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N RUSTAGI
BOILER O & M PRACTICES
AT
TATA CHEMICALS , BABRALA
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Presentation Structure
1. Tata Chemicals,Babrala
- Introduction- Production acilities.
- Po!er and steam net!or"- #ilestones achie$ed
%& '(erational Practices
)& #aintenance Practices
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Introduction
• Tata Chemicals *td. ounded in 1+)+.
• Com(rises o t!o di$isions
- Chemical i$ision located at #itha(ur, Guarat.
- ertili/er i$ision located at Babrala, U.P.
• ertili/er Com(le0 commissioned in ec. 1++ and com(rises o
- Ammonia Plant based on lo! ener23 (rocess o 4aldor To(soe, enmar". - Urea Plant based on Snam(ro2etti, Ital3, technolo23.
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- Related acilities o 'sites 5 Utilities consistin2Ca(ti$e Po!er 5 Steam Generation Plant,
Coolin2 To!ers, # 6ater Plant, AmmoniaStora2e, Na(htha Stora2e, 7luent TreatmentPlant etc..
• ertili/er Com(le0 at Babrala is one o the si0 inland located com(le0es based on a cross-countr3 4B8 94a/ira-Bia(ur-8a2dish(ur: natural
2as (i(eline.
Introduction
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Pri/es ba22ed in %;;%
1.National 7ner23 Conser$ation A!ard - %;;% irstPri/e,instituted b3 the Bureau o 7ner237icienc3, #inistr3 o Po!er, G'I.
%.AI runner-u( a!ard or
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Pri/es ba22ed in %;;%
.7n$ironment, A2riculture and Rural e$elo(mentA!ard - %;;% 9rom the Indian #erchants<Chamber:.
=. -STAR Ratin2 or saet3 b3 the British Saet3 Council-U.>.
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Production acilities
Ammonia
Power & Steam Cooling Towers
BaggingUrea
Instrument Air De-mineralisation
Ammonia Storage
NH3
CO2
Dispat!
H"#roar$ons
Inert %as
Urea
Bagge#
Urea
B" oa#
B" ail
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Po!er 5 Steam Net!or"
• ertili/er Com(le0 has an inte2rated ener23 net !or". • All the (o!er consumed in the com(le0 is 2eneratedinternall3 in the com(le0 in Gas Turbine Generators.
• 6e ha$e t!o 1+.= #6 2as turbines or ull reliabilit3 on the (o!er ront !ithout ha$in2 UPS7B 2ridconnection..
• The !aste heat rom GTGs e0haust 2as is utili/ed
or 2eneratin2 steam in 4RUs. 4RUs are (ro$ided!ith su((lementar3 irin2.
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Po!er 5 Steam Net!or"
• All the su(erheated steam consumed in the com(le0is 2enerated in Ser$ice Boiler, 4eat Reco$er3 Unitso GTGs and 6aste 4eat Boilers o Ammonia Plant.
• The entire amount o # 6ater used in the com(le0
is (reheated in the Ammonia Plant and su((lied todeaerators o Ammonia Plant and Ca(ti$e Po!er 5
Steam Generation Plant.
• The total (o!er and steam 2eneration in CPSGP are
a((ro0. 1+ #6 and 1); TP4 res(ecti$el3.
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Po!er 5 Steam Net!or"
Ser'ie Boiler %T% - ( HU - 2 HU - ( %T% - 2
Power )or elet #ri'es((( ata* +(,, C steam
H"#roar$ons
aste Heat Boilers Super !eaters
Ammonia Plant
HP Steam to tur$ines
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Po!er 5 Steam Net!or"
Ser'ie Boiler
an# HU-(.2
aste Heat
Boilers
D/ ater Pre-
Heaters
Deaerator in
Ammonia Plant
Deaerator in
CPS%P
Col# D/
ater
Hot D/
ater
B0
Ammonia Plant
B0 Pre-
Heaters
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Ser$ice Boiler &
• #A>7
• ST7A# PR7SSUR7
• ST7A# T7#P.
