Training Centre: IFFCO, Phulpur Unit PRESENTED BY :-

Training Duration: 09/06/2015 to 09/07/2015 Sandeep yadav

Training Area: Plant Area MEE2k12

Project Topic: Boilers CSJMA12001390272

UIETCSJMU KANPUR UP

Indian Farmers Fertiliser Co-operative Limited(IFFCO) was registered on November 3,1967 as a multi-unit co-operative society.

IFFCO society is engaged in production and distribution of fertilisers.

IFFCO Phulpur is a ammonia-urea plant in state of Uttar Pradesh in 1980.

Today IFFCO is making substantial contribution to increase food grain production.

1. Two Power plants.

2. Two Furnaces & Two Chimneys.

3. Water Treatment System & Brick making unit.

4. Single ECU System.

5. Packaging & Transportation Division.

Natural gas is taken from GAIL through pipe lines and stored in gas reservoirs.

Natural gas is dissociated at high temperature & pressure into a furnace.

Hydrogen, Nitrogen and Carbon dioxide gases are obtained after dissociation.

Hydrogen & nitrogen is send to ammonia plant while Carbon dioxide is stored separately.

3H2 + N2 = 2NH3

Ammonia and hydrogen is reacted into mixing

plant where urea in vapour form is obtained.

2NH3 + CO2 = NH2CONH2

This urea vapour is condensed by natural

convection in a chimney of hieght 104 mitres.

At the base of chimney small spherical urea is

obtained which is further sent to packaging

unit by means of conveyer belt.

“As per Indian Boiler Act 1923, a boiler is a

closed vessel with capacity exceeding 22.75

liters used for generating steam under

pressure”

The steam produced may be supplied to:

Power Generation

Heating

Space heating

Hot water supply

Industrial Processes

Sugar mills

Chemical industries

Boiler Make & Year :XYZ & 2003

MCR(Maximum Continuous Rating) :10TPH (F &

A 100oC)

Rated Working Pressure :10.54 kg/cm2(g)

Type of Boiler: 3 Pass Fire tube

Fuel Fired: Oil

Steam Generator # 1,2 & 3 :

Manufacturer :M/S BHEL

Type of unit :Radiant, High pressure, balanceddraft,

Water tube, Bi drum, pulverized coal fired.

Max. continuous rating ( MCR) : 125 MTPH of each boiler

Rated steam pr. & temp. at S.H. outlet : 108 kg/cm2(g) and 465 deg c

Steam Generator # 4 :

Manufacturer : M/S BHEL

Type of unit : High pressure, pressurized furnace ,

single drum dual fuel fired (oil+ gas )

Max. continuous rating ( MCR) : 200 MTPH

Rated steam pr.& temp. at S.H. outlet : 115 kg/cm2 (g) and 515 deg c

Turbo generator # 1:

Maximum output : 12.5 MW

Rated voltage : 11 KV

Turbine speed : 6500 RPM

Reduction G.B. output shaft Speed : 3000 RPM

Turbo generator # 2:

Maximum output :18 MW

Rated voltage : 11 KV

Turbine speed : 5500 RPM

Reduction G.B. output shaft Speed : 3000 RPM

Pressure parts :

1. Boiler drum.

2. Economizer.

3. Super heater & Desuperheater.

4. Water wall tubes.

5. Safety valves

6. Drum level gauge glass

7. Blow down with valves & CBD tank

8. Bank Tubes

9. Remote control impulse lines with valves

10. Down comers and Riser tubes

Other auxiliaries:

1. Furnace wind box and secondary air damper

2. Soot Blowers

3. Coal mills for coal pulverization

4. Oil & Gas burners with igniters

5. Induced draft and forced draft fan

6. Electrostatic precipitator and rapping system

7. Boiler feed pumps

8. Make up water pumps

9. Deaerator

10. H.P. heater /L.P. heaters

l1. Air pre heater

There are requirement of fuel, air & water to run the Boilers for steam generation.

Therefore the power plant operation comprises of following cycles:

1) Feed water cycle

2) Steam cycle

3) Fuel cycle

4) Air cycle

5) Flue gas cycle

The feed water cycle of power plant run with closed loop (based on Rankine cycle) with about 10-15% make up water demand because of loss of steam and continuous blow down in process.

The condensate from Urea/Ammonia and TG condenser collected in makeup water tanks. The shortage of condensate is made up by DM water from water treatment plant.

The required feed water quality is maintained by adding chemicals & controlling the purity of condensate returned from process plants.

It is then pumped to Deaerators via LP heaters by running makeup water pumps (total 4 nos.). The deaerator will remove dissolved gaseous impurities and residual is removed by Hydrazine dosing in outlet of Deaerator.

