Beruflich Dokumente
Kultur Dokumente
SBSSTC, Ferozepur
BACHELOR OF TECHNOLOGY
SUBMITTED BY
Rahul Chadha
Roll No. 1250718 (Batch 2012)
AUGUST DECEMBER 2015
Mechanical Engineering
Shaheed Bhagat Singh State Technical Campus
Moga Road, Ferozepur-152004
DECLARATION
This is to certify that the above statement made by the candidate is correct to the best of
my/our knowledge.
The INDUSTRIAL TRAINING Viva-Voce Examination of RAHUL CHADHA has been held on
. . . . . . . . . . . . and accepted.
ABSTRACT
The main idea behind the establishment of NFL, Bathinda is to manufacture and marketing of Urea
and Neem Coated Urea.
For the production it has five sections :
1. Ammonia Plant
2. Urea Plant
3. Captive Power Plant
4. Steam Generation Plant
5. Off-sites and Utilities
Place: Bathinda
Rahul Chadha
iii
AKNOWLEDGEMENT
The industrial training in an industry/project site is an essential part of curriculum for completion
of degree. I am grateful to authorities at National Fertilizer Limited, Bathinda for permitting me
to undergo six month industrial training in their esteemed organization. During this training I have
learnt a lot for which I pay heartiest gratitude to Mr. Kulwant Singh (Sr. Manager of HRD) ,
Mr. Rajesh Maurya (Deputy Manager) and staff member of NFL Bathinda who helped in all
respects in fulfilling my cherished desired of getting a successful industrial training .
Place: Bathinda
Rahul Chadha
iv
CONTENTS
Declaration.......i
Certificate...........ii
Abstract..................iii
Acknowledgements............iv
List of Figures...................vii
List of Tables...........viii
Abbreviations.............ix
Chapter 1: Introduction to organization..........1
1.1 Brief introduction of Organization......1
1.2Salient features of Bathinda Unit.........2
Chapter 2: Production sections...............3
2.1 Ammonia Plant...........3
2.2 Urea Plant................8
2.3 Captive Power Plant.............11
2.4 Steam Generation Plant................17
2.5 Off-sites and Utilities.......20
2.6 Pumps.......22
2.7 Compressor......25
2.8 Maintenance.........28
Chapter 3: Project Review........30
3.1 Objective.......30
3.2 Review..........30
3.3 Observations deduced ..........30
Chapter 4: Project Work.......31
4.1Study of Turbine, Nozzle ,Condenser and Turbo-Generator............31
4.2Study of Feed water heater and Feed water Control station.......35
4.3Study of Boilers.......37
Chapter 5: Results and Discussions......39
5.1 Observations.........39
5.2 Layout of Captive Power Plant and Steam Generation Plant...........40
v
vi
List of figures:
Fig 1.1 Production Performance........................................................................................................2
Fig 2.1 Block diagram of Ammonia Plant..........................................................................................7
Fig 2.2 Block diagram of Urea Synthesis...........................................................................................9
Fig 2.3 Urea Synthesis......................................................................................................................10
Fig 2.4 Water tube Boiler..................................................................................................................13
Fig 2.5. Shows General concept of power generation by Steam turbine..........................................14
Fig. 2.6 Cooling Tower.....................................................................................................................21
Fig 2.7 Rotary Pump.........................................................................................................................22
Fig 2.8 Centrifugal Pump..................................................................................................................23
Fig 2.9 Reciprocating Pump.............................................................................................................24
Fig 2.10 Reciprocating Compressor.................................................................................................26
Fig 2.11 Axial Flow compressor.....................................................................................................27
Fig 4.1 Steam passing through turbine.............................................................................................31
Fig 4.2 Shows steam processed through Turbine to boiler...............................................................32
Fig 4.3 shows 3D view of nozzle partitions and buckets placing.....................................................33
Fig 4.4 Sectional view of condenser.................................................................................................33
Fig 4.5Feed water heater...................................................................................................................35
Fig 4.6 feed water control station layout..........................................................................................36
Fig 4.7 sectional view of boiler........................................................................................................37
Fig. 4.8 Economizer..........................................................................................................................38
Fig. 5.1 Layout of Captive Power Plant and Steam Generation Plant.............................................40
vii
List of tables:
Table 2.1 Shows the sections of Ammonia Plant and its features.....................................................3
Table 2.2 Shows Compressor in Ammonia Plant and its features......................................................4
Table2.3 Showing configurations of turbine.....................................................................................15
Table 4.1 TG operating parameters before and after Overhauling ..................................................34
Table 5.1 Boiler operation requirements...........................................................................................39
Table 5.2 Temperature of steam/water.............................................................................................39
Table 5.3Spray water quantity..........................................................................................................39
viii
ix
Chapter 1
Introduction to organization
1.1 Brief introduction of Organization:
NFL, a Schedule A & a Mini Ratna (Category-1) Company, having its registered office at New
Delhi was incorporated on 23rd August 1974. Its Corporate Office is at NOIDA (U.P). It has an
authorized capital of 1000 crore and a paid up capital of 490.58 crore out of which Government
of Indias share is 90% and 10% is held by financial institutions & others.