• ST7A# CAPACIT?
• T'TA* 47ATING AR7A
• IBR N'.
• RU# PS@ S7T PR7SS.• >S 47A7R PS@
• Therma0 Babcoc" 5 6ilco0 *td.
• 11= >2cm
• =%;C
• 11; #T4r #CR
• %D+D #
• UP =;+
• 1)1 9S: 5 1)%9N: >2cm• 1%% >2cm
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Ser$ice Boiler &
Area %)% #
Area %=E.= #
Area D.= #
Area %E1%#
Area DF#
Air Preheater
Su(er heater- %
7conomiser - 1
Su(er heater- 1
7conomiser - %
Su(er heater- )
Area %;%% #
Ser$ice Boiler lo! ,ia2ram
7$a(orator or
urnace !ater
Steam
,rum
,esu(er4eater-1
,esu(er
4eater-%
eed
ater
>S Steam
To
Chimin3
Na(htha
NG
, an
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Gas Turbine&
GTG1 GTG%
• #a"e & Thomassen International B$.
• #odel & PG=)E1PA
• Base 'ut(ut 9Natural Gas: & 1+==; >6
• Base 'ut(ut 9istillate: & 1+1+; >6
• Commissionin2 ate & eb1++ A(r1++• Control S3stem & #>-I@ #>-I@
• ired Time 94rs: & E;DF1.= =EFF)
• ired Starts & %%1 1+D
1 ri$en 7Hui(ment #odel & Generator ABB, S!eden
1 Accessor3 Gear #odel Sl.No & lender AA =1CA
1 *oad Gear Bo0 #odelSl.No. & #aa2 G- F; RU
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Po!er 5 Steam Net!or" 9GTG4RU:
T
47AT
R7C'-
@7R?
UNIT
94RU:
IN*7T AIR
I*T7R
AIR
C
AIR
C'#PR7SS'R TURBIN7
G7N7RAT'R
C.C.
*'A G7AR
C'#BUSTI'N
C4A#B7R
U7*
9NG4SNAP.:
>S ST7A#
77 6AT7RSTAG7-%
STAG7-1
I7S7*
7NGIN7
'R INITIA*
START
G
9AUJ.IRING:
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4eat Reco$er3 Unit 94RU:&
• #A>7
• ST7A# PR7SSUR7
• ST7A# T7#P.
• ST7A# CAPACIT?
• T'TA* 47ATING AR7A• IBR N'.
4RU-1
4RU-%
• RU# PS@ S7T PR7SS.
• >S 47A7R PS@
• *5T
• 11= >2cm
• =%;C
• +F.= #T4r
• )+11#
. UP-=1;;
. UP-=1+%
• 1); 9S: 5 1)19N: >2cm
• 1%% >2cm
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Po!er 5 Steam Net!or" 94RU:
FEED WATER
520°C
SUPERHEATER - 1
EVAPORATOR - 1
EVAPORATOR - 2
ECONOMISER - 1
GT 7J4AUST
STAG7-1 BURN7RS
STAG7- %
BURN7RS
SUPERHEATER - 2
ECONOMISER - 2
ECONOMISER - 3
RCP
BLOW
DOWN
EXHAUST
510°C652°C
510°C
350°
C
145°C121°C
320!°C DRUM
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%;;;-;1 %;;1-;% %;;%-;)
Co-2en. 7icienc3 o GTG4RU, K E+.E F+.) +1.+
Ser$ice Boiler 7icienc3, K +.%+ +.% +=.==
F%.EE +;.F; +%.+='$erall 7icienc3 o CPSGP, K
#ilestones Achie$ed
GTG 7icienc3, K %1.) %.)1 %=.%D
- 4eat Reco$er3 Unit ;.))D ;.)%E ;.)))
