two or three hours when the crystals should have
regained their original blue color.
NGR
TECHNICAL DATA:-
Resistance 6.35 Ω
Voltage 11/1.73KV
Current 1000A for 15 seconds
Temperature 3000C
51
The transformer is permanently attached to NGR. NGR is
also used for providing CTs for the protection of the
transformers.
Our generators (TG1 and TG2) have NGR of the same rating
because both generators and transformers are at same
potential so we should have one NGR in line at one voltage
level.
LIGHTENING ARRESTERS
ISOLATOR
EARTH SWITCH
52
the isolator. When isolator is in line earth switch cannot take
into the line. Earth switches are connected to the system, only
when isolators are disconnected from the system.
BUCHHOLZ RELAY
CONSTRUCTION
PRINCIPLE OF OPERATION
53
internal fault, the gas generation is rapid, causing the
displaced oil to surge through the relay. This oil flow impinges
on the lower float is thus deflected closing its mercury switch
and completing the trip circuit of the circuit breaker.
54
MAINTAINANCE
BYPASS ISOLATOR MAINTAINANCE BYPASS LINE
º º
STATIC
º º º RECTIFIER INVERTER º º º
INPUT SWITCH OUTPUT
ISOLATOR ISOLATOR
1+1 PARALLEL
CONTROL
º
﴾
º
CONTROL
UPS
OUTPUT
LOGIC
BATTERY º
SUPPY
º
﴾
º COMMON BATTERY
KIT
1+1 PARALLEL
CONTROL
STATIC
º º º RECTIFIER INVERTER º º º
INPUT SWITCH OUTPUT
ISOLATOR ISOLATOR
º º º
BYPASS ISOLATOR STATIC BYPASS LINE
º º
MAINTAINANCE MAINTAINANCE BYPASS LINE
BYPASS ISOLATOR
55
INTRODUCTION
Lightening Arrestors
Lightening Arrestors are the devices that are used to protect
overhead transmission lines.PTs
switchgears.Transformers etc.When they are subjected to over
voltage surges due to lightening caused by atmospheric
disturbances due to unfavourable conditions or by impulse
wave voltages.
NECESSARY REQUIRMENTS
56
CURRENT TRANFORMER
CORE
WINDING
CONSTRUCTION
57
It consists of steel tank, porcelain insulator, steel top
chamber mounted on the top of the insulator. The C.T.
fabricated steel tank on bottom supports the hair pin
condenser primary, which passes through the porcelain
housing, mounted on the top of tank and terminates in top
chamber. The condenser primary posses through the ring type
secondary, which are placed in the tank and suitable clamped
against any movement in transit or use. The secondary
windings are connected to the terminals located in a
weatherproof terminal box on the side of the tank. It is
important that C.T is always kept in vertical position so that
gas forming a cushion at the top remains at top only.
POTENTIAL TRANSFORMER
TANK
Fabricated from mild steel plates. It houses the core and coil
assembly, secondary terminal box form an integral part of
tank. The secondary leads and neutral leads of primary
windings are taken out through LV bushing in secondary
terminal box. Secondary terminal box is fitted with necessary
fuses and link connections required. The neutral lead lf HV
terminals are solidly earthed inside secondary terminal box.
POWER TRANSFORMER
58
In MRS switchyard three power transformers are there
which are used to step down 132 KV to 11 KV so as to
distribute this supply to various plants such as Ammonia, Urea
etc. Two transformers work at a time and the third one is spare
one used in case other one develops a fault.
DISCRIPTION:-
ON- 20,000
Rated voltage at no load HV – 132790V
LV - 11000V
SV – 6600V
Rated current HV LV
OB 115.2
1391.0
ON 87.0
1049.8
Phases 3
3
Frequency 50 Hz
Type of cooling ON/OB
Impedance voltage 10.19%
(20 MVA Base)
Max. Ambient temperature 450C
Top oil temperature rise 450C
Winding temperature rise 550C
Year of manufacture 1976
LIGHTENING TRANSFORMER
DESCRIPTION: -
59
KVA 1,000
Volts at H.V 11,000
No Load L.V 433
Amperes H.V 52.48
L.V 1333
Phases HV LV
3
3
Frequency 50 Hz
Impedance voltage 5.72%
Oil volume 200litres
Wt. of oil 1,044 Kg.
Wt. of core and winding 1,640 Kg.
Total weight 4,300 Kg.
CABLE
HORN GAP
60
i.e. 80% of 650 KV 0520 KV. The distance between path and
insulator should be more than 1/3 of the gap length i.e. b >
1/3. Precise protection is not possible by rod gap. The
advantage of gap is low cost and easy adjustment on site
WORKING OF MRS
61
AMMONIA PLANT
INTRODUCTION
62
Two feeders from MRS incomer A and incomer B feed the
11kV bus at ammonia control panels for 11kV are provided by
L&T. each panel is provided with circuit breaker of 630A,
300MVA which are activated by the relay in case of fault.