NFL has five gas based Urea plants viz Nangal & Bathinda in Punjab, Panipat in Haryana and two
plants at Vijaipur in District Guna, Madhya Pradesh. The above plants at Panipat, Bathinda &
Nangal which were earlier based on fuel oil (LSHS) have recently been converted on Natural Gas,
an eco-friendly fuel. Vijaipur plants of the company were also revamped for energy savings &
capacity enhancement during 2012-13, thus increasing its total annual capacity from 20.66 LMT
from 17.29 LMT, an increase of 20%. The company has a total annual installed capacity of 35.68
LMT and is the 2nd largest producer of Urea in the country with a share of about 16% of total Urea
production in the country. The products being manufactured and sold by NFL under brand name
KISAN' include Urea, Neem Coated Urea, Bio-Fertilizers (solid & liquid). Besides manufacturing
of fertilizers, the company is also producing allied Industrial products like Nitric Acid, Ammonium
Nitrate & Ammonium Nitrite, Sodium Nitrite, Sodium Nitrate etc. The company is also
endeavoring trading of imported fertilizers like DAP, MoP etc. The Company is also in the process
of setting up a Bentonite Sulphur plant at its Panipat Unit to cater the requirement sulphur deficient
soil. NFL has a wide marketing network across major part of India comprising of a Central
Marketing Office at NOIDA, three Zonal Offices at Bhopal, Lucknow & Chandigarh, 12 State
Offices and 38 Area Offices. NFL has been mandated to revive the closed plants of Fertilizer
Corporation of India Limited (FCIL) at Ramagundam in collaboration with M/s EIL and M/s FCIL
by setting up a Urea plant of annual capacity of 12.71 LMT for which a Joint Venture (JV)
Company has been formed as Ramagundam Fertilizers & Chemicals Limited (RFCL). Currently,
various pre-project activities are in full swing.Presently, company has a total manpower of 3843
employees.
511500 MTPA
Capital Investment:
349.41 Crores
Initial
Commencement of
October 1, 1979
Production:
Commencement of
Production on Gas
after Revamp:
1.2 Process
Ammonia:
Urea:
Raw material:
Captive Power
Plant:
2 x 15 M
Chapter 2
Production sections
2.1 Ammonia Plant
The ammonia plant NFL Bathinda is based on partial oxidation of fuel oil. The Ammonia Plant
has the following processing units:Table 2.1 Shows the sections of Ammonia Plant and its features
Sr. No.
Unit/section
Supplier
Features
1.
M/S HITACHI
JAPAN
2.
Gasification
Refractory gasifiers of
series 700.
m/S SHELL
INTERNATIONAL
3.
4.
Recti sol(de-
Selective absorption of
sulphurisation)
M/S LURGI
temperature methanol
Recti
Total rergeneration
sol(decarbonisation)
M/S LURGI
Shaheed Bhagat Singh State Technical Campus, Ferozepur
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5.
