1|Page

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

UREA PRODUCTION
IN THE COUNTRY (2004-2005)

OF

NFL

IN

2|Page

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.

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 Companys 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 NFLs popular brands are sold over a large marketing
territory spanning the length and breadth of the country.

The Company also

3|Page

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 45%. 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 percentage of sale outside ECA was raised to 50% in Rabi 2003-04, The
same portion prevails for 2004-05 and Kharif 2005.

Need for NFL 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.

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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
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 and Panipat are fuel-oil based,
and at Bathinda and Guna are gas-oil based. The overall installed capacity of NFL plants
is 10.42 lakh MT per annum.

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Strategically Located - Urea Plants

Leading

Capital

Plants

Producer

Cost,

Capital

of

Feed

Nitrogenous

Stock

Cost Feed Stock

(Rs.Crore)

Fertilizers

&

Plants

in

the

Country.

Capacity

Existing Capacity
(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

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PRODUCTS OF NFL

National Fertilizers is producing Kisan Urea, Kisan Khad and Ankur on

commercial scale. NFL is also marketing number of Industrial products produced as ByProducts during the formation of Kisan Urea, Kisan Khad and Ankurin its plant itself.

FERTILIZERS PRODUCTS
Kisan Urea:
Kisan Khad:

INDUSTRIAL PRODUCTS (BY PRODUCTS)

Nitric Acid (HNO3)
Anhydrous ammonia (NH3)
Ammonium Nitrate (NH4NO3)
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

7|Page

company Toyo Engineering corporation limitedand 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.

REQUIREMENTS OF RAW MATERIAL / INPUTS

Fuel Gas

850 MT / Day

Coal

1680 MT / Day

Water

13 MGD

Power

28 MW

PROJECTs BENEFITS
Increased Food Output
Employment to nearly 800 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 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 .

8|Page

STEAM GENERATION PLANT

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 480C temperature to Ammonia
Plant.
In todays 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

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steam load consumption increases then the third boiler play its part in order to avoid any
faulty condition.

FUELS USED
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 Gas : As the Boilers are designed to work on both Coal as well as Fuel Gas so fuel gas can also be pu
Generally coal alone is not burnt Initially but Fuel Gas 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

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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
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 Gas Burners and Start Up
Burners/Igniters are arranged at two elevations. Thus there are 8 Gas Burners and 8
Igniters.
Igniters use LPG .
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.

O2

CO2

Heat

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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 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 240 C by the flue Gases and taken to Steam Drum. Steam
Drum Acts as storage tank and also separates water from the steam at 315 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.
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. 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.

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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

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.

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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.

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CAPTIVE POWER PLANT

INTRODUCTION
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

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and controlled. It allows fully automatic start-up, shut-down of boiler, turbine and other
auxiliaries.

NEED FOR C.P.P.

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 trippings had an ill effect on machines and equipments extending the restartup 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.

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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, 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:

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DESCRIPTION
MITSUI RILEY TYPE BOILER
Maximum evaporation

2,30,000 kg/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:
coal supply system.
primary air system.
seal air system.

COAL SUPPLY SYSTEM

Coal
bunkers

Coal
feeders

Crushers
dryers

Ball tube
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:-

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Make

MEIDEN

Degree of protection

IP 55

No of poles

Frequency

50Hz

RPM

1475

Power factor

0.89

Insulation class

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 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.

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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

No of poles

Voltage

3300V

Frequency

50Hz

Current

98A

Power factor

0.89

Type of construction

IEC-34

Power rating

445kW

Connection

Temp. risk limit normal

700C

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.

20 | P a g e

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

Rated power

320kW

Voltage

3300V

Power factor

0.85

Current

71A

RPM

980

Poles

Connection

CAPTIVE POWER PLANT

21 | P a g e

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

Rated power

295kW

Voltage

3300V

Power factor

0.83

Current

67.5A

RPM

735

Poles

Connection

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.

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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 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.

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Latest instrumentation has been used in this plant. Baileys net work-90
microprocessor based instrumentation system is being used. The NETWORK 90
SYSTEM is a distributed process control system. Using a series of integrated control
nodes. The network 90 system allows controlling process variables like flow, pressure
and temperature according to a control configuration. There is operator interface unit
(OIU) like a TV screen on which various parameters can be displayed and controlled. It
allows fully automatic start-up/shut-down of boiler, turbine and other auxiliaries.

DESCRIPTION

Make

Simmering Graz Panker, Austria

Type

Multifunction (28 stages)

Capacity

65 T/H at 15 MW

RPM

6789 at 50 Hz

Critical speed

3200-3600 RPM

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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:

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 MITSUI TOATSU TOTAL RECYCLE C IMPROVED PROCESS liquid
Ammonia is recycled since it is easier to handle but require equipments like Rectification
Column storage tanks etc. and higher capacity liquid Ammonia pumps.
In this section, urea is synthesized in urea is synthesized in urea reactor CO2 is
received from Ammonia Plant at a pressure of 0.2 kg/cm2 and 20oC and is compressed in
a Centrifugal booster compressor, UGB-101 to 32 kg/cm2 in a 3 stage unit.

The

Compressor supplied by M/s BHEL has a normal capacity of 25256 NM3/hr and has 2
barrels 2 M.C.L. 805 and MCL 455. The drive of the Compressor is a extraction and
condensing type of steam turbine supplied by M/s BHEL. The turbine is driven by 40K
super-heated steam and has a rated output of 5792 KW.

25 | P a g e

UREA SYNTHESIS
2NH3 + CO2= NH2 COO NH4

H = -37.64 Kcals.(i)

NH2COO NH4= NH2 CO NH2 + H2O,

H = 6.32 Kcals..(ii)

Where as reaction (i) is exotheromic and rapidly goes to completion (ii) is

endothermic and is always incomplete. The overall reaction is exothermic and hence heat
has to be removed continuously for the equilibrium reaction to proceed. The conversion
of ammonium carbamate to urea depends upon:

i)

Reaction temp. and pr.

ii)

Mol ratio of NH3/CO2, H2O/CO2 of the feed reactants.

iii)

Residence time

The conversion increases with the increase of temp. NH3/CO2 ratio and residence
time and decreases with H2O/CO2 ratio since the presence of water tends to shift reaction
(ii) in the backward direction. The Pr. employed depends on the reaction temp. and has
to kept higher than the dissociation pressure of ammonium carbamate at that temp.
Further since the dehydration of ammonium carbamate to urea takes place in Liq. phase
only, the Pr. employed must also be higher than the Vap. Pr. of ammonium carbamate
which is rather high.

Higher ratio of NH3/CO2 increases conversion and helps to minimize corrosion. As

this ratio increases the load on recovery section increases since excess NH3 over
stoichiometric requirement has to be recovered and recycled back to reactor. This excess
Ammonia can either be recycled as (a) Liq. NH3 or (b) carbamate, in which case it
becomes necessary to inject CO2 into carbamate condensers.
The compressed CO2 is washed with water in a packed bed tower called methanol
Absorber for removal of entertained methanol in CO2 which is normally 1000 ppm. The
washed CO2 is further compressed to a pressure of 260 kg/cm in a two stage compressor,

26 | P a g e

UGB-102 supplied by M/s KOBE STEEL, JAPAN. This reciprocating Compressor has a
normal capacity of 26260 Nm/hr and is driven by a 2.2 MW Synchronized motor. Anti
corrosion air at the rate of 65 Nm/hr is fed to CO2 at the suction of Centrifugal CO2
Booster Compressor.
Liquid Ammonia at 11C and 18 kg/cm pressure is received in the Ammonia
Reservoir, UFA-401 from the Horton Sphere. Ammonia Booster Pump UGA-404 A & B
booster the pressure of the feed pumps UGA-101 A D. The Ammonia Feed Pumps are
of URACA MAKE driven by 3.3 kV/450 KW and have capacity of 53.2 m/hr., 178
RPM and 89% efficiency. The ammonia feed pumps deliver the liquid ammonia at 260
kg/cm to Ammonia Pre-heater. The pre-heated ammonia at 65C is fed to the Urea
Reactor at bottom.

