ACKN0WLEBuENENT

llLLL A SLnSL Cl 8A8L ACPlvLMLn1S A1 1PL 1lML Cl CCMLL1lCn Cl M? CnL MCn1P

vCCA1lCnAL 18AnlnC ln lllCC (lnulAn lL81lLlZL8S CCCL8A1lvL LlMl1Lu) A CLC8ALL?
8LCCCnlZLu Anu 8Lu1Lu CCCL8A1lvL CCMAn? ln 1PL llLLu Cl lL81lLlZL8`S
lnuS18lLS
l PAvL nC PLSl1A1lCn ln ASSL81lnC 1PA1 l CCuLu nC1 CL1 SuCP 1?L Cl CCnlluLnCL ln
An? C1PL8 CCMAn? WPlCP l PAvL CC1 ln lllCC
l1 lS M? C8LA1 LLASu8L 1C Lx8LSS M? SlnCL8L C8A1l1uuL 1C M8 u kALl?A (uCM
1u SLC1lCn) lC8 1PlS uLL ln1L8LS1 lnSl8A1lCn Anu vALuA8LL AuvlCL uu8lnC 1PL
Ln1l8L CCu8SL Cl vCCA1lCnAL 18AlnlnC
l AM ALSC 1PAnkluLL 1C M8 C MA1Pu8 (MAnACL8 1u SLC1lCn) Anu M8 kk
AnuA? (MAnACL8 1u SLC1lCn) lC8 1PL8L klnu Anu SuC81lnC nA1u8L
l8CM 1PL CC8L Cl M? PLA81 l CC8uALL? Lx1Lnu M? 1PAnkS 1C M8 1A8un kuMA8
1PAku8 SLnlC8 LnClnLL8 (LLLC18lCAL MAln1lnAnCL) lA8 ClvlnC PlS MC8AL SuC81
PLLluL nA1u8L Anu uLL knCWLLuCL lC8 1PL CA88?lnC Cu1 1PL 18AlnlnC
l CCnvL? M? PLA81L? 1PAnkS 1C ALL Cl 1PL S1All MLM8L8S Cl lllCC ACnLA unl1 lC8
1PLl8 PLL Anu ASSlS1AnCL uu8lnC M? 18AlnlnC L8lCu

ASPu1CSP SAxLnA
8 1LCP
LLLC18lCAL Anu LLLC18CnlCS
LnClnLL8lnC
CALCC1lA`S CCLLLCL Cl LnCC
Anu 1LCPnCLCC?
C8LA1L8 nCluA


NBAN FARNARS FERTLERS C0-
0PERATE LNTEB
ln18CuuC1lCn
llllCC Aonla complex ls one of Lhe glanL cooperaLlve ferLlllzer manufacLurlng lndusLrles ln
lnulA
1hls ls complex conslsL of Lwo ammonla manufacLurlng unlLs wlLh capaclLles as 1330 M1u
uslng M/s Paldor1opsoe uenmark process Lechnology
1hls complex conslsL of four urea manufacLurlng unlL wlLh capaclLles as 1100 M1u each uslng
M/s snamrogeLLl lLaly process Lechnology
AparL from Lhe above maln process we are havlng oLher offslLe and uLlllLy faclllLles Lo augmenL
Lhe maln process unlLs
under offslLe faclllLles we are havlng demlnerallzed waLer LreaLmenL planL for maklng boller
feed waLer coollng waLer clrculaLlon for process medlum coollng aL varlous heaL exchanger
aparL from Lhe above faclllLles we are also havlng lnsLrumenL alr supply unlLs planLs alr supply
unlL lnerL gas supply unlLs effluenL LreaLmenL unlLs ammonla sLorage unlLs naphLha sLorage
unlLs

CapLlve power generaLlon planL wlLh Lwo unlLs of gas Lurblnes havlng capaclLles of 24 MW each
supplled by M/s PlLachl !apan sLeam generaLlon planL of 130 1P hlghpressure sLeam aL 103
kg/cm2 pressure aL 310 degc 1wo bagglng planLs wlLh auLomaLlc bagglng machlnes 1o run Lhe
LoLal complex we are havlng deLalled organlzaLlon seLup conslsLlng of varlous agencles









8kILI DLSCkI1ICN
1he lllCC complex aL Aonla conslsLs of Lwo ammonla unlLs of 1320 M1/day capaclLy and Lwo
urea unlLs of 1300 M1/day each capaclLy wlLh Lhe requlred offslLe faclllLles
lor efflclenL and unlnLerrupLed runnlng of a ferLlllzer planL a rellable source of power ls very
much essenLlal All Lhe ma[or roLaLlng equlpmenLs of ammonla and urea planL are drlven by
elecLrlcal moLor 1o meeL Lhe demand of hlgh pressure sLeam and dependable elecLrlcal power
Lhe sLeam and power generaLors have been lnsLalled 1he sLeam generaLor of Aonla unlL wlll
supply hlgh pressure sLeam Lo process planLs and gas Lurblne generaLor wlll meeL Lhe power
requlremenL of Lhe planL 1here are Lwo gas Lurblne generaLor (C1C) Cne SLeam
CeneraLor(SC) and Lwo PeaL 8ecovery SLeam CeneraLlng unlLs(P8SC)

1he C1C manufacLured by M/S PlLachl llmlLed !apan has a capaclLy Lo generaLe 23280 MW aL
lSC base raLlng (mean Lemp13 deg c 60 humldlLy) 1he C1C have been deslgned Lo operaLe
on naLural gas (nC) hlgh speed dlesel (PSu) or naphLha fuels 1he exhausL of C1 aL abouL 300
deg c wlll he used ln P8SC Lo generaLe sLeam aL hlgh pressure 1wo P8SC unlLs each havlng
capaclLy Lo generaLe 80 1/hr aL 116 aLm and 313 deg c ls manufacLured by M/s kawasakl heavy
lndusLrles !apan P8SC ls a packed Lype boller havlng bank Lubes asseL of super heaLers ue
super heaLers and economlzer 1he Lemp of exhausL gas from C1C ls lncreased by
supplemenLary flrlng 1he exhausL of C1C ls havlng sufflclenL quanLlLy of excess alr whlch ls
uLlllzed for combusLlon of supplemenL fuel and so no separaLe lorced urafL(lu) fan has been
provlded lor sLeam Lemp conLrol dlrecL waLer spray Lype aLLemperaLor has been provlded
beLween prlmary and secondary super heaLers

1he SC unlL ls a waLer Lube double drum naLure clrculaLlon oll (low sulphur hlgh sLarL LSPS)or
naLural gas grld boller manufacLured by M/s MlLsul Lngg Co !apan
1he capaclLy of SC unlL ls 130 Lon/hr of super heaLed sLeam aL a pressure of 116 aLm and Lemp
313 deg c Lhe SC ls deslgned Lo use nC or LSPS fuel for regular flrlng lor lnlLlal llghL up of Lhe
SC PSu wlll be used Lhe SC ls pressurlzed furnaces wlLh no lnduced lu fan 1wo lu fan one
Lurblne drlven and oLher moLor drlven have been provlded beLween prlmary Lo supply
combusLlon alr A dlrecL spray Lype uesuper heaLer has been provlded beLween prlmary and
secondary super heaLer Lo conLrol sLeam LemperaLure





GAS TURBINE LNLkA1Ck (GTG)
kINCILL
1he gas Lurblne llke any over heaL englne ls a devlce for converLlng a parL of fuel` chemlcal
energy lnLo useful avallable power
lL does Lhls ln Lhls manner slmllarly ln many ways Lo Lhe sysLem used by four sLroke cycle
reclprocaLlng lnLernal combusLlon englne Alr ls drawn ln Lo Lhe compressor usually Lhrough an
alr fllLer slLuaLed ln a lllLer house" Lo remove any harmful solld parLlcle from Lhe alr sLream
1hls alr ls Lhen fed Lo Lhe combusLlon sysLem where lL mlxed wlLh ln[ecLed fuel burn and lLs
energy Lo Lhe alr

ETAILE ESCRIPTION OF STEAM GENERATION
1he MlLsul Mu (mlddle Lo seml large lndusLrlal boller) Lype sLeam generaLor ls of ouLdoor use
self sLandlng naLural clrculaLlon Lype 1he sLeam generaLor ls deslgned Lo flre PSu LSCS/lC
and nC wlLh four seL of oll and gas comblnaLlon burners
1he sLeam generaLor comprlses a waLer cooled furnace a convecLlon bank sLeam and waLer
drum header for collecLlng and dlsLrlbuLlng waLer and sLeam prlmary and secondary super
heaLer frames caslng lnsulaLlon eLc
u8uM Anu ln1L8nALS
1he Mu Lype boller ls provlded wlLh a sLeam drum and a waLer drum 8oLh of Lhe drum have a
man hole on each end of malnLenance and lnspecLlon 1he sLeam drum ls equlpped wlLh seLs of
sLeam purlflers lnslde Lo obLaln Lhe requlred sLeam purlLy
1he sLeam drum ls equlpped wlLh lnLernal plpes for feed waLer chemlcal and conLlnuous
belowdown as well as sLream purlfler 1he lnLernal plpes are arranged so as Lo lnsure good
dlsLrlbuLlon of feed waLer and chemlcals ln Lhe drum and Lo collecL relaLlvely hlghly
concenLraLed boller waLer for blow down 1he nozzles for feed waLer and chemlcals are of
double plpe Lype so as Lo reduce Lhermal sLresses due Lo Lhe Lemp dlfference
llnally Lhe sLeam passes Lhrough Lhe scrubbers 1hls comprlses a no of corrugaLed meLal
plaLes When Lhe sLeam flows Lhrough lL any remalnlng waLer parLlcles are efflclenLly removed
1hls occur due Lo sharp change ln Lhe flow dlrecLlon




