CONTENTS

PREFACE 3

INTRODUCTION 5-
12

STEAM GENERATION PLANT 13

-19

CAPTIVE POWER PLANT 20 -

57

MAIN RECEIVING STATION 58 -

63

AMMONIA PLANT 64 -
75

UREA PLANT 76 -
84

OFFSITES AND UTILITIES 85

- 90

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.

PERCENTAGE SHARE OF NFL IN

UREA PRODUCTION
IN THE COUNTRY (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.

The Vijaipur Plant was a land mark achievement in

project management in India. The plant was completed well
within time and approved project cost. In recognition of this
achievement, the project was awarded the First Prize in
Excellence in Project Management by Govt. of India.
Subsequently the Vijaipur plant doubled its capacity to 14.52
lakh MTs by commissioning Vijaipur Expansion Unit i.e.
Vijaipur-II in 1997. The plant annual capacities have now been
re-rated w.e.f. 1.4.2000 from 7.26 lakh MT of Urea to 8.64 lakh
MT for Vijaipur-I & Vijaipur-II Plants each.

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.

NFL, a profitable public sector undertaking operates

under the administrative control of Deptt. of Fertilizers in the
Ministry of Chemicals & Fertilizers.

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.

NFL over the years has developed a team of dedicated

professionals in the areas of production, maintenance, project
management, safety and environment control. These
professionals are sought after in the Industry both in India &
abroad for their Specialized Services.

NFL is known in the industry for its work culture; value

added human resources, safety, environment, concern for
ecology and its commitment to social upliftment. All NFL
plants have been certified for ISO-9002 for conforming to
international quality standards and International Environmental
Standard i.e. ISO-14001. With the certification of Corporate
Office/Marketing operations under ISO-9001:2000, NFL has
become the first Fertilizer Company in the country to have its
total business covered under ISO-9001 Certification.

The System of marketing of Urea has undergone a change

w.e.f. 1.4.2003 when company has been allowed to market
25% of its produce outside ECA during Kharif 2003. This

4
percentage of sale outside ECA was raised to 50% in Rabi
2003-04, The same portion prevails for 2004-05 and Kharif
2005.

NFL enters into a Memorandum of Understanding (MoU)

with the Government for each year under which the
Government undertakes to assist NFL with regard to
availability of inputs, obtaining ECA allocations commensurate
with the availability of fertilizers from NFL plants etc. NFL on
its part undertakes to adhere to its production and movement
plans, achieve its ECA allocation and provide regular feed back
to the Administrative department.
During the past two and half decades, there has been
steady increase in fertilizers consumption and to meet this rise
in consumption of fertilizers, it was required to create an
additional capacity in order to meet the increasing needs. As
oil and gas prices has been increasing day by day since 1973
which effected the whole Industrial sector worldwide led to the
change in Energy concept in the whole world and so was India
forced to increase its nitrogenous Production by switching to
new improved Technology which could make use cheaper and
economical source of raw material.

The National Fertilizers Limited (Public Undertaking) was

thought to plan two modern large capacity single steam
nitrogenous fertilizers plant in order to meet the increasing
demands.

On 23rd August 1974, NFL was formed and registered to

set up two modern large capacity Nitrogenous Fertilizers
plants.

NFL, Bathinda (Punjab)

NFL, Panipat (Haryana)

each with the capacity of 5-11 lakh tones /annum.

As to set up any plant there are some essential

conditions that support the existence and working of plants for
years, so Bathinda was basically selected as one of the site of

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.

The old plant at Nangal was commissioned in 1961 followed by

expansion which was commissioned in 1978. Bathinda and
Panipat plants were commissioned in 1979. Guna Plant which
is the latest plant of NFL was commissioned in Dec, 1978 and
is now in full production.

6
Strategically Located - Urea Plants

7
 Leading Producer of Nitrogenous Fertilizers in the Country.

Capital Cost, Feed Stock & Plants Capacity

Plants Capital Cost Feed Stock Existing Capacity

(Rs.Crore) (Lakh MT/Yr.) MT/Year
Ammonia Urea CAN Bio-Fert.
Nangal-I 91.26 Naptha 0.66 - 3.181 -
Nangal-II 299.19 F.Oil/LSHS 2.97 4.785** - -
Panipat 338.41 F.Oil/LSHS 2.97 5.115 - -
Bathinda 349.41 F.Oil/LSHS 2.97 5.115 - -
Vijaipur-I 516.00 Natural Gas 5.016* 8.646* - -
Vijaipur-II 1071.00 Natural Gas 5.016* 8.646* - -
Indore 1.42 Strains - - - 100

Total 2666.55 19.602 32.307 3.181 100

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:

INDUSTRIAL PRODUCTS (BY PRODUCTS)

Nitric Acid (HNO3)

Sulphur (S)
Anhydrous ammonia (NH3)
Ammonium Nitrate (NH4NO3)
Methanol (CH3OH)
Nitrogen (N2)
Carbon dioxide (CO2)
Sodium Nitrate
Oxygen (O2)
Carbon (C) from slurry

IMPLEMENTATION AND PROJECT COST OF NFL

BATHINDA UNIT

As NFL, Bathinda unit was planned to complete in 36

months from the Zero date 26 Sep.1974, so contract for
completing this task was given to the well known Japanese
company “Toyo Engineering corporation limited”and Indian
Consultancy Companies as well.
The overall approval cost of Bathinda Unit was Rs.
240.47 Crores with a foreign exchange component which was
mainly from Japanese Yen.

REQUIRMENTS OF RAW MATERIAL / INPUTS

9
Fuel Oil /LHLS 850 MT / Day
Coal 1680 MT / Day
Water 13 MGD
Power 28 MW

PROJECT ’s BENEFITS

Increased Food Output

Employment to nearly 6000 persons
Both Central and State Government has been benefited by way
of excise duties and other local taxes on Raw materials and
other products.
Scope for marketing by-products such as Sulphur , CO2 ,
Nitrogen , Oxygen , Carbon etc.

NFL won many major awards related to Safety , Productivity ,

Pollution control , Longest accident free period .

- An OHSAS-18001 certified unit .

- An ISO-9002 and ISO-14001 certified unit .

STEAM GENERATION PLANT

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

It is colourless, odourless and tasteless .

Very economical
Non polluting
Can be used as heat exchanger.
It can be easily distributed to various sections of plant.

Steam is generated in Boilers(Water tube boilers

mounted on common base fitted with mountings and fittings)
and then distributed to other parts of plants . For governing the
quantity of fuel to be burned and for maintaining the required
pressure their are many automatic fuel feeders, equipments
and auxiliaries like pressure gauge etc.

In the Boilers used at National Fertilizers Limited

(Bathinda unit); coal, oil natural gas are used as a fuel for
production 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.

Fuel 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 .Flue gases produced which
are very hot surrounds the water tubes (Tubes carrying
water).When hot flue gases surrounds the water tubes, the
temperature of water in tubes starts rising ,as a result Steam is
generated.

WHY AND WHERE STEAM IS REQUIRED

As National Fertilizers Ltd, Bathinda unit has its own

Steam Generation Plant where steam is produced which is
used for driving Turbo Compressors, Heating Purposes, for
various reactions taking place in the plant itself.
Steam is mainly consumed in the Ammonia Plant as nearly 6 to
7 tonnes of steam is required to produce 1 tonne of Ammonia.
High Pressure Turbines are being used where high pressure
and temperature is to be maintained so SGP section plays a
important role for maintaining the said condition.
There are three boilers (VU-40 type supplied by M/S BHEL)
of 150 tonne/hr capacity .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

12
formation takes place. In the beginning coal is burnt with fuel
oil in order to get desired temperature.

FIRING SYSTEM :

As coal brought from various sites is in form of big pieces

of various sizes , so first it is reduced in smaller pieces known
as pulverized coal which is then further grinded using BOWL
MILLS so that it burns completely in the furnace to give proper
combustion.
Coal received from material handling plant is stored in
coal bunker and is fed to bowl mill through a coal feeder .Hot
air is also supplied in the mill for heating the coal and
conveying it to furnace through a fan called EXHAUSTER FAN
which takes suction from the mill and maintains it under
negative pressure. Oversize and un grind able material like
stones are thrown out by the mill. Pulverized fuel i.e mixture of
coal and air is supplied to Coal Burner through Exhauster. Coal
burners are arranged tangentially on all the four corners of the
rectangular furnace at three elevation levels. Thus there are
total 12 Burners. In between these, three elevations Oil
Burners and Start Up Burners/Igniters are arranged at two
elevations. Thus there are 8 Oil Burners and 8 Igniters.
Igniters use Light Diesel Oil (LDO) .
Oil Burners use Heavy Fuel Oil .
The Furnace is a cubical suspended enclosure with water tubes
forming its four walls. The furnace is designed with sufficient
volume to provide for complete and efficient combustion at all
loads without flame impingent by the reaction of carbon
present in coal and the oxygen present in the air to form
Carbon-Di-Oxide.

C + O2 ▬► CO2 + Heat

WATER AND STEAM SYSTEM

As the steam being used should be free from impurities

like minerals, silica, oxygen, Iron etc. in order to insure Safe
and Efficient working of Steam turbines and Boilers. For this

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.

FLUE GAS SYSTEM

The products of combustion in the furnace consist of

carbon-di-oxide, nitrogen, ash, oxygen and sulphur-di-oxide.
After leaving the furnace the heat
Of these gases called FLUE GASES, is utilized at various levels.
First the steam from steam drum is heated in two super
heaters to get the required temperatures of 4950C and then
feed water in BANK TUBES is also heated and the gases leave
bank tubes at around 4970C next the heat is utilized to heat
feed water in the ECONOMIZER and gases are cooled down to
3200C. These gases are further cooled down to 1500C in
ROTARY AIR HEATER where the air is required for combustion
and conveying the coal is heated up. Temperature is not
reduced further because at lower temperature oxides of
sulphur present in flue gases are converted to ACID which
damages the down stream equipments. These gases then pass
through ELECTRO STATIC PRECIPITATOR (ESP) where ash is
removed. From ESP these gases pass on to INDUCED DRAFT
FAN which maintains draft in the furnace and finally the gases
are let off to the atmosphere through a chimney about 80mtr
high.

