IFFCO Aonla plant consists of two ammonia plants.

Each plant having a

capacity of 1520 tons ammonia per day and four streams of urea plant each
of 1300 tons per day capacity. The ammonia plant is based on HOLDER
TOPSO technology.

DESCRIPTION OF AMMONIA PROCESS :

Ammonia is product of hydrogen and nitrogen,where ratio of hydrogen
and nitrogen is 3:1.

Natural gas is supplied to the plant at the pressure of 40 kg/cm.Sq g.Gas

cotains sulphur components in small quantities which are removed by
passing the gas through desulphurisation unit.Gas is mixed with recycle
hydrogen and preheated to 390 deg.Celsius.

Heated gas mixture is pass over a nickel molybednum catalyst where

sulphur gets hydrogenated.Hydrogen sulphide formed is absorbed in ZnO
bed and sulphur free gas is then sent to reforming section.In case of short
supply of natural gas the hydrogen feed can be supplymented by naptha
after heating it to 380 deg. Celsius in naptha preheater and naptha
superheater and then passing it through naptha desulphuriser containing
cobalt molybednum catalyst to convert sulphur to hydrogen sulphide.This
hydrogenated naptha is mixed with hydrogenated natural gas feed before
entering the zinc absorber.

In reforming section gas mixture from desulphurisation section is mixed

with superheated medium pressure steam and passed over nickel
catalyst,packed in tubes in primary reformers.Here reforming reaction
takes place which is endothermic.Heat is supplied by side fire
burner.Primary reformers exit gas is mixture of
hydrogen,carbondioxide,Methane,CO and steam at a temp. of 800 deg.
Celsius.The gas is then sent to sec. Reformer and part of this mixture is
burnt with measured Quantity of air supplied by process air
compressor.Gas product at Elevated temp. is pass through nickel catalyst
and the reforming section is completed.As secondary reformer exit temp.
is high ,990 deg. Celcius, heat is recovered in RG waste heat boiler,
producing steam and then in process gas superheater where steam is
superheated and gas gets cooled at 350 deg. Celsius .The gas at 350 degree
celsius is then passed through shift converters containing copper
promoted iron based catalyst.The exit gas is cooled down by shift waste
heat boiler,trimheater and BFW preheated to a temperature of 200 deg.
Celsius. Then the gas passed through low temperature shift converter
containing Zn-Cu catalyst.In both these reactors CO is converted to
carbondioxide and small quantities of methane,CO,argon.

Oxides of C and H are poisionous to synthesis catalyst therefore shift

converter exit gas send to carbondioxide absorber where gas is scrubbed
with hot aqueous GV solution.

After absorbing carbondioxide the GV solution is stripped at low pressure

in two GV regenerators.Here carbondioxide is liberated which is cooled
and then sent to UREA plant.Stripped solution is circulated back for
absorbing carbondioxide the gas leaving the absorber contains small
amount of CO and carbondioxide.These oxides are converted to methane
in methanator to reduce then to very low levels.In methanator the oxides
of C react with H at 320-340 deg.celsius over nickel catalyst to form
methane.Methane is inert to synthesis catalyst.After methanation ,gas is
cooled down to 38 deg.celsius and sent to synthesis gas compressor.

Purified synthesis gas is compressed in three stage of synthesis gas

compressor.The recycle gas of hydrogenation is taken from first stage
discharge.Synthesis gas is cooled after every stage and condensate is
separate out.Final discharge pressure of synthesis gas compressor is
220kg/cm sq.g.Copressed gas is cooled in water cooler ,makeup gas chiller
and then mixed with cooled converter outlet gases.The mixture of makeup
gas and recycle gas is finally cooled to 12deg.celsius in ammonia chiller.

Ammonia gets condensed and is seprated in H.P ammonia seprator.The

liquid is thus seprated is the product of ammonia.Uncondensed gas that
comes out from seprator are also known as recycle gas is then warm in
heat exchanger,compressed in recycle stage of syn. Gas compressor and
sent to ammonia converter containing promoted iron cayalyst after
getting heated by converter outlet gases about 30% coversion takes place
in converter.
Then this product which is sepratrd out by above process i.e ammonia is
let down from ammonia seprator to let down vessel, from liquid ammonia
is sent to UREA plant.

The manufacture of ammonia involves following steps :

*Natural gas
*Desulphurisation
*Primary reformer
*Secondry reformer
*Shift conversion
*process condensate stripping section
*Carbondioxide removal section
*Methanator
*Ammonia synthesis section
*Refrigeration system
*Ammonia wash section

1. Natural Gas Supply :

Natural gas which is used as feed back stock for
ammonia plant and power generation plants is supplied at the
battery limit by Gas Authority of India Ltd. From gas wells
located in Bombay High Bassein through pipe line.