FURNACE
1he furnace has an ample volume Lo secure compleLe combusLlon of speclfled fuel 1he furnace
walls are of welded longlLudlnal fln Lubes panels Lo form a compleLely gas LlghL enclosure 1he
furnace floor ls covered wlLh a layer of refracLory brlcks so as Lo shleld Lhe Lubes from radlanL
heaL Lo secure a good clrculaLlon of waLer 1he fronL wall ls equlpped wlLh burner ln Lwo rows
1he rear wall forms a parLlLlon wall dlvldlng Lhe convecLlon secLlon from Lhe furnace 1he rear
Lubes from a nose baffle Lo provlde a super heaLer space a upper parL of Lhe furnace 1he slde
walls are provlded wlLh lower and upper header whlch ls connecLed Lo waLer and sLeam drums
wlLh connecLlon plpes SufflclenL numbers of observaLlon holes ls provlded on Lhe fronL slde
walls Lo check Lhe flrlng condlLlon and for malnLenance
Super heater
1he super heaLer ls provlded wlLh Lwo sLages of super heaLers ln prlmary and secondary super
heaLer boLh of Lhem are of convecLlon and pendenL Lype 1he prlmary super heaLer ls locaLed aL
Lhe lower gas Lemp parL whlle Lhe secondary le aL Lhe hlgher Lemp parL 1he sLeam flows
conLour Lo gas ln Lhe prlmary super heaLer and parallel ln Lhe secondary heaLer
1he super heaLers Lubes are hung Lo super heaLers whlch are mounLed on Lhe furnace header
1herefore Lhermal expanslons of Lhe Lube are hung Lo Lhe super heaLer headers whlch are
mounLed on Lhe furnace header 1herefore Lhermal expanslon of Lhe Lubes and headers ls free
whlch avolds excesslve sLresses
8eLracLable sooL blowers and access doors are provlded beLween Lhe prlmary and secondary
super heaLer for cleanlng and malnLenance

DLSULk nLA1Lk
1he de super heaLer ls also provlded on Lhe connecLlng plpe beLween Lhe prlmary and
secondary super heaLers Lo conLrol Lhe flnal sLeam pressure
leed waLer ls sprayed ln Lhe sLeam flow Lhrough a spray nozzle whlch reduces Lhe sLeam Lemp
lmmedlaLely downsLream of Lhe nozzle a Lhermal sleeve ls furnlshed so as Lo avold dlrecL
conLacL of sprayed waLer Lo Lhe connecLlng plpe wall
LCCNCMISLk
Lconomlzer ls Lhe furnlshed downsLream Lhe convenLlon bank Lo recover wasLe heaL from flue
gases
1he economlzer comprlses a number of splral wound flnned Lubes lnleL and ouLleL headers and
sufflclenL frames and caslng lL ls supporLed by Lhe sLeel sLrucLure uslng sllde shoes Lo caLer
wlLh horlzonLal Lhermal expanslon

8eclprocaLlng Lype sooL blower wlLh mulLlple nozzles ls furnlshed Lo effecLlvely clean Lhe
heaLlng surfaces

8CILLk ILLD WA1Lk SS1LM
1he requlremenL of waLer far Lhe boller ls meL from Lhe waLer LreaLmenL planL ln Lhe waLer
LreaLmenL planL uM waLer Lemp ls ralsed Lo 60 deg c by passes lL Lhrough reLurn condensaLe
cooler before sendlng Lo sLeam generaLlon planL ln deaeraLor dlssolve gases o
2
and co
2
are
removed up Lo 0003 ppm by ralslng Lhe waLer Lemp Lo 126 deg c and sLrlpplng aL a pressure
of 144 kg/cm sq by sLeam ln deaeraLor sLorage Lank cyclohexamlne and hydrazlne are dosed
Lo ralsed Lhe P of waLer Lo 8393 and furLher chemlcal LreaLmenL of Lhe boller waLer Lo
remove Lhe remalnlng oxygen Lo nll
8oller feed waLer pump Lakes sucLlon from dearaLer 1he pump dlscharge aL pressure of 162
kg/cm sq g and Lemp 126 deg c Lhrough economlzer lL enLers Lhe boller drum 1here ls boller
feed waLer preheaLer locaLed beLween pump dlscharge and economlzer Lo ralse Lhe 8lW Lemp
from 126 deg c Lo 140
0
C ln case Lhe boller ls on LSPS flrlng 1hls rlse ln Lemp ls essenLlal Lo
avold condensaLlon of oxldes of sulpher on coll surface and Lo prevenL corroslon
1he ouLleL of 8Wl preheaLed ls dlvlded lnLo Lwo branch leads Lo Lhe uesuper heaLer of Lhe SC
and P8SC unlLs Lo conLrol Lhe sLeam Lemp and leads waLer Lo SC P8SC unlL Lhrough respecLlve
economlzer feed waLer uLlllzes Lhe wasLe heaL from Lhe flue gases and Lemp of waLer ralsed Lo
190 Lo 310
o
C respecLlvely
DLAkA1IN nLA1Lk
uearaLor ls very lmporLanL ln Lhe boller feed waLer sysLem lLs baslc funcLlon ls Lo remove o
2

and co
2
dlssolved ln waLer Lo a conslderable exLanL and sLore waLer for supplylng Lo boller feed
pumps

DLAkA1Ck
1he dearaLor funcLlons on heaL and mass Lransfer process ln dearaLor Lhe nozzles and Lrays
have been provlded Lhrough whlch waLer ls sprayed and dlsLrlbuLed lnLo flne dropleLs Lo
lncrease Lhe surface area lf waLer 1he process removed Lhe dlssolved gases Lo some exLenL
1hen Lhe sLeam ls mlxed wlLh waLer ln mlxed wlLh waLer ln mlxed box named scrubber 1hls
process also removes Lhe dlssolved gases 8y Lhe above process ln waLer C
2
conLenLs geL
reduced Lo 0003 ppm
S1CkAL 1ANkS
1hls ls for sLorlng of Lhe feed waLer whlch ls deaeraLor 1he sLorage Lank ls deslgned Lo prevenL
subsequenL peneLraLlon of oxygen durlng Lhe feedlng waLer process afLer Lhe necessary

deaeraLlon 1he Lemp of Lhe waLer ls also kepL consLanL lnslde Lhe sLorage Lank by coverlng Lhe
Lank wlLh lnsulaLlon maLerlal
CCM8U1ICN AIk SS1LM
1he alr requlred for Lhe combusLlon of alr ln sLeam generaLor ls meeLlng by Lwo cenLrlfugal
Lypes forced drafL fan (lu fan) Cne fan ls drlven by elecLrlcal moLor whlle oLher by sLeam
Lurblne uurlng Lhe sLarLup of Lhe SC moLor drlven fan ls Laken ln servlce ln case sLeam ls noL
avallable Lo drlven Lhe Lurblne
1he lu fan sucks Lhe alr from Lhe aLmosphere and dlscharge Lo Lhe furnace aL a pressure of
90mm300mm waLer gauge 1he quallLy of alr ls conLrolled by Lhe vane provlded aL Lhe sucLlon
slde of lu fan 1wo alr heaLers have been provlded ln Lhe dlscharge ducL of lu fans whlch are
known as sLeam oll heaLer 1hese alr heaLers ralse Lhe Lemp Lo 143
o
C
DLSCkI1ICN CI nkS
CLnL8AL
1he boller conslsLs of and arranged ln Lhe same caslng as follows
O Super heaLer
O LvaporaLor wlLh sLeam drum
O Lconomlzer
All Lubes are splral flnned and arranged ln verLlcal rows wlLh sLaggered Lube arrangemenL Lo
horlzonLal gas flow All Lubes clrculL orlglnaLes from lnleL header and dlscharge Lo ouLleL header
and besldes Lubes and lLs header are arranged so LhaL all Lube bank secLlon ls fully dralnable
Whole boller ls supporLed wlLh Lhe boLLom caslng on Lhe foundaLlon
S1LAM DkUM
SLeam drum ls of all welded consLrucLlon fabrlcaLed from carbon sLeel maLerlal and equlpped
wlLh sLeam purlfler of baffle screen Lype ln sLeam drum and necessary nozzle and connecLlons
1he drum has been mounLed on above Lhe boller ls supporLed wlLh down corner plpes

LVACkA1Ck
LvaporaLor secLlon ls composed of several componenLs whlch conslsL of number of Lubes wlLh
splral fln and each lnleL and ouLleL header Lach componenL ls made up of waLer clrculaLlon
clrculLs separaLely LvaporaLor elemenLs are boLLom supporLed by lower header holdlng plaLes
WA1Lk CICULA1ICN SS1LM

1he waLer clrculaLlon clrculL conslsLs of sLeam drum down comer plpes down comer headers
supply plpes sLeam generaLlng Lubes (evaporaLors) and rlser plpe 1he baslc sysLem funcLlon
are fallows
Sub cooled waLer ln Lhe sLeam drum ls led Lo Lhe down comer header down comer plpes and ls
dlsLrlbuLed Lo each evaporaLor lnleL header from down comer header 1he mlxLure of waLer
and sLeam generaLed by Lhe heaL absorpLlon of evaporaLor flows from evaporaLor ouLleL
header Lo sLeam drum Lhrough Lhe rlser plpes

SULk nLA1Lk
Super heaLer ls of convenLlon Lype counLer flow dralnable lnverLed ulooped Lubes wlLh splral
flns Super heaLers secLlon ls locaLed ln Lhe hlghesL gas Lemp zone and maLerlals are deslgned
Lo saLlsfy Lhe requlremenL of operaLlon condlLlons Super heaLer elemenLs are boLLom
supporLed by lower header holdlng plaLes

LCCNCMI2Lk
Lconomlzer ls of counLer flow dralnable verLlcal Lubes wlLh splral flns Lconomlzer selecLlon ls
composed of several componenLs whlch conslsL of no of Lubes and lnleL header (lower) and
ouLleL header (upper) 1hese componenLs are connecLed ln serles wlLh several economlzer
Lubes Alr venL and draln valve ls provlded on Lhe upper and lower header respecLlvely
Lconomlzer elemenLs are boLLom supporLed by lower header holdlng plaLes






CCnCL1 Cl 1PL lnS18uMLn1A1lCn

In any manufactur|ng process or product|on un|ts the techno|ogy of us|ng |nstruments
for the measurement and contro|||ng of phys|ca| and chem|ca| propert|es of the
mater|a|s |s ca||ed instrumentotion

1he lnsLrumenLaLlon used ln chemlcal LreaLmenL or converslon lndusLrles ls called
process |nstrumentat|on
MeasuremenL along wlLh conLrolllng faclllLy ls called contro| system
1he varlable LhaL ls ob[ecL of measuremenL as well as conLrol ls called measured
var|ab|e or contro||ed var|ab|e
1he varlable LhaL affecLs Lhe value of measured or conLrolled varlable ls called
man|pu|ated var|ab|e

