Contents

s no INTRODUCTION Page No

1 Urea plant 2-4

2 STEAM GENERATION PLANT 4-7

3 MECHANICAL WORKSHOP 7-12

4 CONSTRUCTION / FUNCTIONS OF MAJOR 12-13

EQUIPMENTS.

5 MATERIAL OF CONSTRUCTIONS OF MAJOR 13

EQUIPMENTS.

6 DM WATER PLANT. 14

7 PROJECT ON 2ND STAGE CARBAMATE RECYCLE 15-25

PUMP PC-4.

1
NTRODUCTION

National fertilizers ltd. is central government undertaking public sector under mini ratna
category. it produces urea fertilizer under its brand name KISAN UREA. It has four
manufacturing units in Bathinda, panipat , vijaypur and nangal. Its marketing offices are
scattered in all over india. Its corporate office is in NOIDA(U.P).

I completed my industrial training in its nangal unit.

Nangal is situated in Ropar district of Punjab. National fertilizers ltd nangal was initially under

fertilizer corporation of india which lator on was transferred to national fertilizers ltd.

It is now gas based plant which produces urea, nitic acid , ammonium nitrate etc.

Its urea production capacity is 478500 MT per year.

This unit has following plants in it.

1. Ammonia plant
2. Urea plant
3. Bagging plant
4. Ammonium nitrate plant.
5. Steam generation plant
6. Nitric acid plant

Natural gas is received from GAIL and by reforming process ammonia and carbon dioxide are
produced from this gas in ammonia plant.

Ammonia and co2 thus produced in ammonia plant are sent in urea plant where ammonia and
carbon dioxide are reacted at desired pressure and temperature to produce urea.

Urea thus produced is sent to bagging plant via conveyor belts where it is stored in Urea silo
and transported to various parts of country by goods trains and trucks as per demand and
central govt guidelines.

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Steam required for various process and steam turbines is produced in steam generation
plant.steam generation plant has 4 boilers , 3 are coal fired and one is oil fired.

Nitric acid is produced in Nitric Acid plant. In ammonium nitrate plant liquid ammonium nitrate
is produced.

My training was in UREA PLANT and DM WATER PLANT.

1) Process flow diagram of Urea Plant:

a) Basics of Urea Synthesis.

NH3 + CO2 NH2COONH4 (Ammonium Carbamate)

-H2O

NH2CONH2 (Urea)

b) Description of process flow Diagram:

For ammonia synthesis, both ammonia and CO2 are received from Ammonia Plant.

Ammonia received from ammonia plant at 30 Kg/cm2 and CO2 at 0.4 and 11 Kg/cm2.
Both ammonia and CO2 pressurizes up to 220 Kg/cm2 in ammonia pumps and CO2
compressors respectively.
After Pressurization, both are sent to Reactors.
Initial urea synthesis started at this stage (P=220 ata,T=195*C) and Urea Solution generated
containing Urea up to 36%.

After primary stage this Urea Solution passes through three decomposition stages at
different pressure and temperature.
In 1st stage (P=70 ata,T=190*C) 55% Urea decomposes.

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 In 2nd stage (P=12 ata,T=156*C) 66% Urea decomposes. . In 3rd stage (P=3 ata,T=130*C) 73%
Urea decomposes.

In all 3 stages Carbamate formation takes place and it is pumped to old Reactor at 220
Kg/cm2 by carbamate pumps.

After three decomposition stages Urea Solution passes through two vacuum Conc. Stages.

In 1st vacuum Conc. Stage (P=0.35 ata,T=130*C) 92% Urea formation takes place.

In 2nd vacuum Conc. Stage (P=0.04 ata,T=140*C) 99.70% Urea formation takes place.

After that Urea Solution is sent to Prilling Tower where it is poured in Prilling Bucket and
Urea Solution converted into small droplets and these droplets after falling from 80 meter
height converted into solid form .

After that it goes to SILO through Conveyer belts passing through neem coating station.

In SILO it will be stored and as per requirement it will be sent to Bagging Stations for dispatch.