2. Desulphurisation :
Natural gas contains sulphur compounds in the
form of sulphides, disulphides, mercaphans, etc. whichwhere
poisnous to the catalysts used in ammonia plant. The process of
removal of these sulphur compounds is called desulphurisation
and is done in two steps.

a. Hydrogenation :
The first step is hydrogenation of sulphur
compounds in presence of catalyst. Hydrogen reacts with organic
sulphur compounds to form hydrogen sulphide in the
hydrogenerator.
b. Sulphur Absorber :
Hydrogenated natural gas at 39Kg/cm.sq pressure
and 380-310C is passed through the sulphur absorbers.Each
reaction contains 13.8 m cq of ZnO catalyst.

3. Primary Reformer :
Desulphurised gas at 37 kg/cm sq and 380C is mixed
with superheated MP steam there for 12 FRC and by pass valve
to get a steam/carbon at a temp. 373C enters process gas &
steam preheater in waste heat recovery section of reformer .
There are following points to be used.

a. Variable in Reforming section :

The following parameters in general, affect the
exist methane content in primary reformer.
• Temperature
• Pressure
• Steam carbon ratio

b. Flue gas waste Heat Recovery section :

Under desired operating condition the flue gas
leaves primary reformer at 1030C & the heat is recovered in
various stages.

c. Combustion air :
Combustion air to the side fired burners &
auxiliary steam superheater burners is supplied by combustion
air. Blower after preheating to 247C in the combustion air
preheater .
4. Secndary reformer :
Secondary reforming, which includes combustion &
reaction of primary reformed gas with process air takes place in
secondary reformer.Secondary reformer is a conical cylindrical
vessel, high pressure shell is insulated from inside with
refractory matereial to protect at shell from high temperature.

5. Shift Conversion :
Shift conversion means reaction of CO & steam to form
carbondioxide and hydrogen. The conversion takes place in
three reacters.
• High temperature shift conversion
• Heat recovery from HT shifted gas
• Low temperature shift conversion

6. Process condensate stripping section :

The condensate stripping section treates process
condensate from three sepraters & benfield overhead condensate
of benfield regenerators. The condensate stripping removes a
subtaintial part of ammonia carbondioxide methanol from
condensate, before is sent to boiler feed water prepration unit
outside ammonia plant battery limits.

7. Carbondioxide Removal Section :

In this section bulk of carbondioxide in shifted gas is
removed by absorption using 30% benfield solution.

8. Methanation :
For ammonia synthesis very pure gas mixture of
hydrogen & nitrogen in the ratio of 3:1 is required & ever small
amount of carbondioxide & CO in gas can poison the ammonia
synthesis catalyst.
9. Ammonia synthesis :
 It takes place in the ammonia synthesis converter
according to following reactions at elevated temp. & pressure.
3H2 + N2 = 2NH3 + heat
This is an eq. reaction. Gaseous ammonia is condensed by cooling
& chilling then seprated as liq. ammonia. The unconverted gases
are recycled. The conversion of reactants into ammonia is
favoured by high pressure &low temprature.

10. Refrigeration system :

The primary purpouse of refrigeration system is to
make available liq. refigent ammonia of different temperatures
which required for circulation through chillers for condensing
produts ammonia from converter outlet.

Ammonia wash section :

It serves to recover most of ammonia contain in the
gaseous & to reduce the ammonia content in the secendary fuel
to primary fuel.

a. Ammonia absorption
b. Anmmonia distilation
EQUIPMENTS

1. HP Waste Heat Boiler :

To recover heat by cooling the hot process gas from
secondary reformer by generation of HP steam.
The boiler section is equipped with general process, gas
by pass so that the boiler cutlet temperature can be controlled
automatically.

Surface area : 460.3 m sq

Shells per unit : 1
Type : Horizontal fire tube waste heat
boiler.

2. Gas Exchanger :
It is used to heat inert gas from the discharge of
nitrogen blower by exchanging heat with inert gases returning
from the start up circuits.
The nitrogen gas from S.U circuit flowing through tube
sides gets cooled down from 450-160 C. N from nitrogen blower
in enters the shell side and gets heated from 100-393C.
Surface area : 433 m sq
Type : BEM

3. Primary Reformer :
To reform hydrocarbon with steam in the pressure of
proted nickel catalyst. It is a single row reformer with two
radiant chambers, each chamber being divided in eight sections.
It consits of two main parts :
• The radiant section—which contains the catalyst tubes
• The convection section – which contains a no. of convection
coils for preheating of various steams, superheating of steam
4. Flue Gas Boiler :
To maintain draft in primary reformer furnace by
drawing to gas through the convection section & discharging it
to the atmosphere through stack.

5. Flue Gas Blower Turbine :

Flue gas fan is provided with two at shaft ends with
cluthes. One drive is a back pressure steam turbine.Turbine is
coupled with flue gas through gear box.Other drive is an electric
motor. In normal operation steam turbine is kept in service.

6. Combustion Air Blower :

To supply, combustion air to the burners of
primary reformer. Combustion air is from the hot area between
the two radiant chambers of the primary reformer furnace by
com. Air blower . CAB is driven from one side by a back
pressure steam turbine & on the other side of motor turbine
&motor are clutched with the combustion air blower.In normal
operation turbine shall be line while motor shell be line .