Lvery sclenLlflc and Lechnlcal dlsclpllne develops a language of lLs own Lo convey
lnformaLlon and ldeas ln general lnsLrumenLs and lnsLrumenLaLlon lLems are ldenLlfled
and represenLed by a sysLem of leLLers and numbers of slmple baslc plcLorlal





uevelopmenL of process lnsLrumenLaLlon
8CC81lCnAL AC1lCn (1928)


ln1LC8AL AC1lCn (1930)

nLuMA1lC 18AnSMl11lnC S?S1LM (1938)

MluuLL SlZL nLuMA1lC lnS18uML1A1lCn (1948)

PALl SlZL LLLC18CnlC lnS18uMAn1A1lCn (1938)

uuC lnS18uMLn1A1lCn (1963)

SCC (SuL8vlSC8? CCMu1L8 CCn18CL) 1970


uCS (ulS18l8u1Lu CCn18CL S?S1LM) 1974


Concept of Measurement 1ransm|ss|on Mon|tor|ng Contro|
ln general process lnsLrumenL measuremenL Lransmlsslon monlLorlng conLrolllng ls elLher
pneumaLlc verslon or elecLronlc verslon
O neumat|c vers|on |nstrumentat|on
ln case of pneumaLlc verslon Lhe drlvlng force wlll we lnsLrumenL alr

1he nomlnal lnsLrumenL alr supply wlll be 20 psl Lo 41psl
l e (14 kg/cm
2
or 28kg/cm
2
)
1he ouLpuL of pneumaLlc lnsLrumenL wlll be 313 psl or 630 psl
l e (0210 kg/cm
2
or 0420 kg/cm
2
) aL zero and span/maxlmum lnsLrumenL range
O L|ectron|c vers|on of |nstrumentat|on
ln case of elecLronlc verslon Lhe drlvlng force wlll we elecLrlc supply
1he nomlnal lnsLrumenL supply varles from one lnsLrumenL Lo oLher 1he common
supplles are 113/230 vAC or 24 vuC
1he ouLpuL from Lhe lnsLrumenL wlll be 420 mA uC or 13 vuC analog slgnal and
someLlmes dlglLal slgnal


Contro| system
ConLrol sysLem ln any process lndusLry may be pneumaLlc sysLem or elecLronlc sysLem
or dlglLal sysLem

uependlng upon Lhe lndlvldual requlremenL Lhe Lype of lnsLrumenLaLlon shall be
declded



Slgnal
SysLem













1kANSDUCLk

A Lransducer ls an lnsLrumenL whlch converLs one Lype slgnal energy Lo oLher Lype of
slgnal energy

lor example Lyplcal 420 mA elecLrlcal currenL slgnal can be changed Lo 313 psl
pneumaLlc alr slgnal by uslng CurrenL Lo pneumaLlc converLer (l/ ConverLer)


r|nc|pa| of Cperat|on
An l/ converLer baslcally conslsLs of Lwo comparLmenL Cne comparLmenL ls
mechanlcal and Lhe oLher ls elecLronlc clrculL comparLmenL
uemodulaLor
CsclllaLor
Analog
1o ulglLal
Slgnal
MlC8A8CCLSSC8
Sensor LlnearlzaLlon
8earranglng
uamplng
ulagnosLlcs
Lnglneerlng unlLs
communlcaLlon
ulglLal Lo
Analog slgnal
Converslon
ulglLal
communlcaLlon
Memory Module
LlnearlLy
consLanLs
8ange
consLanLs
1ransmlLLer
conflguraLlon
Span Zero


SLnSC8













CuLpuL pneumaLlc alr
slgnal 313 Sl
L|ectron|c C|rcu|t
1he clrculL recelves Lhe lnpuL elecLrlc 420 mA slgnal and compress wlLh Lhe slgnal comlng from
Lhe boosLer sLage ouLpuL Lhrough a solld sLaLe pressure sensor
Solld sLaLe pressure sensor ls a parL of Lhe elecLronlc clrculL and monlLors Lhe boosLer sLage
ouLpuL 1hls sensor uses sLraln gages prlnclple 1he feedback conLrol glves Lhe advanLage llke
crlsp dynamlc performance and readlly compensaLes for ouLpuL changes lnducLed by Lhe
vlbraLlons or slgnals leakages due Lo wear and Lear of Lhe pneumaLlc componenLs
Magnet|c actuator
1hls acLuaLor assembly performs Lhe Lask of converLlng elecLrlcal energy currenL Lo moLlon
when Lhe currenL Lhrough Lhe coll changes Lhe poslLlon of Lhe acLuaLor when lL senses a
dlscrepancy beLween Lhe pressure sensed by Lhe sensor and Lhe pressure requlred by Lhe lnpuL
slgnal
||ot Stage
1hls sLage conLalns Lwo opposlLe flxed nozzle Lhe supply nozzle and Lhe recelver nozzle 1hls
also conLalns Lhe deflecLor whlch ls Lhe movlng elemenL 1he supply nozzle ls connecLed Lo Lhe
alr supply and provldes a hlgh veloclLy alr sLream 1he recelver nozzle capLures Lhe alr sLream
and converLs ln Lo Lhe back pressure whlch ls Lhe ouLpuL of Lhe plloL sLage Whenever Lhe lnpuL
LlecLronlc
clrculL
MagneLlc
acLuaLor
lloL
sLage
8oosLer
sLage
8osemounL
solldsLaLe
pressure
sensor
LlecLrlcal lnpuL slgnal 420 mA

elecLrlc slgnal varles Lhe acLuaLor coll whlch ls connecLed Lo Lhls deflecLor elemenLs moves and
accordlngly Lhe alr slgnal recelver nozzle varles
8ooster Stage
1he recelver nozzle conLrols Lhe boosLer sLage whlch has a poppeL valve deslgn An lncrease ln
recelver nozzle pressure poslLlons of Lhe valve ln Lhe boosLer sLage Lo produce an lncrease ln
Lhe Lransducer ouLpuL slgnal A decrease ln recelver nozzle pressure poslLlons Lhe valve ln Lhe
boosLer sLage Lo allow exhausL Lo occur 1hus decrease ln Lhe Lransducer ouLpuL slgnal 1hls
boosLer sLage operaLes aL generally aL 31 galn as compared Lo Lhe plloL sLage
Contro| h||osophy
1he conLrol phllosophy for any process conLrol ls malnly Lwo Lypes
l Cpened loop conLrol
ll Closed loop conLrol
Cpen |oops
Cpen conLrol loop conslsLlng of measuremenL Lransmlsslon and lndlcaLlon
recordlng manual operaLlon of Lhe valves and alarmlng feaLures ls called open loop



C|osed |oop
Closed loops conslsLlng of measuremenL Lransmlsslon and lndlcaLlon recordlng
along wlLh conLrolllng feaLures 1hls loops works on feedback prlnclple




measuremenL
Lransmlsslon
lndlcaLor recorder alarm


Lrror deLecLor
8equlred
value



CCN1kCL VALVL
lLs plays very lmporLanL role ln auLomaLlc conLrol of modern planL 1he baslc funcLlon of conLrol
valve Lo creaLe varlable reslsLance ln plpe llne lL ls generally undersLood as a LhroLLllng and
modulaLlng equlpmenL powered by pneumaLlc hydraullc or elecLrlc operaLed devlces
(acLuaLors) lL ls mosL commonly known as flnal conLrol whlch recelves an ouLpuL slgnal from
conLrol elemenLs of an auLomaLlc conLrol whlch recelves an ouLpuL slgnal from conLroller and
geLs open or closes accordlngly 1here are many Lypes of conLrol valves some of Lhem are
buLLerfly conLrol valves glove conLrol valves damper conLrol 1hese may be used as onoff or
regulaLlon 1hey are havlng loL of parLs and dlffer accordlng Lo Lhe deslgn from one anoLher
Maln parLs of a conLrol valve are plug seaL acLuaLor body yoke dlaphragm packlng coupllng
eLc whlch are shown below













Measure 1ransmlsslon
lndlcaLlng
8ecordlng
ConLroller
Measurement
CSl1lCnL8
4 Lo 20 mA
lnpuL slgnal
AC1uA1C8
?CkL ACklnC SL1M
CCuLlnC
lLulu
Cu1
LuC SLA1 CACL CululnC

ILANLS
kCD
l/ CCn


CCN1kCL VALVL
llrsL parL ls senslng elemenL whlch ls usually a LransmlLLer 1hls ls a devlce whlch measures Lhe
process varlables whlch ls Lo be conLrolled such as pressure Lemp flow level
1he second parL ls conLroller Lhe LransmlLLer ouLpuL ls send Lo Lhe conLroller whlch
deflnes and measures Lhe error beLween Lhe polnL on Lhe deslred value and Lhe acLual
value of Lhe process varlables and lnLern send a correcLlve slgnal l e conLroller o/p
1he Lhlrd parL ls flnal conLrol valve whlch varles Lhe fluld flow Lo change Lhe process
varlables Lo deslre value
1he maln parLs of conLrol valve are
O AcLuaLor
O ?oke
O 1rlm
Ma[orlLy of Lhe conLrol valve used dlaphragm acLuaLors lL may be power cyllnder acLuaLor
ulaphragm acLuaLor usually has neoprene dlaphragm relnforced wlLh flber glass coLLon or nylon
for normal amblenL LemperaLure (lor hlgher Lemp above 80n
o
C vlLon or flber glass fabrlcs)
wlLh rolled edge placed lnLo caslng



DIAnIkAML
A flexlble pressure responslve elemenL whlch LransmlL force Lo Lhe dlaphragm plaLe and
acLuaLor sprlng
CkL
A sLrucLure by whlch Lhe dlaphragm case assembly ls supporLed rlgldly on Lhe bonneL assembly
(A) ul8LC1 AC1lnC ulAPl8ACM AC1uA1C8
lL ls pneumaLlcally operaLed 1he pressure LlghL chamber ls above Lhe dlaphragm an lncrease ln
pressure move sLeam downward opposlng Lhe sprlng acLuaLor sLeam move upward wlLh loss of
operaLlng alr supply neL o/p LhrusL acL ls deference beLween dlaphragm force and opposlng
sprlng force
(8) 8LvL8SL AC1lnC ulAP8ACM AC1u8L 1he acLuaLor ln whlch Lhe alr slgnal ls connecLed Lo
Lhe lower chamber and Lhe seal around Lhe acLuaLor sLem Lo made Lhe pressure LlghL and
venLlng ln upper chamber Lo aLmosphere sprlng mounLlng arrangemenL changed accordlngly
Pere Lhe alr pressure moves sLeam up opposlng Lhe sprlng force AcLuaLor sLem more
downward wlLh loss of operaLlng alr supply