The Recycled Carbamate solution of CO2 concentration, 7.5 Lit per 25 ML, at 105C
and 260 kg/cm pressure is delivered to the Urea Reactor at bottom by Recycle
Carbamate Solution Pumps UGA-102 A & B. These pumps are centrifugal type and are
driven by backpressure steam turbine, supplied by M/s EBARA of Japan and have
capacity of 81 m/hr.

The three feeds i.e. CO2 liquid Ammonia and Recycled pump solution are fed to a Ti
lined multi wall Urea Reactor. The Urea Reactor is a multi wall shell having wall
thickness of 37mm x 4 = 148mm as thickness. Ti liner thickness is 6mm from bottom to
7900mm, 5mm upto 3950mm, 4mm for next 3950mm and 3mm for rest height. Top and
bottom dish end cladded Layer Urea Reactor. The Urea Reactor is a 12-layered C.S.
vessel with Ti Liner thickness of 5 mm, 4 mm and 3 mm for the 1/6, 1/6 and 2/3rd of
total height of the Reactor from Bottom. The Reactor top temperature is maintained at
200C maximum. The effluents from Urea Reactor from top are let down to 17.5 kg/cm
pressure through a pressure control valve PCV-101 and fed to the high pressure
Decomposer at 124C.

27 | P a g e

DECOMPOSITION SECTION
MISTSUI TOATSU TOTAL RECYCLE C IMPROVED PROCESS is a conventional
process.

The decomposition reaction, NH4 COO NH2-------2NH3 + CO2 is favoured by lower

pr. of system or by low partial pr. of one of the reaction products i.e NH3 and CO2.
Conventional Process mean the process where decomposition is affected by lowering in
pressure in successive stages followed by indirect heating whereas the processes where
decomposition takes place by lowering the partial pr. of either NH3 or CO2 followed by
indirect heating are called STRIPPING PROCESSES.

The Reactor effluents at 17.5 kg/cm and 124C enters the upper part of High
Pressure Decomposer UDA-201 having 4 sieve trays at upper and falling film heater at
lower section. The flashed gases go up and liquid flows down through sieve trays. On
trays the high temperature gas from Reboiler, U-EA-201 and falling film heater contacts
with the liquid flowing down. The sensible heat of gas and heat of condensation of water
vapour are used to evaporate the excess ammonia and to decompose the carbamate.

This helps in minimizing water evaporation and thus reducing water recycle to
reactor. The Reboiler further heats the liquid by 12 kg/cm steam to release excess
ammonia and carbamate as gases. The temp. at middle is maintained at 151C by a
temperature control valve TCV 201. The temp. at bottom is maintained at 165C
through TCV-202. The falling film heater is used to minimize residence time in order to
reduce Biuret formation and hydrolysis of urea.

Anti corrosive air is fed to high Pr. Decomposer and Reboiler through air compressor
UGB-201 @ 2,500 ppm as air. Overhead gases from HD are absorbed in HAC (High
Pressure Absorber Cooler). The bottom liquid flows to L.D. (Low Pressure decomposer)
at 2.5 K, 145C Upper Part, having 4 sieve trays. A similar phenomenon occurs in the
low Pr. Decomposer. The Reboiler UEA-202 provides heat using 7 kg/cm steam for

28 | P a g e

decomposition and hot stream from H.D. heats up solution from LD in a Exchanger
before entering the upper part. The temperature is maintained at 130C at middle by
TCV-203. Small amount of CO2 is fed below packed bed for improved stripping of
decomposed gases. The over head gases from low Pr. Decomposer are absorbed in low
Pressure Absorber U-EA-402. Bottom liquid flows to 3rd stage of Decomposer called
Gas Separator U-DA-203. The upper part of gas Separator operates at 106C, 0.3 K and
lower part with packed bed operates at 92C and atmospheric pressure. The sensible heat
of solution from low pressure decomposer is enough for evaporating the over head gases.
In the lower part air, containing trace amount of NH and CO2 is blown under the packed
bed, by off gas recycle blower UGB-401. The Urea solution is concentrated to 70 72%
and sent to crystallization section.

CRYSTALLIZATION AND PRILLING SECTION

The Urea solution obtained from the last Decomposition stage i.e. Gas Separator contains
27% H2O since for every mole of urea one mole of H2O is formed. Urea has to be
concentrated to 99.5% before prilling.
MTC C- IMPROVED PROCESS employes Crystallisation remelt Prilling route
and uses spray nozzles for prilling. The prilling tower is of induced draft type.

The solution from Gas Separator enters lower part of Crystallizer, U-FA-201. The
upper part is vacuum concentrator with two stage ejectors and Barometric condenser.
In Vacuum concentrator, operating at 75 mm Hg and 60C, water is evaporated and
supersaturated urea solution comes down through barometric low into the crystallizer,
where Urea crystals grow. The heat required for water evaporation comes from:

i)

Sensible heat of feed urea solution.

ii)

The heat of urea crystallization

29 | P a g e

iii)

Heat recovered by urea slurry circulated through High Pressure Absorber.

The Crystallizer is operated at 60C and atmospheric pressure, so that slurry
leaving the bottom contains about 30-35% urea crystal by weight.

Hot water from hot water pump is used in jackets of crystallizer and pipe to avoid
crystal build up on vessel walls, which may cause choking otherwise.

The urea slurry is pumped from Crystallizer bottom to Centrifuges U-CF-201 A-E
(1000 rpm, 43 Te/hr of slurry ) maintaining minimum recirculation to Crystallizer to
prevent chocking of lines.

Biruate remains with mother liquor, which after separation from the urea crystals in
the centrifuges is recycled back to the system. Because of excess ammonia in reactor
biurate, thus recycled is converted back to Urea.

NH2CO NH CO NH2 + NH3 ------- 2 NH2 CO NH2

(Biuret )
Urea crystals separated from slurry with 2 4 % moisture are discharged to
fluidising dryer UFF-301 at 110C.

The mother liquor flows down to Mother Liquor

Tank, provided with steam coils. Mother Liquor is pumped back to crystallizer via LCV207. A part of mother liquor going to low Pr. absorber has been cut off and instead dust
chamber overflow solution has been lined up.
Air is blown from Blower U-GB-301 (82360 NM3/hr) and heated to 110C in air
heater. This hot air dries the crystals to 0.1 to 0.3% moisture content. Dried crystals are
conveyed by a pneumatic duct to cyclones at the prilling tower top. The collected
crystals are melted in melter ( 137C ) and Urea melt is sprayed through 12 Nos. acoustic
granulators. Prills are cooled in fluidizing bed called CFD, installed a the Prilling Tower
Bottom. Air/cyclone is scrubbed for urea dust in dust separators (2 Nos.). Air containing

30 | P a g e

Urea dust from P.T. column is scrubbed with water and passed through 144 sets of
polyurethane filters before exhaust to atmosphere to reduce air pollution.