- Ser$ice Boiler ;.E)= ;.E) ;.E%=
S(eciic 7ner23 Cons., Gcal#T
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'(erational Perormance & %;;; to %;;)
• INCR7AS7 'P7RATI'NA* R7*IABI*IT? B?INC'RP'RATING #'II7 %) TRIP *'GIC 'R TRIPR7*AT7 PARA#7T7R ' S7R@IC7 B'I*7R, 4RUs ANGTGs.
• 'P7RATI'N ' S7R@IC7 B'I*7R AT %= TP4 *'A 6IT4
T6' BURN7RS IN 'P7RATI'N.• *'AING ' S7R@IC7 B'I*7R IN CAS7 ' 7#7RG7NC?
B? AUT' IGNITI'N ' )rd 5 th BURN7RS.
• 'P7RATI'N ' 4RU 6IT4 NG IN 1st STAG7 5 NAP4T4A IN%nd STAG7 AS U7*.
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'(erational Perormance & %;;; to %;;)
•
CRITICA* ACTI@ITI7S *I>7 START UP, S4UT '6N,C4ANG7'@7R ' I*T7RS, 6AT7R 6AS4, U7* C4ANG7
'@7R IN S7R@IC7 B'I*7R, 77 PU#P C4ANG7 '@7R
7TC. 6IT4 C47C>*IST.
• 'N7 GTG IS IN 'P7RATI'N 6IT4'UT AN? 7JT7RNA* GRI
SUPP'RT.
• 'P7RATI'N ' GTG AT @ARIAB*7 C'NTR'* ' IG@ AS
P7R *'A.
• 'P7RATI'N ' GTG 6IT4 7@AP'RATI@7 C''*INGURING SU##7R 5 PR7 47AT7R URING 6INT7R
S7AS'N.
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'(erational Perormance &%;;; to %;;) E"#$%& C'"(#$)*+,'" - I",+,*+,)#( T*#".
Ser$ice Boiler o(eration !ith to( t!o Burners on NG uel or
na(htha uel !ith ast *oadin2 acilit3 in case o 7mer2enc3
b3 auto i2nition o )rd 5 th burners.
- Achie$ed ma0imum ca(acit3 utili/ation o 4RU b3
o(eratin2 Ser$ice Boiler on minimum load o %= TP4.
- Achie$ed o$erall sa$in2 o 1%= N#)4R in 4RU and
Ser$ice Boiler.
- '032en anal3/er relocated rom Air Pre-4eater outlet to its
inlet or eecti$e monitorin2 o e0cess air.
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'(erational Perormance &%;;; to %;;) E"#$%& C'"(#$)*+,'" - I",+,*+,)#( T*#".
4RU dual uel o(eration i.e. 1st Sta2e burner on NG uel !hile
%nd Sta2e on na(htha uel &
- 4el(ed in o(timi/ed use o Natural Gas a$ailable rom GAI*.
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'(erational Perormance &%;;; to %;;) E"#$%& C'"(#$)*+,'" - I",+,*+,)#( T*#".
'(eration o #otor ri$en Boiler eed 6ater Pum( in (lace o
Turbo ri$en Pum( &
- Achie$ed the reduction in S(eciic 7ner23 consum(tion o
Urea b3 use o (o!er in (lace o steam.
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'(erational Perormance &%;;; to %;;) E"#$%& C'"(#$)*+,'" - I",+,*+,)#( T*#".
7ner23 Conser$ation due to sto((in2 o one GTG
97ner23 sa$in2 o 1EE=1D Gcalannum :
• %) lo2ics !ere incor(orated in GTG4RSG or o(erational
reliabilit3.
• To!nshi( and *i2htnin2 load decreased b3 $arious
initiati$es.
• 4o!den 9lash Ammonia: Com(ressor reHuent startu(
a$oided.
• ACT (um( 9one number: sto((ed.
• 'ne G@ (um( sto((ed.
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'(erational Perormance &%;;; to %;;) E"#$%& C'"(#$)*+,'" - I",+,*+,)#( T*#".
