tata chemical babrala

8/18/2019 Tata Chemical Babrala

1/33

1

N RUSTAGI

BOILER O & M PRACTICES

AT

TATA CHEMICALS , BABRALA


2/33

2

Presentation Structure

1. Tata Chemicals,Babrala

- Introduction- Production acilities.

- Po!er and steam net!or"- #ilestones achie$ed

%& '(erational Practices

)& #aintenance Practices


3/33

3

Introduction

• Tata Chemicals *td. ounded in 1+)+.

• Com(rises o t!o di$isions

- Chemical i$ision located at #itha(ur, Guarat.

- ertili/er i$ision located at Babrala, U.P.

• ertili/er Com(le0 commissioned in ec. 1++ and com(rises o

- Ammonia Plant based on lo! ener23 (rocess o 4aldor To(soe, enmar". - Urea Plant based on Snam(ro2etti, Ital3, technolo23.


4/33

4

- Related acilities o 'sites 5 Utilities consistin2Ca(ti$e Po!er 5 Steam Generation Plant,

Coolin2 To!ers, # 6ater Plant, AmmoniaStora2e, Na(htha Stora2e, 7luent TreatmentPlant etc..

• ertili/er Com(le0 at Babrala is one o the si0 inland located com(le0es based on a cross-countr3 4B8 94a/ira-Bia(ur-8a2dish(ur: natural

2as (i(eline.

Introduction


5/33

5

Pri/es ba22ed in %;;%

1.National 7ner23 Conser$ation A!ard - %;;% irstPri/e,instituted b3 the Bureau o 7ner237icienc3, #inistr3 o Po!er, G'I.

%.AI runner-u( a!ard or


6/33

6

Pri/es ba22ed in %;;%

.7n$ironment, A2riculture and Rural e$elo(mentA!ard - %;;% 9rom the Indian #erchants<Chamber:.

=. -STAR Ratin2 or saet3 b3 the British Saet3 Council-U.>.


7/337

Production acilities

Ammonia

Power & Steam Cooling Towers

BaggingUrea

Instrument Air De-mineralisation

Ammonia Storage

NH3

CO2

Dispat!

H"#roar$ons

Inert %as

Urea

Bagge#

Urea

B" oa#

B" ail


8/338

Po!er 5 Steam Net!or"

• ertili/er Com(le0 has an inte2rated ener23 net !or". • All the (o!er consumed in the com(le0 is 2eneratedinternall3 in the com(le0 in Gas Turbine Generators.

• 6e ha$e t!o 1+.= #6 2as turbines or ull reliabilit3 on the (o!er ront !ithout ha$in2 UPS7B 2ridconnection..

• The !aste heat rom GTGs e0haust 2as is utili/ed

or 2eneratin2 steam in 4RUs. 4RUs are (ro$ided!ith su((lementar3 irin2.


9/339


• All the su(erheated steam consumed in the com(le0is 2enerated in Ser$ice Boiler, 4eat Reco$er3 Unitso GTGs and 6aste 4eat Boilers o Ammonia Plant.

• The entire amount o # 6ater used in the com(le0

is (reheated in the Ammonia Plant and su((lied todeaerators o Ammonia Plant and Ca(ti$e Po!er 5

Steam Generation Plant.

• The total (o!er and steam 2eneration in CPSGP are

a((ro0. 1+ #6 and 1); TP4 res(ecti$el3.


10/3310


Ser'ie Boiler %T% - ( HU - 2 HU - ( %T% - 2

Power )or elet #ri'es((( ata* +(,, C steam

H"#roar$ons

aste Heat Boilers Super !eaters

Ammonia Plant

HP Steam to tur$ines


11/33

11


Ser'ie Boiler

an# HU-(.2

aste Heat

Boilers

D/ ater Pre-

Heaters

Deaerator in

Ammonia Plant

Deaerator in

CPS%P

Col# D/

ater

Hot D/

ater

B0

Ammonia Plant

B0 Pre-

Heaters


12/33

12

Ser$ice Boiler &

• #A>7

• ST7A# PR7SSUR7

• ST7A# T7#P.