POLLUTION AND THEIR DISPOSAL

Along with optimum utilization of company’s resources to

achieve maximum profitability, our unit has always performed
its duty to keep the environment clean. We have installed
latest available pollution control instruments and equipments.

14
The chief pollutants generated in SGP are ASH and SULPHUR –
DI-OXIDE. Their separation and disposal are discussed in brief.

ASH:

Ash is the incombustible material contained in raw coal

which has about 40% ash. It also consists of heavy metals like
vanadium and nickel. If inhaled it can be harmful to human
beings.
After combustion of coal, ash remains as such. About 20%
ash of total ash generated consist of higher wt. particles which
fall down to BOTTOM ASH HOPPER provided at the bottom of
the furnace. Ash slurry is formed here due to water level
maintained in the bottom ash hopper. This is taken out by
water ejector once in eight hours and sent for disposal in
lagoons.

FLY ASH:

Fly ash is the ash containing light particles. It forms the

major portion that is 80% of the ash generated. It is carried
away from the furnace along with the flue gases. The ash
particles are removed from the gases in electro-static
precipitators as shown in block diagram after air-pre heaters.

ELECTRO-STATIC PRECIPITATORS:

The electro-static precipitators’ forces to separate out dust

particles from the flue gas. High voltage is applied between
electrodes arranged in rows alternately. Due to high voltage
gas particles are ionized. Most of the ions are negatively
charged. They stick to dust particles and carry them to
positively charged electrodes which are in the form of a
rectangular plate. Thus dust particles stick to those plates.
These plates are rapped periodically to dislodge the deposited
dust which is collected in the hopper below.
Ash is ejected from these hoppers by water jet and it forms ash
slurry. Fly ash slurry and bottom ash slurry are mixed together
and sent to ash slurry disposal ponds outside the factory where
the slurry settles down and overflowing clear water is recycled
back to the system.

15
SULPHUR-DI-OXIDE:

Sulphur-di-oxide is formed due the presence of sulphur in

coal which varies from 0.1% to 0.5%. For safe disposal of SO2
minimum chimney height has been recommended by pollution
boards, depending upon the quantity of sulphur-di-oxide
generated per hour. In our case it comes out to be around 75
mts. taking maximum amount of SO2 generated. Chimney
height of SGP boiler is 80mtrs.
Suitable instrumentation has been provided for monitoring all
the parameters and important analyzers and cutouts of a part
or even complete boiler has been provided in case of
emergency.

MAIN EQUIPMENT

ECONOMIZER

The main function of Economizer is to preheat the boiler

water before it is introduced into the steam drum. It recovers
some of the heat from the flue gases leaking out of the boiler.
The economizer is located in the second pass of the boiler
above the air heater. Each section is composed of number of
parallel tubes circuit which is arranged in the horizontal rows.
All tubes circuit originated from inlet header and discharge at
outlet header.
Feed water is supplied to inlet water header via free of stop
and check valves. The feed water flow is upward through the
economizer that is in counter flow to the hot flue gases. Any
chance of steam generation within the economizer is
eliminated by the upward water flow that is led to the drum via
the economizer outlet link.

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

Mainly the function of De super heater is to reduce the

temperature of the steam. De super heater are provided in
super heater connecting links to permit reduction of steam
temp. When necessary and to maintain the temperature at
design values within the limits of the nozzle capacity.
Reduction in the steam temperature is accomplished by
injecting spray water into the path of the steam; the spray
water source is the boiler feed water system. It is essential that
the spray water should be chemically pure and free of
suspended and dissolved solids. Containing only approved
volatile organic treatment materials in order to prevent the
chemical deposition in the super heater.

DRUM

It is necessary to separate the saturated steam from the

steam water mixture for circulation type boiler. This
performance is achieved by steam separators arranged in the
drum.

CAPTIVE POWER PLANT

INTRODUCTION:

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.

Since inception, Bathinda unit was drawing electric power

from Punjab State Electricity Board (P.S.E.B). Electricity is the
main driving force after steam in the plant, being used for
moving auxiliary equipments. The unit requires 27MW of
power/hr when running at full load. There are two 15 MW
turbo-generators to generate power. Under normal running
conditions of the plant and healthiness of the P.S.E.B. grid, we
generally run in synchronism with the grid merely drawing the
power corresponding to the minimum charges to be paid to
state electricity board. In case of any disturbance in the grid,
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. In case only one turbo
generator is in line and grid cuts off, urea plant is cut off
automatically to balance the load with one generator. As soon
as the grid becomes stable, the generators are again
synchronized with it. The power generation of each generator
can be varied with 2 MW to 15 MW maximum, provision exists
to run the generator on 10 % extra load continuously for one
hour only.

Operation of C.P.P. is based upon microprocessor based

computerized instrumentation which allows automatic
operation, start up, shut down of the whole or part of the plant.
Latest instrumentation has been used in this plant. It allows
controlling process variables like flow, pressure, temperature,
power factor, voltage, frequency, etc. There is operator
interface unit (IOU) 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.

NEED FOR C.P.P. :

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:

1. Any disturbance in the PSEB grid used to trip the whole

plant. Lot of money was lost due to this as each re-startup
costs around 40 to 50 lakhs rupees. Moreover, frequent
tripping’s had an ill effect on machines and equipments
extending the re-startup period.

2. Three boilers of 150Te/hr steam capacity were initially

installed in SGP to keep 25 boilers running and one stand by as
designed steam requirement was less than 300Te/hr. but in
actual operation steam requirement was more and all three
boilers had to be run and there was no breathing time for their
maintenance. As new boiler was to be installed for CPP, its
capacity was so designed that it could export around 60Te of
steam for process requirement so that only 2 boilers of SGP
would be run keeping the 3rd as stand by.
With these points in mind CPP was installed. The functioning of
CPP can be sub-divided into parts:

BOILER AND ITS AUXILIARIES : For generation of high

pressure superheated steam.

TURBO-GENERATOR AND ITS AUXILIARIES: To generate

power, using steam from the boiler.

Operation of CPP is based upon microprocessor based

computerized instrumentation which allows automatic
operation, start up, shut down of the whole or the part of the
plant.

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,

19
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% higher.
Boiler feed water required for steam generation can 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:

DESCRIPTION

MITSUI RILEY TYPE BOILER

Maximum evaporation 2,30,000kg/hr
Design process for boiler 124kg/cm2G
Steam temp at outlet 4950C
Heating surface 1250M2

FUEL COAL SYSTEM

The purpose of fuel coal system is to pulverize coal to dry coal

and to convey the pulverized coal from ball tube mill to burners
by primary air for coal firing.
Fuel coal system consists of three systems:

20
coal supply system.
primary air system.
seal air system.

COAL SUPPLY SYSTEM

Coal Coal Crushers Ball tube

bunkers feeders dryers mill

PRIMARY AIR SYSTEM

The primary air system performs two functions. It provides the

proper amount of air required to convey the pulverized coal to
the burners and the heat necessary to dry coal so it can be
pulverized and burned efficiently. The details of primary air fan
are:-

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

SEAL AIR SYSTEM

The seal air is distributed to the components by the sealing of

the mill system by the sealing air fan. The sealing air fan takes
suction from silencer and discharges it to a common header.
The controller for each mill system provides a constant
differential pressure to protect against coal leaking into the

21
bearings and seals. This system should be in service before
being placed in operation.

CRUSHER DRYER SYSTEM

Crusher-dryer performs the CRUSHING function. Metered coal

from the feeders blends with a properly heated amount of air
from the primary air fan and enter the crusher dryer. The non
clogging pre crushing flash dryer operates continuously at
constant speed. Rotating hammers drive the incoming coal
against a breaker plate and adjustable crusher block,
increasing the surface area of the coal and mixing it with the
incoming preheated air.

BALL TUBE MILL

Grinding the coal to the proper fineness is done by ball tube

mill. The crushed coal and air mixture from the crusher dryers
enter the mill through the mill inlet boxes on both ends of the
mill. The mill barrel rotating at constant speed, contains
thousands of kilograms of various sizes of hardened steel balls
which cascade down upon the entering coal and pulverize it to
talcum powder consistency. The heated primary air, entering
with coal, not only completes the drying process, but now
conveys the coal dust from the mill through the mill output
boxes to the classifiers on both ends of the mill. The
specifications of the ball tube mill are as:-

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.

FORCED DRAFT FAN

The forced draft fans supply the proper amount of secondary

air required to support the combustion of the fuel delivered to
the boiler. The details of the FD fan are:

Make MEIDEN
Rating Continuous
Insulation class F
Rated power 320kW
Voltage 3300V
Power factor 0.85
Current 71A
RPM 980
Poles 6
Connection Y

INDUCED DRAFT FAN

The induced draft fans control the furnace draft by drawing

the gases of combustion through the boiler, regenerative air
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 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:

In C.P.P. two generators of 15MW capacity generate a voltage

of 11KV which is fed to the two transformers in the yard. The
rating of the transformers is 31.5/25 KVA, these two values
depend upon the cooling which we provide, as here 25KVA
capacity is when cooling is oil natural air natural and 31.5KVA
capacity is when cooling is oil natural air forced. Both these
transformers 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.

TURBINE:

The turbine used is supplied by M/S SGP of AUSTRIA. 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. HP1 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 vaccum to extract maximum
steam enthalpy. The output of the turbine depends on flow of

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.

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. Bailey’s

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.

DESCRIPTION :-

Make Simmering Graz Panker,

Austria
Type Multifunction (28 stages)
Capacity 65 T/H at 15 MW
RPM 6789 at 50 Hz

25
Critical speed 3200-3600 RPM

GENERATORS

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. In case only one TG is in
line and grid cuts off, urea plant is cut off automatically to
balance the load with one generator. As soon as the grid
becomes stable, the generators are again synchronized with it.