STEAM GENERATION PLANT

INTRODUCTION

The steam generation plant consists of the following sections:

1. Coal yard

2. Coal pulverizing section

3. Burner furnace and fuel section

4. Boiler section

5. Boiler feed water

6. Heaters

7. Ash Collecting Equipments

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COAL YARD

One main constituent of the fuel generation of steam by boiler is coal.

Coal is received from different collieries of BCCL and CCL,it is unloaded either manually
or tippler and stacked in coal yard. The capacity is 3000 ton since coal used is run of
mine,it contains shale, stones, metallic pieces etc. Magnet is used to separate the
metallic pieces while stones are picked manually.Those not picked are rejected by the
mill.
PROCEDURE FOR COAL FEEDING

Coal from the coal yard is shifted to the hopper with help of dozers.from where they are
transmitted to the conveyer belt ET-4 from vibrating feeders 2A and 2B.On the end of
ET-4 there is a magnet which separates the metallic piecesfrom the coal before feeding
it to the crusher the two crushers MC-R and MC-IR which otate at 720 rpm,of ring
granulate type having normal capacity of 120 ton/hr,crushes the raw coal to the size of
less than 25 mm. From crusher coal is ET-5 where two persons are deployed for
manual picking of any metallic pieces or stone in the crushed coal. From ET-5 coal is
transmitted to ET-6 for filling of 6 bunkers for feeding the coal to mills

COAL QUALITY REQUIREMENT

Moisture content-6-10%

Volatile matter-16-20%

Fixed Carbon-39-45%

COAL PULVERIZING SECTION

Coal from the coal yard fed to the six bunkers situated above the feeders.The coal
pulverizing section consists of

1.Feeders

2.Pulverizer

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FEEDER

The crushed coal of size 25 mm is delivered from the bunkers to the feeders.The
feeders feed the coal at initially control rate to mill where it is further pulverized to
required size.

The type of feeder is used in steam generation plant is rotary type,which has the
capacity of 3-17.2 ton/hr.The speed of feeder is maintained at 2.5-15.2 rpm which is
controlled by variator.

WORKING OF FEEDER

A spider extends through a cylinder core which forms the base of feed role.The spider is
keyed to the feed role shafts.The cylinder core is made in two halves and bolted to
opposite side of feeder body.Plates riveted to spider revolve around split stationary
cylindrical core.The coal form each pocket is emptied to into the mill at a rate which
depends upon the speed of the feeders

Hot air is admitted through the cylinder core and dischargrd through a slot in the lower
part of the core.The hot air helps in drying the coal and to keep it from clogging between
the feed roll blades.

To avoid overloading of the mill motor,due to overfeeding ,an interrupting relay is uded
to cut off the coal feed if the ball mill becomes overloaded

PULVERIZER

The bowl mill is used to pulverize the coal and with help of exhauster,it is fed to the
furnace.The raw coal delivered to the mill is free from foreign material and have been
previously crushed to the size 25mm.

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BURNER FURNACE AND FUEL

FUEL

Coal is used as a principal fuel. Light oil is used mainly for igniters, startups and warm
ups. Fuel is used for stabilization and load carrying. Here diesel oil is used as light oil
and LOW SULPHUR HEAVY STOCK(LSHS) is used fuel oil. Light oil is used until the
temperature of burner reaches 400 degree Celcius. Another fuel used is tail gases.
Since tail gases contain appreciable amount of carbon monoxide which can be burned
in proper ignition conditions. The tail gases have non flammable gases such as nitrogen
and water which makes tail gases difficult to ignite.

BURNER ASSEMBLY

The burners are located at the corners of combustion chamber having theirs centre
coaxial with the centre of combustion chamber. Each burner has 5 compartments,
connected with the wind box. Burners compromise of 4 assemblies of compartmented
fuel and air nozzle arranged vertically in an insulated wind box with dampers and fuel
connections.

There are 8 coal nozzles per boiler i.e. 2 per corner having 457mm width. The oil guns
are located in between two coal compartments. The top and the bottom compartment
are leant for air between which are located the two coal compartment and central air
compartment. The two coal nozzles tips are provided with fuel air which flows primary
coal stream. Each oil burner is served by an eddy plate igniter located close to the air
gun at the same elevation.
MECHANICAL WORKSHOP

Mechanical workshop at NFL unit mainly committed to the maintenance and repair
work. Various maintenance jobs are done here as per the job orders given by different
plants of NFL unit. The mechanical department has futher different workshops namely-:

Machine shop

Fabrication shop

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 Machine shop

Machining of a material involves repeated removal of material from the job to give away
the required shape and size.