CO shift
M/S TECH
6.
Absorption
M/S BORSIG
refrigeration
7.
M/S HITACHI
8.
Ammonia Synthesis
M/S HALDOR
TOPSOE
The compressor of ammonia plant has the following major equipment:Table 2.2 Shows Compressor in Ammonia Plant and its features
Sr. no.
Section
Supplier
Features
1.
Air compressor
1,40,000NM3/hr
capacity 15.45 KW
turbine
2.
Nitrogen compressor
-do-
30,000 NM3/hr
capacity 6.9 MW
turbine6.9
3.
4.
Oxygen compressor
Synthesis compressor
Compressor-DEMAG
Turbine-AEG
6.59 MW turbine
BHEL Hyderabad
1,10,000 NM3/hr
capacity 2.8MW
turbine
Against the rated capacity of 900Te/day , plant has produced a record production of 1011Te and
has been constantly running above 105% for past few years. The harmless gases like CO2 and are
Shaheed Bhagat Singh State Technical Campus, Ferozepur
4
vented through a cold flare outlet of 80m height. The toxic gases are burnt so that there
combustion products are not harmful to the environment.
78.03%
Oxygen
20.93%
Argon
0.93%
Carbon
0.93%
It is provided for getting oxygen and nitrogen required for production of NH3 from air is the first
section from atmosphere and is pre-cooled. Then further cooled in air chiller. Then moisture and
dust etc. are removed by passing through alumunia molecular seves. Final products i.e. N2 and O2
are obtained when air is rectified in the rectifying column. Product O2 is the first compressed and
then led to reactors in shell gasification process. For partial oxidation of food stock for producing
raw gas is separated toH2, H2S and CO2, CO2 is send to the urea plant, H2S is sent to sulphur
recovery plant. On the other hand N2 and H2 are given to N.W.U. in the ratio of 1:3 to get pure
synthesis gas to manufacture NH3.
iii) De-Sulphurisation:
Sulphur compound are removed in this section because otherwise these poison the catalyst present
in the next section. Methanol has a property of absorbing different gases at different temp.
Absorption process is carried out at low temp. and high pressure, H2O and COS are removed in the
raw gas to only 0.1 PPM in this unit by absorbing with MeOH. MeOH is regenerated by N2 by
stripping and H2S is sent to sulphur recovery plant.
iv) Shift Converter:
In this unit get CO2 and H2 from CO and steam at high temp. by passing the gas catalyst as per the
following reaction:
CO(g) +H2O(steam) ......... H2 + CO2
In this industrial method of producing H2 as per le chatlier principle for high concentration of
product excess is to be introduced and temp. should kept low and reaction rate is high. So
compromise is made and temp. is around 350-500 oC. Fe is used as catalyst in reaction.
v) CO2 Removal:
In this unit we get a mixture of gas(H2, CO2) from shift conversion and CO2 is removed from H2
by absorbing CO2 with methanol of low temp. This mixture of MeOH and CO2 is stripped by N2
where CO2 is regenerated and send to UREA PLANT, in this unit we get 98% of H2 and send to
N.W.U.
4:1
H2O :CO2
0.54:1
%Conversion
70%
250 kg/cm2
Carbonate
250 kg/cm2
Ammonia
250 kg/cm2
Temperature:
2000 C
Color: white
Carbon dioxide from battery limit at 1.02 Kg/cm2 is compressed to 30 Kg/cm2 in a 3-stage
centrifugal booster compressor which runs at 4730 kw and 7930 rpm. After first stage of
compression the compressed air goes to the intercooler and then to heat exchanger and comes back
for the second stage compression then again to the intercooler and then again to the heat
exchanger. The lubrication is provided by mobile oil.The compressed air at 30 Kg/cm2 is sent to
the 2-stage reciprocating kobe compressor in which air is firstly compressed to 90 Kg/cm2 to 250
Kg/cm2. Stage 1 consists of two cylinders and stage 2 consists of one cylinder. Now this
compressed carbon dioxide is sent for reactor.