• ST7A# CAPACIT?

• T'TA* 47ATING AR7A

• IBR N'.

• RU# PS@ S7T PR7SS.• >S 47A7R PS@

• Therma0 Babcoc" 5 6ilco0 *td.

• 11= >2cm

• =%;C

• 11; #T4r #CR

• %D+D #

• UP =;+

• 1)1 9S: 5 1)%9N: >2cm• 1%% >2cm


13/33

13

Ser$ice Boiler &

Area %)% #

Area %=E.= #

Area D.= #

Area %E1%#

Area DF#

Air Preheater

Su(er heater- %

7conomiser - 1

Su(er heater- 1

7conomiser - %

Su(er heater- )

Area %;%% #

Ser$ice Boiler lo! ,ia2ram

7$a(orator or

urnace !ater

Steam

,rum

,esu(er4eater-1

,esu(er

4eater-%

eed

ater

>S Steam

To

Chimin3

Na(htha

NG

, an


14/33

14

Gas Turbine&

GTG1 GTG%

• #a"e & Thomassen International B$.

• #odel & PG=)E1PA

• Base 'ut(ut 9Natural Gas: & 1+==; >6

• Base 'ut(ut 9istillate: & 1+1+; >6

• Commissionin2 ate & eb1++ A(r1++• Control S3stem & #>-I@ #>-I@

• ired Time 94rs: & E;DF1.= =EFF)

• ired Starts & %%1 1+D

1 ri$en 7Hui(ment #odel & Generator ABB, S!eden

1 Accessor3 Gear #odel Sl.No & lender AA =1CA

1 *oad Gear Bo0 #odelSl.No. & #aa2 G- F; RU


15/33

15

Po!er 5 Steam Net!or" 9GTG4RU:

T

47AT

R7C'-

@7R?

UNIT

94RU:

IN*7T AIR

I*T7R

AIR

C

AIR

C'#PR7SS'R TURBIN7

G7N7RAT'R

C.C.

*'A G7AR

C'#BUSTI'N

C4A#B7R

U7*

9NG4SNAP.:

>S ST7A#

77 6AT7RSTAG7-%

STAG7-1

I7S7*

7NGIN7

'R INITIA*

START

G

9AUJ.IRING:


16/33

16

4eat Reco$er3 Unit 94RU:&

• #A>7

• ST7A# PR7SSUR7

• ST7A# T7#P.

• ST7A# CAPACIT?

• T'TA* 47ATING AR7A• IBR N'.

4RU-1

4RU-%

• RU# PS@ S7T PR7SS.

• >S 47A7R PS@

• *5T

• 11= >2cm

• =%;C

• +F.= #T4r

• )+11#

. UP-=1;;

. UP-=1+%

• 1); 9S: 5 1)19N: >2cm

• 1%% >2cm


17/33

17

Po!er 5 Steam Net!or" 94RU:

FEED WATER

520°C

SUPERHEATER - 1

EVAPORATOR - 1

EVAPORATOR - 2

ECONOMISER - 1

GT 7J4AUST

STAG7-1 BURN7RS

STAG7- %

BURN7RS

SUPERHEATER - 2

ECONOMISER - 2

ECONOMISER - 3

RCP

BLOW

DOWN

EXHAUST

510°C652°C

510°C

350°

C

145°C121°C

320!°C DRUM


18/33

18

%;;;-;1 %;;1-;% %;;%-;)

Co-2en. 7icienc3 o GTG4RU, K E+.E F+.) +1.+

Ser$ice Boiler 7icienc3, K +.%+ +.% +=.==

F%.EE +;.F; +%.+='$erall 7icienc3 o CPSGP, K

#ilestones Achie$ed

GTG 7icienc3, K %1.) %.)1 %=.%D

- 4eat Reco$er3 Unit ;.))D ;.)%E ;.)))