1?LS Cl 1PL CCn18CL vALvL
a) Clobe Lype
b) valve Lype
c) 8uLLerfly Lype
d) Cn/off Lype
e) Sander paLenL Lype(for acldlc naLure llquld alkall Lype servlce)

SLC
1he SLC programmable lndlcaLlng conLroller ls a mlcroprogrammlng based lnsLrumenL whlch
provldes slgnal compuLaLlon and funcLlons as well as sequence loglc funcLlons
ln addlLlon Lo slmple lu conLrol baLch conLrol and hold l conLrol Lhe conLrol funcLlon of of
SLC lnclude varlable galn conLrol and dead Llme compensaLlon conLrol and Lhe slngle SLC can
slmulaLe Lwo conLrol ln a cascade conLrol or auLo selecLor conLrol conflguraLlon
rocess lnsLrumenLaLlon
ln process lndusLry Lhe followlng parameLers are measured
ressure
Level
llow
1emperaLure
Speed
vlbraLlon
Analyzer
kLSSUkL MLASUkLMLN1
ressure ls an lmporLanL varlable ln process lndusLry whlch ls measure monlLor conLrolled llke
flow varlable 1he unlL of pressure measured ln Lhe lndusLry ls pound per square lnch kg/cm
2

and lnches of waLer column/lnches of Lhe Pg eLc
Malnly Lhere are Lhree scales of pressure measuremenL l e gauge pressure absoluLe pressure
and vacuumed pressure scale
rlmary pressure senslng elemenLs are as follows

MAnCML1L8S
8Cu8uCn 1u8L
8LLLCWS Anu CASuLLS
ulAP8ACM 1?L

LLVLL MLASUkLMLN1
SLlll anoLher lmporLanL funcLlon ln conLrolllng conLlnuous process ls level conLrol 1o obLaln
maLerlal balance proper funcLlonlng of fracLlonaLlng Lower/recLor and also Lo regulaLe Lhe flow
of lnLermedlaLe and flnlshed producL Lhe level measuremenL conLrolllng ls closely assoclaLed
ML1nCD CI LLVLL MLASUkLMLN1
ulrecL meLhod of level measuremenL 1hey are used for local lndlcaLlons Lxample Cauge
callbraLlon Lapes dlp sLlcks bob Lape slghL glass and floaL operaLed mechanlsm

Inferent|a| measurement
1hey are used for remoLe lndlcaLlons recordlng conLrolllng of level lor example ulsplacer
meLhod based on law of 8uoyancy hydrosLaLlc head u 1ransmlLLer (pneumaLlc
elecLronlc)conducLlon Lype capaclLance Lype radlaLlon Lype sLraln gauge load cell eLc
DISLACLk ML1nCD
MosL common meLhods are dlsplacer Lechnlque 1he operaLlon based on Archlmedes`s
prlnclple 1he dlsplacers are made cyllndrlcal hollow body makes use of Lhe buoyancy prlnclple
1he force change Lo read ouL by some oLher devlce or a LransmlLLer 1he Lorque ls Lhe besL
known meLhod 1he moLlon of Lorque ls Lhe besL known meLhod 1he moLlon of Lorque ls
converLed lnLo Lhe elecLrlcal/elecLronlc or pneumaLlc slgnal varlous oLher meLhods of
converLlng dlsplacemenL of dlsplacer lnLo moLlon are flexlble dlsc sprlng balance force balance
moLlon balance
3 I|ow Measurement
ln a conLlnuous chemlcal process conLrol of maLerlal flow of one varlable may also conLrol Lhe
oLher varlable Such as Lhe Lemp conLrol of Lhe sysLem can be achleved by Lhe
conLrolllng/regulaLlng Lhe flow of Lhe heaLlng or coollng medla Many chemlcal process are
senslLlve Lo raLlo of lngredlenL for proper reacLlon requlres correcL proporLlon of maLerlal Lo
achleve quallLy producL roducL properLles are affecLed by varylng Lhe raLlo of raw maLerlal
flow Lhe fluld may be llquld gas or solld Lhe accuraLe flow conLrol ls nearly essenLlal
knowledge of some baslc characLerlsLlcs of fluld and fluld and flow ls necessary for chooslng
besL meLhod of flow measuremenL whlch need Lo be consldered lncludes vlscoslLy denslLy
speclflc gravlLy compresslblllLy LemperaLure pressure and fluld vlscoslLy lamlnar o LurbulenL





Var|ous Methods of I|ow measurement
ulfferenLlal pressure meLhod varlable area meLhod MagneLlc llow meLer oslLlve
dlsplacemenL (Lurblne meLer) LargeL meLer and ulLra sonlc flower meLer
ulfferenLlal pressure meLhod
venLure Lube
llow nozzle
ressure Laplng ln venLure Lube
varlable area meLer
MagneL flowmeLer
1urblne flowmeLer
1argeL ulLrasonlc meLers
CLher meLhod of flow measuremenL
1here are varlous oLher meLhod of flow measuremenL are avallable 1hey are LemperaLure
vorLex meLer Swlrl meLer Cval gear meLer meLer Lhermal Lhermal flow meLer mass flow
meLer nuclear magneLlc resonance meLer angular momenLum flow meLer eLc

1LMLkA1UkL MLASUkLMLN1
1he measuremenL of LemperaLure ls an lmporLanL parameLer ln Lhe process lndusLry MosL
common scales use Lo measure Lhe LemperaLure are lahrenhelL CenLlgrade
ML1nCDLS CI 1LM MLASUkLMLN1
MosL common meLhods meLhod of Lhe LemperaLure MeasuremenL lncludes Class
LhermomeLer Lhermocouples lllled bulbs blmeLalllc elemenLs reslsLance bulbs pyromeLer
(opLlcal lnfrared) SelecLlon of LemperaLure sensor and lLs relaLed sysLem depends prlmarlly
on four facLors Lhe cosL of Lhe sysLem accuracy 8ellablllLy adapLablllLy Lo Lhe process
1o have more rellable safe and Lrouble free operaLlons nowadays people prefer dlglLal
conLrol sysLem for process conLrol
1kANSMI11Lk
lL ls an lnsLrumenL whlch measure and Lhen converL Lhe concerned process
measuremenL Lo a remoLe lndlcaLlng recordlng or conLrolllng devlce
1ransmlLLers are of Lwo Lypes pneumaLlc Lype elecLronlc Lype




neumat|c type transm|tters
ln case of pneumaLlc verslon Lhe drlvlng forces wlll be lnsLrumenL alr
1he nomlnal lnsLrumenL alr supply wlll be 20psl or 40psl
le (14kg/cm
2
or 28kg/cm
2
)
1he ouLpuL of pneumaLlc lnsLrumenL wlll be 313 psl or 630 psl le (0210 kg/cm
2
or
0420 kg/cm
2
) aL zero and spam/maxlmum lnsLrumenL range

Instrument a|r
CuallLles of lnsLrumenL alr
1he pressure of Lhe lnsLrumenL alr shall always remalns consLanL preferably ranglng beLween
90 Lo 100Sl (around 70 kg/cm
2
)
1he lnsLrumenL alr should be as dry as posslble
1he lnsLrumenL alr should be as clean as posslble
1he lnsLrumenL alr should noL conLaln any oll or oLher conLamlnanLs
8as|c pneumat|c transm|tter
1he drlvlng or power supply ls lnsLrumenL alr aL 20 psl (14kg/cm
2
)
1he lnpuL ls process varlable
1he ouLpuL ls 313 Sl or (0210kg/cm
2
)
Correspondlng Lo mlnlmum and maxlmum varlaLlon of process varlable
L|ectron|c 1ransm|tter
1he maln source for operaLlon of elecLronlc LransmlLLer ls 110/230 vAC or 24vuC Also
some Lyplcal LransmlLLer may requlre oLher levels also
1he lnpuL Lo Lhe elecLronlc LransmlLLer ls Lhe concerned process varlable under
measuremenL
1he ouLpuL of Lhe elecLronlc LransmlLLer ls generally 420 mAdc/ 13vdc Also some
Lyplcal LransmlLLers may glve oLher levels of ouLpuL slgnals as per Lhe requlremenL of
furLher sysLem whlch ls connecLed wlLh Lhls LransmlLLer
r|nc|p|e of operat|on
Malnly any elecLronlc LransmlLLer conslsLs of Lwo funcLlonal unlLs 1hey are prlmary unlL and
secondary unlL rlmary unlL whlch ls exposed Lo process varlable under measuremenL
lnLerface 1hus process varlable exerLs pressure on Lhe senslng dlaphragm causlng Lhe elecLrlcal
capaclLance or lnducLance change Secondary unlL conslsLs of requlred elecLronlcs clrculLry

Lakes Lhe capaclLance or lnducLance slgnal from prlmary unlL 1hen Lhls slgnal wlll be converLed
Lo Lhe slgnal as requlred by Lhe connecLlng conLrol sysLem
8r|ef deta||s of pr|mary un|t
1he prlmary unlL conslsLs of cell conLalnlng Lwo dlaphragm acLlng as Lo plaLe of an elecLrlcal
capaclLance Lype sensor lf Lhe sensor ls lnducLance Lype Lhe dlaphragm are connecLed Lo a
lnducLance coll and magneLlc core 1he deLalls are shown ln Lhe flgure
8r|ef deta||s of the secondary un|t
Demodu|ator and Csc|||ator
1he demodulaLor ls a dlode brldge LhaL recLlfles Lhe AC slgnal from Lhe sensor based on
frequency changed osclllaLor clrculL (lrequency Z H ) 1he ouLpuL of Lhe
demodulaLor/ osclllaLor clrculLry ls a LemperaLure compensaLed dc currenL proporLlonal Lo Lhe
applled lnpuL process varlable pressure
Ana|og to d|g|ta| convers|on
1he analog Lo dlglLal converLer Lhe currenL from Lhe demodulaLor ln Lo a dlglLal form 1he
mlcroprocessor Lhen uses Lhls value Lo deLermlne Lhe value Lo deLermlne Lhe value of Lhe lnpuL
pressure
M|croprocessor
1he mlcroprocessor conLrols Lhe operaLlon of Lhe elecLronlc LransmlLLer ln addlLlon lL performs
Lhe calculaLlons for sensor llnearlzaLlon reranglng englneerlng unlL converslon damplng
square rooL sensor Lrlm LransmlLLer dlagnosLlcs and dlglLal communlcaLlons
Memory Modu|e 1he memory module holds all conflguraLlon characLerlzaLlon and
dlglLal Lrlmmlng daLa LhaL can be changed by Lhe LransmlLLer sofLware 1he daLa ln Lhls
memory remalns lnLacL even when no power ls applled