Then Boiler feed water pumps takes suction from the deaerator and pumped water to boiler drum through a HP heater & Economizer

TO MWT B

FROM DM

PLANT

TG# 2

TO MWT B

LSL

LSLL

U# 2 TURBINE

COND

I/ C SUCTION

MWP P# 1

M WP

C

M WP

D

RECIRCULATION

I/ C MWP P# 1

DISCHARGE

TO HOTWELL

PT FTPT FT

FT

VENT

PROCESS I/ C

P# 1 - P# 2

U# 2 PROCESS

CONDENSATE FT

FEED TANK

DEARATOR# 2

CTP

1

CTP

2BFP#5 TBFP#6

I/ C D2 -D1

I/ C FEED WTR

HEADER

TO BOILER#4

CBD RECOVERY

4 at a STEAM FROM A# 2

4 at a I/ C P1-P2

13/4 ata PRDS

M WT

CL P HEATER

CONDENSATE AND MAKE UP WATER CYCLE

LT

LIC

FT

FT

TO TRIP MWP

LIC

LT

P

T

TE

LTLIC

PT

TEDEA OVER

FLOW LSLL LSLL LSLL

PT

I

TO TRIP BFP

Steam Cycle:

Saturated steam generated in boiler is further superheated in

primary super heaters & final super heaters so as to achieve design

steam temperature to 465C at 105 kg/cm2(g)& 515C at 115

kg/cm2(g) in P-1 & P-2 header respectively for use in process and

Turbines.

Different type of steam & its uses :

1) 115 Ata steam:

Oil & gas fired boiler generates to supply it ammonia-2 /

urea-2 plant and to Turbo generator-2 for power generation.

2) 105 Ata steam:

The All three coal fired Boilers generate steam at this

pressure & supply steam to ammonia-1, urea-1 and turbo gen-1.

3) 13 Ata steam:

This steam is used for feed water heating in HP heaters , soot

blowing, driving BFP turbine & FD fan turbine, steam coil air pre

heater, steam jet air ejectors of condenser, LSHS drive turbine..

Urea-1

Amm-1 TG-1

BOILER

VENT

AMMONIA#2AMM#2 BYPASS LINE

5505- B

MSSV1A MSSV- 4B

BOILER# 4

START UP

VENT

TO CEP

PUMPS

TURBINE

CONDENSERFROM FW

HEADER

FROM FW

HEADER

TO CONDENSER

TO L P HEATER

TBFP# 6

TO DEARATOR

13/4 ATA

PRDS

P2-P1

I/C

ATOMISING

STEAM

LSHS

TUBINE

FD FAN

4A

5505- A

TO GSC

TO EJECTOR

115/11 ATA

PRDS

B#3 SB LINE

TO HOT WELL TO GLAND SEALING

FROM FW

HEADER

TO VENT

TO MWT

TO VENT

TO CONDENSER

TO GSC

TO SCAPH

B#3B#2 B#1

Fuel Cycle:

In coal fired Boilers coal of low grade (which are given to the

fertilizers) is used as fuel to boil the water. In oil & gas fired boiler oil

called LSHS/FO and gas named as RLNG is used.

The furnace of coal fired boilers is supplied with 2-types of fuel viz.

1) RLNG for initial light up with gas igniters (8 nos.) & for

supporting flame of coal fire 2) Pulverized coal.

The coal fired boilers are design for high ash low grade coal having

quality as :

Calorific value (kcal/kg) : 4700 (design)

Fixed carbon : 36 %

Moisture : 7%

Ash content :33%

Volatile Matter : 24%

DRUM

F.S.H

FURNACE P.S.H

ECONOMISER

VENT

PILOT G.V

PCV FCV

PCV FCV

FGTV

LSHSTV

STEAM VALVE

4

15

6

2

3

FT

DRUM

9602

PR.REGULATOR

9602

RTV

Fuel Firing Overview:

Air Cycle:Two Nos. of Forced draft fans in each coal fired

Boilers supply air through regenerative APH to bowl

mill and furnace.

The primary air for coal pulverization & coal dust

conveyance to furnace and secondary air for

combustion of fuel. The air at outlet of FD fans is pre

heated in steam coil air pre heater prior to entry in

APH.

The heat of hot flue gases is utilized to raise the temp.

of air before entry to furnace for fuel combustion.

Flue Gas Cycle:

The product of combustion are withdrawn by two nos.

Induced Draft fans through bank tubes, Economizer,

APH & ESP and finally discharge to atmosphere through

tall chimney.

The coal contains approximately 33 % ash of which 15

% fall in bottom hopper and rest 85 % fly with flue gas

to be collected in economizer hoppers and EP hoppers.

The Fly ash collected in ash hoppers is conveyed to ash

silo using dry fly ash disposal system & then transported

to cement plants by trucks and tankers. The bottom ash

is removed & disposed off in the ash ponds in the form

of slurry by means of hydro vectors.