MECHANICAL DETAILS
• Casing : Horizontal split
• Impeller type : Single thick blade
• Impeller dia : 23.85 mm
• Bearing type : Casing bubbet
• Coupling : Flexible type
• Lubricating sys. : Oil ring oil
•Fluid handed : Air

7. Secondary Reformer :
 To reform the uncovered methane coming out of
primary reformer with addtion of process air . Reformed gas is
partially burnt with oxgen in the air& heat in combustion is
utilised for the endothermic methane reforming reaction.

8. Steam Boiler :
To cool the process gas from reboiler & regenerate LP
steam by utilising this heat.
This is a kettle type boiler with two parellel boundless.

No. of units : 2
Calculated outside surface : 757 m sq
Installed area : 768 m sq

9. Hydraulic Turbuine :
Pressure let down of GV rich solution coming from GV
absorber & going to HP regenerator by running the hydraulic
turbine & in process utilising, this pressure energy to bring down
steam consumption in GV steam line circulation pump turbine.
Hydraulic turbine mounted on the common shaft of GV pumps
with in automatic overrunning cluthe betwwen the two & co-
driver for pump.

10. Flash Vessels :

To separate out liquidb ammonia from flashed gases at
0.05 kg/cm sq g.
Specifications :
• supplier : G.R Engineering works Ltd. Mumbac
• Pressure : 0.05 kg/cm sq g.
• Temperature : -32.2C
11. Ammonia Condenser :
To condence ammonia vapours from the discharge
of refrigeration compressor.
SPECIFICATIONS:
• Suppliers : Llyod steel , Mumbai
• Surface area per unit : 2910 m sq
• Shells per unit : 2
• Length of tubes : 9360 mm
• Outer dia : 19.50 mm
• Inner dia : 14.83 mm

12 . Condensate pumps :
To pump speed condensate from surface condenser
to steam condensate header.

SPECIFICATIONS :
* No. of required : 2
* Pump Supplier : IDP , Italy
* Capacity rated : 20 m cq per hrs
* Pumping temp. : 52 C
* Dicharge pressure : 8.51 kg/ cm sq g
* Pump speed : 2985 rpm
* Efficiency : 44.2%
* Rated power : 10.5 Kw

AMMONIA STORAGE SYSTEM

Introduction :
 For efficient and continuos running of plant, two
refrigerated ammonia storage tank each of 10,000 MT are
installed to store liquid ammonia produced by ammonia plant.
Ammonia is stored in liquid condition at atmospheric pressure
by reducing its temperature to -33C and in this condition it is
stored in cylindrical flat bottomed tank as the pressure of the
tank must with stand only that imposed by liquid head.

The escape of ammonia under pressure is potentially more

dangerous than the scape of ammonia stored at ammonia storage
tank.

Type : Flat bottom, double cup in cone doomed roof,

for atm. Pressure.
Capacity : 10,000 MT of liquid ammonia

Ammonia Dispatch pump

Type : centrifugal
No. of stages : 6
Capacity : 55 m cq/hr
Drive : Electric motor
Speed : 2937 rpm
Function : To supply liq. ammonia to urea plant and
loading gantry

PUMPS:
 Three classes of pump finds use today-centrifugal, rotary
and reciprocating. The terms apply only to the mechanics of
moving the liquid. Each class is further sub-divided into a no. of
different types as follows :

Class Type
Centrifugal volume
diffuser
turbine

Rotary gear
vane
cam and piston
screw
lobe
Shuttle block

Reciprocrating Direct-acting (simplex)

Power (including crank
& flywheel)

Diaphragm(quadruplex)
Rotatry piston

1.CENTRIFUGAL PUMPS:
The chemical industries are major
users of process pumps of all types but in particular centrifugal
pumps . These centrifugal pumps are made of special material to
handle acids. Alkaline, corrosive solutions. The different types of
centrifugal pumps are briefly described below.
a. Volute type pumps :
The impeller discharges liquid into a
progressively expanding spiral casing,proportioned to reduce
the liquid velocity gradually. By this means some of the velocity
energy of the liquid is converted into static pressure.

b. Diffuser-type pumps :
In this type, the stationary guide vanes surround
the runner on impeller in a diffuser type pump. These gradually
expanding passage change the direction of liquid flow and
convert velocity energy to pressure head.

c. Turbine Type pumps :

Also known as vertex, periphery & regenerative
pumps, liquid in this whirled by the impeller vanes at high
velocity for nearly one revolution .

d. Cam & Piston pumps :

It is also called rotary plunger pumps, the cam &
piston type consist of an eccentric with a slotted arm at its top.
Rotation of a shaft cause an eccentric to trap liq. in the casing.
As rotation continous, liq. is forced from the casing through the
pump outlet.