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

DIFFERENT PARTS OF TURBO GENERATOR

STATOR

a) STATOR BODY

The stator body is totally enclosed structure, suitably ribbed

internally to ensure high rigidity. It is designed mechanically to
withstand internal pressure of explosion of any type inside.
Rigid ends shields close the casing and support the fan shields
and shaft seals. The end shields are made in two halves for
convenience during erection and inspection.

27
 b) STATOR CORE

The stator core is made up of segmental, vanish-insulated

lamination of cold rolled grain oriented silicon steel assembled
in an interleaved manner on core bars. The core consists of
several packets separated by steel spacers for radial cooling of
the core by coolant.

c.) STATOR WINDINGS

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.

The overhang portion of the coils is secured and lashed with

glass chord to bandage rings and special brackets of non
magnetic steel, which in turn fixed to the core press rings. On
short circuit, the forces between the conductors tend to open
the cone formed by over hang portion of the coil, but the
movement is effectively prevented by supports.

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

The rotor winding is made from hard drawn silver bearing

copper. Rotor winding is held in position against centrifugal
forces by duralumin wedges in the slot portion and by non
magnetic steel retaining rings in the overhang portion. Gap
pick up system is employed for direct air-cooling of windings.
Several groups of ventilation holes are milled on the sides of
the rotor coil for passage. The rotor slot wedges are of special
profile with elliptical holes milled in to match the ventilation
ducts (holes) on the winding stack.
The main slot insulation in the form of U-trough made of
glass cloth impregnated with epoxy resin. The U-profile
facilitates easy flow of gas from one side to the other side of
the coil stack. The inter turn insulation consists of layers of
glass cloth glued to bottom of each conductor and consolidated
on required condition of temperature and pressure. The end
windings are packed with block of glass laminates to separate
and support the coil and to restrict their movement under
stress due to thermal and rotational forces. The end windings
are insulated from retaining rings with the help of glass epoxy
moulded segments. Copper segment type damper winding is
provided in the end zones of rotor during asymmetrical and
asynchronous operation.

c) ROTOR SHAFT

Shaft end and rotor are integrally forged of high quality

steel. The slots receiving the field windings are matched and
machined into the rotor body.
Space heater
One space heater is located at the base of the stator to avoid
humidity when the generator is not running phase.

29
SOLE PLATES

The slot plates on which the generator is bolted and

secured ensure perfect stability without vibrations and permit
a very simplified process of erection and contingently of
disconnecting of turbo generator.

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

Totally enclosed, cooled with cold air supplied by the main

generator (without bearings)
Invented alternator with stationary field and rotating armature.
It feed the generator field through a rectifier bridge mounted
on the shaft.

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

The frame consists of a laminated magnetic ring on which

main pole core is bolted. The field coils are secured on the pole
cores.

30
RECTIFIER BRIDGE

Rectifiers are mounted in Grates Bridge and use two types

of cells. Each arm of bridge uses 3 cells in parallel and each
elementary rectifier bridge is a protected fuse.

EXITATION AND REGULATION CHANNEL

The main generator excitation system consists of an exciter

from the shaft end of the main generator and outputting to its
own rotor circuit. The exciter consists of an inverse generator
and a bridge of rotating rectifier.
An excitation device supplying the exciter field winding.
A compound part comprising transformer TS, TSE and diode
bridge RD.
A shunt part comprising transformer TEX1 + TEX2 and the
controller thyristor bridge THY. The diode and Thyristor Bridge
are connected in series to supply the exciter inductor.
A controller with limiter regulating the excitation of the exciter
through the thyristor bridge (AVR).

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: -

Increased power supply: -

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.

INCREASED NOISE REJECTION : -

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.

REDUNDANT Vs NON REDUNDABT CONFIGURATIONS:-

In a non-redundant configuration the system is sized such

that both UPS modules are required to feed the potential load
and if one of the two modules develops a fault or for some
reason shut down, the other module also automatically shuts
down.
In such an event the load is transferred to an unprocessed
bypass supply.
In a redundant module configuration the system is sized such
that the potential load can be provided by just one of the two
modules. Under normal circumstances both modules are
operational and share the load current equally; but if one
module develops a fault, or is shut down, the second module is
able to take over the full load demand and continue to provide
it with processed, backed-up power.
7400 Module Design:-

The UPS basically operates as an AC- DC-AC converter.

The first conversion stage (from AC to DC) uses a 3 phase fully
controlled silicon controlled rectifier (SCR) bridge rectifier to
convert the incoming mains supply into a regulated 432V DC
bus bar.
The DC bus bar produced by the rectifier provides both battery
charging power and power to the inverter section-which is of a
transistorized / IGBT based pulse width modulation (PWM)
design and provides the second conversion phase i.e.
reconverting the DC bus bar voltage back into an AC voltage
waveform.
During normal operation both the rectifier and inverter sections
are active and provides regulated load power whilst
simultaneously float charging the battery. In the event of a

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

BYPASS ISOLATOR STATIC BYPASS LINE

BYPASS
º º º
SUPPLY

UPS
MAINS º STATIC OUTPUT
º º RECTIFIER INVERTER º º º
SUPPLY
SUPPLY INPUT SWITCH OUTPUT
ISOLATOR º ISOLATOR
BATTERY
ISOLATOR
º

BATTERY

Fig.1 Series 7400 UPS isolator configuration

BYPASS SUPPLIES :- The circuit block annotated ‘Static

Switch’ in figure 1 shown above contains an electronically
controlled switching circuit which enables the critical load to be
connected either to the inverter output or to a bypass power
source via a ‘static bypass line’. Normally the load is connected
to the inverter; but in the event of a UPS overload, or inverter
failure, it is automatically transferred to the static bypass line
due to static switch action. To provide a clean (no-break) load
transfer between the inverter and static bypass line, the
inverter output and bypass supply must be fully synchronized
during normal operating conditions.

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:-

SYNCHRONIZATION:- as the outputs from both the UPS

modules are connected together to provide a single load
supply, it is imperative that the inverters are fully synchronized
in frequency and phase. This is achieved by digitally locking
the two inverters control oscillator. The inverter control
oscillators are not only locked together but are also made to
track the bypass frequency. This is done so as to provide a
clean (no-break) load transfer between inverter and static
bypass line.
A “common battery” option kit contains a DCDT (DC current
transformer) which is fitted to the battery power lines and
monitored by the parallel control logic. Each module monitors
its battery charge current and compares it with the charge
current provided by the other module. This enables a module
to match its charge current to that of its partner by effecting
the voltage control over the rectifier section.

PROTECTION SYSTEM FOR ELECTRICAL NETWORK

IN C.P.P

With the installation of C.P.P at N.F.L Bathinda, almost all

groups of power engineering have been covered. Their main
groups are mainly :

Generation
Transmission
Distribution

34
Utilization

For handling the quantum of power, intricate protection

system is required. Financial reliability for protection is another
requirement. It has been seen if all requirements are met with
the system can be handled well.

In the C.P.P following fields of electrical engineering can be

formed. The general protection provided is:-

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)

FEEDER TRANSFORMER OR DISTRIBUTION

TRANSFORMER

Over current & earth fault

Restricted earth fault

35
Backup earth fault
Buchholz
Differential

TRANSMISSION LINE

Differential (pilot wire)

Over current
Earth fault

HIGH TENSION MOTORS

Over current
Phase imbalance
Earth fault
Thermal overload (sustained)
Locked rotor
Under voltage

LOW TENSION MOTORS

Fuse
Thermal overload

TYPES OF PROTECTION AT VARIOUS POINTS IN

C.P.P

L.T MOTOR FEEDERS AND DISTRIBUTION FEEDERS

Thermal overload
Backup protection as M.C.B (miniature circuit breaker)
Fuse protection

Incomers of M.C.C’s (motor controlling current)

Current breaker with short circuit protection of M.C.B’s

36
OUTGOING L.T FEEDERS AT 415V P.C.C (POWER
CONTROL CENTRE)

IDMTL over current with high set instantaneous element

extreme inverse.

INCOMING OF 415V P.C.C

IDMTL over current relay

Restricted earth fault relay for transformer
Backup earth fault relay for transformer
Buchholz tripping transformer
Under voltage
Winding temperature alarm only
Oil temperature

HT MOTOR FEEDERS FOR 3.3KV SWITCH BOARD

Earth fault element

Over current element
Negative sequence element
Overload element
Locked rotor element
Incoming feeders for 3.3KV switch Board
IDMTL over current relay
Restricted earth fault relay
Backup earth fault relay
Buchholz tripping transformer
Under voltage
Winding temperature alarm only
Oil temperature
Oil level

OUTGOING FEEDERS FOR 10MVA TRANSFORMER

(11/3.3KV)

IDMTL Over current with high set instantaneous protection

Differential protection inter tripping.

OUTGOING FEEDERS FOR 2 MVA TRANSFORMER

(11/415V)

37
IDMTL Over current with high set instantaneous protection
Differential protection inter tripping

OPERATIONAL LIMITS OF TURBO GENERATOR

There are five principal electrical design and operational limits

and each is discussed shortly below:-

ROTOR CURRENT LIMIT

This limit is set by the type and classification of the rotor

windings insulation. Most of the alternators are insulated to
class B and this means that the insulating material used will
withstand temperatures up to 130°C and above this
temperature the winding insulation deteriorates with heat
leading to a short hand life and ultimate failure.
In the turbo generator used in C.P.P insulation material is of
class F hence provides the maximum temperature range up to
240°C.

STATOR CURRENT LIMIT

As stated for the rotor current limit, the maximum allowable

temperature for the type winding insulation material used
limits the stator current. The temperature to which windings
are subjected will depend mainly on stator current flowing
through them assuming that the stator winding coolant inlet
temperature and flow rate are reasonably constant.
The manufacture therefore stipulates the maximum allowable
stator current and this will correspond with the maximum
allowable temperature for the class of insulation used.
If the alternator is operated with the maximum rated current
flowing at the rated generator terminal voltage, then the
maximum continuous MVA rating will be achieved.

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.

