Download - Iffco Phulpur Project on Power Plant
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IFFCO PHULPUR
AT A GLANCE
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INTRODUCTION
IFFCO PHULPUR UNIT was conceived on DEC.
1980.
The uni is !ocaed a "# $% awa& '(o% )!!aha*ad+ a
Phu!,u( Tehsi! on )!!aha*ad-aun,u( Hi/hwa&.
I was inau/u(aed *& !ae P(i%e inise( (s.
INDIR) )NDHI. I is he *i//es ,!an in hewo(!d usin/ N)PTH) as he 'eed soc$. 2u now
RLN 3Re !i4ue'ied Ni(o/en as5 is used wih
N)PTH) as we!!.
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MAIN INPUTS OF THE PLANT
FUEL OIL 6 100 ones 7da& 3su,,!ied *& IOC5
N)PTH) 6 1900 ones7da& 3su,,!ied *& IOC5
CO)L 6 1000 ones7da& 3su,,!ied *& cene( coa!
Fie!d !d.5
R) )TER6 "0 ones7da& 3,u%,ed '(o% *o(ee!!5
ELECTRIC POER6 #
)IR 6 F(o% )%os,he(e
CHEIC)L: )ND LU2RIC)NT:6 Pe(o! oi!
INSTALLED ANNUAL CAPACITY:
U(ea 6 ".;89 %i!!ion T
NPN? and #= o
he oa! >PO@? ,(oduced in he coun(&.
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IFFCO PHULPUR UNIT -1
AT A GLANCE
Foundaion sone !aid6 anua(& 1;+ 19A#
Toa! cos6 Rs.0@0 %i!!ion
Be(o dae o' ,(oducion6 a& ;+ 19A;
Dae o' co%%e(cia! ,(oducion6 a(ch 8+ 1981
Toa! )(ea6 10A0 )c(esToa! ,(oducion6 #9@00 T U(ea
7ea(
PLANT CAPACITY CONSULTANTS)%%onia P!an 11@ TPD 7s PULL)N
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IFFCO PHULPUR UNIT -2
AT A GLANCEP!an6 "0 )c(es
Toa! cos6 Rs.11900 %i!!ion
Be(o dae o' ,(oducion6 ),(i! 0+ 199@
Dae o' co%%e(cia! ,(oducion6 Dec + 199A
Toa! ,(oducion6 @;00 T URE)
7ea(
PLANT CAPACITY CONSULTANTS)%%onia P!an 11@00TPD 7s H)IDER TOP:OE
3)%e(ican Co%,an&5
U(ea P!an 1@8;TPD 7s P.D.I.L
3Ia!ian co%,an&5
P(oduc Hand!in/ #000TPD
Powe( 2oi!e(s 100T7HR 7s 2HELTu(*o ene(ao( 118 7s 2HEL
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TOTAL AREA: 1070 ACRES
P!an 6 "0 )c(es
Townshi, 6 #80 )c(es
Co(de 6 1@0 )c(es
)sh Pond 6 10 )c(es
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FERTILIZER INDUSTRY
The 'e(i!ie( indus(& in India consiss o' h(ee %ao(
,!a&e(s6
The /ove(n%en owned ,u*!ic seco( unde(a$in/s.
Coo,e(aive socie& !i$e IFFCO+
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INTRODUCTION
INDI)N F)RER: FERTILIBER COOPER)TIGE LTD.Po,u!a(!& $nown as IFFCO is a we!! $nown 'e(i!ie( co%,an&+
(e/ise(ed on "(d Nov. 19;A. IFFCO is *asica!!& a 'e(i!ie(
co%,an& and is o*ecive is o ,(oduce 'e(i!ie( and o dis,ach i.
I is a coo,e(aive socie& and oda& ";000 coo,e(aive socieies
a(e is %e%*e(.
IFFCO a!one con(i*ue 18= o' ni(o/enous and 1;."= ,hos,ho(ic
'e(i!ie( ,(oduce in he coun(&. IFFCO has sha(es o' Cen(a!ove(n%en+ :ae ove(n%en and Indian Fa(%e(s. IFFCO has
awa(ded I:O 900 'o( %a($ein/ 'e(i!ie(+ s(en/henin/
coo,e(aives and ,(ovidin/ se(vices o 'a(%e(s and (u(a!
co%%uni& ua!i& %ana/e%en.
The IFFCO has 'ou( *(anches na%e!& IFFCO PHULPUR+ IFFCO
)ONL)+ IFFCO
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INDIAN FARMERS FERTILIZER
COOPERATIVE LTD.Phu!,u( Uni+ )!!aha*ad 3)!!aha*ad5
UNIT PROFILE:
Du(in/ %id - ;0?s he coo,e(aive seco( in India was
(es,onsi*!e 'o( dis(i*uion o' A0= o' 'e(i!ie(s consu%ed in hecoun(&. This seco( had inade4uae in'(as(ucu(e o dis(i*ue
'e(i!ie( *u had no ,(oducion 'aci!iies o' is own and hence
de,enden on ,u*!ic7,(ivae seco(s 'o( su,,!ies. To ove(co%e his
!acuna and o *(id/e he de%and su,,!& /a, in he coun(&+ a new
coo,e(aive socie& was conceived o s,eci'ica!!& cae( o he
(e4ui(e%ens o' 'a(%e(s o' he coun(& h(ou/h hei( own
coo,e(aive socieies c(eaed his new insiuion o sa'e/ua(d hei(
ine(ess. The nu%*e( o' coo,e(aive socieies associaed wihIFFCO has (isen '(o% @A in 19;A o %o(e han ";+000 now. IFFCO
co%%issioned he a%%onia Ju(ea co%,!e a
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(adiion o' IFFCO he ,(oec was co%,!eed %o(e han wo
%onhs ahead o' schedu!e. )s a (esu! o' hese e,ansion ,(oecs
IFFCO?s annua! ca,aci& has *een inc(eased o ".;9 %i!!ion ones
o' U(ea and NP
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Phu!,u( sie since *asic in'(as(ucu(e 'aci!iies we(e avai!a*!e a
Phu!,u(.
Phu!,u( Uni-II was co%%issioned in Dece%*e( 199A and consiss
o' 1"@0 TPD )%%onia ,!an and 00 TPD U(ea ,!an a!on/wih associaed o'' sies 'aci!iies *ased on !aes sae o' a(
echno!o/ies.