INSIDE PRILLING TOWER

RECOVERY SECTION
The gases from Gas separator are condensed in off gas condenser UEA-406 to 62C
and enter the bottom of off gas Absorber DA-402 (OGA). Condensed liquid flows down
to off Gas Absorber Tank UFA-203. After cooling to 36C, liquid is sent to top portion
of OGA as absorbent. OGA bottom fluid is recycled as absorbent at OGA middle
position (2nd bed).

Air from top of OGA is blown to gas Separator by GB-401 Blower. The gases from
Low Pr. Decomposer are absorbed in Low Pr. Absorber (EA-402) bubbling a Sparger.
Dust Chamber over flow solution (10-15% Urea) is used as absorbent. Low Pr. Absorber
Temp. is controlled at 45C and CO2 concentration 2.2 Lit/25 ml.

31 | P a g e

Solution from L.A. is pumped by GA-402 A/B to High Pr. Absorber (DA-401)
middle through mixing cooler where liquid ammonia is mixed and serves as medium in
the absorber.

The gases from HD top are bubbled through a sparger in High Pr. Absorber cooler
EA-401, where 65% of CO2 is absorbed. Remaining gases from HAC go to HA and are
cooled down to 80C max. in middle cooler at the bottom of H.A. 35% CO2 is absorbed
in packed bed by a mixture of lean carbamate from Low Pr. Absorber through FCV-401
and liquid ammonia from GA-404 A/B (Temp. 60C max) through FCV-402. The
scrubbed gas then passes through five Nos. of bubble cap trays in order to absorb residual
CO2 by a mixture of aqueous ammonia (GA-405 A/B) and liquid ammonia (GA-404
A/B) through FCV-403. Ammonia gas from High Pr. Absorber, Temp. 50C is pure and
condensed in five Nos.of condensers (EA-404 A-E) and purge condenser EA-403.
Liquid Ammonia flows down to Ammonia Reservoir FA-401. Non-condensable gases
(inerts mostly) flows to Ammonia Recovery Absorber (EA-405 1 to IV). Recovery loop
pressure is controlled by PCV-405 (16.5 17.5 K) at top of EA-405 IV. Cold steam
condensate is fed (FCV-408) for absorption. Aqueous ammonia is with drawn from
Recovery Absorber Bottom by GA-405 A/B.

32 | P a g e

IMPROVEMENTS CARRIED OUT FOR AUGMENTATION OF

PLANT CAPACITY
Urea plant at Bathinda has a rated capacity of 1550 Te/day. With retro fittings and
innovative operational practices, the plant is being run at 105-110% on consistent basis.
The retro fittings carried out are listed as under:-

1) CO2 Booster Compressor

1. The capacity was increased by 3200 Nm/hr by increasing the suction pressure
from 0.08 kg/cm to 0.18 kg/cm.
2. The suction header from Ammonia Plant has been provided with insulation so as
to deliver the CO2 gas to Booster suction at a temperature approximately 6C
lower than the normal value.

2) Ammonia Booster Pumps

Impeller dia of the booster pump was increased from 284 mm to 310 mm and the
motor rating changed from 52 KW to 72.5 KW, the delivery flow of the booster pumps
increased by 10%.

3) Ammonia Recovery System

1. The capacity of ammonia pump UGA-405 was increased from 8.0 m/hr to 18
m/hr.
2. The material of construction of recovery absorbers tubes changed from carbon
steel to S.S.

33 | P a g e

4) Prilling Section

1. The conventional spray nozzles for molten urea changed to Accoustic

Granulators. This has improved the product quality considerably.
2. Secondary air flow increased by removing obstructions on air path.
3. Water spray system provided for cooling ambient air during summer months at
the inlet of CFD Blower.

The innovative operational practices introduced is :

Utilisation of Dust Chamber Over-flow solution

The process route of utilization of dust chamber over flow solution via gas separator
has been changed to via low-pressure absorber. This has contributed in increase in
production of about 9 Te/day.

WATER AND POLLUTION

AIR POLLUTION
The sources of air pollution in urea plant is the air from prilling tower which is the
process of cooling of molten urea being sprayed from the top of the tower gets
entertained with urea dust. In order to contain the urea dust emissions in the Exit air, the
air is scrubbed with water and subsequently passes through 144 polyurethane filters
before being discharged to atmosphere. The normal emission level in the exit air is 30-40
mg/Nm against the prescribed norms of 50 mg/Nm.

34 | P a g e

LIQUID POLLUTANTS
The sources of liquid pollutants in Urea Plant are :-

i) Dust Chamber over-flow solution

The over-flow dust chamber is being completely utilized after introduction of
innovative operational practice mentioned above.

ii) Dilute urea solution during start-up and shut-down of plant

To take care of the dilute urea solution during start-up and shut down of the plant 3
SS Tanks of 100 m, 100 m and 200 m capacity have been provided. The three tanks
are equipped with steam coils for concentration of the Urea solution. The solution, thus
stored, is reprocessed after the plant conditions are normalized.

iii) C.F.D. Washing

The frequency of CFD Washing is 1 months during summer months and three
months during winter months. The washed water from CFD containing urea is stored in a
pacca solution pit of 250 m capacity. This pit has been provided with a pump and the
stored solution is reprocessed during normal operation of the plant.

iv) Leaks from pumps and effluents generated during flushing of strainers:
The pollutants generated are diverted to a effluent pit.

The effluent is subsequently sent to the Bio Urea Hydrolyser in the Effluent
Treatment Plant for Hydrolysis of the Urea.

35 | P a g e

HYDROLYSIS OF UREA
In aqueous solution, urea is sufficiently stable upto 80C. Above that temp. it
changes into Ammonium isocyonote and subsequently into ammonium carbonate.

CO (NH2)2 = NH4 NCO

NH4 NCO + 2 H2O = (NH4)2CO3
Which changes into ammonium hydro-carbonate and this ultimately dissociates into
ammonia and carbon-di-oxide.

(NH4)2 CO3 = NH4 HCO3 + NH3

NH4 HCO2 = CO2 + H2O + NH3
The overall hydrolysis reaction is shown by the equation:
(NH4)2 CO3 + H2O 180C

2NH3 + CO2

NFL has been the market leader for manufacturing and marketing of Urea. The
capacity utilization during the year 2004-2005 has been 106.2%.

36 | P a g e

37 | P a g e

OFFSITES AND UTILITIES PLANTS

D.M. WATER PLANT

Water in its natural form contains a no. of dissolved salts such as sulphates, chlorides
and Nitrates of calcium Magnesium and Sodium. If water is used as such in Boilers for
raising steam, these salts will form scale on the tubes , which in addition to heat losses
leads to many other problems. Hence, removal of these salts from the water becomes
quite essential. ION exchange resins are used for this purpose of salts removal.

The deminerlising water plant of NFL Bathinda was supplied by M/s ION
Exchange (India) Ltd. Delhi.

It consisted of Four units each of Cation, Anion, Primary Mixed bed, and Six
secondary Mixed Bed and three units of condensate cation. At the time of setting up of
captive power plant, another stream to augment the existing capacity of Polish Water
generation was installed by M/s BPMEL. It consisted of one unit each of cation, Anion,
Primary Mixed Bed, two secondary mixed beds and two condensate cations.