CONCLUSION
The conclusion of this traning and project report is to visualise
all the main engg processes and also learn about what
management actually do in the industry which we cannot learn
in our college . The main aim of my training is to study the
human nature and behavior of workers with their co employ,
supervisor, relation between managers and supervisors and
outsiders.
In IFFCO I visualise that they are better utilise their
resources , production with minimum waste , better
communication and cooperation between all the related
department.
And finaly I am very thankful to all the staff
members and training Department of IFFCO for their great
cooperation to complete my training and project successfully.
 STEAM TURBINES
A steam turbine is a rotating machinery which transforms heat
& potential energy of steam to kinetic energy to drive another
rotating machinery. The steam is expanded from high pressure
to low pressure either in nozzles or in the blade & K.E so
obtained is supplied to rotary blades where it is transform into
mechainical work. The power is made available at the turbine
shaft directly or with the help of redution gears.

Working principle

The power for rotation is available to the turbine by virtue of net

enthalpy difference between the inlet steam & the exhaust
leaving the turbine.

H = H 1 - H2
The high pressure is expanded in a nozzle where K.E of steam is
increased resulting in the emission of high velocity jet from the
nozzle. The jet is directed to strike a set of moving vanes or
blades mounted on a shaft. The steam while sliding over the
curved surface of the vanes imparts the force which ultimately
provides motive power at the turbine shaft.

Parts of the Turbine

1. Nozzle :
Where the steam is expanded to increase the K.E.
The nozzle has a tappered cross section reducing to minimum
size called throat & then it has a divergent length upto a
maximum size called exit.

2. Rotor Assembly :
Consisting of moving blade on a shaft.

3. Blades & Vanes:

Which may be moving or fixed type. The moving blade are
mounted on the rim of wheel or rotor. The fixed vanes are meant
for guiding the steam to the moving vanes , from one stage to
another & are fitted in diaphragms which in turn are fitted in
casting.

4. Cylindrical Casing Assembly :

Consisting of frame work for supporting the whole
structure.

5. Diaphragms :
For providing seprating walls between different
stages.

6. Bearings :
To support & provide min. friction to the shaft
rotation.
7. Glands :
For prevention of steam leakage.

Flow of Steam through Nozzles

The steam nozzle is passage or duct having varying cross section

by means of which the internal energy of steam is converted into
K.E. The steam enters the nozzle at high pressure with an
negligiable velocity. In the converging portion upto throat, the
pressure & enthalpy decreases while the steam expands
isentropically & adiabatically. The velocity of steam increases in
this length at a greater rate then its specific volume increases.
Hence the reducing taper is provided upto the throat. After the
throat the pressure & enthalpy continue to drop onwards, while
the K.E further increases, but the rate of this inc. is not larger
than the rate of inc. of specific volume, hence passage area has to
be increased. For this reason the nozzle diverges between the
throat & the exit.
The expansion of steam in an ideal nozzle is isentropic &
accompanies condensation process. If the initial state of steam is
superheated, the condensation should start after it has proceeds
a shorter distance till it has become saturated.

Types of Turbines :

A. Based upon the exhaust pressure of steam, turbine can be

classifieds as :

(a) condensing turbine

(b) back pressure turbine
Condensing Turbine :
These have a exhaust of stweam at a below atm.
Pressure.These turbine requires elaborate arrangement of
exhaust of auxiliaries such as the surface condenser, condensate
pumps, vaccum ejector, gland steam condenser etc.

Back pressure Turbine :

These have exhaust of steam at higher pressure &
temperature. The exhaust steam can be utilised for uther
industrial processes or heating purposes.

B. Based upon the method by whioch K.E of steam is converted

into shaft work, steam turbines are classifieds as :

(a) Impulse turbine

(b) Reaction turbine

Impulse Turbine :
In the steam turbines employing the principal, the
steam at inlet press. & temp., but at the low velocity expands
through the nozzles to exhaust pressure, there by gaining of high
velocity. The nozzles are stationary, & secured either in a
diaphragm or directly in the casing. The turbine works on the
principle of impulse, where the K.E of the jet is used to exert a
force on a set of moving blades. The entire heat drop in steam is
occuring by its expansion, in nozzles or in fixeds blades.

Reaction Turbine:
These turbines employ the pr. Of reaction, i.e a
backward force developed opposite to a certain action. The
steam is allowed to expand in the moving blades also, which acts
as nozzles. The reaction force along with that due to change of
momentum of steam, on these blades provide the motive power
to the turbine. The entire pressure drop is achieved over a series
of fixed & moving blades in succession. The fixed blades also acts
as a guide vanes to regulate the dir. Of steam flow & at the same
time allow it to expand to a higher velocity.

Compounding of Steam Turbines

If the entire pressure drop of the steam is carried out in a single

stage, then the velocity of steam entering the turbine could be
very high & so will be the turbine rotor velocity. Such a high rpm
of the turbine rotor is not useful for practical purposes & also
there is a danger of structural failure of the blade due to exessive
centrifugal stresses.

Furthre more the velocity of steam at the exit of turbine is

sufficiently high single stage blades are used, thereby giving a
considerable loss of K.E .

These difficulties associated with single stage turbine can be

solved by compounding. The combination of the stages are
known as compounding. Compounding involves the reduction of
blade speed for a given overall pressure drop and can be done by
one of the two methods.