MINIMUM ROTOR CURRENT LIMIT

The power supplied to the alternator at constant speed is

proportional to the torque applied to the alternator rotor by the
turbine. This power must be counter balanced by an opposing
electrical torque from within the alternator else the rotor would
accelerate.
If the grid system voltage and the frequency conditions are
assumed to be constant, then the maximum balancing torque
which the alternator can sustain dictated by the level of the
magnetic flux which is created by the rotor field current in the
air gap providing a magnetic coupling between the stator and
the rotor. The stronger the magnetic coupling, the more firmly
locked is the rotor to the system.
If more steam is admitted into the turbine and hence an
increase in rotor torque, then the magnetic coupling will be
stretched and will ultimately be broken, resulting in the rotor
accelerating and the speed rising above that of the system.
This will cause a considerable electrical disturbance to the
system and may also cause severe overheating of the both
stator and the rotor.

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.

UNSYMMETRICAL SHORT CIRCUIT PERFORMANCE

The duration of unsymmetrical short circuit should be such that

the product of square of negative sequence component of
current is expressed in terms of per unit value of stator current
and it’s duration in seconds does not exceeds eight.

MOTORING ACTION

Motoring of the turbo generator is allowed within the limitation

of turbine.

VARIOUS STATES OF TURBO GENERATOR IN RUNNING

VARIATION IN TERMINAL VOLTAGE

Generator can develop rated power at rated power factor.

When the terminal voltage changes with ± 5% of the rated
value, the stator current should accordingly be changed within
limits of ± 5%.

FREQUENCY VARIATION

The generator can be operated continuously at rated output

with a frequency variation of ± 5% over the rated value.
However the performance of the generator with frequency
variation is limited by the turbine capability.

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.

OERATION UNDER UNBALANCED LOAD

The turbo generator is capable of operating continuously on

an unbalanced system loading provided that conditions such
continuous negative phase sequence current during this period
shall not exceed 5% of the rated stator current.
It implies that maximum difference between lines current is
about 100% of the rated value. At the same time current is
maximum loaded phase should not exceed the permissible
value for given condition of operation of the turbo generator
under balanced loads.
If the unbalanced load parameters exceed the above
permissible limits then measures should taken immediately to
eliminate or reduce the extent of unbalance within 3 to 5
minutes. In case it is not possible to achieve this, then the
machine has to be run down and tripped.

STATOR CORE HEATING LIMIT

With high values of stator current at leading power factor,

heating of the end section of the stator core tend to occur.
However, the end heating limit would normally only be reached
if the stability limit were exceed and under normal stable
operation, the end heating limit is not reached.

OPERATION OF THE TURBO GENERATOR

CHECKS BEFORE STARTING/INITIALIZING THE SET

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

Only after ensuring the completeness and the availability of

all the above the set should be started and taken up gradually
up to full rated speed. During the course of running up, bearing
vibrations, rubbing if any inside the generator or abnormal
noise should be investigated carefully. Also note down the
temperature of bearing and seal Babbitt and drain oil.

When the generator comes to the rated speed check the

following

Temperature of bearing and seal Babbitt and drain oil.

Performance of bush gear.

Phase sequence of generator with the help of residual

magnetism.
Bearing vibration in all directions.

2. SWITCHING IN OF EXITATION

After ensuring that the mechanically the set is normal switch

on field breakers and regulate excitation as per the selected
mode (auto or manual).

SYNCHRONIZATION

The generator should be synchronized with the system only

by means of a precise synchronization method after the
following conditions are strictly satisfied.
The phase sequence of the generator voltage and system
voltage is identical.

42
 Effective values of both voltages are same.
Both the voltages are in phase.
Frequencies of both the voltages are same.

LOADING

The rate of loading of the generator is mainly limited to the

turbine and the boiler. However the generator should be
gradually loaded accordingly to the load requirements. The
governor of the turbine is adjusted as necessary for speed and
load sharing. The automatic voltage regulator is adjusted for
desired value of generated voltage and power factor.

PROTECTIONS INSTALLED FOR TURBO

GENERATOR

WINDING TEMPERATURE

Whenever the winding temperature of generator goes beyond

105°C then alarm will attract everybody attention and if we are
not in a position to control the winding temperature at 120°C
then generator breaker and excitation system will be tripped.

BEARING TEMPERATURE

In case the bearing temperature goes above 95°C first alarm

informs then after 100°C generator breaker, excitation system
and turbine will be tripped.

OVERLOAD

Continuously overloading increases the temperature to such

an extent that generator insulation will be damaged and its
useful life reduces. The overloading may be because of over
current for remarkable period or cooling system failure.
Therefore we have ITG 7231 type of relay. This relay has the
setting 9.84in for 1.2secs. Only alarm is there incase of
overloading and no tripping.

43
 NEGATIVE SEQUENCE

Alternators, being normally designed to supply balanced

three phase currents, coils only support a limited amount of
unbalance in the phase currents. Out of balance in these
currents, which causes abnormal heating of the rotor of the
machine may in fact have a highly damaging effect (Note
negative sequence current cause six times heating as
compared to normal balance currents). The unbalanced 3phase
stator current is induced in rotor. They cause heating of rotor
and damage the rotor. Unbalance stator current also cause
severe vibrations currents rotates at synchronous speed in a
direction opposite to the direction of rotation of rotor.
Therefore double frequency currents are induced in the rotor.
We have ITI 7621 relay to detect negative sequence current
and CT for this relay is of 1000/1A ratings.

LOSS OF EXITATION

Opening of field switch of field circuit breaker can cause loss

of excitation. The behavior of generator depends upon whether
the generator is connected singly to a load or whether
generator is connected in parallel with other units or the
system.
If it is a single unit supplying a local load, the loss of field
caused loss of terminal voltage and subsequently loss of
synchronism depending up on the load condition.
If the generator is connected in parallel with other units it can
draw the magnetizing currents from the bus bar and
continuous to run as induction generator. Large magnetizing
currents cause heating of generator.
In fact under normal operation condition an alternator supplies
reactive power and its impedance is therefore of a capacitive
nature. On the other hand, under synchronous conditions it
absorbs reactive power and its impedance becomes inductive.
We have YTM 7111 to detect loss of excitation. C.T ratio is
1000/1A and 11KV/1.73KV/110*1.73VP T.

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

Whenever there is under power it means there is some fault

on the alternator and alarm comes. The relay used for under
power is WTGA 7133. it is used for balance or unbalanced
network operating on active power, on 3-phase 3-wire system
with a definite time characteristics. Relay gets supply from
1000/1A and 11KV/1.73KV/110*1.73V C T and relay setting is
3% of power for 2 seconds.

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

Over voltage are caused by over speeding or due to faulty

operation of voltage regulator. This condition leads to
insulation breakdown. Relay TTG 7111 is used for this purpose,
is a single- phase time delay ED relay having settings.

UNDER/OVER FREQUENCY

Under frequency means V/f ratio of system changed. This

causes more flux drawing, which has an effect of saturation of
magnetic core. This causes increase in losses and overheating,
which should not be maintained in order to avoid premature

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.

ROTAR EARTH FAULT

Normally generator rotor remains insulated from earth. So

when a earth fault occurs it is not so serious but second earth
fault will damage rotor because single earth fault does cause
the flow of current. Since the rotor circuit is underground.
When the second earth fault occurs parts of the rotor winding
is by passed and the current in the remaining portion may
increase. This causes unbalance in rotor and may cause
mechanical as well as thermal stresses result in damage to the
rotor in some cases vibrations have caused damaged to
bearings and bending of rotor shaft. Such failure has caused
extensive damage.
We have TTE 7015 relay to detect any earth fault. This relay
operates on the current injection principle

EQUIPMENTS INSTALLED IN C.P.P SWITCHYARD

TRANSFORMER

TECHNICAL DATA:-

Type of Cooling ONAF/ONAN

Phase 3
Capacity HV- 31.5/25MVA

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

(a) TAP CHANGERS (ON LOAD)

Tapping are provided on the high voltage windings to give a

variations of high voltage from +12.5% to –12.5% in 21 steps.
Tap position 11 give us 132K.V. Taps position of lower value
gives us high voltage and vice-versa. Voltage difference of 1.65
KV i.e. –0.5% is maintained in between two tap positions.

(b) COOLING FANS

We have twelve numbers of cooling fans for our

transformers (12 for each). They are divided into four groups,
each group comprising of three fans. Each fan has 380mm
diameter and rating of 41m3 of air per minute. They get started
automatically when the temperature reaches 650C.

(c) CORE

The magnetic circuit is a three-limbed core type

construction, each limb being joined with the tip and bottom
yokes by inter leaved metal joints. The laminations are made
from high-grade non-aging silicon alloy cold rolled steel. The
yokes are clamped by means of end plates with bolts and legs
are clamped by means of clamp plates. The clamp plates has a

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

Windings are arranged in concentric formation with SV

windings next to core, and then LV windings coiled over the SV
windings. HV tapping coil is placed to the LV winding coil. HV
main coil is placed next to the HV tapping coil.

(e) TERMINAL ARRANGEMENT

The HV line terminal bushings are of the out door, oil

impregnated condenser type and the arching norms are fitted
with a gap setting of 500 to 800 mm. The neutral terminal
bushing for both HV and LV are of porcelain stem type without
arching horns. SV windings are also of porcelain stem type. An
air insulated cable box is provided on LV line side.
The HV line bushings, HV neutral bushings and LV neutral
bushing are mounted on turret. The SV bushings are mounted
directly on the cover of transformer tank. LV cable box is
mounted on tank wall of the transformer.

(f) TANK

The tank is a welded milk steel plate construction. The tank

is designed to withstand a vacuum of 5tors absolute of
mercury.

(g) OIL TEMPERATURE INDICATOR

The equipment operating on the principle of liquid

expansion provides local indication of the top oil temperature.
The temperature is given by a thermometer bulb with is
connected by capillary tubing to the local indicator. The pocket
of the indicator is to be filled with oil. The indicator is fitted
with maximum pointes and two mercury switches. Out of which
one is used for alarm and other is for tripping switches are

48
suitable for 5A, 250V AC or D.C. oil alarm temperature is 800C
and tripping temperature is 900C.