Ene(/& consu%,ion )%%onia and U(ea %anu'acu(in/ is hi/h!&
ene(/& inensive and i con(i*ues %o(e han 80= o' he oa! cos
o' ,(oducion in a *i/ wa&. ),a( '(o% cos o' ,(oducion (educion
in ene(/& saves he va!ua*!e 'as de,!ein/ nau(a! (esou(ces such
as Na,ha and Coa!. The(e'o(e+ he ene(/& conse(vaion is a %ao(co(,o(ae o*ecive a IFFCO and i is coninuous ,(ocess a is
unis.
IFFCO Phu!,u( co%,!e has *eco%e one o' he !owes ene(/&
consu%in/ unis a%on/s Na,ha *ased 'e(i!ie( ,!ans in India. I
has su*sania!!& (educed is ene(/& consu%,ion du(in/ h(ee
&ea(s as shown in he 'o!!owin/ a*!e.
PLANT Year-200 Year-200! Year-2007)%%onia-I 9.;#8 9.;1 9.#;;
U(ea-I A.;89 A.;"; A.#89
)%%onia-II 8.09# A.989 A.9##
U(ea-II ;.111 ;.001 ;.0#
U(ea3IKII5 ;.A0 ;.;# ;.@9
Noe6 )!! 'i/u(es a(e in $ca!7T.
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THE OTHER "RANCHES OF IFFCO
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IFFCO #ALOL UNIT6
This is IFFCO?s 'i(s uni siuaed in ua(a+ co%%issioned in19A@and e,anded in 199A. The oa! inves%en is Rs. 1#9A
c(o(es. The %ain ,(oduc o' his uni is )%%onia and U(ea.
Ca,aci& o' )%%onia 3NH"5 1100T7Da& and he
echno!o/& invo!ved is Pu!!%an
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IFFCO AONLA UNIT:
This uni is siuaed in 2a(ei!!& 3UP5+ co%%issioned in 1988 and
e,anded a!so in 1988. This uni has wo ,!ans )1 and ).
Inves%en o' ,!an )1is Rs.;@1.; c(o(es and o' ,!an ) is
R:.9@#.A c(o(es.
The %ain ,(oduc o' his uni is a!so )%%onia 3NH"5 and U(ea
3NHCONH5.
Toa! ca,aci& o' )%%onia 3NH"5 "000T7Da& and he
echno!o/& invo!ved is H.T.).:+ Den%a($.
Toa! ca,aci& o' U(ea 3NHCONH5 @1AT7Da& and he
echno!o/& invo!ved is :na%,(o/ei+ Ia!&.
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IFFCO PHULPUR UNIT
This uni is siuaed in Phu!,u(+ a*ou "0
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T$e +a(a+,%8 & A//&,a NH:
P$a3e P'a% MT9Da8 C&3*'%a%9S*((',er1. 11@ 7: Pu!!%an
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ENVIROMENT POLICY
IFFCO Phu!,u( is conscious o' is (es,onsi*i!i& owa(ds
%ainainin/ a sa'e and c!ean envi(on%en+ and is co%%ied *&-
Ensu(e eco!o/ica! *a!ance M ,(oducion o' ,o!!uion.
Co%,!& wih (e!evan !aws+ (e/u!aion and socie&?s
(e4ui(e%en.
ini%ie wase *& (ec&c!in/7(eui!iaion and o,i%ie
nau(a! Resou(ces consu%,ion.
P(o%oe /(een su((oundin/ h(ou/h ,!anin/ o' (ees a(ound
%anu'acu(in/ M !ivin/ (ees.
UALITY POLICY
IFFCO Phu!,u( is co%%ied o achieve sais'acion o' is co-
o,e(aive socieies+ 'o(%in/ co%%uni& and ine(na!7ee(na!
cuso%e(s *& %anu'acu(in/ and su,,!&in/ s,eci'ied 4ua!i& U(ea
h(ou/h6
Deve!o,%en o' hu%an (esou(ces.
Co-o,e(aion and ea% s,i(i.
I%,(ovin/ echno!o/& 'o( enhancin/7%ainainin/
,(oducivi& ad /(owh
C(eain/ sa'e+ hea!h&+ wo($in/ condiion and eco'(iend!&
envi(on%en.
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PO;ER PLANT
Fo( he 'u!'i!!%en o' he :ea% and ,owe( (e4ui(ed *& )%%onia
and U(ea ,!an+ whe(e a(e 'ou( No. o' *oi!e(s insa!!ed M su,,!ied*& 2HEL H&de(a*ad.
The s,eci'icaions o' he # *oi!e(s insa!!ed in P1 M P a(e as
'o!!ows6
P'a% N&. &
9C/2
Te/(.
0C
T*r
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Powe( ,!an o' IFFCO is su,,!ied sea% *& 'ou( *oi!e(s nu%*e(in/
u, o 'ou( '(o% one h(ee *oi!e(s a(e %ain!& coa! 'i(ed.
hi!e he nu%*e( 'ou( is %ain!& oi! 'i(ed *oi!e( a!! o' h(ee *oi!e(s
a(e ve(ica! *oi!e(s+ *oi!e(s wih a wae( in u*e a((an/e%en *oi!e(nu%*e( 'ou( is havin/ ca,aci& o' 00 T7h( whi!e ohe( ones a(e
havin/ ca,aci& o' 1@ T7h( he(e'o(e oa! ca,aci& o' a!! he 'ou(
*oi!e(s is @A@ T7h( he(e a(e wo u(*ines /ene(ao(s which a(e he
hea( o' ,owe( ,!an he& a(e *(in/ T-1 M T-.
T-1 1.@
T- 18
Thus he oa! ou,u o*ained *& ,owe( ,!an is "0.@ . These
wo /ene(ao(s (e4ui(e wo sea% u(*ines+ 'o( hei( wo($in/.
Tu(*ine 1 'o( 1.@ /ene(ao( is o' @ sa/es whi!e he u(*ine'o( 18 /ene(ao( is havin/ " sa/es. The " sa/e u(*ine is
*ein/ shown in 'i/u(e *oh he u(*ines a(e i%,u!se (eacion
u(*ine he 'i(s sa/e o' u(*ine is ,u(e!& i%,u!se and is ca!!ed
Cu(is whee! i is (es,onsi*!e 'o( su,,!&in/ ,owe( o he %oo( ha
is he %ain ,owe( o ,(oduce o(4ue is ,(ovided *& his whee! i
!eads o he iniiaion o' %oion o' %oo(+ he u(*ine has *e!ow
sa/es6
Cu(is whee!+ one whee! and 'i(s sa/e o' u(*ine.
