PRABHA GUPTA

Asst. Mgr(Inst.)
Intoduction to Phulpur Unit
Ammonia-I : 1215 MTPD
Ammonia-II : 1740 MTPD
Urea-I : 2115 MTPD
Urea-II : 3030 MTPD
Power Plant-I : (125*3)TPH+12.5MW
Power Plant-II : 200 TPH + 18.0 MW
 Block Diagram of AMMONIA Plant
PROCESS AIR

LNG FEED
PRIMARY SECONDARY HIGH
TEMPERATURE LT
REFORMER REFORMER GAURD
SHIFT CONVERTER
STEAM

CO₂

SYNYTHESIS LOW
GV TEMPERATURE
COMPRESSOR & METHANATOR
CONVERTER SECTION SHIFT CONVERTER

AMMONIA
CHILLERS SEPERATOR
FINAL AMMONIA PRODUCT

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 Block Diagram of UREA Plant
Ammonia

REACTOR HP STRIPPER MP PRE-DECOMPOSER

CO2

VACUUM LP DECOMPOSER MP DECOMPOSER

SECTION-I

VACUUM UREA SOLUTION

PRILL TOWER
SECTION-II PUMP

Final Urea product

5
 Measurement of Process parameters
 PRESSURE
 TEMPERATURE
 FLOW
 LEVEL

SV + E(t) PID MV Final control O/P

- Controller Element

PV

Feedback
E(t)=SV-PV Error signal
SV=Set Value
PV=Process Value
MV=Manipulated Value

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 Pressure measurement
Most liquid and all gaseous materials in the process industries are
contained within closed vessels. For the safety of plant personnel and
protection of the vessel, pressure in the vessel is controlled. In addition,
pressure is controlled because it influences key process operations like
vapor-liquid equilibrium, chemical reaction rate, and fluid flow.

Junction
Box(JB)
Isolator NIU FCS
Press. Tx(PT)
(4-20 mA)
4-20 mA
I/P Junction
Converter Box(JB)
Isolator NIU FCS

0.2-1.0 Kg/Cm2

Press. Control Valve(PV) 77

 Pressure Sensors
 Bourdon Tube
 Bellows
 Diaphragm
 Capacitive or inductance
 Resistive, strain gauge
 Piezoelectric

88
 Temperature measurement
Temperature control is important for separation and
reaction processes, and temperature must be
maintained within limits to ensure safe and reliable
operation of process equipment

Junction
Box(JB)
Isolator NIU FCS
Thermocouple
( mVolts)
4-20 mA
I/P Junction
Converter Box(JB)
Isolator NIU FCS

0.2-1.0 Kg/Cm2

Temp. Control Valve(TV) 99

Temperature Sensors
 Thermocouples
 Resistance Temperature Detectors (RTD)
 Thermistor
 Bimetallic
 Filled systems
 Optical pyrometers

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 Flow Measurement
The instrument to conduct flow measurement is
called flow meter.
❖ Measure of a Product Gas, Liquid or Solid
❖ Two Forms: Volumetric and Mass
❖ Volumetric: Measure of a Volume or Space such
as gallons or liters
❖ Mass: Measure of the Weight of a material in lbs
or grams

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 Continued….

Junction
Box(JB)
Isolator NIU FCS

Flow Tx(FT)
(4-20 mA)
4-20 mA
I/P Junction
Converter Box(JB)
Isolator NIU FCS

0.2-1.0 Kg/Cm2

Flow Control Valve(FV)

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Flow Sensors
❖ Differential Pressure
 Orifice
 Flow Nozzle
 Venturi
 Pitot Tube
 Annubar
 Elbow
❖ Variable Area Rotameter
❖ Positive Displacement
 Nutating Disc
 Oval Gear
❖ Magnetic
❖ Turbine
❖ Ultrasonic
❖ Vortex
❖ Coriolis

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 Level Measurement
 Level of liquid in a vessel should be maintained above the exit pipe
because if the vessel empties the exit flow will become zero, a situation
that would upset downstream processes and could damage pumping
equipment that requires liquid. Also, the level should not overflow an
open vessel nor should it exit through a vapor line of a closed vessel,
which could disturb a process designed for vapor.