Machine shop has various machines that are being used for the machining processes of
the jobs from the plant. Some of the machines in the shops are

SLOTTER MACHINE

LATHE MACHINE

GRINDER MACHINE

BORING MACHINE

DRILLING MACHINE

MILLING MACHINE

PLANNER MACHINE

SHAPER MACHINE

LATHE MACHINE

Lathe is a power driven, general purpose machine used for producing mostly cylindrical
jobs or work pieces. As the piece of metal to be machined is rotated on the lathe, a
single point cutting tool is advanced racially in to the workpiece, removing the metal
material in forms of chips. Main difference between lathes where as in the the other
machines cutting tools is moved an the work piece remains stationary.

Types of lathe machines found in the NFL mechanical workshop

Centre lathe or engine lathe It is most important and widely used machine in the lathe
family. its name is derived from the fact that the earlier machine tools were driven by

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separate engines or from the central engine with over head belt and shafts .The
stepped cone pulley or gear head are often used for varying the speed of the lathe
machine

Turret lathe

It is a production machine used to perform a lot of task or operation on a single job with
minimum wastage of time.Indexable square tool is Provided on the cross slide or the
mounting turning and parting of tool. The Turret usually accommodates tools for
different operations like drilling ,counter sinking etc

Capstan lathe

These are similar to turret lathe and incorporate capstan slide which moves on a
clamped in any position.It is the best suited for the large scale production of small parts
because of its light weight and short stroke of capstan slide

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 SLOTTER MACHINE

Slotter machine is also called as vertical shaper machine .the difference being that the
ram is in vertical direction instead of horizontal position. Also the table or bed is
mounted on a heavy base and provided with mechanism that make possible forward
backward and side to side movement .it also has adjusted head mechanism.

Advantages of vertical shaper or slotter machine:-

1. Setting of the job is more convenient because it is easier to see, align, measure,
clamp

2. Press generated by the cutting stroke is better supported by the table bed

3. Circular and hollow jobs can be worked upon

4. Ram of vertical shaper can be adjusted up to 10 degrees.

Main functions of slotting machine :-

Internal key ways

Tapered key ways

Slots

Centric slots

Internal gear

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 SHAPER MACHINE

Shaping machine is generally called as shaper. Shaper is being used for both
production and tool room work. The shaper can machine a flat surface on horizontal,
vertical, angular plane. On this type of machine, many types of work pieces can be
machined depending upon the tools used and the manner of adjusting the various parts
of the machine. Size of the shaper is determined by the largest sized cube that can be
machined on it. Working principal is quick return mechanism and forward stroke is
cutting stroke and backward is idle stroke.

Difference in shaper and lathe machine:-

In shaper straight cutting is done where as in lathe circular cutting is done In shaping
machine the tool moves in reciprocator fashion whereas in the lathe machine the tool
remains stationary and the work piece moves.

Parts of Shaping Machine are:-

BASE: it is the reservoir for supply of oil circulated to the moving parts of machine

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 ARPON: it supports the table

RAM: It is the main moving part of the shaper machine. It holds anddrives the cutting
tool back and forth across the work .

Construction / Functions of major equipments:

a) CO2 Compressors:

Total 2 in numbers.
CA-1 & K-1/N
CA-1 is three stage reciprocating compressor. It takes suction at 11 Kg/cm2 and Discharges
at 220 Kg/cm2.
K-1/N is four stage reciprocating compressor. It takes suction at 0.4 Kg/cm2 and Discharges
at 220 Kg/cm2.

b) Ammonia Pumps:

Total 3 in numbers.
2 in running and 1 in stand by condition.
10 PA-1R,10PA-1A,10PA-1CN
It takes suction at 30 Kg/cm2 and Discharges at 220 Kg/cm2.

c) Carbamate Pump:

Total 4 in numbers.
3 in running and 1 in stand by condition.
10 PA-2R, 10PA-2B,10 PA2A, 10PA-2CN.
It takes suction at 70 Kg/cm2 and Discharges at 220 Kg/cm2.
d) Urea Reactor:
Total 2 in numbers.
Both remains in line.
R1N (Old Reactor) - 14 Trays.
R2N (New Reactor) - 09 Trays.