Hi/h ,(essu(e side has 1; sa/es ha is 1; se o' whee!s.
Ine(%ediae ,(essu(e sa/e has c!eve( sa/es.
Low ,(essu(e side i has 'ou( sa/es and is !as ,a( o' (oo(.
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Eer>8 C&3*/(%,&
)%%onia M U(ea %anu'acu(in/ is hi/h!& ene(/& inensive and i
con(i*ues %o(e han 80= o' he oa! cos o' ,(oducion U(ea.The(e'o(e+ a s!i/h chan/e in ene(/& consu%,ions a''ecs he cos
o' ,(oducion in a *i/ wa&. ),a( '(o% cos o' ,(oducion (educion
in ene(/& saves he va!ua*!e 'as de,!ein/ nau(a! (esou(ces such
as Na,hha M Coa!. The(e'o(e+ he Ene(/& conse(vaion is a %ao(
co(,o(ae o*ecive a IFFCO and i is a coninuous ,(ocess a is
unis. IFFCO-Phu!,u( co%,!e has *eco%e one o' he !owes
ene(/&-consu%in/ unis a%on/s Na,hha *ased 'e(i!ie( ,!ans in
India. I has su*sania!!& (educed is ene(/& consu%,ion du(in/
!as h(ee &ea(s. The deai!s a(e hi/h!i/hed *e!ow6
P'a% 2001-02 2002-0 200-06
)%%onia-1 9.;#8 9.;1 9.#;;
U(ea-1 A.;89 A.;"; A.#89
)%%onia- 8.09# A.989 A.9##
U(ea- ;.111 ;.001 ;.0#
U(ea 31K5 ;.A0 ;.;# ;.@9
N&%e:)!! 'i/u(es a(e in $ca!7T
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DESIGN AND OPERATING
SPECIFICATIONS TUR"INE
TYPE: E?%ra+%,& +*/ +&)e3,> %*r
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STATOR:
Go!a/e6 11
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D.C. su,,!& is 'ed o 'ie!d ci(cui o' he /ene(ao( and a(e
,!aced on sha' ise!' o ove(co%e he ,(o*!e% o' a(cin/ and
*(ushes.
Eer>8 C&3era%,& C&//,%/e%
P&',+8 a) Or>a,Ba%,&a' Se% *(.
)s ene(/& con(i*ues %o(e han 80= o' cos o' ,(oducion and
sha(, (ise in ene(/& cos+ ene(/& conse(vaion (eceives o, ,(io(i&
o' IFFCO Phu!,u(.
Eer>8 Maa>e/e% P&',+8:
On a(ch @+ 001 IFFCO Phu!,u( 'o(%u!aed is Ene(/&
ana/e%en Po!ic&+ which saes6 IFFCO is co%%ied o
%anu'acu(e and su,,!& o' 4ua!i& u(ea wih %ini%u% ,ossi*!e
ene(/& h(ou/h6 )do,ion o' !aes deve!o,%en and echno!o/ies.
2ee( o,e(aion and %ainenance ,(acices. ini%ie wase *&(ec&c!in/ 7 (eui!iaion and o,i%ie (esou(ce consu%,ion+
c(eain/ awa(eness a%on/ each and eve(& individua! a*ou ene(/&
conse(vaion+ c(eain/ sa'e hea!h& wo($in/ condiions and eco-
'(iend!& envi(on%en.
Eer>8 C&3era%,& Ce'':
The ene(/& consu%,ion is %onio(ed on dai!& *asis. Phu!,u( unihas consiued a as$ 'o(ce+ headed *& oin ene(a! ana/e( J
Technica!. The as$ 'o(ce co%,(ises o' senio( ,e(sons '(o% va(ious
de,a(%ens+ vi P(oducion+ ainenance+ Ui!iies+ Technica!
:e(vices+ Finance M accouns ec. I %ees ,e(iodica!!& o discuss
he va(ious !oss ,oins eihe( due o ,!an o,e(ain/ (ou*!es o(
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owin/ o desi/n !i%iaions o( deve!o,%en o' new echno!o/&.
2esides his+ 'o( i%,(ovin/ he ene(/& e''icienc& wihin he
eisin/ 'aci!iies+ sudies a(e ca((ied ou and %odi'icaions a(e
done in-house . The En/inee(s and o,e(ao(s 7 echnicians
conneced o each ,!an a(e (e/u!a(!& sen 'o( in house7 ouside(ainin/ ,(o/(a%%e(s and :e%ina(s on ene(/& conse(vaion o
c(eaed hei( ine(es in his a(ea as we!! as %a$e he% awa(e o' he
va(ious %ehods 7 deve!o,%ens in he 'ie!d o' ene(/&
conse(vaion. Re,ued ,(o'essiona!s a(e invied as Facu!& 'o( he
n-house ,(o/(a%%e(s.
Eer>8 C&3era%,& A+$,ee/e%3:
Phu!,u( uni has a!wa&s *een a !eade( in ado,in/ new
deve!o,%ens in he 'ie!d o' 'e(i!ie( ,(oducion and nu%*e( o'
%odi'icaion 7 (eva%, has *een ca((ied ou ove( he &ea(s+ which
have (esu!ed in su*sania! i%,(ove%en in ene(/& consu%,ion.
ao( %odi'icaions ca((ied ou in Phu!,u(-1 a(e !ised as *e!ow6
PHULPUR-I
1. Pu(/e as (ecove(& uni in )%%onia-1 ,!an Ne i%,(ove%en
in ene(/& savin/6- 0.1108 ca!7 o' )%%onia
. :&nhesis Conve(e( Re(o'i Ne I%,(ove%en in ene(/&
savin/6 - 0.11A ca!7 o' )%%onia.
". Lo-Hea 2en 'ie!d (e(o'i in CO (e%ova! s&se% Ne
I%,(ove%en in ene(/& savin/6 - 0.09; ca!7 o' )%%onia.
#. odi'ied CO Co%,(esso( Tu(*ine in U(ea ,!an Ne
I%,(ove%en in ene(/& savin/6 - 0.1; T :ea% 7 oi' U(ea.