Filtered water is received from Raw Water Filtration Plant into two filtered water
reservoirs Feed water pumps discharge water from these reservoirs to cation units. There
are total five feed water pumps each having a capacity of 130 m/hr and four cation units.
Three of these are charged with 13125 litres of cation resin and fourth unit is having
11900 of resin. Cationic lons like Na+, Ca++ and Mg++ present in the water are removed
in the CATION UNITS 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.

38 | P a g e

Cationic resins are made of sulphonated Polystyrene SO3 H+ can be represented as RH+ .
Anionic resin is similarly made but is chloromethylated and then aminated. The final
product is quarternary ammonium compound a strong base and is represented by ROH.

CATION UNIT
In the cation unit free H+ lon of the resin is replace by Ca++ . Mg++ or Na+ lons
as per the following reactions:

RH + NaCl

RNa + HCl

2RH + Mg SO4

R2Mg+H2SO4

2RH + Ca (HCO3)2

R2Ca + 2 CO2 + 2 H2O

Neutral salts are converted to respective mineral acid and alkaline salt spilt into
CO2 gas. The outlet water will have a low pH.

DEGASSER
From the cation units water move to degasser. Here free CO2 content of the
water is stripped off with the help of air by passing the water over rasching ring packed
bed. Water from Degasser is received into three Nos. degassed water sumps each having
a capacity of 40m. From these sumps degassed water pumps discharge water into anion
units. There are total five Nos. of pumps and each having a capacity of 150 m/hr.

39 | P a g e

ANION UNITS
Anionic impurities of water besides CO2 and Silica are removed in the Anion
Units. There are total four nos. of Anion Units. Two; units are having 7920 Ltrs. Of
resin while rest of the two are having 5965 and 8400 Ltrs. Of resin. Anions present in the
water get removed as per the following reactions :

2 ROH + H2SO4

R2 SO4+2H2O

ROH+HCl

RCl+H2O

2 ROH + H2SiO3

R2 SiO3 + 2 H2O

Once the unit gets exhausted, it is regenerated with counter current flow of 4%
NaOH solution.

M I X E D B E D U N I T S (PRIMARY)
Certain amount of sodium and silica ions gets slipped from cation and anion units.
Very large volume of resin is required to check these leakage if tackled individually.
Hence, these are removed in mixed bed units. It consists of a bed of mixed cation and
anion resins which acts as infinite pairs of cation and anion units.

A mixed bed unit will produce water of conductivity around 0.5 micro mho/cm. This
water is stored in DM water tanks. These are two Nos. of DM water tanks each having a
capacity of 1500 m. 1400 Ltrs. Each of cation and anion resin is charged in three mixed
bed units while in fourth unit this quantity is 1800 Ltrs.

40 | P a g e

C O N DE N S A T E C A T I O N U N I T S
Steam condensate is received from Ammonia, Urea and CPP. It contains lonic
and colloidal iron. Colloidal iron is removed in colloidal filters while ionic iron is
removed in condensate cation units. Condensate coming from Ammonia and Urea Plants
is first cooled to around 45OC in condensate cooler.

There are total five Nos. of

condensate cation units. Three units are charged with 1810 Ltrs. Of resin while two are
charged with 4200 Ltrs. Of resin. After polishing the condensate it is stored in DM
Water Tanks.

SECONDARY MIXED BED UNITS

DM Water from DM water tank is pumped to secondary mixed bed units with the
help of DM water pumps, for achieving the desired level of purity of water there are total
5 Nos. of pumps and each having a capacity of 190 M3/hr.in the secondary mixed bed
units final traces of impurities are removed again with the help of mixed bed of cation
and anion resins. There are total six Nos. of these units. Four of these are charged with
1400 Ltrs. Of cation resin and 2200 Ltrs.of ANION Resin while rest of the two are
charged with 1600 Ltrs.and 2600 Ltrs.of cation and anion resins. After passing through
secondary mixed bed units polish water of following specifications is obtained.

PH :

7 +_ 0.2

Conductivity :
Total iron as Fe :

0.2 Micro mhos/cm

0.015 mg/lit

Silica : 0.015 mg/lit

Hardness :

Nil.

Polish water thus obtained is stored in Polish Water Tanks. There are two polish
water tanks each having a capacity of 1500 M3. It is pumped to Ammonia Plant and
Captive Power Plant with the help of five Nos. Polish water pumps each having a
capacity of 220 M3/hr.

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FLOW DIAGRAM OF DEMINERALIZATION OF WATER

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:

42 | P a g e

SI no.

System

Consumer

1.

CT-1

Ammonia plant

2.

CT-2

Urea

plant,

boilers,

instrument

air

compressors, service air

compressors,
dissolving

caustic

facility

and

sulphur recovery plant

3.

CT-3

Crystallization section of
urea plant

4.

Emergency pumps ( Ammonia storage area,

can

be

connected instrument

with CT-1 or CT-2)

compressors

air
emergency

diesel set
Emergency cooling water pump is in continuous service for ammonia storage area. It
takes suction normally from CT -2; 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;

43 | P a g e

INSTRUMENT AIR COMPRESSOR HOUSE

There are four compressors of reciprocating type. 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:
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

44 | P a g e

BAGGING PLANT
The Bagging Plant can be divided into two main sections:

1.

Storage System

2.

Reclamation System

Under Storage system, 3 conveyors, come, namely; PJD-101, PJD-102, PJD-103,

PJD-103 is the over head conveyor inside silo. One tripper is provided over PJD-103
which can be placed at any convenient position depending upon the requirement. By
means of the tripper, the material can be poured over any vibrofeeder desired. Tripper is
designated as PJD-104.

The reclaimation system comprises six electro magnetic vibrofeeders, seven No.
of belts conveyors namely PJDs 106, 107,109, 109A Seven No. of weighing machines,
stitching machines & loading platform namely A-0 A-1,A-2, B-1, B-2, C-1 and C-2. In
addition to these there are 3 bunkers / platform, one empty bag storage and one filled
bags storage. By operating flap gate No. 102, the material can be directly fed to PJD-107
without taking it to silo.

The plant has a capacity to load 2250 Te/day of packed material either in Road
Wagons or Road Trucks or in both. The loading platforms can accommodate seven
trucks at a time or three and half BCN Type wagons or 7 CRT type wagons.

The weighing machines are microprocessor based and have speed of 12 to 14

bags per minute. The machines run with an accuracy of +- 50 grams. The system of
counter checking of weight of filled bags is rigorously followed to ensure correct
weightment.

45 | P a g e

The plant is provided with a Central Control Room from where the system is
started or stopped. The two systems of Storage and Reclaiming are separately provided
with safety inter-locks to trip the belts in case one belt in the link trips.

The Urea silo is designed to accommodate 30 days production. For reclaiming

Urea from silo, front end Pay Loaders are used.

The plant is also provided with an empty bag Storage and over-head E.O.T. crane
for shifting the bags from the storage to the loading platform.

The filled bags storage is provided for stacking the filled Urea Bags.

Both jute and HDPE bags are used for filling of product Urea. The stitching
thread used is poly thread is used.

The consumption of bags is approximately 104 lakhs per annum and of thread
41600 KMs.