(a) Velocity compounding :

There is only one set of nozzles
and two or more rows of moving blades. Rows of moving blades.
Rows of fixed blades in between the moving blades is provided.
The function of fixed blade is only to direct the steam coming
out from first moving row to next moving row without altering
pressure velocity of steam. The heat energy drop takes place in
the nozzle at first stage and it converts in to K.E. The K.E of the
steam gain in the nozzle is successively used by the rows of
moving blades and finaly exhaused from the last row of blades
on the turbine rotor. eg.curtis turbine .

(b) Pressure compounding:

A number of simple impulse
turbine sets arrange in series known as pressure compounding .
The turbine is provided with one row of fixed blades at the entry
of each row of moving blades. The total pressure drop if the
steam does not take place in a single stage nozzle but it is divided
equally in all the rows of fixed blade which work as nozzles. eg.
Relean turbine.

(c) Pressure and velocity compounding:

It is a combination of
pressure and velocity compounding.

TURBINE GOVERNING

The performance of a given turbine is specified by plotting steam

consumption in kg/h as a function of shaft output at the turbine
coupling. Steam turbines are required to operate at constant
speed over a range of loads varing from 0 to115% of rated
output. In these cases, the steam chest pressure and thus the
temperature remain constant. Therefore if a variation in output
is to be affected , it is necessary either to throttle the steam at the
main valve or to reduce the mass flow by cutting of one or more
nozzles through which the steam enters the blades.

METHODS OF GOVERNING
(1) Throttle governing
(2) Nozzle governing

Trottle governing:
In throttle governing, the main valve
leading steam into the turbine is gradually closed as the load
falls, thus keeping the speed constant. This leads to trottling of
steam and a consequent reduction in main flow rate.

Nozzle governing:
In turbine using nozzle governing, the steam
supply from the main valve is split into two or more lines, each
line feeding a set of nozzles. The significant advantage of nozzle
governing is that the throttling is minimised but not totally
eliminated.

WORKSHOP MACHINES
(1) LATHE MACHINE

(2) UNIVERSAL MILLING MACHINE

(3) SHAPER MACHINE

(4) SLOTTING MACHINE

(5) RADIAL DRILL MACHINE

(6) HORIZONTAL BORING MACHINE

(7) POWER HACKSAW

(8) GRINDING MACHINE

-SURFACE GRINDER
-TOOL & CUTTER GRINDER

LATHE MACHINE
PARTS OF THE LATHE:

BED :
The bed of a lathe acts as the base on which the different
fixed and operating parts of the lathe are mounted. This facilited
the correct relative location of the fixed parts and the same time
provides ways of a well guided and controlled movement of
operating. It must be a very rigid and robust construction. Lathe
bed sare usually single piece casting , the material cast iron
facilitating an easy sliding action. Bed casting are usually made
to have a box action .

HEAD STOCK:
The head stock is that part of the lathe which serves as a
housing for the driving pulleys and back gears, provides bearing
for the machine spindle and keeps the lather in alignment with
the bed. It consist of the following parts

• Cone pulley
• Back gears and back gear lever
• Main spindle
• Live centre
• Feed reverse lever

TAIL STOCK :
It is mounted on the bed of the lathe such that it
is capable of sliding along the later maintaning its alignment with
the head stock. The main function of tail stock is to provide
bearing is made to possess a number of parts which collectively
help in the successful function. The body is a single piece casting
to which it fitted a separate plate at the bottom called the bottom
plate.

CARRIAGE:
The lathe carriage serves the purpse of supporting
guiding and feedin the tool against the job during the operation
of the lathe. It consists of following main parts

• Saddle
• Cross slide
• Compound rest
• Tool post
• Apron and apron mechanism
• Split nut

LEGS:
They are the supports which carry the entire load on m/c
over them. The brevailing practice is to use cast legs. Both the
legs are firmly secured to the floor by means of foundation bolls
in order to prevent vibrations in the machine.

Universal Milling Machine

It is the most versatile of all the milling machine & after
lathe it is most useful machine tool as it is capable of performing
most of the machining operations. Its table can be swivelled on
the saddle in a horizontal plane. For this, circular guide ways are
provided on the saddle along which it can be swivelled.
Following are the principle parts of milling machine
• Base
• Column
• Knee
• Saddle
• Table

SHAPER MACHINE
Shaper is a versatile machine which is primarily intended for
producing flat surfaces. These surfaces may be horizontal,
vertical or inclined. This machine involves the use of single point
tool held in a properly designed tool box mounted on a
reciprocating ram. It can be safely adopted for producing curved
& irregular surfaces also.

Pricipal parts :
• Base
• Column
• Cross-head
• Table
• Ram
• Tool head
• Vice

SLOTTERING MACHINE

A slottering machine or slotter has its own importance

for a few particular classes of work. Its main use in cutting
different types of slots & its certainly proves to be most
economical so far as this kind of work is concerned. Its other uses
are in machining irregular shapes , circular surface and other
premarked profiles. Both internal as well as external. Its
contruction is cuts during the downward stroke only.