D|g|ta|toana|og converter A pulse wldLh modulaLlon dlglLalLoanalog converLer and
assoclaLed clrculLry changes Lhe correcLed dlglLal slgnal from Lhe mlcroprocessor Lo a 4
20 mA analog slgnal haL ls applled Lo Lhe ouLpuL loop

D|g|ta| commun|cat|on 1he dlglLal communlcaLlon clrculLry provldes an lnLerface
beLween Lhe LransmlLLer and Lhe exLernal devlces llke connecLed conLrol sysLems

Integra| zero and span button lnLegral span and zero buLLons are used for callbraLlon of
Lhe LransmlLLer manually

Sketch of r|mary un|t
CapaclLance Lype sensor



ressure ressure


Inductance sensor




lnducLance coll
MagneLlc core ferrlLe dlsc


Sensor dlagram rocess ConnecLlon





Iunct|ona| 8|ock D|agram of L|ectron|c 1ransm|tter

Class LhermomeLer
8lmeLalllc LhermomeLer
Llquld or vapor fllled 1emp gauge
1hermocouple based on

Secondary unlL
SLCCnuA8? unl1
LLLC18CnlCS

1he seebeck effect
e|t|er effect
1hompson effect
1he reverslble heaL effecL ln a clrculL made up from lron and copper wlre wlLh a cold [uncLlon aL 0
o
C Lhe
emf lncrease as Lhe Lemp of hoL [uncLlon lncrease 8uL as Lhe Lemp approaches a maxlmum Lhe raLe of
lncrease ls reduced unLll flnally reaches zero Cnce pasL Lhe maxlmum Lemp Lhe emf decreases
meanlng LhaL Lhe polarlLy of Lhe wlre ls reversed MosL common used Lhermocouple wlres are Lhe
comblnaLlons of
lron ConsLanLan 0 deg Lo 1400
o
l
ChromelAlumel 300deg Lo 2300
o
l
laLlnum/ rhodlumplaLlnum 1000 deg Lo 2700
o
l
Copper ConsLanLan 300 deg Lo +700
o
l

8eslsLance LemperaLure deLecLors (81u)
8L 8
o
(1+aL)
Commonly used reslsLance maLerlal ls plaLlnum nlckel copper nlckellron and 1ungsLen manganese
1he baslc readouL devlces are 8eslsLance 8rldge nullbalance poLenLlomeLer lnsLrumenLs
kad|at|on pyrometer and opt|ca| pyrometer
1hls Lype of Lemp measurlng lnsLrumenLs are used Lo measure Lhe hlgh Lemp where Lhermocouple ls
noL appllcable
Speed Measurement
1he speed senslng devlce covers several dlfferenL prlnclple of operaLlon lncludlng
elecLromagneLlc lnducLlon volLage generaLlon magneLlc senslng 1he accuraLe speed
measuremenL of hlgh speed equlpmenL ls Lhe requlremenL ln modern process lndusLry
1ype of speed sensor
Magnet|c p|ckup sensor
lL conslsLs of a cyllndrlcal permanenL magneL behlnd as sofL lron pole plece around whlch a coll
has been wound When a ferrous meLal ln placed ln fronL of Lhe pole peace Lhe magneLlc flux ls
hlgh and Lhe flux drop off as a ferrous meLal ls passed A volLage generaLe whlch ls proporLlonal
Lo Lhe raLe of change of flux ln Lhe pole plece and proporLlonal Lo Lhe speed wlLh whlch Lhe
ferrous mass makes Lhe flux bulld up or collapse 1he ferrous maLerlal ls made ln a gear form
wlLh deslre nos of LeeLh 1he volLage ls lnversely proporLlonal Lo Lhe clearance beLween plckup
and gear LooLh surface 1he frequency of volLage ls llnearly proporLlonal Lo rpm le rpm x nos of

gear LeeLh/ 60 1he magneL plckup LachomeLer sysLem may be used ln any Lype of roLaLlng or
movlng equlpmenL 1he elecLronlc frequency Lo currenL converLers converLs Lhe lnpuL
frequency dlrecLly proporLlonal Lo rpm of Lhe machlne Slnce Lhls plck up generaLes a slgnal
whose frequency ls proporLlonal Lo Lhe shafL speed wlLh excellenL accuracy lL ls a valuable Lool
for lndusLrlal appllcaLlons





Pouslng
ermanenL
magneL

I|gure Magnet|c Sensor
1achomeLer CeneraLor
lL ls an elecLromechanlcal devlce Lo generaLe volLage ouLpuL proporLlonal Lo Lhe shafL speed



AC 1achometer
AC LachomeLer conslsLs of a generaLor sysLem roLor and a hlgh reslsLance lndlcaLor When Lhe
roLor roLaLes Lhe volLage ls lnduced ln generaLor wlLh a magnlLude proporLlonal Lo Lhe roLor
speed Lhe speed measurlng range ln 300 Lo 10000 rpm










8oLor
AC power ouLpuL wlndlng


CuLpuL
volLage

I|gure a|ternat|ng current 1achometer

DC 1achometer
ln uC LachomeLer magneL flux ls orlenLed by permanenL magneL and ouLpuL wlndlng ls
aLLached Lo Lhe roLor As speed lncrease causlng proporLlonal lncrease ln ouLpuL volLage 1hls
LachomeLer ls deslgned for speed range 10 Lo 3000 rpm
VI8kA1ICN MLASUkLMLN1
vlbraLlon ls Lhe perlodlc moLlon of movlng ob[ecL back and forLh repeaLedly over Lhe same
paLh lL ls relaLed Lo hlgh speed roLaLlng and reclprocaLlng equlpmenL vlbraLlon monlLorlng ls 1
meLhod used Lo deLecL Lhe equlpmenL problems allowlng repalr Lo be made prlor Lo LoLal
fallure reduclng downLlme and avoldlng producLlon losses
vlbraLlon monlLorlng equlpmenL ls normally deslgned Lo measure Lhe vlbraLlon ln dlsplacemenL
vlbraLlon measure unlLs are usually glven ln mlls (Lhe Lhousands parL of one lnch) and represenL
peak Lo peak value ln meLrlc sysLem Lhe ampllLude of vlbraLlon sLaLes ln mlcrons Cne
damaglng componenL of vlbraLlon ls acceleraLory shock Lhe desLrucLlve force lL ls deLermlned
by Lhe frequency and ampllLude of dlsplacemenL and consLanL k" where k depends on unlL of
frequency and ampllLude C Al2k


1ype of v|brat|on sensor
|ezoe|ectr|c sensor
1hey are manufacLured from varlous Lype of crysLal sandwlched beLween meLal conLacL ln a
capLure ln a capsule form When lL sub[ecLed Lo an acceleraLlon force a volLage charge ls
produced Lhls ls dlrecLly proporLlonal Lo acceleraLlon (C kl kma)
L|ectromechan|ca| sw|tches
As Lhe name elecLromechanlcal lL conslsL of an armaLure suspended on a frlcLlonless flexote
plvot and held ln poslLlon by a permanenL magneL when peak acceleraLlon exceed Lhe preseL
level Lhe armaLure acLuaLe Lhe swlLch Lo open or close Lhe elecLrlcal clrculL
Stra|n gauge
Wldely used as vlbraLlon monlLors measure a change ln elecLrlcal reslsLance whlch ls
proporLlonal Lo Lhe force due Lo acceleraLlon SLraln gauge ls a Lhln foll bounded on a carrler
paper plasLlc or epoxy A semlconducLor may be lnsLead of wlre or foll 1he reslsLance elemenL
ls compound of four sLraln gauges whlch form a WheaLsLone brldge 1he unbalance of brldge
due Lo Lhe acceleraLlon ls monlLored by an elecLronlc measurlng lnsLrumenL ln Lhe unlL of
vlbraLlon
rox|m|ty probes
1he monlLorlng and measurlng of radlal vlbraLlon and axlal LhlrsL on a large machlne Lraln are
made successfully wlLh Lhe proxlmlLy plckups 1he shafL vlbraLlon ls measured wlLh respecL Lo
Lhe bearlng houslng 1he Lurblne and compressor vlbraLlon are measured wlLh Lwo proxlmlLy
plckup probes locaLed on Lhe same dlameLer as Lhe bearlng [ournal Cne of Lhe Lwo probes
should be mounLed horlzonLal and Lhe oLher verLlcally roxlmlLy probes are also used Lo
measure wear on Lhe LhrusL bearlng and Lo monlLor axlal movemenL of Lhe shafL 1he proxlmlLy
probes work on Lhe eddy currenL prlnclple 1he volLage ouLpuL depends Lhe gap beLween probe
Llp and Lhe shafL 1he vlbraLlon monlLorlng lnsLrumenL measure and record average peak Lo
peak ampllLude ln mllls of dlsplacemenL and also should have an auLomaLlc self checklng
clrculLs Ck fallure lndlcaLor and alarms shuL down and reseL feaLures