Ammonia from battery limit is send for reciprocating pump which are 4 in number (4th being stand
by) to be compressed. Large pumping action of pumps is achieved by 400 Kw,3300V Electric
motor. The turbulent liquid is stabilized in spherical shaped resonator. now compressed NH3 is
sent to the reactor at around 200 Kg/cm2.
2.3.5 Boiler:
The basic principle of this boiler is the same as discussed earlier for SGP boiler that is formation of
steam by heating boiler feed water inside furnace fired by coal and heavy oil, utilization of heat of
the gases and venting these gases at a safe height. Main differences between the two boilers are:
SGP boiler is tangentially fired where as CPP boiler is front fired with 6 coal burners and 6 oil gun
fixed inside the coal housing. SGP boiler can be loaded up to 30% load with oil firing only
whereas CPP boiler can be fully loaded with oil alone. Height of combustible zone in CPP boiler is
more and it has residence time of 1.5 sec where SGP boiler has 1.0 sec.Mills used for
pulverizations of coal in SGP are negative pressure bowl mills whereas in CPP ball tube mill are
used which are positive pressure mills. Due to more residence time and better pulverization the
efficiency of CPP boiler is about 4%
be fully generated in CPP itself. A part of the steam generated is exported for process use in
ammonia plant and rest is utilized for power generation in turbo generators as described below:
Shaheed Bhagat Singh State Technical Campus, Ferozepur
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2, 30,000kg/hr
124 kg/cm2G
4950C
Heating surface
1250M2
step up the voltage level to 132KV. From the transformers the three phases pass through the
lightning arrestors (LA). After this, they pass on to the isolator. After this the two lines pass on to
the TRANSMISSION pole called DOUBLE CIRCUIT TRANSMISSION. Then these lines go to
the M.R.S. i.e. main receiving station.
2.3.9 Turbine:
M/S SGP of AUSTRIA supplies the turbine used. It is condensing cum extraction turbine designed
as single casing reaction turbine with single control stage and high pressure (HP), mild pressure
(MP) and low-pressure (LP) reaction parts.
The turbine is fed with high-pressure steam at 100kg from boiler and flows through various control
valves for normal and emergency operation. It gets high velocity through the nozzle group and
then passes over the impellers fixed on to the rotor and fixed diffusers thus rotating the turbine.
The enthalpy of steam is utilized in steps. Steam is also extracted from various stages. HP 1 at
10.4kg/cm2, HP2 at 8.1kg/cm2, feed water bleed at 4.3kg/cm2 and LP bleed at 0.9kg/cm2.The
exhaust steam from the turbine is condensed in a condenser maintained under vacuum to extract
maximum steam enthalpy.
The output of the turbine depends on flow of 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.The exhaust steam is condensed
in a condenser using cooling water.
The resulting condensate can be fed back to LP heater but is normally sent to the polishing water
plant. As shall be clear from the attached block diagram various bleeds from the turbine are
utilized for heating purpose. HP1 and HP2 are used for heating boiler feed water in HP1 and HP2
heaters. Feed water bleeds is used for heating the feed water tank and LP bleed is used for heating
the polish water make up to the feed water tank.
A lubrication system is also there to lubricate the various bearings of the turbine, gears and
generator. Normally the oil pump driven by the turbine shaft supplies oil but auxiliary motor
driven pumps are used for start up and during shutdown.
A turning gear has been provided for slow cooling of turbine rotor. Latest instrumentation has been
used in this plant. Baileys net work-90 microprocessor based instrumentation system is being
used.
The NETWORK 90 SYSTEM is a distributed process control system. Using a series of integrated
control nodes.
The network 90 system allows controlling process variables like flow, pressure and temperature
according to a control configuration.
There is operator interface unit (OIU) like a TV screen on which various parameters can be
displayed and controlled. It allows fully automatic start-up/shut-down of boiler, turbine and other
auxiliaries.