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Material of Construction of Major Equipments:

a) Carbamate Pump:
Cylinder HVD-1(Duplex Type SS)
Valve Body SS316L/ SS329
Manifold SS 316L
b) Ammonia Pump:
Cylinder CS
Valve body CS
Manifold CS
c) Urea Reactor:
R1N (Old Reactor)
12 mm original Liner SS316L UREA GRADE.
Rest is of CS.
R2N (New Reactor)
8 mm original Liner 25-22-2(2Re69)
Rest is of CS.
d) Carbamate Condenser:
Tube material 2Re69
Plate material also 2Re69
e) Piping Materials:
Ammonia Region Carbon Steel
Carbamate/Urea Region SS316 L

Initially capacity of urea plant was 1000 metric ton per day. In year 2000 it was revamped
by M/S UREA CASALE. Now after revamp its urea production capacity is 1450 metric ton per
day.

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 DM WATER PLANT

Demineralization (DM) is the process of removing mineral salts from water by using the ion
exchange process.

Raw water may contain Cautions and Anions as listed below.

The following ions are widely found in raw waters :

Cations
Anions
Calcium (Ca2+)
Chloride ( Cl-)
Magnesium (Mg2+)
Bicarbonate (HCO3-)
Sodium (Na+)
Nitrate (NO3-)
Potassium (K+) Carbonate (CO32-)

Before taking use of raw water it is necessary to remove suspended particles and ions for long life
and proper effectiveness of equipments.

In DM Water treatment Plant, typical treatment Steps are as...

a) Raw water collection in Sedimentation Tank.

b) Gravel Filters removal of suspended Solids.

c) Caution resin bed SAC (Caution I) & SAC (Caution II) - removal of positive charged ions.

d) Anion resin bed WBA (Anion I) - removal of negative charged ions.

e) Degasser to remove dissolve gases.

f) Anion resin bed SAB (Anion II) - removal of negative charged ions.

g) Mixed resin bed- for polishing effect.

After these steps, high quality DM water produces and it will be stored in Storage Tanks and will
be used in boiler or in cooling purpose as per requirement.

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 Project on 1and Stage carbonates Recycle pump PC-4

A pump is an machine that expends energy to increase the pressure of a fluid (liquid or gas)
and move it from one point to another.

In practice the term pump refers to a machine that pumps liquid .

While a machine that pumps gas is specifically referred to as vacuum pump, compressor,
blower, or fan.

There are various classification of pumps. According to the method energy is imparted to the
liquid: kinetic energy pump, or displacement pump.

1. A centrifugal pump is of kinetic energy type - it imparts energy to a liquid by means of

centrifugal force produced by a rotating impeller.

2. A displacement pump imparts energy by mechanical displacement. Piston, diaphragm,

plunger, screw, vane, and gear pumps are some examples.

PARTS OF CENTRIFUGAL PUMPS

IMPELLER which gives kinetic energy to fluid.

DIFFUSER OR VOLUTE CASING it generates pressure by increasing area based on

Bernaulli principle.

SHAFT it holds all impellers of pump.

GLAND PACKING OR MECHANICAL SEAL- it prevents any possible leakage from

pump.if fluid handled is hazardous then mechanical seal is used,

If fluid handled is non hazardous then gland packing may be used.

BEARINGS it holds the shaft and helps in providing rotory motion .

BEARING HOUSING- Bearings are inside bearing housings which is full of lubricating oil
for providing lubrication to bearings.

COUPLING it helps in connecting the pump with prime mover.

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 BALANCING DISC- Balancing disc helps in balancing the forces so that it runs in balanced
position.

Above shown is the volute casing of a centrifugal pump.