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@. Insa!!aion o' P(e-Concen(ao( in U(ea ,!an 3In ea( 001-05
Ne I%,(ove%en in ene(/& savin/ 'eau(es which have *een
inco(,o(aed in he new ,!an since desi/n sa/e a(e as 'o!!ows6
PHULPUR-II
as u(*ine d(ive+ wih Na,hha as 'ue!+ 'o( ,(ocess ai(
co%,(esso(.
Hea (ecove(& uni conneced o he /as u(*ine 'o(
/ene(ain/ hi/h-,(essu(e sea%s o %ee he
(e4ui(e%en o' )%%onia and U(ea P!an. ediu% ,(essu(e ,(ocess condensae s(i,e(.
G-Low ene(/& CO (e%ova! s&se%.
Pu(/e as (ecove(& uni *ased on e%*(ane :e,a(aion Techni4ue
has *een insa!!ed in Dec. 001 which has (esu!ed in ene(/&
savin/ *& 0.11 ca!7T o' a%%onia. The(e has *een a sead&
dec!ine in s,eci'ic e!ec(ica! and he(%a! ene(/& consu%,ion.
Ene(/& consu%,ion in Phu!,u(-I has *een *(ou/h down '(o% he!eve! o' 1.@ ca!7T in iniia! &ea(s o he cu((en !eve! o' A.@
ca!7T i.e. a (educion o' a*ou #0=. :i%i!a(!& in Phu!,u( J II
he ene(/& consu%,ion is i%,(ovin/ da& *& da& and i is a a !eve!
o' ;.0 ca!7T o' u(ea which is !owes a%on/ he cone%,o(a(&
na,hha *ased ,!ans in he coun(&. Fo!!owin/ a*!e shows he
ene(/& consu%,ion ,ae(n M savin/s achieved in ene(/& du(in/
!as h(ee &ea(s+ which shows a (e%a($a*!e (educion.
PLANT 2000-01 2001-02 2002-0 200-06 Re)*+%,&
&er 2001
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)%%onia-1 10.10@ 9.;#8 9.;1 9.#;; ;."
U(ea-1 8.11@ A.;89 A.;"; A.#89 A.A1
)%%onia- 8.""# 8.09# A.989 A.9## #.;8
U(ea- A.0A ;.111 ;.001 ;.0# 1#.8
N&%e:)!! 'i/u(es a(e in $ca!7T Recen!&+ IFFCO-Phu!,u( uni-
II *a//ed P(esi/ious Naiona! Ene(/& Conse(vaion )wa(d-
00" '(o% ov. o' India+ inis(& o' Powe(.
Eer>8 C&3era%,& P'a3 a) Tar>e%3:
Ene(/& conse(vaion is an on/oin/ ,(ocess a IFFCO Phu!,u( unihas !aunched is %ao( Ene(/& :avin/ P(oec 3E:P5 wo(h Rs.1@0
C(o(es 'o( is eisin/ )%%onia M U(ea ,!ans. This ,(oec is
schedu!ed o *e i%,!e%ened in " ,hases *& he &ea( 00;.
Fo!!owin/ %ao( ,(o,osa!s a(e in hand a Phu!,u( uni as a ,a( o'
is 'uu(e ,!ans 'o( ene(/& conse(vaion.
E,r&/e% a) 3ae%8:
IFFCO Phu!,u( Uni is oa!!& co%%ied 'o( %ainainin/ an eco-
'(iend!& envi(on%en. Fo( con(o!!in/ ai( ,o!!uion+ ,!ans have
*een ,(ovided wih 2a/ Fi!e(s+ E!ec(o :aic P(eci,iao(s+ Dus
E(acion :&se%s+ ec. ) !ush /(een *e! wih a*ou " !a$h (ees
has *een deve!o,ed a!! a(ound he 'aco(& ,(e%ises+ which is a
nau(a! %eans o' ai( ,u(i'icaion. To ove(co%e he ,(o*!e% o' '!&
ash dis,osa! /ene(aed in he Ca,ive.
Powe( ,!an+ a dense ,hase d(& '!& ash dis,osa! ,!an has *een
insa!!ed which di(ec!& 'i!!s he '!& ash in c!osed an$e(s 'o(
(ans,o(aion o' he ash o he ce%en ,!ans %anu'acu(in/
Po(!and ,oo!ana ce%en. Phu!,u( Uni has a!wa&s ,u is *es
e''o(s 'o( conse(vin/ wae(. The e''!uen /ene(aed in he ,!an is
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(ec&c!ed *ac$ a'e( ,u(i'icaion in Reve(se Os%osis P!an. Even
he sewa/e wae( /ene(aed in he ownshi, is (eused in he ,!an
a'e( (ea%en in sewa/e (ea%en ,!an. The ,!an is (unnin/ on
e(o e''!uen discha(/e and oa! (ec&c!e *asis. The ,(esen s,eci'ic
wae( consu%,ion is he !owes a%on/ he 'e(i!ie( indus(& inhe coun(&. P!an and is ownshi, have I:O 1#001 ce(i'icaion
which s,ea$s vo!u%es a*ou is envi(on%ena! co%%i%en. The
co%,!e has won he 1s Envi(on%en Ece!!ence awa(d '(o%
Indo-e(%an (eenech 'oundaion and TERI awa(d on
Envi(on%en Ece!!ence 'o( indus(ies wih u(nove( o' Rs.@00
c(o(e and a*ove. :i%i!a(!& sa'e& o' e%,!o&ees is he ,(i%e
conce(n o' %ana/e%en a IFFCO Phu!,u( and a!! %easu(es a(e
a$en so ha no unowa(d incidence oo$ ,!ace. The sa'e&co%%iee headed *& chie' o' he Fi(e M :a'e& de,a(%en %ees
(e/u!a(!& and discusses he sa'e& (e!aed ,(o*!e%s wih ,!an
,e(sonne! and (e%edia! acions a(e a$en acco(din/!&. No. o'
(ainin/ ,(o/(a%%es a(e o(/anied inc!udin/ ,(acica!
de%ons(aion o' sa'e& (e!aed e4ui,%ens a sie o c(eae
awa(eness a eve(& !eve!+ IFFCO Phu!,u( has own nu%*e( o'
sa'e& awa(ds '(o% va(ious a/encies such as+ F)I+ inis(& o'
La*o(s+ ec.