Normally two operators, one Heavy Equipment Operator, 7 stitchers, 7 fillers and
28 loaders besides sealman and weight checking staff are deployed every shift. The Shift
Engineer coordinates the operational activities of the plant and also coordinates with the
Transportation Section for the movement of finished goods.

The spilled urea or the urea from the ruptured bags is recycled back to the system
by 2 bucket elevators, which transport the material from the loading platform to the
Conveyor PJD-109.

Normally Loco-motive is used for shunting of Rail wagons. However, a winch is

also provided to take care of exigencies when the loco-motive is not available.

46 | P a g e

PROJECT REPORT
Project Overview:
The project gives the brief overview of the project and the main aim is to study about
the description of existing VS new boilers and its accessories.

BRIEF DESCRIPTION OF BOILERS AT BATHINDA UNIT

The Steam generation plants at Bathinda unit have identical 3 nos pulverized coal tired
boilers (VU-40 BHEL make) at each place with design capacity of I50 Te / hr of steam at
pressure 105 ata & temperature 495 C. These boilers were commissioned in 1978.
The Fourth boiler supplied by MES (MITSUI ENGINEERING & SHIPBUILDING CO.
LTD.), Japan is designed to operate at MCR load (230 TPH) either with combination of
coal & FO or FO exclusively. The boiler was commissioned in 1988. Fuel Oil is
continuously used at optimum level as support fuel.

DETAILS OF EXISTING BOILERS:

MES Make Boiler: The Boiler (Mitsui-Riley RX type) is of two drums type with
welded wall, radiant and conventional super heaters and economizer. The firing
system is balanced draft type with forced draft fan and induced draft fan and main
fuels are pulverized coal and FO / LSHS. The boiler is of natural circulation type.

MES make boilers are equipped with DCS system (Bailey Japan (now ABB)
make Network 90 with MFC 01 controllers and ABBs PPB system as HMI)
for control of process parameters, electrical drives. BMS system is integrated into
the same DCS. Trip interlock is realized through solid-state electronic system of
M/s Bailey. All field instruments are electronic microprocessor.

47 | P a g e

EXISTING BOILER PARAMETERS

Unit No.

Make

MES, Japan

Boiler capacity (TPH)

230 SG

Super heated steam outlet pressure

105 kg /cm

Super heated steam outlet temperature

495 5 c

Fuel Case I

Variable Coal + Fixed FO

Case II

Variable FO up to 100% MCR

No of Burners

14

Main Burners

6 Dual Fuel Burners (Coal + Oil)

Pilot Burners

6 (with LDO Firing)

Start up Burners

2 (With LDO Firing)

Year of Commissioning

1988

TECHNICAL DATA OF 210 T / HR. CAP. FRONT FIRED

PULVERISED FUEL FEED MESS BOILER.
EXISTING TECHNICAL DATA
BOILER / FURNACE UNIT
Type Of Unit 1

Two drum natural circulation top supported.

Type Of FURNACE

Dry bottom front firing.

Steam temperature control

2 stage spray control.

DRUM
Design Code
Design Pressure (kg/cm2g)

Overall length (Meters)

(shell plate length)
a. Number of Drums

IBR with amendments up to 1985

Steam Drum

Water Drum

124.0

124.5

9.3

8.5

(7.2)

(6.9)

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b. Drum centre to centre distance

Internal diameter (mm)

6.5

1630/1676

1181/1219

(tube / shell plate side)

Thickness of shell plate

148.7/102.8

(min nished thickness)(mm)

(tube / shell plate)

Thickness of head plate

96

Material IBR

IBR REG 234-C. S-47

(equivalent ASME)

(ASME: SA-515 Gr.70)

Minimum tensile strength

47

108.8/71.2

70

at room temperature (kg/Sq. mm)

0.2 percent proof stress

19.2

at design temperature (kg/Sq. mm)

STEAM SEPARATORS
Type

Cyclone and dryer carton

Number

31 Cyclones and 32 dryer cartons.

Arrangement

Double sided in line

Size overall diameter (mm)

255

BOILER BANK
1) Arrangement

In line

2) No of gas passes

a. Heating surface (M2)

Furnace 1250
Bank

b. Furnace volume (M3)

1000

990

HEADERS
Location

Nos.

Size

Type Of Connection

OD(mm)

49 | P a g e

a. Lower front Furnace

406.4 Welded

b. Lower rear Furnace

406.4 Welded

c. Lower sides Furnace

273.1 Welded

d. Upper sides Furnace

273.1 Welded

ECONOMISER
Type Bare Tube
Tube spacing(mm)
a. Vertical

88.9

(transverse to gas flow)

b. Horizontal

63.5

(Parallel to gas ow)

Tube arrangement

In-line

Number of assemblies

28

(transverse row to gas ow)

Number of assemblies

44

(Parallel row to gas ow)

a. Direction of gas ow

Down ow

b. Direction of water flow

Up ow

Tube material IBR

IBR REG 36/42-C, S -41/51-S-C

(equivalent ASME)

(ASME, SA-210 Gr. A1)

Size of tube OD (mm)

63.5

Heating surface m2 (approx)

1520

Header diameter, Length and thickness(mm)

273.1 4740, 30

SUPERHEATERS
Design Code

IBR with amendments up to 1985

Design pressure (kg/cm2g)

124 LTSH ITSH HTSH

a. Type

Pendent

b. Number of assemblies

(transverse row to gas ow)

38

Pendent
38

19

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c. Number of elements per

66

24

assembly
(parallel row to gas ow)

Flow

Parallel

Counter

a. Tube diameter (mm)

44.45

63.5

57.15

50.8

b. Tube thickness (mm)

4.4

6.3

5.7

5.1

c. Transverse pitch (mm)

812.8

152.4

152.4

304.8

d. Longitudinal pitch (mm)

50.8

127

114.3

101.6

Material

IBRREG

ASME ASME IBRREG

(equiv. ASME}

56A-2.25

Combined

SA-

SA-

56A-

2 .25

CRIMO

213

213

CRIMO

-39-S-C

Gr.

Gr.

-39-S-C

(ASME SA-213

T11

T11

(ASME

SAGr, T22)

213 Gr,

T22)

No of groups

38

38

19

66

24

(transverse row to gas ow)

Tubes per group
(transverse row to gas ow)

DESUPERHEATER FOR SUPERHEATER

a. Type of De-superheater

Water spray

b. Number

2 (1 SETS for 1st STAGE)

(1 SET for 2nd STAGE)

c. Material

11/4 Cr-1/2 M0 (ASTM A182 Gr. P11)

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d. Necessary piping, valves

Yes

and ttings provided.

e. Size (mm)

1st stage

2nd stage

25.4

38

(inside DIA)

REGENRATIVE AIR HEATER

Type

Ljungstrom

Bearing Type & Size

Thrust bearing 780 mm

Basket material
-cold end

Corrsion Resistant Low Alloy Steel

-Hot end

Mild Steel

Arrangement

Vertical

Number of passes

Effective height of

Cold end

Hot end

Baskets (mm)

300

1950 (2x975)

Heating surface total

12340

(approx) (m2)

STEAM COIL AIR PREHEATER

Type

Fin Tube

Aux_ Steam Parameters

- Flow (kg/hr)

4010 (LSHS at 100% MCR)

- Temp (C)

300

- Pressure (kg/cm2)

11

Construction details

Welding Type (Header to tube)

Overall size (mm)

2815L x 655W x 4245H

Design Temperature

(LSHS 30% MCR)