7 ANAL1ICAL MLASUkLMLN1
AnalyLlcal Lechnlques for on llne measuremenL and conLrol are belng reflned and lmproved Lo
provlde essenLlal characLerlsLlcs of Lhe process whlch deLermlne quallLy reproduclblllLy and
proflLablllLy 1he chromaLography pP conducLlvlLy LurbldlLy denslLy molsLure
measuremenL oxygen analysls for combusLlon eLc Lhese are common analyLlcal measuremenL
ln process lndusLry 1he process analyzers are almosL always callbraLed emplrlcally on sLandard

sample prepared and analyzed by laboraLory lor Lhls reason process callbraLlon cannoL be
beLLer Lhan laboraLory analysls
Chromatography
lL ls a meLhod of physlcally separaLlng and quanLlLaLlvely ldenLlfylng Lwo or more componenLs
ln a mlxLure by dlsLurblng Lhem beLween Lwo phases one phase belng sLaLlonary bed of
absorbed surface and Lhe oLher phase a carrler gas whlch percolaLes Lhrough and Lhe sLaLlonary
bed When Lhe sample ls ln[ecLed ln Lo carrler sLream Lhe componenLs of sample mlxed wlLh
carrler and absorbed ln Lo sLaLlonary bed 1he bed subsLraLe has an afflnlLy for each
componenLs of Lhe sample slnce Lhe afflnlLy varles wlLh each componenL llghLer componenLs
are swepL away (eluLed) fasLer Lhan Lhe heavler As a resulL of Lhls acLlon down Lhe enLlre
lengLh of Lhe column Lhe llghLer componenL reaches Lhe end of Lhe column before Lhe heavler
ones 8y Lhe use of proper lengLh of Lhe column Lhe componenLs are separaLed by each oLher
and Lhe lndlvldual eluLlon Llmes serve Lo ldenLlfy Lhe parLlcular componenLs 1he analyzlng
secLlon of Lhe chromaLograph (valves column and deLecLor) locaLed ln Lhe fleld near sample
polnL and conLrolllng and monlLorlng secLlon (LC recorder eLc) are locaLed ln conLrol rooms
keference e|ectrodes
1hls accompllshed Lhe reference volLage whlch does noL change wlLh pP 1he commonly used
ref elecLrodes elecLrodes are calomel elecLrode sllver chlorlde llquld [uncLlon Lype Lhe
elecLrlcal conLlnulLy achleved Lhrough a llquld [uncLlon who permlL elecLrolyLe Lo flow ouLward
ln Lo Lhe sample soluLlon Lhrough mlcroscoplc openlng (palladlum wlre asbesLos flber 1he flL
[uncLlon grounded glass sleeve)
Cxygen ana|yzer
1he demand of oxygen analysls due Lo lLs essenLlal role ln oxldaLlon combusLlon and lndusLrlal
process appllcaLlon has led a large no of varled Lechnlque applled Lo process for o
2
analysls
aramagnet|c def|ect|on type o

ana|yzers
1he sLrong aLLracLlon of C
2
by magneLlc fleld 1he paramagneLlc suscepLlblllLy ls measured
dlrecLly by deLermlnlng Lhe change of magneLlc force acLlng on Lhe LesL body suspended ln
unlform magneLlc force acLlng on Lhe body suspended ln a unlform magneLlc fleld whlle LesL
body ls surrounded by sample gas
1herma| magnet|c C

ana|yzers
1hls sysLem uLlllzed Lhe prlnclple of paramagneLlc suscepLlblllLy of C
2
wlLh Lhermal conducLlvlLy
due Lo magneLlc suscepLlblllLy of C
2
ln a sample gas passlng Lhrough a balanced wheaL sLone
brldge 1he change ls deLecLed ampllfled dlsplayed by clrculLry ln proporLlon Lo Lhe of C
2
ln
sample


as ana|yzers Alr quallLy monlLors Lhls lnclude Lhe measure of CC CC
2
CC
4
P
2
nC
2
SC
2

as alr polluLanLs ulfferenL Lypes of measures are lnfrared absorpLlon Lhermal conducLlvlLy and
CaschromaLograph

SLLD1kCNIC
1M
Mark VI turb|ne contro| system
Mark vl ls used for Lhe conLrol and proLecLlon of sLeam and gas Lurblnes ln elecLrlcal generaLlon
and process planL appllcaLlon
1he maln funcLlons of Lhe mark vl Lurblne conLrol sysLem are as follows
OSpeed conLrol durlng Lurblne sLarLup
OAuLomaLlc generaLor synchronlzaLlon
O1urblne load conLrol durlng normal operaLlon on Lhe grld
OroLecLlon agalnsL Lurblne over speed on loss of load
1he mark vl sysLem ls avallable as a slmplex conLrol or a Lrlple modular redundanL (1M8)
conLrol wlLh slgnal or mulLlple racks and local or remoLe l/C 1he l/lnLerface ls deslgned for
dlrecL lnLerface Lo Lhe sensors and acLuaLors on Lhe Lurblne Lo ellmlnaLe Lhe need for
lnLerposlng lnsLrumenLaLlon and Lo avold Lhe rellablllLy and Lo avold Lhe rellablllLy and
malnLenance lssues assoclaLed wlLh LhaL lnsLrumenLaLlon

MAlN PLANTS AND lTS AUXlLAHY FAClLlTlES

IACILI1ILS CAACI1
1 AMMCnlA LAn1 1330 M1u
2 u8LA LAn1 2200 M1u
3 CWL8 LAn1
a) Cas Lurblne generaLor 160 Mw
b) Maln boller 30 M1/Pr
c) P8SC 160M1/Pr
4 P LAn1
a) urea slpo 43000 M1
b) 8agglng faclllLles 8 bagglng sLaLlon
3 CllSl1L lAClLl1lLS
a) Ammonla sLorage 2000 M1
b) uM waLer planL 360 M3/Pr
c) Condemn safe pollshlng unlL 240 M3/Pr


d) Coollng Lowers
l Ammonla planL C1 20700 M3/Pr
ll urea planL C1 18000 M3/Pr
e) lC lanL 600 M3/Pr
f) Compressed alr sysLem 6000 M3/Pr
g) 8aw waLer sLorage 33696m
h) 8orewe pump 36000 M3/Pr
6 Lnvl8CMLn1AL CCn18CL
a) rocess condensaLe sLrlpper 93
b) 1urblne condensaLe pollsher 130
c) ulsc oll separaLors 13
d) urea hydrolyser 60
e) nA1u8ALlZA1lCn plLs
f) Ammonla planLs 130
g) WaLer LreaLmenL planL 300
h) CenLrallzed efflclenL LreaLmenL planL
l) ChromaLe removal unlL 480
[) Alr and sLeam sLrlpplng unlL 60
7 ll8L llCP1lnC lAClLl1lLS
a no of hydranLs 377 nCS hydranLs
b llre waLer pumps 6 nCS of M3/Pr capaclLy each
c loam Lender 2 nCS
d llre [eep 1 nCS equlpped wlLh flre
flghLlng faclllLles
e llre exLlngulshers 400 nCS of dlfferenL Lypes
f AuLomaLlc flre deLecLors 360 nCS
g Manual call polnL 190 nCS
h AuLomaLlc flxed foam lnsLallaLlon
8 AMl SL1 173 MvA
9 LlCulu luLL S1C8LCL lAClLl1lLS
a naphLha sLorage 12000 kL
b 1reaLed PSu sLorage 230 kL
c luel oll sLorage 73000 kL
10 CCMu1L8 lAClLl1lLS
a Maln frame 12M8 maln memory
11 CCMMunlCA1lCn lAClLl1lLS
a) nlCknL1
b) lAx
c) PC1 LlnL
d) 1 1LLLPCnLS

lnS18uMLn1A1lCn S?S1LM
CCN1kCL SS1LM
1he conLrol sysLem of ammonla 1 employs slngle loop conLroller and dcs only daLa
acqulslLlon 1hese slngle loop conLrollers are all mlcroprocessor based mod lnsLrumenLs

SAIL1 IN1LkLCCk SS1LM
SLaLlc loglc sysLem wlLh mosalc dlsplay evenL recordlng has been employed ln ammonlall
3 ANNUCIA1Lk SS1LM
Lach mod 30 lnsLrumenL lnsLalled ln Lhe conLrolled room of ammonla 1
lanL has an alarm sysLem SLlll lllCC declded LhaL for proper servlclng and
1o maL LracL Lhe aLLenLlon of Lhe operaLor an annunclaLor sysLem ls provlded
IN AMMCNIA
lanL no currenL Lo pneumaLlc converLs are used ln Lhe loops lnsLead of Lhese elecLro
pneumaLlc are used
AMMCNIA
Lmploys seven dlfferenL LCS All Lhese plcs's are redundanL Lype
1here ls a separaLe LC for each compressor alr drler de super heaLer sLarLup heaLer
All Lhe solenold valves are exploslon proof Ammonla employs Parrlon make solenold
valve
DIS1kI8U1ICN CCN1kCL SS1LM
WlLh Lhe lnLroducLlon of mlcroprocessor lL has become feaslble Lo dedlcaLe dlglLal processlng unlL ls
based on mlcroprocessor wlLh necessary memory lnLerface devlce and lnpuL ouLpuL hardware Lo conLrol
a relaLlvlLy small no of loops Many lndependenL mlcroprocessor sysLem are uLlllzed Lhe monlLor and
conLrol an enLlre planL A serlal dlglLal Lransmlsslon llnks Lhe conLrollers and allows a masLer compuLer
or operaLor lnLerface devlce Lo communlcaLe wlLh Lhem 1he operaLe lnLerface ls usually a C81 console
wlLh Lhem 1he operaLor lnLerface drlven by a mlcroprocessor no supporL compuLer sysLem ls requlred
C81 console ls a compuLer ln lLself and can perform compuLer llke funcLlon such as presenL Lubular and
graphlcs dlsplays Lhus drlve prlnLers and sLore hlsLorlcal daLa for logglng and holdlng ln many
dlsLrlbuLed sysLem console ls scan and alarm funcLlon Lhus ellmlnaLlng Lhe need for a hard wlred
communlcaLlon sysLem ush buLLon and sLaLus lndlcaLlon sysLem can perform by Lhe C81 console does
noL affecL Lhe operaLlon of Lhe conLroller unlLs whlch provlde auLomaLlc lu conLrol ConLrols mounLed
on Lhe fronL of Lhe unlL 1hls allows operaLor conLrol of Lhe processlng lndependenL of Lhe C81 console


kCILC1 MICLS1C1LS

1 uaLe of submlsslon of feaslblllLy reporLed Lo Lhe concerned mlnlsLry 23/03/1983
2 uaLe of approval 21/01/1984
3 l8 approval obLalned 23/10/1984
4 CompleLlon of dlscusslng wlLh consulLanL 23/10/1984
3 Submlsslon of consulLlng agreemenL Lo go 30/10/1984
6 CovL approval of consulLlng agreemenL 11/12/1984
7 SlgnaLure of consulLlng agreemenL 11/12/1984
8 Land acqulslLlon 13/12/1984
9 Zero daLe 08/01/1983
108homl poo[a 18/04/1983
11WaLer LreaLmenL planL commlssloned March 1987
12132 kv subsLaLlon commlssloned March 1987
13ower planL commlssloned AugusL 1987
14Mechanlcal compleLlon 08/01/1988
13AvallablllLy of nC gas feed sLock 19/09/1988
16CommencemenL of ammonla producLlon 13/03/1988
17CommencemenL of urea producLlon 18/01/1988
18SLarL of commerclal producLlon 16/03/1988
19lanL dedlcaLed of naLlon by rlme MlnlsLer 17/03/1989