(h) WINDING TEMPERATURE INDICATOR

This equipment gives continuous indication of the

temperature of the windings and initiates alarm when the
temperature exceeds a certain limit and tip off the transformer
from the circuit when temperature approaches a dangerous
level and controls cooling fans. Capillary tubing to the local
indicator connects thermometer bulb. The indicator is fitted
with a maximum pointer and four mercury switches. Out of the
four one contact is for alarm, other for tripping, third one is for
controlling fan and fourth is spare switches are suitable for 5A,
250V AC or DC. Winding alarm temperature is 900C and
tripping temperature is 1050C.

(h) BUCHHOLZ RELAY

A double float buchholz relay is fitted in the pipe

connection between the conservator and the main transformer
tank and is provided with two sets of mercury contacts. One
mercury contact is in the upper part and the other one is in the
lower part. These mercury switches are in aluminum buckets,
leads from which are taken to the moulded terminal box.

When a minor fault occurs, heat liberated during arching

generates gas in the oil, which is trapped in the relay. As gas
accumulates the oil level in the relay falls, leaving the top
bucket full of oil and the assembly tilts, closing the mercury
switch that initiates the alarm. With a major fault, gas
generation is rapid and displaced oil surges through the relay
and impinges on the baffle plate, causing the lower assemble
to tilt and close the mercury switch to complete the trip circuit.

Protection is given by both buckets elements against falling

oil level, giving first the alarm and then tripping before the
danger level is reached. The other faults against which
protection is given by the relay are:-

49
 INCIPIENT FAULTS : - Short circuited core lamination,
broken down core bolt insulation, local overheating of windings
etc.

MAJOR FAULT : - Short circuit between phases and

between turns, earth faults, punctures of insulation inside the
transformer tank.

Mercury switches will carry 2A at 250V AC or D.C.

continuously and will carry 40A at 250V AC or D.C for 0.5secs.

(i) CONSERVATOR

As the temperature of oil increases or decreases there is

corresponding rise or fall in oil volume. To account for this,
expansion vessel i.e. conservator is connected to the
transformer tank. The conservator has got capacity between
maximum and minimum oil level equal to 7.5% of total oil level
in transformer.
The conservator is provided with a magnetic oil level gauge
at one of the end covers, which has a low oil level alarm. The
dial indicates empty, ¼.350C, ¾ and full. An isolating valve is
provided in feed pipe. The conservator is also fitted with filling
holes and a drain valve.

(j) DEHYRATING BREATHER

The conservator is connected to outside atmosphere

through a dehydrating breather to make sure that the air in the
conservator is dry.

Air entering the breather is first drawn through an oil seal

and passes upward through the silica get crystal to the
connecting pipe at the top. During the upward passage of air
any moisture present is absorbed by the dry silica gel.

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.

(k) RELIEF VENT

In case of severe fault in the transformer the internal

pressure may be built up to a very high level, which may result
in explosion of tank. To avoid such a contingency, a relief vent
is provided on the tank cover. This consists of a 250mm
diameter pipe fitted on the cover. It is provided with a Bakelite
paper diaphragm at top, which break and relieve pressure in
case of excessive pressure build up. To equalize pressure, top
of the relief vent is connected to top of conservator by
equalizing pipe.

NGR

NGR means Neutral Grounding Resistance. Our transformer is

grounded through resistance in the neutral to earth path. The
purpose of NGR is to suppress the earth fault current during
the earth fault.

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

Lightening arrestors are wholly connected between phase

and ground in distribution system, near the terminals of large
medium voltage rotating machines and in HV. EHV sub stations
to protect the apparatus insulation from lightening surges and
switching surges i.e. impulse voltage wave.

The lightening arrester offers low resistance to high voltage

surge and diverts the high voltage surge to ground. Therefore
the insulation of protected installation is not subjected to the
full impulse wave. Lightening arresters discharge current
impulse surge to earth and dissipate energy in the form of
heat. After discharging the impulse voltage wave to the earth,
the resistor blocks in the surge arrester offers a high resistance
to the normal power frequency voltage and acts as open
circuit. Surge arresters are not against temporary power
frequency over voltages. They provide protection against
impulse voltage wave. The normal practice is to locate the L.A
as close as possible to the equipment to be protected.

ISOLATOR

Isolator is a switching device, which can be opened or closed

only under no current condition. An isolator disconnects a part
of system, from live parts under no load condition.

EARTH SWITCH

Earth switch is a switch that connects a conductor to the

earth so as to discharge the charge on the conductor to the
earth. Earth switches are generally installed on the frame of

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

This relay is generally used for the protection of oil-

immersed transformer. All types of faults occurring with oil
filled transformer are accompanied by more or less violent
generation of gases, which liberates heat from the oil. This
phenomenon has been utilized to provide complete internal
protection of the transformer. The falling of oil level, which
may lead to dangerous situation, is also detected by the relay
in time.

CONSTRUCTION

The relay is hydraulic device arranged in the pipeline

between the main transformer tank and the conservator tank.
It comprised a cast housing which contains two floats-upper
and lower. Each float carries a mercury switch; the leads are
taken to terminal box. The necessary petcocks for gas release,
site testing and a drawing plug on the body of housing are
provided. Inspection windows are fitted on both sides of the
relay housing to see the level & to ascertain the volume of gas
collected on calibrated scale in cubic centimeter. Mercury
switch rating is chose 2A at 240 AC or DC.

PRINCIPLE OF OPERATION

When the transformer is healthy, the entire relay housing

remains filled with oil and buoyancy of the respective floats
tilts the mercury switch to open position. But when a slight
fault occurs, small gas bubbles are generated and these
attempting to pass from the tank to the oil conservator.

As this gas accumulates, the oil conservator will be tapped

in the upper portion of the relay housing. The oil level in the
relay depresses causing the upper float to tilt thus closing their
mercury switch. The alarm circuit that is connected to this
switch gets energized to ring an alarm bell. With severe

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.

If transformer suffers a loss of oil, causing the oil level drop

below the level relay, the buoyancy of both the floats vanishes
one after the other, tilting the respective floats. First the alarm
and the surge element will operates to close their respective
circuits.

54
 MAINTAINANCE
BYPASS ISOLATOR MAINTAINANCE BYPASS LINE
º º

BYPASS ISOLATOR STATIC BYPASS LINE

º 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

Fig.2 Two modules using a common battery

MAIN RECEIVING STATION

55
INTRODUCTION

It is clear from the name itself that this section is mainly a

receiving end of power from all the sources of power such as
CPP and PSEB. The main motive of this station is to collect all
the power from the sources and then to synchronize them,
resulting into a uniform supply and then to carry on distribution
to different plants located in the NFL premises. It may be kept
in mind that synchronization actually takes place in MRS. After
that MRS steps the in coming common busbar supply of 132KV
to 11KV by making use of three transformers of 132/11KV
rating, out of which one transformer is spare. Also metering of
incoming supply is done so as to record the total energy
consumed. The 11KV thus generated is supplied to the various
plants such as Urea, Ammonia, CPP etc.

ELECTRICAL EQUIPMENT USED IN MRS YARD

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

1) It should be able to drain the surge from the line in

minimum time.
2) It should offer high resistance to the flow of the power
current.
3) No system disturbance must be introduced by the operator
of lightening arrestors
4) Always be in perfect term to perform the function occupied
to it.

56
 CURRENT TRANFORMER

It is used for measuring large alternating currents. The

primary windings consists of only one or few turns and is
connected in series with load circuit and carries the load
current to be measured. The secondary consists of many turns
than primary and have the instrument like ammeter, directly
connected across it. As the load impedance on the secondary
is very small, so CT operates on short circuit condition. Also the
current in secondary winding is not governed by load
impedance on the secondary but depends upon the main
circuit current.

CORE

CT is designed with a view to minimize the current ratio and

phase angle errors. Core is made from high permeability and
low magnetic material such as silicon steel. Losses are also
kept down by keeping low values of flux densities. The
transformer may be shell type or having a rectangular or ring
shaped core. The shell form gives considerable protection to
windings but is more difficult to build up. The rectangular forms
provide ample space for insulation and are suitable for high
voltage work. Ring form is used when the primary current is
large.

WINDING

The coils are wound close together in order to reduce the

secondary leakage reactance. Copper strips are used for
primary winding and No. 14 S.W.G. copper wire is generally
used for secondary winding. The winding must be designed
with a view that they must withstand the forces experienced
by them. The very large forces which develop when a short
circuit takes place on the system in which the transformer is
connected.

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

It consists of core winding, porcelain insulator, steel tank

with integral secondary terminal box, top chamber.
Core and windings
132 KV PT consists of primary winding and secondary winding
mounted concentrically on a core carrying mutual flux. The
voltage being measured acts across the primary winding that
has large number of turns and connected across the circuit.
The secondary winding which has a much smaller number of
turns is coupled magnetically through the magnetic circuit to
primary winding.

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:-

Type OFTR 31500/132 E

Standard IS 2026
Make NGEF
Rated KVA OB- 26,500

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: -

Make General Electric Co. of India

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

From transformer L.V side to 11 KV bus we have fine cable

per Phase of 400 sq.mm is running. These cables are made up
of XLPE (Cross linked polythene). We have XLPE cables in our
C.P.P Switchyard. XLPE has following properties:

(i) Inherent moisture resistant

(ii) High flexibility
(iii) Simple accessories
(iv) Smaller size
(v) Outstanding dielectric properties
(vi) High temperature resistant
(vii) Mechanically strong

HORN GAP

Horn gap is the simplest protection of line insulators,

equipment.
The conductive rods are provided between the line terminal
and earthed terminal of the bushing of transformers with an
adjustable gap. Medium of gap is air. The gap is adjusted to
breakdown at about 20% below flash over voltage of bushing

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

Power is drawn from PSEB grid through double circuit 132KV

overhead lines at M.R.S. This 132KV transmission lines have
toppings with different equipment before stepped down for e.g.
lightening arresters, C.Ts, insulators etc. ln MRS a bus bar is
made which at 132KV, 800A, 3500 MVA. Now this supply at
132KV is stepped down to 11KV by using step down
transformer of 20/26.5 MVA (132/11 KV). There are three such
transformers. New bus bar is made at 11KV, 1600A, and
3250MVA. From the MRS the power is supplied to different
plants. There are feeders from Ammonia, Urea, CPP, SGP. This
supply is further step down to 3.3KV, 415V-using transformers
for operating H.T and L.T motors respectively. Different sub
stations of various plants receive energy at high voltage and
reduce this voltage to a value appropriate for further
distribution and provide facilities for utilization of energy.