- inlet (C)

30

- Outlet (C)

100

Heat transfer area

814

52 | P a g e

provided (m2)
Tube outside dia x

approx. 16 x 2 x 38

Thickness x pitch
(mm x mm x mm)

FEEDERS
Type and Make

Type: Gravimetric feeder

Make: Yamato scale Co., Ltd

Capacity

max. 17 ton / h. feeder

Overall dimensions

4.1L X 2.0w X 1.8w (m)

Reference to dimensioned

Ref. No. EO18

sketch
Construction materials

Body: Carbon steel

Inner surface Stainless steel

Accessories provided

Ref. No. EO18

Motor rating, type make

ditto and 0.75 KW for weighing conveyor

0.40 KW for clean-out conveyor

53 | P a g e

DETAILS OF PROPOSED FUEL CONVERSION WORK FUEL

CHANGEOVER FROM FO / LSHS TO NG / RLNG IN MES
BOILERS (BOILER #4)
The upgrade for fuel change over project of each plant broadly comprises of following
sub systems:
a. New Pulverized coal cum NG Fired Burners equipped with gas ignitor and flame
scanner.
b. Burner Register dampers (Manual operated / Auto operated Secondary air damper
along with actuators.
c. Modification of Wind box to install the new along with insulation and cladding.
d. Burners throat refractory modification.
e. NG Piping from pressure reducing station to Boiler #4.
f. NG control station and field instruments for monitoring and safety shutdown.
g. NG train to burners with safety shut off valve.
h. NG piping for igniters / support firing.
i. New DCS system for BMS and boiler operation and control.
j. Cabling from field instruments of NG system to the new DCS panels.

DETAILS OF PROPOSED FUEL CONVERSION WORK FUEL

CHANGEOVER FROM FO / LSHS TO NG / RLNG IN MES
BOILERS (BOILER #4) INSTALLED AT BATHINDA
The upgrade for fuel change over project of each plant broadly comprises of following
sub systems:
a. New Pulverized coal cum NG fired Burners equipped with gas ignitor and flame
scanner.
b. Burner Register dampers (Manual operated) / Auto Operated Secondary air dampers
along with actuators.

54 | P a g e

c. Modification of Wind box to install the new burners along with insulation and
cladding.
d. Burners throat refractory modification.
e NG Piping from pressure reducing station to Bolier #4.
f. NG control station and field instruments for monitoring and safety shutdown.
g NG train to burners with safety shut off valves.
h. NG piping for igniters / support firing.
i. New DCS system for BMS and Boiler operation and control
j. Cabling from field instruments of NG system to the new DCS panels.

RECEIVING, INSPECTION, HANDLING STORAGE AND

INSTALLATION INSTRUCTION OF NEW PC S TYPE
BURNERS
RECEIVING, INSPECTION AND HANDLING
Conrm receipt of all equipment on each Bill of Material. A systematic inventory
procedure for the storage area will facilitate retrieval and installation. Inspect the burners
for damage upon receipt and prior to off-loading to storage. Conrm the bracing is in
place and secure and that damage did not occur due to shifting in transit. Ln particular,
inspect the linkages, operator handles, and pilot taps to conrm no pieces are bent or
broken. Confirm the vane drive rings are properly arranged on the guides and have not
moved during shipment.
The PC S Type Burners are to be off-loaded into a suitable storage area using the lifting
lugs. These components are shipped on pallets which are intended to protect the
equipment during transport and storage, but the pallets are not suitable for lifting by
forklift. Do not lift the burners or ports using the barrel stiffener bars or any other burner
hardware except the lifting lugs.
The burner weight is approximately 2200 kg, not including the actuator or burner elbow
The burners should be left attached to their pallets to prevent damage to linkages, drive
rings, etc. until immediately before lifting to install on the walls. lf for some reason the

55 | P a g e

pallet must be removed ahead of time, blocking must be used to prevent damage to
components.

STORAGE
The PC S-Type Burners have the following short-term (3 months or less) storage
requirements:
a. The burners to be stored in such a manner as to protect them from water and dirt and to
avoid damage from collision and falling objects or debris. They are to be left on their
shipping pallets while in storage.
b. All electrical and electronic equipment are to be stored indoors in a semi- controlled
environment with a non-condensing atmosphere.
c. All small loose pieces (bolts, nuts, clips, etc.) will be adequately prepared and packed
for protection against rust and impact damage. These are to be stored in such a manner as
to protect them from water and dirt, and to avoid damage from collision and falling
objects or debris. These should be stored in their shipping containers until they are
needed for installation.

INSTALLATION INSTRUCTIONS
General
The following instructions describe procedures to remove PC fired burners and install PC
S-Type Burners. Removal instructions are provided for future reference, for the unusual
situation where removal is necessary to facilitate major maintenance or for burner
replacement due to catastrophic damage of some kind. Installation instructions are
provided as they combine with burner replacement. For initial burner installation as part
of new boiler construction, installation will generally commence with item F. Consult the
respective Erection Arrangement drawings for Erection Notes and further detailed
information. The Erector is to determine the most suitable means of removing the
existing burners and installing new burners. Each burner elevation and location needs to
be checked, taking into account access and interferences with platform steel, building

56 | P a g e

steel, auxiliary equipment, steam piping, fuel piping, cable trays etc. The erector must
identify and install new burners in their appropriate locations by burner or port number,
as per General Arrangement drawings. Numbers are stencilled on each burner.
Very important point: Prior and during the erection I installation of the burners please
note to take Care regarding burner swirl orientation which is CW - Clockwise direction or
CCW - Counter Clockwise Direction as per the burner drawings. The direction of burner
orientation CW and CCW is to be ascertained by standing in front of the wind box on the
firing oor prior to installation and carrying out full welding. Follow welding
requirements in accordance with the drawings.
BURNER DATA
Size & Type of Burner

18" Coal Nozzle and 38" PC S-Type

Emission Guarantees by Burner

NA

No. of Burners per boiler

Six (4 Operating + 2 Standby)

Capacity of each Burner (%MCR)

25%

Type of air control & accessories

Lead lag arrangement, FD fan Inlet guide

Vane

Burner Throat Dia, inch

38"

Type & No. of Gas spuds

One No. Super Spud (Main Spud)

Construction of Spuds

Fix Spud

Swirler/ impeller information

Impeller

Burner turndown (Coal)

1: 2.25

Burner turndown (NG/RLNG)

1:4

Q Fired per Burner, Mkcal/hr

40.0

Total Fuel (NG / RLNG) Fired, kg/hr

12550

Fuel (NGI RLNG) Fired per Burner, kg/hr

3138

Minimum Fuel (NG / RLNG) Fired per Burner,

785

kg/hr
Burner Inlet Pressure during maximum Fuel

0.7

(NG/ RLNG)Firing, kg/cm2

Burner Inlet Pressure during minimum Fuel
(NG / RLNG) Firing kg/cm2

0.05

57 | P a g e

Main NG Header Pressure Very High Trip

1.5

kg/cm2
Main NG Header Pressure Very High

1.4

Alarm,Kg/cm2
Main NG Header Pressure Very Low Trip

0.01

Kg/cm2
Main NG Header Pressure Very Low

0.02

Alarm,kg/cm2

NOTES:
4 Burners (any two levels) may be operated during PC firing.
Performance of PC Burners is subjected to Pulverized Coal size at the burner inlet as
below
99% passing through 50 mesh
75% passing through 200 mesh
Any four Burners in two elevation (Bottom & Middle) suggested to be operated during
solo NG ring for the load range of 70% to 100% MCR. Based on the actual performance
of the Boiler on solo NG firing (particularly the SH performance) the operation
philosophy will be finalised and provided.