POWER SYSTEM NETWORK Ol l.l.l.C.O. AONLA UNlT

As weII as we aII know IhaI Ior runnng an ndusIry I shouId have a good power
sysIem whch wII handIe worsI Io worsI condIon very easIy. As per I Ihe energy
crses rases Ihen who I may IoIeraIe7
The answer s IhaI we shouId ready Io Iace IhaI condIon and durng Ihe desgnng oI
power sysIem neIwork oI an ndusIry I shouId Iaken n Io consderaIon and I comes
under Ihe requremenI durng Ihe desgnng oI Ihe ndusIry so IhaI who we gaI power,
whaI wII be Ihe maxmum approxmaIe appIed Ioad and abouI Ihe IarII.
The "Power sysIem neIwork" oI Ihe "AonIa unI" s very good or we can say IhaI s
made by Iaken aII Ihe mporIanI and non mporIanI aspecIs nIo Ihe consderaIon. The
ndusIry s producng power Irom Ihe wasIe maIeraI produced and Ihe Iew wasIe
maIeraI n Iorm oI gases oI Iqud or we can say non usabIe . e. whch couId noI be
used any where s exhausIed oI evoIved.
The IIICO compIex aI AONLA conssI oI an ammona unI oI 13S0 MT,Day capacIy
and Iwo urea unI oI 11000MT,Day each capacIy wIh Ihe requred oIIsde IacIIes.

Ior eIIcenI and unnIerrupIed runnng oI IerIIzer pIanI a reIabIe source oI power s
very much essenIaI. AII Ihe measure roIaIng equpmenI oI Ammona and Urea pIanI
and drven by eIecIrc moIor. To meeI Ihe demand oI hgh pressure sIeam and
dependabIe power, Ihe sIeam and power generaIon generaIor has been nsIaIIed. The
sIeam generaIor oI AONLA UNIT wII suppIy hgh pressure sIeam Io process pIanI and
gas Iurbne generaIor wII meeI Ihe power requremenI oI Ihe pIanI.



ElecIrical supply source

As Lhe planL ls deslgned l e ACnLA1 unlL ls deslgned Lhen Lo run lLs varlous
planLs Lhe esLlmaLed LoLal power consumpLlon ls abouL 12 MW 1o overcome lL a
gas Lurblne generaLor ls lnsLalled lL ls also Lhlnk LhaL problem an anoLher source
was Laken from uCL Lo run Lhe planL durlng Lhe same Llme perlod A quesLlon
may come lnLo conslderaLlon LhaL whaL wlll happen lf LoLal power falls l e durlng
exLreme emergency condlLlon?

1o overcome Lhls problem on dlesel generaLor was lnsLalled for Lhe safe
shuLdown of Lhe planL As a new unlL open l e ACnLA ll slmllar power source
were used 1he esLlmaLed power consumpLlon of LhaL ls 8 kW Cnly one dlesel
generaLor seL ls lnsLalled ln addlLlon of ACnLAll unlL Lhe overall approxlmaLed
power consumpLlon ls 213MW Lhe power sysLem malnly deals wlLh Lhree polnLs
whlch are havlng equal welghL age and Lhese are

1ower generaLlon
2Mode of Lransmlsslon
3ower dlsLrlbuLlon


ower d|str|but|on |n IIICC ACNLA un|t

lor good deslgnlng of dlsLrlbuLlon sysLem we have Lo keep all Lhe planLs ln Lo conslderaLlon so
LhaL among all planLs whlch unlL ls lmporLanL le Lo whlch unlL Lhere ls necessary of supplylng
power durlng crlses llrsLly we have Lo esLlmaLe all Lhe unlLs and Lhese are follows

Ammonla lanLl
urea lanLl
Coollng Lowerl
Ammonla planLll
urea planLll
Coollng Lowerll
ower planL and offslLe
SubsLaLlon 12343 ammonla sLorage s/s and fuel oll s/s
1ownshlp
ln planL an 11 kv swlLchgear has been lnsLalled whlch ls ln arrangemenL of rlng sysLem as
shown ln flgure (a) lL has slx bus secLlon whlch are as follows
nLl non essenLlal busl
nlll non essenLlal busll
SLl seml essenLlal busl
SLll seml essenLlal busll
Ll essenLlal busl
Lll essenLlal busll
Ll and Lll as Lhe name shows LhaL Lhey are essenLlally feed so Lhey are normally feed by gas
Lurblne l e C1 C2 Lhese buses are feeded wlLh Lhe help of uCL power supply 1hus
bus secLlon nL1 nL2 are feeded by Lhe uCL supply sources geLLlng from 1x1 1x2
Slmllarly Se1 Se2 as Lhe name speclfled LhaL seml essenLlal bus 1 2 respecLlvely wlll work
accordlng Lo requlremenL of Lhe lndusLrles and power supply



ower d|str|but|on |n coo||ng towerI

Cne 413v swlLchgear has also been lnsLalled Lo feed 413 v supply Lo L1 moLor of coollng
Lower 1hls swlLchgear has Lhree lncomers and Lwo bus coupler CuL of Lhese Lwo lncomer one
recelves from ammonla 11 kv secLlon '8' Lhrough power from urea planL 11 kv swlLchgear 'A'
Lhrough sLep down 1x 11/333kv secLlon '8' swlLchgear emergency power from AMl seL1

ower d|str|but|on |n ammon|a p|ant II
1he elecLrlcal dlsLrlbuLlon based on a sysLem wlLh Lwo secLlonallzed bus bar [olned by a bus
Llebreaker Lach bus bare ls fade by an lndependenL fdr ConnecLed Lo dlfferenL bus or volL
SysLem ln Lhe nexL hlgher rank

kV systems
1he 11 kv sysLem conslsLs of Lwo fdr each 100 raLed feedlng Lhe 11 kv bus bar [olned by a
bus Lle breaker 1he 11 kv swlLch board ls comprlslng of 22 panels and feed power Lo Lhe 11 kv
moLors locaLed ln ammonla planL ammonla coollng Lower urea coollng Lower heaLer 1x L1
1x of ammonla s/s cL s/s
1he slngle llne dla Cf lL ls ln flg Lhe deLalls of ouLgolng fdr are glvlng ln Lable A
ane| no 8kr kat|ng Lqu|p Descr|pt|on
1230 A synLhesls sLarLup heaLer
1230 A 2 MvA 1x ldr
3 1230 A 2 MvA 1x ldr
1230 A 2 MvA 1x ldr
1230 A 630 kvA llghLenlng 1x ldr
6 1230 A MoLor ldr (8lW pump) M 3610C
7 1230 A MoLor fdr (CW pump urea) 4801C
8 1230 A MoLor ldr (spare)
9 1230 A 1x ldr 4000 kvA
1230 A 1 panel
1230 A l/C one form / panel no 20
1230 A 8us coupler
3 1230 A l/C2 from / panel no 13
1230 A 4MvA 1x
1230 A MoLor fdr (CW pump 1430 kW)
6 1230 A MoLor ldr (semllcan solun on pump 1100 kW)
7 1230 A MoLor ldr (spare)
8 1230 A 1x ldr 2000 kvA
9 1230 A 1x ldr 2000 kvA (spare)
1230 A n2 Sv heaLer 1x


AMMCNIA MAIN SUS1A1ICN
kV SWI1CnLAk
8uS L
1
8uS

L
2



11 kv 8uS
8uS CCuLL8

3 2 4 3 6 14 13 13 16




18AnSlC8ML8


1 C81 C82 are open

AMMCnlA 18 AMMCnlA AMMCnlA AMMCnlA lu88 183x8 M 180k AMMCnlA CCCLlnC
ML lC8 3xA MCC lu81 (1000 kvA) (33kv) CCCLlnC MCC u22 1CWL8
(630 MvA) (16000 (2000 kvA) (4000 kvA) uM (2000 kvA) (1100kvA)
kvA)


Where L for LssenLlal 8us
under volLage 8elays
u/ v
u/ v

AU1CMA1IC CnANL CVLk nAVL 8LLN kCVIDLD ICk
1nkLL CI1CUI1 8kLAkLk SS1LMS

33 kV 8US SS1LM
1he 33 kv sysLems conslsL of Lwo feeders feedlng 33 kv 1hese kv bus le breaker Lhrough
nC2 1x raLed 4 MvA 11 kv/343 1hese 1x geL 11 kv supply from ammonla 11 kv swlLch
board 1hls swlLchboard comprlses of 14 panels and locaLed ln maln Llec s/s feedlng power
Lo all 33 kv moLor ls offslLe compressor house
V CC MCC (MAIN s]s)
lL conslsLs of Lwo source of normal power Lhrough no 2 1x raLed 2000 kvA 11/433 kv 1x
whlch feed Lhree bus bar [olned by Lle breakers 1hlrd source ls from uC seL lnsLalled 1hls
board ls also locaLed ln maln s/s ammonla planL
ane| no 8reaker rat|ng Lqu|pment
1 630 A Spare moLor fdr (430 kW)
2 630 A n2 blowers moLor fdr (44 kW)
3 630 A CombusLlon alr blowers (880 kW)
4 630 A Alr compressor offslLe (300 kW)
3 630 A Spare moLor fdr (400 kW)
6 1 anel
7 1230 A l/C A
8 1230 A pros coupler
9 1230 A l/C 8
10 1230 A 1 panel
11 1230 A Lean soluLlon pump seL fdr (430 kW)
12 630 A fuel gas blowers (9840 kW)
13 630 A CC
2
blowers (400 kW)
14 630 A Spare moLor fdr (840 kW)

LMLkLNC SUL SS1LM
1he sLarLlng slgnal Lo uC seL ls glven when boLh le 1 2 have under volLage SlmulLaneously
a closlng slgnal ls glven Lo 8C 1 and 8C2 lrrespecLlve of wheLher Lhey are closed before under
volL or noL When Lhe emergency supply reaches 'C8L' lL closed auLomaLlcally lf Lhe followlng
condlLlons are fulfllled
2 C81 C82 are open
3 8C1 8C2 are open

NCkMAL CLkA1ICN
ln Lhe normal operaLlon Lhe Lwo lncomer C81 C82 are closed 8C 1 ls closed and 8C 2 ls
opened or 8C 1 ls ln open condlLlon shall be ready for auLomaLlc 1he worklng of auLomaLlc
ls requlred lf 1 or bus 2 losses lLs supply uue Lo faulLs oLher Lhan over currenLs s/c and over
currenLs s/c sLand by L/l Lhe auLomaLlc changeover works accordlngly
1 Conslderlng C81 C82 8C1 closed wheLher 8C2 open under normal condlLlon lf Lhe
under volLage ls deLecLed on Lhe bus Lhe closlng of 8C2 shall be 8C2 done Lhereby
provldlng power on Lhe bus havlng whlch has sensed under volL on Lhe bus
2 1he normal condlLlon can be resLored manually when power supply has been sLored Lo
be normal





'T1.
T1.


