Presentation on

Industrial Training

At

Submitted by-

Nikhilesh Joshi

• National Fertilizers Ltd, Vijaipur unit is one of the four units of M/S

National Fertilizers Limited.

• It is a Government of India undertaking.

• The other units are located at Nangal and Bhatinda in Punjab and at

Panipat in Haryana.

• NFL Vijaipur is at 1st place on the basis of Production.

• It is operated with 2 separate units i.e. Line 1 and Line 2.

• The Line 1 plant had gone in Commercial Production on July 1988.

• Line 2 started the Commercial Production on 31st March 1997.

• The total capacity of both lines is Ammonia 3100 ton/day and Urea

6300ton/day.

• Captive Power refers to power generation from a unit

set up by industry for its exclusive consumption.

• Industrial sector is one of the largest consumers of

electrical energy in India.

• Industries are now increasingly relying on their own

generation (captive and cogeneration) rather than on

grid supply.

WHY ON CAPTIVE POWER PLANT???

Non-availability of adequate grid supply

Poor quality and reliability of grid supply

High tariff as a result of heavy cross subsidisation

30% of the total energy requirement of the Indian industry is currently

met through in house power plants

Steam Power

Plant

45%

Diesel Run

Power Plant

40%

Gas/Naptha Run

Power plant

15%

• In NFL, CPP is based on power generation by Gas Turbine

Generators (GTG).

•Gas turbine works on Joule's Cycle or Brayton Cycle.

•There are 3 units of Gas turbine Generators.

•Each unit has the capacity of 17.225 MW.

•The total power consumption of whole plant is 32MW.

• Only 2 GTGs are operated at a time and the 3rd is kept in

stand by.

PLANT POWER REQUIRED

AMMONIA I 1490 -3170 KW

AMMONIA II 1000 – 3500 KW

UREA I 3500 – 4000 KW

UREA II 3500 – 4000 KW

C. P .P 300 – 1250 KW

COOLING TOWER 6500 – 7500 KW

OFF SIDE 1100 – 4500 KW

•Main GT Manufactures are General Electrics, Simons

Westinghouse & Alstom.

•Efficiency approx 40% for gas turbine.(even higher for

cogenerated plant).

•Low Green Gas Emission (C02, NOx & Sox)

•Cheaper comparing to other technology e.g. CCS.

•Lifetime 30-40 years.

• Gas turbine Accessories including Diesel engine, Lubrication

Pump, Coupling.

• Suction air Filters

•17 stage Axial flow Compressor.

•10 Interconnected Combustion chambers with 1 Electric

Igniter.

•2 Stage Radial flow Turbine.

•Reduction gear arrangement with the reduction of 0.60.

• Generators and Exciter.

GENERATOR

WATTS 17.22 MW

VOLT 11.0 K

PF 0.83

Freq 50.0 Hz

HPV NG Supply

14.3 bar

LPV

EXHAUST

539° C

Reduction

Gear

Compressor Turbine

Exciter

Air

6.89 bar

DIESEL ENGINE - 1.A diesel engine to rotate the shaft at1500 rpm for primary start up.2. By the using of clutch the connection of diesel engine and shaft are disconnected.

Compressor- 1.It is a 17 stage compressor which gives pressure ratio of 6.88/1.2. These blades are operated on 56 degrees for GTG I and GTG II. 3 In case of abnormal heating it used to operate up to 85 degrees.

Combustion Chamber- 1.10 Combustion Chambers are fitted

radially outward of the compressor.

2.Theses are equipped with Igniter, Linear and Transition set .

3. The mixing of compressed air and NG takes place in Linear.

4.The Transition set provides the path for air flow.

Turbine- 1. 2 stage turbine is used in GTG.

2. Which rotate at 5100rpm by the action of hot flue gases.

Reduction Gear- 1. It reduces the rpm up to 3100 while

transferring to the generator.

Generator- It is a device to generate the electricity by

converting the mechanical energy into electrical energy.

Exciter- It charges the rotor within the generating

alternator.