Junction
Box(JB)
Isolator NIU FCS
Level Tx(LT)
(4-20 mA)
4-20 mA
I/P Junction
Converter Box(JB)
Isolator NIU FCS

0.2-1.0 Kg/Cm2

Level Control Valve(LV) 14

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Level Sensors
❖ Level transmitters
 Float
 Displacement
 Differential pressure
 Capacitance
❖ Level gauge

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Distributed Control System(DCS)
 Manufacturer : Yokogawa India Ltd.
 Model : Centum vp
 Major system components
◦ Information & command station (ICS)
◦ Field control station (FCS)
◦ Engineering work station (EWS)
◦ Communication gateway unit (AGC)
◦ Nodes with I/O cards

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DCS : Power Plant
 Honeywell Automation India Ltd. (HAIL)
 Windows 2000 Server
 Experion PKS (C-200/R201)
 Single Redundant Network
 FTE Communication
 Operator Station:Flex & Console
 MIS System : Report Generation

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 Block Diagram :
I/O
FTA MODULES C-200

FIELD CONTROL FTA PMIO CONTROLLER

PANEL MODULE
STATION SERVER

OWS SERVER ETHERNET

SW

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 SECURITY LEVEL:

Security Description
LVL1 View only mode

LVL2 View only mode with alarm Acknowledge

OPER Level 2 plus control of field parameters

SUPR Level 3 plus filed parameters of level 4,configure standard

system infrastructure such as reports

ENGR Level 4 plus user configured field parameters

MNGR Unlimited access

System Diagnostic Check:

C200 Controller System Diagnostics: This includes

 Parity Check
 Battery Check
 Watch Dog Timer
 Redundancy Circuit / Module
 I/O Module Error / Failure
 I /O Rack Status Information
Network Communication Diagnostics: This includes
 Message Checksum
 Alarm and event recovery for device failure
 Operator station status information
 Printer Status Information
 Software Revision Information
 Network Health Information
 MAIN EQUIMPENTS OF POWER PLANT:
EQUIPTS BOILER# 1,2,3 BOILER # 4 TG-1 TG-2
MAKE M/S BHEL M/S BHEL M/S BHEL M/S BHEL

TYPE BIDRUM, WATER BIDRUM, WATER TWO STAGE, EXTN TWO STAGE,
TUBE,TANGENTIALLY TUBE,FRONT TYPE, CONDENSING, EXTN
PC FIRED, RLNG / OIL FIRED TURBINE TYPE,CONDEN
Pr -110KG/CM2 Pr -115KG/CM2 SING TURBINE
TEMP - 465 DEG C TEMP -515 DEG C

C&I DCS OF HAIL, DCS OF HAIL, DCS OF HAIL, DCS OF HAIL,

SERVER-CLIENT SERVER-CLIENT SERVER-CLIENT SERVER-
SYSTEM ARCHITECTURE ARCHITECTURE ARCHITECTURE CLIENT
BASED,EPKS,C- BASED,EPKS,C- BASED,EPKS,C- ARCHITECTUR
200,WINDOWS BASED 200,WINDOWS 200,WINDOWS BASED E
AND SMART BASED AND SMART BASED,EPKS,C
ELECTRONIC FIELD AND SMART ELECTRONIC FIELD -200,WINDOWS
Tx. ELECTRONIC Tx. BASED
FIELD Tx. AND SMART
ELECTRONIC
FIELD Tx.

FUEL COAL & RLNG RLNG OR LSHS HP STEAM HP STEAM

YEAR 1980-81 1997-98 1980-81 1997-98

 MAIN EQUIPMENTS OF COAL FIRED BOILER-1,2&3
EQPTS QTY TYPE CAPACITY FUNCTION
FD FAN TWO ELECT MOTOR 25M3/SEC TO PROVIDE
DRIVE,RADIAL, COMBUSTON AIR
SINGLE SUCTION

ID FAN TWO ELECT MOTOR 35M3/SEC TO CREAT INDUCED

DRIVE,RADIAL, DRAFT FROM
SINGLE SUCTION FURNACE TO CHIMNEY

COAL MILL THREE ELECT MOTOR 12.4TPH, PULVARISATION OF

DRIVE,BOWL MILL COAL SIZE- COAL
200 MESH

COAL 12 TANGENTIALLY , 4 TPH COMBUSTION OF

TILTING TYPE PULVARISED COAL
BURNER
RLNG EIGHT/E TANGENTIALLY , THERMAX COMBUSTION OF RLNG
IGHT TILTING TYPE / MAKE FUEL /
BURNR /
HT IGNITOR INITIATE FIRING.
IGNITOR
SCANNER EIGHT UV SCANNER FIRE EYE FLAME DETECTOR
MAKE
SAD 7x4 MODULATING AIR DISTRIBUTION
 CENTRALISED CONTROL ROOM INSTRUMENTS (OLD Vs NEW) :