- Ser$ice Boiler ;.E)= ;.E) ;.E%=

S(eciic 7ner23 Cons., Gcal#T


19/33

19

'(erational Perormance & %;;; to %;;)

• INCR7AS7 'P7RATI'NA* R7*IABI*IT? B?INC'RP'RATING #'II7 %) TRIP *'GIC 'R TRIPR7*AT7 PARA#7T7R ' S7R@IC7 B'I*7R, 4RUs ANGTGs.

• 'P7RATI'N ' S7R@IC7 B'I*7R AT %= TP4 *'A 6IT4

T6' BURN7RS IN 'P7RATI'N.• *'AING ' S7R@IC7 B'I*7R IN CAS7 ' 7#7RG7NC?

B? AUT' IGNITI'N ' )rd 5 th BURN7RS.

• 'P7RATI'N ' 4RU 6IT4 NG IN 1st STAG7 5 NAP4T4A IN%nd STAG7 AS U7*.


20/33

20

'(erational Perormance & %;;; to %;;)

•

CRITICA* ACTI@ITI7S *I>7 START UP, S4UT '6N,C4ANG7'@7R ' I*T7RS, 6AT7R 6AS4, U7* C4ANG7

'@7R IN S7R@IC7 B'I*7R, 77 PU#P C4ANG7 '@7R

7TC. 6IT4 C47C>*IST.

• 'N7 GTG IS IN 'P7RATI'N 6IT4'UT AN? 7JT7RNA* GRI

SUPP'RT.

• 'P7RATI'N ' GTG AT @ARIAB*7 C'NTR'* ' IG@ AS

P7R *'A.

• 'P7RATI'N ' GTG 6IT4 7@AP'RATI@7 C''*INGURING SU##7R 5 PR7 47AT7R URING 6INT7R

S7AS'N.


21/33

21

'(erational Perormance &%;;; to %;;) E"#$%& C'"(#$)*+,'" - I",+,*+,)#( T*#".

Ser$ice Boiler o(eration !ith to( t!o Burners on NG uel or

na(htha uel !ith ast *oadin2 acilit3 in case o 7mer2enc3

b3 auto i2nition o )rd 5 th burners.

- Achie$ed ma0imum ca(acit3 utili/ation o 4RU b3

o(eratin2 Ser$ice Boiler on minimum load o %= TP4.

- Achie$ed o$erall sa$in2 o 1%= N#)4R in 4RU and

Ser$ice Boiler.

- '032en anal3/er relocated rom Air Pre-4eater outlet to its

inlet or eecti$e monitorin2 o e0cess air.


22/33

22


4RU dual uel o(eration i.e. 1st Sta2e burner on NG uel !hile

%nd Sta2e on na(htha uel &

- 4el(ed in o(timi/ed use o Natural Gas a$ailable rom GAI*.


23/33

23


'(eration o #otor ri$en Boiler eed 6ater Pum( in (lace o

Turbo ri$en Pum( &

- Achie$ed the reduction in S(eciic 7ner23 consum(tion o

Urea b3 use o (o!er in (lace o steam.


24/33

24


7ner23 Conser$ation due to sto((in2 o one GTG

97ner23 sa$in2 o 1EE=1D Gcalannum :

• %) lo2ics !ere incor(orated in GTG4RSG or o(erational

reliabilit3.

• To!nshi( and *i2htnin2 load decreased b3 $arious

initiati$es.

• 4o!den 9lash Ammonia: Com(ressor reHuent startu(

a$oided.

• ACT (um( 9one number: sto((ed.

• 'ne G@ (um( sto((ed.


25/33

25


GTG IGV kept ON AUTO MODE after adjusting cooling air

flows to wheel space

• Net sa!ing "#dail$ a! %&&n'()hr sa!ing*+ ,,&&-

Gcal)annu'

• GTG NG consum(tion reduced rom DFF to D%FF nmLhr.