LInear

Combustion

Chamber

Transition

Set

Combustor

Linear

Points GTG1 and GTG2 GTG3

Model PG5361P PG5371PA

Compressor 17 Stage 17 Stage

Turbine Alstom TI

Cycle Open/Cogeneration Open/Cogeneration

Fuel Naphtha/NG/Diesel Naphtha/NG/Diesel

Power 17.225 MW 17.225MW

•Heat coming from GTG is used in HRU.

•Heat recovery unit(HRU) is boiler in NFL.

•Boilers are Kawasaki water tube boiler in HRU 1,2 and 3.

•HRU(Boiler) Produces steam by GTG exhaust and

Supplementary firing .

•Supplementary firing is needed for producing steam at

required pressure.

Point of comparison HRU 1 and 2 HRU 3

Steam generated per hour 150 tones 120 tones

Pressure of generated steam 40 atm. (40kg/cm2) 120 atm. (120kg/cm2)

Steam temperature 382ºC 562ºC

Drum pressure 100kg/cm2 130kg/cm2

Type of boiler Water tube Water tube

Superheating Yes up to 382ºC Yes up to 562ºC

Economizer Yes Yes

Power generated 17MW 20MW

Steam drum 50% steam 50%steam

No. of drums 2 2

Maximum rating 180 tones/hr 120 tones/hr

Bypass Stack

NG

Drum

Econ

omiz

er

BFWBurners (6)

(Supplement fire)Screen

SH2SH1

QuenchingSteam

FD Fan

325 deg C

537 degree

115 deg

506d

egTurbine

•Type of boiler=Kawasaki Water tube type(Horizontal).

•Maximum continuous rating=180 ton / hr

•Maximum allowable working pressure=53 kg/cm²

•Steam temp. ( at super heater outlet )=382 ºc

•Feed water temp. ( at Economizer inlet )=115 ºc ( NG as fuel )

•Draft method=forced draft

•Heat source=gas turbine exhaust with supplementary fuel (NG or

Naphtha )

•Heating surface area=economizer : 9563 m², superheater : 600 m²

• Location= outdoor

•Type of boiler-Horizontal, Water tube boiler.

•Maximum continuous rating=120 ton / hr

•Operating pressure-115 kg/cm²

•Steam temp.-525 + or - 5 ºc

•Feed water temp. ( At economizer inlet )=115 ºc ( NG as fuel )

•Draft method=forced draft

•Heat source=gas turbine exhaust with supplementary fuel ( NG or

Naphtha )

•Heating surface area=2005 m².

•Location-Outdoor.

•Water containing dissolved gases causes many corrosion problem.•Dissolved oxygen causes pitting corrosion. •Carbon dioxide corrosion is frequently encountered in condensate system.•Hence deaerator is widely used to remove dissolved gases from water & thereby control corrosion.•Pressure deaeration with steam as the purse gas is used to prepare boiler feed water. Steam is chosen as the purse gas because:1. It is readily available 2. It heats the water & reduces the solubility constant 3. It does not contaminate BFW4. Most of the steam condensed& becomes a part of the deaerated water.

•Pre treatment plant is used for treatment of Raw water before

using in the plant and drinking water.

•Water pre treatment consist of the following-1-Pre chlorinator

2-Aerator

3-Flash mixture

4-Clarifloculator

5-Gravity sand filter

Preclorinator-Chlorine dosing in raw water at the rat of 5-7 ppm

depends on bacterial count of raw water.

Aerator- 1.Air and water are brought into intimate contact.

2.The air and water contact time and the water volume ratio must be

sufficient for adding oxygen and reduce dissolved gases like NH3,

CO2, H2S.

Flash mixer- Helps in the formation of micro flocks and proper

utilization of coagulant and other chemicals dosed at the flash mixer.

Clarifloculator- To remove finally divided and suspended particles

presented in raw water which imparts turbidity of water.

Gravity sand filter- Sand filter essentially consists of rows of earthen

ware pipes having holes at regular intervals to accommodate.

•Balancing of the impeller shaft of pump-oThe pump is used in water treatment plant.

oThe shaft had unbalance at the angle of 130º

oThe material was removed from the rotor and unbalance is reduced to

2 microns.

•2 day’s Preventive Maintenance of Urea Storage Silos-

including Scrapper Machine.oFitting the bucket of conveyor.

oThe drive shaft of the 2 Chain gear box was changed because of

failure.