2.3.10 Description of Turbine:A simple tabular data shows the description and configurations of turbine currently operated in the
plant:
Table2.3 Showing configurationof turbine
Make
Type
Capacity
65 T/H at 15 MW
RPM
6789 at 50 Hz
Critical speed
3200-3600 RPM
2.3.11 Genrator:
CPP is having two number turbo generators of capacity 15MW each. The generators are type SAT
three phase, 50Hz, 11kV, 984amps, at 0.8 power factor rating supplied by M/S JEUMONT
SCHNEIDER OF FRANCE. These are totally enclosed self ventilated type with two lateral airs to
water coolers for cooling. The alternators are able to bear 10% overload for one hr with an increase
in temp. of 100C while maintaining the voltage as near as possible to the rated one. The excitation
is compound and brush less with exciter rotor and Rectifier Bridge mounted on the extended main
shaft on non driving end. The excitation is controlled automatically with automatic voltage
regulator and a PLC controller. All protection relays installed for protection of generator are solid
state having high accuracy, quick response and low power consumption. Under normal running
conditions of the plant and healthiness of the PSEB grid, we generally run in synchronism with the
grid merely drawing the power corresponding to minimum charges to be paid to state electricity
board. In case of any disturbance in the grid measured by higher low frequency, high rate of
change of frequency, low voltage etc. our system gets isolated from the grid automatically. With
both generators running, we are able to feed power to the whole plant, thus production is not
affected.
2.3.12 Uninterrupted Power Supply: The uninterruptible power supply system is connected between a critical load, such as digital
drives & automation, distributed digital process control system, telecom equipment, programmable
logic controller, mission critical applications, computer and its three phase mains power supply
under all rated load and input supply conditions.
The system offers the user with the following advantages: i) Increased power supply: ii) 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.
i) 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.
ii) Oil :
As the Boilers are designed to work on both Coal as well as Fuel Oil so fuel oil can also be
pumped to Boiler for combustion.
Generally coal alone is not burnt Initially but Fuel Oil (LSHS) is mixed coal and then sent to the
furnace for combustion in order to get desired temperature .
2.6 Pumps:
Mechanical equipments used to propel liquid under pressure from one location to another through
piping. It basically increases the liquid pressure as the liquid circulates through the pump.
i) Rotary Pumps:
Rotary pumps are used for moving extremely heavy or viscous commodities such as grease,
asphalt, heavy fuel oils and sometimes heavy crude oils. There are three main types of rotary
pumps: gears, cams and screw
2.7 Compressor:
Compressors, in simple words, can be described as a mechanical devices used to increase the
pressure of air or gas. Compressors provide sufficient pressure for gases and vapors. In most
piping installations, compressors are used primarily for the creation of highly pressurized air for
different parts of the plant, such as utility air, pneumatic valves. Compressors can develop pressure
as high as 20,000 psig.
There is a wide range of compressors ranging from reciprocating to rotary. Filters, separators,
receivers, silencers and coolers are pieces of equipment that make up a whole compressor unit. The
compressor units are elevated above the grade level and are provided with an enclosed are to keep
the unit dry.
Two major problems associated with compressor units are :
unwanted foreign material in the system and liquid retention. Both can cause serious damage to
the unit.
Sufficient room around the compressor unit must be provided for maintenance and operation,
including access to valving and piping.
2.8 Maintenance:
2.8.1 Maintenance Objective:
1. To achieve minimum breakdown and to keep the plant in good working condition at lowest
possible cost.
2. Machines and other facilities should be kept in such a condition which permits them to be used
at their optimum capacity without any interruption or hindrance.
3. Availability of the machines, building and services required by other sections of the factory for
the performance of their functions at optimum return on investment be in material, machinery or
personnel.
ii) Engineering:
It involves alterations an improvements in existing equipments to minimize breakdowns. It also
includes inventorying outside technical assistance.
iii) Repair:
It includes carrying out corrective repairs to alleviate unsatisfactory conditions. Such a repair is
usually of emergency nature.
iv) Overhaul:
It includes planned , scheduled reconditioning of plant facilities such as machinery etc. It also
involves replacement, reconditioning, reassembly, etc.