INSTRUMENT OLD INST TYPE MAKE NEW INST MAKE/MODEL

/MODEL TYPE
SINGLE LOOP PNEUMATIC,FORCE BESTOBELL, MULTI LOOP HONEYWELL /
CONTROLLER BALANCE FLEXAIR FBB DCS FEATURE EXPERION PKS
COMPUTING PNEUMATIC,FORCE BESTOBELL, DCS FEATURE HONEYWELL /
RELAY BALANCE FLEXAIR FBB EXPERION PKS
HI & LO PNEUMATIC,FORCE BESTOBELL, DCS FEATURE HONEYWELL /
SELECTION SW BALANCE EXPERION PKS
INDICATOR PNEUMATIC,FORCE BESTOBELL, DCS FEATURE HONEYWELL /
BALANCE FLEXAIR FBB EXPERION PKS
MULTIPOINT PNEUMATIC,FORCE BESTOBELL, DCS FEATURE HONEYWELL /
RECORDER BALANCE FLEXAIR FBB EXPERION PKS
MULTIPOINT ELECTRONIC IL,CLEARSPAN DCS FEATURE HONEYWELL /
RECORDER 120L EXPERION PKS
ALARM SYSTEM FASIA WINDOW TYPE IIC DCS FEATURE HONEYWELL /
ANNUNCIATOR EXPERION PKS
DRAFT GAUGE DIRECT INDICATOR H GURU FIELD. SMART HONEYWELL
LOGIC RELAY ELECTRICAL 220AC,220DC SIEMENS DCS FEATURE HONEYWELL /
EXPERION PKS
FLAG / TRIP ELECTRICAL 220AC,220DC ENGLISH DCS FEATURE HONEYWELL /
RELAY ELECTRIC EXPERION PKS
 FIELD INSTRUMENTS ( OLD & NEW ) :
INSTRUMENT OLD INST TYPE MAKE / MODEL NEW INST MAKE /
TYPE MODEL
FIELD PNEUMATIC, BESTOBELL / IN DCS HONEYWELL /
CONTROLLER MOTION BALANCE CAMPO JAG EXPERION PKS

FIELD PNEUMATIC, BESTOBELL / SMART HONEYWELL /

TRANSMITTER FORCE BALANCE DELTAPI NA ELECTRONIC ST 3000
TRANSMITTER

TEMP SENSOR THERMOCOUPLE GENERAL RETAINED RETAINED

K-TYPE, RTD Pt-100 INSTRUMRNTS

CONTROL PNEUMATIC INSTRUMENTATION RETAINED WITH RETAINED / I/P

VALVE ACTUATOR ,GLOBE LTD I/P CONVERTER OF ABB

POWER DOUBLE ACTING RGS & HAGON RETAINED WITH RETAINED / I/P
CYLINDER I/P CONVERTER OF ABB

PRESSURE SNAP ACTING DANFOSS RETAINED RETAINED

SWITCH
LIMIT SWITCH MECHANICAL CUTTLER HAMMER PROXIMITY TYPE P&F
WITH LED
Vibration monitoring system
 WHAT IS VIBRATION??
Vibration is Oscillating motion in response to some excitation
force (forcing function) either as an impact or periodic force.
 Vibration Measurement is the measurement of the dynamic
motion of the machine components relative to a known
reference.
VMS used in plant:
Bently Nevada 3300 series(A-I/II ,U-I/II &P/P)
Bently Nevada 3500 Series(CO2 Blower in A-I)

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 UPS SYSTEM
UPS: Uninterrupted Power Supply

AC INPUT RECTIFIER INVERTER LOAD

BATTERY
Causes of UPS Failure:
O/P overload
Inverter overvoltage
Inverter Under voltage
I/P Breaker tripped
Fuse blown
Fan failure
Battery voltage low
Inverter failure
Rectifier failure

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Continued…

 Ammonia-I: Instrumentation Limited(IL) 40KVA

 Urea-I: Instrumentation Limited(IL) 40KVA
 Ammonia-II: Fuji Electric System 100KVA
 Urea-II: Fuji Electric System 100KVA
 Power Plant: Siemens 60KVA

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Maintenance Procedures
 Preventive maintenance
◦ Analyser sample flow adjustments
◦ Liquid analyser electrode cleaning
◦ Cleaning and painting of field instruments

 Work request based maintenance

◦ Work requests are issued on Maintenance management system
on computer indicating problem and safety permit if required.

 Breakdown maintenance

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Continued….
 Scheduled maintenance
◦ Physical inspection
◦ Calibration
◦ Cleaning & Lubrication
◦ Repair / Part replacement

 Annual maintenance
◦ Calibration of critical instruments
◦ Control valve trim inspection & repair

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