61
 AMMONIA PLANT

INTRODUCTION

Ammonia is the key intermediate product for manufacture

of urea. Ammonia plant has production capacity to produce
900Te/day of ammonia based on partial oxidation of residual
fuel oil by shell gasification process. The plant is laid out in
single stream except for the three gasification units. The raw
synthesis gas from the gasifier is further processed for H2S
removal by low temperature Rectisol Process and then sent to
CO shift section to convert CO to H2 and CO2. The process gas
is then fed to CO2 removal section where CO2 is removed by
low temperature Rectisol Process. The decarbonated gas is
sent to Nitrogen wash unit for final purification by scrubbing
with liquid nitrogen at -1900C & 37 kg/cm2 pressure. After final
purification in nitrogen wash unit, Hydrogen and Nitrogen ratio
in synthesis gas is maintained @ 3:1 and is compressed to
190kg/cm2 pressure and ammonia synthesis is carried out.

The oxygen required for partial oxidation and nitrogen

requirement for synthesis gas as well as utility nitrogen is
produced in the air separation plant.

The plant has been supplied as a package unit by M/S HITACHI

and was plagued with constraints during the initial years of
operation. These constraints have now been overcome by:
Interconnecting the screw refrigeration compressor with the
main refrigeration compressor of the synthesis section.
Changing the material of construction of the air pre coolers at
the upstream of the chilling unit from C.S. tubes to S.S. tubes.
Increasing the packed volume of mol. Sieve in the ASU dryers.
Modifying the air drier post filtration system of air before
entering the cold box.

POWER DISTRIBUTION IN AMMONIA PLANT

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.

EQUIPMENTS INSTALLED IN AMMONIA PLANT

M.M.G SET
Specifications regarding the AC continuous running power
supply equipment that is used in ammonia plant.

1. INDUCTION MOTOR

Type Totally enclosed, fan cooled

Output 75 kW/140 kW
Volts 415 V
Frequency 50 Hz
Speed 475 RPM
Insulation E class
Phases 3
Current 1.25/260 A
Poles 4
Ambient temp 45°C
Weight 825Kg

2. A.C.GENERATOR

Type Guarded drip proof

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)

Type guarded drip proof

Output 75KVA/210KVA
Volts 415V
Frequency 50Hz
Speed 1500RPM
Insulation B class
Phases 3
Current 370/700A
Poles 4
Ambient temp 45°C
Weight 880Kg

PRINCIPLE OF OPERATION

STARTING

The 3-phase AC input (415V, 50Hz) received by the input

terminals is supplied to the induction motor via the input
switch and magnetic switch. To close push button is it is
depressed and auxiliary relay becomes energized causing
magnet switch to close. When timer times out having
measured off the time required for the input current to be
reduced to a given level, auxiliary relays becomes energized
and IM starting is completed, permitting light to go out.
Simultaneously, the initial excitation circuit of the ACG is
closed, opening again once ACG voltage has been established,
so that the system is then ready for operation.

REGULATION OF ACG OUTPUT VOLTAGE

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.

REGULATION OF ARMATURE VOLTAGE AND SPEED OF

DCM

This regulator serves as an automatic voltage regulator

(AVR2/ASR), when DCM is driven by IM, senses changes in the
voltage of the motor armature and battery to keep the
difference in voltage between them at a constant level, and
reduces the decline in the AC power failure. AVR2/ASR also
serve as an automatic speed regulator , when the motor
operates on battery power after an AC power failure and feeds
its output to the fields of motor.

BATTERY POWER SLECTION IN AC POWER FALIURE

A power selection circuit is formed when the output

voltage of the ACG has been built up. Low voltage relay and
low frequency relay connected to the AC input power source or
counter electromotive relay becomes energized when the
power supply voltage and frequency falls below 85% of rating
and 47.5Hz and following operation takes place automatically:

BATTERY POWER SLECTION :

With relays such as low voltage relays and low frequency
relays energized, auxiliary relays are energized causing DC
electromagnetic switch to close, hence, power switch is
changed over from AC to battery and AC electromagnetic
switch is opened simultaneously. When timer has counted 4
sec (0.5 to 5sec), it sends a signal power supply from the
commercial AC power source to the ACG.

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.

A.C. POWER RESTORATION :

When AC power voltage and frequency are restored to

90% or more of the rated voltage and 47.5Hz or more,
detection relays are energized and following operation take
place:

AC POWER SELECTION

Power supply to the charger is restored. When recovering

charge is completed, a floating charge is automatically starts.

PROTECTION

Following protections are provided which cause immediate

and automatic shutting off power supply and giving a warning
signal.

(a) DCM over current

(b) DCM over speed (when field current is reduced to zero,

speed may become infinite.

(c) Overtime battery drive: equipment operates for about

15min, after an AC power failure, according to the setting on
time before it stops automatically and issues a warning signal.

(d) Abnormal battery voltage (voltage drop).

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.

(f) Abnormal DCG voltage

(g) ACG over current

(h) IM over current

(i) Abnormal power

(j) Abnormal increase in bearing temperature

(k) ACG grounding

(l) Control circuit

TRANSFORMER

Two 10MVA transformers are installed in the ammonia plant

which steps incoming the incoming supply of 11kV from MRS to
3.3kV to be used for HT motors.

DESCRIPTION :

Make General Electric Company of

India
Temperature rise in oil 45°C
Ratings 10,000kVA
Volts at
H.V 11,000
L.V
3,460
Amperes H.V 524

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

AUTOMATIC SPEED REGULATOR FOR DC MOTOR

This serves as an AVR for DC motor which is driven by an

induction motor, senses a change in the voltage of the motor
and battery to reduce the difference in voltage between them
to a minimum, reduces the decline in the AC o/p voltage and
rush current of the motor to a minimum in an AC power failure
and serves as an automatic speed regulator when the motor
operates on battery power after AC power failure. This
equipment comprises a voltage detection circuit, speed
detection circuit and auxiliary relays for voltage & speed
selection.

WORKING PRINCIPLE

DETECTION CIRCUIT

This equipment uses two detection circuits; one to detect

changes in voltage when DC motor is driven by induction
motor, known as voltage detection circuit, And the other to
detect changes in speed, when the DC motor operates on
battery power, known as speed deviation detection circuit
Along with detection circuit, an amplifying circuit is also
present. Since the differential voltage is quite small, it is
necessary to amplify it to sufficient power to make effective
control possible. This is carried out with a magnetic amplifier.

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.

AUTOMATIC VOLTAGE REGULATOR AC

GENERATOR

The output voltage of the AC generator is caused to fluctuate

by changes in the speed and load variations. The AVR serves to
keep the output of ACG at a constant level so that load is
stabilized. The schematic diagram of AVR is shown:

CIRCUIT DIAGRAM OF AVR

MAIN
REFERNCE AMPLIF SYN C KT SCR CT ACG
VOLTAGE &OSCILL CKT
ER ATOR SCR

RECTIFIED & VOLTAGE

DIVIDER

OPERATION OF AVR

The output of the reference voltage generator is compared

with the feed back voltage by the detector. If the voltage of the

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

IT is uniquely designed self excited compound wound

generator.

MAIN FEATURES TYPE KA-70 SERIES

1. Brush exciting system adopted so that elimination of slip

rings & brushes that require heavy maintenance is possible.

2. The most important characteristics fro diesel generator is

voltage regulation for which new AVR which directly controls
the filed current with the thyristor circuit incorporated in the
rotor section.
By virtue of new AVR, KA-70 series generator can start up
cage rotor type motor with the same rotor with conventional
brushless type generator can stand up. Voltage regulation
under steady operation is within ±1.0%.
The KA-70 series generator has a cylindrical rotor. To obtain
uniform distribution of temperature rises in cores and windings
in axial direction, both sides of rotor are provided with cooling
fans.
The standard mountings of the exciter are over hung type on
the bracket of the counter coupling side. The rotary (thyristor &

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

The generator frame is constructed of welded steel plates.

The basic structure and size are common to those of induction
machines. The stator & rotor cores employ Silicon steel
laminations. The stator is an armature while rotor is a magnetic
field assembled in the cylindrical type structure.
Slot for field winding are provided at the same interval along
about 2/3 the entire periphery Cu bars as end rings are used to
make up a squirrel cage type damper winding.
The armature winding along with the core is put in a vaccum
tank and impregnated with ‘MEW’ resin. After completion of
thorough treatment of the winding, the core is installed in the
frame. In this arrangement of field winding in the slots,
temperature distribution is uniform and effect of cooling is
favourable. The field winding is fixed rigidly to the core by use
of resin treated glass fiber wedges. Then bearing is of plain
type on a single bracket support system for the standard
machine.
Initial flush excitation is required & provided from outside to
establish voltage at the time of starting.
In general cases, batteries for controlling may be utilized as
power source for this purpose.

AVR OPERATION

The AVR to be mounted on the rotor makes a comparison

between the constant setting voltage & the AC output phase
voltage. The setting voltage is obtained from ACEX induced
voltage through rectifier circuit. The ACG output voltage VAG is
obtained from the rotor through rotary transformer RT. This
comparison is carried out in the detector circuit. The resultant
differential component is amplified at the amplifier comprising
IC’S and transistors. The gate signal is obtained at the phase
shifter is used for phase control of thyristor output voltages.

71
This finally to control the ACG field current to keep the ACG
voltage always constant.

EXCITER CONSTRUCTION

This exciter is located on the stator side while the rotor

accommodates an armature circuit, arranged in rotary
armature system. The exciter cores are made up of punched
silicon steel laminations. Both armature and field winding are
of class B type insulation. Insulations and resins bands at the
ends of the rotor are made on same way as those for
generators.