Shaheed Bhagat Singh State Technical Campus, Ferozepur
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Emergency: Necessary to stop serious loss or violation, automatic approval, start within 24
hr., schedule or unscheduled.
Urgent: Necessary to ensure production reliability and/or prevent quality loss, approval
required, schedule for specific date within 3 days.
Future: Work not covered by others priorities, approval required, scheduled, starts within 30
days.
Shutdown: Work that can be postponed or can be completed when a unit is shut down,
approval required, scheduled during shutdown. Unscheduled equipment breakdowns, requiring
corrective maintenance, occur in all plants an usually warrant an emergency or urgent
priority.
Chapter 3
Project Review
3.1 Objective:
To study the process of steam generation in Steam Plant and Captive Power Plant.
3.2 Review:
In Steam Generation Plant we study the various phases through which steam is generated to
produce electricity for NFL Plant. We study these under the guidance of Mr. Rajesh Maurya
(Deputy Manager) and Mr. Devinder Kumar (S.O. SG) who clear the path to understand the whole
production system. The study of these plant includes:
Study of H.P heater, L.P heater and Feed water Control station
Study of Boilers
Chapter 4
Project work
4.1 Study of Turbine, Nozzle, Condenser and Turbo-Generator:
Here is the description of the Turbines , nozzle and generator which are currently operated in
NFL, Bathinda unit.
At this point the pressure is decreasing as the steam is redirected through the nozzles. The
expanding steam continues to flow through the rows of nozzles and buckets, each time striking the
buckets which causes the main shaft to rotate and produce power. By the time the steam is ready to
leave the turbine, almost all of its usable energy has been removed. The pressure drops from inlet
to exhaust can range from 300 PSI to over 3000 PSI and can vary considerably dependent upon the
turbine and boiler design.
For base loads diesel generators are usually preferred, since they offer better fuel efficiency,
but on the other hand diesel generators have a lower power density and hence, require more
space.
The efficiency of larger gas turbine plants can be enhanced by using a combined cycle, where
the hot exhaust gases are used to generate steam which drives another turbo generator.
Table 4.1 TG operating parameters before and after Overhauling
Sr.No.
Parameters
Date
(Before O/H)
(After O/H)
Turbine Load
MW
8.0
8.0
Steam Consm.
Te/Hr
42
37.0
Steam Cons.
Te/MWh
5.25
4.63
W.C.Press.
Kg/Cm2
24.8
28.36
Temp.
Deg.C
404
405
HP-2 press
Kg/Cm2
11.6
10.9
Temp.
Deg.C
345
339
HP-1 press.
Kg/Cm2
NA
NA
Temp
Deg.C
NA
NA
LP bleed Pr./
Kg/Cm2
0.11
-0.03
Temp.
Deg.C
212
Kg/Cm2
*281 (not
correct)
3.95
Temp
Deg.C
271
261.8
Exhaust Press.
Kg/Cm2
-0.91
-0.94
Temp.
Deg.C
47
41.36
Axial thrust
MM
0.15/0.13
0.17/0.18
10
3.1
4.2 Study of Feed water heaters and Feed water Control station:
This section includes the whole feed water system comprising of feed water heater and feed water
control station.
Drum level
In order to handle the situation, the steam flow rate should also be considered for drum level
control. It can be done by adding the steam flow rate as a feed forward signal to the output of the
level controller. Hence, the supply of the feed water flow is compensated for changes in the steam
flow rate demand. With this strategy as the steam flow rate changes the demand for the feed water
flow rate also changes in the right direction and minimizes the effect of shrink and swell on the
drum level.
4.3 Boiler:
The NFL, Bathinda Plant uses water tube boiler for steam generation.