Principle parts
• Base
• Column
• Table
• Ram

RADIAL DRILLING MACHINE

Drilling is an operation through with holes are produced in a
solid metal by means of a revolving called drill. Since it is not
possible to produced a perfectly true hole by drilling, it is
considered as a rogging operation.
This machine is a very useful because of its wider range of
action. Its priciple use in drilling holes on such works which is
different to be handled frequently with the use of the machine
tool as moved to the desired position instead of moving the work
to bring the later in position for drilling.

Operation :
• Drilling
• Reaming
• Boring
• Counter Boring
• Counter Sinking
• Spot facing
• Tapping

HORIZONTAL BORING MACHINE

When small holes are to be hold particularly in small jobs which
can be conceniently held in chucks , the operation of boring can
easily be done on centre lathes or far larger & heavy jobs special
boring are to be used which make the operation easy and
efficient.
Types of machine :
• Maximum travel of the sprindle
• Maximum travel of table
• Spindle speed and feed
• Power of electric motor

PARTS :
• Bed
• Column
• Head stock
• Table and saddle
• End support column or stay

POWER HACKSAW
The machine is designed & constructed to provides means for
claiming the work & a reciprocating action to saw blade bears
down by mechainical power. Since the cutting is not continous
this machine cuts the metal at a compratively slower rate than
the other metal sawing machine. On the other hand it carries an
advantageous feature also in the several bear or flats etc of the
stock material can be claimed at a time and cut simultaneously.
Another advantage is that its operation does not need a continous
attention as the machine handle stops automatically as soon as
the cut is over.

Parts :
• Blow guide
• Bed
• Table
• Stoke adjustment
• Wheels
• Knob valves
GRINDING MACHINE
SURFACE GRINDER :
Surface grinder do almost the same
operation as the planners shappers or milling machines but with
more precision/primarily they are intended to machine flat
surfaces although irregular curved or tapered surfaces can also
be grind on them. There are in workshop reciprocating type
surface grinder is used. A reciprocating table type surface
grinder may have or horizontal spindle of the grinding wheel or
a vertical spindle.The horizontal spindle machines are widely
used in tool room. The work piece is usually held on a magnetic
chuck on these machines.

TOOL AND CUTTER GRINDER

These machines are primarily
intended for tool room work for grinding cylindrical & tapered
multitech cutting tool like milling, cutters ,hobs, drill, reamers
taps, broaches & gear shapper cutter.

They are also capable of doing light

cylindrical surface & internal grinding operation.These
grinders largely on there high veriatility to the large no. of
attachments that carries.
MAIN PARTS
• Base
• Hydraulic system
• Wheel head spindle crossfed & axial movement
• Mechanism
• Head stock
• Tail stock
• Coolent system

INTRODUCTION
IFFCO AONLA UNIT is located in the gangetic plains of UP in
Bareilly distt. About 28 km of south-west on Bareilly - Aonla
road.
IFFCO Aonla unit , an ammonia – urea complex, is
comparised of two phases ; Aonla 1 & Aonla 2. The total capacity
of Aonla unit including both phase is 10,03,200 MTPA for
ammonia & 17,29,200 MTPA for urea having two streams of
ammonia & 4 streams of urea. The natural gas from HBJ
pipeline is being supplied from Bombay High, is feedstock for the
plants. Both Aonla 1 & 2 units are acheiving average annual
capacity utilization of 100%.

IFFCO AONLA is one of the most efficient, quality concious &

environment oriented unit. The plant has been certified for ISO
9001:2000 & OHSAS – 18001:1999 by M/S. NQA – QSR, New
Delhi.
Both plants and township have been certified for
ISO- 14001 by M/S. BVQT, London.

BOILERS IN POWER PLANT

To meet the steam demand of IFFCO Aonla Fertiliser complex,
three high pressure boilers have been installed in power plant.
There are two waste heat boiler called Heat Recovery Steam
Generators( HRSG ) provided in down stream of gas turbines &
one no. main boiler called Steam Generator( SG ).

STEAM GENERATOR (SG) :

The steam generator is a water tube double drum
natural circulation, oil or NG fired boiler. The capacity of SG is
150 MT/hr of superheated steam at a pressure of 115KG/cm sq
& 515 C temperature. The SG is pressurised furnace with no
induced draft fan. Two forced draft fans, one turbine driven &
other motor driven supply combustion air. A direct spray type
De-superheater has been provided between primary &
secondary superheater to control steam temperature. The SG is
designed to fire HSD, LSHS/FO & NG with four sets of oil & gas
combination burner.

The SG comprises a water cooled furnace, a convection, steam &

water drums, headers for connecting & distributing water &
steam drums, primary & secondary superheaters, frames,
casing, insulation etc.

FURNACE :

The furnace has sufficient volume to secure complete combustion

of fuel. The furnace walls are of welded longitudinal fin tubes
pannels to form completely gas tight encloser. The furnace floor
is covered with layer of refractory bricks so as to shield tubes
from radient heat to secure a good water circulation. Front wall
is equipped with four burner in two rows . The rear wall forms
a partition dividing the connection section from furnace. Rear
tubes forms a nose baffle to provide a superheater space at the
upper part of furnace. The side walls are provided with lower &
upper headers which are connected to water & steam runs with
connecting pupes.