.Iou! u1n InD!
II s pIace where producIon oI urea Irom NH
3
and CO
2
Iake pIace. In I Irom Ihe
reacIon oI Ihese Iwo Iqud Urea s Iormed and Ihen I s converIed n Io soId urea n
perIng Iower by Ihe process oI normaI gas soIdIcaIon.

AIIer reacIon oI NH
3
& CO
2
n reacIon I passes Ihrough varous compressor, vaIve
vacuum separaIor, and oIher devces, I s Iormed Io urea nearIy 99.6 pure. In Ihs
pIanI each has Iwo reacIon are urea-I has Iwo secIon and same wIh Urea-II.

In urea pIanI varous mechancaI devces are used. In I we have cenIrIugaI pump, PSV,
mechancaI seaIs, each pIaces on mporIanI roIe n I. Ior dIIerenI Iype equpmenI
dIIerenI Iype equpmenI dIIerenI Iype oI aII are aIso used Io ncrease IIe as I reduce
IrcIon, ncrease cooIness. In IIICO AonIa UnI we have Iwo pIanIs
1. URLA PLANT 1
2. URLA PLANT 2


jjj1|)j j1|j1 |j) |j)1
1he elecLrlcal dlsLrlbuLlon ls based on a sysLem wlLh Lwo secLlonallzed bus bar [olned by Lle
breaker Lach bus bare ls fed by an lndependenL feeder
kV SubStat|on
() kV System
1he 11 kv sysLem conslsLs of Lwo fdr each 100 raLed feedlng Lhe11 kv bus bar [olned by a bus
Llebreaker 1he 11 kv swlLch board ls comprlslng of 22 panels and feeds power Lo Lhe 11 kv
moLors locaLed ln ammonla planL ammonla coollng Lower urea coollng Lower heaLer 1x L1
1x of urea llne AuLomaLlc changeover has been provlded for Lhree clrculL breaker sysLem
1 under normal condlLlon Lhe Lhree ckL 8reaker are as follows
a lncome clrculL breaker closed
b 8us Lles breaker open
2 ln case of power fallure ln an l/ fdr AuLomaLlc swlLchlng wlll Lake place accordlng Lo
Lhe sequence below
a lncome clrculL breaker closed
b 8us Lles breaker open
3 A manual swlLchlng devlce wlLhouL power supply cuL off ln provldlng for Lhe Lhree ckL
8kr lor a Lemporary parallel devlce whlch allows closlng all Lhe Lhree ckL 8kr lor a
shorL duraLlon and Lhen Lrlps Lhe selecLed bkr as per followlng sequence
a Closlng of bus Lle bkr WlLh a sequence of openlng of reselecLed lncomlng fdr
When boLh Lhe lncomes are closed lnlLlally and bus Lles ls open
b Closlng of reselecLed lncomer fdr openlng of Lle bkr When oLher lncomlng fdr
bus Lle are closed lnlLlally

() 33 kV System
1he 33 kv sysLems conslsLs Lwo feeders feedlng 33kv 1hese kv bus le breaker Lhrough no2
1x raLed 4 MvA 11 kv/ 343 1hese 1x geL 11 kv supply from ammonla 11 kv swlLchboard 1hls
swlLchboard ls comprlslng of 14 panels and locaLed ln maln Llec S/S feedlng power Lo all 33 kv
moLor locaLed ln ammonla planL and one compressor moLor ls offslde compressor house
(3) V CC's MCC's
1here are 2 CC ln boLh Lhe S/S whlch ls belng feed from Lhe 11 kv swlLch board Lhrough 1x 2
of each CC ln S/S lll 1he board ls supplylng power Lo Lhelr respecLlve MCCs LSWC board



() DC Supp|y
uC supply for conLrol and llghLenlng ls belng obLalned from ammonla planL uC wlLh board
1oLal emergency load from AMl seL for urea planLs sls llmlLed Lo 410 kW
() LSW
1here ls 3Cn 413 board whlch feed power Lo emergency load of Lhe planL Cne board ls
lnsLalled ln each S/S Lhese are geLLlng power from Lwo sources Cne ls from CC for normal
power and oLher ls from Lhe Lmergency uC seL ln slngle llne ln normal condlLlon normal
power bkr kepL closed and emergency bkr ls open as soon as power reaches Lhe emergency
bkr lL closed and feed Lhe bus AfLer Lhe power resumes normal condlLlon can be resLored
manually

'1T -.11 T.5T1T J1.J15

8aLlng 230 kvA 8Ll lSS 2026
no load Pv 11 kv maxl AM8 Lemp 30
0
C
v/g Lv 0433 kv maxl Lemp rlse oll/uu20 30/33
0
C
CurrenL Pv 1312 A lmpedance v/g 302
Lv 3333 A core and wlndlng welghL 730 kg
hase 3 welgh of oll 280kg
l 30 Pz oll qly llL 313
Coollng CnAn LoLal welghL kg0 1330
S no 0! no 2292/3 year of mfg 1987
3S1u 210/8/2292





ue energles 1ransformer before operaLlng swlLch


846 343 1 2n
2u 2
2v 1u 2u
846 343 1
2
1W 1v 1v 2v
2 846 343 1

W|nd|ng connect|on 1w 2w

Insu|ator test|ng kV
8as|c |nsu|at|on |eve| Sw|tch pos|t|on nV nV No |oad|ng
lnpuL volLage Pv 73 1 36 11330 Lv
kv peak Lv 2 64 11273
3 47 11000 433
l volLage Pv 28 4 23 11000
kv rms Lv 3 38 10723




2W

1LCnNICAL SLCIIICA1ICN CI MC1Ck
MC1C8 1AC nC M 1801 C
LCulMLn1 uLSC8l1lCn CCCLlnC 1CWL8 uM
MAkL lu! LLLC1 CC L1u
1?L/l8AML SlZL MLA 7630 3
8A1lnC (kW/P) 1200 kW
luLL LCAu Cu88Ln1 810 A
8M 390
lnSuLA1lCn CLASS (l)
CCCLLn1 46oC
CLLS 10
l 82
vCL1ACL/ CCnn 11000/SLar
C8LASL A8CSPLLL 13
8L 320 CMS
C8S 123 CMS
SACL PLA1L8S 800 WA11
1 o PASL 40 vCL1S

n1 MC1Ck
l u lAn
MC1C8 1AC nC Mk 120 l
LCulMLn1 uLSC8l1lCn luLL CAS lAn
MAkL ?ASkAWA LLLC1 MlC CC L1u
8A1lnC (kW/P) 830 kW
luLL LCAu Cu88Ln1 172 A

8M 1490
SuL? vCL1ACL/CCnn 3300/ uLL1A
8C1C8 CASL
CLL 4
AM 1LM8L8A1u8L 46
0
C
SACL PLA1L8S 240 v PASL




MAIN1LNANCL SCnLDULL
#0AllY HAltTFtAtCF#
a Lxamlne earLh connecLlon and moLor leads
b Check moLor wdg for overheaLlng
c Lxamlne conLrol equlpmenL
d ln Lhls case of oll uslng lubrlcanL M/c
l Lxamlne Lemp of bearlng
ll Lxamlne bearlng Lo see LhaL ouL uslng are worklng
lll Add oll necessary
lv Check plays
#wFFKlY HAltTFtAtCF#
a Check belL Lenslon ln case when Lhls ls exerclse lL should lmmedlaLely be reduced and ln
case of sleeve bearlng M/C Lhe alr gap beLween roLor and sLaLor should be checked
b 8low ouL wdgs of proLecLed Lype moLor slLuaLed ln duly locaLlons
c Lxamlne sLarLlng equlpmenL for brunL conLacLs where moLor ls sLarLed and sLopped
frequenLly
d Lxamlne oll ln Lhe case of oll uslng lubrlcaLed bearlng for conLamlnaLlon of dusL dlrL eLc
(Lhls could flnd ouL by Lhe color of oll)
# H0tTHlY HAltTFtAtCF #
a Cver haul conLrollery conLrollers
b lnspecLed and clean oll Ck1 breakers
c 8enew oll ln hlgh speed bearlng ln damp and duLy locaLed
d Check beddlng of brushlng lf sllp rlng moLor
e Check Lhe condlLlon of grease
# AttuAl HAltTFtAtCF#
a Check all hlgh speed bearlng and renew lf necessary
b Low ouL all wlndlng of moLor Lhoroughly wlLh clean and dry alr Make sure LhaL Lhe
pressure ls noL as hlgh as damage Lhe lnsulaLlon
c Clean and varnlsh Lhe dlrLlly wlndlngs
d Cver haul moLor sub[ecL Lo serve operaLlng condlLlon
e 8enew swlLch and fuse conLacLs lf badly flned
f 8enew and sLarLers sub[ecLed Lo damper corroslve elemenL
g Check reslsLance of earLh connecLlon
h Check lnsulaLlon reslsLance of earLh and beLween phases of moLor wlndlngs conLrol gear
and wrlLlng
l Check alr gap