Steam generation steps in boiler:
i) The steam flow in the boiler begins when water enters thedrum from the economizer then travels
to the furnace where it is heated.
ii) A water-steam mixture is generated in the furnace water wall tubes and returns to the drum
through a series of headers and connecting pipes.
iii) Steam leaving the steam drum then passes through a bank of tubes known as the superheater
where the steam is heated further.
iv) The steam is then sent to the high-pressure turbine section.
i) Superheater:
A superheater is a device used to convert saturated steam or wet steam into dry steam used in
steam engines or in processes, such as steam reforming. There are three types of superheaters
namely: radiant, convection, and separately fired. A superheater can vary in size from a few tens of
feet to several hundred feet (a few metres to some hundred metres).
ii) Air-Preheater:
An air preheater (APH) is a general term used to describe any device designed to heat air before
another process with the primary objective of increasing the thermal efficiency of the process.
They may be used alone or to replace a recuperative heat system or to replace a steam coil.
iii) Reheater:
They are the same as the super-heaters but as their exit temperature is a little bite less than superheaters and their pressure is 20%-25% less than the super-heater, they can stand less quality
material alloys.
iv) Economizer:
An economizer serves a similar purpose to a feedwater heater, but is technically different. Instead
of using actual cycle steam for heating, it uses the lowest-temperature flue gas from the furnace
(and therefore does not apply to nuclear plants) to heat the water before it enters the boiler proper.
This allows for the heat transfer between the furnace and the feedwater to occur across a smaller
average temperature gradient (for the steam generator as a whole). System efficiency is therefore
further increased when viewed with respect to actual energy content of the fuel.
Chapter 5
Results and Discussions
5.1 Observations:
During the study of Captive Power Plant and Steam Generation Plant under which the various
operating components are bounded to be kept in the maximum and minimum range so as the plant
should work under optimum conditions. Here is the list of observation found during the working
condition of plant are as follows:
Table 5.1 Boiler operation requirements
Sr. no.
1
2
3
4
5
6
Operations
Observations
230 T/hr
124 Kg/cm2
115.5 Kg/cm2
10.5 Kg/cm2
105 Kg/cm2
3.2 Kg/cm2
Evaporation capacity
Design Pressure Drum
Operating Pressure Drum
Superheater system pressure drop
Operating Pressure Superheater
Economizer Pressure drop
Table 5.2 Temperature of steam/water
Sr. no.
1
2
3
4
5
6
C
8
9
Operation
Drum operation
Entering low temperature superheater
Leaving low temperature superheater
Entering L.T.H.S after de-superheating
Leaving L.T.H.S temperature
Entering high temperature superheater
Leaving high temperature superheater
Entering economizer water
Leaving economizer
Observations
322oC
322oC
383oC
347oC
435oC
414oC
495oC
200oC
259oC
Sr. no.
1
2
Operation
First spray water quantity between L.T.H.S & I.T.H.S
Second spray water quantity between I.T.H.S & H.T.H.S
Observations
14.5 Ton/hr
6.60 Ton/hr
Fig. 5.1 Layout of Captive Power Plant and Steam Generation Plant
Chapter 6
Cautions during Problems
This chapter includes the measure and list of procedure to be followed to prevent accident and
component losses. Here is the list of five main and common problems may occur during the
general working of the plant.The set of procedure for :
Chapter 7
Conclusion
The introduction of the system of a job training in industries added new dimension to the technical
education in the state of Punjab . Such a practical training not only focuses visions of the students
but also helps us to encounter heavy machinery and study its working . This goes a long way to
understand the engineering theory more vividly and grasp it easily. Efforts have been made to
study National Fertilizers Limited, Bathinda Unit. in systematic and proper way under the valuable
guidance of Mr. Rajesh Maurya(DM) and expressed this in the report little bit I have understood.
Working in an industry is quite different from college study. There is no prescribed book or
syllabus and whatever is to be learnt has to be from hands on experience on the job. I feel that
objectives of training are fully achieved and I have learnt a lot about functioning of an industry.
BIBILIOGRAPHY:
1. Official Website of NATIONAL FERTILIZERS LIMITED www.nationalfertilizers.com
2. Official Websites of the TOYO Engineering which Started up NFL plant- www.toyoindia.com
3. Official Website of the HALDOR TOPSOE India Pvt. Ltd. www.topsoe.com
4. My Mentor at NFL plant Mr. Rajesh Maurya & Mr. Kulwant Singh