GTG IGV kept ON AUTO MODE after adjusting cooling air
flows to wheel space
• Net sa!ing "#dail$ a! %&&n'()hr sa!ing*+ ,,&&-
Gcal)annu'
• GTG NG consum(tion reduced rom DFF to D%FF nmLhr.
9Net sa$in2 as (er Gail *4@ is %;; nmLhr:
• 4RSG NG consum(tion reduced rom ))+ to ;)+. 9Net
sa$in2 as (er Gail *4@ is );; nmLhr:• The 70haust Stac" tem( reduced rom 1=%c to 1)=c.
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#aintenance PracticesM
.EAT /E0OVE/1 UNIT2 ) 2E/VI0E 3OI4E/ 5 DU/ING TU/NA/OUND 6O44O7ING MAINTENAN0E
8/A0TI0E2 A/E 6O44O7ED
ST7A# RU# INSP7CTI'N 'R INT7RNA*S.
BURN7RS U7* B*'C> @A*@7S INSP7CTI'N ANPR7@7NTI@7 #AINT7NANC7.
S7R@IC7 B'I*7R BURN7R R7RACT'R? INSP7CTI'N
AN R7PAIRING.
A** INSTRU#7NT CA*IBRATI'N. AN, AUJI*IAR? AIR AN 5 SCANN7R AN #'T'R
PR7@7NTI@7 #AINT7NANC7.
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#aintenance PracticesM
AN, AUJI*IAR? AIR AN 5 SCANN7R AN I#P7**7RC*7ANING.
AN IN*7T A#P7R C'NTR'* #7C4ANIS#
INSP7CTI'N AN PR7@7NTI@7 #AINT7NANC7.
INSP7CTI'N AN #AINT7NANC7 ' 77 C'NTR'*
@A*@7S.
'N *IN7 SA7T? @A*@7 T7STING 9TRA@I T7ST:.
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AIR PR7 47AT7R TUB7 C*7ANING AN INSP7CTI'N
BURN7R INSP7CTI'N AN I#7NSI'N #7ASUR7#7NT.
#'T'R 'P7RAT7 @A*@7S RI@7 AN ACTUAT'R
PR@7NTI@7 #AINT7NANC7.
TRIP AN INT7R*'C> C47C>ING.
#aintenance PracticesM
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Plannin2 o Ne! Initiati$es
./U ) 2E/VI0E 3OI4E/
INSTA**ATI'N ' #AGN7TIC R7S'NAT'R IN NAP4T4A *IN7
'P7RATI'N ' S7R@IC7 B'I*7R 'N A*T7RNAT7 C47AP7RU7*
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Plannin2 o Ne! Initiati$es
GTG SUCTI'N AIR I*T7RS R7P*AC7#7NT 9C7**U*'S7 T'
S?NT47TIC:
R7#'@A* A*T7RNAT7 ARRANG7#7NT 'R 7@AP'RATI@7AIR C''*7R T' R7UC7 PR7SSUR7 R'P .
AT'#IING AIR C'#PR7SS'R 5 C''*7R R7#'@A*.
G7N7RAT'R R7OU7NC? R7UCTI'N T' SA@7 7N7RG?.
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Need ?our 4el(MM.
6e are acin2 some (roblems in our 4RU 5 GTG *i"e&
• ISTURBANC7 IN IRING ' 4RU STAG7-II BURN7RS, N7AR7RT' SI7 6A**S, 'P7RATING 'N NAP4T4A U7*.
• 4IG4 PR7SSUR7 R'P ACR'SS SUP7R47AT7R IN 4RU*7AING T' *I#ITATI'N IN 4IG47R ST7A# G7N7RATI'NRAT7.
•
4IG4 6477* SPAC7 T7#P7RATUR7 AT #IN. IG@ P'SITI'NURING SU##7R.
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Need ?our 4el(MM.
• 4IG4 PR7SSUR7 R'P ACR'SS IN*7T AIR I*T7RS ' GTGURING 'G AN RAIN? S7AS'N
• C4'C>ING ' AT'#ISING AIR C''*7R IN GTG.
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Than" ?ou