Panels 1-5 and 12-17 are fed to 415V panel through
11kV/415V, 2MVA transformer and panels 6 and 11 feed the
3.3kV panel through transformer of rating 11/3.3kV, 10MVA.
Bus coupling is provided between buses A&B from ammonia
there are two feeders to coal handling (1.6MVA), boilers
(2MVA), and D.M plant (2MVA). If one of the feeders fails or
there is any abnormality then the total load is transferred on
the other feeder by using bus coupler. The 11kV supply is then
further stepped down to 3.3kV and 415V using step down
transformers, 3.3kV is used for H.T. motors and 415V is used
for L.T. motors. This plant also has the facility of battery room.
M.M.G SET
Specifications regarding the AC continuous running power
supply equipment that is used in ammonia plant.
1. INDUCTION MOTOR
2. A.C.GENERATOR
63
Output 75KVA/210KVA
Volts 415V
Frequency 50Hz
Speed 1550RPM
Phases 3,4 wire
Current 97.5/292A
Poles 4
Power factor 0.8
3. D.C.MOTOR(DCM)
PRINCIPLE OF OPERATION
STARTING
64
An automatic voltage regulator controls the output voltage
of the ACG, the input for which is obtained from the ACG
output, AVR detects the deviation of ACG voltage from its
setting value and feeds its output to fields. With the making of
the load, since the output of AVR alone is insufficient to lower
generator output in order to compensate, so that always a
stable output is supplied to the load.
65
OPERATION OF BATTERY POWER :
When auxiliary relay is energized. It causes magneto
switch to be actuated. As a result, the DCM goes on operating
on battery power for about 15 min unless operation is stopped
by malfunction.
Shunting off power supply to the charger: when magneto
switch is closed, a signal is sent to the charger, shunting off
power supply to the charger.
Signal transmission: relay contacts in the protection circuit are
connected in parallel and a signal is transmitted to the
instrument panel.
AC POWER SELECTION
PROTECTION
66
(e) ACG voltage abnormal: the abnormal ACG voltage is
decided by A.C. voltage, relays with H-side set to 45605V and
relays on L-side are set to 373.5V and frequency relays set on
45.3Hz on H-side and L-side and timer causes auxiliary to be
energized thereby, shunting off the power supply and giving a
warning signal.
TRANSFORMER
DESCRIPTION :
67
L.V. 1,669
Phase H.V. 3
L.V.
3
Temperature 55°C
Impedance 9.40
Insulation level H.V. 88kV
L.V. 16kV
Quantity of oil 5,000 litres
Weight of oil 4,375 Kg
Weight of core and windings 9,500 Kg
Total weight 21,000 Kg
WORKING PRINCIPLE
DETECTION CIRCUIT
68
However, since this is still insufficient power to control the
device, this output is further amplified with a magnetic
amplifier, thus making a two stage amplifying circuit. This AC
output is converted to DC with a selenium rectifier, the control
field system added & the output differential reduced to zero.
MAIN
REFERNCE AMPLIF SYN C KT SCR CT ACG
VOLTAGE &OSCILL CKT
ER ATOR SCR
OPERATION OF AVR
69
ACG rises, the difference in voltage detected by the detector
appears as a positive signal or negative signal at the terminal
of operational amplifier. As a result terminal of operational
amplifier is negatively charged by this signal causing the
transistor to be turned off and the output potential of the
amplifier rises. As this potential is applied to the sync
generator and oscillator it is applied to the base off transistor
so that its collector current decreases. As a result, the charging
of capacitor is delayed so that the oscillating cycle of UJT is
prolonged, thus delaying the gate signal. In other words the
firing angle of thyristor increases causing a decrease. In the
field current of the ACG & thus a drop in ACG output voltage if
the output voltage of ACG falls the AVR operates in reverse
direction, thus maintaining its rated voltage.
DIESEL GENERATOR
70
silicon’s) and electrical components in the mold package are
mounted at the end of the shaft.
The tacho-generator used fro speed detection is mounted on
the shaft on counter coupling side.
GENERATOR CONSTRUCTION
AVR OPERATION
71
This finally to control the ACG field current to keep the ACG
voltage always constant.
EXCITER CONSTRUCTION
ROTOR RECTIFIERS
STARTING
STOPPING
72
1. When restoring the normal power the power supply in the
emergency panel shall be changed automatically from
emergency to normal power supply.