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T$e P&er S83%e/ +&/(r,3e3 & &*r 'ee'36
Geera%,&
Tra3/,33,&
D,3%r,
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The(e a(e wo u(*ine /ene(ao(s T1 and T havin/ (aed ou,u
,owe( o' 1.@ and 18 a 11
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) Tu(*o ene(ao( *asica!!& consiss o' wo ,a(s6
:ao(
Roo(
The a(%au(e windin/ is %ouned on a saiona(& e!e%en ca!!ed
:T)TOR and 'ie!d windin/s a(e %ouned on a (oain/ e!e%en
ca!!ed ROTOR.
The sao( consiss o' a cas-i(on '(a%e+ which su,,o(s he
a(%au(e co(e+ havin/ s!os on is inne( ,e(i,he(& 'o( housin/ he
a(%au(e conduco(s. The (oo( is !i$e a '!&whee! havin/ a!e(naeN and : 'ied o is oue( (i%. The %a/neic ,o!es a(e ecied '(o%
di(ec cu((en su,,!ied *& a D.C. sou(ce. In %os cases necessa(&
eciin/ cu((en is o*ained '(o% a s%a!! D.C. :hun ene(ao(
ca!!ed as ecie( which is *e!ed o( %ouned on he sha' o' he
)!e(nao( ise!'.
NOTE:) IFFCO Phu!,u(+ T has an ecie( o' #".@G and
10.8)+ whi!e T1 is /iven D.C. su,,!& h(ou/h an ee(na! D.C.sou(ce.
2ecause he 'ie!d %a/nes a(e (oain/+ his cu((en is su,,!ied
h(ou/h wo s!i, (in/s. Recen!& *(ush!ess eciaion s&se%s have
*een deve!o,ed in which a "-Q a.c. ecie( and a /(ou, o'
e!ec(onic (eci'ie(s su,,!& d.c. o he a!e(nao(.
NOTE6 T uses 2(ush!ess eciaion :&se%+ whi!e T1 useswo :!i, Rin/s 'o( eciaion o' is 'ie!d windin/.
OPERATING PRINCIPLE:
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hen he (oo( (oaes+ he sao( conduco(s 3*ein/ saiona(&5 a(e
cu *& Jhe %a/neic '!u+ hence he& have induced e.%.'.
,(oduced in he%. 2ecause he %a/neic ,o!es a(e a!e(nae!&N and
:+ he& induce an e.%.'. and hence cu((en a(%au(e conduco(s+
which '!ows in one di(ecion and hen in he ohe(. Hence ana!e(nain/ e.%.'. is ,(oduced in he sao( conduco(s+ whose
'(e4uenc& de,ends on he nu%*e( o' N and : ,o!es %ovin/ ,as a
conduco( in one second and whose di(ecion is /iven *& F!e%in/?s
(i/h hand (u!e.
RATINGS:
The (ain/s o' he T?s a(e /iven as6
Raed s,eed6 "000 RP
Insu!aion CL6 2
F(e4uenc&6 @0HB
T&,e6 Te(i 800-188
Phase6 "
:,ecies6 @#:e(. No.6 1"##
Coo!an6 )i(
Raed ,owe(6 1.@ 3T-15
P.F.6 0.8
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Go!a/e6 10G
Cu((en6 "A0 )%,s
E@CITER
Go!a/e6 1"G
Cu((en6 1@0 )%,s
OUTPUT
Powe(6 10 7h( 3T.. J 15
1".@7h( 3T.. -5
Go!a/e6 1@9G
Cu((en6 @90 )%,s.
RADIAL FAN
T&,e6 NDG J 1; 2)2
No. o' 'ans6 30ne 'an d(iven *& oo( and
anohe( d(iven 2& u(*ine5
),,!icaion6 Fo(ced d(a' 'an
Tu(*ine (ain/6 A@
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PURCHASED PO;ER
IFFCO Phu!,u( ,u(chases @ G) o' ,owe( '(o% UPPCL.
Fo( his ,u(,ose UPPCL ,(ovides IFFCO Phu!,u( wih wo(ans%ission !ines o' 1.@ G) each a 1"
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GENERATED PO;ER PURCHASED PO;ERTG-1 TG-2 UPPCL
LINE-1
UPPCL LINE-
2
M; 10."8 1@.@@ 0.00 0.00
AMP A;0.0A 98".@# 0.00 0.00
#V 10.9A 11.11 0.00 0.00
HB #9.AA #9.A8 0.00 0.00
PF 0.A9 0.8; 0.00 0.00
LINE-1 LINE-2
)CTU)L
GOLT)E
10.;0 10.A@
:ET GOLT)E 11.00 11.00
NOTE:)!! he daa in he a*ove a*!e a(e as on 1A7;7010
TRANSMISSION
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The(e a(e wo (ans%ission !ines '(o% UPPCL havin/ ca,aci& o'
@0 G) each+ a !ine vo!a/e 1"
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F&r %$e ),3%r,e
'ee'3 *)er>r&*) +a
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DISTRI"UTION
The dis(i*uion o' e!ec(ica! ,owe( a IFFCO Phu!,u( Uni is donea di''e(en vo!a/e !eve!s.
Go!a/e !eve!s ,(evai!in/ in he dis(i*uion newo($-
1"
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40/90
I can (aise o( !owe( he vo!a/e n a ci(cui *u wih a
co((es,ondin/ dec(ease o( inc(ease in he cu((en.
;OR#ING PRINCIPLE OF
TRANSFORMER:The ,h&sica! *asis o' a (ans'o(%e( is %uua! inducion *eween
wo ci(cuis !in$ed *& a co%%on %a/neic '!u. In is si%,!es
'o(%+ i consiss o' wo inducive coi!s which a(e e!ec(ica!!&
se,a(aed *u %a/neica!!& !in$ed h(ou/h a ,ah o' !ow (e!ucance.
The wo coi!s ,ossess hi/h %uua! inducance. I' one coi! is
conneced o a sou(ce o' a!e(nain/ vo!a/e+ an a!e(nain/ '!u is
seu, in he !a%inaed co(e+ %os o' which is !in$ed wih he ohe(
coi! in which i ,(oduces %uua!!& induced e.%.'. 3acco(din/ o
'a(ada&s !aw o' e!ec(o %a/neic inducion e dI7dT5. I' he coi!
ci(cui is c!osed+ a cu((en '!ows in i and so e!ec(ic ene(/& is
(ans'e((ed 3eni(e!& %a/neica!!&5 '(o% he 'i(s coi! o he second
coi!. The 'i(s coi!+ in which e!ec(ic ene(/& is 'ed '(o% he ac
su,,!& %ains+ is ca!!ed P(i%a(& indin/ and he ohe( '(o% which
ene(/& is d(awn ou+ is ca!!ed seconda(& windin/. In *(ie'+ a
(ans'o(%e( is a device ha6
T(ans'e(s e!ec(ic ,owe( '(o% one ci(cui o anohe(
I does so wihou a chan/e o' '(e4uenc&
I acco%,!ishes i *& e!ec(o%a/neic inducion and
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he(e he wo e!ec(ic ci(cuis a(e %uua! inducive
in'!uence o' each ohe(.