ROTOR RECTIFIERS

For this series is composed of mold packed AVR electronic

components together with conventional rectifier elements. The
peripheral section is used as a rotary transformer for
transferring the detected terminal voltage to the rotary
section.

CONDITION FOR AUTO STARTING OR STOPPING

STARTING

When under voltage on one of the tree panel’s emergency

diesel engine starts automatically.
When the engine start and the generator voltage is
established command shall be given to the normal supply
breaks in the emergency panel.
After a certain confirming times, generator circuit breaks
shall be closed automatically and generating will be steady to
operate under normal running conditions. Simultaneously, a
closing command shall be given to emergency supply breaks in
emergency panel.

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.

2. After all normal supply is restored and change over from

emergency supply to normal supply is finished, generator B
shall be opened and the engine will be stopped automatically.
Generator will be started after 8 seconds of power failure and
shall be able to supply load corresponding to rated capacity
within 3033 seconds after supply.

CONVENTIONAL SELF EXCITED GENERATOR

The exciting circuit of the exciter is provided with compound

CT’S to assure the ability of excitation even against large
voltage dip due to short circuit failure offers an exact
accomplishment of selective separation of faulty loads. The
static exciting circuit for the exciter is composed of small
components all assembled in a single frame & installed in the
generator panel. This system eliminates a special exciter panel
often required for self excited compound type.

UREA PLANT

In this plant 1500 metric tons of uncoated pilled urea per

stream day are produced by signal train wing

The plant can be divided into four sections

73
Synthesis Section
Decomposition Section
Recovery & Crystallization
Prilling section

Different steps being carried out in these sections for urea

production can be described as follows

SYNTHESIS SECTION

In this section, urea is synthesized in urea is synthesized in

urea reactor
(DC-101) under high pressure and temperature from CO2 liquid
ammonia and recycle carbonate solution, the temp and
pressure in the urea synthesis reactor, and ratio of ammonia to
CO2 are so selected that maximum conversion of CO2, to urea
is achieved with minimum cost.

DECOMPOSITION SECTION

The gas liquid mixture from urea synthesis section (reactor)

flows to the decomposition section, where all the excess
ammonia and ammonia carbonate are separated from aqueous
urea solution by thermal decomposition in high pressure
decomposer (HD) and low pressure decomposer (LD) gas
separator (GS)

RECOVERY SECTION

The gases from gas separator go to off gas condenser cool

down to 61ºC by C.W. and enter into the bottom off gas
absorber. Similarly gases from H.D.L.D are condensed /
absorbed in high-pressure absorber, low-pressure absorber is
MP loop ammonia is separated in H.A. and it is condensed and
recycled back to ammonia reservoir. The inert gases along with

74
residual ammonia passes through purge, ammonia condenser,
vapour ammonia condensed and recycled back to ammonia
reservoir.

In recovery absorbers, ammonia is absorbed in aqueous

thus formed about 80% by wt. is with draw from lowest
absorber and fed to the top of high absorber.

CRYSTALLIZATION AND PRILLING SECTION

The urea solution coming from gas separator (DA-203) is

pumped to the lowest part of the crystallizer, which consists of
two parts. The upper part is a vacuum concentrator with
vacuum generator in which vacuum is or sated by a two stage
steam ejector having barametric condenser and an indirectly
cooled interstage condenser the lower part crystallizer where
urea crystals are suspended in the solution

The urea slurry is pumped from bottom of the crystallizer

to centrifuges. In centrifuges urea crystals are separated from
slurry. The urea crystals with about 2.5% moisture are
discharged to fluidizing dryer. The separated mother liquid
tank and is pumped back to crystallizer and low-pressure
absorber.

The drilled crystals from dryers conveyed by a pneumatic

pipe to the top of prilling tower and crystals are collected in
cyclone and fed to melter. In melter, the crystals are melted
and molten urea flows down to head tank through strainer for
distributors and from distributors it falls down in prilling tower
(IA-301) being cooled and solidified in the process.

The urea dust collecting equipment is provided to minimize

air pollution by tower effluent; dust chamber is provided for
scrubbing. Then the air is exhausted to atmosphere by induced
fan for pt. After water mist from scrubbing section is eliminated
by the filters.

The urea slurry is pumped from bottom of the crystallizer

to centrifuges. In centrifuges urea crystals are separated from
slurry. The urea crystals with about 2.5% moisture are

75
discharged to fluidizing dryer. The separated mother liquid
tank and is pumped back to crystallizer and low-pressure
absorber.

The drilled crystals from dryers conveyed by a pneumatic

pipe to the top of prilling tower and crystals are collected in
cyclone and fed to melter. In melter, the crystals are melted
and molten urea flows down to head tank through strainer for
distributors and from distributors it falls down in prilling tower
(IA-301) being cooled and solidified in the process.

The urea dust collecting equipment is provided to minimize

air pollution by tower effluent; dust chamber is provided for
scrubbing. Then the air is exhausted to atmosphere by induced
fan for pt. After water mist from scrubbing section is eliminated
by the filters.

NFL has been the market leader for manufacturing and

marketing of Urea. The capacity utilization during the year
2004-2005 has been 106.2%.

76
POWER SUPPLY SYSTEM :

In urea plant, two feeders of 11kV supply are received

from MRS in urea substation at 11kV panel. This is further

77
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.

Normally similar feeders are divided into two groups and

fed from alternative sections. It is being done to have
availability of partial equipments in case of limitation to some
sections. These two feeders are connected together through
bus coupler so that when one feeder fails, the bus coupler
operates and the load connected to that feeder gets connected
to the other feeder automatically.

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

Synchronous motor is not self starting. The current in a

synchronous motor is approximately in phase opposition in
phase to the EMF generated current, remains high for longer
period to avoid the tripping of motor circuit. The effect of
armature reaction is to increase the flux in leading half of each
pole. The flux is distorted in the direction of rotation and the

78
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.

STARTING OF SYNCHRONOUS MOTOR

When the rotor of three phase synchronous motor is stationary,

the rotating magnetic field due to stator currents produces an
alternating torque on the rotor i.e at once instant the rotor is
moved clockwise and other counter clockwise. Since a net
torque is zero, a synchronous motor is not self starting. The
method to bring the motor up to synchronism is as follows:-

By damping grid in pole shoes:- these grid consist of copper

bars short circuited at each end. The rotating magnetic flux
induces current in these grids and the machine accelerates.
During the starting period the rotor field winding is usually
closed through the armature of exciter, normally a DC shunt
generator carried on the extension of the shaft and current in
the stator is limited to permissible value. When the machine
has reached nearly full speed, the rated voltage is applied to
stator winding and the exciter voltage will have built up
sufficiently to magnetize the rotor poles. The resultant
magnetic flux due to stator current is then moving past the
rotor poles at a slow speed and produces a slow frequency
alternating torque superimposed upon that exerted by the
damping grids. Consequently the rotor is accelerated at one
instant and retarded at other and the fluctuation of speed is
sufficient to bring the rotor up to synchronous speed. Once this
speed has been attained the rotor can run in synchronism.

79
SYNCHRONOUS MOTOR SELECTION CRITERIA

We are having 2200kW, 11kV synchronous motor for running

CO2 compressor UNB102. Why this motor was selected? Why
we have not gone for an induction motor or steam turbine?

REASONS : -

LOW SPEED RESIPROCRATING COMPRESSOR

CO2 compressor popularly known as KOBE compressor is a low

speed reciprocating compressor. We need very constant speed
for this compressor. Normal induction motor has effect of
voltage, frequency & mechanical loading on its speed due to
said reasons, so this synchronous motor is selected.

POWER FACTOR IMPROVEMENT

In electrical AC system, voltage and current are concurrent.

They always deviate with each other by some angle when
drawn vertically. Cosine of this angle is known as power factor.
LOW POWER FACTOR HAS SUCH DIS ADVANTAGES : -

IT affects the efficiency of generating station. Large electrical

equipment such as transformers, motors are inductive in
nature and they result in low pf of the system. Resistive loads
have limiting pf. Capacitive loads are used to improve pf, which
takes care of the motor of the loads. If we would have used an
induction motor of 200kW, then capacitor requirement to
improve the pf must have increased considerably. To
overcome that problem, synchronous motor has been used,
which maintains its own pf along with improving the pf of the
system.

PROTECTION OF MOTORS

All the equipments are provided with sufficient & efficient

protection system. For HV motors, sophisticated relays such as
CIM relays,CAU relays etc are provided which monitor the

80
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.

ADVANTAGES OF SYNCHRONOUS MOTOR

The ease with which the pf can be controlled. An

overexcited synchronous motor having a leading pf can be
operated in parallel with induction motors having lagging pf
thereby improving the power factor of the supply.
The speed is constant and independent of the load this is
mainly used when the motor is required to derive another
alternator to generate a supply of different frequency.

DISADVANTAGES OF SYNCHRONOUS MOTOR

1. Cost per kW is higher then induction.

2. DC supply is necessary for rotor excitation. Small DC shunt
generator carried on the extension of the shaft usually
provides this.

81
 OFFSITES AND UTILITIES PLANTS

D.M. WATER PLANT

Water in its natural form contains no. of dissolved salts

such as sulphates, chlorides and nitrates of calcium
magnesium and sodium. If water is used as such in the boilers

82
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.

It consisted of three units each of cation, anion, mixed

bed, four secondary mixed bed and three units of condensate
cation. At the time of setting up of a captive power plant,
another stream to augment the existing capacity of polish
water generation was by M\s BPMEL. It consisted of one unit
each of cation, anion, primary mixed bed, two secondary
mixed bed and two condensate cations.

Filtered water is received from raw water filtration plant

into two filtered water reservoir feed water pumps discharge
water from these reservoir tom cation units. These are total
five feed pumps each having a capacity 0f 130m3/hr and four
cation units. Three of these are charged with 13125L of cation
resin and fourth unit is having 11900 0f resins. Cation like Na+,
Ca++, and Mg++ present in the water are removed in the cation
unit once exhausted, these units are regenerated with the
counter current flow of dilute sulphuric acid.