UREA PLANT
73
Synthesis Section
Decomposition Section
Recovery & Crystallization
Prilling section
SYNTHESIS SECTION
DECOMPOSITION SECTION
RECOVERY SECTION
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residual ammonia passes through purge, ammonia condenser,
vapour ammonia condensed and recycled back to ammonia
reservoir.
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discharged to fluidizing dryer. The separated mother liquid
tank and is pumped back to crystallizer and low-pressure
absorber.
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POWER SUPPLY SYSTEM :
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stepped down to 3.3kV & 415kV through transformers in urea
plant. There are two 11kV/3.3kV 10MVA transformers and four
11kV/415V 1.6MVA transformers. The stepped down voltage
i.e. 3.3kV and 415V is further fed to H.T. and L.T. motors. 3.3kV
motors are directly fed from motor control centre. Further new
buses are made at 415V and hence 415V motors are fed from
power control centre.
SYNCHRONOUS MOTOR
DESCRIPTION
Output 2200kW
Speed 333.3RPM
Poles 18, excited field voltage- 55V
Voltage 11kV, excited field voltage-13A
Power factor 0.8
Current 153A
Motor field volts 220V, motor field current-152A
Armature insulation class Motor-B, exciter-B
Field insulation class Motor-B, exciter-B
Space heater 2.5kW, 240V
Make TOKYO SHIBAURA ELECTRICAL CO
LTD
Purpose For CO2 compressor
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lines of flux in the gap are skewed in such a direction as to
exert a clockwise torque on the rotor. Since the resultant
magnetic flux due to stator current rotates at synchronous
speed, the rotor must also rotate at the same speed. As in case
of induction motor if load is increased, speed slows down but in
case of synchronous motor if there is increased in load then
there is no change in speed. But in case of synchronous motor
if there is increase in load the there is no change in speed. But
in case the RPM decreases, the motor will stop running even a
point difference in RPM causes the motor to stop running.
Varying the field current can control power factor of
synchronous motor.
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SYNCHRONOUS MOTOR SELECTION CRITERIA
REASONS : -
PROTECTION OF MOTORS
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current drawn by the motors while running and isolate the
individual feeder in case the current exceeds the present
values. There is one more relay called 86-P, which must be pf
of your interest. Normally when any HV motor is started, 86-P
relay is to be got reset. This relay monitors various parameters
that are to be fulfilled before the main equipment is started.
These parameters are lube oil pressure, seal oil pressure, value
positions, dampers position etc. in case the requisite
parameters are not fulfilled , the 86-P relay will get reset
hence the equipment cannot be started. For LV motors,
protection is fuses and thermal overload relay fuses & relay are
selected in accordance with size of motor, starting and running
conditions for monitoring of process parameters, one interlock
contact is given in the starting circuit of the motor, which
restricts the starting of the equipment if the parameter is not
met. There are some other interlock also depending upon the
service of equipment such as conveyors etc thermal overload
relay is bimetallic conductor exceeds the limits bimetallic
conductor expands in uneven fashion and actuate the trip
system, tripping the motor. Fuses are provided as back up
protection and for severe faults.
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OFFSITES AND UTILITIES PLANTS
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for raising steam, these salts will form scale on the tubes,
which in addition to heat losses lead to many other many
problems. Hence, removal of these salts from the water
becomes quite essential. Ion exchange resign are used for this
purpose of salt removal.
The de mineralizing water plant of NFL Bathinda was supplied
by M/s ION exchange (India) ltd Delhi.
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Claus gas for 26.5MT/ of sulphur production but due to switch
over to LSHS as ammonia production only 800 to 1000Nm3/hr
of Claus gas is generated and 18-20 TPD sulphur is generated.
Presently Claus gas contains 30-40% of H2S against 47.5% in
original design.
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however, provision is there so that it can take suction from CT-
1
DESIGN BASIC
Barometric pr. = 971 millibars
Dry bulb temp. = 390C
Wet bulb temp = 280C
Degree of approach = 50C
Relative humidity = 81.1% at 31.40C
CORROSION
SCALING
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Scaling is the deposition of sparingly soluble salts. The most
common scalants in cooling water systems are carbonates and
sulphates of calcium and magnesium and phosphates of
calcium, magnesium zinc and iron. The carbonates and
sulphates of calcium have inverse solubility with respect to
temp. And pH when the solubility of these salts exceed, they
tend to precipate out of solution and deposit on metal surface.
Scale inhibitors are used which keep the scaling salts in
dispersed state and do not allow them to deposit.
FOULING
MICROBIOLOGICAL GROWTH
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A.) NITRIFYING BACTERIA: these bacteria oxidize ammonia
to nitrates and nitrites which when dissolved in water reduce
the pH of circulating water and cause general corrosion. It is
the most severe problem at NFL Bathinda.