CIRCUIT "REA#ERS:
) ci(cui *(ea$e( is used 'o( %a$in/ o( *(ea$in/ a ci(cui.
The(e a(e va(ious &,es o' ci(cui *(ea$e(s used a IFFCO Phu!,u(
uni which a(e# as 'o!!ows6
T8(e & C,r+*,% "reaer3 *3e):
OC2- a 1"
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42/90
VACCUM CIRCUIT "REA#ER
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43/90
12#V AT THE TRANSMISSION
LEVEL:
E!ec(ica! ,owe( is ,u(chased '(o% UPPCL a 1"
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PO;ER DISTRI"UTION PANEL
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DISTRI"UTION AT . #VINTERMEDIATE LEVEL:
E!ec(ica! ,owe( a 11
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Thi(& h(ee 1170.##0
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47/90
11 #V INTEGRATED GRID AT
PO;ER PLANT
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48/90
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The a*ove sin/!e !ine dia/(a% shows he 11
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T$e &''&,> 3,>'e ',e ),a>ra/3 ,''
re(re3e% %$e e'e+%r,+a' (&er ),3%r,
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UTILISATION
The oa! e!ec(ica! ,owe( consu%,ion in he va(ious ,!ans o' heuni is a*ou @ . )nd he ,owe( consu%,ion a he ownshi,
is 1.
The e!ec(ica! ,owe( is %ain!& consu%ed in d(ivin/ %oo(s+ ,u%,s
and in he i!!u%inaion ,u(,oses. The %oo(s used in he ,!an a(e
%ain!& s4ui((e! ca/e inducion %oo(s due o hei( (o*us
cons(ucion and ve(& !ess (e4ui(e%en o' %ainenance.
The e!ec(ica! ,owe( consu%ed *& va(ious ,!ans is /iven as
'o!!ows6
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PO;ER CONSUMPTION PLANT
;ISE
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53/90
PO;ER CONSUMPTION IN UNIT 1
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S. N& PLANT NAME ACTUAL
LOAD IN#;
REMAR#S
1. POER PL)NT 1 "AA.0# INCLUDIN
CHP
2. )ONI) 1 198.00
. URE) 1URE) 1+ NE "."
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PO;ER CONSUMPTION IN PO;ER
PLANT 1:
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S.
N&
E=(%.
Na/e
T&%a'
I3%a''e)
R*,>
N&3.
#;
Ra%,>
T&%a'
R*,>L&a)
A+%*a'
'&a)
S%a)
1. 2oi!e(
Feed Pu%,
1 9@0 9@0 A;0.00 Tu(*
2. i!! %oo( 9 # 80 110 89;.00
. )sh ae(Pu%,
" 1A@ "@0 80.00
6. C Pu%, " 1@0 "00 #0.00
. CT Fan 9" 18; 1#8.80
!. ID Fan ; # 10 #80 "8#.00
7. FD Fan ; # 1"0 @0 #1;.00
4. isce!!ane
ous
" @A.;0
TOTAL 6224.00
#;
42.60
#;
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57/90
PO;ER CONSUMPTION IN
AMMONIA PLANT 1:
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58/90
S.
N&
E=(% Na/e T&%a'
I3%a''e)
R*,>
N&3
#;
Ra%,>
T&%a'
R*,>L&a)
A+%*a'
L&a)
S%a)
1. CO 2!owe( 1 1 #A0 #A0 "A;.00
2. CT Fan ; ; 110 ;;0 @8.00
. C Pu%, - C 1 1 10"0 10"0 8#.00
6. C Pu%, - C
LOP 'o( 101
1 0 1" 0 0.00 Tu(*
. LOP 'o( 10" 1 0 @@ 0 0.00 Tu(*
!. LOP 'o( 10" 1 0 "A 0 0.00 Tu(*
7. CO :(i,,e(Re'!u Pu%,
1 "0 "0 #.00
4. Gacuu%
Condensae
Pu%,
1 1 @@ 0 0.00 Tu(*
5. Co!d
)%%oniaPu%,
1 1 @@ 0 0.00 Tu(*
10. Ho )%%onia
Pu%,
1 0 18.@ 0 0.00 Tu(*
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TOTAL 200.00
#;
1460.00
#;
PO;ER CONSUMPTION IN UREA- 1
PLANT:
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60/90
S.
N&
E=(% Na/e T&%a'
I3%a''e)
R*,>
N&3
#;
Ra%,>
T&%a'
R*,>
L&a)
A+%*a'
L&a)
S%a)
1. HP )%%
Pu%,
" " #80 1##0 [email protected]
2. Ca(*a%ae
Pu%,
"10 ;0 #9;.00
. ed. P(.
Ca(*a%ae
Pu%,
1 A@ A@ ;0.00
6. e!ed U(ea
Pu%,
1 90 90 A.00
. Condensae
Pu%,
1 "0 "0 #.00
!. LOP 'o( co
co%,
1 @@ @@ ##.00
7. H&d(o!&se(
,u%,
1 110 110 88.00
4. U(ea cw
,u%,
" @"0 10;0 8#8.00
5. U(ea c 'an # " 1@0 #@0 ";0.00
TOTAL 61.70
#;
26.!
#;
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NE; . #V INSTALLATIONS IN
UREA I IN CEP-2004
COOLIN )TER PUP #0
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62/90
PO;ER CONSUMPTION IN
OFFSITE-1 PLANT:
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63/90
S.
NO
E=(%. Na/e T&%a'
I3%a''e)
R*,>
N&3.
#;
Ra%,>
T&%a'
R*,>
L&a)
A+%*a'
L&a)
1. 2o(e we!!s 1# ; 8 #9 "9".;0
FIRE MCC-1
2. Fi(e e!ec(ic
,u%,
" 1 0 0 1A;.00
. oc$e& ,u%, 1 18.@ 18.@ 1#.80
SOFTENING 1
6. T(ans'e( ,u%, " 1 A@ A@ ;0.00
. )/iao( ,u%, # 1 @.@ @.@ #.#0
-
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S.
