AT
TATA CHEMICALS , BABRALA
N RUSTAGI
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Presentation Structure
1. Tata Chemicals,Babrala
- Introduction
- Production facilities.
- Power and steam network
- Milestones achieved
2: Operational Practices
3: Maintenance Practices
Introduction
Tata Chemicals Ltd. founded in 1939.
Comprises of two divisions
- Chemical Division located at Mithapur, Gujarat.
- Fertilizer Division located at Babrala, U.P.
Fertilizer Complex commissioned in Dec. 1994
and comprises of
- Ammonia Plant based on low energy process of
Haldor Topsoe, Denmark.
- Urea Plant based on Snamprogetti, Italy,
technology.
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Introduction
- Related facilities of Offsites & Utilities consisting
Captive Power & Steam Generation Plant,
Cooling Towers, DM Water Plant, Ammonia
Storage, Naphtha Storage, Effluent Treatment
Plant etc..
Fertilizer Complex at Babrala is one of the six
inland located complexes based on a cross
-country HBJ (Hazira-Bijapur-Jagdishpur) natural
gas pipeline.
Production Facilities
Ammonia Storage
Hydrocarbons
NH3
Ammonia
Urea
Urea
Bagging
CO2
Bagged
Urea
Power & Steam
Cooling Towers
Dispatch
By Road
By Rail
De-mineralisation
Instrument Air
Inert Gas
Hydrocarbons
Service Boiler
GTG - 1
HRU - 1
GTG - 2
HRU - 2
HP Steam to turbines
Super heaters
Ammonia Plant
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Deaerator in
CPSGP
Hot DM
Water
Cold DM
Water
Service Boiler
and HRU-1/2
Ammonia Plant
DM Water PreHeaters
Deaerator in
Ammonia Plant
BFW PreHeaters
Waste Heat
Boilers
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Service Boiler :
MAKE
STEAM PRESSURE
115 Kg/cm
STEAM TEMP.
520C
STEAM CAPACITY
2696 M
IBR NO.
UP / 5049
KS HEADER PSV
122 Kg/cm
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Service Boiler :
Service Boiler Flow Diagram
Naphtha
To
Chiminy
Air Preheater
NG
Steam
Drum
Evaporator or
furnace water
Area 2022 M
Super heater- 3
Area 232 M
KS Steam
FD Fan
Super heater- 2
Feed
Water
Economiser - 1
Desuper
Heater-2
Area 257.5 M
Area 468M
Desuper
Heater-1
Super heater- 1
Economiser - 2
Area 446.5 M
Area 2712M
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Gas Turbine:
GTG1
GTG2
Make
Model
PG5371PA
19550 KW
19190 KW
Commissioning Date
Feb1994
Apr1994
Control System
MK-IV
MK-IV
Fired Time
70681.5
57883
Fired Starts
221
196
Maag/ G- 80 /RU
(Hrs)
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FEED WATER
AIR
FUEL
(NG/HSD/NAP.)
COMBUSTION
CHAMBER
DIESEL
ENGINE
FOR INITIAL
START
STAGE-2
STAGE-1
KS STEAM
C.C.
INLET AIR
FILTER
D
HEAT
RECOVERY
UNIT
(HRU)
LOAD GEAR
C
AIR
COMPRESSOR
T
G
TURBINE
GENERATOR
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MAKE
STEAM PRESSURE
STEAM TEMP.
STEAM CAPACITY
TOTAL HEATING AREA
IBR NO.
HRU-1
HRU-2
DRUM PSV SET PRESS.
KS HEADER PSV
L&T
115 Kg/cm
520C
98.5 MT/Hr
3911M
. UP-5100
. UP-5192
130 (S) & 131(N) Kg/cm
122 Kg/cm
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121C
FEED WATER
145C
ECONOMISER - 1
ECONOMISER - 2
ECONOMISER - 3
EVAPORATOR - 2
510C
350
EVAPORATOR
-1
C
SUPERHEATER - 1
DRUM
320.8C
STAGE- 2
BURNERS
BLOW
DOWN
RCP
520C
SUPERHEATER - 2
652C
510C
GT EXHAUST
STAGE-1 BURNERS
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Milestones Achieved
2000-01 2001-02 2002-03
Specific Energy Cons., Gcal/MT
- Service Boiler
0.735
0.734
0.725
0.336
0.327
0.333
94.29
94.42
95.55
GTG Efficiency, %
21.34
24.31
25.26
89.34
91.94
90.80
92.95
79.74
82.77
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Maintenance Practices
HEAT RECOVERY UNITS / SERVICE BOILER :
DURING TURNAROUND FOLLOWING MAINTENANCE
PRACTICES ARE FOLLOWED
INSPECTION
AND
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Maintenance Practices
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Maintenance Practices
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Thank You
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