PERFORMANCE:
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TYPE KIRLOSKAR,
HITACHI
MODEL TC-
BTD-AH
CYLINDER BORE X No.
FIRST STAGE
487mm
SECOND STAGE
267mm
STROKE
200mm
SPEED
590RPM
CAPACITY:
At suction conditions: 1884mc/Hr At
600 RPM
Suction pressure 0.99
Kg/cm Sq
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Steam Generation plant is mainly installed for production
of steam and then distributed to various parts of the plant.
Here this section of plant installed in National Fertilizers
Limited, Bathinda unit produces and supplies steam at 100 Kg /
cm2 pressure and nearly 480°C temperature to Ammonia Plant.
In today’s world steam has gained importance in Industries. It
may be used for power processes and heating purposes as
well.
There are three boilers capable of producing steam at the
rate of 150 Tonnes/hr installed in CPP which were supplied and
erected b BHEL. Generally two boilers are enough to meet the
requirements but third boiler is simultaneously running
because if steam load consumption increases then the third
boiler play its part in order to avoid any faulty condition.
Make SEIMENS
Rating Continuous
Insulation class B
Rated power 160kW
Voltage 415V
Power factor 0.85
Current 258A
RPM 940
Poles 6
Connection Λ
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heaters, delivering them to the stack. Thus the FD fan provides
combustion air for the furnace while the ID fan removes flue
gases from furnace through chimney. The details of the ID fan
are:
Make SEIMENS
Rating Continuous
Insulation class B
Rated power 150kW
Voltage 415V
Power factor 0.83
Current 275A
RPM 770
Poles 8
Connection Λ
Each Boiler of SGP has two Induced draft fan and two
Force draft fan. These boilers are Water Tube Boilers i.e water
is inside the tubes and hot air surrounds it when coal is burnt
,this makes the water in the tubes boil and steam formation
takes place. In the beginning coal is burnt with fuel oil in order
to get desired temperature.
From above study we come to know that ID fans in the
boilers are used to removes flue gases from furnace through
chimney and the FD fan provides combustion air for the
furnace.
In earlier days these ID and FD fans were connected to the
3 phase Squirrel cage Induction Motor through VS coupling (it
is just like a mechanical coupling between fan and motor).
So when we need less air to force to the boiler from the
Forced Draft fan / Induce draft fan we just make this VS
coupling so arranged to our requirement that only that much
air enters to the boiler i.e. VS coupling can be understood as a
dampers which accordingly allows a passage for air to pass as
set.
When we needed less supply of air from these fans to the
boilers, we just close the dampers mechanically to that much
extent that only the required air passes but this mechanical
Damper system was having severe disadvantages :
As the motor connected to the ID /FD fans always was
running on full load but we were not utilizing whole energy of
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motor as when air entering from these fans was less or on full
capacity, then also the motor was running on same load.
So lot of energy was wasted.
To overcome this problem VARIABLE FREQUENCY
DRIVE (VFD)
was installed which not only made the system work efficiently
but saved a lot of Energy.
As by using VFD we just can vary the frequency accordingly
which can be used to vary the speed of the motor connected to
ID/FD fans.
So by reducing the rpm of the motor by varying
frequency ,we was able to take only that much air to the boiler
needed for proper combustion and remove flue gases from the
Boiler.
WHAT IS DRIVE
Example 1:
DRIVE 91
AC supply --------→ --------→ Variable
DC
Voltage - Fixed
Frequency - Fixed
Example 2:
The motor produces torque and this torque makes the motor
shaft to rotate. The motor shaft is coupled to the machine shaft
and therefore the machine shaft also rotates. Through the
coupling mechanical power at the motor shaft gets transferred
to the machine. The motor rotates because of mechanical
energy produced in the motor.
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1. Its Robust nature.
2. Small size and Weight.
3. Negligible maintenance.
4. Low Cost.
WHAT IS AC DRIVE ?
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The speed of the rotor is determined by the “synchronous
speed” of the motor. The synchronous speed is the speed of
the rotating magnetic field produced by current in the motor
winding.
The synchronous speed is determined by the frequency of
supply and the number of poles for which the motor is wound.
WHAT IS SLIP ?
% Slip Ns - Nr / Ns * 100
=
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The percentage slip value depends upon the load on the motor
but one can assume it to be around 4 – 5 % at full load.
Thus there are two ways by which we can vary the speed
electrically.
The first method will provide step less variation whereas the
latter will provide variation in steps.
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DO WE EXPECT ONLY VARIABLE SPEED FROM AN
AC DRIVE ?
E = 4.44 × F × Ø × Z
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