NO
E=(%. Na/e T&%a'
I3%a''e)
R*,>
N&3.
#;
Ra%,>
T&%a'
R*,>
L&a)
A+%*a'
L&a)
S%
!. C!a(i'ie(
,u%,
# 1 1@ 1@ 1.00
RA; ;ATER I
7. :e(vice wae(
,u%,
" 1 A@ A@ ;0.00
4. D(in$in/
wae( ,u%,
" 1 1@ 1@ 1.00
5. U(ea se(vice
wae( ,u%,
1 "0 "0 #.00
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CONTD.
S.
NO
E=(%. Na/e T&%a'
I3%a''e)
R*,>
N&3.
#;
Ra%,>
T&%a'
R*,>L&a)
A+%*a
' L&a)
S%a
N&3
#;
Ra%,>
T&%a'
R*,>
L&a)
A
L
1!. Dewae(in/ ,u%, 1 "0 "0 #
AIR
COMPRESSOR
1
17. IR co%,(esso( 1 1 A;@ A;@ ;
14. LOP IR Co%, 1 . . 1.
TOTAL 216.!0 17
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67/90
PO;ER CONSUMPTION IN UNIT 2
-
7/25/2019 Iffco Phulpur Project on Power Plant
68/90
S.N& PLANT NAME ACTUAL
LOAD IN
#;
REMAR#S
1. POER PL)NT 19#0.00
2. )ONI) A0.08 INCLUDIN
CDR
. URE) @89.## INCLUDIN
CEP
6. OFF:ITE: 1A0."
. 2)IN @00
TOTAL 1726.46 &r
17.2M;
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69/90
PO;ER CONSUMPTION IN PO;ER
PLANT:
-
7/25/2019 Iffco Phulpur Project on Power Plant
70/90
S.
N&.
E=(%.
Na/e
T&%a'
I3%a''e)
R*,>
&3.
#;
Ra%,>
T&%a'
R*,>
L&a)
A+%*a'
'&a)
S%a)
-
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5. )C 1 1 A@ A@ ;0.00
Cond.
S.
N&
E=(%.
Na/e
T&%a'
I3%a''e)
R*,>
&3.
#;
Ra%,>
T&%a'
R*,>L&a)
A+%*a'
'&a)
S%a)
-
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72/90
PO;ER CONSUMPTION IN
AMMONIA PLANT 2:
-
7/25/2019 Iffco Phulpur Project on Power Plant
73/90
S.
N&
E=(% Na/e T&%a'
I3%a''e)
R*,>
N&3
#;
Ra%,>
T&%a'
R*,>
L&a)
A+%*a'
L&a)
S%a)
1. H (ec&c!e
co%,(esso(
0 "00 0 0.00
2. I D Fan 1 1 8#0 8#0 Tu(*
. F D Fan 1 1 8#0 8#0 Tu(*
6. )i( coo!e( 'an 1 1A.@0 1A.@0 1#.00
. CO *!owe( 1 1 @10 @10 #08.00
!. )%%onia CT
'an
A A 8 @A# #@9.0
7. :e%i!ean so!n
,u%,
" 1 1100 1100 880.00 Tu(*
4. Lean so!n
,u%,
1 #@0 #@0 ";00.00
5. Cond ,u%, 1 1 1@ 1@ 1.00
-
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'o( E-""01
10. Ge(ococ$
'i!e( ,u%,
1 1A.;0
11. nd
condensae,u%,
1 1@ 1@ 1.00
12. Ecess cond
,u%,
1 1@0 1@0 10.00
CONTD
1. 1s ,(ocess
condensae
,u%,
S
1 1 "0 "0 #.00
16. nd
,(ocess
condensae
,u%o
1 1 A@ A@ ;0.00
1. LOP 'o(
TP ""01
" " @.@ 1;.@0 1".0
1!. HP
ci(cu!aion
,u%, 'o(
H"#;1
1 1 A.@ A.@ .00
17. )%%onia
,(oduc
,u%,
1 "0 "0 #.00
14. HP
ci(cu!aion
,u%,
# 1 A.@ A.@ ;.00
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15. 2oi!e(
'eed wae(
,u%,
" 1 1#@0 1#@0 11;0.00 Tu(*ine
20. Cond,u%, 'o(
E-";01
1 1 1@ 1@ 1.00
CONTD
21. LOP 'o(
TP ";01
" 1 @.@ @.@ #.#0
22. F!ue /as
C ,u%,
)
1 A@ A@ ;0.00
2. 1s wash
wae( ci(cu
,u%,
1 #@ #@ ";.00
26. D wae(
,u%,
1 1 110 110 88.00
2. )%%onia
C ,u%,
# 1 1@A0 1@A0 1@;.00 Tu(*ine
2!. )u LOP'o( TP
"801
# @.@ 11 8.80
27. Fue!
na,hha
1 1 0 0 1;.00
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'eed ,u%,
24. OG R
"0# in!e
1 1 A.@ A.@ ;.00
TOTAL 4025.00 !62.00
PO;ER CONSUMPTION IN CDR
PLANT:
-
7/25/2019 Iffco Phulpur Project on Power Plant
77/90
S.N&
E=(%Na/e
T&%a'I3%a''e)
R*,>N&3
#;Ra%,>
T&%a'R*,>
L&a)
A+%*a'L&a)
S%a
1. F 2!owe(
'o( CDR
1 1 #A@ #A@ "80.00
2. CO
co%,(esso(
1 1 1;0 1;0 18.00
. F C
,u%,
1 A@ [email protected] ;0.00
6. 1s wash
wae( ci(.
,u%,
1 #@ #@ ";.00
. Rich so!n
,u%,
1 @@ @@ ##.00
!. Re/. (e'!u
,u%,
1 9." 9." A.##
7. Lean so!n
,u%,
1 @@ @@ ##.00
4. ND wash
wae( ci(.
,u%,
1 "0 "0 #.00
5. :ea% 1 1@ 1@ 1.00
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78/90
condensae
,u%,
10. F wa(e
wash ,u%,
1 #@ #@ ";.00
11. Causic'eed ,u%,
1 1 9." 9." A.##
TOTAL 57.!0 774.44
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PO;ER CONSUMPTION IN UREAPLANT 2:
1 AREA
S.