SUPERHEATERS :

SG is provided with two stage of superheaters i.e primary &

secondary superheaters. Both of them are convection & pendant
type. Primary superheater is located at lower gas temperature
path while secondary is higher temperature path. The
superheater tubes are hung to superheater headers which are
mounted on the furnace header. So the thermal expansion of
superheater tubes & headers is free which avoids excessive
stresses.

DE-SUPERHEATER :

A de-superheater is provided on the connecting pipe between

primary & secondary superheaters to control the final steam
temperature. Feed water is sprayed into a steam flow through a
steam nozzle which reduces the steam temperature.

BOILER CONVECTION BANK :

The convection bank is provided in downstream of superheater

and comprises a no. of vertical tubes which are connected to
steam & water drums by expanding their ends. The higher gas
temperature parts of convection bank becomes riser while the
lower temperature parts become rated down comers. Also both
the side walls are insulated from free gas with refractory bricks
& work as unheated downcomers. The tubes also bear the weight
of steam drum. Adequate no. of excess doors andsoot blowers are
provided for easy maintenance and effective cleaning of tubes.

ECONOMISER :
An economiser is provided in downstream in the boiler
convection bank to recover waste heat from flue gases. The
economiser comprises a no. of spiral wounds fined tubes , inlet &
outlet headers & sufficient frames & castings. It is supported by
the steal structure using slide shoes to cater to horizontal thermal
expansions. A reciprocating type soot blower with multiple
nozzle is furnished to effectively clean the heating surfaces.

Auxiliary Equipments Of Boiler

1. Gas Air Heater(GAS) :
The combustion air discharge to furnace by F.D. fans is heated
to 145C for proper combustion of fuel. The heat is trasfered to
inlet air by gas air heater, which takes up waste heat from flue
gas. Heat is absorbed by element surfaces of GAH passing
through hot gas stream, then transferred to inlet air stream.

2. Steam Coil Air Preheater :

Function of steam coil air heater is to control the temp.
oF outgoing flue gas to eliminate chances of condensation of
corrosive gas on the elements of GAH and cosequent corrosion
of heating elements. It raises air temp. upto about 50C.

3. Pressure Safety valves (PSV) :

To protect the boiler drum from excessive pressure, two
no. of PSVs are provided on top the steam drum. Another safety
valve is provided SH steam outlet header.

CONTENTS
• Introduction to Aonla Unit

• Acknowledgement

• Brief Description Of Ammonia Plant

• Brief Description Of Workshop machines

• Brief Description Of Inspection

• Brief Description Of Pumps

• Description Of Steam Turbines

• Study Of Boilers In Power Plant

• Conclusion
 ACKNOWLEDGEMENT

Its my great pleasure to express my sincere gratitude and

indebtness to Mr. D.Kalia, manager training, IFFCO AONLA
UNIT for his deep interest profile insperation, invaluable advice
during the entire cource of vocational training.

I am also thankful to Mr. K.K. Pandey,Sr. training officer

IFFCO AONLA UNIT for there kind and supporting nature.

I also thankful to Mr. V. K. Sharma , head of training and

placement Department, HCST, MATHURA, (U.P.), for taking
their personal interest and giving valuable guidance for my
training in IFFCO AONLA, Bareilly,U.P.

I would also thanks to Mr. O.P. Kathuria, Joint General

Manager (Maint.), Mr. Akash Verma (Manager), Mr. S.N.Patel
Sr.engineer(mech.), for giving his moral support, kind heartness
, helpful nature and depth of knowledge carring out the training.

AJAY YADAV

B-Tech, M.E.

HCST, MATHURA,( U.P.)

A
VOCATIONAL TRAINING

PROJECT

AT
IFFCO
INDIAN FARMERS FERTILISER COOPERATIVE
LIMITED

AONLA UNIT

BAREILLY, U.P.

SESSION- ( 2005-2006 )

SUBMITTED BY
AJAY YADAV
B- Tech, M.E.
HCST, MATHURA (U.P.)
 INSPECTION

LIST OF WORKING INSTRUMENTS:

A- Vibration/sound level measurements;

1-IRD 880 vibration analyser/balancer

2-IRD 308 vibration/sound level meter
3-DATA PAC 1500

B- Temperature measurement ;

1- MIKRON M90D
2- Wahl contact typer thermometer 1370MX
3- Thermeltiks

C- Thickness measurement ;

1- Panametrics thickness gauge 36DL

2- Pulsacho thickness meter MP200L
3- Coatmeter
4- Rubber thickness meter

D- Liquid Penetrant Inspection;

1- Dye penetrant
2- Cleaner
 3- Developer

E- Magnetic particle inspection ;

1- MAGNAFLUX Y7 AC/DC (YOKE TYPE)

F- Hardness measurement;

1- POLDI hardness tester

2- ECQOTIP hardness tester
3- SHOPE “A” hardness tester
4- SHOPE “D” hardness tester

G- Bearing Inspection/ Speed Measurement;

1- Shock pulse analyer A2011

2- Shock Pulse testor T2000
3- Electronic Stethoscope ECS-12 with amplifier
4- Engineering Stethscope
5- Read type techometer

H- Ultrasonic Flaw Detection;

1-Ultrasonic flaw detector USC-48

2-Ultrasonic flaw detector USM-35
I- Eddy Current Inspection;

1-ECT MAD4D: Multichallenge and multicurrent

frequence eddy current testing machine.