NEW PC-S TYPE BURNERS

INTRODUCTION
The burners are of Babcock & Wilcox (USA) design. Type PC "S Type" with Central
NG Gun Gas Spud, total 6 Nos. burners installed on each boiler, mounted two abreast
endosed in the existing wind box which is mounted on the boiler front wall. the burners
are dual fuel fired capable of firing Pulverized coal and Natural Gas up to 100% MCR
Steam generation. The offered burner is proven and in operation world over supplied by
Babcock & Wilcox(USA). The burners are Designed. Engineered and Manufactured by
Thermax Limited Pune under the technology transfer agreement between the two
companies The indnidual burners are designed to operate only as follows:
a. Individual burners on Solo Pulterised Coal or Natural Gas firing.

58 | P a g e

b. Burners can be fired in combination firing mode with Natural Gas and Pulverised Coal
together. Individual burners on Variable Pulverised Coal firing and Variable Natural Gas
Firing (During Pulverised Coal firing the burners shall start in a pair only of the
designated elevation selected by the operator)

The burners have the capability to fire Pulverized coal equivalent to 100% steam
generation by operating any 4 numbers (any two levels) with 25% NG support firing
through the main NG burners i.e. Minimum 6.25% each burner capacity. It is always
advice to keep the pilot burners firing NG in operation till PC firing is stabilised.
Each PC S Type" burner is equipped to fire pulverized coal up to maximum rated burner
input of 40.0 Mkcal/hr At this input the unit can be operated at maximum rated load with
any two of the three mills in service while supplying pulverised coal to four (04) burners.
The burners are installed and located in a common wind box. where secondary air
admitted to the wind box is equally available to all the burners.
Each burner is equipped with an FPS gas-fired igniter.

GENERAL INFORMATION & DESCRIPTIONS

GENERAL INFORMATION
The PC S Type burner offers more reliable field performance through improvements in
mechanical and functional design The PC S Type burner is ideally suited for front wall
fired units The PC S Type burner provides for independent control of air flow and air
turbulence to each burner. Secondary air flow to the burner is controlled by the positioing
of an adjustable sliding damper installed at the entrance to the air sleeve.
TO Provide proper mixing of the fuel and air swirl is imparted by means of adjustable
spin vanes located in the air sleeve The burner orientations are as follows;
CW Clockwise burner.
CCW Counter clockwise burner

59 | P a g e

The orientation of the burner depends on the direction of opening of spin vanes. If the
spin vanes are opening in the clockwise direction then the burner is CW and vice versa as
viewed from boiler front/firing floor. An air flow monitor located in the air sleeve
upstream of the spin vanes, allow for air measurement to individual burners and
facilitates balancing of air flow on multi burner applications. Thus it provides a local
indication of relative secondary air flow to facilitate sliding disk adjustment to balance
SA among the burners. Hence individual burner combustion air differential pressures
(Differential Pressure) "DP" can be measured in mmwc.

SECONDARY AIR DISTRIBUTION AND CONTROL.

Secondary air is provided from two FD fans (Existing) and is preheated initially in two
Steam coil air preheaters (Existing) and later in common Regenerative Air Heater
(Existing) Flow control of this air is provided by FD fan inlet Vane. Secondary air, along
with primary air, is controlled to satisfy theoretical and excess air requirements for good
combustion throughout the operating range during coal firing. The secondary air flow
shall always be kept at 30% of the MCR air flow flowing through all the burners nearly
equally during tho first light up or cold start of the boiler on NG firing with a single
burner In addition. total boiler airflow is always maintained at or above 30% of full load
air flow ensuring the total boiler airflow is always throughput which shall not be reduced
below the purge flow rate of the boiler regardless of load.
Hot secondary air (SA) entry from the air heaters flows toward the furnace through
bottom portion of the wind box of the unit. Hot SA duct is equipped with an air flow
(Existing) measuring device. The secondary air flow is subsequently distributed to the
burners.
The SA is freely admitted to the burner wind box and available to all burners in that wind
box, SA flow to each burner is regulated by an automated pneumatic actuator device
which controls the burner adjustable sliding air damper at the entrance to the air sleeve.
SA enters the burner past the sliding air damper, continues through the burner throat
adjustable spin vanes located in the airsleeve and exits through the burner throat into the
furnace To provide proper mixing ol the fuel and air, swirl is imparted by means of
adjustable spin vanes located in the air sleeves.

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COAL FlRlNG 0PERATlON AND ADJUSTMENTS (EXISTING NFL SCOPE)

The Pulveriser / Mill primary air damper controls the primary air flow rate to the burners,
while the coal feeder controls fuel flow. The burner line isolation valves are intended to
isolate the pulveriser and related equipment from hot furnace gases and provide rapid and
positive fuel shut off. These valves should always be either fully Opon or fully cloud,
They should never be used to adjust coal rate to the burners. The ratio of primary air to
coal shall be 1.25@79.5 C, as well as the temperature of the mixture, is established to
satisfy several pulveriser and burner requirements,
Normal coal/air temperature exiting the pulveriser is about 79.50 C. Excessively high
temperatures lend to cause choking in the burner nozzle, and increase the Possibility of
nozzle fires. Low temperatures can result in Insufficient drying of the coal, pulveriser
choking and poor combustion. Operating with high primary airflow will tend to decrease
coal fineness, adversely affecting combustion and increasing unburned carbon, High PA
also increases erosion and can cause flame instability. Low primary air flow may result in
plugged burner lines, burner line fires, dribble at the pulveriser, and poor coal distribution
discharging from the coal nozzle.
Natural Gas fired igniters are provided on the main burners and are of Continuous duty
equivalent to 10,0% capacity of main burner These igniters are must to be kept in
continuous services firing natural gas throughout the main PC burner operation on
pulverized coal while the pulverised coal is being delivered from each pulveriser and
burner, These igniters are firing natural gas as a support flame to the main pulversied fuel
in order to be self sustaining and stabilize the main flames of pulverised coal at
conditions when flames may not be self-sustaining. Flame stability, while firing coal, is
impacted by several factors. Primary air flow and coal / air temperature have already
been discussed. ln addition, the ignition properties of the coal are of prime importance.
Key factors include the quantity and quality of volatile matter; and the quantity of inert
matter (ash and moisture). Coals with lower volatile matter and/or increased inert matter
will result in reduced flame stability. Boiler load and load on the particular pulveriser will

61 | P a g e

also Impact stability, as will the firing pattern of burners in service. Below 40% of the
respective capacity of the pulveriser the flames are not expected to be self sustaining and
Stable. Flame stability has to be assessed during early operation on coal. These
assessments have to include reduced load conditions on the boiler and on individual
pulveriser/burners, Flame scanners are also installed on the main PC fired Burners which
are intended to safeguard operation and prevent burner operation without stable and
satisfactory flames.
Control of the fuel to active burners and airflow to burners is best accomplished by
properly adjusted automatic combustion controls. Conditions may arise where automatic
Operation is not possible or not desirable for both the fuel and air. In these cases, operate
with both in manual operation Always operate with the fuel and air controls in the same
mode either both on manual or both on automatic.
Combustion system tuning is performed to determine the optimum operating for the PC S
Type burners, The PC S Type burner spin vane settings are to be finalized for all burners
during early operation ring pulverized coal. The final settings should be flirty uniform
tor all burners. The burner air dampers are positioned by automated linear actuators for
appropriate Cooling or light off position, and operating position. with specific settings
determined for each burner. Coal and air distribution to the furnace and resultant ow
patterns through the furnace, change in correspondence to which pulversiers are in
service.
Tuning it performed varying which pulverisers are in service to determine and document
those adjustments necessary to accomplish this.
The amount of cleaning and intervals between cleaning of the furnace walls depends
upon the unit design, type of operation. and the ash slag characteristics of the coal
burned.