Impeller has a suction eye from where fluid enters. Impeller is mounted on shaft . when pump is
running this impeller rotates at high speed and fluid handled enters inside its suction eye. This rotation
of impellers gives high kinetic energy to this fluid. When this fluid comes out from impeller it enters
inside volute casing or diffuser casing. This casing (either volute or diffuser ) is of continuously
changing area, when fluid passes through this its kinetic energy is converted to pressure energy based
on bernaulli principle.

This is how a pump generates pressure .

Impellers may be of two types either closed impellers or open impellers as shown in following

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 picture.

A complete assembled single stage centrifugal pump is shown below.

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Centrifugal pumps may be divided as follows.

SINGLE STAGE

MULTISTAGE

A centrifugal pump having only one impeller is said to be single stage centrifugal pump.

A centrifugal pump having more than one impeller is said to be multistage centrifugal pump.

PC-4 is 2nd stage carbamate recycle pump in urea plant .

This pump was assembled and replaced. This pump is a multistage pump having 9 impellers
.During maintenance of this pump following steps
were taken..
1. To assemble this pump first a new shaft was taken and it was checked and
Its runout was taken by putting the shaft on two bearings sets at both ends
And by rotating it by hands then reading runout reading in dial gauge which came out to be
below 0.03 mm.

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 2. After checking shaft runout , faces of all impellers and intermediate bushes were checked and
those faces which were not true were machined from mechanical workshop and their trueness
came in the range of 0.03 mm.
3. When all faces became true then assembly of rotor was carried out. Starting from first
impeller every impeller was fitted and intermediate bushes were also fitted and then both sides
mechanical seal sleeves and bearing sleeves were fitted. Following is the impeller of PC-4
pump.

4. Finally nut was tightened and and rotor run out was taken, it came around 0.1mm and then it
was sent to mechanical workshop for balancing of rotor. Following picture shows complete
rotor of pc-4 pump.

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 5. Rotor was balanced on balancing machine in mechanical workshop .
6. When Rotor was balanced after numbering on every impeller and bushings
It was dismantled.
Now assembly of the pump started by holding shaft vertically in first casing
And diffuser on a stand .
7. Second diffuser was put above that and then impeller and total float was taken.
8. Total float came out to be 8 mm.
9. Now next diffuser was fixed and then next impeller , again total float was
Taken and in this way whole pump assembly was carried out by maintaining total float .

where total float became below 8 mm , then wearing rings which lowered this float were machined
accordingly. All PTFE wearing rings were fixed inside metallic wearing rings before fixing diffusers.

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 intermediate steps of assembly of the the pump is shown in following pictures

21
22
 10. When final casing was boxed up, pump was lied down in horizontal position.

Total float was again measured to be 8 mm.

11. Now with the help of balancing disc 50-50 adjustment was carried out.
Rotory part of balancing disc is shown in following picture.

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 12. At last by fixing both bearing housings balancing disc gap was maintained
13. Both sides mechanical seals were fitted.
14. Both sides bearing housings were fitted.
15. This pump was replaced with existing pump, all connecting lines boxed up.
16. Balancing line also boxed up.
17. Alignment carried out.
18. Pump handed over to operation department and they tested its mechanical seals for
confirming that there is no leakage. They tested mechanical seals at 20 kg/cm2 pressure and
there was no leakage from seals.
19. Pump got electrically energized by electrical department.
20. When energized it was taken in line and it was running normal.

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 TECHNICAL OBSERVATIONS:-
SHAFT RUN-OUT:- 0.04 MM
ROTOR ASSEMBLY RUN-OUT:- 0.10 MM
TOTAL FLOAT:-8.00 MM

DISCHARGE FLOAT:- 3. 60 MM
BALANCING DISC GAP:- 0.3 MM

IMPELLER WEARING RING CLEARANCE:- 1) METAL-TO-METAL = 1MM

2) METAL-TO-PTFE= 0.3MM

BUSH TO DIFFUSER CLEARANCE:-1) METAL-TO-METAL= 1MM

2) BUSH-TO-PTFE =0.15
END COVER GAP:- 1.85 MM
BEARING SPACER SIZE:-13.55MM
LABYRINTH BUSH CLEARANCE 0.6 MM

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