The present day resins are made of cross linked

polystyrene and cross linking is done by di vinyl
benzene.Cation resins are made of sulphonated polystyrene
SO3H can be represented by as RH.anionic resin is similarly
made but is chloromethylated and then is animated. The final
product is quaternary ammonium compound a strong base and
is represented by ROH.

SULPHUR RECOVERY PLANT

Sulphur recovery plant of NFL Bathinda has been designed

and engineered by M/S TOYO ENGINEERING CORPORATION,
JAPAN. It was originally designed for processing 1710 Nm3/hr of

83
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.

COOLING WATER SYSTEMS

The cooling water systems provided at NFL Bathinda are

closed recirculating type supplying cooling water to various
consumers in the plant. There are total three systems
supplying cooling water to different sections as mentioned
below:

Sl no. System Consumer

1. CT-1 Ammonia plant
2. CT-2 Urea plant,
boilers,
instrument air
compressors,
service air
compressors,
caustic dissolving
facility and
sulphur recovery
plant
3. CT-3 Crystallization
section of urea
plant
4. Emergency Ammonia storage
pumps ( can be area, instrument
connected with air compressors
CT-1 or CT-2) emergency diesel
set

Emergency cooling water pump is in continuous service for

ammonia storage area. It takes suction normally from CT -2;

84
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

Various other design conditions for all three cooling water

systems are given below;

COOLING WATER TREATMENT

Cooling water treatment is done to avoid following problems:

Corrosion
Scaling
Fouling
Microbiological growth

CORROSION

Corrosion is basically an electrochemical reaction by which

metal tends to return to its more stable state of oxide. The
main factors responsible for corrosion in cooling water systems
are low pH, dissolved gases, conductivity of water, presence of
certain corrosive ions such as chlorides and sulphates.
Various types of corrosion occurring in cooling water systems
are general corrosion, pitting, galvanic corrosion cracking,
stress corrosion cracking erosion and microbiological attack.
The approach to protect metal from corroding in cooling water
systems involves the formation and maintenance of a
sufficiently strong inhibitor film on the cathodic, anodic or both
areas.

SCALING

85
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

Fouling is the deposition of suspended matter. The most

common foulants in cooling water systems are dust, silt, clay
organics like oils and hydrocarbons and the microbiological
slime. These foulants are air borne as well as water borne.
Fouling does not merely results in drop in heat transfer
efficiency but also gives rise to under deposit corrosion
leading severe pitting. Fouling is normally enhanced due to low
water velocity. Low molecular weight polyanionic compounds
are used as anti foulants. These components get absorbed on
the surface of the foulest particles and increase the negative
charge. Thus when all particles are sufficiently negatively
charged they repel each other and thus dispersion is achieved.

MICROBIOLOGICAL GROWTH

Following tree types of microorganisms are responsible from

this type of problem:

ALGAE: it is normally observed on the exposed area o cooling

tower as it requires sunlight for growth.

FUNGUS: fungus is found on the wooden surface as it requires

surface and carbon source.
BACTERIA: Three important type of bacteria are:

86
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.

B.) SULPHATE REDUCING BACTERIA: these anaerobic

bacteria’s reduce sulphate ions to H2S
This causes local pH to drop. The hydrogen sulphide thus
formed reacts with metal surface to form metal sulphide.
These deposits are very hard to remove and lead to severe
pitting.

C.) IRON BACTERIA: iron bacteria directly oxidize the metal

causing severe pitting.
In general most of the species of bacteria present in cooling
water secrete slime. This slime acts as a binding medium for
the suspended matter and leads to fouling. The fouling
deposits in turn give shelter to aerobic bacteria which cause
direct corrosion.
In addition to chlorine and bromine use of non oxidizing
types of biocides is most. Various types of non oxidizing types
of biocides are methylene-bis-thiocynate, quaternary
ammonium compounds, isothiazoline, dichlorophenes etc.
these biocides are normally blended with effective surface and
penetrating agents. There by they can penetrate into the
deposit layers and can kill anaerobic bacteria.

INSTRUMENT AIR COMPRESSOR HOUSE

There are four compressors of reciprocating type. Air is

sucked from atmosphere and fed to L.P. stage. Air is sucked
from atmosphere and fed to L.P. stage. Air is compressed at
2.4 Kg & sends to H.P. stage after passing through intercooler
where air compressed up to 9Kg. This air is cooled to -15 ˚C. It
is oil and dust free.

PERFORMANCE:

87
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

PROJECT STUDY OF VARIABLE

FREQUENCY DRIVE

88
 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.

Each Boiler has 2 ID fans(INDUCED DRAFT FAN) and 2FD

fans (FORCED DRAFT FAN).

FORCED DRAFT FAN

The forced draft fans supply the proper amount of secondary

air required to support the combustion of the fuel delivered to
the boiler. The details of the FD fan are:

Make SEIMENS
Rating Continuous
Insulation class B
Rated power 160kW
Voltage 415V
Power factor 0.85
Current 258A
RPM 940
Poles 6
Connection Λ

INDUCED DRAFT FAN

The induced draft fans control the furnace draft by drawing

the gases of combustion through the boiler, regenerative air

89
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

90
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.

INTRODUCTION TO BASIC CONCEPTS TO BE

UNDERSTOOD

WHAT IS DRIVE

The power required by the machines for its working is

generally provided by electric motors.

The electric motor take electrical energy input and convert it

into rotational mechanical energy out put. This mechanical
energy drives the machine.

The electric power made available by State Electricity Board ,

at times for certain applications need to be modified and
controlled in a specific manner before giving it to the motor to
get the desired performance from the motor.

So Drive is nothing but the product that takes the available

electric power , converts it into the required form and then
gives it to the motor and in addition , provides required
protection to the motor and the system.

Example 1:

DRIVE 91
 AC supply --------→ --------→ Variable
DC
Voltage - Fixed
Frequency - Fixed

Example 2:

AC supply --------→ DRIVE

--------→ Variable Freq.
Voltage - Fixed
Frequency - Fixed Variable
Volt.
AC
supply

WHAT MOTOR PROVIDES ?

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.

HOW MOTORS ARE CLASSIFIED ?

There are various ways by which a motor can be classified.

One way is to classify motors on the Basis of type of electric
supply it needs.
1. DC motors need DC Supply
2. AC motors need AC Supply

As most widely used AC motor is 3 phase squirrel Cage

Induction Motor. This is because of its few favourable factors
such as :

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 1. Its Robust nature.
2. Small size and Weight.
3. Negligible maintenance.
4. Low Cost.

WHAT IS AC DRIVE ?

The electronic product that gives the desired power to AC

Motor is called AC Drive.
AC Drive takes Fixed Voltage, Fixed Frequency and converts
into variable frequency and Variable Voltage AC supply, that is
why this Drive is called “ VARIABLE FREQUENCY DRIVE
”.

WHY WE NEED TO GIVE POWER TO AC MOTOR

THROUGH AN AC MOTOR ?

The AC motors are normally rated for the rating of State

Electricity Board supply which in our case is 3 phase, 415 V,
50 Hz AC supply. When this supply is given to the motor, the
motor rotates practically at constant speed i.e. close to its
rated speed at all loads. If one needs variable speed at the
motor shaft then supply to the motor will have to be given
through an AC Drive.

HOW SPEED DEPENDENCE OF AC MOTOR IS

DIFFERENT THAT OF DC MOTOR ?

The speed of the DC motor is decided by the voltage applied to

its armature/field winding. In the case of AC motor the speed is
decided by the frequency of supply given to the motor.

WHAT IS RATED SPEED ?

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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.

The formula for synchronous speed (Ns)

Ns = 120 f / P
Where f is frequency in Hz.
and P is number of Poles for which the motor is wound.

e.g. The synchronous speed (Ns) for 4 pole motor running on

50 Hz is 1500 RPM.

e.g. The synchronous speed (Ns) for 2 pole motor running on

60 Hz is 3600 RPM.

It should always be kept in mind that the Rotor of the motor

always rotates at a speed little lower than the synchronous
speed.
Generally the rotor speed is less around by 4 %.

e.g. The speed of a 4 pole squirrel cage Induction motor

running on 50 Hz will therefore be around (1500 - 4 % of 1500)
= 1440 RPM.

WHAT IS SLIP ?

As we know now that the Rotor of a squirrel cage Induction

motor can never rotate at synchronous speed. The difference
in synchronous speed (Ns) and the actual rotor speed (Nr) is
called slip.

The slip is always expressed in percentage and is given by the

following formula.

% 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.

HOW CAN WE VARY THE SPEED OF AN AC

MOTOR, ELECTRICALLY ?

The speed of the rotor is decided by the synchronous speed,

which in turn is decided by the frequency of supply and the
number of the poles for which the motor is wound.

Thus there are two ways by which we can vary the speed
electrically.

1. Vary the frequency of supply given to the motor.

2. Change the number of poles for which the motor is
wound.

The first method will provide step less variation whereas the
latter will provide variation in steps.

STEP LESS VARIATION

STEPPED VARIATION

There is a limitation with regard to the possible number of

steps using pole changing method . Generally 2 to 4 speeds
are feasible.

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DO WE EXPECT ONLY VARIABLE SPEED FROM AN
AC DRIVE ?

Although the primary function of an AC Drive is to get variable

speed at motor shaft, the other important parameter that
needs to be taken care is to maintain torque producing
capability of the motor constant at all speeds. i.e. from
minimum to the rated speed of the motor.

IF SPEED OF THE MOTOR DEPENDS UPON THE

FREQUENCY, THEN TORQUE DEPENDS UPON
WHAT ?

The torque in any motor primarily depends upon motor flux

and the rotor current. In order to maintain torque producing
capability of the motor at rated value at all speeds . The rotor
current will then be totally dependent on the torque
demanded by the load i.e. more load or load torque
requirement less will be the rotor current.

DO WE NEED TO VARY THE VOLTAGE ALSO ?

Along with frequency we need to vary the voltage also in same

proportion i.e. if we make the frequency half then voltage
given to the motor should therefore control power switching
devices in such a manner that we get a supply of whose
frequency as well as voltage can be varied. In this variation we
should keep the ratio of the voltage to frequency constant.

E = 4.44 × F × Ø × Z

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