N&
E=(%
Na/e
T&%a'
I3%a''e)
R*,>
N&3
#;
Ra%,>
T&%a'
R*,>
L&a)
A+%*a'
L&a)
S%a
1. )%%onia,u%, 1 8;0 8;0 ;88.00
2. Ca(*a%ae
,u%,
1 "90 "90 "1.00
. Ca(*a%ae
so!n ,u%,
1 "A "A 9.;0
6. C ,u%, 1 "0 "0 #.00
. )%%onia
*oos u,
,u%,
1 8;0 8;0 ;88.00
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!. P
F!ushin/
1 110 110 88.00
7. )%%onica!wae(
,u%,
1 "0 "0 #.00
4. U(ea %e!
,u%,
1 @@ @@ ##.00
Cond
S. N& E=(%.
Na/e
T&%a'
I3%a''e)
R*,>
N&3
#;
Ra%,>
T&%a'
R*,>
L&a)
A+%*a'
L&a)
S
5. U(ea
(ecove(&
,u%,
1 1@ 1@ 1.00
10. LP
F!ushin/
,u%,
1 "0 "0 #.00
11. P(ocess
condensa
e ,u%,
1 1A.;0
12. H&d(o!&s 1 1@0 1@0 10.00
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e( ,u%,
1. )%%oni
ca! ,u%,
1 1@ 1@ 1.00
16. ase
wae(
'eed
,u%,
1 "0 "0 #.00
1. ase
wae(
(ans'e(,u%,
1 "0 "0 #.00
1!. P-
#)72
1 @@ @@ ##.00
CONTD
S.
N&
E=(%.
Na/e
T&%a'
I3%a''e)
R*,>
N&3.
#;
Ra%,>
T&%a'
R*,>L&a)
A+%*a'
L&a)
S%a)
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21. LOP
'o(
a%%.
,u%,
# . #.# ".@
61 Area
S. N& E=(% Na/e T&%a'
I3%a''e)
R*,>
N&3
#;
Ra%,>
T&%a'
R*,>L&a)
A+%*a'
L&a)
1. )%%onia
,u%,
1 8;0 8;0 ;88.00
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2. Ca(*a%ae
,u%,
1 "90 "90 "1.00
. Ca*a%ae
so!n ,u%,
1 "A "A 9.;0
6. C ,u%, 1 "0 "0 #.00
. )%% *oos
,u%,
1 "0 "0 #.00
!. )%%onica!
wae( ,u%,
1 11 11 8.80
7. U(ea %e!
,u%,
1 11 11 8.80
4. P 1)72 1 @.@ @.@ #.#0
S. N& E=(% Na/e T&%a'
I3%a''e)
R*,>
N&3
#;
Ra%,>
T&%a'
R*,>L&a)
A+%*a'
L&a)
5. P-#)72 1 @@ @@ ##.00
10. P-A)72 1 1A.;0
11.
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co%,(esso(
1. U(ea C
,u%,
" 1"00 ;00 080.00
1!. U(ea CT
'an
@ @ 9A #8@ "88.00
TOTAL !7.4 25.06
NE; INSTALLATIONS IN UREA II
)ONI) PUP OTOR: OF @
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TOTAL INSTALLED LOAD IS !.6 #;
NOTE:I is o *e noed ha he %oo(s insa!!ed in he ,!ans a(e
%ain!& Inducion %oo(s.
TOTAL LOAD
LO)D OF TON:HIP I: 1
I:CELL)NEOU: LO)D I: 0.@
LO)D OF P1 I: 11.8@
LO)D OF P I: 1A.@
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SO TOTAL LOAD OF THE PLANT AFTER CEP IS
0.! M;
LOAD SHEDDING SCHEMETHROUGH LMS
L: (e'e(s o Load ana/e%en :&se%. I uses a P(o/(a%%a*!e
Lo/ic Ci(cui 3PLC5. The PLC is he *ac$*one o' L:.
Pr&>ra//a
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desi/ned 'o( (ea! i%e con(o! in indus(ia! a,,!icaions.
The L: s&se% %onio(s he who!e e!ec(ica! ,owe( s&se% and
wheneve( he(e is (e4ui(e%en i cus he ,owe( su,,!& o he non
c(iica! e!e%ens o' he ,!ans.
In he 'o!!owin/ a*!e we have /iven he !oad sheddin/ sche%e
when T 1 is unavai!a*!e o( we can sa& on!& T is avai!a*!e.
Thus he oa! e!ec(ica! ,owe( /ene(aion !i%is due o
unavai!a*i!i& o' T1 *u he (e4ui(e%en o' he IFFCO Phu!,u(
uni unde( no(%a! condiions is "0.; .
Thus e!ec(ica! ,owe( (e4ui(e%en o' he who!e uni can no *e
%e+ hus he e!ec(ica! ,owe( su,,!& is /iven o on!& c(iica!
e!e%ens o' he ,!an.
T$*3 %$e '&a) 3$e)),> 3+$e/e $e &'8 TG 2 ,3
aa,'a
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6. POER PL)NT 1.9# URE) 1
CP3"
. URE) @.9 CO
2LOER
!. 2)IN 0.# 2OREELL:+
CHP
7. OF:ITE: 1 M 1. TON:HIP
4. IN:T )IR
COPRE::OR:
1. ):H )TER
PUP:
5. I:C 0.@ N M :T)RT
UP HE)TER
TOTAL LOAD 2.5! NON PL)NT
2LD:
In he 'o!!owin/ a*!e we have /iven he !oad sheddin/ sche%ewhen T is unavai!a*!e o( we can sa& on!& T 1 is avai!a*!e.
Thus he oa! e!ec(ica! ,owe( /ene(aion !i%is *u he
(e4ui(e%en o' he IFFCO Phu!,u( uni unde( no(%a! condiions is
"0.; .
Thus e!ec(ica! ,owe( (e4ui(e%en o' he who!e uni can no *e
%e+ hus he e!ec(ica! ,owe( su,,!& is /iven o on!& c(iica!
e!e%ens o' he ,!an.
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;HEN ONLY TG1 IS AVAILA"LE
S. N& PLANTS TO "E
#EPT ALIVE
LOAD IN
M;
PLANTS TO
"E TRIPPED
1. ) 1 1.9 URE) 1M
2. ) A. 2)IN
1M
. POER PL)NT 1 ".A )
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CP31@A0