Anda di halaman 1dari 33

BOILER O & M PRACTICES

AT
TATA CHEMICALS , BABRALA

N RUSTAGI
1

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.
3

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.

Prizes bagged in 2002

1.National Energy Conservation Award - 2002 First


Prize,instituted by the Bureau of Energy
Efficiency, Ministry of Power, GOI.
2.FAI runner-up award for 'the best overall
performance of an operating ammonia and urea
plant - 2002'.
3.Golden Peacock Environment Management Award
-2002 First Prize (World Environment Foundation).

Prizes bagged in 2002

4.Environment, Agriculture and Rural Development


Award - 2002 (from the Indian Merchants'
Chamber).
5. 4 -STAR Rating for safety by the British Safety
Council-U.K.

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

Power & Steam Network


Fertilizer Complex has an integrated energy net work.
All the power consumed in the complex is generated
internally in the complex in Gas Turbine Generators.
We have two 19.5 MW gas turbines for full reliability
on the power front without having UPSEB grid
connection..
The waste heat from GTGs exhaust gas is utilized
for generating steam in HRUs. HRUs are provided
with supplementary firing.

Power & Steam Network


All the superheated steam consumed in the complex
is generated in Service Boiler, Heat Recovery Units
of GTGs and Waste Heat Boilers of Ammonia Plant.
The entire amount of DM Water used in the complex
is preheated in the Ammonia Plant and supplied to
deaerators of Ammonia Plant and Captive Power &
Steam Generation Plant.
The total power and steam generation in CPSGP are
approx. 19 MW and 130 TPH respectively.

Power & Steam Network

Hydrocarbons

Service Boiler

GTG - 1

HRU - 1

GTG - 2

HRU - 2

Power for elect drives

111 ata, 5100 C steam

HP Steam to turbines

Waste Heat Boilers

Super heaters
Ammonia Plant

10

Power & Steam Network


BFW

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

11

Service Boiler :

MAKE

Thermax Babcock & Wilcox Ltd.

STEAM PRESSURE

115 Kg/cm

STEAM TEMP.

520C

STEAM CAPACITY

110 MT/Hr MCR

TOTAL HEATING AREA

2696 M

IBR NO.

UP / 5049

DRUM PSV SET PRESS.

131 (S) & 132(N) Kg/cm

KS HEADER PSV

122 Kg/cm

12

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

13

Gas Turbine:
GTG1

GTG2

Make

Thomassen International Bv.

Model

PG5371PA

Base Output (Natural Gas)

19550 KW

Base Output (Distillate)

19190 KW

Commissioning Date

Feb1994

Apr1994

Control System

MK-IV

MK-IV

Fired Time

70681.5

57883

Fired Starts

221

196

Driven Equipment / Model

Generator / ABB, Sweden

Accessory Gear Model /Sl.No

Flender /AA 51CA

Load Gear Box Model/Sl.No.

Maag/ G- 80 /RU

(Hrs)

14

Power & Steam Network (GTG+HRU)


(AUX.FIRING)

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

15

Heat Recovery Unit (HRU):

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

16

Power & Steam Network (HRU)


EXHAUST

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
17

Milestones Achieved
2000-01 2001-02 2002-03
Specific Energy Cons., Gcal/MT
- Service Boiler

0.735

0.734

0.725

- Heat Recovery Unit

0.336

0.327

0.333

Service Boiler Efficiency, %

94.29

94.42

95.55

GTG Efficiency, %

21.34

24.31

25.26

89.34

91.94

90.80

92.95

Co-gen. Efficiency of GTG/HRU, %


Overall Efficiency of CPSGP, %

79.74
82.77

18

Operational Performance : 2000 to 2003

INCREASED OPERATIONAL RELIABILITY BY


INCORPORATING MODIFIED 2/3 TRIP LOGIC FOR TRIP
RELATED PARAMETER OF SERVICE BOILER, HRUs AND
GTGs.

OPERATION OF SERVICE BOILER AT 25 TPH LOAD WITH


TWO BURNERS IN OPERATION.

LOADING OF SERVICE BOILER IN CASE OF EMERGENCY


BY AUTO IGNITION OF 3rd & 4th BURNERS.

OPERATION OF HRU WITH NG IN 1st STAGE & NAPHTHA IN


2nd STAGE AS FUEL.

19

Operational Performance : 2000 to 2003

CRITICAL ACTIVITIES LIKE START UP, SHUT DOWN,


CHANGEOVER OF FILTERS, WATER WASH, FUEL CHANGE
OVER IN SERVICE BOILER, FEED PUMP CHANGE OVER
ETC. WITH CHECKLIST.

ONE GTG IS IN OPERATION WITHOUT ANY EXTERNAL GRID


SUPPORT.

OPERATION OF GTG AT VARIABLE CONTROL OF IGV AS


PER LOAD.

OPERATION OF GTG WITH EVAPORATIVE COOLING


DURING SUMMER & PRE HEATER DURING WINTER
SEASON.