62 | P a g e

MAINTENANCE AND REPAIR

PC S TYPE BURNER ASSEMBLY
The adjustable spin vanes in the air zones should not require periodic adjustment except
with some major fuel changes. If circumstances require different settings for the spin
vanes, then adjustability must be maintained as follows. Check the operation of spin
vanes on out of service burners while the unit is hot. Those burners with binding vanes
have to be inspected during an outage for damage blockage by foreign material, or
interferences and the condition corrected as necessary. Repair or replace any broken
components. After maintenance the adjustable components have to be returned to the
previously determined optimum settings (which should be the as-found settings), and
tabulated for future reference.

IGNITER DATA
Type & Make of the Igniter

4" Stationary FPS Gas Fired Igniter

Fuel
Guide Tube Diameter

NG
4

Maximum Heat Release

Minimum Heat Release
Turndown

20 Million Btu / hr
5Million Btu/hr
4:1

No of Igniter for each Burner

Continuous Cooling / Combustion Air
Requirement
Gas pressure at Igniter Inlet

One
85 to 140 scfm @ 2"-4" wc above
furnace pressure
2 to 23 psig (14 to 160 kPa) (0.14 to 1.65
kg/cm)
1.76*

Igniter Gas header pressure very High

Trip value, kg/cm
Igniter Gas header pressure very High
Alarm value, kg/cm
Igniter Gas header pressure very Low
Trip value, kg/cm
lgniter Gas header pressure very Low
Alarm value, kg/cm

1.70*
0.10*
0.12*

BOILER START UP (EXISTING PROCEDURE TO BE

FOLLOWED)
COLD STARTUP (EXISTING PROCEDURE)
1. Preparation Works
2. Drafting System Function.
3. Secondary Air Slide Damper Function.
4. Furnace Purge Function

63 | P a g e

5. MFT Function (Pilot Gas Piping)

6. Pilot Gas NG Burner Light up.
7. MFT Function (Main Gas Piping)
8. Main NG Burner tight up.
9. Pressure Raising Function.
10.Boiler Loading Function.
11.FueI Change Function from Naturai Gas to Putverized Coat.

FURNACE PURGE
Boiler purge is a process of flowing air through the ducts, furnace, and all gas passages of
the boiler, flues, and stack to remove any gaseous or accumulated combustibles. Boiler
purge shall be completed before the MFT system can be reset. Prior to boiler start and
burner light up (start-up), the air and gas passages of the boiler as well as the ESP,
RGAH etc. will be purged of any combustibles that may have accumulated. An open flow
path through the boiler from the inlet of the FD Fan(s) to the stack must be ensured. The
purging will be accomplished by maintaining a constant air flow.
Purging cycle will start automatically when the purge permissive are established and
an air flow of > 50.0% (130.0 TPH) of MCR air Flow must be maintained flowing
through the entire flue gas path for at least five minutes continuously in order to achieve
five volume changes before a furnace purge is considered complete allowing the operator
to manually rest the Master Fuel Trip.
The operator is permitted to give a command to the MFT reset button after boiler purge is
complete. The MFT relays are reset by giving command to reset button sequentially
resetting the BMS logic and all BMS MFT relays while the button is depressed.
Once the purge is complete, a continuous purge at the purge rate must be maintained.
Failure to do so will inhibit the starting of additional fuel equipment until the continuous
purge rate is re-established for five minutes.
Two attempts for Pilot lgniter light available. After two unsuccessful light up attempts the
unit shall go for purge.
The Master Fuel Trip relay system will de-energize to directly stop all fuel input to the
furnace. No interposing logic, relays or other devices will be permitted between the
Master Fuel Trip Relay(s) and the equipment to be shutdown.
Unit shall go to re purge if burner start command is not issued for more than 20
minutes.

CHANGE OVER FUNCTION FROM NATURAL GAS TO

PULVERISED
1. On each boiler there are two Main load carrying burners installed in the boiler
front abreast to each other. There are three elevations namely Bottom elevation,
Middle and Top. Two Number burners are installed in one elevation, hence total
6.0 Number Main Load Carrying Burners are installed at the above three
elevations which is able to fire in solo mode firing Natural Gas or Pulverised Coal
any one fuel at one time / instance in one elevation or in combination mode
Natural Gas and Pulverised Coal together in same burner and at same elevation.
Two burners on each elevation create one group, hence for three elevations, there

64 | P a g e

2.

3.
4.

5.

6.

7.

8.

shall be three groups. Group 1 consist of Burner No. 1 and 2 at Bottom

Elevation, Group 2 Consists of Burner No. 3 and 4 at Middle Elevation, and
Group 3 consists of Burner No. 5 and 6 on the highest elevation.
Each Main Burner is provided and installed with a Single igniter pilot gas burner
having a full load capacity of 10.0% of the Main burner capacity, firing Natural
Gas as a fuel delivering a continuous support flame while the Main burner is
ring Pulverised Coal till the PC firing stabilises, once the PC firing stabilises the
pilot gas burner to be removed by manual intervention of the Operator. Each
burner is provided and installed with a Single Main NG burner having a full load
capacity, firing Natural Gas as a fuel delivering a continuous support flame while
the Main burner is firing Pulverised Coal.
Ensure that the igniter pilot / Main or Both Natural Gas fired burners of the
appertaining elevations are always taken in service prior to giving command to
start the main burners on pulverised coal.
Select any one elevation (Two Main Burners) where Pulverised coal is to be
introduced / fired, ensuring either the main burners are in operation with Natural
Gas and I OR pilot natural gas burners are also taken in service manually.
Since the four Main NG burners are in operation and in service, Increase the flow
of Secondary Combustion Air from the FD Fans, increasing the excess air, prior
to starting the Primary Air fan and opening the primary air fan dampers which is
supplying the burners fed by the mills. This is to assure that adequate combustion
air is available to all the operating burners.
Light up Natural Gas Fired Pilot gas igniter or Support burners in both the Main
Burners one by one or each at a time in the appertaining elevations where
Pulverised Coal is to be fired / introduced. Ensure that both the Igniter / Pilot
burners are in continuous service during stabilization of PC Firing. Follow the
Pilot burner start procedure as described in Cold Boiler Startup.
Ensure with the Local Operator at the firing floor that the central Natural
Gas Firing gun along with super spud is in position.

65 | P a g e

REFERENCE
1.
2.
3.
4.
5.
6.

Library of National Fertilizers Limited.

Official website of NFL www.nationalfertilizer.com.
Data from different departments of NFL.
Great guidance of Mr. Anil Swarup (Head, HRD department, NFL).
Project Co-ordinator Mr. Rajesh Maurya.
Some data from www.scrib.com.