9Net sa$in2 as (er Gail *4@ is %;; nmLhr:

• 4RSG NG consum(tion reduced rom ))+ to ;)+. 9Net

sa$in2 as (er Gail *4@ is );; nmLhr:• The 70haust Stac" tem( reduced rom 1=%c to 1)=c.


26/33

26

#aintenance PracticesM

.EAT /E0OVE/1 UNIT2 ) 2E/VI0E 3OI4E/ 5 DU/ING TU/NA/OUND 6O44O7ING MAINTENAN0E

8/A0TI0E2 A/E 6O44O7ED

ST7A# RU# INSP7CTI'N 'R INT7RNA*S.

BURN7RS U7* B*'C> @A*@7S INSP7CTI'N ANPR7@7NTI@7 #AINT7NANC7.

S7R@IC7 B'I*7R BURN7R R7RACT'R? INSP7CTI'N

AN R7PAIRING.

A** INSTRU#7NT CA*IBRATI'N. AN, AUJI*IAR? AIR AN 5 SCANN7R AN #'T'R

PR7@7NTI@7 #AINT7NANC7.


27/33

27


AN, AUJI*IAR? AIR AN 5 SCANN7R AN I#P7**7RC*7ANING.

AN IN*7T A#P7R C'NTR'* #7C4ANIS#

INSP7CTI'N AN PR7@7NTI@7 #AINT7NANC7.

INSP7CTI'N AN #AINT7NANC7 ' 77 C'NTR'*

@A*@7S.

'N *IN7 SA7T? @A*@7 T7STING 9TRA@I T7ST:.


28/33

28

AIR PR7 47AT7R TUB7 C*7ANING AN INSP7CTI'N

BURN7R INSP7CTI'N AN I#7NSI'N #7ASUR7#7NT.

#'T'R 'P7RAT7 @A*@7S RI@7 AN ACTUAT'R

PR@7NTI@7 #AINT7NANC7.

TRIP AN INT7R*'C> C47C>ING.



29/33

29

Plannin2 o Ne! Initiati$es

./U ) 2E/VI0E 3OI4E/

INSTA**ATI'N ' #AGN7TIC R7S'NAT'R IN NAP4T4A *IN7

'P7RATI'N ' S7R@IC7 B'I*7R 'N A*T7RNAT7 C47AP7RU7*


30/33

30

Plannin2 o Ne! Initiati$es

GTG SUCTI'N AIR I*T7RS R7P*AC7#7NT 9C7**U*'S7 T'

S?NT47TIC:

R7#'@A* A*T7RNAT7 ARRANG7#7NT 'R 7@AP'RATI@7AIR C''*7R T' R7UC7 PR7SSUR7 R'P .

AT'#IING AIR C'#PR7SS'R 5 C''*7R R7#'@A*.

G7N7RAT'R R7OU7NC? R7UCTI'N T' SA@7 7N7RG?.


31/33

31

Need ?our 4el(MM.

6e are acin2 some (roblems in our 4RU 5 GTG *i"e&

• ISTURBANC7 IN IRING ' 4RU STAG7-II BURN7RS, N7AR7RT' SI7 6A**S, 'P7RATING 'N NAP4T4A U7*.

• 4IG4 PR7SSUR7 R'P ACR'SS SUP7R47AT7R IN 4RU*7AING T' *I#ITATI'N IN 4IG47R ST7A# G7N7RATI'NRAT7.

•

4IG4 6477* SPAC7 T7#P7RATUR7 AT #IN. IG@ P'SITI'NURING SU##7R.


32/33

32

Need ?our 4el(MM.

• 4IG4 PR7SSUR7 R'P ACR'SS IN*7T AIR I*T7RS ' GTGURING 'G AN RAIN? S7AS'N

• C4'C>ING ' AT'#ISING AIR C''*7R IN GTG.


33/33

33

Than" ?ou

tata chemical babrala

Documents