20

Operational Performance :2000 to 2003


Energy Conservation - Initiatives Taken
Service Boiler operation with top two Burners on NG fuel or
naphtha fuel with Fast Loading facility in case of Emergency
by auto ignition of 3rd & 4th burners.

- Achieved maximum capacity utilization of HRU by


operating Service Boiler on minimum load of 25 TPH.
- Achieved overall saving of 125 NM3/HR in HRU and
Service Boiler.
- Oxygen analyzer relocated from Air Pre-Heater outlet to its
inlet for effective monitoring of excess air.

21

Operational Performance :2000 to 2003


Energy Conservation - Initiatives Taken
HRU dual fuel operation i.e. 1st Stage burner on NG fuel while
2nd Stage on naphtha fuel :

- Helped in optimized use of Natural Gas available from GAIL.

22

Operational Performance :2000 to 2003


Energy Conservation - Initiatives Taken
Operation of Motor Driven Boiler Feed Water Pump in place of
Turbo Driven Pump :

- Achieved the reduction in Specific Energy consumption of


Urea by use of power in place of steam.

23

Operational Performance :2000 to 2003


Energy Conservation - Initiatives Taken
Energy Conservation due to stopping of one GTG
(Energy saving of 177516 Gcal/annum )

2/3 logics were incorporated in GTG/HRSG for operational


reliability.

Township and Lightning load decreased by various


initiatives.

Howden (Flash Ammonia) Compressor frequent startup


avoided.

ACT pump (one number) stopped.

One GV pump stopped.

24

Operational Performance :2000 to 2003


Energy Conservation - Initiatives Taken
GTG IGV kept ON AUTO MODE after adjusting cooling air
flows to wheel space.

Net saving (@daily av. 500nm/hr saving)= 44008


Gcal/annum.

GTG NG consumption reduced from 6488 to 6288 nm/hr.


(Net saving as per Gail LHV is 200 nm/hr)

HRSG NG consumption reduced from 4339 to 4039. (Net


saving as per Gail LHV is 300 nm/hr)

The Exhaust Stack temp reduced from 152c to 135c.

25

Maintenance Practices
HEAT RECOVERY UNITS / SERVICE BOILER :
DURING TURNAROUND FOLLOWING MAINTENANCE
PRACTICES ARE FOLLOWED

STEAM DRUM INSPECTION FOR INTERNALS.

BURNERS FUEL BLOCK VALVES


PREVENTIVE MAINTENANCE.

SERVICE BOILER BURNER REFRACTORY INSPECTION


AND REPAIRING.

ALL INSTRUMENT CALIBRATION.

FD FAN, AUXILIARY AIR FAN & SCANNER FAN MOTOR


PREVENTIVE MAINTENANCE.

INSPECTION

AND

26

Maintenance Practices

FD FAN, AUXILIARY AIR FAN & SCANNER FAN IMPELLER


CLEANING.

FD FAN INLET DAMPER CONTROL MECHANISM


INSPECTION AND PREVENTIVE MAINTENANCE.

INSPECTION AND MAINTENANCE OF FEED CONTROL


VALVES.

ON LINE SAFETY VALVE TESTING (TRAVI TEST).

27

Maintenance Practices

AIR PRE HEATER TUBE CLEANING AND INSPECTION

BURNER INSPECTION AND DIMENSION MEASUREMENT.

MOTOR OPERATED VALVES DRIVE AND ACTUATOR


PRVENTIVE MAINTENANCE.

TRIP AND INTERLOCK CHECKING.

28

Planning of New Initiatives


HRU / SERVICE BOILER

INSTALLATION OF MAGNETIC RESONATOR IN NAPHTHA LINE

OPERATION OF SERVICE BOILER ON ALTERNATE CHEAPER


FUEL

29

Planning of New Initiatives


GTG

SUCTION AIR FILTERS REPLACEMENT (CELLULOSE TO


SYNTHETIC)

REMOVAL / ALTERNATE ARRANGEMENT FOR EVAPORATIVE


AIR COOLER TO REDUCE PRESSURE DROP .

ATOMIZING AIR COMPRESSOR & COOLER REMOVAL.

GENERATOR FREQUENCY REDUCTION TO SAVE ENERGY.

30

Need Your Help.


We are facing some problems in our HRU & GTG Like:

DISTURBANCE IN FIRING OF HRU STAGE-II BURNERS, NEARER


TO SIDE WALLS, OPERATING ON NAPHTHA FUEL.

HIGH PRESSURE DROP ACROSS SUPERHEATER IN HRU


LEADING TO LIMITATION IN HIGHER STEAM GENERATION
RATE.

HIGH WHEEL SPACE TEMPERATURE AT MIN. IGV POSITION


DURING SUMMER.

31

Need Your Help.

HIGH PRESSURE DROP ACROSS INLET AIR FILTERS OF GTG


DURING FOG AND RAINY SEASON

CHOCKING OF ATOMISING AIR COOLER IN GTG.

32

Thank You
33

Anda mungkin juga menyukai