J- Mislaneous inspection instruments;

1-Ferrite Contents Meter

2-Olympus Iplex Videoscope
3-Gaussmeter Model 620
4-Gaussmeter Model 5080
5-Auto Degaussing System
6-High frequency high voltage spark plug
7-Balance Machine HD7000/HDC300CS
 VIBRATION SERVICE CHART

M/C Disp./vel. Disp./vel. Disp./vel. Disp./vel.

RPM FAIR SL.Rough ROUGH V.ROUGH

1500 25/2 50/4 100/8 200/16

3000 12/2 25/4 50/8 100/16

6000 6/2 12/4 25/8 50/16

8000 4.5/2 10/4 20/8 40/16

10400 3/2 7/4 14/8 28/16

 BALANCING

Unbalance wt. Is simply defined as unequal distribution

of wt. On rotating it produces unwanted vibration and
unwanted forces.
Even a little unbalanced wt. Can create a
lot of vibration and disturbances.

TYPE OF UNBALANCE

1- STATIC ( Force or kinetic unbalance )

2- COUPLE
3- QUASISTATIC
4- DYNAMIC
BASICS OF VIBRATIONS

Vibration is simply the motion of m/c or m/c parts back

and fro from its position of rest.

Causes of vibration
With few exceptions mechanical troubles in m/c causes
vibration.
Some common problem which produces vibration are:

1- Unbalance of rotating parts

2- Misalignment of coupling and bearing
3- Bent shaft
5- Worth ecentric or damaged gear
6- Bad drive belts and drive chaines
7- Bad bearing
8- Torque variation
9- Electromagnetic forces
10- Aerodynamic forces
11- Hydraulic forces
12- Looseness forces
13- Rubbing
14- Resonance
 CHARACTERSTIC OF VIBRATION

1. Frequency
2. Displacement
3. Velocity
4. Acceleration
5. Phase
6. Spike energy

TIME PERIOD-
The time taken to complete one full cycle.

Frequency-
It is inversly proportional to time period.
Frequency = 1/ Time period

Vibration frequency is usually expressed as no of cycles

that occurs each minute.
VIBRATION DISPLACEMENT-
Total distance
travelled by vibrating part from one extrem limit of travel
to other extrem limit of travel his refered to as “peak to
peak displacement” it is expressed in MILS.
Where 1MIL = 1000 of an inch
Or 1MIL = 1000 micron

VIBRATION VELOCITY-
Vibration velocity is
contineously changeson the peak point it is 0. Since the
wt. Comes to 0 velocity when it have to go in opp.
Direction.
Velocity is maximum at neutral position. Vibration
velocity is expressed in terms of inches per second peak of
english unit.

VIBRATION PHASE-
Phase is defined as the position of
vibrating part at a given instant with refrence to fixed
point or another vibrating parts.

VIBRATION SPIKE ENERGY MEASUREMENT

Still another characterstic of vibration
that is special intrest is SPIKE ENERGY
MEASUREMENT. This is fairly abstract quantity that
can not be readilly releated to picture of vibrating wt.
It includes very short duration
high frequency spike like plus of vibration energy that
occurs in machinary as a result of

1- Surface flaws in rolling element if bearings or gears.

2- Rub impact of metal to metal contact in rotating m/c.
3- High pressure steam on air leaks.
4- Cavitation of flow, turbulance in fluid

OTHER CHARACTERSTICS:

1- Forced vibration – Vibration caused by vibratory

forces.
2- Free vibration- When m/c is allowed in absence of
external force
3- Driving frequency- It is frequency of forced vibration
4- Natural frequency- It is the frequency of free
vibration.

M/C TOOLS VIBRATION TOLLERANCE

TABLE:

M/C TOLERANCE
TYPE IN MILS
1- Grinder

Thread grinder 0.01 - 0.06

Conter grinder 0.03- 0.08
Cylinder grinder 0.03 - 0.10
Surface grinder 0.03 - 0.2
Gardner grinder 0.05 - 0.2
Centerless grinder 0.04 - 0.1

2- LATHE 0.2 –1.0

3- BORING M/C 0.06 – 0.1

COMMON BEARING FAILURE AND

THEIR CAUSES:

1- Surface fatigue
2- Spalling
3- Abrasion
4- Atmospheric corrosion
5- Fretting
6- True brinlling
7- False brinlling
8- Electeical damage
9- Smearing
10-Scoring
11-Assembly damage
12-Overheating
13- Misalignment
15- Unbalance loading
16- Fractures
17- Retainer failure